Banas Dairy ETP Training Report

Training Report on Effluent Treatment Plant at Banas Dairy 2013
Acknowledgement
I am extremely happy to come out with this training report on Effluent

Treatment Plant, a part of environment management in Banas Dairy.
Teaching is the important knowledge, but training develops habit. It

assures that technical student cannot be perfect without practical knowledge.
Hence, the training is great valuable for engineering student; the actual aim of in
training making is to get all operation and process which are carried out in
industries and more about the environment management.
I have divided the subject into the small chapter so that the topics can be
arranged and understood properly.
I am extremely thankful to P. D. Patel Sir Manager of Engineering

Department of Banas Dairy to sanction us for this training. I am also vigorously
thankful to Er. N. P. Pvaya and Rutul Sir for their guidance and support that they
have extended. I have jointly made every possible effort to eliminate all the errors
in this report. Without them effort, the completion of the training would not have
been possible.
I am also greatly thankful to the entire company staff that helped us in the
completion of this training directly or indirectly. We would like to take
opportunity to thank our college staff and parents to encourage us to join this
training.
College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 1

Content:
1. Environment Management 3
2. Introduction of Banas Dairy 7
3. Effluent Treatment Plant 13
4. Effluent Treatment Process 25
5. Effluent Testing Methods 33
Sampling Point 37
Units in ETP 38

1. Environment Management
Environmental resource management is "a purposeful activity with the goal to
maintain and improve the state of an environmental resource affected by human
activities". Environmental resources management aims to ensure that ecosystem
services are protected and maintained for equitable use by future human generations, and
also, maintain ecosystem integrity as an end in itself by taking into consideration ethical,
economic, and scientific (ecological) variables. Environmental resource management tries
to identify the factors that have a stake in the conflicts that may rise between meeting the
needs and protecting the resources.
Environmental resource management can be viewed from a variety of

perspectives. Environmental resource management involves the management of all
components of the biophysical environment, both living (biotic) and non-living (abiotic).
This is due to the interconnected and network of relationships amongst all living species
and their habitats.
The environment also involves the relationships of the human environment, such
as the social, cultural and economic environment with the biophysical environment. The
essential aspects of environmental resource management are ethical, economical, social
and technological which provide for formulation of principles and help in making
decisions. The scientific and technical nature makes environmental resource management
profession to operate in a humanistic and rational mode in the world.
Significance and need of study
Rapid population growth in world causes untold suffering and all related hazards.
It causes pollution and the resources like air, water etc. reduce the quality of life of man.
It causes resource scarce. For these reason Environmental education is need for
population consciousness.

Water:
Environmental water contamination is the leading worldwide cause of death and

disease and it adversely affects over 1 billion people every day in developing countries.
In the world, struggle with water pollution caused by natural disasters and human
activities. Ground and well water sources may also become contaminated due to the
problems associated with industrial dumping, hydraulic fracking, and agricultural
byproducts and wastewater.
Water pollution is caused by domestic sewage (84%) and industrial sewage

(16%). Though the latter has fewer loads on water body, it contains toxic matter
(inorganic and organic) which are more hazardous. It affects plants and organisms living
in these bodies of water. In almost all cases the effect is damaging not only to
individual species and populations, but also to the natural biological communities. So that
the resource ‘water’ is further available in good quality to all of its users.
Air
Air is a part of Earth’s atmosphere, and one of its most important natural
resources. Air is shared and used by all – humans, animals and plants - to sustain life.
Near major industrial centers and in big cities, the air often is of unsatisfactory quality.
Air quality degradation is not new – since the middle of the 19th century, the atmosphere
of the major British cities was regularly polluted by coal smoke in winter, giving rise to
an infamous mixture of fog and smoke known as smog.
Today the emphasis has shifted from the pollution problems caused by industry to
the ones associated with motor vehicle emissions. Also, some methods of waste disposal
release air pollutants and greenhouse gases into the atmosphere. The deterioration of air
quality caused by these different activity sectors is affecting human health and
ecosystems. All contributors to pollution (i.e., industries, transport companies, companies
involved in waste disposal or deforestation activities, but also individual motorists,
individual tree felling, as well as individual burning of wastes) ought to coordinate efforts
so that the resource ‘air’ is further available in good quality to all of its users.
Solid Waste
Municipal Solid waste management (MSWM) constitutes a serious problem in

many third world Cities. Most cities do not collect the totality of wastes generated, and of
the wastes collected, only a fraction receives proper disposal. The insufficient collection
and inappropriate disposal of solid wastes represent a source of water, land and air
pollution, and pose risks to human health and the environment. Over the next several
decades, globalization, rapid urbanization and economic growth in the developing world
tend to further deteriorate this situation.
In early days people were not facing such big problems of disposal became of
availability of space and natural material but now a day's congestion in cities and use of
nonbiodegradable materials in day life create many problems. It is directly deals with our
hygiene and psychology. So, proper management of solid waste has become unavoidable.
Waste water treatment
By definition, process means a series of actions or changes. Treatment facilities

incorporate numerous processes which in combination achieve the desired water quality
objectives. These processes involve the separation, removal and disposal of pollutants
present in the wastewater.
The treatment of wastewater is accomplished by four basic methods or

techniques; physical, mechanical, biological and chemical. Physical methods of treatment
include the use of tanks and other structures designed to contain and control the flow of
wastewater to promote the removal of contaminants. Mechanical treatment techniques
involve the use of machines, both simple and complex in design and operation. The
action of bacteria and other micro-organisms are biological methods of treatment, which
play a vital role in the removal of pollutants which cannot be effectively achieved by
other means. Chemical treatment methods enhance the efficiency of other process
operations and provide specialized treatment as a result of their addition at various
treatment stages.

Areas of to Reduce Water Consumption in Dairy
Increased energy consumption
‒ For example, replacing an evaporative (“wet”) cooling system with an air cooled
(“dry”) system can sometimes increase the facility energy consumption.
Increased wastewater (trade waste) contaminant concentrations:
‒ Overall quantity by mass (e.g. kg/day) may not increase, but concentration might.
‒ Talk to your water corporation to determine whether increasing concentrations are
a safety issue in the sewer or whether a treatment option may become available as
a result – e.g. a higher BOD may mean an opportunity for the generation of
biogas and secondary generation of electricity.
Increased maintenance requirements may occur, depending on the project.
Water saving benefits
There are significant benefits that can be realized through becoming more water
efficient. These include reductions in:
Costs - water, wastewater discharge and wastewater treatment, maintenance. Remember,

the cost of water is not just the cost of purchase, but includes, handling, heating, holding,
treating and discharging – often a 20-30 X multiplier.
Energy consumption - energy and water costs are very often linked, e.g. reducing hot
water for cleaning saves heating costs as well.
Wastes - wastewater treatment often results in the generation of prescribed wastes, which
are costly to dispose of.
Carbon footprint - drops when energy use is prevented or saved and may be worth $20
per tonne CO2e or more.

Other benefits include:
 Increased productivity
 Improved public image
 Increased staff morale/engagement
 Improved Occupational Health and Safety
Characteristics of the effluents after treatment (AS per GPCB standards):
Parameter : Standards
Ph : 6.5 – 8.5
Suspended solids : < 100 ppm
Total dissolved solids : < 2100 ppm
BOD : 30 ppm
COD : 100 ppm
Oil and grease : 10 ppm

2. Introduction of Banas Dairy

Banas Dairy is a well known dairy in Gujarat and is a leading supplier of milk
products to Banaskantha District. Banas Dairy Ltd; is a large-scale unit. Banas Dairy is
located at the distance of 4 km from Palanpur, which is headquarter of Banaskantha
district.
The district of Banaskantha lies closely to the south of Rajasthan, covered by

Aravali Hills in the East, the desert of Kutch in the West and North-West. Banaskantha
district lies between 23.50 to 24.230 North Latitudes and 700 to 72.30 East longitude. A
Total geographical area of the Banaskantha district is 12248 square Km of which 72% is
cultivable while 12% land is irrigated by tube wells canals, etc.
The area covered under forest is only sq. Km of total 20.99 Lac livestock
population- 8.54 Lac Cattle and 12.45 Lac Buffalo as per the cattle census 2011. The total
land acquired by Banas Dairy is 122 acres.
Today Banas Dairy is one of the fully automatic dairy plants with its holding
capacity of 10, 00, 000 lit/day. The central control room controls the whole process. The
controls air-conditioned plant controls the environment.
Banas Dairy also has a very good network of milk suppliers. Raw milk is supplied
by the village co-operatives by the means of tankers and there tankers can bring around
10000-15000 liters of milk. Banas Dairy has a very strong team of distribution and
retailers.
Banas Dairy markets its products under a very powerful brand name “AMUL”. It
produces a wide variety of products like Milk, Milk Powder, Ghee, Ice-cream, Amul
butter and Amul Cool etc. The Countries where the dairy products exported are Abu-
Dhabi, Alziria, Nepal, and Tanzania etc.

History
The momentum actioned in Banaskantha district under the leadership of Late

Shri. Galbabhai N. Patel, a former leader of this backward district, with the help, co-
operation & guidance of Late Shri. Mansinghbhai Patel, the chairman of Dudhsagar
Dairy of Mehsana, did pioneering work & organized primarily milk co-operatives as
village level in Banaskantha district.
On 10th March 1966, the day has been an important day in the history of Banas
Dairy, when Palanpur and Vadgam Talukas organized 8 milk co-operative societies &
started producing milk for Mehsana Dairy. It continued until Nov. 1969, by then 44 co-
operative societies were organized for producing milk for Mehsana Dairy.
Banas Dairy was registered under the co-operative act on 31thJanuary 1969 as
“Banaskantha Dist. Co-operative Milk Producers’ Union Ltd.”. The foundation stone
was laid on 14thJanuary, 1971, near Jagana village to setup a dairy under the Operation
Flood-I launched by NDDB.
On 5th Feb 1971, the dairy started functioning with a handling capacity of 1.5 lack
liter of milk. The manufacture of Ghee was started on 28thJuly 1971. From Jan. 1975,
manufacture of skim milk powder was started. A Cattle Feed Plant was setup in 1977,
having capacity of 100 MT per day, which was further raised to capacity 140 MT per day
in 1992 & the present capacity has been expanded up to 450 MT per day. From
17thMarch, 1980 sending milk to Mother dairy, Delhi was started. Shri. Galbabhai Patel
Co-operative training center was started at Palanpur on 1984. New product Amulya
instant milk mix was started from December, 1986.
The establishment of Chilling Centers at various places in the district marked

another remarkable achievement. The first setup was the Khimana Chilling Center on
17thJuly, 1972 followed by Dhanera on 17th Sept, 1972. It took almost 7 years to setup the
Tharad Chilling Center on 2ndNov, 1983 & just after one year the last of the chilling
centers was established at Radhanpur & Danta on 1st Nov, 1984.

The dairy took a quantum leap in the year 1998, when it decided to go for a highly
automated plant. The foundation stone of Banas-II dairy plant was laid on 2nd Oct, 1998.
Initially the old plant (Banas-I) was established with 1.5 LLPD milk processing capacity,
but from 28thJuly, 1971 the capacity was increased up to 4.0 LLPD. A sub-project Banas
Dairy Phase II (fully automated plant) was started having 6.5 LLPD processing capacity.
All together with Banas I & Banas II, the dairy plant able to process 10.5 LLPD.
The plant has manufacturing capacity of 110 TPD Milk Powder, 40 TPD Table
Butter, 8 TPD Ghee, 1 LL of Milk packing, 20,000 liters of Ice-cream & 6000 liters per
hour of UHT Milk. The dairy was awarded ISO-9002 & HACCP certification on
15thJuly, 1999. Apart from the milk business, the dairy has also ventured into reverse
supplying of products. It has started selling tea under the brand name “Banas Tea” &
presently looking for other products.
The dairy is also supplying cattle feed to the milk producers through dairy co-
operative societies. It has recently started an Internet project “Chirag”, in which it
provides Internet connection to the rural areas on subsidized rates. In order to enhance &
sustain milk production & quality & taking care of animal health, the dairy is also
providing input services at the grass root level milk co-operative societies. The input
services like Co-operative development program & Internet Consultant Development
program contributes in educating producer members for socio-economic development.
Looking over the competition in the market, the dairy has taken several steps for
reducing operational & energy cost & to satisfy its internal (Milk Producers) and external
customers as well. Several energy conservation projects have been taken & implemented
successfully & various projects are undergoing. Decision for going an ultra modern
energy efficient, Banas II dairy plant is also an example of energy consciousness &
commitment of management toward energy conservation. It is needless to mention that
Banas Dairy is the single major industrial establishment of Banaskantha District and the
55% of the economic transactional value is related to this esteemed organization; hence
the cooperative is rightly called “An Oasis in the Dessert” by the local rural folk.

Prestigious Moments
National Productivity Awards
 The award for the best performance in productivity – Dairy development &
production in cooperative sector (Product Plant) – conferred upon by Dr.
Balram Jhakhar, Union Minister of Agriculture at New Delhi. 1992-93
 The award in recognition of best performance in productivity – dairy

processing industries – conferred upon by Dr. Shanker Dayal Sharma, Hon.
President of India at New Delhi. 1993-94
 The award in recognition of the IInd best performance in productivity – dairy

development & production in cooperative and public sector (product plant) –
conferred upon by Dr. Shanker Dayal Sharma, Hon. President of India at New
Delhi. 1993-94.
 The award in recognition of the best productivity performance – dairy

processing industries – conferred upon by Shri Sikander Bakht, Minister of
industries at New Delhi. 1996-97
 The award in recognition of the second best productivity performance – dairy

processing industry – conferred upon by Shri Krishan Kant, Hon. Vice
President of India at New Delhi. 1997-98
 In the year 1992-93, the union completed 25 years of meaningful existence the
service of the farmers of the district and celebrated its “Silver Jubilee Year”
on May 7, 1994.

Main Objectives of Banas Dairy
 To form cooperative societies at rural level,

 To create permanent market of milk and to provide compensative milk prices
according to the quality of the milk to farmers,
 To make farmers free from the exploitation of private merchants and dairies,
 To provide animal husbandry expansion services and education by scientific
method, and
 To make animal husbandry occupation economic, supportive and collaborative to
agriculture so that rural poor can be self sufficient.

3. Effluent Treatment Plant
A steady rise in the demand for milk and milk products in many countries has led
to advancements in veterinary science, which has subsequently led to steady growth in
the production of milk per head of cattle. This has caused enormous growth of dairy
industries in most countries of the world. Consequently, the amount of wastewater
generated and discharged from these industries has also increased.
The dairy industry wastewaters are primarily generated from the cleaning and
washing operations in the milk processing plants. It is estimated that about 2% of the total
milk processed is wasted into drains. The wastewaters generated from milk processing
can be separated into two groups—the first group concerns wastewater having high flow
rates and the second concerns the effluents produced in small milk-transformation units.
Effluent Treatment Plant in Banas Dairy
As per water pollution prevention act of Gujarat state, the quality of effluent that
is discharged by the dairy is required to be as per standards laid down by the “Gujarat
Pollution Control Board” to achieve this purpose waste water is treated in new effluent
treatment plant.
Design Base
Design of an industrial ETP is highly site specific. Major general considerations

are site characteristics and wastewater characteristics. Pretreatment standards for waters
entering the collection system serving the ETP, and treatment standards for effluent
discharged from the ETP also are significant design considerations. Within the
framework of site and wastewater characteristics and treatment standard treatment
process selection involves consideration of numerous factors, such as treatment
efficiency, reliability, and cost.

Site Characteristics
Site characteristics such as topography, soils, geology, hydrology, climate, and

land use require some consideration when designing a sewer network and ETP.
Topography and depth to bedrock strongly influence the cost of sewer installation, with
elevation distributions that allow gravity flow and adequate depth for burial of pipe most
desirable. Soil thickness and soil characteristics such as clay content, sand content,
organic matter, and permeability are major considerations when certain treatment
options are being considered for ETPs, including land treatment, pond/lagoon treatment,
or granular media filtration. Unfavorable hydrologic site conditions include:
 Aquifer recharge zones

 Flood-prone areas
 Wetlands
 Seasonally high water table
Important climatic factors to consider include precipitation, especially when

infiltration/inflow is a problem with sewers, and evapotranspiration when treatment
processes being considered rely wholly or in part on evaporation of treated wastewater.
Land use may affect the area of land that is available for a facility, which in turn may
affect the selection of treatment process options. Land-intensive treatment options such
as stabilization ponds may not be feasible if land is not available or is too expensive.
The dairy industry involves processing raw milk into products such as consumer
milk, butter, cheese, yogurt, condensed milk, dried milk (milk powder), and ice cream,
using processes such as chilling, pasteurization, and homogenization. Typical by-
products include buttermilk, whey, and their derivatives.
Waste Water Characteristics
Dairy effluents contain dissolved sugars and proteins, fats, and possibly residues
of additives. The key parameters are biochemical oxygen demand (BOD of milk in the
untreated effluent; chemical oxygen demand (COD), which is normally about 1.5 times

the BOD level; total suspended solids : phosphorus (10–100 mg/l), and nitrogen (about
6% of the BOD level). Cream, butter, cheese, and whey production are major sources of
BOD in wastewater. The waste load equivalents of specific milk constituents are: 1 kg of
milk fat = 3 kg COD; 1 kg of lactose = 1.13 kg COD; and 1 kg protein = 1.36 kg COD.
The wastewater may contain pathogens from contaminated materials or production
processes. A dairy often generates odors and, in some cases, dust, which need to be
controlled. Most of the solid wastes can be processed into other products and byproducts.
The effluent treatment plant was design for the total effluent generation from
Banas I, II & III project having following characteristics.
Flow : 3500 cubic meter per day {average}

: 4000 cubic meter per day {peak}
pH : 5.5 to 11
COD : 3500 mg/l
BOD @ 27° C : 2500 mg/l
Suspended solids : 1200 mg/l
Dissolve solids : 2500 mg/l
Oil & grease : 1100 mg/l
Ammonical Nitrogen : 150 mg/l
The treated effluent will meet the following norms.

Flow : 3500 cubic meter per day {average}
: 4000 cubic meter per day {peak}
pH : 7.5 to 8.5
COD : 100 mg/l
BOD @ 27° C : 300 mg/l
Suspended solids : 100 mg/l
Dissolve solids : 1000 mg/l
Oil & grease : 10 mg/l
Ammonical Nitrogen : < 50 mg/l

Treatment Units of Effluent Treatment Plant
A. For Banas I & II

1. Bar Screen
Flow : 1600 cu. m./day
Length : 1m
Width : 2m
Side water depth : 0.5 m
2. Fat removal tank
Length : 14 m
Width : 5.5 m
Detention time : 2 hrs
Drying beds for fat drying only : 4 nos
3. Equalization tank
No. of tanks : 3
Volume : 1009 cubic meter
Size : 18.9 × 19.4 at top and
2.5 m × 3 m at bottom
No. of tanks : 1
Depth : 3m
For mixing 1 equalizing : 3 nos of floating arators
HP : 7.5 – 1 no & 2-3 nos
Pumps : 2 nos
HP : 10
B. For Banas III

1. Screen chamber
Length : 1m

Width : 1m
2. Collection Sump
Detention time : 1 hr
Volume : 62.5 cubic meter
Diameter : 5.7 m
Material of construction : R.C.C. M 25
Pumps : 20 l/second with 10 m head
No. of pumps : 2 [ 1 W + 1 S]
Type : Horizontal centrifugal pump
Material of construction : CI with SS impeller
3. Travelling bridge oil skimmer tank

Detention time : 1 hr
L:W : 3:1
Length : 9m
Width : 3m
Oil skimmer : Travelling bridge type
Hp : 1
Oil & grease inlet : 1100 mg/l
Oil & grease outlet : 50 mg/l
COD in : 3500 mg/l
COD out : 3000 mg/l
Here, the combination of Banas I, II & III plant effluent in Flash mixture I.


COD in : 3000 mg/l
Suspended Solids : 1200 mg/l
C. For Banas I, II & III

4. Flash mixture tank I
Detention time : 5 min
Volume : 12.15 cu. m
Length : 2.2 m
Width : 2.2 m
Mixing : Slow speed agitator
HP : 3
Material of construction : Stainless Steel
5. Flash mixture tank II

Length : 2.2 m
Width : 2.2 m
HP : 3

6. Flash mixture tank III

Length : 2.2 m
Width : 2.2 m
HP : 3
7. Primary Clarifier
Surface overflow rate : 20 cu. m/ sq. m./day
Diameter : 15 m
Side water depth : 3m
COD in : 3000 mg/l
COD out : 2000 mg/l
BOD in : 1000 mg/l
BOD out : 750 mg/l
Suspended Solids in : 1200 mg/l
Suspended Solids out : 100 mg/l
Qyt. of Suspended : 5500 kg/day
% of solids : 5
Total volume of sludge : 110 cu. m
8. Primary treated effluent collection sump

Detention time : 30 minutes
Volume : 72 cu. m

Diameter : 5.5 m
Material of construction : R.C.C. M 25`
No. of pumps : 2 [1 W + 1 S]
Pump Capacity : 50 l/sec
Head : 12 m
Type of pump : Horizontal centrifugal
9. Aeration tank
COD in : 2000 mg/l
COD out : 100 mg/l
BOD in : 750 mg/l
BOD out : 30 mg/l
Organic load in terms of COD : 7000 kg/day
F/M : 0.6 based on COD
MLSS concentration : 2500 mg/l
Volume : 6200 cu. m
Volume of aeration tank available : 7400 cu. m
Total HP required : 350
No. of aerators : 7
HP of each aerators : 50
[If the plant is to be provided for 3000 cu. m/day flow then total aeration capacity
will be 300 HP.]
The aeration requirement will be as under:
Total no. of blower : 3[ 2 W + 1 S]
Total air required : 7200 cu. m/hr at 5500 mm WG
Capacity of each blower : 3600 cu. m/hr
HP of each blower : 120
Total no. of membranes : 720

10. Secondary Clarifier

Flow : 3500 cu. m/day
Surface over flow : 12 cu. m/day
Total area : 291 sq. m
Existing clarifier area : 165 sq. m
Additional area required : 126 sq. m
Diameter of existing (old) clarifier : 14.5 m
Diameter of additional (new) clarifier : 13 m
Pumps for recycle : 25 l/sec with 12 m head
Type : Horizontal centrifugal
Material of construction : Cast Iron (CI)
11. Sludge Sump

Primary sludge quantity : 5500 kg/day
Volume of primary sludge : 110 cu. m
Secondary sludge quantity : 90 kg/day
Volume of secondary sludge : 9 cu. m
Volume : 10 cu. m
Length × Width : 2m×2m
Mixing : Slow speed mixer
HP : 3
No. of mixer : 1
Sludge pump : 10 cu. m/hr
Head : 1.5 m
Type : Screw

12. Sludge Thickner

Quantity of Sludge : 5600 kg/day
% of solids : 5
Sludge pump : 10 cu. m/hr
Head : 35 m
Type : Screw
13. Anarobic Digester

Total Solids concentration : 4750 kg/day
Total volatile solids : 3000 kg/day
Digester loading : 2 kg/cu. m
Volume : 1500 cu. m
Diameter : 17 m
Total gas produced : 1500 10 cu. m/day
Equivalent to power : 2000 KWh
14. Sludge Drying Bed

Volume of digested sludge : 43 cu. m/ day
Quantity of digested Sludge : 3154 kg/day
No. of beds : 9
Area : 703 sq. m
Size of each : 12.5 m × 6.25 m
Depth : 1m
15. Pump house cum office: 1

16. Chemical room: 1

4. Effluent Treatment Processes
Dairy wastewaters are generally treated using biological methods such as

activated sludge process, aerated lagoons, trickling filters, sequencing batch reactor
(SBR), anaerobic sludge blanket (UASB) reactor, anaerobic filters, etc. Oftentimes the
post-treatment of dairy wastewater is also done using the physico-chemical treatment
methods consisting of coagulation/flocculation by various inorganic and organic natural
coagulants, and membrane processes like nanofiltration (NF) and/or reverse osmosis
(RO). Membrane processes produce purified water without milk proteins and lactose and
which could be recycled. At the same time the recovered proteins and lactose can be used
for non-human consumption.
Here the effluent treatment process in Effluent Treatment Plant at Banas Dairy is
described below.

Effluent Treatment Plant Layout

Figure: Flow diagram of effluent treatment plant

Preliminary Treatment
The initial stage in the wastewater treatment process (following collection and
influent pumping) is preliminary treatment. Raw influent entering the treatment plant
may contain many kinds of materials (trash). The purpose of preliminary treatment is to
protect plant equipment by removing these materials that could cause clogs, jams, or
excessive wear to plant machinery. In addition, the removal of various materials at the
beginning of the treatment process saves valuable space within the treatment plant.
Preliminary treatment may include many different processes. Each is designed to remove
a specific type of material - a potential problem for the treatment process. Processes
include: wastewater collections (influent pumping, screening, shredding, grit removal,
flow measurement, pre-aeration, chemical addition, and flow equalization). Bar racks or
mechanical screens remove paper, rags and other large solids. Sand and grit are removed
by gravity settling in a grit chamber.
Equalization system
Figure: Preliminary Treatments

Screening
Raw effluent is initially passed through screen to trap all the floating material like
wooden plank, plastic bags, paper etc. Initially its passed through coarse screen and later
on through fine screens .all the material trapped in the screen are removed manually with
the help of racks .The screened material are disposed off suitably.
Oil & Grease Removal

Many of industrial units discharge oil in waste water due to leakage of oil from
the system .Grease also comes in water from lubricating system. The oil I & Grease are

required to be removed in oil\Grease removing chamber effluent enters and due to

availability of more cross sectional area, velocity of effluent suddenly drops down. Since
the specific gravity of oil & Grease is lower than water, it floats on the top surface. From
top surface oil & Grease are removed by manual skimmer.
Equalization
The flow of effluent varies from time to time .At the same time quality of effluent
changes during different periods of the day. Since the treatment plant is designed for a
particular flow rate and quality, it is essential to have an equalization tank prior to main
treatment units. In this equalization tank a detention period for effluent is given to take
care of surge load and also the Flow during lean period. The effluent in the equalization
tank is pumped at constant flow rate to treatment plant.
Chemical Addition
Chemical addition is made (either via dry chemical metering or solution feed
metering) to the waste stream to improve settling, reduce odors, neutralize acids or bases,
reduce corrosion, reduce BOD, improve solids and grease removal, reduce loading on the
plant, add or remove nutrients, add organisms, and aid subsequent downstream processes.
The particular chemical and amount used depends on the desired result. Chemicals must
be added at a point where sufficient mixing will occur to obtain maximum benefit.
Chemical Used in the treatment of Waste Water
 Alum
 Lime
 Polyelectrolyte
Primary Treatment
Following preliminary treatment, the water moves on to a clarifier or settling tank.
This is primary treatment. Here, under very calm conditions, sewage solids settle to the
bottom of the tank. Not all of the solids are removed here in the primary clarifier because
very small, light particles take too long to settle. These small particles and dissolved
organic matter are removed later. The solids that collect at the bottom of the tank are
called primary sludge and are pumped from the tank for treatment elsewhere in the plant.

The purpose of primary treatment (primary sedimentation or primary

clarification) is to remove settleable organic and floatable solids. Normally, each primary
clarification unit can be expected to remove 90 to 95% settleable solids, 40 to 60% TSS,
and 25 to 35% BOD. Primary treatment reduces the organic loading on downstream
treatment processes by removing a large amount of settleable, suspended, and floatable
materials. Primary treatment reduces the velocity of the wastewater through a clarifier to
approximately 1 to 2 ft/min, so that settling and floatation can take place. Slowing the
flow enhances removal of suspended solids in wastewater. Primary settling tanks remove
floated grease and scum, remove the settled sludge solids, and collect them for pumped
transfer to disposal or further treatment.
Clarifiers used may be rectangular or circular. In rectangular clarifiers,
wastewater flows from one end to the other, and the settled sludge is moved to a hopper
at the one end, either by flights set on parallel chains or by a single bottom scraper set on
a traveling bridge. Floating material (mostly grease and oil) is collected by a surface
skimmer. In circular tanks, the wastewater usually enters at the middle and flows
outward. Settled sludge is pushed to a hopper in the middle of the tank bottom, and a
surface skimmer removes floating material.
Figure: Primary Clarifier

Secondary Treatment
Activated Sludge/Aeration
Microorganisms such as bacteria and protozoa can use the small particles and
dissolved organic matter, not removed in primary treatment, as food. Secondary or
biological treatment is performed in a tank containing a "soup" of starved microbes called
activated sludge. These microbes require air to live and thus air is pumped into the tank.
Microorganisms in this aeration tank use the dissolved and particulate organic matter as
food, producing more microorganisms. Thus the waste materials that left the primary
clarifier are changed into microorganisms which can be collected and separated from the
water in the next step.
The activated sludge process is a treatment technique in which wastewater and
reused biological sludge full of living microorganisms are mixed and aerated. The
biological solids are then separated from the treated wastewater in a clarifier and are
returned to the aeration process or wasted. The microorganisms are mixed thoroughly
with the incoming organic material, and they grow and reproduce by using the organic
material as food. As they grow and are mixed with air, the individual organisms cling
together (flocculate). Once flocculated, they more readily settle in the secondary
clarifiers. The wastewater being treated flows continuously into an aeration tank where
air is injected to mix the wastewater with the returned activated sludge and to supply the
oxygen needed by the microbes to live and feed on the organics. Aeration can be supplied
by injection through air diffusers in the bottom of tank or by mechanical aerators located
at the surface. The mixture of activated sludge and wastewater in the aeration tank is
called the mixed liquor.
The mixed liquor flows to a secondary clarifier where the activated sludge is
allowed to settle. The activated sludge is constantly growing, and more is produced than
can be returned for use in the aeration basin. Some of this sludge must be wasted to a
sludge handling system for treatment and disposal. The volume of sludge returned to the
aeration basins is normally 40 to 60% of the wastewater flow. The rest is wasted.

Figure: Activated sludge and Clarifier

Clarifier
It then remains to separate out the microorganisms (activated sludge), so that just
clean water is left. This is done in a secondary clarifier which operates in the same
manner as the primary clarifier described previously. Some of the solids collected in the
secondary clarifier (return activated sludge) are sent back to the aeration tank to treat
more wastewater and the excess (waste activated sludge) is pumped to another location in
the plant for further treatment. The clean water that flows out the top of the clarifier is
sent into the treated water tank and then sent along for irrigation and watering to garden.
Solids Management
Removed solids at various points in the wastewater treatment process: primary
sludge composed of the sewage solids collected in the primary clarifier and waste
activated sludge from the secondary clarifier. This sludge presents two problems. First, it
is rich in organic matter and will consume oxygen and create foul odors if delivered to
the environment without further treatment. Second, even though it's called sludge, it is
mostly water and is difficult to handle in final disposal.

Thus sludge processing involves two steps:
 digestion - to break down the organic matter

 dewatering - to reduce the water content and make it easily handled
The treated sludge is then sent on for final disposal.
Digestion
Organic matter is broken down an made inert in a process called anaerobic
digestion. Specialized bacteria, able to live without oxygen (anaerobic condition), use the
biodegradable organic matter as a food source, producing carbon dioxide and methane
gas and inert organic matter similar to peat moss.
Anaerobic digestion is a two-step process. In the first step, bacteria and sludge are
mixed together in a heated tank called a digester. This is where the biological activity
takes place and biodegradable organic matter is broken down producing gases and inert
organic matter. The sludge is then delivered to the second step. This digester is not mixed
and the sludge separates with gases at the top of the digester, liquid in the middle and
solids on the bottom. Gases that have risen to the top are collected and burned. The liquid
is returned to the beginning of the plant to be treated again. Solids are sent to the next
step for dewatering.
Figure: Digestion Process

Dewatering
There are several different ways to remove water from sludge. One of these is
called a belt filter press. Sludge is placed between two cloth belt filters that pass over a
series of drums or rollers squeezing out the liquid. At the end of the press, a knife scrapes
the sludge cake off of the belt filter. Liquid removed during pressing is returned to the
beginning of the plant for further treatment. The sludge cake is then sent on for final
disposal.
I. Sludge is pumped to the belt press and is delivered at the top where it is spread
evenly across cloth belts by black rubber dividers
II. Sludge then passes between cloth belts, squeezing water out which is returned to
the beginning of the plant for further treatment.
III. The dewatered sludge "cake" passes over a knife edge, separating the sludge from
the cloth belt and delivering through a passage (blue) to a waiting truck below.
Final Disposal
Digested, dewatered sludge can be disposed of by burial in a landfill or by
burning (incineration). Landfills which receive sludge must be designed to prevent
contamination of nearby surface or groundwater supplies. The gases and particles
produced in incineration must be collected as well to protect air quality.
Digested, dewatered sludge is also applied to agricultural land and made available
to the public for personal use as a soil conditioner and fertilizer. This disposal option
requires that the sludge be treated to reduce (for agricultural use) or eliminate (for public
use) pathogens. Sludges treated in this manner are called biosolids and their application is
controlled to protect the public health and welfare.

5. Effluent Testing Methods
There are such parameters are tested as par GPSC Norms, which is pH, SS, DO,
TSS, TDS , B.O.D. C.O.D. and Oil & Grease.
1. pH
pH is defined as the negative log of hydrogen ion concentration. It indicated the

acidity and alkalinity of water samples. The hydrogen ion concentration is influenced by
biological activities. Besides in addition of chemical substance, presence of organic
matter in large quantity may lower the pH we value due to release of CO2 and SO2. The
pollution load in most of the chemical industries is in large quantity in the form of acid
and alkali in manufacturing unit. The wide variation in the pH value of effluent can affect
the rate of biological reaction and survival of various microorganisms.
The presence or absence of various ionic species can have the direct relation with
pH of the effluent. Subsequently, such effluent can influence the quality of soil. The
reaction between effluent flowing from open drainage system and the soil has direct
relevance to the pH of the effluent. It is therefore necessary to evaluate with respect to the
pH value. In the present investigation the pH value of untreated effluent was 2 to 12 and
treated effluent was 6.5 to 8.
2. Dissolved oxygen (DO)
Dissolved oxygen is one of the important parameter in water quality assessment.

Its presence is essential to maintain a variety of forms of biological life in water and the
effects of the water discharged in water body are largely determined by oxygen balance
of the system. Non-polluted surface water remains normally saturated with the dissolved
oxygen. Oxygen can be rapidly removed from the water by discharge of oxygen
demanding waste.

Inorganic reducing agents such as hydrogen sulphide ammonia, nitrites and

ferrous ions and certain available oxidisable substances also tend to decrease oxygen in
water. The solubility of atomospheric oxygen in fresh water ranges from 14.0 mg/L at
00C to about 7.0 mg/L at 350C under at 1 atm. pressure. The importance of DO in
aquatic ecosystem in bringing out various biological changes and its effect of metabolic
activities of organisms has been discussed by many ecologists. The winter can be
attributed to the higher solubility of oxygen at low temperature. Unllike the lake system
river water quality cannot be characterized by concentration of nutrients dissolved
oxygen.
Most of the fishes require at least 5 mg/l dissolved oxygen for at least 16
hours/day and near less than 3 mg/l for 8 hour is natural water containing 8 to 10 mg/l. In
the present investigation dissolved oxygen of untreated effluent was totally Nil. Due to
Oil and grease in effluent form milk which inhibits or prevents the entrance at
atmospheric oxygen into effluent and the amount of dissolve oxygen present in treated
effluent was 3.5 mg/l.
3. Biochemical oxygen demand (BOD)
Biochemical oxygen demand (BOD) is defined as amount of oxygen required by

microorganisms while stabilizing biological decomposable organic matter in a waste
under aerobic conditions. Since the test is mainly a bioassay procedure, involving
measurement of oxygen consumed by bacteria. While stabilizing organic matter under the
aerobic conditions, it is necessary to provide standard conditions of nutrient supply.
Absence of microbial organisms in effluent because the low solubility of oxygen in
water. Wastes are always diluted to ensure that the demand does not increase in available
oxygen. Low value of BOD is comparatively in winter months may be due to lesser
quantity of total solids, suspended solids in water as well as to the quantitative number of
microbial population. Waste water of dairy industry contain large quantities of milk
constituents such as casein, lactose, Fat, inorganic salts, besides detergents and sanitizers
used for washing. All these components contribute largely towards their high biochemical
oxygen demand.

4. Chemical oxygen demand (COD)
The chemical oxygen demand test (COD) determines, the oxygen required for
chemical oxidation of organic matter with the help of strong chemical oxidant. The COD
is a test which is used to measure pollution of domestic and industrial waste. The waste is
measure in terms of equality of oxygen required for oxidation of organic matter to
produce CO2 and water. It is a fact that all organic compounds with a few exceptions can
be oxidizing agents under the acidic condition. COD test is useful in pinpointing toxic
condition and presence of biological resistant substances. Importance of organic matter in
the ecology of bloom firming cynobacteria has also reported by many workers. In the
present study the value of COD of untreated effluent was 1230 mg/l and that of treated
effluent was 94 mg/l.
5. Total dissolved solids (TDS)
The maximum concentration of total dissolved solids in summer, which increased

in rainy seasons. The minimum value was found in winter probably because of
stagnation. In summer most vegetation is decaying, so rise in the amount of dissolved
solids was neutral as the products of decaying matter which were settled in the water. The
total solid concentration in waste effluent represents the colloidal form and dissolved
species. The probable reason for the fluctuation of value of total solid and subsequent the
value of dissolved solids due to content collision of these colloidal particles. The rate of
collision of aggregated process is also influenced by pH of these effluents. In the rainy
season less concentration of total dissolved solids are obtained, due to the concentration
of the dissolved solids are obtained due to the dilution of waste effluents with rain water.
6. Total solids (T.S)
The term solid refers to the matter either filterable or infilterable that remains as
residue upon evaporation and subsequent drying at a defined temperatures employed for
drying and ignition. Different forms of solids are defined on the basis of method applied
for their determination. The total solids are sum of the values of the total dissolved solids
and that suspended solids. The solid varies in proportions to temperature and rarely

varied inversely to the water level. High concentration of total solids during summer was
probably due to low level of water. The direct relationship between rainfall and total
solids was attributed to an increased load of soluble salts from the catchments areas as a
result of surface run off.
In effluent, total solids, total dissolved solids, total supended solids are compolsed
mainly of carbonates, bicarbonates, chlorides, sulphate, phosphate, nitrate, Ca, Mg, Na,
K, Mn and organic matter. Stills and other particles, polluting water increase the
concentration of total solids. In the present study the value of total solid present in
untreated effluent was 1310mg/l and treated effluent was 560 mg/l.
7. Total suspended solids (T.S.S.)
Suspended solid do not mean that they are floating matters and remain on top of
water layer. They are under suspension and remain in water sample. BIS has not set any
limit of total suspended solid for drinking water. Total suspended solids play an
important role in water and waste water treatment. Presence of suspended solid in water
sample causes depletion of oxygen level.
8. Oil and grease
The oil and grease content of domestic and certain industrial waste and of
sludge’s is an important in handling and treatment of these materials for ultimate
disposal. Oil and grease may influence waste-water system. If present in excessive
amount, they may interfere with an aerobic and anaerobic biological process and lead to
decreased waste water treatment efficiency. Knowledge of quantity of oil and grease
present in effluent is helpful in proper design and operation of waste water. Industrial
waste contains high quantity of oil and grease which may cause a serious problem if
discharged into water body without treatment.

Sampling Point
Raw Effluent Treated Effluent
Inlet Aeration Tank Outlet Aeration Tank
Aeration Tank

Units in ETP
Inlet Sludge in Anarobic Digester Outlet sludge of Anarobic Digester
Primary Clarifier Secondary Clarifier
Equalization Tank Fat Removal Tank

Banas Dairy ETP Training Report

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Training Report on Effluent Treatment Plant at Banas Dairy 2013

I am extremely happy to come out with this training report on Effluent

Teaching is the important knowledge, but training develops habit. It

I am extremely thankful to P. D. Patel Sir Manager of Engineering

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 1

2. Introduction of Banas Dairy 7

3. Effluent Treatment Plant 13

4. Effluent Treatment Process 25

5. Effluent Testing Methods 33

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 2

Environmental resource management can be viewed from a variety of

Significance and need of study

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 3

Environmental water contamination is the leading worldwide cause of death and

Water pollution is caused by domestic sewage (84%) and industrial sewage

Municipal Solid waste management (MSWM) constitutes a serious problem in

Waste water treatment

By definition, process means a series of actions or changes. Treatment facilities

The treatment of wastewater is accomplished by four basic methods or

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 5

Areas of to Reduce Water Consumption in Dairy

Increased energy consumption

Increased wastewater (trade waste) contaminant concentrations:

Increased maintenance requirements may occur, depending on the project.

Water saving benefits

Costs - water, wastewater discharge and wastewater treatment, maintenance. Remember,

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 6

Other benefits include:

Characteristics of the effluents after treatment (AS per GPCB standards):

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 7

2. Introduction of Banas Dairy

The district of Banaskantha lies closely to the south of Rajasthan, covered by

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 8

The momentum actioned in Banaskantha district under the leadership of Late

The establishment of Chilling Centers at various places in the district marked

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 9

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 10

National Productivity Awards

 The award in recognition of best performance in productivity – dairy

 The award in recognition of the IInd best performance in productivity – dairy

 The award in recognition of the best productivity performance – dairy

 The award in recognition of the second best productivity performance – dairy

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 11

Main Objectives of Banas Dairy

 To form cooperative societies at rural level,

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 12

3. Effluent Treatment Plant

Effluent Treatment Plant in Banas Dairy

Design of an industrial ETP is highly site specific. Major general considerations

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 13

Site characteristics such as topography, soils, geology, hydrology, climate, and

 Aquifer recharge zones

Important climatic factors to consider include precipitation, especially when

Waste Water Characteristics

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 14

Flow : 3500 cubic meter per day {average}

The treated effluent will meet the following norms.

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 15

Treatment Units of Effluent Treatment Plant

A. For Banas I & II

B. For Banas III

College of Renewable Energy And Environmental Engineering, S.D.A.U. Page 16

3. Travelling bridge oil skimmer tank