PRE FEASIBILITY REPORT PROPOSED EXPANSION OF COMMON EFFLUENT TREATMENT PLANT (CETP) (0.8 MLD TO 3 MLD)

Transcription

1 PRE FEASIBILITY REPORT FOR PROPOSED EXPANSION OF COMMON EFFLUENT TREATMENT PLANT (CETP) (0.8 MLD TO 3 MLD) AT SURVEY NO. 467, PHARMEZ- SPECIAL ECONOMIC ZONE, SARKHEJ-BAVLA ROAD, NH-8, VILLAGE MATODA, TALUKA SANAND, DISTRICT AHMEDABAD-RURAL, GUJARAT BY M/S. ZYDUS INFRASTRUCTURE PVT. LTD.

2 EXECUTIVE SUMMARY OF THE REPORT M/s. Zydus Infrastructure Private Limited is planning expansion of existing Common Effluent Treatment Plant (CETP) from 0.8 MLD to 3 MLD, located at Pharmez Special Economic Zone, Sarkhej- Bavla Road, NH-8 A, Village Matoda, Taluka Sanand, District Ahmedabad, Gujarat. No Defense Installation, Biosphere Reserve, National Park/Wild Life Sanctuary and Ecologically Sensitive Area within 10 km radius. Expansion will be carried out in open space available within premises and no additional land will be acquired. Total area of the project is m 2 out of which m 2 area will be utilized for the proposed expansion from m 2 of open area. PROJECT COST Cost of the proposed project would be around Rs. 5,000 Lacs. REQUIREMENTS FOR THE PROJECT Land: Around m 2 land area from total existing land area i.e m 2 will be unitized for the expansion project. Water: Total water requirement for the proposed expansion project will be approximately 158 KLD during operation phase and will be sourced from CETP treated water for reuse but for the domestic purpose ground water is/will be utilized through bore well. Fuel: For the proposed expansion project total fuel 550 lit/hr i.e. FO/HSD/LDO will be required for the D.G. sets and boiler which will be purchased form nearest petrol pump in drum and transported by road only. Manpower: The proposed expansion project will be required total employment approximately 40 persons. WASTE WATER GENERATION AND ITS TREATMENT:- The proposed expansion project of M/s. ZIPL CETP is treating total industrial effluent of member units in Pharmez SEZ, industrial effluent is collected by the tankers and scientifically treatment is carried out in CETP by latest technology prevailing. Further, treated water is given to member units for reuse. The quantity of sludge and MEE salt generated during the treatment is sent to TSDF for land filling, the same practice will be followed in proposed expansion also. NOISE POLLUTION AND CONTROL MEASURES: Following noise control measures to be adopted in the proposed project: 1. Noise is/will be generated from transportation of effluent, motors and D. G. sets which are minimal an D. G. set is for the emergency purpose which is/will be controlled by regular maintenance and development of greenbelt all along the boundary walls. 2. Temporary noise will be generated during construction due to movement of vehicles. GREEN BELT DEVELOPMENT Around m 2 area i.e. more than 33 % of total plant area is/shall be developed as green belt at plant boundary, road side, around offices & buildings.

3 CHAPTER NO. INDEX CONTENT 1 INTRODUCTION OF THE PROJECT 1 2 PROJECT DESCRIPTION 2 3 SITE ANALYSIS 7 4 PLANNING BRIEF 9 PAGE NO. 5 PROPOSED INFRASTRUCTURE 11 6 REHABILITATION AND RESETTLEMENT (R & R) PLAN 12 7 PROJECT SCHEDULE & COST ESTIMATES 13 8 ANALYSIS OF PROPOSAL 14

4 CHAPTER 1 INTRODUCTION OF THE PROJECT 1.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT M/s. Zydus Infrastructure Pvt. Ltd. (ZIPL) is having CETP and is engaged in the treatment of waste water collected from the individual units of Special Economic Zone (SEZ). Waste water is collected by the tankers and sends to the estate where scientifically treatment is being undertaken and treated effluent is sent to member units for the reuse. The proposed expansion project falls under the schedule Physical Infrastructure including Environmental Services, Project or Activity 7(h), Common Effluent Treatment Plants, Category B. The project is promoted by the Mr. Kailash Bahuguna, the COO of the plant. There are three directors of the project, they are highly educated and experienced in the business, and their names are given below: Shri. Pankaj R. Patel Smt. Taraben R. Patel Shri. Sharvi P. Patel 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT M/s. Zydus Infrastructure Private Limited (ZIPL) has proposed expansion of Common Effluent treatment Plant in a Special Economic Zone exclusively for pharmaceutical formulation units at village Matoda Sari, Taluka Sanand, District Ahmedabad in Gujarat. 1.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION The volume of waste water generated from member unites the High Tech Pharmaceutical (Formulation) Manufacturing Special Economic Zone. At present, the project is having permission for the treatment of 800 KLD effluents as per CCA from Gujarat Pollution Control Board, in expansion project it will go to 3000 KLD which will solve the problem of member units. It will also give clear idea for the thinking of their member units expansion. 1.4 EMPLOYMENT GENERATION DUE TO THE PROJECT As this is the expansion project of existing unit where 35 nos. manpower are already working, these manpower are consist of plant management staff, office staff, engineers, operators and other skilled and unskilled manpower. For the proposed expansion project additional 5 nos. of manpower will require for which preference will be given to locals. 1

5 CHAPTER 2 PROJECT DESCRIPTION 2.1 TYPE OF PROJECT The proposed expansion project is for the treatment of industrial effluent of member units in Pharmez SEZ at Ahmedabad. Expansion will be carried out from 0.8 MLD to 3 MLD. 2.2 LOCATION WITH COORDINATES Location : Pharmez SEZ Village : Matoda, Taluka : Sanand, District : Ahmedabad, State : Gujarat Coordinates at the project site: Latitude: 22 52'48.99"N Longitude: 72 24'23.15"E A map depicting administrative boundary showing project site, National Highway, major, medium and other roads with the railway lines is presented in figure 1. The major water bodies with the rivers and the river beds are illustrated in the map to provide a better understanding of the project area. FIGURE 1: MAP SHOWING PROJECT SITE, TOWN, NATIONAL HIGHWAY, STATE HIGHWAYS, RAILWAY LINES, ROADS ETC. 2

6 2.5 PROJECT DESCRIPTION WITH PROCESS DETAILS M/s. Zydus Infrastructure Pvt. Ltd. (ZIPL) is having CETP and is engaged in the treatment of waste water collected from the individual units of SEZ. Waste water is collected by the tankers and sends to the estate. Throw away water is subjected to the primary physico-chemical treatment followed by biological treatment in Membrane Bio-Reactor (MBR) unit. Reverse Osmosis (RO) treatment to provide treated waste water of reusable quality. RO reject is passing through Multiple Effect Evaporator (MEE). Sludge generated at various stages shall be dewatered in decanter and sludge drying beds. SCHEME OF TREATMENT Treatment scheme shall be divided into the following components: 1. Waste water treatment (Primary & Secondary except MBR) 2. MBR Process 3. Reverse Osmosis Process 4. Multiple Effect Evaporator and Solid Separator 1. WASTE WATER TREATMENT PLANT (PRIMARY & SECONDARY) All member units transfer their waste water to the tankers and from there it gets transfers to the equalization tank of CETP. Air has been supplied to the bad water for mixing by using blower. Equalized throw away water flows to neutralization tank for auto ph correction. From there it flows to clarifloculator for removal of suspended solids. Clarified waste water then passes through fine screen to be subjected to biological process in MBR system. Sludge generated in clarifloculator, MBR process and solid separator is collected in a sludge sump, from there it is pumped to decanter centrifuge dewatering. 2. MBR PROCESS Membrane Bio Reactor is a modified and advanced version of activated sludge process, used when waste water needs to be treated into reusable water. The technology is extensively used all over the world and recently introduced in India. PROCESS OVERVIEW The typical wastewater treatment plant is comprised of the following unit operations: 1. Pre-Aeration Basin 2. Membrane Bio Reactor (MBR) 3. Waste Activated Sludge Handling 4. Membrane Chemical Clean-In-Place (CIP) System 5. System Controls 1. PRE-AERATION BASIN Mixed liquor then flows by gravity from the Clarifloculator to the Pre-Aeration Basin after passing through fine screen, where air is supplied to incoming wastewater and recycled mixed liquor from MBR to provide oxygen for carbonaceous BOD removal and ammonia conversion to nitrates through nitrification. 2. MBR The partially stabilized mixed liquor from Pre-Aeration Basins will then pumped into the MBRs. The MBRs employ flat plate membranes, which provide several advantages over other membrane separation systems, including reduced fouling, reduced cleaning cycles and gravity operation capability. For each membrane unit in the MBR, integral diffusers furnish air to membrane cleaning and mixing requirements. The added air also supplements the oxygen supplied in the Pre-Aeration Basin for biological treatment. The part of the mixed liquor is recycled back to the Pre-Aeration Basins by gravity. The MBR is designed to produce permeate using pumps. The permeate is pumped from the membrane units via the permeate pumps. Permeate flow is controlled using modulating control valves and regulated to match hydraulic demand. Permeate is then sent to Advanced Separation System for further treatment. Membranes provide greater than 6-log removal of bacteria and 4-log removal of viruses, so disinfection requirements should be greatly reduced from that required with conventional activated sludge technologies. 3

7 3. MEMBRANE CHEMICAL CIP (CLEANING IN PLACE) SYSTEM On average, it is necessary to chemically clean a membrane unit every six months. The membrane units are cleaned in place quickly and efficiently by simply injecting a dilute solution of bleach into the permeate line. The cleaning solution remains in the membranes for 1 to 3 hours and then normal operation is resumed. The chemical used to clean the membranes depends on the substrate treated in the MBR. For organic substrates bleach is recommended and for inorganic substrates oxalic or citric acid should be used. Recovery cleanings are generally scheduled events; however, an operator can quickly assess the status of the membranes by observing the change in transmembrane pressure over time. During a cleaning of one basin, the other basins are left online and operated at slightly higher flux rate as required to meet plant demand. 4. SYSTEM CONTROL A Programmable Logic Controller (PLC) monitors & manages all critical process operations. Process automation is provided with this PLC. A PLC is essentially an industrial computer capable of reading both discrete and analog signals, performing logical functions and then generating discrete and analog outputs. The operator interfaces with the PLC through a graphical user interface (GUI). Equipment is automatically controlled, through local switches and transmitters. For maintenance and safety purposes, pumps, mixers, blowers and screens are all equipped with local controls. 5. WASTE ACTIVATED SLUDGE HANDLING Waste activated sludge generated as a by-product of the activated sludge process will be wasted directly from the MBR basins on a regular basis. Waste sludge will be removed via sludge wasting pump and handled in the sludge storage handling facility. 3. REVERSE OSMOSIS PROCESS The effluent from the MBR basin will go into final sump. The effluent is then pumped to RO system for advanced solid separation. The effluent from the final sump can directly be taken to the fresh water sump directly without advance solid separation system if the quality of effluent is convincing. Reverse osmosis (RO) was the first cross flow membrane separation process to be widely commercialized. RO removes virtually all organic compounds and 90 to 99% of all ions. A large selection of reverse osmosis membranes is available to meet varying rejection requirements. RO can meet most water standards with a single-pass system and the highest standards with a double-pass system. RO rejects 99.9+% of viruses, bacteria and pyroxenes. Pressure, on the order of 200 to 1,000 psig (13.8 to 68.9 bar), is the driving force of the RO purification process. It is much more energy efficient compared to heat-driven purification (distillation) and more efficient than the strong chemicals required for ion exchange. No energy-intensive phase change is required. 4. MULTIEFFECT EVAPORATION SYSTEM A multiple-effect evaporator, as defined in Chemical Engineering, is an apparatus for efficiently using the heat from steam to evaporate water. In a multiple-effect evaporator, water is boiled in a sequence of vessels, each held at a lower pressure than the last. Because the boiling point of water decreases as pressure decreases, the vapor boiled off in one vessel can be used to heat the next, and only the first vessel (at the highest pressure) requires an external source of heat. While in theory, evaporators may be built with an arbitrarily large number of stages, evaporators with more than four stages are rarely practical. The reject of the Multi effect Evaporator shall be taken to equalization tank again for retreatment. The treated effluent from the MEE shall be stored in the fresh water sump for further reuse. 4

8 2.6 (A) DETAILS OF HAZARDOUS WASTE GENERATION DURING OPERATION SR NO TYPES OF HAZARDOUS WASTES WASTE CATEGO RY QUANTITY OF WASTE GENERATED (MT/MONTH) EXISTING PROPOSED TOTAL 1. CETP Sludge MEE/ Decanter Salt Used Oil DISPOSAL FACILITY Sludge is/will be collected from sludge drying bed and stored in scientifically designed hazardous waste storage area having impervious layer with leachate collection system and finally sent to TSDF of M/s. Naroda Enviro Projects Ltd., Naroda Salt is/will be collected from sludge drying bed and stored in scientifically designed hazardous waste storage area having impervious layer with leachate collection system and finally sent to TSDF of M/s. Naroda Enviro Projects Ltd., Naroda Used oil will be generated from machineries and will be collected, stored, transported and disposed by selling to registered reprocessors. (B) DETAILS OF DOSING CHEMICALS SR. NO. 1 HAZARDOUS CHEMICALS Polyaluminium Chloride (PAC) QUANTITY (KG/MONTH) EXISTING PROPOSED TOTAL Lime Nutrients for biological treatment Polyelectrolyte (PE) (C) EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY OR MOBILE SOURCES STACK NO. STACK ATTACH TO EXISTING SCENARIO Boiler for Multiple 1 Effect Evaporator (03 TPH) D. G. Set 2 (720 KVA) PROPOSED SCENARIO STACK HEIGHT (M) FUEL & QUANTITY FO/HSD/LDO 300 Lit/Hr FO/HSD/LDO 100 Lit/Hr AIR POLLUTION CONTROL SYSTEM Adequate stack height Acoustic Enclosure PARAMET ER PM SO 2 NOx PERMISSIB LE LIMIT 150 mg/nm ppm 50 ppm 5

9 STACK NO. 3 STACK ATTACH TO D. G. Set (3 x 320 KVA) STACK HEIGHT (M) 12 FUEL & QUANTITY FO/HSD/LDO 150 Lit/Hr AIR POLLUTION CONTROL SYSTEM Acoustic Enclosure PARAMET ER PM SO 2 NOx PERMISSIB LE LIMIT 150 mg/nm ppm 50 ppm 2.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE The proposed expansion project is for the treatment of common effluent of member units from which treated water is/will be sent to its member units for reuse. 2.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE WATER REQUIREMENT AND ITS SOURCE Total water requirement for the proposed expansion project will be 158 KLD which mainly for cooling, boiling, domestic uses, gardening & for others uses. Total water requirement shall be met from CETP treated water reuse. Domestic water is/will be met through ground water using bore well POWER REQUIREMENT AND ITS SOURCE Total power requirement for the proposed expansion project would be 630 KW (130 KW existing and 500 KW proposed). Power supply shall be taken from Uttar Gujarat Vij Company Limited (UJVCL). In case of emergency or power failure D.G. sets of 720 KVA existing 320 x 3 proposed will be used. It will be used to fulfill power requirement. 2.9 QUANTITY OF WASTES TO BE GENERATED AND ITS MANAGEMENT / DISPOSAL WASTEWATER GENERATION Water requirement will be mainly for cooling, boiling, domestic uses, gardening & for others uses. Total 85 KLD wastewater will be generated. Total effluent will be treated in the CETP itself along with effluent generated from members unit and treated water will be sent to member units for the reuse purpose. 6

10 CHAPTER 3 SITE ANALYSIS 3.1 CONNECTIVITY The proposed expansion of CETP will be done in the existing premises located at Survey No. 467, Pharmez- Special Economic Zone, Sarkhej-Bavla Road, NH-8 A, Village Matoda, Taluka Sanand, District Ahmedabad, Gujarat Road Connectivity The project site is well connected with the National highway and State Highways. SR. NO. ROAD DISTANCE DIRECTION 1 National Highway 8-A Adjacent in North West 2 State Highway 144 Around 4.5 km in S South 3 State Highway 4 Around 5.4 km in SE South East 4 State Highway 142 Around 10.2 km in E East Rail The Area is well connected by Railway. The Bavla Railway Station is about 6.7 Km in SSW direction Airport The nearest airport to the project will be Ahmadabad Airport at aerial distance of 30 km in NE direction Communication The site has access of telephone and mobile connectivity. 3.2 LAND FORM, LAND USE AND LAND OWNERSHIP The area of the existing project site is 17, m 2 which is private land. Only m 2 land will be utilized for the expansion purpose of CETP. 3.3 TOPOGRAPHY Topography of the area is plain. 3.4 EXISTING LAND USE PATTERN Land is non agriculture. There is no Forest, National park, Wild life sanctuary within a radius of 10 Km. Details of existing land use is given in the following table: TABLE 2: DETAILS OF EXISTING LAND USE NO. PARTICULAR NAME & ITS DISTANCE 1. Nearest National Highway NH-8A Adjacent in NW 2. Nearest city Ahmedabad city at around 23 km in NNE and 3. Nearest River Sabarmati River at 9.0 km in E 4. Nearest Railway station Bavla Railway Station at aerial distance of 6.7 km in SSW 5. National park/reserve Forest, Biosphere, etc. None within a radius of 10 Km 6. Seismicity Zone III 7

11 3.5 EXISTING SOCIAL INFRASTRUCTURE Within the 10 km radius area of the proposed expiation project, social infrastructure like Hospitals, Schools, Colleges, Temples etc. are present. 3.6 CLIMATIC DATA Ahmedabad has a hot, semi-arid climate, with marginally less rain than required for a tropical savanna climate. There are three main seasons: summer, monsoon and winter. Aside from the monsoon season, the climate is extremely dry. The weather is hot from March to June; the average summer maximum is 41 C (106 F), and the average minimum is 27 C (81 F). From November to February, the average maximum temperature is 30 C (86 F), the average minimum is 15 C (59 F), and the climate is extremely dry. Cold northerly winds are responsible for a mild chill in January. The southwest monsoon brings a humid climate from mid-june to mid-september. The four climatic seasons viz. pre-monsoon, monsoon, post-monsoon and winter could be considered as comprising of the following months: Pre-monsoon : March, April and May Monsoon : June, July, August and September Post-monsoon : October and November Winter : December, January and February Sometimes, the monsoon commences in mid-may and ends in mid-september. Therefore, the boundaries between the seasons are not very rigid TEMPERATURE DETAILS The hottest months were March to June highest temperature is between 31 ºC to 41 ºC. The coldest months were November, December, January and February when temperature drops to 15 ºC. During the other months, temperature was more or less moderate in nature and pleasant to bear RELATIVE HUMIDITY (RH) Relative Humidity is generally high during the period from June to September. The diurnal variations are least during monsoon season. The diurnal variation is highest during summer period RAINFALL The average annual rainfall is around 800 mm from June to September. 8

12 CHAPTER 4 PLANNING BRIEF 4.1 PLANNING CONCEPT 4.2 LAND USE PLANNING For the proposed expansion project, only m 2 land will be required which will be utilized from existing private land of 17, sq. m. Detailed Land use breakup of the land area is given in following table. TABLE 3: EXISTING CETP UNITS DETAIL SR.NO NAME OF THE AREA NOS. AREA (IN METER) 1. Equalization tanks I x x FB 2. Equalization tanks II x x FB 3. Neutralization tank I x 2.70 x Neutralization tank II x 2.70 x Dosing Tank x 1.50 x Dosing Tank x 1.00 x Clarifloculator I DIA x 2.50 SWD x 0.50 FB 8. Clarifloculator II DIA x 2.50 SWD x 0.50 FB 9. Fine screen platform x Pre air chamber I x x MBR Basin I x 4.30 x Fine screen Platform II x Pre air chamber II x x ( FB) 14. MBR Basin II x 4.30 x Final Sump I x x FB 16. Final Sump II x 6.72 x FB 17. Sludge Sump x 9.00 x FB 18. Hazardous waste storage area x Decanter Shed x 6.00 x Chemical Storage Area x 6.00 x Blower Room x 5.00 x RO Block x Leachate Collection Tank x RO reject tank x x MEE Block x Offline Lagoon M MCC Panel Room PLC/ DG x x 4.50 Maintenance room 28. Office / Laboratory Building x Fresh water Sump x x Watch man cabin x Toilet Block x Septic Tank x 3.00 x Boiler Room (MEE) x

13 SR.NO NAME OF THE AREA NOS. AREA (IN METER) 34. Cooling Tower x Fuel Storage Yard x Control Room x Decanter Shed (MEE) x 4.00 TABLE 4: PROPOSED CETP UNITS DETAILS SR.NO NAME OF THE AREA NOS. AREA (IN METER) 1. Equalization tanks III x x FB 2. Neutralization tank III x 2.70 x Clarifloculator III DIA x 2.50 SWD x 0.50 FB 4. Fine screen III Platform x Pre Air Basin III x x FB 6. MBR Basins III x 6.00 x Blower & Pump Foundation 01 As per requirement 10

14 CHAPTER 5 PROPOSED INFRASTRUCTURE 5.1 INDUSTRIAL AREA Around 17, m 2 land area is already acquired, land requirement for the expansion project will be utilized from existing available land. 5.2 GREEN BELT Around m 2 area is/will be allocated for the development of the green belt all along the boundary wall. 5.3 SOCIAL INFRASTRUCTURE The existing facility of primary health care centers, roads, railways etc. available within nearby area will be utilized. 5.4 CONNECTIVITY The project site is well connected with existing transportation infrastructures; therefore no additional provision is required. 5.5 DRINKING WATER MANAGEMENT The water requirement for the proposed expansion CETP is/will be met from ground water and surface water. 5.6 SEWERAGE WATER SYSTEM The domestic waste water is/will be disposed in soak pit via septic tank. 5.7 INDUSTRIAL WASTE WATER MANAGEMENT Industrial effluent generated from various activities of the CETP is/will be treated along with effluent of member units and treated waste water is/will be sent to member units for reuse. 11

15 CHAPTER 6 REHABILITATION AND RESETTLEMENT (R & R) PLAN Rehabilitation and Resettlement (R&R) plan is not applicable for the proposed expansion project. 12

16 CHAPTER 7 PROJECT SCHEDULE & COST ESTIMATES 7.1 PROJECT IMPLEMENTATION SCHEDULE Implementation of project within a pre-determined time frame is an important factor for the success of a project. Timely implementation saves on various costs like interest, administrative overheads and helps to realize the goals as per pre-determined objectives. Implementation of Project involves co-ordination of different activities at various levels of the firm and amongst different outside agencies. The construction is likely to start after getting Environmental Clearance and NOC/CTE from the authorized committee. 7.2 ESTIMATED PROJECT COST The capital cost of the project is estimated at about approx Rs. 5,000 lacs for the expansion of the project. 13

17 CHAPTER - 8 ANALYSIS OF PROPOSAL 8.1 FINANCIAL AND SOCIAL BENEFITS The capital cost of the proposed expansion of CETP site is estimated at about Rs. 5,000 lacs. For the coming of this project surrounding area will get developed due to this project and through the Corporate Social Responsibility (CSR) activities, socio-economic status of the region will also get developed. 14