EFFLUENT TREATMENT PLANTS (ETPS): Improving Performance . - WWTP
EFFLUENT TREATMENT PLANTS (ETPS):Improving Performance &Reducing PollutionETP Update.indd 112/02/19 7:50 PM
As a federal enterprise, GIZ supports the GermanGovernment in achieving its objectives in the field ofinternational cooperation for sustainable development.Published by Deutsche Gesellschaft fürInternationaleZusammenarbeit (GIZ) GmbHRegistered offices Bonn and Eschborn, GermanySustainable and Environment-Friendly Industrial ProductionProject 1st Floor, B 5/1, Safdarjung Enclave New Delhi110029 T: 91 11 49 49 53 53 F: 49 11 49 49 53 51I: www.giz.de, http://seip.urban-industrial.in/Responsible N. Raghu BabuAuthorNitesh PatelKrithika BanerjeePhoto credits GIZ; OthersLayout Trinankur BanerjeeNew Delhi, February 2019ETP Update.indd 212/02/19 7:50 PM
TABLE OF CONTENTS1Introduction5Recommendations& ImplementationStatusETP Update.indd 32Issues and GapsIdentified6Facts and Data –ETP Improvement3MethodologyAdopted7ETP Planning /Upgradation –Approach4Capacity buildingof technicians/operators ofETPs/CETPs8Success Stories12/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing PollutionINTRODUCTIONThe process of industrialization is adverselyimpacting the environment globally. Pollutiongenerated by incorrect management of industrialwastewater is one of the major environmentalproblems in India as well, especially withburgeoning small scale industrial sector in thecountry. To address the pollution dischargeof industries, adoption of cleaner productiontechnologies and waste minimization initiativesare now gaining ground.Effluent Treatment Plants (ETPs) are consideredas one of the viable solution for small to mediumenterprises for effective wastewater treatment.An Effluent Treatment Plant (ETP) is an integralpart of production processes with relevance towastewater, the sewer/drainage system at the siteand the pollutants with their respective limitvalues that have to be reduced. In addition,the ETP also facilitates in reduction of numberof discharge points in an industrial estate forbetter enforcement by environmental regulatoryagencies in terms of pollution reduction andenvironmental improvements. However, many ofthe operating ETPs are not performing optimallydue to various technical and managerial reasons.Industrial wastewater treatment describes theprocesses used for treating wastewater that isproduced by industries as an undesirable byproduct. The treated industrial wastewater (oreffluent) may be reused or released to a sanitarysewer or to surface water in the environment. Themain objectives of an ETP are:4ETP Update.indd 412/02/19 7:50 PM
Meeting of requirements of legislative standards Contribution for environmental protectionand sustainable developmentIntroduction Water recycling for further use Reduction of water consumption Reduction of operative production costsWhat is an ETP? ETP (Effluent Treatment Plant)is a process design for treatingthe industrial waste water forits reuse or safe disposal to theenvironment. Influent: Untreated industrialwaste water. Effluent: Treated industrial wastewater. Sludge: Solid part separated fromwaste water by ETP.ETPSludge5ETP Update.indd 512/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing Pollution6ETP Update.indd 6Need of an ETP ? To clean industry effluent and recycle it forfurther use. To reduce the usage of fresh/potable waterin Industries. To cut expenditure on water procurement. To meet the Standards for emission ordischarge of environmental pollutants fromvarious Industries set by the Governmentand avoid hefty penalties. To safeguard environment againstpollution and contribute in sustainabledevelopment.Treatment levels and Mechanismsof an ETP?Treatment levels:Treatmentmechanisms: Preliminary Physical Primary Secondary Chemical Tertiary (or advanced) BiologicalISSUES AND GAPS IDENTIFIED1. Lack of Knowledge for selection oftreatment process:Wastewater, dependingon its characteristics is subjected to differenttreatment options. Industries usually donot have access to latest technologicaladvancements in effluent treatment process,the lack of information results in variousassociated issues in efficient operation of anETP.2. Superfluous / Underrated ETPs: Industriescommission their ETP solely on technicalexpertise of consultant without actual data onwaste water generation quantity and qualityfrom the production processes and thus theinstalled ETPs result as either superfluous orunderrated.12/02/19 7:50 PM
Issues and Gaps IdentifiedLack of Knowledgefor selection oftreatment processNo source ofTechnology andevolution processfor ETPProcessImplementationwithout Lab & PilotTrailsUnderrated ETPsSelection of wrongTreatment Processfor ETPsIssues andGaps in ETPOperationSupplier driveninstallation / Novettingmechanism7ETP Update.indd 712/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing PollutionActivities coveredUnder the Sustainable and Environment-friendlyIndustrial Production Project (SEIP), variousactivities were taken up in all three project sites,namely, Uttarakhand, Delhi and Gujarat to enhancethe performance improvement of ETPs and CETPs:In Uttarakhand (IIE SIIDCUL): Upgradation & ZLD for CETP Improvement of ETPs in Individual industriesIN Delhi (Patparganj, Lawrence Road, Mayapuri) Conceptual design for new CETP at Patparganj Improvement of performance of existing CETPs Improvement of ETPs in Individual industriesIn Gujarat (GIDC Estate Vapi) Moisture reduction of CETP sludge Improvement of ETPs in Individual industries3. Inefficient ETPs:Often, there is nomechanism applied to check whether theproposed treatment scheme is suitablefor treatment of effluent with specificquality generated through their respectiveprocesses. Industries follow the supplierdriven approach in selection of treatmentscheme.4. Process Inefficiencies: Industries usuallyoperate ETPs without any actual lab orpilot tests being performed for particulareffluent quality treatment, resulting inprocess inefficiency and non-complianceof discharges effluent. Also, the resourceconsumption (Chemicals, Energy etc.) arealso not assessed in ETP operation resultingin non-viable system and difficulties ofoperation.8ETP Update.indd 812/02/19 7:50 PM
To systematically improve the situation, IIEHaridwar, the Industrial Estates at LawrenceRoad, Mayapuri and Patparganj in Delhi and theIndustrial Estate Vapiwere included as project sitesunder the“Sustainable and Environment-friendlyIndustrial Production (SEIP)”. In cooperation withtheState Infrastructure and Industrial DevelopmentCorporation of Uttarakhand Ltd (SIIDCUL), DelhiState Industrial and Infrastructure DevelopmentCorporation Ltd. (DSIIDC) and Gujarat IndustrialDevelopment Corporation (GIDC), the project isbeing implemented by the Deutsche Gesellschaft fürInternationale Zusammenarbeit (GIZ) GmbH tofind solutions to improve the efficiency and efficacy ofwastewater treatment plants and reduce pollution.The SEIP Project aims at mitigatingenvironmental problems caused by industrialproduction focusing on industrial wastewaterand solid waste management. Since theproject’s initiation in 2015, technical solutionsas well as business and management modelsto reduce acute environmental pollution andto improve resource efficiency in industrialproduction have been piloted in a total offive Indian industrial estates. One of theaims of the project is to demonstrate that thepollution caused by municipal wastewater andindustrial effluent can be reduced by efficientmanagement of wastewater and functionalityof treatment plants.Methodology AdaptedMETHODOLOGY ADOPTEDA German consultancy GOPA Infra was hiredto assess the ETPs installed in industries. InJuly 2017, national and international expertsfrom GOPA Infra visited theindustries to collect9ETP Update.indd 912/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing Pollutiondata and samples in order to dopreliminaryassessments. Many industries with ETPs werechosen to undergo a detailed assessmentforimprovements.Regulatory pressure, economicmotivations as well as the wish to act moreresponsibly andsustainably were drivers for thecompanies to invite the consultants to undertakethe assessmentsand to subsequently implementthe solutions.It was proposed to take up detailed studiesfor upgradation/ improvement of ETPs fromnineteen industrial units in the selected industrialestate in the State of Uttarakhandand Gujarat thatgenerate effluents and have afunctional EffluentTreatment Plant installed.The overall approach was as follows: Develop Questionnaire Gather field/ unit level information Analyse data and shortlist few industries (max.9 nos from multiple sectors) for detailed studyand demonstration Conduct detailed studies to understand specificconcerns faced by the units and developspecific solutions including Best AvailableTechnologies. Support in Implementation phase. Document benefits achieved and share withother industries to bring in multiplier effect. C APACITY BUILDING OF TECHNICIANS/OPERATORS OF ETPS/CETPSIndia’s industrial wastewater is treated by over 170CETPs, mostly located within the industrial areas,and several thousand ETPs installed at individualindustries. Proper operation of Effluent TreatmentPlant (ETP) / Common Effluent Treatment10ETP Update.indd 1012/02/19 7:50 PM
these treatment plants. Therefore, many watertreatment plants are operated inefficiently andtheir positive effect towards the prevention ofpollution is unnecessarily limited.Under SEIP, a number training programmeswereconducted to enhance the skills of the technicians,operators and helpers of ETP/CETP. The aimof these trainings was to raise the awarenessand develop the skills of helpers and operatorsof ETPs/CETPs using the knowledge andexperience of the resource persons who areexperts in this field. It was a step make themaware of the fundamental aspects of operationand maintenance of ETP/CETP. The trainingsintend to improve their skill and performanceleading to enhanced compliance and improvedenvironmental pollution control. It wouldfurther help them to understand the aspects ofCapacity building of technicians/operators of ETPs/CETPsPlant (CETPs) is the key to compliance to Water(Prevention & Control of Pollution) Act, 1974and amendments made thereby. There is, however,a whole team of ETP / CETP operators who areresponsible for the functioning of the pollutioncontrol systems. The ETP/CETP operationalskills are acquired mostly through on-job training.Trainees usually start as attendants or operatorsin-training and learn their skills on the job underthe direction of an experienced operator. Theylearn by observing and doing routine tasks. ETPoperation is a team work. It requires proper teamselection, training need assessment, training, onjob trainings, laboratory and statistical analysis forensuring desired performance, trouble forecastingand trouble shooting. However, inadequateoperations and managerial skills are one of themain reasons for the inefficient operation of11ETP Update.indd 1112/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing PollutionAdvantages of professionaltraining and skill development Professional training of the personneloperating CETPs and ETPs isparticularly necessary to unlock thispotential. Well-trained staff is able to maintain thewastewater treatment plants optimallyand run them with maximum efficiency. The professional training of the staffand technicians operating wastewatertreatment plants does not merely benefitthe environment; it has a clear positiveimpact on the profitability of singlecompanies with ETPs and companieslocated in industrial parks with CETPsas well as the water quality of close riversand waterbodies.health and safety in a better way to assist themto achieve cost-effective operation, improvedperformance and abatement of environmentalpollution.The trainings conducted competent by technicalexperts aimed to help industries in effectivetreatment of their wastewater. The trainingprogram was delivered based on the NationalSkills Qualification Framework (NSQF) designedby SCGJ for the operators and technicians. TheQualification Pack has 3 compulsory NationalOccupational Standards – SGJ/N6601: Operate the WastewaterTreatment Plant SGJ/N6602: Monitor and MaintainWastewater Treatment Plant SGJ/N6605: Work Safety at Wastewatertreatment plant.12ETP Update.indd 1212/02/19 7:50 PM
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14ETP Update.indd 1412/02/19 7:50 PMEffluent Treatment Plants (ETPs): Improving Performance & Reducing Pollution
The summary of the recommendations implemented are depicted in the Infographics given 15414ETP Update.indd 151Reduction of pollution load of waste water discharged to CETP (COD, others) alsothrough in-house improvements2Reduction in waste water discharge (quantity)3Recycling of treated waste water4Reduction in sludge generation through ETP process optimisation5Reduction in energy consumption at ETP and achieving better quality of treatedwaste water6Reduction of air emissions from waste water and ETP and achieving better qualityof treated water7Improvement in pre-treatment systems (Oil and Grease ns & Implementation StatusRECOMMENDATIONS & IMPLEMENTATION STATUSTextile IndustryChemical IndustrySoaps and Cosmetics IndustryBeverages IndustryCosmetics and Detergents IndustryPharmaceutical FormulationsHealthcareMetal FinishingAyurvedic Soaps1512/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing PollutionEFFLUENT TREATMENT PLANT (ETP UPGRADATION IN DIFFERENT PRODUCTION COMPANIES)Measures UndertakenApproach AdoptedReduction of pollution load ofwaste water discharged to CETP(COD, others) also through in-houseimprovements Reduction in waste water discharge Recycle of treated waste water for in-house processes Reduction of water used in processes 15 – 20% reduction in waste water discharge quantity to CETPRecycling of treated waste water Reuse of treated waste water in the dyeing process of dark color yarns which do not require highwater quality About 15 – 20% of total fresh water used for dyeing of black shades saved (reduced 80 KLD to 50KLD) Reuse of last wash for first wash of next batchReduction in sludge generation throughprocess optimisation Soaking of lime in water before charging it to the treatment plant instead of direct charge (whichleads to an increase in sludge) Dividing the tanks for ferrous-sulphates and lime of the wastewater treatment plant, so that thesesubstances do not neutralize each other, become ineffective and end up as sludge (25% sludgereduction) Installation of mixing mechanisms and constant water flows in the tanks Customize dosing of chemicals according to requirements of wastewater treatment Use of ferrous sulphates of at least 80 % purity and lime with minimum of 75 %t purityImproving in-house practices such as reducing wastage of raw materials, chemicals and auxiliariesImproving the pre-treatment and precipitation process and mechanical processesReplacement of all defunct media from PSF/ACFUse of appropriate poly electrolyte for better coagulation25 – 75% reduction in COD16ETP Update.indd 1612/02/19 7:50 PM
IndustryResultsLatex ProductManufacturer 75% reduction of COD level Annual cost saving of 225,000 INR Removal of odourPersonal Care ProductMfg. More than 20 % reduction in COD Annual cost saving of 60,000 INRYarn Dyeing 25 % sludge reduction 15% - 20% of total fresh water used for dying of black shades, saved (Reuse) Annual cost saving of 96,000 INRCosmetics & Personal CarePharmaceutical Facts and Data – ETP ImprovementFACTS AND DATA – ETP IMPROVEMENT28 % reduction of COD level20% reduction in chemical use25% reduction of COD level25-30% reduction in SludgeAnnual cost saving of 1,80,000 INR17ETP Update.indd 1712/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing PollutionETP PLANNING / UPGRADATION – APPROACHAnalysis ofwater andwastewater atvarious pointsLaboratory TrialsSteps to befollowed inplanningupgradation /modernisationof ETPsPlant TrialsprobablesuppliersConsultationsthroughout theprocess18ETP Update.indd 1812/02/19 7:50 PM
ETP Planning / Upgradation – Approach Success StoriesSUCCESS STORIESSeveral case studies have shown positive results:1Rubber ProductsPlant: ControlledOdour nuisancewith improvementin efficiency of thetreatment unitETP Update.indd 191912/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing Pollution2Yarn Dyeing Unit:Successfullyrecycled treatedwaste water fordyeing of darkcoloured yarns.Target: ZeroLiquid DischargeCosmeticsgoods producingcompany:Reducing ETPoperationalcosts throughoptimum useand minormodificationsof existinginfrastructure20ETP Update.indd 2012/02/19 7:50 PM
Success Stories3Soap and personal care productcompany: Achieved efficiencyof ETP operations throughupgradation of FOG (fat, oil,grease) trap leading to monetarysavings of appr4,000 – 5,000*1INR/month21ETP Update.indd 2112/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing Pollution4Large-scale textile company removed the problems inthe settling of solids in the ETPs clarification tanks dueto insufficient capacity of clarifier tanks by increasingthe increase the capacities of the Primary and SecondaryClarifiers.22ETP Update.indd 2212/02/19 7:50 PM
Success Stories5A textile colouring company improved the problems in the coagulation and flocculation process in the primarytreatment section of the ETP, improper settling of colour particles by adjusting the dosing of Lime and FerrousSulphate and addition of polyelectrolyte.ETP Update.indd 232312/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing Pollution6Poor filtration of sludge beforeinterventionBetter filtration of sludge after interventionAnother cosmetics goods manufacturing company achieved sludge and COD reduction along with improved and faster drying of sludge24ETP Update.indd 2412/02/19 7:50 PM
DharmendarDharmendarDwiveTechnicianGrauer& Weildi(India) Limited,VapiDwiveTechnician“I knewknewwork butasnot athe“Imy workmyas a technicianscience behind it. meinunderstandingthecausesscience behind it. The skillingbehind different problems. This will certainlyprogrammaof GIZathelpedhelp me in troubleshootingthe plant.meI feelinunderstandingcausesbyconfidentthat my knowledgethehas increased99 percent!”problems.behind differentThis will certainly help me introubleshooting at the plant.I feelMr. PratapPatel,Owner ofM/s SterlingPigments andColours, Vapi“Wehavedrasticallyimproved COD, BOD,Sludge and most importantlycolor which was my biggestheadachetoimproveupon. All the reductionswere achieved just by finetuning the dosing which isremarkable. I am thankingGIZ for saving INR 128,000per year which is a rewardfor the efforts and alsomotivational for furthertertiaryimprovement.So, this is my upvote tosustainability.”Success Stories TestimonialsTestimonials:25ETP Update.indd 2512/02/19 7:50 PM
Effluent Treatment Plants (ETPs): Improving Performance & Reducing PollutionMr. Rangaram,ETP Operator&Technicianof M/s SterlingPigments andColours“I am very much amazedafter the achievement ofresults. The colour almostvanished and we have gotcrystal clear effluent.’’Mr. AnandSreerajPlant Head,Faze ThreeLtd., VapiThe improvements which weimplemented at our Primaryand Secondary Clarifiers aregiving us better results. Weare now able to maintain 25% MLSS in the aeration tank.Due to this improvement, thequality of the water that weare discharging to the CETPis much improved. We arenow also planning to installTertiary Treatment, such asRO or UF.26ETP Update.indd 2612/02/19 7:50 PM
TestimonialsMr. BheemannaChikkerur,Admin Head,Faze Three Ltd.Frequent interactions withthe German experts andthe GIZ-Vapi-team ledto improvements in SSand Colour removal byincreasing the capacityof the Primary andSecondary Clarifiers. FazeThree Ltd. is keen to domore for environmentalimprovement.27ETP Update.indd 2712/02/19 7:50 PM
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and sustainable development ETP Sludge What is an ETP? ETP (Effluent Treatment Plant) is a process design for treating the industrial waste water for its reuse or safe disposal to the environment. Influent: Untreated industrial waste water. Effluent: Treated industrial waste water. Sludge: Solid part separated from waste water .
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Perc-Rite Drip Dispersal System Models SERIES MODEL Package Description ABD WD-15 Washdown 15 GPM Pretreated Effluent 1-4 zones ABD WD -25 Washdown 25 GPM Pretreated Effluent 1 4 zones ASD ASD-15 15 GPM Septic Tank Effluent & Pretreated Effluent 1-8 Zones ASD
Unit One Controls MILLSTONE STA TION RADIOLOGICAL EFFLUENT MONITORING AND OFFSITE DOSE CALCULATION MANUAL (REMODCM) SECTION III: MILLSTONE UNIT ONE RADIOLOGICAL EFFLUENT CONTROLS TABLE OF CONTENTS (Cont'd) Table Number III.C-I III.C-2 III.C-3 III.C-4 Figure Number III.D-I Table Name Radioactive Liquid Effluent Monitoring Instrumentation
SUMP/EFFLUENT PUMPS (115 Volt-Single Phase Only) SRM4 SUMP/EFFLUENT/SEWAGE PUMPS (115 or 230 Volt-Single Phase) OWNER'S MANUAL Submersible Sump Effluent . The discharge pipe must be the same size as the pump discharge 1-1/2" for SSM33 and SSM33I, 2" for SRM4 or larger. In order to insure sufficient fluid velocity to prevent
from the inlet and outlet of effluent treatment plant and brought to the laboratory for the analysis of different environmental parameters. The samples were analyzed using the standard methods for the examination of water and wastewater. [Clisceral. et al 1998] Description of Effluent Treatment Plant The Effluent Treatment Plant (ETP) had been con-
In Cyprus the use of the discharge of effluent from urban wastewater treatment plants is regulated by: Advanced Treatment According to the Law, sewage treatment is of Tertiary Degree, which is higher than the requirements of Directive 91/271/EEC.
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