Dabur Report (1)

8/6/2019 Dabur Report (1)

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PROJECT REPORT ON EFFLUENT TREATMENT

PLANT

(23rd JUNE-23rd JULY)

SUBMITTED BY:-

SAURABH AGARWALB.Tech(Biotech)

IVTH YEAR

AMITY UNIVERSITY

LUCKNOW CAMPUS



CONTENTS

1) History of Dabur 2

2) Dabur at a glance 6

3) Product Profile 7

4) Introduction to Quality Assurance 9

5) Microbiology Lab. 10

6) Effluent Treatment Plant 14

7) Water Treatment

A) Reverse Osmosis Plant 32

B) De-Mineralized water Plant 38

8) Conclusion 39

9) Reference 40

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Dabur India Ltd. made its beginnings with a small pharmacy, but has continued to learn and grow to a

commanding status in the industry. The Company has gone a long way in popularising and making easilyavailable a whole range of products based on the traditional science of Ayurveda. And it has set very highstandards in developing products and processes that meet stringent quality norms. As it grows even further,Dabur will continue to mark up on major milestones along the way, setting the road for others to follow.

1884 - Established by Dr. S K Burman at Kolkata

1896 - First production unit established at Garhia

1919 - First R&D unit established

Early 1900s - Production of Ayurvedic medicinesDabur identifies nature-based Ayurvedic medicines as its area of specialisation. It is the first Company toprovide health care through scientifically tested and automated production of formulations based on ourtraditional science.

1930 - Automation and upgradation of Ayurvedic products manufacturing initiated

1936 - Dabur (Dr. S K Burman) Pvt. Ltd. Incorporated1940 - Personal care through Ayurveda

Dabur introduces Indian consumers to personal care through Ayurveda, with the launch of Dabur AmlaHair Oil. So popular is the product that it becomes the largest selling hair oil brand in India.

1949 - Launched Dabur Chyawanprash in tin packWidening the popularity and usage of traditional Ayurvedic products continues. The ancient restorativeChyawanprash is launched in packaged form, and becomes the first branded Chyawanprash in India.

1957 - Computerisation of operations initiated

1970 - Entered Oral Care & Digestives segmentAddressing rural markets where homemade oral care is more popular than multinational brands, Daburintroduces Lal Dant Manjan. With this a conveniently packaged herbal toothpowder is made available ataffordable costs to the masses.

1972 - Shifts base to Delhi from Calcutta1978 - Launches Hajmola tablet

Dabur continues to make innovative products based on traditional formulations that can provide holistic care inour daily life. An Ayurvedic medicine used as a digestive aid is branded and launched as the popular Hajmolatablet.

1979 - Dabur Research Foundation set up

1979 - Commercial production starts at Sahibabad, the most modern herbal medicines plant atthat time

1984 - Dabur completes 100 years

1988 - Launches pharmaceutical medicines

1989 - Care with funThe Ayurvedic digestive formulation is converted into a children's fun product with the launch of HajmolaCandy. In an innovative move, a curative product is converted to a confectionary item for wider usage.

1994 - Comes out with first public issue

1994 - Enters oncology segment

1994 - Leadership in health careDabur establishes its leadership in health care as one of only two companies worldwide to launch the anti-cancer drug Intaxel (Paclitaxel). Dabur Research Foundation develops an eco-friendly process to extractthe drug from its plant source

1996 - Enters foods business with the launch of Real Fruit Juice

1996 - Real blitzkrieg

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Dabur captures the imagination of young Indian consumers with the launch of Real Fruit Juices - a newconcept in the Indian foods market. The first local brand of 100% pure natural fruit juices made to internationalstandards, Real becomes the fastest growing and largest selling brand in the country.

1998 - Burman family hands over management of the company to professionals

2000 - The 1,000 crore markDabur establishes its market leadership status by staging a turnover of Rs.1,000 crores. Across a span of over a 100 years, Dabur has grown from a small beginning based on traditional health care. To a commandingposition amongst an august league of large corporate businesses.

2001 - Super specialty drugsWith the setting up of Dabur Oncology's sterile cytotoxic facility, the Company gains entry into the highlyspecialised area of cancer therapy. The state-of-the-art plant and laboratory in the UK have approval fromthe MCA of UK. They follow FDA guidelines for production of drugs specifically for European and Americanmarkets.

2002 - Dabur record sales of Rs 1163.19 crore on a net profit of Rs 64.4crore

2003 - Dabur demerges Pharmaceuticals business

Dabur India approved the demerger of its pharmaceuticals business from the FMCG business into a separatecompany as part of plans to provider greater focus to both the businesses. With this, Dabur India now largelycomprises of the FMCG business that include personal care products, healthcare products and AyurvedicSpecialities, while the Pharmaceuticals business would include Allopathic, Oncology formulations and Bulk

Drugs. Dabur Oncology Plc, a subsidiary of Dabur India, would also be part of the Pharmaceutical business.

Maintaining global standards

As a reflection of its constant efforts at achieving superior quality standards, Dabur became the firstAyurvedic products company to get ISO 9002 certification.

Science for nature

Reinforcing its commitment to nature and its conservation, Dabur Nepal, a subsidiary of Dabur India, has setup fully automated greenhouses in Nepal. This scientific landmark helps to produce saplings of raremedicinal plants that are under threat of extinction due to ecological degradation.

2005 - Dabur aquires Balsara

As part of its inorganic growth strategy, Dabur India acquires Balsara's Hygiene and Home productsbusinesses, a leading provider of Oral Care and Household Care products in the Indian market, in a Rs 143-crore all-cash deal.

2005 - Dabur announces bonus after 12 years

Dabur India announced issue of 1:1 Bonus share to the shareholders of the company, i.e. one share for everyone share held. The Board also proposed an increase in the authorized share capital of the company fromexisting Rs 50 crore to Rs 125 crore.

2006 - Dabur crosses $2 bin market cap, adopts US GAAP.

Dabur India crosses the $2-billion mark in market capitalisation. The company also adopted US GAAP in linewith its commitment to follow global best practices and adopt highest standards of transparency andgovernance.

2006 - Approves FCCB/GDR/ADR up to $200 million

Moving forward on the inorganic growth path, Dabur India decides to raise up to $200 million from theinternational market through Bonds, FCCBs, GDR, ADR, QIPs or any other securities.The capital raised will beused to fund Dabur's aggressive growth ambitions and acquisition plans in India and abroad.

2007 - Celebrating 10 years of Real

Dabur Foods unveiled the new packaging and design for Real at the completion of 10 years of the brand. Thenew refined modern look depicts the natural goodness of the juice from freshly plucked fruits.

2007 - Foray into organised retail

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Dabur India announced its foray into the organised retail business through a wholly-owned subsidiary, H&BStores Ltd. Dabur will invest Rs 140 crores by 2010 to establish its presence in the retail market in India with achain of stores on the Health & Beauty format.

Dabur at a Glance

Dabur India Limited has marked its presence with some very significant achievements and today commands amarket leadership status. Our story of success is based on dedication to nature, corporate and process hygiene,dynamic leadership and commitment to our partners and stakeholders. The results of our policies and initiativesspeak for themselves.

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Leading consumer goods company in India with a turnover of Rs.2233.72 Crore (FY07)

2 major strategic business units (SBU) - Consumer Care Division (CCD) and Consumer Health

Division (CHD)

3 Subsidiary Group companies - Dabur Foods, Dabur Nepal and Dabur International and 3 stepdown subsidiaries of Dabur International - Asian Consumer Care in Bangladesh, African ConsumerCare in Nigeria and Dabur Egypt.

13 ultra-modern manufacturing units spread around the globe

Products marketed in over 50 countries

Wide and deep market penetration with 47 C&F agents, more than 5000 distributors and over 1.5million retail outlets all over India

CCD, dealing with FMCG Products relating to Personal Care and Health Care

Leading brands -

Dabur - The Health Care Brand

Vatika-Personal Care Brand

Anmol- Value for Money Brand

Hajmola- Tasty Digestive Brand

and Dabur Amla, Chyawanprash and Lal Dant Manjan with Rs.100crore turnover each

Vatika Hair Oil & Shampoo the high growth brand

Strategic positioning of Honey as food product, leading to market leadership(over 40%) in branded honey market

Dabur Chyawanprash the largest selling Ayurvedic medicine with over 65%

market share.

Leader in herbal digestives with 90% market share

Hajmola tablets in command with 75% market share of digestive tablets

category

Dabur Lal Tail tops baby massage oil market with 35% of total share

CHD (Consumer Health Division), dealing with classical Ayurvedic medicines

Has more than 250 products sold through prescriptions as well as over the counter

Major categories in traditional formulations include:

- Asav Arishtas- Ras Rasayanas- Churnas- Medicated Oils

Proprietary Ayurvedic medicines developed by Dabur include:

- Nature Care Isabgol- Madhuvaani- Trifgol

Division also works for promotion of Ayurveda through organised community of traditional practitioners

and developing fresh batches of students

PRODUCT PROFILE

Dabur name today is synonyms with Ayurvedic products. The company has some very strong brands

such as Dabur lal dant manjan, Chyawanprash, Hajmola, Pudin hara, Real juice etc. In recent yearsDabur has diversified into manufacture of allopathic medicines in the antibiotics, an antacids and

Hypersensitive segments.

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http://www.dabur.com/en/products/Health_Care/Health_Supplements/Chyawanprash/

http://www.dabur.com/Medicines

http://www.dabur.com/Medicines

http://www.dabur.com/en/products/Health_Care/Health_Supplements/Chyawanprash/



The company has a spun off the strategic business units for the manufacture and marketing of its

numerous product ranges and brands. The company’s product range can be classified in the following product categories: -

1) Export Division –

In both the areas of health and beauty care the post few years have witnessed a resurgence of interestand faith in herbal and natural remedies, the world over. The company has made an all effort to makeits presence felt in the market. As a result, Dabur is exporting to over 35 countries in the world and

exports have contributed to rs. 169 crore for the year ending. The major products being exported are

Amla hair oil, Chyawanprash, Hajmola candy, Cardamont- extract, Shilajit.

The company has up a separate company called Dabur International ltd., which will focus solely on the

export market.

2) Consumer health Division –

Dabur India has launched its new herbal product, Dabur glucorid-KP, for diabetes mellitus, whichcontains karela (bitter gourd) freeze-dried powder along with other components.

The new pill, launched across the country from Hyderabad, aims to correct the carbohydrate and lipidmetabolic disorders. With the unique combination of herbs, it is expected to regulate the sugar

metabolism, protect the body against free radical damage, delay or arrest various problems of disturbed

sugar metabolism.

3) Cosumer Care Division –

a) Health Care –

Dabur's Health Care range brings for us a wide selection of herbal products, to provide complete care

for varying individual needs. They derive their products from the time-tested heritage of Ayurveda,

backed by the most modern scientific test and trials. That ensure unfailing quality and safety in

anything we pick.The products are Dabur Chyawanprash, Glucose-D, honey, Dabur Lal Tail, Hajmola, Pudin Hara,

Hingoli, Anardana, Shilajit, Dabur Balm, Sankh pushpi etc.

b) Personal Care –

Dabur presents its range of herbal personal care products, created to make us look and feel good deep

down. Bringing together the gentle touch of nature and Ayurveda’s wisdom. Backed by the unfailing

quality of Dabur Products.

The products are Amla Hair Oil, Vatika Hair Oil, Gulabari, Vatika Fairness Face Pack, VatikaShampoo, and Dabur Red Toothpaste Gel etc.

4) Pharmaceutical Division –

For the sale of Ethical Allopathic Medicines and Bulk Drugs both for Indian and export market. Thisdivision has recently commenced activity and formulates drugs and Pharmaceuticals for ailments, such

as Rheumatic and Muscular pain, Anticancer like Constrastin, Angina, Pectoris and Hyper. Dabur has

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already tied up with an American company to supply an intermediate chemical, which goes into

making an anticancer drug called “Texol”.

5) Ayurvedic Division –

After more than a century of producing health care products and Ayurvedic medicines, the company

has extended its activities to the Animal health care field with a range of Ayurvedic specialties.

6) Food Division –

In the area of foods, Dabur has stepped and its widely accepted ethnic pastes are in regular demand.

The “Real Juices” is having its own importance for the absence of any chemical preservatives in it. The pure Lemon juice replacing the lemon in use.

INTRODUCTION TO QUALITY ASSURANCE

• It is the total arrangement made with the object of ensuring that pharmaceutical products are of

the quality required for their intended use.

• The system of quality assurance appropriate to the manufacture of pharmaceutical products

should ensure that:

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a) Pharmaceutical products are designed and developed in a way that accounts of the

requirements of GMP and associates codes such as those of good laboratorypractice GLP and good clinical practice (GCP).

b) Production and control operations are clearly specified in a written form and GMPrequirements are adopted.

c) Arrangements are made for the manufacture, supply, and use of the correct starting and packaging material.

d) All necessary control on starting materials, intermediated products, and bulk products and other

in process controls, calibrations and validations are carried out.

e) The finish product is correctly processed and checked, according to the defined procedures.

f) Pharmaceutical products are not sold or supplied before the authorized person have certified

that each production batch has been produced and controlled in according with the

requirements of the label claim and any other regulations relevant to the production, control

and release of pharmaceutical products.

g) Satisfactory arrangements exist to ensure, as for as possible, that the pharmaceutical products

are stored by the manufacturer, distributed and subsequently handled so that quality ismaintained through out their shelf life.

h) There is a procedure for self – inspection and/or quality audit that regularly appraises theeffectiveness and applicability of the QA system.

• To achieve the quality objective reliably there must be a comprehensively designed andcorrectly implemented system of QA incorporating GMP and QC.

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MICROBIOLOGY LAB.

To distinguish the food of acceptable quality from food of unacceptable quality required the

application of what are known as microbiological criteria. Three different types of microbiologicalcriteria have been identified.

1) A microbiological standard is a criteria specified in a law or regulation. It is a legal requirementthat foods must meet and is enforceable by the appropriate regulatory agency.

2) A microbiological specification is a criteria applied in commerce. It is a contractual condition

of acceptance that is applied by a purchaser attempting to define the microbiological quality of a product or ingredient, failure of the supplier to meet the specification will result in the rejection of

the batch or a lower price.

3) A microbiological guideline is used to monitor the microbiological acceptability of a product or

process. It differs from the standard or specification in that it is more often advisory thanmandatory.

The microbiological laboratory of QA is well equipped and maintained. All the microbiological work

is carried out in it.

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COMMONLY USED INSTRUMENTS IN MICROBIOLOGY LAB

• AUTOCLAVE

It is used for moist heat sterilization, which is carried out at 121°C for 30 minutes

at 15 psi. Media is sterilized by autoclave.

• HOT AIR OVENIt is used for dry heat sterilization. Glassware’s, petriplates and pipettes are packed

in stainless steel containers and kept at 180°C for 2 hrs.

• INCUBATOR

It is used for providing favorable temperature conditions for the growth of culture

organisms. Generally the temperature of incubator is operated at 37°C for the

growth of microorganisms.

•

BOD INCUBATOR It is used for fungal growth at 22°C.

• CYCLOMIXER

It is used to mix the suspended particles.

• STOMACHER LAB BLENDER

It is used for dissolving sample without the destruction of the organism for which

the cost is to be carried out. Sample + dilution is placed in the recommended bags

provided the total volume should be with in recommended capacity of the machine

(80 – 400 ml).

• CENTRIFUGE

It is used to separate the suspended matters as pallets/button/residue from the liquid

as supernatant.

• LAMINAR AIR FLOW UNIT

LAF unit is used for providing sterilized airflow by means of High Efficiency

Particulate Air (HEPA) filters.

• MICROSCOPE

It is used to observe stained specimen, counting microbes.

• pH METER

It is used to obtain pH value of different sample calibration is done carried out with

standard buffer solution of pH 4.0, 7.0,10.0

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• WEIGHING BALANCE

It is a precious weighing instrument for small load. It is used primarily in

professional and technical application. It is calibrated against standard weights.

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ANALYSIS OF RAW WATER

TEST SPECIFICATION RESULT

Total Plate Count Not more than 100 cfu/ml < 10cfu/ml

Coliforms Absent Complies

E. coli Absent Complies

Salmonella spp Absent Complies

P. aeruginosa Absent Complies

S. aureus Absent Complies

ANALYSIS OF R.O. WATER

TEST SPECIFICATION RESULT (II-A)

(AFTER

CARTRIDGE)

RESULT( III

-A)

(AFTER

RO)

RESULT(IV

-A)

(AFTER

RO)

RESULT (V-

A)

(AFTER

DEGASSER

1)

Total PlateCount

Not more than100 cfu/ml

< 10 cfu/ml < 10 cfu/ml < 10cfu/ml

< 10 cfu/ml

Coliforms Absent Complies Complies Complies Complies

E. coli Absent Complies Complies Complies Complies

Salmonella spp Absent Complies Complies Complies Complies

P. aeruginosa Absent Complies Complies Complies Complies

S. aureus Absent Complies Complies Complies Complies

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EFFLUENT TREATMENT PLANT

INTRODUCTION –

The effluent treatment facility is installed for biological treatment of the effluent emanating. The

effluent bears large amounts of organic matter. The direct discharge of the effluent into the water

bodies causes depletion, of DO of the water. Hence, in order to meet the recommended standards of

quality of the effluent, it is necessary to treat the effluent before it is finally disposed off. Thistreatment facility provides for removal of major pollutants from the effluent.

There are three reasons why most companies consider on – site treatment of wastewater: -a) To avoid prosecution

b) To remove restriction on the output of the factory

c) To save money

d) To protect public health in the service areae) To protect the water quality in the waterway which receives the treated effluent from the

processes.

f) To protect the environment which receives any residuals from the treatment processes.

Industries carry out cost/benefit studies to show how to achieve the greatest benefit from the

investment in effluent treatment. They design plants for the treatment of industrial effluents tailored tothe requirements of the site and the industrial process, and they can arrange a complete service through

to installation and commissioning of the effluent plant.

Wastewater from industrial processes can be difficult to treat. The cost of disposing of the effluent tothe public sewer is determined by the volume, the polluting load, the suspended solids in the flow and

the treatability of the effluent.

It may not be possible to treat the effluent with municipal sewage, or it may be cost-effective to treat

the effluent on site. The plant may be designed to reduce the strength of the effluent to a level suitable

for discharge to the sewer, or to a standard suitable for discharge to the environment, or to optimise the

balance between on-site costs and disposal charges.

Industrial wastewaters are typically much stronger than domestic sewage, and require a different

approach if they are to be treated economically.Many of the existing treatment plants are developments of municipal technology. It can be difficult to

achieve the required effluent standards, and large amounts of sludge are produced.

Sludge disposal is becoming one of the greatest problems both for the industrial wastewater treatment

plants. The available routes for disposal are reducing rapidly, and costs are escalating.

Modern aerobic treatment plants produce far less sludge with a smaller footprint on the site. Anaerobic

plants produce minimal sludge with a by-product of methane, which can be used in the upstream

processes for heating or power generation.

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TREATMENT PROCESS –

PROCESS CONCEPT -

The raw effluent, bears large amount of suspended solids and oxygen consuming organic matter. The

conceptual approach of the treatment includes the removal of suspended particles, dissolved organicmatters and handling of sludge for disposal.

The heart of this treatment scheme is the aerobic biological reactor, which are designed on the basis of activated sludge process. The activated sludge treatment process basically involves the stabilization of organic matter by the action of various microorganisms as depicted in the following equation.

Organic + Microorganisms + Oxygen + Nutrients = New cells + Carbon dioxide + Ammonia +

Energy

This could be restated in engineering term as-

Waste + 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 preformed biological flocks (MLSS) come in contact with the incoming waste in the aeration tank

under highly aerobic environment, and oxidize the organic matter to more stable materials. Theefficiency of the system mainly depends upon the concentration of active microorganism present to

perform the assimilation of organic matter. The activated sludge, in general, consists bacteria and

protozoan, rotifers etc. in the presence of DO. The desirably environmental condition like sufficientDO, substrate and nutrients are required for cell growth and energy for various metabolic functions. It

is essential that the biological flock should readily separate from the treated wastewater in the finalclarifier.

The oxygen supply is required for the following: -

1. Oxidation of organic matter (substrate removal)

2. Endogenous respiration of microorganisms.

3. Nitrification

Oxidation of nitrogenous materials is slower. Nitrification generally begins after carbonaceous demandis satisfied and occurs in two steps: -

Nitrosomonas

2 NH₄ + 3O₂ 2 NO₂ + 2H₂O + 4 H⁺ Nitrobacter

2 NO₂‾ + O₂ 2 NO₃‾

Excess or deficient quantity of food (incoming BOD) adversely affects the physical quality of

biological sludge. The activated sludge system is designed on the basis of a particular food to

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microorganism ratio. This ratio is in practice indicated by the quantity of BOD in influent per unit

quantity of mixed liquor suspended solids per unit time. This may be expressed as kg, BOD/kg,MLSS/day. The volatile suspended solid, which repression is between 60 – 70% of MLSS is used as a

measure of active cells in the system. The optimal pH for an active biological aeration system is

between 6.5 – 9.0.

In the aeration tank required MLSS concentration is maintained by recirculating the biological solids

separated in the final clarifier.

The surplus biological sludge (and the sludge from the secondary clarifier) needs further dewatering,

which is achieved in sludge drying beds. The final effluent is suitable for discharging into the inland

surface water.

PROCESS UNITS -

The units are designed for maximum of efficiency within certain flow range and effluentcharacteristics. Close control and co–ordination of the operation of different units are required within

limits of design.

Efficient plant operation is possible only when the operator is fully conversant with the equipmentsand function of each unit. This effluent treatment facility consists of the following units: -

1) Storage tank 2) Equalization tank

3) Neutralization tank

4) Primary clarifier 5) Anaerobic Hybrid Reactor

6) Aeration tanks – 1 & 2

7) Final clarifier – 18) Final clarifier – 2

9) Sludge drying beds

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UNIT DISCRIPTION AND OPERATION -

1) STORAGE TANK -

OBJECT –

The function of storage tank is that it collects and store the raw effluent from different part of the

factory.

PROCESS –

The raw effluent is collected from the different part of the factory and stored. The storage tank is of 40

feet in height. The capacity of the tank is two lack liters. Now from the storage tank the raw effluent is

passed to the equalization tank with the help of pump. The pH of the raw effluent in the storage tank is5.5 – 6.5, which generally come out from the factory.

2) EQUALISATION TANK -

OBJECT –

The function of equalization tank is to equalize the raw effluent emanating from different processing

units.

PROCESS –

The effluent is collected in an existing combined effluent from where it is pumped to the existingaeration tank, which serves as an equalization tank. The floating aerator is operated to homogenized

effluent is pumped to the neutralization tank.

3) NEUTRALIZATION TANK -

OBJECT –

The function of the neutralization tank is to neutralize the raw effluent, which is generally acidic in

nature.

PROCESS –

The raw effluent, which is usually acidic (pH-5.5 to 6.5) in nature is neutralized by adding the

saturated solution of NaOH, So, the final pH of the neutralization tank is adjusted to pH- 8.0 to 9.0.

Then the raw effluent after has been treated in neutralization tank is allowed to passed in the primaryclarifier through gravity.

4) PRIMARY CLARIFIER –

OBJECT –

The function of PC is to remove suspended heavy particles from the raw effluent.

PROCESS –

In this tank, the heavy particles along with the sludge, which the bacteria have degraded settles down

at the bottom of the tank and the water flows on top of it. A rotator is fixed in the middle of the tank,so that the heavy particle along with the sludge which has been settle down does not block the outlet

of the PC. In this tank mostly the inactive heavy particles along with little amount of sludge is thrown

out in the Sludge drying beds. The pH of the PC is maintained to 7.0 to 8.0.

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5) ANAEROBIC HYBRID REACTOR -

OBJECT –

This unit is provided for the anaerobic treatment of the effluent.

PROCESS –

The effluent after treated in PC is passed to the AHR through gravity. The design of the AHR is in a

way that at the bottom of this tank anaerobic bacteria’s beds are made. The effluent which comes fromPC react with the anaerobic bacteria and the break up of organic compounds takes place with the production of Methane gas which can be seen in the form of bubbles on the upper layer of the water in

the tank. The pH of the AHR is maintained to 7.0-7.5 because the anaerobic bacteria are stable in this

pH. If there is much fluctuation in the pH of this tank the anaerobic bacteria can die.

6) AERATION TANKS 1 & 2 -

OBJECT –

This unit is provided for aerobic biological treatment of the effluent for the reduction of organic matter

in the effluent.

PROCESS –

The effluent from the AHR is received in the aeration tank stage-1 by pumping and is aerated by thehelp of “OXYRATOR” mechanical surface aerators in the presence of previously developed

biological sludge (Mixed Liquor Suspended Solids i.e. MLSS). The food / microorganism ratio is

maintained at about 0.6 and 0.137 in the first and second stage aeration tanks respectively which

correspond to about 3500 mg / ml.

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OPERATION -

The start up of the activated sludge process can be accomplished by using seed sludge available fromnight soil develop a suitable microorganism population expressed as MLSS.

The following method is recommended for the initial development of MLSS in the aeration tank: -

The use of seed sludge (Night soil) provides the reliable means of start up. Seed sludge may be added

in the aeration tank to provide approx. 500mg/ltr. MLSS. The tank is to be filled up with fresh water prior to the addition of seed sludge. The seed sludge is to be aerated by running both the aerators and be continued for at least 24 hrs. in order to make the sludge into aerobic. With the seed sludge aerated,

raw effluent into the aeration tank is to be introduced at approx. 25% of the design flow. If possible,

aeration must be continued by all aerators and feeding of effluent increased in daily increments of 25%. If there is no indication of the process deterioration. This enables the treatment process to

produce a quality effluent as the MLSS concentration is increasing. During this operation also be

added the requisite quantity of nutrients in aeration tank.

Required nutrients viz. N and P are added with aeration tanks by pumping a solution of Urea and

DAHP. The aerators also help to keep the biological solids in suspension. The mixed liquor from the

aeration tanks is subjected to gravitational settling in the hopper bottom secondary clarifier.

7) FINAL CLARIFIER 1 -

OBJECT –

The function of final clarifier-1 is to separate biological solids from the mixed liquor first stage

aeration tank.

PROCESS –

The mixed liquor from the first stage aeration tank is received in the clarifier by gravity. The clarifier is hopper bottom type. The sedimentation of sludge is withdrawn by pumps and is recirculated back

into the aeration tank stage-1 for maintaining the MLSS. Provision is given to transfer the sludge into

the stage-2 aeration tank through the necessary connections given on the delivery line of the sludge

recirculation pump.

OPERATION –

The clarifier is filled up with effluent by gravity. The biological solids get settled by gravity at bottom.

Keep the suctions valves corresponding to each hopper portion of clarifier open. Recirculate the

settled sludge by operating pump back into the aeration tank continuously. If the MLSS exceed therequired level, or sludge needs to be wasted, divert the sludge into aerobic.

7) FINAL CLARIFIER –2 -

OBJECT –

The function of final clarifier-2 is to separate the biological sludge from the mixed liquor from the

aeration tanks before the final effluent is disposed off.

PROCESS –

The mixed liquor from the aeration tank is received in the clarifier by gravity. Final clarifier-2 is acircular sedimentation tank with the central chute inlet peripheral overflow laundar. The sedimentation

of sludge takes place by gravity setting. The settled sludge is collected to a central circular channel

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around the inlet chute by a rotating scarper. Scraper is driven by a central drive head. The settled

sludge is pumped back into the aeration tank. The clarified effluent from the annular laundar isdisposed off through the V- Notch.

8) SLUDGE DRYING BEDS -

OBJECT – This unit is meant for dewatering and drying the excess biological sludge.

PROCESS –

The excess biological sludge from the stage-1 aeration tank after aerobic digestor is conveyed to thesludge drying beds by gravity. The excess sludge from the stage-2 aeration tanks withdrawn to the

sludge drying beds by pumping. Each bed comprises of course sand broken stone as sand media

support and under drain. The dewatering of sludge is affected by percolation of associated water through the filter media while the sludge is retained on the media surface. The sludge over the media

gets dried up by natural drying and removed manually for disposal as landfill. The percolated water is

pumped to the aeration tank-2.

OPERATION –

Allow the sludge to flow to the drying beds. Once the sludge thickness comes to about 300 mm

charging of sludge is to be stop and the bed is isolated to dry up by natural evaporation. This takesabout 10 days.

After drying and dewatering, the sludge cakes are removed manually and are disposed off.

INSTRUMENTS :

pH meter – It is used to obtain pH value of different sample calibration is done carried out with

standard buffer solution of pH 4.0, 7.0,10.0

Weighing Balance – It is a precious weighing instrument for small load. It is used primarily in

professional and technical application. It is calibrated against standard weights

Hot Air Oven – It is used in dry heat sterilization. It is used at 180°C for two hours.

Reflux Apparatus – It is an apparatus in which iodine flask is fitted along with the solution and

heated. When the solution is heated nothing is lost from it.

Vacuum Suction Pump – It is used to suck the water from the sample.

BOD Incubator – Specially designed to meet the requirements for incubation of bacteria to

decompose organic matter in wastewater at temperature 25°C.

20



SPECIFICATION OF ETP -

S.No. Test Tank name Specification

1. pH Raw

PCAHR

FC-1

FC-2 Neutralization tank

5.00 – 6.50

7.00 – 8.007.00 – 7.50

5.50 – 9.00

5.50 – 9.007.50 – 9.00

2. COD RawPC

AHR

FC-1FC-2

NMT 3500 mg/ltr NMT 3000 mg/ltr

NMT 2500 mg/ltr


3. DO AT-1

AT-2

NMT 5.0 mg/ltr

NMT 5.0 mg/ltr

4. BOD Raw

AHR

FC-1FC-2

NMT 1800 mg/ltr

NMT 1500 mg/ltr


5. SS Raw

PC

FC-1FC-2

NMT 2000 ppm

NMT 1500 ppm

NMT 100 ppm NMT 100 ppm

6. MLSS AT-1AT-2

NMT 2000 ppm NMT 3000 ppm

21



TESTING -

GENERAL –

It is impertative to analyze regularly the operational parameters and maintain a systematic record as aready reckonar. Sampling and testing should be done as per the methods prescribed in:

1) Standard methods for the examination of water and wastewater. (APHA, AWWA, WCPC

1975)2) Manual for the examination of water, sewage and industrial waste. (ICMR)

3) Methods of sampling and test for sewage and industrial effluent.

(IS-2488 PART-1 1966)

SAMPLING POINTS –

S.No. SAMPLE SAMPLING POINTS

1)2)

3)

4)

Raw effluentFinal effluent

Mixed liquor suspended solid

Return sludge

Equalization tank Final clarifier launder

Aeration tanks

Return sludge line (Stage 1 & 2)

METHOD OF SAMPLING –

Samples are to be taken at regular intervals to check whether the plant is giving the desired output and

any corrective measures are called for. It is essential that the collected samples be truly representativeof the product. While collecting samples the following procedures are to be adhered to: -

1) Samples are to be collected in dry, clean-stoppered bottles.2) The bottles are to be rinsed thoroughly before collection of samples.

3) While collecting samples from channel, launder it, sample is to be collected only fromsurface. Avoid the bottles touching or scraping the surface of the structure.

4) Stopper the bottles after collection of sample.5) Attach a tag, on the bottle indicating date, time and name of sample and tests to be carried

out.

6) While collecting composite samples it is suggested that the samples be preserved inrefrigerator to avoid any biological activity within the samples.

22



METHODS OF ANALYSIS -

pH -

The pH of water refers to its hydrogen ion activity and is expressed as the logarithm of the reciprocalof the hydrogen ion activity in moles per litre at a given temperature. The practical pH scale extends

from 0 (Very acidic), to 14 (Very alkaline), with 7 corresponding to exact neutrality at 25°C. Whereas

alkalinity and acidity are measures of the total resistance to pH change or buffering capacity of asample, pH represents the free hydrogen ion activity.

PRINCIPLE –

Although the hydrogen electrode is recognized as the primary standard, the glass electrode is lesssubject to interferences and is used in combination with a calomel reference electrode.

The glass reference electrode pair produces a change of 59.1 mg/pH unit at 25°C.

APPARATUS –

1) Electronic pH meter with temperature compensation arrangement.

2) Glass electrode; are available for measurement over the entire pH range with minimum

sodium ion-error types for high pH- high sodium samples.3) Reference electrode; Use calomel, silver-silver chloride or other constant potential

electrode.

PROCEDURE –

Firstly, calibrate the pH meter with the buffer solution of pH -7.0 and then the pH - 4.0. After

calibrating it the electrode is washed with DM water and finally the pH is taken of the sample. After doing the work again the electrode is washed with DM water and then the electrode is dipped in DM

water.

One-Day Analysis: -

Raw – 6.8PC – 8.2AHR – 7.2

FC-2 – 8.2

N-TANK – 8.58

SUSPENDED SOLID -

Estimation of suspended solid plays a important role for the process evaluation. These solids aremostly of organic species and contributes pollutants load to the treatment system. SS is analysed once

in a week.

PRINCIPLE –

This test is based on the evaporation of the residues obtained after filtering a known volume of sample,

to dryness under standard conditions and weighing the residue after drying.

APPARATUS –

Gooch Crucibles - 50 ml. Capacity

Measuring cylinder - 100 ml. CapacityVacuum pump

Dry heat Oven

23



SAMPLE –

Raw - 100 ml.

PC - 100 ml.

FC-1 - 50 ml.FC-2 - 50 ml.

PROCEDURE – 1) Firstly weigh the apparatus without any sample.2) Filter the well-known sample (Raw, PC, FC-1 & FC-2) through the Gooch

crucible under suction, dry at 103 to 105 °C to constant weight. Cool and weigh.

The increase in weight equals the total suspended solid.

CALCULATION –

Weight of crucible Weight of empty

Suspended solids + dry residue - crucible

Mg/litre = ________________________________________ X1000

Volume of sampleOne-Day Analysis: -

RAW: - 44.9035gm – 44.8786gm = 0.0249 X 10

= 249 X 2mg= 498 ppm.

PC: - 44.4568gm – 44.4371gm = 0.0197 X 10= 197 X 2mg

= 394 ppm

FC-1: - 55.8496gm – 55.8484gm = 0.0012 X 10= 12 ppm

FC-2: - 55.9635gm – 55.9635gm = 0.0010 X 10= 10 ppm

MIXED LIQUOR SUSPENDED SOLID (MLSS) –

MLSS is a rough quantitative measure of the microorganisms that are playing an important role in

biological degradation of organic matters in the aeration tank. MLSS is analyzed once in a week.

Routine analytical estimations of the mixed liquor solid is essentially required to enable an effectivefunctioning of the aeration system and its significances are represented as follows: -

1) Indicates whether the quantum of biomass presence in aeration tank is sufficient to meet the biological degradation or not.

2) Whether the biomass population is more or less in compared to the designed food supply

(BOD) to the aeration system.3) Helps controlling the adjustment of biomass in the aeration tank.

24



PRINCIPLE –

The tests are based on the evaporation of the mixed liquor sample to dryness under standard conditions

and weighing the residue after drying. MLSS is the weight of residue, of the known filtered mixedliquor, on evaporation at 103 to 105°C.

APPARATUS –

Gooch Crucible - 50 ml.capacity

Measuring cylinder - 100 ml. Capacity

Vacuum pumpDry heat Oven

SAMPLE –

AT 1 - 50 ml.

AT 2 - 50 ml.

PROCEDURE –

1) Firstly weigh the apparatus without any sample.

2) Filter the well-known sample (AT-1 and AT-2) through the Gooch crucible under suction, dry at103 to 105 °C to constant weight. Cool and weigh. The increase in weight equals the total suspended

solid.

CALCULATION –

Mixed liquor Weight of crucible Weight of empty

suspended solids + dry residue - crucible

Mg/litre = ________________________________________ X1000

Volume of sample

One-Day Analysis: -

AT-1: - 44.1165gm – 44.0909gm = 0.0256 X 10= 256 X 2mg

= 512 ppm

AT-2: - 44.0905gm – 44.0166gm = 0.0739 X 10= 739 X 2mg

= 1478 ppm

SLUDGE VOLUME INDEX -

In an activated sludge sewage treatment process, the suspended microbial mass coming out of theaeration tank is separated from the bulk of the liquid phase by plain sedimentation of the suspended

matter. Further, since the microorganisms are recirculated to the aeration tank it is advisable to have a

concentrated sludge. Due to overloading of the activated sludge plant, the sludge does not settle properly resulting in a poor effluent. A poorly settling sludge may also result from an unbalance of

25



nutrients in the incoming sewage. The sludge volume index (SVI) is primarily measured to know the

settling characteristic of the sludge. It is the defined as the volume in ml. occupied by 1 gm. of dryactivated sludge. After settling the mixed liquor for 30 min. the sludge settlebility characteristic may

be assessed from values of sludge volume index as follows: -

SVI VALUE –

Less than 20 Settlable solids20-40 Sludge formation Stage

40-70 Settled sludge excellent

70-100 Well settled sludge

100-150 Reasonably good settled

More than 150 Poor settled sludge

APPARATUS –

Measuring cylinder - 1000 ml.

SAMPLE –

AT –1 and AT –2 - 1000 ml.

PROCEDURE –

a) Fill 1000 ml. of sample in 1000 ml. measuring cylinder.

b) Allow settling for 30 minutes and noting the volume of sludge occupied in ml.c) At the same time determine the MLSS.

CALCULATION –

SVI is computed from the following equation: -

ml. settled sludge X 1000

SVI = ________________________

mg./liter MLSS

One-Day Analysis: -

95 X 1000

SVI = = 73.071300

26



CHEMICAL OXYGEN DEMAND -

The COD determination provides a measure of oxygen equivalent of that portion of he organic matter

in a sample that is susceptible to oxidation by a strong chemical oxidant. In the absence of a catalyst

however, this method fails to include some organic compounds (such as acetic acid), which are biologically available to the stream organisms, while including some biologic compounds, which are

not part of the immediate biochemical load on the oxygen assets of the receiving water.

The use of exactly the same technique each time is important because only a part of the organic matter is included, the proportion depending upon the chemical oxidant used the structure of the organic

compounds and the manipulative procedure.

The dichromate reflux method has been selected for the COD determination because it has advantages

over other oxidants in oxidizability, applicability to a wide variety of samples and ease of

manipulation.

PRINCIPLE –

A boiling mixture of chromic and sulphuric acids destroys most types of organic matter. A sample is

refluxed with known amounts of potassium dichromate and sulphuric acid, and the excess dichromateis titrated with ferrous ammonium sulphate. The amount of oxidizable organic matter, measured, as

oxygen equivalent is proportional to the potassium dichromate consumed. COD is analyzed daily.

APPARATUS –

a) Reflux apparatus consisting of a flat bottom 250 to 500 ml. capacity flask with ground glass joint and condenser with 24/40 joint.

b) Hot plate

c) Titrator d) Reflux flasks

e) Simple flask

f) Pipette

REAGENTS –

1) Potassium dichromate 0.25 N – Dissolve 12.25 gm of potassium dichromate.

previously dried at 103°C for 24 hrs, in DM water and dilute to 1000 ml.

2) Ferrous ammonium sulphate 0.1 N – Dissolve 39.2 gm FAS in about 400 ml water,

add 40 ml concentrated H SO , then dilute it to 1000 ml DM water. This solution must be₂ ₄ standardizing against standard potassium dichromate solution daily.

3) Ferroin Indicator – Dissolve 1.735 gm of 1, 10 phenonthroline dihydrate together

with 695 mg ferrous sulphate crystalline, in DM water and dilute to 100 ml.

4) Siver sulphate5) Mercuric sulphate

SAMPLES –

Raw - 1 ml.

PC - 2 ml.

AHR - 5 ml.FC-1 - 10 ml.

FC-2 - 10 ml.

27



PROCEDURE –

a) Firstly, take known quantity of samples in reflux flasks.

b) Then, 20 ml. DM water in Blank and others make the volume 20 ml. with DM water.

c) After that add 400-mg. mercuric chloride, 10 mg. silver sulphate, 10 ml. potassiumdichromate and finally add 30 ml. concentrated sulphuric acid.

d) Keep it for 2 hrs. for reflux on reflux apparatus.

e) Then cool it for 30 minutes.f) After cooling add 100 ml. DM water.g) Then, titrate with 0.1 N ferrous ammonium sulphate using ferrion indicator. Take as the

end point the orange color change to blue, then green and lastly to reddish brown, even through

the blue- green may reappear within minutes.

CALCULATION –

(a-b) N X 8000

COD in mg./liter =

ml. sample

Where:

COD = Chemical Oxygen Demand

a = ml. Ferrous ammonium sulphate for Blank b = ml. Ferrous ammonium sulphate for sample

N = Normality of Ferrous ammonium sulphate

Normality = 0.25 X 10 / Volume consume of FAS for Blank

One-Day Analysis: -

Blank = 24.8 Normality = 0.1008

RAW = 23.5 1.3 X 0.1008 X 8000 / 1 = 1048.30 mg/ltr.

PC = 21.7 3.1 X 0.1008 X 8000 / 2 = 1249.00mg/ltr.AHR = 22.5 2.3 X 0.1008 X 8000 / 5 = 370.90mg/ltr.

FC-1 = 23.9 0.9 X 0.1008 X 8000 / 10 = 72.50 mg/ltr.

FC-2 = 23.8 1.0 X 0.1008 X 8000 / 10 = 80.64 mg/ltr.

BIOCHEMICAL OXYGEN DEMAND -

PRINCIPLE –

Biochemical Oxygen Demand is defined as the amount of O₂ required by microorganism while

stabilizing biologically decomposable organic matters in a waste under aerobic conditions. The BOD

test is widely used to determine: -

1) The pollutional load of wastewater.

2) The degree of pollution in lakes and streams at any time and their self-purification

capacity.3) Efficiency of sewage treatment plant.

Since the test is mainly a bioassay procedure, involving measurement of oxygen consumed by bacteriawhile stabilizing organic matter under aerobic condition, it is necessary to provide standard conditions

28



of nutrient supply, pH, absence of microbial growth inhibiting substances and temperature. Because of

low solubility of oxygen in water strong sewage is always diluted to ensure that the demand does notincreases the available oxygen. The test is conducted for 3 days at 25°C as 70 to 80% the waste is

oxidized during this period.

APPARATUS –

a) BOD Bottles - 300 ml. capacity b) Incubator c) Titrator

d) Pipette

e) Iodine flask

REAGENTS –

1) Phosphate buffer – Dissolve 8.5 gm KH₂PO₄, 21.75 gm K ₂HPO₄, 33.4 gm Na₂HPO₄.

7H₂O and 1.7 gm NH₄Cl in DM water and dilute to 1000 ml and adjust pH to 7.2

2) Magnesium sulphate – Dissolve 22.5 gm MgSO₄ .7H₂O and dilute to 1000 ml.

3) Calcium Chloride – Dissolve 27.5 gm of Anhydrous Calcium Chloride and dilute to 1000

ml.4) Ferric Chloride – Dissolve 0.25 gm FeCl₃ .6H₂O and dilute to 1000 ml.

5) Manganous Sulphate – Dissolve 36.4 gm of MnSO₄ .H₂O and dilute to 100 ml. filter if

necessary. This solution should not give color with starch when added to an acidified solution of

KI.

6) Alkali Iodide-Azide – Dissolve 500 gm of NaOH and 150 gm of KI and dilute to 1000 mlwith DM water. Add 10 gm of sodium azide (NaN₃) dissolved in 40 ml of DM water. This

solution should not give color with starch solution when diluted and acidified.

7) Starch Indicator – Prepare paste of 0.5 gm starch powder in DM water. Pour the solution

in 100 ml boiling water, allow to boil fpr few minutes. cool and then use.

8) Sodium thiosulphate 0.025 N – Dissolve 6.25 gm of sodium thiosulphate in boiled and

cooled DM water, dilute to 1000 ml preserve by adding 5 ml chloroform. Standardize before eachtitration.

SAMPLES –

Seeded Blank - 2ml. FC-1 and 2ml FC-2Raw - 1 ml.

AHR - 2 ml.

FC-1 - 30 ml.FC-2 - 30 ml.

METHOD –

PREPERATION OF BUFFER SOLUTION –

Firstly prepare the buffer solution. Take 5000 ml. of BOD bottle. In this BOD bottle, add 3600 ml. DM

water. After that add 4 ml. of every reagent known as Magnesium sulphate solution, Ferric Chloridesolution, Calcium Chloride solution and Phosphate Buffer solution. And mix well.

Take prescribed samples in BOD bottles and make upto neck with buffer solution. Two sets of sampleis to be analyzed i.e. for 0 day and 3rd day. Add 2 ml. of manganous sulphate solution followed by 2

ml. of Alkali Iodide – azide solution, weight for 5 – 10 minutes till the precipitation are settled. Now

29



add 2 ml of concentrated H₂SO₄ and shake well. Take 203 ml of it into the 500 ml Iodine flask, add 5-

10 drops of starch solution as indicator and titrate with 0.025 N sodium thiosulphate till the color

changes from brown to colorless. Note the volume of 0.025 N sodium thiosulphate consumed.

Seeded blank is also performed to see the growth in final treated water, it is not taken in calculation.

CALCULATION –

Note the Blank difference. Note the 0 day and 3rd day difference.

BOD = sample difference – Blank difference X 300/sample taken

One-Day Analysis: -

0 Day 3rd Day Blank Differenece = 0.2mlS.Blank = 7.5 7.3

Blank = 7.4 7.2

Raw = 7.4 5.9 (1.5 – 0.2) X 300 / 1 = 390 mg/ltr.AHR = 7.5 6.3 (1.2 – 0.2) X 300 / 2 = 150 mg/ltr.

FC-1 = 7.6 6.8 (0.8 – 0.2) X 300 / 30 = 6 mg/ltr.

FC-2 = 7.5 6.8 (0.7 – 0.2) X 300 / 30 = 5 mg/ltr.

DISSOLVED OXYGEN -

PRINCIPLE –

DO is one of the most important indicators of the quality of water for aquatic life. O ₂ dissolves freely

in water as a result of photosynthesis, community, respiration, diffusion at the air water interface, and

wind driven mixing. Temperature, pressure and salinity determine the amount of DO water can hold,

or its saturation level. DO concentration below 3.0 mg/l are generally consider harmful to aquatic life,

but requirements vary according to species, temperature, life stage, activities and concentration of dissolved substances in the water.

APPARATUS –

a) BOD bottles

b) Measuring cylinder

c) Titrator d) Iodine flask

e) Pipette

REAGENTS –

1) Manganous Sulphate – Dissolve 36.4 gm of MnSO₄ .H₂O and dilute to 100 ml.

filter if necessary. This solution should not give color with starch when added to an acidified

solution of KI.2) Alkali Iodide-Azide – Dissolve 500 gm of NaOH and 150 gm of KI and dilute to

1000 ml with DM water. Add 10 gm of sodium azide (NaN ₃) dissolved in 40 ml of DM water.

This solution should not give color with starch solution when diluted and acidified.

3) Starch Indicator – Prepare paste of 0.5 gm starch powder in DM water. Pour thesolution in 100 ml boiling water, allow to boil fpr few minutes. cool and then use.

30



4) Sodium thiosulphate 0.025 N – Dissolve 6.25 gm of sodium thiosulphate in boiled

and cooled DM wsater, dilute to 1000 ml preserve by adding 5 ml chloroform. Standardize before each titration.

SAMPLES –

FC – 1

FC – 2

METHOD –

Take 300ml of sample of FC – 1 and FC –2 in 300 ml BOD bottle. Add 2 ml. of manganous sulphate

solution followed by 2 ml. of Alkali Iodide – azide solution, weight for 5 – 10 minutes till the precipitation are settled. Now add 2 ml of concentrated H₂SO₄ and shake well. Take 203 ml of it into

the 500 ml Iodine flask, add 5-10 drops of starch solution as indicator and titrate with 0.025 N sodium

thiosulphate till the color changes from brown to colorless. Note the volume of 0.025 N sodium

thiosulphate consumed.

CALCULATION –

DO in mg/ltr = Volume consumed of 0.025 N Hypo

One-Day Analysis: -

FC 1 – 2.0 mg/ltr.

FC 2 – 3.5 mg/ltr.

ABOUT WATER -

Chemical formula : H2OMolecular weight : 18

pH : 7.0

R.O.PLANT

31



INTRODUCTIONThe microbial ecology of water is of great importance in the industries due to its multiple uses as aconstituent of many products as well as for various washing and cooling processes. Two main aspects

are involved: the quality of the raw water and the processing it receives and the distribution system.

Both should be taken into consideration when reviewing the hazards to the finished product and anycritical control points.

Microorganisms indigenous to fresh water include Pseudomonas spp. Alcaligenes spp. Flavobacterium spp. Chromobacter spp. and Serratia spp. such bacteria are nutritionally

undemanding and often have a relatively low optimum growth temperature. Bacteria, which are

introduced as a result of soil erosion, heavy rainfall and decaying plant matter, include Bacillus

subtilis, B.megaterium, Klebsiella aerogenes and Enterobacter. Contamination results in the

presence of Proteus spp. E.coli and other Enterobacteria, Streptococcus faecalis and

Clostridium spp. bacteria which are introduced as a result of animal or plant debris usually die

as a result of the unfavorable conditions.

An examination of stored industrial water supplies showed that 98% of the contaminants were

Gram-negative bacteria; other organism isolated were Micrococcus spp. cytophaga spp.,

yeast , yeast like fungi and actinomycetes.

WATER QUANTITY

• About 70% of earth surface is covered in water.

• Total water = 3.26 X 108 km3 = 100%

a) About 97.14% sea

b) About 2.16% semi permanent ice

c) About 0.63% ground water

d) About 0.03% inland sea, lakes, river and in the soil

e) About 0.0001% in atmosphere

• Human and other organisms use only 0.26% water.

• And 0.014% water is used for drinking purpose only.

Raw Water

The quality of water from the main supply varies with both the source and the local authority, and

whlist it is free from known pathogens and from fecal contamination such as E.coli, it may contain

other microorganisms. When the supply is derived from surface water the flora is usually moreabundant and faster growing then that of supplies from a deep-water source such as a well or spring.

This is due to the surface water receiving both microorganisms and nutrients from soil and sewagewhilst water from deep sources has its microflora filtered out. On prolong storage in a reservoir, water

born organisms tend to settle out, but in industrial storage tanks the intermittent through-put ensures

that, unless treated, the contents of the tank serves as a source of infection. The bacterial count mayrise rapidly in such tanks during summer months and reach 105 - 106 ml-1.

One of the uses of mains water is for washing chemicals used in pharmaceutical preparation to removeimpurities or unwanted by products of a reaction, and although the bacterial count of water may be

32



low, the volume used is large and the material being washed may be exposed to a considerable number

of bacteria.

The microbial counts of the main water will be reflected in both softened and deionised water, which

may be prepared from it.

WATER PRODUCED BY REVERSE OSMOSIS -

Water produced by R.O. is forced by an osmotic pressure through a semi-permeable membrane, whichacts as a molecular filter. The diffusion of soluble dissolved in water is impeded, and those with a

molecular weight in excess of 250 do not diffuse at all. The process, which is the reverse of the natural

process of osmosis, thus removes microorganisms and their pyrogens. Post –RO contamination may

occur if the plant after the membrane, the storage vessel or the distribution system is not kept free frommicroorganisms.

PROCESS

In filtration process, the suspended matter in the liquid is effectively removed by passing the liquidcontaining suspended matter through the filtering medium (a suitable porous material). Filtration,

therefore, is employed in treatment of industrial water to remove or to reduce suspended solids andturbidity.

ACTION PLAN OF R.O.SYSTEM –

This can explain with the following headings: -The water is collected from the ground through bore wells and is collected in the storage tank. Now,

from the storage tank the raw water is passed to the duel media filter through pumps for filtration.

PRE TREATMENT STEP –

DUAL MEDIA FILTER –

Along with the underground water, organic, inorganic and microbiological impurities comes, so withthe help of dual media filter these suspended impurities are removed.

Contents of DMF –

The dual media filter consists of a pressure vessel with filtering media kept inside. Filter mediacommonly employed are graded and washed filtering sand of effective size 0.5 mm to 1.5 mm resting

on a supporting perforated nozzle plate. The nozzle plate has a number of filter nozzles mounted over

it which have very fine clearance flow passes through it. The sand bed depth is 550 mm. A top layer of Anthracite of size 1.5 mm to 2.5 mm. is provided which increases the filtering life of the media.

Backwashing of DMF –

Backwashing of filter bed has to be carried out periodically (normally once in 24 hrs) more frequently

if pressure drops across the bed exceeds 1.0 kg/cm2, which indicates accumulation of dirt in the bed.

Backwashing should be done with filtered water at a minimum head of 10 mWC.

Normally filter should not be fed with water carrying suspended matter and turbidity content more than

50 mg/ltr. Feed water provided shall be within 22°C to 40°C. the feed water provided shall be free from

–

33



1. Hydrogen sulphide

2. Manganese3. Oil and grease

4. Organic.

After 22 hrs of operation, the filter should be backwashed at the specified minimum backwash flowand time as indicated in the technical data. During initial commissioning, the backwash operation may

have to be extended for longer period till the time clean flow is observed at the backwash outlet.

During the process the inlet valves, outlet valve, drain valve and air vent valve is closed. Then open backwash valve and backwash drain valve and adjust the pump discharge valve to get the desired backwash flow. After backwash the filter is to be rinsed at flow. To rinse it close backwash and

backwash drain valve, open inlet valve and drain valve. Open air vent valve and close once all air has

been vented when starting it after DMF has been drained. After rinsing the filter is ready for service.Close the drain valve and open the outlet valve.

DOSING OF CHEMICALS –

The two chemicals, which are inoculated into the water, which has been filtered through DMF, are HCl

(Hydrochloric acid) and SHMP (Sodium Hexa Meta Phosphate). The water, which comes from dual

media filter, is high in CaCO3 and MgCO3, when it react with HCl it forms Carbonic acid, CaCl2 and

MgCl2.

CaCO3 + HCl CO2 + H2O + CaCl2

MgCO3 + HCl CO2 + H2O + MgCl2

The CaCl2 and MgCl2, which forms, act as descaling agent for the membrane of RO. The carbonic

acid, which forms during the process lower, downs the pH of water to 5.0 to 6.0. This pH is requiredfor the stability if the RO membrane. The SHMP plays a vital role in protecting RO membrane because

it act as an antiscaling agent

HCl SHMP

Dosing rate (ltr/hr) 3.0 3.0Strength of solution in the tank ( %) 23% 1.3%

CARTRIDGE FILTER –

Now the water along with the chemicals moves forward through the cartridge filter. The function of the cartridge filter is to remove the suspended impurities, which have been passed from the dual media

filter. The size of the cartridge filter is 5 micron.

HIGH PRESSURE PUMP –

With the help of this pump the water is thrown forward with increased pressure i.e. from 5 kg/cm2 to

30 kg/cm2. The water is move forward with the help of impellers, which have been feeted in the

high-pressure pump, which is made up of Stainless steel, chromium and nickel. Now the water alongwith the 30-kg/cm2 pressures is moved forward to the RO system.

34



POST TREATMENT STEPS: -

RO SYSTEM –

The water, which comes for the filtration, has the pH 5.0 to 6.0 because it provides stability to the

polyamide filter of which it is made up off. The water enters the membrane from one side and thenfilters through the membrane so product water is obtained which is passed to the second membrane for

further filtration and finally it is passed to the Degasser. From both the membrane filter reject water is

thrown out which carry more hardness in it.

RO Design

The two-pass RO system should be designed to prevent areas where microbial growth may occur.

Since bacteria cells are as small as 0.2 m in diameter, they may grow in minute crevices and cracks in awater purification system. Bacteria will also adhere to most surfaces, and a colony or biofilm will form

within 48 hours. Bacteria multiply rapidly, and within days noticeable levels may appear at sample

locations and in the purified water.Some typical places conducive to bacterial growth include threaded connections, ball valves,

imperfection pores in polyvinyl chloride (PVC) piping, dead leg piping (non circulating lengths of pipe

greater than three to six pipe diameters), non sanitary instruments, and areas behind seals and non

sanitary sampling valves. These areas are typically difficult to sanitize because they are stagnant, andchemical cleaning and sanitizing agents cannot reach the area of microbial growth. If a fluid is flowing

across the internal surfaces of the machine, it is easier to destroy bacteria with sanitization. The design

of the RO machine is critical; the machine design must minimize the number of dead legs or stagnantareas, use sanitary design membrane elements and instruments, and employ sanitary piping for the

second-pass permeate.

Bacterial reduction by RO

Bacteria levels of pharmaceutical and dialysis systems should be monitored in the permeate and in the

system downstream of the RO. If installed and operated correctly, RO membrane elements should provide a 3-log reduction (99.9%) in bacteria. If the bacteria levels in the product water of the RO are

higher than the bacteria levels in the feed, it is likely that bacteria are multiplying on the surface of the

membrane and downstream. Table A shows the results of a study conducted on a 7.5-gallons-per-

minute (gpm), two-pass RO in a controlled environment. ln this study, feed water was seeded with Brevundimonas diminuta (formerly known as Pseudomonas diminuta) to measure the reduction

potential of a two-pass RO system over time.

There are several ways to reduce potential microbial growth in a membrane system: minimize

available nutrients; reduce water stagnation; and provide continuous chemical control and/or

intermittent chemical control.

35



DEGASER –

The water after purification from the RO system is passed to the Degaser. The water is thrown fromthe shower from the upper side and from the lower side air is blown. When both combine together,

then they react to form pure water and CO2 (which is blown away). The pure water has high pH-7.0,

and then the water is collected in the Degaser.The carbonic acid, which was present before, reacts with the air to form water and CO2.

H2CO3 H2O + CO2

STORAGE TANK –

Now from the Degases the water is stored in the storage tank, which is made up of FRP (Fiber

Reinforced Plastic).

MEMBRANE CLEANING

It needs only a very small amount of foulant to have a very profound effect on the membranes. e.g. For a flow rate of 0.2 m3/hr , only 1 ppm. of foulent present, in one months running results in over 4.5 kg

of scale or deposit on the membrane surface. This is the reason why so much trouble is taken with the

design of RO membrane.

All RO membranes should be chemically cleaned. It should therefore, be ensured that the membranesare flushed clean of highly saline water at every shut down so as to extend period between cleaning

operations.

Cleaning is indicated whenever the following conditions become apparent – product flow rate drops by 10 % on what amount to the same thing, the pressure has to be increased by

10 % to maintain the same flow.

The product water quality falls significantly i.e. the conductivity rises by 20 to 30 % over initialconditions.

The differential pressure across the various stages rises by 15 % across the particular stage. This is

differential pressure, which is difference between the pressure gauge readings across any pressurevessel array.

Irrespective of the above the membrane must be clean after every 2 months operation of the RO plant.

The shelf life of the membrane generally has 3 years. It is recommended that the membrane should bereplaced after 6 CIP (Clean In Place).

ANALYSIS IN RO PLANT –

Mainly three tests are done in this plant i.e. pH, Conductivity and Hardness of water.

pH –

The pH is checked with the help of pH meter. During the flow of water through the various systems of

this plant.

Conductivity –

This is done with the help of conductivity meter and further Total Dissolved Solid (TDS) is taken out.

Calculation –

T.D.S. = Conductivity X 0.667

Hardness –

The hardness of water is due to the presence of Ca and Mg.

36



Reagents –

Ammonia Ammonium Chloride Buffer Solution – Take 16.9 gm of ammonium chloride in 250 ml. Volumetric flask and dissolve in it 143 ml of

ammonia liquid and make up the volume up to 250 ml DM water.

EDTA 0.01 M –

Take 3.723 gm of EDTA in 1 ltr. Volumetric flask and dissolve it in 400 ml. of DM water and finally

make up the volume up to 1 ltr.

Eriochrome Black T Mixer (indicator) –

Triturate 1 gm. of Eriochrome Black T indicator with 99 gm. of sodium chloride in mortar pestle up to

the fine powder and use few crystal of this dry powder as indicator.

Method –

Take 100 ml. of sample in Conical Flask, add 1 ml. of ammonia ammonium chloride buffer solution init. Now add few crystals of indicator and mix well, reddish color appears. Now titrate with 0.01M

EDTA solutions up to bluish black color end point. Note the volume of 0.01M EDTA used.

Calculation –

Vol. (Titration) X Normality (0.01) X Factor (0.001) X 106

Hardness of water =Sample vol. taken X Stated Normality (0.01)

One-Day Analysis: -

SAMPLE pH CONDUCTIVITY HARDNESS

Raw water 7.21 3890 740

C – 1 6.96 3900 740

C – 2 7.04 3980 740P – 3 5.90 55 00

P – 4 5.66 112 00

P – 7 5.60 118 00

P – 8 5.58 168 00

37



D. M. PLANT

INTRODUCTION –

D.M. generally means, demineralized water or deionised water. This water is prepared by passing ROwater through anion and cation exchange resin bed to remove the ions. Thus, any bacteria present in

the RO water will also be present in the deionised water, and beds which are not regenerated frequently

with strong acid and alkali are often heavily contaminated and add to the bacterial content of the water.This problem has prompted the development of resins able to resist microbiological contamination.One such resin, a large pore, strong-base, microreticulatar, quaternary ammonium anion exchange

resin which permits microorganisms to enter the pore cavity and then electrostatically binds them to

the cavity surface, is currently being marketed. The main function is as a final cleaning beddownstream of conventional demineralising columns.

Deionised water is used in pharmaceutical formulation, in various industries, for washing containers

and plant, and for the preparation of disinfectant solution.

PROCESS OF ION EXCHANGE SYSTEM –

The RO water carrying the high conductivity in it i.e. ions is removed through the system with the help

of following process –

Cation Unit –

It is a cylindrical tank unit in which synthetic resins are filled, which is charged by HCl to remove thealkalinity of water and to reduce the conductance of water by the presence of alkaline matters. When

the resin is charged with HCl on the surface of the resin the Cl group binds all along it surface. When

the RO water moves through it get neutralized in the tank and a Na bind to Cl to form NaCl, which isneutral in nature. Now, this water passes through the anion unit.

Anion Unit –

It is also a cylindrical tank unit and filled with synthetic resins, which is charged by NaOH to remove

the acidity of water and to reduce the conductance of water by the presence of acidic matters. When the

resin is charged with NaOH on the surface of the resin the Na group binds all along its surface. When

the RO water which have been passed from cation unit now moves through this unit it get neutralized by binding to the Na group. Now this water is passed through mix bed unit.

Mix Bed Unit –

This is a cylindrical tank in which resins are filled in two layers by separating from the middle. These

resins are also charged with NaOH and HCl. This unit is made in such a way that both the resins do not

mix with each other but are separated with a layer in middle and both are charged separately. Thefunction of this unit is that if any ion not removed by the previous tanks is finally removed with the

help of this unit. Now, this water is passed through UV Chamber.

a. U. V. Chamber –

The function of this chamber is mainly disinfections.

b. Storage Tank –

After the treatment the water is stored in the Storage tank. This is the water, which is used in the

various processes in the industry.

38



CONCLUSIONQuality Assurance assures that all the products released from the company are upto their mark. All the products are thoroughly tested by each chemist and microbiologist encharge. No product is released fro

the company if they do not satisfies the standard by products, which are given by the company.

In the Food Manufacturing and Cosmetic Good companies the food is directly related to human being

and it directly affects the health and the hygiene of living being, if it is not a good quality, so the

product manufactured are a good quality only and assures the standards of it.

I was mainly focused on the microbial load of the product and the effluent wastewater treatment,

which was the heart of the company.

Personal health and hygiene is also maintained during doing any testing of the products.

39



REFERENCES

1. Poffer N.Norman; Food Science, III ed. (1987), CBS Publishers and

Distributers,

Delhi.

2. Colwell R.R. and Grigorova R.; methods in Microbiology, Vol. 19,

(1987),

Acedemic Press INC. Florida.

3. Varnam H.A. and Evans G.N.; Foob Borne Pathogens, (1991), Wolfe

PublishingLtd. England.

4. Nielsen S. Suzanne; Introduction to Chemical Analysis of Foods, (1994),Jones an Bartlett Publisher, Boston, London.

5. Miller M. James and Crowther B. Jonathan; Analytical Chemistry in

G.M.P.Environment (2000), John Wiley and Sons, U.S.A.

6. United State Pharmacopoeia, The national Formulation, Ist ed. (2002),United State

Pharmacopeial Convention, INC., U.S.A.

7. Indian Pharmacopoeia, Vol. I, II, III (1996), Controller of Publications, Delhi.

8. British Pharmacopoeia, Vol. I, II (2001), Deptt. of Health, U.K.

9. Aneja R.K.; Experiments in Microbiology, Plant pathology and Biotechnology, IV

ed. (2003), New Age International (P) Ltd., New Delhi.

10. Internet

40



Ion Exchange System

REVERSE OSMOSIS PLANT

41

CationUnit

R - H+

AnionUnit

R + OH-

MixBedUnit

U.VCHAMBER

HCl

Sol.

DrainDrain

Process Flow

Charging

NaOH Sol.

STORAGE

TANK

R.O.WATER



Raw

water

tank Pump

D M F

Cartridge

filter

HP

Pump

P1

P2

• Reject water

StorageTank

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