MMA CETP MAHAD

MMA CETP,
MAHAD
Seven Billion Dreams.
One Planet. Consume
with Care
 Contents
• Historical Background of CETP
• Effluent characteristics & Challenges of MIDC,
MAHAD
• Improving Effluent Treatment & Management
• Journey towards Sustainability
 Historical Background….
MMA CETP Mahad
 Purpose of Existence
 The Mahad Industrial Area came into existence in the later part of
eighties to overcome the water pollution related problems of the area.
 Tremendous water pollution in surrounding of industrial area and Savitri
River & creek
 Thought process developed in early nineties to develop a CETP
 However, actual development activity started only in 1998-99.
 The treatability studies were conducted in the year 2000 by M/s.
Paramount Ltd., Baroda.
 The DPR was prepared in Nov. 2000 & technical appraisal done by IIT,
Mumbai in 2001.
 Primary treatment commissioned in 2003. Although the project execution
was delayed due to financial difficulties,
 The project was completed and was fully operational only in June 2005.
 Industry membership status

Large Scale Industries 16

Large Scale
Medium Scale Industries 16 Closed & Industries, 12%
Temporary
Small Scale Industries 40 Closed
Industries, 26% Medium Scale
Industries, 12%
Total 72
Green 28
Green
Small Scale
Closed/Temp. Closed 35 Industries, 21%
Industries, 30%
TOTAL 135
 Category wise distribution of Industries
Industries Small Medium Large Total
Chemicals 66 15 9 90
Pharmaceutical 1 1 3 5
Dyes & Dye Intermediate 2 2 0 4
Textile 2 0 2 4
Pigment 0 0 1 1
Paper 0 0 1 1
Packing 1 0 0 1
Engineering 3 2 0 5
Others 23 1 0 24
Total 98 21 16 135
• Historical Background of CETP
• Effluent characteristics & Challenges of
MIDC, MAHAD
• Improving Effluent Treatment & Management
• Journey towards Sustainability
Nature of Waste water – MAHAD MIDC

Flow cu. m/d 5500 – 6000

pH 4.5 – 8.5

COD mg/L 4500 – 5500

BOD mg/L 1200 – 1600

TSS mg/L 2000 – 4000

TDS mg/L 10000 – 15000

Design Capacity
Plant Capacity 7.5 MLD
Avg. influent qty 6.5 MLD
Aeration volume Capacity 11500 Cub Mtr
Designed COD 3500 ppm
Designed BOD 1000 ppm
 CETP FLOW DIAGRAM
Primary Treatment Secondary Treatment Tertiary Treatment
Lime PAC

Industrial
Effluent Pump Biotower Pump
Grit Oil pH Flash Biotower
Equalisation Clariflocculator Feed
Chamber Trap Correction Mixer
Sump
Grit
Receiving Sump with Filtrate Pump
Floating Aerators Overflow
Polyelectrolyte
Centrate SDB

Drying Dewatered Decanter

And Sludge
Pump
Disposal Backwash Polyelectrolyte
To
MWML Thickener

Pressure Pressure
Sand Sand PAC Lime
Filter Filter
Nutrients
Pump Pump

MIDC Beef extract

Reaction Flash
Disposal Clarifier
Sump Clarifier Mixer
Flow
Pump Distributor
Polyelectrolyte
Discharge
Aeration Tank 1 and 2
To Air
with Diffused Aeration
saline zone Blower
& 9 No floating
At
aerators
ovale
Post Commissioning of MAHAD CETP &
Performance During 2006 to 2010
Design Inlet Outlet
Flow cu.m/d 7500 5500 – 6000 5500 - 6000

pH <4.0 4.5 – 8.5 7.0 – 8.0

COD mg/L 3500 4500 – 5500 1800 – 2500

BOD mg/L 1500 1200 – 1600 120 – 160

TSS mg/L 500 2000 – 4000 < 100

TDS mg/L 2500 10000 – 15000 8000

• Mahad MIDC area was declared in the list of
Dirty thirty in world survey report in year
2004
 CETP Poor Performance –
Environmental Aspects & Impacts
 Higher inlet COD along with
heavy sludge and dark color.
 Operation issues- infrastructure &
staff.
 Bribing to sampling team.
 Irregular recovery of COD
charges.
 Leakages of storm water through
damaged pipeline
chambers resulting high flow to
MMA CETP and overflow to river.
• Inadequate treatment leading to
Frequent agitation and public
nuisance from Khadipatta due to
obnoxious smell and dark color of
effluent in creek.
• Lost goodwill in society.
• Frequent breakdown of effluent
pipeline due to sludge &
liberation of gases due to
anaerobic conditions resulted
shutdown of whole Mahad
industries many times- Economy
loss to industries
• Demand for drinking water in
Khadipatta.
 CETP Poor Performance – Aspect & Impact
on Environment continued..
• Due to Non-performance of CETP resulted into following…
• Discharge line breakage and pollution of water source
• Intermittent effluent discharge by MIDC due to villagers agitation
• Production loss
• Pollution problems in and around MIDC
• Sludge accumulation in receiving sump and other equipments like clarifiers
and civil tanks.
• Implication
• Show-cause notice by MPCB
• Revoke of Bank Guarantee of Rs. 25.00 lacks
• Imposition of Penal charges by MPCB
• Serving closure notice to CETP and to all industries
• Huge cost of sludge removal and disposal to MWML site
• Historical Background of CETP
• Effluent characteristics & Challenges of MIDC,
MAHAD
• Improving Effluent Treatment &
Management
• Journey towards Sustainability
 Challenges/Problems
• Very few factories in the MAHAD MIDC area had an ETP with full fledge
treatment facilities at the start of the CETP project
• Member Industries were ready to pay penalties rather than treating their
effluents culture more prevalent.
• No Concept of Recycle, reuse by member industries.
• Poor Operation & Infrastructure - inefficient aerators and blowers, Poor
Laboratory infrastructure for accurate & fast analysis.
• High Hydraulic load during monsoon season due to the poor & damaged
concrete chamber and old pipelines of incoming effluent.
• Frequent breakdowns of Effluent disposal pipelines from CETP to Ovale.
• CETP Staff not Competent enough, More prone or get trapped to Bribery
leading manipulation of data .
• CETP run on contractual .
• Poor recovery of treatment charges from industry.
 Improving Effluent Treatment & Management
From 2012 onwards

• Steps taken for improvement of plant Operation & Maintenance

• Contractual operation & Maintenance suspended and Society overtook
the O & M and all director spend sufficient time for monitoring and day to
day work in society.
• Replacement of inefficient aerators and blowers by efficient surface
aerators, screw compressors and instrumentation.
• Up-gradation of Laboratory infrastructure for accurate & fast analysis.
• Regular preventive maintenance of plant machinery and sumps.
• Restructuring and strengthening of Civil structures.
• Installed online monitoring system on influent and treated effluent
 Improving Effluent Treatment & Management continued…

• Appointment of qualified staff & Training to staff for their skill

improvement. Improvement of pay-package, incentives , stern action
against employees who were indulged in malpractices.
• CETP started focuses on how to manage and monitor the different
units/industries of ETP, Improved Competence of their field staff and
Laboratory staff on how to collect, sealing and preserve samples from
different units of ETP and send it to the laboratory for analyzing, which
parameters have to be analyzed, how frequent sample has to be taken from
different industries etc,
• With consistent follow-ups by CETP and rounds of meetings, several
member industries developed plans, constructed and enhanced treatment
facilities in their ETPs.
 Improving Effluent Treatment & Management continued…

• Knowledge Development of Effluent Treatment - The CETP arranged

several workshops and Seminars for the Member industry owners and
management, where representatives from ETP designers and suppliers
provided know-how and latest technological solutions to those who
already have an ETP and facing problems regarding operating and
monitoring ETP and also to member industries who are intending to install
new treatment facilities in their own industry.
• Arranged internal visits to the best performing industries in terms of
Effluent treatment management.
 Improving Effluent Treatment & Management.. Contd…

• Determining effluent characteristics – Monitoring individual industries

ETP/ Zone wise performance. ( As Guided by Dr. Rakesh Kumar, NEERI)
• The CETP has been assisting these member industries by reviewing and
monitoring the operating efficiency of ETPs and also providing support in
ETP management to improve efficiency and where possible try to reduce
the running costs of the ETP.
• Visit of Executive committee member during night vigilance sampling to
support sampling chemist in case of disputes/resistance for taking sample
and also if required calling local MPCB officer to witness the facts.
• Deputed 24 hours monitoring duty of sampling chemist if industry is not
cooperating and discharge high COD effluent.
• Valuable contribution of founder Members Mr. Suresh Bhonsle ,Mr.
Mohanti & Mr. J.Z. Patil
• Appointment of technical consultant Mr. Hemant Rane .
 Improving Effluent Treatment & Management continued…

• Turning Point
• During Dec- 2014 , Executive Body, CETP took vital decision to evaluate
individual ETP performance by doing Stage-wise sampling and analysis.
• This resulted into identifying of poor performing & defaulter industries.
• These industries pressurized for the up gradation of ETP Management
systems in their Units.
• Most of the identified and defaulter industries improved their
performance. This resulted into substantial reduction in Organic load .
• CETP Management has taken stringent actions on industries who has still
remain defaulters and name of such industries notified to MPCB for
further actions.
• Within six months CETP inlet COD drastically reduced from the range of
1500 to2000 ppm to 700 to 900 ppm ( April 2015 onwards)
• Since last one year treated effluent norms maintained as per consent
limit
 Improving Effluent Treatment & Management..
Contd…

• Weekly Executive body meeting to review MMA CETP performance and

resolve operation and sampling team issues.
• Calling defaulting industry in weekly executive body meeting and, taking
action plan for improvement, in case repeated violation reporting to MPCB
for further action
• Joint Analysis In case of deviation/difference in MMA CETP and member
industry reading - Giving chance for Joint analysis of sealed sample and
consider that analysis for billing purpose.
• Appointment of ISO consultant to implement Quality management
systems, Environmental & legal compliance, Health & safety practices.
• Incentive scheme for best performance of staff through performance
appraisal system.
• Involvement of Sr. NGO Dr. Patwardhan for their valuable inputs.
 Management
Built up strong team to combat the pollution
• Executive Committee Members-11
• Technical Committee-4,
• Sampling & Vigilance team-4,
• General Manager-1
• Plant Operations’ Manager-1,
• Mechanical Engineer-1
• Environmental Officers- & Chemists – 8,
• Operators-11,
• Technicians-4,
• Senior Account-1,
• Office staff-3,
• Operation Helpers ( from surrounding villages) --30
 Improved performance from year 2015

• Effluent color Almost colorless.

• Inlet COD 700 to 900 ppm
• Inlet BOD 100 to 150 ppm
• Outlet COD 190 to 250 ppm
• Outlet BOD 50 to 90 ppm
Incoming Effluent Color before & and after
Effluent Color Before & After at bio-tower
Effluent Color Before & After at Disposal point
Disposal point down stream
 Average Stage Vise COD Reduction year
2015
1800

1600

1400

1200

1000 In let eff. COD mg/lit

800
A.Primary COD mg/lit
600
Secondary COD mg/lit
400
Tertiary COD mg/lit
200

0
JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC
 Average Stage Vise BOD Reduction for year
2015
600

500

400

300 Inlet eff. BOD mg/lit

200 A.Primary BOD mg/lit

Seconday BOD mg/lit

100

Tertiary BOD mg/lit

0
JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC
 100
150
200
250
300
350
400

50

0
1/5/2015
1/15/2015
1/26/2015
2/9/2015
2/16/2015
3/2/2015
3/16/2015
3/30/2015
4/13/2015
4/20/2015
5/5/2015
5/18/2015
5/30/2015
6/8/2015
6/18/2015
6/29/2015
7/13/2015
7/20/2015
7/27/2015
8/3/2015
8/5/2015
8/17/2015
8/27/2015
9/7/2015
9/18/2015
9/28/2015
10/12/2015
10/26/2015
11/16/2015
11/30/2015
12/14/2015
12/29/2015
COD outlet
BOD outlet
MPCB RESULT FOR YEAR 2015 OF CETP

MPCB Results year 2015

MPCB Results year 2015
 MPCB RESULT FOR YEAR 2016 OF CETP
300

250 240 240

224
216
208 208 210.4
200
200 192 192
184

150
MPCB REPORT 2016 OUT LET BOD
MPCB REPORT 2016 OUTLET COD
100 90 90 90
80 80
72 70 73.2
60
50 50
50

0
 ROLE OF MEMBER INDUSTRIES IN IMPROVING
CETP PERFORMANCE
• Few of Large scale & RED category Industries upgraded their ETP by using
new technology like MEE, RO, aeration systems and thus started recycle
and re-use of effluent in their own plant/ processes resulted organic Load
as well reduced the hydraulic load to CETP.
• Member industries started fall in line as per direction given by Hon. High
Court i.e synchronization of products
• Few of the Industries adapted the Waste to Wealth concept and thus
converting their wastage in to the by-product and reusing in-house or
selling as byproduct to the other need industries for their actual uses. This
lead to reduction in TDS levels
• The industry like H. acid manufacturer which was using spent acid for the
isolation, generated gypsum and iron oxide sludge is selling to the cement
and still manufacturing industries.
 Key of success
• Timely Repairs of damaged chambers on effluent collection lines by MIDC
to avoid storm water leakage and to reduce hydraulic load on CETP.
• MIDC Focused on preventive maintenance of effluent lines from CETP to
Ovale.
• Executive engineer MIDC has always played vital role between Khadipatta
public and CETP body to improve communication and relations.
• Actions considered and improvements made as per guidelines of Dr.
Rakesh Kumar from NEERI during DPR to do the backward integration of
incoming COD load.
• With the support of local MPCB officer and MMA CETP joint visits are
conducted to Defaulting units.
• Quarterly review meetings with Local Govt. authority , SRO & RO- MPCB,
NGO to review public complaints due to pollution problems in MIDC and
Khadipatta and to tackle the issues at local level.
 Action Taken in 2014-2016
 First in Maharashtra to Install Online monitoring system as per CPCB guidelines.

 Modified the Laboratory by providing/up-grading the testing equipments with qualified chemists.

 Segregation of MIDC residential colony sewage with separate line and connecting directly to
aeration for Bio-Mass seeding.

 Nine number of sumps have been constructed at different location in order to monitor the
pollution levels.

 Treatability study of incoming effluents in context to change in the characteristic of the

incoming effluent

 Enhancing the operation and monitoring by integrating the advanced instrumentation.

 First in Maharashtra (2nd in India) to qualify for IMS certification for effective
implementation of QMS , Environment, Health & safety for efficient quality
operations.
(ISO-9001:2008, ISO-14001:2004 & OSAH-18001:2007) certificate is granted by ICS
certification body
 Social Activities

A. Providing drinking water to Khadipatta Villages

through MIDC and reimburse 90% payment.
B. Financial help to schools for e-learning.
C. Provided free mobile hospital facility to all villages in
Mahad.
Permanant Mobile hospital Seva to surrounding
Villages & Adivasi Vadi Areas for Mahad Taluka
Permanant Mobile hospital Seva to surrounding Villages
& Adivasi Vadi Areas for Mahad Taluka
Permanant Mobile hospital Seva to surrounding Villages
& Adivasi Vadi Areas for Mahad Taluka
Impact of best MMA CETP performance
• Villages covered in ecosensitive zone passed resolutions to
delete their name from the ecosensitive zone list and
supported for expansions and inviting for new industries.
• Surrounding peoples started involving in various industrial
welfare programs.
• Due to scientific approach and best performance of CETP
students from various universities approaching for academic
project work under guidance of our tech experts e.g. recently
Mr. Amit Late from MPCB FO has been published his research
paper on process of Sodium sulphate recovery in the
international conference of Water Environment, Energy &
Society at Bhopal.
• Started giving respect to industry
Support Required from MPCB/MIDC for Sustainable
Development of Industry

 ECO sensitive zones to be reconsidered to enhance the Industrial growth

in Mahad MIDC.
 For the Development of the Mahad Industrial area permission to new in
coming industries.
 Additional /standby disposal line required from Village Muthavali to
Ovale village and extension of the line to the saline zone as per reports
given by NIO. Proposal is under process with MIDC but need to speed up
Video Clip

VID-20160302-WA0002.mp4
Future plans.. Journey towards Sustainability
A. Treatability study with new MBR technology to
increase MMA CETP capacity for industrial growth.
B. Provide support for sewage treatment of Birawadi
village.
C. Set up compost plant in MMA CETP for canteen
waste disposal of all industry and other
biodegradable waste in surrounding.
D. CSR activities for surrounding villages.
 OUR GOALS

Continuously achieve MPCB prescribed norms

1
2 Conservation of the natural resources
3 Work to achieve the Golden point
for balancing of ECO system
4
5 Safe planet for coming next Generation
6
Provide Green environment to the society

Seven Billion Dreams.

One Planet.
Consume with Care
• Backup slides
We work together
 Action Taken in 2010-2015
• Installed high efficient aeration system by providing 9 Nos. of aerators (Total 270
H.P.)with cost of Rs: 65 lacs,
• Revamping of Chemical dosing system with cost of Rs: 15 to 20 lacs,
• Civil work of receiving sump’s pump house & sump enclosed wall jacketing with cost of
Rs: 15 lacs, to arrest the leakages of receiving tanks.
• Modification of Bio Tower, Flocculater & Scrappers in Primary & Secondary clarifiers
with cost of 4.5 lacs,
• Revamping of sand filters with cost of Rs: 2.5 lacs,
• Replacing old pipe lines with cost of Rs: 5lacs,
• Segregation of low COD effluent of 2.5 MLD & feeding to tertiary treatment .
• Installed 2 number of sound proof and energy efficient air blowers of 37kv each of Atlas
Copco make. In this case we save 30-40% energy of air blowers in Jun 2014
• Dissolved oxygen level increased from 0.7 to 1.5 ppm.
• Improved F/M Ratio from 1.5 to 0.9
• Optimized the Dosing Pumps capacities in Chemical House to improve the Physico
Chemical Treatment in Jan2015
• Replaced old inefficient pumps by Screw Pumps in Primary & Reaction Clarifiers and
Sludge Thickener for de-sludgeing
 Success story of Industries
PHOTO GALLARY: ETP, MEE & Spray Dryer
Crocodile at the CETP Disposal point