PRE-FEASIBILITY REPORT FOR 02 MLD CAPACITY …environmentclearance.nic.in/writereaddata/Online/TOR/08_Apr_2017... · PRE-FEASIBILITY REPORT FOR 02 MLD CAPACITY CETP BY SIRMOUR GREEN

PRE-FEASIBILITY REPORT FOR02 MLD CAPACITY CETP BYSIRMOUR GREEN ENVIRON

LIMITED

SHIVALIK SOLID WASTE MANAGEMENT LIMITED

PRE-FEASIBILITY REPORT FOR CETP PAONTA SAHIB

Prepared by: Shivalik Solid Waste Management Limited Page i

Table of content

1.1 EXECUTIVE SUMMARY ............................................................................................................................1

2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION.......................................4

2.1 Identification of the project ......................................................................................................................4

2.2 Details of the Project Proponent.............................................................................................................6

2.3 Brief Description of Nature of the Project ...........................................................................................6

2.4 Need for the project and its importance to the Country or Region .............................................6

2.5 Employment Generation (Direct and Indirect) due to the Project ..............................................7

3 PROJECT DESCRIPTION.............................................................................................................................8

3.1 Type of Project Including Interlinked and Interdependent Projects, If Any.............................8

3.2 Location ..........................................................................................................................................................8

3.3 Details of Alternate Sites ...........................................................................................................................9

3.4 Size or magnitude of operation ...............................................................................................................9

3.5 Project description with characteristic of effluent of industries..................................................9

3.6 Effluent Transportation as Per Topography.................................................................................... 30

3.7 Details of Pipeline From Industry To CETP...................................................................................... 31

3.8 Raw Material Required Along With Estimated Quantity, Likely source, marketing areaof final product/s, mode of transport of raw material and Finished Product..................................... 31

3.9 Resource Optimization/ Recycling and Reuse envisaged in the project, if any,................... 31

3.10 Availability of Water Its Source, Energy/ Power Requirement and Source .......................... 31

4 SITE ANALYSIS ........................................................................................................................................... 35

4.1 Connectivity................................................................................................................................................ 35

4.2 Topography ................................................................................................................................................ 36

4.3 Existing land use pattern........................................................................................................................ 36

4.4 Soil Classification ...................................................................................................................................... 36

4.5 Climatic & Rainfall .................................................................................................................................... 36

4.6 SOCIAL INFRASTRUCTURE AVAILABLE ........................................................................................... 37

5 PLANNING BRIEF....................................................................................................................................... 38

5.1 Planning Concept (type of industries, facilities, transportation etc.) Town and CountryPlanning/Development authority Classification .......................................................................................... 38

5.2 Population projection.............................................................................................................................. 38


Prepared by: Shivalik Solid Waste Management Limited Page ii

5.3 Land use planning..................................................................................................................................... 38

5.4 Assessment of Infrastructure Demand (Physical & Social) ......................................................... 38

5.5 Amenities/Facilities................................................................................................................................. 38

6 PROPOSED INFRASTRUCTURE ........................................................................................................... 39

6.1 Industrial Area (Processing Area)....................................................................................................... 39

6.2 Green Belt.................................................................................................................................................... 39

6.3 Connectivity (traffic and transportation road/rail/metro/water ways etc.)........................ 39

6.4 Drinking water management ................................................................................................................ 39

6.5 Sewerage system....................................................................................................................................... 39

6.6 Industrial waste management.............................................................................................................. 39

6.7 Solid waste management........................................................................................................................ 39

6.8 Power requirement & supply/source ................................................................................................ 39

7 REHABILITATION AND RESETTLEMENT (R&R) PLAN ............................................................. 40

8 PROJECT SCHEDULE & COST ESTIMATES ...................................................................................... 41

8.1 Cost Estimates............................................................................................................................................ 41

8.2 DETAILS OF OPERATIONAL COST ...................................................................................................... 43

9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) ........................................................ 47

List of Table

Table 2-1: SALIENT FEATURES OF THE PROJECT .......................................................................................3

Table 3-1: Details of Plot wise Industries in Gondpur Industrial Area...................................................9

Table 3-2: Industrial Units outside Gondpur Industrial Area................................................................ 13

Table 3-3: Detailed Analysis of Effluent Samples from Industries given below .............................. 15

Table 3-4: Standards for Discharge of Effluent........................................................................................... 18

Table 3-5: Stage wise detail of process with capacity is .......................................................................... 20

Table 3-6: Filter press detail............................................................................................................................. 25

Table 3-7: Detail of Reverse Osmosis ............................................................................................................ 27

Table 3-8: Description of Electrical Equipment ......................................................................................... 34

Table 8-1: Details of mechanical equipment and cost.............................................................................. 41

Table 8-2: Details of electrical equipment and cost .................................................................................. 41

Table 8-3: Details of instrumentation and cost .......................................................................................... 42


Prepared by: Shivalik Solid Waste Management Limited Page iii

Table 8-4: Details of equipment for ZLD and cost ..................................................................................... 42

Table 8-5: Details of land, roads, sewerage lines and cost...................................................................... 42

Table 8-6: Total cost of CETP ........................................................................................................................... 43

Table 8-7: Tentative treatment cost – sector wise .................................................................................... 45

List of Figures

Figure 3-1: Flow diagram of process flow.................................................................................................... 21

Figure 3-2: Layout diagram of proposed CETP at plot no 96-97.......................................................... 29

Figure 3-3: Water balance of the proposed CETP...................................................................................... 32

Figure 4-1: Map of Gondpur Industrial Area & Location of CETP......................................................... 36

List of Annexure

Annexure- I Allotment Letter

Annexure-II Buffer Map of 1o km study area

Annexure—III Process flow diagram of CETP


Prepared by: Shivalik Solid Waste Management Limited Page 1

1.1 EXECUTIVE SUMMARY

The concept of effluent treatment, by means, of a collective effort, has assumed reasonable

gravity by being especially purposeful for cluster of small scale industrial units. Common

effluent treatment plant (CETP) not only helps the industries in easier control of pollution,

but also act as a step towards cleaner environment and service to the society at large.

Small scale industries, by their very nature of job cannot benefit much from economies of

scale and therefore the burden of installing & operating pollution- control equipment,

falls heavy on them. Realizing this practical problem, under the policy statement for

abatement of pollution the Government extends the scheme for promoting combined

facilities for treatment of effluent for clusters of small scale industrial units and also to

provide technical support to them.

The concerted approach of common effluent treatment provisions has many advantages.

Wastewater of individual industries often contain significant concentration of pollutants;

and to reduce them by individual treatment up to the desired concentration, becomes

techno-economically difficult The combined treatment provides a better and economical

option because of the equalization and neutralization taking place in the CETP. Other

important issues for the merit of common treatment include scarcity of land at the

industry's level and a comparatively easier availability of professional and trained staff for

the operation of CETP, which is otherwise difficult, at the individual industry level. For the

regulatory authorities also, common treatment facility offers a comparatively easier

means of ensuring compliance of stipulated norms.

The Proposed CETP at Gondpur Industrial Area near Paonta Sahib falls in district Sirmaur

of Himachal Pradesh. The Sirmaur district lies between 77°01’12” and 77°49’40” East

longitude and 33°22’30” and 31°01’20” North latitude in the outer Himalayan ranges

commonly called as Shivaliks. The district is predominantly mountainous with deep

valleys lying between ranges of varying elevations. Longest length from west to east is 77

kms and the maximum width from north to south is 80 kms. The district is bounded by

Shimla district in the north, Uttarakhand in the east, Yamuna Nagar district of Haryana in

the south - west and Solan district in the north-west. The geographical area of the district

is 2825 Sq. Km. which is almost 5.07% of the total geographical area of the State. Like

other parts of Himachal Pradesh, it has beautiful landscapes, bracing climate, big and small

game and legendry temples which hold abiding attraction for the tourists. River Giri is the

biggest river in the district which originates from Kotkhai/Jubbal Tehsil of Shimla district

and flows down in the south-east direction. It ultimately joins the river Yamuna near

Paonta Sahib.

The industrial Association of Paonta through Sirmour Green Environ Limited, a company

registered in India having its registered office at 50, Industrial Area, Gondpur, Paonta

Sahib, District-sirmour, Paonta sahib, Himachal Pradesh, India – 173025, proposes to set



up Common Effluent Treatment Plant (CETP) to serve Gondpur industrial area and

industries located in nearby area within 10 km zone for management of industrial

effluents and to protect ecology from further deterioration. The proposed CETP is

expected to treat around 2 MLD industrial effluents including Sewage component.

Generated solid waste would be transported to authorized TSDF site. No liquid waste

would be required to be disposed off in inland surface water due to Zero Liquid Discharge

ZLD System; The waste water after treatment shall be recycled for industrial & agriculture

purpose.

The project site is well connected with road and railways. Paonta Sahib City is Approx 3.70

km, SW direction away from the project site. Dehradun Railway Station Approx. 42 km, in

ESE direction and Jolly Grant Airport, Dehradun: 62 km, in SE Direction away from project

Site.

FIGURE -1 SHOWING DISTRICT SIRMAUR & PAONTA SAHIB



The salient features of the proposed project are given in table below:

Table 2-1: SALIENT FEATURES OF THE PROJECT

Location LATITUDE: 30o 28' 24.91” N

LONGITUDE: 77o 37’ 36.93” E

Land Area Plot measuring about 4500 Sq. Mtr. has been allotted for the

proposed CETP

Screening Category 7(h), Category A as per EIA Notification 14th Sep, 2006 and

amended thereof.

Project Profile The Proposed CETP is expected to treat around 2 MLD industrial

effluents along with sewage with ZLD System from the industries

located in Gondpur industrial area and other industries located in

10 Km radius

Cost of the Project Approx. Rs. 10.7 Crores

Resource Requirement

Source & Quantity of

Water

Water for construction and domestic purpose will be met from

Tube well.

Power 2 X 630 KVA = 1260 KVA.

Power Backup: 200 KVA – 1 Nos.

Man Power Approx. 25 to 30 skilled and unskilled labours will be engaged

during construction of CETP project.

Environmental Management System

Effluent Treatment

Scheme

Proposed CETP with ZLD technology is for the effluent mainly

from clusters of pharmaceutical Industries with sewage.

Flue Gas Emission No flue gas emissions except from operation of DG set as standby

power source.

Hazardous Waste ETP Sludge, Used oil, Discarded containers/liners.



2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of the project

District Sirmaur has taken long strides in the field of industrial development, particularly

after the announcement of special industrial package - 2003 and it has emerged as 2nd

largest Industrialized District in Himachal Pradesh. Today, it has more than 1600 Micro,

Small, and Medium & Large Industries with total capital investment of about Rs. 4000

Crores and providing direct employment to more than 26000 workers

The rapid growth of industry in two industrial areas in the district, the details of which

are as under:-

Name of

Industrial AreaNo. of Plots Area in

(Bighas)Plots Allotted

VacantNo. of plots No. of parties

Kala Amb 67 221.03 67 52 0

Paonta Sahib 126 585.17 124 76 2

Some of the reputed Industrial houses like Sun Pharma, Mankind Pharma, Marico, Bajaj oil,

Carlsberg Beer, Himalayan Mineral Water, Akorn inc, Blue Star, United Biscuits, Pioneer

Embroidery, Himalaya International Ltd, Tirupati Group, etc. have established their

manufacturing facilities in the District.

The I.A. Gondpur was established in 1974-75 in a stretch of 585 Bighas The industrial units

located in I.A. Gondpur have strength of approximately 3000 workers. The total number of

industries set up in this area is 76. Due to rapid industrial growth and increase in

production capacities in some of industries, the treatment of effluent has become

uneconomical at individual level besides the space constraint. Hence Sirmour Green

Environ Ltd, Paonta Sahib, Distt. Sirmour, H.P proposes to setup CETP of 2 MLD capacity

based on Zero Liquid Discharge (ZLD) technology at Gondpur near Paonta sahib in HP.

This will help in reducing capital and operating cost of treatment of effluent.



FIGURE -2 STATELITE VEIW OF GONDPUR INDUSTRIAL AREA

The Common treatment is always cheaper than small scattered treatment units. The other

benefits of CETP are;

• Availability of land which is difficult to be ensured by individual units in the event

they go for expansion of individual treatment plants.

• Contribution of nutrient and diluting potential, making the complex industrial waste

more amenable to degradation.

• The neutralization and equalization of heterogeneous waste makes its treatment

techno-economically viable.

• Professional and trained staff can be made available for operation of CETP which is

not possible in case of individual plants.

• Utilization of treated wastewater & disposal of sludge becomes more organized.

The CETP project is to treat the effluent being generated from the industries located in the

Gondpur industrial area and its periphery. Waste water thus generated by the associated

industries will be collected through pipeline network and through tankers for treatment.

Due to ZLD System, the waste water after treatment would be recovered and recycled to

industrial units for cleaning, flushing and gardening. The CETP with Zero Liquid Discharge



System is to eliminate any discharge of wastewater into the water body or surrounding

environment.

2.2 Details of the Project Proponent

Sirmour Green Environ Limited is a company registered in India having its

registered office at 50, Industrial Area, Gondpur, Paonta Sahib, District-Sirmour,

Paonta sahib, Himachal Pradesh, India - 173025. The company was registered on

July 19, 2010 with Registrar of Companies Himachal Pradesh as a Public Company

limited by shares.

2.3 Brief Description of Nature of the Project

The proposal is to set up the CETP with ZLD of 2 MLD for the effluent from industries

located in Gondpur industrial area and industries located in nearby region. The cluster of

industries encompasses mainly pharmaceutical formulation units and some lime & food

processing units. There will be dedicated closed circuit pipeline network system for the

effluent to be received at CETP beside tankers to bring effluent from industries located in

the periphery.

2.4 Need for the project and its importance to the Country or Region

There are as many as 38 pharmaceutical formulation units in Gondpur industrial area

besides other units in the periphery have been facing lot of problems in treatment of their

effluent, as it contains high TDS, Color and COD & BOD. This was also the issue faced by the

industries in the other states in northern India. Pharmaceutical effluent also contains high

BOD, COD and TDS level. Some time presence of refractory chemicals is found even in the

formulation units.

The industrial Association of Paonta through Sirmour Green Environ Ltd, Paonta Sahib

intends to install Common Effluent Treatment Plant (CETP) of the capacity of 2 MLD with

ZLD System to serve Gondpur industrial area and industries located in nearby region for

management of industrial effluents and to protect ecology from further deterioration.

The Objective of setting up of CETP is:

To Achieve Economy of scale in waste treatment, thereby reducing the cost of

pollution abatement for individual industry.

To take care of the problem of lack of technical assistance and trained personnel as

needed for skill operation of effluent treatment plant.

To solve the problem of lack of space as the centralized facility can be planned in

advance to ensure that adequate space is available

To reduce the problem of monitoring by the pollution control boards.



To organize the appropriate disposal of treated waste water including reuse and

sludge generated to authorized facility.

2.5 Employment Generation (Direct and Indirect) due to the Project

The proposed project will provide direct and indirect employment. Around 20-25 person

would be deployed during construction phase of proposed project. And 11 persons shall

be employed during operation stage. During construction phase local worker would be

utilized from nearby villages..



3 PROJECT DESCRIPTION

3.1 Type of Project Including Interlinked and Interdependent Projects, If Any

This project is for establishment of common environmental infrastructure i.e. CETP with

ZLD for treatment of effluent being generated by clusters of pharmaceutical industries.

The Common Effluent Treatment Plant (CETP) is listed at serial no. 7(h) of the Schedule of

EIA Notification 2006 and falls under Category A due to it’s the location of CETP is coming

within 10 km of Simbalwada wild life sanctuary The project is not interlinked with any

other project.

3.2 Location

The proposed location of the project is situated at Plot No. 96-97 Gondpur Industrial Area

The site Coordinates are 30028’24.91”N Latitude and 77037’36.93”E Longitude Location

map is given in Figure below-

FIGURE 3: VICINITY MAP OF THE PROJECT SITE

Project Sites



3.3 Details of Alternate Sites

No alternative site has been examined for the proposed project, as the location has been considered on

basis of the distance of mainly from clusters of pharmaceutical industries from CETP site for

transportation of effluent.

3.4 Size or magnitude of operation

The proposed project is to establish Common Effluent Treatment Plant with ZLD system treating of 2

MLD capacity waste effluents coming from industries of Gondpur industrial area. The plant will consist

of treatment units comprising physical, chemical and biological treatment including dewatering of

sludge and other required infrastructure.

3.5 Project description with characteristic of effluent of industries

3.5.1 The proposed Common Effluent Treatment Plant facility will be treating the waste water mainly

from the clusters of pharmaceutical industries located at Gondpur industrial area and in surrounding

area. The member industries of CETP with ZLD will be required to give primary treatment and monitor

specified quality parameters and flow rate of the effluent on daily basis while discharging into the

system connected with CETP on regular basis.

The table below shows the distribution of industrial plots in Gondpur Industrial Area and industries

outside Gondpur industrial area. Most of the industries fall under industrial categories of

Pharmaceuticals followed by Soap & detergent and calcium carbonate which produces effluent.

Table 3-1: Details of Plot wise Industries in Gondpur Industrial Area

Sr.No

Name Of Unit. Plot No Land Area(Sq. Mtrs)

Industry (TypeAnd Capacity)

Discharge inKL

1 M/S Superior TyreRetreads

1A 422 Tyre Retreading NA

2 M/S Shree ShyamIndustries

1 1200 Fans NA

3 Industrial Sheds withHPSSI&EC

2-9 5340 - NA

4 M/S Stark Batteries 7-A 800 Carpet NA

5 M/S Fair Deal Industries 8-A 540 Electric wire NA

6 M/S Quality FoodProducts

10 640 LS Powder NA

7 M/S Virk Associates 11&12 1440 Lead NA

8 M/S Paonta Health CareIndustries

12 A 860 Sugar Syrup NA



9 M/S Sharp Tools 14-16 5075 Cutting Tools NA

10 M/S Process EquipmentIndia

17 1800 Boiler NA

11 M/S Regency Ferro &Allied Products

18 3000 Ferro Silicon NA

12 M/S Regency Carbide 19 3840 Calcium Carbide NA

13 M/S InternationalCylinders (P)Ltd

20 4800 LPG Cylinders NA

14 M/S H H Industries 21 1000 Soap NA

15 M/S BhagwatiChemicals

22 1000 Hydrated Lime NA

16 M/S Pharma Force lab 23 & 24 1000 Pharma products 1.5

17 M/S CopmedPharmaceuticals

25-26 2000 Pharma products 1.1

18 M/S Chhiba Agroproducts

27 1000 Toilet cleaners. NA

19 M/S M I Industries 28-29 2250 Hydrated Lime NA

20 M/S Cal ChemIndustries India Ltd

30,109,1

0-113

12700 Calcium Carbonate NA

21 M/SLime Chemicals Ltd 31-35 34196 Calcium Carbonate NA

22 Green Belt 36-45

23 M/S Medo forcehealthcare

46 1480 Pharmaceuticals 5.5

24 M/S Zee LaboratoriesLtd


25 M/S Zee LaboratoriesLtd

Behind 47 6100 Pharmaceuticals 8.1

25 M/s RelaxPharmaceuticals Unit -I

48A & B 3200 Pharmaceuticals 1.9

26 M/S RelaxPharmaceuticals, Unit-II

49A 1280 Pharmaceuticals 1.31


49B 1280 Pharmaceuticals 0.35





29 M/S LaboratePharmaceuticals


30 Green Belt 52 -

31 M/S Pharma Force LabsUnit I

53-55 5600 Pharmaceuticals 2.3

32 M/S Him Stone Rubber(P) Ltd

56-57 3600 Cycle Tyre NA

33 M/S Avalon Cosmetic (P)Ltd

58-59 3000 Powder & talc 9.0

34 M/S Om Besco superfrictionsP.ltd.

60-63 4535 Railway Brake Shoe

35 M/S Jolly Industries 64 1000 Fire Bricks

36 M/S Shree Shanti NathElectricals

65 1000 Electric Iron

37 M/S Sai Bliss Drug &Pharmaceuticals


38 M/S Bhagwati Chemical 68 1000 LS Powder NA

39 M/S Bhagwati ChemicalIndustry

69 1000 Hydrated Lime

40 M/S Valley Industries 70 1000 M.S.Bun

Pharmaceuticals gs

NA

41 M/S Savita Industries 70 - V.P.Rings

42 M/S N.S.Industries 71 1000 Pharma printing NA

43 M/S N.S,Industries 72 1000 Pharma printing NA

44 M/S Regency bio-carePvt. Ltd.

73 1000 Cosmetics NA

45 M/S Relax

Pharmaceuticals


46 M/S Himachal AgroChemical Industry

75 1000 Ginger

47 M/S Poanta ProcessEquipments

76 1000 Pharmafabrication

48 M/S A D Printers 77 1000 Printing

49 M/S Mehar Industries 78 1000 Adhesive

50 M/S Standard Mfg.Corpn.

79 1000 Pharmaceuticals

51 IADA Tube Wells 80



52 M/S Jai Murthy Mineral& Chemical

81-82 & 1A 7420 CalciumCarbonate

180

53 M/S HimalayaCarbonate

83 3080 CalciumCarbonate54 M/S Himalaya Intt. Ltd 84 & 87-90 13420 Compost Unit NA

55 M/S Pharma Force labunit-II


56 M/S A.S.Packers 91-93 5680 Corr. Boxes NA

57 M/S VenketashwaraFerro Alloys

94 1900 Calcium Carbide

58 M/s Lime Chemicals 95 7000

59 M/S Sapphire PetCorp..of India

96 1000 Pet Bottles

60 M/S AccurateHealthcare


61 M/S Solvopet 98 1500 Pet Bottles NA

62 M/S AtheneLaboratories

99 1800 Cosmetics &Toiletries

9.0

63 M/S A.S.Packers 100 1500 Print Cartons NA

64 M/S UpkaarPharmaceuticals


65 Service BuildingComplex

102 - - -

66 M/S Elder

Pharmaceuticals Ltd

103 7200 Pharmaceuticals NA

67 M/S Sirmour PetIndustries

104 600 Pet bottles. NA

68 M/S Pharma petIndustries

105 500 Pet bottles NA

69 M/S Elder HealthcareLtd

106-107 930 Pharmaceuticals

70 M/S StandardSurfactants

114 1250 Soap

71 M/S H.P Chamber ofComm & Inds

115 500 Chamber Office NA

72 M/s Ajit MittalCorporation

52-A 552 Printing

73 Lenark Laboratoies EL SS Cosmetics 9.0



74 Sirmaur Remedies Nahan Road Pharmaceuticals 3.0

75 Mankind Specilites NearGondpur

Pharmaceuticals 3.0

76 Vet Vista Pharmaceuticals 3.0

Total 260.4 KL

Table 3-2: Industrial Units outside Gondpur Industrial Area

Sr.No Name of Unit Address Product Discharge (In KLD)

1 M/s Nanz Med SciencePharma Pvt. Ltd.

Rampur Ghat Pharmaceutical 20

2 M/s Glide Chem Pvt. Ltd Rampur Ghat Pharmaceutical 0.5

3 M/s Jeps Pharmaceuticals Rampur Ghat Pharmaceutical 0.5

4 M/s Bioveda ActionResearch Co.

Rampur Ghat Herbal Cosmetics 10

5 M/s Mankind Pharma-Ill Rampur Ghat Pharmaceutical 2.6

6 M/s Next Wave India Rampur Ghat Pharmaceutical 12

7 M/s Nitin Life Sciences Rampur GhatPharmaceutical

5

8 M/s Mankind Pharma-I Kishanpura Pharmaceutical 12 (ETP+STP)

9 M/s Mankind Pharma-II Kishanpura Pharmaceutical 33

10 M/s Ban Lab Pvt Ltd Dhaula Kuan Cosmetics 20 (ETP+STP)

11 M/s Merico Industries Dhaula Kuan Cosmetics ----

12 M/s Zeon Life Sciences Rampur Ghat Pharmaceutical 50 (ETP+STP)

13 M/s Mahan Foods Bio sys Rampur Ghat Pharmaceutical 32-50 (ETP+STP)

14 M/s Tirupati Life Sciences. SurajpurPharmaceutical

10



15 M/s Sirmaur Remedies Nahan Road Pharmaceutical 3.0

16 M/s Mankind Specialties Near Gondpur Pharmaceutical 3.0

17 M/s Vet Vista Near Gondpur Pharmaceutical 3.0

Total 209.6

With a land area of nearly 585.17 Bighas housing nearly 75 units in Paonta industrial belt which

accommodates small gamut of wet processing plants mainly pharmaceuticals, followed by Calcium

Carbonate plants and some small engineering units. This in addition to about 15 to 20 waste water

generating units mainly pharmaceutical & a dairy industry located in 10 Km periphery of proposed site for

CETP and expansion in future may form heterogeneous character of the effluent to be discharged into the

common effluent treatment plant. Some of units are not in operation and are presently closed.

Effluent Quantity indicated above is as per consent issued by HPPCB. Quantum of waste water

generation from the units presently not in operation was not available. Also measurement of discharge

from some industry did not match with figures of Consent data. As per Department of Industry about

500 KLD of water is supplied to industries located in Gondpur Industrial Area through piped water

supply. Also most of the units have bore wells within their premises for water supply for industrial

processes. Taking above facts into consideration and scope of future expansion, the proposed CETP is

designed for treating 1.5 MLD of Industrial effluent and 0.5 MLD of domestic Sewage.

Most of the units are equipped with their own waste treatment system. But, the complexity of the

effluent characters makes it very difficult to meet the statutory standards even despite the best efforts

made by the entrepreneurs. The easy bio degradability is hardly encountered in pharmaceutical sector

due to refractory COD.

Adoption of appropriate technology may be one criterion as far as the degradability of waste chemicals

is concerned, but the economic affordability of meeting the recurring expenditure is the paramount

desirable parameter in selecting the treatment scheme.

More over units are scattered over large industrial area, monitoring mechanism along with conveyance

cost is another major concern while deciding the mode of transportation of effluent. With a view to

circumventing the above constraints, the sector wise load estimation seems to be a mandatory part of

preliminary exercise.

While investigating the effluent qualitative aspects, we find that, the effluent from pharmaceutical

industries is sometimes harsh in the breakdown of non biodegradable recalcitrant. Calcium Carbonate



12

effluent poses a problem of suspended solid removal. Concern is management of TDS level of the

resultant treated stream.

In addition, there are some miscellaneous wastes such as washing from engineering units, which do not

possess the biological matter and pose little problem. The quantum of such effluent is quite small

compared to the earlier ones enumerated above. Table-3 shows the nature of effluent from

pharmaceutical units based on the actual sampling and experimental evaluation major pharmaceutical

plants.

Key characteristics of wastewater that has been considered in designing of the CETP include flow, and

physical, chemical, and biological characteristics of the wastewater.

There are number of assumptions made in estimating the load calculation:

> On safer side, the water consumption has been made equivalent to the quantity ofeffluent/sewage generation.

> The latest list of units provided by the concerned DIC

> Some of the units though very small but for reference, it is not omitted from the list.

> There are effluent treatment plants in major water consuming industries. It is expected that the raweffluent will be discharged and not after treatment.

> A factor of safety is necessary for the plant design.

Table 3-3: Detailed Analysis of Effluent Samples from Industries given below

Unit/ Parameter Sample

Identification

Unit Result

1 Mediforce Health Care Pvt. Ltd. ETP Water (Untreated Composite)

COD mg/l 604

TDS mg/l 495

TSS mg/l 61

Oil & Grease mg/l 43.33

BOD mg/l 235

2. Comped pharmaceutical (P) Ltd. Unit

3. Relax Pharmaceutical (P) Ltd. Unit-II

ETP Water (Untreated Composite)II

COD mg/l 3098



TDS mg/l 708

TSS mg/l 11

Oil & Grease mg/l 40

BOD mg/l 1080

4 Relax Pharmaceutical Ltd. Unit I ETP Water (Untreated Composite)

COD mg/l 19941

TDS mg/l 14986

TSS mg/l 207


BOD mg/l 11462

5 Pharma Force lab Unit- I ETP Water (Untreated Composite)

COD mg/l 272

TDS mg/l 830

TSS mg/l 65


BOD mg/l 75

6 Copmed Pharmaceutical Ltd. Unit-1 ETP Water (Untreated Composite)

COD mg/l 759

TDS mg/l 1530

TSS mg/l 62


BOD mg/l 420

7 Pharma Force Lab Unit-III ETP Water (Untreated Composite)

COD mg/l 1533

TDS mg/l 3878

TSS mg/l 178


BOD mg/l 1061

8 Pharma Force Lab Unit-II ETP Water (Untreated Composite)



COD mg/l 3593

TDS mg/l 2224

TSS mg/l 30


BOD mg/l 2350

9 Sirmour Remedies (P) Ltd. ETP Water (Untreated Composite)

COD mg/l 3051

TDS mg/l 3036

TSS mg/l 250


BOD mg/l 2050

10 Next Wave India Ltd. ETP Water (Untreated Composite)

COD mg/l 1905

TDS mg/l 868

TSS mg/l 70


BOD mg/l 980

The Treated effluent is required to meet the discharge standards laid down for CETP under EPA for

disposal into inland sewers. In this case the proposed CETP is designed for zero liquid discharge,

whereby after tertiary treatment (Reverse Osmosis) the BOD shall further reduce, and the treated

effluent will meet such limits as will be prescribed by the HPPCB and to meet the requirement of

recycle & reuse of treated water by the industrial units.

Discharge standards prescribed by CPCB based on the disposal methodology are as under: General

Standards for discharge of Environment Pollutants, GSR 422(E)-of CPCB, India, THE

ENVIRONMENTAL (PROTECTION) RULES, 1986 1[SCHEDULE - VI], (See Rule 3A) Part - A: Effluents.

Standards laid down for Common Effluent Treatment Plants as per Environment (Protection Rules,

1986 for treated effluent Quality are given below:



Table 3-4: Standards for Discharge of Effluent

[Concentration in mg/l except pH & Temperature]

Parameters Into Inland Surface

Waters

On Land for

Irrigation

Into Marine

Coastal Area

pH 5.5-9.0 5.5-9.0 5.5-9.0

BOD (3 days at 27oC) 30 100 100

Oil & Grease 10 10 20

Temperature Shall not exceed 400C in

any section of the

stream within 15

meters downstream

-- 450C at the point of

discharge

Suspended Solids 100 200 (a) for processwastewater- 100

(b) For coolingwater

effluent 10 percent

above totalsuspended matter ofeffluent coolingwater

[Concentration in mg/l except pH & Temperature]

Parameters Into Inland Surface

Waters

On Land for

Irrigation

Into Marine

Coastal Area

Dissolved Solids(inorganic)

2100 2100 --

Total residual Chlorine 1.0 -- 1.0

Ammonical nitrogen (as N) 50 -- 50

Total Kjeldahl Nitrogen (as

N)

100 -- 100

Chemical Oxygen Demand 250 -- 250

Arsenic (as As) 0.2 0.2 0.2

Mercury (as Hg) 0.01 -- 0.01



Lead (as Pb) 0.1 -- 1.0

Cadmium (as Cd) 1.0 -- 2.0

Total Chromium (as Cr) 2.0 -- 2.0

Copper (as Cu) 3.0 -- 3.0

Zinc (as Zn) 5.0 -- 15

Selenium (as Se) 0.05 -- 0.05

Nickel (as Ni) 3.0 -- 5.0

Boron (as B) 2.0 2.0 --

Percent Sodium max -- 60 --

Cyanide (as CN) 0.2 0.2 0.2

Chloride (as Cl) 1000 600 --

Fluoride (as F) 2.0 -- 15

Sulphate (as SO4) 1000 1000 --

Sulphide (as S) 2.8 -- 5.0

Pesticides Absent Absent Absent

Phenolic compounds (as

C6H5OH)

1.0 -- 5.0

It is further proposed to treat the final effluent to tertiary level by providing RO (reverse Osmosis) to

meet the water quality to be reused by the industries & RO reject shall be finally treated through MEE to

make the scheme ZLD (Zero Liquid Discharge). Provisions shall also be kept for using the treated

effluent to be used by nearby farmers for irrigation for sustainable development of area as it faces water

shortage during summer season.

The Sludge generated from the CETP shall be sent to authorized TSDF site at Nalagarh

3.5.2 DESIGN OF 2 MLD CETP

1) Trade Effluent Generated from the Industrial units = 1.5 MLD

2) Sewage Inflow from Industrial units and residential area in the region = 0.5 MLD

3) Total flow = 2MLD



3.5.3 INLET CHARACTERISTICS OF EFFLUENT

BOD 1100 mg/L

COD 2500 mg/L

TDS 2500mg/L

TSS 250 mg/L

3.5.4 TREATMENT PROCESS:

The following treatment process is followed for the purpose of treatment of Effluent.

Physio chemical Process:

A) Screen & Grit Removal.

B) Sedimentation

C) Filter press. Biological Process:

D) Activated sludge Process diffused aeration.

Stage wise detail of process with capacity is given below;

Table 3-5: Stage wise detail of process with capacity is

Sr. No. NAME CAPACITY

1. Screen Chamber 27 KL

2. Oil & Grease Trap 27 KL

3. Equalization tank 504 KL

4. Primary settling tank 1 & 2 275 KL

5. Aeration Tank 1,2 & 3 350 KL

6. Secondary settling tank 1 &

2

550 KL

7. Polishing tank 64 KL

8. Multi grade filter (MGF) 150 KL/hr

9. Activated Carbon Filter

(ACF)

150 KL/hr



Figure 3-1: Flow diagram of process flow

The Effluent from various industries like lime, pharma and other misc. industries will be collected into

an equalization tank after passing through a bar screen, coarse screen, oil and grease trap for the

separation of insoluble bigger size particles and the separation of minor amount of oil or greasy matter

present in the effluent.

Since the effluent is laden with some sludge or settable solids, the equalization tank will be equipped

with air sparking system in order to keep them in suspended mode preventing its deposition at the

bottom which would be otherwise a serious nuisance as far as the maintenance point is concerned. The

collection tank shall have two partitions. Thus, it would help the uninterrupted 24 hours’ storage facilitywith simultaneous maintenance operation without any hindrance.

The resultant stream would then be withdrawn at the design flow rate and would be taken into a pre-

settler fitted with mechanical scrapper for the separation of suspended solids or if any. The clarifier

effluents would then passed into the aeration chamber. The aeration system has been designed with the

principle of activated sludge process but would function with a very high food to microorganism ratio

(F/M) this would facilitate to handle high amount of BOD load in a small volume. A specified MLVSS has to

be maintained in the aeration chamber as per the influent load characteristics. The mixed liquor containing

MLVSS would then flowed to a secondary clarifier for the separation of biomass. The clarified effluent



thereafter passed into aeration tank-II which will be made functional with the principle of attached growth

by adopting MBBR technology. The attached growth model has been preferred over suspended growth

model for meeting very low BOD (less than 10 mgs/L) and with the modular concept enhanced load in

future could be handled efficiently because of the very low retention time is required to achieve a high

treatment efficiency in MBBR module.

High hydraulic volume in both the cases have been preferred in order to derive the high efficiency of

oxygen transfer of submerged aeration system. Another important point here is that the activated

sludge process will be operated for accelerating the growth kinetics which will help in the management

of residual refractory chemicals which are encountered in each type of waste to some extent (may be

negligible). Hence, continuous wastage of biomass and its withdrawal from the reactor would definitelyhelp in obtaining the treated effluent of very high quality.

The treated effluent at this stage would attain BOD level less than 10 mgs/L, it would be free from

turbidity. Thus the appearance will be crystal clear. As a factor of safety such effluents would be taken

through some reaction tanks for physico-chemical treatments and subsequently passing through

clarifiers for the removal of sludge from the treated effluent containing flocks. A dosing of necessary

chemicals like coagulants, alkali or other chemicals may be added into the reaction tank for this

purpose. The clarified effluents would be collected into an intermediate sump and would be pumped to

a multi grade filter system prior to Reverse Osmosis Process.

3.5.5 DESIGN OF MAIN UNITS TO BE PROVIDED FOR THE CETP

i. Screen Chamber:

Before collection tank, mechanically operated medium/ fine bar screen is proposed to be

provided to arrest any matter before the pumping and to avoid any clogging of pumps in

collection tanks.

Size- 3M x 3M x 3M (L x B x D)

Material of Construction- RCC

Capacity- 27 KL

ii. Oil & Grease Trap:

Provision of Oil & Grease Trap is proposed as a part of treatment process in order to arrest the

oil & grease before collection tank, as the oil & grease above the prescribed limit causes

problem in treatment of effluent.

Size- 3M x 3M x 3M (L x B x D) Material of Construction- RCC Capacity- 27 KL



iii. Collection cum Equalization Tank:

The CETP will be receiving various streams of effluent from different types of industries depending

upon their own manufacturing process and raw materials used. The characteristics of effluent

discharge will also be different, in order to have a appropriate treatment, homogenous mixture of

effluent with definite characteristics will be needed for which collection tank will be provided with

agitation through diffused aeration. This is for the purpose of proper mixing of effluent and also to

keep the suspended solids in suspension form, which may later be separated in PST.

Size- 12M x 12M x 3.5M (L x B x D)

Material of Construction RCC

Capacity- 504 KL

Retention period 8 hr

iv. Primary Settling Tank 1 & 2:

Primary Settling Tank is provided to settle the settleable impurities. In Primary Settling Tank 1

Chemicals dosing will be done for flocculation, pH Neutralization etc. All organic or inorganic

impurities in suspended state will be settled before the aerobic treatment. The mechanism for the

Primary Settling Tank will be up flow of the effluent and the effluent will be drained through

Launder to the Aeration Tank. The scrappers will be provided to collect the sludge. The sludge

will be transferred to the sludge drying beds through sludge pumps.

Size- 10M (Diameter) x 3.5M (Height)MOC- RCCCapacity – 275 KLRetention Period – 3 Hr.

Numbers of units – 02 No.

Sludge Collection Mechanism Bottom Scrapers

v. Aeration Tank 1,2 & 3 :

The aeration tanks are proposed to provide aerobic treatment to the effluent in order to reduce

the BOD level to the required parameters. The activated sludge process will be followed for the

aerobic treatment. The aeration tank will be provided with diffused aeration through vertical

fine bubble disc type diffusers. In order to maintain the dissolved oxygen level the proper

blowers with required capacity will be installed. To maintain proper MLSS and microorganism

MBBR Media will be loaded in the aeration tank 3. The Sludge Recirculation system will also be

provided to maintain the proper MLSS.

Size- 10 M x 10M x 3.5M ( L x B x D)

MOC- RCC

Capacity- 350 KL

Retention Period – 18 Hrs.

Number of Units – 03 No.

vi. Secondary Settling Tank:1 & 2



Secondary Settling Tank is very important in the activated sludge process in order to ensure

final outlet quality of effluent and also recirculation of activated sludge to the aeration tank to

maintain the MLSS level.

Size- 10 M (Diameter) x 3.5M (Height)

MOC- RCC

Capacity- 550 KL

Retention Period 3 Hr.

Number of unit. 2

Sludge Collection Mechanism Bottom Scrapers

v. Polishing/ Pre-filtration Tank:Polishing tank is proposed to collect the treated effluent before filtration process. The purpose of

the tank is to arrest the escaped micro flocks from the secondary clarifier and also to check the

parameters of the treated effluent before filtration process.

Size- 4M x 4M x 4M (L x B x D)

MOC- RCC

Capacity- 64 KL

Quantity- 01 No.

viii. Multi Grade Filter:

Multi grade filter is proposed to arrest the micro flocks escaped from the SST. The multi grade

filter is provided with three layers of different sizes of material.

Size- 2M (diameter) x 2.5 M (Height)

MOC- Mild Steel

Filter Media – Cut Scone 20mm,

Pebbles 10mm

Silica Sand 5/16 mesh size

Backwash System – provided

Flow Rate 150 KL /Hour

ix. Activated Carbon Filter

Activated carbon Filter is proposed to remove color, odor and other such dissolved impurities

from the treated effluent.

Size 2M (Diameter) x 2.5 M (Height)

Filter Media Activated Carbon

Type granular



MOC Mild Steel

Back Wash System Provided

Flow Rate 150 KL/Hour

x. Filter Press

TECHNICAL DATA SHEET OF 1000 x 1000mm M.S. FILTER PRESS (40 Chambers)

M.S. Filter Press is Suitable for 4 Stay Bosses Special design P.P. Recessed Plates with Cylinder &Power Pack Unit

Table 3-6: Filter press detail

Type Recessed (Center Feed)

Plate size 1000 x 1000mm

Number of Chambers 40

Plate Thickness 70mm +/- 2mm

Thickness of Cake 40mm +/- 2mm

Filtration Area 52.5m2.

P.P. Zero Plate 01 No.

P.P. Dummy Plate 02 Nos.

P.P. Recessed Plate 39 Nos.

M.O.C. Of P.P. Plates. Polypropylene.

Wet cake Volume 990 liters.

Operating Temperature with Pressure Max. 80’C @ 4 kg/cm2

Operating Pressure Max. 4 Kg/cm2

Hydraulic Closing 60 Tons Lock-Nut Type

Filter Press Structure with Epoxy painted. Mild Steel ( IS 2062 Grade )

Closing Device. 2 H.P. Motor Lever operated Power Pack

Unit to operate Main Cylinder.

Nozzle connections. P.P.

M.S. Flat Bars With S.S.304 Top Side

Cladding

200 x 32mm Thk.

P.P. Filter Cloths 10 to 15 microns INCLUDED

xi. Reverse Osmosis Plant for

TREATMENT SCHEME

1. Sand Filter



2. Carbon Filters

3. Anti Scalent Dosing System.

4. Micron filtration system , Bag Filter / Cartridge Filtrations

5. Reverse Osmosis System

6. R.O. Cleaning / Flushing Systems

1. Sand Filter

One MSRL Pressure Vessel complete with Top and bottom distribution system, frontal

Piper with multiport valve.

One Initial charge of filter media

Unit Diameter - 1400 mm

Unit Height - 2000 mm

Flow Rate - 35 m3/Hr

Working Pressure - 2.5 Kg/Cm2

2. Carbon Filter

One MSRL Pressure Vessel complete with Top and bottom distribution system, frontal

Piper with multiport valve.

One Initial charge of filter media

Unit Diameter - 1400 mm

Unit Height - 2000 mm

Flow Rate - 35 m3/Hr

Working Pressure - 2.5 Kg/Cm2

3. Anti Scalent Dosing System

One Electronic metering Pump complete with suction delivery valves and required

Flexible high pressure tubing

Capacity: 10 Ltrs / Hr.



Back Pressure: 5 Bars

Make: E-Dose / Rainbow

One HDPE 100 Ltrs Capacity Chemical Tank

4. Micron Filtration Bag Filter

Two SS Bag filter housing length 7X30, inlet / outlet connection 3” with air release valve

Two Set of 10 micron rating bag filter size 30” long

5. Micron Filtration Cartridge Filter

One SS Micron filter housing length 7X30, inlet / outlet connection 3” with air release valve

One 5 micron rating polypropylene cartridge size 30” long

6. Reverse Osmosis

Specification of Each R.O. System Compact M.S. skid

a) Front table for control instruments - One

b) Pre filter made of SS – 4 No.

c) Set of Glycerol filled pressure gauges – 8 No.

d) High pressure pump mainly made of stainless steel make (CNP) – 1 No.

e) Set of RO Pressure vessel made of glass fiber (make UKL / Pentair /Equivalent) – 6 No.

f) Set of RO membrane (Hydranautics / TORAY) – 30 No.

g) Set of ball valves – made of heavy duty UPVC / SS

h) Set of Rota meters (ASTER / UKL)

i)Set of UPVC / SS fitting

j)Control Panel

k) Online TDS meter with sensor – (ASTER / Digital)

Table 3-7: Detail of Reverse Osmosis

TECHNICAL DATA RO 25,000 LPH (02

SETS)

Permeate flow rate m3/hr 25.0

Operating pressure in bar 15



Recovery max in % 80

Raw water consumption in m3/HR 32.5

Raw Water pressure in bars 3

Rejection rate Approx in % 98

Current in V/Hz 400/50

Power installed in KW 40

No. of pressure vessels 6

Type of pressure vessel 8040-5

Type of membranes in inch 8040

No of Membranes 30

Sludge Generation

Wet Bio Sludge = 836/0.6=1393 Kg (40%Moisture content)

Chemical Sludge = 500/0.6=833 Kg (40 % Moisture content)

Total Sludge is = 1393+833=2226 Kg

Approximate = 2.2 Ton



Figure 3-2: Layout diagram of proposed CETP at plot no 96-97



17

3.6 Effluent Transportation as Per Topography

The Effluent from the various industries shall be transported through tankers and fixed

pipeline. The transportation through tankers will be from the units located away at far

distance from the CETP site and the topography is such that the effluent cannot be

transported through pipeline. For the purpose of transportation of effluent from nearby

units, survey was conducted and as per the topography it was decided that the effluent

from nearby units shall be transported through pipeline.

All the pipes shall be laid 2 ft below the ground level taken from the level of industry from

where the pipeline shall be laid. All the pipes will be sealed in the concrete 30 cm below the

ground and would run parallel to the road on the side. The vehicular load is not to be taken

on the concealed pipe. The booster stations will be installed at the appropriate points. All

the pipes will be fitted with pressure gauge etc which will be used in the assessment of

flow rate and will help the maintenance staff for trouble shooting. The booster stations

will ensure the desired flow with or without clogging.

The material of construction of pipe will be FRP with a pressure rating 10 to 12 kg/cm2

much above the operating pressure taking care of thermal expansion safety factor.

The effluent may be acidic or alkaline due to single point discharge from the unit hence,

FRP pipe will not be affected. The effluent is expected to contain suspended solids which

may upset the design pressure otherwise the low friction factor will eliminate this

problem, keeping the low pressure drop over the entire length. Moreover, FRP has

temperature tolerance. Hence, discharge of 60oC is not going to affect the transportation

process. At the manhole flange joint is being provided for easy maintenance. All branches

for the disposal to the header or sub header must be done through pumping with desired

pressure.



3.7 Details of Pipeline From Industry To CETP

Total length of pipeline to be laid as per the survey is- 3500 M

Diameter of the pipe - 12 inches

Material of Pipe GRP/FRP

Depth of lying of pipeline 24 inches

No. of Chambers- As per the requirement andlocation

Pressure 10 kg/cm3

THE DETAILS OF PIPELINE FROM CETP TO INDUSTRY) FOR TREATED RO WATER:

Total length of pipeline to be laid as per the survey is- 3500 M

Diameter of the pipe - 3 inches

Material of Pipe GI

Depth of lying of pipeline 24 inches

No. of Chambers- As per the requirement andlocation

Pressure 15 kg/cm3

3.8 Raw Material Required Along With Estimated Quantity, Likely source,

marketing area of final product/s, mode of transport of raw material and

Finished Product

Raw material required for construction and setting up of Common Effluent Treatment

Plant are cement, steel, aggregates & sand for civil works and steel will be for construction

purpose.

3.9 Resource Optimization/ Recycling and Reuse envisaged in the project, if any,

The proposed CETP project is to be upgraded with Zero Liquid Discharge (ZLD), hence the

treated water would be recovered and recycled for industrial purposes.

3.10 Availability of Water Its Source, Energy/ Power Requirement and Source

3.10.1 Water Requirement

The total quantity of water required for CETP will be 4.5 KLD which will be provided by

already available piped water supply system. The num ber of working people will be

approximately 11. Considering water consumption of 45 l/d/capita, the domestic



water requirement will be about 0.5 KLD. There will be use of some water for the

preparation of sensitive dosing chemicals to be used in the microfiltration and washing of

membrane to an extent of 3 KLD. There may be requirement of makeup water for the

purpose of cooling of equipment of 1 KLD.

The water required for dust suppression and washing is not included in the water

requirement. The treated effluent will be used for irrigation of green belt, dust

suppression and for washing. This amount will be (2KLD+1KLD+1KLD) being equal to 4

KLD. In this way, 4KLD water will be saved. Similarly, it is planned to recycle and reuse

most of the treated effluent in member industries, thus saving the freshwater

requirement as a whole in industrial area. Power Requirement

Power requirement will be sourced from existing supply scheme. In case of power failureD.G. set will be used having capacity of 200 KVA.

Figure 3-3: Water balance of the proposed CETP



PUMPS

1. Sludge pumps for PSTQty 02 No’sType Sludge TypeSuction 4”Delivery 4”Capacity 50 L P /SecBHP 7.5 HP

2. Sludge Pumps For SSTQty 02 No’sType Sludge TypeSuction 4”Delivery 4”Capacity 50 L P /SecBHP 7.5 HP

3. Pumps For FiltersQty 02 No’sType Sludge TypeSuction 4”Delivery 4”Capacity 50 L P /SecBHP 5 HP

4. Chemical Dosing PumpsQty 03 NosType CentrifugalBHP 1HPCapacity 100 Liters/Hour

MOC SS 316 Body with PolypropyleneImpeller

5. Treated effluent pumps Qty 02 No’sType Centrifugal TypeSuction 4”Delivery 4”Capacity 50 L P /SecBHP 5 HPType centrifugal

6. Screw Pump for Filter PressType Screw PumpBHP 5HPQuantity 02 Nos.

MOTORS

1. Motors for BlowersQty 05 NosType Induction Motor



BHP 10 HPRPM 1400

2. Motors for Sludge Scrappers (For PST & SST)Qty 04 NosType GearedBHP 5 HP

3. Motors for agitatorsQty 03 NosType Flange Type VerticalBHP 01 HP

4. Motor for Filter Hydraulic Pump for Filter PressQuantity 01Type Flange type verticalBHP 02HP

5. Electrical PanelMOC Mild SteelSWG 14Protective Coating Powder CoatingMCCB To be provided

6. Type of starterUp to 5 HP rating DOLAbove 5 HP Star Delta

Table 3-8: Description of Electrical Equipment

Sr No Description of Electrical Equipment Load

1. Sludge Pumps for PST 04 Nos of 7.5 HP each 30 HP

2 Sludge Pumps for SST 03 Nos of 7.5 HP each 22.5 HP

3. Pumps for Filters 02 Nos of 5 HP each 10 HP

4. Pumps for Treated Water 02 Nos of 5 HP each 10 HP

5. Chemical Dosing Pumps o3 nos of 1 HP each 03 HP

6. Motors For Blowers 05 Nos of 10 HP each 50 HP

7. Motors For Mechanical Scraper 04 Nos of 5 HP each 20 HP

8. Motors for Agitators o3 Nos of 1 HP each 03 HP

9. Screw Pump to transfer Sludge to Filter Press 5HP (02 No.) 10 HP

10 Hydraulic Pump for Filter Press 02HP 02HP

11 High-Pressure Pumps for RO 30 HP (02 Nos.) 60HP

Total Power Load 220.5 HP/ 165 KW



4 SITE ANALYSIS

4.1 Connectivity

4.1.1 Nearest Railway Station

Dehradun Railway Station: Approx. 42 km, in ESE direction

4.1.2 Nearest Airport

Jolly Grant Airport, Dehradun: 62 km, in SE Direction.

4.1.3 Nearest Highway

NH-72 is at a distance of approx. 3.0 km in the SW direction.

4.1.4Landform, Landuse and Land Ownership

The Site of Common Effluent Treatment Plant / is identified and marked on layout. At

present, the project land is vacant. The land/plots are allotted by department of industries

Layout of Industrial area is shown in the Map below.



Figure 4-1: Map of Gondpur Industrial Area & Location of CETP

4.2 Topography

The proposed site is located at 30028’24.91”N Latitude and 77037’36.93”E Longitude

on a almost flat terrain. It has an average elevation of 405 meters.

4.3 Existing land use pattern.

The land falls in the industrial area and the proposed project site is earmarked for CETP.

4.4 Soil Classification

The soil in the district varies from thin and bare soil of high mountains to rich deep

alluvial soil of the valleys. In the hilly area i.e. northern part soils are veneer and brown in

colour, these are high base status soil of humid regions. In the southern part, combination

of shallow black, brown and alluvial soils are found. The proposed site for CETP is located

in the southern part of the district having rich alluvial soil.

4.5 Climatic & Rainfall

The climate is sub-tropical interspersed between cold weather, hot weather and

southwest monsoon. The cold weather commences in November and continues till the end

SITE FOR CETP SITE FOR OFFICE &

CHEMICAL STORAGE

MAP OF GONDPUR INDUSTRIAL AREA & LOCATION OF CETP



of February, which is characterized by cloudless days and very cold nights with much fog

and dew. May and June are usually the hottest months. During monsoon period (June to

September) the weather remains humid.

Due to significant variations in altitudes in the district the temperature also varies

considerably. Minimum temperature goes below 0°C in higher reaches during winter and

the maximum temperature exceeds 38°C in lower reaches during the summer season.

Temperature varies from 8°C to 38.6°C.

RAINFALL: The area receives 1600 – 1700 mm average rainfall. Out of this 90% rainfall

constitutes during the period middle of June to end of September.

4.6 SOCIAL INFRASTRUCTURE AVAILABLE

The infrastructure amenities available in the area denote the economic wellbeing of the

region like hospitals & healthcare centers, schools, colleges, banking facility; community

centers etc which are available nearby.



5 PLANNING BRIEF

5.1 Planning Concept (type of industries, facilities, transportation etc.) Town and

Country Planning/Development authority Classification

The CETP unit is proposed for the treatment of waste water of clusters of industries

mostly pharmaceutical formulation units located in the Gondpur industrial area and

industries located in nearby region.

Waste water will be transported to CETP through dedicated pipeline network and through

tankers from peripheral industrial units .

The CETP site is located in the industrial area on plots allotted by the Department of

Industries.

5.2 Population projection

The project will employ mostly workers from nearby villages during construction phase.

There will not be any increase in population due to the project.

5.3 Land use planning

The open space inside the CETP area will be suitably landscaped and covered with the

vegetation of indigenous variety. Green Belt area will be developed with suitable verity of

trees.

5.4 Assessment of Infrastructure Demand (Physical & Social)

The proposed CETP falls in industrial area therefore all facilities / amenities like medical,

educational, housing, transportation, communication, shopping etc are available nearby

places. Since, local workers will be employed for this purpose therefore; no long term

infrastructure will be required.

5.5 Amenities/Facilities

Man power will be required on permanent and temporary basis. Total 11 skilled and

unskilled labours will be engaged in shift at CETP. Rest room and toilet facility shall be

provided at the plant site.



6 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

Being a CETP, New unit will make office space, laboratory, storage area as well as

treatment units & use of the facilities for land, storage of raw material and handling,

additional water & power demand, and use of road and rail network for transportation.

6.2 Green Belt

Green belt will be developed according to CPCB guidelines. Plants of the various species

will be developed in the plant and peripheral areas.

6.3 Connectivity (traffic and transportation road/rail/metro/water ways etc.)

The project site is well connected to NH-72 road.

6.4 Drinking water management

About 5 KLD of water will be required for construction and operation. The water will be

met from nearby bore well.

6.5 Sewerage system

Toilets will be constructed at the site which will be connected with the septic tanks within

the site itself.

6.6 Industrial waste management

Sludge generated from treatment units would be sent to TSDF site. Hazardous waste like

used oil & containers/liners will be sent to the authorized recyclers.

6.7 Solid waste management

Solid waste generated during the wastewater treatment process is mainly sludge which

will be generated depending upon the effluent characteristics and hydraulic load and the

same would be transported to the authorized TSDF site for final disposal.

6.8 Power requirement & supply/source

Power Available: 2 X 630 KVA. = 1260 KVA

Backup Power supply source – 1 No D.G Sets of 200 KVA



7 REHABILITATION AND RESETTLEMENT (R&R) PLAN

The site is free from any settlement so there is no need of displacement of the people for

proposed project, hence, No R&R applicable.



8 PROJECT SCHEDULE & COST ESTIMATES

8.1 Cost Estimates

The total cost of project is estimated about Rs. 10.7Crores. the breakup of cost is as

follows

Table 8-1: Details of mechanical equipment and cost

Sr. No. D E S C R I P T I O N QTY Cost

1. Moving Bridge and Scrappers for Primary

and Secondary Settling Tanks

04 No. 72,00,000

2. Twin Lobe Blowers with motors 05 No. 13,00,000

3. Multi grade Filter 02 No. 12,00,000

4. Activated Carbon Filter 02 No. 14,00,000

5. Air Diffusers 400 No 8,00,000

6. ETP Pipeline with Fittings and Valves 2 Lot 15,00,000

7. Dosing Tanks 03 No. 9,00,000

8. Agitator for Dosing Tank 03 No. 7,50,000

9 Filter Press 01 9,00,000

Total 1,59,50,000

Table 8-2: Details of electrical equipment and cost

Sr. No. DESCRIPTON QTY COST

1. Sludge Pumps 7.5HP 04 no. 2,88,000

2. Centrifugal Pump 5HP 06 No. 3,12,000

3. Induction Motors 7.5HP 04 No. 84,000

4. Dosing Pumps 03 No. 60,000

5. Geared Motor 2HP for Moving Bridgeand Scrapper for PST’s and SST’s

03 Nos. 2,40,000

6. Electrical Meter 01 No. 15,000



7. Electrical Panel 01 No. 1,80,000

8 D G Sets 200KVA 01 No. 15,00,000

9. Electrical Wiring 400 Mtr. 5,80,000

Total 32,59,000

Table 8-3: Details of instrumentation and cost

Sr. No. D E S C R I P T I O N QTY COST

1. Online pH Meter 02 no. 20,000

2. Online TDS Meter 01no 8,000

3. Electromagnetic Flow Meter 02 no. 2,80,000

Total 3,08,000

Table 8-4: Details of equipment for ZLD and cost


1. Reverse Osmosis Plant for ZLD 02 1,32,00,000

2. Multi Effect Evaporator 01 60,00,000

Total 1,92,00,000

Table 8-5: Details of land, roads, sewerage lines and cost


1. Roads Constructed up to proposed CETP 80,00,000

2. Sewerage Lines laid 30,00,000

3. Cost of Land for proposed CETP 4500 Sq.Mtr. @Rs. 3520/Sq.Mtr

1,58,40,000

Total 2,68,40,000



Table 8-6: Total cost of CETP

Sr. No Description of Work Cost

1 Civil Work 1,58,25,000

2 Mechanical Work 1,59,50,000

3 Electrical Work 32,59,000

4 Instrument 3,08,000

5 Lab Equipment’s and Chemicals 50,00,000

6. Mode of Collection and Disposal of Effluent( 2 Tanker) 40,00,000

7. Cost of pipeline from Industry to CETP (The CostIncludes Earthwork and Construction ofChambers)

1,21,80,000

8 Cost of pipeline from CETP to industry( ThePipeline shall be laid along with effluent Pipeline)

23,45,000

9 Transportation of material 8,00,000

10 Details of Equipment’s for ZLD and cost 1,92,00,000

11 Details of Land, Roads, Sewerage lines and cost 2,68,40,000

12 Electrical Transformer and Transmission line 5,00,000

13 Erection and Commissioning 15,00,000

14 Grand Total 10,77,07,000

15 Total (Lacs) 107.70

8.2 DETAILS OF OPERATIONAL COST

A. Evaluation of Chemical cost

Treatment Cost of Sewage/ Effluent(Chemicals):

Lime = 0.3X12=3.6/KL (Rate of Lime Rs. 12/Kg Assumed)

Poly electrolyte = 1X350/1000 = 0.35/KL (Rate of P.E. Rs. 350/Kg Assumed)

FeSO4 (ferrous Sulphate) = 0.1X20 = 2.0/KL

BOD Load = 2000X1.1 (Flow Assumed =2000KLD) = (2200X5/100)X(22/25)=96.8 Kg

= (2200X5/100)X(22/25)= 96.8 Kg



42

Cost = 96.8X7 =677.6 ( in Rs)

Cost/KL = 677.6/2000 =0.33 /KL

DAP Cost = 96.8X29=2807.2

DAP Cost/KL =2807.2/2000 = Rs 1.4/KL

B. Process Cost

Pumps

Blowers

Motors

Agitators

Total Power Consumption =119KW

Load Factor =0.65

KWH =119X0.65X24 =1856.4

Power Cost Rs=6/KWH Rs=11138

Fixed Electricity Expanses Rs = 27000

Total Electricity Expanses Rs = 11138+27000= 38138

Power Cost/KL = 38138/2000. = Rs 19/KL

Total Basic Cost = 19+7.68=26.68 say Rs =26.7

C. Cost of BOD Removal in

Kg/m3

Basic Cost Rs =26.7Transportation =20Maintenance =2

Depreciation =3.36

Manpower Charges =2.4

Sludge Processing =2

Profit =2Treatment Cost Rs. = 26.7+20+2+3.36+2.4+2+2 = Rs 58.46/KL

= 0.058/L

BOD Reduction Cost Rs. =26.7/1.1+20+2+3.36+2.4+2+2 = Rs 56.03/Kg

COD/BOD =2.5



COD Removal Cost/Kg =56.03/2.5

Rs. =22.41Cost/Kg

Note: BOD load is calculated on the average basis of BOD of individualindustry by adding BOD load of all industries and divided by number ofindustries.Average BOD load for the above Rate Calculation is taken as 1100 mg/ ltr.

In case BOD is more than the average load the following formula for calculationof Treatment Cost can be taken as:(i) BOD load of the industry.(ii) Flow of the industry

Rate Calculated by taking BOD load@ 1100 (mgs/L) / BOD load in Kg/KL X BODLoad of Industry

For Examples.

BOD Load of Industry presumed as 1500 mg/ltr.

Rate calculated as per BOD = 1100 mg/ltr

The Treatment Cost of Effluent with BOD of 1500 mg/ltr.

= (58.46/1100) X 1500 = Rs. 79.71 /KL

System Development on Effluent charges Estimation

The treatment cost based on average characteristics is tabulated below:

Table 8-7: Tentative treatment cost – sector wise

Sr.

NO.

SECTOR BASIC

TREATM

ENT

COST /KL

CONVE

YANCE

MAINTAN

ANCE

(20%)

DEPRECI

ATION

PROF

IT

(15%

)

TOTAL/

KL

1 PHARMA Rs. 26.7 Rs. 20 Rs. 2 Rs. 3.36 Rs. 2 Rs. 58.46

2 SOAP &

DETERG

ENT

Rs. 26.7 Rs. 20 Rs. 2 Rs. 3.36 Rs. 2 Rs. 58.46



ADDITIONAL OPERATIONAL COSTS OF ZERO DISCHARGE EQUIPMENTS

(RO AND MEE)/KL

Taking into consideration all cost operation and maintenance of RO & MEE including cost

of fuel, chemicals, replacement of membrane (in case of RO) etc. Additional cost of

treatment per kiloliter of treated waste water (up to secondary level) for making the

scheme Zero liquid discharge shall be as follows

Cost of operation & maintenance of RO – Rs 25 /KL.

Cost of operation & maintenance of MEE – Rs 25000 /KL.



9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

Project is for establishment of CETP for the effluent mainly from clusters of

pharmaceutical Industries. The imposition of new scale of, statutory standards on effluent

treatment with water reclamation potential may require, in addition, a new infrastructural

investment on the pollution control system of the individual units. This may be the driving

point for the overall participation in the proposed CETP with ZLD from industries to bring

down drastically the pollution level. The charges to be levied on new scale on the basis of

pollution load, breaking the orthodox style, would equally keep operational their own

equipment. An attempt on water recovery for its recycling in the proposed CETP design

may be an exemplary in the country with a start up in this Zone.

***********

Documents

PRE-FEASIBILITY REPORT FOR 02 MLD CAPACITY …environmentclearance.nic.in/writereaddata/Online/TOR/08_Apr_2017... · PRE-FEASIBILITY REPORT FOR 02 MLD CAPACITY CETP BY SIRMOUR GREEN