Manimed Pharma: Effluent Treatment Plant Installation

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Manimed Pharma: Effluent Treatment Plant Installation

Project : Effluent Treatment Plant Installation

Client : Manimed PharmaCeutical

Plant Location : Ahmedabad, Gujarat.

Design Concept :

Plant Capacity……………………. 2 M3/hr
Flow Rate…………………………… 0.334 M3/hr
Service Cycle………………………. 6 hrs

     Plant Capacity

Inlet Parameter of  Effluent Waste Water :

Sr. No. Parameter Unit Averages
1.        pH…………………………….. -………………………………… 6-8
2.        TDS……………………………. ppm…………………………… 1200-2000
3.        TSS…………………………….. ppm…………………………… 200-400
4.        Color………………………….. ppm…………………………… 40-100
5.        BOD…………………………… ppm…………………………… 190-300
6.        COD…………………………… ppm…………………………… 450-5000
7.        Oil & Grease………………. ppm…………………………… 2
8.        Sulphate…………………….. ppm…………………………… 99-200
9.        Chloride……………………… ppm…………………………… 400-600
10.    Ammonical Nitrogen….. ppm…………………………… 39-100
11.    Sodium……………………… ppm…………………………… 520-600

Inlet Effluent Parameter

Outlet Parameter of  Treated  Effluent :

Sr. No. Parameter Unit Averages
1.        pH…………………………….. -………………………………… 6.5   to 7.8
2.        TDS……………………………. ppm…………………………… 1200
3.        TSS…………………………….. ppm…………………………… 100
4.        Color………………………….. ppm…………………………… 100
5.        BOD…………………………… ppm…………………………… 30
6.        COD…………………………… ppm…………………………… 100
7.        Oil & Grease………………. ppm…………………………… 2
8.        Sulphate…………………….. ppm…………………………… 1000
9.        Chloride……………………… ppm…………………………… 600
10.    Ammonical Nitrogen….. ppm…………………………… 50
11.    Sodium……………………… ppm…………………………… 520

Outlet Effluent Parameter

Effluent Treatment Process :

ETP Process Layout

ETP Process Layout

 

Sr No. ETP Process  Unit Size(LxBxH) in M Capacity (Liter)
0 Effluent Inlet – –
1 Oil & Grease Chamber 0.5 x 0.5 x 1 500
2 Collection cum neutralization tank 2 x 1.5 x 2 6000
3 Settling Tank 2 x 2x 2 8000
4 Sludge Drying Bed 1.2 x 1.2 x 2 2880
5 Pressure Sand Filter 0.2 x 1.2 100
6 Activated Carbon Filter 0.2 x 1.2 100
7 Water Supply for Gardening Propose – –
8 Water Evaporation System 500 Liter/Day 500 Liter/Day

ETP Process Unit Detail

Effluent Treatment Process Description :

Sr.No. Process Unit Process Description
1.        Oil & Grease Chamber Washing water from Tablet, Ointment unit  transfer to   Oil & Grease Tank to trap the Oil Content.  Oil and water will be separate through  density difference.  Water having more density forms the lower layer and oil having less density  forms the upper layer.
2.        Collection cum Neutralization Tank Effluent from oil & grease tank  transfer to collection cum neutralization tank by gravity base. Initially pH of effluent water set up  at 8.5 by chemical dosing of  direct flocculants. Sub sequently   pH raise to 10.5-11.5 by lime dosing. Chemical mixing is done by Agitator having 1 HP Gear Motor & SS Impeller Shaft.  Initially  chemical dosing will help to maximum sludge separation.

Coagulation-Flocculation Separation :

The use chemical re-agent to destabilize and increase the size of the particles ; mixing; increasing of flog size

pH of effluent  will be maintain at 7.8  settled for  3 hrs  then supernant transfer to   settling tank and residual sludge transfer to sludge drying bed through  1 HP mud pump.
3.        Settling Tank Treated effluent from collection cum neutralization tank transfer to settling tank by water transfer pump. Flocculated  water will be settled to remove  the turbidity of water.
4.        Pressure Sand Filter Settled water will be treasnfer to pressure sand filter by water transfer pump. Pressure sand filter remove suspened solids.
5.        Activated Carbon Filter Filtered water from pressure sand filter will be filter out in activated carbon filter to remove the chlorine content and residual.
6. Water supply for gardening Filter out water of carbon filter utilize for gardening purpose
7. Evaporation System If  area  is not enough to avaible for gardening then water will be evaporate in Water Evaporator.

ETP Process Description

Technical Specification :

Oil & Grease Chamber
1 Quantity 1 Nos
2 Type Manual Batch- Density Difference
3 Size 500 Liter
4 MOC Civil Work- 225mm Brick Plaster
Collection Cum Neutralization Tank
1 Quantity 1 Nos
2 Capacity 6000 Liter
3 Design As per drawing
4 MOC Civil Work-225mm Brick Plaster
Alum Dosing System
1 Dosing  Tank capacity 100 Liter
2 MOC HDPE
3 Operation Manual Valve Type
4 Chemical Alum
5 Make Suntex
Poly Electrolyte Dosing System
1 Dosing Tank Capacity 100 Liter
2 MOC HDPE
3 Operation Manual Valve Type
4 Chemical Anion/Cation Polyelectorlyte
5 Make Suntex
pH Maintenance Dosing System
1 Dosing Tank Capacity 100 Liter
2 MOC HDPE
3 Operation Manual Valve Type
4 Chemical HCL / NaOH
5 Make Suntex
Settling Tank
1 Quantity 1 Nos
2 Capacity 8000 Liter
3 Design AS per drawing
4 MOC Civil Work- 225mm brick plaster
Pressure Sand Filter
1 Quantity 1 Nos
2 Capacity 0.5 m3/hr
3 Design Data Min. & Max. Press.  (2.4 -3.5 kg/cm2)
4 MOC FRP
5 Make Pentair
6 Mode of Operation Manual Multiport Valve
7 Media Type Filtration graded sand  & pebbles
8 Design Velocity 6 M/hr
Activated Carbon Filter
1 Quantity 1 Nos
2 Capacity 0.5 m3/hr
3 Design Data Min. & Max. Press.  (2.4 -3.5 kg/cm2)
4 MOC FRP
5 Make Pentair
6 Mode of Operation Manual Multiport Valve
7 Media Type Filtration graded sand  & pebbles
8 Design Velocity 6 M/hr
Sludge Drying Bed
1 Quantity 1 Nos
2 Capacity 2880 Liter
3 Design AS per drawing
4 MOC Civil Work- 225mm brick plaster
Water Evaporation System
1 Evaporator Type Electric Heated
2 Evaporator 500 Litres/day
3 Size 2 Ft [Dia.] x  2.75 Ft [ Height]
4 MOC MS IS 2062
5 Thickness 6 MM Flat Bottom
6 Heating Media Electric
7 Quantity of Heater 3 Nos.
8 Heater Capacity 3 KW Each
9 Total load of heaters 9 KW
10 Insulation With outer side insulation 40 mm with glass wool and coated by 26 gauge aluminium  sheet   with other required connection inlet and outlet
11 Electric.
Dial Type  Thermocouple  “J” Type
Contactor – Schneider  Make
MCB-Schneider Make
Liquid level controller  –  shut off heater when water level low
RYB Light
On/OFF  Push Button – L&T Make
Interconnecting  Piping & Valves
1 Quantity Offered One Lot.
2 Type UPVC /HDPE/GI As applicable Complete Interconnecting  Piping Within The Battery Limits
3 Valves Ball Valve and manual valves as required
4 Supports Pipe Supports  for interconnecting  piping
Instrumentation
1 Pressure Gauges At Feed of carbon filter & pressure sand filter
2 Flow meter Discharge of  Activated Carbon Filter & Pressure Sand Filter
3 Energy Meter HPL Make; Analoge Type KWH Meter 3Ph Four Wire 10-60 Amps

Technical Specification

Civil Work Specification :

Sr. No. ETP Process Unit Size [ L x B X H ] Capacity [ Liter] Civil Work Type Work Scope
1 Oil & Grease Chamber [ 0.5 x 0.5 x 1] M 500 250 mm brick work Client
2 Collection Cum Neutralization Tank [ 2 x 1.5 x 2 ] M 6000 250 mm brick work Client
3 Settling Tank [ 2  x 2 x 2] M 8000 250 mm brick work Client
4 Sludge Drying Bed [ 1.2 x 1.2 x 2] M 2880 250 mm brick work Client

Civil Work Specification

Installed Plant Process Unit  Layout :

ETP Process Layout

Sr No. ETP Process  Unit Size(LxBxH) in M Capacity (Liter)
0 Effluent Inlet – –
1 Oil & Grease Chamber 0.5 x 0.5 x 1 500
2 Collection cum neutralization tank 2 x 1.5 x 2 6000
3 Settling Tank 2 x 2x 2 8000
4 Sludge Drying Bed 1.2 x 1.2 x 1 2880
5 Pressure Sand Filter 0.2 x 1.2 100
6 Activated Carbon Filter 0.2 x 1.2 100
7 Water Supply for Gardening Propose – –
8 Alum Dosing System – 100
9 Poly Electrolyte Dosing System – 100
10 pH Control System – 100
11 Water Evaporation System – 500

ETP Process Unit Detail

Installation Qualification :

Sr. No. Item Name Specification Checked By Status
Oil & Grease Chamber
1 Quantity 1 Nos MTPL Ok
2 Type Manual Batch- Density Difference MTPL Ok
3 Size 500 Liter MTPL Ok
4 MOC Civil Work- 225mm Brick Plaster MTPL Ok
Collection Cum Neutralization Tank
1 Quantity 1 Nos MTPL Ok
2 Capacity 6000 Liter MTPL Ok
3 Design As per drawing MTPL Ok
4 MOC Civil Work-225mm Brick Plaster MTPL Ok
Alum Dosing System
1 Dosing  Tank capacity 100 Liter MTPL Ok
2 MOC HDPE MTPL Ok
3 Operation Manual Valve Type MTPL Ok
4 Chemical Alum MTPL Ok
5 Make Suntex MTPL Ok
Poly Electrolyte Dosing System
1 Dosing Tank Capacity 100 Liter MTPL Ok
2 MOC HDPE MTPL Ok
3 Operation Manual Valve Type MTPL Ok
4 Chemical Anion/Cation Polyelectorlyte MTPL Ok
5 Make Suntex MTPL Ok
pH Maintenance Dosing System
1 Dosing Tank Capacity 100 Liter MTPL Ok
2 MOC HDPE MTPL Ok
3 Operation Manual Valve Type MTPL Ok
4 Chemical HCL / NaOH MTPL Ok
5 Make Suntex MTPL Ok
Settling Tank
1 Quantity 1 Nos MTPL Ok
2 Capacity 8000 Liter MTPL Ok
3 Design AS per drawing MTPL Ok
4 MOC Civil Work- 225mm brick plaster MTPL Ok
Pressure Sand Filter
1 Quantity 1 Nos MTPL Ok
2 Capacity 0.5 m3/hr MTPL Ok
3 Design Data Min. & Max. Press.  (2.4 -3.5 kg/cm2) MTPL Ok
4 MOC FRP MTPL Ok
5 Make Pentair MTPL Ok
6 Mode of Operation Manual Multiport Valve MTPL Ok
7 Media Type Filtration graded sand  & pebbles MTPL Ok
8 Design Velocity 6 M/hr MTPL Ok
Activated Carbon Filter
1 Quantity 1 Nos MTPL Ok
2 Capacity 0.5 m3/hr MTPL Ok
3 Design Data Min. & Max. Press.  (2.4 -3.5 kg/cm2) MTPL Ok
4 MOC FRP MTPL Ok
5 Make Pentair MTPL Ok
6 Mode of Operation Manual Multiport Valve MTPL Ok
7 Media Type Filtration graded sand  & pebbles MTPL Ok
8 Design Velocity 6 M/hr MTPL Ok
Sludge Drying Bed
1 Quantity 1 Nos MTPL Ok
2 Capacity 2400 Liter MTPL Ok
3 Design AS per drawing MTPL Ok
4 MOC Civil Work- 225mm brick plaster MTPL Ok
Water Evaporation System
1 Evaporator Type Electric Heated MTPL Ok
2 Evaporator 500 Litres/day MTPL Ok
3 Size 2 Ft [Dia.] x  2.75 Ft [ Height] MTPL Ok
4 MOC MS IS 2062 MTPL Ok
5 Thickness 6 MM Flat Bottom MTPL Ok
6 Heating Media Electric MTPL Ok
7 Quantity of Heater 3 Nos. MTPL Ok
8 Heater Capacity 3 KW Each MTPL Ok
9 Total load of heaters 9 KW MTPL Ok
10 Insulation With outer side insulation 40 mm with glass wool and coated by 26 gauge aluminium  sheet   with other required connection inlet and outlet MTPL Ok
11 Electric. MTPL Ok
  Dial Type  Thermocouple  “J” Type    
  Contactor – Schneider  Make    
  MCB-Schneider Make    
  Liquid level controller  –  shut off heater when water level low    
  RYB Light    
  On/OFF  Push Button – L&T Make    
Interconnecting  Piping & Valves
1 Quantity Offered One Lot. MTPL Ok
2 Type UPVC /HDPE/GI As applicable Complete Interconnecting  Piping Within The Battery Limits MTPL Ok
3 Valves Ball Valve and manual valves as required MTPL Ok
4 Supports Pipe Supports  for interconnecting  piping MTPL Ok
Instrumentation
1 Pressure Gauges At Feed of carbon filter & pressure sand filter MTPL Ok
2 Flow meter Discharge of  Activated Carbon Filter & Pressure Sand Filter; MTPL Ok
3 Energy Meter HPL Make; Analoge Type KWH Meter 3Ph Four Wire 10-60 Amps MTPL Ok

Installation Qualification

Operation  specification :

Sr. No. ETP Process Unit Segment Action Required Frequency
1 Energy Meter To note down energy meter reading in ETP Manual before starting the electricity in ETP Plant Daily
2 Water Flow Meter To note down the energy meter reading of activated carbon discharge point and water evaporation inlet unit Daily
3 pH Check To Check the pH of effluent Inlet Daily
4 ETP Inlet Point To Check the flow of effluent from process unit to ETP is proper Weekly
  To remove the plastic and other non- treatable waste  from inlet Weekly
5 Oil & Grease Unit To  check the whether Oil is collect in first part of unit or not. Daily
  To collect the excessive oil from past of oil & grease unit through manual operation Weekly
  If there is excessive emulsion type sludge then manually required to extract and dry in sludge drying bed. Weekly
6 Collection cum Neutralization Tank To Take the dosing operation of Non- ferric Alum as per given SOP Calculation Daily
  To Start the Agitator for mixing propose Daily
  To Take the dosing operation of Poly Electrolyte as per SOP Calculation Daily
  To Maintain the pH@7.0   by dosing of  pH Control Daily
  To check the chemical mixing performance through  natural circulation by visual observation. Daily
  If mixing is not proper than ETP Operator will require  to recirculation of water through Water Pump Daily
  If there is excessive sludge found in tank then manual operation for sludge removal required Monthly
7 Alum Dosing Dosing Tank To fill up the alum dosing solution in tank whenever required. Dosing process will be follow the SOP Calculation Daily
8 Poly-Electrolyte Dosing Tank To fill up the poly electrolyte dosing solution tank whenever required. Daily
9 pH Control Unit To fill up the acid/base whatever required for pH Control Weekly
10 Effluent Transfer To transfer the effluent from collection cum neutralization tank to settling tank Daily
11 Effluent Settling Tank To maintain the minimum 4 Hrs.  retention time for water settling tank Daily
  To Drain out sludge in sludge drying bed Weekly
12 Effluent Transfer To Transfer the settled effluent from settling tank to pressure sand Filter by water transfer pump Daily
13 Pressure Sand Filter To Transfer the effluent from settling tank to pressure sand filter by water transfer pump Daily
  To rinse water in pressure sand filter using manual multiport valve operation for 10  minute for 3 times continue. Daily
  To backwash the water in pressure sand filter using  manual multiport valve operation for 10 minute for 3 times continue. Daily
14 Activated Carbon Filter To Transfer the effluent from settling tank to Activated carbon filter by water transfer pump Daily
  To rinse water in Activated Carbon filter using manual multiport valve operation for 10  minute for 3 times continue. Daily
  To backwash the water in Activate Carbon filter using  manual multiport valve operation for 10 minute for 3 times continue. Daily
15 Water Evaporation System To start the water evaporation if gardening area is not enough  for treated water ETP Daily
16 Treated Water Supply for  Gardening To utilize the activated carbon filter water for gardening purpose Daily

Operation Specification

Standard Operation Process for ETP :

Oil &  Grease Tank :

  • To check the supernatant liquid of oil & grease tank
  • If Oil & grease residual found then manually extract by bucket.
  • Check the pH of Effluent

Collection cum Neutralization Tank

  • Start the Water Transfer pump.
  • To Start the agitator for chemical mixing in effluent water.
  • If pH is acidic or neutral then Raise the pH of effluent up to 9 by dosing of lime [150 Gram in 2000 Liter]
  • After raising the pH upto 9, Start the dosing of alum [200 gram in 2000 Liter ] or maintain the pH 7 by dosing of Alum.
  • Once the pH maintain at 7 Start the Cationic polymer dosing [56 gram in 2000 Liter]
  • Maintain water mixing at least 20 minute after the dosing of cationic polymer.
  • [If color residual found in final treated water then also add the bleaching powder in 5 ppm concentration]
  • Stop the water mixing and start the Water Transfer in Settling Tank

Settling Tank

  • Maintain the water settling for 6 Hrs.
  • Transfer the supernatant water for filtration of Evaporation propose.
  • Transfer the settled solid of settling tank to sludge drying bed [Operation is once a week]

Filtration

  • Start the water transfer pump of filtration unit.
  • Operate the activated carbon filter in Rinse & Back Wash mode for 15 minute.
  • Operate the pressure sand filter in Rinse & Back Wash mode for 10 minute.
  • Transfer the treated water for gardening propose.

Evaporation.

  • Feed the water from settling tank to Evaporator and operate evaporator till water completely evaporated.

Sludge Discharge

  • Dried sludge required to supply for GPCB Authorize landfill site

Chemical Requirement in Daily Operation

Sr. No. Chemical Detail Dosing Required for 2000 Liter Effluent Chemical requirement for 100 liter dosing tank for daily operation of 2000 Liter Effluent Treatment
1 Lime 150 Gram /Day 150 Gram /Day
2 Alum 200 Gram / Day 200 Gram /Day
3 Cation polymer 56 Gram /Day 56 Gram /Day
4 Bleaching Powder 37 Gram /Day 37 Gram /Day

 

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