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ICI KHEWRA
BY
DEPARTMENT:
YEAR 2006
ANALYSIS OF WATER EXTRACTION PLAN FROM THE RIVER BED FOR
ICI KHEWRA
1. INTRODUCTION
The ICI plant was established in 1929 at Khewra, district Jhelum and commercial
production began in 1944. The original plant capacity of 18,000 tones of soda ash has
been increased to 225,000 tones per annum by 2007, through a number of expansion
projects. The most recent modernization and expansion was carried in 2002. The
Company is again planning to invest Rs 915 million in the Soda Ash Plant to expand the
plant capacity by 500000 tones per annum. ICI Pakistan's Soda Ash plant is currently
meeting about 75% of the country's requirement for Soda Ash by using locally made
equipment and raw material, and providing savings to the nation's foreign exchange
reserves.
ICI require large quantities of water for various industrial operations. For the present
time water is being extracted from two major sources; one is Watli spring and the other is
river Jehlum. Wells are installed at the bank of river Jehlum in Bella field having 12” to
18” diameter and depths of 30 to 40 feet. ICI is getting 2000m3/day from the wells
installed at Bella field. Due to expansion of Soda Ash plant ICI require 4000m3/day
water.
Bella field
Proposed
wells
Existing wells
Normal
flow
Sweet water aquifer
Moved interface
2. PROBLEM STATEMENT
The ground water is saline due to salt range in the area. A small thickness of sweet water
aquifer is available in the Bella due to recharge from the river. Due to extraction of sweet
water from the wells installed in the Bella, the interface between the saline water and
sweet water has moved upward and towards the sweet water .Now due to lateral and
vertical up conning of saline water some of the wells in the Bella field have been
abandoned. ICI plan to install some new wells in the river bed near the bank to meet the
additional water demand. Skimming wells are planned due to limited sweet water zone
and small thickness of the sweet water aquifer, to extract the sweet water induced by the
recharge from the porous bed of the river.it is considered thet the lateral flow from the
river Jehlum due to better transmission characteristics of river bed material will minimize
the risk of salinization and abandonment of proposed wells. A half trapezoidal dike will
be constructed and proposed wells will be installed on top or land ward side for easy
access and pretension from damage against river floods.
Delivery pipe
Pump
Fresh water
Upcoming of
saline water
Saline water
3. OBJECTIVES
3. Formulate a 3-D numerical model to analyze well pumping and salt intrusion.
4. Analyses of the proposed water extraction plan in terms of depth and spacing of
the wells to provide protection against the lateral and vertical intrusion of the
saline water.
4. LITERATURE REVIEW.
According to C. Langevin & E. Swin 2005, SWIFT2D surface-water flow and transport
code, which solves the St Venant equations in two dimensions, was coupled with the
SEAWAT variable-density ground-water code to represent hydrologic processes in
coastal wetlands and adjacent estuaries. A sequentially coupled time-lagged approach
was implemented, based on a variable-density form of Darcy's Law, to couple the surface
and subsurface systems. The integrated code also represents the advective transport of
salt mass between the surface and subsurface. The integrated code was applied to the
southern Everglades of Florida to quantify flow and salinity patterns and to evaluate
effects of hydrologic processes. Model results confirm several important observations
about the coastal wetland: (1) the coastal embankment separating the wetland from the
estuary is overtopped only during tropical storms, (2) leakage between the surface and
subsurface is locally important in the wetland, but submarine ground-water discharge
does not contribute large quantities of freshwater to the estuary, and (3) coastal wetland
salinities increase to near seawater values during the dry season, and the wetland flushes
each year with the onset of the wet season.
Telford, et al., 1976 states that electrical geophysical prospecting methods detect the
surface effects produced by electric current flow in the ground. Using electrical methods,
one may measure potentials, currents, and electromagnetic fields that occur naturally or
are introduced artificially in the ground. In addition, the measurements can be made in a
variety of ways to determine a variety of results. There is a much greater variety of
electrical and electromagnetic techniques available than in the other prospecting methods,
where only a single field of force or anomalous property is used. Basically, however, it is
the enormous variation in electrical resistivity found in different rocks and minerals that
makes these techniques possible.
In South Africa, pumping tests are performed for mainly two reasons: to determine the
long-term sustainable yield of a borehole and to estimate aquifer parameters. The manual
highlights the non-linear relationship between the abstraction rate and the drawdown,
which is common in most South African aquifers. Fracture dewatering is dependent on
the abstraction rate, which, in turn, will have an effect on the water level in the borehole.
This feature should be treated with caution when assigning sustainable yields. (Report No
1116/1/02, 2002)
According to Natural resources Canada 2004, the resistivity measurements are derived
from the waveforms received during the constant current 'on' time of the square
waveform, after the initial IP charging effects are over. Resistivity measurements are
made with the same arrays as are used in the IP measurements. Single point resistance
measurements can also be made using a single downhole current/potential electrode (Pb)
and a return/reference electrode on the surface.
As per Alberta Government 2004, In some areas of Alberta, drillers frequently access two
or more aquifers through one well. This is done to provide a higher well yield and to
ensure a more reliable water supply. This is ONLY done for domestic wells where there
is little water available. However, analysis of pumping test data can only evaluate one
aquifer, not two or more simultaneously. The two-hour minimum pumping test gives an
overall pumping rate, but values of Q20 for each individual aquifer cannot be reliably
determined if more than one aquifer is accessed by a single well. Each aquifer should
have its own well and independent pumping test to learn the safe yield. During many
two-hour tests conducted on domestic wells during drilling operations, a bailer is used
instead of a pump. A bailer does not provide the constant and measured flow rate of a
pump. In this circumstance, only recovery data can be obtained to estimate transmissivity
values. Production with compressed air during drilling or following well completion is
another way of conducting a test that uses recovery data. Transmissivity values calculated
only from recovery measurements are less reliable than those obtained from a formal
pumping test where drawdown and recovery measurements are taken. Aquifer parameters
derived from short-term recovery tests performed during, or immediately following,
drilling operations aren't very useful, but they do provide preliminary estimates of the
transmissivity and yield of the aquifer zone.
5. METHODOLOGY
1. Collection of the pumping test data for the project area and for the river bed and its
analysis to:
o Find the location of interface between the sweet and saline water.
3. Formulation of discharge & salt flow model using MODFLOW and MT3D.
o Using the parameters of the aquifer and the prevailing conditions of the
project area in the MODFLOW and MT3D to get the maximum discharge
o To determine the no of wells, capacity of wells and the distance between the
4. Calibration of the Model. Analysis of the present & planned layout of wells
5. Suggestions about the perfection of plan and future salt intrusion concentrations.
Analysis of the proposed water extraction plan from the river bed
whether it will work properly or not, to match the requirements of ICI to fulfill water
needed for the industrial operations now increased demand due to expansion in the works
of ICI.
5.2 Background:
The original plant capacity of 18,000 tonnes has been increased
to 225,000 tonnes per annum, through a number of expansion projects. The Company is
currently investing Rs 915 million in the Soda Ash Plant to expand the plant capacity by
50,000 tonnes per annum and will result in improved operating efficiencies and higher
productivity. For the present time water is being extracted from two major sources; one is
Watli spring and the other is river Jehlum. Wells are installed at the bank of river Jehlum
in Bella field of 12” to 18” diameter and are of depths 30 to 40 feet. From the wells
installed at Bella field ICI is getting 2000m3/day.Due to expansion of Soda Ash plant ICI
require 4000m3/day water.
Pumping test data for the site to evaluate the aquifer parameters. Electric
resisitivity survey to find the interface between the saline water and fresh water.
MODFLOW simulates steady and nonsteady flow in an irregularly shaped flow system
in which aquifer layers can be confined, unconfined, or a combination of confined and
unconfined. Flow from external stresses, such as flow to wells, areal recharge,
evapotranspiration, flow to drains and flow through river beds, can be simulated.
Hydraulic conductivities or transmissivities for any layer may differ spatially and be
anisotropic (restricted to having the principal directions aligned with the grid axes), and
the storage coefficient may be heterogeneous. Specified head and specified flux
boundaries can be simulated as can a head dependent flux across the model's outer
boundary that allows water to be supplied to a boundary block in the modeled area at a
rate proportional to the current head difference between a "source" of water outside the
modeled area and the boundary block. In addition to simulating ground-water flow, the
scope of MODFLOW has been expanded to incorporate related capabilities such as solute
transport and parameter estimation.
6. UTILIZATION OF RESEARCH.
This Study would aim at evaluating the implementations of universal MODFLOW and
MT3D model for the correct implementations of ground water extraction problems.
8. REFERENCES
Terzaghi, K., and Peck, R. B., “Soil Mechanics in Engineering Practice”, John Wiley
& Sons, 1967.
“Ground Water and Wells”, UOP Johnson Division, St. Poul, 1966.
9. COMMENTS OF SUPERVISOR
Ground water modeling is a useful tool to analyze and evaluate ground water
and solute flow hydraulics together with interaction to boundaries. Well system require to
be sustainable in terms of water yield , water quality and damage by floods etc. this study
will analyze a special water extraction system for ICI Khewra site and will be helpful in
designing successful water extraction plans for industrial and municipal purposes
elsewhere.
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Signature of Supervisor Signature of Student
No. CEWRE/Acad/06/
Dated: ---------------------
The above proposal duly recommended by the Centre’s Board of Studies on its meeting
Engineering and Technology, Lahore for obtaining the approval of the Vice Chancellor.
DIRECTOR, CEWRE