Wastewater Management System

Wastewaters generated
Cosmos will be generating the following wastewaters (see tables-1 & 2 for
details):

1. Process effluent: 44.3 (say 50 ) m3/day

2. Domestic effluent: 11-15 m3/day
3. Non-process wastewater with quality closer to DM water: 60 m3/day
4. Non-process wastewater with quality closer to raw water: 57 m3/day
5. Non-process wastewater with high TDS: 9 m/day

Table-1: Process Wastewater

S.N Source of the Quantit Remarks
o. wastewater y
(m3/day)

1. Wash water from 9.6 Need proper treatment prior to disposal

external washing of
vials of B-lactum
2. Wash water from 4.8 Need proper treatment prior to disposal
external washing of
vials of Oncology
3. From tablet coating 3.3 Need proper treatment prior to disposal
through use of RO
water
4. From bin washing 3.2 Need proper treatment prior to disposal
through use of RO
water
5. From dry granulation 1.5 Need proper treatment prior to disposal
through use of RO
water
6. From quality control 1.0 Need proper treatment prior to disposal
through RO water use
7. From compression 0.6 Need proper treatment prior to disposal
through use of RO
water
8. From small utensil 0.5 Need proper treatment prior to disposal
washing through RO
water use
9. From solution 0.4 Need proper treatment prior to disposal
preparation through
RO water use
10. From cleaning in 0.8 Need proper treatment prior to disposal
 laundry through use of
RO water
11. From miscellaneous 1.7 Need proper treatment prior to disposal
sources through RO
water use
12. CIP of Lyophilizer with 7.5 Need proper treatment prior to disposal
RO water
13. From tablet coating 2.6 Need proper treatment prior to disposal
through use of RO
water
14. From loading through 1.6 Need proper treatment prior to disposal
use of RO water
15. From dry granulation 0.8 Need proper treatment prior to disposal
through use of RO
water
16. From quality control 1.0 Need proper treatment prior to disposal
through RO water use
17. From small utensil 0.5 Need proper treatment prior to disposal
washing through RO
water use
18. From miscellaneous 2.2 Need proper treatment prior to disposal
sources through RO
water use
19. From loading area 0.5 Need proper treatment prior to disposal
through use of pure
steam
20. From the SIP of 0.2 Need proper treatment prior to disposal
liophilizer by pure
steam
Total 44.3 Say 50 m3/day

Table-2: Non-process wastewaters and recyclable waters

S.No Wastewater/condensate stream Quantity
.
Recyclable as Recyclable Rejects
boiler as raw water
feedwater/softwa
ter
1. Multigrade filter backwash --- 14 ---
water
2. UF reject stream and UF --- 24.8 ---
backwash water (19.2+5.6)
3. Regeneration wastewater of --- 2.6 1.4
softwater plant
4. Boiler blowdown water --- --- ???
5. Cooling tower blowdown water --- --- ???
6. DM water plants regeneration --- 15.7 7.7
wastewaters (11+4.7) (5+2.2)
7. Reject streams of RO plants 18.5 (12.9+5.6) --- ---
8. Residual water of WFI plants ??? (..+..) --- ---
9. Residual water of pure steam ??? (..+..) --- ---
generators
10. Vial washing water 20.5 (12.8+7.7) --- ---
11. Water from BUNG processors 13.5 (9.0+4.5) --- ---
12. Autoclaving of seals, utensils, 2.2 --- ---
etc.
13. Vial washing with WFI in 2.3 --- ---
Oncology
14. CIP water of lyophilizer with WFI 3.0 --- ---
in Oncology
Total >60 57.1 >9.1

Non-process wastewater of quality closer to DM water will be generated at the

following locations:

1. Reject streams at the RO plants of both B-lactum and Oncology units (18.5
m3/day)
2. Washwater generated at Vial washing and BUNG processors in both B-lactum
and Oncology units (34 m3/day)
3. Water for injection used in the CIP of lyophilizers and in the vial washing of
Oncology (5.3 m3/day)
4. Steam condensate generated at the autoclaving of seals, utencils, etc., in B-
lactum unit (2.2 m3/day)
5. Residual water blown down from the water for injection and pure steam
generating units (quantity not known)

These waters are the least polluted and have very low or negligible TDS. These will
be collected separately and reused as makeup boiler feed water and also as
makeup water in the circulating cooling water systems and cooling towers. Return
steam condensate will be the main source for the boiler feed water. In case of
insufficiencies, soft water will be used in the circulating cooling water systems.

Non-process water with quality closer to raw water will be generated at the
following locations:

1. Backwash water of the multigrade filter (14 m3/day)

2. Reject stream of the ultrafilter (24.8 m3/day)
3. Backwash stage and rapid rinse stage wastewater from the regeneration of
the ion exchange resin beds of the soft water plant and of the DM water
plants (18.3 m3/day)
These wastewaters have slightly higher TSS levels and otherwise better than the
raw water in quality. These waters will be collected into a sump. From there, these
waters will be pumped, filtered through a multigrade filter and taken back into the
raw water tank for reuse as raw water.

Non-process wastewater with high TDS will be generated at the soft water plant and
at the DM water plants in the chemical run and rapid rinse stages of the ion
exchange resins regeneration. These wastewaters will be collected and reused in
place of domestic water in all the toilet flushes and urinals and ultimately allowed to
enter the domestic wastewater generated.

Of all the wastewaters generated, only two types of wastewaters, namely process
wastewaters (50 m3/day) and domestic wastewaters (11-15 m3/day) need
treatment in the effluent treatment plant to comply with the prescribed effluent
standards and proper disposal. Characteristics of the typical process wastewaters
are shown in table-3. Domestic wastewater has been considered to have the
characteristics shown in table-4 for the design purposes.

Characteristics of the process wastewater

S.No Parameter (units) Sample- Sample- Sample-3
. 1 2
1. COD (mg/L) 189 2978 235

2. BOD3 at 27C (mg/L) 22 975 64

3. Total –P (mg/L as P) <0.2 <0.2 0.46

4. TKN (mg/L as N) 8.74 2.94 2.76

5. Nitrate (mg/L as N) 0.37 4.8 2.77

6. Nitrite (mg/L as N) <0.5 <0.5 <0.5

7. Alkalinity (mg/L as 8 20 27
CaCO3)
8. Acidity (mg/L as CaCO3) 6 13 8

9. TDS (mg/L) 316 896 238

10. TSS (mg/L) 4 5 25

11. Sulfide (mg/L) <1.0 <1.0 1.1

12. Phenolic compounds 0.03 0.08 0.3

(mg/L)
13. Oil and grease (mg/L) 1.4 12.1 5.3
Table-4: Characteristics of the domestic wastewater considered in the STP design
S.No. Parameter Value
1. TSS (mg/L) 300
2. VSS (as % of TSS) 65
3. BOD5 at 20°C (mg/L) 250
4. COD (mg/L) 450
5. TKN (mg/L) <35
6. Total-P (mg/L) 1-7

Scheme of treatment for the wastewaters

The process wastewaters will be collected into a detoxification tank. In this tank the
wastewater will be dosed hypo for the detoxification and maintained for the desired
minimum contact time. The detoxified wastewater will be allowed to overflow into a
dechlornation sump, wherein the wastewater will be dechlorinated (through dosing
sodium metabisulfite). Dechlorinated wastewater will then be pumped and taken
into an up-flow anaerobic filter. Depending on the need, phosphoric acid, urea and
even the other micronutrients will also be dosed into the wastewater at this place
prior to the pumping.

Treated effluent of the anaerobic filter will be allowed to overflow into an Activated
Sludge Treatment unit (ASP). Both the aeration tank and the secondary clarifier of
this ASP will be integrated into a single unit. Diffused aeration system will be used
for the supply of the air required for both mixing and oxygenation. Treated effluent
of the ASP after clarification will be filtered through an upflow multigrade filter and
allowed to flow into a subsurface flow constructed wetland system under gravity.
Treated effluent of the constructed wetland system will be collected into a sump,
and, from the sump, as and when required, the treated effluent will be pumped and
used for irrigation of the green belt plantation, hedges and lawns. Excess of the
treated effluent, if any is left, specially during odd weather, will be allowed to drain
water along with the storm water.

Domestic wastewater of the plant will be collected into a small pit and from there
pumped into a 2-stage baffled anaerobic reactor. Treated effluent of this reactor will
be pumped and taken into the ASP of the effluent treatment plant for further
treatment and disposal along with the process wastewater.

Sludge accumulating in the upflow anaerobic filter and in the upflow anaerobic
filter, and excess sludge of the ASP will be drained into an aerobic sludge
stabilization and thickening pit. Diffused air will be used in the sludge pit for the
sludge stabilization. Clear wastewater overflowing the sludge pit from the
thickening process will be allowed to flow into the domestic wastewater pit for
pumping and treatment along with the domestic wastewater. The stabilized sludge
of the pit will be dredged out and disposed off through using as soil conditioner in
the green belt plantations.

The Effluent Treatment Plant

The effluent treatment plant has been designed for treating 50 m3/day of process
wastewater and 11-15 m3/day of domestic wastewater. The schematic process and
material flow diagram of the Effluent Treatment Plant (ETP) used is shown in
figure-1.

Hypoc

Process effluent Detox

The Effluent Treatment Plant proposed will include the following units:
1. Detoxification tank (with provisions for hypo dosing)
2. Dechlorination sump (with provision for dechlorinator dosing) and pumps
3. Upflow anaerobic filter
4. Domestic wastewater pit and pumps
5. 2-stage baffled anaerobic reactor
6.
7.
ASP (activated sludge treatment plant) with integral secondary clarifier
Multigrade filter Domestic Anae
Domestic effluent baf
8.
9.
Sub-surface flow constructed wetland system
Treated effluent sump and pumps
effluent pit rea
supernatant

Stabilized sludge Slud

 10.Sludge thickening and stabilization pit
11.Diffused aeration systems (3 numbers)

Dimensional and capacity details of the facilities of the

ETP
Detoxification tank
It is within the boundary limits of the process and industrial project consultant.
However the tank should have provisions for the overflow of detoxified wastewater
into a dechlorination sump. Further, at the outlet end of the detoxification tank, a
provision may be made for the monitoring of residual chlorine. Residual chlorine in
the overflowing water will be maintained at the desired level through the dosing of
hypo in the detoxification tank.

Dechlorination sump and pumps

This sump can be an integral part of the detoxification tank (as a second
compartment) receiving the overflows from the detoxification tank. Effluent holding
capacity of this sump can be 5 m3. Provisions may be made in this tank, for the
dosing of sodium metabisulfate and also the nutrients (urea, phosphate and other
nutrients if needed), for mixing the tank contents and for monitoring the residual
chlorine in the dechlorinated wastewater. A 10 m3/hour capacity pump (with one
standby pump provision) may be used for pumping the dechlorinated effluent into
the upflow anaerobic filter. Dosing of the sodium metabisulfite, monitoring of
residual chlorine and pumping of the dechlorinated wastewater may activated by
the liquid level in the sump.

Upflow anaerobic filter

This filter will be of 4 m x 4 m x 4.5 m liquid depth (0.3 m freeboard). It will have a
central vertical inlet pipe of 150 mm internal diameter delivering the wastewater at
the bottom below the packed medium. The packed medium will be supported over a
stainless steel metallic grid of 8 to 10 mm size openings. Thickness of the packed
medium will be 2.0 m, and below the packing, 2.0 m free space will be allowed for
facilitating storage of the sludge and for the maintenance of a sludge blanket.
Treated effluent will be siphoned off from 0.3 m below the liquid surface into the
ASP. Plastic medium of 20-30 mm size and density slightly higher than that of water
will be used. Bottom of the tank will be sloped towards center by 1 in 10/12. A drain
will be provided at the bottom in the center of the tank for facilitating occasional
draining out of the accumulated excess sludge.

Domestic wastewater pit and pumps

All the domestic wastewater generated will be allowed to flow under gravity into
this pit. This pit will have about 3 m3 capacity. A pump (and one standby pump) of
30 m3/hour capacity will used for pumping out the accumulated domestic
wastewater. As and when the wastewater pit gets filled with the domestic
wastewater, the pump will get activated and the wastewater will be pumped and
emptied into the 2-stage baffled anaerobic reactor.

2-stage baffled anaerobic reactor

The two stage baffled anaerobic reactor will have an effluent zone of 4.5 m depth
and a free board of 0.3m. Each of the stages will be a rectangular chamber of 2.0 m
length and 2.0m width. The incoming wastewater will be released at the bottom at
about 0.3m height in the stage-1 chamber and allowed to rise upwards. From the
top of the stage-1 chamber without disturbing the floating scum layer the
wastewater will be withdrawn subsurface at 0.3 depth from the liquid surface and
released at the bottom of the stage-2 chamber. From the top of the stage-2
chamber, the wastewater will be withdrawn subsurface at 0.3 m depth from the
liquid surface and discharged into the activated sludge process (ASP) unit. Please
see figure-2 for details. The piping used will be of 250 mm internal diameter. Both
the stages of the baffled anaerobic reactor will have a sloping bottom (1 in 10/12)
towards the center and at the center in the bottom drains will be provided for
draining out the accumulated excess sludge.

Cover slab
300
Inlet

Stage-1 of
Anaerobic
baffled reactor
ASP (activated sludge treatment plant) with integral secondary
clarifier
A tank of 4m x 4m x (4.3m + 0.5m) dimensions and 68 m 3 liquid holding capacity
4500
will be used as the ASP. A cylindrical tube of 2.5 m internal diameter and 2.5 m
liquid depth and 0.5 m free board open from both the sides and located in the

Stage-1 of
Anaerobic
center of the aeration tank will be used as the secondary clarifier. At the bottom of
the clarifier for deflecting the air bubbles while allowing sliding of the settled sludge
back into the aeration tank a circular plate of 3 m diameter will be used below the
cylindrical secondary clarifier at 1.5 m height from the bottom. Top face of this
circular plate will be made conical in order to ensure sliding of the settled sludge
into the aeration tank. On the top at the liquid level a clarified effluent trough
running along the diameter with overflow weir on both the sides will be provided.
This trough will carry the clarified effluent into the multigrade filter for filtration. For
facilitating aeration, a diffused aeration system will be provided in the aeration
tank. Provision will be made for draining out the excess activated sludge in the form
of mixed liquor into the sludge pit. Please see figure-3 for details. Secondary
clarifier in the ASP can be plastic sheet on angled steel frame.

Clarified secondary effluent will be collected from the secondary clarifier and
allowed to flow into the multigrade filter for the filtration.

Two stage multigrade filter

Effluent from the secondary clarifier will be passed through a two stage multigrade filter in order
to remove suspended solids and also reduce the coliform count. In both the stages the wastewater

750
will flow upwards through the filter bed. Each of the two stages will be (2 m x 1.5 m) rectangular
cells and have a hopper bottom (1 in 10/12 slope towards center). The filter will be covered by a
concrete slab with a manhole for facilitating occasional maintenance.

Both the stages of the multigrade filter will have a 1.2 m thick graded gravel layer, a bottom
sludge storage space of 1.5 m depth and a top filtered water storage reservoir (of 1.0 m depth).
Freeboard of these units will be 0.6 m. See figure-4 for details. Size of the gravel used will be
decreased from stage-1 to stage-2 and from bottom to top in the beds. Please see table-5 for the
profile of the graded gravel beds. The graded gravel bed will be supported on a metallic grid of
8-10 mm size openings provided at 1.5 m height from the bottom.

Table-5: Profile of the graded gravel used in the 2 stage multigrade filter
Stage-1 Stage-2
Layer Layer Size in
Size in
thickness thickness mm
mm
in mm in mm
200 20-40 200 20-40
150 16-8.0 150 16-8.0
100 3.5-7.0
850 3.5-7.0
750 1.5-3.0

Both the stages will be provided with drains at the bottom in the center for facilitating the filter
back washing and removal of the accumulated sludge. A central vertical inlet pipe (of 125 mm
internal diameter), capped at the top and connected to the outlet of the previous unit (previous
stage of the filter or the clarified effluent piping of the secondary clarifier) will be used to deliver
the influent wastewater below the graded gravel bed layer. Form the filtered water reservoir of
the first stage, water is extracted subsurface and loaded as influent into the central vertical inlet
pipe of the second stage. Form the second stage, the filtered water is allowed to overflow and
flow under gravity into the subsurface flow constructed wetland system. Please see figure-4 for
details. Inlets of both the stages of the multigrade filter will have regulatory valves for stopping
effluent flow during backwashing.

When head loss across the 2 stage multigrade filter increases to 0.7 m, wastewater inflow to the
filter will be closed and the sludge accumulated in the bottom hopper and in the graded gravel
bed will be removed through backwashing the bed and draining out the water into the domestic
wastewater pit.
 600

1000
Inlet
valve
Constructed wetland system (CWS) 1
Inlet 1200
The constructed wetland system will be of 200 m length, 2 m width and 0.4 m depth
plus 0.2 m freeboard. The system will have a brick retaining walls on sides. The
system will include a 4 m long non-vegetated inlet section, a 94 m long vegetated
middle section and a 2 m long non-vegetated outlet section.

The inlet section will have 0.4 thick layer of 13-25 mm size gravel. The treated
effluent inlet pipe will be submerged in the gravel layer and the treated effluent will
come out into the CWS through a perforated pipe.

C tp
ra
v
ic n
le 15
The vegetated section will have a bottom 150 mm thick layer of 13-25 mm size
gravel, a middle 150 mm thick layer of <13 mm size gravel and a top 100 mm thick
layer of sand (preferably coarse sand). Two rows of reeds (Phragmitis sp.) will be
planted at 1 m spacing in the middle gravel layer in this section.

The non-vegetated outlet section will be having 0.4 m thick layer of <13 mm size
gravel. A perforated pipe submerged in the gravel layer within the top 300 mm
depth will be used to collect and convey the treated effluent into the treated
effluent sump.

Please see figure-5 for details on the CWS.

Under-drain
system
Significant portion of the treated effluent will be lost through evapo-transpiration
and through percolation into the underground. Annually once harvesting removal of
the reed biomass may be needed. The harvested biomass has economic value and
can even be sold out.

Inlet pipe
Inlet section V
0.2 m
C
A B
A

Treated effluent sump Elevation

A tank of 2 m length, 2 m width and 2 m liquid depth will be used as the treated

4.0 m
effluent sump. Treated effluent from the CWS will be allowed to overflow into this
sump under gravity. A overflow drain will be provided for this sump for allowing
overflow of the excess treated effluent into the storm water drain of the industrial
unit. Depending on the need the treated effluent will be pumped and disposed off
within the industrial units premises through irrigation of the lawns, hedges and

Perforated pipe
ornamental plants and the green belt plantation. If any of the treated effluent is left
unutilized, specially during the rainy season, that will be allowed to overflow into
the storm water drain for disposal.
Sludge thickening and stabilization pit
Sludge drained out from the anaerobic filter and from the 2 stage baffled anaerobic reactor and
sludge wasted from the ASP will be collected into this sludge thickening and stabilization pit.
This pit will be of 6 m length, 2.5 m width and 3.0 m depth and a freeboard of 0.3 m. It will have
both vertical and inclined baffles for facilitating overflow of supernatant without disturbing the
settled sludge and the floating scum. The outlet will have a flow regulating valve. Please see
figure-6 for details. The clear supernatant separated will be allowed to return into the domestic
wastewater pit for further treatment and disposal along with the domestic wastewater. Sludge of
the pit will be allowed to get thicken and stabilize within. For facilitating the thickening process
diffused air will be supplied. Once in 6 months, sludge from the pit will be dredged out disposed
off through using as soil conditioner in the green belt plantation.

2.1 m

3.3 m

3m
Diffused aeration systems (3 numbers)
A single diffused aeration system will be used to supply air to both the ASP and the
sludge thickening and stabilization pit. This system will include three route blowers
(each of 50 Nm3/hour capacity and delivery pressure of 0.6 kg/cm2), two in
operation and one standby, 18 diffusers (each with about 5 Nm 3/hour air delivering
capacity) and necessary piping and fittings. The diffusers will be fixed at about 300
mm height from the bottom of the tank. ASP will have 8 fine bubble disc diffusers
(of silicon membrane) provided on a rectangular air main located at 0.5 m distance
from the sides at the bottom. The sludge thickening and stabilization pit will have
10 diffusers (coarse bubble non-porous orifice type) in two rows of 5 each at 1.0 m
spacing. No diffusers will be placed in the last 1.5 m length at the outlet end of the
pit.

Hydraulic design of the ETP

Maximum water level in the detoxification tank, ground level of the industrial unit at the location of CWS
(constructed wetland system) and invert level of the sewer conveying sewage to the ETP have been used
as reference levels in the hydraulic design. Maximum water level in the detoxification tank has been taken
as –X m below/from the ground level, invert level of the incoming sewer to the ETP as –Y m from the
ground level, and ground level at the CWS as 0.000 m were considered in the hydraulic design.

The Baffled anaerobic reactor, the upflow anaerobic filter, the ASP and the 2-stage multigrade filter all
will be accommodated in a single civil structure of the following dimensions:

• Width: 4 m (excluding the walls): in case of the 2-stage baffled anaerobic reactor and the 2-stage
multigrade filter the width includes includes the dividing wall thickness.
• Length: 11.5 m (excluding the walls)
• Depth: 4.8 m (in case of the 2-stage multi grade filter height can be reduced to 4.3 m from the
top)

Overflow of filtered water from the 2nd stage of the multigrade filter should be at least 0.5 m above the
ground level.

The dechlorination tank can be an integral part of the detoxification tank and liquid depth in it will be at
least 0.3 m below that of the detoxification tank.

The domestic wastewater pit can have 1.5 m liquid depth and its freeboard will be atleast 0.2 m greater
than the depth to the invert level of the sewer conveying domestic wastewater to the ETP.