Effluent Treatment Plant Tech Report for LAIL Sugar Mill

2014
Techno Feasibility Report of

Effluent Treatment Plant,, LAIL
/2014
05/07/2014
Lokmangal Agro Ind.Ltd.
Subhash Nagar, Bi.Bi.Darphad,
Tal-North Solapur , Solapur
TECHNICAL DISCUSSION ON MODIFICATION OF

EXISTING ETP PLANT
Revision - 1
Under the Guidance of,
Mr.Mohan Pise ,
Technical Director,
Lokmangal Sugar Ethanol Co-genaration Ind.

Ltd.,Bhandarkavthe,Tal-S. Solapur,Solapur
05/07/2014
TECHNO FEASIBILITY REPORT OF LAIL ,ETP
PLANT
LAIL,BI BI Darphal Revision - 1
INDEX
SL.NO DESCRIPTION PAGE NO.

1 Introduction 2
2 Present Status 2
3 Quality and quantity of effluent 2
3.1 Effluent Generation & Capacity of Proposed ETP 2
3.2 Plant Capacity 3
3.3 Raw Effluent Characteristics 3
3.4 Effluent Standards 4
4 Treatment process 4
4.1 Treatment process 4
4.2 Unit Description 5
4.2.1 Fine Screen Channels 5
4.2.2 Oil & Grease Removal 6
4.2.3 pH Control 6
4.2.4 Equalization Tank 6
4.2.5 Buffer Tank 7
4.2.6 Up flow Anaerobic Sludge Blanket Reactor 7
4.2.7 Aeration Process 8
4.2.8 Secondary Clarifier 9
4.2.9 Disinfection 9
4.2.10 Disposal of Treated Effluent 11
4.2.11 Sludge Dewatering System 11
5 List of Equipments and capacities 11
6 Mass Balance 20
7 Process flow diagram 22
8 P&ID 23
1|P a g e
05/07/2014
PLANT
EFFLUENT TREATMENT PLANT
1. INTRODUCTION.
LAIL having 2500 TCD of sugar cane crushing capacity. It include existing 1250
TCD sugar cane crushing capacity started at year 2002 & then expanded to the
further 1250 TCD.
Similarly we modified our ETP for handling existing 1250 TCD effluent load and
expanded 1250 TCD capacity Effluent load at before crushing season 2014-2015
started .Now ETP is adequate or the handling the load of 2500 TCD can crushing
capacity .
2. PRESENT STATUS
ETP is adequately design for handling the effluent load of 2500 TCD cane crushing
capacity of plant .having primary, secondary& tertiary treatment process with V
notch,Bar screen ,Bagasse & grid settling chamber, Oil & Grease skimmer,
Equalization Tank complete with aeration grid ,Buffer Tank, Chemical Dosing Tank
for neutralization of effluent, Modified UASBR with setting tank arrangements,
Aeration tank complete with aeration grid, diffuser and blower, Secondary clarifier,
Sludge drying bed, MGF feed tank, MGF, Flow meter,Sump for collection of treated
water.
3. QUANTITY & QUALITY OF EFFLUENT
3.1. Effluent Generation & Capacity of Proposed ETP
Lokmangal Agro Ind.Ltd is operating of effluent treatment plant for sugar cane
crushing in premises. Total capacity of ETP of Existing & Expansion manufacturing
unit is 300m3/day .
Effluent Generation from existing Unit (1250 TCD)
Sr.No Description Quantity Unit

1 Industrial Process 125 m3/day
2 Cooling Water 7 m3/day
2|P a g e
05/07/2014
PLANT

Blow down
3 Domestic Effluent 50 m3/day
Total 184 m3/day
Effluent Generation from expansion Unit (1250 TCD)
Sr.No Description Quantity Unit

1 Industrial Process 91 m3/day
2 Cooling Water 18 m3/day
Blow down
3 Domestic Effluent 3 m3/day
Total 113 m3/day
Total Effluent Quantity (Existing & Expansion=2500TCD)= 297 m3/day
3.2. Plant Capacity
Sr.No. Description
ETP Capacity (Modified ) 300 m3/day
Plant Operation Time 24 Hours per day
Treatment Process : UASB Reactor followed by Extended
Aeration as activated sludge with MGF
3.3. Raw Effluent Characteristics
As per raw waste water characteristics data, technical data of existing ETP is
mentioned as below. Based on water supply to different processing & product the
corresponding BOD and COD levels are mentioned. This shows that the BOD and
COD values expected are relatively higher. In view of this and considering overall
scenario and in future entire Effluent will be conveyed, the design raw effluent
characteristics considered as are given in Table below.
CHARACTERISTICS OF RAW WASTEWATER
S.N. Parameter Concentration* Inlet Effluent (assuming)

1 pH 4-11
3|P a g e
05/07/2014
PLANT

2 Total Suspended Solids (TSS) 500
3 BOD (3 days at 27 0 C) 2500 mg/l
4 COD 5000 mg/l
5 TDS 1800 mg/l
6 O&G 30 mg/l
3.4. Effluent Standards
It is proposed to reuse the treated effluent for irrigation & gardening purpose
within the norms prescribed by Maharashtra Pollution Control Board standards
(MPCB). It is proposed to provide disinfection for reduction of coliforms to treated
effluent before discharge.
The tolerance limits for discharge of treated effluent into inland surface water as
considered for design of proposed plant is given in Table.
CHARACTERISTICS OF TREATED WASTEWATER
S.N. Parameter limits

1 pH 6.5 8.5
2 BOD (3 days at 27 0 C) < 100 mg/l
3 TSS < 100 mg/l
4 COD < 250 mg/l
4. TREATMENT PROCESS
This section gives the scope of Work for Effluent treatment plant (ETP). The scope
includes process requirements to achieve final discharge quality standards. The
plant capacity and modules are as indicated below:
ETP of capacity 300 m3/day developed as per the details indicated.
4.1. Treatment Process
Based on the existing system, proposed Upflow anaerobic sludge blanket (UASB)
reactor, Extended Aeration Treatment process is recommended as proposed
process for the plant. The details of proposed system in illustrated in this section.
4|P a g e
05/07/2014
PLANT

4.2. Process Unit Description
The Final Raw effluent discharge from sugar plant from suitably design open
channel & closed pipe as per topographic arrangement of the site.
The proposed scheme of Effluent Treatment Plant would consist of the following
units and as indicated in Figure-1. Sizing and specifications of unit operations given
below are indicative only.
The Effluent Treatment Plant will consist of:
1. V notch
2. Bar screen
3. Bagasse & grid settling chamber.
4. Oil & Grease skimmer.
5. Equalization Tank complete with aeration grid
6. Buffer Tank.
7. Chemical Dosing Tank for neutralization of effluent.
8. Modified UASBR with setting tank arrangements.
9. Aeration tank complete with aeration grid, diffuser and blower
10. Secondary clarifier
11. Sludge drying bed
12. MGF feed tank
13. MGF
14. Flow meter
15. Sump for collection of treated water
4.2.1. Bar Screen/Fine Screen Channels
The main purpose of screens in wastewater treatment is to remove

large particles or debris that may cause damage to pumps and
downstream clogging. It is also recommended that the physical
screening of sugar wastewater should be carried out as quickly as
possible to prevent a further increase in the COD concentration as a
5|P a g e
05/07/2014
PLANT

result of the solid solubilization. Precautionary measures should be
taken to prevent the settling of coarse matter in the wastewater
before it is screened. These requirements include the ratio of depth to
width of the approach channel to the screen, which should be 1:2, as
well as the velocity of the water, which should not be less than 0.6
m/sec. Screens will be cleaned manually and the screened material
disposed of at a landfill site. Fine screen shall consist of SS bars
placed across the channel to trap the floating materials. The Bars
shall arrest the floating materials, which have to be removed
periodically. one manual Fine Screens are considered. The screening
process shall be done by bar Screens with 10 mm clear opening to
trap the floating materials. The screens shall be designed to handle
ultimate peak flow.
O & G Design
Flow 300 m3/day
Flow 12.50 m3/hr
HRT 1.2 hr
Volume required 15 m3
4.2.2. Oil & Grease Removal
The screened effluent shall flow through oil and grease skimmer. Oil
and grease will be removed in oil and grease separator and effluent
will be passed through equalization tank.
4.2.3. pH Control
This may be directly attributed to the different process parameters.

The optimum pH range for biological treatment plants is between
6.5 and 8.5. Extreme pH values can be highly detrimental to any
biological treatment facility, not only for the negative effect that it
will have on the microbial community, but also due to the increased
corrosion of pipes that will occur at pH values below 6.5 and above
10. Therefore, some form of pH adjustment as a pretreatment step is
advised before wastewater.
4.2.4. Equalization Tank
Equalisation tank is used to overcome the operational problems

caused by variations in influent wastewater flow and characteristics
of wastewater. It improves the performance of downstream process
6|P a g e
05/07/2014
PLANT

and to reduce the size and cost of downstream treatment facilities.
The equalization tank will be provided with aeration of coarse
bubble type to avoid settlement of solids and turning septic. The
principal benefits of equalization tank are
Biological treatment is enhanced due to elimination of shock
loading
Effluent quality and thickening performance improved in
biological process and improved consistency of solids loading
Improves chemical feed control and process reliability
Equalisation tank
Flow 300 m3/d
13 m3/hr
HRT 12 hr
Volume 150 m3
SWD 3
C/s area 50
Compartments 1
4.2.5. Buffer Tank
In buffer tank the complex organics in the wastewater is subjected to

hydrolysis. The hydrolyzed effluent shall be pumped from the buffer
tank for anaerobic treatment in the UASBR reactor.
Design Flow 12.50 m3/hr

Detention Time 12.0 hrs
Volume Reqd. 150.0 m3
Provide Liquid Depth 3.0 m
Area Required 50.0 m2
Diameter 8.0 m
4.2.6. Up flow Anaerobic Sludge Blanket Reactor
UASB reactor consists of mainly feed distribution network at the

bottom, sludge blanket approximately mid height of reactor and the
gas, liquid, solid separator at the top of reactor. In UASBR process
the bacteria responsible for digestion process are present in the form
of sludge blanket. The bacteria grow and reside as bacterial flocks
suspended in the up flow effluent stream. The bacteria take upon
organic content of waste water to metabolize it and produce biogas
7|P a g e
05/07/2014
PLANT

and biomass. UASB reactor operates in the mesophillic range of
temperature, i.e.36-40 deg cel. The pH inside the reactor is usually
kept around 7.2 while proper ratio of volatile acid and alkalinity is
maintained.
Biogas is collected at the top of the reactor and burnt in flare stack.
The anaerobically digested effluent is collected from the network of
gutters and launder and sent to extended aeration tank.
Up-flow Flow Sludge Blanket Rector :-
UASBR 1st UASBR 2nd
Design Flow 6.25 m3/hr 6.25 m3/hr
Organic Load 750 Kg COD/d 750 Kg COD/d
Design Organic Kg Kg
6.00 6.00
Loading Rate COD/m3.d COD/m3.d
Recirculation
50.0 % 50.0 %
selected
Volume Reqd. 150 m3 150 m3
Detention Time 24.0 Hrs 24.0 Hrs
Provide min
24.0 Hrs 24.0 Hrs
Detention Time
Volume. 150.0 m3 150.0 m3
Upflow Velocity 0.3611 m/hr. 0.3611 m/hr.
settling velocity 0.70 m/hr. 0.70 m/hr.
4.2.7. Aeration Process
The secondary treatment is consists of Aeration basin and secondary

clarifier. Raw effluent after anaerobic treatment will be conveyed by
gravity into the aeration Basins for biological treatment of organic
matter. BOD will take place in aeration basin. The aeration basin
will be oxygenated using fine air bubble diffused aeration and will
effectively bio-degrade the organic matter to the required BOD level
of purity.
The bacteria grow by using the organic content in the raw effluent,
and the dissolved oxygen available. Due to constant aeration,
continuous mixing takes place. The bacterial growth increases to a
certain extent. The bacterial reaction is carried out in two stages, for
maximizing the BOD removal efficiency. Air supply is done through
fine bubble diffused aeration grit. To maintain MLSS concentration
8|P a g e
05/07/2014
PLANT

in aeration tank, RAS pumps will pump the settled sludge from
clarifier to inlet of chamber of aeration tank. The wasted sludge will
be taken to sludge drying beds.
DESIGN OF AT
Data
Flow 300 m3/d
BOD 625 mg/l
BOD to ETP 625 mg/l
Diluted Flow 300 m3
AT
Flow 300 m3
BOD 625 mg/l
Outlet BOD 70 mg/l
MLSS 4500 mg/l
F/M 0.1
Volume 304 m3
D.T. 1.39 days
Kg BOD load 19
4.2.8. Secondary Clarifier
The effluent from aeration basin will be passed through secondary

clarifier where sludge will be settled and supernatant will overflow
to treated water tank. The sludge is allowed to settle in the tank with
considering maximum surface overflow rate. The nitrogen removal
takes place in the tank which further reduces the air requirement.
Secondary Clarifier
Flow 300 m3/day
SOR 6 m3/m2/day
Volume required 78 m3
4.2.9. Disinfection
Disinfection of treated effluent is for destruction or removal of

coliform capable of causing disease. The most commonly used
processes in disinfection are chlorine. Chlorine is widely used for
9|P a g e
05/07/2014
PLANT

disinfection in India. The disinfection of treated effluent will take
place by keeping treated effluent in contact with chlorine for 30
minutes.
4.2.10. Disposal of Treated Effluent
Treated effluent after chlorination will be stored into treated water

storage tank for 15 days. Further treated waste water will be
provided for irrigation purpose.
4.2.11. Sludge Dewatering System
In the aerobic digestion the sludge is sufficiently mineralized and

does not need any further treatment before dewatering and disposal.
Sand filtration drying beds will be provided, where sludge will be
dewatered by filtration through sand bed and drying of the
dewatered sludge by solar radiation. Sludge drying beds are
constructed in brick masonry with a sand media supported by gravel
bed and suitable under-drainage arrangement.
Sludge Generation At Effluent Treatment Plant
3. Extended Aerobic System
B. Suspended Solid Sludge
Flow, m3/d 300
Inlet TSS, mg/L 550
Outlet TSS, mg/L 347
TSS Removed, Kg/d 61
Sludge, Kg/d 61.1
Sludge Consistency, % 2.5
Volume of Sludge, m3/d 2.4
A. Biological Sludge from UASB
Flow, m3/d 300
Inlet BOD, mg/L 2500
Outlet BOD, mg/L 625
BOD Removed, Kg/d 563
% Sludge Generation 10
Sludge, Kg/d 56.3
B. Biological Sludge from AT
Flow, m3/d 300
10 | P a g e
05/07/2014
PLANT

Inlet BOD, mg/L 563
Outlet BOD, mg/L 113
BOD Removed, Kg/d 135
% Sludge Generation 10
Sludge, Kg/d 13.5
Total Sludge Generation, m3/d 7
Drying time 7.0
Application Depth 0.3
5. List Of Equipments & Capacities
Specification Table No 1
UNIT SCREEN CHAMBER

Duty For removal of fine floating matter
No. of units 1
Size 1*1.1*0.9
MOC Brick work
Existing Status Cement bonding with bricks becomes loose in plaster side.
Specification Table No. 2
UNIT OIL & GREASE TRAP/Skimmer (existing)

Duty To remove oil and grease
Number of One
Units
Size 4.5*2.7*1.3 SWD + 0.3 FB -1st ,
2.6*2.7*1.3 SWD + 0.3 FB 2nd
2.3*2.7*1.3 SWD + 0.2 FB 3rd
Used tank volume is 15.79 m3 for settling tank & 17.2 m3
11 | P a g e
05/07/2014
PLANT
MOC Brick work (existing)
UNIT EQUALISATION TANK

Duty To attenuate variations in flow and characteristics of wastewater.
Number of One
Units
Size 14.7*10.5*1 m SWD + 0.7 m FB, used tank volume =154 m3
MOC RCC
Specification Table No.4
UNIT Buffer Tank

Duty To provide the nearly condition to bacterial feed, hydrolysis
No. of units One
Size 14.7*9.45*1 SWD + 0.7 m FB

used tank volume 139 m3
MOC RCC /Brick work
UNIT Dosing Tank -chemical dosing tank

Duty Preparation of Dosing chemicals
No. of units One
Size 2.6*2.6*1.4 SWD + 0.3 m FB

used tank volume 9.4 m3
MOC RCC /Brick work
12 | P a g e
05/07/2014
PLANT
UNIT Digester 1st & 2nd

Duty Reduction of pollution in anoxic condition
No. of units Two
Size 5.75 m dia*5.8 m SWD + 0.5 m FB

used tank volume 150 m3 each
MOC RCC foundation of tanks( tanks MOC- MS)
UNIT Buffer tank to Digester 1st & 2nd feed line

pump foundation
Duty For resting the pump & its drive
No. of units Two
MOC RCC
UNIT Flair Stack, Pressure breaker ,Vacuum backer

Duty For safety purpose
No. of units Each two
Size As per design

MOC RCC
UNIT SETTLING TANK

Duty To enable solid liquid separation
No. of units Two
Size 5.12*5.1*2.45 m SWD

MOC RCC
13 | P a g e
05/07/2014
PLANT
UNIT AERATION TANK

Duty To enable oxidation of the wastewater
Number of One
Units
Volume 16*7.6*2.5 m SWD + 0.5 m FB
MOC RCC
UNIT SECONDARY SETTLING TANK

Duty To enable solid liquid separation
No. of units One
Size 7.7 m internal dia X 1.7 SWD + 0.2 m FB

MOC RCC
UNIT SLUDGE DRYING BEDS

Duty For dewatering and drying of sludge.
Number of Units Four
14 | P a g e
05/07/2014
PLANT
Size 7.7*4.2*1 m each +0.2 m FB
MOC Base in PCC and walls in brick work.
UNIT Pump foundation of Sludge recirculation pumps

Duty -
Number of Units Two

Size -
MOC RCC
UNIT Pump foundation of MFG feed pumps (NEW)

Duty -
Number of Units Two

Size -
MOC RCC
UNIT Final treated collection tank

Duty To collect treated effluent
Number of Units One
Size 4500 m3 holding capacity
MOC RCC
UNIT ETP laboratory (NEW)
15 | P a g e
05/07/2014
PLANT
Duty For performing the Analysis
Number of Units One

Size As per standard ( 12*12 feet)
MOC Brick work
5.2 Mechanical works:
Specification Table No. : 17
UNIT SCREENS
Duty To retain coarse matter in

wastewater
No. of units Two ( coarse screen)
Screen spacing 10 mm center to center
Size 10 mm thick and 50 mm deep
MS Raking arm 1 no. 1.3 m long
MOC MSEP.
UNIT OIL SEPERATORS (EXISTING)
Duty To enable skimming of oil floating on the surface of Oil

& Grease tank
No. of units One
Size Gear mechanism for skimming of oil with belt.
MOC -
16 | P a g e
05/07/2014
PLANT

UNIT Feed PUMPS
Duty Lift the food from buffer to Digester
No. of units Two (1 W + 1 S at peak conditions)
Capacity 20 cum/hr.
Head 10-12 m.
UNIT CLARIFIER MECHANISM
Duty To provide effective separation of organic floc from effluent.
No. of units one
Size Suitable Clarifier mechanism ,Scraper arm speed shall be 20-

30 RPH.The central shaft directly coupled through a
reduction gear box of Radicon / Elecon /Shanthi or
equivalent make.
UNIT AERATION GRID FOR EQUALISATION TANK
Duty To bubble air for mixing and to avoid solids from settling
No. of units One complete with piping network and Existing blower
Size To suit size of equalization tank. Header on center of

tank with 4 inch pipe line, with attaching 2 inch pipe line
at after every 1 meter interval on both side,core system
pipe line having 3-5 mm holes for air passing.
Type Piping network with header and laterals.
MOC UPVC
17 | P a g e
05/07/2014
PLANT
UNIT Dosing Tank Stirrer
Duty Proper stirring of solution .
No. of units one
UNIT BLOWERS (Existing)
Duty To supplement air to the air grid.
No. of units Two ( 1 operational & 1 stand-by)
Rating 20 HP each; 786 m3/hr @ 4 kg/cm2
Type Twin lobe rotary type.
UNIT AERATION GRID FOR AERATION TANKS

Duty To supply air from blower to diffusers.
Number of Units One
Size To suit size of aeration tank.

MOC UPVC
Specification Table No. :26
UNIT DIFFUSERS
Duty To supplement air in aeration tank for bio-chemical oxidation.
No. of units 50
MOC EDPM rubber fine bubble diffusers.
18 | P a g e
05/07/2014
PLANT
UNIT SLUDGE RECIRCULATION PUMP
Duty To recycle sludge from settling tank to aeration

tank.
No. of units Two ( one as 100% stand-by )
Capacity 10 cum/hr.
Head 10 m.
Type Non clog, centrifugal pumps.

Inter Connecting pipes & valves:-
SI. No. From To Flow type

1 Bar Screen Oil & Grease Trap By gravity
2 Bar Screen Chamber Bagasse & Grid settling-By gravity
chamber
3 Bagasse & Grid settling Oil & Grease skimmer By gravity
chamber
4 Oil & Grease skimmer Equalisation Tank By gravity
5 Equalization Tank Buffer Tank By gravity
6 Buffer UASBR 1 & 2 By pump
7 UASBR 1 & 2 Settling tank By gravity
8 UASBR 1 & 2 SDB By gravity
9 Settling Tank Aeration Tank By gravity
10 Aeration tank Secondary Clarifier By gravity
11 Secondary Clarifier MGF feed tank By gravity
12 MGF feed tank MGF By pump
13 MGF Final Main Drain By pump
14 Clarifier sludge SDB By pump
19 | P a g e
05/07/2014
PLANT
6. MASS BALANCE STREAMS TABULATION FOR EACH UNIT OPERATION FOR 2500 TCD SUGAR CANE CRUSHING PLANT
Tentative Percent Reductions across each Stage of Treatment

O&G
Details Flow m3/d pH COD mg/L BOD mg/L TSS mg/L TDS mg/L
mg/L
Characteristics of combined effluent 300 4.0 - 11.0 5000 2500 550 60 1800
% Reduction in Primary O & G Trap 0 0 0 90 0
Characteristics of effluent after O & G 300 7.0 - 8.0 5000 2500 550 6 1800
% Reduction in Primary Anaerobic
80 75 10 15 15
(UASBR)
Characteristics of effluent after UASBR 300 7.0 - 8.0 1000 625 495 5 1585
% Reduction in primary settling tanks 10 10 30 15 0
Characteristics of effluent after Settling
300 7.0 - 8.0 900 563 347 4 1585
Tank
% Reduction in AT 70 80 0 0 0
Characteristics of effluent after AT 300 7.0 - 8.0 270 113 347 4 1585
% Reduction in Secondary CL 5 5 85 0 0
Characteristics of effluent after Sec CL 300 7.0 - 8.0 257 107 52 4 1585
% Reduction in MGF/Clorination 10 15 0 0 0
Characteristics of effluent after MFG 300 7.0 - 8.0 231 91 52 4 1585
20 | P a g e
05/07/2014
PLANT
7. Process Flow Chart
23 | P a g e
05/07/2014
/2014
TECHNO FEASIBILITY REPORT OF LAIL ,,ETP
PLANT
24 | P a g e
05/07/2014
PLANT
8. P&ID
33 | P a g e
05/07/2014
PLANT
34 | P a g e
05/07/2014
PLANT
35 | P a g e
05/07/2014
PLANT
36 | P a g e

Effluent Treatment Plant Tech Report for LAIL Sugar Mill

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Effluent Treatment Plant Tech Report for LAIL Sugar Mill

Uploaded by

Copyright:

Available Formats

2014

Techno Feasibility Report of

TECHNICAL DISCUSSION ON MODIFICATION OF

Under the Guidance of,

Lokmangal Sugar Ethanol Co-genaration Ind.

LAIL,BI BI Darphal Revision - 1

SL.NO DESCRIPTION PAGE NO.

LAIL,BI BI Darphal Revision - 1