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ENVIRONMENTAL INFRASTRUCTUREAT

VATVA, AHMEDABAD

The Green Environment Services Co-op. Society Ltd.Office & CETP Site: Plot No.: 244-251, Phase: II, GIDC Estate, Vatva, Ahmedabad 382 445.

Phone: (079) 25892283, 25832449, 25832520, 25835652. Fax: (079) 25893614.Web Site: www.gescsl.com E-mail: info@gescsl.com

GESCSL – Objectives

GESCSL was formed in 1992 with the main objective to abate pollution andconserve energy and environmental resources to achieve sustainable growthand development in all areas. To achieve this objective approximately a sum ofRs. 100 crore has been spent to set up the following EnvironmentalI f F ili i d M SInfrastructure Facilities and Management Systems…

– Establishment and operation of common facilities for the collection,treatment (CETP) and disposal of industrial effluent in the estate of Vatvahaving membership of 674 industrial units.

– Establishment and operation of common secured landfill facility (SLF) forthe safe disposal of solid waste being generated by industrial units in Vatvaand elsewhere.

– Organizing joint programmes with academic institutions and industriesfocusing on energy efficiency, cleaner production practices andenvironmental awareness.

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COMMON WASTE MANAGEMENT SYSTEMs

The Common Waste Management System in the estate of Vatva consists of the following components…

– Industrial Wastewater Management

Internal Collection System

Common Effluent Treatment Plant

Disposal into Mega Pipeline

– Solid Waste Management

C S d L dfill F ilit (SLF)Common Secured Landfill Facility (SLF)

– Spent Acid Management

INTERNAL COLLECTION SYSTEM

• No. of industrial units served : 674

• Area covered: 13.5 km2.

• System Description:

– Collection of industrial wastewater by gravity into 92 sump rooms.

– Conveyance of wastewater by gravity from Sump rooms to 7 Pumpingstations.

– Pumping of wastewater from pumping station to CETP for treatment.

– Monitoring of wastewater quality to assess acceptability. Sampling ofdischarge of every unit to determine CETP inlet parameters.

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COMMON EFFLUENT TREATMENT PLANT

Design Criteria:– Flow Rate: 16000 m3/d – pH: 6.5 – 8.5– TSS: 600 mg/l

COD: 3000 mg/l– COD: 3000 mg/l– BOD: 1200 mg/l

Land Area: 28000 m2

Treatment Technology: Conventional activated sludge type biological process supplemented by Electro-oxidation.

Major Treatment Units:– Equalization Tank– Electro-oxidation Plant– Flash Mixer– Flocculator– Dissolved Air Floatation Unit – Aeration Tank– Secondary Clarifiers

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ELECTRO-OXIDATION SYSTEM

AERATION TANK

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ULTIMATE DISPOSAL OF TREATED EFFLUENT

Treated effluent from the Secondary Clarifier is taken to Final PumpingStation from where it is pumped to AMC’s mega pipeline carrying the treatedeffluent to the down stream of Pirana Sewage Treatment Plant through aclosed pipeline, where it is mixed with treated sewage of Pirana SewageTreatment Plant before disposal into River Sabarmati.

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SLUDGE TREATMENT & DISPOSAL

• Primary Sludge and Secondary sludge are collected in Sludge Holding Tanksfor treatment.

• Sludge is pumped to Decanters for de watering• Sludge is pumped to Decanters for de-watering.

• Treated sludge is ultimately disposed to Secured Landfill Disposal Site atVillage Vinzol, developed by The Green Environment Services Co. operativeSociety Limited.

LABORATORY

The CETP has in-house well equipped laboratory.

A l i l l b E i d i h hi h i f i– Analytical lab: Equipped with hi-tech instruments for continuousanalysis of wastewater samples.

– Microbiological lab: For microbiological testing of Aeration Tank mixedliquor and activated sludge.

– TOC lab: Equipped with hi-tech TOC Analyzers.

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CETP UP-GRADATION PROGRAMME

• The Electro-oxidation Plant based on German technology has been installedand is at present under stabilization and optimization.

• In the Electro-oxidation Process generation of strong oxidizing agents takesg g g gplace in situ under the influence of electric current in a well designed electrocell. These oxidizing agents oxidize as well break up the organic moleculesrendering them in the oxidized state and / or converting them inbiodegradable form. The effluent after this pre treatment is further treated inCETP where biological processes in the presence of chemical additivesdegrade the organics at the desired level.

• Further Proposed Up-gradation– Installation of a new Primary Clariflocculator. It will be utilized for

imparting physico-chemical treatment to the incoming combined effluentimparting physico-chemical treatment to the incoming combined effluentto ensure low levels of suspended solids before it enters Electro-oxidationPlant. This will also help in reducing maintenance and cleaning downtimein the subsequent units.

– Installation of additional Aeration Tank to achieve longer aeration time,more flexibility in operation and to enhance biological removal ofpollutants.

COST OF PROJECT

Initially the common facilities for the collection, treatment (CETP) andconveyance of treated effluent were set up at the cost of Rs. 33.28 crore.

The break-up of this cost is as under…

Internal Collection Systems Rs. 10.17 crore

Treatment units (CETP) Rs. 18.00 crore

Conveyance line upto Sabarmati near AMC Pirana STP Rs. 05.11 crore

Sub Total Rs. 33.28 crore

Expenditure towards additional equipment and Rs. 11.74 crorep q pinstallation / modification of new units

Phase: I Up-gradation Rs. 06.70 crore

Phase:II Up-gradation Rs. 22.69 crore

Sub Total Rs. 41.13 crore

Total Project Cost: Rs. 74.41 crore

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OPERATING COST OF CETP• Rs. 15 – 18 per m3 of effluent

RATE OF CHARGING• Rs. 20 per kg of TOCp g

SECURED LANDFILL FACILITY

• Detailed engineering design, construction and operation are carried out as per theguidelines of CPCB.

• Initially SLF No. 1 & SLF No. 2 were constructed. Later these two sites wereexpanded and after full capacity utilization were capped and green vegetal layerwas developed.

SR.NO.

PARTICULARS SLF - 1 SLF - 2 EXPANSION OF SLFs 1 & 2

1 DevelopmentStage

Phase: 1 Phase: 2 Phase: 3

2 Capacity 74287 MT 170004 MT 128441 MT

3 Period of Operation

April 1998to January 1999

February 1999 to October 2001

October 2001 to February 2003

4 Total Cost (Rs. in Crore)

0.93 1.66 0.81

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SECURED LANDFILL FACILITY

A new Cell (SLF No. 3) was constructed and was put on use in March 2003.Currently this cell is in operation.

SR. NO. PARTICULARS SLF - 3

1 Development Stage Phase: 4

2 Capacity 675000 MT

3 Commencement of Operation March 2003

4 Q tit f S lid W t D d J l 636319 045 MT4 Quantity of Solid Waste Dumped as on July2010

636319.045 MT

5 Total Cost (Rs. in Crore) 11.10

Thus the total capacity created for the safe disposal of solid waste is 1050000MT with an INVESTMENT of Rs. 14.50 CRORE.

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OPERATING COST OF SLFOPERATING COST OF SLF• Rs. 250 per MT of solid waste.

RATE OF CHARGING• Rs. 400 per MT of solid waste.

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ENVIRONMENTAL MONITORING

We have set up a full fledged Analytical Laboratory equipped with necessaryanalytical instruments and facilities. Qualified and trained personnel lookft th ti f SLF d l b tafter the operation of SLF and laboratory.

The monitoring includes the followings…

– Analysis of solid waste received at SLF and leachate.

– Ambient Air Quality Monitoring

– Monitoring of Ground Water Quality

Th d f ll f h b l i i d d d il blThe records of all of the above results are maintained and are made availableto the concerned authorities whenever required.

SPENT ACID MANAGEMENT(Centralized Industrial Waste Exchange and By-product Recovery Facility)

Spent sulphuric acid is generated in the industrial units involved in the manufacture of dyes, dye-intermediates and other chemicals where sulphuric acid or oleum are used as raw materials. Theconcentration of sulphuric acid in the spent acid is normally in the range of 10-30%. The individualindustries find it difficult to store, handle or treat it effectively. It was therefore decided to establish thisf i i i f O S AC A AG f i i i ifacility in the name of NOVEL SPENT ACID MANAGEMENT to carryout the following activities…

– Segregation and collection of spent acid received at site in different tanks depending on theconcentration of sulphuric acid and other properties.

– The colour less and concentrated spent acid will be directly supplied to the actual user to utilize it asa raw material in the process or as neutralizing agent in the treatment of wastewater.

– Part of the spent acid will be supplied to the manufacturers of ferrous sulphate, alum, single superphosphate etc.

The relatively dilute and reasonably colourless spent acid will be neutralized using hydrated lime for– The relatively dilute and reasonably colourless spent acid will be neutralized using hydrated lime forthe production of Gypsum which will be supplied to the cement manufacturing plants.

– The spent acid having colour and other contaminants will be neutralized with hydrated lime and theresulting sludge will be disposed of into Secured Landfill Facility.

– The wastewater generated as the filtrate will be treated in the ETP consisting of primary andsecondary treatment facilities and the effluent after treatment will be sent to CETP of GESCSL forfurther treatment and joint disposal.

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SALIENT FEATURES

Total Waste Handling Capacity 1.5 million liters / day

Average Acid Content 20 % wt. / wt. H2SO4

Waste to be Reused 0.5 to 0.8 million liters / day

Waste to be Converted to Gypsum 0.4 to 0.5 million liters / day

Saleable Gypsum Producedon Neutralization

Approx. 300 tones / day

Registered Members 130 (likely to go up to 200)

Total Project Cost Rs. 30 crore

Charging Pattern: Rs. 400 per MT up to 20 % AcidityRs. 20 per MT for every 1% acidity exceeding 20%

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ACHIEVEMENTS

The major achievement due to the implementation of the environmentalinfrastructure projects namely CETP and common SLF in the estate of Vatvais stoppage of discharge of industrial wastewater on land and open drains andprevention of water pollution in this area. This also gave clean and aestheticlook to the estate.look to the estate.

The other achievements of GESCSL associated with the establishment andoperation of these projects are as under…

– CETP is certified for ISO 9001:2008, ISO 14001:2004 and ISO 18001:2007 forprovisions of services for effluent collection, treatment and discharge.

– Secured Landfill Facility is certified for ISO 9001:2008, ISO 14001:2004 and ISO18001:2007 for provisions of services for collection and storage of solid waste.

– Winner of Golden Peacock Environment Management Awards 2010 & 2008.

– Winner of Greentech Gold Award 2008 and Silver Award 2007

ENVIRONMENT EXCELLENCE AWARDs

GOLDEN PEACOCK ENVIRONMENT MANAGEMENT

AWARD - 2010

GOLDEN PEACOCK ENVIRONMENT MANAGEMENT

AWARD - 2008

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Thank you