Project Proposal for 150 KLD sewage treatment plant for Ahalya eyeHospital Palakkad

MOLECULES ENVIRO CARE

First floor KKM Buildings, West of KSRTC, Near GDM Auditorium

Kayamkulam, Alappuzha dist. Phone 0479-2444005, 9447792843

Email: moleculesenvirocare@gmail.com info@moleculesenvirocare.com

Web: www.moleculesenvirocare.com

MEC/QT/STP/049/150KLD/10/12

Date:23/1/2013

To,

Ahalya eye hospital,

Palakkad

Sub: Quotation for Sewage Treatment Plant of 150 KLD Capacity for women and Mens hostel

Dear Sir,

On the basis of the telephonic discussion followed by your request we here by presenting our competitive quote for the design ,manufacture, erection and commission of a 150 KLD Sewage Treatment Plant at your mens and womens hostel at your Hospital site at Palakkad. All necessary information including the specifications of electromechanical equipments are given below for your kind reference. We hope that our quotation is very competitive and would be considered by you for immediate implementation.

Awaiting for your valuable confirmed work order at the earliest.

Thanking You,

Yours faithfully,

For MOLECULES ENVIRO CARE

SPECIAL ADVANTAGES

1. Highly energy efficient

This plant can work with less than 50% of electricity compare with the consumption of the conventional plant.

2. Highly User friendly as no operator required

The plant is worked on the principles of gravity flow, so that no plant operator is required for any transfer operation from one process to another.

3. Least space is required compare to conventional plant

As the design is very compact it occupies very less space compaired to the conventional plant . Being each tank is made on the basis of the volume required for a particular retention time the plant size will reduce without effecting the retension time.

4. Highly Eco friendly as no excess sludge formation or harmful by products

This plant is worked on the principle of Anaerobic followed by aerobic activated sludge process by using SAFF/MBBR technology producing the least sludge which is highly rich with bacteria and recycled to aeration tank.

5. Perfect in MCRT

Natural gravity flow with a constant velocity ensure perfect MCRT(Mean cell retention time) so that perfect Bio degradation is ensure.

6. Perfect MLSS concentration

Required MLSS(Mixed liquor suspended solid) is maintained by controlling the RAS (Return activated sludge) and WAS (waste activated sludge) flow so that optimum BOD and COD reduction are ensure

7. perfect F/M ratio(food to micro organism ratio)

Perfect Food to micro organism is maintained by providing the calculated DO(dissolved oxygen) level dosing of micro and macro nutrients to the reaction basin.

8. Least maintains

Least maintains is required as there is not much use of electrical, mechanical, electronic equipments

9. Least rescoring cost

Least rescoring cost as there is no consumables are use generally except for special cases.

10. Non stop working of plant

Plant work continuously round the clock without the presents of the plant operator ensure perfect purification of required quantity.

Project At A Glance

i) STP 150 KLD

1) This plant is designed to work on up-flow technology that is each tank volume is designed on the basics of retention time required to come up a layer of water from the bottom part of the tank to the over flow channel at the top away from the water fall into the bottom of the next tank for further process and operation.

2) The plant is designed in such a way that first the raw sewage pumped directly into the overhead tank. Whose bottom is 1M to 1.5M above from the top of the remaining tanks. So the water flows from overhead tank to the other tanks simply on gravity force. Without the consumption or use of electricity or other source of energy in any process operation.

3) Pump is required only for :i) Lifting the sewage water to over head tank.ii) For filtering the treated water from the pre filtration tank PSF & ASF.iii) For sludge recycling / removing from primary and secondary clarifier.

iv) Very less man power required just for supervising the whole process, because all pumping operation are automatic by use of float switch.

INTRODUCTION

Ahalya eye hospital is a well managed hospital having a number of branches in and around kerala,the hospital is vey much specialized in the treatment of eye and connected diseases, the main hospital and head office is kept near to the Kanjikuzhi industrial estate of Palakkad district in Kerala, here they have a big hospital complex with various section like eye hospital, ayurveda hospital, diabetic hospital, women and children hospital etc. this particular project is mean for the women and children hospital. Approximately 750 residence are there in the mens and womens hostel together. The aim of this project is to design, construction, erection and commissioning of a 150 KLD STP for the treatment of 150 kiloliters of the waste water generated from the various sections of the hostel and treated it in to that quality standard as set by the Kerala State Pollution control Board to put in to any water or land body as per the environmental protection act 1986 and the section 25 of the water (Prevention and control of pollution) act 1974.

WATER BUDJET

Description Quantity Average Consumption per unit

Total

Total number of inmates 750 200 150000

Total approximate qty per day

Spare capacity 10000

150000

10,000

Required plant capacity 1,60,000

kiloliter

Plant capacity of 150 KLD as per your request.

SCOPE OF THE PROJECT

Approximately 1.5 lakhs litters of waste water is expected to generate from the varioussections of the Women and mens Hostel of Ahalya eye hospital at Palakad district. Itinclude the sewage and sullage.10 thousand spare capacity have kept to meet with the requirement of peak hours also coinsured here. The aim of the project is to design construct, erect and commissioning 150 KLD STP plant to meet with the waste water treatment process to convert the generating waste into that quality standard as set by KSPCB to put into any land or water bodies as per the Environmental protection act 1986 and section 25 of the (Prevention and control of pollution) act 1974.

TECHNOLOGY

The proposed S T P is designed to function on Anaerobic followed by Aerobicactivated sludge process, a 3 stage operation say, primary, secondary and tertiarytreatment, a fundamental technology widely using all over the world incorporated with SAF technology (Submerged Anaerobic Fixed Film Reactor) The term, activated refers to a biological process for treating waste water. Here a particular type of micro organisms (bacteria) are cultured and maintains in the treatment basin which eat up the bio mass and converted into simple inorganic materials like CO2 and H2O in aerobic as

well as an-aerobic conditions in separate reactors. In order to increase the an-aerobic growth and there by reducing the maximum bio-load. We introduce bio-duck media in the an-aerobic reactor to increase the surface area of the substratum for attached growth. So that the BOD and COD reduction in this stage is maximum in order to conform the remaining BOD removal the water is again treated in aerobic reactor with continuous supply of oxygen through fine bubble diffuser membrane kept at the bottom

the reactor. The air is blowed into it by using a positive displacement twin lobed root air blower. Here the Bod and COD reduction become completely assured.

Organics + Bacteria --> CO2 + H2O + L.M.Organics + Bacteria

In Aerobic reactor calculated amount of air (o2) is supplied from the bottom of the reactor through fine bubble diffuser membrane by using a positive displacement twin root air blower which in cress the DO level(dissolved level )in the aerobic reactor which enable the aerobic bacteria to grow. In order to in cress the attached growth in the aerobic reactor it is advisable to introduced MBBR in aerobic reactor. The MLSS developed in the reactor are settled in the secondary clarifier and can be separated or recycled to aerobic reactor for dis intrigration. The sludge thus produced in the secondary clarifier is highly rich with active bacteria hence it is called Activated sludge process.

THE PROCESS INCORPORATE

Removal of bigger objects, debris and other particle by bar screen

Law density physical separation for the removal of Oil, Grease

High density physical separation by Grit chamber

Neutralization for PH correction

Gravity settling for solid liquid separation

An-aerobic operation incorporation with SAFF(Submerged An-aerobic Fixed Film Reactor) for BOD COD reduction.

Aerobic reaction with the calculated supply of Oxygen for BOD COD and turbidityreduction.

Coagulation/ Flocculation and solid liquid separation.

Filtration for turbidity reduction

Adsorption for degasification and discoloration.

Dis-infection by chlorination etc..

Controlling systems by using Electrical panel Control Board.

DESIGN BASIS

Parameter Unit Influent characteristic

Effluent characteristic

KSPCB Standard

PH - 4 to 13 7 to 8 5.5 to 9

TSS Mg/ Ltr 300 to 400

12. Pre-filtration collection

13. Pressure filtration

14. Chlorine dosage by using dosing pump

15. Carbon treatment

16. Final output collection and pumping to reuse

PROCESS DESCRIPTION

1- PRIMARY TREATMENT

1.1 Bar screen for Sewage

The primary use of this unit is to remove any kinds of debris, large objects and solid substance etc that may inter fear in the subsequent unit operations. We are using a Box type of screen made of MS frame with mesh of 3.5mm size which can be removed and clean periodical. The size of the screen is 1mX1.5mX1m

1.2 Grit chamber

The primary function of the grit chamber is to remove any soil grit or heavy materials which may come along with influent. Grit chamber is a two compartmental chamber with standing pit at bottom to accumulate the grit or soil which can be manually remove periodically. The size will be 1mX1.5mX1m

1.3 Oil and Grease Trap

Oil and grease trap is specially design 4 compartmental chamber with removable lid. The oil, grease, fat or any low density material which may come along with the influent and may interfere in subsequent process operation is to be removed in this stage. Being the material is low density float on the surface of the influent which can be trapped by using properly designed flap trap. The oil and grease accumulate on surface can be manually removed periodically. The size of the oil and grease trap is 2.5x1x1.

1.4 Sullage Collection

Sullage, the wash water from the bathrooms, wash basins, kitchen etc.of theestablishments are collected in a sullage collection tank of required dimension of RCCtank after passing through a scientifically designed Bar screen, grit chamber followed by oil and grease trap through proper and scientific way of plumping arrangement.2 to 3 H P self priming mono block pump is kept for the pumping of this sullage to the over head collection tank for further process operation by gravity flow.

1.5 Precipitation Tank/Neutralization

The water from the over head collection tank is arrange to flow by gravity into the bottom of the precipitation tank at a constant velocity by controlling the control valve. The sullage water may contain soap, detergents, higher fatty acid materials , salt and chemicals etc. The dosing of neutralization chemicals can be done at this stage, so as to required PH of 6.5-8.5. The agitation due to the diffused air enhance the reaction of neutralization uniformly.

1.6 PRIMARY CLARIFIER/SETTING TANK

Here the water after precipitation is transferred in to the bottom of a properly designed hopper bottom clarifier by gravity flow. A retention time of 4 hrs minimum is given here for the gravity settling the precipitated salts or other solid substances. The hopper bottom part of the clarifier help the effective settling of the solid through a small volume and sludge can be pumped in to sludge drying bed by using a sludge pump. The clear water without solid suspended particles or inorganic materials are over flow through over flow channels kept at the top portion of the clarifier with stoppers. which will pass on through channels into the next equalization chambers.

1.7 EQUALISATION TANK /PRE-AERATION TANK

Here effluent from the primary clarifier will come into the bottom part of the equalization chamber where coarse bubble diffuser membranes are systematicallyarranged in the bottom part of tank through proper piping arrangements and foundations. An air is blowed through the coarse bubble diffuser membrane by using Twin-Tri lobe root air blower and using proper valves arrangements. So that the effluent will be equalized the sewage from sewage collection tank can be added at this stage. The equalization will give a homo genius composition and equal Bio load at each and every part of the raw effluent.

II - SECONDARY TREATEMENT OPERATION (Biological process)

2.1 ANAEROBIC TANK

Here the water from the Equalization chamber flow into the bottom part of the an-aerobic rector by gravity. The anaerobic tank here is filled with high surface area bio-dek packing materials with honey comp structure and having a specific surface area of 157m2/m3 for the attached growth of bacteria in anaerobic condition. This ensure high

anaerobic microbial growth and anaerobic microbial biomass reduction from the initial organic load in effluent a retention time of 10.7 hrs for the effective reduction of bio load. A BOD reduction 60% TO 70% expected in this stage.

2.2 AERATION TANK

The effluent from anaerobic reactor is now transferred in to the bottom part of the aerobic reactor by overflow method. The aerobic reactor, where the fine bubble diffuser membranes are kept the bottom of the aeration tank as per suitable design and through proper piping and foundation arrangement. Here aerobic bacterial growth is become maximum in suspension condition due to the availability of the sufficient oxygen from the diffused air from the route air blower. Aerobic bacteria attain the highest growth rate and eaten up maximum bio-degradable sludge and thereby reducing organic load in the effluent water. A twin-tri lobe root air blower of 350m3 capacity and air pressure of 0.4 Kg is used to give sufficient supply of air. High quality diffuser membrane of cylindrical type ensures the uniform permeability and the circulation of the air with in the aeration rector. It produce a fine flow of air bubbles in each and every corner of the tank without giving a chance for anaerobic condition even in the corners. The non clogging nature of the specially designed diffuser ensures maximum oxygen transfer. Re-circulation of bio sludge (MLSS) from clarifier/settling tank to the aeration tank ensures very high reduction of organic load and reduction of BOD from 350mg/L too less than 5-10mg /l. (considering only 90%efficiency of the plant ) re-tension time of this aeration tank is not less than 8hrs.

2.3 FLASH MIXER

Treated water from the aeration basin is over flowed into the bottom part of the flash mixer were selected course bubble diffuser membrane are kept at uniform distance with proper distance and piping arrangements. A airflow of 8 m3/ hr is blown from the twin lobe root air blower to agitate and mix the treated water due to the agitation electro static charges on the solid suspended particles which may assist in coagulation/myscle formation in fourth coming stage of secondary clarifier operation. A dosage of poly electrolyte in this stage may increase the sedimentation/ flocculation more effectively and to achieve more clarity in the treated effluent.

III-TERTIARY TREATMENT

3.1 SECONDARY CLARIFIER/Tubular clarifer

Here the aerated water is then transferred in to the bottom part of properly designedhopper bottom secondary clarifier by over flow method and retention time of not less than 6 to 8 hrs minimum is given here. So that an activated bio sludge and pealed of bio-mass and any other solid particles are settled by gravity settling process. The hopper bottom part of the clarifier help the effective settling of the solid through a small volume and this activated sludge can be recycled in to the aeration tank. Tubular packing at an angle of 45 degree have kept at the top portion of the conical part for the siphoning of the clear water from the secondary clarifier to the pre-filtration tank. A sludge recycling pump is kept to recycle the sludge from the pit of the secondary clarifier to aeration tank which is highly rich with bacteria required for the bio degradation in aerobicreactor.

3.2 COLLECTION AND DISTRIBUTION

Product water from after disinfection and filtration can be collected in tank in suitablecapacity can be recycles for flushing of toilets or for gardening and agricultural purpose.

3.3 SLUDGE DEWATERING

The sludge may be generated in the bottom pits of the primary and secondary clarifier. The sludge from the primary clarifier mainly or precipitated fatty acid, Minerals and organic substance which may not be useful for subsequent unit operation can be pumped in to a sludge drying bed. Here beds of pebbles and sand is kept at the bottom part of the tank with suitable drain out. The solids suspended particle in the sludge will remain on the top of the bed and water may percolated through the bed and come out of the drain line and can be recycled into the collection tank for recycling. The sludge from the secondary clarifier is mainly due to excess bio-mass synthesized due to organic load in the waste water and may rich with disintegrating bacteria. This sludge may called as activated sludge can be recycled to the aeration tank for the further reaction or can be pumped in to gravity sludge dewatering beds or sludge drying bed as mentioned above.

3.4 PRE FILTRATION

The clear over flow from the secondary clarifier is collected in a pre filteration tank of suitable capacity it is an intermediate collection tank here the treated water is then added with 1-2PPM of chlorine/Sodium hypo chlorate for the disinfection purpose retention time of 6-7 hrs can be given here before pumping into the PSF and ACF for the filtration and adsorption.

3.5 PRESSURE FILTER

A pressure filter of suitable size is made of FRP wave cyber vessel filled with selected media of filtration in order to filter out the suspended particle of the treated water. Here pebbles/sylax of various mesh size are arranged in various layer so as to get the affective filtration. Particle upto the the size (750 mm dia and 1800mm height) of 100 micron is filtered in this stage. The vessel is having top and bottom opening with multi port valve for easy handling of filter, backwash and rinse operation.

3.6 ACTIVATED CARBON CHAMBER

A pressure filter of 750 mm dia and 1800mm height made of FRP wave cyber vessel filled with activated carbon of 900 iodine value and 8x32 mesh size which will absorb all dissolved gases colour pigments and other phrases of unwanted compounds The vessel is having top and bottom opening with multiport valve for easy handling of filter, backwash and rinse operation.

3.7 CHEMICAL DOSAGE Dosing of chemicals or chemical dosing in different stages of process operation.

1. The sullage is to be dozed with proper chemical like lime or HCL for the precipitation of the unwanted organic and inorganic component. If Acidity of sullage is higher which can be dosed with lime water and if the alkalinity is higher which can be dosed with HCL. The quantity is depend upon acidity and alkalinity level of the sullage The PH of the water can be set to 6.5 to 8.5 in this stage by addition of suitable acid/alkali depend up on the nature of sullage.

2. A dosage of 2 ppm of liquid chlorine should be given after the filteration to remove all micro organisms like bacteria in the product water from the plant.

3. Poly Eloctrolite dosing:

A calculated quantity of poly electrolyte is advisable in the flash tank for the miscle formation or flocculation. the poly electrolyte will flocculate the small suspended particle and may be settle down in the secondary clarifier by gravity settling operation.

PANEL BOARD

The entire plant is operated by using a properly designed electrical control panel board with pus h button switches, necessary meters, circuit breakers, contactors, connecters etc... for the efficient protection of the electrical equipment like blowers pumps etc... from fluctuation of voltages/current high-tech devises with buss bar and perfect panel wiring give efficient results in control operations.

SPECIFICATION OF ELECTRO MECHANICAL EQUIPMENTS

SL.No EQUIPMENT QUANTITY SPECIFICATION MAKE

1 Bar Screen 1 NosSize-1mX1.5mX1m, Frame size-40x40x8angles inside with -20x20x5MS flats

MOLECULES

2 Sewage Pump 2 Nos3 phase monoblock self priming pump,2 HP capacity10 to 24 m head and 336 Liter per minute for a head of 10m1.5 inlet outlet and 10.5 mm solid handling capacity.

CRI

3Sludgerecycling pump 1 Nos

3 phase monoblock self priming pump,1HP capacity15 m head ,13 m3/hr at 13 m head.

CRI

4 Twin Lobe Root Air Blower

2 NosAirCapacity: 350m3/hrs 0.4Kg pressure,7-10 HP motor rating

BETA

5 Filter feed pump

2 Nos3 phase monoblock self priming pump,1HP capacity15 m head ,13 m3/hr at 13 m head.

CRI

6Coarse bubble diffuser membrane

20- 30 Nos Disc type EPDM material Energy Equipment/ Equilent

7Fine bubble diffuser membrane

15-20 Nos Long type EPDM material Energy Equipment/ Equilent

8Bio-Dek packing media(SAFF)

A lotHoney Comb Structure made of PVC 0.3 mm thickness, size 600 x 1100 mm inclined tubular type.

MM AQUA

9 Electrical Panel Board

1 NosComponents/ parts used in the panel board is either of Siemens/ L&T make

MOLECULES

10 MBBR A lot Round type made of PVC with slots

MM AQUA or Equalent or equalent

11 Pressure sand filter

1 NosSuitable capacity, FRP wave cyber vessel 750 mm Dia, 1800 height with 60nb multi port valve

MOLECULES

11 Activated carbon filter

1 NosSuitable capacity, FRP wave cyber vessel 750 mm Dia, 1800 height with 60nb multi port valve. filled with activated carbon of 1100 loading value.

MOLECULES

12Chlorinator/ Dosing pumpNeutralization dosing pump

2 Nos 5 litters/Hr UKL,NUTON or equalent

13Flocculating agent dosing

2 Nos 5 Litters/ HrUKL,NUTON or equalent

Costing

1. The cost of Electro Mechanical equipments with above mentioned specification , its supply including SAFF and MBBR in Anaerobic and Aerobic reactors having all air line made of GI pipe and water line by PVC pipe with all fittings

Rs. 13,77,630

2. Designing (Including Detailed Drawing) supervision (periodical) and other miscellaneous charges Rs. 1,25,000

3. Erection including the pumping and electrical work( only plant) ,cabling ,painting, (colour coding of pipe line) Rs. 1,40,000

4. Testing and commissioning including the cost of consumable for the commissioning work

Rs. 50,000

TOTAL PROJECT COST EXCLUDING THE RCC WORK FOR 150 KLD STP INCLUSIVE OF

SAFF AND MBBR MEDIA

VAT AND SERVICE TAX WILL BE EXTRA ON ACTUAL BASIS

Rs. 16,92,630

TAXES

Service tax on compounding basic 4.8% of the contract amount

Educational sess 2 % of 4.8%

Higher educational sess 1% of 4.8 %

VAT on compounting basic

3% of the contract amount excluding the interstate purchase

13.5 % of the bill amount of the interstate purchase only.

YOUR SCOPE

1. All civil work including plant room or tress work or any other construction required for the successful commissioning of the plant will be your scope.

2. Raw sewage inlet through barscreen,grit chamber and oil and grease trap to a collection tank of suitable capacity near to the STP should be provided by the customer and necessary collection tank or pumping and distrubution for reuse are not included in our scope of supply.

3. Proper air vent for the treatment tank, if required should be provided by the customer

4. Electrical cabling and plumping up to the STP site (raw sewage and treated water) will be the scope of customer.

5. 3phase electrical connection of 25-30 HP(connected load) 415 V 75 Hz with single phase preventer & pure water line of 1 should be given up to STP site

6. Proper lighting arrangement and generator if required should be provided successful erection and commissioning of the plant

7. Material will be delivered at the sight and thorough inspection from our factory and proper store room facility should be given to keep the materials equipments and tools at the sight.iny case of any loading unloading dispute from the local people should tackled without affecting the work at the sight.

8. Customer should provide operator to operating the plant to whom we may give guidance and training.

9. Any other things, which is not mentioned in this proposal is customer scope.

OUR SCOPE

Our scope includes the designing, , Erecting and Commissioning of the plant successfully at your premises, and ensure the product water from the plant is meet with the quality standard set by Kerala state pollution control board to put in to any land or water bodies as per the Air (prevention and control of pollution) Act 1981 and water (prevention and control of pollution) act 1974. We also may do the needful documentation work on behalf of the customer to get the approval from KSPCB.

GUARENTY AND SERVICE

One year guarantee for any manufacturing defects and one year free service, after one year service for any period of time according to the convenient of the customer on AMC basis. We also provide option of plant operational service for any period of time according to the demand of the customer.

TERMS AND CONDITIONS

1. Advance: 60% advance along with techno commercial confirmed orderand 30 % at the time of reching the electro mechanical equipments at site and 10% after sucessful commesioning of the plant .

2. Installation: 30 to 45 days after complection of the RCC work upto our satifaction.

3. Validity: 60 days from the date of offer.

Fright

Fright will be done by you extra on actual basic.

Insurance

Transist insurance if required will be arranged by you other wase if want to arrange by as 3% of invoice value will be extra.

FORCE MAJEURE

The delivery indicate in the offer is some good faith and is subjected to force majeure. The company may not responsible for a nonperformance or delay due to war, invasion, government order, restrictions strikes civil disobedience lock out ,riots, fire, epidemics, sabotages ,floods, accidents, trade embargos, earthquakes, t-tsunami, break down of machinery ,delay or inability obtain the correct labor, raw materials, wagon, shipping space or any other reason what so ever beyond our natural control, effecting us or our principle suppliers

WARRANTY

The plant shall be warranted for the period of one year from the date of commissioning and during this period we will give free service for any manufacturing defect however, this does not include handling defects, negligence in operation, improper usage for changing operation condition.

JURISDICTION

All transactions are subjected to kayamkulam.

For MOLECULES ENVIRO CARE

(S.Padmasuran)

(CEO & Director)