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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]