IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects –...

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IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011 by International Workshop PPP Models and Technological Solutions for Sewage and Waste Management &

Transcript of IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects –...

Page 1: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

IIT Bombay

IIT Delhi

IIT Guwahati

IIT Kanpur

IIT Kharagpur

IIT Madras

IIT Roorkee

Model Projects – Suggested Approach

Way Forward?

September 22-23, 2011

by

International Workshop

PPP Models and Technological Solutionsfor Sewage and Waste Management

&

Page 2: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Model Projects

September 22-23, 2011

International Workshop

PPP Models and Technological Solutionsfor Sewage and Waste Management

1. Cluster of Pulp and Paper Industries in Uttarakhand and Uttar Pradesh

2. Tannery Effluents and Sewage Treatment in Kanpur, Uttar Pradesh

3. Sewage Treatment in Patna, Bihar4. Sewage Treatment in Kolkata, West Bengal5. Distillery Industries in Ganga Basin

Page 3: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Ganga Basin Drainage Area of the Ganga River Covering 11 States in India (AIWFS Data)

Page 4: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Haryana

Rajasthan

Madya Pradesh

West Bengal

Bihar

UP

Kanpur

Yamuna

Ganga

Ganga

Ram

Ganga

Kali

Yamuna

Gomti Ghagar

Gandak

Son

Ganga

Kosi

Delhi

BanarasAllahabad

Uttarkashi

Rishikesh

Haridwar

Garh Mukteshwar

Patna

Lucknow

Mathura

Agra

Page 5: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

State Governm

ent

Central Governm

ent

Public

ULBs

Service Provider

/ Operator

DBFO Model for STPs

Page 6: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• The service provider/operator builds, and then maintains and operates the facility for the contract period after commissioning.

• Responsibility for the arrangement of uninterrupted power supply for the facility is with the service provider/operator.

• The service provider/operator and ULB will have joint rights (as stipulated in the contract) for the commercial exploitation of the products, i.e., treated water, sludge and sludge-derived products generated through sewage treatment. A special purpose vehicle (SPV) may be set up for this purpose by the service provider/operator and ULB using the PPP model.

• Any treated sewage, sludge, etc. discharged from the sewage treatment facility during the contract period to be disposed of by the service provider/operator in a safe manner and as per provisions of the contract.

DBFO Model for Sewage Treatment - Essential Components

Page 7: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• The facility reverts back to the ULB after the end of the contract period unless the contract duration is extended.

• Any liabilities arising out of site contamination during the construction period and contract period for operation of the facilities by the service provider/operator lie with the service provider/operator, even after conclusion of the contract period.

• The facility reverts back to the ULB after the end of the contract period unless the contract duration is extended.

• Any liabilities arising out of site contamination during the construction period and contract period for operation of the facilities by the service provider/operator lie with the service provider/operator, even after conclusion of the contract period.

DBFO Model for Sewage Treatment - Essential Components

Page 8: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

In this model, the income to the service provider/operator will be from two sources:

▫ Payment made to the service provider/operator in the form of annuities. The expected amount of annual payments (for each year of operation after commissioning) will be clearly specified in the contract. However, the actual annual payments shall be linked to the quantity of treated sewage (of specified quality) produced by the service provider/operator in that year.

▫ Profit (if any), from commercial exploitation of resources generated through sewage treatment, i.e., sale of treated water, sludge and sludge-derived products, as per provisions specified in the contract.

In return, the service provider/operator is expected to invest the entire funds required for initial creation of the sewage pumping and treatment infrastructure as per the approved DPR and also take care of operation and maintenance of the facility through the operation and maintenance contract period.

DBFO Model for Sewage Treatment - Essential Components

Page 9: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

State Pollutio

n Control Board

Central Pollutio

n control Board

Industry Associati

on(Company Ltd)

Industry

Service Provider

/ Operator

DBFO Model for Industry

Page 10: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• Most of the ETPs perform much below the expected level and most of the times effluent discharge norms are violated.

• Lack of knowledge and expertise to manage the ETPs and lack of resources and man power for enforcing the regulations and taking actions have been cited for poor performance.

• In several instances causes beyond technical and financial are responsible for unabated pollution of rivers.

DBFO Model for Industry Clusters/Groups

Page 11: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• It is recommended that ETPs are planned on DBFO model with third party involvement as a company floated by the Association of Industries. The ETPs will be in the premises of the industry. Land for the ETP is to be provided by the industry.

• The company will be responsible for managing the effluent recycling plants through service provider/operator using DBFO model and will receive funds in the beginning of the year from each of the industry towards supply of treated water of industrial grade produced from effluents discharged by the same industry.

• The service provider/operator will get the payment based on quantity of industrial grade water produced from the effluents on monthly basis.

• Renewing consent to operate the industry may be linked to deposition of funds in the accounts of the company floated by the Association.

DBFO Model for Industry Clusters/Groups

Page 12: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Model Project 1: Cluster of Pulp and Paper Industries in

Uttarakhand and Uttar Pradesh

Page 13: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pollution of River Ganga: Contribution of Pulp and Paper Industries

Through Tributaries - Ram Ganga and Kali

Wastewater Discharge in Ram Ganga

Uttarakhand: 162 mld; Uttar Pradesh: 74 mld

Industrial Waste in Kali

86 mld; 13,000 TPD BOD Load

Pulp and Paper Industries Contribution:

Through Ram Ganga Uttarakhand: 146 mld (90%); Uttar

Pradesh: 39 mld (53%)

Through Kali 37 mld (43%)

Page 14: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Delhi

Mumbai

Chennai

Kolkata

Gangotri Glacier

Ganga Sagar

Bay of Bengal

River Ganga – Origin (Gangotri) to Destination (Ganga Sagar)

Page 15: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Ganga Ramganga

Kali

Kannauj u/s (Fatehgarh)

On River Kali at Kannauj

On River Ganga (Ramganga) at Kannauj

Kannauj d/s (after confluence of Ramganga and Kali)

Kanpur u/s at Bithoor

Kanpur u/s at Shuklaganj

Kanpur d/s at Jajmau/Jane

“Kannauj – Kanpur” Stretch

Page 16: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

Clusters: Kashipur – Thakurdwara (15+3+3+3)

Muzaffarrnagar (8+7+2+6)

Meerut (2+3+3)

Moradabad (4)

Water Consumption/Wastewater Generation is High; Not Closely Spaced;

Conveyance Costs are High; CETPs are not viable options; Particularly if ZLD is to

be achieved

Page 17: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinPresent Status

Scale of Operation: 25 – 250 TPD

Mills with 100 TPD Producing Bleached Variety of Paper have

CRP

Others making Craft Paper from Agro Residues do not have CRP

All mills have ETP PC, AT, SC

Performance!

Page 18: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

Category

Existing Water Consumptionm3 / T paper

(Average)

Achievable Water

Consumptionm3 /T paper*

(Average)

Best Achieved Water

Consumptionm3 /T paper

(Average)

Bench mark for water

Consumptionm3 /T paper

(Average)A1: Agro BasedWriting & printing paper mills

100 80 60 50

A2: Agro Based Kraft paper mills 75 45 45 30

B1: RCF Based Writing & printing paper, Duplex board, newsprint

50 20 30 20

B2: RCF basedKraft paper mills 35 10 15 10

Water Requirements for Four Different Categories

* as per discussions with the representatives of the pulp and paper industries

Page 19: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

ParametersRaw

Water

Effluent

A1: Agro Based Writing

& printing paper mills

A2: Agro Based Kraft paper mills

B1: RCF Based Writing & printing

paper, Duplex board, newsprint mills

B2: RCF Based

Kraft paper mills

pH 7.5 -7.8 7.0 -7.8 6 6.8 -7.3 6TDS, mg/l 290 1100-6800 1560 800-1720 840-3240TSS, mg/l Nil 384-1950 466 160- 4387 56-680COD, mg/l Nil 776-5048 1010 262-1715 704-2016BOD, mg/l Nil 450-2234 543 180- 958 593-1058Colour Nil - * -* - -Turbidity, NTU Nil 35-19 106 2 -35 22- 299Hardness, mg/l as CaCO3

180 -185

* Mills are using RCF only at present

Typical Characteristics of Water and Wastewater

Page 20: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

Capacity, MLD

Treatment Cost up to Tertiary Treatment without RO , `/m3

(including capital, O & M, and Reinvestment Cost assuming 15

Years Life of ETP as on 2010)

Treatment Cost up to Tertiary Treatment with RO , `/m3

(including capital, O & M, and Reinvestment Cost assuming 15

Years Life of ETP as on 2010)0 – 5 15 100

5 - 20 10 100

Estimated Capital and Operation and Maintenance Costs for ETPs

Note: Actual cost will be technology and location specific

Page 21: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

Grade of PaperProduction cost

` / T paperSelling Price` / T paper

A1: Agro BasedWriting & printing paper 32000 – 34000 38000 – 40000

A2: Agro BasedKraft paper ( 100 % agro) 19000 – 20000 23000 – 24000

B1: RCF Based Writing & printing paper 32000 – 33000 35000 – 36000

B2: RCF BasedKraft paper 22000 – 22500 23000 – 24000

Estimated Production Cost and Selling Price for Different Grades of Paper

Page 22: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

Category

Achievable Water

Consumptionm3 /T paper*

(Average)

Average Productio

n Cost` / T

paper

Estimated Cost, ` / T paper Percentage Increase in the

Average Production

Cost

Chemical Recovery from

Black Liquor Using CRP/CCRP

Complete Recycling of Effluent

Attaining Zero

Discharge Paradigm

A1: Agro BasedWriting & printing paper mills

80 33000 163 1,200 (5,875)#

1,363 (6,038)#

4.1(18.3)#

A2: Agro BasedKraft paper mills

45 19500 163 675(3,225)$

838(3,388)$

4.3(17.4)$

# Considering 25 and 55 m3/T paper without and with RO treatment respectively; $ Considering 15 and 30 m3/T paper without and with RO

treatment respectively; Cost of recovery of solids from RO Reject on drying is included in the RO treatment

Estimated cost of Water Reuse/ Recycle after Tertiary Treatment in a Typical Mill of Capacity 25 TPD Paper and Pulp Mill

Page 23: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga Basin

Category

Achievable Water

Consumptionm3 /T paper*

(Average)

Average Production Cost

` / T paper

Estimated Cost, ` / T paper Percentage Increase in

the Average Production

Cost

Chemical Recovery from

Black Liquor Using

CRP/CCRP

Complete Recycling of Effluent

Attaining Zero

Discharge Paradigm

B1: RCF Based Writing & printing paper, Duplex board, newsprint mills

20 32500 Not Applicable 300 (2,000)*

300 (3,000)*

0.9(6.2)*

B2: RCF BasedKraft paper mills

10 22250 Not Applicable 150 (1,000)*

150 (1,000)*

0.7(4.5)*

Estimated cost of Water Reuse/ Recycle after Tertiary Treatment in a Typical Mill of Capacity 25 TPD Paper and Pulp Mill

*Considering RO treatment; Cost of recovery of solids from RO Reject on drying is included in the RO treatment

Page 24: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinRecommendations: B1 and B2 Categories

• Increase in average production cost for B1 and B2 categories of industry is in the range of 4 – 6 %.

• The cost of tertiary treatment of the trade effluent is not prohibitive and is technically feasible.

• Achieving zero liquid discharge implies only an increase in cost of the paper production by a few percent of the production cost for B1 and B2 category of industry and must be enforced to save the precious resources like river Ganga in particular and Ganga system in particular.

• The implementation of this may result in slight reduction in profit margin or alternatively the cost will be passed on to the consumers.

• Thus it is strongly recommended that the “polluter pays principle” must be strongly adhered to achieve zero discharge paradigm in case of the pulp and paper industries.

• This will immensely help saving the rivers, in particular the river Ganga, from adverse impacts without significant impact on the industry or economy or employment opportunities.

Page 25: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinRecommendations: A1 and A2 Categories

• Increase in average production cost for A1 and A2 categories of industry to attain zero discharge paradigm is in the range of 17-19 %.

• This is on the higher side. • However, in the nations’ larger interest zero discharge paradigm must be

enforced to protect rivers like Ganga, and the Ganga system. • At the same time these category of industry are important from several

considerations including utilization of renewable agro based residues that will otherwise be burnt and create air pollution problems.

• Hence closure of these types of industry is not in the larger interest.

Page 26: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinRecommendations: DBO Model for ETPs

• The past experiences reveal that most of the ETPs perform much bellow the expected level and most of the times effluent discharge norms are violated.

• Number of reasons, including lack of knowledge and expertise to manage the ETPs, has been cited by the industry for poor performance.

• Also the regulating agencies, such as State Pollution Control Boards (SPCBs), have cited many reasons including lack of resources and man power for enforcing the regulations and taking actions for unabated pollution of rivers due to discharge of industrial effluents.

• In several instances, as shown in the case of pulp and paper industries, causes beyond technical and financial are responsible for unabated pollution of rivers.

Page 27: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinRecommendations: DBO Model for ETPs

• Experience with other industrial sectors, particularly in water scarce areas, suggests that third party involvement and ETPs producing industrial grade water have been performing well.

• As such it is recommended that ETPs are planned on design, build and operate (DBO) model with the involvement of a company floated by the Association of Industries.

• This company will be responsible for managing the effluent recycling plants through service provider using DBO model and will receive funds in the beginning of the year from each of the industry towards supply of treated water of industrial grade produced from effluents discharged by the same industry.

• The ETPs will be in the premises of the industry. Land for the ETP is to be provided by the industry. The service provider will get the payment based on quantity of industrial grade water produced from the effluents on monthly basis.

• Consent to operate the industry is to be given only upon deposition of funds in the accounts of the company floated by the Association of Industries by the member industries.

Page 28: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinHighlights

· Pulp and Paper Industries, both agro and RCF based, are important for growth and development.

· Shifting towards zero liquid discharge paradigm is feasible and must be implemented to save rivers and help maintain “Nirmal and Aviral Dhara”.

· Improvements in technology and following best practices can lead to substantial reduction in water consumption and lower the cost of attaining zero discharge paradigm.

· Black liquor from agro based pulp and paper industries must be sent to CCRP for smaller units (< 100 TPD). Larger units may be allowed to have their own CRP.

· Pulp and Paper Industries, both agro and RCF based, are important for growth and development.

· Shifting towards zero liquid discharge paradigm is feasible and must be implemented to save rivers and help maintain “Nirmal and Aviral Dhara”.

· Improvements in technology and following best practices can lead to substantial reduction in water consumption and lower the cost of attaining zero discharge paradigm.

· Black liquor from agro based pulp and paper industries must be sent to CCRP for smaller units (< 100 TPD). Larger units may be allowed to have their own CRP.

Page 29: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinHighlights

· ETPs must be upgraded to tertiary level treatment. Some or all, depending on requirement, tertiary treated water may have to be treated using RO.

· The cost of treatment up to tertiary treatment including RO treatment may increase the production cost only by 4-6 % for RCF based industries and must be enforced.

· The cost of treatment up to tertiary treatment including RO treatment may increase the production cost by 17-19 % for agro based industries, but also must be enforced. However, some concessions may be offered to promote agro based industries.

· CETPs do not appear to be viable for Pulp and Paper Industries in the identified clusters in the Ganga River Basin. However, all ETPs are to be managed by a company formed by association of industries.

· ETPs must be upgraded to tertiary level treatment. Some or all, depending on requirement, tertiary treated water may have to be treated using RO.

· The cost of treatment up to tertiary treatment including RO treatment may increase the production cost only by 4-6 % for RCF based industries and must be enforced.

· The cost of treatment up to tertiary treatment including RO treatment may increase the production cost by 17-19 % for agro based industries, but also must be enforced. However, some concessions may be offered to promote agro based industries.

· CETPs do not appear to be viable for Pulp and Paper Industries in the identified clusters in the Ganga River Basin. However, all ETPs are to be managed by a company formed by association of industries.

Page 30: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pulp and Paper Industries in Ganga BasinHighlights

· Consent to operate the industry is to be given only on annual advance payment to the company for producing industry grade water by operating state-of-the-art ETP in each industry.

· DBO model is to be applied for all ETPs. Service provider is to be selected by the company and paid on the basis of quantity of industry grade water produced from the effluents.

· Flow meters to be installed at the inlet and outlet of each ETP.

· Industries are allowed to take fresh water only to make up for the losses due to evaporation, minor leakages, etc.

· Consent to operate the industry is to be given only on annual advance payment to the company for producing industry grade water by operating state-of-the-art ETP in each industry.

· DBO model is to be applied for all ETPs. Service provider is to be selected by the company and paid on the basis of quantity of industry grade water produced from the effluents.

· Flow meters to be installed at the inlet and outlet of each ETP.

· Industries are allowed to take fresh water only to make up for the losses due to evaporation, minor leakages, etc.

Page 31: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Model Project 2: Tannery Effluents and Sewage Treatment in Kanpur, Uttar Pradesh

Page 32: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Pandu River

Ganga R

iver

Ganga R

iver

Typical City / Town

Page 33: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• There are 418 tanneries in Jajmau, the total installed capacity is 39270 hides per day.

• Average capacity to process number of hides in all tanneries in Jajmau area (operational and temporarily closed) is anywhere between 20000 to 30000 hides per day with average weight of hide of about 28 kgs.

• About 1400 liters of water is consumed per hide in processing from raw to finish. Corresponding estimated effluent quantity would be 24 to 28 MLD.

Different aspects of Upgradation of Tanneries CETP @ Jajmau, Kanpur – IL&FS Study

Page 34: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• Jajmau is mixed agglomeration of tanneries, houses, shops and other commercial establishments in a very intricate fashion.

• About 4-8 MLD sewage is expected to get mixed with effluent. Thus design flow for the plant is estimated to be 32 MLD.

Different aspects of Upgradation of Tanneries CETP @ Jajmau, Kanpur – IL&FS Study

Page 35: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Costs Involved in the Tanning ProcessBuffalo Cow Goat

Cost of Raw HideMarket Price for Raw Hide, Rs. 700-1000 800-2000 60-120

Surface Area, sq.ft 34-40 32-36 4-5

Price per sq ft. 17 – 30 20-50 12 – 30

Cost of Tanning, Rs /sq. ft1. Raw Hide to Wet Blue 6.5 – 7.0 5.0 – 6.0 3.0 – 4.0

2. Wet Blue to Crust Felt (Chroming / Oiling)

8.0 – 9.0 6.5 – 7.0 4.0 – 5.0

3. Crust Felt to Finished Leather 4.0 – 5.0 3.0 – 3.5 2.5 – 3.0

Total CostProduction Cost, Rs. / sq. ft 40 - 45 50 – 55 30 - 35

Domestic Selling Price, Rs. / sq. ft 45 - 50 55 - 60 35 - 40

Export Price, Rs. / sq. ft 4-5 % higher than domestic selling priceProduction Cost Price per Hide, Rs. 1400-1800 1600 - 2000 120 - 180

Page 36: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Characteristics of Tannery Effluents to be Received at CETP in Jajmau, Kanpur

Parameters Suggested Design Value after Pre- settling and Equalization

pH 7.0-9.0 Total solids 10000-13000

TSS 2000-3000 TDS 8000-10500 COD 4000-6000 BOD 1800-3000

N-NH4 100-250 Cl 3000-4500

Sulfides 150-300 SO4 800-1500

Total Chrome 40-80

All values in mg/l except pH

Different aspects of Upgradation of Tanneries CETP @ Jajmau, Kanpur – IL&FS Study

Page 37: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

•Industries agree to constitute a special purpose vehicle (SPV) for implementing the project.

•SPV will be responsible for operating and maintaining all components of the up-graded CETP and to meet the discharge norms stipulated from time to time.

Different aspects of Upgradation of Tanneries CETP @ Jajmau, Kanpur – IL&FS Study

Page 38: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

The desired features in any renovated tannery wastewater facility proposed for the Jajmau area in future are the following:

• The portion of wastewater from tanneries containing high concentrations of chromium should be conveyed to a chrome recovery plant. The recovered chrome and other solid residues from the chrome recovery plant must be reused or disposed in a hazardous waste landfill. Effluent from the chrome recovery plant to be sent to the CETP for further treatment.

• The remaining tannery wastewater must be screened for removal of large objects at the tannery premises itself, before discharge into the tannery wastewater conveyance system.

Tannery Wastewater Treatment: Desired Features

Page 39: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

• Treated tannery wastewater to be reused / recycled in the tanneries, such that the freshwater requirement in tanneries is reduced.

• No direct use of treated tannery effluent for sewage farming. Direct discharge of treated tannery wastewater into the river Ganga is not allowed.

• Tannery wastewater in the conveyance system must be screened again before being pumped through rising mains to the CETP.

• CETP to be designed for the treatment of tannery wastewater to tertiary levels.

• The tertiary treated wastewater may be diluted with treated domestic sewage for reduction of TDS, and/or other advanced processes (e.g., RO with suitable reject management) must be incorporated for reduction in TDS concentration.

Tannery Wastewater Treatment: Desired Features

Page 40: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Comprehensive Cost of Wastewater Treatment per Buffalo Hide as per ZLD Concept

Production Cost, Rs. / Hide 1400 - 1800

Cost of Wastewater Treatment (without RO), Rs./ Hide

75 – 90 (4.1 – 6.5 % of Production Cost)

Cost of Wastewater Treatment (with RO), Rs./Hide

225 – 300(12.5 – 21.5 % of Production

Cost)

Cost of Wastewater Treatment Currently Paid by the tanneries in Jajmau to UPJN, Rs. / Hide

4(0.22 – 0.28 % of Production

Cost)

Page 41: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Sewage Treatment in Kanpur, UP

Parameters

Name of Sewage Treatment Plant

5 MLD Plant at Jajmau

130 MLD Plant at Jajmau

36 MLD CETP at Jajmau

Year of Construction 1987-89 1999 1994Installed Capacity (MLD) 5 130 36Current Utilized Capacity (MLD) 4 60 22-26

Adopted TechnologyUp-flow Anaerobic

Sludge Blanket (UASB)

Activated Sludge Process (ASP)

Up-flow Anaerobic Sludge Blanket (UASB)

Capital Cost (Rs. in Millions) 9.5 310 235O&M Cost/Year (Rs. in Millions) 113 56.7Mode of Disposal To Irrigation channel or in the Ganga River

Remarks -The plant is under loaded

due to inadequate sewage conveyance and pumping infrastructure

-

Page 42: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Model Project 3: Sewage Treatment in Patna, Bihar

Page 43: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Summary of Information on Sewage Treatment Plants in Patna, Bihar

ParametersSewage Treatment Plant

Saidpur Beur Pahari Karmali Chak

Year of Construction 1936 1969 - Under construction

Installed Capacity (MLD) 45 35 25 4

Current Utilized Capacity (MLD) 33 16 Not in

operation Under construction

Adopted Technology Activated Sludge Process (ASP)

Activated Sludge

Process (ASP)Aerated

Lagoon(AL) Oxidation Pond (OP)

Total WW Generation: 143 MLD Total STP Capacity (installed): 110 MLD

Utilized Capacity : 49 MLD

Page 44: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Summary of Information on Sewage Treatment Plants in Patna, Bihar

ParametersSewage Treatment Plant

Saidpur Beur Pahari Karmali Chak

O&M Cost(Rs. in millions)

Fund Requirement 7.96 12.5 7.815

Under constructionFund Allocation 0.708 1.104 4.33

Mode of Disposal For Irrigation & Ganga River

For Irrigation &

Punpun River

For Irrigation & Ganga River

For Irrigation

Remarks

The STP is under-utilized due to

insufficient pumping by the

intermediate pumping stations

The plant is not working

continuously due frequent

power failures

The plant is not in operation

due mechanical and electrical

failures

In complete construction due to the problem of acquisition of

land

Page 45: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Spatial Distribution of STPs in Patna, Bihar

Page 46: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Model Project 4: Sewage Treatment in Kolkata, West Bengal

Page 47: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Summary of Information on Sewage Treatment Plants in Kolkata City, West Bengal

Parameters

Sewage Treatment Plant

Garden Reach Bangur South Suburban(East) BhagaJatin

Year of Construction 1996 1997 2002 -

Installed Capacity (MLD) 47.5 45 30 5

Current Utilized Capacity (MLD) 30 20-25 - -

Adopted Technology Activated Sludge Process (ASP)

Activated Sludge Process (ASP)

Oxidation Pond (OP)

Aerated Lagoon(AL)

Capital Cost (Rs. in millions) 774.4 114 - -

Mode of Disposal River Ganga through canal

River Ganga through canal

River Ganga through canal

River Ganga through

canal

Total WW Generation: 618 MLD Total STP Capacity (installed): 127.5 MLD

Utilized Capacity : 50 - 55 MLD

Page 48: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Model Project 5: Distillery Industries in Ganga Basin

Page 49: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Estimated Pollution Load from Distilleries in the States of Gangetic Planes

State Number of Distilleries

Installed Capacity (million liters/year)

Effluent Generated

(million liters/year)

BOD load (tonnes/

year)

Bihar 13 88 1323 10584Haryana 5 41 615 4920Madhya Pradesh 21 469 7036 58288Rajasthan 7 14 202 1616Uttar Pradesh 43 617 9252 74016West Bengal 6 24 371 2968

Page 50: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Spatial Distribution of Sugar and Distillery Industries in the Ganga Basin

Page 51: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Distillery Industries in Ganga Basin

• The problem posed by distillery effluents runs, literally, pretty deep- run-off effluents percolate into surrounding fields, thereby polluting soil and damaging its structure.

• The task at hand is twofold: to dispose of effluents in an environment-friendly manner, and to reclaim the effluent-loaded sites that have turned into wastelands.

• The CPCB has been advocating Zero Liquid Discharge (ZLD) for distilleries. However, the situation on ground is that almost all industries do not even meet the specified effluent discharge standards. It is necessary to adopt the concept of ZLD through state-of-the-art technological solutions and introduce third party (other than industry and regulating agency) through appropriate DBFO models.

Page 52: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Epilogue

• Prospects of generating resources through sale of treated water, energy from waste, and sludge or sludge derived products.

• Changes and/or introduction of new policies/legislations/regulations at the central, state and local government level to facilitate establishing market for or generating resources from sale of treated water, energy and sludge or sludge derived products.

• Performance assurance to be obtained from private party and required payment guarantee for successful implementation of the proposed or any other DBFO or equivalent models.

• Prospects of finding private entities interested in technology transfer and investments in recycle and reuse of sewage and industrial effluents.

Page 53: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Epilogue

• Framework for concession agreements or contract documents amongst urban local bodies (ULBs), state governments, central government and private entities for sewage treatment and reuse/recycle.

• Framework for concession agreements or contract documents amongst industries, industry associations, state and central government and private entities for treatment and reuse/recycle of industrial effluents.

• Road map for working on technology transfer and developing PPP models for management of both sewage and industrial effluents.

• Road map for building on model projects through bilateral and/or other funding agreements for achieving the target of Clean Ganga Mission of the Government of India by 2020.

Page 54: IIT Bombay IIT Delhi IIT Guwahati IIT Kanpur IIT Kharagpur IIT Madras IIT Roorkee Model Projects – Suggested Approach Way Forward? September 22-23, 2011.

Thank You !!