STUDY OF EFFLUENT TREATMENT IN MILMA AND

DESIGN OF WASTEWATER TREATMENT PLANT

A PROJECT REPORT
Submitted by

ABISHEK A KKE18CH002
ASWIN ANIL KKE18CH017
MUHAMMED MUSAMMIL P KKE18CH043
SUDHIN DAS E KKE18CH061
to
The APJ Abdul Kalam Technological University
in partial fulfilment for the requirements for the award of the Degree
of
Bachelor of Technology
In
Chemical Engineering

Department of Chemical Engineering

Government Engineering College
Kozhikode
June 2022

DEPARTMENT OF CHEMICAL ENGINEERING 1

 DECLARATION

We hereby declare that the Project report (“STUDY OF EFFLUENT TREATMENT IN

MILMA AND DESIGN OF WASTEWATER TREATMENT PLANT”), submitted for
partial fulfilment of the requirement award of degree of Bachelor of Technology of the APJ
Abdul Kalam Technological University, Kerala is bonafide Project presentation done by us.
The submission represents my idea in my own words and where ideas other have been included,
I have adequately and accurately cited and referenced the original source. I also declare that I
have adhered to ethics of academic honesty and integrity and have not misrepresent or
fabricated any data or idea or fact in my submission. I understand that any violation of the
above will be cause for disciplinary action by the institute and or the University and can also
evoke penal action from the sources which have thus not been properly cited or from whom
proper permission has not been obtained. This report has not been previously formed the basis
for the award of any degree, diploma or similar title of any other University.

Place: Kozhikode Signature :

Date: ABISHEK

ASWIN ANIL

MUHAMMED MUSAMMIL P

SUDHIN DAS E

DEPARTMENT OF CHEMICAL ENGINEERING 2

 DEPARTMENT OF CHEMICAL ENGINEERING
GOVERNMENT ENGINEERING COLLEGE, KOZHIKODE

CERTIFICATE

This is to certify that the report entitled STUDY OF EFFLUENT TREATMENT

IN MILMA AND DESIGN OF WASTEWATER TREATMENT PLAN,

submitted to the APJ Abdul Kalam Technological University in partial fulfilment of the
requirements for the award of the Degree of Bachelor of Technology in chemical engineering
is a bonafide record of the seminar presented by him/her. This report in any form has not been
submitted to any other University or Institute for any purpose.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Dr. Gigi Sebastian Dr. Beula. C
Professor Associate Professor
Dept. of Chemical Dept. of Chemical
Engineering Engineering
GEC Kozhikode GEC Kozhikode

DEPARTMENT OF CHEMICAL ENGINEERING 3

 ACKNOWLEDGMENT

Dedicating this Project to the Almighty God whose abundant grace and mercies enabled its
successful completion, I would like to express my profound gratitude to all the people who
have inspired and motivated me.

I would like to thank Dr. Beula C, HOD of the Department of chemical engineering, for
allowing me to use the facilities available. I would like to thank all other faculties at this
occasion.

I hereby express my deep sense of gratitude to my guide Dr. Gigi Sebastian, Department of
Chemical Engineering for his valuable guidance, constant encouragement and creative
suggestion offered during the course of preparation of the Project and accompanying report.

My profound gratitude to all the staff and faculties of the department for their valuable support,
kind co-operation and help provided for the successful completion of the Project.

DEPARTMENT OF CHEMICAL ENGINEERING 4

 ABSTRACT
This study involves general study of effluent treatment plant in Milma and design of
wastewater treatment plant. In Milma huge amounts of water are used during the process
producing effluents containing dissolved sugars and proteins, fats, and possibly residues of
additives. Waste waters are primarily generated from the cleaning and washing operations. Due
to the high pollution load of diary waste water, the milk processing industries discharging
untreated/partially treated waste water cause serious environmental problems. Mainly four
common ways to treat wastewater include physical water treatment, biological water treatment,
chemical treatment, and sludge treatment. That is discussed detailed in this report. Design
includes detailed process of Activated Sludge reactor.

The report also presents the oxygenic photo granule (OPG) process, a light-driven process for
wastewater treatment, developed based on photo granulation of filamentous cyanobacteria and
non-phototrophic bacteria. OPG process was operated in stirred-tank reactors without aeration.
Reactors were seeded with hydrostatically grown photo granules and operated in a sequencing
batch mode to treat wastewater. A novel method of cultivating Oxygenic Photo Granules
(OPGs) which are natural aggregates predominantly consisting of cyanobacteria from the
activated sludge and using it to treat the wastewater in the secondary treatment is under
development. After the primary treatment, OPGs help to substitute the high energy-consuming
aeration equipment which deems the secondary process more sustainable. Cultivation of OPGs
is influenced by many factors including the intensity of light used during cultivation, the
concentration of sludge etc. Manipulating these factors, we can cultivate OPGs in the most
efficient way possible.

DEPARTMENT OF CHEMICAL ENGINEERING 5

 CONTENTS

TITLE PAGE NO

CHAPTER 1 ........................................................................................................................... 10
INTRODUCTION ................................................................................................................... 10

CHAPTER 2 .......................................................................................................................... 16
LITERATURE REVIEW ........................................................................................................ 16
2.1 FAT REMOVAL 16
2.2 SCREENING AND SETTLING 16
2.3 ACTIVATED SLUDGE PROCESS 17
2.4 PHOTOGRANULES 18

CHAPTER 3 ........................................................................................................................... 19
GENERAL STUDY OF EFFLUENT TREATMENT IN MILMA PLANT .......................... 19
3.1 GENERAL INFORMATION 19
3.2 UNITS OF EFFLUENT TREATMENT PLANT 22
3.3 UNIT DESCRIPTION AND OPERATION 22
3.3.1 RAW EFFLUENT COLLECTION SUMP AND PUMP 22
3.3.2 OIL AND GREASE TRAP 23
3.3.3 PRIMARY AND SECONDARY AERATION TANK: 24
3.3.4 FINAL CLARIFIER: 28
3.3.5 V-NOTCH CHAMBER: 29
3.3.6 SLUDGE DRYING BED 30
3.3.7 SLOW SAND FILTER 31
3.3.8. LAGOONS 31
3.3.9. ULTRAFILTRATION 32

CHAPTER 4 ........................................................................................................................... 34
DESIGN OF ACTIVATED SLUDGE REACTOR ................................................................ 35

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CHAPTER 5 ........................................................................................................................... 46
EXPERIMENTAL STUDY OF OXYGENIC PHOTOGRANULE PROCESS FOR
AERATION-FREE WASTEWATER TREATMENT ............................................................ 46
5.1 GENERAL OUTLINE 46
5.2 OPG CULTIVATION 46
5.3 ADVANTAGES OF OPG’S OVER ACTIVATED SLUDGE PROCESS 48
5.4 SUMMARY 49

CHAPTER 6 ........................................................................................................................... 50
CONCLUSIONS...................................................................................................................... 50

REFERENCES ........................................................................................................................ 51

DEPARTMENT OF CHEMICAL ENGINEERING 7

 LIST OF FIGURES

FIGURE PAGE NO

Fig 3.1 Entrance of Trivandrum Milma diary. 21

Fig 3.3.2 Oil and Grease Trap 24
Fig 3.3.3 Aeration Tank 27
Fig 3.3.6 Sludge drying bed 30
Fig 3.3.8 Lagoon 32
Fig 3.3.9 Ultrafiltration 33
Fig 3.3.10 Flow diagram 34
Fig 5.2 Cultivation of OPG 46
Fig 5.3 Graph of removal efficiency 48

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 LIST OF TABLES

TITLE PAGE NO

Table 4.1 Marshall & Swift Equipment cost Index 43

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 CHAPTER 1

INTRODUCTION

1.1 GENERAL BACKGROUND

Milma was established in April 1980 by Kerala Co-operative Milk Marketing Federation
(KCMMF). The mission of Milma is ‘Farmer’s Prosperity through consumer satisfaction’. The
objective of Milma is to build up a viable dairy industry in the State and to provide constant
market and stable price to the dairy farmers for their produce. The dairy industry includes the
transformation of raw milk into pasteurised and sour milk, yoghurt, hard, soft and cottage
cheese, cream and butter products, ice cream, milk and whey powders, lactose, condensed milk,
as well as various types of desserts. The general distinctions among these foods are due to the
reuse of non- -fat milk and whey (a by-product in cheese manufacturing) and the evaporation
of the free water from the coagulum as well as from milk and whey powders.

With the rapid industrialization observed in the last century and the growing rate of milk
production (around 2.8% per annum), dairy processing is usually considered the largest
industrial food wastewater source, especially in Europe. Moreover, in around 50% of the
world’s whey production, especially concerning acid whey, it is untreated prior to disposal.
The effluents originating from various production technologies are not discharged
simultaneously, thus forming a stream with wide qualitative and quantitative variations.

Notwithstanding the differences in composition, attributable to the manufactured product and

technological operations, dairy effluents are distinguished by their relatively increased
temperature, high organic content and a wide pH range, which requires special purification in
order to eliminate or reduce environmental damage. Treatments of dairy wastewaters include
the application of mechanical, physicochemical and biological methods. Mechanical treatment
is necessary to equalise volumetric and mass flow changes. It also reduces parts of the
suspended solids. Physicochemical processes are effective in the removal of emulsified
compounds, but reagent addition increases water treatment costs. Another disadvantage is the
very low elimination of soluble chemical oxygen demand (COD). Therefore, biological
wastewater treatment systems are preferred due to the highly biodegradable contaminants

DEPARTMENT OF CHEMICAL ENGINEERING 10

Rapid growth of industries has not only enhanced the productivity but also resulted in the
production and release substances into the environment creating health hazards and effected
normal operations, flora and fauna. There wastes are potential pollutants when they produce
harmful effects on the environment and generally released in the form of solids, liquid effluent
and slurries containing a spectrum of organic chemicals. The pollution is a necessary evil of all
development. To combat the plethora of environmental evils of present-day society, efficient
and environmentally safe organic waste treatment technologies are needed, beside like other
industries that have serious waste disposal problem the dairy industry is faced with the prospect
of having to erect a large number of relatively small treatment plant.

Liquid effluent from dairy industry poses environmental problems like water and soil pollution.
Oil and grease in effluent generated from Dairy industry poses a major threat to the
environment Besides the lactose present in another polluting component. The dairy industry in
India is expected to grow rapidly and the waste generation and related environmental problems
are assumed as of increased importance. Poorly treated effluent with high levels of pollutants
caused by poor design, operation or treatment systems creates major environmental problems
when discharge to surface water or land.

Waste water generated in a dairy contains highly putrescible organic constituents. This
necessitates prompt and adequate treatment of the waste water before its disposal to the
environment. This organic load is basically constituted of milk (raw material and dairy
products), reflecting an effluent with high levels of chemical oxygen demand (COD),
biochemical oxygen demand (BOD), oils and grease, nitrogen and phosphorus. The automatic
cleaning system – CIP (cleaning in place) – discard rinse waters with pH varying between 1.0
and 13.0, further complicating the question of treatment. BOD is directly related to milk wastes
(90% to 94% of the effluent BOD), and in some cases losses can reach 2% of the volume
processed by the industry.

Milk is received at the plant or receiving unit in standard 80-lb cans. It is dumped to a weigh
vat and the cans are washed in a can washer and returned to the producer. From the weigh vat
milk is pumped to a storage tank or, if it is a receiving station, the milk is cooled and pumped
to a tank truck for hauling to a bottling or processing plant. About 50% of the milk produced
in this country is used as whole milk. A small amount of this is bottled as raw milk, but the
major portion is pasteurized prior to further handling. Biogas, a mixture consisting primarily

DEPARTMENT OF CHEMICAL ENGINEERING 11

of methane and carbon dioxide, is produced from dairy through anaerobic digestion, a natural
process that breaks down organic material in an oxygen free environment and it is well
documented process for treating organic waste. Fortunately, the wastewater can be made
potable and usable by employing wastewater treatment technologies that filter and treat the
wastewater by removing contaminants such as sewage and chemicals.

This project includes an experimental study of oxygenic photo granules for wastewater
treatment. Over the past few years, there has been a growing interest in the use of phototrophic
granular biomass for wastewater treatment. Different from traditional bio granule types, such
as aerobic granular sludge (AGS), 6−10 this phototrophic granular biomass contains a
significant level of photosynthetic microorganisms. Hence, these phototrophs may
autonomously produce O₂ needed for oxidation of organic matter and nitrification, which in
the AGS process is often provided by energy-intensive aeration. Similar to the AGS process,
the phototrophic granular process allows effective biomass separation from water and enhances
the system operation in small footprint.

The generation of wastewater has been rapidly increasing with population growth, urbanization
and industrialization. Most of the wastewater treatment methods are energy- intensive and have
some disadvantages like high surplus biomass production, low flexibility with respect to
fluctuating loading rates. So biological treatment methods are given more importance as it is
environment friendly, resulting in less chemical use and energy input. Microbial granulation
can be used as an alternative method to attain high treatment efficiency. In aquatic
environments, algae and bacteria play a crucial role in nutrient cycling and contaminants
removal by biosynthesis and biological metabolic process. A combined system of algae and
bacteria has been extensively studied for application in wastewater treatment. These aggregates
are often called as granules. Their specific gravity allows them to settle in the aqueous
environment rapidly. Granules used in biotechnology have so far mostly involved non-
phototrophic biomass. Only recently, in the wastewater treatment context, the development of
oxygenic photo granules (OPG) has been described as a promising novelty. OPG’s are the most
recent addition to the family of bio-granules for biotechnological applications.

Oxygenic photogranules (OPGs) are complex microbial biofilms with the ability to remove
COD and nitrogenous compounds from wastewater without external aeration. OPGs are
composed of syntrophic cyanobacteria, heterotrophic bacteria, and microalgae. Cyanobacteria

DEPARTMENT OF CHEMICAL ENGINEERING 12

and microalgae provide sufficient oxygen to support nitrification and the transformation of
organics by heterotrophic bacteria. OPGs also generate oxygen from photosynthesis and may
push the diversity of microorganisms to an extreme by providing a steep redox gradient across
the granule diameter as demonstrated for microbial mats. That makes combined nitrification or
denitrification activities or phosphorous removal in single-stage biomass. In addition, oxygen
that is produced by the photo granules could reduce or entirely eliminate costly mechanical
aeration of activated sludge in wastewater treatment at the same time, autotrophic CO2 fixation
in photo granules produces biomass that could serve as a renewable energy source. Much
successful OPGs cultivation has been performed under a variety of conditions and from a
variety of municipal waste streams around the world. It is an algal sludge granule wastewater
treatment process based on photo granulation of activated sludge into OPGs. During
maturation, granules increase their net density via compaction. OPGs are dense, spherical and
easily settleable granules that work without external aeration and consume more carbon
dioxide, reducing the greenhouse gas emissions. Thus, it has the potential to reduce the
municipal wastewater treatment cost.

Activated sludge exposed to light transforms into OPGs in a closed static environment without
external aeration or nutrients. During a cultivation, compaction and phototrophic growth phases
occurs. Gliding movements allow cyanobacteria to self-organize into stable population
patterns. A mature granule takes approximately 42 days to develop and is defined by the
retention of a granule’s structure after firm shaking is applied. Statically cultivated OPGs have
been successfully seeded in bench-scale sequencing batch reactors for wastewater treatment
Reactor OPGs have high settleability which facilitates the recovery and reuse of biomass as
bio-feedstock. Though researchers have achieved promising results at the bench scale, we are
still trying to understand how these granules form under both static and hydrodynamic
conditions.

DEPARTMENT OF CHEMICAL ENGINEERING 13

1.2 OBJECTIVE

The main objectives of the work are

• General Study of effluent treatment in Milma plant.

• Design of Activated sludge reactor.
• Experimental study of OPG’s.

1.3 TOPIC SELECTION

Diary waste water is characterized by high COD and BOD, which has a drastic effect on aquatic
life. Therefore development of effective water treatment method has high importance in
environmental protection. Conventional waste water treatment consists of preliminary,
primary, secondary and tertiary treatments that are based on biological, physical and chemical
process. Even though conventional methods offer some degree of waste removal they possess
many disadvantages. That are:

• Requires a large area.

• Issue of ecological disposal of the sludge waste.
• High cost of construction.
• Requires technically skilled man power for operation and maintenance.

Whereas advanced treatment technique offers several advantages over conventional methods,
they are:

• Environmental compatibility
• Little or no need of addition of chemicals
• Characterised by simple equipment
• Easy operations
• Low cost
• Versatility
• Low temperature and pressure requirements.

DEPARTMENT OF CHEMICAL ENGINEERING 14

So in this report we decided to design a activated sludge reactor for treating the diary waste
water. And are doing an experimental study of OPGs to make the treatment method more
economical.

DEPARTMENT OF CHEMICAL ENGINEERING 15

 CHAPTER 2

LITERATURE REVIEW

Dairy Wastewater Treatment Common techniques for treating dairy industry wastewaters
include grease traps, oil water separators for separation of floatable solids, equalization of flow,
and clarifiers to remove SS. Biological treatment consists of the aerobic and anaerobic process.
Sometimes anaerobic treatment followed by aerobic treatment is employed for the reduction of
soluble organic matter (BOD) and biological nutrient removal (BNR) is employed for the
reduction of nitrogen and phosphorus. Sometimes chlorination of the effluent is also done for
the purpose of disinfection before reusing the water.

In dairy capacity of waste generated is 4 lakhs litre per day. Waste is treated in a daily basis.
The waste produced form all the products are treated with the same procedure and at same
time.

2.1 Fat Removal

A common problem in dairy effluent treatment plant is precipitation of fat as a result of the
lower pH & temperature in the treatment plant. The operation of fat trap is enhanced by
enhanced by ensuring that the effluent is as possible. Milk fat is a liquid at a temperature greater
than 35ᵒC and is difficult to remove in a fat trap. More fat is removed in fat trap at acidic pH
values to be emulsified and there for is not removable in the fat trap.

2.2 Screening & Settling

It gives little reduction in BOD mechanically brushed & inclined screens with 1-5 mm opening
typically are used to remove curd particles & large solid objects and detritus chamber or solid
settling tank is incorporated to remove grit.

2.3 Activated sludge

DEPARTMENT OF CHEMICAL ENGINEERING 16

Activated sludge system used commercially for dairy waste includes fill and draw high rate,
deep shift, extended aeration & contact stabilization. Activated sludge treatment involves an
aeration process followed by clarification step and a return of varying amounts of active
biomass to the aeration tank. The activated sludge involves the production of an activated mass
of microorganisms that stabilize the waste under aerobic conditions. The microorganism mass
consists principally of bacteria, but also protozoa and other cells (Metcalf et al. 2003). This
mass is kept in suspension in the reactor by using appropriate mixing methods, and oxygen is
provided to fulfil the aerobic conditions of the system (Metcalf et al. 2003). The wastewater
influent is kept in contact with the biomass for a certain period (Hydraulic Retention Time)
after which the mixture of both substances, the so-called mixed liquor suspended solids
(MLSS), flows to the secondary clarifier where the microbial mass is settled and thickened
(Metcalf et al. 2003). Part of this settled solids are recirculated back to the aerobic reactor
(return activated sludge, RAS) in order to keep the concentration of biomass high, an important
factor to ensure the efficiency of the system. The other part of the sludge is discarded every
day from the system (waste activated sludge, WAS) into the sludge treatment stage (Von
Sperling 2007, Metcalf et al. 2003).

The Raw Effluent from the various unit processes of the Dairy, bearing pollutant loads of varied
nature flows to the Effluent Treatment Plant. The treatment scheme envisaged for the
abatement of pollutant loads mainly incorporates oil and grease removal, biological treatment
followed by gravity sedimentation. The process effluent bearing floating materials shall be
allowed to flow through a screen for retaining the floating materials. The screened effluent
bearing substantial amount of oil and grease and suspended solids, is led to an oil and grease
trap. The separation of oil from the effluent follows the principle of gravity separation, wherein,
due to lower specific gravity of oil, the free oil floats on the surface in an oil water mixture.

The heart of the treatment process is the aerobic biological treatment, which is designed on the
basis of extended aeration principle of activated sludge process. The activated sludge treatment
process basically involves the stabilization of organic matter by the action of various micro -
organisms as depicted in the following equation: Organics + Micro - organism + Oxygen +
Nutrients ---- > CO2 + NH3 + Energy + New cells This relation could be restated as: Waste
water + Sludge + Air ----- > Surplus sludge + End products in this biological process, a part of
the newly synthesized sludge undergoes oxidation called Endogenous respiration. Cells +
Oxygen ---- > End products- Less cells the performed biological floc (expressed as MLVSS)

DEPARTMENT OF CHEMICAL ENGINEERING 17

come in contact with the incoming effluent in the aeration tank under highly aerobic
environment and oxidize the organic matter to more stable materials.

The efficiency of the aeration system depends on the concentration of active micro - organisms
present to perform the assimilation of organic matter. The activated sludge in general consists
of bacteria, micro-organisms like protozoa, rotifers etc. in the presence of dissolved oxygen.
The desirable environmental conditions like sufficient dissolved oxygen, substrate, nutrients
are required for cell growth and energy for various metabolic functions. It is essential that
biological floc should readily separate from the treated effluent in a settling unit before
disposal. Excess or deficient quantity of substrate adversely affect the physical quality of
biological sludge.

2.4 Photogranules

Adil Muhammed published a paper (2021) where author concluded that oxygenic
photogranules process is better than activated sludge process for treating wastewater, especially
for the removal of chemical oxygen demand and nutrients such as nitrate and phosphate. Sludge
produced after treatment can be used for generating bioenergy feedstock, e.g. biodiesel,
fertilizer, bioethanol and biomass that can be burned to produce heat and electricity.

Activated sludge process requires external aeration for treating sewage. Hence it consumes a
large amount of energy in the form of electricity. But OPG treats sewage effectively without
external aeration. Therefore, OPG process is a cost-effective method for the treatment of
sewage.

DEPARTMENT OF CHEMICAL ENGINEERING 18

 CHAPTER 3

GENERAL STUDY OF EFFLUENT TREATMENT IN MILMA

PLANT

3.1 GENERAL INFORMATION

Operates Milk processing units in different parts of Kerala under the trade name Milma.
Important Milma products are Milma smart milk, Milma toned milk, Milma rich milk,
skimmed milk curd, Milma butter milk, Milma ghee, Milma slip-up. The steps in milk
processing operations carried out in a diary plant are:

• Blending: obtain a specific fat content

• Clarification and cream separation remove any sediments and bacteria
• Cream separation is carried out at 40ᵒC at 5000-6000 rpm
• Heat treatment, primary pasteurization destroys lipase activity and other milk
• Enzymes and also to destroy pathogenic bacteria
• Homogenization -makes a stable emulsion of milk fat and milk serum
• Packaging

The dairy industry involves processing raw milk into products including milk, butter, and
cheese, yogurt, using processes such as chilling, pasteurization, and homogenization. Typical
by-products include buttermilk, whey, and their derivatives. Huge amounts of water are used
during the process producing effluents containing dissolved sugars and proteins, fats, and
possibly residues of additives. Waste waters are primarily generated from the cleaning and
washing operations. Due to the high pollution load of diary waste water, the milk processing
industries discharging untreated/partially treated waste water cause serious environmental
problems.

Four common ways to treat wastewater include physical water treatment, biological water
treatment, chemical treatment, and sludge treatment. The detailed process description is given
bellow.

DEPARTMENT OF CHEMICAL ENGINEERING 19

3.1.1 Physical water treatment In this stage, physical methods are used for cleaning the
wastewater. Processes like screening, sedimentation and skimming are used to remove the
solids. No chemicals are involved in this process.

One of the main techniques of physical wastewater treatment includes sedimentation, which is
a process of suspending the insoluble/heavy particles from the wastewater. Once the insoluble
material settles down at the bottom, you can separate the pure water.

Another effective physical water treatment technique includes aeration. This process consists
of circulating air through the water to provide oxygen to it. Filtration, the third method, is used
for filtering out all the contaminants. You can use special kind of filters to pass the wastewater
and separate the contaminants and insoluble particles present in it. The sand filter is the most
commonly used filter. The grease found on the surface of some wastewater can also be removed
easily through this method.

3.1.2 Biological water treatment This uses various biological processes to break down
the organic matter present in wastewater, such as soap, human waste, oils and food.
Microorganisms metabolize organic matter in the wastewater in biological treatment. It can be
divided into three categories:

• Aerobic processes: Bacteria decomposes the organic matter and converts

it into carbon dioxide that can be used by plants. Oxygen is used in this
process.

• Anaerobic processes: Here, fermentation is used for fermenting the waste

at a specific temperature. Oxygen is not used in anaerobic process.

• Composting: A type of aerobic process where wastewater is treated by

mixing it with sawdust or other carbon sources.

Secondary treatment removes most of the solids present in wastewater, however, some
dissolved nutrients such as nitrogen and phosphorous may remain.

DEPARTMENT OF CHEMICAL ENGINEERING 20

3.1.3 Chemical water treatment As the name suggests, this treatment involves the use of
chemicals in water. Chlorine, an oxidizing chemical, is commonly used to kill bacteria which
decomposes water by adding contaminants to it. Another oxidizing agent used for purifying
the wastewater is ozone. Neutralization is a technique where an acid or base is added to bring
the water to its natural pH of 7. Chemicals prevent the bacteria from reproducing in water, thus
making the water pure.

3.1.4 Sludge treatment This is a solid-liquid separation process where the least possible
residual moisture is required in the solid phase and the lowest possible solid particle residues
are required in the separated liquid phase.

An example of this includes dewatering of sludge from industrial wastewater or sewage plant
where the residual moisture in dewatered solids determines the disposal costs and the centrate
quality determines the pollution load returned back to the treatment facility. You need to
minimize both.

Fig 3.1 Entrance of Trivandrum milma diary.

DEPARTMENT OF CHEMICAL ENGINEERING 21

3.2 UNITS OF EFFLUENT TREATMENT PLANT

1. Raw Effluent
2. Oil and Grease trap
3. Primary Aeration
4. Secondary Aeration
5. Clarifier
6. V-notch
7. Sludge drying bed
8. Slow Sand filter
9. Lagoons
10. Ultra-filtration

3.3 UNIT DESCRIPTION AND OPERATION

3.3.1 RAW EFFLUENT COLLECTION SUMP AND PUMP

Unit Description:

Number of Raw effluent collection sump: 1 no.

Material of construction: RCC

Dimensions of the tank: 4.2 m dia x 5.75 m TD

Liquid depth in the tank Capacity of the tank: 1.15 m

No. of bar screen: 16 m

Material of construction: MS

No of screen channel: 1 no

Operation:

• Ensure that the floating materials retained and the screening removed regularly
and disposed off to avoid blockage of the raw effluent conduits.

DEPARTMENT OF CHEMICAL ENGINEERING 22

 • Ensure that the pumps are sufficiently primed prior to initiating the pump
operation.
• Check the pH of the effluent at inlet of oil and grease trap regularly. pH of the
raw effluent should be maintained in the neutral range.
• During every shift composite samples are to be taken of the raw effluent t and
treated effluent.

3.3.2 OIL AND GREASE TRAP

Operation:

Raw effluent bearing bil and grease from collection pump is pumped to the oil and
grease trap where oil due to its lesser specific gravity floats to the surface. The oil and grease
trap is provided with a baffle upstream of the outlet weir for retaining the floating oil. The
effluent devoid of oil overflows the outlet weir and is led to the primary aeration tank

Unit Description:

Number of tanks: 1 no.

Material of construction: RCC with baffle walls

Dimensions of the tank: 9.75 m x 3.42 m x 1.9 m TD

Liquid depth in the tank: 1.5 m

Capacity of the tank: 50 m

Detention time in the oil and grease trap : 1.6 hrs.

DEPARTMENT OF CHEMICAL ENGINEERING 23

 Fig 3.3.2 Oil and Grease Trap

3.3.3 PRIMARY AND SECONDARY AERATION TANK:

Loading Data:

Incoming effluent flow to aeration tank: 750 m3/day

BOD, 5days @ 200C: 1200 mg/L

MLSS: 4000 mg/L

F/M ratio: 0.15

Unit Description:

Primary aeration tank: 1 no.

Material of construction: RCC

Dimensions of the tank: 32.4 m x 10.8 m x 3. 3m TO

DEPARTMENT OF CHEMICAL ENGINEERING 24

 Liquid depth of the tank: 2.8m

Capacity of the tank: 989 m

Detention period: 31

No. of aerators: 2 nos.

Secondary aeration tank: 1no

Material of construction: RCC

Dimensions of the tank: 19 m x 19 m 10 m x 3.15m TD

Liquid depth of the tank: 2.65 m

Capacity of the tank: 504 m

Detention period:16 hrs.

Operation & Process Monitoring:

The start-up of the activated sludge process involves the development of a microbial culture
and gradually acclimatising the culture to treat the raw efiluent. The initiation process could be
achieved by either inducting a / seed sludge or directly from the raw effluent to develop a
suitable micro-organism population expressed as Mixed Liquor Suspended Solids (MLSS).
The start-up using the raw effluent that is done by adhering to the following steps.

Fill the aeration tank with ra raw effluent. Aerate the raw effluent in the aeration tank
continuously for 8 hours. After the initial aeration, the aerator be turned off and the tank
contents allowed to settle for 30 - 60 min. Allow additional effluents to enter the aeration tank
displacing the tank supernatent. The duration of the introduction of fresh effluent into the tank
is to be decided with respect to the available effluent flow.

The mixture is then re-aerated and allowed to settle as before. This procedure be adopted till
the MLSS concentration in the aeration tank reaches a level of 500 mg/1. At this stage the
aeration tank could be put on operation on continuous flow. The initiation of the continuous
operation of the aeration tank may be taken up on increments of 25, 50, 75 and 100% designed

DEPARTMENT OF CHEMICAL ENGINEERING 25

flow. increments being decided based on the quality i treated effluent discharging from the
aeration tank.

During the cultivation of the micro-organisms in the start-up, regular MLSS and dissolved
oxygen analysis are to be conducted on the contents of the aeration tank. Check influent COD,
BOD and SS contents regularly and determine COD/BOD ratio of the effluent. These tests
enable a quick measure of the efficiency of the activated sludge treatment process and a quick
means of estimating the ratio of organics (BOD5) to the microbial population (MLSS) usually
referred to as the food to micro-organism ratio (F/M). The relationship among COD/BOD/SS
allows the COD test to be used for process control in lieu of much longer BOD5 test.

When the MLSS in the aeration tank reaches around the designed level, careful attention is
required to sustain the MLSS in the aeration tank. In maintaining so, regular checks on the
aeration tank and return sludge, MLSS and SVI are necessary. Based on these observations,
required quantity of sludge is to be recirculated to the aeration tank and the excess sludge
wasted. It is imperative that once the designed MLSS concentration is achieved and the system
is operating satisfactorily discharging quality effluent, the sludge wastage / recirculation
operation be controlled effectively.

The figure of 4000 mg/1 of MLCS is considered in respect of the designed BOD and inflow
only. However, it may also so happen that either of BOD and inflow rate may vary in the actual
course of operation. In the case of variation being on the higher side, ensure that the quality
and quantity that is being fed in the aeration tank is within 5% of the design, failing which the
performance of the activated sludge system may deteriorate. In the case of variation towards
lower side, the actual required MLSS to maintain the desired F/M ratio is calculated and
sustained in the aeration tank to achieve a balanced performance from the system.

In general, the aerators are to be run continuously along with continuous sludge recirculation.
However, in the case of non-availability flow of effluent, the frequency of aerator operation
may be suitably adjusted so as to retain a residual dissolved oxygen concentration in aeration
contents above 2.0 mg/1. In case of pre-planned shutdown for a longer period, the entire sludge
from the clarifier be returned to the aeration tank. In such cases, after re-commissioning, the
final effluent characteristics may be poor initially but shall improve after a short duration of
continuous operation as the system restabilise.

DEPARTMENT OF CHEMICAL ENGINEERING 26

 Fig 3.3.3 Aeration Tank

DEPARTMENT OF CHEMICAL ENGINEERING 27

 Fig 3.3.3 Aeration Tank

3.3.4 FINAL CLARIFIER:

Operation:

The mixed liquor from the secondary aeration tank overflowing outlet weir enters the
clarifier by gravity. The mixed liquor discharges at the central feed pipe. The direction of the
flow in the clarifier is first downwards and then upwards. Due to quiescent conditions
prevailing in the clarifier and the velocity of rise being very less, the biological solids settle on
the floor of the clarifier. The settled sludge is continuously scraped to the central sludge pit by
the MS scraper mechanism driven by a central drive head coupled to a motor. The clear effluent
overflows through the peripheral V-notch weir and flows through the launder for disposal. The
settled sludge from the sludge pit is withdrawn regularly and transferred either to the primary
aeration tank or the sludge drying beds through 2 nos. (1W + 15) return sludge pumps.

DEPARTMENT OF CHEMICAL ENGINEERING 28

 Unit Description:

No. of unit :1 no.

Material of construction: RCC

Dimensions of the tank Liquid depth of the tank: 2.5 m

Capacity of the tank: 68 M

Detention period: 2.1

Number of return sludge pumps provided: 2 nos.

3.3.5 V-NOTCH CHAMBER:

Operation:

The treated effluent from the clarifier launder flows by gravity to V-notch chamber and
is led for disposal. The chamber is equipped with V-notch for measuring the flow of treated
effluent. The flow measurements through V-notch help in arriving at a water balance and in
the processed they help in detecting the pipe leakages or other hidden losses in the plant. The
flow in a 90° V-notch is calculated as per the following formula:

Q cubic ft./sec = 2.5 H5/2

Where Q =Flow of effluent in cubic feet/sec

H= Head of water on the notch weir in feet

Unit Description:

Dimensions of the chamber: 3 m x 2 m x 1 m

Material of construction: RCC

No. of tank: 1 no

No. of V-notch provided: 1 no

DEPARTMENT OF CHEMICAL ENGINEERING 29

3.3.6 SLUDGE DRYING BED

Operation:

The excess biological sludge from the clarifier is pumped into sludge drying beds. The
filtrate flows into raw effluent collection sump by gravity. The dried cake is removed and
disposed of suitably.

Unit Description:

No. of beds: 6 nos.

Material of construction: Brick masonary with 150 m dia open-jointed stoneware

pipes as underdrains.

Filter Media: Graded gravel and sand

Dimensions of each bed: 11 m x 7 m x 1.2 m

Effective area of each bed: 77 m3

Fig 3.3.6 Sludge drying bed

DEPARTMENT OF CHEMICAL ENGINEERING 30

3.3.7 Slow Sand filter

The basic principle of the process is very simple. Contaminated freshwater flows through a
layer of sand, where it not only gets physically filtered but biologically treated. Hereby, both
sediments and pathogens are removed. This process is based on the ability of organisms to
remove pathogens.

Although the physical removal of sediments is an important part of the purification process,
the relevant aspect is the biological filtration. The top layers of the sand become biologically
active by the establishment of a microbial community on the top layer of the sand substrate,
also referred to as ‘schmutzdecke’. These microbes usually come from the source water and
establish a community within a matter of a few days. The fine sand and slow filtration rate
facilitate the establishment of this microbial community. The majority of the community are
predatory bacteria that feed on water-borne microbes passing through the filter. Hence, the
underlying principle of the SSF is equivalent to the bio-sand filtration. While the former is
applied to semi-centralized water treatment, the latter mainly serves household purposes.

3.3.8. Lagoons

In the lagoon, wastewater is treated through a combination of physical, biological, and

chemical processes. Much of the treatment occurs naturally, but some systems use aeration
devices to add oxygen to the wastewater. Aeration makes treatment more efficient, so that less
land area is necessary.

Wastewater enters and leaves the lagoon through inlet and outlet pipes. Modern designs place
the inlet as far as possible from the outlet, on opposite ends of the lagoons, to increase detention
times and to prevent short-circuiting. Some lagoons have more than one inlet. Outlets are
designed depending on the method of discharge. They often include structures that allow the
water level to be raised and lowered.

Aerators, which are used instead of algae as the main source of oxygen in aerated lagoons,
work by releasing air into the lagoon or by agitating the water so that air from the surface is
mixed in. Aeration always causes turbulence and mixing in the lagoon. Different aerator
designs produce either fine or coarse bubbles, and work either on the water surface or

DEPARTMENT OF CHEMICAL ENGINEERING 31

submerged. Subsurface aerators are preferable in climates where the lagoon is likely to be
covered by ice for part of the year.

Fig 3.3.8 Lagoon

3.3.9. Ultrafiltration

Ultrafiltration process is widely used in dairy and food industries. The pore size of UF
membrane (0.001-0.01 µm) is lesser than NF and RO membrane. The pressure applied during
UF is between 1-10 bar. The UF process membranes are especially characterized on the basis
of molecular weight cut off (MWCO) rather than a pore size of membrane material. Even
several membranes manufacturers treat MWCO as basic criteria for accessing the efficiency of
membrane separation. MWCO ranges from 1-200 kDa for UF processes.

Ultrafiltration (UF) is a water purification process in which water is forced through a

semipermeable membrane. Suspended solids and high-molecular-weight solutes remain on one
side of the membrane, the retentate side, while water and low-molecular-weight solutes filter
through the membrane to the permeate side.

DEPARTMENT OF CHEMICAL ENGINEERING 32

 Fig 3.3.9 Ultrafiltration

DEPARTMENT OF CHEMICAL ENGINEERING 33

 Fig 3.3.10 Flow diagram

DEPARTMENT OF CHEMICAL ENGINEERING 34

 CHAPTER 4

DESIGN OF ACTIVATED SLUDGE REACTOR

Qо : Volumetric flow rate of influent (m³/day)

Qw : Volumetric flow rate of the liquid containing microorganism to be wasted (m³/day)

S : Substrate concentration (mg/l)

X : Biomass concentration (mg/l)

Xo : concentration of microorganism mass in influent (mass of volatile suspended solids or

VSS per unit volume) (mg/l)

Xe : Concentration of microorganism mass in effluent (mg/l)

Xw : Concentration of microorganism mass in wasted sludge (mg/l)

V : Volume of the aeration tank

DEPARTMENT OF CHEMICAL ENGINEERING 35

ASSUMPTIONS

1. The content in the aeration tank are completely mixed.

2. The influent substrate concentration (So) remains constant.
3. The system operates under steady state condition.

AERATION TANK

1. Mass balance for microorganism (Biomass) under steady state condition

𝑅𝑎𝑡𝑒 𝑜𝑓 𝑖𝑛𝑓𝑙𝑜𝑤 𝑜𝑓 𝑅𝑎𝑡𝑒 𝑜𝑓 𝑜𝑢𝑡𝑓𝑙𝑜𝑤 𝑜𝑓

𝑁𝑒𝑡 𝑅𝑎𝑡𝑒 𝑜𝑓 𝑐𝑒𝑙𝑙 𝑔𝑟𝑜𝑤𝑡ℎ
[𝑚𝑖𝑐𝑟𝑜𝑜𝑟𝑔𝑎𝑛𝑖𝑠𝑚 𝑖𝑛𝑡𝑜 ] − [𝑚𝑖𝑐𝑟𝑜𝑜𝑟𝑔𝑎𝑛𝑖𝑠𝑚 𝑓𝑟𝑜𝑚] + [ ]=0
𝑖𝑛 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚
𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚

(QоXо)–((Qо-Qw)Xe + QwXw) + V (dX/dt)net = 0 …………………………………(1)

μnet = 1/X(dX/dt)net

(dX/dt)net = dX/dt - k d X…………………………(2)

Dividing eqn (2) by X

(dX/dt)net /X= (dX/dt / X) - k d ……………………………(a)

1
μnet = μ-kd = …………………….……(b)
Ɵc

Assume Xо and Xe = 0 ………………………….(c)

QwXw=V*X* μnet ……………………….…(3)

μnet = QwXw / V*X ……………………….....(4)

Where μnet = net specific growth rate (day-1)

μ = specific growth rate (day-1)

kd = endogenous decay constant (day-1)

Assume Xо and Xe = 0 …………………….(c)

DEPARTMENT OF CHEMICAL ENGINEERING 36

2. Mass balance for substrate (s) utilization under steady state condition

𝑅𝑎𝑡𝑒 𝑜𝑓 𝑖𝑛𝑓𝑙𝑜𝑤 𝑜𝑓 𝑅𝑎𝑡𝑒 𝑜𝑓 𝑜𝑢𝑡𝑓𝑙𝑜𝑤 𝑜𝑓

𝑅𝑎𝑡𝑒 𝑜𝑓 𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒
[ 𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒 𝑖𝑛𝑡𝑜 ] − [ 𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒 𝑓𝑟𝑜𝑚 ] + [ ]=0
𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛
𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚 𝑡ℎ𝑒 𝑠𝑦𝑠𝑡𝑒𝑚

𝑑𝑠
(𝑄0 𝑆0 ) - ((𝑄0 − 𝑄𝑊 ) 𝑆𝑒 + 𝑄𝑊 𝑆𝑊 ) + V = 0 …………………………. (5)
𝑑𝑡

3. Yield Coefficient(Y)

It is the ratio of mass of cell formed to mass of substrate utilized.

𝑅𝑎𝑡𝑒 𝑜𝑓 𝑏𝑖𝑜𝑚𝑎𝑠𝑠 𝑝𝑟𝑜𝑑𝑢𝑐𝑒𝑑

Y= 𝑅𝑎𝑡𝑒 𝑜𝑓 𝑏𝑖𝑜𝑚𝑎𝑠𝑠 𝑢𝑡𝑖𝑙𝑖𝑠𝑒𝑑

𝑑𝑥⁄
= (−𝑑𝑠 𝑑𝑡 )
⁄𝑑𝑡

−𝑑𝑥⁄
𝑑𝑠⁄ = 𝑑𝑡
𝑑𝑡 𝑌

Substituting this condition on (5)

∗
𝑄0 (𝑆0− 𝑆𝑒 ) = (𝑉⁄𝑌) 𝜇 ∗ 𝑋 ………………………………..(6)

V/Qо= Ɵ = (𝑆0− 𝑆𝑒 )𝑌/μ*X

(S0− Se )
Y =μ
Ɵ∗X

From (b) we can reform the above equation as,

1
μ-kd = [(𝑆0− 𝑆𝑒 )𝑌/Ɵ*X]-kd = μne= Ɵc

1
= [(𝑆0− 𝑆𝑒 )𝑌/Ɵ*X]-kd …………………………….(7)
Ɵc

4. Design Parameters

Average sewage generated per day = 750000 L/day

DEPARTMENT OF CHEMICAL ENGINEERING 37

Influent flow rate, Qo = 750 m3/day

Influent substrate concentration, So = 350 mg/l

Effluent substrate concentration, Se = 10 mg/l

Influent and effluent biomass concentration (xo and xe) = 0

5. MLSS Concentration

The concentration of the liquid and microorganism in the aeration tank is known as mixed
liquor and the suspended solids are called mixed liquor suspended solids (MLSS)

Let, concentration of MLSS (X) = 4000 mg/l

Underflow concentration from secondary clarifier (XW) = 12000 mg/l

6. Bio-Kinetics Parameter

Yield coefficient (Y) = 0.6174 mg VSS/mg BOD5

Decay coefficient (kd) = 0.0309 day-1

Maximum specific substrate utilization factor (k) = 3.17 day-1

Saturation constant (ks) = 311.7 mg/l

7. Mean cell residence time/sludge retention time (Ɵc)

It is the average time (days) that a micro-organism will spend in the activated sludge process.

DEPARTMENT OF CHEMICAL ENGINEERING 38

Combining equation (4) & (b)

1 µmaxSe
= - Kd
Ɵc Ks+Se

µmax = k *Y

= 3.17*0.614

= 1.94638 day

1 1.94638∗10
= – 0.0309
Ɵ𝑐 311.7+10

= 0.02961 day-1

Ɵc= 33.76 ≈ 34 days

8. Hydraulic retention time (Ɵ)

It is the amount of time in hours for waste water to pass through an aeration tank.

From equation (7),

Ɵ𝑐 y(So− Se)
Ɵ= *
𝑋 1+ KdƟc

34 0.615 (350−10)
=4000 * 1+[0.0309∗34]

= 1.57 day = 37.88 hr

9. Volume of the aeration tank (V)

𝑉
Ɵ = 𝑄𝑜

V= Ɵ*Qo

750
= * 37.88
24

= 1183.90 m³

DEPARTMENT OF CHEMICAL ENGINEERING 39

10.Organic loading rate (F/M ratio)

Food to microorganism ratio (F/M) expresses the substrate loading per unit time per unit
mass of bio-mass in aeration tank.

𝐹⁄ = 𝑄𝑜 𝑆𝑜
𝑀 𝑉 𝑋

𝑆𝑜
= Ɵ∗𝑋

350
= 1.57∗4000

= 0.0557 mg/mg day

Extended aeration, 0.04<F/M<0.15

Hence, F/M ratio is acceptable.

11. Excess sludge wasting

Mass of sludge wasted each day (QwXw)

𝑉∗𝑋
QwXw = Ɵ𝑐

1183.90∗4000
= 34∗1000

= 140.2725 kg/ day

Volume of the sludge wasted (Qw)

QwXw = 140.2725

Xw = 12000 mg/l

140.2725
Qw = = 11.6893 m³/day
12000× 10−3

12. Sludge recycle ratio (α)

𝑄𝑟
α = 𝑄𝑜

QR = Sludge recirculation rate (m³/day)

DEPARTMENT OF CHEMICAL ENGINEERING 40

To find QR,

Bio-mass balance around secondary clarifier,

(Qo + QR)*X = (Qo - Qw)Xe+ (Qw + QR) Xw

Xe = 0

(Qo + QR)*X= (Qw + QR) Xw

(750+QR)*4000 = (11.6893+QR)*12000

QR = 357.465 m³/ day

Therefore sludge recirculation rate= 357.465 m³ /day

𝑄𝑟
α = 𝑄𝑜

357.465
= 750

= 0.4766

This ratio is within the range of a for conventional plant i.e. 0.25 to 0.5

13. Treatment efficiency

So−Se
Efficiency= 𝑆𝑜

350−10
= × 100 = 97.14%
350

14. Oxygen requirement in aeration tank

O2 balance at steady state condition can be written as

𝑀𝑎𝑠𝑠 𝑜𝑓 oxygen 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝐵𝑂𝐷

𝑇𝑜𝑡𝑎𝑙 𝑎𝑐𝑡𝑖𝑣𝑒 𝑚𝑎𝑠𝑠 𝑜𝑓
[ 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 ]=[ 𝑟𝑒𝑚𝑜𝑣𝑒𝑑 ] -1.42 [ ]
𝑜𝑟𝑔𝑎𝑛𝑖𝑠𝑚 𝑤𝑎𝑠𝑡𝑒𝑑 𝑝𝑒𝑟 𝑑𝑎𝑦
𝑝𝑒𝑟 𝑑𝑎𝑦 𝑝𝑒𝑟 𝑑𝑎𝑦

DEPARTMENT OF CHEMICAL ENGINEERING 41

 Qo(So−Se)
mO2 = 𝑓∗(103𝑔/𝑘𝑔) − 1.42 Px

where,

mO2= mass of oxygen required per day, kg/day

Px= mass of sludge wasted each day in terms of volatile suspended solids (vss), kg/day

f= conversion factor for converting BOD5 to ultimate BOD

We have mass of sludge wasted each day (Px)= 140.2725 kg/day

f= 0.675

750∗(350−10)
mO2 = − (1.42 ∗ 140.2725)
0.675∗1000

mO2 = 178.59 kg/day

At 25ᵒC, Density of air= 1.185 kg/ m³

The mass fraction of O2 in air = 0.232

O2 transfer efficiency for conventional system is generally in the range of 5-10%

Assume O2 transfer efficiency at 25ᵒC =10%

The volume of air required at 10% of O2 transfer efficiency is,

178.59
=1.185∗0.232∗0.1

= 6496 m³/day

DEPARTMENT OF CHEMICAL ENGINEERING 42

SETTLING TANK

1.Design Parameters

Influent flow rate to the settling tank (Q) = QR+Q0

= 357.465+750 = 1107.465 m³/day

➢ Surface loading/ over flow rate varying between 24 to 30 𝑚3 /day/𝑚2 of plan area or
1000 to 1250 L/hr / 𝑚2 of plan area.
➢ Detention period in the tank within the range of 2 to 4 hrs

Assume, a detention period = 2 hr

over flow rate = 24 𝑚3 /day/𝑚2

2. Volume

1107.465
Capacity = * 2 = 92.28 𝑚3
24

Plan area = L *B
𝑄
=𝑜𝑣𝑒𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒

1107.465
= 24

= 46.144 𝑚2

Using width of the tank as 6m, i.e , B= 6m

46.144
L= 6

= 7.69 m

𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
Depth = 𝑝𝑙𝑎𝑛 𝑎𝑟𝑒𝑎

92.28
=46.144

=2m

Settling tank can be provided with a dimension of 7.69*6*2

DEPARTMENT OF CHEMICAL ENGINEERING 43

Here we have to provide extra depth for sludge storage, sludge depth = 0.5 m

Assuming that a free board of the tank = 2+0.5+0.5=3m

Hence tank size to be used shall be = 7.69*6*3

10. COST ESTIMATION

Cost Estimation is defined as the compilation of all the cost of elements of a project or effort
included within an agreed upon project scope. Correct estimation is done in accordance with
principle outlined by Max. S. Peters and Klaus D. Timmermans.

We have the total purchased equipment cost of 35,13,850 for the year 2014.

Year 2014 2021

Cost index 1536 1700
Table 4.1 Marshall & Swift Equipment cost Index

Total Purchased equipment cost for the year 2014 = Rs. 3513850

Total Purchased equipment cost for the year 2021= Rs. 3513850 * (1700/1536)

= Rs. 3889026

1. Direct costs:

Purchased Equipment Cost (100%) = 38,89,026

Equipment installation Cost (25%) = 9,72,256

Instrumentation Control (10%) = 3,88,902

Piping Cost (25%) = 9,72,256

Electrical Installation (15%) = 5,83,353

DEPARTMENT OF CHEMICAL ENGINEERING 44

 Service Facilities (50%) = 19,44,513

Land (5%) = 1,94,451.3

Total Direct Cost = 89,44,751

2. Indirect Cost

Engineering and Supervision (30%) = 11,66,707

Construction Expense (10% of total Direct cost ) = 8,94,475

Contingency (10% of direct cost ) = 8,94,475

Total Indirect Cost = 29,55,657

3. Fixed Capital Investment = 1,19,00,408

4. Working Capital ( 74%) = 28,77,879

5. Total Capital Investment = Fixed Capital Investment + Working Capital

= 1,47,78,287

DEPARTMENT OF CHEMICAL ENGINEERING 45

 CHAPTER 5

EXPERIMENTAL STUDY OF OXYGENIC PHOTOGRANULE

PROCESS FOR AERATION-FREE WASTEWATER
TREATMENT

5.1 GENERAL OUTLINE

Oxygenic photo-granules (OPGs) are a type of biological aggregate with an approximately

spherical form, typically from a milli-meter to a centi-meter scale. OPGs are characterized by
the cloth-like layer of phototrophic organisms, predominantly filamentous cyanobacteria.
Oxygen production by these phototrophs through photosynthesis is typically coupled to
oxygen consumption of heterotrophic biomass, releasing CO2 that is presumably utilised in a
syntrophic relationship by autotrophic phototrophs. This study presents the oxygenic photo
granule (OPG) process, a light-driven process for wastewater treatment, developed based on
photo granulation of filamentous cyanobacteria and non-phototrophic bacteria. OPG process
was operated in stirred-tank reactors without aeration. Reactors were seeded with
hydrostatically grown photo granules and operated in a sequencing batch mode to treat
wastewater. A novel method of cultivating Oxygenic Photo Granules (OPGs) which are natural
aggregates predominantly consisting of cyanobacteria from the activated sludge and using it to
treat the wastewater in the secondary treatment is under development. After the primary
treatment, OPGs help to substitute the high energy-consuming aeration equipment which
deems the secondary process more sustainable. Cultivation of OPGs is influenced by many
factors including the intensity of light used during cultivation, the concentration of sludge etc.
Manipulating these factors, we can cultivate OPGs in the most efficient way possible.

5.2 OPG CULTIVATION

Activated sludge samples were collected from the aeration basin of the Sewage Treatment
Plant, Milma Diary, Kunnamangalam, Kozhikode . The experimental procedure involves
filling of the glass vials (15 ml) with 8 ml sludge. Granulation takes place within the vials.
During granulation, the vials are kept undisturbed. The incubator is illuminated with LED lights
of 18 W, throughout the day at room temperature. The vials are illuminated for 24 hours using

DEPARTMENT OF CHEMICAL ENGINEERING 46

LED bulbs within the incubator. The biomass in one vial yields precisely one photogranules
that is typically situated at the bottom of the vial. The vials are observed at regular intervals to
check on the progression of OPG growth. To determine the success of granulation, the shake
test was performed by using three firm vertical shakes and then observing the vial contents.
When a granule remained without particulates in the bulk liquid, granulation was considered
as successful.

Fig 5.2 Cultivation of OPG

DEPARTMENT OF CHEMICAL ENGINEERING 47

 Fig 5.2 Cultivation of OPG

5.3 ADVANTAGES OF OPG’S OVER ACTIVATED SLUDGE

PROCESS

Oxygenic photogranule process is better than activated sludge process for treating wastewater,
especially for the removal of chemical oxygen demand and nutrients such as nitrate and
phosphate. Sludge produced after treatment can be used for generating bioenergy feedstock,
e.g. biodiesel, fertilizer, bioethanol and biomass that can be burned to produce heat and
electricity. Activated sludge process requires external aeration for treating sewage. Hence it
consumes a large amount of energy in the form of electricity. But OPG treats sewage effectively
without external aeration. Therefore, OPG process is a cost-effective method for the treatment
of sewage.

DEPARTMENT OF CHEMICAL ENGINEERING 48

 Fig 5.3 Graph of removal efficiency

5.4 SUMMARY

Domestic, municipal and industrial wastewater treatment is very important and required great
attention before the discharge of water into the water resource. The novel method of treatment
of wastewater using Oxygenic Photo Granules (OPGs) shows promising results. As the
technologies are moving towards sustainability, the energy-efficient treatment process using
OPGs is very significant. In this work, the energy-intensive aeration process is substituted by
OPGs. Result obtained from this work gives a clear indication that wastewater treatment using
OPGs are efficient process compared to the conventional activated sludge process. OPGs allow
the recovery of chemical energy from wastewater in the form of bioenergy feedstock. There is
a considerable reduction in waste sludge generation and energy cost. The treatment of
wastewater using OPGs is currently being done on a pilot-scale which upon scaling up will
lead us one step towards sustainability.

DEPARTMENT OF CHEMICAL ENGINEERING 49

 CHAPTER 6

CONCLUSIONS
The Project work was aimed to study technologies available for treatment of dairy wastewater.
It is concluded that due to variation in quality and quantity of dairy wastewater, all previous
discussed treatment technologies need to be combine with conventional effluent treatment plant
with tertiary treatment. It is possible to reduce COD, BOD and other constituents from dairy
wastewater with the help of advance technologies available.
The activated sludge process consists of maintaining an active floc in a tank supplied with
oxygen so that maximum contact is made between the incoming waste water and the
microorganisms in the floc. In the conventional process, a rectangular tank is usually used and
the waste water is introduced into a concentration of microorganisms maintained in the tank.
Air is introduced, either in the form of bubbles through diffusers or by turbulent agitation of
the liquid by an impeller. The microbe concentration is maintained in the tank by returning a
certain portion of the sludge that passes through the tank and is settled out in a secondary
sedimentation basin. The activated sludge process produces new cell material which will
become part of the activated sludge mass. Part of the settled material therefore, must be
disposed of, and a portion must be introduced into the incoming raw waste water in order to
have an active population of microorganisms that will feed on the organic compounds. Also
this project involves the detailed design of an activated sludge reactor. Also an Experimental
study of Oxygenic photogranules also included in this. This can be substitute the aeration tank
in the current design and reduce the capital cost.

DEPARTMENT OF CHEMICAL ENGINEERING 50

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