PROJECT PROPOSAL FOR EFFLUENT TREATMENT SYSTEM ZERO LIQUID DISCHARGE (ETP, RO, NF & EVAPORATOR PLANTS) SUBMITTED TO M/s. ATLAS PROCESSING MILLS, S.F.No.1288,1292,1293,2453,1303,1320,1321,1323,1326 to 1334, Andankoil West Village, No.1/168, Sivasakthi Nagar, Periyandankoil Post, Manmangalam Taluk, Karur District. CAPACITY: 550 KL PER DAY FOR COTTON YARN DYEING, COTTON FABRIC DYEING & PRINTING EFFLUENT For ATLAS ere MILLS PartnerCONTENTS 1. Introduction, 2. Manufacturing process ~ Write up with Flow chart. 3. List of Raw materials proposed to be used. 4, Effluent generation, Characteristics & Treatment Scheme. 5, Water Balance Chart. 6. Effluent Treatment Plant ~ Process Description 7. ETP — Equipment details. 8. ETP — Civil work details. 9. Sludge Generation & Handling, 10. RO plants- Operating parameters. 11. RO Plants ~ Equipments details. 12. Design adequacy for ETP, RO 13. List of machineries with Effluent Generation Details1, INTRODUCTION Mis. Atlas Processing Mills is an existing Dyeing unit located in S.F.No.1288, 1292, 1293, 2453, 1303, 1320, 1321, 1323, 1326 to 1334, Andankoil West Village, Manmangalam Taluk, Karur District. The unit has obtained Consent to Establishment order for the production of Bleaching and Dyeing of cotton yam- 117 T/Month and Bleaching and Dyeing of Fabrics- 195 T/Month with Trade effluent generation of 750 KLD. The unit has provided ETP to treat 750 KLD trade effluent and RO Plant to treat 550 KLD trade effluent. This report has been prepared for the complete treatment systems inclusive of effluent characteristics, volume generated and different treatment sections. PRODUCTION CAPACITY PROPOSE) 1, Bleaching and Dyeing of Cotton Yam: 117 T/Month 2. Bleaching and Dyeing of Fabrics 195 T/Month Effluent generated from the processing is 550 KLD for which the treatment system has been installed.2. MANUFACTURING PROCESS a, COTTON YARN (CABINET DYEING ) The quality yams are being purchased from the regular purchaser. The Yam purchased is next processed to the boiling & bleaching stage. They are boiled and bleaching at the correct temperature say at 90 degree Celsius in the Cabinet Machine. After the boiling of the yams at the correct temperature it is ready for the dyeing process. The correct proportions of the dyes are put in the cabinet machine in the cold water and yarns being dyed. If the shade is acceptable we shall continue the process of soaping in the machines. The dyed wet yarns processed are let into the hydro machine for the evacuation of the water in the yam, The yarn is processed into the machine for the complete dry of the yar. The Dyeing process is completed and the dyed yar is ready for packing and dispatch. MANUFACTURING PROCESS FLOW CHART (CABINET DYEING) YARN \ WETTING WASHING BLEACHING BOILING NEUTRALISE DYEING waskne DRYING PACKING DISPATCHb. COTTON YARN (CHEESE DYEING ) GREY RECEIPT Grey yarn from different particles is checked against their quantity & quality and is entered in the stock ledger. CHEESE PREPERATION Grey yarns are prepared in cheese springs as per colour and weight as per delivery challans for respective machines for processing SCOURING & BLEACHING The above process is carried out with caustic flakes, wetting agents and hydrogen peroxide at a temperature of 98°C for a period of 45 minutes to remove dirt, oils, waxes and other foreign impurities present in the grey yarn. Uniformly scouring and bleaching help to absorb dye stuff. DYEING This operation is done to give the fabric the desired colour. Dyeing is carried out in the Cheese dyeing machines using dyes of various kinds like Reactive dyes, Disperse dyes etc... as per the requirement, Chemicals like Caustic, Soda ash are also added. After dyeing the yarn is thoroughly washed for removing unfixed colour. For pleasing appearance and to remove unwanted chemicals soaping is done. SQUEEZING The yarn is squeezed in mechanical squeezers to remove the excess water. DRYING Wet yam is dried in the driers to remove the moisture. REWINDING Dyed and dried yarn is wound to cone from cheese for delivery. FINAL INSPECTION ‘The finished cones are taken for final inspection to check and correct the process defect before it goes to the customer. PACKING & DESPATCH The inspected cones are packed with poly ethylene paper to protect from moisture and avoid handling defect and are dispatched to the customer.GREY CHEESE PREPARATION y INSPECTION v SCOURING & BLEACHING- (NaOH & H,02) v DYEING v WASHING NEUTRALIZING (ACETIC ACID) v SOAPING | WASHING v SQUEEZING Y DRYING v CONE WINDING v FINAL INSPECTION ’ PACKING & DISPATCH [ANUFACTURING PROCESS FLOW CHART (CHEESE DYEING)¢. DYEING OF COTTON FABRIC (JIGGER DYEING GREY INSPECTION The grey Cotton cloths from our Head Office and from other customers are received and take it for processing according to the requirements given by the customer. SCOURING & BLEACHING This pre treatment process is carried out to remove the natural and added impurities (during spinning and other process) present in the fiber. This process is carried out at the temperature of maximum 105°C for about 45 min with the help of Detergent, Sodium Hydroxide and Hydrogen Peroxide chemicals with very low quantity. It helps to uniform penetration of dyes results in uniform shade on the fabric. DYEING This process is carried out to get the bleached fabric in to dye one. This is done based on the shade which was given by the customer in the Jigger dyeing machine, Reactive dyes are used as the fabrics are of cotton (cellulose fiber). After the completion of dyeing, the fabrics are washed with cold, Hot water, neutralized with Acetic acid, and soaped to remove the un- fixed colors and finally fixing agents are added to improve the fastness and to avoid bleeding of colors from the fabric, and then the fabric is taken from the dyeing machine and send it for squeezing. SQUEEZING This process is carried out to squeeze and reduce the excess water present in the dyed fabric. The fabric is passed through a mangle of two press rolls, where the pneumatic air pressure is adjusted to get the optimum efficiency without affecting the fabric. FINISHING The squeezed fabries are taken in to the Stenter machine for drying and finishing, ‘The finishing chemicals like softener, bio- finish are added in the mangle and are dried in the oil heated radiator chambers at the temperature of 160°C. FINAL INSPECTION The finished and compacted fabrics are taken for final inspection to check and correct the process defect before it goes to the customer. PACKING & DESPATCH ‘The inspected fabrics are packed with polyethylene paper to protect from moisture and avoid handling defect and are dispatched to the customer.MANUFACTURING PROCESS FLOW CHART (JIGGER DYEING MACHINE) GREY CLOTH v INSPECTION | SCOURING & BLEACHING- (Soap, NaOH & H,02) v DYEING Y WASHING ¥ NEUTRALIZING (ACETIC ACID) ¥ SOAPING v WASHING v SQUEEZING Y FINISHING v FINAL INSPECTION ’ PACKING & DISPATCH3. LIST OF RAW MATERIALS FOR PROCESSING OF YARN- 117 T/ MONTH & FABRIC- 195 T/MONTH Sl.No. | Name of the Raw Material 1 | Grey Yarn 2 | Grey Fabric 3 | Wetting Oil | 0.90 4 ‘Caustic Soda 5 Peroxide 2 6 7 8 Stabilizer | 045 Acetic Acid 3.70 9 | Common Salt (Nacl) 70.20 10 | Soda Ash & Caustic 46.80 Tipeeliscent 12 | Leveling Agent 13 | Reactive Dyes3. LIST OF RAW MATERIALS FOR PROCESSING OF YARN- 117 T/ MONTH & FABRIC- 195 T/MONTH | SL.No. | Name of the Raw Material Ss 1 Grey Yarn | 117.00 2 195.00 [3 oO 0.90 [4 [Caustic Soda i 5.15 5 | Peroxide 8.46 6 | Peroxide Killer 0.24 7 [Stabilizer 0.45 8 | Acetic Acid 3.70 9 | Common Salt (Nacl) 70.20 10 | Soda Ash & Caustic ; | 46.80 nn [Soap 1.00 12 | Leveling Agent 0.175 [13 | Reactive Dyes | __ 1204, EFFLUENT GENERATION, CHARACTERISTICS & TREATMEN’ STEPS: EFFLUENT GENERATION DETAILS: Bleaching and Dyeing of Yarn Cabinet Dyeing- 200 Kgs x 150 Lit = 30000 Lit 30,00 KLD Cheese Dyeing- 4130 Kgs x 40 Lit = 165200 Lit 165.20 KLD Cheese Dyeing- 170 Kgs x 75 Lit = 12750 Lit 12.75 KLD Bleaching and Dyeing of Fabries Figger Dyeing 7500 Kgs x 30 Lit = 225000 Lit 225.00 KLD Wet Process includes CBR, CBP, WR = 117050 Lit 117.05 KLD TOTAL 550000 Lit 550.00 KLD It is proposed to treat the composite effluent (dye bath and wash water together) in the pre-treatment. The treatment description is explained in subsequent pages. EFFLUENT CHARACTERISTICS & TREATMENT STEPS: Characteristics of effluent generated from the Dyeing Industry: Sr. | Parameter Composite | Unit No __| effluent 1___| Colour Dark = 2 | Total dissolved solids | 3000-6000 | ppm 3__ [PH 7 10.0-11.0 | — 4 [CoD 700-900 ppm 3__| BoD 300-350 | ppm 6 | Total suspended solids | 100-200 ppm 7 |Total Hardness as 75-100 ppm CaCo3 3 [Temperature «4 <38 Deg [9 [Silica as SiO2______| 20-30 Ppm 10 | Total iron as Fe ETP > RO stage 1->Ro stage 2 > Ro stage 3 > Ro stage 4 > Multiple Effect Evaporator > ATED‘TREATMENT FLOW CHART WITH RECOVERY DETAILS DYEING EFFLUENT: 550 KLIDAY t COLLECTION TANK + PRIMARY CLARIFIER, + AERATION TANK + SECONDARY CLARIFIER + TERTIARY CLARIFIER { MEDIA FILTER | ‘TREATED WATER TANK RO STAGE ~1, FEED: 5S0KL, © ———® PRODUCT WATER: 385 KL RECOVERY: 70% RO STAGE ~2, FEED: 165KL, © ———® — PRODUCT WATER: 82.50 KL RECOVERY: 50% RO STAGE ~ 3, FEED: 82.50KL, ———® PRODUCT WATER: 41.25 KL RECOVERY: 50% RO STAGE 4, FEED: 41.25 KL, ———® — PRODUCT WATER: 10.31 KL RECOVERY: 259% MULTIPLE EFFECT EVAPORATOR + CONDENSATE WATER: 29.39 KL (S EFFECTS) FEED: 30.94 KL, RECOVERY: 95% ATED, FEED: 1.55 KL ——+ _ CONDENSATE WATER: 1.00 KL RECOVERY: 65% (EVAPORATION LOSS- 0.55 KL)5. WATER BALANCE CHART TOTALWATER RTOUIRENOD Dowisne = ROR GaRORING 200K. INOUSTRAL = ST 0DRL COOLNGTOWER: 2081 Tor: snk le—[ooxssni okt ‘MA. ATLAS PROCESSING MILLS: WATER BALANCE CHART TOTALMNE WATER “GSKLAKY 215K RE UP WATER OR NOUR OE rostucen ses AgECONDARATE ATPOCONDESATE rat TOTAL RATERRBCOVERY sis) 300) 08) ‘sash, ferme rane soak | ORL paver goes OSTA coon ow rom. TOTAL MaKe We WATER: hk 2K ae rR 200K [renemeinare voR0 i] | aoe aces pecovenen 50 ft m i z POSTAGE 1 RD: so RECOVERY + TOSTAGE-2 RD WSL, RETO i TROCSSA Me Sie oT 1 fooucrwatex: sock = 0K, + GORGES FED. SKL RECOVERY TOSTAGE a ep a4, nocoRy 29 bs a ‘MGLTPLE ECT EVARORATOR {SSTACE) RD ss RECORY 934 T am ae ‘baa TEVAPORATON LOS. SSK. oH6, ERFLUENT TREATMENT PLANT ~ PROCESS DESCRIPTION The effluent generated from the Dyeing sections is collected in a collection tank through a Bar Screen for removal of fibrous materials & solid particles. The collection tank will be having a capacity of 24 hours discharge. The effluent will be homogeneous before further process. Both these collection compartments will be alternately used From collection tank the effluent is pumped to chemical coagulation channel. Fine particles present in colloidal nature are subject to coagulation by adding lime and a suitable coagulant (Alum or ferrous sulphate or ferric chloride etc) in to the effluent stream and mixing. A polymer addition will improve the coagulation process. Addition of these chemicals shall be done by gravity into a mixing tank. The chemical preparation tanks will have agitators. Then the effluent is let into Primary clarifier, which is a circular type tank with a hopper shape bottom for sludge drain off. A low speed racked arm will scrap the settled sludge to center of the clarifier and when the valve is opened all accumulated sludge will get drained. The clear water overflows to aeration tank while sludge is sent to Sludge drying bed. For the purpose of growth & survival of micro organisms the PH of the inlet water is adjusted to 7.0 - 8.0 by adding sulphuric acid, Aeration is done using energy efficient diffused aeration system, which results in ‘compact layouts and reduces the power consumption. Air from the blower is diffused through the Diffuser grid. It consists of porous membranes of 12” dia disc type of EPDM material. The diffusers are of non-buoyant type, which during shutdown condition contracts and close round the PVC support frame to prevent any back-flow. ‘The diffuser is designed to ensure uniform permeability and to produce a flow of fine air bubbles and provides high contact area and more contact time due to slow rise of the bubbles which makes the system very efficient in terms of oxygen transfer efficiency thus low installed HP for the blower drive and hence low operational cost. ‘After a residence of 24 hours in the aeration tank the aerated effluent flows to secondary settling which a circular clarifier with racker arm mechanism is. Settled sludge will be recycled back to the aeration tank for maintaining the required MLSS in the Aeration tank. Excess sludge will be drained from the system and sent to Sludge drying bed ‘The clear water is collected in another tank, and passed through a Fine sand filters will meet the requirement of RO Plant feed water conditions. The treated effluent will have the following characteristics: ‘SILNo_| Parameter _ I Value | 1___| Colour [ | = PH CoD. _ —[ BOD; at 20 Deg C <0 ig Total suspended solids <107, SPECIFICATION FOR EFFLUENT TREATMENT PLANT — 550KLD. SLNo Description Qty | unit 1 Raw effluent pumps, 37.5 M3/h, 30 M head, 7.5 HP, non clog self 2 | Nos | priming, centrifugal. Anala/eqt. (1W + 1S) | _| T 1 2 Agitators for chemical mixing. and flo flocculator | 2 | Nos yew ———_{—|*} 3. | Air Blowers, 650 Cum/h, 5 mwe head, Kay make twin lobe type, | 2 | Nos | __| with 15 HP motor (1 W +1 8). | 4 Diffusers, 12"dia Disc type EPDM imported, SSl/eqt make, Air flow | 140 | Nos rate considered 3 Cum/h per diffuser 5 _ | Sludge recycling pumps, 15 cunV/h, Self pri, non clog, Johnson/eqt, | 2 | Nos 7.5 HP (1 W+1S) — 6 | Primary Clarifier mechani ‘Sm dia central driven type. 1 HP. 2 | Nos 7__| Secondary Clarifier mechanism, 9m dia central driven type. 1 HP 1 | No 8 | Tertiary Clarifier feed pumps 37.5 cum/h, 30m head, 7.5 HP 2 | Nos 9 | Tertiary Clarifier mechanism, 9m dia central driven type. 1 HP 1 | No 10 | PH correction with PH sensor, indicator and Dosing pump Anala/eqt 2 | Sets | make, 11 | Pipeline, fittings, valves etc. 1 | Set 12 _| Filter Feed pumps, 37.5 M3/h, 35 M head, 7.5 HP, non clog self 2 | Nos priming, centrifugal. Anala/eqt. (IW + 1S) ee | 13. | Multigrade Filter Filter, Flow- 37.5 m’/h, 1.60m dia x 2.40m Hs, 1 No MS FRP lined 14 | Acid & Sodium Hypochlorite dosing, 10 LPH Anala/eqt with tank 2 | Nos 15 | Electric panel board. 1 | No8. ETP Civil Tank Det ( SL.No. | 1 ~ | Collection Tank DESCRIPTION DIMENSION IN Metres ] 12.75 x 9.25 x 3.70 | 2 {Dye Bath Collection Tank = 3 Aeration Tank (2.20 x 9.25 x 3.70 Clarifier 5.00 Dia x 4.20 16.00 x 8.20 x 4.00 4 | Aeration Tank Spare 6.40 x 8.20 x 4.00 5__| Lime Tank [4.60% 1.60x1.50 6___| Ferrous Tank 1.20x1 “7___ | Flash Mixer - 1.60 x 1.60 x1.50 8.__| Floculator Tank ~ 1 [1.60 1.60 x1.50 9.__| Polyelectrolyte Tank 500 Lits Capacity 10. | Chlorine Reactor 2,50 x 2.50 x 1.00 Secondary Clarifier _ 9.00 Dia x 3.10 Secondary Treated Water Tank 3.90 x 7.90 x 2.80 Tertiary Clarifier 9,00 Dia x 3.10 Tertiary Treated Water Tank ~[3.90-x 7.90 x 2.80 Spare Tank 5.75 x 3.90 x 3.20 Spare Tank 1__|2.60x3.90 x 3.20 ‘Spare Tank __ 1_[3.90x2.75 x 3.20 Dye Bath UF Feed Tank 1__[3.10x3.90x3.20 Dye Bath UF Feed Tank 2 [310x1.50x320 RO Feed Tank 1 | 6.50x 8.00 x 3.20 ROM Feed Tank 1 [6.50x5.75x3.20 RO Ill Feed Tank 1_[8.00x3.90x3.20 ROIV Feed Tank 2__[3.10x 1.50x3.20_ Spare Tank 2 _[6.50x2.75x3.20 Primary Treated Water Tank 1 [10.40 x 5.70x 4.00 _ RO Permeate Water Tank 2 [10.40 x 5.70 x 4.00 Sludge Drying Beds 24 [4.10 x 4.10 x 1.00 Sludge Bed Collection Tank “1 [2.30x1.70x2.20 Solar Evaporation Pans 8 [1000x1170 Cooling Tower _ 1 [3.20x3.20x 1.00 Seal Water Tank a 1_[1.40x 1.10 x 1.30 Evaporator Feed Tank 1_|7.60x 4.60 x 3.20 Boiler Feed Tank 1_[2.50%2.50 x 2.50 Boiler Blow Down Tank 1 [1.10% 1.90% 1.30 Evaporator Condensate tank “111.80 x2.50-x 1.30 Process Condensate Tank 1 [1.50% aaa RO Waste Water Tank 1 [2.00 x 0.70 x 1.70 UF (Dye Bath) Membranes alata 3_| Standard Size UF (Wash Water) Membranes 15__| Standard Size RO Stage I- Brackish Water Membranes 24 [0.20x 1.00 RO Stage Ii- Sea Water Membranes 10_[0.20x 1.00 RO Stage III- Sea Water Membranes ‘8 [0.20% 1.00 RO Stage IV- Sea Water Membranes 3__|0.20x 1.00 _ MEEG Effects) 1__|80KLD Capacity ATED 1__[10KLD Capacity9. SLUDGE GENERATION & HANDLING: for 550 KL As the process selected is a physico- chemical followed by biological nature, sludge generated from biological section is used as manure. CHEMICAL SLUDGE PROCESS: Quantity of chemicals added: Lime@600ppm = 330 Ke/day. FeSO4@500ppm = 275 Ke/day. ‘Total Suspended solids in Effluent (TSS) 200 ppm ~ 110 Kg/day Total sludge on dry weight basis = 715 kg/day This sludge will be disposed to any authorized cement kiln for co-processing. BIOLOGICAL SLUDGE PROCESS: Quantity of sludge generated: 50% of the BOD removed, BOD removed: 550 x 250 = 138 kg/day, Hence Bio sludge will be 69 kg/day. This sludge will be used as manure. MODE OF DISPOSAL Chemical sludge will be disposed of in CEMENT FACTORY10. REVERSE OSMOSIS PLANT: OPERATING PARAMETERS 1 Stage Re Total treated effluent Total Feed Quantity Plant running hours Feed flow rate Permeate flow rate Recovery % Reject flow rate Feed Pressure Required Feed TDS Permeate TDS Reject TDS 2 Stage RO: Total Feed Quantity Plant running hours Feed flow rate Permeate flow rate Recovery % Reject flow rate Feed Pressure Required Feed TDS Permeate TDS Reject TDS 3" Stage RO: Total Feed Quantity Plant running hours Feed flow rate Permeate flow rate Recovery % cumulative Reject flow rate Feed Pressure Required Feed TDS Permeate TDS Reject TDS 4" Stage RO: Total Feed Quantity Plant running hours Feed flow rate Permeate flow rate Recovery % cumulative Reject flow rate Feed Pressure Required Feed TDS Permeate TDS Reject TDS 550 KL per day 550 KL per day 22 hours 25 Cumh. 1750 Cum/h 70% 7.50 cum/h 450 psi 6000 ppm <300 ppm. 20000 ppm. 165 KL per day 20.6 Hours per day 8 Cumh. 4 Cum/h, 50 % 4 cumh 1000 psi. 20000 ppm <400. ppm. 40000 ppm 82.5 KL perday 20.6 Hours per day 4 Cumh. 2. Cumh 50% 2 Cumh. 1000 psi max. 40000 ppm. < 500 ppm. 57000 ppm. 41.25. KL per day 13.50 Hours per day 6.00 Cum. 1.50 Cum/h, 25% 4.50 Cumh. 300 psi max. 57000 ppm. < 54000 ppm. 60000 ppm.11, RO PLANTS — EQUIPMENTS DETAILS. SPECIFICATION FOR RO PLANT STAGE 1: 550 KLD: SILNo Description Qty | Unit 1 | Filter feed pumps, 37.5 Cu.mv/h, 3.0 kg/em? pr., 5 HP horizontal, | 2 | Nos. Monoblock, SS 316, Anala/eqt make. 2 | Cartridge filter housing in $S-316 to hold 40" Long 10 cartridges, set | 5 micron, 37.5 cum/h, 3 | Antiscalent dosing- 6 Iph cap. Diaphragm type Pump & 100 liters No. tank, Pump make: Anala/eqt | 4 | SMBS dosing-6 Iph cap. Diaphragm type Pump & 100 liters tank, No. I Pump make: Anala/eqt | 5 | Acid dosing -6 Iph cap. Diaphragm type Pump & 100 liters tank, No | Make: Analaleqt 6 | Membrane housing, 8"dia, 6E L, FRP material for 300 psirating, | 6 | Nos | Pentair make. 7 | Pressure switches, low & high 2 | Nos 8 | pH meter for acidified feed water, Aster make 1 | No 9 | Conductivity meter for feed water, Aster make 1 | No 10 | ORP indicator for feed water | No 11 | Flow meters for product & reject water, 0- 37.5 cumvh 2 | Nos. 12 | Pressure gauges for cartridge filter, RO membranes inlet, 3. | Nos. intermediate & Outlet ete, | 13 | Piping and valves( in SS for high pressure lines & PVC for low Lot pressure lines) 14 | Skid in Mild Stee! to support various components No 15 | Cleaning pump- 37.5 m3/h, 5 bar, SS 316, 7.5 HP, Johnson/eqt No 16 | Cleaning tank-in FRP 1000 liters capacity, inlet, outlet etc No 17 | Electrical pane! 1 | No 18 | RO High pressure Pump 37.5 Cu.m/h, 300 PSI, 20 HP, Grundfos 1 No make, Vertical stainless steel 316, multi stage centrifugal type. 19 | RO Membranes, 8040 Brackish water type of Hydranautics,USA | 24 | Nos make,SPECIFICATION FOR 2"? STAGE RO PLANT- 165 KLD: Description Filter feed pumps, 15 Cum/h, 3.0 kg/cm? pr., 5 HP horizontal, | Monoblock, SS 316, Anala/eqt make. 2 | Cartridge filter housing in SS-316 to hold 30" Long 5 cartridges, | 1 | set $ micron, 15 cum/h, | 3 | Antiscalent dosing- 6 Iph cap. Diaphragm type Pump & 100 liters. | 1 | No. tank, Pump make: Anala/eqt 4 | Acid dosing -6 Iph cap. Diaphragm type Pump & 100 liters tank, | 1 | No | Make: Anala/eqt | 5 | Membrane housing, 8"dia, SE L, FRP material for 1000 psi rating, | 3 | Nos Pentair make. | 6 | Pressure switches, low & high 2 | Nos 7 | pH meter for acidified feed water, Aster make 1 | No 8 | Conductivity meter for feed water, Aster make 1 | No 9 | Flow meters for product & reject water, 0 — 15 cum/h 2 | Nos. 10 | Pressure gauges for cartridge filter, RO membranes inlet, 3. | Nos intermediate & Outlet ete. 11 | Piping and valves( in SS for high pressure lines & PVC for low 1 | Lot pressure lines) 12 | Skid in Mild Stee! to support various components 1 | No 13 | Cleaning pump- 15 m3/h, 5 bar, SS 316, 10 HP, Johnson/eqt 1 No 14 | Cleaning tank-in FRP 1000 liters capacity, inlet, outlet ete. 1 | No 15 | Blectrical panet 1 | No 16 | RO High pressure Pump 15 Cunv/h, 1000 PSI, 40 HP, Plunger 1 | No pump 17 | RO Membranes, 8040 Sea water type of Hydranautics, USA make. 10 | NosSPECIFICATION FOR 3" STAGE RO PLANT- 82.50 KLD: SLNo Description Qty | Unit 1 | Filter feed pumps, 6 Cumm/h, 3.0 kg/cm? pr., 5 HP horizontal, 2 | Nos, Monoblock, SS 316, Anala/eqt make. 2 | Cartridge filter housing in SS-316 to hold 30" Long 3 cartridges, | 1 | set 5 micron, 6 cum/h. 3 | Antiscalent dosing- 6 Iph cap. Diaphragm type Pump & 100 liters | 1 | No. tank, Pump make: Anala/eqt 4 | Acid dosing -6 Iph cap. Diaphragm type Pump & 100 liters tank, | 1 | No Make: Anala/eqt 5 | Membrane housing, 8"dia, 4E L, FRP material for 1000 psi rating, Pentair make. 6 | Pressure switches, low & high 7 | pH meter for acidified feed water, Aster make 1 | No | 8 | Conductivity meter for feed water, Aster make 1 | No | 9 | Flow meters for product & reject water, 0 — 6 cunv/h 2 | Nos. | 10 | Pressure gauges for cartridge filter, RO membranes inlet, 3. | Nos. | intermediate & Outlet etc | 11 | Piping and valves( in SS for high pressure lines & PVC for low 1 | Lot | pressure lines) 12 | Skid in Mild Stee! to support various components 1 | No | 13 | Cleaning pump- 6 m3/h, 5 bar, SS 316, 10 HP, Johnson/eqt 1 | No | 14 | Cleaning tank-in FRP 1000 liters capacity, inlet, outlet etc. 1 | No | “15 | Electrical panel _ : 1 | No | 16 | RO High pressure Pump 6 Cum/h, 1000 PSI, 40 HP, Plunger 1 | No | pump 17 | RO Membranes, 8040 Sea water type of Hydranautics,USA make. | 8 | NosQty | Unit 1 | Filter feed pumps, 5 Cum/h, 3.0 kg/em? pr., 5 HP horizontal, 2 | Nos. Monoblock, SS 316, Anala/egt make. | 2 | Cartridge filter housing in SS-316 to hold 30" Long 3 cartridges, | 1 | set | 5 micron, 6 cum/h, | 3 | Antiscatent dosing- 6 Iph cap. Diaphragm type Pump & 100 liters | 1 | No. tank, Pump make: Anala/eqt | 4] SMBS dosing-6 Iph cap. Diaphragm type Pump & 100 liters tank, | 1 | No. | Pump make: Anala/eqt 5 | Acid dosing -6 Iph cap. Diaphragm type Pump & 100 liters tank, | 1 | No | Make: Anala/eqt | 6 | Membrane housing, 8a, SE L, FRP material for 1000 psi rating, | 1 | No | Pentair make. 7| Pressure switches, low & high 8 | pH meter for acidified feed water, Aster make 9 | ORP indicator for feed water 10 | Flow meters for product & reject water, 0-5 cum/h 11 | Pressure gauges for cartridge filter, RO membranes inlet, 3. | Nos intermediate & Outlet etc. 12 | Piping and valves in SS for high pressure lines & PVC for low 1 | Lot pressure lines) Skid in Mild Steel to support various components 1 | No Cleaning pump- 5 m3/h, 5 bar, SS 316, 10 HP, Johnson/eqt 1 | No 15 | Cleaning tank-in FRP 1000 liters capacity, inlet, outlet etc. 16 | Electrical panel 17 | NF High pressure Pump 5 Cum/h, 1000 PSI, 7.5 HP, SS pump 18 | NF Membranes, 8040 Sea water type of Hydranautics,USA make12, DESIGN ADEQUACY REPORT: ETP ADEQUACY REPORT: Quantity of Effluent: 550 KLD 1. Collection Tank Size = 12.75x 9.25 x3.70mx2Nos 2.20 x9.25 x 3.70 m Volume = 948.04 m? Considering 24 hrs retention Volume required = 550 m* 2. Primary Clarifier Size = 5,000x4.20m x2Nos Volume = 164.85 m? Flow = 25 m'/hr Retention Time = 4 hrs Volume Required = 100 m* 3. Aeration Tank: Size = 16.00 8.20x4.00m 6.40 x 8.20 x 4.00 m Volume = 734.72 m* Considering 24 hrs retention Volume required = 550 m’ 4, Secondary Clarifier 9.000 x3.10m Volume = 197.11 m* Flow = 25 m'/hr Retention Time = 4 hrs Volume Required = 100 m* 5. Tertiary Clarifier Size = 9.000x3.10m Volume = 197.11 m? Flow = 25 m’/hr Retention Time = 4 hrs Volume Required = 100 m* Size Hence adequate Hence adequate Hence adequate Hence adequate Hence adequate6. ROI Feed Tank Size = 6.50x8.00x3.20m Volume = 166.40 m* Considering 4 hrs retention Volume required = 100 m* Hence adequate 7. RO Il Feed Tank Size = 6.50x5.75x3.20m Volume = 119.60 m’ Considering 12 hrs retention Volume required = 82.50 m* Hence adequate 8. RO III Feed Tank Size = 8.00x3.90x3.20m Volume = 99.84 m? Considering 12 hrs retention Volume required = 41.25 m* Hence adequate 9. RO IV Feed Tank Size = 3.10x 1.50 x3.20mx2Nos Volume = 29.76 m? Considering 12 hrs retention Volume required = 20.62 m* Hence adequate 10. RO Permeate Tank Size = 10.40 x 5.70.x 4.00 m x2 nos Volume = 474,24 m* Considering 12 hrs retention Volume required = 259.53 m? Hence adequate 11, Sludge Drying Beds Quantity of effluent 550 KLD. Considering 1% sludge generation = 5.5 m? For 6 days: 33 m3 SDB Size: 4.10 x 4.10 x 0.45 mx 24 Nos Volume = 181.55 m? Hence adequate 12. Solar Evaporation Pans Size = 10.00 x 11.70 mx 8 Nos Total area = 936 sqm, (10071 sqft.) Hence adequateRO MEMBRANES ADEQUACY DETAILS Membrane Size [No.of | Capacity ] Required | Feed Capacity | Design ‘Adequate Membrane | in KLD in KLD | Flow Rate | Details ROI(8"*40") yy 580 24*22Hrs* | 24200Lt8/| 70% | Yes Brackish water 1100 Lts= 580 | Membrane ‘membrane ROM ("40") 10 176 165 [10*22Hirs* | 17600Lts/ | 50% Yes Sea water 800 Lts=176 | Membrane membrane 7 _ : - ROI ("#40") 8 88 82.5 [8*22Hrs* | 11000Lis/ Yes Sea water 500 Lis=88 | Membrane [eel ieee A ROIV (8"*40") 3 132 | 41.25 |[3*22Hrs* | 44000L0s/| 25% Yes Sea water 2000 Lis.= 132 | Membrane ‘membrane RO, MEE, SEP DETAILS Stage | Sie No. of Vessels No. of (Element) piessiranes 1 ROI 8” # 40"-6 4 4 2 ROI Br + 40r-5 2 10 3 ROUT gre 4or-4 8 4 ROIV 8” # 407-3 1 3 5 Multiple Effect Evaporator 30.94 KLD Required ~ 80 KLD Provided -5 Stages No.of | Feed Capacity | Required | Condensate | Reject | Adequate Laid M?/ Day M?/Day M'Day | MY/Day 5 80.00 30.94 2939 135 Yes Agitated Thin Film Dryer 1,55 KLD Required ~ 10 KLD Provided ee | Required | Mixed Salt | Loss Reject | Adequate ‘M?/ Day with M'/Day | M’/Day moisture M’/ Day sesemea| | 155 Salt- 250 0.55 ‘NIL | Yes kg. = 6 ‘Solar Evaporation Pan Details | | Reject- Required in Sqm. | Provided in Adequate |__KLD. | sqm. : | 936 Sqm.‘3. LIST OF MACHINERIES, PRODUCTION CAPACITY WITH EFFLUENT GENERATION DETAILS FOR EXPANSION ACTIVITIES BLEACHING, DYEING OF YARN/FABRICS 1. Cabinet Dyeing Machines SI.No. | Machine |No.of | LotDay | Production/Day | Liquor | Effluent Remarks Machines Ratio Generation in _— Liters/Day oo 1 1 100Kg | 1:150 15000 1 1 50Kg| 1150 | 7500 1 | 40Kg|_1:150 6000 | | 1 1 10Kg| _1:150 1500 _| | TAL 200 Kg 30000 | 2. Cheese Dyeing Machines SI.No. | Machine | No.of | Lot/Day | Production/Day | Liquor | Effluent | Remarks Capacity | Machines Ratio | Generation LitersDay 2 ~2000Kg| 1:40 80000 | Fongs Mic 2 1014Kg| _1:40 40560 | Fongs Mic a) 600Kg| 140 | 24000 | Fongs Mic 2 400Kg| 140 "16000 | Fongs Me 2 ~ ‘116Kg| 140 ‘4640 | Fongs Mie 2 ~~ 150Kg| 1:75 11250 | Local | 2 | ~20Kg| 1:75 “1500 | Local | [ - 4300Ke{ | 177950] 3. Jigger Dyeing Machines SI.No. [Machine | No. of LovDay | Production/Day | Liquor | Effluent ‘Remarks Capacity | Machines | | Ratio | Generation in | Liters/Day 1 500Ke| 6 1s | 4500Ke| 130 135000 2 | 350Kg 2 15 1050Kg| 1:30 31500 3 | 300Kg| 3 15 1350Kg| 130 40500 | | 4 | 150kg| 2 | 450Kg| 130 13500 | _| 3 soke| 2 | 15 | 150Ke| 130 | 4500/ _| { TOTAL | ~C7500Kg [225000 |4, Wet Process includes CBR, CBP, WR- 117050 TOTAL EFFLUENT GENERATION= 30000 + 177950 + 225000 + 117050 = $0000 Lit. (550 KLD) PRODU 1, Bleaching and Dyeing of Cotton Yarn: 4500 Kg/Day (117 T/Month) (Cabinet Dyeing- 200Kg/Day & Cheese Dyeing- 4300 Kg/Day) 2. Bleaching and Dyeing of Fabrics: 7300 Kg/Day (195 T/Month) (igger Dyeing- 7500 Kg/Day) LIST OF ADDITIONAL MACHINERIE! 1. Mercerizer -1No 2. Cold Pad patch Machine -1No 3. Continuous Washing Range -1No 4. Hot Air Stenter and Chamber -1No 5. Shrinking Range ~ Zero Zero Machine - 1 No 6. Screw Compressor -1No 7. Chiller -2Nos 8. Radio Frequency Drier -1No 9. Hydro Extractor -2Nos 10. Voltage Stabilizer for RF Drier -2Nos 11. Soft Dye Package Winder = 1 Set 12. Rewinding Machine -1Set 13, Hoist ~ EOT -1No 14, Heat recovery system -1No