AJRAKHPUR HASTKALA VIKAS SANGATHAN

PRE-FEASIBILITY REPORT

C.E.T.P – AJRAKHPUR PROPOSED CAPACITY- 150KLD

Project Location Common Plot No 1 of Survey No. 694 of Paddhar-Ajrakhpur Village

PREPARED BY: SHIVALIK SOLID WASTE MANAGEMENT LTD, ZIRAKPUR

PRE-FEASIBILITY REPORT

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SHIVALIK SOLID WASTE MANAGEMENT LTD. I

TABLE OF CONTENTS

1 EXECUTIVE SUMMARY................................................................................................................................. 1

2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION ............................................. 2

2.1 Identification of the project .................................................................................................................................. 2

2.2 Details of the Project Proponent ......................................................................................................................... 3

3 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ......................................................................... 4

4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY OR REGION .................. 4

4.1 Employment Generation (Direct and Indirect) due to the Project ....................................................... 5

5 PROJECT DESCRIPTION ............................................................................................................................... 5

5.1 Type of Project Including Interlinked and Interdependent Projects, If Any .................................... 5

5.2 Location ......................................................................................................................................................................... 5

5.3 Details of Alternate Sites ........................................................................................................................................ 6

5.4 Size or magnitude of operation ........................................................................................................................... 6

5.5 Project description with characteristic of effluent of industries ........................................................... 6

5.6 Discharge Cum Recovery Standard ................................................................................................................. 12

5.7 Transportation as per topography .................................................................................................................. 14

5.8 Raw Material Required ......................................................................................................................................... 15

5.9 Resource Optimization/ Recycling and Reuse envisaged in the project, if any, ........................... 16

5.10 Availability Of Water Its Source, Energy/ Power Requirement And Source .................................. 16

6 SITE ANALYSIS ............................................................................................................................................ 16

6.1 Connectivity............................................................................................................................................................... 16

6.2 Topography ............................................................................................................................................................... 17

6.3 Land use pattern. ..................................................................................................................................................... 17

6.4 Soil Classification .................................................................................................................................................... 17

6.5 Climatic & Rainfall .................................................................................................................................................. 17

6.6 Social Infrastructure Available .......................................................................................................................... 18

7 PLANNING BRIEF ........................................................................................................................................ 19

7.1 Planning Concept (type of industries, facilities, transportation etc.) ................................................ 19

7.2 Population projection ............................................................................................................................................ 20

7.3 Land use planning ................................................................................................................................................... 20

7.4 Assessment of Infrastructure Demand (Physical & Social) ................................................................... 20

7.5 Amenities/Facilities ............................................................................................................................................... 21

8 PROPOSED INFRASTRUCTURE .............................................................................................................. 21

8.1 Industrial Area (Processing Area).................................................................................................................... 21

9 REHABILITATION AND RESETTLEMENT (R&R) PLAN .................................................................. 21

10 PROJECT SCHEDULE & COST ESTIMATES ...................................................................................... 22

11 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) ......................................................... 24

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SHIVALIK SOLID WASTE MANAGEMENT LTD. II

LIST OF TABLES

TABLE 1: SALIENT FEATURES OF THE PROJECT ............................................................................................................................. 4 TABLE 2: AJRAKHPUR ARTISAN UNIT MONTHLY PRODUCTION DETAILS ........................................................................ 7 TABLE 3: ACHIEVABLE VALUES VIS-À-VIS STATUTORY NORMS .......................................................................................... 12 TABLE 4: DETAILED SPECIFICATIONS OF CIVIL ITEMS ............................................................................................................. 14 TABLE 5: WATER CONSUMPTION PATTERN .................................................................................................................................. 16 TABLE 6: CLIMATOLOGICAL DATA FOR IMD STATION BHUJ .................................................................................................. 18 TABLE 7: IMPLEMENTATION PLAN ..................................................................................................................................................... 20 TABLE 8: ESTIMATED COST OF THE PROJECT ............................................................................................................................... 22 TABLE 9: DETAILS OF POWER COST ................................................................................................................................................... 22

LIST OF FIGURES

FIGURE 1: SHOWING DISTRICT KUTCH .................................................................................................................................................................. 2 FIGURE 2: STATELITE VEIW OF AJRAKHPUR BLOCK PRINTING CLUSTER. .................................................................................. 3 FIGURE 3: LOCATION MAP WITH BUFFER AREA (5KM) ............................................................................................................................. 6 FIGURE 4: ENVIRONMENT SENSITIVITY MAP (10KM RADIUS) ............................................................................................................. 9 FIGURE 5:HYDRAULIC FLOW DIAGRAM ............................................................................................................................................................... 11 FIGURE 6: DETAILED PIPELINE SYSTEM ............................................................................................................................................................. 15 FIGURE 7: PIE CHART FOR OPERATING COST. ................................................................................................................................................. 24

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1 EXECUTIVE SUMMARY The concept of effluent treatment, by means, of a collective effort, has assumed reasonable gravity by being especially purposeful for cluster of small scale industrial units. Common effluent treatment plant (CETP) not only helps the industries in easier control of pollution, but also act as a step towards cleaner environment and service to the society at large. Small scale industries, by their very nature of job cannot benefit much from economies of scale and therefore the burden of installing & operating pollution- control equipment, falls heavy on them. Realizing this practical problem, under the policy statement for abatement of pollution the Government extends the scheme for promoting combined facilities for treatment of effluent for clusters of small scale industrial units and to provide technical support to them.

The Proposed CETP at Ajrakhpur Block Printing Cluster in Village Ajrakhpur, Tehsil Bhuj in district Kutch of Gujarat. Kutch District, at 45,692 square kilometres (17,642 sq mi), is the largest district in India. The administrative headquarters is in Bhuj which is geographically in the center of district. Other main towns are Gandhidham, Rapar, Nakhatrana, Anjar, Mandvi, Madhapar, Mundra and Bhachau. Kutch has 969 villages. Kala Dungar (Black Hill) is the highest point in Kutch at 458 metres (1,503 ft). Kutch District is surrounded by the Gulf of Kutch and the Arabian Sea in south and west, while northern and eastern parts are surrounded by the Great and Little Rann (seasonal wetlands) of Kutch. When there were not many dams built on its rivers, the Rann of Kutch remained wetlands for a large part of the year. Even today, the region remains wet for a significant part of year. The district had a population of 2,092,371 as of 2011 census, of which 30% were urban. The district is well connected by road, rail and air. There are four CETPs in the district: Naliya, Kandla, Mundra, and Bhuj. Bhuj is well connected with Mumbai airport. Being a border district, Kutch has both an army and an airforce base.

Ajrakhpur is a place in Bhuj which is in Kutch district of Gujarat State. ‘Ajrakh’ is an ancient block printing style which is famous for use of natural dyes. Small & tiny textile processing units who are engaged in this activity are clustered around Ajrakhpur which is popularly known as ‘Ajrakhpur Block Printing Cluster’. The present strength of the cluster is 49 dyeing, printing & washing units and it is expected that in near future another 50units may migrate to this cluster. Presently, the units have a monthly production capacity of nearly 2,87,512 meters.

The waste water discharge is proposed to be collected through piping conduits under gravity to the site of common effluent treatment plant (CETP). The treatment scheme proposed in this project will not only treat the effluent to meet the standards specified by the central/state pollution control authority but also will make provision for water recuperation & recycling. Due to the very nature of effluent which has major textile refractory materials and moderate BOD load, the effluent will undergo thorough decolorization & detoxification with heavy metal removal and thereafter will be clarified through dual biological treatment like MBBR & Activated Sludge Process (ASP). Finally, a chemi-polish touch is needed for the control of hardness, silica, iron etc. The treated effluent will then pass though a battery of conventional filtration & microfiltration which are necessary for water recuperation & recycling. The treatment will generate some sludge which will be dewatered through filter press, stored and then disposed off in a controlled manner. The conveyance systems for in-coming untreated effluent to the CETP and the out-going treated water from CETP for reuse are not considered as an integral part of the project. The project is proposed in Tehsil Bhuj of District Kutch shown in Figure 1.

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The estimated cost of the project is Rs.146 lacs. The manpower involved in the project during construction phase is 6 Nos and while during operational phase will be 4 Nos.

Figure 1: Showing District Kutch

2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project Ajrakhpur industrial cluster (developed in 32Acres area) is situated on approx. 16 km from Bhuj city

towards Bhuj-Bhachau Highway as shown in Figure 2-1. Bhuj City has good connectivity of Bus and

Rail Network with other cities of Gujarat and India. The airport in Bhuj is also having connectivity

with national and international cities.

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Figure 2: Statelite Veiw Of Ajrakhpur Block Printing Cluster.

The present level of effluent discharge of all the processing units of the cluster is 150 m³/day (KLD) for which there is a CETP is proposed of 150KLD. Ajrakhpur is worldwide known for the art of Ajrakh Block Printing Style. Mostly natural dyes are used in dyeing & printing which includes a mixture of camel dung, soda ash and castor oil, waste iron, myrobalan, madder, indigo, pomegranate peel boiled in water, sprays of turmeric water, root of rhubarb etc. These blocks printing styles are century old traditions being followed till date.

2.2 Details of the Project Proponent

Proponent Name: Dr. Ismail Mohmed Khatri Proponent Agency: Ajrakhpur Hastkala Vikas Sansthan (AHVS) Proponent Agency Address: Ajrakhpur Paddhar, Post: Kukma, 370105. Tal- Bhuj District -Kachchh, State- Gujarat, India. Trust Regd No: F/1178/ Kutch.GUJ/1002/Kutch.Dt.16-8-2004.

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3 BRIEF DESCRIPTION OF NATURE OF THE PROJECT The proposal is to set up the CETP of 150KLD for the effluent from industries located in Ajrakhpur Block Printing Cluster. The present strength of the cluster is 49 textile processing units and it is expected that in near future another 50 units may migrate to this cluster. Presently, the units have a monthly production capacity of nearly 2,87,512 meters. The salient features of the proposed project are given in table 1 below:

Table 1: Salient Features of The Project

Location Latitude: 23°13'53.11"N Longitude: 69°47'41.35"E CETP project is proposed at Common Plot No 1 of Survey No. 694 of Paddhar-Ajrakhpur Village.

Land Area Plot measuring approx. 4,608 Sq.m. has been allotted for the proposed CETP

Screening Category 7(h), Category A as per EIA Notification 14th Sep, 2006 and amended thereof.

Project Profile The Proposed CETP is expected to treat around 150 KLD industrial effluents from the industries located in Ajrakhpur Block Printing Cluster.

Cost of the Project Rs. 146 Lacs.

Resource Requirement

Source & Quantity of Water

Proposed borewell (1Nos.) at site.

Power 40KW Power Backup: 10 KVA – 1 Nos.

Man Power Manpower required during Construction phase is 6 Nos. Manpower required during operational phase is 4 Nos.

Environmental Management System Effluent Treatment Scheme

Proposed CETP is for the effluent mainly from Small & tiny textile processing units who are engaged in this activity are clustered around Ajrakhpur which is popularly known as ‘Ajrakhpur Block Printing Cluster’.

4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY OR REGION Presently 49 units are running in Ajrakhpur cluster and approx. 50 units are expected to come from Dhamadka in coming future. Only seven units uses chemical dyes (Ramazol and Azo free Napthol) and rest of the units are using natural dyes. Units remain operating from 8 AM to 4PM from Monday to Sunday. In rainy season, production decreases due to problem in drying of washed cloths. Printing and dyeing has a wide spread coverage of products inclusive of Bed-Sheet, Saree, Yarde, Dress material, Dupatta and shawl etc. These products have both domestic and export markets. The details of 49 textile manufacturers who are presently working in this small textile cluster. The total production capacity of the units is nearly 2, 87,512 meters per month.

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The Ajrakhpur Hastkala Vikas Sansthan through Northern India Textile Research Association intends to install Common Effluent Treatment Plant (CETP) of the capacity of 150KLD to serve Ajrakhpur Block Printing Cluster for management of industrial effluents and to protect ecology from further deterioration. The Objective of setting up of CETP is:

To Achieve Economy of scale in waste treatment, thereby reducing the cost of pollution abatement for individual industry.

To take care of the problem of lack of technical assistance and trained personnel as needed for skill operation of effluent treatment plant.

To solve the problem of lack of space as the centralized facility can be planned to ensure that adequate space is available

To reduce the problem of monitoring by the pollution control boards. To organize the appropriate disposal of treated waste water including reuse and sludge

generated to authorized facility.

4.1 Employment Generation (Direct and Indirect) due to the Project The proposed project will provide direct and indirect employment. Six persons would be deployed during construction phase of proposed project. And four persons shall be employed during operation stage. During construction phase, local worker would be utilized from nearby villages.

5 PROJECT DESCRIPTION

5.1 Type of Project Including Interlinked and Interdependent Projects, If Any

This project is for establishment of CETP for treatment of effluent being generated by clusters of textile processing units. The Common Effluent Treatment Plant (CETP) is listed at serial no. 7(h) of the Schedule of EIA Notification 2006 and falls under Category B. The project is not interlinked with any other project.

5.2 Location The proposed location of the project is at Common Plot No 1 and 2 of Survey No. 684/1.2.3 of Paddhar- Ajrakhpur Village. The site Coordinates are 23°13'53.11"N Latitude and 69°47'41.35"E Longitude. Location map showing buffer area 5km is given in Figure 3 below-

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Figure 3: Location map with Buffer area (5Km)

5.3 Details of Alternate Sites No alternative site has been examined for the proposed project, as the location has been considered on basis of the distance of mainly from clusters of Textile processing units from CETP site for transportation of effluent.

5.4 Size or magnitude of operation

The proposed project is to establish Common Effluent Treatment Plant of 150 KLD capacity to treat effluents coming from industries of Ajrakhpur Block Printing Cluster. The plant will consist of treatment units comprising physical, chemical and biological treatment including dewatering of sludge and other required infrastructure.

5.5 Project description with characteristic of effluent of industries

The proposed Common Effluent Treatment Plant facility will be treating the waste water mainly from the clusters of Textile processing units located at Ajrakhpur Block Printing Cluster.

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The details of 49 textile manufacturers who are presently working in this small textile cluster are enlisted in Table-2 in the following pages. The total production capacity of the units is nearly 2, 87,512 meters per month.

Table 2: Ajrakhpur Artisan Unit Monthly Production Details

*Production in Meters

Sr. No.

Name of Entrepreneur Bed

Sheet Saree Yardes

Dress set

Dupatta Othe

rs Total

1 Khatri Rahemtullah Hasam 1200 837.5 2038

2 Khatri Aurangzeb Abdulrazak 325 1000 100 1425

3 Khatri Dr.Ismail Mohammad 1120 325 5000 2000 100 8545

4 Khatri Abbas Ibrahim 1200 1200

5 Khatri Faruk Shakur 8040 8040

6 Khatri Sufiyan Abdulgafur 800 800

7 Khatri Sikandar Osman 80400 80400

8 Khatri Abdulkarim Tarmamad 130 400 300 830

9 Khatri Musa Tarmamad 2000 2000

10 Khatri Osman Tarmamad 20100 20100

11 Khatri Samad Jusab 10000 10000

12 Khatri Kadar Yakub 3000 300 3300

13 Khatri Mohammadhusen Sumar 1300 3000 2010 1200 7510

14 Khatri Mustaq Abdullah 6000 6000

15 Khatri Indris Sumar 6000 6000

16 Khatri Abdul Raheman Budha 560 650 2000 1340 600 200 5350

17 Khatri Abdul Razak Abdul

Raheman 1950 1000 1000 3950

18 Khatri Abdul Rasid Abdul

Raheman 1950 1000 1000 3950

19 Khatri Juned Abdul Raheman 6000 6000

20 Khatri Faiz Jusab 800 800

21 Khatri Kadar Salemamad 1000 800 1800

22 Khatri Junas Aamad 130 670 400 1200

23 Khatri Junas Aamad 200 80 280

24 Khatri Karim Ismail 1500 1500

25 Khatri Ibrahim Isha 97.5 1000 1098

26 Khatri Abdulrahim Anwar 65 3000 3065

27 Khatri Halim Usman 1000 1000

28 Khatri Rauf Abdulrazak 560 650 1005 50 2265

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Adoption of appropriate technology may be one criterion as far as the degradability of waste chemicals is concerned, but the economic affordability of meeting the recurring expenditure is the paramount desirable parameter in selecting the treatment scheme. More over units are scattered over large industrial area, monitoring mechanism along with conveyance cost is another major concern while deciding the mode of transportation of effluent. With a view to circumventing the above constraints, the sector wise load estimation seems to be a mandatory part of preliminary exercise.

Key characteristics of wastewater that has been considered in designing of the CETP include flow, and physical, chemical, and biological characteristics of the wastewater.

No Wildlife Sanctuary or Interstate/International boundary lies within 10km of proposed project site. Environmental Sensitivity map showing 10km radius is given in below figure 4:

29 Khatri Jusab Suleman 2000 2680 4680

30 Khatri Sikandar Habib 1500 1500

31 Khatri Mustaq Habib 325 2500 2680 800 6305

32 Khatri Yakub Sumar 800 800

33 Khatri Nasir Ismail 1000 1000

34 Khatri Museb Ahemad Abdullah 1600 1600

35 Khatri Basir Anwar 650 4000 3350 1000 9000

36 Khatri Abdulrahim Abdulrazak 560 650 1005 50 2265

37 Khatri Khalid Amin 65 800 80 945

38 Khatri Imran Hasam 130 2000 1340 200 3670

39 Khatri Gani Hasam 33500 600 34100

40 Khatri Abdul Latif Ismail 2000 2000

41 Khatri Mustaq Aadam 2400 2400

42 Khatri Khalid Osman 4000 4000

43 Khatri Sikandar Sumar 2010 1200 3210

44 Khatri Aadam Junas 7500 7500

45 Khatri Salman Junas 1200 1200

46 Khatri Suleman Daud 3000 3000

47 Khatri Hasan sidhik 4000 200 4200

48 Khatri Satar Karim 1512 540 540 2592

49 Khatri Hasam Sumar 700 400 1100

4312 9393 98900 160968 12220 1720 28751

2

Total Monthly Production (Meter) = 2,87,512 Meters

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Figure 4: Environment Sensitivity Map (10km radius)

DESIGN OF 150 KLD CETP

Total water consumption is expected to be 150KLD. (i.e. process, lab & other wash, domestic, additional factor).

Assuming negligible quantity of evaporation loss and human intake, the waste generation will be of same amount i.e. 150 KLD.

As the CETP is proposed to operate for one shift only, the effluent peak flow rate will be very high.

There are multiple point discharges through separate drain attached to each unit which has shortest distance of 40 meters and furthest distance of 350 meters from the CETP

Though actual discharge is very low, the peak and average flow will be reasonably high due to one shift operation of CETP and discharge process being adopted.

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INLET CHARACTERISTICS OF EFFLUENT

BOD 150 mg/L

COD 425 mg/L

TDS 1695 mg/L

TSS 75 mg/L

TREATMENT PROCESS:

The treatment scheme starts with the collection of process effluent and other domestic effluent into an equalization tank after passing through an oil and grease trap. Due to rapid discharge, the peak flow rate would be high which will be absorbed into the equalization tank of sufficient storage capacity. Before oil & grease trap the effluent will pass through Bar & Coarse screen which has to be cleaned manually at regular intervals. The mixed effluent from equalization tank would then be subjected to a physico-chemical treatment in a reaction tank having multiple chambers fitted with agitators where Acid & Ferrous Sulphate dosing will be carried out followed by lime dosing for PH enhancement. This leads to final precipitation of chromium and dye stuff materials which gives effluent clarification.

Subsequently, it will be taken into a tube settler for settling of flocks through settling process. The overflow from the settler-1 will be imparted an aerobic treatment for the reduction of BOD/COD. Aerobic system will function on the principle of attached growth and suspended model. This lowers BOD/COD load easily. It also partially removes color successfully through bio-adsorption. The process is effective enough for handling peak load and easy for trouble-shooting.

The effluent would now pass through a secondary clarifier for the separation of bio-mass and its recycling as per design requirement in to the aeration tank. This reduces BOD/COD value of the treated effluent to virtually a negligible level. Moreover, it removes foul smell, improves effluent transparency, residual color etc. The system needs nutrient dosing of Nitrogen (N) & Phosphorus (P) as per ratio BOD: N: P::100: 5: 1 to promote the bio-growth. The chemicals to be used in the process are lime (2250kg/month), ferrous sulphate (1350kg/month), Poly electrolyte (4.5kg/month), Other chemicals (2250 kg/month). All these chemicals will be stored in storage room.

The partially treated effluent will then pass through a series of reaction chambers for final polishing through precipitation technique. The oxidation process would remove color more than 99%, improve transparency and make the effluent fit for subsequent polishing treatment. At this stage, part of the effluent could be discharged into green belt as the treated effluent characteristics would be meeting the statutory norms of the state pollution control board. For the purpose of recycling, the partly polished effluent will be passed through battery of conventional filters consisting of multi-grade filter, iron filter in order to achieve cent percent transparency. Afterwards, it will be taken through a series of cartridge filters. The detailed hydraulic flow diagram of the proposed treatment scheme is given in figure 5 :

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Figure 5:Hydraulic Flow Diagram

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5.6 Discharge Cum Recovery Standard

The achievable values of the final treated effluent will be superior as compared to the statutory norm laid down by the state pollution control board as represented below in Table 3 subject to the effective operation of the plant. However, the discharge flow rate of the will vary as per production and shall not exceed the design flow rate.

Table 3: Achievable Values Vis-À-Vis Statutory Norms

5.6.1 SLUDGE MANAGEMENT

The proposed treatment scheme will result generation of sludge which requires efficient management. It is important to manage it from the point where the sludge is generated to the disposal of sludge. The details are given below: Sludge generation point

There will be following two types of sludge generated during the treatment.

1. Chemical Sludge

Chemical sludge generated during the physico-chemical treatment in the reaction tank 1&2 would be settled in the bottom of the tube settlers. The wet sludge from tube settlers shall be pumped at regular interval of time and collected into sludge sump.

2. Bio- Sludge

S.No. PARAMETERS ACHIEVABLE

VALUES STATUTORY

NORMS UNIT

1. APPEARANCE CRYSTAL CLEAR 2. pH 6-8 6-9

3. SUSPENDED SOLID ≤ 50 ≤ 100 mg/l

4. OIL & GREASE ≤ 5 ≤ 10 mg/l

5. CHEMICAL OXYGEN DEMAND ≤ 150 ≤ 250 mg/l

6. BIO-CHEMICAL OXYGEN DEMAND

≤ 15 ≤ 30 mg/l

7. SURFACTANT ≤ 2 - mg/l

8. SULPHIDE ≤ 2 ≤ 2 mg/l

9. CR (VI) ≤ 0.05 ≤ 0.1 mg/l

10. BIO ASSASY 90% of survival 90% of survival of test animals after 96 hours in the 100%

effluent

mg/l

11. TOTAL DISSOLVED SOLID ≤ 2100 ≤ 2100 mg/l

12. HARDNESS 100 mg/l

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The biological sludge is generated during the secondary treatment. This is a biological treatment takes place in MBBR & AERATION TANK and produces Bio-sludge which will be collected in the bottom of secondary clarifier and is recycled continuously to the aeration tank as a essential feature of the process. Once the required concentration of micro-organism in the aeration tank has been reached for optimum operation, its further increase is prevented by regulating the quantity of sludge recycled.

5.6.2 Quantity of Sludge Generated

The wet sludge shall be pumped at constant rate through the screw pump from sludge sump for dewatering through filter press. Filter press are installed at elevated platform. The dewatering through filter press converts the wet sludge in to sludge cake which would be collected in water proof polythene bags. The quantity of dry sludge generated during the treatment is given below:

a. Dry Chemical Sludge Quantity

Rate of sludge generation: 1st Tube-settler- 200 mg/L 2ndTube-settler – 50 mg/L Total rate of chemical sludge generation: 200 + 50 = 250 mg/L

Total weight of dry chemical sludge/day (for 150KL) = 0.25 X 150 = 37.5 kg

b. Dry Bio Sludge Quantity

Rate of sludge generation: 100 X 0.3 mg/L

Total weight of dry Bio sludge/day (for 150KL) = 0.03 X 150 = 4.5 kg

5.6.3 Bio-Sludge Disposal

The waste bio-sludge from biological treatment (less in quantity) is biodegradable and rich in nutrients can be used as manure for plantation/tress. However, after the treatment capacity increases, the quantity of the bio-sludge will be increased proportionately.

5.6.4 Temporary storage of chemical sludge at CETP site

Being hazardous, the chemical sludge is to be managed with utmost care. Before its disposal, the above sludge is proposed to be stored temporarily at the CETP site in a store made of made of brick wall. The floor level of the store shall be at 0.5m above the ground level with 1.5 mm HDPE lining to avoid the leaching and the shed shall be water proof.

5.6.5 Disposal of chemical sludge

The disposal of chemical sludge generated from CETP shall be carried out through authorized agency prescribed by State Pollution Control Board as per the norms of Hazardous waste management and Handling Rule 2016. There are few agencies that are authorized for hazardous waste treatment, storage & disposal facility (TSDF) in the state of Gujarat.

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5.6.6 DESIGN OF MAIN UNITS TO BE PROVIDED FOR THE CETP

Table 4: Detailed Specifications of Civil Items

5.7 Transportation as per topography

As mentioned earlier, there is a cluster of 49 textile units & in future it is expected that 50 more units will migrate to the cluster and use the CETP. The proposed CETP will be located at the centre of the cluster. The individual unit will function only in single shift operation basis which increases the peak discharge reasonably higher than the average discharge flow rate if it operates on 24 hours basis.

The effluent discharge from the participating units will be taken to the CETP site through 150 mm dia. PVC Pipe, already laid down. The distance from the nearest unit is 40 meters and 350 meters length is used to take the effluent from furthest unit.

The available slope for the pipeline already laid down is 1:200. The hydraulic drop provided is 1.75 meter vis-a-vis the estimated pressure drop for the furthest unit assuming full conduit flow is 1.17 meter which is quite safe for the present peak flow rate. With the increase in the effluent discharge, the peak flow rate will also be increased. Then, the estimated pressure drop will increase up to 5.02 meter which will exert a back flow unless the diameter of conduit is increased. Moreover, the migrating units in future will be established further away from the CETP which will demand additional pressure drop. In brief, the conveyance network is able to convey the present level of effluent flow rate but will have a bad impact in Ph-2 when the peak flow will get doubled along with the increase in distance of the units from the proposed CETP.

The detailed pipeline system is shown in figure 6:

Sr. No. ITEMS PARTICULARS QTY.

1 EQUALIZATION TANK-1

size: 4 m x 4 m x 3 m (swd: 2m)

moc : rcc

01 No

2. EQUALIZATION TANK-2

size: 7 m x 6 m x 6 m (swd: 5m)

moc : rcc

01 No

3. STORAGE TANK size: 6.0m x 4.0m x 3.0m

moc: rcc

01 No

4. SLUDGE SUMP size: 3.0 m x 3.0 m x 3.5m

moc: rcc

01 No

5. LAB, PANEL & OFFICE ROOMS size: 5.0 m x 4.0 m x 5.5 m

moc: brick masonry

01 No

6. SLUDGE DRYING BEDS size: 5 m x 4 m x 1m

moc : brick- masonry

01 No

7. FOUNDATION For tube settlers 01 Lot

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Figure 6: Detailed Pipeline System

5.8 Raw Material Required

Raw material required for construction and setting up of Common Effluent Treatment Plant are cement, steel, aggregates & sand for civil works and steel will be for construction purpose.

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5.9 Resource Optimization/ Recycling and Reuse envisaged in the project, if any, The treated effluent will be used for disposal onto green area.

5.10 Availability of Water Its Source, Energy/ Power Requirement and Source

5.10.1 Water Requirement

The water demand at the project CETP is 5KLD which will be used in labs and by workers at project

site.

The detailed of present water consumption pattern is shown in following Table-5:

Table 5: Water Consumption Pattern

S. No. Water Consumption Front Consumption

(KLD) 1. PROCESS HOUSE 120 2. LAB, OTHER WASH 5 3. COOLING NIL 4. SOFTENER FOR BOILER NIL 5. BOILER NIL 6. DOMESTIC 15 7. ADDITIONAL FACTOR 10 TOTAL 150

5.10.2 Power Requirement

Power requirement will be 40KW. In case of power failure D.G. set (1Nos.) will be used having capacity of 10 KVA.

6 SITE ANALYSIS

6.1 Connectivity

6.1.1 Nearest Railway Station Kukma Railway Station, Kutch: Approx. 3 km, in SW direction

6.1.2 Nearest Airport Bhuj Airport, Kutch: Approx. 14km, in WNW Direction. (Aerial Distance)

6.1.3 Nearest Highway NH-42 is at approx. 0.5 km in the North direction.

6.1.4 Landform, Landuse And Land Ownership The Site of Common Effluent Treatment Plant is identified and marked on layout. NOC is issued by Paddhar Village Panchayat for using the land to set up Common Effluent Treatment Plant by Ajrakhpur Hastkala Vikas Sangathan.

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6.2 Topography The proposed site is located at 23°13'53.11"N Latitude and 69°47'41.35"E Longitude on a almost flat terrain. It has an average elevation of 114 meters.

6.3 Land use pattern. The land falls in the industrial area and the proposed project site is earmarked for CETP.

6.4 Soil Classification The soils found in Kachchh district can broadly be grouped into four types, i.e., Shallow Black soils, Residual Sandy soils, Coastal Alluvial soils and Desert soils. The Shallow black soils are found in central and north-central parts of the Kachchh mainland and in Khadir and Bela Islands. These soils have developed from basaltic rocks and rocks of Jurassic period. The depth of soil ranges from a few cm to 30 cm. Broadly, these soils are poor in fertility.

The Residual Sandy soils have developed in-situ from the parent material originated from red sandstone and shale and are found over the areas underlain by Bhuj Sandstone. All these residual soils are shallow in depth. They are reddish brown in colour with fine weak granular structure to poorly developed one. These soils are sandy to loamy sand in texture dominated by coarse sand. These are non-calcareous, neutral to alkaline in reaction with poor base saturation. They are affected due to salt accumulation. From fertility point of view, they are poorly supplied with plant nutrients and, as such, support the crops with short duration and less water requirement.

The hilly soils occur in the hilly areas central part of the district. The soil profile is not well developed because of the steep slope and erosion. They have developed from the parent materials in the respective areas. They are shallow in depth composed of undecomposed rock fragments and poor in fertility. The Coastal Alluvial soils are found all along the southern coast. These soils are sandy clay loam to clay in texture. The soil reaction varies with situation ranging from neutral to highly alkaline. These soils are normally medium in fertility. At places, these soils are saline in nature The two Ranns (deserts) of Kutch namely little Rann and great Rann have the soils which are formed as a result of the geological processes of Pleistocene age. The alluvial deposits due to the river system flowing through the area have subsequently been overlain by the Aeolian deposits. These soils are fairly deep, light grey in colour. The texture is sandy to sandy loam with silty clay loam in some areas. The salt content is very high with the sodium chloride as the dominant salt. The profile study reveals the presence of sufficient amount of gypsum throughout the profile.

6.5 Climatic & Rainfall

Temperatures vary considerably from season to season. The summers are generally hot and winters are cool. Mean maximum temperature ranges between 26.7°C during January to about 39.5°C during May and the mean minimum temperatures vary between 9°C during January and 27°C during June.

The relative humidity in Kachchh as per IMD varies between 43.5% during March and 77% during August. The wind velocity in the district varies from about 124 km/d during November and 375 km/d during June. The potential Evapo-transpiration, calculated using Penman‟s Method varies between 3.4 mm/d during December and 9.2 mm/d during may.

Long-term average annual rainfall for Bhuj IMD station is 378.2 mm. Most of the rainfall (about 345 mm) is received during south-west monsoon between June and September. The climatological data for IMD station Bhuj is given in following table 6:

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Table 6: Climatological Data for IMD Station Bhuj

Month Max Tem p (De g.C)

Mini Temp (Deg.C )

Humidity (%)

Wind Spd. Kmpd

Sunshine

(Hours)

Solar Rad. (MJ/m 2/d)

Eto (mm/d)

Rainfalll (mm)

January 26.7 9.0 47.0 138.2 8.9 16.7 3.6 2.0 February 29.8 12.0 45.5 149.0 9.5 19.5 4.5 1.1 March 34.9 17.6 43.5 177.7 10.1 22.8 6.2 2.9 April 38.7 22.1 44.5 217.2 10.8 25.6 7.9 0.7 May 39.5 25.2 53.5 330.3 11.4 27.1 9.2 1.7 June 37.1 27.0 65.0 375.2 8.7 23.1 7.7 33.9 July 33.6 26.2 75.0 346.5 5.3 17.9 5.4 136.3 August 32.5 25.2 77.0 307.0 5.4 17.6 4.9 120.7 September 33.7 23.8 70.5 229.8 7.9 20.2 5.4 54.2

October 35.9 20.6 52.5 141.8 9.6 20.4 5.3 15.4 November 32.4 15.5 48.0 123.9 9.3 17.6 4.1 7.7 December 28.1 10.5 49.0 131.0 8.9 15.9 3.4 1.6 Total - - - - - - - 378.2 Average 33.6 19.6 55.9 222.3 8.8 20.4 5.6 -

6.6 Social Infrastructure Available

6.6.1 EDUCATION SYSTEM IN BHUJ

Alfred High School, the first high school of Kutch, established in 1870, is also an architectural heritage of the town. Krantiguru Shyamji Krishna Verma Kachchh University is located in Bhuj. The university has 41 colleges affiliated, nineteen of which are in Bhuj. The university gives degrees in Arts, Science, Commerce, Law Education, Management, Pharmacy, Social Welfare, Medicine and Engineering.

6.6.2 Primary and Secondary

Alfred High School

Archna St. Xavier's School

Doon Public School

Army Public School

Indirabai Girls High school

Matruchhaya Kanaya Sala

R D Varsani High School

Sanskar School

Seth Virji Devsi Highschool

Shree Swaminarayan Secondary and Higher Secondary School

Swaminarayan Kanya Vidyalaya

White house Public School

6.6.3 Higher education

Adani Institute of Medical Science

Government Engineering College, Bhuj

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Government Polytechnic

Lalan College

Industrial Training Institute

J B Thacker Commerce College

Sanskar College

TRANSPORTATION

Bhuj is connected to Ahmedabad, Mumbai, Delhi, Gandhinagar, Pune, Visakhapatnam and other

major cities of India by railway trains. It has a domestic airport from which daily flights connect to

Mumbai, with flights operated by Jet Airways and Air India. State Transport buses are available from

the ST stand in the middle of the town to various places in Gujarat. Additionally, many private tour

operators also run frequent buses to major cities in and outside Gujarat. Kandla Airport is 53 km

from Bhuj. The city can be navigated by the city bus and auto rickshaw.

7 PLANNING BRIEF

7.1 Planning Concept (type of industries, facilities, transportation etc.)

The CETP unit is proposed for the treatment of waste water of clusters of industries mostly textile processing units located in the Ajrakhpur Block Printing cluster. Waste water will be transported to CETP through dedicated pipeline network. NOC is issued by Paddhar Village Panchayat for using the land to set up Common Effluent Treatment Plant by Ajrakhpur Hastkala Vikas Sangathan. The implementation plan is shown in below table 7.

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Table 7: Implementation Plan

7.2 Population projection The project will employ mostly workers from nearby villages during construction phase. There will not be any increase in population due to the project.

7.3 Land use planning The open space inside the CETP area will be suitably landscaped and covered with the vegetation of indigenous variety. Green Belt area will be developed with suitable verity of trees.

7.4 Assessment of Infrastructure Demand (Physical & Social) The proposed CETP falls in industrial area therefore all facilities / amenities like medical, educational, housing, transportation, communication, shopping etc are available nearby places. Since, local workers will be employed for this purpose therefore; no long term infrastructure will be required.

Sr. No.

Activity Month

1 Month

2 Month

3 Month

4 Month

5 Month

6 Month

7 Month

8 Month

9

1 Preparation of tender document

2 Tendering

3 Assessment of tender

4 Award of contract

5 Construction of civil work

6 Supply of electro-mechanical equipments

7 Assembly & erection of components

8 Piping work

9 Electrical & instrumentation work

10 Laboratory set up

11 Trial run & commissioning

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7.5 Amenities/Facilities

Man power will be required on permanent and temporary basis. Total 4 skilled labours will be engaged in shift at CETP. Rest room and toilet facility shall be provided at the plant site.

8 PROPOSED INFRASTRUCTURE

8.1 Industrial Area (Processing Area)

Being a CETP, New unit will make office space, laboratory, storage area as well as treatment units & use of the facilities for land, storage of raw material and handling, additional water & power demand, and use of road and rail network for transportation.

Green Belt

Green belt will be developed according to CPCB guidelines. Plants of the various species will be developed in the plant and peripheral areas.

Connectivity (traffic and transportation road/rail/metro/water ways etc.)

The project site is well connected to NH-42 road.

Drinking water management

About 5 KLD of water will be required during operation. The water will be met from proposed borewell.

Sewerage system

Toilets will be constructed at the site which will be connected with the septic tanks within the site itself.

Industrial waste management

Sludge generated from treatment units would be sent to TSDF site. Hazardous waste like used oil & containers/liners will be sent to the authorized recyclers.

Solid waste management

Solid waste generated during the wastewater treatment process is mainly sludge which will be generated depending upon the effluent characteristics and hydraulic load and the same would be transported to the authorized TSDF site for final disposal.

Power requirement & supply/source

Power Available: 40KW Backup Power supply source – 1 No D.G Sets of 10 KVA

9 REHABILITATION AND RESETTLEMENT (R&R) PLAN

The site is free from any settlement so there is no need of displacement of the people for proposed project, hence, No R&R applicable.

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10 PROJECT SCHEDULE & COST ESTIMATES

Cost Estimates

The estimated cost of the project is Rs 146 Lacs

Table 8: Estimated cost of the project

Particulars Cost

Estimated cost of Electro-mechanical items 69.00

Estimated cost of Civil items 22.00

Contingency 5.00

Design & drawing Cost 10.00

Overhead Cost 5.00

Implementation & Monitoring Cost 15.00

Six months handholding expenses 20.00

Total Estimated Project Cost (Rs. in Lacs) 146.00

10.1.1 DETAILS OF POWER COST

Table 9: Details of Power Cost

Sl. No.

Description Motor Rating (HP)

No of units

Installed

Working unit

Installed Load (HP)

Working Load (HP)

Working Hour/

day

(KWH/ day)

1 Effluent Withdrawal Station

3.0 2 1 6.0 3.0 8.0 17.9

2 Reaction Tank-1 1.0 2 0 2.0 0.0 0.0 0.0

3 Reaction Tank-2 1.0 4 0 4.0 0.0 0.0 0.0

4a Blower -1 5.0 1 1 5.0 5.0 12.0 44.8

4b Blower -2 7.50 1 0 7.5 0 0 0

5 Sludge Recycling Pump

2.0 2 1 4.0 2.0 4.0 6.0

6 Dosing Tank 1.0 2 2 2.0 2.0 8.0 11.9

7 Dosing Pump 0.5 4 4 2.0 2.0 8.0 11.9

8 Lime Dosing Pump 1.0 1 1 1.0 1.0 8.0 6.0

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9 Filtration Pump 5.0 2 1 10.0 5.0 6.0 22.3

10 Sludge (Screw) Pump

3.0 1 1 3.0 3.0 4.0 9.0

11 Laboratory/Lighting 7.5 1 1 7.5 7.5 5.0 28.0

Total 54.0 30.5 157.8

Based on the above load, the ‘Power Cost’ has been worked out as under:

Conversion factor (HP to KW) 0.746

No of working days/ month = 30

Load Factor = 0.65

KWh/month = 3077

Power Source Power Tariff (Rs/unit)

Cost/Month (Rs)

SEB – 95%

11 32151

DG – 5%

19 2923

Total Power Cost /month = Rs 35074

Power Consumption Rs /KL = 7.8

Sanction Load (KVA) = 55 (in, sanction may be taken for 35 KVA)

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Figure 7: Pie chart for Operating Cost.

11 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) Unlike other CETP/ETPs, the CETP at Ajrakhpur is characterized by a very high peak flow rate

compared to its daily discharge rate, since all the units run on single shift basis. Though the present

drainage is capable enough for effluent transportation .

The proposed treatment capacity being quite low (150 KLD), the cost of the treatment will be Rs 32/-

per KL. It can be inferred that as the capacity of treatment is low, it is not able to sustain various

expenses such as manpower (partly), maintenance, overhead etc which are fixed in nature giving a

rising impact on the treatment cost.

The treatment scheme has covered both physico- chemical & Biological treatment followed by a

chemi-polish and filtration mechanism which offers a very good quality reclaimed water for its

recycling. Therefore, its success may be a role model for handling the effluent of small scale Textile

units in future.

It is observed that majority of the products manufactured in this cluster are exported due to the

extensive demand of the goods being made using eco-friendly natural dyes. Further, use of

‘sustainable technology’ using effluent treatment promotes water conservation. This is expected to

24%

16%

33%

13%

6%

8%

RECURRING EXPENDITURE

ELECTRICAL POWER COST

CHEMICAL COST

MANPOWER COST

OVERHEAD COST

MAINTENANCE COST

SLUDGE PROCESSING COST

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give boost the export from this cluster due to its compliance for ecological balance. In this

perspective, it will be highly beneficial to adopt the proposed CETP not only for the growth of the

cluster in that region but also for the greater benefits for the society.