Post on 08-Sep-2021
ZERO LIQUID DISCHARGE (ZLD) PLANTPONDY API UNIT
2
ZLD FLOW DIAGRAM
PRE-TREATMENT
BIO-TREATMENT - I
STRIPPER
MULTIPLE EFFECT EVAPORATOR (2FFE &
3FCE) / PUSHAR CENTRIFUGE
RO - IBIO-TREATMENT - II
ATFD - 2 Nos.
RO - IIIRO - II
HIGH TDS PROCESS EFFLUENT
PERMEATE REUSE
LOW TDS EFFLUENT
PERMEATE REUSE
SLUDGE FOR DISPOSAL
REJECT
REJECT
REJECT
PERMEATE
CONDENSATE
SLUDGE FOR DISPOSAL
SLUDGE FOR DISPOSAL
SEWAGE TREATED EFFLUENT WATER
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ZLD - DESCRIPTION
Treatment Scheme for Effluent Treatment and Zero Liquid Discharge (ZLD)
Low Pollutant Stream (LPS):
Low Pollutant Stream is separately collected in the Equalisation tank and then subjected to Physico-chemical treatment for neutralisation and suspended solid separation. The Physico-chemical treatmentconsists of neutralisation, flash mixing, flocculation cum primary clarification and is sent to BiologicalTreatment Plant-II (BTP-II) and treated along with domestic waste water.
The BTP-II consists of two stage aeration (Primary & Secondary) treatment with Aeration tank-1 followedby Bio-Clarifier -1 and Aeration tank-2 followed by Bio-Clarifier -2. The bio-clarifier overflow water goesto tertiary clarifier and then to Filter feed tank. From Filter feed tank, it is fed to Pressure sand filter (PSF)and Activated Carbon Filter (ACF). ACF treated water is taken to RO Plant –II for further treatment.
4
ZLD - DESCRIPTION
High Pollutant Stream (HPS) :
High Pollutant Stream predominantly from process is separately collected in the Equalisation tank alongwith reject of Reverse Osmosis Plant III (RO III) and then subjected to Physico-chemical treatment forneutralisation and suspended solid separation. The Physico-chemical treatment consists ofneutralisation, flash mixing, flocculation and primary clarification.
The physico chemical treated water is taken to Stripper/ Multiple Effect Evaporator (MEE) plant forevaporation / concentration. The concentrate from MEE is further concentrated to a dry solid in AgitatedThin Film Dryer (ATFD). The evaporated condensate from MEE and ATFD are taken for further treatmentin Biological Treatment Plant –I (BTP-I). The concentrated chemical sludge from ATFD is disposed toauthorised co-processer for cement industry / authorised Secured Land Fill (SLF)site.
The BTP-I consists of two stage aeration (Primary & Secondary) treatment with Aeration tank-1 followedby Bio-Clarifier -1 and Aeration tank-2 followed by Bio-Clarifier -2. The bio-clarifier overflow water goesto Tertiary clarifier followed by Filter feed tank. From Filter feed tank, it is fed to Pressure Sand Filter(PSF) and Activated Carbon Filter (ACF). The filtered treated water is taken to RO Plant - I for furthertreatment.
5
ZLD - DESCRIPTION
Reverse Osmosis Plants (RO I, RO II & RO III):
The treated water from Biological treatment plant – BTP I & II are processed through RO-I & II respectively and the permeate water from the RO is recycled through non process / process applications.
The reject from the RO I & II are fed to RO III for further recovery of water. Permeate from RO III is used for non process application / recycled as feed to RO II. Reject from RO III is sent to Multiple Effect Evaporator (MEE) for further processing.
The permeate water from the RO meets the potable water specification on all physio chemical analysis.
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HPS – FLOW DIAGRAM
OIL SKIMMER
EQUALIZATION NEUTRALIZATIONPRIMARY CLARIFIER
HPS EFFLUENTTO MEE
FEED TANK
TO PRIMARY
SLUDGE TANK
HPS EFFLUENT PRE TREATMENT
7
MEE FLOW DIAGRAM
STRIPPER
PRE-HEATER FFE - I FFE - II FCE - I FCE - II FCE - IIIMEE FEED TANK
LP STEAM
HIGH COD CONDENSATE
THICKENER HYDROCYCLONE
PUSHAR CENTRIFUGE
ML TANK
VTFD - IIVTFD - I
HP STEAM
RECIRCULATION
SALT FOR DISPOSAL
CONDENSATE TANK
CONDENSATE
CONDENSATE
CONCENTRATE
TVR
RO III reject
HPS Primary treated Effluent
TO BTP - I
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HPS – FLOW DIAGRAM
CONDENSATE TANK
BIO -REACTOR - I
BIO -CLARIFIER - I
PRIMARY SLUDGE
TANK
FILTER FEED TANK
PSF
BIO -REACTOR - II
BIO -CLARIFIER - II
TERITARY CLARIFIER
ACF
BIO SLUDGE
TANK
BIO-SLUDGE THICKENER
SLUDGE FOR DISPOSAL
TO RO I FEED TANK
DECANTER CENTRIFUGE
DECANTER CENTRIFUGE
PRIMARY SLUDGE
THICKENER
SLUDGE FOR DISPOSAL
SLUDGE FROM HPS PRIMARY CLARIFIER
SLUDGE
SLUDGE
CONDENSATE FROM MEE / ATFD
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LPS – FLOW DIAGRAM
OIL SKIMMER
EQUALIZATION NEUTRALIZATIONPRIMARY CALRIFIER
BIO -REACTOR - I
BIO -CLARIFIER - I
FILTER FEED TANK
PSF
BIO -REACTOR - II
BIO -CLARIFIER - II
TERITARY CLARIFIER
ACF
LPS EFFLUENT
TO RO II FEED TANK
TO BIO SLUDGE TANK
TO PRIMARY SLUDGE TANK
STEW
SLUDGE
Non process Effluent
Domestic Effluent
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ZLD – MEE PLANT
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ZLD - BIOLOGICAL TREATMENT PLANT
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ZLD - RO PLANT
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