O_&_M_Manual_for_Sugar Industry

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Transcript of O_&_M_Manual_for_Sugar Industry

OPERATION & MAINTENANCE MANUAL EFFLUENT TREATMENT PLANT

1

INDEX1. PREAMBLE

2. DESIGN BASIS

3. PROCESS DESCRIPTION

4. TECHNICAL SPECIFICATIONS

5. PROCESS START- UP & CONTROL

6. PREVENTIVE MAINTENANCE

7. EQUIPMENT MANUALS

8. DRAWINGS

2

PREAMBLE

3

PREAMBLEThe Effluent Treatment Plant has been designed to treat 240 KLD Effluent.

Salient features of treatment plant:1. The treatment plant consists of Physical and biological processes. The biological process consists of double stage anaerobic & aerobic systems. 2. For aeration, Diffused Aeration System with imported Diffusers and Air Purging Grids are provided. Air is supplied through a twin lobe Air Blower of required capacity. This system ensures fine bubble dispersion and better Oxygen transfer efficiency.

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DESIGN BASIS

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DESIGN BASIS: I) II) FLOW RAW EFFLUENT CHARACTERISTICS Unit m3/hr mg / lt. mg /lt. mg /lt. mg /lt. : : Effluent Inlet 800 - 1000 5.0 to 9.0 200- 300 350 - 400 150 250 10 - 20 800-1000/DAY

Parameter Flow ( KLD) Ph TSS COD BOD @ 27 C Oil & Grease III)

TREATED EFFLUENT CHARACTERISTICS:

Parameter Suspended Solids Bio-Chemical Oxygen Demand (3 days at 27deg C )

UNIT mg /lt. mg /lt.

Sewage Outlet < 5 < 20

6

PROCESS DESCRIPTION

ETP PROCESS DESCRIPTIONPHYSICAL TREATMENT 7

Effluent Treatment plant is constructed to treat 10, 00,000 liter per day waste water generated from sugar factory by primary physico-chemical treatment and two stage biological treatments. Raw waste water streams by gravity passes through bar screen chamber. Here large floatable particles shall be separated manually .After screening, the effluent collected by gravity to the Oil removal Tank where Oil and Grease shall be removed from the effluent by the mechanism provided. The effluent is then passed to the Equalization tank .To keep the contents of the equalization tank effluents in suspended from one number floating type aerator is provided in each tank. Effluent from equalization tank shall be fed to flash mixer unit where Lime solution is added to raise the pH of the effluent. Over flow from flash mixer shall be collected in tube settlers to settle the suspended solids. Settled sludge sent to sludge drying beds for dewatering. Overflow from settling tank shall be collected in feed tank. Effluent from the feed tank shall be further treated biologically to reduce COD and BOD. BIOLOGICAL TREATMENT Effluent shall be pumped to anaerobic fixed film digester from feed tank. Major part of organic load shall be removed here. The anaerobic organisms will degrade the high concentrated organic matter present in the effluent. In this digester plastic media is used as a medium for attachment of microorganisms, which will in turn convert the complex organic matter into simple compounds like CH4, CO2 & H2O. Outlet from anaerobic digester shall be further treated aerobically. Over Flow from the anaerobic digester is passed to the biological system i.e. Bio-tower (BT). Bio-tower is designed as a roughening tower for COD/BOD reduction from the influent. Bio-tower is constructed with civil columns and beam supports .Bio-tower is filled with PVC structured fill media .Effluent by gravity collected in the BT sump and effluent recycled to the top with the help of Bio-tower recycling pump. While sprinkling from the top media attached microorganisms will degrade the organic matter as BOD. Part of effluent sent to next stage treatment by recycling pipeline, Second stage biological system i.e. ASP System.

Activated sludge process system comprises of aeration tank followed by secondary clarifier. In aeration tank organic load as BOD shall be degraded by the help of cultivated microbial culture. 8

Constant mixed liquor suspended solids (MLSS) will be maintained in aeration tank in definite proportions by recycling the bio sludge trapped by the secondary clarifier. At aeration tank air shall be supplied from air blower to the diffused aeration system. Floating type aerators are also provided at lagoons for the supply oxygen to microorganisms. From dosing tank, nutrients like nitrogen & phosphorous shall be added to the effluent at aeration tank in the ratio of BOD: N: P as 100: 5: 1 Recycling of bio-sludge from secondary Clarifier will be done by non clog, centrifugal, semi open type continuous duty suitable capacity sludge recirculation pumps. The overflow from secondary clarifier meets the norms prescribed by the Concerned Pollution Control Board for safe disposal. The excess sludge from the primary settling tank& secondary clarifier shall be withdrawn to proposed sludge drying beds where sludge get dewatered and dried sludge cakes can be used as a good manure for gardening. Outlet from secondary clarifier is collected in Chlorine Contact tank where chlorine Solution is added to kill pathogen bacteria.

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TECHNICAL SPECIFICATIONS

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1.0.1.1.

UNITS & EQUIPMENTS OF E.T.P. CIVIL UNITS PARTICULARS Bar Screen Chamber Oil Removal Tank Oil Collection Pit Equalization Tank Lime Dosing Tank Flash Mixer Tank Tube Settler Tank Feed Tank Anaerobic Reactor Bio-Tower Settling Tank Aeration tank Secondary Clarifier Chlorine Contact Tank Sludge Drying Beds Filtrate Chamber Control Panel Room and Lab QUANTITY One No. One No. One No. One No. One No. One No. One No. One No. One No. One No. One No. One No. One No. One No. Six Nos. Two Nos. Two Nos.(1+1)

SR.NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

1.2.

MECHANICAL UNITS / EQUIPMENTS PARTICULARS Bar Screens Oil & Grease Mechanism 11 QUANTITY Two Nos. One No.

SR.NO. 1. 2.

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Flash Mixers Lime Dosing Pump Tube Deck Media Sludge Removal Pump Floating Aerator Raw Effluent Feed Pumps AR Feed Pumps Bio-Fills Bio-Tower Recycling pump Settling Tank feed well Air Blowers Diffusers Nutrient Dosing System Secondary Clarifier Mechanism Bio-Sludge Recycling Pump

Two Nos. One No. 12 M3. Two Nos. Two Nos. Two Nos. Two Nos. 300 M3/ 166 M3. Two Nos. One No. Two Nos. Fifteen nos. Two Nos. One No. Two Nos.

2.0. TECHNICAL SPECIFICATIONS FOR UNITS & EQUIPMENTSA. CIVIL UNITS 1. BAR SCREEN CHAMBER Type Volume Size Construction Description : : : : : Rectangular 5.07 M3. 1400 x 3000 x 1000mm + 300mmFree Board RCC An open Tank with suitable size. Arrangement for bar screen fixing MOC of the tank is in complete RCC M20. Internal water proof plaster and external sponge finish plastering. External Green colour ISI grade Cement paint two coats. Internal anti corrosive painting Quantity 2. : One No.

OIL REMOVAL & COLLECTION TANK Type Volume Size : : : Rectangular Separation Tank 27.2 M3 Collection Tank 1.5 M3 2000 mm x 8500 mm x 1200 mm SWD + 400 mm FB 1000 mm x 1000 mm x 2000 mm SWD + 500 mm FB 12

Construction Quantity

: :

R.C.C. M20 & MS EP One No.

3. LIME DOSING TANK Type Volume Size Construction Quantity : : : : : Square 4.05 M3 1000 mm x 1000mm x 1500mm SWD + 300 mm FB MS EP One No.

4. EQUALISATION & COLLECTION TANK Type Volume Size Construction Quantity : : : : : Rectangular 600 M3 10000 mm x 20000mm x 2500mm SWD + 500 mm FB MS EP One No.

5. FASH MIXER TANKType

: : : : :

Square 12.167 M3 2300 mm x 2300mm x 2000mm SWD + 300 mm FB MS EP One No.

Volume Size Construction Quantity 6.

TUBE SETTLER TANK Type Volume Size : : : Rectangular 50.4 M3 4500 mm x 4000 mm x 3000mm SWD + 300 mm FB 13

Construction Quantity

: :

MS EP One No.

7. FEED TANK Type Volume Size Construction Quantity : : : : : Square 44.8 M3 4000 mm x 4000mm x 2500mm SWD + 300 mm FB RCC M 20 One No.

8. ANAEROBIC REACTOR Type Volume Size Construction Quantity : : : : : Circular, Closed 841 M3 10400 mm x 8900 mm SWD + 1000 mm FB. R.C.C M 20 One No.

9. BIO-TOWER Type Volume Size Construction Quantity : : : : : Rectangular 384 M3 8000 mm x 8000 mm x 5500 mm SWD + 1000 mm FB. R.C.C M 20 One No.

10. SETTLING TANK

Type

:

Circular 14

Volume Size Construction Quantity 11. AERATION TANK Type Volume Size Construction Quantity

: : : :

100 M3 4600 mm x 2500 mm SWD + 500 mm FB R.C.C M 20 One No.

: : : : :

Rectangular 250 M3 5000 mm x 10000 mm x 4500 mm SWD + 500 mm FB. R.C.C M 20 One No.

12. SECONDARY CLARIFIER Type Volume Size Construction Quantity : : : : : Circular 381 M3 9000 mm x 2500 mm SWD + 500 mm FB R.C.C M 20 One No.

13. CHLORINE CONTACT TANK Type Volume Size Construction Quantity : : : : : Rectangular 50.4 M3 3000 mm x 6000 mm x 2500 mm SWD + 300 mm FB. R.C.C M 20 One No.

14. SLUDGE DRYING BEDS Type Total Area : : Square/Rectangular 210M2 15

Size Construction Quantity

: : :

5000 mm x 5000 mm x 1400 mm BBM Six Nos.

15. FILTERATE CHAMBER Type Volume Size Construction Quantity : : : : : Rectangular 9 M3 1500 mm x 1500 mm x 2000 mm R.C.C M 20 Two Nos.

B.

MECHANICAL UNITS I. BAR SCREEN Application Location Type Tank Size MOC Quantity : : : : : : Screening floatable solids At Screen Chamber Manual 1400 x 3000 x 1000 mm + 500 FB MSEP One No.

II. OIL & REMOVAL MECHANISM Application Location Type Tank Size Rated Power Make Quantity : : : : : : : To Trap Oil & Fat Oil & Fat Removal tank Semi automatic & scraping type 4.5 x 4.0 x 2.5 mm SWD + 0.3 FB 0.5 HP Gaitsu One No. 16

III.FLASH MIXER Tank Size Speed Drive Quantity : : : : 1500 x 1500 x 1500 mm SWD + 300 mm FB High 1.0 HP Two Nos.

IV. LIME DOSING PUMP Application Location Capacity Drive Make Quantity : : : : : : Dosing of Lime Flas