PROCESS DESIGN CALCULATIONS

OF

5 KLD EFFLUENT TREATMENT PLANT

CLIENT:-

HIND TERMINAL PRIVATE LIMITED

KILA RAIPUR-01, DEHLON, LUDHIANA, PUNJAB-141118

ETP CONTRACTOR:

KELVIN WATER TECHNOLOGIES PVT. LTD.

PLOT NO 81, SECTOR 5, IMT MANESAR
GURUGRAM, HARYANA-122051
MOBILE: +91-9812241001, 9812646262
Email: info@kelvinindia.in, kelvinwatercare@gmail.com
Website: www.kelvinindia.in
 CONTENT

S. No. PARTICULARS
1.0 INTRODUCTION OF ETP
2.0 EFFLUENT CHARACTERISTICS
3.0 DETAIL PROCESS& OPERATIONS
4.0 SCHEME OF EFFLUENT TREATMENT
5.0 DESIGN DETAILS OF ETP

1.0 INTRODUCTION OP ETP

AVERAGE FLOW – 5 m3/ Day

FLOW PER BATCH = 2 Nos.
CAPACITY OF TREATMENT PER BATCH = 2.5 CUM
WORKING HOURS = 10 Hr.

Effluent treatment plant, also known as ETP is a wastewater treatment process (WWTP) that is used to
treat wastewater. It's mostly used in industries like pharmaceuticals, textiles, and chemicals where extreme
water contamination is a possibility. Effluent Treatment Plant plays a significant role in the treatment of
industrial wastewater as well as domestic sewage. Organic matter, inorganic matter, heavy metals, oil &
grease, suspended particles, and other contaminants are treated in the wastewater treatment process of an ETP
plant. Chemical treatment and treatment are the several types of wastewater treatment plants 5 m3/day.

2.0 EFFLUENT CHARACTERISTICS

Inlet & Outlet parameters shall be considered for designing the Effluent Treatment Plant.
Treatment Plant as under: -

INLET OUTLET
S. No. PARAMETER
(Raw Effluent) (After Treatment)
1. Quantity of wastewater, 5 m3/Day 5 m3/Day
2. pH 6.5-8.5 6.5-8.5
3. TSS, mg/l 70-130 <50
4. Oil & Grease, mg/l <40 <10
5. COD, mg/l 300-450 <100
6. BOD, mg/l 20-60 <20
3.0 DETAILED PROCESS & OPERATIONS

TREATMENT SCHEME CONSISTS OF FOLLOWING EQUIPMENTS

Sr. EQUIPMENT/ QTY LOCATION

No. Tanks
1. Bar Screen Chamber 1No Before Oil & Grease chamber

2 Bar Screen 1No In Bar screen chamber

3 Oil &Grease Tank 1 No After Bar Screen Chamber

4 Oil skimmer 1 No In Oil& Grease chamber

5 Collection Tank/Equalization 1 No. At Starting point of the

Tank ETP.
6 Air Blower 1 No. Near Collection Tank

7 Coarse Bubble Air Diffusers 1lot In Collection Tank

9 Aeration Grid 1lot In Collection Tank

10 Effluent Transfer Pump 2 No. Near Collection Tank

11 Reaction Cum Tube Settler 1 No. After Collection tank

Tank
12 Dosing tanks 3 Nos. Near Reaction Tank
13 Dosing pumps 3 Nos. Near Dosing Tank

14 Sludge Drying Bed 1 No. Near Drying Bed

15 Filter Feed Tank 1 No. After Reaction Tank

16 Filter Feed Pump 2 No. Near Filter Feed Tank

17 MGF- Multi grade filter 2 No. Near Filter Feed Tank

ACF- Activated Carbon
Filter
1. BAR SCREEN CHAMBER :
The bar screen chamber in an Effluent Treatment Plant (ETP) serves as the initial stage for removing
large solid debris and floating objects from incoming wastewater before it undergoes further treatment
processes

2. BAR SCREEN:
Bar screens are essential components used in Effluent Treatment Plants (ETPs) to remove large solid
debris, such as plastics, rags, sticks, and other large particles, from wastewater before it enters
subsequent treatment processes.

3. OIL &GREASE CHAMBER:

An oil and grease chamber is a specific component used within an Effluent Treatment Plant (ETP) to
target the removal of oils, greases, and other floating contaminants from wastewater

4. OIL SKIMMER:
Oil skimmers play a crucial role in an Effluent Treatment Plant (ETP) for the removal of oils, grease, and
other floating contaminants from wastewater.

5. COLLECTION CUM EQULIZATION TANK:

An equalization tank in a wastewater treatment plant serves as a holding or buffer tank to balance
and regulate the influent flow rate and composition before it enters the treatment process. Its primary
functions include

• Flow Equalization: It evens out fluctuations in the incoming flow rate. Wastewater flow can vary
widely throughout the day due to factors like industrial discharges, rainfall, or peak usage times.

• pH and Chemical Balance: It helps to balance and stabilize the pH level and chemical composition
of the wastewater. Variations in pH and chemical content can hinder the efficiency of treatment
processes. The equalization tank allows for mixing and adjustment, ensuring the incoming water
meets the treatment requirements.

• Reducing Peak Loads: By spreading out the influent flow and characteristics over time, the
equalization tank helps prevent overloading the treatment system during peak flow periods.

• Enhancing Treatment Efficiency: A more consistent and controlled influent stream allows the
downstream treatment units to operate more effectively and efficiently. It helps in maintaining a
stable environment for biological processes, reducing the likelihood of upsets or failures

6. Air Blower:

Air blowers play a crucial role in an Effluent Treatment Plant (ETP) for wastewater treatment. Here's
how they are typically used:

• Aeration: Air blowers are primarily used for aeration purposes in ETPs. The oxygen helps the
chemical reaction to break down chemical matter in the wastewater, facilitating the decomposition
of pollutants.
 • Mixing: Blowers aid in the mixing of wastewater and activated sludge. They create turbulence and
keep the mixture well-agitated.
• Oxidation: By blowing air into the water, the blowers promote the oxidation of pollutants. This
process helps convert some contaminants into less harmful forms, enhancing the overall treatment
efficiency..
• Odor Control: In some cases, blowers can also be used for odor control by aerating certain areas to
reduce the presence of foul-smelling gases.

7. Effluent Transfer Pump

Start effluent transfer pump for supply of effluent to CHEMICAL REACTION TANK/ CLARIFIER
when collection cum equalization till tank is full with effluent or have a sufficient level of effluent.

8.Reaction/Clarifier Tank
Effluent from Collection tank is taken into reaction tank, dose all chemicals like Lime, Alum & Poly
Electrolyte at reaction tank for pH adjustment and neutralized the impurities like COD, BOD, TSS

9 . Filter Feed Tank :

The treated water from the Reaction Tank/Clarifier is to be taken into filter feed tank.

Operation:

• Start P2 (Filter feed Pump) to feed the MGF & ACF (Multigrade filter & Activated CarbonFilter)
• Stop P2 (Filter feed Pump) when the filter feed tank is almost empty.
• Backwash once in day

10. MGF & ACF

a).Multigrade Filter(MGF):MGF is a physical filtration process used to remove suspended solids and
particles from wastewater

b). Activated Carbon Filter (ACF): ACF utilizes activated carbon to remove contaminants and impurities
from the water. Activated carbon has a large surface area and unique adsorptive properties that make it
effective in the treatment process

Finally treated water goes through the MGF & ACF. pH of outlet water should be 6.5-8.5

BACKWASH PROCEDURE FOR MGF AND ACF:

 The pressure gauge located on the multiport valve or on top of the vessel will indicate when this procedure
is needed. Backwashing of MGF and ACF are only needed when pressure in pressure gauge increases 2.5 to
3.5 kg/cm2 while starting up or as per our ETP SOP

11.Sludge Drying Bed:

When it is observed that flow from reaction tank is low then it implies that it is having sludge, which can
be removed by opening of valve fixed at the bottom of the REACTIONTANK/CLARIFIER. Sludge
shall be transferred into the sludge drying bed for dewatering.

Operation:
• Frequency of remove Dry sludge from top of the sludge Drying Bed should be 1-2days.

12.Chemical Dosing
Chemical dosing in an Effluent Treatment Plant (ETP) involves the controlled addition of specific
chemicals to the wastewater at different stages of treatment. The primary purposes of chemical dosing
include:

• pH Adjustment: Chemical dosing is frequently used to regulate and balance the pH level of
wastewater. By adding acids or alkalis, the pH of the effluent can be adjusted to meet the optimal range
required for subsequent treatment processes. Maintaining the correct pH is crucial for the efficiency of
biological and chemical treatments.
• Coagulation and Flocculation: Chemicals like coagulants (e.g., aluminum sulfate, ferric chloride) and
flocculants (e.g., polymers) are dosed into the wastewater to induce the formation of larger particles
from smaller colloidal particles.
• Disinfection: Chemical dosing may include the addition of disinfectants such as chlorine or ozone to
kill or deactivate harmful microorganisms present in the wastewater.
• Odor Control: Chemicals may also be dosed to control foul odors emanating from the wastewater.
Odor control agents, like oxidizing agents or deodorizers, are added to mitigate unpleasant smells
before the effluent is discharged or reused.
4.0 SCHEME OF EFFLUENT TREATMENT PLANT

The scheme of the treatment in the plant is shown in figure below.

5.0 DESIGN DETAILS OF ETP

a) Design Details of Bar Screen Chamber

DESCRIPTION VALUES
Design Flow (Qp) 0.5 m3/hr
Hydraulic Retention Time. (HRT) 18 Min.
Tank Volume (V) 0.15 cum
Dimension 500 (L) x 500 (W) x 600 (H)
Location Starting of ETP plant

b) Design Details of Oil & Grease Chamber:

DESCRIPTION VALUES
Design Flow (Q) 0.5 m3/hr
Hydraulic Retention Time. (HRT) 32 min
Tank Volume (V) V= Q x HRT =0.27 m3
Dimension Taken 800 (L) x 500 (W) x 700(H)
Location After Bar Screen Chamber

c) Design Details of Collection Cum Equalization Tank:

DESCRIPTION VALUES
Inlet Flow (Q) 5m3/day
Hydraulic Retention Time. (HRT) 24 Hrs
Effective Tank Volume 5 m3
Dimension 2200 (L) x 1500 (W) x 1500 (SWD) + 300 (FB)
Location After Oil & Grease Chamber

d) Design Details of Reaction Cum Settling Tank:

DESCRIPTION VALUES
Design Flow (Q) 5 m3/day
No. of Batches taken 2 Nos.
Treatment per batch 2.5 cum/ batch
Tank Volume Capacity of per batches = Tank Volume
Tank Volume 2.5 kl

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e) Design Details of Filter Feed Tank

DESCRIPTION VALUES
Design Flow (Q) 2.5 m3/Per batch
Effective Tank Volume 2kl
Location After Reaction Tank

f) Design Details of Sludge Drying Bed:

DESCRIPTION VALUES
Design Flow (Q) 2.5 m3/Per batch
Sludge per batch 3-5%
Sludge 0.125 Cum/batch
Total Sludge Generation 0.125 cum/batch x Nos. Batch
= 0.250 Cum/batch
Taken Tank Volume 0.3 cum

g) Design Details of Treated Water Tank:

DESCRIPTION VALUES
Design Flow (Q) 2.5 m3/Per batch
Taken Tank Volume 2kl or as per end uses
Location After MGF & ACF

h) Design Details of Multi Grade Filter:

DESCRIPTION VALUES
Design Flow 2.5 m3/Per batch
Flow Taken (Q) 1 cum.hr
Filtration velocity (V) 12 m/hr
Area A= Q/V= 0.083 m2
Diameter of filter 325 mm
Proposed filter model 325x1350
Location After Filter feed tank

2
i) Design details of Activated Carbon Filter:

DESCRIPTION VALUES
Design Flow 2.5 m3/Per batch
Flow Taken (Q) 1 cum.hr
Filtration velocity (V) 12 m/hr
Area A= Q/V= 0.083 m2
Diameter of filter 325 mm
Proposed filter model 1354 (325 x1350)
Location After ACF

j) DESIGN DETAILS OF PUMPS

I) Design details of Effluent Transfer Pump

DESCRIPTION VALUES
Pump details 1m3/hr@ 10 m head
Pump Capacity Calculation =Plant capacity/working Hrs.
=5000ltr/10
=500ltr/hr or 0.5 m3/hr
Therefore ,we select pump with 1m3/hr
capacity ,we can regulate the flow using
valves
Static Head = 5.33 m
Head loss in pipe lines by Darcy-Weisbach = 0.27 m
equation = Formula used= f x l x v2/ 2 x g x d
Head loss in pipe lines by Hazen Williams = 2.755 m
formula = Formula used = 10.67*C-1.85*D-
4.87*Q1.85*L
Note: Head loss taken is the highest value of head loss by Darcy Weisbach and
Hazen Williams formula.
Head loss due to valve and fittings = 0.18 m
= Formula used = k x v2/2g
Total Head = 5.33 + 2.755 + 0.18 = 8.265 m
Pump Head with 20% factor of safety = 8.265 + (8.265x20%) = 9.918 m ~ 10 m

3
II) Design details of Filter Feed Pump

DESCRIPTION VALUES
Pump details 1m3/hr@ 35 m head
Pump Capacity Calculation =Plant capacity/working Hrs.
=5000ltr/10
=500ltr/hr or 0.5 m3/hr
Therefore ,we select pump with 1m3/hr
capacity ,we can regulate the flow using
valves
Static Head = 8.7 m
Head loss in pipe lines by Darcy- = 0.67 m
Weisbach equation = Formula used= f x l x v2/ 2 x g x d
Head loss in pipe lines by Hazen = 5.534 m
Williams formula = Formula used = 10.67*C-1.85*D-
4.87*Q1.85*L
Note: Head loss taken is the highest value of head loss by Darcy Weisbach and
Hazen
Williams formula.
Head loss due to valve and fittings = 0.28 m
= Formula used = k x v2/2g
Total Head = 8.7 + 5.534 + 0.28 = 14.514 m
Pump Head with 20% factor of safety = 14.514 + (14.514x20%) = 17.416 m ~ 17.5
m
Safety factor for filter backwashing 2 = Overall head x 2= 17.5 x 2 = 35 m
times

k) Air Blower :

DESCRIPTION VALUES
Oxygen requirement 1.25 kg/kg COD
COD Load per Day COD (mg/l)x Q/1000
= 300x5/1000 = 1.5 kg/Day
Standardized amount of O2 required = 1.5x1.25/10= 0.18/h
Density of air 1.206 kg/m3
Std. O2 transfer efficiency (S.O.T.E.), % 7.5 % (air diffuser)
membrane type diffuser (6-8%)
% Oxygen in air by weight 23%
Air Required in Equalization Tank = 0.18/(1.2x0.075x0.23) m3/h
= 9.05 m3/h ~ 10 m3/h
Air Blower Blower capacity ~ 10 m3/h

4
k) Oil Skimmer :

DESCRIPTION VALUES
Flow rate 5 KLD
Oil and grease concentration 40 mg/l
Operating hours 10 hours/day
Total oil and grease per day Flow rate×Oil and grease concentration
=5000 l/day×40mg/l
=(5000l/day×40mg/l)100
=2000 l/day
Capacity 2 Liter per day