At TDK Green Enviro Private Limited Village Tadkeshwar ... · Kim Char Rasta is rapidly growing...

TDK Green Enviro Private Limited

1

Pre Feasibility Report

For

20 MLD Common Effluent Treatment Plant (ZLD)

With Recycling of Treated Waste Water

For

Textile Processing Industries

At


Village Tadkeshwar, Taluka Mandvi

Dist Surat, Gujarat


2

Table of Content

Sr. No Description Page No.

1. Executive Summary 4

2. Introduction of the project/ Background Information 6

2.1 Project proponent 6

2.2 Description of the Project: 6

2.3 Need for the project 6

2.4 Demand‐Supply Gap. 6

2.5 Employment Generation due to the project. 7

3. Project Description 8

3.1 Type of project including 8

3.2 Location of the project 8

3.3 Criteria for Site Selection. 9

3.4 Size or magnitude of operation. 9

3.5 Project description with process details 10

3.6 Raw material requirement 21

3.7 Resource optimization 21

3.8 Availability and source of water, energy/power 21

3.9Schematic representations of the feasibility drawing which give

information of EIA purpose

22

4. Site Analysis 23

4.1 Connectivity 23

4.2 Land Form, Land use and Land ownership. 23

4.3 Topography 23

4.4 Existing Infrastructure 23

4.5 Soil Investigation 24

4.6 Climatic data from secondary sources 25

5. Planning Brief 25

5.1 Planning Concept 25

5.2 Amenities/Facilities. 25

6. Proposed Infrastructure 26


3

7. Project Schedule & Cost Estimates 27

7.1 Project Schedule 27

7.2 Estimated project cost 27

8. Analysis of proposal 28

8.1 Conclusion 28

Attachment

1. Process Flow Diagrams


4

1.0 Executive Summary

Kim and Karanj region in Surat district near NH 8 (Ahmadabad-Mumbai National highway),Kim Char Rasta is rapidly growing textile cluster mainly consisting of weaving industries,yarn preparatory, Water Jet Looms and Yarn Dyeing. As an extension of these clusteradjacent villages of Molvan, Chammuchal and Tadkeshwar are rapidly growing in terms ofIndustrialization. Many Textile Industries are willing to set up Yarn Dyeing, Dyeing andPrinting Units, and Denim Processing Units as raw materials for these units such as greycloth is available in this region. In Surat District along with polyester processing, Cottonprocessing is also gaining momentum. These potential textile processing industries need rawwater supply as well as a common facility for collection, treatment and recycling of wastewater generated from these units.

TDK Green Enviro Private Limited is proposing to set up common effluent treatment plant of20 MLD Capacity in this region which will receive waste water generated from these textileprocessing industries through underground drainage network. This waste water will beprovided primary, secondary and tertiary treatment so that treated waste water will besuitable for recycling back to textile processing industries for reuse in their industries.

There are already proposals for settling up of textile / industrial park in this region namely,Yes Green Infra Pvt Ltd and Tadkeshwar Infra Pvt Ltd. Both of them have already showntheir keen interest for becoming member of proposed CETP. In addition there are manysmall and medium scale yarn dyeing units in this region who are willing to become memberof CETP. In proposed Kim and Karanj region industries are not allowed to discharge onsurface water drain and they have to be on ZLD based. For small and medium scaleindustries installation and operation of ZLD system is a technically and economically nonviable proposition. The proposed CETP which will be based on ZLD system will help textileprocessing industries in this region to grow and sustain.

TDK Green Enviro Private Limited is a closely held public limited. The promoters of thecompany has experience to set up, operation and management of Textile Parks, TextileUnits and Common Effluent Treatment Plant successfully.

Proposed project is to be taken up at the site located at Block No 1163/1, 1163/2, 1163/3,1164, 1171, 1175/1, 1175/2, 1178, Village Tadkeshwar, Taluka Mandvi, Dist Surat, Gujarat.The site is situated at a Latitude: 21°21'48.06"N, Longitude: 73° 2'13.84"E.

The nearest significant human settlement from the site is located at distance of approx 2 kmfrom the site i.e. village Tadkeshwar in north-east direction. There are no ecologicallysensitive areas like national parks, sanctuaries within 10 km radius of the site.

The proposed project will have following major components Effluent Conveyance System (20 MLD Capacity) Common Effluent Treatment Plant (20 MLD Capacity)


5

UF+RO Plant for tertiary treatment (20 MLD Capacity) MEE Plant ( 2 MLD ) Recycle water pumping station and recycle water network

Water required for operation of CETP will be taken from the recycle water source only.Electric power will be sourced from GSEB. Hazardous waste generated from plant will besent to TSDF site for further disposal.

Estimated cost of proposed project is Rs 180 Cr and is estimated to be completed in 24Months time after receipt of Environmental clearance.

Proposed CETP in the region will have following advantages and benefits

1. Existing local small and medium scale industries in the region can become member ofCETP and give their waste water for treatment and recycling. Thus with the upcoming CETPin region compliance level of these industries will increase by many times.2. Recycle water from the CETP to its member industries will reduce the extraction ofground water or use of surface water by the industries and there will be water conservationin the region.3. There are upcoming textile parks in the region and proposed CETP will boost growth oftextile industries in the region which will provide great boost for the direct and indirectemployment in the region, development of ancillary industries in the region.

1.1 Regulatory Compliances & Applicable Laws/Regulations:

Following will be applicable laws and regulations1. The Water (Prevention and Control of Pollution) Act, 1974. (Amended 1988)2. The Water (Prevention and Control of Pollution) Rules, 1975.3. The Water (Prevention and Control of Pollution) Cess Act, 1977. (Amended 1991)4. The Water (Prevention and Control of Pollution) Cess Rules, 1978.5. Air (Prevention and Control of Pollution) Act, 1981. (Amended 1987)6. The Air (Prevention and Control of Pollution) Rules 1982-83.7. The Environmental (Protection) Rules 1986. (Amended 2002)8. The Environmental (Protection) Act, 1986.9. Hazardous Waste (Management, Handling and Transboundary Movement) Rules,

201611. Environmental (Protection) Rule Environmental Statement 1992-1993.12. Environmental (Protection) Rule Environmental Standard 1993.13. Environmental (Protection) Rule Environmental Clearance 1994.14. Environmental (Protection) Rules Environmental Standard 1996.15. The Factories Act, 1948.16. The Motor Vehicle Rules, 1989. Rules 115 (2)17. Noise Pollution (Regulation & Control) Rules 2000.


6

2. Introduction of the Project

2.1 Project proponent

TDK Green Enviro Private Limited site located at Block No 1163/1, 1163/2, 1163/3, 1164,1171, 1175/1, 1175/2, 1178, Village Tadkeshwar, Taluka Mandvi, Dist Surat, Gujarat. Projectproponent has experience in establishment and operation of textile and industrial park andCETP successfully in the region. In order to promote the development of textile processingindustries in the region and to support small and medium scale industries involved in yarndyeing in the region, project proponents have proposed common effluent treatment plantbased on ZLD and with recycling of treated waste water back to industries.

2.2 Description of the Project:

The proposed project is for installation of common effluent treatment plant (CETP) of 20MLD capacity based on Zero Liquid Discharge (ZLD). Treated waste water will be recycledback to industry for reuse as industrial waste water.

2.3 Need for the project

Need for the project is described as under

Kim and Karanj region in Surat district near NH 8 (Ahmadabad-Mumbai Nationalhighway), Kim Char Rasta is rapidly growing textile cluster mainly consisting ofweaving industries, yarn preparatory, Water Jet Looms and Yarn Dyeing. As anextension of these cluster adjacent villages of Molvan, Chammuchal and Tadkeshwarare rapidly growing in terms of Industrialization. Many Textile Industries are willingto set up Yarn Dyeing, Dyeing and Printing Units, and Denim Processing Units asraw materials for these units such as grey cloth is available in this region. In SuratDistrict along with polyester processing, Cotton processing is also gaining momentum.These potential textile processing industries need raw water supply as well as acommon facility for collection, treatment and recycling of waste water generatedfrom these units.

There are two to three textile parks are already approved in the region. For thedevelopment of these textile parks facility of Common Effluent Treatment Plant isneeded in the region.

2.4 Demand - Supply Gap.

Kim and Karanj area consist of many textile industries such as weaving, yarn preparatory, yarndyeing etc. In these area atleast two textile park which is proposed to consist of textileprocessing industries are aalready approved. A common effluent treatment plant (CETP) in thisarea is need of time for the sustainable development of existing industries as well as for furtherdevelopment of textile processing industries in this region. Since in this region disposal oftreated waste water is not allowed, CETP based on ZLD is must which will comply with thenorms and will also recycle treated waste water back to industry.

2.5 Employment Generation due to the project.


7

With the proposed CETP project there will be development of at least 15-20 textileprocessing industries in the region which will provide direct and indirect employmentgeneration in the region. It is estimated that proposed project will generate 75 directemployment at CETP level and about 3000 indirect employment. Additionally development oftextile processing industries in the region will result in development of small scale ancillaryindustries which will generate additional indirect employment.


8

3. Project Description:

3.1 Type of project :

The proposed project is 20 MD Capacity Common Effluent Treatment Plant based on ZLDwith recycling of treated waste water for textile processing industries.

3.2 Location of the project:

Proposed project is to be taken up at the Block No 1163/1, 1163/2, 1163/3, 1164, 1171,1175/1, 1175/2, 1178, Village Tadkeshwar, Taluka Mandvi, Dist Surat, Gujarat. The site issituated at a Latitude: 21°21'48.06"N, Longitude: 73° 2'13.84"E.


9

3.3 Criteria for Site Selection:

Kim and Karanj region in Surat district near NH 8 (Ahmadabad-Mumbai National highway),Kim Char Rasta is rapidly growing textile cluster mainly consisting of weaving industries,yarn preparatory, Water Jet Looms and Yarn Dyeing. As an extension of these clusteradjacent villages of Molvan, Chammuchal and Tadkeshwar are rapidly growing in terms ofIndustrialization. Many Textile Industries are willing to set up Yarn Dyeing, Dyeing andPrinting Units, and Denim Processing Units as raw materials for these units such as greycloth is available in this region. The proposed site is in vicinity to existing yarn dyeing unitsand proposed upcoming textile park in the region.

3.4 Size/Magnitude of operation

Summary of proposed expansion of existing CHWTSDF is tabulated as under

Sr No Project Component Total Capacity1 Common Effluent Treatment Plant (ZLD

Based)20 MLD


10

3.5 PROCESS DETAILS / PROJECT COMPONENTS:

The proposed CETP will have ultimate capacity of 20 MLD which will be developed in phasewise manner of 20 MLD capacity each phase. Development of CETP will be on modular basis.CETP will be designed for zero liquid discharge (ZLD). Entire treated waste water will berecycled back to member industries.

3.5.1 Effluent Quantity

CETP is designed for Effluent Quantity of 20 MLD

3.5.2 Effluent CharacteristicsEffluent characteristics considered for design at the inlet of CETP is tabulated in Table 1 asunder

Table 1: Effluent Characteristic at the inlet of CETP

Sr. No. Parameter Unit Values

1 pH pH Unit 5.5 to 9.0

2 COD mg/L 1800

3 BOD, 3 days 27 C mg/L 700

4 Oil and Grease mg/L 50

5 TDS mg/L 3000

6 Suspended Solids mg/L 300

Following considerations are taken while fixing the inlet design parameters for the CETP. The proposed member industries will be textile processing units, yarn dyeing unit,

weaving unit or allied textile units only and will not have any other chemicalsynthesis or pharmaceutical industries.

The inlet effluent parameters considered above in Table 1 is in line with the averageeffluent characteristics found in textile dyeing and printing or textile processingindustries.

All industries will be required to provide following facility at their discharge pointbefore connection to the drainage system of the CETP

o Oil and Grease Trapo Fixed type screen with Screen chambero Equalization Tank of Min 6 Hours Retention Timeo pH correction and Primary Settling Tank if Suspended Solids are more than

300 mg/l

o Pump for pumping effluent into conveyance system


11

o Outlet Flow Meter (Magnetic type or Open channel type) with recordersystem with temper proof provision.

No high TDS Effluent (i.e. more than 3000 mg/l) will be discharged into CETPdrainage line.

3.5.3 Treated Effluent Characteristics

Treated Effluent Characteristics from the Zero Liquid Discharge Plant (ZLD) which will berecycled back to industries is tabulated under in table 2

Table 2 Treated Effluent Characteristic from ZLD Plant (to be recycledback to industries)

Sr. No. Parameter Unit MPCB Norms

1 pH 7.00-8.50

2 Temperature °C Ambient at Discharge Point

3 BOD 3 days 27 C mg/L < 30

4 Turbidity mg/L NIL

5 COD mg/L < 250

6 Oil and Grease mg/L < 0.010

7 Dissolved Solids (Inorganic) mg/L < 750

8 Total Residual Chlorine mg/L < 0.02

9 Ammonical Nitrogen (as N) mg/L < 5

10 Arsenic (as As) mg/L < 0.2

11 Mercury (as Hg) mg/L < 0.01

12 Lead (as Pb) mg/L < 0.1

13 Cadmium (as Cd) mg/L < 1

14 Chromium Total (as Cr) mg/L < 2

15 Copper (as Cu) mg/L < 3

16 Zinc (as Zn) mg/L < 3

17 Selenium (as Se) mg/L < 0.05


12

18 Nickel (as Ni) mg/L < 3

19 Cyanide (as CN) mg/L < 0.2

20 Fluoride (as F) mg/L < 2

21 Sulphide (as S) mg/L < 2.8

22 Phenolic Compound (as C6H5OH) mg/L < 1.0

23 Hexavalent Chromium (as Cr+6) mg/L < 0.1

24 Pesticides mg/L Absent

25 Boron (as B) mg/L < 2

26 Chloride mg/L < 250

27 Sulphate (as SO4) mg/L < 250

3.5.3 Mode of Disposal

There shall not be discharge from the CETP. Entire treated waste water will be recycled backto member industries

3.5.4 Treatment Scheme

Screening through Coarse Screen

Collection and Transfer to Equalization Tank

Oil and Grease Removal System

Fine Screening

Equalization provided with Air Mixing

Treatment with Lime solution to raise pH to 8.5 in Flash Mixer 1

Treatment with Ferrous Sulfate / alum solution to bring down pH to 7 in Flash Mixer

2

Flocculation using Polyelectrolyte in flocculator

Gravity settling in Primary Clarifier

Biological Treatment Using SBR (Cyclic Activated Sludge Process)

Disc Media Filter

Treatment to achieve Zero Liquid Discharge (ZLD)

o UF Plant (As pretreatment)


13

o RO Plant ( 3 stages) to achieve to 90 to 92% Recovery

o RO Reject treatment through Pellet Reactor / MVR / Multiple Effect

Evaporator

o Recycle of recovered water.

o Recovered salt to dispose to TSDF site

Sludge dewatering (Primary and Biological sludge, segregated) through Mechanical

Sludge Dewatering system.

3.5.5 Process Description

Receipt, Screening and Equalization

Effluent will be received at CETP through underground effluent conveyance system. Effluentwill be first pass through Coarse Screen for removal of large particles and debris presence ineffluent. Coarse screen is installed in Coarse Screen Chamber. Coarse screen will restrictparticles of 20 mm and above size. Coarse screen will be L-type screen and such twoscreens will be provided in series. In order to remove debris or particles collected on coarsescreen, it is periodically taken out from screen chamber using EOT hoist. From Coarsescreen chamber effluent is passed through grit chamber, in which grit will settle at thebottom of the grit chamber and through grit removal mechanism it will be removed from thebottom of the chamber.

From Grit Chamber effluent is collected in underground Receiving Sump. From EffluentReceiving sump waste water is pumped using Effluent Feed Pump to the pre settler cum oiland grease removal system. From here effluent will enter into Fine Screen. Operation ofEffluent Feed Pump will be automatic using level switch installed in Receiving Sump.

Fine screen is installed in fine screen chamber. Mechanical type fine screen is provided torestrict particles up to 10 mm size. As a standby to mechanical type fine screen, fixed typefine screen is also provided. Particles collected on fine screen is transferred mechanically onbelt conveyor for collection.

Effluent from fine screen is then collected in Equalization Tank. For successful plantoperation it is very essential to have uniform quality and quantity of effluent available tofeed for treatment. Equalization tank is provided to take care of variation in effluent qualityand quantity. Equalization tank is provided with 8 hours hydraulic retention time.Equalization tank is provided with coarse bubble air diffusers for complete mixing of wastewater using air from Air. Complete mixing will also help to avoid settlement of suspendedparticles in Equalization tank bottom which in long turn reduces tank operating conditionand develop septic condition at the bottom of equalization tank. Equalization tank isprovided with level indicator and transmitter for measurement of level and volume ofeffluent in the tank. Equalization tank is also provided with pH meter for indication andrecording.

Physico Chemical Treatment and Primary Clarification

Equalized effluent from Equalization Tank is transferred to Physico Chemical TreatmentSection of the CETP using effluent feed pump. Effluent feed pump discharge line is provided


14

Magnetic Type Flow Meter with Recorder for control, monitoring as well as recording ofeffluent treated in the plant. Physico Chemical Treatment Plant will consists of treatment ofwaste water using chemicals and flocculants mainly to precipitate, flocculate and coagulatepart of waste water components and to remove this mass by using gravity settling inprimary clarifiers. During physico chemical treatment suspended solids, precipitated dyesmolecules and soluble oil particles are removed which reduces load on biological treatment.Effluent from Effluent Feed Pump is first taken to two series of Flash Mixers 1 & 2 for thereaction of Effluent with lime slurry and then ferrous sulfate or Alum solution. The pH ofeffluent is raised in the range of 8.5 to 9.5 using lime slurry in Flash Mixer 1. Effluent fromFlash Mixer 1 is then taken to Flash Mixer 2 where Ferrous Sulfate is added to carry outflocculation and coagulation of suspended and precipitated particles. Dosing of lime solutionand ferrous sulfate solution is automatically controlled through on line pH meter andcontroller system provided for flash mixer 1 and flash mixer 2. From Flash Mixer 2 effluent istaken to Flocculation zone of Clariflocculator where suitable polyelectrolyte shall be addedto increase settling rate of flocculated and coagulated mass. Two flash mixer is seriesfollowed by flocculator will ensure complete reaction of lime slurry and ferrous sulfate / alumsolution with effluent to achieve desired result before effluent enters into Clarification zoneof Primary Clariflocculator. Here, separation of precipitated solids from the waste water bysettling under gravity. Clear overflow from primary clariflocculator is conveyed to Aerationtank for biological treatment. Settled sludge at the bottom of the clariflocculator istransferred to Primary Sludge Sump.

Cyclic Activated Sludge Process / SBR provides highest treatment efficiency possible in asingle step biological process. The System is operated in a batch reactor mode. Thiseliminates all the inefficiencies of the continuous processes. A batch reactor is a perfectreactor, which ensures 100% treatment. Four modules are provided to ensure continuoustreatment. The complete process takes place in a single reactor, within which all biologicaltreatment steps take place sequentially. No additional settling unit, Secondary Clarifier isrequired. The complete biological operation is divided into cycles. Each cycle is of 3 – 5 hrsduration, during which all treatment steps take place.

Explanation of Cyclic Operation:

A basic cycle comprises:

Fill – Aeration (F/A) Settling (S) Decanting (D)

These phases in a sequence constitute a cycle, which is then repeated.

A Typical Cycle


15

During the period of a cycle, the liquid is filled in the Aeration basin up to a set operatingwater level. Aeration Blowers are started for aeration of the effluent. After the aeration cycle,the biomass settles under perfect settling conditions. Once settled the supernatant isremoved from the top using a overflow decanting system (Decanter). Solids are wastedfrom the tanks during the decanting phase. These phases in a sequence constitute a cycle,

which is then repeated.


16

Treated waste water from SBR process is taken to tertiary treatment plant for furthertreatment.

Tertiary TreatmentClear wastewater after biological treatment shall be subjected to tertiary treatment. Thetertiary treatment consists of Disc Media filter. Effluent from biological treatment shall iscollected in intermittent storage tank. From here effluent is further subjected to treatmentthrough disc media filter which removes suspended solids so that final treated waste watermeets the feed norms for UF+RO plant. Back wash from Disc Filter is taken back to wastewater Receiving sump for further treatment. Treated effluent from disc media filter iscollected in Holding tank. Treated effluent from here is fed to ZLD plant consisting ofUF+RO+Evaporation (MVR+MEE) system. Separate Magnetic type flow meter is provided atthe outlet of feed pump to RO system for recording and monitoring of treated waste waterdischarged to ZLD plant.

Sludge Dewatering SystemSludge slurry from bottom of clariflocculator is collected in primary sludge sump andexcess bio mass from secondary clarifier is collected in bio sludge sump. From both thesludge sump, sludge slurry is pumped through screw / gravity thickener for thickening of thesludge slurry. Thickned sludge is collected in thickened sludge tank. From here thicknedsludge is fed to mechanical sludge dewatering system (Filter Press / Belt Press) using screwpumps. Here sludge shall be filtered and collected in form of wet cake. Filtrate generatedfrom filter press shall be taken back at the inlet of primary clarifier. Cake from sludgedewatering system is stored in sludge storage area for disposal to TSDF site.

ZLD PlantZero Liquid Discharge Plant consist of Ultrafiltration (UF) and Reverse Osmosis Plantfollowed by Thermal evaporation System (MVR+MEE).

Tertiary treated effluent is fed to first Ultrafiltration (UF) Plant as pretreatment to ReverseOsmosis (RO) Package Plant. UF Plant removes turbidity and any left out colloidal mattersbefore effluent is fed to RO plant for desalination. UF Plant reject is fed back to equalizationtank for further treatment.

RO packaged unit is designed to handle 20 MLD treated waste water. RO Packaged systemis designed based on modular basis. The number of modules will be decided during detailedengineering with selected vendor. RO Packaged plant consists of 2/3 stage RO system(depending on final design by vendor) to achieve Min 90% recovery of water and overall saltrejection at Min 90%. RO package system consist of RO pretreatment unit. RO pretreatmentunit consists of Chemical Dosing such as Acid Dosing, SMBS Dosing and Antiscalent Dosingfor controlling the various types of fouling in the membranes. In addition to chemical dosingRO treatment will consist of micron filters (Bag type of disposable type) to maintainacceptable turbidity level for the RO membranes. After pretreatment section, waste water ispumped at high pressure (as per the TDS level of the effluent) to RO membrane modules.Reject from RO system is stored in RO reject storage tank. From this tank RO reject is fed toThermal Evaporation System consisting of MVR and MEE. The expected salt level in the feedof thermal evaporation system is 3 to 3.5% w/w.

Thermal System consist of MVR (Mechanical Vapor Recompression) system. Hereevaporation process is conducted under vacuum at temperature of approx 60 deg C.


17

Evaporated water vapor is recompressed using compressor to raise temperature of vapor atapprox 70 deg C. This vapor is again fed as heating medium to system for evaporation ofwaste water at about 60 deg C. Heat transfer surface can be of plastic media / metallicmedia depending of final engineering of the system. Concentrated mass from MVR issubjected to crystallization for precipitation of salts. Sometime along with MVR, MEE is alsoprovided for final concentration of liquid up to 35% salt concentration.

Such MEE can be 3 or 5 effect MEE depending on final engineering of the process.Concentrated mass from the final stage is taken out and fed to in built / separatecrystallizer for cooling and crystallization of precipitated salts. Crystallized mass is fed toPusher type centrifuge for separation of salts from the mother liquor. Mother liquor isrecycled back to MEE system for evaporation. Salts are collected and sent to hazardouswaste storage area for disposal to TSDF site.

Condensate collected in condensate storage tank is recyclable water. However, there maybe chance of carryover of color along with condensate. In order to take care of suchincidence polishing filter consisting of activated carbon filter is provided. After polishingtreatment, condensate is transferred to Disposal tank. From Disposal tank water is availablefor recycling to industries.

Utilities

Following utilities is required for the operation of CETP.

Boiler

Saturated steam is required for the evaporation of effluent in MEE system. For generation ofsaturated steam coal fired boiler of 20 Tons/hr capacity for of 8 kg/cm2 g rating is provided


18

in the plant. Coal Fired Boiler system will be fluidized bed type / fixed bed type. The boilersystem will consist of Boiler Feed Water Tank, Boiler Feed Water Pump, Boiler with coal firedfurnace, Air pollution control system consisting of ESP and ID Fan with Stack. Suitable watertreatment plant is also provided as per the requirement of boiler feed water.

Cooling Tower

Induced draft cooling tower with cooling water circulation pumps are provided for supply ofcooling water for MEE system, surface condensers and other misc requirement in MEEsystem. Cooling Tower system will consist of cooling tower with cooling tower fan, coolingwater circulation pumps, piping and valves, cooling tower chemical dosing system and sidestream filter.

Instrument Air System

Instrument air compressor with dryer system is required for MEE system, control valves.Instrument air system shall consists of instrument air compressor with dryer, air receivertank, piping and valve.

Electrical

11/22/33 KVA power will be received at site. This power will be first fed to HT Panel andthen step down to 440 V in step down transformer. From transformer LT power is fed toPCC panel. PCC Panel will distribute power to MCC panels for CETP stream 1, CETP stream 2,RO Plant I and II, MEE Stream 1 and MEE stream 2, Boiler and plant and domestic lighting.


19

3.5.6 Site Infrastructure

Following infrastructure is proposed to be provided at site other than plant as describedabove

1. Entry & Exit2. Haz Waste Storage Area3. Coal Storage Yard.5. Administrative Building6. DG Sets7. Plant Internal Road8. Green Belt on periphery of the plant.9. Safety equipments / Fire Fighting Equipments10. Site Security & Surveillance11. Laboratory and Pilot Plant

3.5.7 Environment Management and Pollution Control

1. Air Pollution Control2.

Sr No Sources of AirPollution

Fuel Used MitigationMeasures

Stack /Vent

Pollutants

1 Boiler, 20 T/hrCapacity

Coal(Imported)90Tons/Day

APC systemconsisting ofCyclone Separator,ESP

30.5 Mhigh

PM, SOx,NOx


20

2 DG Set(EmergencyPower Supply):750 KVA x 3 Nos

LDO Nil 10 Mhigh

PM, SOx,NOx

3 Coal Dust fromCoal Storage Yard

Coal storage yard tobe provided with 10M high GI Sheetscover on peripheryalong with WaterSprinkling systemfor dust supression

PM

4 Fly Ash Dust fromFly Ash handlingsystem

Enclosed fly ashhandling systemwith fly ash silo andexhaust connectedto Fly Ash Bag filter

10 MHigh

PM

2. Water Pollution

Sr No Sources ofWaste WaterGeneration

Total Quantity TreatmentScheme

Mode ofDisposal

1 Cooling TowerBlow Down

50 KL/Day ZLD Based CETPconsisting ofRO+MEE

Recycled backas make upwater

2 Boiler Blow Down 15 KL/Day ZLD Based CETPconsisting ofRO+MEE


3 Water TreatmentPlant

15 KL/Day ZLD Based CETPconsisting ofRO+MEE


4 Domestic 20 KL/Day Packaged STP Irrigation /Green BeltDevelopment /Dedustingapplication forroad


21

3. Hazardous Solid Waste Management

The detail of Hazardous Waste Management System is as under ……

Cat.No.

Solid /Hazardous

Waste

Source ofWaste Generation Quantity Disposal

Hazardous Waste

34.3 CETP Sludge From CETP-ChemicalSludge

50 MT/Day Disposal to SecuredLand Fill Site / Cementco-processing asGypsum sludge

5.1 Used Oil Plant &Machinery

50 Liters/Year Collection / Storage /Transportation / sent toregistered recycler /reuse as a lubricant /Incineration

33.3 Used drums/barrels/containers /bags/ linerscontainers /barrels / liners

Along withwaste

- Storage, Cleaning, sellto authorized recycler /To CHTSDF site

37.3 MEE Salts From MEE 80 MT/Day Reuse/Recycle as salt(based on feasibility) /Disposal to SecuredLand Fill

Solid Waste

CETP Sludge Biologicalsludge

20 MT/Day Cement Co-Processing

Bottom Ash / FlyAsh from CoalBoiler

Coal Boiler 12 MT/Day Cement Co-Processing /Land Use / BrickManufacturer /Construction agregate

4. Noise Pollution

Noise pollution in CETP is generated mainly from Air Blowers used for Equalization andAeration Tank and various ID/FD Fans used for due to rotary machinery such as pumps andblowers in the CETP plant. Noise level in this machinery shall be maintained under controlwhile selection of equipment, provision of acoustic enclosure, where ever required. Whereever required isolation room shall be provided. Operators and plant persons shall beprovided with suitable PPEs while working near these machineries. Preventive maintenanceschedule shall be maintained to ensure that noise generation in the plant is within level.Green Belt provided in periphery of the plant shall be useful for reduction of noise leveloutside the premises.


22

3.6 Raw Material Consumption

The proposed is being a Common Effluent Treatment Plant, effluent from industry is majorinput to the facility. Following are major other chemicals used in the proposed facility

SrNo

Name of Chemical Projected Consumption

1 Hydrated Lime 10 TPD2 Ferrous Sulfate 5 TPD3 Poly Electrolyte 50 Kg/Day4 DAP and Urea (Commercial) 200 Kg/Day5 Boiler/Cooling tower/ RO Plant / MEE

ChemicalsAs required, Max 500 Kg/day alltogether

3.7 Resource Optimization:

The proposed project is designed based on zero liquid discharge (ZLD). Entire treated wastewater will be recycled back to industries for reuse in the process. Thus the proposed projectwill not only aimed to provide treatment of waste water but will also conserve naturalresource water by recycling treated waste water back to industry.

Additionally proposed project will also provide sludge drying system to reduce quantity ofmoisture in sludge. Sludge will be sent for cement co-processing on acceptance of same bycement industries.

Fly Ash collected from boiler will be sold / sent outside to brick manufacturers or forconstruction / land fill application.

3.8 Availability and source of water, energy/power

Water

Water balance for the facility is provided as under. Water required for plant operation will besourced from treated water only.

Sr No Waterconsumption

Quantity Waste WaterGeneration

Quantity

1 IndustrialCooling WaterMake Up

600 KL/Day Cooling TowerBlow Down

50 KL/Day

Boiler Make Up 400 KL/Day Boiler Blow DownWater TreatmentPlant

15 KL/Day15 KL/Day

2 Domestic 25 KL/Day Domestic 20 KL/Day

3 Gardening 20 KL/Day


23

Total industrial water required for the proposed facility is 1000 KL/Day. This will be obtainedfrom the treated waste water from the plant.

Treated sewage will be used for green belt development.

Domestic water of 25 KL/Day will be sourced from the ground water source.

Power

Total Power Required for the proposed facility is 2000 KVA.

Fuel Consumption

Coal is used as fuel for the steam boiler. LDO is used as fuel for DG set for emergencyoperation only.

Sr No Equipment Fuel Consumption1 Steam Boiler Coal 90 TPD2 DG Set (750 KVA x 3) LDO 300 Lit/Hr

3.9 Schematic Representation of Drawing

Kindly refer Annexure 1 for schematic flow diagram


24

4.0 Site Analysis

4.1 Connectivity

Sr No Feature Place/ Distance

1 Project Location Latitude: 21°21'48.06"N, Longitude: 73°

2'13.84"E.

2 Nearest City Surat,30 Kms

3 Nearest Railway station Kim, 12.0 Kms

4 Nearest Airport Surat, 30 Kms

5 Nearest village Tadkeshwar

6 National highway NH-8 10 KM on West

7 River Tapi apprx.7.5 KM in SW

4.2 Land form, land use and land ownershipThe proposed site at present is owned by promoters. At present no crop is taken on thisland. The proposed land will be converted to NA land before execution of the project.

4.3 Topography

The land at the project area is mostly fine clay to clay loam with moderated to high watercapacity. Various crops are being grown in surround the project area like Banana,vegetables, sugar cane, rice etc. The project area is mostly covered with crop land and byfallow scrubs and bushes. As there are some industrial cluster in vicinity of proposed sitesuch as Kim, Karanj, Chamucchal and Lindiyad, the area is well built up area. There is noany sanctuary or national park with in 10 KM radius of the proposed project sites.

4.4 Existing Infrastructure

Existing infrastructure such as road and rail, connectivity as described above is adequate forthe proposed project.


25

4.5 Soil InvestigationSoil in this area is fine texture, moderate to goof water holding capacity, moderate to slowpermeability. Soil in this area is moderate to good for agriculture

4.6 Climate data from secondary sources

Climate wise, the year can be broadly divided into

(i) Winter Season (November to February)(ii) Summer Season (March to May)(iii) South-West Monsoon Season (June to September)(iv) Transition Month (October)

Winter is the most pleasant season in the area. Clear blue skies with stray high clouds,occasional light cool winds blowing towards South - West direction are the characteristics ofthe season. In January and February, light breeze prevails in the afternoon. Mornings arechilly and during nights, temperature often drops below 10 C. January and December arethe coolest months. April and May are the hottest months, May being the hotter of the two.The heat is sometimes oppressive. The maximum temperatures exceed 40 C on certainextreme days.

The South - West monsoon sets in by about the second week of June. South westerly windsblow from May and last till the end of September. About 95 % of the annual rainfall in thearea occurs during the months of June to September. The normal annual rainfall is 2000 mm.The average number of rainy days is about 40 days. The monsoon withdraws towards theend of September and temperature rises temporarily during October.


26

5. Planning in Brief:

5.1 Planning Concept

The proposed facility is Common Effluent Treatment Plant of 20 MLD Capacity designed forthe treatment of industrial waste water from the textile processing industries. The project isdesigned based on Zero Liquid discharge (ZLD). Treated waste water will be recycled backto industries for further use.

The entire project will consist of components such as effluent conveyance system up to inletof CETP, Common Effluent Treatment Plant including RO and MEE System, Utilities such asBoiler, cooling tower and electric station, and recycling waste water pumping station andpipeline for supply of treated waste water back to industries.

5.2 Amenities/Facilities:

Following will be major components of the projects

1. Effluent conveyance system of 20 MLD Capacity

2. CETP with RO and MEE for treatment of 20 MLD waste water

3. Coal fired steam boiler of 20 T/hr capacity, Coal storage Yard and Ash Handling system

4. Cooling towers, compressed air system, DG sets and Plant lighting

5. Plant internal roads and sheds.

6. Fire hydrant system.

7. Green Belt


27

6. Proposed Infrastructure

Proposed infrastructure consists of project components as mentioned above in point no 5will be created at the proposed site including effluent conveyance system and recycle waterconveyance system. Facility will also consist of storm water management system,Environmental Management System and Power Supply System as described in this report.


28

7. PROJECT SCHEDULE & COST ESTIMATES:

7.1 Project Schedule:

7.2 Estimated project cost

Summary of Project Cost

Sr No Plant Section Rs in Lacs

1.1 Effluent Conveyance System 1200.001.2 CETP (20 MLD) 3500.001.3 RO (20 MLD) 8000.001.4 MEE (2 MLD) 3500.001.5 Recycling Network 1800.00

A Total CETP 18000.00


29

8. ANALYSIS OF PROPOSAL:

8.1 CONCLUSION:

Kim and Karanj area in Surat District is a growing textile cluster and need a CommonEffluent Treatment Plant for sustainable development of the area. Industries in this area isdependent on ground water supply and if CETP based on 100% recycling is established inthis area, it will not only result in ensured treatment of waste water generated from theseindustries bit will also largely reduce the exploration of ground water by industries in region.Also with the establishment of CETP in this region there will be more growth of industries inregion resulting direct and indirect employment, development of small scale ancillaryindustries in the region. Overall proposed CETP in this region will have positive impact withrespect to environment and socio economic development.

At TDK Green Enviro Private Limited Village Tadkeshwar ... · Kim Char Rasta is rapidly growing...

Documents

Transcript of At TDK Green Enviro Private Limited Village Tadkeshwar ... · Kim Char Rasta is rapidly growing...