1. PREAMBLE: 1.1 AMRUT DISTILLERIES PVT LTD (ADPL) is a company with a history dating back to the late 1940 s. In the six decades and more since its inception as a fledgling and novice organization in the field of liquor making, ADPL has made giant strides in the quality of its products, diversity of its product portfolio, nature of its clientele and in the geographic spread of its market. 1.2 While ADPL is today acknowledged as an important player in the IMFL industry in the country, its products have created waves even outside India, most notably in the European Union and in the North American continent. Its product AMRUT INDIAN SINGLE MALT WHISKY (ASM) and its variants are today accepted as among the best Single Malt products that the world has to offer. Evidence of its global standing is the plethora of awards that ASM and its variants have won at no less than 25 different international forums. The crowning glory is of course the rating as the 3rd Finest Whisky in the world that was accorded to AMRUT FUSION Single Malt Whisky. 1.3 Apart from ASM, our premium rum, TWO INDIES, another premium whisky MAQINTOSH SILVER EDITION WHISKY, etc have also gained widespread appreciation and acceptance. It is therefore no exaggeration to state that the company is poised to build on its well-earned reputation to scale ever greater heights. 1.4 With appreciation pouring from all directions, demand for the company s products has also been rising continuously over the past few years. To meet the rising demand while maintaining and enhancing the quality of its products, the company has drawn up expansion plans comprising (i) (ii) (iii) Production of 10,000 liters per month of spirit out of jiggery; and Increase in malt & grape distillation capacity from the existing 7,500 liters per month to 60,000 liters of Malt Spirit and 7,500 liters of Grape Spirit per month; Increase in the bottling capacity from the present 1, 50,000 cases per month to 2, and 50,000 cases per month.
1.5 The table below shows the existing capacity of all products and the expected capacity after expansion plans proposed to be implemented. Sl. Item Unit Capacity Present Proposed 1 Extra Neutral Alcohol liters p.m. 5,00,000 5,00,000 (Re-distillation of Rectified Spirit) 2 Malt Spirit & Grape Spirit - do - 7,500 67,500 3 Jiggery Spirit - do - -- 10,000 4 Bottling of IML cases p.m. 1,50,000 2,50,000 1.6 OBJECTIVE OF ADEQUACY REPORT This Adequacy report is prepared to check the adequacy of the existing ETP, and recommend the required up-gradation of CETP as necessary to meet the combined existing and proposed effluent load due to the proposed expansion and for treating the same and conserving the entire treated effluent on own land for irrigation confirming to KSPCB on land discharge standards. Further, it is to be noted that their will not be any additional Air Pollution Sources envisaged due to the proposed expansion. 2. MANUFACTURING PROCESS WRITE UP: PRODUCTION OF SPIRIT OUT OF JAGGERY Process Description: Commercial Jaggery will be used for the manufacture of spirit out of jaggery. In this process, jaggery is broken into smaller size and pitched into the ferment or by adding soft water in the ratio of 1 unit of jaggery to 4.8 units of water. The mixture is stirred well till all the jaggery is completely and well dissolved in the water. The ph of the wash is adjusted to 4.5 and Brix is checked in the ferment or. Special yeast is added to the mixture in the ferment or and fermentation is allowed at ambient temperature. Fermentation usually takes 3 to 4 days to complete. Once fermentation is complete, the fermented wash is filled in the Typical Brandy Pot still. This is a special pot-still and has small column still wash plates attached to it which help in rectifying the spirit to the desired level while also retaining the natural molasses congeners. Low wines are collected in this distillation.
The Low Wines, along with the Heads and Tails of the previous batch are charged into the still and the second distillation is carried out by Fractional Distillation in which Heads, Hearts and Tails are distilled off based on boiling points. The Hearts, that is, the pure Jaggery Spirit is reduced to 63% Above and filled in Oakwood casks for maturation. After the spirit attains the desired level of maturation, the matured jaggery spirit is used in Rum blending as a component, contributing typical sweetish sugarcane and spicy character to the product. Addition of matured jaggery spirit with all natural congeners intact lends a special edge to the Rum over the conventional flavored rums. Annexure 1 is enclosed in the project report. It shows the process flow for production of spirit out of Jaggery. Investment: The infrastructure and manpower available at the existing Kumbalgodu unit are adequate for production of spirit out of jaggery. As production of grape spirit at this unit has been on the decline in the recent past, there is surplus capacity available which could be easily deployed towards production of jaggery spirit. Hence no additional investment is required for this purpose. 3. PRODUCTION OF MALT SPIRIT PROCESS DESCRIPTION: Mashing: Barley malt is milled and mashed with hot water and allowed to rest for an hour and drained, cooled and pumped into the ferment or. Yeast is immediately pitched to the ferment or. Thereafter, the second hot water is added and the mix is allowed to rest for 40 minutes. After 40 minutes, the mix is drained, cooled and then pumped into the ferment or. The third hot water is added and collected and pumped to the third water tank for use of first water of the next brew at required temperature. The whole cycle of mashing takes about 6 hours. Fermentation: Two such brews are put in one ferment or under sterile conditions and allowed to ferment in a temperature controlled environment. Fermentation usually takes about 5 days to complete.
Distillation: The fermented wash is distilled in typical copper pot-stills to get low wind at 18 19% Above and this wash distillation takes approximately 9 hours. The next charge of wash is repeated in the same manner to get another low wine. Tow such low wines with Heads & Tails of previous batches are mixed together and distilled in spirit still to collect the middle fraction and Heads & Tails. The second distillation takes around 16 17 hours to complete. Maturation: The new make spirit is reduced to 62.8% Above by adding de-mineralized water (DM Water) and filled in American Oakwood barrels for a minimum period of 4 years. Bottling: The required quantity of matured malt spirit is drawn from the selected barrels in the required proportions and blended with Extra Neutral Alcohol (ENA). Where required, DM Water is further added to reduce the strength to the required levels. The color of the blend is adjusted as per quality specifications and then filtered through sparkler filter before bottling. Process Flow Diagram & Project Investment are enclosed separately in the project report: 4. BOTTLING PLANT The existing infrastructure and other facilities are sufficient for bottling of 2, 50,000 c/s per month and no additional investment is required. As and when required, the plant may be operated on two shifts to meet production requirements. The bottling plant does not generate any effluents. 5. WATER The Water Balance of the entire plant both existing and after expansion is shown in Annexure 1 of this report.
ANNEXURE-I Commercial Jiggery can be used for the manufacturing of spirit out jiggery. In this process we take the Jiggery and break it into the smaller size and pitched it into the ferment or by adding the soft water in the ratio. It is stirred well till all the Jiggery gats completely dissolved in the water. The ph of the wash is adjusted to 4.5, Brix is checked in the ferment or. A special yeast is added in the ferment or and fermentation is allowed at ambient temperature. Fermentation may take 3 to 4 days to complete. Once the fermentation is complete, the fermented wash is taken in the typical Brandy pot still which is special in the sense that it has a small column still wash plates attached to it that helps in rectifying the spirit to our desired level so that the natural molasses congeners are retained in the spirit. Low wines are collected in this distillation. These Low wines along with the Heads and Tails of the previous batch are charged into the still and the second distillation is carried out by following the Fractional Distillation in which we distil off the Heads the hearts and the tails based on the boiling points. The hearts that is the pure jiggery Spirit is reduced to 63% above. And filled in the casks for maturation. After attaining the desired maturation, it can be used in the Rum Blending as a component, contributing the typical sweetish sugarcane and spicy character to the product as all these natural congeners are retained in the by following a specially developed technique of fractional Distillation in the typical pot still thereby giving a special edge to the Rum product over the conventional flavoured rums. ANNEXURE II FLOW DIAGRAME JAGGERY PULVERIZATION FERMENTATION DISTILLATION JAGGERY SPIRIT MATURATION BLENDING & BOTTLING
FLOW DIAGRAM-MALT PLANT MILLING SECTION CIP TANKS CLEARWORTTO GRIST STORAGE HOT WATER TANK MASH TUN TO SPENT GRAIN SILO PLATE HEAT EXCHANG ER FERMENTOR WASH STILL CHILLED WATER TANK MALT RECEIVER+LOW WINE RECEIVER SPIRIT STILL
ANNEXURE 3 WATER REQUIRMENT SUMMARY 1. Malt Spirit Production 33,200 SL. ITEM WATER REQUIRED PER DAY I II III IV V VI VII VIII MALT SPIRIT PRODUCTION [capacity 3.6 tons of malt per day ] For Mashing ( 5800 litres per batch X 4 batches) For washing mashtun (2250 litres per batch X 4 batches) For ferment or cleaning JAGGERY SPIRIT PRODUCTION [capacity 1 ton per day] Dilution Water Wash Water Sub-total 23,200 9,000 1,000 33,200 4,200 500 4,700 Sub-total GRAPE SPIRIT PRODUCTION Cleaning water 500 RE-DISTILLATION PLANT Dilution Water Discharged water as spent Lees from Plant 40,000 Note: All discharge water from the Re-distillation 40,000 Plant is recycled to the Boiler as Boiler Feed water BOILER HOUSE Water requirement (2500 ltr per hour) Less: Water recycled from RD Plant 60,000 40,000 20,000 Sub-total R/O PLANT Feed Water required 65,700 IML BOTTLING PLANTY Water required drawn from R/O Plant Wash water COLING TOWER Sub-total 2,000 2,000 Make-up water requirement Sub-total 15,000 2. Jiggery Spirit Production 4,700 3. Grape Spirit Plant 500 4. RD Plant (dilution water only) 40,000 5. Boiler House (net requirement) 20,000 6. R/O Plant 65,700 7. Wash water for IML Bottling Plant 2,000 8. Cooling Tower (make up water) 15,000 Total 1, 81,100
ANNEXURE 4 Effluent and wash water generated SL. Particulars Effluent water Wash water 1. Malt Spirit Plant 19,128 9,000 2. Jiggery Spirit Plant 4,000 500 3. Grape Spirit Plant 4,000 500 4. IML Bottling 2,000 5. Domestic 15,000 Total 27,128 27,000 SOLID WASTE MANAGEMENT: Quantities of solid wastes before and after expansion and the mode of disposal are detailed in Table given below Details of Solid Waste Management Sl Description of No. waste 1 Broken bottles/glass 2 Corrugated Paper waste Existing Quantity 14.2 tonnes/month 9.5 tonnes/month Proposed Quantity 0.12 Tonne/month 0.015 tonnes/month Mode of Disposal Sent to glass factory Sent to box manufactures for reprocessing 3 Spent grain used barley malt 30.7 tonnes/month 200 tonnes/month To be sold as animal feed for dairy farms 4 ETP sludge 5kgs/day 40kgs/day Will be disposed a manure on land for gardening 5 Waste oil 60 lts/month 10lts/month MS drums to KSPCB authorized agencies. 6 Laminates --- 5.2Tonne/month Will be sold to recyclers 7 Aseptic Packs --- 1.24 Tonne/month 8 PET Bottles ---.196 Tonnes/month 9 Grape Musk --- 37.5 Tonnes/month Will be sold to recyclers Will be sold to recyclers Composting and used as manure
6. BRIEF DESCRIPTION OF EXISTING EFFLUENT TREATMENT PLANT: The entire process effluent classified as Stream-1 after ph correction flows in to Anaerobic Lagoon, followed by Up-flow filter and is further treated by single stage Extended Aeration Activated Sludge Plant. The domestic effluent classified as stream-2 is collected in an independent equalization, from here it is pumped directly @ inlet of the Aeration tank where in it mixes with stream-1 effluent. The combined effluent stream-1 and stream-2 are treated by Single Stage Extended Aeration Activated Sludge Plant. And the entire treated effluent confirming to KSPCB Standards are disposed on land for gardening. 7. WASTE WATER QUANTITY AND QUALITY: (Existing + Proposed Expansion) (Vide Water Balance Chart-Annexure-1) The entire effluent streams are classified in to 4 Streams based on their Organic strength as detailed below: STREAM-1 LOW STRENGTH WASTE STREAM ADPL will have a total work force of around 400 persons which includes both existing and proposed expansion completed. With in house canteen facility. (Accordingly considering the per capita consumption at 55 LPCD Daily water requirement for domestic consumption will be 400x55= 22 KLD Sewage Generation Quantity at 85% of domestic consumption will be 18.7 OR Say 19KLD. The total sewage quantity with the expansion completed will be 19 KLD. STREAM-I Domestic Effluent: Design Flow: 19 KLD BOD-300-400mg/lt COD -600-800 mg/lt TSS -100-200 mg/lt PH-6-8
STREAM-2 LOW STRENGTH WASTE STREAM Washing Effluent Viz: Filter Back wash, RO-reject, Boiler Blow down, Softeners Regeneration Design Flow: 16 KLD PH- 9.8 TDS-1382 mg/lt STREAM -2& 3-MEDIUM STRENGTH WASTE STREAM Washing Effluent Viz: RO Reject, RO back wash, Bottling Washing Machines, Blending Cleaning, Kettle Cleaning Design Flow: (Stream2 + Stream3)16KLD +38KLD=54KLD BOD- 1900-2000mg/lt COD - 3900-4000 mg/lt TSS - 1500 mg/lt ph - 7.8-9 STREAM -4 - HIGH STRENGTH WASTE STREAM + PRE TREATED STREAM2+STREAM-3 Effluent: Spent wash +Spent Leese Design Flow: Stream2,3 & Stream 4 (54KLD+17 KLD=71 KLD) BOD- 5600-6000 mg/lt COD -10,441 mg/lt TSS - 2300 mg/lt ph - 4-5
8. BRIEF DESCRIPTION OF PROPOSED EFFLUENT TREATMENT- PLANT: Stream-1 : Domestic effluent with a maximum flow of 19KLD is gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, followed by equalization for flow balancing with pre-aeration, which will be further pumped in to the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage Extended Aeration Activated Sludge Process (EAASP). Stream-2 & Stream-3: The stream-2 &3 effluents with a maximum flow of (16KLD + 38KLD ) will be gravitated as an common stream in to Bar Screen chamber for physical separation of solids, followed by equalization/neutralization for flow balancing with pre-aeration, and ph adjustment The neutralized effluent will be further mixed with stream-4 at the inlet of existing Anaerobic lagoon. and further treated in the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage EAASP. Where in it mixes with stream-1 effluent for further treatment. Stream-4: The Stream-4 effluents with a maximum flow of 16.76KLD 0R say 17KLD will be gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, and than after ph correction flows in to the existing Anaerobic lagoon, where it mixes with stream 2&3 and than the pre treated stream-4 effluent flows in to the existing aeration tank which shall be used as intermediate equalization tank. The combined stream will be further treated by II stage EAASP. After 2 stage biological treatment. The combined treated effluent post filtration and chlorination will be used on own land for gardening, floor wash, 9. DESIGN OF PROPOSED EFFLUENT TREATMENT PLANT UNITS: I. DESIGN OF STREAM-1 PRE-TREATMENT UNITS: a) Solid Screening : Bar Screen Chamber :(Stream-1-Domestic Effluent) (Proposed): The entire domestic effluent classified as Stream-1 with a maximum quantity of 19 KLD, will be gravitated through a separate network of under ground pipe work into the Bar screen chamber of size:1.0mx1.0mx 1.5m TD..
Provide a chamber of size 1.0m x 1.0m depth to suit sewer gradient, accommodate an inclined bar screen with opening less than 10 mm. Provide a bar screen of 20x6 mm flats with 10 mm spacing in between. Design criteria: Design flow = 19 KLD(Existing=3KLD+Proposed =16KLD) Velocity through screen = 0.8 m/sec Net area of screen = 0.00024/0.8 = 0.00030 sq. m Gross area = 1.2 times the net area of opening Gross area = 1.2x0.00030=0.00036 sq. m. Proposed Size of the screen = 1.0 meter wide x1.0 meter long x 1.5 m TD is adequate. b). Equalisation Tank: (Proposed) The effluent from the Bar Screen Chamber will flow in to the existing equalization tank, of minimum 24hrs capacity. This tank is provided to even out the flow variation, and to provide a continuous feed in to the secondary biological treatment units. Design Flow = 19 cum/day (Existing=3KLD+Proposed =16KLD) Holding capacity proposed = 24 hours Proposed Size of Tank = 3mx3mx 2.1 SWD +0.9m Free board Mode of mixing Proposed = fine bubble diffused aeration for Pre-aeration Hence Adequate c). Raw Sewage Pumps: (Proposed) Since the secondary treatment plant are located on a higher contour, the effluent will be pumped from the equalisation tank in to the Aeration tank. Pumps - 2 No. s = one working and one standby. Type = open impeller non clog pumps. Capacity = 5 cum/hr @ 12-15 m Head Hence Adequate
II. DESIGN OF STREAM-2 & STREAM-3 PRE-TREATMENT UNITS: The Stream-2 &3 effluents with a maximum flow of (16 KLD + 38 KLD ) will be gravitated as an common stream in to Bar Screen chamber for physical separation of solids, followed by equalization/neutralization for flow balancing with pre-aeration, and ph adjustment The neutralized effluent will be further pumped in to the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage EAASP. Where in it mixes with stream-1 effluent for further treatment. a) STREAM-2 & 3: 1. Solid Screening : Bar Screen Chamber : (Proposed). The entire effluent washings, with a maximum quantity of 54 KLD, will be gravitated through a network of under ground pipe work into the Bar screen chamber of size:1.2mx1.5mx 1.5m TD. Provide a chamber of size 1.2m x 1.5m depth to suit sewer gradient, accommodate an inclined bar screen with opening less than 10 mm. Provide a bar screen of 20x6 mm flats with 10 mm spacing in between. Design criteria: Design flow = 54 KLD (Existing=6KLD+Proposed =48KLD) Velocity through screen = 0.8 m/sec Net area of screen = 0.000625/0.8 = 0.00078 sq. m Gross area = 1.2 times the net area of opening Gross area = 1.2x0.00078=0.000936 sq. m. Proposed Size of the screen = 1.2 meter wide x 1.5meter long x 1.5 m TD is adequate. b). Equalization Tank & Neutralization Tank: (Proposed) The effluent from the Bar Screen Chamber will flow in to the existing equalization tank, of minimum 24 hrs capacity. This tank is provided to even out the flow variation, and to provide a continuous feed in to the secondary biological treatment units. Design Flow = 54 cum/day(existing=6kld+proposed =48KLD) Holding capacity Proposed = 24 hours Proposed volume of the tank = 40 cum.-2 No (Hence adequate) Provide 2 No tank each of size = 4mx4mx3.0m TD-2 No
Provide 2 No. Agitators 1 No in each tank with necessary dozing arrangement for rapid mixing and ph correction. c). Raw Effluent Pumps :( Proposed): Since the secondary treatment plants are located on a higher contour, the equalized, neutralized effluent will be pumped from the equalization /neutralization tank in to I stage aeration tank. Pumps - 2 No. s = one working and one standby. Type = open impeller non clog pumps. Capacity = 8 cum/hr @ 12 m-15m Head III. DESIGN OF STREAM-4 PRE-TREATMENT UNITS: STREAM-4: a. SOLID SCREENING: INLET CHAMBER: (Existing): The entire effluent washings, with a maximum quantity of 16.76 KLD or say 17KLD, will be gravitated through a network of under ground pipe work into the existing inlet chamber of size: 1.0mx1.0mx 1.2m TD. Provided a chamber of size 1.0m x 1.0m depth to suit sewer gradient, accommodate an inclined bar screen with opening less than 10 mm. Provide a bar screen of 20x6 mm flats with 10 mm spacing in between. Design criteria: Design flow = 17 KLD (Existing=3KLD+Proposed =14KLD) Velocity through screen = 0.8 m/sec Net area of screen = 0.00020/0.8 = 0.00025 sq. m Gross area = 1.2 times the net area of opening Gross area = 1.2x0.00025=0.0003 sq. m. Existing Size of the screen = 1.0 meter wide x 1.0meter long x 1.2 m TD Is adequate. b. ANAEROBIC LAGOON: (Existing) The effluent from the Inlet Chamber post neutralization will flow in to the existing anaerobic lagoon, of minimum 26 DAYS holding capacity. The anaerobic decomposition will take place specifically designed for high BOD & COD reductions. Design Flow = 17 cum/day (Existing=3KLD+Proposed =14KLD) Design Flow (Stream2+Stream3+Stream-4) = (16+38+17=71 KLD) Design BOD = 6000 mg/lt Envisaged Efficiency post treatment = 70% average BOD at the out let of Anaerobic lagoon = 1800 MG/LT Existing volume of the tank = 1800 cum. (Hence adequate)
c. INTERMEDIATE EQUALIZATION TANK: (Existing Aeration Tank Used As Intermediate Equalization Tank) The effluent over flow from the Anaerobic Lagoon will flow in to the existing Aeration tank now proposed to be used as intermediate equalization tank, of minimum 24hrs capacity. The stream-1, stream2&3 from their respective equalization /neutralization tanks will be pumped in to this Combined Effluent Intermediate Equalization Tank. The combined all 4 streams from the equalization tank will be pumped in to the proposed II stage EAASP plant followed by filtration Design Flow = 90 cum/day (Stream-1+Stream2&3+Stream-4) Holding capacity existing = 33 hours Existing volume of the tank = 125 cum. Existing Size of Tank = 10mx5mx 2.5m SWD Mode of mixing Proposed = F fine bubble diffused aeration for Pre-aeration Hence Adequate d. RAW EFFLUENT TRANSFER PUMPS: (Proposed) Since the secondary treatment plant are located on a higher contour, the effluent will be pumped from the equalization tank in to the proposed I stage Aeration tank. Pumps - 2 No. s = one working and one standby. Type = open impeller non clog pumps. Capacity = 8 cum/hr @ 12-15 m Head Hence Adequate IV. TWO STAGE EXTENDED AERATION ACTIVATED SLUDGE TREATMENT: a. AERATION TANK I STAGE: (STREAM-1+ STREAM2+STREAM-3+STREAM-4) : The Pre-treated effluent (Stream-1, 2, 3&4) is pumped from the respective equalization / neutralization tank in to first stage aeration tank & is further treated by second stage extended aeration activated sludge treatment which results in the reduction of BOD, and COD by 95 to 97%. Design Flow = 90 KLD DESIGN BOD = 1500-2000mg/lt
ASSUMPTIONS MLSS = 4000 mg/lt F/M = 0.10 Total BOD load = 180 kg/day Aeration tank volume required = 450 cu. M Provide Aeration tank size = 15 m x 9 m x 3.5m SWD -1no. Hence adequate. b. DIFFUSED AERATION SYSTEM: Kg of BOD/day = 180 Kg of oxygen required/day = 360 (Considering 2 kg of oxygen required/day for every Kg of BOD removed.) %age of oxygen in air = 0.23 Density of air = 1.2 %age of oxygen transfer at 3.5 m SWD = 0.20 Therefore air requirement in cum/hr = 700 ------A Transfer rate of oxygen in 1mt long membrane diffusers = 10cum/hr Number of membranes required is 700/10 = 70 No Provide 70 meter (i.e 1 meter-70 No in suitable rows to be provided in I stage Aeration tank to ensure uniform air distribution). Hence adequate. c. SECONDARY CLARIFIER I STAGE: The over flow from the I stage aeration tank is taken in to the secondary clarifier for separation of biological floc. Average flow = 90 cu. m/day Design flow = 180 cu.m/day (Considering 2 times the average flow to accommodate for sludge volume) Sludge Re-circulation = 100% Surface loading = 25 cu. m/sq. m/day Required Area of Clarifier = 7.2 sq. m Required Size of clarifier = 4m x4mx3m SWD Provide Size of clarifier = 4mx4mx 3m SWD Hence adequate.
d. AERATION TANK-II STAGE: The over flow from the Clarifier is further treated by Second stage extended aeration activated sludge treatment which results in the reduction of BOD and COD by 95 to 97%. Design Flow = 90 KLD DESIGN BOD = 400 mg/lt (Considering 80% BOD removal in I stage treatment) ASSUMPTIONS MLSS = 4000 mg/lt F/M = 0.10 Total BOD load = 36 kg/day Aeration tank volume required = 90 cu. M Provide a Aeration tank size = 7 m x 4m x 3.5 m SWD -1No Hence adequate e. DIFFUSED AERATION SYSTEM: Kg of BOD/day = 36 Kg of oxygen required/day = 72 (Considering 2 kg of oxygen required/day for every Kg of BOD removed). %age of oxygen in air = 0.23 Density of air = 1.2 %age of oxygen transfer at 3.5 m SWD = 0.2 Therefore air requirement in cum/hr = 150 ------B Transfer rate of oxygen in 1mt long membrane diffusers = 10cum/hr Number of membranes required is 150/10 = 15 Provide 15 meter (i.e 1 meter-15 No in suitable rows to be provided in II stage Aeration tank to ensure uniform air distribution). Provide capacity of blowers 2 No. blowers of capacity 300 cum/hr 2 Nos operating at a pressure of 0.5 KSC pressure, (The provided capacity of blower will meet air requirement for aeration tank II stage, Sewage & Effluent equalization tank for pre-aeration ). Hence adequate
f. FINAL CLARIFIER: The over flow from the II stage aeration tank is taken in to the final clarifier biological floc. for separation of Average flow = 90 cu. m/day Design flow = 180 cu.m/day (Considering 2 times the average flow to accommodate for sludge volume) Sludge Re-circulation = 100% Surface loading = 25 cu. m/sq. m/day Required Area of Clarifier = 7.2 sq. m Required Size of clarifier = 4m x4mx3m SWD Provide Size of clarifier = 4mx4mx 3m SWD Hence adequate. g. SLUDGE DRYING BEDS : -6 Nos To de-water & dry the excess sludge generated from the above treatment. Drying period : 10 days Sludge loading rate : 0.25 kg/sq. m Proposed minimum Size : 5m x 5m x 1.5 m-6 no.s Capacity : 150 Sq. m Hence adequate h. SLUDGE PUMPS: Available 4 No. pumps 2 no for the first stage clarifier & 2no for the second Stage clarifier. With one working and one standby) Capacity : 10 cum/hr @ 12 m head-4 NOS Type : Open Impeller Non Clog centrifugal mono block pumps Solid handling size : up to 50 mm Hence adequate Duty: To pump the excess biological sludge from the second stage clarifier in to the sludge drying beds and return sludge to the respective I & II stage aeration tank.
i) CLARIFIED EFFLUENT SUMP / FINAL TREATED EFFLUENT SUMP : The overflow from the final clarifier are collected in an sump from where it is pumped into an Pressure Sand, and Activated Carbon filter for further polishing of the treated effluent. Design flow = 90 KLD Retention time proposed -22 hours storage =80 cum Proposed tank size = 8m x 4m x 3m TD - 2 No Hence adequate. j. FILTER FEED PUMPING: Pumps - 2 nos. Capacity : One working and one standby. : 15 cum / hr @ 30m Head k. PRESSURE SAND FILTER & ACTIVATED CARBON FILTER : (ACF) The treated effluent are pumped into the Pressure sand filter followed by Activated carbon Filter for polishing the effluent and to reduce turbidity, suspended solids, color. Design Flow : 90 KLD Considering 10 hrs operating of the filter Flow/hr : 9 cum/hr Considering the loading rate at 5 cum/sq. m/hr Required area of the filter : 1.8 sq. m Required diameter of the filter : 2 m diameter -1 No each Hence adequate l. LAND REQUIRED FOR USING TREATED EFFLUENT: The daily generation of treated effluent = 90KLD Out of the total 90KLD of treated effluent about 10KLD will be used for floor washings, Fire fighting make up water Balance 80KLD will be used for irrigation.. Since the soil is sandy loam Considering a loading rate @ 170 cum/sq.m/day Land required for using treated effluent =80x2.47/170= 1.16 acres. Available vacant for utilizing treated effluent is 2.3 acres as against the requirement of 1.16 acres hence adequate.
V. SUMMARY AND CONCLUSION: (WASTE WATER TREATMENT & DISPOSAL): Effluent Treatment and Disposal: This Adequacy report is prepared to check the adequacy of the existing ETP, and the recommend the required up-gradation of CETP as necessary to meet the combined existing and proposed effluent load due to the proposed expansion and for treating the same and conserving the entire treated effluent on own land for irrigation confirming to KSPCB on land discharge standards. Further, it is to be noted that their will not be any additional Air Pollution Sources envisaged due to the proposed expansion. The entire effluent stream are classified into 4 streams, based on their organic strength and BOD loading for source segregation and ease in treatment. Stream-1: Domestic effluent with a maximum flow of 19KLD is gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, followed by equalization for flow balancing with pre-aeration, which will be further pumped in to the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage Extended Aeration Activated Sludge Process (EAASP). Stream-2& Stream-3: The stream-2 &3 effluents with a maximum flow of (16KLD +38KLD ) will be gravitated as an common stream in to Bar Screen chamber for physical separation of solids, followed by equalization/neutralization for flow balancing with pre-aeration, and ph adjustment The neutralized effluent will be further pumped in to the Anaerobic lagoon where it mixes with stream-4 effluent which is further treated in the secondary biological treatment at the inlet of I stage Aeration tank designed as II stage EAASP. Where in it mixes with stream-1 effluent for further treatment. Stream-4: The Stream-4 effluents with a maximum flow of 17KLD will be gravitated as an independent stream in to Bar Screen chamber for physical separation of solids, and than after ph correction flows in to the existing Anaerobic lagoon where it mixes with stream2 & stream3, and than the pre treated stream-4 along with stream2 &3 effluent flows in to the existing aeration tank which shall be used as intermediate equalization tank where it with the mixes with stream-1. The combined stream will
be further treated by II stage EAASP. After 2 stage biological treatment. The combined treated effluent post filtration and chlorination will be used on own land for gardening, floor wash, The design details are presented in Section IV of this report. The project report is enclosed separately along with this report. The layout plan of CETP is enclosed in Annexure -2 of this report. The sludge generated from the ETP will be used as manure for irrigation. The quantity of solid waste it s collection, treatment and disposal are enclosed below. The proposal is submitted to KSPCB for approval. The entire CETP work will be completed in 5 months of time after getting the necessary approval from KSPCB. VI. SOLID WASTE MANAGEMENT: Quantities of Solid wastes before and after expansion and the mode of disposal are detailed in Table given below Details of Solid Waste Management Sl. No. Description of waste Existing Quantity Proposed Quantity Mode of Disposal 1 Broken bottles/ glass 2. Corrugated Paper waste 3. Spent grain used barley malt 14.2 tonnes/month 0.12 Tonne/month 9.5 tonnes/month 0.015 tonnes/month 30.7 tonnes/month 200 tonnes/month Sent to glass factory Sent to box manufacturers for re-processing To be sold as animal feed for dairy farms 4. ETP sludge 5 kgs/day 40 kgs/day Will be disposed a manure on land for gardening 5. Waste oil 60 lts/month 10 lts/month MS drums to KSPCB authorized agencies. 6. Laminates --- 5.2 Tonne/Month 7. Aseptic Packs -- 1.24 Tonne/month 8. PET Bottles ---.196 Tonnes/month 9. Grape Musk --- 37.5 Tonnes/Month Will be Sold to recyclers Will be Sold to recyclers Will be Sold to recyclers Composting and used as manure