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1.

Capacity of HRSCC to be checked

The dimension of the existing HRSCC has been physically measured and its capacity was also
checked. Considering the present load as per the flow measured by TROY personnel in existing
plant condition from 09.05.2011 to 21.05.2011 for both ETS & TFS mode the HRSCC is capable to
treat the influent water to desired extent. However, during O&M phase details study of solid loading
at HRSCC and concerned chemical dosing pattern can provide better understanding.

2. Capacity of sludge pit to be verified and if require capacity will be enhanced along with polymer
dosing system.

Considering the present load as per the flow measured by TROY personnel in existing plant
condition from 09.05.2011 to 21.05.2011 for both process and chrome waste in ETS & TFS mode
the existing sludge basin is capable to treat the influent water to desired extent. However, during
O&M phase the solid loading at Sludge basin and the sludge removal efficiency to the filter press
can be more effectively monitored.

3. Capacity of Filter Press will be checked and if require the same will be provided.

Considering the present load as per the flow measured by TROY personnel in existing plant
condition from 09.05.2011 to 21.05.2011 for both process and chrome waste in ETS & TFS mode
the existing filter press is capable to treat the influent water to desired extent. However, during
O&M phase the solid loading at Sludge basin and the sludge removal efficiency to the filter press
can be more effectively monitored.

4. It will be taken care to prevent the carried over flocks from HRSCC.

There are several reasons for sludge carryover, occasionally either due to dead sludge
accumulation problem or due to disrupted sludge draining frequency and ineffective bottom sludge
scrapping mechanism. Although during our study phase we found that there is no significant TSS
carryover from HRSCC.

5. All the flow rate datas of chrome waste and process waste will be validated.

During our observation period i.e. from 09.05.2011 to 21.05.2011 the effluent generation data from
ETL plant has been taken for ETS & TFS phase both. The flow has been measured by timer record,
installed in the pump which is discharging process waste and chrome waste from the process
facility to the process storage tank and chrome waste storage tank respectively of the effluent
treatment plant.

However for ETL2 the data can’t be taken as during the schedule time the plant was not operating.
Regarding detail discussion SWPL confirmed that ETL 1 & ETL 2 is identical in terms of capacity
and in terms of effluent generation and hence agreed that the the flow data for ETL 1 ETS mode can
also be taken for ETL 2 ETS mode. For TFS mode also the plant did not run as per the schedule and
SWPL official could provide us the timer recorded data for a very short span of time of 1 hr. which is
not effective in terms of indicating the right flow figure.

The timer was installed by the SWPL officials as per as the instruction from STPL. The reading has
been recorded and the necessary info like pump design capacity, design head and actual head was
provided by SWPL.
Flow Rate to the ETP from ETL 1
Process Waste flow rate from ETL 1 17 m3/hr
Chrome Waste flow rate from ETL 1 129 m3/hr
Flow Rate to the ETP from ETL 2 in ETS mode
Process Waste flow rate from ETL 2 17 m3/hr (same as ETL1 flowrate)
Chrome Waste flow rate from ETL 2 129 m3/hr (same as ETL1 flowrate)
Total Flow Rate to the ETP from ETL 2 in TFS
mode
Process Waste flow rate from ETL 2 5 m3/hr
Chrome Waste flow rate from ETL 2 18 m3/hr

Best assessment of flow is possible by prolonged study in terms of O&M phase.

6. As the TDS is one of the major concern areas, so the same will be checked.

There is no serious concern with TDS of ETL effluent treatment plant. However, combined
discharge with CRM 1 & 2 is quite high (above the CPCB final TDS discharge norms) which can
create situations of final discharge with higher TDS value than CPCB standards, particularly when
ETL operates on TFS mode.

7. It will be in thought process to re-cycle the discharge water for reuse.

1. Flow rate of all the effluent will be checked and validated.

Flow rate has been checked for CRM1 ETP. Apart from alkali inlet line in no other inlet pipe the
flow can be measured directly by measuring instrument as in most of the cases the flow to the
effluent treatment plant is through FRP pipe and by gravity.

For Rinse and WPL the flow has been measured by drop test method and for emulsion inlet the
flow has been measured by timer record, installed in the pump which is discharging the oil
emulsion from the emulsion storage tank to the concrete storage tank in the ETP. For alkaline inlet
the flow has been measured by ultra- sonic flow meter in presence of TROY officials.

The timer was installed by the SWPL officials as per as the instruction from STPL. The reading has
been recorded and the necessary info like pump design capacity, design head and actual head was
provided by SWPL.

Alkali Flow Rate to the ETP 2.3 m3/hr


Rinse Flow Rate to the ETP 9.49 m3/hr
WPL Flow Rate to the ETP 5.27 m3/hr
Emulsion Flow Rate to the ETP 23 m3/hr
Total Flow Rate to the ETP 40.06 m3/hr

Best assessment of flow is possible by prolonged study in terms of O&M phase.


2. New oil removal facility will be provided.

The existing oil removal facility is not suitable enough to treat the oily scum waste.The assessment
show that inlet oil value is around 330 mg/l which suggest that almost 97% of oil needs to be
removed to achieve the desired treated value of 10 mg/l. This is not possible with the existing belt
type oil skimmer.The installation of tube type oil skimmer with proper thermal treatment is most
viable for this type of oil removing application.

3. Additional requirement of neutralizer to be verified.

Considering the measured flow rate augmentation is not required. However for isolation application
one similar capacity neutralization tank can be provided.

4. TDS, BOD & COD will be tested for the final discharge effluent

Sampling location
Parameters Date
ETL-ETP
CRM-Final CPCB
Kadani Final
discharge Standard
discharge
pH 7.73 7.52 7.76 6.0 - 9.0 9.5.11
TSS (mg/l) 72 144 26 100 10.5.11
Earlier
572 2107 1182 10.5.11
TDS (mg/l) 2100
Oil & grease
6 8 5 10 10.5.11
(mg/l)
BOD (mg/l) 80 52 68 30 9.5.11
COD (mg/l) 328 210 226 250 9.5.11
Cr6+ (mg/l) BDL BDL BDL 0.1 9.5.11
Total Cr (mg/l) 1.04 BDL 1.96 2 9.5.11

Both TSS and TDS is higher than recommended value for CRM-Final discharge location.

BOD value is also higher for all the final discharge streams.

Even COD is higher at final discharge point (kadani).

However all the above mentioned result is indicative only considering the grab sampling across
different sampling location. Detail study with composite sampling and analysis certainly will yield
better result.

5. TDS, BOD & COD will be considered during augmentation.

Presently although TDS guideline norms is not incorporated into CPCB final discharge guideline for
electroplating industry, the assessment showed that there is an elevated trend for TDS value at CRM
1 & 2. (ElectroplatingIndustry.pdf). Although TDS at final discharge (kadani) is within the desired level
still the higher discharge effluent TDS from CRM always can consequence the possibility of violating
the TDS norm of 2100 mg/l. For these if the SWPL management feels the requirement of
augmentation for TDS then STPL can suggest suitable technology.

BOD can also be improved by suitable augmentation of oil skimming unit which can only be
validated during the O&M phase. Further if no solution is achieved within stipulated period then
biological treatment should be considered.