PROJECT - AT A GLANCE

OBJECTIVE

Environmental restrictions on effluent discharge requires manufacturing units to install pollution control systems to remove color, BOD, COD and TDS. The objective of the report is to design, engineer and supply suitable State of the Art effluent treatment and recycling plant to be installed at M/s. Jinah Automotive India Pvt Ltd, Kilay Village, Sriperumbudur taluk, Kancheepuram District - for treating the trade effluent from their process house to totally remove the color, BOD, COD & TDS to the standards as specified by Tamilnadu Pollution Control Board.

TREATMENT PROCESS The most modern pollution control equipments like Reactivator clarifier, Coalescer pack system , Floating aerators, Pressure Sand Filter ,Activated Carbon Filter , Ultra Filtration system , Reverse Osmosis , Filter press, Degasser tower are used to achieve the final quality as specified by the Tamilnadu Pollution Control Board

TREATMENT RELIABILITY

All the equipments offered have proven performance record. These systems are in operation at automotive industry all over India and abroad.

PREFACE
M/s. Jinah Automotive India Pvt Ltd is setting up their manufacturing unit for fittings at Kancheepuram district. The unit will be installing most modern bleaching and dyeing machines to achieve optimum process efficiency. Because of their better efficiency, they consume less water and chemicals, which results in Environment friendly operation. M/s. Jinah Automotive India Pvt Ltd are interested to install a most modern effluent treatment plant and re-cycling plant at their process house for the treatment of process house effluent with respect to color removal, BOD, COD and TDS to meet the standards specified by Tamilnadu Pollution Control Board.

M/s. CHEMPURE TECHNOLOGIES PVT LTD . was assigned to undertake the above contract for design, engineering, supply, erection and commissioning of Waste water treatment facility to treat and re-use the effluent generated from the process house. This report brings out the details regarding information on manufacturing operations, waste water flow details, characteristics, treatment proposal, design philosophy, choice of equipment and plant description.

PROCESSING CAPACITY

M/s. Jinah Automotive India Pvt Ltd will be installing process machinery to carry out manufacturing of fittings for motor braking system. The unit will have a total capacity for manufacturing 17,200,000 Nos of female fittings per year and 17,200,000 Nos of eye joints.

PROCESS MACHINERY

As discussed earlier, M/s. Jinah Automotive India Pvt Ltd had installed State of the Art process machines for various processes. These machines are the latest available in the world and use the most modern technology to achieve best results with maximum efficiency. The higher efficiency results in stochiometric usage of chemicals, which leads to minimum pollution load. Further the higher efficiency dyes used results in exhaustion levels of 95% which levels only minimum residues in the rinsed effluent. The overall water consumption is also reduced due to short liquor ratio offered by this modern machinery.

PROCESSING DETAILS

BLEACHING The bleaching process is necessary whatever towel is to be given a full white finish or where they are to be dyed in specific shades. In this process the natural coloring matter in the textile material removed by the use of oxidizing chemicals like peroxides and hypochlorites. DYEING Dyeing is necessary to improve the aesthetic and functional values of the yarn. Various classes of dyestuffs are available and are used depending upon specific requirements. The application of different types of dyes requires different types of chemicals. Various salts and auxiliaries are used to aid the process of dyeing. process is reactives only. The dyestuff used in the

PROCESS FLOW SHEET

RAW MATERIAL FORGING

Processes carried out in Korea

SEMI MANUFACTURED MATERIAL CUTTING & MANUFACTURING AUTOMATIC ASSEMBLINGProcesses carried out HEAT TREATMENT SURFACE TREATMENT (Zinc Plating) CARVING INSPECTION FINAL INSPECTION DELIVERY in India

DESIGN RAW EFFLUENT ANALYSIS

We are basing our design on the following typical effluent analysis parameters.

DESCRIPTION PH TDS Trivalent chromium Oil content TSS

VALUES 6.5 8.0 2000 ppm 50 ppm 300 ppm 300 ppm

DOMESTIC EFFLUENT

The characteristics of domestic effluent will be as follows: Parameters pH Suspended solids Total dissolved solids BOD COD Values 7.0 8.0 100 200 ppm 700 800 ppm 200 300 ppm 350 450 ppm

DISHARGE STANDARDS

The following are the discharge standards of Tamilnadu Pollution Control Board for inland surface discharge:

Color Total Suspended solids Total Dissolved solids pH BOD COD Oil & grease

Colorless < 100 ppm < 2100 ppm 5.5 9.0 < 30 ppm < 250 ppm < 10 ppm

TREATMENT SCHEME

The 30 KLD effluent will be collected through pipelines into a below ground collection sump. The wastewater will be pumped to the Reactivator clarifier, where lime, FeCl2 and polymer will be dosed. Then the clear water will be passed into coalescer outlet tank. The 120 KLD effluent will be collected through pipelines into a below ground collection sump where lime and acid dosing for PH corrections, the air required for collection sump will be supplied through floating aerators, then the effluent will pumped to coalescer pack system. The sludge from reactivator clarifier and coalescer pack system will be pumped to sludge holding tank, after it dewatering through filter press Then the overflow effluent from reactivator clarifier & coalescer pack system will be stored in the intermediate tank, from there it will be pumped to PSF and ACF for reduction of suspended solids. The treated effluent from the ACF outlet is stored in the UF feed tank. Then it will be pumped to ultra filtration system with a recovery of 90%. Feed flow to the UF system is 7.5 m 3/hr and 6.75 m3/hr of permeate is recovered from the UF system. UF permeate is stored and fed to the Reverse Osmosis I (RO) designed to operate at a feed flow rate of 6.9 m3/hr with a permeate flow rate of 4.8 m3/hr with 70% recovery. The RO I outlet reject is sent to Reverse Osmosis II designed to operate at a feed flow rate of 4.2 m3/hr with a permeate flow rate of 2.7 m 3/hr with 65% recovery. The permeate flow from RO I & II is will be passed into degasser tower. The reject from RO II is sent to an evaporator at the feed TDS of 20000 ppm 9.6 KLD will get the condensate from evaporator & reject will send to evaporation pond.

TECHNICAL DETAILS

Mechanical Equipment

EFFLUENT TREATMENT PLANT - 30 KLD BAR SCREEN CHAMBER Nos. offered Size Spacing MOC One 2.0 m X 0.5 m 20 mm MSFRP EFFLUENT TRANSFER PUMP - I Nos. offered Flow rate Discharge head Type MOC Drive Make Two nos. (1W+1S) 1.5 m3/hr. 10 mwc Horizontal, Centrifugal, Non clog SS 316 1.0 HP Kirloskar / Anala LIME DOSING SYSTEM - I No. of dosing pump offered Capacity of the pump Mat of Cons of pump Type Mixer Make One 1 m3/hr HMWPE Vertical glandness 1.0 H.P SS316 Process / Equivalent FeCl2 DOSING SYSTEM No. of dosing pump offered Capacity of the pump Mat of Cons of pump One 1 m3/hr HMWPE

Type Mixer Make

Vertical glandness 1.0 H.P SS316 Process / Equivalent POLYMER DOSING SYSTEM

No. of dosing pump offered Type of Pump Capacity MOC Mixer Tank Capacity Make

One. PP - Electronic Metering 0 12 LPH Polypropylene 0.25 HP 200 Ltrs Prominent / UKL REACTIVATOR CLARIFIER

Nos. offered Flow Rate MOC Size Drive

One 1.5 m3/hr MSEP 3.0 M DIA X 2.8 M SWD 1.5 HP/ 1.0 HP SLUDGE TRANSFER PUMP- I

Nos. offered Flow rate Discharge head Type MOC Drive Make

Two nos. (1W+1S) 1.5 m3/hr. 10 mwc Horizontal, Centrifugal, Non clog Cast iron 1.0 HP Kirloskar / Anala EFFLUENT TREATMENT PLANT - 120 KLD

BAR SCREEN CHAMBER - II Nos. offered Size Spacing MOC One 2.0 m X 0.5 m 20 mm MSFRP EFFLUENT TRANSFER PUMP - II Nos. offered Flow rate Discharge head Type MOC Drive Make Three Nos 6.0 m3/hr. 10 mwc Horizontal, Centrifugal, Non clog SS 316 3.0 HP Anala / Equivalent LIME DOSING SYSTEM - II No. of dosing pump offered Capacity of the pump Mat of Cons of pump Type Mixer Make One 1 m3/hr PP Vertical glandness 1.0 H.P SS316 Alfa / Equivalent ACID DOSING SYSTEM No. of dosing pump offered Type of Pump Capacity MOC Tank Capacity Make One. Electronic Metering ( 4 20 mA ) 0 6 LPH Polypropylene 100 Ltrs M- Roy / Prominent

DE EMULSIFIER DOSING SYSTEM No. of dosing pump offered Type of Pump Capacity MOC Tank Capacity Make One. PP - Electronic Metering 0 4 LPH Polypropylene 100 Ltrs M- Roy / Prominent FLOATING AERATOR No. offered Drive Nos. offered Flow Rate CPI Pack Two Nos. 3.0 H.P COALESCER PLATE One 6.0 m3/hr MS angled frame with PVC pack material SLUDGE TRANSFER PUMP- II Nos. offered Flow rate Discharge head Type MOC Drive Make Two nos. (1W+1S) 2.0 m3/hr. 10 mwc Horizontal, Centrifugal, Non clog Cast Iron 1.0 HP Kirloskar / Equivalent EFFLUENT TREATMENT PLANT - 150 KLD FILTER FEED PUMPS Nos. offered Flow rate Head Two (1W+1S) 7.5 m3/hr. 26 mwc

Type MOC Drive Make

Horizontal, centrifugal, Monobloc Cast Iron 2.0 HP Kirloskar / Anala PRESSURE SAND FILTER

Nos. Offered Flow rate Type Size MOC of filter Type of valve Media

One 7.5 m3/hr Vertical 800 mm dia x 1500 mm HOS MSEP Butterfly valves Sand and Pebbles. ACTIVATED CARBON FILTER

Nos. Offered Flow rate Type Size MOC of filter Type of valve Media No. offered Flow rate MOC of filter Bag filter housing No. offered Capacity

One 7.5 m3/hr Vertical 800 mm dia x 2000 mm HOS MSEP Butterfly valves Activated carbon and Pebbles. BAG FILTER One 7.5 m3/hr PP SS 316 UV STERILIZER WITH MS SKID One 7.5 m3/hr

MOC of UV No. of UV lamps & watts Power

SS 316 4 lamps , 520 Watts 1.0 HP SCREW PUMP WITH MOTOR

Nos. Offered Flow rate Head Motor Hp Type MOC Make

Two (1W+1S) 5.0 m3/hr 8.0 bar 3.0 HP Screw type Cast Iron Gekkay / Roto FILTER PRESS

Nos. Offered Flow rate Size Make

One 5.0 m3/hr 610 X 610- 40 Plates Cleartek / Equivalent UF PLANT 7.5 m3/hr (Feed flow rate) UF FEED PUMPS

Nos. offered Flow rate Discharge Head Type MOC Drive Make

Two (1W + 1S) 7.5 m3/hr 26 mwc Horizontal, centrifugal, Monobloc Cast Iron 2.0 HP Kirloskar / Anala CHEMICAL DOSING SYSTEM

No. Offered Type of Pump

One PP - Electronic Metering

Capacity Material of Construction Tank capacity MOC of Tank Make of pump

0 - 6 LPH PP 100 Ltrs HDPE M- Roy / Prominent UF MEMBRANE

No. Offered Membrane area MOC

Two 75 m2 PS UF BACKWASH PUMPS

Nos. offered Flow rate Discharge Head Type MOC Drive Make UF CIP Nos. offered Bag Filter Flow rate Discharge Head Type MOC Drive Make

Two (1W + 1S) 24 m3/hr. 25 mwc Horizontal, centrifugal, Monobloc Cast Iron 5.0 HP Kirloskar / Anala

One 15 m3/hr 15 m3/hr. 25 mwc Horizontal, centrifugal, Monobloc SS 316 3 HP Anala / Kirloskar REVERSE OSMOSIS PLANT STAGE-1

RO I FEED PUMPS No. of offered Flow rate Head Type MOC Drive Make Two (1W + 1S) 6.9 m3/hr. 26 mwc Horizontal, centrifugal, Monobloc Cast Iron 2 HP Kirloskar / Anala ANTISCALANT DOSING SYSTEM No. of offered Capacity MOC of pump Tank Capacity MOC of Tank Make One 0 4 LPH Poly propylene 50 Ltrs High density poly ethylene M- Roy / Prominent ACID DOSING SYSTEM No. of offered Capacity Type MOC of pump Tank Capacity MOC of Tank Make One 0 4 LPH Electronic metering ( 4 20 mA ) Poly propylene 50 Ltrs High density poly ethylene M- Roy / Prominent SMBS DOSING SYSTEM No. of offered Capacity MOC of pump Tank Capacity One 0 4 LPH Poly propylene 50 Ltrs

MOC of Tank Make

High density poly ethylene Positive metering / UKL MICRON FILTER

No.of offered Flow capacity Housing Material of cartridges

One 6.9 m3/hr PP PP HIGH PRESSURE PUMP

No. of offered Capacity Material of construction Head Motor HP Make

One 6.9 m3/hr SS-316 9.1 Bar 7.5 HP Grundfos/ CRI RO I MODULE

No. of offered Material of construction Salt Rejection Recovery No.of elements No.of pressure tubes Elements per tube Size of elements (dia x length) Pressure tube construction

One Thin film composite 98 % 70 % 10 2 5 8 x 40 FRP RO II FEED PUMPS

No. of offered Flow rate

Two (1W + 1S) 4.2 m3/hr.

Head Type MOC Drive Make

26 mwc Horizontal, centrifugal, Monobloc Cast Iron 1 HP Kirloskar / Anala ANTISCALANT DOSING SYSTEM

No. of offered Capacity MOC of pump Tank Capacity MOC of Tank Make

One 0 4 LPH Poly propylene 50 Ltrs High density poly ethylene M- Roy / Prominent ACID DOSING SYSTEM

No. of offered Capacity MOC of pump Type Tank Capacity MOC of Tank Make

One 0 4 LPH Poly propylene Electronic metering ( 4 - 20 m A) 50 Ltrs High density poly ethylene M- Roy / Prominent SMBS DOSING SYSTEM

No. of offered Capacity MOC of pump Tank Capacity MOC of Tank Make

One 0 4 LPH Poly propylene 50 Ltrs High density poly ethylene M- Roy / Prominent MICRON FILTER

No.of offered Flow capacity Housing Material of cartridges

Two (2W + 1S) 4.2 m3/hr PP PP HIGH PRESSURE PUMP

No. of offered Capacity Material of construction Head Motor HP Make

One 4.2m3/hr SS-316 14.4 Bar 7.5 HP Grundfos/ CRI RO II MODULE

No. of offered Material of construction Salt Rejection Recovery No.of elements No.of pressure tubes Elements per tube Size of elements (dia x length) Pressure tube construction

One Thin film composite 98 % 65 % 6 2 3 8 x 40 FRP CLEANING IN PLACE

Nos. offered Flow rate Head Type MOC Drive

One 10 m3/hr. 25 mwc Horizontal, centrifugal SS 316 3.0 HP

HDPE Tank Cartridge filter with housing Make of the pump

500 Ltrs (1 No) 10 m3/hr PP Anala/ Equivalent DEGASSER TOWER WITH PALL RINGS

No. offered Size MOC

One 400mm Dia x 3000mm HOS MSRL DEGASSER AIR BLOWER

Nos. offered Capacity HP Type Make

Two (1W+1S) 155 m3/hr @ 100mm WC 0.25 HP Centrifugal Air Blower Contitherm

Evaporator Our Scope of supply (1Set) COMPLETE SET 1

1. Water Feed Pump to Evaporator 2nos 2. Heat exchanger 2nos 3. Evaporator 1nos 4. Separator -1nos 5. Thermic fluid tank with heaters 1set 6. Concentration Circulation Pump 1no 7. Electrical Panel 1no. Water Feed Pump to Evaporator Flow Head MOC Power Make Heat Exchanger Shell Size Dia Height Total height MOC FF tube Hieght Nos MOC TF Connection Stream Out Let Qty :150mm :6000mm :6500mm : SS304 : 3 inch : 5500mm : 3nos : SS316 : 25mm in&out : 100mm : 3nos : 2000LPH : 25mwc : SS304 : 1hp : grundfos/ITT

Size may vary depends upon the design.

Evaporator Dia HOS MOC Packing Indicator Separator Dia Height MOC Connection Drain EV connection Stream out let : 600mm : 1200mm : SS304 : 25mm : 25mm : 100mm : 75mm : 800mm : 1000mm : SS 304 : Glass wool : Glass indicator

Thermic Fluid Tank LXBXH MOC Capacity Fluid capacity Heating element Type No Of heaters Total Power : 600X600X1500mm : MS : 500Ltrs : 350ltrs : Electrical Heater : SS 316 tubular ; 3nos : 18KW (4.5+4.5+4.5+4.5)

Thermic Fluid Transfer Pump Flow Head Type Power : 750LPH : 25mwc : Internal Gear : 1HP

Concentration Circulation Pump Flow Head MOC Power Make : 12000LPH : 25mwc : SS304 : 1hp : Grunfos/ITT/Tech/eq

Electrical panel III Phase, Single Phase Preventor, RYB indicator, Auto ON/OFF, Manual, RWP,TFP,CCP, instruments A Meter, V Meter, temperature indicator, temperature controller & Thermo couple

ADEQUACY REPORT CIVIL TANK SIZES & EQUIPMENTS

CIVIL TANKS
1) For 30 KLD ETP I) SIZING CALCULATION FOR BAR SCREEN & BAR SCREEN CHAMBER

Average Flow rate = 1.5 m3/hr Peak Factor considered = 3.0 Peak Flow Rate = 4.5 m3/hr

Width of Bar screen chamber = 1.5 x 0.1 = 0.15m Since minimum standard bar screen width is 0.5m we have chosen the same Assumed Invert Level = - 1.0 m TH of Bar screen Chamber =1.6 m BAR SCREEN HEIGHT

Sin 55degree=TH/L L = TH / Sin 55degree Height is 2.0 m There fore the bar screen size 0.5 m x 2.0 m Length of the Bar screen Chamber Length =Tan 55 degree =TH/L = 2.1 M The Bar Screen chamber Size Mentioned is 2.1 m x 0.5 m x 1.6 m Hence the mentioned size is adequate

II) SIZING CALCULATION FOR EFFLUENT COLLECTION SUMP Flow rate = 1.5 m3/hr

Retention Time Considered = 8 Hrs Collection Tank volume = 1.5 x 8 m3/hr

= 12 m3

Collection Tank Size = 2.2 M x 2.2 M x 2.5 M SWD

Air for collection tank =10 m3/hr

No. of CB diffuser =1 No Hence the given tank size & diffuser number are adequate III) SIZING CALCULATION FOR LIME DOSING TANK Volume required Size = = Minimum 1 M3 1.0 M x 1.0 M x 1.0 M SWD

Hence the given size is adequacy

IV SIZING CALCULATION FOR FERRIC CHLOIDE DOSING TANK Volume required Size = = Minimum 250 Ltrs 0.5M x 0.5x 1.0 M SWD

Hence the given size is adequacy

2)FOR 120 KLD ETP I) SIZING CALCULATION FOR BAR SCREEN & BAR SCREEN CHAMBER

Average Flow rate = 6.0 M3/HR Peak Factor considered = 3.0 Peak Flow Rate =18 m3/hr

Width of Bar screen chamber = 1.5 x 0.1

= 0.15m Since minimum standard bar screen width is 0.5m we have chosen the same Assumed Invert Level = - 1.0 m TH of Bar screen Chamber =1.6 m BAR SCREEN HEIGHT Sin 55degree=TH/L L = TH / Sin 55degree Height is 2.0 m There fore the bar screen size 0.5 m x 2.0 m Length of the Bar screen Chamber Length =Tan 55 degree =TH/L = 2.1 M The Bar Screen chamber Size Mentioned is 2.1 m x 0.5 m x 1.6 m Hence the given size is adequate

II) SIZING CALCULATION FOR EFFLUENT COLLECTION SUMP-2 Nos Flow rate = 6 m3/hr

Retention Time Considered = 5 hrs(For Each)

Collection Tank volume

=6x5

= 30 m3

Collection Tank Size = 3.5 M x 3.5 M x 2.5 M (SWD) (For Each)

Air for collection tank = 24 m3/hr(For Each)

No. of CB diffuser

= 3 Nos

Hence the given size is adequate

III) SIZING CALCULATION FOR LIME DOSING TANK Volume required Size = = Minimum 1 M3 1.0 M x 1.0 M x 1.0 M SWD

Hence the given size is adequate

IV) SIZING CALCULATION FOR REACTIVATOR CLARIFIER Capacity of Reactivator Clarifier = 1.5 m3/hr Specific Rate of Filteration Size of the Reactivator Clarifier Hence the given size is adequate 3) FOR 150 KLD(OVERFLOW OF 30 KLD + 120 KLD) = 1.2 m3/m2/hr = 3.0 M Dia x 2.8 SWD

I)SIZING CALCULATION FOR CLARIFIED WATER TANK Average Flow rate: 7.5 m3/hr Retention time Considered = 2 hour Volume of CWT required = 15 m3 The size of the clarified water tank is 2.5 M x 2.5 M x 2.5 M SWD Hence the given size is adequate II) SIZING CALCULATION FOR UF FEED TANK Average Flow rate: 7.5 m3/hr Retention time Considered = 2 hour Volume of UF Feed Tank = 15 m3 The size of the UF Feed Tank is 2.5 M x 2.5 M x 2.5 M SWD Hence the given size is adequate

III)SIZING CALCULATION FOR RO FEED TANK(I)

Average Flow rate: 7.5 m3/hr

Retention time Considered = 2 hour Volume of RO required = 15 m3 The size of the RO Feed tank(I) is 2.5 M x 2.5 M x 2.5 M SWD Hence the given size is adequate

IV) SIZING CALCULATION FOR RO FEED TANK(II)

Average Flow rate: 7.5 m3/hr Retention time Considered = 1.3 hour Volume of RO required =10 m3 The size of the RO Feed tank(II) is 2.0 M x 2.0 M x 2.5 M SWD Hence the given size is adequate V) SIZING CALCULATION FOR REJECT TANK

Average Flow rate: 7.5 m3/hr Retention time Considered ~1.3 hour

Volume of CWT required =10 m3 The size of the clarified water tank is 2.0 M x 2.0 M x 2.5 M SWD Hence the given size is adequate

VI) SIZING CALCULATION FOR SLUDGE HOLDING TANK Sludge Volume per day = 14 M3 The size of the SHT is taken as = 3.2 M x 3.2 M x 1.5 M SWD Air requirement for SHT= 14 m3/hr Hence the given size is adequate

VII) SIZING CALCULATION FOR DEGASSER TOWER Average Flow rate: 7.5 m3/hr Retention time Considered =1 hour Volume of Degasser Tower required = 7.5 m3 The size of the Degasser Tower is 2.3 M x 2.3 M x 1.5 M SWD Hence the given size is adequate

VIII) SIZING CALCULATION FOR EVAPORATION POND Reject Volume produced per day from Evaporator = 3 KLD Evaporation rate considered = 5 L / m2 The size of the Evaporation pond is 25 M x 25 M x 1.0 M Hence the given size is adequate

EQUIPMENTS
I) SIZING CALCULATION FOR PRESSURE SAND FILTER Capacity of PSF No. of units provided Working Units Specific rate of Filtration Size of the Sand Filter = = = = = 7.5 m3/hr One No. One No. 15 m3 / m2 / hr 800 mm Dia x 1500 mm HOS

Hence the given size is adequate

II) SIZING CALCULATION FOR ACTIVATED CARBON FILTER

Capacity of ACF No. of units provided Working Units Specific rate of Filtration Size of the Carbon Filter

= = = =

7.5 m3/hr One No. One No. 20 m3 / m2 / hr

= 800 mm Dia x 2000 mm HOS

Hence the given size is adequate III ) SIZING CALCULATION FOR DEGASSER TOWER WITH PALL RINGS

Capacity of Degasser Tower = No. of units provided Working Units Air Velocity Size of the Degasser Tower = = = =

7.5 m3/hr One No. One No. 60 m3 / m2 / hr 400 mm Dia x 3000 mm HOS

Hence the given size is adequate

IV) SIZING CALCULATION FOR AIR BLOWER FOR DEGASSER TOWER Diameter of the Degasser Tower = 400 mm Air requirement for Aeration tank = 155 m3/hr Air Blower capacity Requirement is = 155 m3/hr @ 100 mmwg Hence the given size is adequate