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Pyujjfjdlfkgjndgh PRE-FEASIBILITY REPORT

OF

PROPOSED 6 MLD COMMON EFFLUENT TREATMENT PLANT (CETP)

AT

HAJIPUR INDUSTRIAL AREA, DISTRICT VAISHALI, BIHAR

BY

M/S. BIHAR INDUSTRIAL AREA DEVELOPMENT AUTHORITY (BIADA)

GOVERNMENT OF BIHAR

EIA Consultant

SMS Envocare Ltd

301, Pentagon P3, Magarpatta City, Hadapsar, Pune, 411028 MS Phone No.: 020-66801111, Fax No. 020-66801100

Web: www.smsenvocare.co.in

Draft Detailed Project Report for Establishment of CETP in HAJIPUR Industrial Area, VAISHALI

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INDEX

SR. NO. PARTICULAR PAGE NO.

CHAPTER 1- INTRODUCTION

1.1 BACKGROUND OF THE PROJECT 1 1.2 SCOPE OF WORK 2 1.3 METHODOLOGY ADOPTED 3 1.4 COLLECTION/ CONVEYANCE OF WASTEWATER 5 1.5 ASSUMPTIONS MADE DURING PREPARATION OF DETAILED PROJECT

REPORT 5

1.6 JUSTIFICATION FOR REQUIREMENT OF CETP 6 CHAPTER 2- PROFILE OF VAISHALI

2.1 CITY PROFILE OF VAISHALI 7 2.2 LOCATION & GEOGRAPHICAL AREA 7 2.3 TOPOGRAPHY 8 2.4 CLIMATE & RAINFALL 8 2.5 DEMOGRAPHY 11 2.6 ECONOMY 11 2.7 TRANSPORT 11 2.8 HISTORY & CULTURE 12

CHAPTER 3- PROFILE OF HAJIPUR INDUSTRIAL AREA

3.1 HAJIPUR INDUSTRIAL AREA 16 3.2 INVENTORY OF INDUSTRIES 17 3.3 INDUSTRIAL SECTORS IN VAISHALI 21 3.4 PRESENT SCENARIO OF WASTEWATER GENERATION 24 3.5 FUTURE PROJECTIONS OF WASTEWATER QUANTITY 25 3.6 CATEGORIZATION OF INDUSTRIES (RED, ORANGE AND GREEN) 26 3.7 MAJOR INDUSTRIES LOCATED IN HAJIPUR, INDUSTRIAL AREA 27

CHAPTER 4- PRODUCTION PROCESS

4.1 PRODUCTION PROCESS 30 CHAPTER 5- QUANTIFICATION & CHARACTERISTICS OF WASTE WATER/EFFLUENTS

5.1 ASSUMPTIONS IN CALCULATION OF WATER CONSUMPTION AND EFFLUENT GENERATION

44

5.2 WATER CONSUMPTION AND EFFLUENT GENERATION 44 5.3 DESIGN CAPACITY OF PROPOSED CETP 46 5.4 CHARACTERISTICS OF WASTE WATER 46 5.5 CHARACTERISTICS OF TREATED WASTE WATER 47

CHAPTER 6- CRITERIA FOR SELECTION OF WASTEWATER TREATMENT

TECHNOLOGIES/SCHEMES

6.1 ACTIVATED SLUDGE PROCESS 48 6.2 SEQUENTIAL BATCH REACTOR (SBR) 49 6.3 MOVING BED BIO-REACTOR (MBBR) 50 6.4 RECOMMENDED TECHNOLOGY 53

CHAPTER 7- PROPOSED SCHEMES

7.1 PROPOSED TREATMENT SCHEME 54 7.2 DETAILED TREATMENT SCHEME 56 7.3 SLUDGE HANDLING SYSTEM 61

CHAPTER 8- DESIGN SPECIFICATION OF TREATMENT UNIT

8.1 SPECIFICATIONS FOR CIVIL UNITS 62 8.2 SPECIFICATION FOR MECHANICAL EQUIPMENTS AND WORKS 67

Draft Detailed Project Report for Establishment of CETP in HAJIPUR Industrial Area, VAISHALI

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8.3 SPECIFICATION FOR ELECTRICAL & INSTRUMENTATION WORKS 74 8.3.1 Automatic Power Factor Control Panel 74 8.3.2 Electr ical Panel 75

8.4 INSTRUMENTATION 76 8.4.1 The Aerat ion System Shall be PLC Controlled for Automatic Operation

through SCADA 76

8.4.2 Online Real Time CETP Water Quality Monitor ing 78 8.5 ELECTRICAL LOAD 78

CHAPTER 9- ENVIRONMENTAL MANAGEMENT PLAN (EMP)

9.1 ENVIRONMENTAL MANAGEMENT PLAN (EMP) 80 9.2 ENVIRONMENTAL MANAGEMENT DURING OPERATION OF CETP 83

CHAPTER 10- CONCLUSION

10.1 CONCLUSION 87

LIST OF TABLES

TABLE. NO. PARTICULAR PAGE NO.

CHAPTER 2- PROFILE OF VAISHALI

2.1 Rainfall intensities (month wise) from Meteorological Depar tment 9 CHAPTER 3- PROFILE OF HAJIPUR INDUSTRIAL AREA

3.1 Summary of Distr ibution of Industr ies & Plot area 18 3.2 Categor ization of Industr ies 19 3.3 Distr ibution of industr ial clusters in HAJIPUR, VAISHALI Region 22

CHAPTER 5- QUANTIFICATION & CHARACTERISTICS OF WASTE WATER/EFFLUENTS

5.1 Distr ibution of industr ial clusters in HAJIPUR, VAISHALI Region 45 5.2 Average Character istics of Combined Untreated Effluent for Design 47

5.3 Character istics of Treated Water as per CPCB/ SPCB

CHAPTER 6- CRITERIA FOR SELECTION OF WASTEWATER TREATMENT

TECHNOLOGIES/SCHEMES

6.1 Comparative of Mer its and Demer its of ASP, SBR and MBBR technologies

52

CHAPTER 7- PROPOSED SCHEMES

7.1 Expected Character ist ics of Effluent after Physico-chemical treatment

56

7.2 Expected Character istics of tr eated Effluent after Biological Treatment

58

7.3 Expected Character istics of final treated effluent after Ter tiary treatment

59

CHAPTER 8- DESIGN SPECIFICATION OF TREATMENT UNIT

8.1 Details of CETP Units and BOQ of Civil work 63 8.2 Pipe Details 67 8.3 Mechanical Items Details 68 8.4 Electr ical Load Sheet 78

Draft Detailed Project Report for Establishment of CETP at Hajipur Industrial Area

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CHAPTER -1

INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

The enhanced pace of developmental activit ies and rapid urbanizat ion have resulted in

stress on natural resources and quality of life. In the present scenar io of increasing

urbanizat ion, vast amount of industr ial, vehicular as well as water pollution occurs due to discharge of effluents without conforming to the environmental norms and standards, the

concern for environmental quality has become an issue of worry. The trend of increasing pollut ion in var ious environmental media is evident from the deter iorating quality of

water , air , soil etc.

Small Scale Industr ial units (SSIs) have a very impor tant role in industr ial development in

the country. Government actively promotes growth of SSI units to induce a balanced economic growth and distr ibute the benefits of industr ial development in an equitable

manner . SSI units generally find it difficult to establish and operate individual Effluent Treatment Plant (ETP) due to their limited plot size and scale of operat ions. However , SSI

units are generally located as clusters in industr ial areas/ estates; the concept of Common

Effluent Treatment Plant (CETP) for the ent ire effluent from the industr ial area has been developed to achieve sat isfactory treatment through their collective effor ts. The

monitor ing and enforcing a CETP as a single pollut ing source also becomes easier for regulatory agencies as compared to monitor ing a large number of SSI units individually.

The cont inuous discharge of par tially/ un-treated industr ial wastewater from the industr ies

leads to contaminat ion of sur face and ground water . Most of the industr ial estates in Bihar are located at the Bank of River “Ganga”. Ganga is no more pure for direct dr inking purpose. Government of India as well as var ious states has taken init iatives to pur ify the

r iver Ganges. Present ly Government has come up with the scheme of “Namami Ganga” to

pur ify r iver Ganga upto 2020. In line with this, State Pollut ion Control Board has taken

initiat ive under the direct ion of Nat ional Green Tr ibunal to establish Common Effluent Treatment Plant (CETP) in the Industr ial Estate to treat the wastewater to meet sur face

discharge norms. Subsequently, Bihar Industr ial Area Development Author ity (BIADA) has floated tender for gett ing Consultancy Services for the Preparat ion of Detailed Project

Repor t (DPR) for Establishment of Common Effluent Treatment Plant (CETP). SMS

Envocare Limited (SMSEL) being pioneer in the field of Environmental Consultancy in India had par ticipated in the Tender and qualified technically and financially and eventually was

awarded the work for the same in the month of August 2015.

After receipt of the work order and execut ion of agreement for the conduct ion of study for the preparation of DPR for establishment of CETP in the five industr ial areas, viz- ( i)


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Patliputra Industr ial Area, ( ii) Hajipur Industr ial Area, ( ii i) Bela, Muzaffarpur Industr ial Area, ( iv) Barar i, Bhagalpur Industr ial Area and (v) Fatuha Industr ial Area; the team of

SMSEL conducted field studies in the month of August –September 2015 and prepared the

Feasibi lity Repor t . Subsequent ly, a presentation has been made before the officials of BIADA under the chairmanship of Managing Director , BIADA. The feedback/ suggest ion

received on the feasibility repor ts has been incorporated in draft DPR.

This Draft Detailed Project Repor t is per taining to Hajipur Industr ial area.

1.2 SCOPE OF WORK

As per NIT/ Tender document/ contract agreement, the following scope of work has been envisaged:

1. Ident ify the type of Industr ies with numbers and categor ies in each Industr ial Area.

2. Undertake detai led pr imary as well secondary surveys to quant i fy the d ischar ge and determine the character ist ics of discharge in terms of influent and effluent

from each unit w ithin the Industr ial Area.

3. Determine the total cur rent discharge and the type and character istics of discharge from a par ticular Industr ial Area and categor ize the industr ies into pollut ing and

ser iously polluting industr ies. 4. Just ifying the Need for sett ing up of the CETP.

5. Suggest and ident ify the most suitable land in consultation with BIADA for setting

up of the CETP. 6. Topographical survey and geotechnical investigat ion of the identified land.

7. Based on the present and future discharge, capacity planning of the CETP and adopt best pract ices in terms of technology while following all norms and

specificat ions.

8. Detailed Engineer ing Design of the CETP, Detailed Plan Drawings showing the

Co- Ordinates , Engineering Drawings with Detailed Quantity and Cost Est imate (cost estimate shall be prepared as per latest schedule of rates of Govt. of Bihar) .

9. Technical and Financial sustainabili ty analysis and implementat ion of framework.

10. Obtain Approval/ clearances on behalf of BIADA from all concerned Author it ies

like, Bihar State Pollut ion Control Board, National Green Tr ibunal etc as may be

required for smooth implementation of the project.


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1.3 METHODOLOGY ADOPTED

Following methodology has been adopted in the Preparation of Draft DPR:

Kick –off meeting: Immediately after receipt of the work order , kick off meet ing

has been made in the Head office of BIADA at Patna. The methodology for the conduction of study has been discussed with the Secretary, concerned Execut ive

Engineer & Asst Engineer of BIADA.

Getting Authorization Letter: Dur ing the meeting, i t has been felt that an Author izat ion letter need to be issued from the office of BIADA to meet with the

Entrepreneurs of the Industr ial Area, Industry’s Associat ion, Bihar State Pollut ion Control Board and other Government offices/ inst itutions in gett ing the available

information. The head office of BIADA issued letter to all concerned officers of Industr ial areas like Execut ive Director , Executive Engineer , Asst Engineer , Junior Engineer , Area-In-Charge etc. The respective Area In-Charge fur ther issued

Author izat ion letter to SMSEL for the easy access to the industr ies. They have communicated at their end to all the industr ies to extend cooperat ion in gett ing

valuable information by SMSEL. A copy of let ters are enclosed in Annexure-I

Collection of Available Secondary Data: The available data with the BIADA office has been collected by the team of SMSEL like Layout Plan of the Industr ial Area,

Updated list of the industr ies with plot size and type of product/ manufactur ing. The

data of operational, closed, under construction, vacant plot also have been collected.

Preparation of Questionnaire for survey: A quest ionnaire has been prepared for

the collection of data per taining to Production Capacity, Product(s) , water consumption, wastewater generat ion, quality of wastewater , existence of ETP, future expansion in the product ion capacity etc to arr ive at the design wastewater

quant ity and character ist ics. A copy of quest ionnaire is placed at Annexure-II.

Conduction of field survey: Team of exper ts from SMSEL conducted field survey to collect information door-to-door from all the operat ional units in the industr ial area.

The schedule of visit to the industr ies has been communicated to the concerned Executive Director as well as Area In-Charge. They were communicated and br iefed

in advance to all the industr ies about the field survey work and data collect ion for CETP work. Dur ing the survey, the representatives of BIADA along with the team of SMSEL visited to the industr ies.

Inventory of Industries: Inventory of industr ies/ inst itut ions with detai ls of address, plot size, types of product, daily production, man-power strength, quantity of process water consumption, existence of ETP etc was studied through door to

door survey of the exist ing plots.

Collection of Representative samples: The necessary wastewater samples have been collected to represent all possible industr ial sectors. The wastewater samples


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have been analyzed in the field through test kits and also analyzed in the Environmental Laboratory of SMSEL/ NABL accredited laboratory.

Meeting with the officials of Bihar State Pollution Control Board (BSPCB): The

exper ts from SMSEL met the Member Secretary of BSPCB and Regional officers looking after the Industr ial Estate. The Regional Officers and their colleagues ident ified the major water pollut ing industr ies located in the industr ial areas who

are the major contr ibutors of wastewater generated from the industr ial area.

Literature Survey: The team of SMSEL has gone through the relevant li terature available in the Books, Journals, Internet Web-sites, and Publication of CPCB etc. The

ear lier prepared repor ts by CPCB, NPC, MoEF, Wor ld Bank, UNIDO, and USEPA etc have been referred for gett ing specific wastewater generation from all possible type

of industr ial sectors located in the industrial area. The relevant wastewater

character istics available from the reputed literature for the different industr ial areas/ industr ial processes have been referred to arr ive at composite and combined

wastewater character istics.

Quantification and Characterization of wastewater: The design flow and character istics have been arr ived based on the estimated wastewater flow and

character istics from the individual operat ional industr ies dur ing the survey per iod

and projection for closed, under-construction and vacant plots. Specific water

consumption figures in var ious sectors of industr ies were taken as per CPCB guidelines, experience of the consultant. For domestic wastewater , CPHEEO Manual

was followed. The weightage average value of BOD of combined effluent for CETP design was calculated by mult iplying est imated daily flow (quant ity) and BOD value

of individual industry.

Estimation of Design flow & characteristics: The design flow and character istics have been arr ived based on total est imated industr ial and domestic wastewater generated from the operating industr ies and fur ther projection for closed, under

construct ion and vacant plots. The combined wastewater characterist ics have been

evolved based on summation of BOD load from all the operational units and

projected BOD load from closed, under construction and vacant plots.

Identification of proposed land for CETP: With the help of concerned Execut ive Director and Area In-charge, the proposed available site(s) of land for CETP have

been seen by the exper t of SMSEL. The same has been cr itically examined for the

feasibili ty of setting up of CETP. It has been discussed with the senior officials of BIADA before finalization of DPR.

Preparation of Feasibility Report: Based on the design flow and character ist ics, the var ious possible treatment schemes have been evolved and discussed. The sizes of var ious treatment units were calculated based on design flow and characterist ics.

The comparative analysis of specificat ion of Civi l, Electro-mechanical par ts, Operation & Maintenance and Power requirement have been made with the latest


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t reatment technologies and discussed in the repor t . Out of alternate treatment schemes suggested in Feasibili ty Repor t, one best suited treatment scheme has been

selected after discussing with the BIADA officials. After necessary changes or

correct ion the Draft Detailed Project Repor t has been prepared for Submission.

Preparation of Draft DPR: After receipt of comments on feasibi li ty repor t and finalization of land for the proposed CETP the detai led Topographic & Geo-

Investigation survey have been carr ied out for the proposed CETP site. Based on

actual ground condit ion detai led costing of Civi l & Electro-Mechanical i tems have

been made based on rear ranged CETP components. Or layout.

1.4 COLLECTION/ CONVEYANCE OF WASTEWATER

Present ly the wastewater is being discharged outside/ inside the premises. There is no existence of conveyance system. As per discussion with BIADA, the same is in process of implementat ion.

There is no storm water drainage system existing in the industr ial areas. Dur ing rainy season, the Storm water gets mixed with the trade & domest ic waste water of the industr ies. Most of the time, i t leads to flooding in the industr ial area due to

absence of drains.

Dur ing the presentation of Feasibi li ty Repor t, it has been clear ly mentioned that there should be separate conveyance system for storm water , domestic and trade

effluent for the proposed site of CETP. It has been accepted by the BIADA officials

1.5 ASSUMPTIONS MADE DURING PREPARATION OF DETAILED PROJECT REPORT

Following assumptions have been followed for the estimat ion of wastewater flow and character istics to design suitable Treatment Scheme for sett ing up of CETP:

The door to door visit has been made in the operational units.

The estimation of flow has been made based on repor ted figures from the

representative of industr ies dur ing the field survey, exper ience of SMSEL exper ts in the same industr ial sectors and authent ic data on specific wastewater generat ion and pollut ion load from the literature/ repor ts and monitored/ est imated value

dur ing survey.

The value for closed and under-construct ion units have been made based on the

Production Capacity/ Product(s) .

The est imated wastewater from the vacant plot has been made for the prominent industr ies available in the industr ial area.

The pre-treatment has been suggested to industr ies those who are generat ing

excess quant ity of Oil/ grease, Total Suspended Solid (TSS), highly Acidic or Highly

Alkaline in nature and Tannery wastewater .


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There is no conveyance system present in the industr ial areas for carrying out the industr ial wastewater generated from individual units. Therefore, i t was assumed

that based on the flow from the individual units, the BIADA will construct suitable

conveyance system with gravity flow ( to extent possible) which leads to proposed site of CETP.

The Storm water drain should be separately constructed by BIADA for the

conveyance of Rain water .

Present ly, there is no Hazardous Waste Treatment, Storage and Disposal Facility

(TSDF) available in Bihar . After commissioning of CETP, the CETP sludge as

hazardous waste would be disposed in the TSDF facili ty as per Hazardous Waste (Management and Handling) Rules. The BIADA has to plan in setting up of TSDF.

The industry designated for “Zero Discharge Limit” has been considered to

discharge only domestic wastewater into the common drain leading to CETP.

The battery limit of Treated water disposal at the CETP point. The BIADA has to ident ify the disposal point for the discharge of treated wastewater from the CETP. It

could be discharged into nearby r iver , municipal drain or reuse in the agr iculture field.

1.6 JUSTIFICATION FOR REQUIREMENT OF CETP

The industr ies and institutes generate waste water from the production process, toi lets

(domestic) and laborator ies etc. Such wastewater has pollutants concentrat ion levels much above the permissible limits prescr ibed by the State Pollut ion Control Boards. Few big

industr ies has installed Effluent Treatment Plants (ETP), however , most of the industr ies discharge their untreated effluent in nearby open land/ drain leading to r iver Ganga.

In view of direct ions from the Central and State Pollut ion Control Boards, BIADA has

decided to install a Common Effluent Treatment Plant (CETP) for proper treatment of untreated wastewater likely to be generated from industr ies. The proposed CETP will help

in achieving end-of-pipe treatment of combined wastewater of all par ticipat ing industr ies

at lower O&M cost and also facili tate better monitor ing by the State Pollut ion Control Board.

*****


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CHAPTER -2

PROFILE OF HAJIPUR, VAISHALI

Hajipur Industr ial Area is located in Vaishali Distr ict of Bihar . The distr ict of Vaishali came into existence in the year 1972. Ear lier it was a par t of Old Muzaffarpur distr ict. Vaishali

has a past that pre-dates recorded history. It is held that the town der ives its name from

King Vishal, whose heroic deeds are nar rated in the Hindu epic “Ramayana”. However , history records that around the t ime Patliputra was the centre of poli t ical activity in the

genet ic plains. Vaishali came into existence as the centre of Ganga, i t was the seat of the Republic of Vajji. Vaishali is credited with being the wor ld’s First Republic to have a duly

elected assembly of representative and efficient administrat ion. Vaishali is bir th place of Lord Mahaveer and work place for Lord Budha.

2.1. LOCATION & GEOGRAPHICAL AREA

Hajipur is the headquar ters of Vaishali distr ict. It is located at 25.68°N 85.22°E. It has an average elevat ion of 46 meters (150 ft). The distr ict is sur rounded by r iver Ganga in the

south, Gandak in the west. Distr ict Muzaffarpur is in the nor th & Samastipur in the east. The

distr ict is in semi tropical Genet ic plane. The state capital Patna is linked with famous

Mahatma Gandhi Setu. The distr ict is spread over 2036 sq.km area

Fig 2.1: District Map of Hajipur


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2.2. TOPOGRAPHY

Vaishali being in Genetic and Gandak plains (Doab), it has r ich fert i li ty in the land and

hence farmers almost take 3 times agr icultural use of its land. The soil texture of this land is

mostly alluvial and hence farmers make commercial use of this quality of soil to grow

vegetables, fruits etc. 2.3. HISTORY & CULTURE

In the ancient t ime, it was known as Ukkacala and was the first village to come after crossing River Ganges at Patna. The vi llage of Hajipur gained significance, as it was the venue of one of the discourses given by Lord Buddha. Buddha preached the Cula Goplalaka Sutta, a Middle Length Discourse, here. Along with that, i t is also of interest because a por tion of Ananda's ashes were enshr ined in the town, the closest disciple of Lord Buddha. Ananda acted as the Buddha's personal attendant for twenty years and outlived him by several decades. Hajipur , ear lier in Br itish India was a small town in Muzaffarpur distr ict situated on the confluence of the Ganges and gandak. Hajipur figures conspicuously in the history of struggles between Akbar and the rebellious Afghan karrani rulers of Bengal.

Hajipur (Vaishali) -find its or igin way back in history from the mahabharata per iod. It is the place where democracy found its or igin around 600BC. Ancient Lichhavi republic was established in this land only. It is the place where Lord Mahavir took bir th and Gautam Buddha delivered his last sermon and announced his Par inirvana

PLACES OF INTEREST

Ramchaura Mandir

The Ramchaura Mandir is a Hindu Temple in the city of Hajipur , Bihar , India. Dedicated to Lord Rama, it is located at Rambhadra near Helabazar , Hajipur . As per local folklore, it is said to have been in existence since Ramayana period and Lord Shr i Ram is believed to have visited this place on his way to Janakpur , where his footpr ints are worshiped. The Ramchaura Mandir has tradition of celebrating Rama Navami, the bir th anniversary of Rama, every year . A small fair is also organised on the eve of Rama Navami. Archeological objects excavated from Ramchaura are kept at the Patna Museum.

Kaun Haara Ghat

It is considered one of the main ghats of Ganga-Gandak, where worshiping and cremation has been per formed for centur ies. This ghat has got i ts name based on an ancient legend. According to this legend, "The famous fight of Gaja (elephant)-Graah (crocodile) , which is well covered in Indian scr iptures, is the reason behind people asking -kaun haara. Hence,


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the name- Kaunhara ghat. Scr iptures tell that Lord Vishnu had to inter fere in the fight to save his devotee Gajaraj, who was being drowned by crocodile. Both Gaja and Graah were gandharvas. But due to some curse they became Gaja and Graah. Lord Visnu ki lled Graah to give him instant salvat ion, and saved life Of Gajaraj.

Nepali Mandir

The temple locates west of Hajipur , on the confluence of the Ganges and the Gandak is situated this unique Shaivite shrine. Made in the late medieval per iod (18th century), by (Mathabar Singh Thapa), the temple br ings-in fresh pagoda-style architecture of the Himalaya Kingdom to the plains of the Ganges. This temple is built largely of wood. Another dist inct ive feature of this temple is i ts fine wooden carving.

Pataleshwar Mandir

Dedicated to Lord Shiva, Pataleshwar Mandir is located at Jadhua Road, Hajipur . As per local folklore, it is said to have been in existence since ancient per iod and Lord Shiva is believed to be in the form of Lingam here.

Bateshwar Nath Temple

Oldest temple of Bihar , India, which is dedicated of Lord Shiva and Situated in East of Hajipur , Bihar , India. As per local folklore, it is said to have been in existence since Mughal Empire and it appeared in middle of thousand year old banyan tree and interesting tale about the temple was self-constructed Temple. The Bateshwar Nath Temple has tradit ion of celebrat ing Vasant Panchami Fest ival every year in (February/ March). A small fair is also organized on the eve of Maha Shivratr i for 1 month. It is a great place to visit for peace of Mind in middle of Agr icultural Land that give you a feel of spir i tuality.

Baithakji Hajipur

Lord Kr ishna Temple Baithakji Hajipur (Aacharya Prabhuji Ki Baithak) is one of the oldest temple of Hajipur . Shr i Mahaprabhuji graced this ear th for 52 years and 2 months dur ing which thr ice aapshr i toured India barefoot only to spread the pr inciples of Pusht imarg. Conducting Shr imad Bhagwat seminars, debating with scholars and heads of other religions and establishing the ethics of "Shudhadvaita Brahmavada" was a great task that aapshr i undertook. Ti ll date also innumerable vaishnavs travel by rai l and road to visit these Baithaks, at t imes travelling on hazardous roads leading to remotely situated Baithaks in forests and on mountains and take immense divine pleasure in paying respects to Shr i Mahaprabhuji and per forming any given tasks (Seva)


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Mahatma Gandhi Setu

The Mahatma Gandhi Setu (br idge) is the impor tant link between nor th and south Bihar . It has been constructed over the Ganges near vi llage Jadhua and connects Hajipur w ith Patna. This is one of longest r iver br idge of Asia having length of 5.75 km. The four lanes pre stressed RCC Br idge was commissioned into service dur ing the year 1982. Traveller gets an enthralling exper ience and panoramic view of lush green banana plantations by crossing the br idge.

Sonepur Cattle Fair

Located opposite Hajipur , is a small place of Sonepur where the for tnight long Sonepur Catt le Fair is held every year star ting from Kar tik full moon day (October / November) . The place goes lively at the onset of w inter w ith the mass holy deep in r iver Gandak by Hindu at Kaun-hara Ghat. Besides being claimed as the biggest animal fair in Asia, the fair enter tain visitors w ith circus, Tamasha (folk plays), Nautanki (folk dances) and sell everything from elephants to birds; agr icultural equipment to vanity items; w inter garments to wooden furniture. Government Depar tment of Rural Development, Depar tment of Agr iculture etc. organises training and exhibit ions for the farmers coming from all over .

Vaishali Mahotsava

Ancient vi llage of Vaishali is located 35 km Nor th-West of Hajipur . The place can be reached by road and offers many archaeological places to see which includes Buddha Stupa, Pillars of Ashoka, Abhisek Puskarani (coronation Tank of Vajji Rulers) etc. Vaishali Mahotsava (great celebrat ion) is held every year on Baisakh Purnima (Full Moon Day of 1st Hindu Month) during mid-Apr il to celebrate the bir th anniversary of 24th Jain Tir thankar Lord Mahavir who born here in the vi llage Kundalpur , 4 km from Vaishali. The soil of this land is blessed by the visit of Lord Buddha tw ice dur ing 3rd century BC.

2.4. ADMINISTRATIVE SET-UP Hajipur , the administrative headquar ters of Vaishali Distr ict, comes under the Patna

Administration Division. Hajipur became the Municipali ty in the year 2002. From 1869 to 2002 the city had Nagar Panchayat as the administrative unit . It is the largest city in the

distr ict . The municipal area of Hajipur is about 19.64 sq. km.

Hajipur Nagar Par ishad has total administration over 24,033 houses to which it supplies basic amenit ies like water and sewerage. It is also author ize to build roads within Nagar

Par ishad limits and impose taxes on proper ties coming under its jur isdiction. The Hajipur

town being bounded by Narayani Gandak r iver in the west and holy Ganges in the south, has scope of fur ther expansion in east and nor th direct ion only.



2.5. DEMOGRAPHICS

Hajipur is a Nagar Par ishad city in distr ict of Vaishali, Bihar . The Hajipur city is divided into

39 wards for which elect ions are held every 5 years. The Hajipur Nagar Par ishad has

populat ion of 147,688 of which 78,047 are males while 69,641 are females as per repor t released by Census India 2011. The li teracy rate was 79.26 per cent, higher than the

national average of 74.04%: male li teracy is 84.78%, and female li teracy is 72.93%. Populat ion of Children with age of 0-6 is 20899 which is 14.15 % of total population of

Hajipur (Nagar Par ishad). In Hajipur Nagar Par ishad, Female Sex Ratio is of 892 against

state average of 918. Moreover Child Sex Ratio in Hajipur is around 884 compared to Bihar state average of 935. Literacy rate of Hajipur city is 76.80 % higher than state average of

61.80 %.

2.6. ECONOMY

The economy of Hajipur is lar gely service or ientated, but i t also has a significant

agr icultural base. The town also has industrial sector . As of 2011, service accounts for 55%, industry 9% and agr iculture 35% of the economy of the town. The real estate is booming

and is equal or more than Patna because it has better planning and it is higher from the sea level from Patna, Hence there is no water accumulat ion as in Patna in rainy season. Apar t

from this there are many upcoming projects from pr ivate and public sectors with three new over br idges connecting with Patna making it one of the fastest growing cit ies of India

2.7. TRANSPORT

Rail Link

Hajipur rai lway station is the headquar ters of East Central Railway Zone. Three rai l lines

connect i t to Muzaffarpur , Chhapra, and Barauni. Impor tant t rains like Guwahati Rajdhani Express , Vaishali Express,Bihar Sampark Krant i Super fast Express, Gar ib Rath Express,

Swatantrata Senani Super fast Express, Sabarmati Express, Lohit Express, Lichhavi Express and all other trains passing through this route have stoppages here.

Air Link

Patna Airpor t - 13.2 miles (21.2 km). Patna airpor t is well connected through road. Buses, taxis, auto available 24*7.



Roads Link

Hajipur is connected to other par ts of India through national and state highways. The major

highways are:

NH 19 touches the city and connects it to Chhapra which fur ther joins Ghazipur city in U.P. NH 19 star ts from Patna and is connected fur ther

w ith Gaya and BodhGaya through state highway.

NH 77 connects Hajipur to Sonbarsa (Nepal border) via Muzaffarpur and Sitamarhi.

NH 103 Star ts from Hajipur and joins NH 28A at Musr i Gharar i (Samastipur) via Jandaha.

SH 74 connect Hajipur to Lalganj, Vaishali.

SH 49 connects Hajipur to Mahuaa,Tajpur , Samast ipur.

SH 93 connects Hajipur to Mahnar , Mohddinagar .

Fig 2.3: Satellite image of Hajipur showing Industrial area, River & Road links



2.8. CLIMATE

The plain ter rain of town and its nearby places was famous for banana, li tchi and mango

plantat ions. The region looks green with plants and trees growing in changing climate.

However , month of May–June are hot and September–March are very cold.

Rainfall intensities (month wise) from Meteorological Department

S.N

o.

Yea

r

Jan

Feb

Mar

ch

Apr

il

May

June

July

Au

g

Sep

Oct

Nov

Dec

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

R/F

%D

ep.

1 201

1

0 -100

1.1

-87

0 -100

19

.6

34

57

.6

115

191

.5

-47

198

.2

-47

188

.8

-34

401

.9

80

11

.9

-84

0 -100

0 -100

2

201

2

25

.6

67

0

-10

0

6.1

-15

15

.1

3

0

-10

0

13

.7

-33

251

.3

-33

304

.6

7

238

.9

7

84

.3

15

0

-10

0

0

-10

0

3

201

3

11

.3

-26

28

233

0

-10

0

10

.5

-28

94

.2

251

104

.3

-82

69

-82

112

.6

-61

95

.5

-57

172

.7

136

0

-10

0

0

-10

0

Note:

(1) The Distr ict Rainfall in millimeters (R/ F) shown below are the ar ithmetic averages of Rainfall of Stat ions under the Distr ict . (2) % Dep. are the Depar tures of rainfall from the long per iod averages of rainfall for the

Distr ict .

(3) Blank Spaces show non-availabili ty of Data.



*****

0

50

100

150

200

250

300

350

400

450

Jan Feb March April May June July Aug Sep Oct Nov Dec

Ra

Months

Graph 2.1: Arithmatic Averages of Rainfall

2011 2012 2013

-150

-100

-50

0

50

100

150

200

250

300

Jan Feb March April May June July Aug Sep Oct Nov Dec%

D

Months

Graph 2.2: Departures (%Dep.) of Rainfall from Long period

averages of Rainfall

2011

2012

2013



CHAPTER-3

PROFILE OF HAJIPUR INDUSTRIAL ESTATE

3.1. HAJIPUR INDUSTRIAL AREA

The BIADA is responsible for promoting and assist ing the rapid development of industr ies in the industr ial areas. In addit ion to the BIADA Industr ial Estate, there is also an Export

Promotion Industrial Park (EPIP) which has been star ted in Hajipur . A list of industr ies

was provided by BIADA for both the industr ial areas and on that basis our team star ted

survey dur ing the month of August and September. List of industr ies included the ent ire industr ies that were operational, under construction, closed, cancelled and vacant plots. It

is divided into EPIP, Phase 1 and Phase 2.

Fig 3.1: Satellite image showing Hajipur Industrial area and EPIP



3.2. INVENTORY OF INDUSTRIES

Hajipur distr ict is the centre of several industr ies. Industr ial Area is spread in around 262.13 acres for both EPIP and Industr ial areas of Hajipur , in which 213 acres are occupied

under working, under construct ion, closed and cancelled units in both EPIP and Industr ial area of Hajipur . Approx. 4.79 acres are vacant in which 3.90 acres is in Hajipur and 0.89 acres in EPIP which has to be allot ted. Most of the industr ies are small and medium scale

type. Distr ibut ions of industr ies with respect to the plot area are summar ized in Table 3.1



Table 3.1 Summary of Distribution of Industries & Plot area

Summary: Total working or functional plot area = 7636346 (Sq. ft),_____________________________________ = 175.30 (Acre)

Total Under construction plot area = 469245 (Sq. ft),_________________________________________ = 10.77 Acre)

Total closed units plot area = 868318 (Sq. ft), __________________________________________=19.93(Acre)

Total cancelled plot area =288160 (sq. ft) __________________________________________=6.62 (Acre) Total plot area =9262069 (sq ft) __________________________________________=212.63 (Acre)

HAJIPUR INDUSTRIAL AREA (EPIP + PHASE 1 & PHASE 2)

WORKING/ FUNCTIONAL UNDER CONSTRUCTION CLOSED CANCELLED

TO

TA

L N

O. O

F I

ND

US

TR

IES

TOTAL

PLOT

AREA

(SQ.FT)

NO

. O

F

IND

US

TR

IES

TO

TA

L P

LO

T

AR

EA

(SQ

.FT

)

% O

F P

LO

T

AR

EA

NO

. OF

IND

US

TR

IES

TO

TA

L P

LO

T

AR

EA

(SQ

.FT

)

% O

F P

LO

T

AR

EA

NO

. O

F

IND

US

TR

IES

TO

TA

L P

LO

T

AR

EA

(SQ

.FT

)

% O

F P

LO

T

AR

EA

NO

. O

F

IND

US

TR

IES

TO

TA

L P

LO

T

AR

EA

(SQ

.FT

)

% O

F P

LO

T

AR

EA

Less Than 0.25 Acres

(10890 Sq. Ft)

44 313,643 4.1 6 38,430

8.2 14 116,380 13.4 1 10,800 3.75 65 479,253

From 0.251 To 0.50 Acres (21786 Sq. Ft)

32 574,283 7.5 1 21,000

4.5 7 152,460 17.6 3 59560 20.67 43 807,303

From 0.50 To 1.0 Acres (43573 Sq. Ft)

21 782,126 10.2 3 124,047

26.4 4 142,098 16.4 1 43,560 15.1 29 1,091,831

From 1.1 To 1.5 Acres

(65360 Sq. Ft)

10 605,101 7.9 2 121,532

25.9 2 130,680 15.0 0 0 0 14 857,313

Above 1.5 Acres

(Above 65361 Sq.

Ft)

25 5,361,193 70.2 2 164,236

35.0 2 326,700 37.6 2 174,240 60.5 31 6,026,369

TOTAL 132 7,636,346 100 14 469,245 100 29 868,318 100.0 7 288,160 100 182 9,262,069

% of Total Plot

Area 82.4

5.07

14.41

3.11



As per above mentioned details collected dur ing industr ial survey, i t was observed that total 182 industr ies are distr ibuted in the industr ial area out of which 132 numbers are

working, 29 are closed, 14 are under construction and 7 are cancelled plots. Categor izat ion of industr ies on the basis of numbers is mentioned in Table 3.2

Table 3.2 Categorization of Industries

Cur rent scenario of distr ibut ion of industr ies with respect to the total plot area occupied by working, under construct ion, Closed, cancelled and vacant has been shown in Graph 3.1

S. No. Types of plots Numbers

1 Working or Functional 132

2 Under construct ion or construct ion to be star ted 14

3 Closed 29

4 Cancelled 7 5 Total number of occupied Industries 182

6 Total number of vacant plots 9

-

10,00,000

20,00,000

30,00,000

40,00,000

50,00,000

60,00,000

70,00,000

80,00,000

Working Under

Construction

Closed Cancel Vacant

Ar

Distribution of Industries

Graph 3.1 Current Scenario of Plot Area wise Industrial

Categorization

1429

9

132

7



Total number of industr ies distr ibuted under 0.25, 0.50, 1.0, 1.5 and above 1.5 acres of area has been discussed respectively in Graph 3.2. The graph shows maximum number of industr ies around 65 are located under 0.25 acres, followed by 43, 29, 14 and 31 number s distr ibuted among 0.50, 1.0, 1.5 and above 1.5 acr es of plot area respectively in Hajipur Industr ial ar ea.

On the basis of the above graph, a pie char t has been prepared wherein the percentage of total plot area occupied with respect to the industr ial categor ies i.e. working, under construct ion, closed, cancelled and vacant plots have been discussed.

0

10

20

30

40

50

60

70

Less than 0.25

Acres

From 0.251 to

0.50 Acres

From 0.51 to

1.0 Acres

From 1.1 to 1.5

Acres

Above 1.5

Acres

65

43

29

14

31Nu

Areawise Distribution of Plots

Graph 3.2: Areawise Distribution of Industrial units



Out of the these five categor ies; maximum plot area has been covered by working industr ies i.e. 80.63% followed by closed industr ies i.e. 14.41% plot area, 4.95% is under construct ion or allotted plots in which construction is yet to be started, cancelled plots are 3.04% and 2.2% are vacant plots.

3.3. INDUSTRIAL SECTORS IN HAJIPUR

Major industr ial sectors located in Hajipur region are summar ized in Table 3.3 in which

sector w ise estimat ion of wastewater generation and projected wastewater is discussed. Also number of funct ional units in each sector is mentioned. In this, we have distr ibuted

each industry in 12 sectors as mentioned below and on that basis we have appraised total wastewater generat ion from domestic plus industr ial activity. Also, we have discussed that how much area is covered by each industr ial sector .

80.63

4.95

14.41

3.04 2.20

Graph 3.3: % of Total Plot Area Occupied

Working

Under Construction

Closed

Cancel

Vacant



Table 3.3 Summary of Sector wise distribution of industries & Wastewater Estimation

Industrial Group

No. of Industry

Functional Closed U/C Cancelled DWW

(lit/day) PWW

(lit/day) *BOD

(mg/l) PDWW

(lit/day) PPWW

(lit/day) Plot area

in Sq ft

Automobile 2 2 0 0 0

1,305

5,000 250

1,305

5,000

32,500

Chemical 10 8 2 0 0

27,790

42,500 350

34,738

53,125

249,462

Engineer ing 14 10 4 0 0

14,625

14,500 250

20,475

20,300

397,068

Food 36 26 5 2 3

167,250

2,791,200 600

231,577

3,864,738

2,496,734

Institution 8 8 0 0 0

114,165 -

0 114,165

-

1,054,092

Mineral Water 8 6 2 0 0

2,520

71,500 100

3,360

95,333

130,079

Others 35 22 7 4 2

18,990

103,750 500

30,211

165,057

1,296,279

Pharmaceut ical 12 5 3 3 1

12,600

17,000 250

30,240

40,800

1,028,395

Plast ic 31 24 4 3 0

24,975

48,400 250

32,259

62,517

583,607

Poultry 19 16 1 2 0

34,560

219,600 500

41,040

260,775

1,776,166

Pr inting 3 2 0 0 1

1,980

5,500 250

2,970

8,250

31,446

Text ile 4 3 1 0 0

3,645

18,000 500

4,860

24,000

186,240

182 132 29 14 7

424,405

3,336,950 3800

547,200

4,599,895

Total

Estimated

Value

3,761,355 525

5,147,095

9,262,068

*Note: Above mentioned BOD is taken for the wastewater generated from Process only.


SMS Envocare Limited Page 22 of Chapter 5

In Hajipur distr ict , we have categor ized each surveyed industry into 12 categor ies. Of these total categor ies maximum percent of plot area in the region has been covered by Food

Processing and Poultry sectors i .e., 27% and 19% respectively. 14% consists of others (include industr ies like Card Board box, Paraffin wax, Cold storage, Cement, pipes, Paper ,

Ply wood, Hume pipes, sold br ick, sim putty, packing mater ial, shoe shops and Tiles. Apart from that, sector like Institution, Pharmaceutical, Plastic, Engineer ing, Text ile and Mineral Water covers total 47%. Rest of the industr ies like Pr inting and Automobile has very less

plot area compared to other sectors.

On the other hand in Graph 3.5, we have discussed about the number of industr ies with respect to the each industr ial sectors. As it is clear ly indicated in the below mentioned

graph that maximum number of industr ies per taining to food processing type that includes Juices, flour , Biscuits, Snacks, Jam & Jelly, Spices, Dal, Besan, Rice mills etc followed by others and Plastic sector while average number of Poultry, Engineer ing, Pharmaceut ical

and Chemical sectors exist in the industr ial area. Very few units are of Mineral water , Pr inting, Texti le, Automobiles sectors and few Inst itutional setups also exist in Hajipur

industr ial area named as CIPET and NIPER.

0.4%2.7%

4.3%

27.0%

11.4%

1.4%14.0%

11.1%

6.3%

19.2%

0.3%

2.0%

Graph 3.4: % of Total Plot Area Occupied by Industrial Sectors

Automobile

Chemical

Engineering

Food

Institution

Mineral Water

Others

Pharmaceutical

Plastic

Poultry

Printing

Textile



Other industr ial units include Card Board box, Paraffin wax, Cold storage, Cement, pipes, Paper , Ply wood, Hume pipes, sold br ick, sim putty, packing mater ial, shoe shops, and Tiles

present in significant numbers.

3.4. PRESENT SCENARIO OF WASTEWATER GENERATION

With all the information/ data collected dur ing the survey, we have appraised present scenar io of wastewater quantity generated from domest ic and industr ial processes. The

same has been discussed in Graph 3.6

2

10

14

36

8 8

35

12

31

19

3 4

NIndustrial Sectors

Graph 3.5 Industrial Sector wise number of Industry



While analyzing the above mentioned graph, i t is apparent that out of total 12 categor ies of

var ious industr ial clusters, maximum domest ic and process wastewater is generated from Food sector followed by sectors per taining to Poultr ies. Other sectors have very less

contr ibut ion compared to Food sector which include sectors like Chemical, Engineer ing, Pr inting, Textile, Automobile, Pharmaceut icals and Mineral water . Inst itut ional setup mainly contr ibutes in domestic wastewater only.

-

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000

30,00,000W

a

Industrial Sectors

Graph 3.6: Current Scenerio of Sectorwise Estimation of Waste

Water Generation

DWW (l i t/ day) PWW (lit / day)



3.5. FUTURE PROJECTIONS OF WASTEWATER QUANTITY

To evaluate the capacity of CETP, we have made few projections on the basis of product manufactur ing and water consumption in domestic and industr ial processes discussed in

Graph 3.7

Projected wastewater generat ion is maximum in case of Food Processing type of industry

which itself may contr ibutes 3.8 MLD and 0.2 MLD dur ing industr ial and domest ic process respect ively. Fur ther maximum contr ibution is due to poultr ies of around 0.24 MLD

including domest ic and process wastewater followed by other sectors like Engineer ing, Mineral water , Pr inting, Text ile, Plastic, Pharmaceutical, Automobile, Chemical and

Inst itut ional setups.

3.6. CATEGORIZATION OF INDUSTRIES (RED, ORANGE AND GREEN)

Out of the ent ire funct ional, Under construct ion, Closed covered dur ing industr ial survey

are fur ther classified into Red, Orange and Green on the basis of pollution load as per

schedule VIII norms stipulated by Ministry of Environment & Forests, Govt. of India

(Annexure-IV) which is shown in below mentioned Char t .

-

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000

30,00,000

35,00,000

40,00,000

45,00,000Pro

Industrial Sectors

Graph 3.7: Projected Waste Water Generation



It can be clear ly seen that maximum nos. of industr ies covered as per the list provided by BIADA falls under Green category which is around 54% that contr ibutes less to the

pollut ion load followed by Orange Category (28%) and Red category is 18%.

3.7. MAJOR CONTRIBUTOR OF WASTEWATER IN HAJIPUR INDUSTRIAL AREA

Based on the survey done by our team in Hajipur Industr ial Area major contr ibutor of wastewater generation belongs to Food processing type includes Rice Mill, Dairy,

Beverages etc. Br ief detai l of these industr ies has been discussed below as:

S. No Name of Industry Address Projected

Wastewater

Sector Category

1 M/ s Sudha Dairy

G-3

1,009,000

Dairy Red

2 M/ s Lumbini Beverages Pvt. Ltd.

H-2

1,006,210

Food/ Beverage

Orange

3 M/ s Aamrapali Food Products

B-5,6&7

122,500

Food Orange

4 M/ s Godrej Agronet

NS-2, NS-1 (P)

107,965

Poultry Orange

5 M/ s Anuj Dairy Pvt. Ltd.

(1086) C-4243, 44(P)

150,000

Dairy Orange

6 M/ s Asma Food & Beverages Pvt. Ltd.

G-3 (P) & G-4 (P)

125,000

Food/ Beverage

Orange

7 M/ s Br itannia C-3, C4 to C11 26,000 Food Orange

Red

18%

Orange

28%

Green

54%

Categorisation of Industries



8 M/ s Sona Biscuits

B-2,D-3, G-1

20,900

Food Orange

9 M/ s Bansal Biscuits Pvt.

B-7(P),8(P), 9(P), B-6(P), B-7(P),8(P), 9(P)

53,360

Food Orange

10 M/ s AFP Manufactur ing Co.(P) LTD

B-5 & A-2, EPIP

29,500

Food Orange

11 M/ s Vaishali Rice Mills Pvt. Ltd

D-3(P),4,5,6

125,000

Rice Orange

12 M/ s Hi Dairy Agro & M/ s Treat Industr ies Ltd

(1024) B-13,14,15,16(P),43(P)

104,050

Dairy Red

13 NIPER

Administr ative Block

54,000

Institute Orange





CHAPTER-4

PRODUCTION PROCESS

4.1. PRODUCTION PROCESS Major ity of industr ies in industr ial area are food processing such as Beverages (soft dr ink and juice), Biscuits, Bread, Rice Mills, Ice-cream, Dairy & Agro, Roller Flour Mill, Poultry, and Hatchery which generate biodegradable wastewater . Few industries such as packaging,

engineer ing, plast ic etc. generate small/ negligible wastewater .

The flow char ts for var ious products of industries are shown in the following pages.

Vegetable/ fruit Processing unit

Flour Mill

Hatchery

Milk Products

Raw Rice Production

Soft Dr ink

Wet Type Flour Mill

Rice Production

Milk

Ice Cream

Cotton Fabr ic (Texti le)

Paint

Pesticides

Detergent

Dal & Besan Mill

Bread

Beverages

Baker ies

RCC/ Cement Pipe

PVC Pipe

Pharmaceut icals

Mineral Water















































CHAPTER-5

QUANTIFICATION & CHARACTERISTICS OF WASTE WATER/ EFFLUENTS

5.1. ASSUMPTIONS IN CALCULATION OF WATER CONSUMPTION AND EFFLUENT

GENERATION

A minimum quantity of 500 lit res, 1000 lit res and 2000 lit res have been considered for small, medium and large sized plots respectively, which either did not repor t the

figures or their products (e.g. packaging and plastic goods) do not require water .

Domestic water consumption for residents of institutes and industr ies is taken @

125 LPCD.

Domestic water consumption for manpower of food processing industr ies is taken @45 to 100 LPCD including for quality testing laboratory and hand wash.

Domestic water consumption for students and staff of inst itutes is taken @25 LPCD.

5.2. WATER CONSUMPTION AND EFFLUENT GENERATION

Dur ing survey, i t was observed that industr ies have neither water meters for measurement

nor awareness on correct figures of water consumption and waste water generation. Except few, most of the industr ies and inst itutes had repor ted arbitrary figures of water

consumption and waste water generation. Foods processing such as Beverages (soft dr ink and juice), Biscuits, Bread, Rice Mills, Ice-

cream, Dairy & Agro products, RO package water industr ies are water intensive, therefore, consume significant quant ity of water due to frequent clean-in-process (CIP) requirement. Accordingly, these units generate huge quantity of biodegradable wastewater .

Industries such as engineer ing, chemicals manufactur ing generate moderate quantity

of wastewater .

Few industr ies such as packaging, plast ic etc. use and generate small/ negligible quantity of wastewater .

Institutes, warehouses, offices and service providers consume water for domest ic

use, laborator ies and gardening etc. The waste water is generated in form of sewage.



Table 5.1 Details of Wastewater Generation from Domestic and Process Activities

Industrial Group

No of Industry

Functional Closed U/C Vacant DWW

(lit/day) PWW

(lit/day) *BOD

(mg/l) PDWW

(lit/day) PPWW

(lit/day) Plot area

in Sq.ft

Automobile 2 2 0 0 0 1,305 5,000 250 1,305 5,000 32,500

Chemical 10 8 2 0 0 27,790 42,500 350 34,738 53,125 249,462

Engineer ing 14 10 4 0 0 14,625 14,500 250 20,475 20,300 397,068

Food 36 26 5 2 3 167,250 2,791,200 600 231,577 3,864,738 2,496,734

Inst itut ion 8 8 0 0 0 114,165 - 0 114,165 - 1,054,092

Mineral Water 8 6 2 0 0 2,520 71,500 100 3,360 95,333 130,079

Others 35 22 7 4 2 18,990 103,750 500 30,211 165,057 1,296,279

Pharmaceut ical 12 5 3 3 1 12,600 17,000 250 30,240 40,800 1,028,395

Plastic 31 24 4 3 0 24,975 48,400 250 32,259 62,517 583,607

Poultry 19 16 1 2 0 34,560 219,600 500 41,040 260,775 1,776,166

Print ing 3 2 0 0 1 1,980 5,500 250 2,970 8,250 31,446

Text ile 4 3 1 0 0 3,645 18,000 500 4,860 24,000 186,240

182 132 29 14 7 424,405 3,336,950 3800 547,200 4,599,895 9,262,068

3,761,355 525 5,147,095

DWW-Domestic Wastewater ; PDWW-Projected Domestic Wastewater PWW-Process Wastewater ; PPWW-Projected Process Wastewater U/ C-Under Construct ion

Note:

*Above mentioned BOD is for process wastewater only.



Hence, it is evident from the Table 5.1:

The total domestic wastewater generation from operational units =424,405 l/ d

The total process wastewater generation from operational units = 3,336,950 l/ d

The total effluent from operational units = 3,761,355 l/ d

The projected domestic wastewater = 547,200 l/ d

The projected process wastewater = 4,599,895 l/ d

The total projected effluent = 5,147,095 l/ d

5.3. DESIGN CAPACITY OF PROPOSED CETP

As per the estimated wastewater generation from industr ies, it is proposed to install a Common Effluent Treatment Plant (CETP) of 6.0MLD (6000KL/ day) capacity for

treatment of industr ial and domestic effluent likely to be discharged by the exist ing industr ies, institutes and including provision for vacant plots.

5.4. CHARACTERISTICS OF WASTE WATER

The wastewater from Food processing industr ies; such as Biscuit, Bakery, Hatchery,

Beverage, Poultry feed, Ice Cream, Juice, Dairy, Flour Mill, Dal Mill, Besan & Sattu; Mineral Water etc.; contains high BOD, COD, TSS and oil/ grease/ fats. However ,

wastewater is easily biodegradable; and it w ill require biological treatment.

Wastewater from Engineer ing, Pr inting, Plastic and chemicals manufactur ing industr ies contains mainly COD, TSS, oil/ grease and less BOD. Hence, it is less biodegradable and

it w ill require physico-chemical treatment.

The BOD of composite wastewater (process and washing/ cleaning) has been worked out to be 525 mg/ l in Table 5.1.

The combined character ist ics of wastewater for design purpose has been shown in

Table 5.2



Table-5.2: Average Characteristics of Combined Untreated Effluent for Design

S. No. Parameters Units Values

1 pH value - 6.5 ~ 8.5

2 Total Suspended Solids (TSS) mg/ l 300~ 400

3 Chemical Oxygen Demand (COD) mg/ l 1400

4 Biochemical Oxygen Demand (BOD, 3 days, 27 0C) mg/ l 525

5 Oil and Grease mg/ l 30~ 40

Design Flow for Proposed CETP: 6000 KLD = 6 MLD

5.5. CHARACTERISTICS OF TREATED WASTE WATER

The treated water from the CETP will meet the stipulated norms of sur face water discharge standard and is placed below:

Table-5.3: Characteristics of Treated Water as per CPCB/SPCB


1 pH value - 6.5 ~ 8.5

2 Total Suspended Solids (TSS) mg/ l <100

3 Chemical Oxygen Demand (COD) mg/ l <250

4 Biochemical Oxygen Demand

(BOD, 3 days, 27 0C)

mg/ l <30

5 Oil and Grease mg/ l <10

*****



CHAPTER-6

CRITERIA FOR SELECTION OF WASTEWATER TREATMENT

TECHNOLOGIES/ SCHEMES

Dur ing the preparation of Feasibility Repor t, var ious options have been cr itically

examined for the consideration of best technologies suitable for the establishment of CETP in industr ial area. The objective of wastewater treatment technology selected for

the treatment of effluent generated from the industr ial area is to provide:

1. Discharge water quality standards by regulatory bodies. 2. Cost Economic. Less Capital and Operating Cost. 3. Complete CETP system built-in in the available land area i.e. Minimum area

requirement. 4. Trouble-free in operation of CETP i.e. simple and reliable maintenance. 5. Consistent delivery of treated wastewater . 6. Withstand var iations in pollut ion and hydraulic load. 7. Recycling/ reuse of the treated effluent for hor t iculture purpose.

Var ious treatment technologies available for wastewater treatment are discussed

below to meet the above mentioned objectives and to opt. the appropriate one for Hajipur Industr ial area:

6.1. ACTIVATED SLUDGE PROCESS

It is a biological wastewater treatment process is w idely used by large communities where large volumes of waste water to be treated economically.

Fig: 6.1 Schematic Diagram of a Conventional Activated Sludge Process Activated Sludge Process (ASP) is a suspended growth aerobic process. It is provided

with pr imary clar ifier to reduce the organic load in biological reactor (aeration basin).

About 40% of organic load is intercepted in pr imary clar ifier in the form of sludge, decreasing the loading in the aeration tank. After aeration tank, the mixed liquor is

Excess Sludge Returned Sludge

Effluent Secondary

Clarifier

Aeratio

n

Tank

PST

Influent



sent to secondary clar ification where sludge and liquid are separated. A major por t ion of the sludge is re‐circulated and excess sludge is sent for the disposal. Merits

Good process flexibility Reliable operation Proven track record in all plant sizes Low odor emission Energy production Ability to w ithstand nominal changes in water character ist ics

Demerits

High energy consumption Skilled operators needed Uninter rupted power supply is required Requires sludge digestion and drying Less nutr ient removal

6.2. SEQUENTIAL BATCH REACTOR (SBR)

It is a fi ll and draw activated sludge system for waste water treatment. Equalization, aeration & Clar ification can all be achieved using a single Batch Reactor . SBR systems have been successful for large industr ial effluents. The SBR typically eliminates the

need for secondary clar ifier .

Fig: 6.2 Schematic Diagram of SBR

Although SBR has shown more maintenance in operation since the process is PLC

based, it shows higher efficiency and less area requirement for the CETP. It is a fi ll‐and‐draw batch aerobic suspended growth (Activated Sludge) process incorporating all the features of extended aeration plant. After screening and

de‐gritting, effluent is fed to the batch reactor. Reactor operation takes place in certain sequence in cyclic order and in each cycle, following operations are involved:



Anoxic Filling tank Aeration Sedimentation/ clar ification Decantation Sludge withdrawal

Merits

Excellent effluent quality Smaller footpr int because of absence of secondary clar ifiers and digester Recent track record available in large applications in India also Biological nutr ient (N&P) removal High degree of coliform removal Less chlor ine dosing required for post disinfection Ability to w ithstand hydraulic and organic shock loads

Demerits

Comparatively high energy consumption To achieve high efficiency, complete automation is required Highly skilled operators needed No energy production Uninter rupted power supply required

6.3. MOVING BED BIO-REACTOR (MBBR)

Moving Bed Biofi lm Reactor is an aerobic attached biological growth process. It does not require pr imary clar ifier and sludge recirculation. Raw sewage, after screening

and de‐ gritting, is fed to the biological reactor. In the reactor , floating plastic media is provided which remains in suspension.

Biological mass is generated on the sur face of the media. Attached biological mass consumes organic matter for their metabolism. Excess biological mass leaves the

sur face of media and it is sett led in clar ifier .

Fig: 6.3 Schematic Diagram of a Moving Bed Bio‐Reactor

MBBR is mostly prefer red for the small effluent flow rates. In large plant, media quantity is very high and it requires long shut down period for plant maintenance. In

fact, it may not be successful for large capacity plants.

Excess Sludge Air Blower

Effluent Secondary

Clarifier

MBBR II MBBR I Influent



Merits

Moving Bed Biofi lm Reactor needs less space Ability to w ithstand shock load with equalization tank option High operator oversight is not required

Demerits

High operating cost due to large power requirements Not much exper ience available with larger capacity plants (>1.5 MLD) Skilled operators needed No energy production Much less nutr ient removal

The comparative of technologies are discussed subsequently for better selection of suitable Treatment technology:



Table 6.1: Comparative of Merits and Demerits of ASP, SBR and MBBR technologies

S.

No.

Defining

Parameters

ASP SBR MBBR/ FAB

1 Type of treatment/ Process

Continuous suspended growth Tr eatment

Fill and Draw regime Continuous Attached growth Treatment

2 System Descr iption (component w ise)

Pr imary treatment-Effluent collection and pumping- Bioreactor

w ith Air distr ibution gr id- Settling Tank- Disinfection - Fi ltr ation

with DMF-ACF. Sludge removal- Sludge digester tank-

Dewater ing of sludge.

Pr imary treatment-Effluent collection and pumping- Bioreactor

w ith Air distr ibution gr id & Decanter - Disinfection. Sludge

removal - Sludge dewater ing

Pr imary treatment-Effluent collection and

pumping - Bioreactor w ith MBBR media & Air

distr ibution gr id- Tube settler - Disinfection-

Fi ltr ation with DMF-ACF. Sludge removal - Sludge digester tank- Dewater ing of sludge.

3 Sludge handling system requirement

Yes with Suitable mechanism



4 Advantages Suitable for Bigger plant capacity. Conventional treatment.

Batch process involves par tial nitr i fication of wastewater . Suitable for

small plant & Big Plants along with Automatic

Operation (PLC Based)

Attached growth pr ocess. Compact plant w ith

resistance to shock load. Easy for

installation. With Bio-digested sludge.

5 Disadvantage High Power & Maximum Space Required, MLSS to be maintained and

Continuous sludge recirculation required. Susceptible to sock loads. Comparatively high AMC cost

High Capital Cost. MLSS to be maintained. Higher degree of

automation & contr ol. Tedious operation needs trained site person. Comparatively high AMC cost

Maintenance of air gr id in MBBR Tank is Cr it ical.

Possibili ty of loss/ car ryover of media. Annual make up of media requir ed.

6 Installation Entire Electr o-Mechanical er ection take place at site, hence

Entire Electr o-Mechanical er ection take place at site, hence

Less Time for MS Package System / Electro-Mechanical



S.

No.

Defining

Parameters

ASP SBR MBBR/ FAB

takes more time takes more time almost 4-6 weeks

7 Capital Cost Least High Cost Medium cost 8 Civil Cost High Cost Least Medium cost 9 Electro-

Mechanical Cost Least High Cost Medium cost

10 Daily Power Cost Medium Least Maximum 11 Area Requirement Maximum Normal Normal 12 Annual

Maintenance cost Maximum Least Normal

13 Operation Easy but requires a continuous observation

Easy but requires a continuous observation

Easy and System operate on i ts own with

Simple Automation 14 Manpower Semiski lled for

continuous basis Skilled for continuous basis

Semiski lled not on continuous basis

15 Automation Not required As per requirement Not required

6.4 RECOMMENDED TECHNOLOGY

Based on the above discussed treatment technologies and appraising present area

availabili ty and type of wastewater generated from different industr ial sectors, i t has been suggested to setup CETP based on Activated Sludge Process. Br ief descr iption of the

proposed treatment scheme based on ASP has been discussed in Chapter -7

*****



CHAPTER -7

PROPOSED TREATMENT SCHEME

Based on the character ist ics of combined wastewater mentioned in Table 5.2, the wastewater contains significant suspended solid (TSS), BOD, COD and Oil & Grease. This requires preliminary treatment (Screen, O&G and Gr it Removal, Equalizat ion) , Physico-

chemical t reatment for removal of TSS and par t ial removal of BOD and COD; Biological

t reatment to achieve BOD level upto 30mg/ l followed by ter tiary treatment (Chlor inat ion

followed by Filt ration) to achieve the prescr ibed norms for disposal into inland sur face water , reuse in hor t iculture and par tial reuse into industr ial process like Automobile

Service Stations.

7.1. PROPOSED TREATMENT SCHEME

The Proposed CETP treatment units consist of all sub-units necessary for three stage

treatment i .e., Pr imary, Secondary and Ter tiary as mentioned below. Based on the

availabili ty of land and type of industry in the industr ial area, Extended Act ivated Sludge

Process has been proposed for Common Effluent Treatment Plant of capacity 6 MLD or 6000 m3/ day. The combined effluent has moderate values of parameters -TDS, BOD, COD, and oil/ grease).

The combined effluent has moderate values of parameters-TDS, BOD, COD, and oil &

grease. It is compulsory for each/ individual industry to install a screen for trade effluent and a septic tank for domest ic wastewater before connecting in to the sewer / drain leading to CETP.

The treatment scheme consists of:

1. Pr imary Treatment (Screening, Oil/ grease skimmer & gr it removal tank,

Equalization) 2. Physico-chemical treatment (Chemicals dosing, Flash Mixer , coagulation, Floculation,

Pr imary Settler , sludge dewater ing) 3. Secondary/ Biological treatment (Extended ASP with clar ifier ) 4. Ter tiary treatment (disinfect ion using chlor ination and fi ltration consist ing of

Pressure sand Filters & Activated Carbon Filters) .

The oil / grease, grit & other similar solids shall be removed in pre-settling/ grit removal chambers. The suspended solids & colour , if any, shall be removed by physico-chemical

t reatment whereas the removal of bio-degradable soluble organic matter shall be achieved in the biological t reatment. Chlor inat ion will be provided to kill the bacter ia in the treated effluent.



Although norms for treated effluent discharge into the inland surface water stipulated

by Bihar State Pollution Control Board shall be achieved after Secondary treatment but

tertiary treatment shall also be provided in our scheme to remove residual/ escaped

organic matter and TSS.

Flow meters shall be installed in the pump pipe line of equalized wastewater and final outlet after filt rat ion. A calibrated 90o V-notch shall be installed for flow measurement, in open channel before equalizat ion tank.

The common effluent treatment plant would have following treatment units:

1) Raw effluent intake and bar screen chamber 2) Raw effluent pump house 3) Effluent receiving/ st illing chamber 4) Flow measurement channel 5) Medium screen 6) Oil/ grease Skimmer and Gr it Removal Tank 7) Equalization tank 8) Chemical House – Solution Preparation and dosing system. 9) Flash mixer and coagulation tanks 10) Flocculation chamber 11) Pr imary Clar ifier 12) Aeration Tanks (Extended ASP) including DO sensors, air -blowers, diffusers and PLC 13) Secondary Clar ifier 14) Return Sludge collection Tanks (with/ w ithout Pump house) 15) Wet sludge collection Tanks and Pump house 16) Sludge dewater ing system – Filter press and Volute press/ Centr ifuge 17) Dewatered/ dry Sludge storage area 18) Chlor ine dosing system. 19) Chlor ine Contact & Pre-filt rat ion Storage Tank 20) Pressure Sand Filters and Act ivated Carbon Filters 21) Treated effluent/ disposal pipe/ channel

The above units shall be provided with necessary mechanical equipment, electr ical

ar rangements, instrumentat ion & automation with SCADA for Aeration operat ion. In addition to above, CETP campus shall have an office and a laboratory with essential

faci lit ies for analysis of common parameters. 7.2. DETAILED TREATMENT SCHEME The effluent from industr ial units in Hajipur shall be collected through RCC drain/ sewer

line approaching to CETP area.

1. Raw Effluent Tank with Screening: Effluent would pass through a pair of bar screens to be installed in intake chamber, then into raw effluent storage tank and pump house. The intake shall have stairs to reach up to screens platform. The screen in the intake



shall be mechanical type for collect ion of screenings on the screen platform. The spacing between bars of screen will capture large mater ials (30mm or more size) from the effluent and hence these would not get entangled with pump impellers and other machinery of the plant.

2. Effluent Receiving Chamber: The raw wastewater collected in the wet well, would be

pumped into effluent receiving chamber. The pumps ( through MC panel) are linked to level controllers for automatic ON/ OFF operation. Effluent from receiving chamber flows (under gravity) into flow measurement channel, provided with Gauge chamber to measure the flow of incoming effluent and a medium spacing (manual cleaned) bar screen to capture finer screenings.

3. Oil/ Grease Skimmer & Grit Chamber: The raw effluent shall pass through Oil/ grease Skimmer and Gr it Removal Tank. The floating oi l and grease present in the effluent is retained in oi l and grease traps. The recovered oil/ scum formed on the top sur face of effluent shall be removed through Oil skimmer and stored in the drums for disposal. The gr it shall be removed from tank floor , though a mechanical scraper . Gr it shall be kept on dewater ing platform for draining out and shall be stored with dewatered sludge.

4. Equalization Tank: The equalizat ion tank of sufficient holding capacity is provided to dampen the flow var iations and shock loads in terms of volume and strength and to achieve a consistent quality in downstream processes.

5. Physico-chemical Treatment: The use of fer rous sulphate during physico-chemical treatment removes TSS in form of sludge. The soluble sulfur in presence of fer rous sulfate forms insoluble precipitate of fer rous sulfide. This removes sulfides from the effluent. Similar ly, chromium present in the effluent would also be removed as chromium hydroxide at alkaline pH maintained by addition of lime. The concentration of phenolic compounds in raw effluent shall be negligible, hence does not require specific treatment for removal.

The expected character istics of effluent after pr imary settler are shown in Table 7.1.

Table 7.1: Expected Characteristics of Effluent after Physico-chemical treatment

S. No. Parameters Units Approx. Values

1 pH - 8.0 - 8.5

2 Total Suspended Solids (TSS) mg/ l 150

3 Chemical Oxygen Demand (COD) mg/ l 600

4 Biochemical Oxygen Demand (BOD, 3-days, 270C) mg/ l 350

5 Oil and Grease mg/ l Less than 15

6 Total residual Chlor ine mg/ l Less than 1

7 Total Chromium as Cr mg/ l Less than 2

8 Phenolic compound as C6H5OH mg/ l Less than 5



6. Flash Mixer 1&2 (Coagulation & Flocculation Tank): The equalized effluent from equalization tank shall be pumped at constant rate into two stage flash mixer followed by flocculat ion tank. Chemical solut ions namely ferrous sulphate and lime solution will be added in flash mixers and poly electrolyte solut ion into the flocculat ion tank with the help of dosing pumps attached to chemical dosing tanks. The chemicals w ith effluent get completely mixed by rapid mixing in flash mixers whereas slow mixing in flocculation tank allows formation of bigger size fast sett ling flocs. The pH of the mixture of fer rous sulphate and effluent in flash mixer is maintained around 8.5 by dosing of lime.

7. Primary Clarifier: After floc formation, this mixture enters into pr imary settler / Clar ifier where sludge sett les at bottom and the clear supernatant effluent flows into Aeration tanks. The sludge is w ithdrawn into wet sludge pit w ith the help of valve provided in the valve chamber. The fi ltr ate shall be discharged into inlet of Aerat ion tanks. The physico-chemical treatment shall remove about 30% of BOD and 40% COD load of the effluent, in addition to complete removal of colour .

8. Biological Reactor (Extended Activated Sludge Process): Major par t of soluble BOD &

COD load (organic mater ial present in the effluent) would be removed by biological treatment in Aeration tank. Extended aeration - Activated sludge process (ASP) allows for the oxidation of bio-degradable matter and conversion into bio-cell mass, carbon-dioxide and water . Extended ASP also generates less sludge compared to the conventional ASP. The desired cell mass concentration in the aeration chamber is maintained by required degree of bio-

sludge recycling from the Return sludge sump (connected to secondary clar ifier) . Proper

mixing of bio-cells mass with influent and necessary oxygen supply for oxidat ion of bio-degradable matter is done by means of air diffusers.

The DO level in aeration tanks shall be maintained by controlling the operation of Turbo

Blowers connected through DO sensor and PLC. Aeration tank including air -blowers

with net work of air pipelines, diffusers and PLC shall be provided. Aerat ion tank shall have two chambers. The oxygen required shall be supplied through fine bubble Diffused

Aeration System with auto control of oxygen (DO) level in the Tanks. The biological act ivity of microbes requires nutr ients i .e. Nitrogen and Phosphorous, which are vital

elements for the growth of biomass in the effluent. The industr ial effluent would contain

wastewater also from canteens, toilets/ septic tanks; therefore, required “N” and “P” are available in the influent. Return sludge would be recycled with the help of pumps so as

to maintain the required degree of MLVSS and excess par t (waste sludge) would be sent into wet sludge collect ion pit.

The expected character ist ics of t reated effluent after biological treatment are shown in

Table 7.2:

Table 7.2: Expected Characteristics of treated Effluent after Biological Treatment



S.

No.

Parameters Units Values

1 pH - 7.5 - 8.0

2 Total Suspended Solids (TSS) mg/ l Less than 100

3 Chemical Oxygen Demand (COD) mg/ l Less than 200

4 Biochemical Oxygen Demand (BOD, 3-days, 270C) mg/ l Less than 25





9. Chlorine Contact Tank: After Secondary clar ifier , about 2.0PPM of chlor ine gas through

chlor inators shall be mixed in to settled effluent which shall be collected in Chlor ine Contact & Pre-filtr at ion Storage Tank for ter t iary treatment. This w ill provide contact time while storage into effluent tank of Pump House before fi ltr ation.

10. Media Filters: Pressure Sand filters and Activated Carbon Filters shall be used in ser ies for fi lt ration. The operation of these fi lters shall be continuous. The back-wash of fi lters shall be carr ied out when residual pressure about 1.0kg/ sq. cm. indicated on the pressure gauge. The back-wash effluent shall be discharged into inlet of Aerat ion tanks/ Equalization tank.

A par t of filtered effluent shall be pumped for preparation of chemicals solution,

required for chemical house of this CETP and water ing the plantation/ hor t iculture in CETP premises. A par t of t reated effluent may be used for construct ion act ivit ies, after

mixing with fresh water . The remaining final t reated ( fi ltered) effluent shall be discharged into exist ing drain which ult imately meets with r iver .

The expected character ist ics of final treated effluent after ter tiary treatment (final outlet of activated carbon fi lters) are shown in Table 7.3:

Table 7.3: Expected Characteristics of final treated effluent after Tertiary treatment


1 pH - 7.0 - 8.0

2 Total Suspended Solids (TSS) mg/ l Less than 50

3 Chemical Oxygen Demand (COD) mg/ l Less than 150

4 Biochemical Oxygen Demand (BOD, 3-days, 270C)

mg/ l Less than 20







The treated effluent would meet the effluent discharge standards as specified by Bihar

State Pollution Control Board/ in latest amended Environment (Protect ion) Act 1986,

subject to fulfi llment all of the following:

i. Implementation of Treatment scheme in totality (CETP units of matching capacity,

shape/ configuration as per the approved drawings/ Detail Project Report . ii . Total Daily Discharge of Untreated effluent (combined influent to CETP) should not

exceed 6.0MLD (6000m3/ day).

ii i. Cont inuous Operat ion of CETP as per guidance of consultant/ technology provider .



Fig 7.1 Flow chart of Proposed Treatment Scheme



7.3. SLUDGE HANDLING SYSTEM

The chemical sludge generated from the physico-chemical t reatment would be collected

into Wet sludge Pit at tached to Sludge Pump house. The wet sludge (TSS range 8.0 to 10.0 g/ L) shall be pumped at constant rate for dewater ing through filter press and centr ifuge /

Volute Press. Fi lter press and centr ifuge are installed at elevated platform. The dewatered sludge cake from the fi lter press would drop into the trolley and shall be stored into dry

sludge storage collect ion shed for a per iod of about one month. Later , the dry sludge shall

be transpor ted to sludge disposal site as per direct ions of Bihar State Pollut ion Control Board.

Waste bio-sludge from biological treatment, though negligible quant ity is biodegradable

and r ich in nutr ients. Bio-sludge shall not be mixed with chemical sludge so that i t can be

used as manure and water for plantat ion within CETP and industr ial area.

*****



CHAPTER -8

DESIGN SPECIFICATION OF TREATMENT UNIT

8.1. SPECIFICATIONS FOR CIVIL UNITS

1) Requirement for all Concrete Structures a) All bedding & leveling concrete shall be minimum 100 mm thick in concrete gr ade M-

10 (1:3:6) unless otherwise specified. b) Liquid retaining structures: The wall & bottom slab thickness shall not be less than

150 mm in any water retaining structure except in launders & channels. The same shall be designed using M-30 concr ete design mix w ith OPC-43 grade and maximum 20 mm aggregate size for all structure members.

c) Other str uctures: concrete shall be M-25. d) Medium reinforcement & cover of concrete shall be as per 7.1 & 7.2 of IS: 3370 par t

II. e) Water retaining structures such as tanks and sumps and concr ete roofs shall be

designed on a no crack basis & against upli ft pressure assuming sub soil water at Ground Level.

2) The size and number s of CETP units and Minimum recommended Sizes are given in the following Table.

3) Any item not covered in this Table, the specifications shall be as that of similar other i tem. The unit ’s sizes had been worked out consider ing var ious design par ameters as applicable to the relevant treatment units w ith appropr iate arrangement and housing of equipment to handle the design flow.

Basic Assumptions for working out cost of civil works

1) Item rates for civil works had been taken as per Bihar Govt. Schedule of Rates (7th Edit ion, Oct 2014) for working out the cost of civi l works.

2) Plinth Ar ea Rates (Aug 2014) had been taken for working out the cost Buildings. 3) Thickness of RCC str ucture member s had been assumed on basis of similar previous works 4) Assumed avg. quantity of r einforcement steel per cu.M. of RCC

a) 60 kg for walls & slabs and b) 80 kg for columns , beams & footings

5) All bui lding had been consider ed RCC fr amed structure with RCC footings, beams, columns, RCC roof slab. However dry sludge store shall have pr efabr icated/ AC sheet roofing.

6) All pump houses as requir ed leak-proof, has been considered RCC walls up to plinth level. Liquid retaining structure shall M-30 concr ete design mix w ith cement OPC-43 grade for all structur e members. Reinfor cement steel shall be TMT high str ength bar s Fe-500.



Table- 8.1: Details of CETP Units and BOQ of Civil work

1) All dimensions in Metres, Areas in Sq.M and Volume in cu.M. 2) For all Platforms, c/ c size, internal size and outer sizes are same.

Part-1: CETP Units - Calculation of Civil Quantities

S.

No. Unit Name Internal Size RCC- WALLS RCC- BASE /SLAB Earthwork / Excavation PCC Vol. Other Items-RCC Total

RCC

(cu.M)

Finishing Works

L-B-D Av.Th

k. Volume L W Av.Thk. Volume L W D Volume Area Vol. Area Av.Thk Volume Inter. Area Exter. Area

1 Raw Effluent Intake & Screen Chamber , incl. staircase

6.0x3.0x5.0 0.4 43.46 8.4 5.35 0.3 13.4 9.35 6.35 4.4 261.24 44.673 4.47 10 0.25 2.5 59.36 129.91 19.4

2 Raw Effluent Tank-Pump House-1

9.0x7.0x7.0 0.5 110.88 11 9.4 0.3 32.15 12.4 10.4 5.4 696.38 107.16 10.72 0 143.03 291.32 33.6

3 Pump Room - Pump House-1

7.0 x 6.0 x11.0 0.5 100.74 9.4 8.4 0.45 35.53 10.4 9.4 5.5 537.68 78.96 7.9 65 0.3 19.5 155.77 248.84 132.48

4 Pump Room - Pump House-2

7.0x7.0 x6.5 0.3 26.46 5.8 5.8 0.45 15.14 6 6 1.5 54 33.64 3.36 58 0.3 17.4 59 142.22 141.12

5 Elevated Receiving Chamber

2.0x 2.0 x2.0 0.25 4.5 2 2 0.3 1.2 4 2 1.5 12 9 0.9 10 15.7 23.06 23.06

6 Open Channel 8.0x0.80x0.80 0.25 1.86 7.5 1.7 0.3 3.83 7.5 1.5 1.5 16.88 12.75 1.28 6(1.5x1.5,0.3) 14 19.69 14.88 14.88

7 Platform for Gr it dewater ing (2nos.)

2.5x2.5x1.0 0 2.5 2.5 0.2 2.5 1 4 0.9 7.2 4 0.8 1 0.25 0.5 3 12.5 10

8 Equalizat ion Tank 25.0 x 20.0 x4.9 0.4 179.54 27 22.4 0.35 214.82 28.4 23.4 4.5 2990.5 613.76 61.38 7 0.25 1.75 396.1 967 183.2 9 Flash Mixing Tank -1 4.70x2.30x 2.40 0.25 9 6 3.55 0.3 6.34 6.95 4.55 0.75 23.72 21.12 2.11 6 0.25 1.5 16.84 48.62 36

10 Flash Mixing Tank -2 4.70x2.30x2.40 0.25 9 6 3.55 0.3 6.34 6.95 4.55 0.75 23.72 21.12 2.11 6 0.25 1.5 16.84 48.62 36

11 Flocculat ion Tank 4.10x4.10x2.40 0.35 14.95 6.5 6.5 0.3 12.48 7.5 7.5 0.75 41.63 41.6 4.16 3 0.25 0.75 28.18 62.52 42.72

12 Lime Solut ion Tanks (2nos.)

1.50x1.50x2.0 0.25 7 2 2 0.2 1.6 0 0 9 0.25 2.25 10.85 40.25 14

13 Ferrous Sul. Solut ion Tanks(2nos.)

1.50x1.50x2.0 0.25 7 2 2 0.2 1.6 0 0 8.6 40.25 14

14 Polyelectrolyte Solut ion Tank

1.30x1.30x2.0 0.25 3.1 2.1 2.05 0.25 1.05 0 0 1 5.15 14.8 12.4

15 Inlet, channel, Launder of Aer .Tank

1.0x 1.0x10.0 0.2 11.28 27 1.4 0.25 9.45 0 0 50 0.2 10 30.73 86.4 86.4

16 Aerat ion Tank, Platforms,Tie Beams, Columns

37.0x27.0x6.1 0.5 480.38 40 29.5 0.4 466.1 41.5 31.5 3.5 4575.4 1165.3 116.53 55 0.3 16.5 962.98 1824.25 442

1.0(W), 0.5x0.3 0.3 9.6 10 19.6 128

17 Return Sludge (RAS) Holding Tank

8.8x8.0 x4.6 0.45 73.28 11 10.5 0.3 35.27 12.3 11.45 4.5 631.18 117.56 11.76 0 108.55 241 35.4

18 Pump Room - RAS Pump House

6.0 x 5.0 x 7.5 0.4 47.2 8.4 7.4 0.45 27.97 9.4 8.4 5.5 434.28 62.16 6.22 55 0.3 16.5 91.67 152.56 23.6

19 CC & Filter Feed Water Storage Tank

9.0 x7.5 x3.6 0.4 49.82 11 9.9 0.3 33.86 12.4 10.9 2.9 391.96 112.86 11.29 6.4 0.15 0.96 84.64 198.82 34.6

20 Filtrat ion Pump House

7.0 x 6.0 x5.5 0.3 20.4 5.8 5.8 0.45 15.14 6 6 1.5 54 33.64 3.36 58 0.3 17.4 52.94 113.99 27.2



Table- 8.1: Details of CETP Units and BOQ of Civil work

1) All dimensions in Metres, Areas in Sq.M and Volume in cu.M. 2) For all Platforms, c/ c size, internal size and outer sizes are same.

Part-1: CETP Units - Calculation of Civil Quantities

S.

No. Unit Name Internal Size RCC- WALLS RCC- BASE /SLAB Earthwork / Excavation PCC Vol. Other Items-RCC Total

RCC

(cu.M)

Finishing Works

L-B-D Av.Th

k. Volume L W Av.Thk. Volume L W D Volume Area Vol. Area Av.Thk Volume Inter. Area Exter. Area

21 Wet Sludge holding Tank (in two par ts)

10.0x6.0 x3.1 0.3 36.74 12 8.3 0.3 30.63 13.3 9.3 3 371.07 102.09 10.21 6 0.25 1.5 68.86 122.45 26.56

22 Pump Room-Wet Sludge Pump House

8.0x5.0x7.50 0.3 61.2 10 7.3 0.3 22.56 11.3 8.3 4 375.16 75.19 7.52 8 0.25 2 85.76 43.99 27.2

23 RCC Platform / Foundns. for PSF

12.0 x 4.5x 1.0 12 2.5 1.25 37.5 13 3.5 0.9 40.95 30 15 37.5 54 33

24 RCC Platform / Foundns. for ACF

12.9 x 4.9x 1.0 13 2.5 1.25 40.31 13.9 3.5 0.9 43.785 32.25 16.13 40.31 63.21 35.6

25 RCC Platform for VOLUTE dewater ing press and Centr ifuge

7.0 x 4.0x 3.0 7 4 0.6 16.8 8 5 1.2 48 28 2.8 7 1 7 23.8 28 8.8

26 Storm water drains w ithin CETP area

0.60x0.80 (av.D)

0.15 121.7 450 0.95 0.15 64.13 450 1 0.9 405 427.5 42.75 185.83 1147.5

27 Grit removal Tank-

Oil skimmer 7.50 Int. Dia 0.3 22.04 8.7 8.7 0.3 17.82 9.7 9.7 1.5 110.79 59.42 5.94 11.66 0.18 2.0983 41.97 134.32 73.48

Central Shaft 0.7 0.25 2.2 1.6 1.6 0.3 0.6 2.6 2.6 1.5 7.96 2.0096 0.2 0 2.8 9.28 9.89

Valve Chamber 1.2x1.2x2 0.2 2.912 2.4 2.4 0.25 1.44 3.4 3.4 2.3 26.59 5.76 0.576 0 4.352 16.52 5.6

Grit Pump sump 2.75x 2.75x2 0.25 7.8 4 4 0.25 4 5 5 2.3 57.5 16 1.6 0 11.8 40.2 12

28 Primary Clarifier 19.0M (ID)x3.0M

0.3 53.69 20 19.9 0.3 93.26 20.9 20.9 2 685.79 310.87 31.09 27.48 0.18 4.9469 151.9 539.98 22.8

Central Shaft 1.2 0.25 6.26 2.4 2.35 0.3 1.3 3.35 3.35 1.5 13.21 4.3352 0.43 0 7.56 27.14 9.11

Valve Chamber 2.0x2.0x2.0 0.2 4.16 3 3 0.25 2.25 4 4 2.3 36.8 9 0.9 6.41 24.8 8

29 Secondary Clarifier 26.0M ID 0.3 74.32 27 27.2 0.3 174.23 28.2 28.2 1.5 936.4 580.77 58.08 37.8 0.18 6.8036 255.36 939.44 31.56

Central Shaft 1.4 0.25 7.77 2.6 2.55 0.3 1.53 3.55 3.55 2.5 24.73 5.1045 0.51 0 9.3 33.81 9.33

Valve Chamber 2.0x2.0x2.0 0.2 4.16 3 3 0.25 2.25 4 4 2.3 36.8 9 0.9 6.41 24.8 8

Total of Quantities 1614.4 1446.4 13972 442.96 168.36 3229.1 8079.27 1682.98

Rate as Per BSR-2014 13200 13200 150 2350 11000 240 200

Amount (Rs. Lac) 213.1 190.92 20.958 10.409 18.519 19.39 3.366

Total Cost of Part-1 (Rs. Lac) 476.665



Part-2: BUILDINGS- on Plinth Area Rate (basis BSR-2014)

S.N. Name / Description Internal Size Area Rate

(Rs./Sq.M)

Amount

(Rs.

Lac)

1 Chemical House- CC & IPS Floor 14.0x9.0 x 5.0 126.00 13120 16.531

2 Pump Room - Pump House-1 7.0 x 6.0 x 8.0 42.00 13400 5.628

3 Pump Room - Pump House-2 9.0 x 7.0 x4.5 63.00 13400 8.442

4 Housing for Turbo Blowers 10.0x 6.0 x 4.0

60.00 13120 7.872

5 PLC Room (Control Center ) 6.0 x 6.0 x 3.30

36.00 13120 4.723

6 Housing for Chlor inators 5.0 x 5.0 x 4.0

25.00 12800 3.200

7 Shed for Chlor ine Tonners 5.0 x 5.0 x 4.0

25.00 9000 2.250

8 Workshop –cum- store 7.0 x6.0 x 4.0 42.00 13120 5.510

9 Panel Room-1 7.00x 6.0 x 4.0

42.00 13120 5.510

10 Panel Room-2 7.0x 6.0 x 4.0

42.00 13120 5.510

11 Air Compressors Housing 4.0 x 4.0 x 4.0

16.00 12800 2.048

12 Dry Sludge Storage shed 12.0x8.0x 3.30 96.00 9000 8.640

13 Room for Watchmen 4.0x3.50x3.50

14.00 12800 1.792

14 Toilets in Plant area 3.50x3.5x3.50

12.25 14000 1.715

15 Office building 15.0x10.0

150.00 15000 22.500

Total Cost of Part-2 101.873

Part-3: Based on Rate Analysis

S.N. Name / Description Unit Qty. Rate Amount

(Rs. Lac)

Remark

1 Boundary Wall surrounding CETP area- 0.25Thk. X 2.0Ht.,with RCC Columns

RM 380 8000 30.40 Length as per site,

2 Per ipheral RCC Road-complete including approach roads to var ious Buildings and Tanks- w ith WBM base, nominal reinft.

sq. M 1600 1600 25.60 Length as per Layout Plan.

Total Cost of Part-3

56.00





Part-4: Based on Lump Sum Cost

S.N. Name / Description Size or Area Amount

(Rs. Lac)

Remark

1 Finishing works, plinth protection of all pump houses and buildings.

Lump sum 10.00 As per site,

2

Misc. CC base, cover ing of pipe with PCC, man holes, Valve chambers, Foundations for 2nos. DG sets.


3

Connection chamber, inlet pipe lines to Pump house and out let disposal channel w ithin CETP boundary


4 Clearance of Old structure at CETP site.

Lump sum 5.00 As per site.

5

Fresh water Over Head Tank &Tube well w ith Submersible pump set

7.0KL, 10.0M staging

1.50

6 Staging/ Platform at top of PSF & ACF

12.0x4.0 at 4.0M ht.

3.00

Total Cost of Part-4

28.50

8.2. SPECIFICATION FOR MECHANICAL EQUIPMENTS AND WORKS

The pipes used shall be as follows:

Table –8.2 Pipe Details

S. No. Type of pipe Class

1. Duct ile Iron S&S K9

2. Cast Iron S&S AB ( for grouted / bur ied under Concrete)

3. Cast Iron Flanged B

4. Rigid PVC 10 Kg f/ sq.cm

5. GI Heavy duty-class B

6. Stainless Steel Medium class

7. RCC Pipe S&S NP3



8.3. PIPE FITTINGS

Fitt ings above 80 NB shall be DI as per relevant specificat ions in IS/ BS conforming. The puddle collars embedded in the wall shall be of DI.

If flanged cast ir on pipes and specials shall be used in the pump houses and to the limit of

both suct ion and delivery pipelines they shall be manufactured and tested according to IS

1536 and 1537 respect ively & Flanges shall conform to IS 1538.

NOTES ON EQUIPMENT MATERIALS

1) Mater ials thickness, where ever not mentioned, shall be sufficient to w ithstand against the loads including allowance for corrosion, wear & tear .

2) Makes of all fabr icated and bought out equipments including major components, shall be as per List of suggested Vendors / makes.

3) Specificat ions given below are indicat ive to specify the equipment requirement and their quantities. Accessor ies for completeness and required operat ional per formance are understood to be included.

Table-8.3 Mechanical Items Details

S.

No.

Equipment Name Specifications Quantity

1

Coarse Screen For inlet / intake

chamber of Pump House-1

Mechanically cleaned. Screenings to be brought up to tank top level using

mechanical conveyor . MC: SS flats 40 x 5 mm

Clear Spacing 30mm. Angle 600 with hor iz. Size: As per process design.

2nos. ( two)

2 Medium Screen Manual cleaned.

MC: SS flats 30 x 5mm.Clear Spacing =20mm. Angle

600 with hor izontal.

Size: As per process design.

1no.

(one)

3 a) Pumps for

untreated effluent Transfer from

Pump House-1 and

Pump House-2.

Type: Centr ifugal, Hor izontal, Flooded Suction.

Mater ial of Construct ion: C.I. Casing, SS impeller , SS Shaft , MS Base plate/ Frame.

Capacity: 250 M3/ hour . Head: 15M of Water .

Motor HP – to be confirmed by manufacturer .

2nos.

( two)



S.

No.


4

Pumps for untreated effluent

Transfer from

Pump House-1 and

Pump House-2

Type: Centr ifugal, Hor izontal, Flooded Suction. Mater ial of Construct ion: C.I. Casing, SS impeller , SS

Shaft , MS Base plate/ Frame.

Capacity: 125 M3/ hour . Head: 15M of Water .

Motor HP – to be confirmed by manufacturer .

4nos. (Four)

5 Pumps for RAS

(Return Act ivated Sludge) Transfer

( for extended ASP)

Type: Centr ifugal, Ver t ical, Submerged.

Mater ial of Construct ion: C.I. Casing, SS Impeller , SS Shaft , MS Base plate / Frame.

Capacity: 180 M3/ Hour . Head: 14M of Water .

Motor HP –to be confirmed by manufacturer .

2nos.

( two)

6.1 Centr ifugal Pumps

for chemical sludge slur ry Transfer

from Pump House

Type: Centr ifugal, Hor izontal, Flooded Suct ion, SP

series pumps. Mater ial of Construction: C.I. Casing, SS impeller , SS Shaft , MS Base plate/ Frame.

Capacity: 8.0 M3/ hour and Head: 30 to 32 M of Water . Sp. Gravity of liquid= 1.08. Motor HP –to be confirmed by manufacturer .

2nos.

( two)

6.2

Screw Pumps for chemical sludge

slur ry from Pump House

Type: Screw / Progressive cavity, Hor izontal, Flooded Suct ion, filter press pump. Mater ial of

Construct ion: C.I. Casing, SS screw, MS Base plate/ Frame. Capacity: 4.0 to 5.0M3/ hour . Head: 45M of Water . Sp. Gravity of liquid= 1.08. Motor HP –to

be confirmed by manufacturer .

2nos. ( two)

7 Pumps for

Filt rat ion Pump House to PSF and

ACF

Type: Centr ifugal, Hor izontal, Suct ion 3.50 meters.

Mater ial of Construct ion: C.I. Casing, SS impeller and Shaft, MS Base Frame.

Capacity: 1no. @ 250M3/ Hour . & 2nos. @ 110 M3/ Hour . Total Head= 30.0 M. Motor HP –to be confirmed by manufacturer .

Total 3nos.

(three)

8

Oil/ grease

skimmer-cum-Gr it

Removal scraper

Type: Mechanical Scraper as clar ifier .

Tank Size- As per Table -Unit Sizes.

Mater ial of Constr .: SS blades and rake arms. Under water parts SS. Bridge- MS, sand blasted

Epoxy painted. Sp. Gravity of mater ial (gr it) = 2.60.

Complete with dr ive, Oil skimmer and trough.

1no.

(one)

9

AGITATORS / MIXERS for Flash

MC: SS-316 Impeller & shaft . Tank Size: As per Table -Unit Sizes.

4nos.



S.

No.


Mixer Tanks-1&2

Turbine type, 4 blades, detachable Impeller . Impeller dia=0.6M approx.

Final RPM= 100approx. HP=2 or as recom. By

manufacturer . Complete including coupling, MS

base Frame.

( four)

10

PADDLE TYPE

FLOCULATORS For Flocculation

Tanks.

MC: SS-316 impeller & shaft .

Tank Size: As per Table -Unit Sizes. V-shaped Paddle type, Detachable Impeller .

Impeller dia= 3.20M approx. Shaft bottom

suppor ted on bush. Final RPM = 15 approx. HP = 2 or as recom. By Mfr .

Complete-Coupling, MS Base Frame.

1no.

(one)

11

AGITATORS /

MIXERS for Lime Solut ion Tanks and F. Sul. / Ferr ic Alum

Solut ion Tank

MC: SS-316 Impeller &shaft.

Tank Size: As per Table -Unit Sizes. Propeller type, Detachable Impeller . Final RPM= 100 approx.

HP = as recom. By Manufacturer . Complete-Coupling, MS Base Frame.

4 no’s

( four)

12

AGITATOR / MIXER For Polyelectrolyte Solut ion.

MC: SS-316 Impeller & shaft . Tank Size: As per Table -Unit Sizes. Propeller type, Detachable Impeller .

Final RPM= 100 approx. HP = as recom. By Manufacturer .

Complete-Coupling, MS Base Frame.

1no. (one)

13

a)

Dosing Pumps for

F S / Fer r ic Alum and Lime Solut ion

Discharge range = 700 to 2000LPH each

Head = 30 Meters of Water Type: meter ing. MoC: SS-316 Motor HP as recommended by manufacturer .

Complete with Base Frame.

4

( four)

13

b)

Dosing Pumps for

PE (Polyelectrolyte)

Solut ion

Discharge range = 500 to 1500LPH each

Head = 30 Meters of Water Type: meter ing. MoC: SS-316

Motor HP as recommended by manufacturer . Complete with Base Frame.

2

( two)

14 Mechanical Scraper

for Pr imary Clar ifier

Clar ifier , size- As per Table -Unit Sizes.

MoC – Water immersed parts and scraper shall

be of SS-304.

Br idge MS, sand blasted, Epoxy painted. All par ts

1 Set



S.

No.


should be Epoxy Painted after sand blast ing and pr imer application. Per ipheral/ Central Dr ive system.

Inner baffle chamber- 4.0M (D) x 1.20M (H). Motor HP as per manufacturer . Motor w ith speed

reduction gear box to get final RPH~ 3. Scraper

base Slope = 1:10 towards centre. MS br idge 1000mm wide, rai ling 1000mm (H),

40mm dia. class B, GI/ MS pipe. Br idge should have MS grat ings of 12x12mm.

Moving scraper arms fit ted with blades, neoprene rubber Squeegee pads. With over load alarm device and on / off remote

push button switch.

15 Mechanical Scraper

for Secondary Clar ifier

Clar ifier , size- As per Table -Unit Sizes.

Inner baffle chamber- 5.20M (D) x 1.20M (H). Water immersed parts and scraper shall be of

SS-304.

All other same as above.

16 Turbo Air Blowers for Air supply

High Speed Centr ifugal Turbo Blowers capacity: 5000M3/ hour at delivery air pressure head 6.25M

of water column. TEFC Motor- HP (200 approx.) and RPM (25000

approx) as per manufacturer .

Complete with accessor ies- noise si lencer and Acoust ics (noise control) enclosure.

2 no’s

(1W +1 SB)

17 Air Diffusers and Air supply grid

Tubular , dia. = 90mm (minimum). Length=1.0M (minimum). PU/ Silicon membrane, w ith SS feed

pipe and SS clamps. Air supply grid- of suitable dia., maximum velocity of air 18m/ sec.

Pipe Mater ials shall be- i) From top of tanks / freeboard to inlet for

diffusers- SS304. i i) Grid for air diffusers – CPVC / SS-304.

Qty. to match air

supply = 5000

cuM/ hr .

18 a)

Filter Press

For Chemical sludge dewater ing

Filter Press: Size: 36” x 36” w ith 35 plates including

end plates. Center feed. Operation- Hydraulic for 2nos and Manual for 1no.

2nos.



S.

No.


MoC: PP plates, End plates- CI, MS Beam and suppor t frame, CI gears, MS shaft.

Polyester filter cloth with spare 2 sets.

Out lets: 25mm Dia. and filt rate channel.

Dewatered cake thick 50mm.

18

b)

Centr ifuge /

VOLUTE press for sludge dewater ing

Capacity =10 KL / hr . Feed sludge Sludge

concentrat ion =8.0 g/ L. Complete with motor , piping, floculator and feed tank.

1no.

19 Air Compressors

for Equalization Tank.

Reservoir volume = 500 Liters approx.

PVC Per forated pipe line at base / floor in Equalizat ion tank.

Operat ing Pr . Range= 7 to 9 kg/ cm2. TEFC motor w ith IP 55 Protection, 3-Phase, 415V,

Motor HP= 15 or as per manufacturer . Complete with Main GI pipeline, Ball valves, Pressure Gauge, Noise si lencer , Belt guard, FRP / GI

cover over motor .

1 (one)

20 Air Blowers for

Chemical Mixing Tanks (in Chemical house)

Twin Lobe Rotary Type.

Blower Capacity: 125M3/ Hr . Air Pressure = 4.0M of water column. Motor = as per manufacturer .

Complete with accessor ies- noise si lencer , Belt Dr ive with Guard.

1 (one)

21 Chlor inators with Tonners

On-line dosing (1.0 to 2.0 kg/ hr .) w ith instrumentation for dosing display and control.

2 (two) sets

22 a)

EOT , Chain Pulley 1.0 MT. Manual operated for pumps, motors and sluice gate li ft ing.

6nos (six)

22 b)

EOT , Chain Pulley 3.0 MT Electr ically operated for centr ifuge / VOLUTE press li ft ing.

1 (one)

23 Piping, valves, fi tt ings

MOC- C.I., MS, G.I. and similar –class B. DI pipes- K9.

HDPE, CPVC, PVC and similar - Heavy duty / Pr .

Class 10kg/ cm2

Lot

24 Centr ifugal pumps

for dewater ing pits

Centr ifugal, ver t ical, motor coupled, flooded

suct ion. MOC: C.I. Casing and impeller , CS Shaft,

Capacity: 5.0 M3/ Hr . Head: 15.0M.

6 nos.

(5W+1S)



S.

No.


TEFC Motor , 3-Phase, IP-55, 415V. HP= 3.0 or as recom. By manufacturer .

Complete with cable.

25 V-notch MOC- 3mm thick SS-304 sheet fi tted in SS frame.

Opening (V) Size=700x350mm.Central angle=90o. Calibrated and embossed flow depth (cm) and flow

rate (cu.M / hr .)

1 no.

26 PSF (Pressure Sand

Filters)

Size: Dia 3.0M x2.50M (H, excl. dishes).

Other Specifications same as GACF, except

Act ivated Carbon layer .

2 nos.

( two)

27.

GACF

(Granular Act ivated Carbon Filters)

Type of Filters – Ver t ical w ith Cylindr ical Cell and

Ellipt ical dish ends. Size: Dia 3.30 x2.50 (H, excl. dishes) .

Operat ion = continuous (24 hours / day) . Working Pressure= 3.0 to 1.25 kg / cm2. Residual Head before Regen=1.0kg / cm2

Air Scour ing inlet =100mm NB Mater ials of Construction –

Casing /shell – 8mm thick MS sheet, inside rubber lined, outside epoxy paint over pr imer. Top & bottom Dishes – 10 mm thick MS sheet, inside

rubber lined, outside epoxy paint over pr imer . Strainers- PVC.

Filter Media Details- Si lica sand, pebbles, gravels as per approved

drawing. Mater ial depth =0.90 M approx. Granular Act. Carbon (GAC)- Coconut shell, depth 600-650 mm.

2 nos. ( two)

The Turbo blowers are energy efficient, have negligible noise compared to other blowers.

Hence, for ASP, only Turbo Blowers shall be provided.

8.4. SPECIFICATION FOR ELECTRICAL & INSTRUMENTATION WORKS

8.4.1 Automatic Power Factor Control Panel

The Automatic Power Factor Control of Suitable KVAR capacity suitable for automatic

operation and control of Power Factor within the set limits, free standing floor mounting



type made out of 2mm CRCA Sheet steel powder coated with channel ir on base frame suitable for operation on 3-phase, 4 wire, 50 Hz equipped with the following: -

Incomer

Suitable sets equipped with 250 A MCCB, PF meter , APFC Relay suitable for sequent ial operation of all capacitor banks.

Outgoing

- Suitable sets of 32A 415V power contactors with fuses.

- Suitable sets of 63A 415 V power contactor w ith fuses. - Capacitors Banks as per design & requirement of power Supply Company.

-LT Panel capacitor Banks shall be mounted in the separate LT Panel Board.

Diesel Generating Set

D.G set of capacity to meet 100% (full load) requirement including all ancillary equipment such as base frame, coupling, coupling guard, control panel and exhaust piping system etc.

including electr ic w ir ing between control panel and start ing batter ies.

8.4.2 Electrical Panel

A separate panel (bay) should be provided for individual pump house. The control panel shall be made up of 2mm sheet steel w ith 7/ 9 tank process powder coating for long life.

The control panel should contain ACB/ MCCB (as per design requirement) of suitable rat ing contacts relays of reputed make.

GENERAL SPECIFICATIONS FOR ELECTRICAL PANELS

There shall be separate Power panels for each pump house, chemical house and blowers etc.

Power panels shall contain Incomer, MCCB, Bus bars, SFU, Relays, Online Indicators, ON/ OFF Rotary switches, Star ters (DOL star ter up to 10 HP and Star -Delta Star ters above 10 HP load) and Spares of suitable capacities and adequate in numbers.

Proper ear thling systems/ ear th pits shall be provided wherever required. Each equipment shall be provided with push button station for local ON/ OFF. Panels shall be indoor type, metal clad, floor mounted, free standing, totally enclosed,

extensible type, air insulated, cubicle type for use on 415 Volts, 3 phase, 50 cycles system with a fault level w ithstand of 31 MVA / 35 MVA RMS.

Panels shall be designed to conform to the requirements of conform to the relevant IS specificat ions and shall be provided with required hardware such as control cabling, contactors, and spares.

The structure shall be mounted on a MS Channel of required size. The design shall ensure that the weight of the components is adequately suppor ted without



deformation or loss of alignment dur ing transit or dur ing operat ions. Panel’s doors and covers shall be of minimum 2 mm thick sheet steel. Sheet steel

shrouds and par ti tions shall be of minimum 2mm thickness. All sheet panels shall be smoothly finished, leveled and free from flaws. The corners should be rounded.

The apparatus and circuits in the power control centers shall be so arranged as to faci litate their operation and maintenance and at the same time to ensure the necessary degree of safety.

All doors / covers providing access to live power equipment / circuits shall be provided with toll operated fasteners to prevent unauthor ized access.

Provision shall also be made for permanently ear thing the frames and other metal par ts of the switchgear .

Specificat ions as per relevant BIS codes shall apply. There shall be separate Power panels for each pump house, chemical house and

blowers etc. Power panels shall contain Incomer, MCCB, Bus bars, SFU, Relays, Online Indicators,

ON/ OFF Rotary switches, Star ters (DOL star ter up to 10 HP and Star-Delta Star ters above 10 HP load) and Spares of suitable capacit ies and adequate in numbers.

Proper ear thing systems/ ear th pits shall be provided wherever required. Each equipment shall be provided with push button station for local ON/ OFF

operation. The following protect ions should be provided in the panel board:-

Over load protection Short circuit protect ion Earth fault protect ion Shunt tr ip & under voltage protection.

OPERATIONAL REQUIREMENT / INTERLINKING OF ELECTRICAL PANEL AND

INSTRUMENTATION

The biological t reatment process (extended ASP) shall be PLC controlled through SCADA.

All MC panels shall have provision of Change –over Switches for operat ion of 100%

equipment through CAPTIVE (DG) Power .

All MCC panels shall have provision of Change –over Switches for operat ion of 100% equipment through CAPTIVE Power (DG set ) for each module. 1. Effluent Transfer Pumps in Pump House-1 (PH-1) :

a) Each Pump for independent operat ion manual/ automatic modes. b) Level sensor in Wet Well w ith Alarm system, when TWL (or Water Depth) reaches 2500 mm above the Base floor .

2. Pumps in Pump House -2 (PH-2) : Each Pump for independent operation manual/ automatic modes.

3. RAS Transfer Pumps: Each pump for automatic operation/ manual modes.

4. Pumps in Wet Sludge Pump House -3 (PH-3) : Each Pump for independent operat ion MANUAL modes.



5. Flash mixer Agitators and Flocculation Paddle Mixers: - to be inter locked with Chemical dosing pumps for synchronous operation.

6. Chemical Solution Tanks Agitators and Air Blowers: Independent and Separate control.

7. Air blowers and all other Equipments: For independent and Separate control for each SBR basin.

8. Pumps in Filtrat ion Pump House -4 (PH-4): Each Pump for independent operat ion

manual modes.

The level controllers of Pump Houses shall be connected to MC panel in such a manner that pump (which was running) star ts operat ing when water level reaches at the upper ON

level and stops when water level reaches at the Lower OFF level in Effluent tank. The level controllers of Raw Effluent Pump House-1 shall be connected to panel in such a

manner that third pump ( first standby) star ts operat ing when water level reaches above the normal TWL level in the wet well.

8.5 INSTRUMENTATION

8.5.1 The Aeration System Shall Be PLC Controlled For Automatic Operation Through

SCADA.

a) ULTRASONIC FLOW METER &TOTALIZER

Compact on-line ultrasonic flow conver ter directly mounted on the ultrasonic flow

sensor .

Input: Effluent of pressure sand filters and Activated carbon fi lters having solid par ticle content < 2%, gas content < 1% (by volume) and TSS less than 100mg/ L. Pipe

dia. 300mm to 500mm.

Output required:

Measurement functionality: Digital display of Flow rate and Total volume. Measur ing range: Flow= 0 to 700 cu.m. / hour .

Measur ing error (under site condit ions) : Not to exceed ± 1.0% of value.

b) ON-LINE pH METER

Compact weather proof and temper- proof on-line probe with Digital display.

Input: Effluent of pressure sand fi lters and Activated carbon fi lters having



Solid par t icle content < 2%, gas content < 1% (by volume) and TSS less than 100mg/ L.

pH range 5.0 to 11.0

Output required:

Measurement funct ionality: on-line pH value.

Measur ing range = 5.0 to 11.0. Perm. Error (under site conditions): Not to exceed ± 2.0% of measured value.

c) On Line Water Quality Monitoring at Common Effluent Treatment Plant

(CETP)

List of Effluent Water Parameter Monitor ing at each process stages at CETP

A) At inlet pH, Flow, BOD, COD, Total Suspended Solids (TSS)

Universal Mult i Controller w ith Display Unit

Wireless Remote Data Logger for Transmit ting Data Using GSM/ GPRS

B) Aeration Basins Dissolved Oxygen measurement and Luminescent display for each Tank.

Nitrate Sensor w ith spectro-photometry pr inciple.

Universal Mult i Controller .

Wireless Remote Data Logger for Transmit ting Data Using GSM/ GPRS.

C) Third Point at filters / final out let – BOD,COD, Nitrate, Total Suspended Solids (TSS), TDS with self-cleaning Universal Mult i Controller

Wireless Remote Data logger for Transmitt ing Data Using GSM/ GPRS

8.5.2 Online Real Time CETP Water Quality Monitoring

As per CPCB guidelines Real Time CETP Water Quality Monitor ing & Central

Network shall be installed for parameters viz. pH, TSS, temperature, Biochemical Oxygen demand (BOD), Chemical Oxygen Demand, Nitrate, and DO. Chlor ine and

Flow with remote as well as local display in control room. The wireless connect ion

shall be prefer red for control room display.

The Water Monitor ing Stations shall provide real time data through GSM/ GPRS network at scheduled intervals automatically or as and when requested by the users.



8.6 ELECTRICAL LOAD

Estimated Electrical Load of CETP Equipment for Estimate purposes

Table-8.4 Electrical Load Sheet

S.

No. Equipment / Drive Name Nos.

KW of

each

Total

KW

Running

KW

1 Centr ifugal Pumps (250 m3/ Hr), in Pump Houses PH-1 & PH-2

2 18.75 37.5 37.5

2 Centr ifugal Pumps (125 m3/ Hr), in Pump Houses PH-1 & PH-2

4 9.3 37.2 0

3 Centr ifugal Pumps (180 m3/ Hr), in RAS Pump House

2 15 30 15

4 Pit Dewater ing Pumps, centr i., 5m3/ Hr 7 1.5 10.5 3

5 Centr ifugal Pumps (250 m3/ Hr), in Pump House PH-4.

1 30 30 30

6 Centr ifugal Pumps (125 m3/ Hr m3/ Hr) , in Pump House PH-4.

2 15 30 0

7 Gr it removal devices, oil skimmers 1 4.4 4.4 4.4

8 Air Compressors 1 7.5 7.5 7.5

9 EOT hoists 6 1.1 6.6 1.1

10 EOT hoists 1 2.2 2.2 2.2

11 Agitator- Lime Dosing Tank 2 1.5 3 3

12 Agitator- F. S. / F.A. Dosing Tank 2 1.5 3 3

13 Agitator- Poly Electrolyte Dosing Tank 1 1 1 1

14 Mixer - Flash Mixer Tank-1&2 4 1.5 6 6

15 Rotary Air Blowers for Chem. house 1 3.7 3.7 0

16 Mixer for Flocculat ion Chamber 1 2.2 2.2 2.2

17 Dosing Pumps for Lime Solution 2 1.5 3 1.5

18 Dosing Pumps For Fer .Sul. / F.A. Solu. 2 1.5 3 1.5

19 Dosing Pump For P E Solut ion 2 1 2 1

20 Pr imary Clar ifier Mechanism 1 2.2 2.20 2.2

21 Secondary Clar ifier Mechanism 1 3.75 3.75 3.75

22 Turbo Air Blowers for Aeration Tanks 2 175 350 175

23 Sludge Feed Centr i. Pumps for PH-3 2 3.75 7.5 3.75

24 Sludge Feed Screw Pump to Filter Press for PH-3

2 7.5 15 7.5

25 Service Water Pump, 6m3/ hr 2 3.75 7.5 3.75



S.

No. Equipment / Drive Name Nos.

KW of

each

Total

KW

Running

KW

26 Centr ifugal Pumps for reuse of Treated effluent in Chem. house

2 2.2 4.4 2.2

27 Instrumentation 1 5 5 5

28 Centr . Pumps for biological sludge from wet Sludge Pump House. 2

3.75 7.50 3.75

29 Centr . Pumps for chemical sludge from Sludge Pump House. 2

3.75 7.50 3.75

30 Screw Pumps 2 3.37 6.74 3.37

31 Filter Press with Hydraulic system 1 1.5 1.50 1.5

32 Centr ifuge for bio-sludge dewater ing 1 15.0 15.00 15.00

33 Twin Lobe Rotary Blowers for Chem. Mixing Tanks and bio-sludge sump 2

3.75 7.50 3.75

34 Miscellaneous- office, lab, workshop, street Light ing etc.

1 20 20.00 15

Total 683.9 369.17

Approximate proposed Installed load = 685 KW.

Approximate proposed Running load =370 KW

*****



CHAPTER - 9

ENVIRONMENTAL MANAGEMENT PLAN

9.1 ENVIRONMENTAL MANAGEMENT PLAN (EMP)

Preparat ion of environmental management plan is required for formulation, implementat ion and monitor ing of environmental protection measures dur ing and after

commissioning of projects. The plans should indicate the detai ls as to how var ious measures have been or are proposed to be taken including cost components as may be

required. Cost of measures for environmental safeguards should be treated as an integral component of the project cost and environmental aspects should be taken into account at var ious stages of the projects:

Conceptualizat ion: preliminary environmental assessment

Planning: detailed studies of environmental impacts and design of safeguards Execution: implementation of environmental safety measures Operation: monitor ing of effectiveness of built -in safeguards

The management plans should be necessar i ly based on considerations of resource

conservation and pollut ion abatement. Some of which are:

1. Liquid Effluents

Effluents from the industr ial area should be treated well to the standards as

prescr ibed by the Central/ State Water Pollut ion Control Boards. Deep well bur ial of toxic effluents should not be resor ted to as it can result in re-

sur facing and ground water contaminat ion. Re-sur facing has been known to cause

extensive damage to crop and livestock. In all cases, effor ts should be made for re-use of water and its conservation.

2. Air Pollution

The emission levels of pollutants from different stack should conform to the

pollut ion control standards prescr ibed by Central or State Boards. Adequate control equipment should be installed for minimizing the emission of

pollutants from the var ious stacks.

In-plant control measures should be taken to contain the fugit ive emissions.

Infrastructural facilit ies should be provided for monitor ing the stack emissions and measur ing the ambient air quality including micro-meteorological data (wherever

required) in the area.



Proper stack height as prescr ibed by the Central/ State Pollution Control Boards should be provided for better dispersion of pollutants over a wider area to minimise

the effect of pollut ion. Community buildings and townships should be built up-wind of plant w ith one-half

to one ki lometer greenbelt in addition to physiographical barr ier .

3. Solid Wastes

The site for waste disposal should be checked to ver ify permeabili ty so that no

contaminants percolate into the ground water or r iver/ lake. Waste disposal areas should be planned down-wind of vi llages and townships.

React ive mater ials should be disposed of by immobilizing the react ive materials

w ith suitable additives. The pattern of fi lling disposal site should be planned to create better landscape and

be approved by appropr iate agency and the appropr iately pretreated solid wastes should be disposed according to the approved plan.

Intensive programs of tree plantat ion on disposal areas should be under taken.

4. Noise and Vibration

Adequate measures should be taken for control of noise and vibrat ions in the industry.

5. Occupational Safety and Health

Proper precaut ionary measures for adopt ing occupat ional safety and health standards should be taken.

6. Prevention, maintenance and operation of Environment Control Systems

Adequate safety precaut ions should be taken dur ing preventive maintenance and

shut down of the control systems. A system of inter -locking with the product ion equipment should be implemented

where highly toxic compounds are involved.

7. House – Keeping

Proper house-keeping and cleanliness should be maintained both inside and outside

of the industry.



8. Human Settlements

Resident ial colonies should be located away from the solid and liquid waste

dumping areas. Meteorological and environmental condit ions should be studied

proper ly before selecting the site for residential areas in order to avoid air pollut ion problems.

9. Transport Systems

Proper parking places should be provided for the trucks and other vehicles by the

industr ies to avoid any congestion or blocking of roads. Sit ing of industr ies on the highways should be avoided as it may add to more road

accidents because of substant ial increase in the movements of heavy vehicles and unauthor ized shops and sett lements coming up around the industr ial complex.

Spillage of chemicals/ substances on roads inside the plant may lead to accidents.

Proper road safety signs both inside and outside the plant should be displayed for avoiding road accidents.

10. Recovery - reuse of waste products

Effor ts should be made to recycle or recover the waste mater ials to the extent possible. The treated liquid effluents can be convenient ly and safely used for

ir r igation of lands, plants and fields for growing non-edible crops.

11. Vegetal Cover

Industr ies should plant trees and ensure vegetal cover in their premises. This is

par t icular ly advisable for those industr ies having more than 10 acres of land.

12. Disaster Planning

Proper disaster planning should be done to meet any emergency situation ar ising

due to fire, explosion, sudden leakage of gas etc. Firefighting equipment and other safety appliances should be kept ready for use dur ing disaster/ emergency situat ion

including natural calamities like ear thquake/ flood.

13. Environment Management Cell

Each industry should ident ify within i ts setup a Depar tment/ Sect ion/ Cell w ith

trained personnel to take up the model responsibi li ty of environmental management as required for planning and implementation of the projects.



9.2 ENVIRONMENTAL MANAGEMENT DURING OPERATION OF CETP

The common effluent treatment faci li ty w ill compr ise of following stages

Pr imary Treatment

Physico-Chemical Treatment

Biological Treatment Ter t iary Treatment (Disinfection using Chlor ination and Filt ration) .

On line monitor ing system for var ious parameters such as pH, TOC and DO is provided.

However , for smooth operat ion and to achieve the treated effluent quality, regular

monitor ing of the plant is very much required. The samples from different stages of t reatment should be collected and analyzed as per details given in the table. Samples will

be analyzed in the CETP laboratory & record will be maintained in the Log-book.



LIST OF PARAMETERS & SAMPLING POINTS LOCATION.

D=Daily. M= Monthly. All parameters in mg/ l except pH, temperature & SVI

Sampling Point Equalization

Tank

Primary

Clarifier

Outlet

Aeration /

SBR Tank

Secondary

Clarifier

Outlet

Pre-filtration

Water

Storage Tank

Final

Treated

Effluent for

Disposal

Tube well-

Fresh Water

samples for

HHSEHS

Parameter

Oil & Grease Thrice/ week Thr ice/ week Thr ice/ w eek Once/ week

pH D D D D D D Once/ week

Temperature D D D D D D Once/ week

COD D D D D M

BOD Twice/ week Twice/ week Twice/ week Twice/ week Twice/ week Once/ week M

TSS D D D Twice/ week D M

NH3-N Once/ week Once/ Month Once/ Month Once/ week M

Total-P Once/ week Once/ Month Once/ Month Once/ week M

SVI Thr ice/ week



In addition to environmental monitoring plan for the CETP, for successful operation and

maintenance of CETP it is very essent ial that CETP receives waste water which is w ithin the

parameters selected for design of CETP. In order to control the inlet parameters of CETP it is very essent ial for the regular monitor ing of industr ies discharging into CETP. It is also essential to carry out regular sampling, surpr ise sampling of discharge waste water from

each member industr ies on 24 hours basis.

If industr ies are found discharging more than the specified inlet parameters of CETP, it

must be brought to notice of industry and they should be given notice for controlling their

outlet parameters. On repeated occurrence of such incidence they should be disconnected t ill compliance is achieved. This clause must be added in the membership agreement w ith

the CETP.

*****



CHAPTER -12

CONCLUSION

12.1. CONCLUSION

It is evident from the study finding that the effluent generated from the industr ial estate/ area is highly polluted and it is not fi t for direct discharge on land or sur face water .

There is no wastewater treatment plant at the individual industry level. Since the

industr ies are small and medium scale, they cannot afford to have cost effective Effluent

Treatment Plant (ETP) to meet the discharge standard st ipulated by the Bihar State Pollut ion Control Board. Therefore, i t is very much essential to set up a Common Effluent Treatment Plant (CETP) to treat the wastewater generated from all the industr ies in the

industr ial area in a cost effective way. There is no dedicated sewerage line for the

conveyance of domestic wastewater which would be treated along with the city domest ic

wastewater in the terminal Sewage Treatment Plant (STP). Therefore, i t is proposed to treat domest ic as well as Trade Effluent in the proposed CETP.

The storm water dur ing the rainy season creates water logging in the industr ial area due to

absence of storm water drainage system. The storm water gets mixed with the hazardous and solid waste generated from the industr ies which are being disposed nearby the

boundary of the industr ies. There is no proper collect ion of Solid and Hazardous waste

generated from the industr ies. Due to poor Hazardous and Solid Waste Management an addit ional highly polluted wastewater stream generated dur ing the rainy season which are

harmful to the soil as well as ground water and sur face water . Therefore, there is a need of proper collect ion and treatment of Solid and Hazardous waste from the industr ial area.

Since there is no Common Hazardous Waste Treatment Storage Disposal Facili ty (TSDF)

exists in Bihar , it is suggested to have TSDF facili ty for proper Handling of Hazardous Waste as per Hazardous Waste Management & Handling Rules of CPCB. Also it is very

impor tant to have separate proper storm water drainage system in the industr ial area. As per discussion with BIADA, they are already in process to construct Drainage Facili ty in the

Industr ial Area.

The treated effluent from the recommended Common Effluent Treatment Plant (CETP) shall be par t ially used for hor t iculture, chemical solution preparation in the CETP itself, for construct ion of the Civil works in the nearby locality ( those who opt to collect from the

CETP), par tially for Automobile service station and water ing on the road side to reduce the

fresh water consumption and sustainabili ty of the environment. The residual part shall be

disposed in the nearby drain which will ult imately meet to the r iver .

The type of industry to be allowed in future in the vacant or cancelled plot has been discussed in the Repor t so that the quantity of wastewater would not be exceed the



recommended capacity of the CETP. The change in the production or expansion in the

existing product ion capacity by the individual industry would be only allowed after due

consent from the BIADA.

The Capital Expenditure for sett ing up of the CETP would be shared by Central Government, State Government, and Entrepreneur of the industr ial area. The operat ing expenses would be borne by the Entrepreneur based on shar ing of quantum of flow and

pollut ion load generated from the individual industry.

As per the EIA notificat ion 2006 from Ministry of Environment & Forests, setting up of

CETP in the designated Industr ial Area requires Environmental Clearance under Category

“B”. Therefore there is a need to obtain Environmental Clearance from State Level Environment Impact Assessment Author ity (SEIAA)/ Bihar State Pollut ion Control Board.

For this, the detai led study is required for Environment Impact Assessment (EIA) .

*****

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