A

REPORT
OF
NEW COMBINED
EFFLUENT AND SEWAGE TREATMENT PLANT
CAPACITY 150 M3/Day

INDEX

INTRODUCTION
WASTE WATER QUALITY & QUANTITY
REQUIREMENT OF COMBINED TREATED
EFFLUENT AND SEWAGE DISCHARGE
TREATMENT OF POLLUTION
SCHEME AND PROCESS DESCRIPTION
PROCESS UNITS

PROCESS UNITS DESCRIPTION

OTHER SPECIFICATIONS
MISCELLANEOUS INFORMATION

LIST OF CHARTS
SCHEMATIC FLOW DIAGRAM OF COMBINED EFFLUENT
AND SEWAGE TREATMENT PLANT

REPORT OF COMBINED EFFLUENT AND

SEWAGE TREATMENT
AREA
The total constructed area of the new facility is 6,000 Sq.meter
approximately. It is well connected by the roads from the main road.

The report covers the following: -

 The characterization of wastewater as per data supplied by the

factory.
The evolution of suitable scheme depending upon its efficacy and
efficiency.
Treatment Process
Units required the basic design criteria of the various treatment
process units/calculations.
Specifications
Miscellaneous Information

2. WASTEWATER QUANTITY & QUALITY

A) SEWAGE WATER
The present manpower of the factory is about 300 people.
SNO. DESCRIPTION No. of
persons

Water
Consumption

1.

45 lit / Person / 15,000 lit / day

Day

2.

Staff + contract 300

Labor
Canteen facility

Total
Water
Required

2,000 lit/day

Floating
Population/
visitors

50

45 lit / Person /
Day

2,250 lit/day

Total

19,250 lit/day

Sewage generated will be 90 % of water

requirement

17,325 lit / day

Considering future expansion, Sewage Treatment 20000 lit / day

Plant Design For

Note: As per the Manual on Sewerage and Sewage Treatment, the water
requirement of commercial places like factories etc is 45 lpcd

B) INDUSTRIAL WASTE WATER

The Effluent is generated from CIP process, Washing of various
equipments in process, Accessories cleaning, Floor washing, spillages etc.
The details are as follows.
Sr.
No.
1
2
3

Description

Water

Tot/ IBC 6 units

CIP
Accessories/floor

in LPM
600
300
400

Qty Duration

of Total

washing in mins.
90
60
90

Water

Qty. in liters.
54,000
18,000
36,000

Washing/

Total

1,08,000

Domestic waste water quantity as per above

calculation is

Total Wastewater for combined plant is

17,325
1,25,325

We have designed the plant on a 150 m3/day safe flow to treat it to an

extent that discharge from the factory will meet the standard norms set by
the competent authority.

3. CHARACTERSTICS OF RAW EFFLUENT & SEWAGE

Sr.

Parameter

Unit

Effluent

Sewage

No.

4.

I.

Design Flow

M3/day

II.

PH

III.

BOD

IV.

126

24

6 -6.5

6.5 - 8.0

Mg/l

145 -200

200 - 250

COD

Mg/l

600 - 700

400 -450

V.

TDS

Mg/l

450 - 500

900 -1000

VI.

TSS

Mg/l

100

150 -200

VII.

Oil & Grease

Mg/l

10 -15

10-15

REQUIREMENT OF TREATED SEWAGE DISCHARGE

Following parameters are required to be achieved before discharging
the sewerage onto land for Irrigation as per the GPCB norms
Sr.No
Parameter
.
Flow
I.
II.

pH

III.

Unit
M3/day

Value
150

6.5 -8.0

COD

mg/l

< 250

IV.

BOD3 @ 27 C

mg/l

< 30

V.

TSS

mg/l

VI.

TDS

mg/l

< 100
< 2100

VII.

Oil & Grease

mg/l

<5

5. TREATMENT OF POLLUTION
5.1 TREATMENT SCHEME
The ETP is of modular construction and the treatment process will consists

of five stages.
For SEWAGE WATER

Stage I : Primary Treatment

Screen Chamber cum Oil & Grease trap, Sewage Equalization Tank
For EFFLUENT

Stage I : Primary Treatment

Screen Chamber cum Oil & Grease trap, Effluent Equalization Tank

Stage II : Chemical Treatment

Chemical Dosing System, Flash Mixer Tank, Flocculation Tank, and
Primary Tube settler Tank

For COMBINED BIOLOGICAL TREATMENT

Stage III : Secondary or biological treatment (Aerobic)

Aeration Tank & Secondary Tube Settler Tank

Stage IV : Tertiary treatment

Filter feed tank, Hypo dosing system, Pressure Sand Filter &
Activated Carbon Filter

Stage V : Sludge Dewatering System

Sludge Drying Beds

5.2 PROCESS SCHEME

PRIMARY TREATMENT FOR SEWAGE WATER

Sewage generated from all section of factory will be first go through a

Screen Chamber cum Oil & Grease Trap for removal of floatable matter &
of floating oil before collecting the Sewage in to the Sewage Equalization
Tank. In this tank air is provided for mixing & equalized. From equalization
tank the Sewage will be pumped to Biological treatment i.e. Aeration Tank

PRIMARY TREATMENT FOR INDUSTRIAL EFFLUENT

Effluent generated from all section of factory will be first passing through a
Screen Chamber cum Oil & Grease Trap for removal of floatable matter
& floating oil before collecting the Effluent in to the Effluent Equalization
Tank. In this tank air is provided for mixing & equalized. From equalization
tank the effluent will be pumped to Chemical treatment.

CHEMICAL TREATMENT for INDUSTRIAL EFFLUENT

In chemical treatment, initially the effluent is pumped to Flash Mixer where

it comes into contact with caustic/ lime which helps in neutralization of the
effluent. From flash mixer it goes to Flocculation tank by gravity where it
comes into contact with alum and polyelectrolyte which helps in flocks
formation of suspended particles. After the flocculation chamber the effluent
goes to Primary tube settling tank where the settled particles are taken
out from the bottom in the form of sludge. The chemical sludge is sent to
sludge Drying Beds for dewatering. The overflow from primary settling tank
goes to Aeration Tank i.e. for biological treatment

SECONDAR BIOLOGICAL TREATMENT (AEROBIC TREATMENT)

Secondary Biological treatment consists of Aeration Tank followed by

Secondary Tube Settler Tank. The Aeration Tank oxidizes the organic
matter in to CO2 & H2O with the help of aeration principle. Aeration Tank is
provided number of air diffusers having suitable capacity to provide
necessary dissolved oxygen into the effluent. Twin-Lobe Blowers are
installed near the aeration tank for the supply of air. In Aeration Tank
MLSS is maintained at 2500 to 4000 mg / lit & Dissolved Oxygen is
maintained as 2 mg / lit. The biological system has to be operated
continuously around the clock hence the constant feed of effluent is
required.
Overflow of Aeration Tank goes to secondary tube settler tank respectively.
Secondary Tube Settler Tank are designed on low overflow rate, is
provided after Aeration Tank to enable separation of solids. A steep slope is
provided in the secondary tube settler tank to eliminate the need of
scrapper mechanism. A part of the sludge is re circulated to the Aeration
Tank in order to maintain MLSS levels and a part is drained to the Sludge
Drying Beds. .

SLUDGE TREATMENT

The Primary (Chemical) Sludge generated from the primary treatment &
The Excess Secondary (Biological) sludge from secondary Treatment will
be send to Sludge Drying Beds for sludge dewatering. The dried sludge
will be put in impervious HDPE bags and stored in factory premises. Filtrate
water will send back to effluent collection tank by gravity.

TERTIARY TREATMENT

The Clarified water collected from the collection launder of the Secondary
tube settler tank is then goes to the Filter Feed Tank. Hypo chloride
solution is dosed in the clarified water for the disinfection of the treated
water. Then the treated effluent will be passed through the Pressure Sand
Filter and Activated Carbon Filter with the help of pump, which polishes
the water before the final discharge. It basically removes any residual
suspended matter or any kind of smell / colour present in the water. Outlet
of ACF is treated water can be used for gardening / irrigation purposes.

6.0 PROCESS UNITS

PROCESS UNIT
Screen Chamber cum Oil &
Grease Trap

BRIEF PURPOSE
For removal Floatable matter & oil from
the effluent & Sewage Water

Equalization Tank

For ensuring continuous and uniform

quality feed to the ETP cum STP system.

Chemical Dosing System

For dosing of Chemical.

Flash Mixer

for Neutralization of effluents

Flocculator

For coagulation & Flocculation of the

Effluent

Primary Tube settler Tank

For settling of coagulated effluent particles

Aeration Tank

For reduction of organic load (BOD) by

aerobic process

Blowers & Diffused Aeration

System

For supplying air for mixing in the

Equalization, Aeration Tank &

Secondary Tube Settler Tank

For settling of biological solids

Filter feed tank

To store the treated effluent for further

polishing

Hypo Dosing System

For disinfection of treated water

Pressure sand Filter

For removing the fine biomass escaping

the tube settler

Activated carbon filter

For removing the color & trace organic

matter

Sludge Drying Bed

For dewatering of the sludge through Solar

Evaporation.

7. PROCESS EQUIPMENTS/UNITS DESCRIPTION

INFLUENT SEWAGE CONDITIONS

Ultimate average flow

: 150 m3/day or 7.5 m3/hr

Peak Factor

: 2

Ultimate Peak Flow, Qp

: 300 m3/day or 15 m3/hr

7.1 SEWAGE COLLECTION CUM PUMPING SUMP

No. of units

: one

Capacity,m3

: 18 (12 + 6)

Size, m x m x m

: 2.0 x 2.0 x 3.0 SWD

MOC

: RCC

7.2. BAR SCREEN/SCREEN CHAMBER

No. of units

: one

Screen Chamber m x m x m

: 1.0 x 2.0 x 0.5

MOC

: RCC/RBC

7.3 EFFLUENT COLLECTION CUM PUMPING SUMP

No. of units
Capacity, m3/day

: one
: 75

Size m x m x m

: 5.0 x 5.0 x 3.0

MOC

: RCC

7.4 BAR SCREEN/SCREEN CHAMBER

No. of units

: one

Screen Chamber m x m x m

: 1.0 x 2.0 x 0.5

MOC

: RCC/RBC

7.5 FLASH MIXER & FLOCCULATOR TANK

No. of units
: one
Screen Chamber m x m x m

: 1.5 x 1.5 x 1.5

MOC

: RCC/RBC

7.6 TUBE SETTLER

No. of units

: one

Type

: Tubedek media filled

Capacity,m3/hr

: 6.5

MOC

: RCC

7.7 AERATION TANK

No. of units
Capacity, m3/day

: one
: 100

Size m x m x m

: 6.0 x 4.0 x 4.0

MOC

: RCC

7.8 AIR DIFFUSION SYSTEM

Air requirement, M3/hr
Type of air system

: 225
: Blower/Twin lobe

Type of diffusers

: Tubular/non/clog

7.9 TUBE SETTLER

No. of units

: one

Type

: Tubedek media filled

Capacity,m3/hr

: 7.5

MOC

: RCC

7.10 FILTER FEED TANK

No. of units

: one

Capacity,m3

:9

Size m x m x m

: 2.0 x 1.5 x 3.0

MOC

: RCC

7.11 SLUDGE DRYING BEDS

No. of units

:6

Capacity,m2

:9

Size m x m x m

: 3.0 x 3.0 x 1 m

Media

: Assorted gravel and sand

MOC

: BM

7.12 PRESSER SAND FILTER

No. of units

: one

Capacity,m3/hr

: 7.5

Size, mm

: 1000 dia. x 2000

Working Pressure, kg/cm2

: 3.5

MOC

: MS internally coated

Media

: Silica sand with graded media

7.13 ACTIVATED CARBON FILTER

No. of units

: one

Capacity,m3/hr

: 7.5

Size, mm

: 1000 dia. x 2000

Working Pressure, kg/cm2

: 3.5

MOC

: MS internally coated

Media

: Activated carbon & graded media

8. OTHER SPECIFICATIONS

A.

UNITS
1.

Foundation for Pumps, Drains,

: RCC & Brick Masonry

Sludge Bed, Screen chamber, etc.

2.

B.

Collection Tank, Clear water tank

R.C.C.

R.C.C.

: 1:1.5:3 (cement: sand: aggregate) mix.

L.C.C.

: 1:4:8 (cement: sand :aggregate) mix.

Plaster

: 1:3 (cement: sand) mortar.

Brick Masonry

: 1:5 (cement: sand)mortar.

EQUIPMENT
1.

Electric Motors

Kirloskar/Siemens/NGEF/Crompton.

2.

Tube Settler :

3.

Pumps

4.

Pipes & Specials :

M.S. B-Class Welded connections.

5.

Valves

Cast Iron with brass spindles.

6.

Electricals

L & T/Siemens

7.

Cables

Aluminium-PVC Armoured

Blower

Everest/ Beta/ Kulkarni

Dosing pumps

Milton Roy/ SR metering/equivalent

10.

Diffusers

MM AQUA/Cooldeck
:

Kirloskar.

Rehu/Southern Cogen/ OTT

9. MISCELLANEOUS INFORMATION
PERIOD OF COMPLETION
A period of about 3 months will be required for execution of proposed
scheme.
AVALIBILITY OF LAND
The factory has sufficient land to accommodate the proposed treatment
scheme. The scheme has also considered of reuse of treated waste water
for irrigation in garden and trees within the factory. The factory has 0.6
acres land available under parks and trees.
TREE PLANTATION
It is proposed to plant rows of spreading crown varieties of evergreen trees
all along the boundary wall of the factory for which sufficient land is
available.
Provision has been made for landscaping with roadside tree plantation and
development of open space.
General development in respect of proper roads, lighting, storm drains will
also be provided for clean environment.
Recommended Trees Silver Oak, Neem , Eucalyptus, Badam, Vad

SCHEME FOR SOLID WASTE HANDLING

1. SOURCE OF WASTE GENERATION:

Solid Waste is generated in following forms in the colony:
i) Domestic Garbage: It consists of following:
a.

Kitchen Degradable Waste

b.

Waste Paper/ Cartons

c.

Waste Plastic

d.

Waste Metal

ii)Sewage Treatment Plant: Bio-Sludge from Sludge Drying

iii)Construction Malba- from various civil construction activities.
iv)Gardening- Dry leaves, Grass & Bush Cutting etc
2. SCHEME OF TREATMENT
a) KITCHEN AND GARDENING WASTE:
All bio-degradable waste along with Gardening waste would be composted
and converted to natural manure using vermiculture. LPDE Film Lined pits
would be made to dump above wastes and converted to manure. The
manure would be used for Horticulture within factory compound.
i.

Construction Malba would be used for landfill in low-lying areas of

factory

SOLID WASTE HANDLING

KITCHEN
BIO-DEGRADABLE
WASTE

GARDENING
WASTE

COMPOST BY
VERMICULTURE

STP SLUDGE

USED AS BIOFERTILIZER

PAPER BASED
WASTE

METAL WASTE

RESALE

PLASTIC WASTE

CONSTRUCTION
MALBA

LAND FILL