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Effluent Treatment Plant
National Institute Of Fashion Technology -Jodhpur Page 1
SUSTAINABLE PRODUCTION
Topic
Effluent Treatment Plant
(Performance Evaluation of Effluent Treatment Plant for Textile Industry)
Submitted by:
Kush Sharma
DFT
NIFT-Jodhpur
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Effluent Treatment Plant
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CONTENTS
Topics Page No.
Abstract 03 Introduction 04
o Pollution Control Boardo Water treatmento Textile waste principleo Evaporation process
Separation process 08 Result and Discussion 10 References 12
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ABSTRACT:
Textile dyeing industries need huge quantity of water for textile dyeing, which they normally pump out
repeatedly from the ground or natural water sources resulting in depletion of ground water level.
In the dyeing process textile industries generate huge quantity of toxic effluent containing colours,
sodium sulphate, sodium chloride, sodium hydroxide and traces of other salts. These are generated after
dyeing and after washing of garments / fabrics. After dyeing the waste water produced is called Dye Bath
water and after washing the waste water generated is called wash water. Dye Bath contains higher solids
in the range 4-5% whereas wash water contains only 0.5-1% solids.
An effluent treatmentplant is operating on biological treatment method (Fluidized Aerobic Bio-Reactor)
with an average wastewaterinflow of 2MLD has been considered for case study. The wastewater is
analyzed for the major water qualityparameters, such as pH, Biological Oxygen Demand (BOD),
Chemical Oxygen Demand (COD) and Total DissolvedSolids (TDS). The effluent samples were
collected on a daily basis for a period of one month. The rawwastewater pH was highly alkaline it was
then bringing down to neutral which was helpful for biologicaltreatment. The BOD, COD of the treated
effluent reduced significantly, whereas very small reduction wasobserved in dissolved solids.
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INTRODUCTION
The textile industry is one of the leading sectors inthe Indian economy as it contributes nearly 14percent
to the total industrial production(business.mapsofindia.com). The untreated textilewastewater can causerapid depletion of dissolvedoxygen if it is directly discharged into the surfacewater sources due to its high
BOD value. Theeffluents with high levels of BOD and COD values arehighly toxic to biological life. The
high alkalinity andtraces of chromium which is employed in dyesadversely affect the aquatic life and also
interferewith the biological treatment processes.The quality of such effluent can beanalyzed by their
physico-chemical and biologicalanalysis. Monitoring of the environmentalparameters of the effluent
would allow having, atany time, a precise idea on performance evaluationof ETP and if necessary,
appropriate measures maybe undertaken to prevent adverse impact onenvironment. The obtained results
were very muchuseful in identification and rectification ofoperational and maintenance problems and it
can bealso utilized to establish methods for improvedtextile industry and plant waste minimization
strategies. The present textile industry is having weavingcapacity of 10 million meter per annum. During
theproduction process, effluent generated in the plantis drain to ETP. The samples collected daily
andanalyzed for Physico-chemical and biologicalparameter except BOD as it takes three days foranalysis
for the period of one month during thetraining period. On average, approximately 200 litersof water are
required to produce l kg of textiles. Therisk factors are primarily associated with the wetprocesses-
scouring, desizing, mercerizing, bleaching,dyeing and finishing. Desizing, scouring andbleaching
processes produce large quantities ofwastewater. The large volumesof wastewater generated also contain
a wide varietyof chemicals used throughout processing. These cancause damage if not properly treated
before being discharged into the environment.
Table 1: Effluent Characteristics from Textile Industry
Process Effluent composition Nature
Sizing Starch, waxes, carboxymethyl cellulose (CMC),
polyvinyl alcohol (PVA), wetting agents.
High in BOD, COD
Desizing Starch, CMC, PVA, fats, waxes, pectins. High in BOD, COD, SS, dissolved solids
(DS)Bleaching Sodium hypochlorite, Cl2, NaOH, H2O2, acids,
surfactants, NaSiO3, sodium phosphate, short cottonfibre
High alkalinity, high SS
Mercerizing Sodium hydroxide, cotton wax High pH, low BOD, high DS
Dyeing Dyestuffs urea, reducing agents, oxidizing agents,
acetic acid, detergents, wetting agents.
Strongly colored, high BOD, DS, low
SS,heavy metals
Printing Pastes, urea, starches, gums, oils, binders, acids, Highly colored, high BOD,
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Thickeners, cross-linkers, reducing agents, alkali oilyappearance, SS slightly alkaline, low
BOD
Source: Yusuff and Sonibare
Pollution Control Board comprises of the following units:
1] Screen Chamber
2] Equalization tank
3] Flash mixer
4]Flocculation Tank
5] Tube Settler-I
6] Fluidized Aerobic Bio-Reactor (FAB-I)
7] FAB-II
8] Tube Settler-II
9] Chlorine Contact Tank
10] Sludge Thickener
11] Centrifuge.
The wastewater generated from the plant iscollectively passed through the screen chamber toremove the
floating matter present in thewastewater. The quality and quantity of thewastewater is maintained in the
equalization tankwhere air blower is provided for the supply ofoxygen. The wastewater then comes to the
flashmixer in which lime and ferrous sulphate are thecoagulants added to the wastewater with
detentiontime of 30 seconds. The floc gets formed due to theslow mixing and resultant settling of floc in
the firsttube settler reduces total suspended solids and BODload on the secondary treatment. The water is
the allowed in the FAB-I where micro-organisms areattached to the media while media is suspended Ithe
wastewater. The growth occurred on the media.The oxidation of organic matter is done with the
help of micro-organisms. The sludge formed due tobiological process gets settled in the tube settler II.
The wastewater treated by secondary treatment isthen allowed in chlorine contact tank to killpathogens
using the hypochlorite as a disinfectant.The treated wastewater is then sending to thecommon effluent
treatment plant for furthertreatment. The sludge settled in the tube settlers isthen sending to the sludge
thickener then it isconcentrated in centrifuge using poly electrolytedosing. The concentrated sludge is
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send to thehazardous waste disposal site. The samples collected on daily basis and brought tothe
laboratory for analysis of various environmentalparameters. The BOD and COD were analyzed
usingStandard Methods for The Examination of Water andWastewater (APHA, 1998). COD was
determined bythe dichromate digestion method while BOD wasdetermined by the dilution method. TDS
is analyzedby portable digital TDS meter manufactured by EIElectronics. TDS meter was checked and
calibratedaccording to the manufacturers specifications. TDS was calibrated using the potassium chloride
solutionprovided by the manufacturer.
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The technology offered by SSP can overcome all problems pertaining to environmental pollution in
respect to textile dying industries.The basic thrust of the technology is to convert entire quantity of
effluent to zero level by separating water and salt using evaporation and separation technology.
The concept and the treatment is based on the removal of the entire COD/BOD and the condensate
coming out to meet the fresh water quality requirement in the process.
Textile Waste Water Handling By Evaporation And Solid Separation Basic Principle:
The technology is based on basic principle of reduction of quantity by concentrating the effluent and
subsequently separation of salt and water.
The Evaporation Process:
Textile Effluent is fed to the vacuum evaporator to concentrate up to 40% solids concentration. The total
process is under vacuum and the vapors generated in the system are re-used to economize steam
consumption in multiple effect evaporation system with thermal vapour recompression system. The
thermal vapour recompression system use Vapours generated in the evaporator and compress it by steam
and the compressed vapours are used as heating medium in the evaporator, in this way steam
consumption is reduced. Water recovered from the evaporator has low COD/BOD value and can be
recycled in the plant.
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Separation Process
(zero liquid discharge section):
DYE BATH / WASH WATER EFFLUENT
The resultant slurry (concentrate) is fed to the thickener and centrifuging section for converting the liquid
concentrate to solid waste. The mother liquor from thickener and centrifuge is recycled back to
evaporator.
The water separated out from evaporator is good enough in quality to recycle in the plant for Dyeing.
Key features:
Zero Liquid Discharge Fully Customized Designed System Highest Steam Economy Low Operating Cost Less Downtime for Maintenance Generation of Reusable Condensate Water Operator Friendly
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RESULTS AND DISCUSSION
For evaluating the performance of ETP,the accurate idea of the composition of effluents isvery important.
This is so because industrialeffluents contain various pollutants that may alterthe quality of the receiving
water and the environment at large. Theresults of daily analysis of pH, COD, BOD and TDS etc are
represented in Table 2.
The color of the effluent was brownish black. Incompleteuse and the washing operations give thetextile
wastewater a considerable amount of dyes. It has been documentedthat residual color is usually due to
insoluble dyeswhich have low biodegradability as reactive blue 21,direct blue 80 and vat violet with
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COD/BOD ratio of59.0, 17.7 and 10.8 respectively.The coagulation and flocculation helps toremove
color of the effluent. The pHof the raw effluent is very high as the incomingwastewater is highly alkaline
in nature. Thebleaching agents used in the process are reasons forhigh alkaline wastewater. The pH
correction is donewith the help of HCL and brings down to neutralwhich is favorable pH for biological
treatment. TDSare composed mainly of carbonates, bicarbonates,chlorides, phosphates and nitrates,
calcium,
magnesium, potassium and manganese, organicmatter salts and other particles. No appreciablechange was
observed in values of dissolved solids intreated effluent. TDS detected could bethe high color from the
various dyestuffs being used in the textile mills.
The COD and BOD of raw effluent varied from 1104to 1475 mg/l and 242 to 358 mg/l respectively.
Higher values of COD and BODin raw effluentattributed to the presence of chemical substancesand
breakdown of raw material used for preparationof fiber respectively. The COD and BOD of
treatedeffluents were reduced significantly to a greaterextent due to the biological treatment process
forwhich the effluent is passed throughFAB I and II.
Most of the studied parameters are well within thepermissible limit prescribed by MPCB because
theindustry has installed adequate treatment system totreat the raw effluent. The treated effluent
isapplicable for land application so it is used for greenbelt development in the industrial premises and
30%of the total effluent treated is reused for thispurpose. The disposal of excess of treated effluentto
common effluent treatment plant is best andeffective and environmentally acceptable option forbetter
downstream conditions.
FAB consists of a tank filled with specially developedmedia. These media are made of special material
ofsuitable density that can be fluidized using anaeration device through diffusers. A biodevelops on the
media, which move along the
effluent in the reactor. The movement within thereactor is generated by providing aeration with helpof
diffusers placed at the bottom of the reactor. Thisthin film on the media enables the bacteria to actupon
the bio-degradable matter in the effluent andreduce BOD/COD content in presence of oxygenfrom the air
used for fluidization.
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REFERENCES
C Parvathi, T Maruthavanan and C Prakash(2009): Environmental impacts of textileindustries.The Indian Textile Journal
PalamthodiShanooba, DhirajPatil and YatinPatil,(2011): Microbial degradation of textileindustrialeffluents. AfricanJournal of Biotechnology10(59).
APHA, AWWA, WPCF,for the Examination of Water and Wastewater.20th edition, AmericanPublic Health AssociationWashington, DC, New York, USA.
Deepti Mishra, Mohdakram khan, Manishmudgal, prabhapadmakaran and B Chakradhar,(2009):performance evaluation of an effluenttreatment plant for a pulp & paper mill. IndianJournal of
Chemical Technology. Vol 16.
K. Sundara Kumar, P. Sundara Kumar, Dr. M. J.RatnakanthBabu, (2010): PerformanceEvaluationof Wastewater Treatment Plant.International Journal of Engineering Science andTechnology,
Vol. 2(12).