MMA CETP MAHAD

Seven Billion Dreams. One Planet. Consume

with Care

MMA CETP, MAHAD

Contents

• Historical Background of CETP

• Effluent characteristics & Challenges of MIDC, MAHAD

• Improving Effluent Treatment & Management

• Journey towards Sustainability

Historical Background….MMA CETP Mahad

Purpose of Existence

The Mahad Industrial Area came into existence in the later part ofeighties to overcome the water pollution related problems of the area.

Tremendous water pollution in surrounding of industrial area and SavitriRiver & creek

Thought process developed in early nineties to develop a CETP

However, actual development activity started only in 1998-99.

The treatability studies were conducted in the year 2000 by M/s.Paramount Ltd., Baroda.

The DPR was prepared in Nov. 2000 & technical appraisal done by IIT,Mumbai in 2001.

Primary treatment commissioned in 2003. Although the project executionwas delayed due to financial difficulties,

The project was completed and was fully operational only in June 2005.

Large Scale Industries, 12%

Medium Scale Industries, 12%

Small Scale Industries, 30%

Green Industries, 21%

Closed & Temporary

Closed Industries, 26%

Industry membership status

Large Scale Industries 16

Medium Scale Industries 16

Small Scale Industries 40

Total 72

Green 28

Closed/Temp. Closed 35

TOTAL 135

Category wise distribution of Industries

Industries Small Medium Large Total

Chemicals 66 15 9 90

Pharmaceutical 1 1 3 5

Dyes & Dye Intermediate 2 2 0 4

Textile 2 0 2 4

Pigment 0 0 1 1

Paper 0 0 1 1

Packing 1 0 0 1

Engineering 3 2 0 5

Others 23 1 0 24

Total 98 21 16 135

• Historical Background of CETP

• Effluent characteristics & Challenges of MIDC, MAHAD

• Improving Effluent Treatment & Management

• Journey towards Sustainability

Nature of Waste water – MAHAD MIDC

Flow cu. m/d 5500 – 6000

pH 4.5 – 8.5

COD mg/L 4500 – 5500

BOD mg/L 1200 – 1600

TSS mg/L 2000 – 4000

TDS mg/L 10000 – 15000

Design Capacity Plant Capacity 7.5 MLD

Avg. influent qty 6.5 MLD

Aeration volume Capacity 11500 Cub Mtr

Designed COD 3500 ppm

Designed BOD 1000 ppm

CETP FLOW DIAGRAM

Industrial

EffluentEqualisation

Receiving Sump with

Floating Aerators

Primary Treatment

Pump Grit

Chamber

Oil

Trap

pH

Correction

Lime

Flash

Mixer

PAC

Polyelectrolyte

Clariflocculator

Biotower

Feed

Sump

Pump

Pump

Secondary Treatment

Biotower

ClarifierReaction

Clarifier

Thickener

Flash

Mixer

PumpPump

PAC Lime

Polyelectrolyte

Decanter

Aeration Tank 1 and 2

with Diffused Aeration

& 9 No floating

aerators

Flow

Distributor

Centrate

Dewatered

Sludge

Drying

And

Disposal

To

MWML

Overflow

Polyelectrolyte

Beef extract

Nutrients

Air

Blower

Pump

Pressure

Sand

Filter

MIDC

Disposal

Sump

Discharge

To

saline zone

At

ovale

Tertiary Treatment

Pump

Backwash

SDB

FiltrateGrit

Pressure

Sand

Filter

Post Commissioning of MAHAD CETP & Performance During 2006 to 2010

Design Inlet Outlet

Flow cu.m/d 7500 5500 – 6000 5500 - 6000

pH <4.0 4.5 – 8.5 7.0 – 8.0

COD mg/L 3500 4500 – 5500 1800 – 2500

BOD mg/L 1500 1200 – 1600 120 – 160

TSS mg/L 500 2000 – 4000 < 100

TDS mg/L 2500 10000 – 15000 8000

• Mahad MIDC area was declared in the list of

Dirty thirty in world survey report in year 2004

CETP Poor Performance –Environmental Aspects & Impacts

Higher inlet COD along with heavy sludge and dark color.

Operation issues- infrastructure & staff.

Bribing to sampling team.

Irregular recovery of COD charges.

Leakages of storm water through damaged pipeline chambers resulting high flow to MMA CETP and overflow to river.

• Inadequate treatment leading to Frequent agitation and public nuisance from Khadipatta due to obnoxious smell and dark color of effluent in creek.

• Lost goodwill in society.

• Frequent breakdown of effluent pipeline due to sludge & liberation of gases due to anaerobic conditions resulted shutdown of whole Mahad industries many times- Economy loss to industries

• Demand for drinking water in Khadipatta.

CETP Poor Performance – Aspect & Impact on Environment continued..

• Due to Non-performance of CETP resulted into following…

• Discharge line breakage and pollution of water source

• Intermittent effluent discharge by MIDC due to villagers agitation

• Production loss

• Pollution problems in and around MIDC

• Sludge accumulation in receiving sump and other equipments like clarifiers and civil tanks.

• Implication

• Show-cause notice by MPCB

• Revoke of Bank Guarantee of Rs. 25.00 lacks

• Imposition of Penal charges by MPCB

• Serving closure notice to CETP and to all industries

• Huge cost of sludge removal and disposal to MWML site

• Historical Background of CETP

• Effluent characteristics & Challenges of MIDC, MAHAD

• Improving Effluent Treatment & Management

• Journey towards Sustainability

Challenges/Problems

• Very few factories in the MAHAD MIDC area had an ETP with full fledge treatment facilities at the start of the CETP project

• Member Industries were ready to pay penalties rather than treating their effluents culture more prevalent.

• No Concept of Recycle, reuse by member industries.

• Poor Operation & Infrastructure - inefficient aerators and blowers, Poor Laboratory infrastructure for accurate & fast analysis.

• High Hydraulic load during monsoon season due to the poor & damaged concrete chamber and old pipelines of incoming effluent.

• Frequent breakdowns of Effluent disposal pipelines from CETP to Ovale.

• CETP Staff not Competent enough, More prone or get trapped to Bribery leading manipulation of data .

• CETP run on contractual .

• Poor recovery of treatment charges from industry.

Improving Effluent Treatment & Management From 2012 onwards

• Steps taken for improvement of plant Operation & Maintenance

• Contractual operation & Maintenance suspended and Society overtookthe O & M and all director spend sufficient time for monitoring and day today work in society.

• Replacement of inefficient aerators and blowers by efficient surfaceaerators, screw compressors and instrumentation.

• Up-gradation of Laboratory infrastructure for accurate & fast analysis.

• Regular preventive maintenance of plant machinery and sumps.

• Restructuring and strengthening of Civil structures.

• Installed online monitoring system on influent and treated effluent

Improving Effluent Treatment & Management continued…

• Appointment of qualified staff & Training to staff for their skill improvement. Improvement of pay-package, incentives , stern action against employees who were indulged in malpractices.

• CETP started focuses on how to manage and monitor the different units/industries of ETP, Improved Competence of their field staff and Laboratory staff on how to collect, sealing and preserve samples from different units of ETP and send it to the laboratory for analyzing, which parameters have to be analyzed, how frequent sample has to be taken from different industries etc,

• With consistent follow-ups by CETP and rounds of meetings, several member industries developed plans, constructed and enhanced treatment facilities in their ETPs.

Improving Effluent Treatment & Management continued…

• Knowledge Development of Effluent Treatment - The CETP arranged several workshops and Seminars for the Member industry owners and management, where representatives from ETP designers and suppliers provided know-how and latest technological solutions to those who already have an ETP and facing problems regarding operating and monitoring ETP and also to member industries who are intending to install new treatment facilities in their own industry.

• Arranged internal visits to the best performing industries in terms of Effluent treatment management.

Improving Effluent Treatment & Management.. Contd…

• Determining effluent characteristics – Monitoring individual industries ETP/ Zone wise performance. ( As Guided by Dr. Rakesh Kumar, NEERI)

• The CETP has been assisting these member industries by reviewing and monitoring the operating efficiency of ETPs and also providing support in ETP management to improve efficiency and where possible try to reduce the running costs of the ETP.

• Visit of Executive committee member during night vigilance sampling to support sampling chemist in case of disputes/resistance for taking sample and also if required calling local MPCB officer to witness the facts.

• Deputed 24 hours monitoring duty of sampling chemist if industry is not cooperating and discharge high COD effluent.

• Valuable contribution of founder Members Mr. Suresh Bhonsle ,Mr. Mohanti & Mr. J.Z. Patil

• Appointment of technical consultant Mr. Hemant Rane .

Improving Effluent Treatment & Management continued…

• Turning Point • During Dec- 2014 , Executive Body, CETP took vital decision to evaluate

individual ETP performance by doing Stage-wise sampling and analysis.

• This resulted into identifying of poor performing & defaulter industries.

• These industries pressurized for the up gradation of ETP Management systems in their Units.

• Most of the identified and defaulter industries improved their performance. This resulted into substantial reduction in Organic load .

• CETP Management has taken stringent actions on industries who has still remain defaulters and name of such industries notified to MPCB for further actions.

• Within six months CETP inlet COD drastically reduced from the range of 1500 to2000 ppm to 700 to 900 ppm ( April 2015 onwards)

• Since last one year treated effluent norms maintained as per consent limit

Improving Effluent Treatment & Management.. Contd…

• Weekly Executive body meeting to review MMA CETP performance and resolve operation and sampling team issues.

• Calling defaulting industry in weekly executive body meeting and, taking action plan for improvement, in case repeated violation reporting to MPCB for further action

• Joint Analysis In case of deviation/difference in MMA CETP and member industry reading - Giving chance for Joint analysis of sealed sample and consider that analysis for billing purpose.

• Appointment of ISO consultant to implement Quality management systems, Environmental & legal compliance, Health & safety practices.

• Incentive scheme for best performance of staff through performance appraisal system.

• Involvement of Sr. NGO Dr. Patwardhan for their valuable inputs.

Management

Built up strong team to combat the pollution

• Executive Committee Members-11• Technical Committee-4,• Sampling & Vigilance team-4,• General Manager-1• Plant Operations’ Manager-1,• Mechanical Engineer-1• Environmental Officers- & Chemists – 8,• Operators-11,• Technicians-4,• Senior Account-1,• Office staff-3,• Operation Helpers ( from surrounding villages) --30

Improved performance from year 2015

• Effluent color Almost colorless.

• Inlet COD 700 to 900 ppm

• Inlet BOD 100 to 150 ppm

• Outlet COD 190 to 250 ppm

• Outlet BOD 50 to 90 ppm

Incoming Effluent Color before & and after

Effluent Color Before & After at bio-tower

Effluent Color Before & After at Disposal point

Disposal point down stream

Average Stage Vise COD Reduction year 2015

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1600

1800

JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC

In let eff. COD mg/lit

A.Primary COD mg/lit

Secondary COD mg/lit

Tertiary COD mg/lit

Average Stage Vise BOD Reduction for year 2015

0

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300

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JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC

Inlet eff. BOD mg/lit

A.Primary BOD mg/lit

Seconday BOD mg/lit

Tertiary BOD mg/lit

MPCB RESULT FOR YEAR 2015 OF CETP

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MPCB Results year 2015BOD outlet

MPCB Results year 2015COD outlet

MPCB RESULT FOR YEAR 2016 OF CETP

60

8090

72 70

90 9080

50 50

73.2

216224

240

208

184

208

240

192 192200

210.4

0

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MPCB REPORT 2016 OUT LET BOD

MPCB REPORT 2016 OUTLET COD

ROLE OF MEMBER INDUSTRIES IN IMPROVINGCETP PERFORMANCE

• Few of Large scale & RED category Industries upgraded their ETP by usingnew technology like MEE, RO, aeration systems and thus started recycleand re-use of effluent in their own plant/ processes resulted organic Loadas well reduced the hydraulic load to CETP.

• Member industries started fall in line as per direction given by Hon. HighCourt i.e synchronization of products

• Few of the Industries adapted the Waste to Wealth concept and thusconverting their wastage in to the by-product and reusing in-house orselling as byproduct to the other need industries for their actual uses. Thislead to reduction in TDS levels

• The industry like H. acid manufacturer which was using spent acid for theisolation, generated gypsum and iron oxide sludge is selling to the cementand still manufacturing industries.

Key of success

• Timely Repairs of damaged chambers on effluent collection lines by MIDCto avoid storm water leakage and to reduce hydraulic load on CETP.

• MIDC Focused on preventive maintenance of effluent lines from CETP toOvale.

• Executive engineer MIDC has always played vital role between Khadipattapublic and CETP body to improve communication and relations.

• Actions considered and improvements made as per guidelines of Dr.Rakesh Kumar from NEERI during DPR to do the backward integration ofincoming COD load.

• With the support of local MPCB officer and MMA CETP joint visits areconducted to Defaulting units.

• Quarterly review meetings with Local Govt. authority , SRO & RO- MPCB,NGO to review public complaints due to pollution problems in MIDC andKhadipatta and to tackle the issues at local level.

First in Maharashtra to Install Online monitoring system as per CPCB guidelines.

Modified the Laboratory by providing/up-grading the testing equipments with qualified chemists.

Segregation of MIDC residential colony sewage with separate line and connecting directly toaeration for Bio-Mass seeding.

Nine number of sumps have been constructed at different location in order to monitor thepollution levels.

Treatability study of incoming effluents in context to change in the characteristic of theincoming effluent

Enhancing the operation and monitoring by integrating the advanced instrumentation.

First in Maharashtra (2nd in India) to qualify for IMS certification for effectiveimplementation of QMS , Environment, Health & safety for efficient qualityoperations.

(ISO-9001:2008, ISO-14001:2004 & OSAH-18001:2007) certificate is granted by ICScertification body

Action Taken in 2014-2016

Social Activities

A. Providing drinking water to Khadipatta Villagesthrough MIDC and reimburse 90% payment.

B. Financial help to schools for e-learning.

C. Provided free mobile hospital facility to all villages inMahad.

Permanant Mobile hospital Seva to surrounding

Villages & Adivasi Vadi Areas for Mahad Taluka

Permanant Mobile hospital Seva to surrounding Villages

& Adivasi Vadi Areas for Mahad Taluka

Permanant Mobile hospital Seva to surrounding Villages

& Adivasi Vadi Areas for Mahad Taluka

Impact of best MMA CETP performance

• Villages covered in ecosensitive zone passed resolutions todelete their name from the ecosensitive zone list andsupported for expansions and inviting for new industries.

• Surrounding peoples started involving in various industrialwelfare programs.

• Due to scientific approach and best performance of CETPstudents from various universities approaching for academicproject work under guidance of our tech experts e.g. recentlyMr. Amit Late from MPCB FO has been published his researchpaper on process of Sodium sulphate recovery in theinternational conference of Water Environment, Energy &Society at Bhopal.

• Started giving respect to industry

Support Required from MPCB/MIDC for Sustainable Development of Industry

ECO sensitive zones to be reconsidered to enhance the Industrial growth in Mahad MIDC.

For the Development of the Mahad Industrial area permission to new in coming industries.

Additional /standby disposal line required from Village Muthavali to Ovale village and extension of the line to the saline zone as per reports given by NIO. Proposal is under process with MIDC but need to speed up

Video Clip

VID-20160302-WA0002.mp4

Future plans.. Journey towards Sustainability

A. Treatability study with new MBR technology to increase MMA CETP capacity for industrial growth.

B. Provide support for sewage treatment of Birawadi village.

C. Set up compost plant in MMA CETP for canteen waste disposal of all industry and other biodegradable waste in surrounding.

D. CSR activities for surrounding villages.

1

OUR GOALS

Continuously achieve MPCB prescribed norms

Conservation of the natural resources

Work to achieve the Golden point for balancing of ECO system

Safe planet for coming next Generation

Provide Green environment to the society

Seven Billion Dreams. One Planet. Consume with Care

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• Backup slides

We work together

Action Taken in 2010-2015• Installed high efficient aeration system by providing 9 Nos. of aerators (Total 270

H.P.)with cost of Rs: 65 lacs,

• Revamping of Chemical dosing system with cost of Rs: 15 to 20 lacs,

• Civil work of receiving sump’s pump house & sump enclosed wall jacketing with cost of Rs: 15 lacs, to arrest the leakages of receiving tanks.

• Modification of Bio Tower, Flocculater & Scrappers in Primary & Secondary clarifiers with cost of 4.5 lacs,

• Revamping of sand filters with cost of Rs: 2.5 lacs,

• Replacing old pipe lines with cost of Rs: 5lacs,

• Segregation of low COD effluent of 2.5 MLD & feeding to tertiary treatment .

• Installed 2 number of sound proof and energy efficient air blowers of 37kv each of Atlas Copco make. In this case we save 30-40% energy of air blowers in Jun 2014

• Dissolved oxygen level increased from 0.7 to 1.5 ppm.

• Improved F/M Ratio from 1.5 to 0.9

• Optimized the Dosing Pumps capacities in Chemical House to improve the PhysicoChemical Treatment in Jan2015

• Replaced old inefficient pumps by Screw Pumps in Primary & Reaction Clarifiers and Sludge Thickener for de-sludgeing

Success story of IndustriesPHOTO GALLARY: ETP, MEE & Spray Dryer

Crocodile at the CETP Disposal point