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    © All Rights Reserved
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    12 views21 pages

    20170328065134

    Uploaded by

    Yakshagna Divve

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    INTRODUCTION M/S PEPSICO INDIA HOLDINGS, SANGAREDDY, is a unit bottling beverages up a unit for manufacturing bottled juices and soft drinks. The manufacturing process con: +3 of making sugar syrup, filtering it and mixing it with soft drinks concentrate and water. The mixture is carbonated and filled in bottles. In case of juices, fruit pulp, sugar syrup, and water are mixed before bottling but no carbonation is done. The generation of effluent is due to bottle washing in 3 stages, cleaning in place (CIP) caustic drainage, filter cloth, floor and vessel washing which is done on a dai, sasis, The present plant had been upgraded to handie 2: effizent quantity of 900 Ki/Day. The Factory had proposed to set up additional facilities for nici2esed capacity by using pet lines of higher capacity. The glass lines required a bottle washer where as pet lines used only clean water rinser. As the pet bottles were uncontaminated and not recyclable. the rinsing water was being recycled back iv.» the plant thus c«.nserving water and reducing the quantum of effluent generated. The ETP had been upgraded to treat 900 ki/day of this 600 kI/day was being discharged un land for irrigation and 300 ki/day was being treated in a tertiary treatment unit and recycled back into the piant for utilites . The total quantity of effiuent generated from bottle washing, syrups and vessel wash, bottling equipment, vessel and floor wash etc. had been segregated into a high UUD stream and a low BOD stream. The plant is to receive a flow of about 565 KL/Day from the high BOD stream with a BOD of 1265 mg/l and about 480 KL/Day from the low BUD stream with 2 BOD of 400 mg/l. The plant is now to be upgraded to handle a flow of 1045 KL/Day. It was previously observed that while the analysis of high strength waste was more at peak flow but average nearly conformed with the design data , the low strength wasi2 was much stronger than the data for which ine plant wes designed .Thus this was affecting the performance of the plant during ** seak season, The observations made at site indicated that 3 ta:ge quantum of product rejection is being drained to the effluent treatment plant through t%se tow strength drain as well. Apparently a pre treatment facility has been provided at site which is treating rejected slice along with sewage. Post this treatment the effluent is conveyed to the ETP. The effluent treatment plant shall be upgra:)+1 for the increase! load. all product rejects will be drained only to the pre treatment facility, where It shall be anaerobically degraded with sewage and overflow of this facility shall be conveyed to the equalization tanks of the ETP. vol Bees 7 Tou Anots¥'C SH aS, _ dolo- Lomi Pe 2 gle The list of units for the effluent treatment plant is as follows:~ Sr.No. Unit Dimension Remark a Screen Chamber-! 12mx0.8m Existing | 0.54 KL 2 | Equalization Tank-l(2Nos.) Ab, [22mx 40mx25mswd | Existing | 924 82= 64 2A_| Equalization Tank-1 4. mx2.Giax2.5mswd existing [26.5 ¥L 3 _| Anaerobic Digester B55 mswd Existing | COOK. 4 | Recirculation Sump Smx25mx25mswd | Existing | TSZT5 KL. 5 | FatTrap 3mx6.6 nx 2.5m swd Existing | S| Z- 6 Equalization Tank-I 5.5 mx5.5mxz2.5.nswd Existing 4qs.62 7 | Equalization Tank-Il! You} |8Mx6.5in yom Swi | Propored | A1G kL B [AnoxieSelector Chambord pe [2mx2mx25mswd | Proposed we 9 | AnoxicSelector Chamber-l ZC [2 mx2mx2.5mswd Pr Wo eration Tankcl — [15m dia 3.5 m awd Bing SLE Fai | Aeration Tank-it iSmdia3.5mswd Proposed | g°9--$ 12 | Secondary Clarifier yp Smdia3mswd Existing | 27 13. | Flash Mixer», Zemx25mx25m Existing | 45.625) 14 | Clariflocculator, > ‘9m dia 2.5 mswd ) 20.5 15 | Treated Effluent Sump amx4mx5m Z go 16 | Pressure Sand Filter 1.2 m dia 2.0 m ht Existing 2h 17 _| Activated Carbon Filter 1.2 mdia 2.0 mht Exi 2G 18 | Softner jim dia ZOm ht Existing 29 19 | Filter Press 0.75mx0.75 m Existing | (30 Plates) 20 | Filter Press | 0915 nx0015m Existing | Plates) 21 | Sludge Drying Beds (4 Nos.) 4.5mx4mx0.7 mswd Existing 22. | Sludge Collection Sump 25mx2.5mx25m Existing The average flow & characteristics of raw effluent collected from the high 80D stream are as follows: Parameter Value ee Flow 565 m'/day : pH 7 i cop 3795 mg/l BOD 1265 mg/l Total Dissolved Solids 1437 mg/l The average flow & characteristics of raw efflusr:t collected from the iow BOD stream are as follows: Parameter Voone Flow ee 480 m*/4ay pH a 8 cop 1200 me/| BOD ii 206 mg/l Total Dissolved Solids 1050 ma/l 12-6 IS.625 The Standard’s for discharge of treated efflucnt on land z* - as follows: Parameter Range Of Values pH between 60to8S BOD ie ~~ 30 me/l cop ee ~ |< 250 mg/l TSS 7 < “100 me/l Oil & Grease < 10 mg/l SCHEME OF TREATMENT The existing facilities will be upgraded to treat 900 m?/ day by Zeeweed WiBR — Membrane Bio Reactor. Screen Chamber-t:-(Existing) A bar screen of dimensions 1.2 m x 0.8 m x 0.& hias Neer ‘stalled at the inlet of the high BOD stream. It is in the form of stainless steel fla:s with : mm gaps or openings which are installed in screen chamber to retain extraneous materials such as bottles, caps, packing material etc. from entering the Equalization Tanks. Equalization Tanks:-(Existing) The effluent flows from the floor drains to the screen chamber. The effluent is being transferred to the Equalization Tanks by gravity. Equalization Tanks 2 nos of size 8.20 m x 4.0 m x 2.50 m swd and one no. of 4.19 rm x 2.0 m x 2.50 m swd have been provided. The third tank has been provided to handle peak loads such as draining of rejects to be fed gradually during dilute effluent periods. A Compressed Air-Grid has also provided in the Equalisation Tanks to diffuse air in the effluent using the Air-Blowers. A Twin-lobe rotary Air-Blower of 150 cum/hr @ 0.4Ke/sq.m are provided to diffuse air in the Equalization Tanks. The two Equalization Tanks are being operated batch-wise. Each batch handles about 3 hours of flow. The rate of transfer as restricted to 28.25 m*/hr. ‘The Equalization Tanks are coated with epoxy paint on the internal surface of the Tanks. The Equalization Tanks are provided to equalie, neutralize nd pre aerate the effluent. The following functions are achieved in the Equstis tun tanks. a. _Equalisation of quality and quantity of e“iiuené thus preventing shock loads to subsequent treatment units. b. —_Expelling of volatile matters if any. c. _Neutralisation of effluent batch-wise if necessary to maintain pH of effiuant between 7 to 8 as it enters the su'isequent biologic. trectment units. d. Prevent septicity from settling in the effluent. e. To facilitate pumping of effluent in the Upflow Anaerobir Filter at a uniform rate. The compressed air requirement is 820 Ipm in each of the Tanks. There are Air-Blowers of capacity 150 cum/hr @ 0.4 kg/cm to provide for compressed air in all three Equalization Tanks. Two numbers of horizontal centrifugal self priming non-clog Pumps and motor sets of capacity 25cum/hr @ 12 m head have been provided to operate in parallel and co transfer the efiluent from the Equalisation Tanks into the Upflow Anaerobic Filter. A bye ass arrangement is provided to re-circulate tl »ffluent back into the Equalization Tank and cause mixing .The pumps are capable of handling. raximum particle size of 10mm Each Equalization Tank holds about 3 hrs of effluent. 1 batch of effluent is being collected will be collected while the other batch is being pumped to the Upflow Anaerobic Digester is restricted to a maximum of 28.25 cum\ir. There is also a which shall be made to dose Urea & D4P in the equalization tanks to maintain a BOD:N:P ratio 100:1:0.5 in accordance with the requirements of the subsequent anaerobic treatment units. A provision of dosing shall be made with the help of a dosing tank , dosing pump & a geared agitator mechanism. Upflow Anaerobic Filter:~ (E ing) ‘An Upflow Anerobic Filter of size 12 m dia & 5.5 m swd has been provided. The Anaerobic Fis maintaing a high concentration of biomass on the surface of poly prypylene media through formation of microbial layer. The effluent flows upwards through a film of sludge. At the top of the reactor separation between gas-solid-liquid takes place. This process is adopted especially ies sigh 80D soluble wastes, The organic loading rate for the Upflow anaerobic sludge is 2.5Kg COD/m*/day and the efficiency for 80D / COD removal is about 60%. The supernatant fron: the Upflow Anaerobic Filter is passed on for aerobic bio degradation in the second stage f biological treatment. Upflow Anaerobic digester uses an anaerobic process whilst forming a film of sludge on the surface of media in the tank. Wasic.vater flows upwards through the bio film layer and is processed (degraded) by the anaerobic microorganisms. The film formation permits a very high mean cell residence time for lower retention time. Solids requiring a high degree of digestion can remain in the reactors for periods up to 90 days. Sugars dissolved in the liquid waste stream can be converted into gas quickly in the digester. The reactor itself is RCC in circular space-saving design. Recirculation sump:- (Existing) The overflow of effluent from Upflow filter Is flowing by gravity into the recirculation sump of size 2.5 m x 2.5 m x 2.5 m swd with recirculation pumps of capacity 60 m*/hr @ 12 m head the pumps are provided to maintain Upflow velocity in the filter the transfer of effluent will happen to the intermediate equalization tank by over flow from the sump where as recirculation will happen at riring velocity of 1m/hr. The oil is being trapped on the surface of the fat trap by providing quiescent condition and providing laminar flow. The fat collected at the oil trough is being pumped to the oil collection tank using a gear pump. The recovered oil is being stored in the factory. Normally oil is not expected in the effluent from the plant however cit may come from tre oil ring vacuum pump and boiler house is being trapped in the fat trap & the fat recovered is being stored and disposed to a notified hazardous waste disposal site The overflow effluent from the outlet launder of fat trap shall flow by gravity to the equalization tanks Il & III from where it is being pumped to the subsequent treatment units. The dimensions of the fat trap are 3 m x 6.8 m x 2.5 m. The effluent is neutralized to a pH of 8.0 by dosing the requisite quantity of acid & alkali in the Fat Trap. A provision of dosing shall be made with the help of a dosing tank, dosing pump & a geared agitator mechani: m Gear Pump For Evacuating Fat From The Fat Trap Fat Collection Trough:-_ (Existing) Aself priming, bi-directional, positive displace»nent Rotary *ump of capacity 1.0 cum/hr @4 kg/cm sq pressure. The pump is in all stainiess evec! (SS - 136) construction with dry - teflon coated DU bush bearing requiring no tui icaticn. The pump is easily cleanable, easily maintainable in 3 - piece construction. The back cover is removable. The right angle mounting brackets facilitate foot mounting of the Pump on base plate with electric motor of appropriate ratings. Make suggested ROTODEL gear pumip :yne 'HGSX' 040. Equalization Tanks:- (Existing & Proposed) The effluent flows from the floor drains to the screen chamber. The effluent is being transferred to the Equalization Tanks by gravity after the oil is removed in the fat trap. An Equalization Tank of size 5.5 m x 5.5 m x 2.50 m swd is existing and one no. of 8 m x 6.5 mx 3 m swd is proposed to be provided. A Compressed Air-Grid has also provided in the Equalization Tanks to diffuse air in the effluent using the Air-Blowers. A Twin-lobe ‘0 rotary Air-Blower of 125 cum/hr @ 0.4kg/sq.cm is provided to diffuse air in she Equalization Tanks. The rate of transfer as restricted to 28.25 m?/hr. The Equalization ‘Tanks are coated with epoxy paint on the internal surface of the Tanks. The Equalization Tanks are provided to equalize, neutr e and pre aerate the effluent. The following functions are achieved in the Equalization Tanks. a. Equalization of quality and quantity o/ «ffiuent thus preventing shock loads to the subsequent treatment units. b. _Expelling of volatile matters if any. . _Neutralisation of effluent batch-wise if necessary to maintain pH of effluent between 7 to 8 as it enters the sul ment units, -equent biological! tra. d. Prevent septicity from settling ir tie effluent. . To facilitate pumping of effluent in the Anoxic Selector Chambers at a uniform rate. The compressed air requirement is 750 Ipm in Equalization Tank-li & 1530 Ipm in the Second Tank. There is an Air-Blower of capacity 125 cum/hr @ 0.4 kg/cm to provide for compressed air in both the Equalization Tanks. ‘Two numbers of horizontal centrifugal self priming non-clog Pumps and motor sets of capacity 50 cum/hr @ 12 m head have been provided & 1 no. of 50 cum/hr @ 12 mis proposed to be operated in parallel and to transfer the effluent from the Equalization Tanks into the Anoxic Selector Chambers. A bye pass arrangement is provided to re- Circulate the effluent back into the Equalizatic: ix and cause mixing .The pumps are capable of handling a maximum particle size of £3 m Aeration Tanks | & Iz: (Existing & Proposed) Aeration Tank | of size 15 m dia & 3.5 m sw with 3 Nos Of 10 iP Aerators is existing. Aeration tank of around 900m3 is proposed with diffused Aeration system for efficient air transfer. Membrane Tan! Effluent from Aeration Tanks shall be transferred to Membrane Tanks. 1.4 Process Description Treated wastewater from UASB unit enters the Membrane Bioreactor and ZeeWeed" MBR System In the distribution channel all incoming wastewater will be combined with the recirculation sludge from the membrane filtration stage. influent wastewater and re-circulated sludge will enter the aeration tank by gravity, Aeration tank will be monitored and controlled for pHt via injection of caustic, Biological process blowers and fine bubble diffusers in the aerobic tans shall provide the oxygen required for the biological process as well as the mixing energy required te keep the mixed liquor in suspension. Dissolved oxygen shall be monitored in each aerobic tank to achieve a desired set point of 2 mg/L. ‘The mixed liquor shall overflow by gravity from the biological tanks to the membrane tanks where the solid/liquid separation takes place by means of the vacuum created by the process pumps. The permeate shall be stored in the permeate storage tank. The mixed liquor from the end of the bioreactor aerobic zone shall proceed by gravity to + the membrane filtration basins. At the outlet of each aerobic tank and inlet of each filtration basin there shall be an isolation valve. Flow shall proceed by gravity through the valve. The sluice gate valve/isolation ‘ele can be used to either isolate of the membrane tank (ie. during cleans). Plant. demarsi shaii e controlled by the feed flow into the system and can be trimmed by the 1 the bloreactor/membrane tank, One permeate pump per membrane train sheti be employed to draw water through the membranes. Treated water shall flow from the permeate pump to the final disposal point. Under normal operation and average day flow conditions, pestaration Is stopped for a specific period of time at regular intervals. This membrane relaxation period, combined with air scouring, effectively remove: solids that have ac-umulateti on the membrane surface or within the fibers and ree electrical costs Same permeate pump with vaiving arrangement shall be provided for backpulsing the membranes. From membrane tanks, Permeate pump shall draw treated ef‘luent through the pores of the membrane fibers and into the backpulse tank. Once full, the treated effluent is automatically diverted away from the backpulse tank to a final disposal point. Clean water (permeate) is suctioned through ZWSOOD membranes by centrifugal permeate pumps. ‘The membranes shall be air scoured with required capacity of membrane aeration blowers fitted with Mechanical Variable speed drive or with pulley arrangemer. Waste activated sludge (WAS), shall be removed to the sludge handing facilities via a side stream on the discharge from the membrane tank by pumping in a controiled manner. Further details of the system design are provided below in the following sections. 1.2 Major Process Components for MP‘ system Mechanical Fine Screen -2 mm ( Punched # hw s.«ifigurailon) GE W&PT requires that the following screening requirssaents are met: Screen raw wastewater with <2 mm punch zole int¢:"s1ly fed rotary drum screen or centre flow travelling band screen or fine brush screen. Design notes: All screen openings are punch hole (dimensions in two dictions}. Bar or wedge wire fine screens are not acceptable. . Alternative screens and/or pre-treatment methods must be approved by GE W&PT in writing; otherwise membrane warreiiy may be void oO o Bioreactor tank 6 Fine bubble diffusers for aeraate tanks © Instruments such as DO meter Biological process blowers logical process chemical feed system Membrane tank with accessories for installing UF membrane ‘A tmembrane train” is @ treatment unit consisting of multiple “cassettes” that art manifolded together, Installed in a concrete OF ‘teal tank (ie, membrane tank) and connected to a common permeate PUMP: Within each membrane tank, the cassettes 3°° connected to permeate header and air supply header(s). The permeate header convey permeate from the cassettes to the permeate pump suction and also delivers egning solutions to the inembranes: The air readers deliver air to cassette aerators for alr scouring to prevent solids accumulation ‘on the membrane surface Design notes: 4,puddle pipes inside membrane tank to canes or SRP. MSis not acceptable. 2, Membrane tank accessories required ‘0 install riecnbranes like beams, brackets, hangers, hold pins to be minimum SS304 grade. 3, permeate header should be $5304L (iinimum) inside membrane tar and FRP, PVC, ‘HDPE on permeate /backpulse pumps suction and discharge. UF membrane We have offered ZWSOOD memren= modules and cassettes and the technical data of the same is highlighted in seco 1 above. In the ‘Zeeweed MBR process, the 4.Biolagieal reactor 2.Membranes 5.Permeate pump & air blower 4, Control pane! 15, Permeate & air piping membrane cassettes are immersed directly in the mixed liquor in the membrane tanks, The 3D drawing above (example) shows the main components of an MBR system Permeate pumps/back pulse pumps (process pumps) with VFD The mernbrane cassettes in each tank shall be connected to a permeate header, which in turn shall be connected to the suction of a Permeate/Backpulse Pump. This set of cassettes, the piping, and the pump is referred to as a membrane train. The vacuum generated by the Permeate Pump draws permzrte from the outside in through the membrane fibres. All Permeate/Backpuls: guys uischarge into a common permeate collection header. All the trains in the plant are operated with a repeating filtration cycle. It consists of two phases: permeation (drawing) of water through tie membranes followed by a short period of reverse flow (backpulsing) or relaxation (no flcx:}. For the proposed ‘membrane filtration system the same pump will be used for permeate and backpulse necessary valving arrangement Pump parts and MO Casing 2c Impeller $5316 Permeate pump priming system -Ejector system After extended standby periods or when a train is first placed into automatic control, an automated valve which connects the top of the membrane train permeate header to an ejector (shown below) and an automated valve which connects the ejector to the Air Compressor opens, The compressed air drives the ejector to create a vacuum :tat draws alr out of the train, pulling water through the membranes until water in the header hits a level switch. This indicates that both vaives can be closed to ensure the system is primed and can be placed in operation. To simplify system control the ejector configuration consists of one unit per train and is controlled by PLC. Make of ejecior should be VACCON/PIAB only, Air Scour Blowers for Membrane Aeration Whenever a membrane train is in preduction, membrane aeration blowers will produce the air scour required to removs so'icis from the membrane surface and maintain membrane permeability. A spe‘, designed and highly efficient aeration system shall be used to scour the outside surface of the membrane and move mixed liquor solids away from the membrane finres. This shall be accomplished by a GE patented aeration system that uses a factory installed aeration grid, which is integrated into the base of each ZeeWeed 500d cassette. The Integration of diffusers within the cassette simplifies the installation of diffusers and enhances the operation of the ‘membrane unit, The blowers discharge into the m-rbrane aeration r:nifolds. This manifold delivers air to the membrane distribut‘un o'r headers installed above each membrane tank (train). These Manifolds are by Customer. o ooo oO Conventional Cyclic aeration : For optimal balance between tise energy requirements ‘of the membrane aeration blowers and the amount of air scouring provided at the membranes, the system can be designed to cycle air withiss each membrane cassette (10:10 mode or 10:30 mode). Eee! cassette is equippeu with two air connections; one air connection from each cassette is connected to one of two air headers at each membrane tank, using a flexible hose. Airflow is cycled from one train header to the other (using pneumatic valves} so that half of each cassette Is aerated at a time Recirculation Pump (RAS pumps) ‘Membrane tank Drain pump The membrane tanks need to be drained for recovery chemical cleaning or other maintenance procedures. This can be achieved by using the above mentioned mixed liquor recirculation: pumps{-RAS-Pumps) or separate drain pumps may be used:— Sludge dewatering system ‘Common membrane chemical cleaning system Control equipment (PLC) Instrumentation - Pressure Transmitters, Temperature T-=asmitters, Leve! Transmitters Turbidity meter and Magflow Meter 1.3 Membrane system operation modes *, Cieaviing processes Operation modes ‘The sections below highlight the main operational, cont’, aspects and cleaning processes of the membrane system for PUMP - FROM (MEMBRANE TANK) configuration Off, Permeation and Stand-ay Modes, Off Mode In OFF mode, devices are off. However, for membrane vrotection, to ensure the membranes are submerged the feed valves are opened. When the water level is above the membranes the feed valves are closed. Filtration/Production/Permeation Mode Filtration, or permeation, consists of drawing clean water from the mixed liquor through the membrane fibers via the permeate pump. Water is produced from each train during the filtration period tor duration of 11 minutes, followed by a 30 second relaxation. The filtration duration cycle is based on GE’s extensive experience with the numerous GE's MBRs in operation throughout the world. There is permeate/process pump per train with 50% standby pump for filtration purposes. The vacuum generated by the permeate pump draws permeate from the outside-in through the membranes and discharges it to the Permeate Storage Tank. The variable speed pumps are controlled by PLC to maintain the permeate-flow demand. ‘The PLC continuously runs a PID loop for Trans Membrane Pressure (TMP) while in 1, The PLC uses the lower of the control outputs from the flow loop and TMP All the permeate pumps are controlled at the same flow set points and are complete with premium efficiency VFD rated motors +c sischarge flow meter. Maximum pump capacity for permeation 's achieved at the highest design level in the process tanks. All pump speeds will graducty ce recse as the liquid level in the process tanks decreases. If during low flow conditions this ievel drops below the design minimum, and the pumps cannot be slowed down any further, one or more trains will automatically go into standby mode. During or below average day flow conditions, all trains will be in uperation provided any trains are not required to go into stand-by mode. All permeate pumps and Mixed Liquor RAS pumps will be operating. All permeate pumps will disch: Permeate Storage Tank permeate header. ‘ye into a common pormeete collection header. The tie Sackpulse Tank are both fed from the common Cleaning and Maintenance Procedures ‘As the feed is drawn through the membranes during filtration, solids are removed which accumulate on the membrane surface. As the solids accumulate, they restrict the flow through the membranes and eventually membrane cleaning is required in order to maintain the filtered water flow rate. Membrane cleaning is absolutely critical to ensure sustainable operation over the life of the plant regardless of membrane type. GE’s MBR system Is designed with the most ‘comprehensive cleaning toolbox, which represents the culmination of years of experience in long-term MBR operation for uncompromised performance over the life of the membranes. Features include the followin Membrane Air Scouring: used 2s a mechanicai cleaning action, Seller has developed and patented the most energy nt membrane air scouring method in the industry. © Relax mode © Backpulse Ability: The ability to ensure an even distribution of chemicals across the fibers through backpulsing under presstr:. ‘his reduces the potentiai for preferential flow of cleaning chemicals. © Cleaning: The ability to clean not only the inside of the membrane surface with maintenance cleaning, but also the outside of the surface with recovery cleaning, Ability to clean quickly anc: easily through fully automated processes such as relaxation, backpulsing, maintenance and recovery cleaning; and wd ‘level approach to maintaining membrcne performance is GE's mul summarized in the following sections. a Membrane Scouring by Aeation Whenever a membrane train is in production, membrane scour aeration is required to maintain consistent permeability of the membrane. of he membrane» take ouay Tixed Liquor solids 0M membrane. ; E nt coarse Di designed hig jabble aeration is used to scour the outside Alr ma Qe Pormeate

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