06.02.

2019

06.02.2019

Rev-0 withdrawn & rev-01 commented during MOM 22-26.10.2018.

2
 CENTRALISED ZERO LIQUID DISCHARGE PROJECT
DESIGN BASIS
Client Contractor Package o Facility Doc. Serial Rev
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Name Name N Code Type N N
LIQUID DISCHARGE
PROJECT (ZLD) NMDC WABAG 54 05 15 BE 1153 1 1 / 30

CENTRALISED ZERO DISCHARGE PLANT

Stamping Area

Document Class: Approval

Discipline : Environment

1 10-Jan-2019 Issued for Review AD NP SSS

0 19-Sep-2018 Issued for Review AD NP SSS
DATE
REV. STATUS REVISION MEMO PREAPARED BY CHECKED BY APPROVED BY
DD-MMM-YY

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Electronic Filename: 10P137-B0012-1153-Process Design Basis.docx
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HOLDS

O O
Hold N Section N Description Actions

[1] 7.1 Operating and Design Pressure of Waste Client

water from Lime and Dolomite Plant

[2] 7.1 Operating and Design Pressure and Line Client

Size of Waste water to Area Sumps

[3] 9.1 Design Pressure of Utility Client

[4] 9.1 Operating Temperature of Instrument Air Client

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CONTENTS
1 Introduction ....................................................................................................................................... 5
2 Reference ........................................................................................................................................... 5
3 Acronyms and Definitions ............................................................................................................... 5
4 Plant Details....................................................................................................................................... 7
5 Process Design Basis ...................................................................................................................... 7
5.1 Characteristic of Feed Water ................................................................................................... 7
5.2 Characteristic of Final Treated Water from ZLD Plant ........................................................... 10
6 Brief Process Description .............................................................................................................. 11
6.1 Pre-Treatment Section ........................................................................................................... 11
6.2 Ultra-Filtration Section ............................................................................................................ 11
6.3 Reverse Osmosis ................................................................................................................... 12
6.4 Degasser Unit ......................................................................................................................... 12
6.5 Evaporator System ................................................................................................................. 12
7 Battery Limit Conditions ................................................................................................................ 13
7.1 Waste Water Streams ............................................................................................................ 13
7.2 Final Treated Water from ZLD ............................................................................................... 14
8 Plant Configuration ......................................................................................................................... 15
8.1 Waste Water Collection Section ............................................................................................. 15
8.2 Pre-Treatment Section ........................................................................................................... 15
8.3 Ultra-Filtration System ............................................................................................................ 15
8.4 Reverse Osmosis System and Degasser System ................................................................. 15
8.5 Evaporator System ................................................................................................................. 16
8.6 Chemical Dosing System ....................................................................................................... 16
9 CHEMICALS USED .......................................................................................................................... 16
9.1 Sodium Hypochlorite .............................................................................................................. 17
9.2 Ferric Chloride ........................................................................................................................ 17
9.3 Dolomite ................................................................................................................................. 18
9.4 Lime ........................................................................................................................................ 18
9.5 Sodium Carbonate ................................................................................................................. 19
9.6 Polyelectrolyte ........................................................................................................................ 19
9.7 Hydrochloric Acid ................................................................................................................... 19
9.8 Caustic ................................................................................................................................... 20
9.9 Citric Acid ............................................................................................................................... 20
9.10 Sodium Meta Bisulphite (SMBS) ........................................................................................ 21
9.11 Antiscalant .......................................................................................................................... 21
9.12 Dewatering Polyelectrolyte ................................................................................................. 22
10 Utilities Conditions ......................................................................................................................... 22
10.1 Instrument Air ..................................................................................................................... 23
10.2 LP Steam ............................................................................................................................ 23

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10.3 Industrial Make up Water ................................................................................................... 23

10.4 Drinking Water.................................................................................................................... 24
11 Waste Disposal................................................................................................................................ 24
12 Air Emission Control ...................................................................................................................... 25
13 Standby Philosophy ....................................................................................................................... 25
14 Process Safeguarding .................................................................................................................... 26
15 Monitoring and Control Philosophy .............................................................................................. 27
15.1 Pre-Treatment Unit ............................................................................................................. 27
15.2 Ultrafiltration Unit ................................................................................................................ 27
15.3 Reverse Osmosis Unit ....................................................................................................... 27
15.4 Miscellaneous ..................................................................................................................... 28
16 BLock flow diagram ........................................................................................................................ 29

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1 INTRODUCTION

M/S NMDC LTD. a public sector unit under Govt. of India is setting up a 3.0 MTPA integrated steel plant 17
km from Jagdalpur at Nagarnar in district Bastar in the state of Chhattisgarh in India.
Mecon Limited, a Govt. of India undertaking has been appointed as the consultant by NMDC LTD. for the
proposed plant. As a part of integrated steel plant, Zero Liquid Discharge plant has been envisaged as a
separate package on turnkey basis.

A part of this steel plant will comprise of a Zero liquid Discharge Plant for the purpose of treatment of the
effluent from the steel plant, recovery and reuse of water as "make up water". The treatment comprises of
Pre-treatment & Advance membrane treatment followed by Evaporator system. The capacity of effluent
3
entering the plant is 180 m /h and the overall efficiency desired from the ZLD plant is 90%.

This document defines the design basis considered for ZLD plant

2 REFERENCE

O O
Ref N Document Title Document N

[1] Contract Technical Specification For Centralized CONTRACT No. MEC/11/40/CTS/Q6QZ/54

Zero Liquid Discharge Plant

[2] General Technical Specification (GTS) - Vol -1 DOCUMENT N°

MEC/GTS/11/R2/Q6QZ/REV 2

[3] General Technical Specification (GTS) - Vol -2 DOCUMENT N°

MEC/GTS/11/R2/Q6QZ/REV 2

[Table 1]: Reference

3 ACRONYMS AND DEFINITIONS

The following terms used in this document have the meaning defined below:
CONTRACT The Form of Agreement together with the documents in order of priority, including
the exhibits, drawings, specifications and documents referred to and in the order of
precedence listed in the Form of Agreement.

CONTRACTOR VA Tech Wabag Limited appointed by CLIENT with specified authority to perform
the WORK in accordance with the CONTRACT for ZLD.

CONSULTANT Mecon Limited will do the Project Management Consultancy and EPCM services
for this PROJECT

OWNER National Minerals Development Cooperation (NMDC)

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PROJECT Zero Liquid Discharge (ZLD)

SCOPE OF WORK The SCOPE OF WORK to be performed and services to be rendered by

CONTRACTOR under the CONTRACT in relation to the realization of the
PROJECT.
WORK Works, tasks and WORK to be performed by the CONTRACTOR as specified in or
to be inferred from the CONTRACT, more specifically set out in the SCOPE OF
WORK which may be modified by CHANGE ORDER.

PACKAGE Zero Liquid Discharge (ZLD)

The acronyms used in this document have the meaning defined below:
ACF Activated Carbon Filter

ATM Atmosphere
CEB Chemical Enhance Backwash

CIP Chemical In Place

COD Chemical Oxygen Demand

HCl Hydrochloric Acid

HP High Pressure

LP Low Pressure
LTD Limited

MGF Multigrade Filter

NTU Nephelometric Turbidity Units

pH Potential Of Hydrogen
PPM Parts per million

RO Reverse Osmosis
SDI Silt Density Index

SMBS Sodium Metabisulphide

TDS Total Dissolved Solids

TMP Trans Membrane Pressure

TSS Total Suspended Solids

UF Ultrafiltration
UV Ultraviolet

ZLD Zero Liquid Discharge

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4 PLANT DETAILS

The Plant is designed taking into account the following climatic data, as describe General Technical
Specification, Volume-I, Document number: MEC/GTS/11/R2Q6QZ/REV 2

Design ambient temperature : 35 (Hold) Deg C (Minimum 2.8 Deg C; Maximum 46.1 Deg
C)

Minimum relative humidity : 27%

Maximum relative humidity : 87%

Elevation above mean sea level : 553 meters.

5 PROCESS DESIGN BASIS

5.1 Characteristic of Feed Water

ZLD plant receives following streams from the respective sumps for Pre-Treatment:

- Waste Water from Area Shop Office for Sinter Plant, BF and LDCP
- Waste Water from Area Shop Office for SMS and Caster

- Waste Water from Area Shop Office for CMOS Building

- Waste Water from ED Works Building

- Waste Water from Blast Furnace Complex

- Waste Water from BOF Complex

- Waste Water from Thin Slab Caster-Tunnel Furnace-HSM

- Waste Water from STP-1 near Railway Yard

- Waste Water from STP -2 North of Coal Handling Plant

- Waste Water from STP -3 North of Oxygen Plant
ZLD plant receives the following streams by extending the pipeline from TP for Pre-Treatment:

- Waste Water from Power & Blowing Station

- Waste Water from Lime & Dolomite Plant

- Waste Water from Oxygen Plant

- Waste Water from Compressed Air Station-1

- Waste Water from Compressed Air Station-2

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5.1.1 Waste Water flow rate

Waste Water will be transferred to Equalization Sump by making suitable header arrangement. Individual
flow rate are as follows:

Description Unit Value

Waste Water from Area Shop Office for Sinter Plant, BF m³/h 3
and LDCP

Waste Water from Area Shop Office for SMS and Caster m³/h 3

Waste Water from Area Shop Office for CMOS Building m³/h 3

Waste Water from ED Works Building m³/h 7

Waste Water from Blast Furnace Complex m³/h 14

Waste Water from BOF Complex m³/h 26

Waste Water from Thin Slab Caster-Tunnel Furnace-HSM m³/h 45

Waste Water from STP-1 near Railway Yard m³/h 4

Waste Water from STP -2 North of Coal Handling Plant m³/h 4

Waste Water from STP -3 North of Oxygen Plant m³/h 4

Waste Water from Power & Blowing Station m³/h 45

Waste Water from Lime & Dolomite Plant m³/h 4

Waste Water from Oxygen Plant m³/h 8

Waste Water from Compressed Air Station-1 m³/h 5

Waste Water from Compressed Air Station-2 m³/h 5

Total Waste Water m³/h 180

[Table 2]: Incoming Waste Water flow rate.

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The characteristics of Waste Water stream are as follows:

Parameters Unit Normal Design

pH - 7.5 8.0 7.5 8.0

Total Suspended Solids mg/l 200 - 500 625

(TSS)

Total Dissolved Solids (TDS) mg/l 9000 - 9200 11200

Oil & Grease mg/l 0.09 0.1 0.1

BOD5 mg/l 5 6.25

COD mg/l 15 18.75

Total Hardness as CaCO3 mg/l < 1500 < 1875

Chloride as Cl mg/l <3800 <3800

Calcium as Ca mg/l 600-800 <1000

Magnesium as Mg mg/l 250-400 <500

Sodium as Na mg/l 1500-1800 2700

Potassium as K mg/l 800-1200 1500

Sulphate as SO4 mg/l 1300 < 2390

Alkalinity Methyl Orange mg/l 600 800 1000

Iron as Fe mg/l 0.4 0.6 0.4 0.6

Manganese as Mn mg/l 1-2 1-2

Barium as Ba mg/l 1.5 3.0 1.5 3.0

Total Silica as SiO2 mg/l 80 - 100 125

Ammonium as NH4 mg/l 1-1.5 1-1.5

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Parameters Unit Normal Design

Arsenic as As mg/l <0.1 <0.1

Lead as Pb mg/l 0.2 0.4 0.2 0.4

Cadmium as Cd mg/l 0.2 0.4 0.2 0.4

Fluoride as F mg/l 3-5 3-5

Temperature Deg C 20 - 35 20 - 35

[Table 3]: Characteristic of Waste Water

5.2 Characteristic of Final Treated Water from ZLD Plant

Final Treated Water Characteristics from ZLD shall be as follows:

Parameters Unit Limit

pH - 7.5 8.5

Total Dissolved Solids (TDS) mg/l < 325

Total Hardness as CaCO3 mg/l < 100

(1)
Total Suspended Solids mg/l Nil

Chloride as Cl mg/l < 50

Sulphate as SO4 mg/l < 20

Biological Oxygen Demand mg/l NIL

(3 days at 27 DegC)

Oil and Grease mg/l NIL

[Table 4]: Characteristic of Final Treated Water

Notes:

1 Guaranteed value of TSS of Final Treated water shall be less than 25 mg/l as per CONTRACT.

2 Operating conditions shall not defer from design conditions.

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3 Plant shall operate strictly in accordance with Operational & Maintenance manual supplied
along with the plant.
4 Any deviation from normal performance shall be reported to CONTRACTOR within detect
liability period.

6 BRIEF PROCESS DESCRIPTION

6.1 Pre-Treatment Section

3
Waste Water received at TP shall be collected in Equalization Cum Common Collection Sump of 4000 m
capacity where shock dosing of Sodium Hypochlorite shall be done. The effluent from equalization tank
shall be pumped to flash mixer unit, where Lime, Dolomite shall be added to increase the pH of effluent, for
reduction in silica content of effluent and coagulant is added to enhance the settling of solid particles
present in effluent. From here it is routed to HRSCC where Silica and TSS is reduced by Coagulant (FeCl3)
and Flocculant Aid (Poly) respectively. HRSCC outlet is collected in Filter Feed Tank from where it is further
fed to Multi Grade Filter (MGF) through Filter Feed Pumps. Continuous dosing of Sodium Hypochlorite us
envisaged in Filter Feed Tank. Clarified water from HRSCC is fed to M.G.F for further reduction of
suspended solids. MGF Outlet is then fed to ACF. Provision of ACF is given for removal of excess chlorine
to make it suitable for UF feed. The sludge from HRSCC is removed from the bottom of the HRSCC into the
sludge collection sump. The sludge has around 3% consistency and is further pumped into the Filter Press
with the help of the Sludge Transfer pumps. The Dewatering polyelectrolyte is added into the sludge for
enhancing the performance of the Filter Press. Dewatered sludge from Filter Press shall be directly
disposed off within 5 km radius outside ZLD battery limit. Supernatant produced from Filter Press and UF
backwash waste is recycled back to Equalization Cum Common Collection Sump for treatment. MGF and
ACF waste is collected in Waste Backwash collection sump. Acid dosing provision is provided at inlet of
MGF for pH correction before it is fed to UF system. Filtered water from MGF is collected in UF Feed Tank.
A backwash sump for MGF is provided for the backwashing of MGF. Backwashing of ACF is done from the
feed itself. Effluent from ACF is passed through UV System for disinfection purpose.

6.2 Ultra-Filtration Section

Waste Water stream after pre-treatment shall be collected in UF Feed Tank and is transferred through UF
Feed pumps to basket strainers followed by Ultra-Filtration System. Additional provision of Coagulant
(FeCl3) dosing is given at inlet to the ultrafiltration system to enhance coagulation and removal of
suspended solids.
Ultrafiltration permeate is collected in the RO-I Feed Tank and is made available for RO Feed. Chemical
waste generated from UF CEB and UF CIP will be sent to neutralization pit. UF backwash waste is
collected in Equalization Cum Common Collection Sump. Backwashing of UF skids is done from RO-I Feed
Tank.

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6.3 Reverse Osmosis

Reverse Osmosis System is considered for reduction of TDS present in the influent water to meet the
required quality. Considering the net water demand, three stage two pass RO system are considered. UF
Permeate is received in RO-I Feed Tank. Along with it, RO-II Reject is also recycled back to RO-I Feed
Tank.
Reverse osmosis-I:

Three numbers (3) of RO skids with Interstage booster pumps are provided out of which two (2) are working
and one (1) standby, which will serve the purpose of reducing the TDS to the desired levels.

RO-I System is designed to ensure the following process requirement:

Recovery: > 85%

RO Recovery and permeate TDS is guaranteed at 35 Deg C water temperature.
The RO membrane projection result is carried out considering the membrane age as 3 years.
RO High Pressure Pumps Head are selected based on the 25 Deg C water temperature as per
CONTRACT
Reverse osmosis-II:

To achieve the desired permeate quality, 50% of Permeate from RO-I skid will be fed to RO-II skid.
However, provisions of routing permeate from RO Pass I skid directly to the degasser tower to blend with
RO-I and RO-II Permeate is also given. Two numbers (2) of two stage RO II skid is provided, out of which
one (1) is working and one (1) is kept as standby, which will serve the purpose of improving the overall
recovery of the plant and reducing the TDS to the desired levels.

RO-II System is designed to ensure the following process requirement;

Recovery: 90%
RO Recovery and permeate TDS is guaranteed at 35 Deg C water temperature.
The RO membrane projection result is carried out considering the membrane age as 3 years.
RO II Booster Pumps head are selected based on the 25 Deg C water temperature as per
CONTRACT.

6.4 Degasser Unit

One number (1) of Degasser Tower with 2 number of degasser blower, out of which one (1) is working and
one is standby (1) is provided. It helps in the reduction of free CO2. RO-II Permeate and RO-I By passed
Permeate is sent to Degasser Tower. Degassed Permeate is transferred to 1 number RO Permeate Tank
which further transfers the Degassed RO Permeate to B/L.

6.5 Evaporator System

The feed to the Evaporator system shall be the streams from RO-I reject. The system shall be based on
evaporation principle. The high purity distillate produced in the system shall be used as process makeup

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water. The salt from the evaporator system shall be disposed off within 5 km area outside the battery limit
of ZLD Plant. The moisture content of the salt shall be maximum 30%.

7 BATTERY LIMIT CONDITIONS

7.1 Waste Water Streams

Waste Water from Area Sump and Other Areas from Outside B/L will be brought to ZLD as per Yard piping
and Equipment layout Doc No. NMDC-Wabag-54-05-15-BE-0002 Rev 2.
Incoming waste water conditions at ZLD battery limit are as follows.

Sl. No Stream 2 Temperature

Pressure kg/cm (g) Pipe Details
Description (Deg C)

Operating Design Operating Line Size PMS

1. Waste Water from

Area Shop Office for Atm 20 35 Hold-2 CS
Atm
Sinter Plant, BF and
LDCP

2 Waste Water from

Area Shop Office for Atm Atm 20 35 Hold-2 CS
SMS and Caster

3. Waste Water from Hold-2

Area Shop Office for Atm Atm 20 35 CS
CMOS Building

4 Waste Water from Atm 20 35 Hold-2 CS

Atm
ED Works Building

5 Waste Water from Hold-2

Blast Furnace Atm Atm 20 35 CS
Complex

6 Waste Water from Hold-2 Hold-2 20 35 Hold-2 CS

BOF Complex

7 Waste Water from Hold-2 Hold-2 Hold-2

Thin Slab Caster- 20 35 CS
Tunnel Furnace-
HSM

8 Waste Water from Hold-2

STP-1 near Railway Atm Atm 20 35 CS
Yard

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Sl. No Stream 2 Temperature

Pressure kg/cm (g) Pipe Details
Description (Deg C)

Operating Design Operating Line Size PMS

9 Waste Water from Hold-2

STP -2 North of Atm Atm 20 35 CS
Coal Handling Plant

10 Waste Water from Hold-2

STP -3 North of Atm Atm 20 35 CS
Oxygen Plant

11 WASTE WATER
FROM POWER & 4 20 35 DN 100 CS
3
BLOWING
STATION

12 WASTE WATER
FROM LIME & Hold-1 Hold-1 20 35 DN 80 CS
DOLOMITE PLANT

13 WASTE WATER
FROM OXYGEN 3 4 20 35 DN 50 CS
PLANT

14 WASTE WATER
FROM 4 20 35 DN 40 CS
3
COMPRESSED AIR
STATION-1

15 WASTE WATER
FROM 3 20 35 DN 40 CS
2
COMPRESSED AIR
STATION-2

[Table 5]: Waste Water conditions at battery limit

7.2 Final Treated Water from ZLD

Outgoing treated water conditions at ZLD battery limit are as follows.

Sl. No Stream 2
Temperature
Description Pressure kg/cm (g) Pipe Details
(Deg C)

Operating Design Operating Line Size PMS

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Sl. No Stream 2
Temperature
Description Pressure kg/cm (g) Pipe Details
(Deg C)

Operating Design Operating Line Size PMS

(1)
1. Final Treated Water 4.5 7 20 - 35 DN 250 CS

[Table 6]: Final Treated Water to battery limit

Notes:

1 Shown figure is for mechanical design only

8 PLANT CONFIGURATION

8.1 Waste Water Collection Section

10 No. waste water Sumps each with 2 No. (2 X100%) of Waste water pumps for each sump is provided
which transfer waste water from B/L to 1 No. of Equalization cum Common Collection Sump.

8.2 Pre-Treatment Section

1 No. Flash Mixer followed by 1 No. HRSCC with scrapper mechanism is provided which helps in reducing
Hardness, Silica and TSS from the Waste Water. 3 No. (3X50%) Multi Grade Filters are provided for further
reduction of Suspended Solids. 3 No. (3X50%) Activated Carbon Filters are provided as a provision as per
CONTRACT requirement. 2 No. Filter Press is provided for dewatering of sludge. The sludge from the
dewatering system shall have a maximum moisture content of 30% and shall be disposed off within 5 kms
outside ZLD Plant Battery Limit. 2 Nos. of UV system shall be provided at the discharge of ACF for
disinfection purpose.

8.3 Ultra-Filtration System

3 Nos. (3X50%) UF Skids are provided as a pretreatment measure before directing it to RO skids.

8.4 Reverse Osmosis System and Degasser System

3 Nos. (3X50%) skids for RO-I Pass are provided which serves the purpose of reducing the TDS level from
the feed (i.e. UF permeate). 2 Nos. (2X100%) skids for RO-II Pass are provided which serves the purpose
of improving the overall plant recovery and reducing the TDS level to less than 325 mg/l. Permeate from the
RO system is passed through 1 No. Degasser Tower and collected into 1 No. RO Permeate Tank. 2 Nos.
(2X100%) Degasser Blowers are provided.

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8.5 Evaporator System

1 set of evaporator system shall be provided to achieve Zero Liquid discharge.

8.6 Chemical Dosing System

1 No. Bulk Acid (33%) Storage Tank is provided with total chemical storage capacity of fifteen (15) days
which includes the acid requirement for the package and two (2) Nos. of unloading cum transfer Pumps are
provided for transfer and unloading of chemicals
1 No. of dosing tank with 2 Nos. (2X100%) Dosing Pumps are provided for, Polyelectrolyte, Dolomite,
Antiscalant - RO-I, SMBS and DWPE.
1 No. of common dosing Tank for Acid dosing- UF CEB, MGF and RO-I feed is provided. 2 Nos. (2 X100%)
of Acid dosing pumps with common standby pump for MGF and RO-I Feed is provided. 2 Nos. (2X100%)
Acid Dosing Pumps for UF CEB is provided. The acid dosing at RO-I Feed is given as a provision.

1 No. of common dosing Tank with 2 No. (2X100%) Dosing Pumps is provided for Sodium Hypochlorite -
Pre-Treatment and UF CEB.

1 No. of Caustic preparation Tank is provided with 2 No. (2 X100%) of Transfer Pump.1 No. of common
dosing Tank for caustic-pH correction and UF CEB is provided with 2 No. (2 X100%) of dosing pump for
each. 1 No. of Caustic Dosing Tank for N Pit is provided.
2 No. (2 X 100%) of dosing tank with 2 No. (2X100%) Dosing Pumps for Soda Ash and Lime is provided

1 No. of dosing tank with 2 (2 X 100%) dosing pumps for Coagulant with common standby pump for
UF and Pre-treatment is provided.

1 No. of Dosing Tank with 2 No. (2X100%) Dosing Pumps are provided for UF CIP and RO CIP is provided.

9 CHEMICALS USED

The following are the chemicals used

Sodium Hypochlorite

Ferric Chloride (FeCl3)

Dolomite

Lime

Sodium Carbonate

Polyelectrolyte

Hydrochloric Acid (33% HCl)

Caustic (100% NaOH)

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Citric Acid

Sodium Meta Bi-Sulphite (SMBS)

Antiscalant

De-watering Polyelectrolyte

9.1 Sodium Hypochlorite

Description Value

Pre-chlorination
Purpose
UF CEB
Available Form Liquid

Commercial grade 10%

Dilution requirement NO

Liquid will be stored in commercially available delivery drums and

Storage
stored in Chemical House.

Dosing tank One No. (1) Of Dosing Tank sized for 24 Hours chemical requirement.

[Table 7]: Sodium Hypochlorite Details

9.2 Ferric Chloride

Description Value

Coagulation for Pre-treatment

Purpose
Coagulation for UF Feed (Provision)
Available Form Liquid

Commercial grade 40%

Dilution requirement NO

Liquid will be stored in commercially available delivery drums and

Storage
stored in Chemical House.

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Description Value

Dosing tank One No. (1) Of Dosing Tank sized for 24 Hours chemical requirement.

[Table 8]: Ferric Chloride Details

9.3 Dolomite

Description Value

Purpose For removal of Silica

Available Form Powder

Commercial grade 100%

Dilution requirement Yes (10%)

Storage Chemicals will be delivered in bags and stored in Chemical House.

Dosing tank One No. (1) Of Dosing Tank sized for 24 Hours chemical requirement.

[Table 9]: Dolomite Details

9.4 Lime

Description Value

Purpose For removal of temporary hardness

Available Form Powder

Commercial grade 90%

Dilution requirement Yes (10%)

Storage Chemicals will be delivered in bags and stored in Chemical House.

Dosing tank Two No. (2) Of Dosing Tanks sized for 24 Hours chemical requirement.

[Table 10]: Lime Details

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9.5 Sodium Carbonate

Description Value

Purpose For removal of Permanent Hardness

Available Form Dry Powder

Commercial grade 100%

Dilution requirement Yes (17%)

Storage Chemicals will be delivered in bags and stored in Chemical House.

Dosing tank Two No. (2) Of Dosing Tanks sized for 24 Hours chemical requirement

[Table 11]: Sodium Carbonate Details

9.6 Polyelectrolyte

Description Value

Purpose For Flocculation

Available Form Dry Powder

Commercial grade 100%

Dilution requirement Auto Polymer Preparation system provided

Storage Chemicals will be delivered in bags and stored in Chemical House.

Dosing tank Auto Polymer system provided

[Table 12]: Polyelectrolyte Details

9.7 Hydrochloric Acid

Description Value

For pH Correction MGF Feed

Purpose For Chemical Cleaning of UF System
Provision to meet desired pH in RO feed

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Description Value

For neutralisation of chemical waste

Available Form Liquid

Commercial grade 33%

Dilution requirement No

Storage Bulk Acid Storage Tank sized for total 15 days requirement.

1 No. tank considered for MGF, UF CEB, and RO feed sized for 24
Dosing tank
hours requirement.

[Table 13]: Hydrochloric Acid Details

9.8 Caustic

Description Value

For Chemical Cleaning of UF System

Purpose pH Correction Final Treated Water
For neutralisation of chemical waste
Available Form Flakes

Commercial grade 100%

Dilution is required for chemical cleaning of UF (20%) & pH Correction

Dilution requirement
(20%) only

Storage 1 No. of Alkali Preparation Tank sized for total 24 hours requirement

1 No. tank considered for UF CEB and pH Correction sized for 24

Dosing tank hours requirement.

1 No. tank considered for N-Pit sized for 24 hours requirement.

[Table 14]: Caustic Details

9.9 Citric Acid

Description Value

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Description Value

RO CIP
Purpose
UF CIP
Available Form Solid, Powder

Commercial grade 50-100%

Dilution requirement Solution will be prepared as per Cleaning recommendation

Chemicals will be delivered in 25-50 kg bags as per local availability.

Storage
Bags shall be stored in chemical house.
Dosing tank Respective CIP Tank will be used for Solution Preparation

[Table 15]: Citric Acid Details

9.10 Sodium Meta Bisulphite (SMBS)

Description Value

Purpose To neutralize any residual chlorine in RO I feed

Available Form Liquid/ Powder

Commercial grade Will depend upon the selection of type

Dilution requirement Yes (35%)

Chemicals will be delivered in 25-50 kg bags and stored in

chemical house.
Storage
Liquid will be stored in commercially available delivery drums
in Chemical House.
Dosing tank 1 No. tank considered for RO-I, sized for 24 hours requirement.

[Table 16]: SMBS Details

9.11 Antiscalant

Description Value

Scale inhibitor, to prevent scaling/fouling of membranes in RO

Purpose
Membrane

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Description Value

Available Form Liquid

Commercial grade 100%

Dilution requirement No

Will be stored in commercially available delivery drums in Chemical

Storage
House.

Dosing tank 1 No. of tank sized for 24 hours requirement

[Table 17]: Antiscalant Details

9.12 Dewatering Polyelectrolyte

Description Value

Purpose To aid dewatering in the Filter Press

Available Form Solid, powder

Commercial grade 100 %

Dilution requirement Auto polymer preparation system provided

Chemicals will be delivered in 25 kg bags/HDPE bags and stored in

Storage
Filter Press Building.

Dosing tank Auto polymer preparation system provided

[Table 18]: DWPE Details

10 UTILITIES CONDITIONS

Following utilities are required at ZLD for operation of the plant.

Instrument air,
LP Steam

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Industrial Makeup water.

Drinking Water

10.1 Instrument Air

Instrument air is used for on-off valves in the plant. The characteristics of instrument air are considered from
Technical Specification for Centralized Zero Liquid Discharge Plant:
MEC/11/40/CTS/Q6QZ/54
Instrument air conditions at ZLD battery limit are as given below:

Pressure kg/cm² (g) Temperature (Deg C) Pipe Details

Operating Design Operating Line Size PMS

(1)
6-7 HOLD - 2 HOLD - 3 DN 25 GI

[Table 19]: Instrument air conditions at battery limit

Notes:

1 Actuator are to be designed for a minimum instrument air pressure of 4.5 (Hold) kg/cm²(g)

2 Shown figure is for mechanical design for pipe and equipment under solar radiation.

10.2 LP Steam

Steam required for Evaporator/ ZLD system shall be made available at ZLD at the battery limit. Steam
conditions at ZLD battery limit are as given below:

Pressure kg/cm² (g) Temperature Deg C Pipe Details

Operating Design Operating Line Size PMS

(1)
11 - 13 19.5 250 DN 150 CS-1

[Table 20]: Steam conditions at battery limit

Notes:

1 Shown figure is for mechanical design only.

10.3 Industrial Make up Water

Industrial quality make-up water will be available for the said plant, from the proposed industrial make-up
water network near the battery limit of ZLD Package. Industrial make-up water conditions at ZLD
battery limit are as given below:

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Pressure kg/cm² (g) Temperature Deg C Pipe Details

Operating Design Operating Line Size PMS

(1)
1 HOLD - 2 20 -35 DN 100 CS

[Table 21]: Industrial Makeup water conditions at battery limit

Notes:

1. Pipe size is tentative and to be finalized.

10.4 Drinking Water

Drinking water for the said plant from the proposed drinking water network will be made available near the
battery limit of ZLD Package. Drinking water conditions at ZLD battery limit are as given below:

Pressure kg/cm² (g) Temperature Deg C Pipe Details

Operating Design Operating Line Size PMS

DN 40 GI
1 HOLD -2 20 - 35
(HOLD)

[Table 22]: Drinking Water supply conditions at battery limit

11 WASTE DISPOSAL

The plant will produce solid wastes from Filter Press for HRSCC and ZLD package
- Sludge cake from Filter Press (HRSCC): Sludge cake generated from dewatering unit through is
disposed off within radius of 5 km outside from the battery limit of ZLD plant during entire O&M
Period by WABAG. The sludge cake shall have a maximum moisture content of 30%.
- Salt from Evaporator System: Salt generated from the Evaporator system is further transferred for
disposal within radius of 5 kms outside the battery limit of ZLD plant during entire O&M Period
by WABAG. Salt generated from the Evaporator shall have a maximum moisture content of 30%.

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12 AIR EMISSION CONTROL

ZLD plant does not emit any gaseous pollutant hence any air emission control is not envisaged for this
package.

13 STANDBY PHILOSOPHY

Standby philosophy of ZLD Unit takes into account the need for maintenance and inspection, as well as
flexibility for operation when Refinery complex is in maintenance and group of units are shutdown. Stand-by
philosophy will be as follows:

2 x 100% for Pump of Area Shop Office for Sinter Plant, BF and LDCP
2 x 100% for Pump of Area Shop Office for SMS and Caster
2 x 100% for Pump of Area Shop Office for CMOS building
2 x 100% for Pump for ED Work Building
2 x 100% for Pump for Blast Furnace Complex
2 x 100% for Pump for BOF Complex
2 x 100% for Pump for Thin Slab Caster Tunnel Furnace HSM
2 x 100% for Pump for STP-1
2 x 100% for Pump for STP-2
2 x 100% for Pump for STP-3
1 x 100 Sodium Hypochlorite Dosing Tank Pre-treatment/UF CEB
2 x 100% Sodium Hypochlorite Dosing Pumps
2 x 100% HRSCC Feed Pumps
1 x 100% HRSCC
1 x 100 Coagulant Dosing Tank
2 x 100% Coagulant Dosing Pump Pre-treatment/UF
1 x 100% Auto Flocculant Dosing System
2 x 100 Flocculant Dosing Pumps
1 x 100% Dolomite Dosing Tank
2 x 100% Dolomite Dosing Pumps
2 x 50% Lime Dosing Tank
2 x 100% Lime Dosing Pumps
2 x 50% Sodium Carbonate Dosing Tank
3 x 50% Sodium Carbonate Dosing Pumps
2 x 100% Sludge Transfer Pumps
2 x 100% Sludge Filter Press
1 x 100% Sludge Drying Bed
1 x 100% Auto DWPE Dosing System
2 x 100% DWPE Dosing Pumps
2 x 100% Filter Feed Pumps
2 x 100% MGF Feed RO-I Acid/Dosing Pumps
3 x 50% Multi Grade Filter
3 x 50% Activated Carbon Filter
2 x 100% Air Scouring Blower MGF
2 x 100% MGF Backwash Pumps
1 x 100% Backwash Sump for MGF
1 x100% Waste Backwash Collection Sump

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2 x 100% Waste Backwash Transfer Pumps

3 x 50% UF Feed Pumps
3 x 50% UF Basket Strainers
3 x 50% UF Skid
2 x 100% UF Backwash Pump
1 x 100% UF CIP Tank
2 x 100% UF CIP Pumps
2 x 100% UF CEB I-A (Caustic) Dosing Pumps
2 x 100% UF CEB I-A (Hypo) Dosing Pumps
2 x 100% UF CEB I-B (Acid) Dosing Pumps
2 x 100% Cartridge Filter Feed Pump RO I
3 x 50% Cartridge Filter RO I
6 x 50% RO I High Pressure Pump
3 x 50% RO I Inter-stage Booster Pump
3 x 50% RO I Skid
1 x 100% Acid Dosing Tank
1 x 100% RO I Antiscalant Dosing Tank
2 x 100% RO I Antiscalant Dosing Pumps
1 x 100% RO I SMBS Dosing Tank
2 x 100% RO I SMBS Dosing Pumps
2 x 100% RO II Booster Pump
2 x 100% RO II Skid
2 x 100% Treated Water Transfer Pump
1 x 100% Caustic Dosing Tank pH Correction/UF CEB
2 x 100% Caustic Dosing Pumps pH Correction
2 x 100% RO Flushing Pumps
1 x 100% Degasser Tower
2 x 100% Degasser Blower
1 X 100% Neutralization Pit ( Single Compartments)
2 x 100% N-PIT Transfer Pump
1 x 100% Bulk Acid Tank
1 x 100% Caustic Dosing Tank N-Pit
2 x 100% Acid Transfer Pump
2 x 100% Caustic Transfer Pump
1 x 100% Evaporator system

14 PROCESS SAFEGUARDING

pH, ORP, Conductivity, Silica and SDI analyser are provided at common inlet header of RO-I skids. It is the
first priority in the RO plant to safeguard the RO membranes from getting exposed to the free residual
chlorine which oxidizes the membrane and leads to degrade permeate quality with partial damage or
complete damage of membranes if exposed for a longer time. In case ORP is high, RO feed is dumped by
opening the dump valve and RO HPP along with all booster pumps shall stop and plant shutdown sequence
shall be followed. Conductivity analyser is provided in the individual RO permeate line. On high conductivity
in the RO Permeate, RO permeate is dumped by opening the dump valve

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15 MONITORING AND CONTROL PHILOSOPHY

All instrumentation for proper functioning of the Plant is provided. The following status indications and
alarms are provided to monitor the operation.

15.1 Pre-Treatment Unit

Flow Transmitter is provided at the discharge of all major Pump header as per P&ID.

Pressure Transmitter is provided at the discharge header of Pumps as per P&ID

Level Indication and high/ low/ low low /high high level alarms in the Equalization cum common
collection sump and Filter Feed Tank.

Temperature Transmitter at the discharge header of HRSCC Feed Pumps

Turbidity analyzer at the discharge header of HRSCC Feed Pumps

pH analyser with High and Low pH alarm at the discharge header of Filter Feed pumps to control
the acid dosing pump at the MGF Feed.

Differential Pressure Transmitter with High alarm across individual MGF Inlet and Outlet.

Differential Pressure Transmitter with High alarm across individual ACF Inlet and Outlet.

Flow Transmitter at Individual MGF outlet.

Flow Transmitter at Individual ACF outlet.

15.2 Ultrafiltration Unit

Level Indication and high/ low/ low low/ high high level alarms in the UF Feed collection Tank.

Differential pressure transmitter across individual Basket strainer.

Flow Totaliser for UF Feed.

Flow indicator cum transmitter and Flow controller at inlet of each UF skid with high alarm

Pressure indicator and transmitter at inlet (Feed side) and outlet (Permeate side) of each UF skid.

Differential Pressure Indicator is provided across UF Feed and Permeate streams.

Multi-channel Turbidity analyzer with tapping from individual UF skid outlet.

15.3 Reverse Osmosis Unit

Level Indication and high/ low/ low low/ high high level alarms in the RO-I Feed Tank.

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Pressure Indicator and Transmitter is provided at the common discharge of RO-I Cartridge Filter
Feed Pump.

pH, ORP, SDI, Conductivity and tapping to turbidity analyzer with high alarm at common inlet
header of RO-I skids shall be provided.

Differential pressure transmitter across individual Cartridge Filter.

Conductivity analyzer with high alarm at individual permeate outlet of RO-I and RO-II skids.

Pressure indicator and Transmitter at the suction of High Pressure Pumps with Low Pressure
Alarm.

Pressure indicator and transmitter at discharge of RO high pressure pump with high pressure alarm

Pressure Transmitter have been provided at Feed and Reject line of individual stages.
Flow Transmitter is provided at the individual skid feed inlet and reject line. In addition to this, Flow
Transmitter is provided at RO-I stage II and Stage III permeate line.

15.4 Miscellaneous

Apart from main system covered above following are the instruments provided for monitoring and control as
a minimum.

Level indicator and transmitter at all intermediate tanks and chemical dosing tank with High- High,
High, Low and Low - Low level alarm are provided

Bulk chemical storage tanks Level indicator cum transmitter is provided with High- High, High, Low
and Low- Low level alarm are provided.

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16 BLOCK FLOW DIAGRAM

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