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www.chemtronicsindia.com Page 1 of 25 Client: Empire Industrial Centrum - Ambernath Technology – “Green STP AD+” Zero Discharge Sewage Treatment Plant Reuse of treated water for Landscape, Irrigation & Flushing Date: 14 th April 2017 – Mumbai [INDIA]
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Page 1: Zero Discharge Sewage Treatment Plant TN Project Report... Page 1 of 25 Client: Empire Industrial Centrum - Ambernath Technology – “Green STP AD+” Zero Discharge Sewage Treatment

www.chemtronicsindia.com Page 1 of 25

Client:EmpireIndustrialCentrum-Ambernath

Technology–“GreenSTPAD+”

ZeroDischargeSewageTreatmentPlant

ReuseoftreatedwaterforLandscape,Irrigation&Flushing

Date:14thApril2017–Mumbai[INDIA]

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Preamble

AsperIndianPollutionControlBoardnormsitismandatorytoreusetreatedwastewaterfornon-potable applications. These applications can be WC flushing, landscape irrigation, cooling towermakeup, floor&glasswashing,diluteanyotherstreamofwastewater,sell tootheragencies,etc.Indian Green Building Council [IGBC] encourages designers to use Energy efficient technology byofferinghigherratingin“LEED”certification.Itisalsomandatorytouseozonetechnology,insteadofchlorine sincedisinfectantsBy-Products [DBPs] arequitenegligible, andozone technology isnon-hazardous&environmentallysafe.

Chemtronicswith alongwith its Switzerland partner has developed a “GREEN STPAD+”which isself-sustained, and conserves water up to the efficiency of more than 95 %. The core treatmentworksonnaturalanaerobicdegradationprocesswithgravityflow&doesnotrequireanyenergytotreatwastewater asperpollutionnorms.Thisunique technologyproduces energy in the formofbiogas to make treated waste comfortably reusable. Ozonation is an integrated as a part of highefficiencytertiarytreatmentproducinghighqualityresults.

Since entire anaerobic tank can bemade underground, it requires very small foot print for plantroomarea.Alsothereisnoneedofanyairhandlingsystemandfoulodormechanismrequiredasalltanksareairtight.TheADtankhasestimatedlifeof100years&issoself-sustainedthatitdoesnotrequire any qualified teamof operators. The processes by product are liquid& gas, due towhichfrequencyofsludgehandlingisonceortwiceayear.

Considering the remote location of the site, we have proposed self-sustained, scientificallydeveloped,naturalrecyclingtreatmentplant,withleastoperation&maintenancecomparedtoanytechnologyintheworld.

Copyright:

“All contents copyright by Chemtronics Technologies (I) Pvt. Ltd. – India & Autark Engineering – Switzerland. All rights reserved. No part of this document or the related files may be reproduced or transmitted in any form, by any means (electronic, photocopying, recording, or otherwise) without the prior written permission of the publisher.

Please note that much of this publication is based on personal experience and anecdotal evidence. Although the author and publisher have made every reasonable attempt to achieve complete accuracy of the content in this Guide, they assume no responsibility for errors or omissions. Also, you should use this information as you see fit, and at your own risk. Your particular situation may not be exactly suited to the examples illustrated here; in fact, it's likely that they won't be the same, and you should adjust your use of the information and recommendations accordingly.

Any trademarks, service marks, product names or named features are assumed to be the property of their respective owners, and are used only for reference. There is no implied endorsement if we use one of these terms.”

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INDEX

1. Preamble .......................................................... Page2

2. Index .......................................................... Page3

3. ProjectProponent;Objectivs........................................... Page4

4. WaterBalance/Budget ............................................ Page5

4.1 ClientsData,DesignConsideration&Estimation,................... Page5

4.2 WaterQuality–Raw&Treated............................... Page6

5. TreatmentTechnology ............................................ Page6

5.1 Concept ............................................ Page6

5.2 Coretreatment, ............................................ Page7

5.3 SalientFeatures ............................................ Page7

5.4 Advantages ............................................ Page8

6. ProcessDescription ............................................ Page9

6.1 Primary&SecondaryTreatment ...................................Page9

6.2 TertiaryTreatment........................................... Page10,11

7. ProcessFlowDiagram ............................................ Page12

8. TechnicalSpecification ............................................ Page13

8.1 ADTankOption1[Civil–BelowGround]..................... Page14,15,16

8.2 FootPrint–Equipment....................................... Page17

8.3 PowerRating ..................................... Page17

8.4 ReclaimEfficiency ..................................... Page17

8.5 LifeSpan .............................................. Page17

9. Operation&Maintenance ............................................ Page18

10. Consumables ............................................ Page18

10.1 Chemical,Manpower,Electricity................................. Page18

10.2 Spares ............................................ Page19

11. AnnualMaintenanceContract......................................... Page19

12. CapitalCost,OperationalCost&Taxes................................. Page20

13. TimeDuration,Savings/ROI ................................. Page21

14. Assumptions........................................................ Page22

15. References.......................................................... Page23

16. CertificationofCollaboration........................................ Page24

17. MoreInformation,Hyperlinks&contactdetails....................... Page25

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ProjectProponent

Nameoftheproject : EmpireIndustrialCentrumatAmbernath

Requirement : SewageTreatmentPlant

Typeofproject : Residential

ApplicationofTreatedWater : Landirrigation,Gardening,WCflushing&anyother

non-potableapplications

Locationoftheproject : Ambernath.

Objective

ü NaturalSelf-Sustaineddesign

ü UndergroundSTP

ü LeastpossibleOperation&Maintenance

ü MostEnergyefficienttechnology

ü Maximumrecoveryofwater

ü LowerFootprint

ü EnvironmentalFriendly

ü Nofoulodor

ü Longlifespan

ü Economical–CapitalCost

ü Economical–OperationalCost

ü Simpletooperate

ü MeetsInternationalPollutionStandards

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WaterBalance/Budget

Theplantisdesignedtotreatsewagegeneratedofhavingfollowingdetails.

(Weneedbelowlisteddetailsorwaterbalance&recycledwaterreusecalculation)

SourceofSewage : Residential

No.ofunits/flats :

Kitchen :

Bathroom[Bathing] :

WashingMachine :

WashBasin :

WaterCloset[WC] :

Misc./Anyothersource : [Specify]

ClientData

SourceofWasteWater : DomesticWasteWatergeneratedfromResidents,Kitchen,Washingmachine,Bathroom,WC,Washbasin,etc.

CapacityofSTP : 400KLD

NumberofUnits/flats : __________nos.

NumberofStaff : __________nos.

ApplicationofTreatedWater : Landirrigation,Gardening,flushing&othernon-potable

application

DesignConsideration&Estimation

Waterrequireperperson : __________litersperday

TotalSewageWaterCapacity : 400KLD(asperclient400KLDisproducedperday)

PlantOperatingHrs : 22–24HRs

PlantFlowRate : 18m3/hr

Treatment : AnaerobicDigestion[AD]+Polishing+Ozonation

GreenSTP/AD+ModelNo. : AD+/STP-400

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WaterQuality–RawSewage&Treated/Recycled

Parameters RawSewageWaterQuality

TreatedWaterQualityForReuse

Color Slightlybrownish Clear

Odor Characteristic Unobjectionable

pH 5.0–8.0 5.5–8.0

TSS 100–150ppm ≤1ppm

BOD(3days28⁰C) 150–200ppm ≤10ppm

COD 300–450ppm ≤100ppm

Oil&Grease 20–25ppm ≤10ppm

TreatmentTechnology

Concept-GreenSTPAD+

Green STPAD+ combines state of the artHighRateAnaerobicReactor (HRAR) technologywith aselection of adequate tertiary treatment methods of filtration & disinfection. This full-blowndecentralizedwastewatertreatmentandreusesystemsisalignedwiththeprojectspecificconditionsand requirements. We provide our clients custom and tailored wastewater solutions withoutstandingeconomicandecologicperformanceswhilemakingmaximalbenefitoutofon-sitereuseof products out ofwastewater treatment. Our STPs are engineered to complywith the respectiveregulationsandnorms.

AD+[AnaerobicDigestion+]isawastewatertreatment,particularlysuitedtoorganicmaterial&iscommonlyusedforeffluent,sewage&greywatertreatment.Anaerobicwastewatertreatmentisabiologicaltreatmentwithouttheuseofairorelementaloxygen.Manygroupsofanaerobicbacteriawork together inabsenceofoxygentodegradecomplexorganicpollutants intomethane/biogasandcarbondioxide.Inanaerobicdigestionthemicro-organismsresponsiblefortheconversionoftheorganicmatterortheotherconstituentsinthewastewatertogases&celltissuesaremaintainedin-suspensionwithin the liquid. Anaerobic digestion is a simple process that can greatly reduce theorganicmatterwithoutusinganyotherresource&anyformofenergy.

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CoreTreatment-HighRateAnaerobicReactorTechnology

HighRateAnaerobicReactors(HRAR)refers tobioreactorswhichcanretainactivebiomass in thereactorindependentlyoftheincomingwastewater(HydraulicResidenceTimeHRT).Slowgrowinganaerobescanbemaintainedinthereactorsathighconcentrations,enablinghighreactionrateperunit reactorvolumeandhighresistanceoforganicorhydraulic shock loads.HRARcanbeused totreat wastewater from various sources and strengths like waste water from domestic sources,hospitalsandindustrieslikedistilleriesorfood-processing.TheHRARweusearecascadedinseriestomulti-stepanaerobicsystems,enablingseparationoftheanaerobic treatment steps (Hydrolysis/Acidogenesis/Acetogenesis/Methanogenesis) withoutdifficult process controlling. With respect to sustainability and cost- effectiveness, anaerobictreatmenthas the coreadvantageof avoiding the lossof energy fordestructionoforganicmatter,whileenergyisreclaimedfromtheorganicwasteconstituentsintheformofmethaneinbiogas.SalientFeatures:

* OverallOrganic&Inorganiccontentreduction(BOD,COD&TSS)withcolor&odor.

* TreatedSewageWaterQuality -MostsuitedforIrrigation&Landscape.

* EnergyEfficiency -Highest–50–90%lessconsumption

* Sustainability -SelfSustained[Autark]

* ReusableOutput -Highest–morethan99%

* Operation&Maintenance -Least–Operatornotrequired

* SludgeManagement -Least–OnceinaYear

* Consumables -Minimum

* LifeSpan -VeryHigh–100Years[CoreTechnology]

* FootPrint -Minimum70–80%less[BeingUnderground]

* Nutrients -Rich

* Process&Technology/R&D -GREENSTPAD+fromSwitzerland

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Advantages–HRAR[AD]:

* LowProcessControl

* LowProcessEnergy

* NoChemicals

* LowSludgeProduction

* MLSSandSVImonitoringnotrequired

* EnergyGenerationintheformofBiogas

* MinimumMechanical&ElectricalParts

* UnderGroundStructure(Canbeaboveground)

* HighShockLoadResistance[Organic&Hydraulic]

* HighTreatmentPerformanceInTermsOfCOD,BOD&TSS

* Self-Sustained

* ReclaimedWatermorethan99.0%

* Innovativestillnaturaltreatmentprocess

* Energyefficient.60–90%lesserpower

* Extremelystabletohydraulicshockloads

* Hightreatmentperformance

* Lowoperatingcost

* Lowspacerequired–beingsubsoil

* Nofoulodour

* Longlife–atleast50years

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ProcessDescription

PrimaryTreatment

Screening: - This is the first unit of the Green STP AD+. Sewage water from sewage collectionchamberiscollectedintoanADtankthroughabarscreenbygravity.Barscreenisprovidedtotrapfloatingmaterialslikeleaf,flowers,cottons,plastic,halfeatenfood,papers,etc.Oil&GreaseChamber: - Sewagewater from the kitchenwhich contains free oil, if not removedcreates scum accumulation and affects the functioning ofmicrobes. To avoid this, oil & grease, achamberisprovidedafterthebarscreenwherefreefloatingmaterialoilisarrestedpriortoentryintheADTank.Accumulatedoilwillberemovedperiodicallyanddisposedofproperly.

SecondaryTreatment

BiologicalTreatment:-

SewagefromOil&GreasechamberwillpassthroughtheADTank.TheADTankisacascadeofthreemajor treatments steps i.e. Settler,HighRateAnaerobicReactor [HRAR]/AnaerobicBaffleReactor[ABR]andupflowAnaerobicFilterwhichisconstructedbelowgroundlevel.Thesethreedifferentphases are built together in a single AD Tank with interconnecting compartments. The AD Tankperformsthecoretreatmentofthesewagewateroxidization&decompositionoforganicpollutantwith the help of anaerobicmicroorganism to provide higher surface area formicro – organisms,floating random media is provided, on which micro- organisms growth takes place. Generallyactivation of AD tank with full sewage load can take 40 to 50 days and come to its optimumefficiency.

1. Settler

The first compartment ofADTank is a settler. The settler has two treatment processes. First is asedimentationinwhichtheliquidpartisseparatedfromthesolidmatterandsecondisstabilization,whichsettlesoutmostofthesolidsinthewastewater.

2. HighRateAnaerobicReactor/AnaerobicBaffleReactor(HRAR/ABR)

In this treatment phase, biological and natural chemical processes are used to digest and removemostoftheorganicmatter.Inthishighrateanaerobicreactor,withoutoxygenmechanicalmixingisapplied.Treatmentisachievedbyanaerobicdigestionbynaturallyselectedanaerobicmicrobial.Thisgivesgoodretentiontimetowastewateranddevelopmentofathicksludgeblanketinthebottomofcompartment.

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Fig.1,AnaerobicDigester[AD]Tank–CivilOnSiteConstruction

3. UpflowAnaerobicFilter

After the HRAR/ABR Treatment sewage water is transferred into up flow Anaerobic Filtercompartment inorder to improve further treatmentefficiency, a filtermediaallowingwidespreadcontactwiththewastewaterstreamisusedwhichisveryefficientinretaininganddigestingtheleftoverpollutants.Theprocessworkswithfixedplasticbiomedia.Thewastewaterpassingoutoftheanaerobicfiltershas90%oftheoriginalpollutionloadremoval.

PolishingTertiaryTreatment

Secondary (biological) treated water from AD Tank will be collected in a equalization tank. Thistreatedwaterisozonatedforpathogendisinfection.Ozonationalsoreducesfoulodor&tintofcolor,if present in treatedwater. PostOzonationwater is filtered by “ChargedActivatedMedia Filter[CAMF]” through a filter feed pump to trap tiny suspended particles from water. Ozonation oftreatedsewagewaterreducetinyorganicandinorganicimpuritiesfromwater.FrombackwashcumTreatedWaterTankwater isused forbackwashingof filters. From this tankwaterwillbefurthercollectedinmaintreatedwatertank.AsperMPCB,ozonationinSTPtertiarytreatmentismandatory.

Equalization

HRAR

BarScreen

UFAF

Settler

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Fig.2,TertiaryTreatment:ChargedActivatedPressureFiltration+OnlineOzonation

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ProcessFlowDiagram

Fig.3,ProcessFlowDiagramof“GreenSTPAD+”

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TechnicalSpecification

Therearetwooptionsforanaerobictankconstruction:

Option1–CivilTankConstructionUnderGround

Option2–CivilTankConstructionAboveGround

Inoption1,theconstructionofthesewagecollectioncumtreatmenttank&treatedwatertanksaretobeconstructedonsitebelowgroundbyouroryourcivilcontractor&wewillgivethedimensionaldrawings.Inoption2theconstructionofthesewagecollectioncumtreatmenttank&treatedwatertanksaretobeconstructedaboveground.Thebio-media&pipegridwillbeinstalledbyourteam,afterthetankisconstructedalongwiththeconstructionoftopslab.Also,thetertiarytreatmentplantwillbesupplied&installedbyourteam.

Inanyoftheoptedoption,oncethetanksareready,theywillbeinoculatedforanaerobicbacteriaatthesite.

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Option1–CivilConstruction–BelowGround

FootPrint–ADTank

Fig.4,ADTank,OxidationTank&FinalTreatedWaterTankcanbelocatedbelowlandscape

Fig.5,ADTank,OxidationTank&FinalTreatedWaterTankcanbelocatedbelowcarpark.

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ActualSitePicture–600KLD-2008

GREENSTPAD+BelowCarParking

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Fig.6,ADTank,OxidationTank,FinalTreatedWaterTank&PlantRoom.

ADTank :UnderGround/AboveGround :950m2[Area]X3.0m[Depth]

OxidationTank :UnderGround/AboveGround :20m2[Area]X3.0m[Depth]

TreatedWaterTank :UnderGround/AboveGround :20m2[Area]X3.0m[Depth]

BackwashWaterTank :AboveGround[Aboveplant] :10m2[Area]X2.5m[Height]

PlantRoom :AboveGround :30m2[Area]X3.5m[Height]

TotalAreaRequired :UnderGround/AboveGround:1,020m2

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FootPrint–Equipment

ADTank : AboveorBelowGround : 990–1,000m2x3.0m[Ht/depth]

PlantRoom : AboveGround : 25-30m2x3.0m[Height]

PowerRating

ABR+AF : 0.0Kw

TertiaryTreatment : 1.5Kwx24hrs =36.0Kwhr[Units]

Ozonation : 2.5Kwx24hrs =60.0Kwhr[Units]

FinaltransferPump : 1.5Kwx24hrs =36.0Kwhr[Units]

PlantRoom[Lights&Fans] : 0.5Kwx1hr =0.5Kwhr[Units]

TotalPowerRating : 6.0Kw[3Phase] =132.5Kwhr[Units]

ReclaimEfficiency

TreatedWaterQuantity : 400KLD : 97–99%Recovery

BiogasProduction : ____m3/day : Electricityof10kw/day*

*at50%efficiency.

Lifespan

ADTank–CoreTreatment : 50Years

TertiaryTreatment : 50Years

OzonationPlant : 20Years

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Operation&Maintenance

InADtankwastewaterflowsnaturallybygravity.Tertiarytreatment&disinfectionprocesscanbeautomaticanddoesnotrequireanyoperator.Onlyaparttimenon-technicaloperatorisrequiredforgeneral supervision & log keeping. Sludge management is also minimal & does not demand forfrequentsludgehandling.

Maintenance&ReplacementFrequency

SludgeMonitoring : Oncein6Months

Sludgeinspection : Oncein6Months

SludgeMaintenance : Settler : OnceinaYear

ABR/AF : Oncein3-4Years

Consumables

Chemicals

NoConsumablechemicalsarerequired.

ManPower

Non-technicaloperatorisrequiredforparttime. : 1hr/day

Electricity

CoreSewagetreatmentplant :0units/day :0.0Kw/m3

TertiaryFiltration :36units/day :0.09Kw/m3

Ozonation :60units/day :0.15Kw/m3

FinalTransferPump :36units/day :0.09Kw/m3

Misc/Plantroomlighting :0.5units/day :0.003Kw/m3

Total :132.5units/day :0.331Kw/m3 [Rs.<4.0perm3]

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Spares

ABR&AF : BiogrothMedia/PipeGrid : 50Years

TertiaryTreatment : FilteringMedia : 50Years

OzoneGenerator : OzoneCell : 2Years

OxygenGenerator : MolecularSelves : 2Years

AnnualMaintenanceContract

Annualmaintenancecontractisavailableposthandoverduringwarrantyperiod&postwarranty,forrestofplantlife.

OperationCharges : Rs.60,000/=peryear

ComprehensiveMaintenanceCharges : Rs.60,000/=peryear

Total : Rs.120,000/=peryear [Rs0.07perm3]

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CapitalCost

CivilTankConstruction [UnderGround] : ₹3.0–3.5Cr

CivilTankConstruction [AboveGround] : ₹2.6–3.0Cr

PlantRoomConstruction : ₹12.0–13.0Lakh

GREENSTPAD+&OzoneTertiaryEquipment : ₹53.0Lakh±2.0%

Installation&Commissioning+Inoculation : ₹4.0Lakh±2.0%

TOTAL Option1 BelowGround : ₹3.69–4.2cr

Option2 AboveGround : ₹3.29–3.7cr

OperationalCost

Consumables&Spares CostperMonthCostPerYear

Electricity [132.5units/day] ₹0.39Lakh ₹4.68Lakh

Operator ₹0.05Lakh ₹0.60Lakh

Chemicals/Misc. ₹0.01Lakh ₹0.12Lakh

Spares&Labor ₹0.05Lakh ₹0.60Lakh

TOTAL ₹0.50Lakh ₹6.0Lakh

Taxes&OtherCharges

AllTaxes,duties&otherincidentalchargesareextraasapplicableaslistedbelow

VatonConstructionmaterial [email protected]%

ServiceTaxonConstructionlabor [email protected]%

VATonEquipmentSupply [email protected]%

ServiceTaxondesign,I&C,inoculation [email protected]%

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TimeDuration

ConstructionofADTank[BelowGround] 7–8months

ConstructionofADTank[AboveGround] 6–7months

ConstructionofthePlantRoom 1–1.5month[simultaneously]

SupplyofTertiaryStageEquipment 1.5–1.8months[Simultaneously]

Installation&CommissioninginADTank 1.0months[Simultaneously]

Installation&Commissioningofequipment 2weeks

Inoculation 1.0weekpostsewagefeed

Startup 2–3months,postinoculation

Savings/ReturnonInvestment

AboveGroundconstruction 30.0m2 SavinginFSI

EnergyEfficient 79%less LEEDPoints/HighROI

Design Indo-Swiss-Innovation LEEDPoints

Sludge/WaterRecovery 2–3%Sludge+99%water LEEDPoints/HighROI

Technology Self-Sustain&EnvironmentalFriendly

Operation 1hr/day[OnlyMonitoring]

LifeSpane 50Years HighROI

Operator 95%less HighROI

Chemical 90%less HighROI

Repairs&Spares 90%less HighROI

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Assumptions

Forcomparison,wehaveassumedstandarddataofAerobicSewageTreatmentPlantof400KLD.

Electricity Rawsewagetransfer 1.5Kw

Blower 3.0Kw

Aerator 15.0Kw

FilterfeedPump 1.5Kw

FinaltransferPump 1.5Kw

Ozonation 2.8Kw

PlantRoom[L&F] 0.5Kw

Total 25.8Kw

Operationtime 24hrs

TotalElectricalConsumption 25.8Kwx24hrs 619.2Kwhr[Units]

ElectricityCostperday [@Rs10/-perunit] Rs.6,193/-

ElectricityCostperyear Rs.22,60,000/-

Chemicals Chlorine [WithoutOzonation] 20ppm

[WithOzonation] 5ppm

Alum 5ppm

Operator 24x7

Repair&Spare Routine

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References

YakshashriBeverage

Lotus I T Park

OPInfra

CairnIndiaLtd–Factory-Bhogat–Jamnagar,Gujarat 12CMD

EssarProjects–Residential–PapuaNewGuinea 50CMD

VasconEngineers–LaborCamp–Andheri 45CMD

AkashDeveloper–Resi–GTP BombayCentral 25CMD

CraftsmanAutomation–Factory-Prithampur[MadhyaPradesh] 15CMD

RhythmResort–Resort–Lonavala 60CMD

ManipalHospital–Hospital–Banglore 600CMD

YakshashriBeverage–Factory–Katjat- 3CMD

LotusITPark–CommercialBuilding–Parel 50CMD

GrandFortCity–Residential–Agra 60CMD

DreamMall-SunriseHospital–Bhandup- 50CMD

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CollaborationCertificate

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PleaseclickonbelowlinkstoknowaboutthemoreInformationon

Details-GreenSTPAD+

Presentation–FeaturesofGreenSTPAD+

Presentation–GreenSTPAD+

Catalogue–GreenSTPAD+

CollaborationSystem

SitePhotos

GreenSTPAD+-Video

SiteVideo–LotusMumbai

SiteVideo–EssarProject–PapuaNewGuinea(PNG)

Clientlist–pleasefindattached

CompanyProfile–Chemtronics’

ContactUs:

ChemtronicsTechnologies(India)Pvt.Ltd.

#28,SatyamIndustrialEstate,SubhashRoad,Jogeshwari(East),Mumbai-400060.INDIA

URL:www.chemtronicsindia.com;Mail:[email protected];Office:+91–22–28259933

ContactPerson:

Mr.SunilShah–Director(Technical)–India–[+91-9321234527]

Mr.NanchozZimmermann(Principle“GREENSTPAD+”Designer)–Switzerland,[email protected]


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