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Hi Tech “Cycle Valley” Project

Village– Dhanansu, District - Ludhiana, Punjab

Conceptual Plan

Punjab Small Industries and Export Corporation Limited 34

CONCEPTUAL PLAN

1. INTRODUCTION

Punjab Small Industries & Export Corporation (PSIEC) Limited was set in 1962 with the objective of

supporting the individual in his endeavour to set up his own industrial unit and help him and the small-

scale industry to grow in Punjab. Today PSIEC Ltd. has grown to become an INR 2,000 million profit

making corporation, with committed workforce of about 1,000 people. The proposed project site

(345.80 acres i.e. 140 Ha) has been set aside by the Government of Punjab for development of a Hi

Tech “Cycle Valley” by Punjab Small Industries and Export Corporation Limited at Village –

Dhanansu, District – Ludhiana, Punjab. The estimated cost (inclusive of land as well as development) is

INR 400 Crores.

The project involves development area greater than 50 Ha and is not housing Category A or Category B

industries. Hence, as per EIA Notification, 2006 and its amendments thereupon, the proposed project

falls under schedule 8(b) i.e. Area Development Project. Affidavit stating that no Category A or B

industries are proposed to come up within the project is enclosed as Annexure I.

2. SITE SURROUNDINGS AND CONNECTIVITY

The area development project is located at Village – Dhanansu, District – Ludhiana, Punjab. The

geographical coordinates of the project site are 30056’34.37” N & 75059’55.42” E. 500 m radius Google

Earth Image of the project site is enclosed as Annexure II (a). 2 km, 5km & 10 km radii of the project

site on Survey of India Toposheet are enclosed as Annexure II (b), (c) & (d).

3.AREA STATEMENT

The total area of project is estimated to be 13,99,389m2 (345.80 Acres). The net planned area for the

project, excluding the school (Jawahar Navodaya Vidyalaya) and existing road area (Dhanansu

Bounkar Link Road & Jawahar Navodaya Vidyalaya Road) will be 12,90,835 m2. Hence the total

development area of the project will be 129.08 Ha. The detailed Area Statement is provided below in

Table 1.

Table 1: Area Statement

S. No Particulars Area (m2)

1. Total Plot Area 13,99,389.00

2. Area under School 1,08,554.00

3. Net Planned Area 12,90,835.00



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4. Area under Industrial Plots

Large Industrial Plots (A1 & A2)

Small Industrial Plots (47 Plots)

7,10,020.00

4,85,623.00

2,24,397.00

5. Electrical Substation 1,41,640.00

6. Common Amenities Plot 21,730.00

7. Convention Center Plot 67,400.00

8. Commercial Plot 6,800.00

9. Common Utilities 24,326.00

10. Common Utilities Plot (Incl. Transport Hub,

Parking & Warehouse)

38,445.00

11. Parking (Small Industrial Plots) 23,247.00

12. Landscape (@ 30% of Net Planned Area) 3,87,250.5

13. Entrance 16,188.00

14. Roads 1,35,821.00

4. POPULATION DETAILS

The total population estimated for the project is 33,868 persons. Details are given in Table 2

Table 2: Population Break up

S. No Unit Type Population Number of

Shifts

Total

Population

1. Large Industrial Plot (A1 – 75 Acres) 5,000 2 10,000

2. Large Industrial Plot (A2 – 35 Acres) 2,500 2 5,000

3. Small Industrial Plot (47 Nos.) (@ 200

persons per plot)

9,400 2 18,800

4. Bank 15 - 15

5. Post Office 8 - 8

6. Police Post 5 - 5

7. Training Station 20 - 20

8. Petrol Pump 5 - 5

9. Effluent Treatment Plant (ETP) 3 - 3

10. Sewage Treatment Plant (STP) 3 - 3

11. Waste Management Area (Industrial) 3 - 3

12. Water Treatment Plant 3 - 3

13. Control Office (For Common Utilities) 3 - 3

14. Total 16,968 - 33,868

5. PROJECT COST

The total estimated project cost will be INR 400 Crores (Inclusive of land and development).

6. WATER REQUIREMENT

The total water requirement will be approx. 4,330.06 KLD during operation phase out of which total

fresh water requirement is 2,207 KLD. The total process water requirement per day for operation of 2



Conceptual Plan


shifts will be 1,140 KLD. The total domestic water requirement (for staff only) will be 1,524.06 KLD.

The recycled water requirement for landscape purpose will be 1,666 KLD, considering the varying

water demand for three different seasons. The source of water supply during construction phase will be

private water tankers and during operational phase will be municipal water supply, Ludhiana. Details

are given below in table 3.

Table3: Water Demand Calculation

S. No Unit Type Population Process

Water

Requirement

(per day per

shift)

Domestic

Water

Requirement

(KLD)

Total Water

Requirement

(KLD)

1. Large Industrial Plot (A1 – 75

Acres)

5,000 2 shifts * 50

KLD = 100

KLD

2 shifts *

0.045 KLD *

5000 persons

= 450 KLD

550

2. Large Industrial Plot (A2 – 35

Acres)

2,500 2 shifts * 50

KLD = 100

KLD

2 shifts *

0.045 KLD *

2500 persons

= 225 KLD

325

3. Small Industrial Plot (47

Nos.) (@ 200 persons per

plot)

9,400 2 shifts * 10

KLD * 47

plots = 940

KLD

2 shifts *

0.045 KLD *

9400 persons

= 846 KLD

1,786

4. Bank 15 0.675 0.675

5. Post Office 8 0.360 0.360

6. Police Post 5 0.225 0.225

7. Training Station 20 0.900 0.900

8. Petrol Pump 5 0.225 0.225

9. Effluent Treatment Plant

(ETP)

3 0.135 0.135

10. Sewage Treatment Plant

(STP)

3 0.135 0.135

11. Waste Management Area

(Industrial)

3 0.135 0.135

12. Water Treatment Plant 3 0.135 0.135

13. Control Office (For Common

Utilities)

3 0.135 0.135

14. Landscape Water

Requirement

Summer

Winter

Monsoon

3,87,250.5

m2

@ 2.0 KLD

@1.8 KLD

@0.5 KLD

775 KLD

697 KLD

194 KLD

775

697

194

15. Total 1,140 KLD 3,190.06

KLD

4,330.06

KLD



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The wastewater calculations for the proposed development is shown in Table 4 below:

Table 4: Wastewater Calculations

Total Process Water Requirement (A) 1,140 KLD

Total Domestic Water Requirement (B) 2,299 KLD (summer); 2,221 KLD (winter) & 1,718

KLD (monsoon)

Total Fresh Water Requirement (C) A + (70% of 1,524.06 KLD) = 1,140 + 1,067 = 2,207

KLD

Total Flushing Water Requirement (D) 30% of 1,524.06 KLD = 457 KLD

Total Domestic Fresh Water Requirement (E) 1,067 KLD

Total Wastewater Generated (80% of E + 100 % of D) = 854 + 457 = 1,311 KLD

STP Capacity (20% higher than volume of

Wastewater generated)

1,750 KLD

Total Process wastewater generated 500 KLD (250 KLD electroplating effluent + 250

KLD pickling effluent)

Common ETP Capacity 500 KLD

The water balance diagrams are shown below in Figure 1, 2 & 3:

Figure 1: Water Balance Diagram (Summer)



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Figure 2: Water Balance Diagram (Winter)



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Figure 3: Water Balance Diagram (Monsoon)

Waste water Generation & Treatment

It is expected that the project will generate approximately 1,311 KLD of domestic waste water. The

waste water will be treated by an onsite STP of 1,750 KLD capacity. Treated water from the onsite STP

will be recycled and utilized for flushing and horticulture purposes.

Proposed Technology (Sewage Treatment Plant)

A receiving sump with screen chamber shall be provided to receive the raw sewage pumped from

various pumping stations before pumping it to the subsequent treatment units. The purpose of screen is

to remove any floating impurities from the sewage.

An O&G trap shall be provided to remove the oil & grease content in the sewage. The oil will be

trapped on the surface of the fat trap by providing quiescent condition and providing laminar flow. It



Conceptual Plan


shall be followed by a grit chamber to remove grit like particles from the sewage before the biological

treatment.

The screened and degritted sewage shall be collected in equalization tanks. It is essential to equalization

of quality and quantity of effluent thus preventing shock loads to subsequent treatment units.

An extended aeration process shall be provided to treat the sewage biologically and remove the organic

load from it. In this process, the dissolved organic matter is subjected to biological degradation by

bacterial action in presence of oxygen & nutrients. This will convert dissolved organic matter into

stable settable matter. A dissolved oxygen content of 2 mg/l to be maintained in the Aeration Tank. Air

sparging arrangement will be provided to mix the contents of Aeration Tank and transfer atmospheric

oxygen into the system. The biological sludge developed in the aeration tank shall be settled and

removed in secondary clarifier. The process of sludge recirculating back into the aeration tank shall be

kept continuous to maintain the desired MLSS. Excess biological sludge shall be evacuated and

collected in a sludge sump. Sludge drying beds shall be provided dewatering of wasted sludge. The

dewatered sludge shall be collected, stored and disposed as directed by the Pollution control board.

After the biological treatment, the treated sewage shall be dosed with sodium hypochlorite for

disinfection. Pressure sand filter and activated carbon filter shall be provided for removal of any

accidental carryover of solids, colour and odour.

Effluent Treatment Plant

Effluent Generation, Drainage System& Treatment

Effluent shall be generated from all small industrial units will be connected to centralized Effluent

treatment plant. Two types of effluent will be generated for which two separate drainage systems are

proposed in the Project. One drainage line will cater to the effluent generated by chrome plating

industry and second will be common for all effluent generated by small industries. The total quantity of

effluent generated which is to be treated in central ETP shall be 500 KLD out of which 250 KLD shall

be generated as electroplating effluent and 250 KLD shall be generated as pickling effluent.

Large Industrial Plots A1 & A2 (75 Acres / 50 Acres) will have their own effluent treatment plant

(ETP) within their plots.



Conceptual Plan


Characteristics of Effluent Generated

Parameter Value

Flow 500 m3/day

pH 6 to 8

Chemical Oxygen Demand 850 mg/l

Total Suspended Solids 700 mg/l

Total Dissolved Solids 1720 mg/l

Oil & Grease 20 mg/l

Proposed Technology for Effluent Treatment Plant

The effluent treatment plant receives effluent from two different streams. The first stream is the

chromium rich effluent from electroplating. Hexavalent chromium ions are of high toxicity even in very

low concentrations & they need to be completely removed from industrial wastes. The first step is to

reduce it to a hexavalent chromium ion by reducing its pH. Sulphuric acid is normally used for this

purpose. Then the next step involves precipitation with alkali & lime. The sludge should be de-watered

whereas the overflow must be collected in an intermediate tank. The effluent from the pickling waste

will be treated with a coagulant such as ferrous sulphate or ferric chloride. This would result into

precipitation of ferric hydroxide after which both streams shall be combined. Once the streams are

combined they shall be treated through an extended aeration scheme along with a settling tank. An

Aeration Tank will be provided as a single stage aerobic process. Air sparging arrangement will be

provided to mix the contents of Aeration Tank and transfer atmospheric oxygen into the system. The

dissolved organic matter is subject to biological degradation by bacterial action in presence of oxygen

& nutrients. This will convert dissolved organic matter into stable settable matter. A Dissolved oxygen

content of 2 mg/l will be maintained in the Aeration Tank. Aeration Tank shall be provided with air

supply from the blowers. Two

Air Blowers will be provided. One of the blowers shall be working whereas the other shall be in

standby mode. A bacteria concentration of 3500 mg/l will be maintained in the Aeration Tank. The

treated effluent shall be disinfected before it shall be filtered through a Pressure Sand Filter & an

Activated Carbon Filter before it is fed through the UF/RO unit for water recovery. The effluent shall

be initially pre-treated to anti-scale, dechlorinate & adjust the pH. UF is a skid mounted membrane

system, which comprises mainly of the hollow fiber UF membrane modules, re-circulation and

pneumatically actuated valves. All these are neatly interconnected into a compact and modular train,

which comes complete with a self-control system. Each UF membrane module consists of thousands of



Conceptual Plan


hollow fibre membranes that can remove virtually all suspended solids, colloids, bacteria and viruses

bigger than 0.01-0.015 micron from the feed stream. It is equipped with a small basket strainer & a bag

filter. The filtrate shall be collected in Ultra Filter Tank. In the filtration process, the rejected suspended

solids form a layer on the surface of the membrane which reduces the membrane permeation rate. This

layer is to be dislodged to maintain the membrane permeation rate. This can be achieved through a

method called backwash or reverse flow. Service interval is set at 30 - 60 minutes with a backwash

interval of 120 seconds, before service is again resumed. The backwash stream is discharged to

Equalization Tanks.

Ultra-Filtration Module shall be followed by online dosing of SMBS, pH Correction & Antiscalent. It

shall be mounted on a skid. The purpose of the RO Membrane is to reduce the TDS of the effluent. To

safeguard the High-Pressure Pumps from dry running a low-level switch shall be connected to the

Feed/CIP tank which trips the motor in case of drop in the water level below the specified level. The

pressurized feed water shall be passed through the RO skid. The RO skid shall comprise of a pressure

vessel containing special fouling resistant RO membrane elements each. All the necessary instruments

like pressure gauge, flow meters, ammeter, voltmeter, etc. shall be provided to monitor the smooth

functioning of the Plant. The reject held in the Reject Holding Tank shall be pumped to the Multiple

Effect Evaporator. The evaporation system shall be specifically designed for handling second stage

reverse osmosis rejects, softener backwash effluent and high TDS effluent streams from the plant. It

shall be a triple effect forced circulation evaporator which shall be fully PLC controlled. Feed effluent

will be preheated by process condensate, Vapor from second effect, first effect followed by Vapors out

from TVR through series of pre-heaters respectively. Then preheated effluent is fed to the first effect.

Feed will flow in forward feed manner in evaporators. All three effects will be Forced circulation type.

Live steam of will be fed to the inlet of TVR as a motive fluid. Partial Vapors from effect 1 will be

sucked by TVR to mix up with live steam which will be given to shell side of 1st effect. Vapors

generated in the first effect will be condensed on the shell side of second effect. Subsequently, the

vapors generated in second effect will be condensed on the shell side of the third effect. Vent Vapors

and vapors from last effect are condensed in Surface condenser. Condensate from first effect will be

flashed on shell side of second effect and collective condensate from first and second effect will be

flashed on shell side of third effect. This will help to increase in steam economy.



Conceptual Plan


Concentrated product from last effect will be transferred to ATFD for further removal of moisture.

Whole Evaporation system operates under vacuum. The concentrated product from evaporator is fed to

Feed Balance Tank of ATFD. This feed is fed at the top of ATFD rotor by feed pump. This feed is then

uniformly distributed with the help of rotor which is rotating at high speed. Due to the rotation of rotor

feed is sprayed on the surface wall. Dry saturated steam used as heating media to each jacket. Steam

condensate taken out from each jacket at the bottom nozzles through steam trap. The dry concentrated

product is taken out at the bottom of the equipment. The evaporated vapors are condensed in surface

condenser by cooling water. Dryer system operates under slight vacuum. Sludge would be collected,

thickened & subsequently dewatered in the treatment units. Thus, a Zero Liquid Discharge system

would be set up.

7. RAIN WATER HARVESTING SYSTEM

The storm drainage systems are designed for rainfall intensity of 100mm/hr and in conformity with the

guidelines.

The runoff water from proposed development area and paved area shall be collected in storm water

drainage system. The drains are minimum 900 mm wide for 10-meter-wide road with 1200 mm depth at

the start points. The drains are minimum 1000 mm wide for 18&24-meter-wide roads with 1200 mm

depth at the start points. The drains are minimum 2000 mm wide for 33-meter-wide roads with 1200

mm depth at the start points. Storm water drains are closed type, constructed of Concrete walls with

base, with plaster in CM 1:4 for the walls on the inside and outside All the road crossings would be in

Encased RC Hume pipes or RCC box culverts.

A total of 6 rainwater harvesting pits of 30 m3 capacity each have been proposed for groundwater

recharge within the project site.

8. PARKING FACILITIES

Adequate provision will be made for car/vehicle parking at the project site. There shall also be adequate

parking provisions for visitors so as not to disturb the traffic and allow smooth movement at the project

site.



Conceptual Plan


For development within all plots, the individual plot owner will be responsible for providing parking

internally. Additionally, provision for parking area of 23,247 m2 (i.e. 174 trucks) for small industrial

plots has been planned for.

9. POWER REQUIREMENT

The power supply shall be supplied by Punjab State Electricity Board. The estimated connected load for

the proposed cycle valley project will be 21 MW.

10. SOLID WASTE GENERATION

Solid waste would be generated both during the construction as well as during the operation phase. The

solid waste expected to be generated during the construction phase will comprise of excavated

materials, used bags, bricks, concrete, MS rods, tiles, wood etc. The following steps are proposed to be

followed for the management solid waste:

• Construction yards are proposed for storage of construction materials.

• The excavated material such as topsoil and stones will be stacked for reuse during later stages of

construction.

• Excavated top soil if any will be stored in temporary constructed soil bank and will be reused for

landscaping of the cycle valley project.

• Remaining soil shall be utilized for refilling /road work / rising of site level at locations/ selling to

outside agency for construction of roads etc.



Conceptual Plan


Solid Waste

Construction Waste

Construction waste,

Broken Bricks, Waste Plaster

Empty Cement

Bags

Used in re-filling,

raising site level

Road Making

Excavated Soil

Top soil conserved for landscaping,

balance used in re-filling

Figure 2: Solid Waste Management Scheme (Construction Phase)

During the operation phase, waste will comprise domestic waste. The total solid waste generated from

the project shall be mainly domestic waste and estimated quantity of the waste shall be approx.8,486 kg

per day (@ 0.25 kg per capita per day for Staff and @0.2 Kg per acre per day for Landscape waste).

Details are provided below in Table 5.

Table 5: Solid waste calculation

S. No Description

of

Population

Occupancy Waste Generated

(Kg per capita / day)

Waste

Generated

(kg/day)

Municipal Solid waste

1. Staff 33,868 @ 0.25 8,467

2. Landscape Waste 96 acres @ 0.2 kg/acre/day 19.2

Total Waste Generation = 8,486 kg/day



Conceptual Plan


Following arrangements will be made at the site in accordance to Municipal Solid Wastes (Management

and Handling) Rules, 2000. E-waste will be managed as per E-waste (Management & Handling Rules,

2011). It will be handed over to Govt. approved vendors.

❖ Collection and Segregation of waste

1. A door to door collection system will be provided for collection of domestic waste in

colored bins.

2. The local vendors will be hired to provide separate colored bins for dry recyclables and

Bio-Degradable waste.

3. For waste collection, adequate number of colored bins (Green and Blue& dark grey bins–

separate for Bio-degradable and Non-Bio-degradable) are proposed to be provided at the

strategic locations of the area.

4. Litter bin will also be provided in open areas like parks etc.

❖ Treatment of waste

• Bio-Degradable wastes

1. Bio-degradable waste will be subjected to Organic Waste Converter and 20% of the subjected

waste will be used as manure.

2. STP sludge is proposed to be used for horticultural purposes as manure.

3. Horticultural Waste is proposed to be composted and will be used for gardening purposes.

• Recyclable wastes

i. Grass Recycling – The cropped grass will be spread on the green area. It will act as manure

after decomposition.

ii. Recyclable wastes like paper, plastic, metals etc. will be sold off to recyclables.

❖ Disposal

Recyclable and non-recyclable wastes will be disposed through Govt. approved agency. Hence, the

Municipal Solid Waste Management will be conducted as per the guidelines of Municipal Solid

Wastes (Management and Handling) Rules, 2000.

Benefits of Organic waste converter:

➢ Aerobic microbial decomposition into compost



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➢ Biomechanical process produces Odour free output in 15 minutes

➢ Compost manure generated can be used for soil conditioning

11. GREEN AREA

Area under landscaping and tree plantation will be 3,87,250.5 m2 and is proposed to be provided

between the industrial plots and along the roads. 50% of the proposed area of the large industrial plots

A1 & A2 will be used for landscaping purposes only.

Ornamental tress like Jacaranda and Gulmohar has been proposed to be planted inside the premises.

Parks will also be developed by the project proponent.

Table 6: List of Trees

S. No. Botanical Name Common Name

1. Bauhenea purpurea Kachnar

2. Acacia auriculoformis Babul

3. Jacaranda mimosaefolia Fern Tree

4. Alstonia scholaris Indian devil tree

5. Bauhinia variegata Kachnar

6. Delonix regia Gulmohar

7. Dalbergias issoo Sheesham (Source: Guidelines for developing Green Belts by CPCB, 2000)

DETAILS OF CONSTRUCTION MATERIALS

List of building materials being used at site:

1. Coarse sand

2. Fine sand

3. Stone aggregate

4. Stone for masonry work

5. Cement

6. Reinforcement steel

7. Pipe scaffolding (cup lock system)

8. Bricks

9. CLC fly ash blocks

10. P.V.C. conduit

11. MDS, MCBs

12. PVC overhead water tanks



Conceptual Plan


13. 2 1/2'’ thick red colour paver tiles

14. PPR (ISI marked)

15. PVC waste water lines

16. S.W. sewer line up to main sewer

17. PVC rain water down take

18. Stainless steel sink in kitchen

19. Joinery hardware- ISI marked

Table7: Materials used for construction & their u values

Type of Construction U values (in W/m2deg C)

Walls:

Plastered both sides 3.24

Solid Unclastered 2.67

Plastered both sides 2.24

Concrete, Ordinary, Dense:

-152mm 3.58

-203mm 3.18

Concrete block:

CLC Fly ash block 1.19

Hollow Concrete block, 220mm, single skin, outside rendered, inside plastered:

CLC Fly ash block 1.70

Roofs Flat

Reinforced concrete slab, 100mm, scarred 63-12

mm, 3 layers bituminous felt

3.35

Floors:

Concrete on ground or hardcore fill 1.13

+ Grano, Terrazzo or tile finish 1.13

+ Wood block finish 0.85

LIST OF MACHINARY USED DURING CONSTRUCTION

(i) Dumper (xi) Labor Lifts

(ii) Concrete mixer with hopper (xii) Pile Boring Machines

(iii) Excavator (xiii) Concrete pressure pumps

(iv)Concrete Batching Plant (xiv) Mobile transit mixer

(v) Cranes

(vi) Road roller

(vii) Bulldozer

(viii) RMC Plant



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(ix) Tower Cranes

(x) Hoist

Documents

CONCEPTUAL PLAN 1. INTRODUCTIONenvironmentclearance.nic.in/writereaddata/FormB/TOR/ConceptualPla… · Conceptual Plan Punjab Small ... CONCEPTUAL PLAN 1. INTRODUCTION ... making