May 2012

General Information and Guidelines for Vehicle Wash Facility in Bhutan

Prepared by:

The National Environment CommissionRoyal Government of Bhutan

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Acknowledgement

The National Environment Commission Secretariat (NECS) would like to express deep gratitude to Centre for Science and Environment (CSE), in particular, Mr. Chandra Bhushan, Deputy Director General, Mr. Sujit Kumar Singh, Deputy Coordinator, and Miss Swati Singh Sambyal, Research Associate, for their invaluable technical input into this guideline. Further, the NECS would like to acknowledge all other individuals, agencies and companies, especially, TATA Motors, New Delhi, for their cooperation extended to the CSE.

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Table of Content

1. Introduction..................................................................................................................................12. Environmental concerns..............................................................................................................13. Establishment of vehicle wash facilities......................................................................................2

3.1 Manual Vehicle Wash............................................................................................................23.2 Semi-automated and automated vehicle wash.......................................................................23.3) Automated vehicle wash facility..........................................................................................5

4. Treatment technologies for wastewater management................................................................144.1 Options for wastewater treatment........................................................................................14

4.1.1 Option 1: Minimum criteria for wastewater treatment.................................................144.1.2 Option 2: Criteria for recycle and reuse of wastewater................................................15

Cost of waste water treatment plant...............................................................................................16Table 4: Before and after treatment values for different parameters.........................................16Table 5: Capital cost for wastewater treatment based on the capacity......................................17Table 5A: Civil work and fabrication........................................................................................17Table 5B: Equipment.................................................................................................................17

4.1.3 Option 3: Wastewater treatment for a standalone washing facility (100 per cent closed loop).......................................................................................................................................21

Note: Cost does not include civil works, land and operation and maintenance cost....................225. Recommendations......................................................................................................................22

5.1 General guidelines...............................................................................................................22Site selection criteria for establishment of vehicle wash facility..................................................22

5.2 Minimum general standards for establishment of vehicle wash facility.............................225.3. Specific recommendations for establishment of vehicle wash facilities............................23

5.3.1 Armed forces................................................................................................................235.3.2 Thimphu City Corporation...........................................................................................235.3.3 Dzongkhag Thromdes – Gelephu, Samdrup Jongkhar and Phuentsholing..................245.3.4 Dzongkhags..................................................................................................................245.3.5 Significant projects.......................................................................................................24

6. Implementation Arrangement...................................................................................................24

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List of Tables

Table 1 Technical specification of steamer 10

Table 2 Technical specification of automatic car wash facility 11

Table 3 System requirements for truck/bus washing system 15

Table 4 Before and after treatment values for different parameters 21

Table 5 Capital cost for wastewater treatment based on the capacity 22

Table 5A Civil work and fabrication 22

Table 5B Equipment 22

Table 6 Approximate Cost 26

List of Flow Diagrams

Diagram 1 Minimum criteria for wastewater treatment plant 19

Diagram 2 Wastewater treatment for integrated washing facility – closed loop

recycling

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Diagram 3 Wastewater treatment at Tata Motors 23

Diagram 4 Wastewater treatment for standalone washing facility 26

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List of Abbreviations

1. NEC National Environment Commission

2. ETP Effluent Treatment Plant

3. sq. ft Square feet

4. PE Poly-ethylene

5. KLD Kilo-litre per day

6. FRPL Fibreglass Reinforcement Plastic

7. RCC Reinforced Cement Concrete

8. HDPE High Density Polyethylene

9. mg/L Milligram per litre

10 KL Kilolitre

11 AC Alternating Current

12 m3/day Cubic metre per day

13 V Volt

14 Hz Hertz

15 min Minutes

16 HP Horse Power

17 m Metre

18 CGI Corrugated Galvanised Iron

19 ml Millilitre

20 mg/l Milligram per litre

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1. Introduction

Under the Environmental Assessment Act 2000 and the Regulation for the Environmental Clearance of Projects 2002, it is mandatory for all industries which generate effluents to comply with the Environmental Discharge Standards 2010.

The National Environment Commission’s (NEC) objective is to effectively enforce the Environmental Discharge Standards in industries including the automobile sector. In particular, effluents discharged from vehicle wash facilities have remained weak, despite the ever increasing number of vehicles in the country. Currently, most of these facilities are located in Thimphu.

As per the survey conducted by NEC on 20th April 2012, there are 20 semi-automated vehicle wash facilities in the Olarongchu automobile workshop area. All these car wash facilities are integrated with existing automobile workshops. Most of these facilities have no effective Effluent Treatment Plant (ETP). Nonetheless, all these car wash units claim that their waste water is channeled into an ETP, a small plant, which is non-functional at Olarongchu automobile workshop. At present, the water used for washing vehicles is not recycled.

Further, there is a total lack of car/vehicle washing facilities in almost all the Dzongkhags except in the Thromdes. Some manual washing facilities either without or non-functional ETP exist in some Thromdes. There is an urgent need for establishment of ETP and additional facilities in Thromdes, in particular, for heavy vehicles.

Despite the large number of car wash facilities in Thimphu, many vehicles are washed in streams and rivers, a practice prevalent across the country. This practice contaminates the water bodies. As per the Waste Prevention and Management Act 2009, washing of vehicles in streams and rivers are prohibited. Therefore, it is essential to facilitate establishment of vehicle wash facilities in various locations across the country.

This proposal contains guidelines and information on types of light and heavy vehicle washing facilities that can be established depending on locations and feasibilities with various options.

2. Environmental concerns

Vehicle washing, in simple terms, involves cleaning the exterior and in some cases, the interior of motor vehicles. Currently, most of the vehicles are washed unlawfully either at home or in rivers and streams, while some do wash their cars at Olarongchu workshop area. Almost all trucks are washed in streams and rivers. The contamination of water bodies by untreated car wash effluents is a prominent and serious environmental hazard. The wastewater may include high levels of oil and grease, silt and unacceptable levels of acidity or alkalinity. The accumulated sediments or sludge may contain heavy metals such as chromium, lead, zinc and nickel. Therefore, to avoid contamination of receiving water bodies, there is an urgent need for establishment of commercial washing facilities across the country to safeguard the environment.

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Effluent (soap and dirty water) from vehicles washed in a modern commercial facility is treated by the ETP before it is released into the surrounding environment. Generally, a conventional vehicle wash uses more soap and water but now there are environment-friendly modern vehicle washing techniques available. This modern technology ensures a proper water recycling system followed by an advanced water treatment methods including biodegradable washing soap.

In practice, there are two kinds of vehicle washing facilities:

i) An integrated service centre, andii) Standalone washing facility.

An integrated washing facility has provisions for both vehicle washing and a servicing centre, whereas in a standalone washing facility, only vehicle washing is carried out. Therefore, an integrated washing facility can cause more pollution as compared to a standalone facility, due to spillage of grease, spent oil, radiator fluid, battery fluids, engine oil, and coolant during servicing.

3. Establishment of vehicle wash facilitiesThere are three options for vehicle washing:

i) Manual vehicle wash;

ii) Semi-automated wash facility; andiii) Automated wash facility.

3.1 Manual Vehicle Wash

A vehicle can be manually washed without using any automatic equipment, except for air compressor, water pressure pump and specific pipes that can deliver a required amount of water pressure for effective washing. This facility may cost Nu. 2, 05,000.00. The car/trucks can be mounted over the ramp (please refer to the annexure A drawing of Ramp with an estimated cost of Nu.1, 10,878.00) connected to a drainage and then to an ETP (please refer to options for waste water treatment 4.1 costing Nu. 4, 50,000.00 - to Nu. 13, 75,000.00 depending on the size and capacity of the plant). The wastewater containing soap and detergents, residues from exhaust fumes and motor oils wash off from the vehicle can be thus treated in the ETP. Therefore, a manual car/vehicle washing facility can cost approximately Nu.7, 65,000.00 - to Nu. 16, 90,787.00.

3.2 Semi-automated and automated vehicle washThe selection of a vehicle wash facility may depend on the economic viability, type of service required by the customers and location, among other factors. A vehicle can be washed commercially through the following modern methods:

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(a) Semi-automatic vehicle wash

In this type of washing facility, the vehicle is lifted up by driving onto a ramp by a hydraulic lift and then washed (see Figures 1, 3 and 4). It is a self-service washing facility where the vehicle remains stationary and is washed using a high-pressure stream of water from a hand-held wand (see Figure 2). Some common equipment used in semi-automated facilities is hydraulic lift, air compressor, servicing machine and water pump. This is the most popular type of vehicle wash used across the globe. On an average, a self-serve facility uses 75 litres of water per vehicle of which 18-20 litres of water is lost through evaporation. Further, the number of vehicles washed per day is relatively low because application of soap or detergent and rinsing is done manually, which utilizes more manpower and thus limits the number of vehicles washed per day. The total cost of this system ranges from Nu. 10, 11,278.00 - to 19, 36,278.00 with ETP and civil construction work for a ramp depending on the requirement of the capacity of ETP.

Figure 1: View of a hydraulic lift Figure 2: Use of high pressure water jet for cleaning

Figure 3: View of ramps Figure 4: Heavy vehicle being washed on a ramp

Source: The photographs were taken during the site visit to vehicle washing facility in Thimphu, Bhutan and heavy vehicle washing facility at TATA Motors, New Delhi.

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The approximate cost of each equipment used in a semi-automatic vehicle wash facility is as follows:

i) Hydraulic lift: Nu. 150,000.00ii) Air compressor: Nu. 150,000.00iii) Servicing machine: Nu. 85,000.00iv) Water pump: Nu. 55,000.00v) Nozzles: price varies as per quality, Nu. 400.00 – Nu. 1,100.00/piece vi) Pipe: Nu. 100.00- Nu. 150.00/metre, vii) ETP: Nu. 450,000.00 - to Nu. 13,75,000.00

b) Steam Car Wash

Nowadays, there is a new technology that utilizes steam for cleaning of vehicles. The steamer is a compact, transferable, electrical, car washing equipment which is manually operated. It uses steam at a temperature below 1000C (2120F) and a steam pressure of 8 bars for cleaning cars (see Figure 5 and 6). It can be used both commercially and at household level (see Table 1: Technical specifications of steamers).

The steamer cleans the exterior, interiors of the car as well as the vehicle engine and tyres. It effectively removes the dirt, oil and grease from the car. For washing very muddy vehicles, some of the steamer models are equipped with a moisture control valve for efficient vehicle cleaning but it consumes more water.

There are several advantages in using steamers. It saves water and requires less capital investment. As it uses steam, no wastewater is generated. It also removes bacteria and bad odour inside the car. The only disadvantage is that steamers need more time to wash a car, approximately 20 minutes, while it takes only 6-7 minutes in an automated car wash facility. One set of this facility costs only Nu, 55,000.00 - to 137,500.00 and is the cheapest among others.

Figure 5: Front-view of a car wash electric steamer

Figure 6: Side-view of a car wash electric steamer

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Table 1: Technical specification of steamer

Water requirement About 3-4 litres of water required per car wash and a maximum of up to 20 litres

Pressure 8 barsTime required per car wash Approximately 20 minutes Operating cost Costs of fuel, water and labour vary from place to

place. To wash an average sized vehicle, it takes about 3-4 litres of water, 350 ml of diesel and 20 min of labour

Cost of equipment Nu. 55, 000.00 -137,500.00Manpower requirement One personPrecautionary measures In cold regions, it is very important to remove

remaining water from the steamer after daily use as the water can freeze and result in rupture and damage the important parts of the steamer

.3.3) Automated vehicle wash facility

In such a facility, the vehicle remains stationary or is dragged into a tunnel where washing operations such as cleaning, rinsing, waxing and drying etc. are performed automatically as the vehicles pass through the washing area.

The advantages of using an automatic vehicle washing are: (a) more vehicles can be washed per day as the time required for washing a car is approximately 6-7 minutes; (b) uses regulated amount of water and chemicals; (c) there is less workforce involvement; (d) washed water can be recycled and reused; (f) it is a modular and built on nut-bolt technology; and (g) washing, cleaning and drying are carried out by machines thereby achieving high efficiency.

In spite of numerous advantages, an automatic vehicle wash facility is capital and energy intensive. An automatic vehicle washing facility adopts various technologies ranging from a high pressure to a multiple brush systems for efficient vehicle cleaning. The cost of these high-end washing systems varies according to the technology used, the make, process adopted and choice of various add-on equipment, such as specialized brushes, vehicle positioning systems, tyre shiner applicator and high pressure blasters.

Examples of types of automated vehicle wash facilities are as follows:

a) Automatic car washing systems

In an automatic car washing system, technologies used for washing car range from brush-type to high-pressure system (see Figures 7 and 8).

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Figure 7: Brush automatic car wash system

Figure 8: High pressure car washing system

Source: KKE Wash Systems, Nagpur, India

The automatic car wash equipment is totally modular and built on nut-bolt technology. Thus, the equipment can be dismantled and installed at another location easily (see Table 2: Technical specification of automatic car wash facility). Due to a high diversity in technology, equipment and design, the cost of an automated vehicle facility vary significantly (see section 3.3 Automatic Vehicle Wash). According to suppliers, the area required for the equipment is approximately 500 sq-ft (about 46 sq m) and additional 200 sq-ft (about 18 sq m) is required for the water recycling system. The size of the plot depends upon the service a washing facility provides. Usually 2,000-3,000 sq-ft (189-279 sq m) is considered to be an adequate area.

Table 2: Technical specification of automatic car wash facilityWashable area Length (L) – 5 m, Width (W) – 2 m, Height (H) 2.2 mBay area Preferred Minimum

Length – 9.75m Length - 9.25 mWidth – 4.5 m Width – 4 mHeight – 3.5 Height – 3.2 m

Blower for car wash Blowers used vary between 16 to 30 HPWater supply 100 litre/minTime required per car wash Approximately 6-7 minutes Air supply 100 lpm@7barElectrical supply 3 phase 440 V AC 50 HzCost of water recycling system Nu. 2.80 lakh for 2 kl (discharge 2,000 litre/hr), Nu.

4.25 lakh for 5 kl (discharge 5,000 litre/hr), Nu. 5.82 lakh for 10 kl (discharge 10,000 litre/hr)* #

Manpower requirement One person* Note 1: Excluding land cost, civil cost and chemical cost# Note 2: For capacity more than 10 KL, the cost will further increaseSource: KKE Wash Systems, Nagpur, India

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The automatic vehicle wash facility has the following components for cleaning and washing: (a) under chassis wash1; (b) pre-wash; (c) soap spray rinse2; (d) brush wash; and (e) blower for washing. In addition to this, the add-on equipment is optional which include tyre shiner spray, silicon wax spray and triple shine foam wax spray. When the car enters the pre-wash area, water is used to loosen dirt, also called the pre-wetting cycle. The soap is sprayed on the vehicle which helps in disintegrating the oil and grease. The rinse cycle is optional if the vehicle does not require a brush wash.

In a brush wash cycle, brushes are activated and they follow the contour of the vehicle for effective cleaning. The brush system comprises of two vertical brushes which wash the front, sides and the rear and one roof brush which washes the front, hood (bonnet), roof and the rear3. The brushes used in an automatic washing facility are of two types (a) soft foam brush (b) PE bristle brushes. Both brushes are soft. They rotate and clean the vehicle. The brush life depends upon the brush pressure, water quality and the climatic condition. A standard PE brush lasts for about 100,000-120,000 vehicle washes, whereas the soft foam bristles last for about 120,000 vehicle washes (see Figures 9, 10, 11 and 12)

Figure 9: Bristle brush Figure 10: Soft foam brush

1 It is used to clean the dirt from the bottom areas of the car, truck and bus. Functionally, under chassis wash is same for the car and truck wash, only dimension of the structure is different.2 Soap is sprayed after pre-wash and wax is sprayed after final rinse.3 Brushes used for car and truck wash are the same. They vary only in diameter. (i) Car wash brush diameter = 1 m (ii) Truck wash brush diameter = 1.2 m

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Figure 11: Close view of the bristle brush Figure 12: Automated brush wash system for cars

Source: KKE Wash Systems, Nagpur, India

The cost of an automated washing facility (car, truck and bus) depends on the type of equipment, design, make and capacity. On top of this, the cost of the land, civil works and construction of ETP should be added. This is an indicative cost and it may vary, depending on the make and type of wash facility opted.

i) Capital cost

The minimum cost of an automatic car wash facility ranges from Nu. 15, 00,000.00 – 17, 00, 000.00 which includes the installation of the basic system, under chassis wash and waxing system. In the market, different technologies are available and thus the cost varies considerably. If one goes for high-technology automatic vehicle wash facility with all accessories and other optional add-ons such as a blower system, then the cost will increase to Nu. 20, 00,000.00 -24, 00,000.00. If one also includes the wastewater treatment and vehicle wash enclosure, the capital cost will further increase to Nu. 25, 00,000.00 -30, 00,000.00.

Note: The cost does not include land cost as well as operation and maintenance cost.

ii) Operating cost

The operating cost per vehicle depends upon the variable and the fixed cost components. The variable cost components includes: (a) electricity; (b) water; and (c) chemical cost. Fixed cost components include: (a) salaries; (b) land rent and maintenance; (c) loan re-payments; and (d) government payment. The operating cost will differs from vehicle-to-vehicle depending upon the length of the vehicles.

As per the supplier, an average water requirement for washing of a car is 100.00 litres. If under chassis wash facility is included, the water requirement will increase to 150.00 litres per car wash. The unit cost per vehicle is variable and depends on the raw materials cost. For instance, in

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Nagpur, India, the unit cost per car wash is Nu. 30.00 (electricity = Nu. 10.00, water = Nu. 10.00, soap = Nu. 10.00 per car) excluding workforce cost.

b) Automatic truck-bus washing facility

Similar to a car wash facility, there are different technologies available for truck and bus. The system varies from high pressure to brush type of washing. The basic stages for truck and bus washing facilities normally comprise of the following components:

i) Under chassis wash;ii) Pre-wash;iii) Foam soap/chemical spray for cleaning;iv) High pressure washing/three brush washing (any of two options); v) High pressure washing, if brush system is used (optional equipment);vi) Skirt brushes4 (optional equipment);vii)Tanker brushes5 (optional equipment); andviii) Exit blower.

The fully automatic truck and bus wash system can be run by an operator. The system moves on ground-mounted rails. The vehicle is driven in position and remains stationary while the gantry moves over the vehicle and executes all operations (see Table 3: System requirements for truck/bus washing system). The washing usually completes in five steps: (a) under chassis – to clean the dirt from the bottom areas of the truck and bus (see Figures 13 and 14); (b) pre-wash –to loosen the dirt on the vehicle; (c) application of the soap/detergent – to clean dirt and oil from the truck and bus; (d) high-pressure or brush washing – to remove soap/detergent and improve the cleaning process; and (e) exit blower – to dry.

Figure 13: High-pressure under chassis wash

Figure 14: Entry point, under chassis wash

Source: KKE Wash Systems, Nagpur, India.

4 Skirt brushes: These are specially designed brushes (1,000 mm diameter), installed on both the sides to wash the lower part of the trucks/bus.5 Tanker brushes: Specially designed brushes used to wash tankers such as water/oil tanker brushes.

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Table 3: System requirements for truck/bus washing systemFeatures SpecificationsWashable dimensions Length: 12-27 m

Width: 2.7-2.8 mHeight: 3.7- 4.6 m

Bay areaPreferred Minimum

ApproximateLength(Varies as perarches selected)

13-20 m 17.5m

Width 6 m 5.5 mHeight 6.5 m 5.9 m

Number of vehicles washed per hour

up to 50-60 vehicles/hr

Blower for truck/bus wash Blowers used vary between 30 to 45 HP Water supply 500-2,000 litres/minuteElectrical supply 3 phase 440 V A C 50 Hz.Cost of water recycling system Nu. 2,80,000.00 for 2 kl (discharge 2,000 litre/hr),

Nu. 4,25,000.00 for 5 kl (discharge 5,000 litre/hr), Nu. 5,82,000.00 for 10 kl (discharge 10,000 litre/hr)* #

Manpower requirement One person* Note 1: Excluding land cost, civil cost and chemical cost# Note 2: For capacity more than 10 KL, the cost will further increaseSource: KKE Wash Systems, Nagpur, India

In case of a truck washing, either a high-pressure or a brush washing system can be used but in case of a bus, brush-washing is more effective. There is no limitation about the shape of a vehicle in case of a high-pressure washing system. The system can wash any vehicle that fits into the system. If a truck is washed by an automatic brush, then, three brushes are used for cleaning – two vertical suspended brushes washing the front, sides and the rear and one horizontal brush washing the front, rear and the top. The brushes sense the contour by sensing the brush pressure on the vehicle.

In an automatic bus washing system, the basic cleaning cycle is similar to a truck wash system. The cleaning is performed by three brushes - one roof brush and two vertical brushes. The roof brush follows the contour of the bus right from the front to the rear. Side brushes wash the front, sides and rear of the bus. The rotating brushes are freely suspended and move inward or outward according to the vehicle dimensions (see Figure 15-19).

i) Approximate cost of an automatic truck wash facility

The minimum cost of an automatic truck wash facility ranges from Nu. 20, 00,000.00 - 22, 00,000.00, which includes the installation of a basic system, under chassis wash system and traffic display system. If one opts for a higher technology for automatic truck wash facility with all accessories, then, the cost will increase to Nu. 26, 00,000.00 - 32, 00,000.00.

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Note: Cost does not include land cost, wastewater treatment cost, truck wash enclosure and chemical cost.

ii) Approximate cost of an automatic bus wash facility

Similar to a truck wash facility, the cost of an automatic bus wash facility ranges from Nu. 15, 00,000.00 – 19, 00,000.00, which includes the installation of a basic system, under chassis wash system and traffic display system. Further, the cost varies considerably, if one opts for a higher technology, for an automatic bus wash facility with all accessories such as a blower system and skirt brushes, cost will increase to Nu. 30, 00,000.00 – 31, 00,000.00.

Note: Cost does not include land cost, wastewater treatment cost, bus wash enclosure and chemical cost.

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Figure 15: The bus enters the wash system Figure 16: Two vertical and a roof brush used for washing

Figure 17: Bus washing Figure 18: Lateral washing through brush

Figure 19: Cleaned bus moves out of the wash system

Source: KKE Wash Systems, Nagpur, India.

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iii) High Speed Automatic Car Wash Equipment (Made in China)

a) Product Details:

Type: Car WasherPlace of Origin: Hebei, China (Mainland)Brand Name: ShangyiModel Number: SY-120Size: 700X350X300cmMaterial: Metal/coilPrice: FOB USD 20, 000.00 to 30, 000.00 per set

b) Detailed Product Description:

Since this equipment has no brush, it does not make any contact. It has high pressure and high speed cleaning efficiency with no scratch on car body post- cleaning. It requires only one minute and forty seconds to wash a whole car. It provides thorough cleaning of oil dirt, stains, silt and surface oxygen complex on the chassis, slots, tyres and any other parts of the car.

Car cleaning liquid is a natural anti-static, pure green product, anti-ultraviolet and with the characteristics of    biodegradability, no-phosphorus, non-toxic, non-pollution. It contains germicide and functions as a disinfectant. The facility also polishes car forming a protective film.

Applicable vehicle type: all kinds of car, standard off-road vehicle, various minibuses etc.

Technology Data

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Whole ParameterInstallation dimension 700*350*310cm   chassis washing function Yes

Track length 700cm   wipe-free function Yes

Work power 380/3PHZXE  50HZ   swiping function Yes

Main control system DELTA   remote control function Yes

Main motor power 15KW   air drying system optional

Whole power 16KW   sewage recycle system optional

Water consumption ≤120L/vehicle   LED advertising screen optional

Power consumption about 0.5kw/vehicle   automatic overhaul alarm function Yes

Washing speed 90seconds   automatic door optional

4. Treatment technologies for wastewater management

In order to control and mitigate the contamination of water bodies from untreated effluents from vehicle wash, it is mandatory for any effluent discharged to meet the Environmental Discharge Standard as per the Environmental Assessment Act. Therefore, it becomes mandatory to install an ETP for operation of any vehicle wash facility. The ETP must be constructed keeping in mind the integrated or standalone washing facility.

4.1 Options for wastewater treatment4.1.1 Option 1: Minimum criteria for wastewater treatment

It may not be feasible to convert all existing vehicle wash facilities into automatic systems due to high capital investment. Therefore, it is important for the vehicle wash facility to install an ETP to ensure that the effluent discharged conforms to the prescribed standard (see Flow Diagram 1: Minimum criteria for wastewater treatment).

A minimum requirement for a vehicle wash facility consists of mud separator or grit chamber and oil and grease separator for the treatment of wastewater before it is discharged into the receiving environment. If the treated wastewater still has a high pollution load, exceeding the prescribed standards, it must be treated further by using chemical methods and/or filtration. The settled sludge from the tank must be cleaned at regular intervals and disposed-off properly based on physico-chemical characteristics of the sludge.

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Oil and grease separator

Before treated wastewater discharges in drain/receiving water body, it must meet the prescribed standard

Mud separator or grit chamber

Flow diagram 1: Minimum criteria for wastewater treatment plant

Approximate cost of wastewater treatment

The combined approximate cost of construction of mud separator (grit chamber) and oil/ grease trap is around Nu. 7.00 per litre. For example, if vehicle wash operator wants to treat 1 KL of wastewater per day, the construction cost will be around Nu. 7,000.00. Note: Cost does not include the operation and maintenance and land cost.

4.1.2 Option 2: Criteria for recycle and reuse of wastewater

The large amounts of wastewater generated from vehicle washing facility can be recycled by choosing adequate wastewater treatment technologies that purifies the wastewater and pipes it back for reuse. The choice of technology depends on the extent of recycle and reuse. There are two types of recycling systems: closed-loop recycle (100%) and partial recycle.

i) Closed-Loop Recycle System is a total recycle system that recycles both wash and rinse water with no discharge of wastewater.

ii) A Partial Recycle System is a system where wash water is separated from the rinse water and recycled.

Note: Wash water contains chemicals whereas rinse water is simply the water used to clean the soap, detergents etc.

In case of a complete close-loop recycle system; wastewater can be treated by installing a grit chamber, where heavy solids settle down first followed by the oil and grease. The water then flows from the equalisation tank to a chemical dosing tank where flocculation takes place. After chemical dosing, the water flows to the settling tank where filtration takes place through activated carbon filters. If the dissolved solid concentration is high, an optional resin chamber should be used. Around 80-95 per cent of water can be reused by selecting an appropriate treatment technology (see Flow Diagram 2: Wastewater treatment for integrated washing facility – closed loop recycling).

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1. Oil water separator / grit chamber or mud separator

2. Equalization Tank

4. Settling Tank

7. Sludge dewatering system

5. Activated Carbon Filter

6. Resin softener (Optional)

3. Chemical Dosing Tank

Flow diagram 2: Wastewater treatment for integrated washing facility – closed loop recycling

Source: A to Z Industrial Services, Indore, India

The treatment done at various stages are as follows:

i) Oil water separator – Oil and grease separators are installed to remove oil and grease based on density differences.

ii) Mud separator or grit chamber – Mud separators are designed to remove the inorganic particles, such as sand, gravel, grit etc. of size 2 mm or larger from wastewater.

iii) Equalization tank – The equalization tanks are provided to balance fluctuating flows or concentrations of wastewater and/or to assist self-neutralization.

iv) Chemical dosage tank – In a chemical dosage tank, certain chemicals like alum and lime are added to aid settling of very fine suspended particles present in wastewaters by changing them into flocculated particles. The amount of chemical used in the dosing tank depends upon the quantity of wastewater to be treated.

v) Settling tank – Settling tanks are designed to remove the flocculated particles from wastewater via the settling phenomenon under force of gravity.

vi) Activated carbon filter – In this type of filter, activated carbon is used to remove odours, dissolved gases, heavy metals etc. from the wastewater.

vii) Resin softener – The main function of resin chambers is to remove dissolved salts by the ion-exchange mechanism.

viii) Sludge dewatering system – In this system, the settled sludge from the settling tank is dewatered and dried mostly by the application of solar heat.

Cost of waste water treatment plantIn a complete closed-loop treatment system, the pollution load can be reduced by more than 95 per cent (see Table 4: Before and after treatment values for different parameters).

Table 4: Before and after treatment values for different parametersParameters Before treatment After treatmentpH 5-9 7-8.5Oil and grease 4,000 mg/l 10 mg/l

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Final treated water (Reuse for car-washing)

SS 2,000-10,000 mg/l 10 to 100 mg/lSource: A to Z Industrial Services, Indore, India

The cost of treatment may vary depending on equipment, technology, manufacturer and location. The capital cost includes civil works, fabrication and erection. For instance, cost may vary as per the size of the plant. For a car washing facility generating 5 m3 of wastewater per day, the cost will be Nu. 450,000.00 and for 50 m3 of wastewater per day, the cost of treatment will be Nu. 1,375,000.00 approximately (see Table 5: Capital cost for wastewater treatment based on the capacity). The operation and maintenance cost may be Nu. 10,000.00 per month for treatment plant up to 15 m3/day, which includes labour cost of Nu. 8,000.00 and chemical cost of Nu. 2,000.00.

Table 5: Capital cost for wastewater treatment based on the capacityFlow 5 m3/day 10 m3/day 15 m3/day 20 m3/day 40 m3/day 50 m3/dayRates 450,000.0

0565,000.00 710,000.00 890,000.00 1,250,000.0

01,375,000.00

Source: A to Z Industrial Services, Indore, India

A detailed fabrication and erection, and commissioning of the plant and machinery including piping is required for a water recycle plant (see Table 5A: Civil work and fabrication and Table 5B: Equipment).

Table 5A: Civil work and fabrication

S.No

Description Nos. Specification

1 Oil & Grease trap/mud separator 01 RCC2 Equalization tank 01 RCC

3 Flash-mixing tank 01 M.S. FRPL4 Flocculation tank 01 M.S. FRPL5 Settling tank 01 M. S. FRPL6 Pre-holding Tank 01 RCC7 Treated water tank 01 RCC8 Sludge dewatering system. 01 Brick work9 PAC/Alum solution tank 01 HDPE10 Lime Solution tank 01 HDPE

Note: M.S.FRPL = Mild Steel Fibreglass Reinforcement Plastic, RCC = Reinforced Cement Concrete, HDPE = High Density PolyethyleneSource: A to Z Industrial Services, Indore, India

Table 5B: EquipmentS. No. Description Nos.

1. Equalization WW pump 012. Flash-mixing tank 013. Flocculator 01

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4. Pre-holding tank pump 015. Treated water tank pump 016. Pressure sand filter 017. Activated carbon filter 01

Source: A to Z Industrial Services, Indore, India

The process of treatment is as follows:

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Case StudyTATA Motors, New Delhi, India

100 per cent recycle of treated wastewater in an integrated semi- automatic heavy vehicle washing facility

Effluent In

Treated water tank

Filtration tank

Sent for re-use

EQ tank Oily water tank Settler tank

Oil separator Chemical Oil

mixing tank skimmer

Oil Drum

Sludge de-watering beds

Aeration tank

Settling tank

Alum, lime, polymer

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Case StudyTATA Motors, New Delhi, India

100 per cent recycle of treated wastewater in an integrated semi- automatic heavy vehicle washing facility

Step 1. Oil/grease separator: The oil and grease are separated on the basis of the density difference and oil gets collected in an oil tank

Step 2. Chemical dosing tank: Alum/lime added as flocculants leading to settling of solids

Step 3. Settler tank with roller oil skimmer (last point for oil collection): Second stage of oil and grease removal, the oil skimmer removes the extra oil present

Step 4. Extra oil collector: The extra oil passes through the pipe and gets collected in a small oil storage tank

Step 5. Settling tank: After aeration, the

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Step 6. Aeration tank: Aeration is done in order to enrich the water and bring down the levels of dissolved gases, BOD, COD and TSS to desired values

water flows in the settling tank where solids settle down

Step 7. Treated tank: The water flows from the settling tank to treated tank.

Step 8. Filtration tank: From treated tank, the water passes through activated carbon filter

Step 9. Water after treatment: Treated water obtained after activated carbon filtration which is reused for vehicle washing purposes.

Step 10. pH 7 is maintained prior to reuse

4.1.3 Option 3: Wastewater treatment for a standalone washing facility (100 per cent closed loop)

In case of a standalone washing facility, the wastewater treatment comprises of four steps: (a) oil sludge separator (b) multimedia filter (c) activated carbon filter, and (d) resin softener.

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1. Oil sludge separators 2. Multimedia filter

Flow diagram 4: Wastewater treatment for a standalone washing facilitySource: KKE Wash Systems, Nagpur, India.

The treatment process is as follows:

1) Oil /sludge separators: Oil/ sludge separators are installed to remove oil and grit particles.

2) Multimedia filter: The filter contains gravel, pebbles and sand of different sizes and specific gravity which remove the debris from the water and allow only clean water to pass through.

3) Activated carbon filter: In this type of filter, activated carbon is used to remove odours, dissolved gases, heavy metals etc. from the wastewater.

4) Resin softener: The main function of resin chambers is to remove dissolved salts by an ion-exchange mechanism.

The approximate cost for installing an ETP plant of capacity 2 KL, 5KL and 10 KL is given in Table 6.

Table 6: Approximate cost 2 KL (discharge 2,000 litre/hour)

5 KL (discharge 5,000 litre/hour)

10 KL (discharge 5,000 litre/hour)

Oil sludge separators Nu. 1, 02,942.00 Nu.1, 42,000.00 Nu. 1, 95,000.00Multimedia filter Nu. 88,000.00 Nu. 1, 17,000.00 Nu. 1, 43,000.00Activated carbon filter Nu. 36,000.00 Nu. 61,000.00 Nu. 80,000.00Resin softener Nu. 60,000.00 Nu. 1, 05,000.00 Nu. 1, 64000.00Note: Cost does not include civil works, land and operation and maintenance costSource: KKE Wash Systems, Nagpur, India.

5. Recommendations

5.1 General guidelines

Site selection criteria for establishment of vehicle wash facilityThe following criteria must be enforced for selection of site for setting-up a vehicle wash facility:

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3. Activated carbon filter

4. Resin softener

Reuse for washing

a) The site must be located at least 100 feet away from any water body.b) The site selected must have sufficient area for setting up the washing facility, parking,

and construction of ETP.c) The site must be located at least 50 feet from any residential area, hospital, school and

commercial area.

5.2 Minimum general standards for establishment of vehicle wash facility

The following are the minimum general standards:

a) The entire vehicle wash facility must be paved with concrete to avoid soil and ground water contamination.

b) The vehicle wash facility must be roofed with CGI to prevent rain from entering the facility.

c) Walls must be built on three sides of the vehicle wash area, with a rounded curb or a drain at the entrance to prevent effluent flowing out into the surrounding areas and also storm water entering into the facility.

d) A drainage system must be built channeling all wastewater into the ETP.e) Wastewater treatment – ETP – must be built to treat all effluent generated from the

vehicle wash, before releasing it into the receiving environment. The minimum treatment facility of an ETP is given in section 4.1.1 Option 1: Minimum Criteria for Wastewater Treatment.

f) Water used for washing the vehicle should be recycled, wherever feasible and where there is scarcity of water. The treatment facility of an ETP for recycling of wastewater is given in section 4.1.2: Option 2 and 4.1.3: Option 3 respectively.

g) Settled solids or sludge from the ETP must be removed regularly to avoid overflowing or clogging of drains.

h) Minimize use of water by ensuring that the water is not running when not in use, for instance while applying shampoo and detergents, etc.

i) The facility must be strictly used for washing the vehicles only.j) The facility must have designated area for storage of waste oil, coolant, grease,

lubricants, ETP sludge etc., in case of integrated washing facility.k) Engine oil, brake oil, coolant must not be allowed to drain into an ETP, in case of

integrated washing facility.l) The truck and bus wash facility may include construction of a ramp as indicated in the

drawing attached as Annexure A. Other equipment includes, but limited to an air compressor, servicing machine, and water pump.

m) ETP flow diagram must be displayed at the facility including details of capacity and type of treatment.

n) Use of a steamer for car washing should be explored (Refer section 3.2).o) Must maintain cleanliness within the facility at all times.p) The employee must be made aware of this guideline through conducting awareness

program.

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q) Must adhere to the provisions under the Environmental Assessment Act 2000, National Environment Protection Act, 2007, Waste Prevention and Management Act, 2009, the Water Act of Bhutan, 2011, and any other relevant rules and regulations of the kingdom.

The following are the optional standard for establishment of vehicle wash facility:

a) Use of solar water heating system for obtaining hot water to reduce the electricity cost.b) Rain water from the roof should be channeled to the water tank used for washing the

vehicles.

5.3. Specific recommendations for establishment of vehicle wash facilities

There is a need to ensure that vehicle wash facilities are established in strategic locations in the country depending on the number of cars, trucks and buses that may avail the service. The NEC would like to recommend the following, as per the location:

5.3.1 Armed forcesa) Armed forces must have vehicle washing facilities for light, medium and heavy vehicles.

However, if there are vehicle wash facilities already in operation, then, the management must ensure that the effluents from these facilities are connected to an ETP (as stated in this report) and also that it conforms to the guideline.

b) The Department of Industry, Ministry of Economic Affairs must ensure that all car wash facilities adhere to the guideline.

c) The NECS shall be the overall monitoring authority.

5.3.2 Thimphu City Corporation

a) The existing vehicle wash facilities in Olarongchu Automobile Workshop area (about 20 car wash facilities) must comply with the guideline

b) Thimphu City Corporation should facilitate establishment of at least one truck washing facility in a strategic location

c) Thimphu City Corporation must facilitate establishment of an automatic vehicle wash facility, if there are interested applicants, following the guideline

d) The Department of Industry, Ministry of Economic Affairs must ensure that all car wash facilities adhere to the guideline.

e) The NECS shall be the overall monitoring authority.

5.3.3 Dzongkhag Thromdes – Gelephu, Samdrup Jongkhar and Phuentsholing

a) The existing car wash facility within the city corporations must ensure that they adhere to the guideline

b) The city corporations must ensure that there is at least one car wash facility and also truck wash facility in a strategic location following the guideline

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c) The city corporations may facilitate an automatic car wash facility, if there are interested applicants, depending on the economic viability, in particular number and types of cars in the area

d) The Department of Industry, Ministry of Economic Affairs must ensure that all car wash facilities adhere to the guideline

e) The NECS shall be the overall monitoring authority.

5.3.4 Dzongkhags

a) Dasho Dzongdags must facilitate that there is at least one car wash facility within the Dzongkhag to prevent washing of cars at home and also in the streams and rivers. In addition, the mobile car wash facility may be more practical and accessible.

b) Dasho Dzongdags must facilitate that there is at least vehicle washing facility within the Dzongkhag to wash heavy vehicles such as trucks in a strategic location

c) The Department of Industry, Ministry of Economic Affairs must ensure that all car wash facilities adhere to the guideline

d) The District Environmental Officers and the NECS shall be the overall monitoring authorities.

5.3.5 Significant projects

a) Large projects, in particular, hydropower projects and Project Dantak, must ensure that there is a car wash facility installed, if the commercially available facilities are not used.

b) The Department of Industry, Ministry of Economic Affairs must ensure that all car wash facilities adhere to the guideline with respect to the industries and projects executed under the Ministry of Economic Affairs. Likewise, all the parent ministries of respective projects with such facilities shall ensure the effective implementation of such facilities.

c) The District Environmental Officers and the NECS shall be the overall monitoring authorities.

6. Implementation Arrangement

1. All the Dzongkhag Thromdes and Dzongkhags must accord high priority for establishment of car wash facility, Truck and Bus washing facilities in their respective territories.

2. For Thimphu Thromde, there is an urgent need to establish an efficient ETP plant at Olarongchu Automobile Workshop in order to treat the waste water immediately to prevent the effluent discharged directly into the Olarongchu stream. The need for additional car washing facilities has to be studied immediately. Thimphu Thromde needs to identify locations for the establishment of Truck and Bus Washing facilities as per the guidelines and recommendations as proposed in this document.

3. All other Dzongkhag Thromdes (Phuentsholing, Gelephu and Samdrup Jongkhar) need to study and propose establishment of semi-automatic or automatic washing facilities for light and heavy vehicles, along with identified locations. It is mandatory to establish an ETP along with the washing facility.

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4. Rest of the Dzongkhags with the support of Dzongkhag Municipalities should have either manual or semi-automatic light and heavy vehicle washing facilities connected to ETP. The mobile car washing facilities is also recommended. The Dzongkhags should propose the number and type of facilities required depending on the number of vehicles and available locations.

5. A VVIP automatic car wash facility needs to be established at a suitable location. 6. To facilitate and expedite establishment of vehicle wash facilities, the government

may consider provision of tax exemption for import of equipment which is environmental friendly technology. In view of the fact that some applicants have been forthcoming with their proposals to establish such facilities in Thimphu and even in Gelephu Thromdes, subsidies may not be necessary and it could have been economically viable business venture. However, in order to expedite the establishment of the facilities in all the Dzongkhags and Thromdes, the government may like to consider provision of subsidies (10% to 30%) or soft loan. The NEC would like to recommend provision of subsidy for establishment of ETP and a soft loan for washing facilities. This is suggested since the Waste Prevention and Management Act 2009 prohibits washing of cars in rivers, streams or in any water body to prevent pollution and that public should have an option already available for washing of cars where the effluent from these facilities are treated using the Effluent Treatment Plant as mandated by the NEC.

7. A mobile car washing facility, as proposed, may be encouraged wherever necessary.8. Provision of tax incentives or subsidies may encourage private sector to establish

vehicle wash facility within 10th Five Year Plan. If vehicle wash facilities are not established within the 10th Five Year Plan, then, some programs and activities may have to be included in the 11th Five Year Plan.

9. The Department of Industry, Ministry of Economic Affairs, as a designated Competent Authority, must ensure that all car/vehicle washing facilities adhere to the guidelines. Likewise, all the parent ministries of respective projects with such facilities shall ensure the effective implementation of such facilities.

10. The Dzongkhag Municipalities functioning under the Dzongkhag Administration will ensure the smooth functioning of such facilities in respective Dzongkhags.

11. The information on cost, equipment and design is only intended to help owners and operators of vehicle wash facilities to plan effectively. The proposed facilities are based on current market price in India except for the Steam Car Wash price made in South Korea and an automated car wash made in China. The Indian technology is recommended in view of the convenience for maintenance and lesser cost of transportation. However, the proponents can explore more sophisticated and even more costly equipment as per their interest and plans.

12. Wherever necessary and if private land is not available at desirable location, the government may lease the required area of land.

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