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SUSTAINABLE PRODUCTION
Topic Effluent Treatment Plant (Performance Evaluation of Effluent Treatment Plant for Textile Industry)
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Topics
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Abstract Introduction o Pollution Control Board o Water treatment o Textile waste principle o Evaporation process Separation process Result and Discussion References
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In the dyeing process textile industries generate huge quantity of toxic effluent containing colours, sodium sulphate, sodium chloride, sodium hydroxide and traces of other salts. These are generated after dyeing and after washing of garments / fabrics. After dyeing the waste water produced is called Dye Bath water and after washing the waste water generated is called wash water. Dye Bath contains higher solids in the range 4-5% whereas wash water contains only 0.5-1% solids.
An effluent treatmentplant is operating on biological treatment method (Fluidized Aerobic Bio-Reactor) with an average wastewaterinflow of 2MLD has been considered for case study. The wastewater is analyzed for the major water qualityparameters, such as pH, Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD) and Total DissolvedSolids (TDS). The effluent samples were collected on a daily basis for a period of one month. The rawwastewater pH was highly alkaline it was then bringing down to neutral which was helpful for biologicaltreatment. The BOD, COD of the treated effluent reduced significantly, whereas very small reduction wasobserved in dissolved solids.
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Pollution Control Board comprises of the following units: 1] Screen Chamber 2] Equalization tank 3] Flash mixer 4]Flocculation Tank 5] Tube Settler-I 6] Fluidized Aerobic Bio-Reactor (FAB-I) 7] FAB-II 8] Tube Settler-II 9] Chlorine Contact Tank 10] Sludge Thickener 11] Centrifuge. The wastewater generated from the plant iscollectively passed through the screen chamber toremove the floating matter present in thewastewater. The quality and quantity of thewastewater is maintained in the equalization tankwhere air blower is provided for the supply ofoxygen. The wastewater then comes to the flashmixer in which lime and ferrous sulphate are thecoagulants added to the wastewater with detentiontime of 30 seconds. The floc gets formed due to theslow mixing and resultant settling of floc in the firsttube settler reduces total suspended solids and BODload on the secondary treatment. The water is the allowed in the FAB-I where micro-organisms areattached to the media while media is suspended Ithe wastewater. The growth occurred on the media.The oxidation of organic matter is done with the help of micro-organisms. The sludge formed due tobiological process gets settled in the tube settler II.
The wastewater treated by secondary treatment isthen allowed in chlorine contact tank to killpathogens using the hypochlorite as a disinfectant.The treated wastewater is then sending to thecommon effluent treatment plant for furthertreatment. The sludge settled in the tube settlers isthen sending to the sludge thickener then it isconcentrated in centrifuge using poly electrolytedosing. The concentrated sludge is National Institute Of Fashion Technology -Jodhpur Page 5
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The concept and the treatment is based on the removal of the entire COD/BOD and the condensate coming out to meet the fresh water quality requirement in the process.
Textile Waste Water Handling By Evaporation And Solid Separation Basic Principle: The technology is based on basic principle of reduction of quantity by concentrating the effluent and subsequently separation of salt and water.
The Evaporation Process: Textile Effluent is fed to the vacuum evaporator to concentrate up to 40% solids concentration. The total process is under vacuum and the vapors generated in the system are re-used to economize steam consumption in multiple effect evaporation system with thermal vapour recompression system. The thermal vapour recompression system use Vapours generated in the evaporator and compress it by steam and the compressed vapours are used as heating medium in the evaporator, in this way steam consumption is reduced. Water recovered from the evaporator has low COD/BOD value and can be recycled in the plant.
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The resultant slurry (concentrate) is fed to the thickener and centrifuging section for converting the liquid concentrate to solid waste. The mother liquor from thickener and centrifuge is recycled back to evaporator.
The water separated out from evaporator is good enough in quality to recycle in the plant for Dyeing. Key features: Zero Liquid Discharge Fully Customized Designed System Highest Steam Economy Low Operating Cost Less Downtime for Maintenance Generation of Reusable Condensate Water Operator Friendly Page 8
The color of the effluent was brownish black. Incompleteuse and the washing operations give thetextile wastewater a considerable amount of dyes. It has been documentedthat residual color is usually due to insoluble dyeswhich have low biodegradability as reactive blue 21,direct blue 80 and vat violet with National Institute Of Fashion Technology -Jodhpur Page 9
The COD and BOD of raw effluent varied from 1104to 1475 mg/l and 242 to 358 mg/l respectively. Higher values of COD and BODin raw effluentattributed to the presence of chemical substancesand breakdown of raw material used for preparationof fiber respectively. The COD and BOD of treatedeffluents were reduced significantly to a greaterextent due to the biological treatment process forwhich the effluent is passed throughFAB I and II.
Most of the studied parameters are well within thepermissible limit prescribed by MPCB because theindustry has installed adequate treatment system totreat the raw effluent. The treated effluent isapplicable for land application so it is used for greenbelt development in the industrial premises and 30%of the total effluent treated is reused for thispurpose. The disposal of excess of treated effluentto common effluent treatment plant is best andeffective and environmentally acceptable option forbetter downstream conditions.
FAB consists of a tank filled with specially developedmedia. These media are made of special material ofsuitable density that can be fluidized using anaeration device through diffusers. A biodevelops on the media, which move along the effluent in the reactor. The movement within thereactor is generated by providing aeration with helpof diffusers placed at the bottom of the reactor. Thisthin film on the media enables the bacteria to actupon the bio-degradable matter in the effluent andreduce BOD/COD content in presence of oxygenfrom the air used for fluidization.
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