7.

EFFLUENT TREATMENT PLANT - PROCESS FLOW DIAGRAM

MEE condensate &

Centrifuge dewater

Equalization tank – I & II

Flash mixer - I Poly Aluminum Chloride

Polyelectrolyte

Flocculator - I

Primary clarifier

Sludge to thickener

Distribution chamber

Lime, Bactus,
Di Ammonium phosphate & Urea

Aeration tank - I

Activated sludge

Secondary clarifier - I

27
Sludge to thickener
 From secondary clarifier - I
Lime, Bactus,
Di Ammonium phosphate & Urea
Aeration tank - II

Activated sludge

Secondary clarifier - II

Sludge to thickener

Storage tank (HDPE)

Flash mixer - II Poly Aluminum Chloride

Polyelectrolyte

Flocculator - II

Tertiary clarifier

Sludge to thickener

Collection sump (SAF) Multi Grade Sand filter

(MGF)

Recycled to Cooling Activated carbon filter

tower & Garden (ACF)
28
 Sludge thickener

Sludge from primary, secondary I&II and tertiary

clarifier

Centrifuge

Polyelectrolyte

Dry Sludge Dewater

Figure: 08. ETP process flow diagram

In-house stabilization To equalization tank
7.1 Process description
The effluent generated from the process is treated by the following three-stage process.

7.2 Primary treatment – (Chemical treatment)

Raw effluent is collected in an Equalization tank and necessary pH adjustment is done in
the Equalization tank. The neutralized effluent is pumped to a Flash Mixer-I where
predetermined quantities of Poly Aluminum Chloride (PAC) and Polyelectrolyte (PE) solutions
are added. The chemical solutions are prepared in respective solution preparation tanks. Flash
mixer mixes PAC and polyelectrolyte solutions with the effluent. Jar test shall be conducted to
optimize the dosages. The effluent mixed with chemical solutions flows to Flocculator-I. Flocs
are formed and that is settled as sludge in subsequent Primary Clarifier. The sludge is withdrawn
and transferred to a Sludge Thickener by pumps. The overflow from the primary clarifier flows
to Distribution chamber.

29
7.3 Secondary treatment- (Biological treatment)

Figure: 09. Aeration tank

A Three stage biological treatment with extended aeration activated sludge process
constitutes the secondary stage of the treatment. The aerobic process is capable of converting
organics to innocuous end products or to cellular mass. The organics are metabolized by a
diverse group of microorganisms to carbon dioxide and water. At the same time a sizeable is
converted to cellular mass.
The effluent from distribution chamber flows to the Aeration tank-I, where the air from blowers
is distributed through non-clog diffusers. The effluent undergoes aerobic oxidation resulting in
the reduction of organic strength of the effluent. Urea and Di-Ammonium phosphate solutions
are added to the aeration tanks to maintain the nutrient requirement and lime solution added for
pH adjustment. The overflow from Aeration tank-I flows to Secondary clarifier-I where the
biomass formed in the Aeration tank-I settles as sludge. The sludge is withdrawn by pumps and
recycled back to Aeration tank-I to maintain the Mixed Liquor Suspended Solids (MLSS). The
excess sludge is sent to the Thickener.

The overflow from the Secondary clarifier-I flows to Aeration tank-II where the air is distributed
through non-clog diffusers and further oxidation takes place. Urea and Di-Ammonium phosphate
solutions are added to the aeration tanks to maintain the nutrient requirement and lime solution
30
added for pH adjustment. The effluent from Aeration tank-II flows to the Secondary clarifier-II.
Tube settlers are installed in the Secondary clarifier-II to increase the settling efficiency.

Figure: 10. Secondary clarifier II (left side) & Tertiary clarifier (Right side)

The biomass formed in the Aeration tank-II settles as sludge. The sludge is withdrawn by pumps
and recycled back to Aeration tank-II to maintain the Mixed Liquor Suspended Solids (MLSS).
The excess sludge is sent to the Thickener.

7.4 Tertiary treatment

The Tertiary treatment consists of chemical treatment and Filtration.

7.4.1 Physical chemical treatment: The overflow from Secondary clarifier-II flows to a storage
tank (HDPE) and it is pumped to a Flash Mixer-II where PAC and polyelectrolyte solutions are
added. The effluent from Flocculator-II flows to Tertiary clarifier where the flocs formed settle
as sludge. Tube settlers are provided in this clarifier, which provides additional settling area for
effective settling. The settled sludge is withdrawn by pumps and transferred to Sludge Thickener.

7.4.2 Filtration: The overflow from Tertiary clarifier flows to a collection sump (SAF) and the
effluent from collection sump is pumped into a Multi grade sand filter (MGF) & Activated

31
carbon filter (ACF). In the MGF and ACF, the fine suspended solids and colloidal particles that
may be present are removed and its Recycled to Cooling tower & Garden.

7.5 Sludge dewatering

The sludge from Primary Clarifier, excess sludge from Secondary Clarifiers-I&II and sludge
from Tertiary Clarifier are pumped to a Sludge Thickener. The thickened sludge from the
thickener is pumped to the Centrifuge for mechanical dewatering. The supernatant liquid from
the thickener flows back to equalization tank for further treatment. The Dewatered sludge from
the Centrifuge is packed, stored and disposed to the common secured landfill facility at
Gummidipoondi.

7.6 Sludge Stabilization

Before sending the stabilized sludge for disposal to TSDF (treatment, storage and
disposal facility) by secured land fill, sludge stabilization done in house stabilization shed. ETP
sludge is stabilized by adding fly ash (generator from boiler) and lime at 1: 1:0.15 ratios in a
stabilizing pit. Mixing of this material is done by using concrete mixer machine. Loss of ignition
(LOI) should maintain less than 12% and pH of stabilized sludge must be 9 to 10. By this
method of operation dust emission and odour nuisance reduce considerably in addition to the
45% of reduction in treatment cost. The stabilized material is homogeneous and meets the
standards prescribed by the Pollution Control Board.

32
7.7 Operational facilities:
Table: 10. ETP operational facilities

Sl. No Description Dimensions (in meters) Capacity(in KL)

1 Equalization tank I 7.2 × 4 × 4 115.2

2 Equalization tank II 6.8 × 4 × 4 108.8

3 Flash mixer I 1 × 1 × 1.5 1.5

4 Flocculator I 1.5 × 1.5 × 1.5 3.37

5 Primary clarifier 3.5 × 3.5 × 2 24.5

6 Aeration tank I 14.5 × 5 × 6.65 482.12

7 Secondary clarifier I 3.5 × 3.5 × 2 24.5

8 Aeration tank II 14.5 × 5 × 6.65 482.12

9 Secondary clarifier II 3.5 × 3.5 × 2 24.5

10 Flash mixer II 1 × 1 × 1.5 1.5

11 Flocculator II 1.5 × 1.5 × 1.5 3.37

12 Tertiary clarifier 3.5 × 3.5 × 2 24.5

13 MGF & ACF 15 3/hr.

7.8 List of equipments

Table: 11. ETP- List of equipments

S.No Equipment name Pressure / Head Flow rate Power

1 Secondary clarifier I pump-01 10 M 10 M3/Hr. 2.2 KW

33
2 Secondary clarifier I pump-02 10 M 10 M3/Hr. 2.2 KW

3 Primary sludge pump-01 10 M 20 M3/Hr. 3.7 KW

4 Primary sludge pump-02 10 M 20 M3/Hr. 3.7 KW

5 Tertiary sludge pump-01 10 M 20 M3/Hr. 3.7 KW

6 Tertiary sludge pump-02 10 M 20 M3/Hr. 3.7 KW

7 Secondary clarifier II pump-01 10 M 10 M3/Hr. 2.2 KW

8 Secondary clarifier II pump-02 10 M 10 M3/Hr. 2.2 KW

9 Centrifuge feed pump-01 30 M 5 M3/Hr. 2.2 KW

10 Centrifuge feed pump-02 30 M 5 M3/Hr. 2.2 KW

11 Tertiary feed pump-01 13 M 15 M3/Hr. 2.2 KW

12 Tertiary feed pump-02 13 M 15 M3/Hr. 2.2 KW

13 Equalization pump-01 60 M 35 M3/Hr. 7.3 KW

14 Equalization pump-02 60 M 35 M3/Hr. 7.3 KW

15 SAF feed pump-01 13 M 15 M3/Hr. 2.2 KW

16 SAF feed pump-02 13 M 15 M3/Hr. 2.2 KW

17 PE pump-01 for centrifuge 10.8 Kg/cm2 600 LPH 0.75 KW

18 PE pump-02 for centrifuge 10.8 Kg/cm2 600 LPH 0.75 KW

19 Lime pump-01 10 Kg/cm2 600 LPH 1.1 KW

20 Primary lime pump-01 10 Kg/cm2 600 LPH 1.1 KW

21 Primary lime pump-02 10 Kg/cm2 600 LPH 1.1 KW

22 Primary PE pump-01 10 Kg/cm2 160 LPH 0.75 KW

23 Primary PE pump-02 10 Kg/cm2 160 LPH 0.75 KW

34
 24 Tertiary PE pump-01 10 Kg/cm2 160 LPH 0.75 KW

25 Tertiary PE pump-02 10 Kg/cm2 160 LPH 0.75 KW

26 HCL pump 10 Kg/cm2 320 LPH 0.75 KW

27 PAC dosing pump-01 10 Kg/cm2 320 LPH 0.75 KW

28 PAC dosing pump-02 10 Kg/cm2 320 LPH 0.75 KW

29 PAC dosing pump-03 10 Kg/cm2 320 LPH 0.75 KW

30 Centrifuge 5 M3/Hr. 11 KW

31 Centrifuge standby 5 M3/Hr. 11 KW

0.78 Kg/cm 2
380 NM3/Hr. 22 KW
32 Air blower-Aeration tank I
0.78 Kg/cm2 380 NM3/Hr. 23 KW
33 Air blower-Aeration tank I (standby)
0.78 Kg/cm2 380 NM3/Hr. 24 KW
34 Air blower-Aeration tank II
0.78 Kg/cm2 380 NM3/Hr. 25 KW
35 Air blower-Aeration tank II (standby)

8. CRITICAL PARAMETERS

8.1 pH
The hydrogen-ion concentration is an important quality parameter of both natural waters
and wastewaters. The usual means of expressing the hydrogen-ion concentration is as pH, which
is defined as the negative logarithm of the hydrogen-ion concentration.

pH = - log10¿

The concentration range suitable for the existence of most biological life is quite narrow
and critical (typically 6 to 9). Wastewater with an extreme concentration of hydrogen ion is
difficult to treat by biological means, and if the concentration is not altered before discharge, the
wastewater effluent may alter the concentration in the natural waters. For treated effluent
discharged to the environment the allowable pH range usually varies from 6.5 to 8.5.

35
8.1.1 pH values for various operations:
Table 12: ETP-pH values
Sl. No Location pH Range
1 Equalization tank I & II 10 to 11
2 Flash mixer I 8 to 8.5
3 Flocculator I 8 to 8.5
4 Primary clarifier 8 to 8.5
5 Aeration tank I 7.5 to 8.0
6 Secondary clarifier I 7.5 to 8.0
7 Aeration tank II 7.5 to 8.0
8 Secondary clarifier II 7.5 to 8.0
9 Flash mixer II 6.5 to 7.0
10 Flocculator II 6.5 to 7.0
11 Tertiary clarifier 6.5 to 7.0

36
 pH profile
13
12
11
10
Eqaulisation tank
9 Primary clarifier I
8 Aeration tank I
Secondary clarifier I
7 Aeration tank II
pH

6 Secondary clarifier II
Tertiary clarifier
5
4
3
2
1
0

Figure 11: ETP-pH profile

8.2 Dissolved oxygen (DO)

Oxygen saturation is a relative measure of the amount of oxygen (O2) dissolved in the
water. Super-saturation can sometimes be harmful for organisms and cause decompression
sickness. Dissolved oxygen (DO) is measured in standard solution units such as mg/L.

8.3 Total dissolved solids (TDS)

A total dissolved solid (TDS) is a measure of the combined content of

all inorganic and organic substances contained in a liquid in molecular, ionized or micro-granular
(colloidal sol) suspended form. Generally the operational definition is that the solids must be
small enough to survive filtration through a filter with two-micrometer (nominal size or smaller)
pores.

8.3.1 Total dissolved solids in various operations:

37
Table 13: ETP-TDS in various operations

 Location TDS(ppm)
Equalization tank 1320 1523 1030 1396
Primary clarifier I 1410 1306 1510 1636
Secondary clarifier I 1796 1755 1720 1656
Secondary clarifier II 1826 2275 2126 2096
Tertiary clarifier 1980 2341 2334 2414

Total dissolved solids profile

3000

2500

2000
Eqaulisation tank
Primary clarifier I
Secondary clarifier I
TDS in ppm

1500 Secondary clarifier II

Tertiary clarifier

1000

500

Figure 12: ETP TDS profile

8.4 Biochemical oxygen demand (BOD)

38
 Biochemical oxygen demand (BOD) is measure of the amount of dissolved
oxygen needed by aerobic biological organisms in a body of water to break down organic
material present in a waste water sample at certain temperature over a specific time period. The
BOD value is most commonly expressed in milligrams of oxygen consumed per litre of sample
during 5 days of incubation at 20 °C. BOD is similar in function to chemical oxygen
demand (COD), in that both measure the amount of organic compounds in water. However,
COD is less specific, since it measures everything that can be chemically oxidized, rather than
just levels of biologically active organic matter.

8.5 Chemical oxygen demand (COD)

The chemical oxygen demand (COD) is commonly used to indirectly measure the amount

of organic compounds in water. Most applications of COD determine the amount
of organic pollutants found in surface water or wastewater, making COD a useful measure
of water quality. It is expressed in milligrams per liter (mg/L) also referred to as ppm (parts per
million), which indicates the mass of oxygen consumed per liter of solution.

8.5.1 Chemical oxygen demand (COD) reduction:

Table 14: ETP-COD reduction
COD %
Locations COD(ppm) reduction(appro
x.)
Equalization tank 15360 11280 11040 12640 -
Primary clarifier I 12080 11600 10800 12400 15 %
Secondary clarifier
I 4400 5680 4960 4880 50 %
Secondary clarifier
II 800 1920 320 320 85 %
Tertiary clarifier 316 412 276 196 75 %

39
 COD profile
18000

16000

14000

12000

10000

8000
COD in ppm

6000

4000

2000

0
nk I I I
ta er er erI er
ri fi ri fi ir fi
on la la rifi la
ti c c la c
liz
a
a ry a ry r yc a ry
ua im nd da rti
Eq Pr c o co
n Te
Se Se

Figure 13: ETP-COD profile

9. Dosage preparation tank capacity:

Table 15: Dosage preparation tank capacity
Sl. No Preparation tank Capacity (in litres)

1 Primary PAC preparation tank 1000 lits

2 Primary PE preparation tank 450 lits
3 Tertiary PAC preparation tank 1000 lits
4 Tertiary PE preparation tank 1000 lits
5 Centrifuge PE preparation tanks 1750 lits

TASK: 05
40
10. CHEMICAL DOSAGE
10.1 Dosage Chemicals Concentration

1. Concentration of PAC for primary clarifier:

Amount of water added to the tank = 900 lits
Amount of PAC added to the tank = 100 lits

1000 lits of solution = 100 % concentration

100× 100
100 lits of PAC = = 10 %
1000
Therefore the concentration of PAC solution for primary clarifier = 10 %

2. Concentration of PE for primary clarifier :

Amount of water added to the tank = 450 lits
Amount of PE added to the tank = 100 gms
Density of water = 1 gm/cc or 1000 kg/m3
For water, 1 lit = 1 kg
1000 ml = 1000 gms
1 ml = 1 gm or
1 ml = 1000 mg (take this value)
100 gms of PE added to the 450 lits of water
100 × 1000 mg of PE = 450 × 1000 ml of water
100000 mg of PE = 450000 × 1000 mg of water
We get,
1 mg of PE = 4500 mg of water
Therefore,
4500 mg of solution = 100 % concentration
1× 100
1 mg of PE = = 0.025 %
4500
So, concentration of PE for primary clarifier = 0.025 %

41
3. Concentration of PAC for tertiary clarifier:
Amount of water added to the tank = 900 lits
Amount of PAC added to the tank = 100 lits

1000 lits of solution = 100 % concentration

100× 100
100 lits of PAC = = 10 %
1000
Therefore the concentration of PAC solution for tertiary clarifier = 10 %

4. Concentration of PE for tertiary clarifier :

Amount of water added to the tank = 450 lits
Amount of PE added to the tank = 100 gms
Density of water = 1 gm/cc or 1000 kg/m3
For water, 1 lit = 1 kg
1000 ml = 1000 gms
1 ml = 1 gm or
1 ml = 1000 mg (take this correlation)
100 gms of PE added to the 450 lits of water
100 × 1000 mg of PE = 450 × 1000 ml of water
100000 mg of PE = 450000 × 1000 mg of water
We get,
1 mg of PE = 4500 mg of water
Therefore,
4500 mg of solution = 100 % concentration
1× 100
1 mg of PE = = 0.025 %
4500
So, concentration of PE for tertiary clarifier = 0.025 %

5. Concentration of PE for Centrifuge operation :

Amount of water added to the tank = 1750 lits
Amount of PE added to the tank = 1 kg = 1000 gms
Density of water = 1 gm/cc or 1000 kg/m3

42
 For water, 1 lit = 1 kg
1000 ml = 1000 gms
1 ml = 1 gm or
1 ml = 1000 mg (take this correlation)
1000 gms of PE added to the 1750 lits of water
1000 × 1000 mg of PE = 1750 × 1000 ml of water
1000000 mg of PE = 1750000 × 1000 mg of water
We get,
1 mg of PE = 1750 mg of water
Therefore,
1750 mg of solution = 100 % concentration
1× 100
1 mg of PE = = 0.057 %
1750
So, concentration of PE for tertiary clarifier = 0.057 %

TASK: 06
10.2 Chemical Dosage Calculation
i. Poly aluminum chloride (PAC) dosage for Primary clarifier in flash mixer-I,
Lab scale test:
500 ml of effluent needs 1 ml of PAC for flocs formation
1 L of effluent needs 2 ml of PAC for flocs formation
Therefore, 2.2 KL/hr of effluent needs = 2×2.2×1000 = 4400 ml/hr.
= 4400/1000 = 4.4 lit/hr.

% Concentration of PAC = 10 %

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

ppm ×2.2
4.4=
10
×1000
100

43
 4.4 ×10 ×1000
ppm= = 200 ppm
2.2× 100

Actual flow rate:

The actual flow rate of Poly aluminum chloride solution measured by 1 lit measuring jar
for a minute.
Flow rate = 120 ml/min = 7.2 lit/hr.

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

ppm ×2.2
7.2=
10
×1000
100

7.2 ×10 ×1000

ppm= = 327 ppm
2.2 ×100

Actual flow rate of PAC (327 ppm) ˃ PAC quantity measured by lab scale test (200 ppm)

From the analysis, PAC actual flow rate to be reduced for better PAC consumption and
effluent load.

ii. Polyelectrolyte (PE) dosage for Primary clarifier in flash mixer-I,

Lab scale test:
500 ml of effluent needs 1 ml of PE for flocs sedimentation
1 L of effluent needs 2 ml of PE for flocs sedimentation
Therefore, 2.2 KL/hr of effluent needs = 2×2.2×1000 = 4400 ml/hr.
= 4400/1000 = 4.4 lit/hr.

% Concentration of PE = 0.025 %

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

ppm ×2.2
4.4=
0.025
×1000
100

44
 4.4 ×0.025 × 1000
ppm= = 0.5 ppm
2.2 ×100

Actual flow rate:

The actual flow rate of Polyelectrolyte (PE) solution measured by 1 lit measuring jar for a
minute.
Flow rate = 180 ml/min = 10.8 lit/hr.

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

ppm× 2.2
10.8=
0.025
× 1000
100

10.8 × 0.025× 1000

ppm= = 1.22 ppm
2.2×100

Actual flow rate of PE (1.22 ppm) ˃ PE quantity measured by lab scale test (0.5 ppm)

From the analysis, PE actual flow rate to be reduced for better PE consumption and
effluent load.

iii. Poly aluminum chloride (PAC) dosage for Tertiary clarifier in flash mixer-II,
Lab scale test:
500 ml of effluent needs 1 ml of PAC for flocs formation
1 L of effluent needs 2 ml of PAC for flocs formation
Therefore, 1.5 KL/hr of effluent needs = 2×1.5×1000 = 3000 ml/hr.
= 3000/1000 = 3 lit/hr.

% Concentration of PAC = 10 %

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

45
 ppm ×1.5
3=
10
×1000
100

3 × 10× 1000
ppm= = 200 ppm
1.5 × 100

Actual flow rate:

The actual flow rate of Poly Aluminum chloride (PAC) solution measured by 1 lit
measuring jar for a minute.
Flow rate = 250 ml/min = 15 lit/hr.

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

ppm ×1.5
15=
10
×1000
100

15 ×10 × 1000
ppm= = 1000 ppm
1.5 ×100

Actual flow rate of PAC (1000 ppm) ˃ PAC quantity measured by lab scale test (200
ppm)
From the analysis, PAC actual flow rate to be reduced for better PAC consumption and
effluent load.

iv. Polyelectrolyte (PE) dosage for Tertiary clarifier in flash mixer-II,

Lab scale test:
500 ml of effluent needs 1 ml of PE for flocs formation
1 L of effluent needs 2 ml of PE for flocs formation
Therefore, 1.5 KL/hr of effluent needs = 2×1.5×1000 = 3000 ml/hr.
= 3000/1000 = 3 lit/hr.

% Concentration of PAC = 10 %

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

46
 ppm × 1.5
3=
0.025
× 1000
100

3 × 0.025× 1000
ppm= = 0.5 ppm
1.5 × 100

Actual flow rate:

The actual flow rate of Polyelectrolyte (PE) solution measured by 1 lit measuring jar for a
minute.
Flow rate = 140 ml/min = 8.4 lit/hr.

ppm× Flow rate∈m 3

LPH =
% of Concentration × 1000

ppm ×1.5
8.4=
0.025
×1000
100

8.4 ×0.025 ×1000

ppm= = 1.4 ppm
1.5× 100

Actual flow rate of PE (1.4 ppm) ˃ PE quantity measured by lab scale test (0.5 ppm)
From the analysis, PE actual flow rate to be minimized for better PE consumption and
effluent load.

TASK: 07

10.3 Nutrients Requirements

For aerobic process,

Biochemical oxygen demand (BOD) : Nitrate (N): Phosphate (P)
100 : 5 : 1

For anaerobic process,

Biochemical oxygen demand (BOD) : Nitrate (N): Phosphate (P)

47
 100 : 2.5 : 0.5

Urea containing 46% of nitrate(N)

Di ammonium phosphate containing 22% of phosphate(P) and 18% of nitrate (N)

COD
BOD load =
3
COD = 11280 ppm (on 09/10/2014 at Equalization tank I)
Therefore,
COD 11280
BOD load = = = 3760 ppm
3 3

BOD load in kg = BOD load × flow rate per day

mg Kl
= 3760 ×60
lit d
kg lit
3760 ×60 ×1000
= lit d
1000× 1000
kg lit
3760 ×60
= lit d = 225.6 kg/d
1000

BOD load = 225.6 kg/day

Nitrate (N) requirement

100 % of BOD load = 225.6 kg
5× 225.6
5 % of BOD load = = 11.28 kg
100

Nitrate requirement in kg = 11.28 kg

Phosphate (P) requirement

100 % of BOD load = 225.6 kg

48
 1× 225.6
1 % of BOD load = = 2.256 kg
100

Nitrate requirement in kg = 2.256 kg

Di ammonium phosphate (DAP) requirement

0.22 kg of phosphate (P) in 1 kg of DAP
1× 2.256
2.256 kg of phosphate (P) = = 10.25 kg
0.22

DAP requirement = 10.25 kg/day

1 kg of DAP containing 0.18 kg of nitrate (N)

10.25× 0.18
10.25 kg of DAP contains = = 1.84 kg
1

10.25 kg of DAP contains 1.84 kg of nitrate

Total requirements of Nitrate (N) = 11.28 kg

Nitrate from DAP is = 1.84 kg
Remaining nitrate requires = 11.28 – 1.84
= 9.43 kg of nitrate

Urea requirement
0.46 kg of nitrate in 1 kg of urea

9.43 ×1
9.43 kg of nitrate = = 20.51 kg of urea
0.46

Urea requirement = 20.51 kg /day

TASK: 08

10.4 COD (Chemical Oxygen Demand) reduction:

49
Inlet COD (Equalization tank on 10/10/2014) = 14640 ppm or mg/lit

Outlet COD (tertiary clarifier outlet on 10/10/2014) = 164 ppm or mg/lit

Inlet COD−Outlet COD

% COD reduction = ×100
Inlet COD

14640−164
= ×100
14640

% COD reduction = 98.87 %

COD reduction in kg,

COD load in kg = Inlet COD in kg/lit × feed flow rate per day
= 14640 mg/lit × 60 Kl/day
kg lit
14640 ×60 ×1000
= lit day
1000 × 1000

COD load in kg = 878.4 kg/day

Therefore
100 % COD load = 878.4 kg of COD
98.87 ×878.4
98.87 % COD reduction =
100

= 868.47 kg/day

10.5 Sludge generation:

Note: 1 kg of COD reduction will generate 0.35 kg of sludge in aerobic process
1 kg of COD reduction will generate 0.1 kg of sludge in anaerobic process
Here,
Sludge generation/day = 868.47 kg/day × 0.35
= 303.96 kg/day

50
TASK: 09
11. Air Requirements in Aeration Tanks I & II
Air required for aeration tanks I & II according to Biochemical demand (BOD),
11.1 Aeration tank I:
Initial COD at Equalization tank (average value) = 12608 ppm
COD 12608
Initial BOD = = = 4202.66 ppm
3 3

Inlet flow rate = 60 KLD

mg Kl
4202.66 ×60 × 1000
Total BOD load in kg = lit D
1000 ×1000
Kg Kl
4202.66 ×60
= lit D
1000

= 252.14 kg/day

BOD concentration in Aeration tank I

mg 100−13
inlet after primary chemical treatment. = 4202.66 × %
lit 100

BOD reduction in primary treatment is 13 %

= 3655.74 mg/lit

BOD load in kg/day in Aeration tank I

mg Kl
3655.74 ×60 ×1000
inlet after primary chemical treatment = lit D
1000 ×1000

Kg Kl
3655.74 × 60
= lit D
1000

51
 = 219.34 kg/day
BOD reduction in Aeration tank I is 48%.
kg 100−48
So, BOD load in Aeration tank I = 219.34 × %
day 100

= 114.05 kg/day

Note: 1 kg of BOD reduction needs 2 kg of Oxygen

Therefore,
Oxygen required for 114.05 kg of BOD in Aeration tank I = 114.05 kg/day × 2
= 228.1 kg/day

Air requirement for 228.1 kg/day of oxygen in Aeration tank I

Oxygenrequirement kg /day

( )( )(
= ( % of oxygen ) × oxygen transfer × blower × salinity correction
for 3 mdepth efficiency factor )
Given data,
% of oxygen in air = 21 % (0.21)
Oxygen transfer for 3m depth = 0.18
Blower efficiency = 80 % (0.80)
Salinity correction factor = 0.98
Therefore,
228.1 kg/day
=
0.21× 0.18 ×0.80 ×0.98

= 7698.27 kg/day
Air requirement for Aeration tank I in kg/day = 7698.27 kg/day

7698.27
Air requirement for Aeration tank I in kg/day =
24

= 320.76 kg/hr.

52
Volume of air requirement in Aeration tank I,

Mass of air∈kg
Density of air = = 1.25 kg/m3
Volume of air∈m 3

Therefore,

Mass of air∈kg 320.76

Volume of air = = = 256.6 Nm3/hr.
Density of air∈kg /m3 1.25

Volume of air requirement for Aeration tank I = 256.6 Nm3/hr.

From the above calculation we need 256.6 Nm 3/hr. of Air required for Aeration tank I
but, Aeration tank I air blower capacity is 380 Nm3/hr.so, the existing air blower capacity is
enough for sufficient BOD reduction.

11.2 Aeration tank II:

BOD reduction in Aeration tank II is 84%.
kg 100−84
So, BOD load in Aeration tank II = 114.05 × %
day 100

= 18.24 kg/day
Note: 1 kg of BOD reduction needs 2 kg of Oxygen
Therefore,
Oxygen required for 18.24 kg of BOD in Aeration tank II = 18.24 kg/day × 2
= 36.48 kg/day

Air requirement for 36.48 kg/day of oxygen in Aeration tank II

Oxygenrequirement kg / day

( )( )(
= ( % of oxygen ) × oxygen transfer × blower × salinity correction
for 3 mdepth efficiency factor )
53
Given data,
% of oxygen in air = 21 % (0.21)
Oxygen transfer for 3m depth = 0.18
Blower efficiency = 80 % (0.80)
Salinity correction factor = 0.98
Therefore,
36.48 kg /day
=
0.21× 0.18 ×0.80 ×0.98

= 1231.18 kg/day
Air requirement for Aeration tank II in kg/day = 1231.18 kg/day

1231.18
Air requirement for Aeration tank II in kg/day =
24

= 51.29 kg/hr.
Volume of air requirement in Aeration tank II,

Mass of air∈kg
Density of air = = 1.25 kg/m3
Volume of air∈m 3

Therefore,

Mass of air∈kg 51.29

Volume of air = = = 41.039 Nm3/hr.
Density of air∈kg /m3 1.25

Volume of air requirement for Aeration tank II = 41.039 Nm3/hr.

From the above calculation we need 41.039 Nm 3/hr. of Air required for Aeration tank II but,
Aeration tank II air blower capacity is 380 Nm3/hr. so, the existing air blower capacity is enough
for sufficient BOD reduction.

TASK: 10
11.3 Hydraulic Retention time (HRT)

54
The hydraulic retention time (HRT), also known as hydraulic residence time is a measure of the
average length of time that a soluble compound remains in a constructed vessel. Hydraulic
retention time is the volume of the tank divided by the influent flow rate. Where using SI
Units Volume is in [m3] and Influent flow rate is in [m3/h]. HRT is usually expressed in hours or
sometimes days.

Holding capacity ∈m3

Hydraulic retention time =
Feed flow rate∈m 3/hr

Feed flow rate = 2.3 m3/hr. (on 17/10/2014)

115.2
i. HRT for Equalization tank I = = 50.08 hrs.
2.3

108.8
ii. HRT for Equalization tank II = = 47.30 hrs.
2.3

1.5
iii. HRT for Flash mixer I = = 0.65 hrs. = 39 min
2.3

3.38
iv. HRT for Flocculator = = 1.47 hrs.
2.3

24.5
v. HRT for Primary clarifier = = 10.65 hrs.
2.3

482
vi. HRT for Aeration tank I = = 209.56 hrs. = 8.73 days
2.3

24.5
vii. HRT for Secondary clarifier I = = 10.65 hrs.
2.3

482
viii. HRT for Aeration tank II = = 209.56 hrs. = 8.73 days
2.3

24.5
ix. HRT for Secondary clarifier II = = 10.65 hrs.
2.3

10
x. HRT for HDPE tank = = 4.34 hrs.
2.3

55
 1.5
xi. HRT for Flash mixer II = = 0.65 hrs. = 39 min
2.3

3.38
xii. HRT for Flocculator II = = 1.47 hrs.
2.3

24.5
xiii. HRT for Tertiary clarifier = = 10.65 hrs.
2.3

520.08
Overall hydraulic retention time (HRT) = 520.08 hrs. = = 21 days 40 min.
24

TASK: 11
12. Wasting of Activated sludge
Wasting of Activated sludge is basically one of two methods:
i. Constant flow rate: the wasting rate of the activated sludge is constant over the entire day,
based upon the number of dry weights of activated sludge that need to be wasted to hold
a specific solid retention time(SRT).
ii. Batch wasting rate: treatment processes that have high SRTs, such as extended aeration
plants, may waste solids from their system in small batches daily, or once per day. This is
usually not recommended, but has provided satisfactory results for many small facilities
with such processes as extended aeration-oxidation ditch

12.1 Sludge wasting calculation

Actual MLSS∈ AT −Designed MLSS of AT

Sludge wasting = ×Volume of aeration tank
MLSS ∈recirculation

56
Designed MLSS for Aeration tank = 3200 ppm

MLSS tested on 15/12/2014, the results are

i. Aeration tank-I = 3,400 ppm

ii. Aeration tank-II = 11,400 ppm
iii. Aeration tank-I recirculation = 20,400 ppm
iv. Aeration tank-II recirculation = 11,600 ppm
v. Tertiary clarifier outlet = 200 ppm

12.2 Sludge wasting for Aeration tank-I,

Sludge wasting =
Actual MLSS∈ AT 1−Designed MLSS of AT 1
×Volume of aeration tank 1
MLSS∈recirculation of AT 1

3400−3200
= × 482
20400
= 4.72 KL
Therefore, 4.72 KL of sludge to be wasted in Aeration tank-I

12.3 Sludge wasting for Aeration tank-II,

Sludge wasting =
Actual MLSS∈ AT 2−Designed MLSS of AT 2
×Volume of aeration tank 2
MLSS∈recirculation of AT 2

11400−3200
= × 482
11600
= 340.7 KL
Therefore, 340.7 KL of sludge to be wasted in Aeration tank-II

TASK: 12
13. F/M (food to microorganism) ratio:
57
 In order for the activated sludge process to operate properly there must be a balance
between the food entering the biological system, and the microorganisms in the aeration basin. A
high F/M ratio means there is a greater quantity of food relative to the quantity of
microorganisms available to consume that food. When the F/M ratio is high, the bacteria are
active and dispersed and they multiply rapidly. But with a high F/M ratio the bacteria will not
form good flocs. Operating the activated sludge process with a high F/M ratio will typically
result in a poor settling sludge in the clarifier and a turbid effluent.
A low F/M ratio means there are many microorganisms but there is a limited amount of
food. Only when the food supply is limited do bacteria begin to develop a thicker slime layer,
lose their motility, and begin to clump together to form flocs that will settle well in the clarifier.
Note: F/M ratio to be maintained between 0.2 to 0.5

F/M ratio =
Volumetric flowrate of effluent ( day
m3
) × BOD(mg /lit )
Volume of aeration ( m 3 ) × MLSS∈aeration tank

13.1 F/M ratio in Aeration tank-I,

Volumetric flow rate of effluent = 3 m3/hr. = 72 m3/day.
COD 13828
BOD = = = 4609 mg/lit
3 3

Volume of Aeration tank-I = 482 m3

MLSS in Aeration tank-I = 3400 mg/lit
72× 4609
Therefore, F/M ratio = = 0.202
482 ×3400

0.202 F/M ratio is sufficient food for microorganism

13.2 F/M ratio in Aeration tank-II,

Volumetric flow rate of effluent = 3 m3/hr. = 72 m3/day

COD 13828
BOD = = = 4609 mg/lit
3 3

Volume of Aeration tank-II = 482 m3

58
MLSS in Aeration tank-II = 11400 mg/lit

Therefore,

72× 4609
F/M ratio = = 0.06
482 ×11400

0.06 F/M ratios is too low food for microorganism

13.3 Centrifuge Sludge Generation

Dewatering quantity ( lit ) × MLSS of thickener (mg/lit)× Running hrs

Sludge generation/hr. =
2 ×106
Dewatering quantity per hour = 3200 lit.
MLSS of thickener (approx.) = 50,000 mg/lit
Running hours of centrifuge = 2 hours
Therefore,
3200× 50,000× 2
Sludge generation = 6 = 160 kg
2 ×10
Sludge generated in centrifuge 1 hour of operation is 160 kg.

TASK: 13
14. TREATMENT COST OF ETP

Power cost
Power (P) ¿ Voltage(V ) ×Current ( A)
Power (P)
=Current ( A)
Voltage(V )
1 Horse Power = 746 watts
i.e., Supply voltage for Equalization tank motor = 480 v

59
Therefore,
10 HP ×746 W
= 15.54 amps
480V
Units consumed = amps × 0.7
= 15.54 × 0.7
= 10.87 units
Table 16: Treatment cost of ETP-power cost

S.No Description KW HP Amps Unit

1 Equalization tank pump 7.47 10 15.54 10.87
2 Flash Mixer I 0.747 1 1.55 1.08
3 Flocculator I 0.747 1 1.55 1.08
4 Primary sludge pump 3.735 5 7.77 5.44
5 Air Blower – I 22.41 30 46.62 32.63
6 Secondary –I sludge pump 2.24 3 4.66 3.26
7 Air Blower-II 11.20 15 23.31 16.31
8 Secondary –II sludge pump 2.24 3 4.66 3.26
9 Tertiary feed pump 2.24 3 4.66 3.26
10 Flash Mixer –II 0.74 1 1.55 1.08
11 Flocculator –II 0.74 1 1.55 1.08
12 Tertiary sludge pump 3.73 5 7.77 5.44
13 SAF pump 2.24 3 4.66 3.26
14 Centrifuge feed pump 2.24 3 4.66 3.26
15 Centrifuge 11.20 15 23.31 16.31
16 Floating aerator 3.73 5 7.77 5.44
17 Agitator for dosing tanks (5 No’s) 3.73 5 7.77 5.44
18 Dosing pumps (5 No’s) 3.73 5 7.77 5.44
19 Raw water pump 2.24 3 4.66 3.26
20 Caustic lye pump 2.24 3 4.66 3.26
21 HCL transfer pump 3.73 5 7.77 5.44
22 PAC transfer pump 3.73 5 7.77 5.44
Total consumed units 141.34

Total power consumed = 141.34 Units

60
Feed taken / hour = 4 KL
Power cost for 1 unit = Rs.10.5
Power cost / 1 hour of operation = 141.34 × 10.5 = Rs.1484.07
1484.07
Power cost / 1 kl of feed consumed = = Rs.371.01
4

Chemical cost
Table 17: Treatment cost of ETP – chemical cost
Cost in Rs./ Consumption Total cost in
S.No Name of Chemical (lit or kg) / month (lit or Rs./ month
kg) (lit or kg)

1 Urea 6.8 500 3400

2 Diammonium phosphate 25.4 300 7620

3 Caustic lye 23 1000 23000

4 Hydrochloric acid(HCL) 7 1000 7000

5 Poly aluminum chloride(PAC) 1 9000 9000

6 Poly electrolyte(PE) 375 75 28125

7 Bactus 3008 3 9024

8 De-foamer 210 5 1050

Total chemical cost per month 88219

Total chemical cost per month = Rs.88219.00

88219
Chemical cost per day = = Rs.2846.00
31
Total effluent treated per day = 96 KL
2846
Chemical cost per KL of effluent treated = = Rs.29.64
96

Man power cost

Table 18: Treatment cost of ETP – man power cost

61
S.No Designation No of person Monthly Salary / month Total salary / month
(Rs.)
1 Operators 3 25,000 75,000
2 Chemist 1 25,000 25,000
3 Contract operators 3 6,000 18,000
4 Casual labor 2 5,000 10,000
Total man power cost per month 1,28,000

Total cost per month = Rs.1, 28,000.00

128000
Man power cost per day = = Rs.4130.00
31
Total effluent treated per day = 96 KL
4130
Man power cost per KL of effluent treated = =Rs.43.02
96

Therefore,
Treatment cost for 1 KL of effluent at ETP = Power cost + Chemical cost + Man power cost
= Rs.371.01 + Rs.29.64 + Rs.43.02
= Rs.443.67
Treatment cost for 1 KL of effluent at ETP = Rs.443.67

15. Instruments details installed in ETP

Table 19: Instruments details-ETP
S.N
Name of the Instrument Quantity Location
o

Electromagnetic flow meter 6 ETP, MEE, ATFD, RO (Inlet low

1
TDS & high TDS; MEE feed: RO

62
 feed: MEE conc.; Recycled water )
4 ETP (Eq.tank I & II; FM-I & II)
2 Online pH meter
2 ETP (AT-I&II)
3 Online DO meter
2 MEE (stripper & MEE)
4 Steam flow meter
6 MEE (stripper, 1st, 2nd, 3rd, steam-2
5 Control valve
nos)
7 MEE
6 Level transmitter
2 ATFD
7 Electronic Rota meter
6 MEE
8 Vacuum transmitter
2 MEE
9 Pressure transmitter
1 MEE/ATFD
10 Condensate recovery pump

16. ETP LABORATORY

16.0 Analytical Procedures

16.1 pH

 Rinse a clean beaker with the sample and then take 100ml of sample in the beaker.

63
  Immerse the electrode of calibrated pH meter in the sample and note pH.
 Rinse the electrode after each pH measurement with distilled water and dry with tissue
paper.

16.2 Total dissolved solids (TDS)

 Take 100 ml sample in clean beaker and measure the conductivity using conductivity
meter.
 Calculate the TDS as below
Total dissolved solids (mg/L) = Conductivity (uS) × 0.65

16.3 Chemical oxygen demand (COD)

16.3.1 Theory

The basis for the COD test is that nearly all organic compounds can be fully oxidized
to carbon dioxide with a strong oxidizing agent under acidic conditions. The amount of
oxygen required to oxidize an organic compound to carbon dioxide, ammonia, and water is given
by:

( a b 3
) a 3
(
C n H a Ob N c + n+ − − c O2 →n CO 2+ − c H 2 O+c NH 3
4 2 4 2 2 )
This expression does not include the oxygen demand caused by the oxidation of ammonia
into nitrate. The process of ammonia being converted into nitrate is referred to as
nitrification. The following is the correct equation for the oxidation of ammonia into nitrate.
+ ¿¿
−¿+H 3 O ¿
NH 3+ 2O2 → NO 3

It is applied after the oxidation due to nitrification if the oxygen demand from
nitrification must be known. Dichromate does not oxidize ammonia into nitrate, so this
nitrification can be safely ignored in the standard chemical oxygen demand test.

16.3.2 Apparatus required

64
  Reflux apparatus of a flat bottom 250 ml capacity flask with ground glass joint and a
condenser.
 COD digester

16.3.3 Reagents
 0.25N Standard Potassium dichromate (K2Cr2O7)
 Mercuric sulfate (HgSO4)
 Sulphuric acid reagent: 25 grams of Silver sulphate (Ag 2SO4) to 2500 ml of Sulphuric
acid and keep over night for dissolution.
 0.1N standard Ferrous ammonium sulphate ( Fe (NH4)2 (SO4)2. 6H2O )
 Ferroin indicator: dissolve 1.485 grams 1, 10-Phenonthroline monohydrate and 0.695
gram FeSO4. 7H2O, HgSO4 LR or AR grade.
 Note: For standardization of ferrous ammonium sulphate, prepared as above, use 10.0 ml
0.25N K2Cr2O7 10 ml H2SO4 and titrate using ferroin as indicator without reflux.

16.3.4 Preparation of standard reagents

i. 0.25N standard potassium dichromate (K2Cr2O7)

Molecular weight of K2Cr2O7 = 294.18 grams
Valancy of K2Cr2O7 =6

Molecular weight
Equivalent weight of K2Cr2O7 =
Valancy
294.18
= = 49.03 grams
6
Weight
=Equivalent weight × Normality
Litre
= 49.03 grams × 0.25 N
Weight
=12.25
Litre

Therefore, 12.25 grams of K2Cr2O7 dissolved in 1 litre of demineralized water.

65
 ii. 0.1N standard Ferrous ammonium sulphate (Fe (NH4)2 (SO4)2. 6H2O)
Molecular weight of Fe(NH4)2 (SO4)2. 6H2O = 392.14 grams
Valancy of Fe(NH4)2 (SO4)2. 6H2O = 1 (Molar = Normal)

Molecular weight
Equivalent weight ofFe(NH4)2 (SO4)2. 6H2O =
Valancy
392.14
=
1
= 392.14 grams
Weight
=Equivalent weight × Normality
Litre
= 392.14 grams × 0.1 N
Weight
=39.214
Litre

Therefore, 39.214 grams of Fe(NH4)2 (SO4)2. 6H2O dissolved in 1 litre of demineralized water.

16.3.5 Procedure

 Take two round bottom flasks

 Add 20 ml of distilled water to one flask and mark as blank
 Add 20 ml of effluent sample to another flask and mark as sample
 10 ml standard potassium dichromate solution to the two flasks
 30 ml H2SO4 is to be added over the walls of the RB flask
 Add pinch mercury sulfate
 Keep RB flasks in COD digester
 Set the temperature to 80o C and add cooling water to condenser
 Switch “On”
 Set the reflux
 Reflux for 2 hours
 Cool for room temperature
 Cool and then wash down the condenser with distilled water

66
  Dilute for a minimum of 100 ml, cool and titrate excess K2Cr2O7 with 0.1N ferrous
ammonium sulphate solution using ferroin indicator. Sharp colour change from blue
green to wine red indicates end-point or completion of the titration.
 Reflux blank in the same manner using distilled water instead of sample
 Calculate COD from the following equation

COD ( mgL )= ( T 1−T 2Volume

) × N ×8000 × dilution factor
of sample ∈ml

Where,

T1 = Volume of ferrous ammonium sulphate solution consumed for blank

T2 = Volume of ferrous ammonium sulphate solution consumed for sample

N = Normality of ferrous ammonium sulphate solution (0.1N)

i.e, Equalization tank I sample on 17/09/2014

( 22.7−3.2 ) ×0.099 × 8000× 20 T

COD (mg/L) =
20

= 15600 mg/L or ppm

16.4 Dissolved oxygen (DO)

16.4.1 Reagent preparation
i. 36.4 gm of Manganese sulphate (MnSO4.H2O) dissolved in 100 ml of DM water.
ii. Alkali iodide azide solution,
Dissolved 50 gm of Sodium hydroxide (NaOH), 15 gm of Potassium iodide (KI) and 1
gm of Sodium azide in 100 ml of DM water
iii. Starch indicator, 0.5 gm of starch dissolved in 100 ml of DM water then boiled for
homogeneous mixture.
iv. Sodium thio sulphate (Na2S2O3) – 0.025N,
6.025 gm dissolved in 1 lit of DM water or

67
 3.0125 gm dissolved in 500 ml of DM water

16.4.2 Procedure
i. Take the sample approximately 300 ml in BOD bottle.
ii. Sample kept in BOD bottle without air bubble and close with tight cork.
iii. Add 2 ml of Manganese sulphate (MnSO4.H2O) to the sample with help of 2 ml pipette.
iv. Then add 2 ml of Alkali Iodide Azide solution to sample. To dip inside the pipette into
the sample bottle and shake well.
v. Precipitation occurred; wait some more minutes for settling (15 min).
vi. Add 2 ml of Sulphuric acid (H2SO4) to sample, it’s clear the precipitation. Again shake
well the container.
vii. Take 204 ml of sample from the container into conical flask.
viii. Add starch as a indicator, starch will change the colour of sample from yellow to dark
blue.
ix. Titrate with Sodium thio sulphate (Na2S2O3) and the end point is disappearance of dark
blue colour (colourless)
x. If take the sample volume of 204 ml is gives straight value of DO.
xi. If take the sample volume of 104 ml , then calculate from the blow equation

Titrate volume × Strenght of sodiumthiosulphate × 8000

DO( ppm )=
Volume of sample taken

i.e., Aeration tank II sample on 17/09/2014

2.5× 0.025× 8000
DO( ppm )=
100
= 5 ppm

16.5 Mixer liquid suspended solids (MLSS)

16.5.1 Apparatus required
 0.45 micron filter papers
 Funnel for filtering

68
  Hot air oven
 Weigh balance

16.5.2 Procedure
 Take 50 ml of sample and 0.45 micron of filter paper
 Weigh the empty weight of filter paper and filtered 50 ml of sample
 Keep the filtrate paper in hot air oven at temperature of 100 ± 5o C for 30 minutes
 After drying take out the filter paper put into the desiccator for cooling
 Take out the filter paper from desiccator and take out the weight of filter paper.
 Then calculate the MLSS from following equation

Weight of filterate filter paper −weight of empty filter paper

MLSS ( mg/ L )=
Volume of sample

17. ETP TREATED EFFLUENT LIMITS

Table 20: ETP Treated effluent limits

S.No Effluent parameters Limits

1 pH 5.5 to 9.0
2 Chemical oxygen demand (COD) 250 ppm
3 Bio chemical oxygen demand (BOD) 30 ppm
4 Total suspended solids (TSS) 100 ppm
5 Total dissolved solids (TDS) 2100 ppm
6 Oil & Grease 10 ppm
7 Chlorides 1000 ppm
8 Sulphate 1000 ppm

18. List of Online monitoring devices:

Table 21: List of Online monitoring devices

S.No Location Description

69
 1 Administration building Total volatile organic compound(TVOC) meter
2 Recovery plant Total volatile organic compound(TVOC) meter
3 Quality control Total volatile organic compound(TVOC) meter
4 Effluent treatment plant Low TDS flow meter
5 Effluent treatment plant High TDS flow meter
6 Effluent treatment plant Recycle water flow meter
7 Effluent treatment plant Online pH meter
8 Production block I Total volatile organic compound(TVOC) meter
9 Production block I / Acid HCL sensor
scrubber
10 Production block II / Acid HCL sensor
scrubber
11 Production block I / Mercaptan sensor
KMNO4 scrubber
12 Production block III / HCL sensor
Acid scrubber
13 Production block III / Total volatile organic compound(TVOC) meter
stack
14 Boiler house Suspended particulate matter(SPM) sensor
15 Boiler house SO2 sensor
16 Boiler house / Thermic SOx sensor
fluid heater
17 Boiler house / Thermic NOx sensor
fluid heater
18 R&D block Total volatile organic compound(TVOC) sensor
19 R&D block HCL sensor

19. MY ROLES AND RESPONSIBILITIES DURING THIS DEPUTATION PERIOD

 Operation and maintenance of all ETP activities.

 Maintaining suitable pH in equalization tanks by adding acidic or alkali solution.

70
  Optimize the dosage of Poly aluminum chloride and Polyelectrolyte in primary & tertiary
flash mixers.
 Ensure the continual addition of lime solution to aeration tanks.
 Adding bacterial culture (Bactus) to aeration tanks.
 Charging pre-determined quantities of Diammonium phosphate & Urea to aeration tanks.
 Ensuring the sludge wasting of primary, secondary & tertiary clarifier.
 Preparation of dosage chemicals (PAC, PE & lime).
 Operation & maintenance of centrifuge.
 Work orders & permits raised for all preventive and break down maintenance.
 Analysis of parameters like pH, TDS, SV, COD & MLSS etc.,
 Make up of treated water to cooling towers.
 Man powers assigned for plant operation and housekeeping.

Multiple effect evaporators (MEE)

 Maintaining sufficient vacuum and steam pressure for better evaporation.

 Adequate effluent levels maintain in each stages of evaporation.
 Operational control with SCADA (supervisory control and data acquisition).
 Checking specific gravity of concentrate and unloading from the final stage.
 Hydro jet tube cleaning to be obtained for all the evaporators, pre-heaters & condensers.
 Work requisition made for all maintenance works.
 Preparation of daily, weekly & monthly reports.
 Operation of ATFD (Agitated thin film drier).

71