ZERO LIQUID DISCHARGE (ZLD) PLANT

PONDY API UNIT

ZLD FLOW DIAGRAM
HIGH TDS PROCESS
EFFLUENT

MULTIPLE EFFECT
EVAPORATOR (2FFE & ATFD - 2 SLUDGE FOR
PRE-TREATMENT STRIPPER DISPOSAL
3FCE) / PUSHAR Nos.
CENTRIFUGE
CONDENSATE
LOW TDS EFFLUENT SLUDGE FOR
BIO-TREATMENT - I DISPOSAL
SEWAGE TREATED
EFFLUENT WATER PERMEATE

REJECT REJECT

BIO-TREATMENT - II RO - II RO - III RO - I

SLUDGE FOR PERMEATE REJECT PERMEATE

DISPOSAL REUSE REUSE

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ZLD - DESCRIPTION
Treatment Scheme for Effluent Treatment and Zero Liquid Discharge (ZLD)
Low Pollutant Stream (LPS):

Low Pollutant Stream is separately collected in the Equalisation tank and then subjected to Physico-
chemical treatment for neutralisation and suspended solid separation. The Physico-chemical treatment
consists of neutralisation, flash mixing, flocculation cum primary clarification and is sent to Biological
Treatment Plant-II (BTP-II) and treated along with domestic waste water.

The BTP-II consists of two stage aeration (Primary & Secondary) treatment with Aeration tank-1 followed
by Bio-Clarifier -1 and Aeration tank-2 followed by Bio-Clarifier -2. The bio-clarifier overflow water goes
to tertiary clarifier and then to Filter feed tank. From Filter feed tank, it is fed to Pressure sand filter (PSF)
and Activated Carbon Filter (ACF). ACF treated water is taken to RO Plant –II for further treatment.

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ZLD - DESCRIPTION
High Pollutant Stream (HPS) :

High Pollutant Stream predominantly from process is separately collected in the Equalisation tank along
with reject of Reverse Osmosis Plant III (RO III) and then subjected to Physico-chemical treatment for
neutralisation and suspended solid separation. The Physico-chemical treatment consists of
neutralisation, flash mixing, flocculation and primary clarification.

The physico chemical treated water is taken to Stripper/ Multiple Effect Evaporator (MEE) plant for
evaporation / concentration. The concentrate from MEE is further concentrated to a dry solid in Agitated
Thin Film Dryer (ATFD). The evaporated condensate from MEE and ATFD are taken for further treatment
in Biological Treatment Plant –I (BTP-I). The concentrated chemical sludge from ATFD is disposed to
authorised co-processer for cement industry / authorised Secured Land Fill (SLF)site.

The BTP-I consists of two stage aeration (Primary & Secondary) treatment with Aeration tank-1 followed
by Bio-Clarifier -1 and Aeration tank-2 followed by Bio-Clarifier -2. The bio-clarifier overflow water goes
to Tertiary clarifier followed by Filter feed tank. From Filter feed tank, it is fed to Pressure Sand Filter
(PSF) and Activated Carbon Filter (ACF). The filtered treated water is taken to RO Plant - I for further
treatment.
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ZLD - DESCRIPTION
Reverse Osmosis Plants (RO I, RO II & RO III):

The treated water from Biological treatment plant – BTP I & II are processed through RO-I & II respectively
and the permeate water from the RO is recycled through non process / process applications.

The reject from the RO I & II are fed to RO III for further recovery of water. Permeate from RO III is used
for non process application / recycled as feed to RO II. Reject from RO III is sent to Multiple Effect
Evaporator (MEE) for further processing.

The permeate water from the RO meets the potable water specification on all physio chemical analysis.

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HPS – FLOW DIAGRAM

HPS EFFLUENT PRE TREATMENT

OIL PRIMARY TO MEE

HPS EFFLUENT EQUALIZATION NEUTRALIZATION
SKIMMER CLARIFIER FEED TANK

TO PRIMARY
SLUDGE TANK

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MEE FLOW DIAGRAM
HPS Primary LP STEAM
treated Effluent
HIGH COD
STRIPPER
CONDENSATE
RO III reject
TVR HP STEAM

MEE FEED TANK PRE-HEATER FFE - I FFE - II FCE - I FCE - II FCE - III

CONCENTRATE
RECIRCULATION
PUSHAR THICKENER
ML TANK
CENTRIFUGE HYDROCYCLONE

CONDENSATE
VTFD - I VTFD - II

CONDENSATE CONDENSATE
TANK

SALT FOR
DISPOSAL TO BTP - I

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HPS – FLOW DIAGRAM

SLUDGE FROM HPS

PRIMARY CLARIFIER

CONDENSATE CONDENSATE BIO - BIO - BIO - BIO - TERITARY

FROM MEE / ATFD TANK REACTOR - I CLARIFIER - I REACTOR - II CLARIFIER - II CLARIFIER
SLUDGE

SLUDGE
PRIMARY
FILTER TO RO I FEED
PSF ACF SLUDGE
FEED TANK TANK
TANK

PRIMARY
BIO DECANTER
BIO-SLUDGE DECANTER SLUDGE
SLUDGE CENTRIFUGE
THICKENER CENTRIFUGE THICKENER
TANK
SLUDGE FOR SLUDGE FOR
DISPOSAL DISPOSAL

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 LPS – FLOW DIAGRAM
Domestic Non process
Effluent Effluent

OIL PRIMARY
LPS EFFLUENT EQUALIZATION NEUTRALIZATION
SKIMMER CALRIFIER

BIO - BIO - BIO - BIO - TERITARY

STEW CLARIFIER - II
REACTOR - I CLARIFIER - I REACTOR - II CLARIFIER

TO PRIMARY
SLUDGE SLUDGE TANK

FILTER TO RO II FEED
PSF ACF
FEED TANK TANK

TO BIO SLUDGE
TANK

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ZLD – MEE PLANT

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ZLD - BIOLOGICAL TREATMENT PLANT

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ZLD - RO PLANT

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Thank You