Executive Summary 1. Introduction of the Project/...

Expansion of Common Effluent Treatment Plant (9 MLD) Bhiwadi, Dist. Alwar, Rajasthan

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Bhiwadi Jal Pradushan Niwaran Trust

Executive Summary

1. Introduction of the Project/ Background Information

The Common effluent treatment plant (CETP) which is operated by Bhiwadi Jal Pradushan

Niwaran Trust (BJPNT) was initially operated by RIICO Ltd. It worked as Effluent Disposal

System (EDS) and in the due course of time was modified to the present condition of CETP. This

CETP was installed to treat industrial effluent of RIICO Ind. Area Bhiwadi but presently this

CETP is treating industrial waste water along with domestic waste water of some villages located

in Industrial area as there is no separate conveyance system for these different types of waste

water.

The CETP which was assumed to receive a maximum of 09 MLD of waste water is now

receiving an average of 11 MLD. This quantum jump in the quantity is the result of rapid

industrialization and addition of domestic waste water. The total waste water discharged from

RIICO I/A. Bhiwadi is being treated and pumped to the final destination by CETP Bhiwadi

which is being operated by M/s. Bhiwadi Jal Pradushan Niwaran Trust (BJPNT) and the cost for

treatment is finally born by the Industrial units.

The CETP is located 0.16 km from Sohna Road and 0.35 km from Bhiwadi Bus Stand away

from the project site.

Identification of Project and Project proponent

Identification of Project

The up-gradation of 9 MLD to 11MLD CETP project falls under Category B schedule 7(h) as

per the EIA notification 14th Sep, 2006 and subsequent amendments in 1st December, 2009 & 4th

April, 2011.

Project proponent

Mr. Satinder Singh Chauhan, Chairman, Bhiwadi Jal Pradushan Niwaran Trust.

Brief description of nature of the Project

The CETP is proposed to treat 9 MLD industrial effluents. The company has got total 11,600 m2

of land. No forest land is involved.


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Greater Bhiwadi already boasts of big multinational companies, namely:- Pepsi, Honda Siel

Cars, Honda Motor cycle, Orient Craft, Jaquar, United Breweries, Ray Ban, Saint Gobain,

Federal Moghul, Gillette, Sakata Ink and Ocap Chasis. Other major industries in the city include

Relaxo Footwear, Lakhani Footwear etc. These companies have acquired huge acres of land in

Bhiwadi, made crores of investment and employed thousands of people. Bhiwadi serves as a

gateway to Rajasthan.

The greater bhiwadi complex is made up of seven industrial clusters known as Bhiwadi (Phase 1

to 4, Ghatal, Samtal and Rampur mundana) Kehrani, Chopanki, Pathredi, sarekhurd and

khuskhera, Tapukara. At these greater bhiwadi industrial complex, cluster wise and combination

of clusters total 5 CETP’S are proposed.

3.2 Location

Fig-1: Location of the Project site

Project Site

Bhiwadi


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3.3 Details of alternate sites

The up-gradation of existing 6 MLD to 9 MLD CETP taking place within the existing plant

boundary therefore no alternate site is selected.

Existing Process Description:

Effluents will be screened before being fed into the downstream treatment units. After primary

treatment the wastewater will be taken into the parallel SBR basins for biological degradation of

organics. The following treatment steps shall be used:

Treatment Steps:

1. Primary Units

Mechanical Fine bar screen

Grit removal

Free Oil Removal

Equalization tank

Pharshall flume

2. Biological Treatment

Sequential batch reactor

3. Sludge Handling and Dewatering

Primary Treatment Units

Screens

The effluents will be screened to remove floating particles, rags, leaves, bags and large

suspended particles using coarse 20 mm manual screens.

Grit removal mechanism


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Inorganic particles like sand and silt will be removed in Grit removal tanks. The Grit removal

tank is equipped with a raking mechanism to separate the settled particles. These fines will be

washed in an organic wash chamber and disposed off suitably using a conveyor belt system. 75 –

80% of all silt particles larger than 150 micron will be removed here, to ensure that they do not

accumulate in any of the downstream units, pipes and channels.

Free Oil Removal

Free oil removal shall be carried out in oil removal tank. The oil removal tank has been designed

for suitable detention time, thus allowing the free oil to float to the surface. The oil thus collected

shall be removed from the top using slotted pipe type oil removal mechanism and will be

disposed off. The clear water will under the baffle in to the outlet chamber from where it will

gravitate to downstream units.

Flow Measurement

The effluents will be then passed through Parshall Flume to measure the incoming flow to the

CETP.

Equalization

After flow measurement, the effluents will be then collected into equalization tank made up of

two compartments, each with holding capacity of 2 hrs and equipped with coarse bubble grid and

blower assembly. Here, the collected effluents will be mixed thoroughly to ensure uniform flow

and characteristics to the downstream units. The equalized effluents will be then pumped to

downstream Sludge Blanket Clarifier for primary clarification.

Primary Clarification in Sludge Blanket Clarifier

Equalized Effluents will be than pumped into Sludge Blanket Clarifier for removal of suspended

solids, which also reduces the organic loads associated to suspended impurities. The Sludge

Blanket Clarifier unit has an inbuilt flash mixer (draft tube) and flocculator and does not require

additional units. Inside a high re circulation rate of settled solids is maintained. This seeds the

incoming effluent and reduces the reaction time for floc formation. Further, as the concentration

of suspended solids is very high in the inner flocculator tube, any fluctuations in the feed quality

with respect to suspended solids does not deteriorate the performance of Sludge Blanket

Clarifier. This high re circulation rate of settled solids provide higher floc concentration for this

process to occur. Also, sludge is thickened to a high concentration as a result of which 3 – 4%


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consistency sludge is withdrawn from the Sludge Blanket Clarifier under flow. This prevents the

need of any further thickening unit and the sludge can be directly taken to the sludge dewatering

unit. The above process also allows the Sludge Blanket Clarifier to be more compact and

consume 10-15% lower chemicals as compared to conventional clarifiers/Clariflocculator.

Biological Treatment Units Comprising Cyclic Activated Sludge Process

Incoming flow to SBR basin is from the inlet work. Influent is routed to pre-reacted chamber of

SBR. Under normal conditions basin receive flow throughout the cycle. At the opposite end of

basin, effluent is removed through decanters discharging via an internal collector pipe. Aeration

is provided via fine bubble membrane diffusers on the floor of the SBR basin.

SBR basin is equipped with the following.

Decanter Actuator

Surplus activated sludge (SAS) pump

Air inlet valve

Ultrasonic level transmitter

High level float switch

Dissolved oxygen transmitter

Additionally the following common equipment is provided:

3 numbers of aeration blowers

SBR Cycles

The SBR cycle for SBR basin comprises a react phase, a settle phase and a decant phase. The

SBR basin operates in a phased sequence.

Cycle Fill and react

phase

Settle Phase Decant Phase Total

Normal flow

basin1

120 min 60 min 60 min 4.0 hrs

Normal flow

basin 2

120 min 60 min 60 min 4.0 hrs


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The primary treated effluents shall be taken into the two numbers of basins. The basins work in

sequence and influent flow is controlled using motorized sluice gates. The basins are complete

with air blowers, diffusers, grid piping, Return Activated Sludge (RAS) pumps; Surplus

activated sludge pumps (SAS), Stainless steel Decanters, Auto valves, PLC etc. All cycles will

be automatically controlled using PLC.

Common Acid Treatment Plant:-

There is an additional Common acid treatment plant exist at adjoining land of CETP,

Bhiwadi for the treatment of spent pickling acid generated from the prickling process of various

stainless steel patta-patti manufacturing units exists in RIICO Industrial area bhwadi. The capex

and opex for this plant is being contributed specially from the Bhiwadi patta-patti manufacturing

units located in Bhiwadi. The waste spent acid is being received at Common acid treatment plant

through a special dedicated tanker for its treatment. The capacity of common acid treatment plant

is 100 KLD. We have got CTE and CTO from the RPCB for 50 KLD. The BJPNT trust recently

applied for obtaining CTE and CTO for 100 KLD. The detail of treatment units is as under:

Particulars:

1. Waste spent acid collection tank

2. Waste acid dilution tank

3. Neutralization tank-1st stage

4. Neutralization tank 2nd stage

5. Chemical dosing tank

6. Sludge slurry collection sump

7. Sludge de-watering system

8. Sludge drying platform/storage yard

9. Control Panel room

10. Chemical store room


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FLOW DIAGRAM OF EXISTING SPENT ACID TREATMENT PLANT:-

Inlet through Tankers

Collection Tank (100 KL)

Dilution Tank (75 KL)

1st stage Neutralization Tank (10 KL)

2nd stage Neutralization Tank (10 KL)

Sludge Slurry Holding Tank (75 KL)

Filter Process (05 Nos.)(36”*36”)

Lime/Caustic

Solution

preparation

Tanks (03 nos.

each having 5

KL Capacity)

Sludge Drying Platform with Covering

Shed (Approx. 3000 sq. ft Area) for sun

drying of hazardous waste.

Filtered water goes to equalization tank

of existing CEPT for further treatment.


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3.6 Raw material

3.7 Resource optimization / Recycling and reuse

The modernization of the project will improve the wastewater quality to reclaim the desired

requirement for the textile industries. After modernization of the existing project the CETP

achieved zero liquid discharge.

3.8 Availability of water its source, Energy / Power requirement and source

CETP have to be equipped with Stand by DG set of suitable capacity as stand-by power for

operation of CETP.

DG Sets: 1000 kVA (500 x 500 kVA)

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their Management

/ disposal

Hazardous solid waste management for the hazardous solid waste generated during effluent

treatment at CETP is tabulated as under:

ETP Sludge – Approx. 25000 kg/day sent for land filling at RWMP site of Udaipur.

Used oil – 500 liters/year sent for incineration


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3.10 Schematic representations of the feasibility drawing which give information of EIA

purpose

4.8 MLD

1.2 MLD

MLD

7.2 MLD

7.2 MLD

6 MLD

6 MLD

6 MLD

6 MLD

6 MLD

6 MLD

Centrate of centrifuge back to equalization tank

200 TPD

150 TPD

TDS = 500 mg/L

Raw Effluent

Sump

Pre

sedimentation

SBR Basin

Clarifloculator

Flash Mixer

Equalization Tank

Ultra Filtration

Reactor Clarifier

Rapid Gravity Sand

Filter

Processed Water to

industries

72 tpd RO Reject to

Raw Effluent from industries

To salt storage Cell

Pure Salt sell to

industries

Reverse Osmosis 1.2 MLD

Sludge to TSDF

Thickener Centrifuge

6 MLD

6 MLD Existing

CETP

6 MLD Proposed ERP


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4.0 Site Analysis

4.1 Connectivity

The project site is well connected through State Highway NH-71B.The nearest bus station is

about 0.35 km (ESE) from the project site.

4.3 Soil Classification

Soils of the district Barmer are classified as follows:

1. Desert soil: Desert soil area is occupied by alluvium and windblown sand, yellowish brown,

sandy to sandy loam, loose, structure less, well drained with high permeability and lies in

northern, western and central part of the district.

2. Sand dunes: These are non-calcareous soil, sandy to loamy sand, loose, structure less and well

drained. It lies in northern, western and central part of the district.

3. Red desertic soil: These are pale brown to reddish brown soils, structure less, loose, and well

drained. Texture varies from sandy loam to sandy clay loam and lies in eastern and south eastern

part of the district.

4. Saline soil of depressions: This type of soil found in salt lakes. They are dark grey to pale

brown, heavy soils with water table very near to the surface and are distinctly saline.

5. Lithosols & Regosols of hills: This type of soil found in isolated hills as lithoslopes. These

soils are shallow with gravels very near to the surface, high textured, fairly drained, reddish

brown in color and lies in south eastern part of the district.

4.4 Climate data from secondary sources

The district Barmer experiences arid type of climate. Mean annual rainfall (1971-2005) of the

district is 281.8 mm whereas normal rainfall (1 901-1 971) is lower than average rainfall and

placed at 277.5 mm. Almost 90% of the total annual rainfall is received during the southwest

monsoon, which enters the district in the first week of July and withdraws in the mid of

September. As the district lies in the desert area, extreme of heat in summer and cold in winter is

the characteristic of the desert. Both day and night temperature increases gradually and reaches

their maximum values in May and June. The temperature varies from 48 degree in summer to 2

degree in winter. Atmosphere is generally dry except during the monsoon period. The humidity

is highest in August with mean daily relative humidity is 43%. The annual maximum potential

evapotranspiration in the district is 1850 mm and it is highest (260 mm) in the month of May and

lowest (77 mm) in the month of December.


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4.5 Social Infrastructure available

Socioeconomic environment will not be affected due to no influx of outside people as the

number of workers will be only 100 and local people will be selected for most of the posts. In

addition, large number of secondary job opportunities will be created due to installation of

CETP. Socioeconomic conditions of the local people will be improved. There will be

improvement in the infrastructural facilities. Aesthetic and hygienic environment will be created

which will be helpful in maintaining good public health with reduction in water borne diseases in

the surrounding environment.

Other benefits will be further growth in industrial development, and improvement in

occupational health & skills and improvement in sanitation. The analysis by matrix

representation indicates that the overall impact is beneficial.

5.0 Proposed Infrastructure

5.1 Industrial area (processing area)

Being an existing CETP, adequate infrastructural facilities are already

available. Modernization unit will make use of the existing facilities for land,

storage of raw material and handling, additional water & power demand, and

use of road and rail network for transportation of raw materials and finished

products.

5.2 Green Belt

Tree Plantation is one of the effective remedial measures of control the air

pollution and noise pollution. It is also causes aesthetic climatologically

improvement of the area as well as sustain and supports the biosphere. It is an

established fact that trees and vegetation act as a vast natural sink for the

gaseous as well as particulate air pollutants due to enormous surface area of

leaves. It is also helps to attenuate the ambient noise level.

In green belt area about 200 trees per acre of land is recommended to give a

thick green cover around the CETP (about total 600 plantation).

BJPNT is planning to develop green belt around the CETP premises.


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5.3 Connectivity

The project site is well connected through NH-71B. The nearest highway is NH-

NH-71B which is adjacent to the project site. The nearest railway station is

Rewari Railway Station, about 21.25 km (W) from the project site. The nearest

airport is IGI Airport, at 48.25 km (NNE) from the project site.

6.0 Rehabilitation and Resettlement (R & R) Plan

No, Rehabilitation and Resettlement (R & R) Plan required as the modernization

of project within the existing premises of plant area.

8.0 Project Schedule & Cost Estimates

Estimated project cost to carry out work for augmentation of existing CETP,

bhiwadi by installation of pre-primary treatment facilities suitable for 14 MLD

effluent and misc.

Modification work in the existing CETP is as under:-

A. Cost estimated for the proposed system

Pre-primary treatment facilities suitable for 14 MLD effluent is 550.00 Lacs.

B. Cost estimate for the MISC. Works (Modifications in existing

system)

1. Installation of process indicators, controllers and recorders for flow measurement is 180.00

Lacs

2. Augmentation of the existing CETP laboratory by construction is 30.00 Lacs

3. Process Optimization of Chemical treatment units is 40.00 Lacs

4. Capacity enhancement of existing aeration tanks by increase of height 1 mtr and installation

of advanced aeration system through non clog type is 250 Lacs

5. Augmentation of existing tertiary treatment units by replacement of graded sand media and

activated carbon media is 130.00 Lacs

6. Capacity enhancement of treated water disposal pumps to meet-out disposal capacity up to

14 MLD is 40.00 Lacs

7. Revival of existing Scrapper mechanism of clarifier is 60.00 Lacs


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8. Misc. Pipe Line, Electrical modification, replacement of motor pumps etc. Work is 90.00

Lacs

9. Civil maintenance work in the existing system is 80.00

So the total Project Cost is 1450.00 Lacs

Executive Summary 1. Introduction of the Project/...

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