ZERO LIQUID DISCHARGE (ZLD) PLANTPONDY API UNIT

2

ZLD FLOW DIAGRAM

PRE-TREATMENT

BIO-TREATMENT - I

STRIPPER

MULTIPLE EFFECT EVAPORATOR (2FFE &

3FCE) / PUSHAR CENTRIFUGE

RO - IBIO-TREATMENT - II

ATFD - 2 Nos.

RO - IIIRO - II

HIGH TDS PROCESS EFFLUENT

PERMEATE REUSE

LOW TDS EFFLUENT

PERMEATE REUSE

SLUDGE FOR DISPOSAL

REJECT

REJECT

REJECT

PERMEATE

CONDENSATE

SLUDGE FOR DISPOSAL

SLUDGE FOR DISPOSAL

SEWAGE TREATED EFFLUENT WATER

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ZLD - DESCRIPTION

Treatment Scheme for Effluent Treatment and Zero Liquid Discharge (ZLD)

Low Pollutant Stream (LPS):

Low Pollutant Stream is separately collected in the Equalisation tank and then subjected to Physico-chemical treatment for neutralisation and suspended solid separation. The Physico-chemical treatmentconsists of neutralisation, flash mixing, flocculation cum primary clarification and is sent to BiologicalTreatment Plant-II (BTP-II) and treated along with domestic waste water.

The BTP-II consists of two stage aeration (Primary & Secondary) treatment with Aeration tank-1 followedby Bio-Clarifier -1 and Aeration tank-2 followed by Bio-Clarifier -2. The bio-clarifier overflow water goesto tertiary clarifier and then to Filter feed tank. From Filter feed tank, it is fed to Pressure sand filter (PSF)and Activated Carbon Filter (ACF). ACF treated water is taken to RO Plant –II for further treatment.

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ZLD - DESCRIPTION

High Pollutant Stream (HPS) :

High Pollutant Stream predominantly from process is separately collected in the Equalisation tank alongwith reject of Reverse Osmosis Plant III (RO III) and then subjected to Physico-chemical treatment forneutralisation and suspended solid separation. The Physico-chemical treatment consists ofneutralisation, flash mixing, flocculation and primary clarification.

The physico chemical treated water is taken to Stripper/ Multiple Effect Evaporator (MEE) plant forevaporation / concentration. The concentrate from MEE is further concentrated to a dry solid in AgitatedThin Film Dryer (ATFD). The evaporated condensate from MEE and ATFD are taken for further treatmentin Biological Treatment Plant –I (BTP-I). The concentrated chemical sludge from ATFD is disposed toauthorised co-processer for cement industry / authorised Secured Land Fill (SLF)site.

The BTP-I consists of two stage aeration (Primary & Secondary) treatment with Aeration tank-1 followedby Bio-Clarifier -1 and Aeration tank-2 followed by Bio-Clarifier -2. The bio-clarifier overflow water goesto Tertiary clarifier followed by Filter feed tank. From Filter feed tank, it is fed to Pressure Sand Filter(PSF) and Activated Carbon Filter (ACF). The filtered treated water is taken to RO Plant - I for furthertreatment.

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ZLD - DESCRIPTION

Reverse Osmosis Plants (RO I, RO II & RO III):

The treated water from Biological treatment plant – BTP I & II are processed through RO-I & II respectively and the permeate water from the RO is recycled through non process / process applications.

The reject from the RO I & II are fed to RO III for further recovery of water. Permeate from RO III is used for non process application / recycled as feed to RO II. Reject from RO III is sent to Multiple Effect Evaporator (MEE) for further processing.

The permeate water from the RO meets the potable water specification on all physio chemical analysis.

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HPS – FLOW DIAGRAM

OIL SKIMMER

EQUALIZATION NEUTRALIZATIONPRIMARY CLARIFIER

HPS EFFLUENTTO MEE

FEED TANK

TO PRIMARY

SLUDGE TANK

HPS EFFLUENT PRE TREATMENT

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MEE FLOW DIAGRAM

STRIPPER

PRE-HEATER FFE - I FFE - II FCE - I FCE - II FCE - IIIMEE FEED TANK

LP STEAM

HIGH COD CONDENSATE

THICKENER HYDROCYCLONE

PUSHAR CENTRIFUGE

ML TANK

VTFD - IIVTFD - I

HP STEAM

RECIRCULATION

SALT FOR DISPOSAL

CONDENSATE TANK

CONDENSATE

CONDENSATE

CONCENTRATE

TVR

RO III reject

HPS Primary treated Effluent

TO BTP - I

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HPS – FLOW DIAGRAM

CONDENSATE TANK

BIO -REACTOR - I

BIO -CLARIFIER - I

PRIMARY SLUDGE

TANK

FILTER FEED TANK

PSF

BIO -REACTOR - II

BIO -CLARIFIER - II

TERITARY CLARIFIER

ACF

BIO SLUDGE

TANK

BIO-SLUDGE THICKENER

SLUDGE FOR DISPOSAL

TO RO I FEED TANK

DECANTER CENTRIFUGE

DECANTER CENTRIFUGE

PRIMARY SLUDGE

THICKENER

SLUDGE FOR DISPOSAL

SLUDGE FROM HPS PRIMARY CLARIFIER

SLUDGE

SLUDGE

CONDENSATE FROM MEE / ATFD

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LPS – FLOW DIAGRAM

OIL SKIMMER

EQUALIZATION NEUTRALIZATIONPRIMARY CALRIFIER

BIO -REACTOR - I

BIO -CLARIFIER - I

FILTER FEED TANK

PSF

BIO -REACTOR - II

BIO -CLARIFIER - II

TERITARY CLARIFIER

ACF

LPS EFFLUENT

TO RO II FEED TANK

TO BIO SLUDGE TANK

TO PRIMARY SLUDGE TANK

STEW

SLUDGE

Non process Effluent

Domestic Effluent

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ZLD – MEE PLANT

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ZLD - BIOLOGICAL TREATMENT PLANT

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ZLD - RO PLANT

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