EXISTING CETP UNITS DETAIL ADDITIONAL DETAILS OF THE PROJECT SR.NO NAME OF THE AREA NOS. AREA (IN METER) 1. Equalization tanks I 01 15.00 x 10.00 x 3.00 + 0.50 FB 2. Equalization tanks II 01 9.00 x 10.00 x 3.50 + 0.50 FB 3. Neutralization tank I 02 2.70 x 2.70 x 1.50 + 0.50 + 0.30 4. Neutralization tank II 02 2.70 x 2.70 x 1.50 + 0.50 + 0.30 5. Dosing Tank 02 1.50 x 1.50 x 1.00 +0.30 6. Dosing Tank 02 1.00 x 1.00 x 1.00 +0.30 7. Clarifloculator I 01 10.00 DIA x 2.50 SWD x 0.50 FB 8. Clarifloculator II 01 10.00 DIA x 2.50 SWD x 0.50 FB 9. Fine screen platform 01 5.00 x 3.0 10. Pre air chamber I 01 15.40 x 13.30 x 2.30 +0.50 11. MBR Basin I 02 6.40 x 4.30 x 2.60 +0.50 12. Fine screen Platform II 01 1.00 x 1.00 13. Pre air chamber II 01 15.40 x 13.65 x (2.30 + 0.50 FB) 14. MBR Basin II 02 6.72 x 4.30 x 2.60 + 0.50 15. Final Sump I 01 13.30 x 11.20 x 3.00 + 0.50 FB 16. Final Sump II 01 11.00 x 6.72 x 2.80 + 0.50 FB 17. Sludge Sump 01 9.00 x 9.00 x 3.00 + 0.50 FB 18. Hazardous waste storage area 01 15.00 x 10.00 19. Decanter Shed 01 10.00 x 6.00 x 3.50 20. Chemical Storage Area 01 14.00 x 6.00 x 3.50 21. Blower Room 02 17.00 x 5.00 x 3.50 22. RO Block 01 31.50 x 12.50 23. Leachate Collection Tank 01 3.00 x 3.00 24. RO reject tank 02 10.00 x 10.00 x 2.75 25. MEE Block 01 9.50 x 3.50 26. Offline Lagoon 01 5250 M 3 27. MCC Panel Room PLC/ DG Maintenance room 01 31.00 x 10.00 x 4.50 28. Office / Laboratory Building 01 12.00 x 8.00 29. Fresh water Sump 01 14.00 x 14.00 x 2.50 +0.50 30. Watch man cabin 01 3.00 x 3.00 31. Toilet Block 01 9.00 x 3.00 32. Septic Tank 01 8.00 x 3.00 x 2.50 + 0.60 33. Boiler Room (MEE) 01 7.00 x 7.00 34. Cooling Tower 01 2.80 x 3.60 35. Fuel Storage Yard 01 15.00 x 7.20 36. Control Room 01 4.00 x 4.00 37. Decanter Shed (MEE) 01 4.00 x 4.00
PROPOSED CETP UNITS DETAILS SR.NO NAME OF THE AREA NOS. AREA (IN METER) 1. Equalization tanks III 01 9.00 x 10.00 x 3.50 + 0.50 FB 2. Neutralization tank III 02 2.70 x 2.70 x 1.50 + 0.50 + 0.30 3. Clarifloculator III 01 10.00 DIA x 2.50 SWD x 0.50 FB 4. Fine screen III Platform 01 3.00 x 2.00 5. Pre Air Basin III 01 15.00 x 14.00 x 4.50 + 0.50 FB 6. MBR Basins III 02 7.00 x 6.00 x 4.60 + 0.50 7. Blower & Pump Foundation 01 As per requirement
PROPOSED LAYOUT OF THE PLANT
HYDROLIC FLOW DIAGRAM OF CETP
SCHEMATIC DIAGRAM OF CETP
EXISTING CETP MECHANICAL UNITS DETAIL SR. NO. 1. 2. 3. 4. ITEM CAPACITY NOS. MOC Raw Effluent Pumps for Equalization Tank - I (Centrifugal Non Clog) Raw Effluent Pumps for Equalization Tank - II (Centrifugal Non Clog) 40 m 3/ hr, 15m Head, 4.00 m Suction Head 28 m 3/ hr, 15m Head, 4.00 m Suction Head 1 + 1 CI 1 + 1 CI Blower for Equalization Tank- I 450 CMH @ 0.45 kg/cm 2 1 + 1 CI Blower for Equalization Tank - II 300 CMH @ 0.45 kg/cm 2 1 + 1 CI 5. Diffusers for Equalization Tank - I 800 mm long Course Bubble 90 PVC diffuser 6. Diffusers for Equalization Tank - II 800 mm long Course Bubble 60 PVC diffuser 7. Agitator for Neutralization Tank - I 3.0 HP 2 SS 8. Agitator for Neutralization Tank - II 3.0 HP 2 SS 9. Agitator for Dosing Tank 1.0 HP 4 SS 10. Dosing Pumps 250 LPH 4 + 4 11. Dosing Pumps 100 LPH 2 + 2 12. Clarifloculator Mechanism - I 10.00 Dia x (2.50 SWD 1 MSEP +0.5FB) 13. Clarifloculator Mechanism - II 10.00 Dia x (2.50 SWD 1 MSEP +0.5FB) 14. MBR Membrane for MBR System - I 750 KLD 1 Lot. -- 15. MBR Membrane for MBR System - II 750 KLD 1 Lot. -- 16. Permeate Pumps for MBR System - I 34.7 m 3 /hr, 10 m head and 3 m suction head 2 + 2 CI 17. Permeate Pumps for MBR System - II 34.7 m 3 /hr, 10 m head and 3 m suction head 2 + 2 CI 18. Recycle pumps from MBR Basin to Pre Air Basin for MBR System - I 62.5 m 3 /hr 2 + 1 CI 19. Recycle pumps from MBR Basin to Pre Air Basin for MBR System - II 73 m 3 /hr 2 + 1 CI 20. WAS Pumps for MBR System - I 11.0 m 3 /hr 1 CI 21. CIP Pumps for MBR System - I 11.0 m 3 /hr 1 22. CIP Pumps for MBR System - I 11.0 m 3 /hr 1 CI 23. CIP Tank for MBR System - I 2 m 3 1 -- 24. CIP Tank for MBR System - II 5 m 3 1 -- 25. Fine Bubble Diffuser for Pre Air Basin for MBR System - I 20 m 3 /hr 38 EPDM 26. Fine Bubble Diffuser for Pre Air Basin for MBR System - II 36.8 m 3 /hr 38 PU 27. Tri Lobe Blower for Pre Air basin & MBR Basin for MBR Basin - I 750 CMH 4 + 1 CI 28. Tri Lobe Blower for Pre Air basin & MBR Basin for MBR Basin - II 750 CMH 4 + 1 CI 29. Decanter 5 m 3 /hr 2 SS 30. Sludge Transfer Pumps 10 m 3 / hr, 30 m 1 + 1 CI 31. Level Switches As per Design 1 Lot 32. DO Transmitter As per Design 2 33. Level Transmitter As per Design 10 34. Magnetic Flow Meter As Per Design 6
SR. NO. ITEM CAPACITY NOS. MOC 35. Vortex Flow Meter As Per Design 4 36. Pressure Transmitter -15/+15 psi 4 -- 37. Turbidity Transmitter 0 100 NTU 2 38. Electrically Actuated Valves As per Design 8 CI 39. Pressure Gauges As per design Lot 40. Instrumentation Cable As per requirement 1 Lot -- 41. PLC with SCADA System As per design 2 Lot -- PROPOSED CETP MECHANICAL UNITS & ITS SIZE SR. NO. 1. 2. ITEM CAPACITY NOS. MOC Raw Effluent Pumps for Equalization Tank - III (Centrifugal Non Clog) 75 m 3/ hr, 15m Head, 4.00 m Suction Head 1 + 1 CI Blower for Equalization Tank - III 300 CMH @ 0.45 kg/cm 2 1 + 1 CI 3. Agitator for Neutralization Tank - III 3.0 HP 2 SS 4. Agitator for Dosing Tank 1.0 HP 4 SS 5. Dosing Pumps 250 LPH 4 + 4 6. Dosing Pumps 100 LPH 2 + 2 7. Clarifloculator Mechanism - III 10.00 Dia x (2.50 SWD 1 MSEP +0.5FB) 8. Fine Screen As per design 2 SS 9. MBR Membrane 1500 KLD 1 Lot. -- 10. Permeate Pumps 70 m 3 /hr, 10 m head and 3 m suction head 2 + 2 CI 11. Recycle pumps from MBR Basin to Pre Air Basin 125 m 3 /hr 2 + 1 CI 12. WAS Pumps 22.0 m 3 /hr 1 CI 13. CIP Pumps 11.0 m 3 /hr 1 CI 14. CIP Tank 5 m 3 1 -- 15. Fine Bubble Diffuser for Pre Air Basin 36.80 m 3 /hr As per Require ment 16. Tri Lobe Blower for Pre Air basin & MBR Basin 1500 CMH 4 + 2 CI 17. Level Switches As per Design 1 Lot 18. DO Transmitter As per Design 1 19. Level Transmitter As per Design 2 20. Magnetic Flow Meter As Per Design 2 21. Vortex Flow Meter As Per Design 2 22. Pressure Transmitter -15/+15 psi 2 -- 23. Turbidity Transmitter 0 100 NTU 2 24. Electrically Actuated Valves As per Design 4 CI 25. Pressure Gauges As per design Lot 26. Instrumentation Cable As per requirement 1 Lot -- 27. PLC with SCADA System As per design 1 Lot -- --
28. Raw Effluent Transfer Pump 60 m 3/hr 1 + 1 CI
OPERRATION DETAIL OF CETP 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. Hydraulic flow diagram of common effluent treatment plant is shown in annexure-ii. 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. 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 doublepass 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.
WATER BALANCE OF CETP (EXISTING) 800 KL Equalization tank 810 KL Primary Treatment 810 KL MBR 810 KL RO 770 KL 40 KL RO Permeate RO Reject 40 KL Multi Effective Evaporator 45 KL 5 KL Steam 795 KL To member units for reuse/ plantation 25 KL 20 KL Condensate Concentrate 10 KL Decanter Filtrate Drying 1000 Kg/day solids to TSDF
WATER BALANCE OF CETP (PROPOSED) 3000 KL Equalization tank 3040 KL Primary Treatment 3040 KL MBR 3040 KL RO 2890 KL 150 KL RO Permeate RO Reject 150 KL Multi Effective Evaporator 170 KL 20 KL Steam 2985 KL To member units for reuse/ plantation 95 KL 75 KL Condensate Concentrate 40 KL Decanter Filtrate Drying 3800 Kg/day solids to TSDF
(A) DETAILS OF HAZARDOUS WASTE GENERATION DURING OPERATION SR NO TYPES OF HAZARDOUS WASTES WASTE CATEG ORY QUANTITY OF WASTE GENERATED (MT/MONTH) EXISTING PROPOSED TOTAL 1. CETP Sludge 34.3 4 11 15 2. MEE/ Decanter Salt - 27 87 114 3. Used Oil 5.1 0.1 0.1 0.2 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 300 900 1200 2 Lime 120 360 480 3 Nutrients for biological treatment 450 1350 1800 4 Polyelectrolyte (PE) 09 27 36
(C) EMISSIONS FROM COMBUSTION OF FOSSIL FUELS FROM STATIONARY OR MOBILE SOURCES EXISTING SCENARIO STACK NO. STACK ATTACH TO Boiler for Multiple 1 Effect Evaporator (03 TPH) D. G. Set 2 (720 KVA) PROPOSED SCENARIO D. G. Set 3 (3 x 320 KVA) STACK HEIGHT (M) 30 12 12 FUEL & QUANTITY FO/HSD/LDO 300 Lit/Hr FO/HSD/LDO 100 Lit/Hr FO/HSD/LDO 150 Lit/Hr AIR POLLUTION CONTROL SYSTEM Adequate stack height Acoustic Enclosure Acoustic Enclosure PARAME TER PM SO 2 NOx PM SO 2 NOx PERMISSIB LE LIMIT 150 mg/nm 3 100 ppm 50 ppm 150 mg/nm 3 100 ppm 50 ppm