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OPERATION & MAINTENANCE

MANUAL
FOR
EFFLUENT TREATMENT PLANT
(Capacity = 30 M
3
/Hr.)
INSTALLE AT
!"# INUSTRIES LT.
$"
A%UATECH EN&INEERIN& SER'ICES LT.
Aquatech Engineering Services Limited
&LOSSAR" OF TERMS
$i(c)*+ica, O-y.*/ 0*+a/0 ($O)1 The strength of the wastewater is often determined by
measuring the amount of oxygen consumed by microorganism like bacteria in biodegrading the
organic matter. The measurement is known as the Biochemical xygen !emand "B!#.
$icroorganisms such as bacteria are res%onsible for decom%osing organic waste. &hen organic
matter such as dead %lants' leaves' grass cli%%ings' cellulose com%onents' manure' sewage' organic
waste like dyes' fats and oils' or even food waste is %resent in a water su%%ly' the bacteria will
begin the %rocess of breaking down this waste. &hen this ha%%ens' bacteria in aerobic %rocess'
robbing other aquatic organisms of the oxygen they need to live' consume much of the available
dissolved oxygen.
(f there is a large quantity of organic waste in the water su%%ly' there will also be a lot of bacteria
%resent working to decom%ose this waste. (n this case' the demand for oxygen will be high "due to
all the bacteria# so the B! level will be high. As the waste is consumed or dis%ersed through the
water' B! levels will begin to decline.
)itrogen and %hos%hates in a body of water can also contribute to high B! levels. )itrates and
%hos%hates are %lant nutrients and can cause %lant life and algae to grow quickly. &hen %lants
grow quickly' they also die quickly. This contributes to the organic waste in the water' which is
then decom%osed by bacteria. This results in a high B! level. The tem%erature of the water can
also contribute to high B! levels. *or exam%le' warmer water usually will have a higher B!
level than colder water. As water tem%erature increases' the rate of %hotosynthesis by algae and
other %lant life in the water also increases. &hen this ha%%ens' %lants grow faster and also die
faster. &hen the %lants die' they fall to the bottom where they are decom%osed by bacteria. The
bacteria require oxygen for this %rocess so the B! is high at this location. Therefore' increased
water tem%eratures will s%eed u% bacterial decom%osition and result in higher B! levels.
&hen B! levels are high' dissolved oxygen "!# levels decrease because the bacteria are
consuming the oxygen that is available in the water. Since less dissolved oxygen is available in the
water' fish and other aquatic organisms may not survive. Textile mill wastewater %ossesses a very
high B! like +,, - .,, mg/l. (t is necessary to reduce this B! value u% to a level less than 0,
mg/l before discharging them into the environment like canals or rivers. (f a water body of high
B! is discharged into the sea or very large river then off course the concentration of B!
decreases due to dilution and have little or no harmful effect on the aquatic life or environment.
Therefore if it is %ossible to discharge a highly toxic effluent in sea or large river no treatment is
necessary.
Though it was not mentioned' the dissolved oxygen "!# is a highly significant %arameter to
define the B! or 1! of a wastewater. The amount of oxygen %resent in a certain amount of
water in dissolved state is known as !. (t is normally ex%ressed as mg/l. &ater may contain !
ranging from , to 23 mg/l but in most cases of normal waters' ! lies between 456 mg/l. Aquatic
lives require certain level of ! to survive in the water. (n case of wastewater the microorganisms
require oxygen to consume the organic wastes. As a result the ! of water decreases
tremendously and becomes a threat to the life of aquatic s%ecies. Textile effluents %ossess very low
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!' which is unsuitable for discharging to the environment. !uring treatment of wastewater air is
blown through the effluent when oxygen is dissolved in the effluent as a result ! level raises and
as the ! increases the B!/1! decreases.
C)*+ica, O-y.*/ *+a/0 (CO)1 This is a means of measuring the ability of wastewater to
sustain aquatic life' essential for the %reservation of the environment. (t also enables %ro%er
assessment of treatment %lant %erformance. Aquatic organisms and animals require dissolved
oxygen to flourish. The 1hemical xygen !emand "1!# test gives an indication of the im%act of
discharge waters on aquatic life by measuring the oxygen de%leting nature of the discharge water.
1! is based on the fact that nearly all5organic com%ounds can be fully oxidi8ed to carbon
dioxide with a strong oxidi8ing agent under acidic condition. 1! is another common measure of
water5borne organic substances 9 the %rocess of measuring 1! causes the conversion of all
organic matter into carbon dioxide. *or this reason' one limitation of 1! is that it cannot
differentiate between biologically active and those which biologically inactive. ne ma:or
advantage of 1! over B! is that 1! can be measured in :ust three hours where as B!
measurement takes at least five days. The value of 1! is always higher than B!' this is
because B! accounts for only biodegradable organic com%ounds while 1! accounts for all
organic com%ounds e.g. biodegradable as well as no biodegradable but chemically oxidisable.
T(ta, 232p*/0*0 S(,i02 (TSS)1 TSS is mainly organic in nature' are visible and can be removed
from the wastewater by %hysical/ mechanical means e.g. screening and sedimentation. TSS is
measured by filtering a certain quantity of effluent and then drying the filtrate at certain
tem%erature e.g. 2,;
,
1 followed by weighing. TSS is ex%ressed as %arts %er million or in
milligram/litre. The %ore si8e of the filter %a%er is very im%ortant in estimating the TSS' the
nominal %ore si8e 2.;3 micro metre.
T(ta, i22(,4*0 S(,i02 (TS)1 T!S are the solids that are actually in solution' similar for
exam%le to mix sugar into hot coffee. !issolved solids generally %ass through the system
unaffected. T!S is the sum total of all of the dissolved things in a given body of water. (t is
everything in the water that<s not actually water. (t includes hardness' alkalinity' cyanuric acid'
chlorides' bromides' sulfates' silicates' and all manner of organic com%ounds. Every time we add
anything to the water' we are increasing its T!S. This includes not only saniti8ing and %=
ad:usting chemicals' but also conditioner' algaecides' and tile and surface cleaners. T!S also
includes airborne %ollutants and bather waste as well as dissolved minerals in the fill water. T!S is
referred to as the total amount of mobile charged ions' including minerals' salts or metals
dissolved in a given volume of water' and is ex%ressed in units of mg %er unit volume of water
"mg/L#' or as %arts %er million "%%m#.

5)*r* 0( i22(,4*0 S(,i02 c(+* 6r(+7
Some dissolved solids come from organic sources such as leaves' silt' %lankton' and dyes and
chemicals used in %rocessing' sewage. ther sources come from runoff from urban areas' road
salts used on street during the winter' and fertili8ers and %esticides used on lawns and farms.
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!issolved solids also come from inorganic materials such as rocks and air that may contain
calcium bicarbonate' nitrogen' iron %hos%horous' sulfur' and other minerals. $any of these
materials form salts' which are com%ounds that contain both a metal and a nonmetal. Salts usually
dissolve in water forming ions. (ons are %articles that have a %ositive or negative charge.
&ater may also %ick u% metals such as lead or co%%er as they travel through %i%es used to
distribute water to consumers.
The effectiveness of water %urification systems in removing total dissolved solids will be reduced
over time' so it is highly recommended to monitor the quality of a filter or membrane and re%lace
them when required.
T!S may be the most misunderstood factor in the whole field of chemical %rocessing and %ublic
health. (n most cases it is misunderstood because no one knows exactly what effect it is going to
have on any %articular body of water. T!S is directly related to the %urity of water and the quality
of water %urification systems and affects everything that consumes' lives in' or uses water' whether
organic or inorganic' whether for better or for worse.
!ifferent standards advise a maximum contamination level "$1L# of ;,,mg/liter ";,, %arts %er
million "%%m## for T!S' however for domestic water su%%liers maintain the T!S within 2;, %%m.
ff course some water su%%lies exceed this level. &hen T!S levels exceed 2,,,mg/L it is
generally considered unfit for human consum%tion. $ost often' high levels of T!S are caused by
the %resence of %otassium' chlorides and sodium. These ions have little or no short5term effects'
but toxic ions "lead arsenic' cadmium' nitrate and others# may also be dissolved in the water.
At low levels' T!S does not %resent a %roblem. (n fact' a certain amount of T!S is necessary for
water balance. =ardness and Total Alkalinity are both %art of T!S. *or textile %rocessing the
acce%table value of T!S is around .;52;, mg/l. The standards for bath and swimming %ool are
between 2',,, and 7',,, %%m' with a maximum of 0',,, %%m. *or irrigation the acce%table values
of T!S are around 2;,, %%m. >se of fertili8ers increases T!S of the environment.
&hen the water eva%orates' it leaves behind all of the solids that had been dissolved in it. This
%rinci%le is used widely to measure the T!S of a %articular body of water. &hen everything else
seems to be all right' and the water still acts unlawfully' check the T!S.
=igh T!S can result in corrosion of metal equi%ment and accessories' even though the water is
balanced.
=igh T!S can cause eye and skin irritation' even though the %= is right and there are no
chloramines in the water. =igh T!S can %ermit an algae bloom' even with 750 %%m chlorine
residual.
(f we drink water of high T!S some of this will stay in the body' causing stiffness in the :oints'
hardening of the arteries' kidney stones' gall stones and blockages of arteries' microsco%ic
ca%illaries and other %assages in which liquids flow through our entire body.
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Micr((r.a/i2+2 8 $icrosco%ic living ob:ects' which require energy' carbon and small amounts of
inorganic elements to grow and multi%ly. They get these requirements from the wastewater and the
sun' and in doing so hel% to remove the %ollutants.
pH 9 A term used to ex%ress the intensity of the acid or alkalinity source. %= re%resents the
effective concentration "activity# of hydrogen ions "=
?
# in water. This concentration could be
ex%ressed in the same kind of units as other dissolved s%ecies' but =
?
concentrations are much
smaller than other s%ecies in most waters. The activity of hydrogen ions can be ex%ressed most
conveniently in logarithmic units. %= is defined as the negative logarithm of the activity of =
?
ions@
%= A 5log B=
?
C
where B=
?
C is the concentration of =
?
ions in moles %er liter "a mole is a unit of measurement'
equal to ..,77 x 2,
70
atoms#. Because =
?
ions associate with water molecules to form hydronium
"=
0

?
# ions' %= is often ex%ressed in terms of the concentration of hydronium ions. (n %ure water
at 77 1 "47 *#' =
0

?
and hydroxyl "=
5
# ions exist in equal quantitiesD the concentration of
each is 2., x 2,
54
moles %er liter "mol/L#. Therefore' %= of %ure water A 5log "2., x 2,
54
# A 5"54.,,#
A 4.,,. Because %= is defined as -log B=
?
C' %= decreases as B=
?
C increases "which will ha%%en if
acid is added to the water#. Since %= is a log scale based on 2,' the %= changes by 2 for every
%ower of 2, changes in B=
?
C. A solution of %= 0 has an =
?
concentration 2, times that of a solution
of %= +. The %= scale ranges from , to 2+. =owever' %= values less than , and greater than 2+
have been observed in very rare concentrated solutions.
The >.S. Environmental Erotection Agency ">.S. EEA# sets a secondary standard for %= levels in
drinking water@ the water should be between %= ..; and 3.;.
Fery high "greater than 6.;# or very low "less than +.;# %= values are unsuitable for most aquatic
organisms. Goung fish and immature stages of aquatic insects are extremely sensitive to %= levels
below ; and may die at these low %= values. =igh %= levels "652+# can harm fish by denaturing
cellular membranes.
1hanges in %= can also affect aquatic life indirectly by altering other as%ects of water chemistry.
Low %= levels accelerate the release of metals from rocks or sediments in the stream. These
metals can affect a fishHs metabolism and the fishHs ability to take water in through the gills' and
can kill fish fry.
The term I%=I was originally derived from the *rench term I%ouvoir hydrogJne'I in English' this
means Ihydrogen %ower.I The term %= is always written with a lower case % and an u%%er case =.
S,30.*8The settable solids se%arated from the liquid during sedimentation "clarification#. The
sludge is very toxic in nature and needs to be dealt with very carefully. >nder no circumstances it
should be mix with the environment again.
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Aquatech Engineering Services Limited
:. INTROUCTION
Aquatech Engineering Services' !haka' have %re%ared this o%erating and maintenance manual for
the Effluent treatment %lant installed at KKKKKKKK.' 1handora' Laliakoir' Ma8i%ur. (t
re%resents the methodology of %rocess o%eration of the effluent treatment %lant and maintenance
of the %lant equi%ments. The manual will be hel%ful to run the effluent %lant effectively and
efficiently.
Every effluent treatment %lant is unique with res%ect to its %rocess flow sheet. This is because the
treatment scheme is ado%ted on the basis of design and in%ut characteristics of the effluent as well
as the sti%ulated %ollution level of the treatment. This in turn de%ends on the ty%e of %rocess' ty%e
of generated waste' whether the treated waste will be discharged or recycled' the nature of water
receiving body where the treated waste will be discharged "if any# and the %ollution laws of the
concerned %ollution authority. (t must therefore be a%%reciated that effluent treatment %lants are
tailor5 made' and hence the mode of o%eration would be s%ecific for the treatment envisaged.
The o%erating manual serves as an im%ortant guideline for the o%erating %ersonnel res%onsible for
the start5 u% and maintenance of the equi%ment and facilities %rovided in the %lant. The instruction
%resents in this manual are based on the ex%erience in o%eration of such %lants. =owever' due to
variable nature of the effluents encountered in each %lant' certain modification of %rocess
o%eration may be necessary de%ending on the degree of variation in the raw effluent quality and
quantity.
This manual includes a brief descri%tion of the basis of design of the ETE' the ado%ted treatment
%hiloso%hy and the %rinci%les of treatment involved. The %lant was designed to treat effluents
generated from the various sections of the knit fabric dyeing and finishing %lant. The scheme
envisages treatment of two se%arate wastewater streams namely the less contaminated water and
more contaminated water. The less contaminated effluents are allowed to by%ass many stages
before uniting together again with mainstream and finally discharged to the environment. This has
been done deliberately to reduce the treatment time and o%erating cost.
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Aquatech Engineering Services Limited
;. $a2ic2 (6 *66,3*/t tr*at+*/t

Environmental %roblems of the textile industry are mainly caused by discharges of wastewater.
Textile %rocessing em%loys a variety of chemicals' de%ending on the nature of the raw material
and end %roduct. Some of these chemicals are different en8ymes' detergents' dyes' acids' sodas
and salts. (ndustrial %rocesses generate wastewater containing heavy metal contaminants. Since
most of the heavy metals are non5degradable into non5toxic end %roducts' their concentrations
must be reduced to acce%table levels before discharging them into the environment. ther wise
these could %ose threats to %ublic health and/or affect the aesthetic quality of %ortable water.
According to &orld =ealth rgani8ation "&=# the metals of most immediate concern are
chromium' 8inc' iron' mercury and lead. Farious ty%es of treatment %rocesses are ado%ted to dye
or %rint or finish the textile materials. !ifferent ty%es of textile %rocess could generate different
ty%es of effluent. Table 2.2 shows the 1haracteristics of wastewater %roduced by a ty%ical knit
dyeing industry.
Ta<,* :.:1 C)aract*ri2tic2 (6 Pr(c*22 5a2t* Str*a+2 (6 =/it 0y*i/. a/0 6i/i2)i/..
SL.NO Pr(c*22i/.
U/it
P(22i<,* p(,,3ta/t2
i/ t)* >a2t* >at*r
5a2t* >at*r
4(,3+*
Nat3r* (6
>a2t*
5at*r
,2 Scouring )a=''&axes' grease
)a
7
1o
0
' )a
7

7
' Si
7
And fragments of cloth.
Small 2, L/ kg
of cloth
Strongly alkaline'
dark color' high
B! "0,N of
total#
,7 Bleaching )a1l' 1l
7
' )a=' =
7

7
'
Acids etc.
$ostly
washing
Alkaline
constitutes' a%%rox
; N of B!
,0 !yeing Farious dyes' salts'
alkalies' Acids'
)a
7
S')a
7
S
7

7
and soa%
etc.
Large Strongly colored'
fairly B! ". N
of the total#
,+ *inishing !ifferent finishing agent' Fery small Low B!
T)* a<(4* ta<,* 2)(>2 t)* 0*tai, 0i2c)ar.*2 at 4ari(32 2ta.*2 (6 pr(c*22i/.? )(>*4*r t)*
(4*ra,, 0i2c)ar.*2 (6 a =/it y* )(32* ar* a2 6(,,(>2@
1olor "organic substance#' )a
7
S
+
"inorganic#' )a=' )a=1l "Sodium hy%ochlorite#' )a
7
S
0
'
Surfactant "LAS' B(AS' 1(AS#' ")=#
0
S
+
' =
7

7
'1=
0
1= "rganic#' %araffin "organic#'
1ellulose' il "rganic#' Soa% "rganic#D all these things are 1! and B!.
The fate of the above mentioned %ollutant chemicals vary' ranging from 2,,N retention on the
fabric to 2,,N discharge with the effluent. Menerally' a wet %rocessing industry generates
wastewater %ossessing various level of toxicity. Textile finishing industry uses large amounts of
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water' mainly because of washing o%erations. (f these wastewaters are discharged into the
environment they will cause serious and harmful im%act not only on under ground and surface
water bodies and land in the surrounding area but also will have an adverse effect on the aquatic
ecological system. Effluents from textile mills also contain various ty%es of metals' which has a
cumulative effect' and higher %ossibilities for entering into the food chain and may cause various
ty%es serious diseases. !ue to usage of dyes and chemicals' effluents are dark in colour' which
increases the turbidity of water body. This in turn ham%ers the %hotosynthesis %rocess' causing the
death of many aquatic %lants. (f aquatic dyes then more oxygen will be required to consume them
by bacteria thus causing a reduction of dissolve oxygen in the water. Farious ty%es of dyes are
used in dyeing of various ty%es of textiles fibres. *ixation ca%ability of different dyes is different.
The higher the fixation ca%acity the lower is the %ollution %roblem. Table 2.7 shows the quantity
of unfixed dyes and %ollutants of various colouration %rocesses while table 2.0 shows the degree
of fixation of various dyes.
Ta<,* :.;1 Typ* (6 p(,,3ti(/ a22(ciat*0 >it) 4ari(32 c(,(rati(/ pr(c*22*2.
*ibre !yes 1lass Ty%e of %ollution
1otton !irect !yes 2. Salts
7. >nfixed dye "; - 0, N#
0. 1o%%er salts' 1ationic5fixing agents.
1otton Oeactive !yes 2. Salts
7. Alkali
0. >nfixed dye "2, -+, N#
1otton Fats !yes 2. Alkali
7. xidi8ing agents
0. Oeducing agents
1otton Sul%hurs !yes 2. Alkali
7. xidi8ing agent
0. Oeducing agent
+. >nfixed dye "7, -+, N#
Eolyester !is%erse !yes 2. Oeducing agent
7. rganic acid
0. >nfixed dye "; - 7, N

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Ta<,* :.31 *.r** (6 6i-ati(/ (6 4ari(32 0y*2.
1lass of dye !egree of fixation "N#
Sul%hur .,54,
Fat 3,56;
A8oic 6,56;
Oeactive ;,53,
!is%erse 3,567
Eigment 66
2@7 $etal 1om%lex !yes on wood 6;566
Basic 64563
Acid 3,560
The %ollution level of textile wastewater is ex%ressed in terms of B!' 1!' TSS' T!S' heavy
metals and also tem%erature of the discharging effluent. At higher tem%erature the rate of transfer
of gaseous oxygen into dissolved oxygen is reduced on the other hand at high tem%erature the
activities of various aquatic s%ecies increases so that they require greater amount of oxygen. Thus
at high tem%erature the demand of oxygen increases while its su%%ly decreases.
Farious ty%es of dyes and chemicals are used in textile wet %rocessing industry. The %ollution
ca%abilities of different chemicals are different. Some are highly %olluted while some are less
%olluted. Table 2.+ shows the %ollution ca%ability of various ty%es of dyes and chemicals in textile
wet %rocessing.
Ta<,* :.A1 P(,,3ti(/ capa<i,ity (6 2(+* (6 t)* c)*+ica,2/ pr(03ct2 32*0 i/ t)* T*-ti,*
I/032try.
&*/*ra, C)*+ica, Typ* i66ic3,ty (6 Tr*at+*/t P(,,3ti(/
Cat*.(ry
Alkalies' $ineral acids xidi8ing agents Oelatively harmless.
(norganic %ollutants.

2
Starch si8es' Fegetable oils' fats and waxes
Biodegradable surfactants' rganic acids
Oeducing agents
Oeadily biodegradable.

7
!yes and fluorescent brighteners
*ibres and %olymeric im%urities
Eolyacrylate si8es' Synthetic %olymer finishes'
Silicones
!yes and %olymers'
!ifficult to biodegrade.

0
&ool grease' EFA si8es' Starch ether and esters'
$ineral oil' Surfactants resistant to
biodegradation' Anionic and nonionic softeners.
!ifficult to biodegrade'
$oderate B!.

+
*ormaldehyde and methylol reactants
1hlorinated solvents and carriers
>nsuitable for
conventional


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1ationic retarders and softeners
Biocides
Sequestering agents' =eavy metal salts
biological treatment'
negligible B!.
;
The level of the %olluting %arameters is very high in textile mill wastewater as com%ared to the
their acce%table values recommended by the !e%artment of Environment' Movernment of Eeo%les
Oe%ublic of Bangladesh "MB#. ff course the acce%table level of the %ollutants varies somewhat
form country5to5country and even within the country. The main reason for this is the wastewater5
receiving environment. (f the effluent is discharged into a very big river or sea in that case vary
little or no treatment is necessary as the wastewater will have very little or no effect on such a
large water body. =owever if the same effluent is discharged into a small river or canal in that case
off course it will be necessary to treat the wastewater since the effluent will have significant effect
on the receiving water. Table 2.; shows the values of the im%ortant %ollutants found in the
wastewater of the KKKKKK A%%arels Limited Table 2.. shows the acce%table values of the
above %ollutants of wastewater suggested by the !e%artment of Environment' MB. (t will be seen
in table 2.;' that reference has been made about a range rather than a %articular value of the
%arameters. This is because the characteristics of textile wastewater are not always same which is
due to the variation of raw materials' dyes and chemicals etc. *or exam%le a factory sometime
%rocess 2,,N cotton and sometime %rocess ;,/;, cotton P %olyester blend or even 2,, N
%olyester. The three different cases will require different dyes and chemicals. *or white goods no
dyes are used at all' in that case the effluent characteristics will be different from that of dyed
effluent. *or si8ed fabrics the effluent characteristics will be different from that of knit fabrics. The
values shown in table 2.; are %resented from our long time ex%erience about the effluent
characteristics of similar %lants. The ETE is designed in a such a way so that if the your factory
changes the %rocessing nature to some other %roducts' even then the et% will be able to handle the
treatment efficiency without any %roblem.

Hy0ra3,ic 0ia.ra+ (6 t)* p,a/t
2,
Aquatech Engineering Services Limited
3. $a2i2 (6 t)* P,a/t *2i./
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3.: S(3rc*
The raw effluent shall be discharge to the %ro%osed effluent treatment %lant from the dyeing and
finishing section of the KKKKK..A%%arels Limited.
3.; %3a/tity
The quantity of effluent to be treated shall be of the order of A 6., m0 / day.
3.3 Capacity (6 t)* E66,3*/t Tr*at+*/t P,a/t (ETP).
The effluent treatment %lant has been designed on the basis of the following
!yeing ca%acity is 2,',,, kg /day
1ontaminated effluent is ;,N
Less 1ontaminated effluent is ;,N
%erated continuously for 23 hours a day.
*low rate of treatment envisaged is 0, m
0
/ hr.

3.A I/,*t E66,3*/t C)aract*ri2tic2
S,.N( Para+*t*r2
>nit
'a,3*2
2 E= 3 -2+
7 B! mg/L +,, 5 .,,
0 1! mg/L 3,, 5 2'7,,
+ TSS mg/L 7,, 5 ;,,
; T!S mg/L 0',,, 5 .',,,
. (L P MOEASE mg/L 0, - .,
4 1L>O 1o5%t unit !ark $ixed
3 TE$EEOAT>OE
,
1 .,
,
1
3.B O3t,*t E66,3*/t C)aract*ri2tic28$a/.,a0*2) Sta/0ar0
Sl.
)o.
&ater quality
%arameters
>nit Standard value for discharging into Q
(nland river n land for irrigation
2 E= 5555 .56 .56
7 B! mg/L R;,., R 2,,
0 1! mg/L R7,,., R +,,
+ TSS mg/L R2;,., R7,,
; T!S mg/L R72,, R 7'2,,
. il P Mrease mg/L R 2, R 2,
4 1olor 1o5%t unit R2;, R2;,
3 Tem%erature
,
1 R0,
,
1 R 0,
,
1
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A. Tr*at+*/t P)i,(2(p)y
As was mentioned the method of treatment of wastewater varies a lot. (t mainly de%ends on the
characteristics of effluent' volume of effluent' level of toxicity to be removed and the ty%e of
environment to receive the effluent. (t was also suggested by some standards that the effluent
might require very little or no treatment at all if the effluent is discharged into a very large river or
sea. The treatment %rocess that has been ado%ted for the Effluent Treatment Elant installed at KK
KKKKKKK.. Limited is known as %hysico chemical and followed by biological. The %hysico
chemical %rocess consists of screening' coagulation and flocculation and sedimentation. The
%hysico chemical %rocess removes a substantial %art of all the %arameters shown in table 0.+
The biological treatment is res%onsible for removal of the rest of the removable B! and some
1! as well. The biological treatment is carried out by moving bed biofilm reactor "$BBO# in
the biological tank. $BBO is a new conce%t of wastewater treatment and was develo%ed by a
)orwegian com%any known as A/(-=a,0/*2C. $BBO is a highly efficient method of reducing
the B! of a body of wastewater.
*igure 2@ $oving bed %lastic media *igure 7@ Bacteria in the %lastic media
*igure 0@ Bacteria in the %lastic media *igure +@ Bacteria in the %lastic grid media
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Aquatech Engineering Services Limited
The $BBOS biofilm technology is based on s%ecially designed %lastic biofilm carriers or
biocarriers that are sus%ended and in continuous movement within the biological tank or reactor of
s%ecified volume. The design of associated aerators' grids' sieves' s%ray no88les and other integral
%arts to the reactor is also of great im%ortance in making u% the system as a whole. The system is
suitable for treating both industrial as well as munici%al wastewater. The textile effluent is led to
the $BBO treatment reactor where biofilm' growing within the internal structures of the
biocarriers' degrade the %ollutants. These %ollutants that need to be removed in order to treat the
wastewater are food or substrate for growth of the biofilm. The biocarrier design is critical due to
requirements for good mass transfer of substrate and oxygen to the microorganisms and there is a
continuous OP! in the area of the $BBO biofilm technology. Excess biofilm sloughs off the
biocarrier in a natural way. An aeration grid located at the bottom of the reactor su%%lies oxygen to
the biofilm along with the mixing energy required to kee% the biocarriers sus%ended and
com%letely mix within the reactor.
Treated water flows from reactor through a grid or a sieve' which retains the $BBOS biocarriers
in the reactor. The various stages of the %lant treatment %rocedure is elaborated as followsD
After biological treatment the effluent is %assed through sand filter and finally though the activated
carbon filter. The activated carbon filter is highly successful in removing B!' 1!' TSS' T!S
P color of the effluent.
A.:. PRE8TREATMENT
A.:.: Scr**/i/. 8 to remove coarse materials
A.:.; ED3a,iEati(/ & SFi++i/. 8 to remove grease & oil and homogenize and to remove
some BOD & COD.
A.;. PRIMAR" TREATMENT
A.;.: C(a.3,ati(/ - to coagulate the suspended solid to coagulate

A.;.; F,(cc3,ati(/ - to flocculate by coagulants

A.;.3 N*3tra,iEati(/ - to adjust the pH beteen !." to #."

A.;.A S*0i+*/tati(/ $ to precipitate small suspended solids
All the above %rocesses contribute to removal of substantial amount of all the %olluting
%arameters.
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A. 3. SECONAR" TREATMENT
$i(,(.ica, tr*at+*/t (M$$R)8 to remove BOD and COD & to decompose organic matter.
A. A. TERTIAR" AN OTHER TREATMENTS
A.A.: &ra/3,ar M*0ia Fi,trati(/8t( r*+(4*2 TSS a/0 a/y (t)*r p(,,3ta/t2 i/ t)* 6(r+
(6 partic,*. T)i2 6i,t*r i2 a,2( 32*63, t( pr(t*ct t)* Acti4at*0 Car<(/ Fi,t*r (ACF)
6r(+ (4*r,(a0i/. <y p(,,3ta/t2 23c) a2 partic3,at*2? (r.a/ic2.
A.A.; Acti4at*0 Car<(/ Fi,t*r8 Car<(/ a02(rpti(/ i2 a pr(4*/ pr(c*22 i/ t*rtiary
tr*at+*/t 6(r t)* pr(c*22i/. <i(,(.ica,,y tr*at*0 >a2t*>at*r2? a/0 i2 (/* (6 t)*
+a/y pr(c*22*2 32*0 i/ t)* a04a/c*0 tr*at+*/t (6 >a2t*>at*r2. T)* ACF i2 32*0
t( r*+(4* r*,ati4*,y 2+a,, D3a/titi*2 (6 r*6ract(ry (r.a/ic2? a2 >*,, a2 i/(r.a/ic
23c) a2 23,6i0*2 a/0 )*a4y +*ta,2 r*+ai/i/. i/ a/ (t)*r>i2* >*,,8tr*at*0
>a2t*>at*r.
A. B. SLU&E MANA&EMENT & ISPOSAL
+.;.2 S,30.* 0i2p(2a, 9 to separate the sludge from the thic% slurry and then dispose of
the sludge as dried ca%e
B. PROCESS FLO5 CHART
2;
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G. Op*rati(/a, Pr(c*22*2
2.
Aquatech Engineering Services Limited
G.:.Pr*8Tr*at+*/t
The effluent generated in a textile wet %rocessing %lant can be broadly classified into two classes
e.g i# Less contaminated and ii# =ighly contaminated. The Less contaminated waters are mainly
generated due to machine washing' floor cleaning' waters coming from the last washing cycles etc.
These less contaminated waters %ose very little threat to the environmentD therefore they can be
discharged directly to the environment or may require little treatment. (f however these waters are
mixed with the main effluent' then the volume of total effluent will be very high and as a result
overall install ca%acity running cost of the ETE will be very high. Therefore the less contaminated
waters are stored in a se%arate tank and from time to time the effluent is %um%ed to the sand filter
followed by carbon filter and finally to the discharge outlet. The more contaminated waters are
guided through the bar screen to the equali8ation tank for various treatments.
G.:.: Scr**/i/. (T( r*+(4* c(ar2* a/0 6,(at +at*ria,2.)
The raw waste water "Oaw Effluent# from the %rocess of the %lant would first be screened through
a manual bar screen strainer channel' where all %articles with dia.T ; $$ as well as small %ieces
of the fiber and floating sus%ended matters like %olythene %a%er' %olythene bags' rags and others
materials are removed by bar screen net. The bar screen consists of %arallel rods or bars and is also
called a bar rack. These devices are used to %rotect downstream equi%ment such as %um%s' lines'
valves etc. from damage and clogging by rags and other large ob:ects. The bar screen is cleaned
manually by means of rakes. The screening is dis%osed off suitably after they are de5watered. The
screened clean effluent flows by gravity to an equali8ation tank.
G.:.; ED3a,iEati(/ a/0 SFi++i/. (T( r*+(4* .r*a2* & (i, a/0 )(+(.*/iE*#

The raw wastewater from the screen channel is collected in the equali8ation tank' where it is
equali8ed with res%ect to its characteristics' homogeneity' flow and an uniform %ollution load as
well as to make bacteria acclimati8ed. =igh5s%eed aerating devices are fixed at the bottom of the
equali8ation tank' which blows air through the waste at a rate about ,.2 1>* of air %er gallon of
effluent. The rising air tends to coagulate the grease and oils and cause them to rise to the surface
where they can be removed by a scra%er mechanism. Besides' the airflow accom%lishes a %ro%er
equali8ation of both varying loading and fluctuating E= values. The equali8ation tank is designed
for hydraulic retention time of around . hours. 1ertain amount of 1! will also be removed by
the dissolved air flotation %rocess. The following benefits are derived from the flow equali8ation
%rocessD
2. Biological treatment is enhanced' as the shock loadings are eliminated or minimi8ed' inhibiting
substances diluted' and %= stabili8ed.
7. 1hemical treatment is im%roved if chemical dosing is controlled to %rovide consistent
%erformance
0. The effluent quality and thickening %erformance of secondary sedimentation units are im%roved
through constant solids loading.
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Aquatech Engineering Services Limited
+. Effluent surface area requirements are reduced' filter %erformance is better' and more uniform
filter5backwash cycles are %ossible.
G.;. Pri+ary8Tr*at+*/t
G.;.: C(a.3,ati(/ a/0 F,(cc3,ati(/ (T( r*+(4* c(,(r a/0 *66,3*/t 232p*/0*0)
The homogeni8ed effluent will then be %um%ed to a flash5mixing tank followed by a flocculation
tank. (n the flash5mixing tank coagulants like lime "1alcium =ydroxide# and flocculants like
ferrous sulfate "*eS
+
# are dosed. This is done for coagulation and removal of the total dye
%articles. The basic idea of adding coagulant is to bring together all the sus%ended and dye
%articles so that they can be %reci%itated out in the flash mixing tank and flocculation tank by
coagulation and flocculation mechanism. The chemical reaction that occurs in the coagulation and
flocculation %rocess is shown belowD
1a ? =
7
1a "=#
7
The above reaction take %lace in lime dosing tank when lime reacts with water and we get calcium
hydroxide solution. This solution reacts with the ferrous sul%hate solution' which as follows
1a "=#
7
? *eS
+
1aS
+
? *e "=#
0
? *eS
+
">nreacted# ? *e "=#
7
Adequate quantity of %olyelectrolyte %olymer solution is dosed in the flocculation tank to enhance
the %rocess of colour removal by the flocculation %rocess. A substantial amount B! and 1!
etc. are removed in the coagulation and flocculation %rocess.
G.;.; Pr*cipitati(/ a/0 S*0i+*/tati(/ i/ T3<* S*tt,*r 8:. (T( r*+(4* t)* 6,(c2 +at*ria,2)
*rom the flocculation tank the effluent is taken by natural gravity in to the tube settler5 2 tank
where the dyes and sus%ended %articles are %reci%itated. The flocs formed are removed in the
downstream tube settler -2 by the hel% of tube settler media. The effluent will further flow by
overflow system to the %= correction tank where requisite quantity of acid will be dosed and %=
will be ad:usted as %er the requirement.
G.;.3 pH C(rr*cti(/ (T( a0H32t t)* i/,*t pH)
The effluent from tube settler5 2 tank is then taken by overflow method to the %= correction
channel for neutrali8ation' where 00N =1l acid is dosed for neutrali8ing the %= value around 4 to
3. The %= correction channel is designed for hydraulic retention time of around 2 57 minutes and
is %rovided with slow s%eed agitator for thoroughly mixing of waste with acid to maintained %=
value.
G.3 S*c(/0ary8Tr*at+*/t
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G.3.: $i(,(.ica, Tr*at+*/t i/ t)* F,3i0iE*0 A*r(<ic $i(8R*act(r (a,2( ca,,*0 M$$R) I : & ;
(T( r*03c* t)* r*+ai/i/. $O / CO a*r(<ica,,y).
The neutrali8ed effluent is then taken by gravity in to the biological treatment aeration tank for
biological degradation of available organic matter to reduce the remaining B! and 1!
aerobically. The biological treatment tanks are designed on extended aeration %rinci%le. The
fluidi8ed Aerobic Bio5Oeactor ( P (( includes two tanks of any sha%e filled u% with small carrier
elements. The two tanks are also called $oving Bed Biofilm Oeactor "$BBO#. The media
elements are made u% of s%ecial grade %lastic of controlled density such that they can be fluidi8ed
using an aeration device. (n course of treatment a bio5film develo%s on the elements' which move
along with the effluent in the reactors. The movement within the reactors is generated by
%roviding aeration with the hel% of diffusers %laced at the bottom of the reactor. The thin bio5film
on the elements enables the bacteria to act u%on the biodegradable matter in the effluent and
reduce the B! content while the ra%id and turbulent movement of the effluent in the %resence of
oxygen available from the air' certain amount of 1! is also removed. The chemical reactions
that took %lace in the *AB reactor can be defined according to the following three %rocessesD
A. xidation %rocess
1=)S ?
7
? Bacteria ? !AE P >OEA 1
7
? )=
0
? Energy
? ther end Eroducts
!AE and >rea is used as food for the microorganism.
B. Synthesis Erocess
1=)S ?
7
? Bacteria 1
;
=
4
)
7
")ew bacteria#
1. Endogenous Oes%iration
1
;
=
4
)
7
? ;
7
1
7
? )=
0
? 7=
7

A%art from the above basics reaction there are some other reactions that take %lace in the *AB
reaction tanks. !uring aeration the oxygen reacts with 1' S and ) which is shown below.
1 ?
7
1
7

S ? 7

S
7


) ?
7
)
7

Some untreated ferrous sulfate and ferric hydroxide reacts with oxygen and the reactions are as
follows'

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Aquatech Engineering Services Limited
*eS
+
?
7
*e
7
"S
+
#
0


*e "=#
7
?
7
*e "=#
0


&hen the %lant is ke%t shut down for short %eriod of time' at that time' off course' it will be
necessary to continue the aeration of Biological reactor 2 P 7. The biological degradation %rocess
in enhanced by the adding some !ia5mmonium Ehos%hate "!AE# and >OEA' which acts as food
for the microorganism. Therefore it will be necessary to su%%ly food for the bacteria. Thus a
combined solution of >rea and !AE are dosed in the biological tank to feed the bacteria.
G.3.; T3<* S*tt,*r 9; (T( r*+(4* t)* <i(,(.ica, 2(,i02 .*/*rati(/. )
*rom the biological reactor the treated effluent flows by gravity to the tube settler -7. The
biological solids generated are removed from the tube settler -7 by the hel% of tube settler media.
G.3.3 Fi,t*r F**0 S3+p (T( c(,,*ct *66,3*/t 6(r /*-t pr(c*22*2)
The treated effluent from tube settler5 7 overflow in to the filter feed sum%. *rom the filter feed
sum% the effluent is %um%ed to the %ressure sand filter at first and then through activated carbon
filter. *rom here the disinfected effluent is %um%ed by means of the %ressure sand filter feed %um%
to the %ressure sand filter. The %um% is normally o%erated in automatically with interlock to the
level switch in the filter sum%.
G.3.A Pr*223r* Sa/0 Fi,t*r (T( r*+(4* 232p*/0*0 +att*r)
*rom the filter feed sum% the effluent is %um%ed to the %ressure sand filter. The filtration takes
%lace in the downward mode. The filter is filled with a layer of graded sand media su%%orted by a
layer of graded gravel. The sus%ended matters in the effluent are filtered out in this unitD the
effluent is then flown into the activated carbon filter.
(t was mentioned in the section ..2 that the less contaminated waters are collected in the se%arate
tank and then %um%ed to the sand filter tank followed by carbon filter and discharge outlet. (t is
necessary to backwash the sand filter every eight hours.
G.3.B Acti4at*0 Car<(/ Fi,t*r (T( a<2(r<*0 t)* 0i22(,4*0 (r.a/ic +att*r)
The treated and filtered effluent from the %ressure sand filter flows into the activated carbon filter.
(n this unit too the feed flow is downward through a layer of granular activated carbon filter in
which dissolved organics of the effluent are absorbed. (t is necessary to backwash the carbon filter
every eight hours.
G.3.G Tr*at*0 E66,3*/t i2p(2*0 O66 (R*a0y 6(r 0i2p(2*0 (66)
The treated effluent emerging from the A1* is directly dis%osed off through the out let channel to
environment.
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G.3.J S,30.* Tr*at+*/t a/0 )a/0,i/.
The sludge generated in the flash mixing tank' flocculation tank' tube settler52' tube settler57 and
biological reactor is taken to a sludge sum%. =ere also aeration is carried out. The waste is then
%um%ed to a Sludge Thickener tank where the sludge is concentrated at the bottom of the tank.
The thickened sludge from the thickener is %um%ed to centrifuge %um% for de5watering. At first
the centrifuge is started and then the thickener feed %um% is started. As the slurry of sludge flows
%olyelectrolyte solution is dosed in the centrifuge as a result the sludge will be se%arated from the
water. The centrifuge is run for 7, to 0, minutes and then switched off.
The de5watered sludge is transformed into cake form. The dried cake may be dis%osed of to
deliver in the brickfield for burning. The overflow from the sludge thickener will be flow back to
equali8ation tank for further treatment.
(n some cases due to the nature of the wastewater characteristics it is not %ossible to dewater the
sludge into a cake form' in that case the sludge is collected in the form of slurry in a bucket :ust
below the centrifuge %um%. After collection of the sludge' it is strongly advised to dis%ose the
sludge in such a way so that it will not come in contact with the environment. A best way to handle
this sludge is to throw them in a dee% hole' when the hole is nearly filled then it will be necessary
to bury the sludge by means of soil.

(n every two days the sludge cake is taken out by o%ening the cover of the centrifuge. After taking
out of the cake the centrifuge is washed and clean by water. The water that has been se%arated
from the sludge will be flown back to equali8ation tank for treatment.
J. Op*rati(/a, Pr(c*03r*
J.: Pr*parati(/ (6 t)* c)*+ica, 0(2i/.
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Before starting the o%eration it will be necessary %re%are all the necessary chemical solutions. The
%rocedures of %re%aring the solutions are described below.
J.:.: Pr*parati(/ (6 t)* Li+* 2(,3ti(/
The daily requirement of the lime solution is calculated and shown in section 3.2. !uring
%re%aring the dosing solution of lime a ;N solution is %re%ared. (n this regard the dosing tank'
which is fitted with a motor and stirrer' is at first filled with 2,,, litres of water. After that ;, kgs
of lime is added and the motor is switched on to stir the solution. The stirring should be continued
on a 7+5hour basis i.e. as long as the %lant runs. After that the solution is ready for dosing in the
flash5mixing tank. (t is necessary to ad:ust the stroke of the dosing %um% to get the desired flow.
J.:.; Pr*parati(/ (6 t)* F*rr(32 S3,p)at* (F*SO
A
) 2(,3ti(/
The daily requirement of the ferrous sul%hate is calculated and shown in section 3.7. !uring
%re%aring the dosing solution of ferrous sul%hate a 2,N solution is %re%ared. (n this regard the
dosing tank' which is fitted with a motor and stirrer' is at first filled with 2,,, litres of water. After
that 2,, kgs of ferrous sul%hate is added and the motor is switched on to stir the solution. The
stirring is continued for nearly 2 hour. After that the solution is ready for dosing in the flash5
mixing tank. (t is necessary to ad:ust the stroke of the dosing %um% to get the desired flow.
J.:.3 Pr*parati(/ (6 t)* P(,y E,*ctr(,yt* (PE) 2(,3ti(/
The daily requirement of the EE solution is calculated and shown in section 3.0. !uring %re%aring
the dosing solution of lime' a ,.,;N solution is %re%ared. (n this regard the dosing tank' which is
fitted with a motor and stirrer' is at first filled with 2,,, litres of water. After that ;,, gms of EE is
added and the motor is switched on to stir the solution. The stirring should be continued on a 7+5
hour basis i.e. as long as the %lant runs. After that the solution is ready for dosing in the flash
mixing tank as well as centrifuge tank. (t is necessary to ad:ust the stroke of the dosing %um% to
get the desired flow.
J.:.A Pr*parati(/ (6 t)* Aci0 2(,3ti(/
The daily requirement of the Acid solution is calculated and shown in section 3.+. !uring
%re%aring the dosing solution of acid' a 7.;N solution is %re%ared. (n this regard the dosing tank'
which is fitted with a motor and stirrer' is at first filled with 2,,, litres of water. After that 4, litres
of 00N =1l is added. After that the solution is ready for dosing in the flash5mixing tank. (t is
necessary to ad:ust the stroke of the dosing %um% to get the desired flow.
J.:.B Pr*parati(/ (6 t)* ia++(/i3+ P)(2p)at* (AP) a/0 Ur*a 2(,3ti(/
The requirement of the !AE and >rea is calculated and shown in section 3.;. !uring %re%aring the
dosing solution of !AE and >rea a ;N mixed solution is %re%ared in the same dosing tank. (n this
regard the dosing tank' which is fitted with a motor and a stirrer' is at first filled with 2,,, litres of
water. After that ;, kgs of !AE and >rea "0; kgs >rea and 2; kgs !AE# are added and the motor
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Aquatech Engineering Services Limited
is switched on to stir the solution. The stirring should be continued for half of an hour. After that
the solution is ready for dosing in the biological tank. (t is necessary to ad:ust the stroke of the
dosing %um% to get the desired flow.
J.; M*t)(0 (6 2**0i/. <act*ria i/ t)* FA$ r*act(r I : & ;.
The following ste%s are to be followed during start u% of *AB reactor.
2. 1heck whether civil work is com%lete in all res%ects as far the civil MA drawings.
7. 1heck any leakage
0. After com%leting the civil work' assemble air %i%es. *ill the water tank. Take trial for air
diffusion. Aeration has to be uniform and there should not be any leakages in the air grid.
+. (f aeration is o.k. drain water and %our *AB media in the reactor.
;. *ill the tank u% to the water level
.. Add 2, tons of filtered cow dung. Ensure that cow dung is free of foreign material and
fibres. $ake ;52,N slurry. *ilter it through 750 mm o%ening mesh. !uring the addition of
slurry in *AB kee% the blowers on. 1ow dung should be fresh "0 to + days# . &e can also
have aerobic culture in *AB in %lace of cow dung. Add this slurry uniformly in all the
com%artments.
4. Aerate the dilute slurry continuously for about ;5. days.
3. !ilute effluent can be loaded after this graduallyD "Starting with 2,N of design B! load'
for initially 453 days thereafter the load can be increased after every +5; days by 2,N
%rovided B! reduction is continuously 4,54;N is observed at the increased B! load.
(f' in cases' the bacteria of the biological reactor dye for any reason like wrong acidity or
alkalinity' nor aeration shock load etc' in that case it will be necessary to seed the bacteria
again. This has to be done by means of adding 2, tons of cow dung as was mentioned in
section . above. (t is not very easy to detect the %resence of bacteria in the biological tank. By
means of using a microsco%e it will only be %ossible to test the %resence of bacteria in the
effluent. A%art from this by testing the B! of the effluent before and after the biological
reactor treatment it will be %ossible to say whether there is any bacteria in the reactor or not. (f
the quantity of B! is same before and after the biological reaction then we can say that there
are no bacteria to reduce the B!. n the other hand' if the B! is reduced' after' treatment
in the biological reactor then we can say that there is bacteria in the biological tanks.
J.3 I+p(rta/t pr(c*22i/. tip2
J.3.:
2. !rain the sludge settled at the bottom of the tube settler at %eriodic interval to avoid carry
over of sludge.
7. 1hangeover from o%erating to stand by equi%ment every day.
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0. Oegularly follow the lubrication and maintenance schedule for all mechanical moving
items.
+. Take sam%les from the locations s%ecified. Analy8e them and maintain logbook regularly
to ensure better control over o%eration of the %lant.
J.3.;
2. !o not let effluent -having %ollutants more than s%ecified range in the %lant .
7. !o not enter in to the closed tank without o%ening the manhole/without draining the
contents of the tank.
0. !o not handle chemicals' dosing system without taking %recautions.
4. !o not allow acidic %= R . or alkaline %= T 3.; or hot "tem% T +,
,
1#
;. !o not drain the *AB reactor under normal o%eration.
J.A Tr(3<,* S)((ti/. .3i0*
J.A.: A*rati(/ Pr(<,*+
Low ! and/or se%tic odor in *AB reactor
Eossible cause )ecessary 1heck and %ossible corrective
actions
>nder aeration 2. 1heck !' should be in the range of 2., to
0., mg/L throughout in the tank.
7. 1heck the air quality delivered by blower' in
case the quantity is less than designD check the
blower for any mechanical %roblem. (n case of
any mechanical %roblem refer the blower
manual for the maintenance.
0. 1heck for adequate mixing in *AB reactor.
Blower o%eration not continuous The blower should be in continuous o%eration
Mrid are damaged (n case the grid is damaged' this will result in
excessive turbulence but low oxygen transfer.
The corrective action should be taken nfor
re%aring the diffuser/grid.
=igh inlet rganic i.e B!/1! load 2.(n case the B!/1! load is higher than
design' the same to be controlled %rior to E.T.E.
(f the increase is for a small %eriod the flow to
the %lant to be reduced to decrease the kg
B!/1! loading.
7.Solid level in the *AB reactor very high' the
settled solids "if any# to be drained. The
draining frequency can be ascertained based on
the site condition.
7+
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J.A.; F(a+i/. Pr(<,*+
Eossible cause )ecessary check and %ossible corrective actions
ver aeration 1heck B! loading "kg/d#' in case the B!
level is much lower than the design basis.
Ad:ust the air quantity to the bio reactor and
maintain minimum !. level as 7., mg/l
Low bacterial level in the *AB reactor Seeding should be done %referably by using
activated sludge from an well5o%erated %lant
)ote5 The foaming %roblem usually occurs during start5u% and is only tem%orary. (f you are under
starting u% do not be alarmed by it.
J.A.3 L(> (-y.*/ 3ptaF* i/ FA$ r*act(r
Eossible cause )ecessary check P %ossible corrective actions
=igh Tem%erature At high tem%erature there will be decreased
oxygen utili8ation.
$aintain the inlet effluent tem%erature between
7;
,
1 to 0;
,
1 maintain organic removal
%= out of range Eliminate source of %= u%set
Ad:ust %= in *AB reactor to between ..; and
3.;
S%ill Eliminate source of s%ill
Evaluate effect of s%ill on active Bio $ass.
Low organic loading Ad:ust the air su%%ly according to the inlet
B! load' simultaneously maintain the !
level T7., mg/l.
J.A.A L(> $i( &r(>t) i/ t)* FA$ r*act(r
Eossible 1ause )ecessary 1heck P Eossible 1orrective Actions
=igh Tem%erature =igh %rocess tem%erature can result in
decreased oxygen utili8ation and as a result low
bacterial growth. A%art from this at high
tem%erature there is %ossibility of dyeing of the
microorganisms.
$aintain the inlet effluent tem%erature between
7;
,
1 to 0;
,
1 to maintain organic removal
%= out of range Eliminate source of %= u%set as it will
adversely affect the Biological %rocess.
7;
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Ad:ust %= in *AB reactor in between ..; and
3.;
(nsufficient aeration (nsufficient aeration may lead to decrease in
bacterial %o%ulation. The aeration should be
continuously carried. Even if the effluent is not
available for a short s%an in a day blowers
should not be st%%ed.
Shock loading The effluent having %ollutant level very high
should be segregated and stored se%arately.
The effluent having toxic %ollutant should be
%revented from entering the ETE.
J.A.B Hi.) 232p*/0*0 2(,i02 ,*4*, i/ t)* t3<* 2*tt,*r II (3t,*t *66,3*/t
Eossible cause )ecessary 1heck P Eossible 1orrective Actions
$edia %osition 1heck the %osition of tube settler media by
lowering the water level' in case any short
circuiting is there' the same is required to be
corrected by correctly %ositioning the media as
%er the drawing.
Excessive storage of sludge in the tube settler. The sludge needs to be drained %eriodically
from the tube settler. (n case the sludge level
increases in the tube settler the same will result
in sludge carry over.
Trough are not cleaned The trough should be cleaned manually
%eriodically.
J.A.G Hi.) CO ((r $O) ,*4*, i/ t3<* 2*tt,*r II (3t,*t *66,3*/t
Eossible cause )ecessary 1heck P Eossible 1orrective Actions
Low Bio mass Seeding of *AB reactor may be required.
=igh organic loading and/or excessive flow (ncrease in the inlet B!/1! load in
com%arison to !esign. (f the increase is for a
short time decrease the flow to maintain the kg
B! loading as far design.
=igh effluent sus%ended solid "SS# (f 1! increase is attributable to high effluent
sus%ended solids' refer to corrective actions for
Uhigh effluent sus%ended solidsV
7.
Aquatech Engineering Services Limited
(nadequate ! 1heck organic loading by measuring 1!.
(ncreased oxygen utili8ation can result from
increased organic loading. Oefer to corrective
actions for Ulow oxygen level in *AB OeactorV
K.E2ti+ati(/ (6 4ari(32 c)*+ica,2
The requirements of various chemicals must be determined by means of :ar test. (t is strongly
recommended to conduct the :ar test whenever any ma:or changes occurs either in selection of
74
Aquatech Engineering Services Limited
%rocess' dyes' or raw material characteristics. !ifferent %rocess condition due to change of raw
material or change of brand of dyes will lead to different ty%es of effluent characteristics.
K.: E2ti+ati(/ (6 D3a/tity (6 ,i+* (Ca,ci3+ Hy0r(-i0*) @5
*rom our ex%erience of running %lants and :ar tests' the quantity of required lime can be estimated
as followsD
(f the flow of effluent is 0, $
0
/=r.
!ose o%timi8ed by :ar test A 300 mg / l.
Therefore'
0, $
0
/hr. W 300 mg /l W 7+ hrs.
CaO required A 555555555555555555555555555555555555555555555 A .,, Lg / day.
2,,,

A 7; kg/hr
K.; E2ti+ati(/ (6 D3a/tity (6 F*rr(32 S3,p)at* F*SO
A.
Based on ex%erience or by :ar tests findings the dosages can be stabili8ed. e.g.
(f flow of effluent is +, 1um / =r.
!ose o%timi8ed by :ar test A 300 mg / l.
Therefore
0, $
0
/hr. W 300 mg /l W 7+ hrs.
F*SO
A
required A 5555555555555555555555555555555555555555555555555 A .,, Lg / day.
2,,,
A 7; kg /hr
K.3 E2ti+ati(/ (6 D3a/tity (6 P(,y*,*ctr(,yt*.
Based on ex%erience or by :ar tests findings the dosages can be stabili8ed. e.g.
(f flow of effluent is 0, 1um / =r.
!ose o%timi8ed by :ar test A +.2. mg / l.
Therefore'
0, $
0
/hr W +.2.mg / l W7+ hrs
Eolyelectrolyte required A 55555555555555555555555555555555555555555555 A 0 kg / day
2,,,
A ,.27; kg / hr
(This amount will be required for dosing in the flash mixing as well as centrifuge feed %um%#
73
Aquatech Engineering Services Limited
K.A E2ti+ati(/ (6 D3a/tity (6 Hy0r(c),(ric Aci0 ( HC,)
These can be o%timi8ed by using Xar test %rocedure given bellow
Based on ex%erience or by :ar tests findings the dosages can be stabili8ed. e.g.
(f flow of effluent is 0, $
0
/=r.
!ose o%timi8ed by :ar test A 04; mg / l
Therefore
0, $
0
/ hr W 04; mg/l W7+ hrs
=1l -00N required A 5555555555555555555555555555555555555555555555 A 74, Lgs / day
2,,,
A 22.7; kgs / hr

K.B E2ti+ati(/ (6 D3a/tity (6 AP a/0 Ur*a
Assume B! content of the feed to the system A 7,, mg/ l.
*low of effluent to the system is 0, $
0
/ hr.
0, W 7,, W 7+
Total B! load A 555555555555555555555555 A 2++ Lgs /day.
2,,,
Basis for activated sludge %rocess is B! @ ) @ E A 2,, @ ; @ 2.
2++ W ;
*or 267 kgs / day B! )itrogen required. A 55555555555555 A 6.. kg /day.
2,,
2++ W 2
Ehos%horus required A 555555555555555 A 2.++ Lg / day.
2,,
)ow' !AE contains 24.6 N %hos%horus' for 2.67 Lg %hos%horus' !AE required.

2.++ W 2,,
A 555555555555555555 A 3.,+ Lgs / day
24.6
A,.0+ kg / hr

!AE contain 23 N )itrogen' therefore )itrogen %rovided by 3.,+ kg !AE is
3.,+ W 23
A 5555555555555555555 A 2.+; kg.
2,,
76
Aquatech Engineering Services Limited
)itrogen shortfall A 3.,+- 2.+; A ..., Lg / day.
)ow' urea contains +. N )itrogen' so for 4..3 Lg )itrogen' >rea required is

..., W 2,,
A 55555555555555555555555 A 2+.0; Lg / day.
+.
A ,.., kg / hr.
Therefore' >rea required is 2+.0; kg/day
!AE required is 3.,+/day
N(t*1 T)* Ur*a a/0 AP 2(,3ti(/2 ar* r*D3ir*0 t( 6**0 t)* <act*ria i.*. t)*y >(rF2 a2
/3tri*/t 6(r t)* +icr((r.a/i2+2. I6? 6(r a/y r*a2(/? t)* p,a/t i2 F*pt 2)3t 0(>/ 03* t(
c,(23r* (6 t)* 6act(ry (r 2(+*t)i/. ,iF* t)i2? *4*/ t)*/ it >i,, <* /*c*22ary t( r3/ t)*
<i(,(.ica, r*act(r a,(/. >it) 0(2i/. AP a/0 Ur*a 2(,3ti(/2. T)i2 i2 <*ca32* i6 t)* <i(,(.ica,
r*act(r2 ar* 2)3t0(>/ t)* <act*ria >i,, 0y* a/0 t)*/ a.ai/ it >i,, <* /*c*22ary t( 2**0 t)*
<act*ria acc(r0i/. t( t)* pr(c*03r* (3t,i/*0 i/ 2*cti(/ J.;.
C)*+ica, C(/23+pti(//0ay L (:00M E66ici*/cy)
1hemicals Yuantity/day Yuantity / hr
1alcium=ydroxide"Lime 1rystal#
3;N Eurity
.,, Lg /day 7;.,, kgs/ hr
*errous sul%hate "*eS+# 3;N
Eurity
.,, Lg/ day 7;.,, kgs/ hr
Eolyelectrolyte"Anionic EE 2,,N
Eurity#
0 Lg /day ,.27; hg/ hr
=ydrochloric acid 00N %urity 74, Lg /day 22.7; kgs / hr
!ia ammonium %hos%hate 3.,+ Lg /day ,.0+ kg / hr
>rea 2+.0; Lg /day ,.., kg / hr
)ote@ The actual quantities will de%end on chemicals %urity ' effluent characteristics and :ar test.
The above indicate consum%tion %attern. These are not guarantee figures
0,
Aquatech Engineering Services Limited
N. C(++i22i(/i/. (6 t)* P,a/t
a. At first sufficient effluent is allowed in the equali8ation tank. After that aeration
should be continued. After aeration for about an hour or two the effluent is %um%ed to the
flash mixing tank.
b. Lime and *errous Sul%hate solution should be dosed as soon as the effluent
accumulated in the flash mixing tank. Soon after dosing' the colour of the effluent will be
changed and the dissolved matters will form small flocks. The effluent will then be flown to
the flocculation tank by overflow and gravity %rinci%le.
c. Eolyelectrolyte is then dosed when the small sludge %articles will concentrated at the
bottom of the tank.
d. *rom the flocculation tank the effluent is over flown to the tube settler 2 where the effluent
is flown u%wards through the tube media. >nder this condition a substantial amount of
sludge will be accumulated at the bottom of this settler tank.
e. The effluent is then goes to the %= correction channel due to the over flow. (t is necessary
to check the %= of the effluent at this stage and if the %= is above 4 then acid solution is
dosed to bring down the %= within a range of ..; to 3.;.
f. The effluent is then goes to the *luidi8ed Aerobic Biological reaction tank Z2 due to the
over flow and gravitation method. $icroorganisms like bacteria are seeded in *luidi8ed
Aerobic Biological reaction tank Z2 P 7 tank' which is described in section 4.7.
g. )utrients are dosed in the *AB reactor for nursing microorganisms like bacteria. &hen this
tank is filled with' the effluent is then flows to the *luidi8ed Aerobic Biological reaction
tank Z 7. At this stage the remaining B!/1! will be reduced. *rom the *luidi8ed
Aerobic Biological reaction tank Z 7' the effluent enters into the tube settler Z 7. This is
also ha%%en due to overflow.
h. As the effluent flows through the tube media the sludge is settled at the bottom of the tank.
i. *rom the tube settler tank Z 7 the effluent goes to the filter feed sum% due to gravity. *rom
the filter feed sum% the effluent is %um%ed to the %ressure sand filter or Mranular $edia
*iltration5to remove carbonaceous B! and nitrogenous and residual in solubilised
%hos%horous. This filter is also useful to %rotect the down stream Activated 1arbon *ilter
"A1*# from overloading by %ollutants such as %articulates' organics.
j. The effluent is then flows to the Activated 1arbon *ilter. 1arbon adsor%tion is a %roven
%rocess in tertiary treatment for the %rocessing biologically treated wastewaters' and is one
of the many %rocesses used in the advanced treatment of wastewaters. The A1* is used to
remove relatively small quantities of refractory organics' as well as inorganic such as
sulfides and heavy metals remaining in an otherwise well5treated wastewater.
k. The water at this stage is safe to be released into the environment.
02
Aquatech Engineering Services Limited
:0. P,a/t S)3t0(>/
(n cases when the factory is ke%t shut down for a short %eriod of time then there will not be any
effluent' in that case it will be necessary to continue aeration and nutrient dosing in the *luidi8ed
Aerobic Biological reaction tank Z 2 P 7' otherwise the bacteria will dye. (f the bacteria dye then
it will be necessary to seed bacteria again following section 4.7.
::. Mai/t*/a/c* (6 t)* p,a/t
::.: $ar Scr**/1
The bar screen should be cleaned everyday
::.; ED3a,iEati(/ p3+p1
The lube oil should be checked before starting the %um%. The valve of the suction line should be
o%ened and cleaned once every seven days.
::.3 F,a2) Mi-i/. a/0 6,(cc3,ati(/ a.itat(r1
A%%ly lube oil before starting the agitator motor. The lube oil should be checked after every seven
days.
::.A Air $,(>*r1
1heck the lube oil before starting the air blower. (f there is no lube oil then a%%ly lube oil and start
the blower. The lube oil %um% should checked frequently.
::.B S,30.* tra/26*r p3+p a/0 c*/tri63.* 6**0 p3+p1
After starting the sludge transfer %um% and centrifuge feed %um% it should be observed for a short
%eriod of time. (f no sludge is found then sto% the %um% and o%en and clean the delivery line.
::.G A.itat(r2 (6 a,, t)* 0(2i/. ta/F21
1heck the lube oil every seven5day. A%%ly lube oil if finishes.
::.J F,a2) +i-i/.? 6,(cc3,ati(/ a/0 t3<* 2*tt,*r ta/F I :1
The tanks should be cleaned very well in every three months. The tube settler media should also
be cleaned.
::.K T3<* 2*tt,*r ta/F I ;1
T)i2 ta/F 2)(3,0 <* c,*a/*0 a6t*r *4*ry 2i- +(/t)2 ti+*.
07
Aquatech Engineering Services Limited
::.N Sa/0 Fi,t*r1
B
(t is necessary to backwash the sand filter every eight hours.
::.:0 Car<(/ 6i,t*r1
(t is necessary to backwash the carbon filter every eight hours.
::.:: C*/tri63.*1
After removal of the cake' the inside of the centrifuge should be cleaned. 1heck the belt of the
motor frequently' if loose change it so that it can rotate freely and easily.
::.:; Pai/ti/. t)* p,a/t1
All the %i%es and $.S tanks should be %ainted every year. The %ainting instruction and other
details are given in A%%endix5(((
::.:3 I/6(r+ati(/ a<(3t 4ari(32 *D3ip+*/t2? part2 a/0 acc*22(ri*21
SR. NO ESCRIPTION SPECIFICATION
,2 Bar Screen



Ty%e - 1oarse
$odel5 Aquatech5,0
Yuantity - 2 " ne #
Si8e - +;, $$ W ;,, $$.
$aterials of construction - $ild Steel
E%oxy Eaint.
rigin5 Bangladesh.
,7 Aeration Mrids for equali8ation tank. Ty%e - Air diffuser
$odel5 Aquatech 5,0
Yuantity5 2 Lot
Si8e5 3, $$' +, $$.
$aterial of construction5 U>V EF1
Tem%erature - 3,
,
1
rigin - Bangladesh.
00
Aquatech Engineering Services Limited
,0. Effluent transfer %um% for equali8ation
tank.

Ty%e - =ori8ontal' 1entrifugal' non 1log
$odel5 X=)S)
1a%acity - 0, m0 / =r.
=ead - 2. $&1
$otor5 0.4 L&' Folt5+,,' 0 E' ;, [.
OE$5 7'6,, OE$
Yuantity5 2 "ne#
Si8e5 Suc. 53, $$ !el.5 ;, $$.
$aterial of construction5 1(
Tem%erature - 3,
,
1
rigin - (ndia.
&ith base frame' cou%ling' bolts etc.
,+ Air blower for equali8ation tank. Ty%e - Twin lobe' rotary air
1ooled' =ori8ontal
$odel5Everest Transmission.
1a%acity - 22, m0 / =r.
!ischarge %ressure - +';,,$$&1
$otor5 0.4 L&' Folt5+,,' 0 E' ;,=8.
OE$5 2'+;, OE$
Yuantity5 2 "ne#
Si8e5 Suc. 5 2,, $$ !el.5 3, $$.
$aterial of construction5 1(
rigin - (ndia.
&ith base frame' F belt' Eressure gau8e'
filter' silencer and non5return valve etc.

,;
Air blower for biological reaction tank

Ty%e - Twin lobe' rotary air
1ooled' =ori8ontal
$odel5 Everest Transmission.
1a%acity - ++, m0 / =r.
!ischarge %ressure - .';,,$$&1
$otor5 2; L&' Folt5+,,' 0 E' ;,=8.
OE$5 2'+;, OE$
Yuantity5 2 "ne#
Si8e5 Suc. - 2,, $$ !el.5 3, $$.
$aterial of construction5 1(
rigin - (ndia.
&ith base frame' F belt' Eressure gau8e'
filter' silencer and non5return valve etc.
0+
Aquatech Engineering Services Limited
,.. *lash $ixture $echanism. Ty%e - Eitch blade turbine im%eller
Fertical.
$odel5 Aquatech5 *$5,0
1a%acity - =eavy duty' suitable for
*lash mixing tank.
$otor5 2.; L&' Folt5+,,' 0 E' ;,=8.
OE$5 2'+;, OE$
Yuantity5 2 "ne#
$aterial of construction5 1(
rigin - Bangladesh.
Mear box5 Aquatech
Oeduction ratio5 2;@ 2
,4. *locculation $ixture $echanism Ty%e - Eitch blade turbine im%eller
Fertical.
$odel5 Aquatech5 *$5,0
1a%acity - =eavy duty' suitable for
*lash mixing tank.
$otor5 2.; L&' Folt5+,,' 0 E' ;,=8.
OE$5 2'+;, OE$
Yuantity5 2 "ne#
$aterial of construction5 1(
rigin - Bangladesh.
Mear box5 Aquatech
Oeduction ratio5 2;@ 2
,3 Tube Settler $edia for tube Settler Z 2 $aterial of construction5 EF1 .
$odel - Aquatech5 TS$5,0
Ty%e 5 =exagonal
(nclination angle - .,
,
deg.
0;
Aquatech Engineering Services Limited
27 Sludge thickener mechanism.

Ty%e - Suitable of thickener tank
$odel5 Aquatech5 ST$5,0
Yuantity5 2 " ne #
$aterial of construction - $ild
Steel.
E%oxy %ainted.
$otor- 2.; L&' Folt5+,,' 0 E' ;,
=8
OE$5 2',,, OE$
Mear box5 reduction ratio. 5 4,@2
rigin5 Bangladesh.
20 Sludge 1entrifuge for cake making.

1a%acity - 2,, Lg / batch
Yuantity5 2 "ne#
$odel5 Aquatech5 =15,0
Ty%e5 =ydro extractor centrifuge
$aterial of construction - $ild
steel
Basket si8e5!ia53;, $$ W ;;,
$$
$otor5 4.; L&' F5+,,' 0 E' ;, =8.
SR. NO ESCRIPTION SPECIFICATION
,6 Tube Settler $edia for tube Settler Z 7
$aterial of construction5 EF1 .
$odel - Aquatech5 TS$5,0
Ty%e5 =exagonal
(nclination angle - .,
,
deg.
2,

Biological *AB $edia for biological
Oeaction tank Z 2 P 7.

Ty%e - 1orrugated
$odel5 Aquatech5*AB5,0
Yuantity - 7 " Two #
$aterials of construction -
Eoly%ro%ylene
Si8e5 7, $$ x 2. $$ height
rigin5 Bangladesh.
22 Aeration grids for biological reaction tank. Ty%e - Air diffuser
$odel5 Aquatech 5,0
Yuantity5 2 Lot
Si8e5 3, $$' +, $$.
$aterial of construction5 U > U
EF1
Tem%erature - 3,
,
1
rigin - Bangladesh.
0.
Aquatech Engineering Services Limited
OE$5 2+;, OE$
rigin - Bangladesh.
2+ *ilter feed sum% %um% Ty%e - =ori8ontal 1entrifugal
Eum%
$odel5 Submersible
1a%acity - 0, $
0
/ =r.
!ischarge %ressure5 2; $&1
=ead - 0; $&1
$otor5 0.4; L&' Folt5+,,' 0 E' ;,
[.
OE$5 76,, OE$
Yuantity5 2 " ne #
Si8e5 Suc. 5.; $$ !el.5 ;, $$.
$aterial of construction5
Body51(
Tem%erature - 3,
,
1
rigin - (ndia.
&ith base frame' cou%ling' bolts
etc.
2; Less contaminated water %um% Ty%e - =ori8ontal/1entrifugal
$odel5 Submersible/centrifugal
1a%acity - 0,$
0
/ =r.
!ischarge %ressure5 2; $&1
=ead - 0; $&1
$otor5 0.4; L&' Folt5+,,' 0 E' ;,
[.
OE$5 76,, OE$
Yuantity5 2 "ne#
Si8e5 Suc. 5.; $$ !el.5 ;, $$.
$aterial of construction5
Body51(
Tem%erature - 3,
,
1
rigin - (ndia.
&ith base frame' cou%ling' bolts
etc.
2. Thickener feed %um% for sludge sum%. Ty%e - =ori8ontal Screw %um%
$odel5 Al%ha =elical
1a%acity - . m
0
/hr.
!ischarge %ressure5 2; $&1
=ead - 2. $&1
$otor5 0.4; L&' Folt5+,,' 0 E' ;,
[.
OE$5 76,, OE$
Yuantity5 7 "Two#
Si8e5 Suc. 5.; $$ !el.5 ;, $$.
04
Aquatech Engineering Services Limited
$aterial of construction5
Body51(
Tem%erature - 3,
,
1
rigin - (ndia.
&ith base frame' cou%ling' bolts
etc
24 1entrifuge feed %um% of hydro extractor
*or sludge cake making

Ty%e - =ori8ontal' 1entrifugal'
Screw' non51log.
$odel5 Al%ha =elical
1a%acity - ;$
0
/=r.
!ischarge %ressure5 2; $&1
=ead - 2. $&1
$otor5 2.; L&' Folt5+,,' 0 E' ;,
[.
OE$5 2'+;, OE$
Yuantity5 2 "ne#
Si8e5 Suc. 53, $$ !el.5 ;, $$.
$aterial of construction5
Body51(
Tem%erature - 3,
,
1
rigin - (ndia.
&ith base frame' cou%ling' bolts
etc

26 Lime "1alcium hydroxide# Ere%aration tank
agitator mechanism.

Location of dosing - *lash mixing
Tank ca%acity - 2',,, liter.
Yuantity5 2" ne#
$aterial of construction5 EF1
Agitator mechanism5 2 " ne #
$otor5 ,.4; L&' F5+,,' 0 E' ;,
=8
OE$ - 2,,, OE$
rigin5 Bangladesh ? (ndia
7, *eS
+
"*errous Sul%hate # %re%aration tank
agitator mechanism.
Location of dosing - *lash mixing
Tank ca%acity - 2',,, liter.
Yuantity5 2"ne#
$aterial of construction5 EF1
Agitator mechanism5 2 "ne#
$otor5 ,.4; L&' F5+,,' 0 E' ;,
=8
OE$ - 2,,, OE$
rigin5 Bangladesh ? (ndia
03
Aquatech Engineering Services Limited
72 Eolyelectrolyte "EE52,, N %urity# tank
agitator.

Location of dosing - *locculation
mixing.
Tank ca%acity - 2',,, liter.
Yuantity5 2"ne#
$aterial of construction5 EF1
Agitator mechanism5 2 "ne#
$otor5 ,.4; L&' F5+,,' 0 E' ;,
=8
OE$ - 2,,, OE$
rigin5 Bangladesh ? (ndia.
B
77 =1L "=ydrochloric acid# dosing tank
agitator mechanism

Location of dosing - E= correction
mixing.
Tank ca%acity5 2,,, liter
Yuantity - 2 "ne#
$aterial of construction - EF1
70 )utrient ">rea P !AE# dosing tank agitator
mechanism.
Location of dosing - Biological
reaction tank.
Tank ca%acity - 2',,, liter.
Yuantity5 2"ne#
$aterial of construction5 EF1
Agitator mechanism5 2 " ne #
$otor5 ,.4; L&' F5+,,' 0 E' ;,
=8
OE$ - 2,,, OE$
rigin5 Bangladesh ? (ndia.
7+ Activated carbon and sand filter feed
Eum%.
Ty%e - =ori8ontal'
1entrifugal/Sub
$odel5 LSB/X=)S)
1a%acity - 0,m0 / =r.
!ischarge %ressure5 7; $&1
=ead - 2. $&1
$otor5 4.; L&' Folt5+,,' 0 E' ;,
[.
OE$5 2+;, OE$
Yuantity5 2 "ne#
Si8e5 Suc. 53, $$ !el.5 ;, $$.
$aterial of construction
Body51(
Tem%erature - 3,
,
1
rigin - (ndia.
&ith base frame' cou%ling' bolts
etc

06
Aquatech Engineering Services Limited
7; Eressure sand filter.

Yuantity5 2 "ne#
Ty%e5 !own flow.
$odel5 Aquatech sand filter.
!iameter5 2'.,, $$
=eight on straight5 2'3,, $$
!esign %ressure5 0.; kg/cm7
$aterial of construction - $ild
steel
Treated flow rate5 0, m0 / =r
!ee% of media5 6,, $$
$edia fill5 Sand media and Mravel
su%%ort.
!uty5 *iltration.
7. Activated carbon filter Yuantity5 2 "ne#
Ty%e5 !ownflow.
$odel5 Aquatech sand filter.
!iameter5 2'.,, $$
=eight on straight5 2'3,, $$
!esign %ressure5 0.; kg/cm7
$aterial of construction - $ild
steel
Treated flow rate5 0, $
0
/ =r
!ee% of media5 6,, $$
$edia fill5 Mranular Activated
carbon su%%ort.
!uty5 *iltration.
74 (nterconnection %i%ing Yuantity5 2 "ne# lot
Butterfly valve' Mate valve' Elbow'
Tee' *lange' Eressure gauge' Ball
valve' )on return valve etc.
::.:AE,*ctrica, Sc(p* (6 S3pp,y
SR. NO It*+2 U/it
,2 Mlands for cables 2 Lot
,7 $otor "As required for the equi%ment listed in mechanical
List# 1rom%ton / Lirloskar/ 1hina
2 Lot
,0 $ain !istribution Board with $11B' $1B' Ammeter'
Foltmeter with selector switch' (ndicator lam%' verload relay
with com%lete distribution board.
2 "ne#
,+ Eower cable from distribution board to different motor. 2 Lot
+,
Aquatech Engineering Services Limited
Local made
,; Eower cable from different motor to o%erating %anel board 2 Lot
,. Suitable cable tray made by $.S. angle P flat bar. 2 Lot
,4 Structural steel su%%ort for cable tray lying in the %lant. 2 Lot
+2
Aquatech Engineering Services Limited
:;. Li2t (6 App*/0i-*2
App*/0i-8I *2cripti(/ a/0 Op*rati(/ (6 Pr*223r* Sa/0 Fi,t*r & Acti4at*0 Car<(/ Fi,t*r
App*/0i-8II T*c)/ica, i/6(r+ati(/ a<(3t P3+p
App*/0i-8III T*c)/ica, i/6(r+ati(/ a<(3t Air C(+pr*22(r
App*/0i-8I' I/6(r+ati(/ a<(3t Pai/ti/.
App*/0i- 9:
T*c)/ica, 2p*ci6icati(/ (6 Pr*223r* Sa/0 Fi,t*r a/0 Acti4at*0 Car<(/ 6i,t*r.
Pr*223r* Sa/0 Fi,t*r
:. N( (6 3/it 1 O/* (:)
;. Typ* 1 Cy,i/0rica,
3. Capacity at /(r+a, 6,(> 1 30

M
3
/)r
A. SiE* (6 3/it ia+at*r 1 :G00++
H*i.)t 1 :K00++
B.Mat*ria, (6 C(/2tr3cti(/ 1 M.S
G. Pr*223r* c(/0iti(/ at Mi/i+3+ >(rFi/. 1 ; F./c+
;
+7
Aquatech Engineering Services Limited
Ma-i+3+ >(rFi/. 1 3.B F./c+
;
J. Pai/ti/. 0*tai,2? I/t*r/a, 1 Ep(-y
E-t*r/a, 1 At 6ir2t r*0 (-i0* a/0 t)*/ *p(-y
K. S3pp(rt 0*tai,2 1 M.S c(/2tr3cti(/ <3i,t i/ 6(3r ,*.2
pr(4i0*0.
N. Ma/)(,* 0*tai,2? N3+<*r 1 O/* (:)
Typ* 1 Circ3,ar
SiE* 1 AB0++
Mat*ria, 1 M.S
:0. Ha/0)(,* 0*tai,2? N3+<*r 1 O/*(:)
Typ* 1 Circ3,ar
SiE* 1 :B0++
Mat*ria, 1 M.S
::. S3pp(rti/. $*0 Typ* 1 &ra0*0 &ar4*,
Sp*ci6icati(/ 1 (:OP8 :P? :Q8 RP? RP 8 OP? OP 8 :/KP?
M*2))
$*0 *pt) 1N00++
:;. Pip*,i/* 0*tai,2? SiE* 1:00 N$
Mat*ria, 1M.S
MaF* 1 AD3at*c)
E/0 c(//*cti(/ 1F,a/.*0
:3. 'a,4* 0*tai,2 SiE* 1:00 N$
Typ* 1$3tt*r6,y
Acti4at*0 Car<(/ Fi,t*r
:. N( (6 3/it 1 O/* (:)
;. Typ* 1 Cy,i/0rica,
3. Capacity at /(r+a, 6,(> 1 30

M
3
/)r
A. SiE* (6 3/it ia+at*r 1 :G00++
H*i.)t 1 :K00++
B.Mat*ria, (6 C(/2tr3cti(/ 1 M.S
G. Pr*223r* c(/0iti(/ at Mi/i+3+ >(rFi/. 1 ; F./c+
;
Ma-i+3+ >(rFi/. 1 3.B F./c+
;
J. Pai/ti/. 0*tai,2? I/t*r/a, 1 Ep(-y
E-t*r/a, 1 At 6ir2t r*0 (-i0* a/0 t)*/ *p(-y
K. S3pp(rt 0*tai,2 1 M.S c(/2tr3cti(/ <3i,t i/ 6(3r ,*.2
+0
Aquatech Engineering Services Limited
pr(4i0*0.
N. Ma/)(,* 0*tai,2? N3+<*r 1 O/* (:)
Typ* 1 Circ3,ar
SiE* 1 AB0++
Mat*ria, 1 M.S
:0. Ha/0)(,* 0*tai,2? N3+<*r 1 O/*(:)
Typ* 1 Circ3,ar
SiE* 1 :B0++
Mat*ria, 1 M.S
::. S3pp(rti/. $*0 Typ* 1 &ra0*0 &ar4*, a/0 acti4at*0 car<(/
Sp*ci6icati(/ 1 (:OP8 :P? :Q8 RP? RP 8 OP? OP 8 :/KP?
M*2))
$*0 *pt) 1N00++
:;. Pip*,i/* 0*tai,2? SiE* 1:00 N$
Mat*ria, 1M.S
MaF* 1 AD3at*c)
E/0 c(//*cti(/ 1F,a/.*0
:3. 'a,4* 0*tai,2 SiE* 1:00 N$
Typ* 1$3tt*r6,y

Op*rati(/ (6 Pr*223r* Sa/0 Fi,t*r & Acti4at*0 Car<(/ Fi,t*r
The filtration section mainly com%rises of following equi%ment
1. Eressure Sand *ilter "ES*#
2. Activated 1arbon *ilter "A1*#
&ater from Tube Settler (( flows by gravity into the filter feed sum%. This is almost treated
effluent' which is then %assed through the %ressure sand filter "ES*# and then Activated 1arbon
*ilter "A1*#.
Op*rati(/1
The Elant is designed to %rovide trouble free service. Each of the above filter units needs to be
backwashed once in 7+ hour or whenever %ressure dro% across ES* and A1* reaches ,.4 kg /cm
7
g
whichever is earlier.
++
Aquatech Engineering Services Limited
The Eressure Sand *ilter P Activated 1arbon *ilters are backwashed in staggered fashion which is
described below.
$acF>a2) (6 PSF
The following ste%s to be followed
St*p8: Air 2c(3ri/. (6 PSF
1lose inlet valve F2 and outlet Falve "i.e inlet valve F2 of A1*#. %en the air scouring valve F.
P air vent valve F4. Switch on the blower and continue air scouring for about ; minutes. Air
scouring of ES* is done to ensure thorough backwash of the filter.
Falve %osition
BBBBBBBBBBBBB
%en F. 'F4
1lose F2'F0'F+'F;'F3'F6
St*p8; $acF>a2)i/. (6 PSF
%en backwash inlet valve F0 and backwash outlet valve F+ . 1ontinue backwash of the filter for
352, minutes. &ater during backwash flows in the u%ward direction thereby cleaning the filter off
dirt accumulated at the to% of the filter media . Backwash water comes out of backwash out let and
same shall be drained . *low rate for filter backwash shall be ., m
0
/hr .
Falve %osition
%en F0 'F+' F3
1lose F2' 'F;'F.'F4' F6
St*p83 Ri/2i/. (6 PSF
1lose backwash inlet P out let i.e. F0 P F+ and o%en service inlet valve F2 and rinse out let
valve F;. Oinse water comes out of backwash outlet and the same shall be drained. 1ontinue
rinsing for ; minutes. Oinse flow rate shall be same as service flow rate i.e. 0,m
0
/hr.
Falve %osition
%en F2 'F;
1lose F0' 'F+'F.'F4'F3'F6
$. $acF>a2) (6 ACF
St*p8: $acF>a2)i/. (6 ACF
1lose rinse outlet valve F; of ES*' service inlet and outlet valve F2 P F7 of A1*. %en
backwash inlet and outlet valve F0 P F+ of A1*. Backwash water flows in u%ward direction in
+;
Aquatech Engineering Services Limited
A1* thereby backwashing the media. 1ontinue backwashing for about 2,52; minutes . Backwash
water comes out from backwash outlet and the same shall be drained .*low rate for A1* backwash
0, m
0
/hr.
Falve %osition
%en A1* F0 'F+' F3
1lose A1* F2' 'F7'F;'F.'F4'F6
ES* All the valve of sand filter close
St*p8; Ri/2i/. (6 ACF.
)ow close the backwash inlet P outlet valve F0 P F+ of the A1* . %en service inlet valve F2 of
ES* and service inlet P outlet valve F2 P F7 of A1* rinse outlet valve F;. 1ontinue rinsing for
about 05; minutes. Oinse water comes out from backwash outlet and the same shall be drained.
*low rate for A1* rinsing 0,m
0
/hr.
Falve %osition
%en A1* F2 'F;' F3
ES* only F2' F3 "All the other valve of ES* closed #
1lose A1* F7'F0'F+ 'F.'F4'F6
St*p83 ACF i/ 2*r4ic* +(0*.
Falve %osition
%en A1* F2 ' F3' F7 all the other valves closed.
*or valve number refer interconnecting %i%ing diagram of ES* and A1*
+.
Aquatech Engineering Services Limited
App*/0i-8II T*c)/ica, i/6(r+ati(/ a<(3t P3+p
+4
Aquatech Engineering Services Limited
App*/0i-8III T*c)/ica, i/6(r+ati(/ a<(3t Air C(+pr*22(r
+3
Aquatech Engineering Services Limited
App*/0i-8I' I/6(r+ati(/ a<(3t Pai/ti/.
+6

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