Neha Mehendale WRM - Process and Energy Studies of an STP

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    Neha Mehendale

    1052 MNW

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    Introduction

    y STPs an important requirement

    y

    Deal with high BOD ofsewage

    y Preventing adverse impact on water bodies

    y Energy intensive process

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    About the organization

    y TechnogreenEnvironmental Solutions,Pune

    y Branches Mumbai,Pune, Kolhapur, Nashik,Solapur and Sangli

    y Services include Air, Water and Soil Quality Management,Solid and

    HazardousWaste Management

    y EIA, Habitat Restoration, Auditing, BiogasPlants, Wastewater

    Treatment

    y Kirloskar Brothers Ltd. , Mahindra & Mahindra,ITC Ltd.,Siemens Ltd.,

    Venkateshwara Hatcheries, Bharat Forge

    Environmental SolutionsgTechno reen

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    Objectives

    y Understanding the process ofSTP

    y Energy consumption at the plant

    y Suggestions for reducing energy costs

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    Time Line

    30th May 4thJune 2011 Reporting at Plant and deciding project plan,PlantVisit

    6thJune 2ndJuly 2011 Study ofSludgeTreatment Process and Unit-wiseanalysis of parameters

    4th 9thJuly 2011 Data Collection for energystudies

    11th 16thJuly 2011 Compilation and Analysis

    18th 23rdJuly 2011 Documentation

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    Bhairobanala S

    TP,P

    une

    y Plant capacity: 130 MLD

    y Input from Kalyaninagar Pumping Station: 30 MLD

    y Area: 5 Hectare

    y Activated Sludge process

    y Plant Commissioned in July 2003

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    Bhairobanala STP,Pune

    y Activated Sludge process

    y Plant capacity: 130 MLDChlorinationTank

    AnaerobicDigesters

    Aeration Tanks

    PrimarySettling Tanks

    SecondarySettling Tanks

    Raw Sewage Sump

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    COD and TSS estimation

    Standard methods forCOD and TSS estimation were used.

    Unit ParameterInlet

    (mg/L)

    Outlet

    (mg/L)Efficiency (%)

    1PST

    COD 301.34 148 50.88%

    TSS 515 277.67 46.08%

    2 Aeration

    Tank

    COD 122 38 68.85%

    TSS 199 61 69.35%

    3SST

    COD 60 24 60%

    TSS 107 28 73.83%

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    Energy Consumption

    y Estimate of different forms of energy was made

    y Electrical

    y Manual

    y Mechanical

    y Information gathered

    y Details ofElectrical Equipment

    y Staff working at planty Use of fuel at plant

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    Energy Consumption

    y Electrical Energy

    Ep = Pt 3.6 (MJ)

    = Power factor (assumed to be 0.9),

    P= Power of the electrical equipment in kWh

    T= corresponding hours of electricity operation,3.6 = energy equivalent 1 kWh

    (Waheed et al., 2008)

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    Energy Consumption

    y Manual Energy

    Ei= Energy equivalent for an adult working for 1 hr, Ni= Number of people,

    Ti= Time spent in Labour

    y Mechanical Energy

    Ef= 56.31 D (MJ)

    56.31 = unit energy value of diesel, MJL-1;D = liters of diesel consumed

    (Waheed et al., 2008)

    iii

    i

    oi

    m TNEE !

    !

    !6

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    Energy Consumption

    Unit OperationElectrical

    (MJ)

    Manual

    (MJ)

    Mechanical

    (MJ)

    Total

    Energy

    (MJ)

    Raw Sewage

    Collection 9720.00 52.56 1.15 20573.71

    Pre-Treatment 233.28 52.56 1.15 546.19

    PrimaryTreatment 524.88 52.56 - 1160.64

    Aeration 37091.52 52.56 - 78356.88

    SecondaryTreatment 233.28 52.56 - 545.04

    Chlorination 291.60 52.56 - 668.16

    SludgeTreatment 4881.77 52.56 64.35 10422.88

    OtherProcesses 526.26 52.56 1132.94 2296.48

    TOTAL 53502.59 420.46 1199.59 55122.64

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    Energy from Biogas

    Considered Inlet COD = 350mg/L, For 130MLD plant COD = 45500Kg/day

    Considering 1.7 Kg COD/ Kg VS and 920 L Biogas/Kg VS (Panter Keith, 2008)

    Amount of biogas from sludge = (45500/1.7) x (920/1000) = 24623.53 m3/day

    1 m3 biogas = 2 KWh (Electrigaz, 2011)

    Energy from biogas = 24623.53 x 2 = 49247.05 KWh/day

    Industrial ElectricityCost in Pune = Rs. 5.4/unit (MAHADISCOM, 2011)

    EnergySavings = 49247.05 x 5.4 = Rs. 2,65,934/day

    Considering 70% Efficiency ofPlant for COD removal,Energy Savings = Rs. 1,86,154/day

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    Observations

    y Current design inconsistent with expansion plan

    y Faulty analytical procedure

    y Non-utilization of biogas as energy

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    Limitations

    y Lab equipment failure and power cuts

    y Unavailability of data

    y Duration of project

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    References

    y APHA, 1998,Standard Methods for Examination of Water and Wastewater,Section 2540 D for TSS and 5220C for COD

    y Bhairoba Nala Plant Layout, 2001,Pune

    y CPHEEO Manual, 1999, Manual on Water Supply and Treatment

    y Electrigaz 2011, Biogas FAQ, Available at , [Acessed on 22/07/2011]

    y H. Singh, D. Mishra, N.M. Nahar, 2002-2004. Energy use pattern in productionagriculture of a typical village in arid zone,India - Part I,II and III,EnergyConversion and Management

    y Kansal A., 2011, Lecture notes on Solid Waste Management and Water QualityManagement

    y MAHADISCOM 2011, Maharashtra State Electricity Distribution Co. Ltd BillCalculator, Available at , [Acessed on22/07/2011]

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    Referencesy MiddlebrooksE.J., MiddlebrookesC.H., Reed S.C., July 1981. Energy

    Requirement for Small WastewaterTreatment Systems, Water PollutionControl Federation, Vol. 53, No. 7, pp. 1172-1197

    y Mittal, V.K., Mittal,T.K. and Dhawan, K.C. 1985. Research digest on energy

    requirements in agricultural sector.y Panell S. D., 2005, Anaerobic Digestion Options for Industrial Wastewater,

    Available at , [Acessed on25/07/2011]

    y Panter Keith, 2008, Mass and Energy Balances in high solids digestionfollowing thermal hydrolysis pre-treatment,Ebcor Ltd.

    y Vaidya M.V., 2008,PMCSTPAudit Report

    y Waheed M.A., Jekayinfa S.O., Ojediran J.O.,Imeokparia, 2008. Energeticanalysis of fruit juice processing operations in Nigeria,Energy, Vol 33, pp. 35-45