Present Presentation is about Phenolic Effluent Treatment Plant in Coke Oven & Coal Chemicals Plant

BACKGROUND Spillage & Excess Flushing Liquor generated in CO&CCP is generally used in hot Coke quenching in other Steel plant. First time in VSP 100% Dry Quenching is introduced. As a result excess flushing liquor & toxic effluent generated in the Plant need to be treated before disposal.

SOURCES OF EFFLUENTS
Excess Flushing liquor after stripping of

Free Ammonia in Ammonia Columns. Purge out water from the contaminated cooling circuit. Oil contaminated effluent generated in Benzol Distillation Plant. Settled water from the Tar Storage Tanks. Effluent collected in different Phenolic Pump House.

Average Quantity & Quality of different Sources

Parameter
Qty. (Cum/hr)

Stripped EFL
70

Purge Out Water

25

Effluent from BDS

20

PH
Phenol (ppm) Cyanide (ppm) Rhodanide (ppm)

7-9
1500-1900 15-25 500-700

7-9
1000-1700 250-300 300-450

7-9
100-200 10-12 30-50

Total Ammonia (ppm)

Oil & Grease (ppm) COD (ppm)

300-500
100-200 7000-8500

200-300
200-300 5000-6000

300-400
300-400 1500-2000

Ammonium Salts. Phenol & its homologues. Thio-cyanides or Rhodanides. Cyanides Hydrogen Sulphide Tar & Oil.

In order to handle and detoxify the effluent the present plant was built and commissioned with Russian Technology in September 1989. The basic design parameters are as below. Capacity 120 Cum/hr.
Sl 01 02 Parameter Phenol Rhodanides Unit Inlet PPM PPM 400 400 Norm Outlet 1 10

03
04 05 06 07 08 09

Free NH3
Total NH3 Tar & Oil TSS Cyanide BOD COD

PPM
PPM PPM PPM PPM PPM PPM

250
600 500 100 20 2500

80 100
500 25 150-200 1.5 3.5 150 300

Tar Settlin g Tank

Oil Flotators 3 4 8 9

Heat Exchanger
7

PT1
A21
10 11

PT2

A11

Air Blower

E2

A15
1st Aerotank P1 P2 2nd

A25
Aerotank

E1

STP.

Equalizing Tanks

Process Flow Diagram for MBC.

The different methods use for the treatment of effluent are Mechanical, Chemicals and Biological.
Heavy particles, settle able materials, tar and heavy oils

are removed by settling. Light Oils are removed by froth flotation mechanism. Organic pollutants like Phenol, Cyanide and Thio-Cyanide are by Biological method using Activated Sludge Process.

PROCESS DESCRIPTION
All Inputs are collected, mixed with air in Pre-Aerators and distributed in Tar Settling Tanks (TST). TST works in parallel. Heavy matter and tar settle in TST and the settled effluent overflow to collecting tank. From collecting tanks effluent is pumped to Oil Flotators via Pr. tanks for oil removal. Two Oil Flotators can work in series or parallel. Oil is removed by froth flotation mechanism. From Oil Flotators effluent overflow to Equalizing tanks by gravity. Here P2O5 is added and pumped to 1st stage Aerotanks for Phenol degradation.

PROCESS DESCRIPTION
In 1st Stage degradation of Phenol take place due to bio-oxidation by activated sludge. Effluent Overflow from 1st stage to intermediate collecting tank from where it is again pumped to 2nd stage Aerotanks. Cyanide and Rhodanides are decomposed here by similar action like 1st stage. Effluent from 2nd stage overflow to intermediate collecting tank and from there it is pumped to STP.

Two numbers Air blowers pumps ambient air into the system as a source of Oxygen.

UNIQUE FEATURES
Use Activated Sludge process for Bio-Oxidation, where

million of bacteria of different species act simultaneously. Use of Diffused Aerators in the Aerotanks to supply of air to the system which ensure uniform aeration and mixing of all parts of tanks. Continuous cultivation of Bacteria at site and periodic addition of fresh Bacteria to the system. Availability of reserved Equalizing tank to mitigate abrupt change in the inputs.

Effluent Quality in April 2009

Sl Parameter Unit Quality at Inlet Norm
01 02 03 04 05 06 Phenol Ammonical N2 Tar & Oil TSS Cyanide COD ppm ppm ppm ppm ppm ppm 400 600 500 100 20 2500

Quality at Outlet Norm

1 500 25 150200 1.5-3.5 300

Actual
842 252 27 167 43 4,720

Actual
0.65 272 7.6 346 0.83 1,000

Shortcomings of the Present System

Inadequate Capacity w.r.t present pollutant load.

Higher Concentration of Pollutant at the inlet.

Lack of Facilities for Treatment of Ammonical Nitrogen. Norm of Cyanide is more than existing Pollution Control

Norm. Ammonical Nitrogen in the treated effluent is more than existing Pollution Control Norm.

Salient Features of New Plant

Volumetric Capacity Enhancement from 120 Cum/hr to 200

Cum/hr. Reduction of Ammonical Nitrogen to 50 ppm. Reduction of Cyanide to 0.20 ppm. De-Colourization. Reduction of Hydrogen Sulphide. Reduction of COD 250 ppm. Cooling of effluent in Flash Evaporator. Use of fine bubble diffused aerators.

Salient Features of New Plant

Patent Technology with established performance in some

of the existing plant in Russia. Simultaneous Bio-Oxidation of Ammonia (both Nitrification & De-nitrification), Cyanide, Thio-Cyanide & H2S with residual Phenol in a single aerobic stage. Use of activated charcoal treatment after biological treatment to reduce Colour & COD of the effluent. Final control of Turbidity of effluent in Sand Bed Filter. Entire treatment is based on Activated Sludge Process.

Brief Outline of New Process

Pre-treatment will be done in the existing Tar Settling Tanks &

Oil Flotator to remove Tar, Oil & Foreign materials. Averaging of effluent will be carried out in the present Equalization Tanks & 1st stage Aero Tanks. The aim to homozonise the incoming effluent as well as to mitigate the effect of any change. 1st Stage Biological treatment for reduction of Phenol up to 2530 ppm will be done in the present 2nd Stage Aero tanks. Single Stage treatment for residual Phenol, Cyanides, ThioCyanides, Ammonical Nitrogen & Hydrogen sulphide will be done in newly constructed tranks. Residual COD & Colour reduction by activated carbon treatment. Reduction of Turbidity in the treated effluent by Quartz filters.

Quality of the Treated Effluent after new facility established.

Sl Parameter Concentration (ppm) As per Project 01 02 PH Phenol 79 1.0 PC Norm 6.5 9.0 1.0

03 04
05 06

Cyanide Thio-Cyanide
Ammonical Nitrogen Hydrogen Sulphide

0.20 2.0
50.00 2.0

0.20 Not Exist

50.00 Not Exist

07
08 09 10

COD
BOD TSS Oil & Grease

250
30 100 10

250
30 100 10

Status of New Plant

Construction is nearly completed.
Flash

Unit for cooling of incoming effluent is commissioned. Testing & Trial of individual Equipment and Unit is under progress. Cultivation of new culture is completed & adequate quantity is available for use. Integrated Commissioning of systems yet to be started.

Our Problems
Increase in the Pollutant load with commissioning of each

new battery. Sharp and abrupt increase in the Pollutant load with reduction of production level. Unexpected change in behavior of the culture/system with every new of blend. Frequent break down of Air blower due to high vibration. Existing methodology to determine Cyanide is unreliable and erratic at lower concentration generally below 1 ppm.