Wastewater Management System for Small Scale

Artisanal Enterprise

Introduction
In Phase-1 of CRD project, a waste management study was conducted in the Akola
village of Rajasthan where Dabu Printing craft is being practised. During the study
few observations were made, which are given as follows:-
1. Around 700-800 litres of wastewater is generated on a daily basis by each
workshop present in the cluster.
2. Effluent is discharged in nearby water-bodies and landfills without being
treated for any dye-stuff.
3. The wastewater gets accumulated in the nearby disposal area where it
becomes a breeding ground for many insects and pests.
4. The effluent gets penetrated into the soil, whose impact is unknown to the
local authorities and residents.
The impact of the waste generated due to the craft practices can cause major issues
such as air pollution, water pollution and soil contamination. This can impact the
health of people residing in the nearby region in the long run.
One of the alarming concerns that arises from these practices is the consumption of
water. As indigo dyeing is involved in the process, it requires washing of the fabric
3-4 times. This leaves residues of dye-stuff in water. As over the years the natural
dyes have been replaced by synthetic dyes for carrying out the craft the effects of
the effluent discharge can be major. In order to manage the effluent discharge and
control the amount of wastewater generated a system is required to manage the
waste. Therefore, a systematic method to find the best solution for wastewater
management for a small scale enterprise is required.
The aim of this document is to delineate the approach for identifying a suitable
wastewater management system customised for a modest artisanal business.

Objective
● To study the feasibility of a wastewater management system for a small scale
artisanal enterprise.
● To understand various testing parameters for effluents to be considered for
recycling.
● To find the level of ETP to be installed for the cluster.
● To install a proper ETP system for recycling wastewater generated in the
cluster.
Methodology

● Characterization of Wastewater:
○ Preliminary Assessment:
■ Understanding the wastewater content for quantity of BODs,
CODs and dye-stuff. Effluent composition is required to find out
the best suitable method.
○ Testing of Water
■ Kit for Analysis
● pH
● Turbidity
● TSS – Total suspended solids
● Temperature
● Dissolved oxygen
● Probable Biochemical oxygen demand (BOD), chemical
oxygen demand COD and Total Organic Carbon (TOC)
● ETP System Design:
○ Finding out the most basic levels of ETPs that can be installed easily.
○ Preliminary and Primary Treatment ETP system
○ Calculating required treatment capacity, retention times, and necessary
equipment (e.g., tanks, filters, chemical dosing systems).
● Sludge Disposal Techniques and Evaluation
○ Limitations and challenges related to sludge formation and disposal.
● Environmental Impact Assessment:
○ Evaluate potential environmental impacts associated with each
treatment method, such as energy usage and sludge generation.
● ETP Installation

Treatment Level Process Involved

Preliminary or Pre-treatment Physical

Primary Treatment Physical and Chemical

Table: processes involved
 Table: Flow of ETP Processes

Working of ETP:-

1. Screen Chamber
Working of a Screening Chamber in an ETP Plant:

1. Influent Wastewater Intake: Raw wastewater from the industrial

processes enters the ETP and flows into the screening chamber.
2. Screening: In the screening chamber, the wastewater passes through a
series of screens with different opening sizes. These screens are
designed to capture larger solid materials, such as plastic, wood,
paper, cloth, and other debris.
3. Removal of Solids: As the wastewater flows through the screens, the
larger solid particles get trapped on the surface of the screens,
preventing them from entering the rest of the treatment process.
4. Solids Collection: The collected solids form a layer on the screens,
gradually building up over time.
 5. Cleaning Mechanism: Many screening systems include cleaning
mechanisms such as rotating brushes, sprays of water, or mechanical
rakes. These mechanisms help dislodge the trapped solids from the
screens and facilitate their removal.
6. Solids Disposal: The dislodged solids are either washed into a
collection bin or conveyed to a separate system for disposal. The
collected solids are usually sent for proper disposal or further
treatment.
7. Screened Wastewater: The wastewater that passes through the
screens is now free from larger solid particles and can proceed to the
next stages of treatment, such as grit removal, primary sedimentation,
or secondary treatment processes.

Purpose:

The screening chamber in an ETP serves several important purposes:

● -Protection of Downstream Equipment: By removing large solids, the

screening process prevents damage to pumps, pipes, and other
sensitive equipment in the subsequent treatment stages.
● Prevention of Clogging: Large solid particles can clog pipes and
treatment units, reducing the efficiency of the ETP. Screening prevents
these blockages.
● Effluent Quality Improvement: Screening ensures that only wastewater
with smaller particles enters downstream treatment processes,
improving the overall quality of the treated effluent.
● Reduced Maintenance: Regular removal of larger solids reduces the
frequency of maintenance and cleaning required for other parts of the
ETP.

Equipment Used:

● Bar Screens: These consist of vertical or inclined bars or rods that are
spaced at specific intervals to allow wastewater to pass through while
capturing larger solids.
● Rotating Drum Screens: These are cylindrical screens that rotate and
allow wastewater to pass through while capturing larger solids on the
outer surface. The captured solids are then removed by a scraping
mechanism.
● Step Screens: These screens have a series of steps or plates that
create a barrier for larger solids. As wastewater flows over the steps,
solids are captured in the gaps.
 ● Automatic Rake Screens: These screens have a mechanical rake
system that continuously moves across the screen surface, collecting
and removing trapped solids.
● Brush Screens: Rotating brushes sweep the screen surface, dislodging
and pushing captured solids into a collection bin.

2. Equalisation
Working of Homogenous Tank:-

1. Wastewater Collection:Wastewater from various sources within the

industrial process is collected and directed into the equalisation
chamber.
2. Mixing and Homogenization:** As wastewater enters the equalisation
chamber, it's mixed thoroughly to ensure that different types of
wastewater streams are blended together. This promotes uniformity
and reduces the potential for shock loads to downstream treatment
processes.
3. Balancing: The equalisation chamber allows the influent to settle and
stabilise, evening out variations in flow rate and pollutant
concentrations. This prevents sudden spikes or dips in the load
entering the rest of the treatment system.
4. Controlled Flow: The controlled and relatively consistent flow of
wastewater is then discharged from the equalisation chamber to the
subsequent treatment processes, such as primary clarification,
biological treatment, or chemical treatment.
Purpose:
● Stabilisation: To equalise the flow rate and pollutant concentrations of
incoming wastewater, preventing shock loads and protecting
downstream treatment processes from abrupt changes.
● Enhanced Treatment Efficiency: By providing a more uniform influence,
the equalisation chamber improves the efficiency and effectiveness of
subsequent treatment stages. It helps treatment processes operate
within their optimal conditions.
● Compliance: Equalization ensures that the effluent discharged from the
ETP meets regulatory standards consistently, reducing the risk of
non-compliance.
Equipment Used:
● Equalization Tank: A dedicated tank or chamber designed to hold and
balance incoming wastewater. The size of the tank depends on the flow
rate and variability of the wastewater.
● Mixing System: Mechanical mixers or aerators are used to ensure
thorough mixing and homogenization of the wastewater within the
chamber.
 ● Inlet and Outlet Structures: These structures control the flow of
wastewater into and out of the equalisation tank, helping to manage the
rate of inflow and outflow.

3. Flocculation
Working of a Flocculation Chamber in an ETP Plant:
1. Inlet: After primary treatment, the wastewater enters the flocculation
chamber. It contains suspended solids, dissolved pollutants, and fine
particles that need to be further treated before discharge.
2. Coagulant and Flocculant Addition: Coagulants (such as aluminium
sulphate or ferric chloride) and flocculants (polyelectrolytes) are added
to the wastewater. Coagulants neutralise charges on particles and form
small clusters, while flocculants help these clusters aggregate into
larger, settleable flocs.
3. Flocculation: The wastewater flows slowly through the flocculation
chamber, allowing coagulated particles to come into contact and form
flocs. Gentle mixing mechanisms, such as paddles or baffles, facilitate
particle collisions without breaking the flocs apart.
4. Aggregation: As the wastewater moves through the flocculation
chamber, the coagulated particles continue to collide and combine,
forming larger and denser flocs.
5. Outlet: The now-flocculated wastewater exits the flocculation chamber
and enters the sedimentation tank. The flocs, which have a higher
settling velocity due to their increased size and density, are more
efficiently separated from the water during sedimentation.
Purpose of a Flocculation Chamber:
● The primary purpose of a flocculation chamber is to facilitate the
aggregation of small, dispersed particles into larger flocs that can settle
more effectively in the subsequent sedimentation tank. The process
helps in the removal of fine suspended solids, colloidal matter, and
some dissolved pollutants, improving the overall efficiency of the ETP
system in terms of achieving effluent quality standards.
Equipment Used in a Flocculation Chamber:
● Mixing Mechanisms: Paddles, baffles, or mechanical mixers are used
to gently agitate the wastewater and promote particle collisions without
causing excessive turbulence.
● Coagulant and Flocculant Dosage System: Equipment for accurate and
controlled addition of coagulants and flocculants to the wastewater.
● Flow Control: Flow regulators or weirs control the rate of flow through
the flocculation chamber, allowing sufficient contact time for flocculation
to occur.
4. Clarifying
Working and Process Flow:
1. Influent Wastewater Intake: Raw wastewater from the industrial
processes enters the primary clarifier.
2. Sedimentation: The wastewater is allowed to flow slowly through the
primary clarifier, where gravity takes effect. Suspended solids and
particles settle under gravity and form a layer of sludge at the bottom of
the clarifier.
3. Clarified Water Collection: The relatively cleaner water, referred to as
the effluent, rises to the surface due to the settling of solids. This
clarified water is collected from the top of the clarifier.
4. Sludge Removal: The accumulated sludge at the bottom of the clarifier
is periodically removed. This sludge contains the settled solids and
organic matter.

Purpose:
● Solid Removal:It removes settleable suspended solids and particulate
matter from the wastewater, reducing the load of pollutants before
further treatment.
● Preliminary Treatment: It's the first step in the treatment process and
prepares the wastewater for subsequent treatment stages.
● Protection of Downstream Units: By removing larger solids, the primary
clarifier helps prevent clogging and damage to downstream treatment
equipment.
● Effluent Quality Improvement: The process improves the quality of the
wastewater effluent, making it easier to meet regulatory standards for
discharge.

Equipment Used:
● Primary Clarifier Tank: A large rectangular or circular tank where
sedimentation takes place. The tank has inlet and outlet structures to
control the flow of wastewater.
● Inlet Structure: This distributes the influent wastewater evenly across
the clarifier, preventing short-circuiting and ensuring even settling.
● Effluent Weir: Located at the top of the clarifier, it collects the clarified
water for further treatment.
● Sludge Removal Mechanism: Various mechanisms can be used to
remove the settled sludge, such as sludge pumps, mechanical
scrapers, or airlift pumps.
● Sludge Collection Hopper: This collects the removed sludge for further
treatment or disposal.

5. Aeration
Working and Process Flow:
 1. Introduction of Wastewater: Raw wastewater from the industrial
processes is introduced into the aeration tank.
2. Aeration: Air or oxygen is diffused into the aeration tank. This aeration
promotes the growth of aerobic microorganisms, such as bacteria and
fungi, which consume the organic matter in the wastewater as their
food source.
3. Microbial Digestion: Microorganisms present in the tank utilise the
organic pollutants as a source of energy and carbon. This process
results in the breakdown of organic compounds into simpler
substances, such as carbon dioxide and water.
4. Settling: After aeration, the mixture of treated wastewater and activated
sludge is allowed to settle in a secondary clarifier or settling tank. The
activated sludge settles at the bottom of the clarifier as a sludge
blanket.
5. Treated Water Removal:** The treated water, now relatively free of
organic pollutants, is carefully drawn off from the upper portion of the
clarifier.

Purpose:
The aeration tank serves the purpose of facilitating the biological degradation
of organic pollutants in the wastewater. The microbial activity in the tank
breaks down complex organic compounds into simpler and less harmful
substances, reducing the overall pollutant load in the wastewater.

Equipment Used:
● Aeration System: This includes diffusers or mechanical aerators that
introduce air or oxygen into the wastewater. The aeration system
provides the necessary oxygen for the growth of aerobic
microorganisms.
● Mixing Mechanisms: Mixers or mechanical agitators are used to ensure
uniform distribution of microorganisms and oxygen throughout the tank.
Proper mixing prevents dead zones and promotes efficient treatment.
● Sludge Return Pump: This pump is used to recirculate a portion of the
settled activated sludge back to the aeration tank, ensuring a
consistent microbial population.
● Secondary Clarifier: This tank allows the activated sludge to settle,
separating it from the treated water before discharge.
Coagulants selection:-
In an indigo dyeing factory, the choice of coagulant for treating effluent would depend
on the specific characteristics of the wastewater and the pollutants present.
Coagulants are chemicals that are added to wastewater to destabilise suspended
particles and contaminants, allowing them to come together and form larger particles
that can be more easily removed through processes like sedimentation or filtration.

Common coagulants used in treating effluent from an indigo dyeing factory include:
● Polyaluminum Chloride (PAC): PAC is a commonly used coagulant that can
effectively remove suspended solids, colour, and some organic pollutants. It
can be useful in treating dye wastewater where colour removal is a key
concern.
● Ferric Chloride (FeCl3): FeCl3 is effective in removing colour, suspended
solids, and certain organic pollutants. It's often used when colour removal is a
priority, which is typically the case in dyeing effluents.
● Polyelectrolytes: Polyelectrolytes are high-molecular-weight polymers that can
aid in the coagulation process by bridging the particles together. They can
enhance the efficiency of other coagulants and improve floc formation.
● Alum (Aluminum Sulfate): Alum is a traditional coagulant used in wastewater
treatment. It can remove suspended solids, colour, and certain organic
compounds.
● Cationic Polymers: These polymers are effective in binding to negatively
charged particles in the effluent, aiding in their removal through coagulation.
● Inorganic Salts: Other inorganic salts, such as ferrous sulphate or calcium
chloride, might also be used based on the specific characteristics of the
effluent.

The choice of coagulant would depend on factors like:-

● Desired Outcome of the ETP
● Composition of the dye stuff in wastewater
● Treatment efficiency
● Presence of other chemicals
● Local environmental regulations.
Basic Design of the ETP:-
 Fig: ETP design for textile industry
The above given figure represents the basic design of an ETP plant used in textile
dyeing and printing units. This can be further modified according to the requirements
for Indigo dyeing and printing facilities. The composition of the effluent will play an
important role in understanding the steps that are required for the installation of ETP.