Pre Feasibility Report

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1 Pre Feasibility Report For 20 MLD Common Effluent Treatment Plant (ZLD) With Recycling of Treated Waste Water For Textile Processing Industries At TDK Green Enviro Private Limited Village Tadkeshwar, Taluka Mandvi Dist Surat, Gujarat 1

2 Table of Content Sr. No Description Page No. 1. Executive Summary 4 2. Introduction of the project/ Background Information Project proponent Description of the Project: Need for the project Demand Supply Gap Employment Generation due to the project Project Description Type of project including Location of the project Criteria for Site Selection Size or magnitude of operation Project description with process details Raw material requirement Resource optimization Availability and source of water, energy/power Schematic representations of the feasibility drawing which give information of EIA purpose Site Analysis Connectivity Land Form, Land use and Land ownership Topography Existing Infrastructure Soil Investigation Climatic data from secondary sources Planning Brief Planning Concept Amenities/Facilities Proposed Infrastructure 26 2

3 7. Project Schedule & Cost Estimates Project Schedule Estimated project cost Analysis of proposal Conclusion 28 Attachment 1. Process Flow Diagrams 3

4 1.0 Executive Summary Kim and Karanj region in Surat district near NH 8 (Ahmadabad-Mumbai National highway), Kim Char Rasta is rapidly growing textile cluster mainly consisting of weaving industries, yarn preparatory, Water Jet Looms and Yarn Dyeing. As an extension of these cluster adjacent villages of Molvan, Chammuchal and Tadkeshwar are rapidly growing in terms of Industrialization. Many Textile Industries are willing to set up Yarn Dyeing, Dyeing and Printing Units, and Denim Processing Units as raw materials for these units such as grey cloth is available in this region. In Surat District along with polyester processing, Cotton processing is also gaining momentum. These potential textile processing industries need raw water supply as well as a common facility for collection, treatment and recycling of waste water generated from these units. TDK Green Enviro Private Limited is proposing to set up common effluent treatment plant of 20 MLD Capacity in this region which will receive waste water generated from these textile processing industries through underground drainage network. This waste water will be provided primary, secondary and tertiary treatment so that treated waste water will be suitable for recycling back to textile processing industries for reuse in their industries. There are already proposals for settling up of textile / industrial park in this region namely, Yes Green Infra Pvt Ltd and Tadkeshwar Infra Pvt Ltd. Both of them have already shown their keen interest for becoming member of proposed CETP. In addition there are many small and medium scale yarn dyeing units in this region who are willing to become member of CETP. In proposed Kim and Karanj region industries are not allowed to discharge on surface water drain and they have to be on ZLD based. For small and medium scale industries installation and operation of ZLD system is a technically and economically non viable proposition. The proposed CETP which will be based on ZLD system will help textile processing industries in this region to grow and sustain. TDK Green Enviro Private Limited is a closely held public limited. The promoters of the company has experience to set up, operation and management of Textile Parks, Textile Units and Common Effluent Treatment Plant successfully. Proposed project is to be taken up at the site located at Block No 1163/1, 1163/2, 1163/3, 1164, 1171, 1175/1, 1175/2, 1178, Village Tadkeshwar, Taluka Mandvi, Dist Surat, Gujarat. The site is situated at a Latitude: 21 21'48.06"N, Longitude: 73 2'13.84"E. The nearest significant human settlement from the site is located at distance of approx 2 km from the site i.e. village Tadkeshwar in north-east direction. There are no ecologically sensitive areas like national parks, sanctuaries within 10 km radius of the site. The proposed project will have following major components Effluent Conveyance System (20 MLD Capacity) Common Effluent Treatment Plant (20 MLD Capacity) 4

5 UF+RO Plant for tertiary treatment (20 MLD Capacity) MEE Plant ( 2 MLD ) Recycle water pumping station and recycle water network Water required for operation of CETP will be taken from the recycle water source only. Electric power will be sourced from GSEB. Hazardous waste generated from plant will be sent to TSDF site for further disposal. Estimated cost of proposed project is Rs 180 Cr and is estimated to be completed in 24 Months time after receipt of Environmental clearance. Proposed CETP in the region will have following advantages and benefits 1. Existing local small and medium scale industries in the region can become member of CETP and give their waste water for treatment and recycling. Thus with the upcoming CETP in region compliance level of these industries will increase by many times. 2. Recycle water from the CETP to its member industries will reduce the extraction of ground water or use of surface water by the industries and there will be water conservation in the region. 3. There are upcoming textile parks in the region and proposed CETP will boost growth of textile industries in the region which will provide great boost for the direct and indirect employment in the region, development of ancillary industries in the region. 1.1 Regulatory Compliances & Applicable Laws/Regulations: Following will be applicable laws and regulations 1. The Water (Prevention and Control of Pollution) Act, (Amended 1988) 2. The Water (Prevention and Control of Pollution) Rules, The Water (Prevention and Control of Pollution) Cess Act, (Amended 1991) 4. The Water (Prevention and Control of Pollution) Cess Rules, Air (Prevention and Control of Pollution) Act, (Amended 1987) 6. The Air (Prevention and Control of Pollution) Rules The Environmental (Protection) Rules (Amended 2002) 8. The Environmental (Protection) Act, Hazardous Waste (Management, Handling and Transboundary Movement) Rules, Environmental (Protection) Rule Environmental Statement Environmental (Protection) Rule Environmental Standard Environmental (Protection) Rule Environmental Clearance Environmental (Protection) Rules Environmental Standard The Factories Act, The Motor Vehicle Rules, Rules 115 (2) 17. Noise Pollution (Regulation & Control) Rules

6 2. Introduction of the Project 2.1 Project proponent TDK Green Enviro Private Limited site located at Block No 1163/1, 1163/2, 1163/3, 1164, 1171, 1175/1, 1175/2, 1178, Village Tadkeshwar, Taluka Mandvi, Dist Surat, Gujarat. Project proponent has experience in establishment and operation of textile and industrial park and CETP successfully in the region. In order to promote the development of textile processing industries in the region and to support small and medium scale industries involved in yarn dyeing in the region, project proponents have proposed common effluent treatment plant based on ZLD and with recycling of treated waste water back to industries. 2.2 Description of the Project: The proposed project is for installation of common effluent treatment plant (CETP) of 20 MLD capacity based on Zero Liquid Discharge (ZLD). Treated waste water will be recycled back to industry for reuse as industrial waste water. 2.3 Need for the project Need for the project is described as under Kim and Karanj region in Surat district near NH 8 (Ahmadabad-Mumbai National highway), Kim Char Rasta is rapidly growing textile cluster mainly consisting of weaving industries, yarn preparatory, Water Jet Looms and Yarn Dyeing. As an extension of these cluster adjacent villages of Molvan, Chammuchal and Tadkeshwar are rapidly growing in terms of Industrialization. Many Textile Industries are willing to set up Yarn Dyeing, Dyeing and Printing Units, and Denim Processing Units as raw materials for these units such as grey cloth is available in this region. In Surat District along with polyester processing, Cotton processing is also gaining momentum. These potential textile processing industries need raw water supply as well as a common facility for collection, treatment and recycling of waste water generated from these units. There are two to three textile parks are already approved in the region. For the development of these textile parks facility of Common Effluent Treatment Plant is needed in the region. 2.4 Demand - Supply Gap. Kim and Karanj area consist of many textile industries such as weaving, yarn preparatory, yarn dyeing etc. In these area atleast two textile park which is proposed to consist of textile processing industries are aalready approved. A common effluent treatment plant (CETP) in this area is need of time for the sustainable development of existing industries as well as for further development of textile processing industries in this region. Since in this region disposal of treated waste water is not allowed, CETP based on ZLD is must which will comply with the norms and will also recycle treated waste water back to industry. 2.5 Employment Generation due to the project. 6

7 With the proposed CETP project there will be development of at least textile processing industries in the region which will provide direct and indirect employment generation in the region. It is estimated that proposed project will generate 75 direct employment at CETP level and about 3000 indirect employment. Additionally development of textile processing industries in the region will result in development of small scale ancillary industries which will generate additional indirect employment. 7

8 3. Project Description: 3.1 Type of project : The proposed project is 20 MD Capacity Common Effluent Treatment Plant based on ZLD with recycling of treated waste water for textile processing industries. 3.2 Location of the project: Proposed project is to be taken up at the Block No 1163/1, 1163/2, 1163/3, 1164, 1171, 1175/1, 1175/2, 1178, Village Tadkeshwar, Taluka Mandvi, Dist Surat, Gujarat. The site is situated at a Latitude: 21 21'48.06"N, Longitude: 73 2'13.84"E. 8

9 3.3 Criteria for Site Selection: Kim and Karanj region in Surat district near NH 8 (Ahmadabad-Mumbai National highway), Kim Char Rasta is rapidly growing textile cluster mainly consisting of weaving industries, yarn preparatory, Water Jet Looms and Yarn Dyeing. As an extension of these cluster adjacent villages of Molvan, Chammuchal and Tadkeshwar are rapidly growing in terms of Industrialization. Many Textile Industries are willing to set up Yarn Dyeing, Dyeing and Printing Units, and Denim Processing Units as raw materials for these units such as grey cloth is available in this region. The proposed site is in vicinity to existing yarn dyeing units and proposed upcoming textile park in the region. 3.4 Size/Magnitude of operation Summary of proposed expansion of existing CHWTSDF is tabulated as under Sr No Project Component Total Capacity 1 Common Effluent Treatment Plant (ZLD 20 MLD Based) 9

10 3.5 PROCESS DETAILS / PROJECT COMPONENTS: The proposed CETP will have ultimate capacity of 20 MLD which will be developed in phase wise manner of 20 MLD capacity each phase. Development of CETP will be on modular basis. CETP will be designed for zero liquid discharge (ZLD). Entire treated waste water will be recycled back to member industries Effluent Quantity CETP is designed for Effluent Quantity of 20 MLD Effluent Characteristics Effluent characteristics considered for design at the inlet of CETP is tabulated in Table 1 as under Table 1: Effluent Characteristic at the inlet of CETP Sr. No. Parameter Unit Values 1 ph ph Unit 5.5 to COD mg/l BOD, 3 days 27 C mg/l Oil and Grease mg/l 50 5 TDS mg/l Suspended Solids mg/l 300 Following considerations are taken while fixing the inlet design parameters for the CETP. The proposed member industries will be textile processing units, yarn dyeing unit, weaving unit or allied textile units only and will not have any other chemical synthesis or pharmaceutical industries. The inlet effluent parameters considered above in Table 1 is in line with the average effluent characteristics found in textile dyeing and printing or textile processing industries. All industries will be required to provide following facility at their discharge point before connection to the drainage system of the CETP o Oil and Grease Trap o Fixed type screen with Screen chamber o Equalization Tank of Min 6 Hours Retention Time o ph correction and Primary Settling Tank if Suspended Solids are more than o 300 mg/l Pump for pumping effluent into conveyance system 10

11 o Outlet Flow Meter (Magnetic type or Open channel type) with recorder system with temper proof provision. No high TDS Effluent (i.e. more than 3000 mg/l) will be discharged into CETP drainage line Treated Effluent Characteristics Treated Effluent Characteristics from the Zero Liquid Discharge Plant (ZLD) which will be recycled back to industries is tabulated under in table 2 Table 2 Treated Effluent Characteristic from ZLD Plant (to be recycled back to industries) Sr. No. Parameter Unit MPCB Norms 1 ph Temperature C Ambient at Discharge Point 3 BOD3days27C mg/l <30 4 Turbidity mg/l NIL 5 COD mg/l < Oil and Grease mg/l < Dissolved Solids (Inorganic) mg/l < Total Residual Chlorine mg/l < Ammonical Nitrogen (as N) mg/l < 5 10 Arsenic (as As) mg/l < Mercury (as Hg) mg/l < Lead (as Pb) mg/l < Cadmium (as Cd) mg/l < 1 14 Chromium Total (as Cr) mg/l < 2 15 Copper (as Cu) mg/l < 3 16 Zinc (as Zn) mg/l < 3 17 Selenium (as Se) mg/l <

12 18 Nickel (as Ni) mg/l < 3 19 Cyanide (as CN) mg/l < Fluoride (as F) mg/l < 2 21 Sulphide (as S) mg/l < Phenolic Compound (as C6H5OH) mg/l < Hexavalent Chromium (as Cr +6) mg/l < Pesticides mg/l Absent 25 Boron (as B) mg/l < 2 26 Chloride mg/l < Sulphate (as SO4) mg/l < Mode of Disposal There shall not be discharge from the CETP.Entire treated waste water will be recycled back to member industries Treatment Scheme Screening through Coarse Screen Collection and Transfer to Equalization Tank Oil and Grease Removal System Fine Screening Equalization provided with Air Mixing Treatment with Lime solution to raise ph to 8.5 in Flash Mixer 1 Treatment with Ferrous Sulfate / alum solution to bring down ph to 7 in Flash Mixer 2 Flocculation using Polyelectrolyte in flocculator Gravity settling in Primary Clarifier Biological Treatment Using SBR (Cyclic Activated Sludge Process) Disc Media Filter Treatment to achieve Zero Liquid Discharge (ZLD) o UF Plant (As pretreatment) 12

13 o RO Plant ( 3 stages) to achieve to 90 to 92% Recovery o RO Reject treatment through Pellet Reactor / MVR / Multiple Effect Evaporator o Recycle of recovered water. o Recovered salt to dispose to TSDF site Sludge dewatering (Primary and Biological sludge, segregated) through Mechanical Sludge Dewatering system Process Description Receipt, Screening and Equalization Effluent will be received at CETP through underground effluent conveyance system. Effluent will be first pass through Coarse Screen for removal of large particles and debris presence in effluent. Coarse screen is installed in Coarse Screen Chamber. Coarse screen will restrict particles of 20 mm and above size. Coarse screen will be L-type screen and such two screens will be provided in series. In order to remove debris or particles collected on coarse screen, it is periodically taken out from screen chamber using EOT hoist. From Coarse screen chamber effluent is passed through grit chamber, in which grit will settle at the bottom of the grit chamber and through grit removal mechanism it will be removed from the bottom of the chamber. From Grit Chamber effluent is collected in underground Receiving Sump. From Effluent Receiving sump waste water is pumped using Effluent Feed Pump to the pre settler cum oil and grease removal system. From here effluent will enter into Fine Screen. Operation of Effluent Feed Pump will be automatic using level switch installed in Receiving Sump. Fine screen is installed in fine screen chamber. Mechanical type fine screen is provided to restrict particles up to 10 mm size. As a standby to mechanical type fine screen, fixed type fine screen is also provided. Particles collected on fine screen is transferred mechanically on belt conveyor for collection. Effluent from fine screen is then collected in Equalization Tank. For successful plant operation it is very essential to have uniform quality and quantity of effluent available to feed for treatment. Equalization tank is provided to take care of variation in effluent quality and quantity. Equalization tank is provided with 8 hours hydraulic retention time. Equalization tank is provided with coarse bubble air diffusers for complete mixing of waste water using air from Air. Complete mixing will also help to avoid settlement of suspended particles in Equalization tank bottom which in long turn reduces tank operating condition and develop septic condition at the bottom of equalization tank. Equalization tank is provided with level indicator and transmitter for measurement of level and volume of effluent in the tank. Equalization tank is also provided with ph meter for indication and recording. Physico Chemical Treatment and Primary Clarification Equalized effluent from Equalization Tank is transferred to Physico Chemical Treatment Section of the CETP using effluent feed pump. Effluent feed pump discharge line is provided 13

14 Magnetic Type Flow Meter with Recorder for control, monitoring as well as recording of effluent treated in the plant. Physico Chemical Treatment Plant will consists of treatment of waste water using chemicals and flocculants mainly to precipitate, flocculate and coagulate part of waste water components and to remove this mass by using gravity settling in primary clarifiers. During physico chemical treatment suspended solids, precipitated dyes molecules and soluble oil particles are removed which reduces load on biological treatment. Effluent from Effluent Feed Pump is first taken to two series of Flash Mixers 1 & 2 for the reaction of Effluent with lime slurry and then ferrous sulfate or Alum solution. The ph of effluent is raised in the range of 8.5 to 9.5 using lime slurry in Flash Mixer 1. Effluent from Flash Mixer 1 is then taken to Flash Mixer 2 where Ferrous Sulfate is added to carry out flocculation and coagulation of suspended and precipitated particles. Dosing of lime solution and ferrous sulfate solution is automatically controlled through on line ph meter and controller system provided for flash mixer 1 and flash mixer 2. From Flash Mixer 2 effluent is taken to Flocculation zone of Clariflocculator where suitable polyelectrolyte shall be added to increase settling rate of flocculated and coagulated mass. Two flash mixer is series followed by flocculator will ensure complete reaction of lime slurry and ferrous sulfate / alum solution with effluent to achieve desired result before effluent enters into Clarification zone of Primary Clariflocculator. Here, separation of precipitated solids from the waste water by settling under gravity. Clear overflow from primary clariflocculator is conveyed to Aeration tank for biological treatment. Settled sludge at the bottom of the clariflocculator is transferred to Primary Sludge Sump. Cyclic Activated Sludge Process / SBR provides highest treatment efficiency possible in a single step biological process. The System is operated in a batch reactor mode. This eliminates all the inefficiencies of the continuous processes. A batch reactor is a perfect reactor, which ensures 100% treatment. Four modules are provided to ensure continuous treatment. The complete process takes place in a single reactor, within which all biological treatment steps take place sequentially. No additional settling unit, Secondary Clarifier is required. The complete biological operation is divided into cycles. Each cycle is of 3 5 hrs duration, during which all treatment steps take place. Explanation of Cyclic Operation: Abasiccyclecomprises: Fill Aeration (F/A) Settling (S) Decanting (D) These phases in a sequence constitute a cycle, which is then repeated. ATypicalCycle 14

15 During the period of a cycle, the liquid is filled in the Aeration basin up to a set operating water level. Aeration Blowers are started for aeration of the effluent. After the aeration cycle, the biomass settles under perfect settling conditions. Once settled the supernatant is removed from the top using a overflow decanting system (Decanter). Solids are wasted from the tanks during the decanting phase. These phases in a sequence constitute a cycle, whichisthenrepeated. 15

16 Treated waste water from SBR process is taken to tertiary treatment plant for further treatment. Tertiary Treatment Clear wastewater after biological treatment shall be subjected to tertiary treatment. The tertiary treatment consists of Disc Media filter. Effluent from biological treatment shall is collected in intermittent storage tank. From here effluent is further subjected to treatment through disc media filter which removes suspended solids so that final treated waste water meets the feed norms for UF+RO plant. Back wash from Disc Filter is taken back to waste water Receiving sump for further treatment. Treated effluent from disc media filter is collected in Holding tank. Treated effluent from here is fed to ZLD plant consisting of UF+RO+Evaporation (MVR+MEE) system. Separate Magnetic type flow meter is provided at the outlet of feed pump to RO system for recording and monitoring of treated waste water discharged to ZLD plant. Sludge Dewatering System Sludge slurry from bottom of clariflocculator is collected in primary sludge sump and excess bio mass from secondary clarifier is collected in bio sludge sump. From both the sludge sump, sludge slurry is pumped through screw / gravity thickener for thickening of the sludge slurry. Thickned sludge is collected in thickened sludge tank. From here thickned sludge is fed to mechanical sludge dewatering system (Filter Press / Belt Press) using screw pumps. Here sludge shall be filtered and collected in form of wet cake. Filtrate generated from filter press shall be taken back at the inlet of primary clarifier. Cake from sludge dewatering system is stored in sludge storage area for disposal to TSDF site. ZLD Plant Zero Liquid Discharge Plant consist of Ultrafiltration (UF) and Reverse Osmosis Plant followed by Thermal evaporation System (MVR+MEE). Tertiary treated effluent is fed to first Ultrafiltration (UF) Plant as pretreatment to Reverse Osmosis (RO) Package Plant. UF Plant removes turbidity and any left out colloidal matters before effluent is fed to RO plant for desalination. UF Plant reject is fed back to equalization tank for further treatment. RO packaged unit is designed to handle 20 MLD treated waste water. RO Packaged system is designed based on modular basis. The number of modules will be decided during detailed engineering with selected vendor. RO Packaged plant consists of 2/3 stage RO system (depending on final design by vendor) to achieve Min 90% recovery of water and overall salt rejection at Min 90%. RO package system consist of RO pretreatment unit. RO pretreatment unit consists of Chemical Dosing such as Acid Dosing, SMBS Dosing and Antiscalent Dosing for controlling the various types of fouling in the membranes. In addition to chemical dosing RO treatment will consist of micron filters (Bag type of disposable type) to maintain acceptable turbidity level for the RO membranes. After pretreatment section, waste water is pumped at high pressure (as per the TDS level of the effluent) to RO membrane modules. Reject from RO system is stored in RO reject storage tank. From this tank RO reject is fed to Thermal Evaporation System consisting of MVR and MEE. The expected salt level in the feed of thermal evaporation system is 3 to 3.5% w/w. Thermal System consist of MVR (Mechanical Vapor Recompression) system. Here evaporation process is conducted under vacuum at temperature of approx 60 deg C. 16

17 Evaporated water vapor is recompressed using compressor to raise temperature of vapor at approx 70 deg C. This vapor is again fed as heating medium to system for evaporation of waste water at about 60 deg C. Heat transfer surface can be of plastic media / metallic media depending of final engineering of the system. Concentrated mass from MVR is subjected to crystallization for precipitation of salts. Sometime along with MVR, MEE is also provided for final concentration of liquid up to 35% salt concentration. Such MEE can be 3 or 5 effect MEE depending on final engineering of the process. Concentrated mass from the final stage is taken out and fed to in built / separate crystallizer for cooling and crystallization of precipitated salts. Crystallized mass is fed to Pusher type centrifuge for separation of salts from the mother liquor. Mother liquor is recycled back to MEE system for evaporation. Salts are collected and sent to hazardous waste storage area for disposal to TSDF site. Condensate collected in condensate storage tank is recyclable water. However, there may be chance of carryover of color along with condensate. In order to take care of such incidence polishing filter consisting of activated carbon filter is provided. After polishing treatment, condensate is transferred to Disposal tank. From Disposal tank water is available for recycling to industries. Utilities Following utilities is required for the operation of CETP. Boiler Saturated steam is required for the evaporation of effluent in MEE system. For generation of saturated steam coal fired boiler of 20 Tons/hr capacity for of 8 kg/cm2 g rating is provided 17

18 in the plant. Coal Fired Boiler system will be fluidized bed type / fixed bed type. The boiler system will consist of Boiler Feed Water Tank, Boiler Feed Water Pump, Boiler with coal fired furnace, Air pollution control system consisting of ESP and ID Fan with Stack. Suitable water treatment plant is also provided as per the requirement of boiler feed water. Cooling Tower Induced draft cooling tower with cooling water circulation pumps are provided for supply of cooling water for MEE system, surface condensers and other misc requirement in MEE system. Cooling Tower system will consist of cooling tower with cooling tower fan, cooling water circulation pumps, piping and valves, cooling tower chemical dosing system and side stream filter. Instrument Air System Instrument air compressor with dryer system is required for MEE system, control valves. Instrument air system shall consists of instrument air compressor with dryer, air receiver tank, piping and valve. Electrical 11/22/33 KVA power will be received at site. This power will be first fed to HT Panel and then step down to 440 V in step down transformer. From transformer LT power is fed to PCC panel. PCC Panel will distribute power to MCC panels for CETP stream 1, CETP stream 2, RO Plant I and II, MEE Stream 1 and MEE stream 2, Boiler and plant and domestic lighting. 18

19 3.5.6 Site Infrastructure Following infrastructure is proposed to be provided at site other than plant as described above 1. Entry & Exit 2. Haz Waste Storage Area 3. Coal Storage Yard. 5. Administrative Building 6. DG Sets 7. Plant Internal Road 8. Green Belt on periphery of the plant. 9. Safety equipments / Fire Fighting Equipments 10. Site Security & Surveillance 11. Laboratory and Pilot Plant Environment Management and Pollution Control 1. Air Pollution Control 2. Sr No Sources of Air Pollution 1 Boiler, 20 T/hr Capacity Fuel Used Coal (Imported) 90 Tons/Day Mitigation Measures APC system consisting of Cyclone Separator, ESP Stack / Vent 30.5 M high Pollutants PM, SOx, NOx 19

20 2 DG Set (Emergency Power Supply): 750 KVA x 3 Nos 3 Coal Dust from Coal Storage Yard 4 Fly Ash Dust from Fly Ash handling system LDO Nil 10 M high Coal storage yard to be provided with 10 M high GI Sheets cover on periphery along with Water Sprinkling system for dust supression Enclosed fly ash handling system with fly ash silo and exhaust connected to Fly Ash Bag filter 10 M High PM, NOx PM PM SOx, 2. Water Pollution Sr No Sources of Waste Water Generation 1 Cooling Tower Blow Down Total Quantity Treatment Scheme 50 KL/Day ZLD Based CETP consisting of RO+MEE Mode Disposal of Recycled back as make up water 2 Boiler Blow Down 15 KL/Day ZLD Based CETP consisting of RO+MEE Recycled back as make up water 3 Water Treatment Plant 15 KL/Day ZLD Based CETP consisting of RO+MEE Recycled back as make up water 4 Domestic 20 KL/Day Packaged STP Irrigation / Green Belt Development / Dedusting application for road 20

21 3. Hazardous Solid Waste Management The detail of Hazardous Waste Management System is as under Cat. No. Solid / Hazardous Waste Hazardous Waste Source of Waste Generation Quantity Disposal 34.3 CETP Sludge From CETP- Chemical Sludge 5.1 Used Oil Plant & Machinery 33.3 Used drums /barrels /containers /bags / liners containers / barrels / liners Along with waste 50 MT/Day Disposal to Secured Land Fill Site / Cement co-processing as Gypsum sludge 50 Liters/Year Collection / Storage / Transportation / sent to registered recycler / reuse as a lubricant / Incineration - Storage, Cleaning, sell to authorized recycler / To CHTSDF site 37.3 MEE Salts From MEE 80 MT/Day Reuse/Recycle as salt (based on feasibility) / Disposal to Secured Land Fill Solid Waste CETP Sludge Bottom Ash / Fly Ash from Coal Boiler Biological sludge 20 MT/Day Cement Co-Processing Coal Boiler 12 MT/Day Cement Co-Processing / Land Use / Brick Manufacturer / Construction agregate 4. Noise Pollution Noise pollution in CETP is generated mainly from Air Blowers used for Equalization and Aeration Tank and various ID/FD Fans used for due to rotary machinery such as pumps and blowers in the CETP plant. Noise level in this machinery shall be maintained under control while selection of equipment, provision of acoustic enclosure, where ever required. Where ever required isolation room shall be provided. Operators and plant persons shall be provided with suitable PPEs while working near these machineries. Preventive maintenance schedule shall be maintained to ensure that noise generation in the plant is within level. Green Belt provided in periphery of the plant shall be useful for reduction of noise level outside the premises. 21

22 3.6 Raw Material Consumption The proposed is being a Common Effluent Treatment Plant, effluent from industry is major input to the facility. Following are major other chemicals used in the proposed facility Sr Name of Chemical Projected Consumption No 1 Hydrated Lime 10 TPD 2 Ferrous Sulfate 5 TPD 3 Poly Electrolyte 50 Kg/Day 4 DAP and Urea (Commercial) 200 Kg/Day 5 Boiler/Cooling tower/ RO Plant / MEE Chemicals As required, Max 500 Kg/day all together 3.7 Resource Optimization: The proposed project is designed based on zero liquid discharge (ZLD). Entire treated waste water will be recycled back to industries for reuse in the process. Thus the proposed project will not only aimed to provide treatment of waste water but will also conserve natural resource water by recycling treated waste water back to industry. Additionally proposed project will also provide sludge drying system to reduce quantity of moisture in sludge. Sludge will be sent for cement co-processing on acceptance of same by cement industries. Fly Ash collected from boiler will be sold / sent outside to brick manufacturers or for construction / land fill application. 3.8 Availability and source of water, energy/power Water Water balance for the facility is provided as under. Water required for plant operation will be sourced from treated water only. Sr No Water Quantity Waste Water Quantity consumption Generation 1 Industrial Cooling Water 600 KL/Day Cooling Tower 50 KL/Day Make Up Blow Down Boiler Make Up 400 KL/Day Boiler Blow Down 15 KL/Day Water Treatment 15 KL/Day Plant 2 Domestic 25 KL/Day Domestic 20 KL/Day 3 Gardening 20 KL/Day 22

23 Total industrial water required for the proposed facility is 1000 KL/Day. This will be obtained from the treated waste water from the plant. Treated sewage will be used for green belt development. Domestic water of 25 KL/Day will be sourced from the ground water source. Power Total Power Required for the proposed facility is 2000 KVA. Fuel Consumption Coal is used as fuel for the steam boiler. LDO is used as fuel for DG set for emergency operation only. Sr No Equipment Fuel Consumption 1 Steam Boiler Coal 90 TPD 2 DG Set (750 KVA x 3) LDO 300 Lit/Hr 3.9 Schematic Representation of Drawing Kindly refer Annexure 1 for schematic flow diagram 23

24 4.0 Site Analysis 4.1 Connectivity Sr No Feature Place/ Distance 1 Project Location Latitude: 21 21'48.06"N, Longitude: 73 2'13.84"E. 2 Nearest City Surat,30 Kms 3 Nearest Railway station Kim, 12.0 Kms 4 Nearest Airport Surat, 30 Kms 5 Nearest village Tadkeshwar 6 National highway NH-8 10 KM on West 7 River Tapi apprx.7.5 KM in SW 4.2 Land form, land use and land ownership The proposed site at present is owned by promoters. At present no crop is taken on this land. The proposed land will be converted to NA land before execution of the project. 4.3 Topography The land at the project area is mostly fine clay to clay loam with moderated to high water capacity. Various crops are being grown in surround the project area like Banana, vegetables, sugar cane, rice etc. The project area is mostly covered with crop land and by fallow scrubs and bushes. As there are some industrial cluster in vicinity of proposed site such as Kim, Karanj, Chamucchal and Lindiyad, the area is well built up area. There is no any sanctuary or national park with in 10 KM radius of the proposed project sites. 4.4 Existing Infrastructure Existing infrastructure such as road and rail, connectivity as described above is adequate for the proposed project. 24

25 4.5 Soil Investigation Soil in this area is fine texture, moderate to goof water holding capacity, moderate to slow permeability. Soil in this area is moderate to good for agriculture 4.6 Climate data from secondary sources Climate wise, the year can be broadly divided into (i) (ii) (iii) (iv) Winter Season (November to February) Summer Season (March to May) South-West Monsoon Season (June to September) Transition Month (October) Winter is the most pleasant season in the area. Clear blue skies with stray high clouds, occasional light cool winds blowing towards South - West direction are the characteristics of the season. In January and February, light breeze prevails in the afternoon. Mornings are chilly and during nights, temperature often drops below 10 C. January and December are the coolest months. April and May are the hottest months, May being the hotter of the two. The heat is sometimes oppressive. The maximum temperatures exceed 40 Concertain extreme days. The South - West monsoon sets in by about the second week of June. South westerly winds blow from May and last till the end of September. About 95 % of the annual rainfall in the area occurs during the months of June to September. The normal annual rainfall is 2000 mm. The average number of rainy days is about 40 days. The monsoon withdraws towards the end of September and temperature rises temporarily during October. 25

26 5. Planning in Brief: 5.1 Planning Concept The proposed facility is Common Effluent Treatment Plant of 20 MLD Capacity designed for the treatment of industrial waste water from the textile processing industries. The project is designed based on Zero Liquid discharge (ZLD). Treated waste water will be recycled back to industries for further use. The entire project will consist of components such as effluent conveyance system up to inlet of CETP, Common Effluent Treatment Plant including RO and MEE System, Utilities such as Boiler, cooling tower and electric station, and recycling waste water pumping station and pipeline for supply of treated waste water back to industries. 5.2 Amenities/Facilities: Following will be major components of the projects 1. Effluent conveyance system of 20 MLD Capacity 2. CETP with RO and MEE for treatment of 20 MLD waste water 3. Coal fired steam boiler of 20 T/hr capacity, Coal storage Yard and Ash Handling system 4. Cooling towers, compressed air system, DG sets and Plant lighting 5. Plant internal roads and sheds. 6. Fire hydrant system. 7. Green Belt 26

27 6. Proposed Infrastructure Proposed infrastructure consists of project components as mentioned above in point no 5 will be created at the proposed site including effluent conveyance system and recycle water conveyance system. Facility will also consist of storm water management system, Environmental Management System and Power Supply System as described in this report. 27

28 7. PROJECT SCHEDULE & COST ESTIMATES: 7.1 Project Schedule: 7.2 Estimated project cost Summary of Project Cost Sr No Plant Section Rs in Lacs 1.1 Effluent Conveyance System CETP (20 MLD) RO (20 MLD) MEE (2 MLD) Recycling Network A Total CETP

29 8. ANALYSIS OF PROPOSAL: 8.1 CONCLUSION: Kim and Karanj area in Surat District is a growing textile cluster and need a Common Effluent Treatment Plant for sustainable development of the area. Industries in this area is dependent on ground water supply and if CETP based on 100% recycling is established in this area, it will not only result in ensured treatment of waste water generated from these industries bit will also largely reduce the exploration of ground water by industries in region. Also with the establishment of CETP in this region there will be more growth of industries in region resulting direct and indirect employment, development of small scale ancillary industries in the region. Overall proposed CETP in this region will have positive impact with respect to environment and socio economic development. 29

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