Design Project Report 1

An Effluent Treatment Plant In Automotive Axles, Mysuru-A CASE STUDY
TABLE OF CONTENTS
LIST OF TABLES i
LIST OF FIGURES i
LIST OF PLATES i
LIST OF ACRONYMS i
CONTENT page No
SYNOPSIS
INTRODUCTION
1.1 A Brief History of AAL
1.2 Land
1.3 Salient Feature of the Plant Site
1.4 Products
1.5 Effluent Treatment Plant
1.6 The Environmental Quality Policy Adapted by AAL
1.7 Objectives
II LITERATURE REVIEW
2.1 Back Ground of Waste water Treatment
2.2 Characteristics of Wastewater
2.3 Treatment of Industrial Wastewater
2.4 Treatment of Wastewater in AAL
III ENVIRONMENTAL MANAGENENT PLAN
3.1 Preface
3.2 Noise Pollution Control
3.3 Rain water Harvesting
3.4 Green Belt Development
Dept. of Studies in Civil Engineering, BIT Page 1

3.5 Monitoring Schedule for Environmental parameters

3.6 Corporate Responsibility for Environmental Protection
IV MANAFACTURING PROCESS
4.1 About the Regional Workshop
4.2 Manufacturing
4.3 Raw Materials
4.4 Processes
4.5 Sources of Wastewater
V DESCRIPTOIN OF EXISTING PROCESS
5.1 Preface
5.2 Description
5.3 Design Calculations of Effluent Treatment Plant
5.4 Treatment Effluent Characteristics
VI PROPOSED TREATMENT UNIT
6.1 Water and Wastewater Management
6.2 proposals for New Effluent Treatment Plant
6.3 End Use Envisaged
6.4 The Effluent Treatment Principal
6.5 Design Calculation of Proposed Effluent Treatment Plant
6.6 Regulatory Compliance-Legislative Requirements
VII CONCLUSIONS
REFERENCES

LIST OF TABLES
TABLE 1.1-Plant Location and Details
TABLE 1.2-Salient Feature of the Plant Site
TABLE 1.3-Types of Products Produced
TABLE 2.1-Characteristics of Wastewater from the Selection Industries
in India
TABLE 3.1-Land use Breakups
TABLE 3.3-Environmental Parameters
TABLE 5.1-Intel Parameters
TABLE 5.2-Outlet Parameters
TABLE 6.1-Water Balance Chart
TABLE 6.2-Water requirement
LIST OF FIGURES
FIGURE 5.1-Flow Chart Showing Treatment Units in ETP
FIGURE 6.1-Flow Chart Showing Treatment Units in ETP
LIST OF PLATES
PLATE 1-Drive Solo Axle Differential
PLATE 2-Single Reduction Tandem Forward Axle

LIST OF ACRONYMS
AAL : Automotive Axle Limited

BOD : Bio-chemical Oxygen Demand
COD : Chemical Oxygen Demand
IS : Indian Standards
PCB : Pollution Control Board
ETP : Effluent Treatment Plant
MS : Mild Steel
GI : Galvanized Iron
TDS : Total Dissolved Solids
TSS : Total Suspended Solids
CO2 : Carbon di-oxide
SPM : Suspended Particulate Matter
NOX : Oxides of Nitrogen
HC : Hydrocarbon
dB : Decibels
KLD : Kilo Liter per Day
CREP : Corporate Responsibility For
Environment Protection
KSPCB : Karnataka State Pollution Control
Board

SYNOPSIS
Automotive Axles Limited (AAL) was established in 1981, AAL is joining venture of
kalyani group and Arvin Meritor Inc, USA. With manufacturing facilities located at
Mysuru, the company is currently the largest independent manufacture of rear drive axle
assemblies in country, over the year, automotive axle limited has developed an impressive
domestic clientele that includes Ashok Leyland, Telco, Vehicle Factory, Jabalpur,
Mahindra and Mahindra, Volvo and Bharat Earth Movers. The infrastructure at AAL
spans highly specialized manufacturing process involves friction welding, CO2 welding,
CNC machine, Flexible machine centre and a range of specially build machine for
production of axle and brakes. The facilities also comprised Gleason gear manufacturing
equipment backed by a modern heat treatment shop including continuous carbonizing and
sealed quench furnaces. Range of rear drive axle catering to commercial vehicle ranging
from 6 Tons to 35 Tons GCW, Scam actuated quick change air breaks for commercial
vehicle and trailer axles for 10 Tons to 13 Tons GVW.
The project works comprises of study of various unit of existing effluent treatment plant
(ETP) at AAL Mysuru, along with characteristic of raw and treat effluent. The ETP is
designed to treat industrial effluent. The ETP consist of an equalization tank,
neutralization tank, aeration tank, settling tank, filter media, sludge drying beds etc.
Automotive axle limited now proposed to set up 200 KLD capacity effluent treatment
plant, with the state or art technology. The proposed manufacturing process is basically
the same as existing process. Environmentally significance operation will be identified at
suitable mitigation measures will be adopted to safeguard adverse impact on the
environment.

CHAPTER 1:
INTRODUCTION

CHAPTER-1
INTRODUCTION
1.1 A Brief History of AAL

Automotive axles limited (AAL) is a public limited company established in 1981 under
the company act,1956, jointly promoted by Bharat Forge Limited, Poona and Arvin
Meritor, Inc, USA (formerly known as Rockwell International Corporation), with its
Registered Office and Works situated at Hootgalli Industrial Area, Off Hunsur Road,
Mysuru 570018. AAL is engaged in manufacture rear drive axle, tandem axles, trailer
axles, housing, Gear and sets and brake components including therefore with strong
technical and state-of-art technology support from Arvin Meritor, USA.
The company measured domestic customer are Ashok Leyland limited, Tata motors,
Mahindra and Mahindra, Volvo India limited, Force motor limited, Asia motor work,
Eicher motor limited, and Sawarajmazda limited. The major domestic customers are
Ashok Leyland Limited, Tata Motors, Mahindra & Mahindra Volvo India Ltd, Force
Motors Limited, Asia Motor Works, Motors Ltd and Swarajmazda Limited. The major
overseas customers are Arvin Meritor plants in the US, Italy, Turkey, France, Brazil,
China and Australia.
Effective first April 1999, marketing of our products (domestic and export are made
throughout Meritor HVS (India) limited, Mysore.
AAL was awarded ISO/TS-16949:2002 certification during July 2005, and environmental
management system EMS–ISO 14001:2004 certification during July 2006.

1.2 Land
The existing plant of AAL is located in an area of 20.23 hectors (50.00 acres) of land,
which was acquired from KIADB. The breakup of land used is given below in table 1.1:
Table 1.1: Plant location and details
LAND USE Sq.Mtrs
Total land area 202335
Built-up area 39860
Greenbelt 86036
open space 76440
1.3 Salient Feature of Plant Site

The silent features of the plant site is given below in the table 1.2
The table 1.2: silent feature of the plant site.
FEATURES DETAILS
Maximum Temperature 38ºC
Minimum Temperature 15.9 ºC
Average Rainfall 800 mm
Topography Plain land, gently sloping towards NE
Nearest water Body(River) Kaveri River
Nearest Highway Mysuru Mangalore Highway
Nearest Railway Station Mysuru Railway station- 8 km
Nearest Village Hootagalli 1 km
Kooragalli 0.2 km
Nearest City Mysore-10 km
Nearest Airport Mysore-20 km

1.4Products
AAL manufactures the following products which are given in table 1.3
Table 1.3: Types of products produced
SL PRODUCTS:
NO:
1 Axle Housing
2 Complete Axles
3 Break Components
4 Gear Sets
5 Front steer Axle-New Product
6 Six rod Bogie suspension- New Product
1.5 Effluent Treatment Plant

Most companies operate effluent treatment plant to reduce the potential for pollution of
receiving water to comply with discharge consent condition. Effective management and
control of the process use for effluent treatment will help you to:
1. Reduce the operating cost and thus increase profits.
2. Achieve more effective compliance with legislation.
3. Improve the company’s public image.
Improving the performance ETP will reduce the sites operating cost and make it easier for
the site to comply with its discharge consent conditions. Sites discharging to sewer will
also reduce their trade effluent charges.
The five steps to effluent management are:
1. Characterize all effluents produce on sites:
2. Implement a waste minimization program to reduce the volume and
Strength of effluents:
3. In cooperate in process conditioning and treatment, where appropriate
4. Determine and install segregation facilities to tailor treatment options
5. Optimize performance of ETP.

1.6 The Environment Quality Policy Adapted by AAL

The workers at automotive Axle limited are committed to achieve better environmental
by:
 Conserving natural resource by optimal usage and prevention of pollution by adopting

best available technologies
 Reduction waste generation by promoting suitable recovery, recycle and reuse methods.
 Complying with all applicable legal and other requirements.
 Creating awareness among employees regarding their role in environmental management
system.
 Periodical review of environmental management system performance for continual
improvement by framing objectives and targets.
1.6 Objective of the Present Study:

1 Safeguards in the project feasibility and design phases.
2 An effort made to arrive at the mass balance of water used and the wastewater released
in the industry considering the raw materials and the production process.
3 Qualification of the waste water based on the detail provide by the industry personal,
the characteristic of waste water from similar industry has been considered in the
designing the sequence of treatment.
4 Physical, chemical and biological treatment system has been designed to arrive at the
permissible limit pursuit by the state control board for suitable end use.
5 To obtain inform assessment of potential environmental issues to support consults
report in discussion with interested government agencies, non government organization
and the community.

CHAPTER 2:
LITERATURE
REVIEW

CHAPTER-2
LITERATURE REVIEW
2.1 Background of Waste Water Treatment
The ultimate disposal of wastewater can only be on to the land or into the water but
whenever the water courses are used the ultimate disposal, the waste water is given a
treatment to prevent any injury to the aquatic life in the receiving water. Normally the
treatments consist of the removal of suspended and dissolved solid through different units
of the treatment plant. Engineer can design a treatment plant to accomplish required
degree of treatment. But a complete treatment or 100% removal of the pollution load is
uneconomical and never aimed in any waste treatment plant. The water course can
assimilated certain portion of the population load without affecting seriously the water
quality and environment. In fact, the treatment plant accomplishes a major part of
cleaning work and the nature, the disposal of the effluent into the water course.
The extend and types of treatment required however depend upon character and quality of
both sewage and source of disposal.
2.2 Characteristics of Waste Water

The characteristics of raw waste are essential in the planning for effective and economical
method of water pollution control. Due to the varying nature of industrial wastage, many
of the recent installation have design their effluents units with due to consideration to raw
waste characteristics and the effluent characteristics, as established by the Indian Standard
Institution, state pollution control board, or by the local administrative authorities.
Thus the study of characteristics and the behavior of waste water are essential for its safe
disposal. This study will help in determining the degree and types of treatment required to
a given waste water and thus to avoid the pollution of the source its disposal.
Waste water obtained from the industries is generally much more polluted then the
domestic or even commercial waste waters. The industries are generally prevented by a
legal law from discharging their un treat effluents. It therefore becomes necessary for the
industries to treat their waste water in their individual treatment plant, before discharging
their effluents either on land or lakes or river, or in municipal sewers, and he case may be.
The selections of the sequence particular treatment processes depend on the
characteristics of the waste water, and also depend upon the permissible requirement of
effluents.

The pollution characteristics of certain typical Indian industries in table 2.1
2.3 Treatment of Industrial Waste Water

Industrial waste water usually contains several chemical pollutants and toxic substance in
two large proportions. The characteristics of the produced waste water will usually vary
from industry to industry, and also vary from process to process even in the same
industry. Such industrial waste water cannot always be treated easily by the normal
method of treating domestic sewage, and some specially designed methods may be
necessary.
Depending upon the quantum, concentration, toxicity and presence of non biodegradable
organic in industrial waste water, its treatment may consists of anyone or more following
processes:
1. Equalization
2. Neutralization
3. Physical treatment
4. Chemical treatment
5. Biological treatment
2.3.1 Equalization
The influent to an industrial wastewater treatment system (IWTS) varies in flow and
concentration of pollutants because the discharges from the manufacturing and utility
processes are not constant. This variation affects the operation of the IWTS and could
adversely affect the effluent quality from the plant. The objective of equalization is to
minimize or control fluctuations in wastewater characteristics in order to provide
optimum conditions for subsequent treatment processes
2.3.2 Neutralization
It is a Chemical Reaction in which an ACID and a BASE react quantitatively with each
other. In a reaction in water, neutralization results in there being no excess of hydrogen or
hydroxide ions present in solution. The pH of the neutralized solution depends on the acid
strength of the reactants.
2.3.3 Physical Treatment

Physical Treatment consists of

i) Sedimentation:- sedimentation is employed to separate the heavier settle able solids

and hence this process is provided when the industrial wastewater contains heavy
inorganic solids.
ii) Floatation:- floatation consists of creation of fine bubbles in the waste tank, by
introduction of air into the tank from the bottom. The rising air bubbles, attach themselves
to the fine suspended particles, increasing their buoyancy, and finally lifting them to
liquid surface for consequent removal by skimming.
2.3.4 Chemical Treatment

Chemical treatment is often necessary before the biological treatment, though sometimes,
it may not be required. The various chemical treatment processes are
i) Reverse Osmosis: - In this treatment process, the wastewater containing dissolved salts
are filtered through semi permeable membrane at a pressure higher than the osmotic
pressure.
ii)Electro dialysis: - In this process, dissolved salts from wastewater are separated by
passing an electric current through wastewater tank.
iii)Chemical Oxidation:- In this process, chemical oxidation chemicals like chloride and
ozone are used to reduce substance like ammonia and cyanide, etc from the wastewater,
in addition to reducing BOD load on biological treatments.
iv)Chemical Coagulation: - It is adopted in treating raw water supplies, and helps in
sedimentation of unsettle able micro and chemical impurities, which get absorbed in the
gelatinous flocs, formed by the chemical reactions between coagulants or between
coagulants and alkalis present in the water. In treatment of IWW, Such chemical are
generally added to help out the precipitation of impurities like phosphorus. This process is
known as chemical precipitation. This method is also used in the removal of nitrogen
compounds and sometimes toxics metal from IWW.
v)Adsorption: - It is generally used to remove non-biological organics, color, odor etc
from wastewater. The process involves passing the pretreated wastewater through the
beds of activated carbon.
vi)Deionization: - Deionization involves a similar passage of wastewater through the
beds of synthetic ion exchange resins, where some undesirable cat ions or anions of the
wastewater get exchanged for Na or H ions of the resins.

vii)Thermal Reduction: - It requires burning and consequent oxidation of some toxic

and refractive substances, like organics cyanides, which may be present in certain, specify
IWW.
viii)Air-Stripping: - In air stripping, the liquid waste is poured down through a packed
tower, equipped with an air bowled at the bottom. This method is modification of aeration
process, use for removal of gases from the wastewater.
2.3.5 Biological Treatment:-

If the BOD/COD ratio is more than 0.6, the waste water is biologically treatable without
acclimatization; end if the ratio is less than 0.6 ends up to 0-3, then acclimatization is
needed for biological treatment and if the ratio is less than 0.3, biological treatment may
not be necessary
Acclimatization consists of the gradual exposure of the waste in increasing concentration
to the seed or initial micro biological population under a controlled condition.
For a balance growth of micro organisms in a biological treatment reactor, the ratio of
BOD; Nitrogen; phosphorus should be 100; 5; 1 for aerobic systems end 100; 2.5; 0-5 for
anaerobic systems.
Industrial organic waste is difficult or impossible to be treating by physical or chemical
method alone. In such cases, they are commonly treated by biological method, either
aerobically or an aerobically.
a)Aerobic Treatment Methods:-
The various biological treatment units which work under aerobic conditions are
i)Trickling filters: - trickling filter a bed crushed rock gravel or other suitable medium
through which the waste water trickles through. Air penetrates by natural or forced
ventilation. Biological groups develop as a film on the medium from microorganisms
present on the waste water. As the organisms grow, the organic waste is consumed as
food and metabolize into simpler and harmless compounds. In India, biological filters are
used for treatment of industrial waste such as antibiotic waste, synthetic drug waste etc.
ii)Activated sludge process: - in ASP, the organic waste is brought in contact with
microorganisms in large aeration tank. It may be of diffuser type or mechanical type,
presented waste flows continuously into the aeration tank for detention and aeration with
a period varying several hours. Mixed liquor overflows and is settled in the secondary
clarifier and a clear supernatant is separated from the active agglomerated sludge.
iii)Aerated lagoons and oxidation ponds:- They are the low cost treatment methods
which are more suitable for rural background, where in availability of land and sunlight is

in plenty and does not require skilled labor force, hence preferred in rural side. They can
be used to treat several IW also including biological waste. They provide opportunities
for sedimentation and equalization.
b)Anaerobic treatment methods:-many organic wastes, if left over for a long time
becomes our or acidic and produce gases such as methane and foul smelling gases.
Gradually, reactions will subside, which is indicated by reduction of smell and after
several weeks organic waste would be stabilized, during which it is converted into
carbon-dioxide, water and methane and a stable material like sludge. This process serves
as a means of treating organic waste which are high in BOD. This method is used to treat
wastewaters from meat packing industries, distilleries, paper and pulp, tanneries’ etc.
Table 2.1 Characteristics of Wastewater from Selected In India

SL Name of Amount Unit of pH SS Typical Typical Typical BOD Characterist
NO The w/w production Value Mg/ BOD5 COD BOD5/C Load ics
Industry produced l Mg/l Mg/l OD Kg of
per unit of Ratio product
production
1 Dairy 7m3 M3 7.2-8.0 700 800 1340 0.66 5.7 Oil and Grease
putrescibility
3 3
2 Distillery 14m M 3.9-4.3 4500 40,000 80,000 0.5 560 High
- TDS,CL,SO4
1200
0
3
3 Fertilizer 9m Tonnes 7.5-9.5 3700 30 - 0.09 - High NH3 and
Urea NO2
High arsenic
and oil
3 Oil 1.7m3 Tonnes - 200- 200 - - 0.34 High qty of

Refinery 400 free and
emulsified oil
H2S
3
5 Paper and 300m Tonnes of 6.5-8.2 1000 160 610 0.26 50 Lignin, colour
Pulp paper -
3000
6 Sugar 3m3 Tonnes 4.6-7.1 220- 300-2000 600-4400 0.7-0.5 - Low pH,High
Mills 800 Alkaline
7 Textiles 25m3 Tonnes of 7.0- 375 375 525 0.166 8.75 Zn,Polysulphid
crushed 10.0 es

2.4 Treatment of Wastewater in AAL

The main sources of wastewater at this AAL are the lapping waste, floor wash effluents,
coolant wastewater, phosphatising effluent, paint booth effluent. Wastewater from these
units is separately collected and transported through drains and later gets combined at a
junction points and from there it reaches the effluent treatment plant situated at the
backside of the workshop units.
In AAL, various physical, chemical and biological treatments are conducted on the
wastewater, to get an effluent of proper standards.
The various units in ETP are
1. Equalization Tank
2. Neutralization Tank
3. Aeration Tank
4. Settling Tank
5. Sand Filter
6. Sludge Drying Bed

CHAPTER 3:
ENVIRONMENTAL
MANAGEMENT
PLAN

CHAPTER 3
ENVIRONMENTAL MANAGEMENNT PLAN
3.1 Preface
Environmental Management Plant (ETP) for an industry identifies standard and
procedures, responsibilities, pollution control measure, performance criteria, resource and
Work practices that protect human health and the environment. The purpose of EM plan
is to propose environmental protection commitments to protect the environmental values
affected by the proposed industrial activities and to help the administering authority to
define the mitigation management strategies. The EM plan should identify and describe
the environmental values and all potential environment impacts that will be caused by the
industrial activities and define the critical environment values. For each of the
environmental values to be protected, commitments must proposed and identify the
environmental protection objective(s), standards(s), measurable indicators(s) and control
strategy to demonstrate how the objective(s) will be achieved. The environmental
protection commitments assessments and environmental best practice and proven
research. The commitments should also include provision for monitoring and must be
technically and financially achievable i.e. be measurable and based on proven technology.
Once developed the EM plan can continue to be measurable and used as a planning
document for the industrial activities to provide the operator with a strategic frame work
for environmental management.
Automotive Axle Private Limited (AAL) is a medium scale public limited company
located at Hootagalli Industrial Area, Mysuru. No agricultural activity is seen in the
vicinity of the site (10-KM radius). However human settlement at Hootagalli village of
about 5000 population is about 1Km, Belwadi village of about 3000 population is about
1.3 Km and Koorgalli village of about 2000 population is 0.2 Km from the industry.
About 12-Km radius Krishna raja Sagar Dam lies towards North-West.

3.2 Noise Pollution Control

AAL has identified various areas of noise generated and it is mitigating at the source
which is shown in Table 3.1 below
Table 3.1: source of noise generated
SL. NO. Source
1. Housing Line
2. Gear Shop
3. Heat Treatment
4. DG Sets
5. Carrier Line
6. Paint Shop
Following measure has been adopted, to reduce noise levels at along its path, during the
operational phase.
 All machineries have been grouted on heavy foundations

 DG set has been installed in a well-insulated acoustic enclosure (with suitable wall
thickness) to attenuated noise with minimum number of movable barriers. Also thick
vegetation species have been planted around the DG set enclosure to critical noise
propagation still further.
 Specifying the noise standards to manufactures of machineries.
 In corporation of sound absorbers to blowers and compressors.
 Sound control measure to steam vents.
 Proper maintenance of machineries, especially oiling and greasing of bearing and gears
etc.
 Avoiding vibration of machineries such as speed, balancing etc.
 Use of personnel protective equipments such as earmuff and earplug for person working
in such locations.
 Plantation of green trees around the factory building and premises to control the intensity
of noise to the surrounding area.

The major source of noise pollution is from DG sets. The noise levels at the plant
boundary are 75 dB. The noise is abated acoustically.
3.3Rain Water Harvesting

AAL plant at Hootagalli Industrial area is spread over nearly 50 acres of land. The plant
has roof area of about 82627 Sq.m. Rain water pipes are provided to convey water from
roof tops directly to rain water collection tank.
Since the plant is located in mysuru, the data available from mysuru rain gauge station
can be used for rainwater estimations. The average yearly rainfall can be taken as 800mm.
Then assuming the collection efficiency of 80%, the harvestable rainwater from roof
alone is 82627 x 0.8 x = 52,881 cum/year (52.88 Million Liter).
AAL has constructed a rainwater-collection tank of capacity of 1200 cum & use the water
for nearly 9 months.
The Run-off generated from the open areas is considerably less as most of water
infiltration in to the ground. The land being gravelly sand, the percolation rate is very
high. Hence, the total run-off generated from the remaining open area is 119723 x 0.8 x
0.3 = 28,733 cum/year (28.7 Million Liter), Assuming run-off co-efficient of 0.3.
Large quantity of storm water is generated during rainy days. Rainwater collection and
harvesting plan has implemented to conserves the water resources and to improve the
underground water table. The project site area segregated into different premises for
effective management of storm water. Storm water gutters are designed and constructed
based on contour data of the premises and rainfall data of the region. Necessary measures
shall be taken into control the quality of storm water.
3.4 Green Belt Development
The existing plant of AAL is located in area of 50.00 acres of land, which was acquired
from KIADB. The breakup of land use is given below in TABLE 3.2
Table 3.2: Land use breakups
Land use Sq.Mtrs
Total land area 202335
Built-up area 39860
Greenbelt 86036
open space 76440

About 42.3% 0f area is utilized for gardening. AAL has the following plantations at its
premises.
Plantations-Coconut area – 500 Nos
Neem Tree – 50 Nos
Silver Oak Tree – 1500 Nos
Ornamental – 1000 Nos
Teak – 3500 Nos
Medicinal Plants – 2000 Nos
To future improve the green belt, 3 row plantations along the boundary will be carried out
in phases starting from June-07.

3.5Monitoring Schedule for Environmental Parameters

The parameters which are monitored in AAL are given below in Table 3.3
Table 3.3 Environmental Parameters.
Sl. Particulars Monitoring Duration of Parameters
No Frequency Monitoring
I Air Quality
1 Ambient Air Once in 24 hrly TSPM,RPM,

Monitoring month sample
Projects NOX, SO2
premises
2 Stack Once in a Grab SO2,SPM,

Monitoring month NOX,HC,CO
II Waste and Wastewater

Quality
1. Ground water Once in a Grab As per

at two Month KSPCB
locations (up- 23requiremen
gradient & t
down
gradient) of
treated
effluent
discharge
area/land
III Wastewater Quality
1 Inlet to STP Daily Composite -
2 Treated Daily Composite -

effluent prior
to discharge
III Solid Quality

1 Within Once in Composite As per

project month sample KSPCB
premises at 1 Requirement
location
2 Ecological Seasonal Visual Survival rate

preservation and observation
up gradation
IV Noise Quality Once in a month 24 Hrs Noise level is dB

Monitoring
3.6 Corporate Responsibility for Environmental Protection (CREP)

AAL has taken various initiatives in the existing plant for reducing the pollution load by
implementing the following activities.
a Resource conservation
b Elimination at source
c Recovery and reuse
3.6.1 Resource Conservation

AAL has initiated objectives and targets for conservation of resources like energy and
water. In the last few year AAL has achieved considerable decrease in energy water
consumption in plant in the given below.
3.6.2 Energy Conservation Measures
1. Older Thyristorized Welding power sources have been replaced with new generation
inverted based welding power sources.
2. Additional 500 KVAR APFC panel with harmonic filters have been installed to improve
power factor to 0.9.
3. Installation of recuperated closed burners in old CCF that is being rebuilt. (Under
progress)
4. Installation of State of Art Phoenix Gear / Pinion cutting machines operating without
Cutting oil. (Dry Machining)

5. Installation of a LPG fired Rapid Tempering furnace in place of 2 no’s of Electrically

heated Pit type Tampering furnace of 90 KW.
3.6.3 Water Conservation

AAL has implemented rainwater-harvesting system of storage capacity 12 Lakh Liters
and is recharging the Ground water with over flow water since 3 years.
3.6.4 Ambient Air Quality and Room Temperature Improvement

AAL has installed 50 Nos of Fume Killers & Dust extractors & also 600 Nos of wind
driven Turbo ventilators on factory roof.
3.6.5 Corporate Social Responsibility

AAL has been contributing towards the well being of the community in which it operates.
Some of the high lights are:
1. Free medical checkup for the government school children and senior citizen of rural area
surrounding the company.
2. Contributed a vehicle for Akshaya Patra scheme of ISKON for distribution of mid day
meals for school children.
3. Distribution of note books to school children
3.6.6 ISO Certificate

ISO 9001:1994 Quality Certification by TUV
QS-9001:1998 Quality Certification by Underwriter Laboratories Inc.
ISO/TS-16949:2002 Quality Certification by Underwriter Laboratories Inc.
ISO-14001:2004 EMS Certification by Underwriter Laboratories Inc.

CHAPTER 4:
MANAUFACTURING
PROCESS

CHAPTER 4
MANUFACTURING PROCESS
4.1 About the regional workshops
AAL is a joint venture company promoted by Bharat Forge Limited(A Kalyani Group
Flagship) and Rockwell automotive USA presently Known as ARVIN MERITOR of
USA, established in the year 1981 at mysuru (India). AAL has been a pioneer in the
manufacturing of drive axles, non drive axles (front axles), tandem axles and largest
manufacture of pneumatically actuated brakes for commercial vehicles in the country and
more products, commercial products started in July of 1982.
The technology of AAL is based on design of Meritor, USA i.e., the design are provided
by Meritor and the manufacturing of the parts, the components and even assembly occurs
in plant. The design provided by the in plant manufacturing engineering department to
make it conductive for manufacturing with the available facilities. The marketing of
products of automotive axles is taken care by Meritor.
The products of AAL are evaluated by Rockwell extensive design and testing facility of
tray, USA and at European head quarter at Cameri, Italy.
6.1 Manufacturing
The manufacturing facility comprises of highly specialized plant and equipment, Major
components of all types of axles are processed in dedicated lines comprising many
focused workstations. AAL is now poised for a quantum leap in volumes and states of the
art in its pursuit of meeting challenging demands of domestic and global commercial
vehicle markets.
Some of the products manufactured at AAL are drive and non drive, single and tandem
rear brakes and special gear drive for transportation equipment for almost up to the largest
tonnage for on and off highway applications. Rockwell was the first to develop use of
hypoid gear for heavy duty transportation and has developed and perfected the planetary
gear, the hypoid helical, double gear reduction gear system for practical application for
rapidly growing industry.

AAL has received many certificates of recognition from International organization.

AAL’s major domestic customer are Ashok Leyland, Mahindra and Mahindra, Telco,
BEML, Volvo, Eicher, Bajaj Tempo, and major international customers are Daimler
Chryslar, Iveco, Ford, Arvin Meritor, Mercedes Benz in Indonesia. The company has
motivated workforce maintaining production round the clock all the days of the year.
6.2 Raw Materials
The major raw materials for the manufacture of drive, front axle, brakes, gears including
GI sheets, aluminum sheets, casting, mild steel rods of various and lengths, which are
procured from manufactures in bulk through valid tenders. The other minor raw materials
needed are electrical and other mechanical fitting, paints etc.
6.3 Processes
The product which is manufactured in AAL is having the following process which is
described below.
1. Axle housing
In a method of manufacturing axle housing of sheet metal hollow axles, the steps of:
Forming
Machining
Fitting
Clamping
Connecting
Painting
Final
Figure 4.1- Units in Axles Housing
1. Forming a beaded edge on each side of a sheet metal axle housing by means of plastic
deformation;

2. Machining both the axle housing and the hollow axle so as to have mutually abutting
front surface;
3. Fitting the hollow axles each in one of the beaded edge of the axle hosing alone said
mutually abutting front surface;
4. Clamping the axle housing with the fitted in hollow axle in a clamping device;
5. Connecting the hollow axle with the axle with the axle housing alone said mutually
abutting front surfaces by means of electrode beam welding.
Description
It is known to manufacture axle housing with hollow axle in a manner in which the
hollow axle their flanges for receiving break equipment are connected to the extremities
of axle housing by means of welding.
Finishing of the various parts is carried out after welding. However, since welding is
effected by means of apparatus in which the work pieces have to be clamped in exact
position, on their wings axle housing have to be provided with guilging surfaces whereby
the wall thickness of a work piece and, consequently, its welding surface areas
considerably decrease.
In addition, hollow axle to be connected by of welding are liable to warping caused by
heat generated during welding and, there for, they may be finished only after welding has
taken place which requires special machining technology and special machine tools as
well.
6. Painting: In painting section the surface is initially ribbed with the sand paper, to obtain a
slightly rough surface, for a good painting coating. Slight dents on axle are made proper
before painting starts. The axle is then painted with surface paint and left for 8 hours. The
surface is cleaned again, using sand paper and water before the next coat of paint by the
spray gun. From this section, the axles go to final section.
7. Final: All the balancing work is carried out in this section, and then snickering and
labeling work is carried out.
2. Manufacturing components (Components Section)
In this section of workshops, the various GI sheets, Aluminum sheets, Casting, Mild steel
rods of various gauge and length components required for axle are made ready. The axle
made by the above components is casted into various shapes. After cutting and shaping of
the above raw materials, they are taken through a series of operation, by which they
acquire the ability of derusting and keep the metal surfaces in good condition for painting.
This series of treatment are called as the ‘Phosphating Treatment’. The major operation in
this treatment is in the given flow chart given in Table 4.2.

Degreaser
Water Wash-1
De-ruster
Water Wash-2
Wash Wash-3
Phosphating Bath
Water Wash-4
Passivation Tank
Dryer-Hot air blower
Figure 4.2- Units in Phosphating Section
i) De-Greaser units:- Degreasing is the first units operation in the phosphating treatment. It
is done to make the MS rods freed out grease and other oily dust particles. Here an
alkaline degreaser is used. This alkaline degreaser is none foaming powder metal cleaner
for iron and steel. It removes industrial soil from the surface of iron and provides
considerable economy and efficiency for degreasing of ferrous metals which subsequently
go in phosphating treatment and electroplating by immersion processes.
The alkaline degreaser is a white powder with soft lumps and soluble in water with a Ph
of 12, alkaline embattlement of the mild steel alkalinity will percentage where mild steel
plates are attacked by water of highly alkalinity and dissolving the organic coating like oil
and grease, separates with molecules of sodium hydroxide and floating on surface of bath.

ii) Water Wash-1:- The MS rods from the degreaser units are washed in water wash tank,
situated immediately after the degreaser unit.
iii) De-ruster unit:- This process mainly aims at de-rusting the MS rods. For this purpose a
chemical called Derust is used. It is a phosphoric based, specially formulated to work at
room temperature, to remove light oil, rust etc, a special process of jet water washing can
remove mill scales also. This chemical is free from acidic fumes and irrigation to the skin
unlike other picking acids.
Derust is mixed in ratio 1:3 depending upon thickness of rust, oil and scale. The MS
components are to immersed for about 15-20 min to be cleaned.
iv) Water Wash-2 and 3:- After the derusting operation, the components are rinsed in water
wash units and allowed to go to phosphating.
v) Phosphating unit:- The chemical used in this is called as phoscoat AVZ-20. It is a
compound of zinc phosphate lit is mainly used in Zinc Phosphating. It is a colorless clear
liquid of pH 3.5-4.
Phosphate coating can be produced by the chemical reaction of base metal with aqueous
solution. It gives rise to the formation of surface film consisting of crystalline Zinc- Iron
phosphate complex. This gives the MS rods, a dust-free and grease free surface.
vi) Water Wash-4:- The excess chemicals from the surface of MS rods are washed by
immersing it in a tank of water wash unit no 4.
vii) Passivation Tank: - This tank is used for a final rinse using a chemical called passivator,
which rinses the MS rods, after phosphating for a good paint adhesion. This final rinse
helps in neutralization hard water salt usually present in water and leaves the metal
surface in good for painting.
viii) Dryer-Hot air blower: - After the phosphating operations, the MS rods are allowed to
dry in dryer units. From here, the rods will move to the painting section (red oxide plant)
and later to stores.
6.4 Sources of Wastewater

The main source of wastewater at this workshop is the Paint Booth Effluent/Phosphating
effluent, floor wash/lapping, coolant effluent.
The washing and painting operation of axles are the main contributors of wastewater from
this unit. This source of wastewater accounts for the daily inflow to the ETP.
In the phosphating plant, the wastewater and the picking waste from the degreaser,
deruster, phosphating tank and passivator forms the main source of industrial wastewater.
This unit of phosphating does not work in daily means. It works in shift, as per the

requirements of the axle units and other sections. The chemicals and the water from wash
tank are removed and allowed to disposal to ETP for treatment, once in 10-15 days
irrespective of whether the work is happening or not. Wastewater from these units is
separately collected and transported through drain and later gets combined at the
junction.point and from there it reaches effluent treatment plant situated at the back side.
CHAPTER 5:
DESCRIPTION OF
EXISTING
PROCESS

CHAPTER 5
DESCRIPITION OF EXISTING ETP
5.1 Preface
The Effluent treatment plant situated in the premises of AAL, Mysuru consist of the
following units.
1. Fine screen chamber
2. Collection tank
3. Reaction tank
4. Parallel plate separator
5. Ultra Filter
6. Clariflocculator
7. Pre Filtration tank
8. Pressure Sand Filter
9. Activated Carbon Filter
10. Aeration tank
11. Settling tank
The treated plant is designed to treat the effluent of following characteristics
Flow 50m3/day
(Considering 12 hours pumping)
The inlet parameter of the influent reaching ETP are as follows and given below in
Table 5.1. The values are average taken for a 12 hours pumping
Table 5.1: Inlet parameters
Sl no Parameters Values
1 pH 6.5-8.5
2 BOD 250-300
3 COD 500-800
4 TSS 400-500

The outlet parameters required, as per ISI standards are given in Table 5.2 below:
Table 5.2: Outlet parameters
Sl no Parameters Values
1 pH 6.5-7.5
2 BOD <30 mg/l
3 COD <250 mg/l
4 TSS <50 mg/l
5.2 Description of Existing ETP

The following points describe the various steps by the ETP works
1. The Paint Booth Effluent / phosphating effluent, floor wash / lapping and coolant
effluent.
2. The collection effluent is overflowing to parallel plate separator; from there it is taken to
clariflocculator.
3. The neutralized effluent is overflowing to parallel plate separator, from there it is
Taken to clariflocculator.
4. The sludge which is obtained is passed to a filter press where in filtrate is passed to the
pre-filtration.
5. The treated effluent is then passed to pressure sand filter and then to activated carbon
filter.
6. The treated effluent is later aerated in the aeration tank and settled in setting tank.
7. For future dilution and reuse it is passed to the STP.
System Capabilities
 Removes suspended and colloidal solids
 Removes complex organics
 Reduces COD
 Maintains neutral pH

 Removes odor from effluent
5.3 Design of Effluent Treatment Plant:

1. Design Data
Effluent characteristics:-
Flow : 48KLD
pH : 6.88
COD : 1800 mg/ltr
Suspended Solids : 112 mg/ltr
Oil & Grease : 40-50 mg/ltr
2. Collection Tank:
A) Collection Tank – for paint booth effluent
To equalized the flow parameters and to remove retention period of 4 hrs of flow.( Before
the effluent enter in to the parallel plate separator)
Pumping hours = 12
Flow rate = 50KLD/12= 4.17 KL/Hr
Volume of Collection tank required = 4x4.17=16.66KL
Provide motorized Oil and Grease Trap
B) Collection Tank- II for Floor wash/lapping
To equalize the flow parameter and to provide Retention period of 4 hrs of flow.(Before
the effluent enters in to the parallel plate separator)
Pumping hours = 12
Flow rate – 100KLD/12=8.33KL/Hr
Volume of Collection Tank require = 4x8.33=33.33KL
Provide Motorized Oil and Grease Trap.
C) Collection Tank- III for Coolant effluent
To equalized the flow parameters and to provided retention period of 4 hrs of
flow.(Before the effluent enter in to the Parallel plate separator)
Pumping hour = 12
Flow Rate = 50KLD/12=4.17KL/Hr
Volume of Collection Tank required = 4x4.17=16.66KL
Provide Motorized Oil and Grease Trap.
D) Reaction Tank

De- emulsification of Oil and Grease by Alum addition and to maintain pH of 0.8
Pumping hour = 12
Flow Rate = 50KLD/12=1.7 KL/Hr
Volume of Reaction Tank required = 4x4.17=16.67 KL
3. Parallel Plate Separator

Detention time 2 hours
To prepare the effluent with lime addition in the flash mixing tank for precipitating metal
sludge.( Flash mixing size of 1m x 1m )
Flow rate = 48KLD/12= 4 KL/Hr
Volume of Tank required= 2 x 4 = 8 KL
4. Clariflocculator Tank:
Considering sludge recycling to aeration tank from settling tank @ 100% is 48 x
2=96KLD
Consider surface loading @25 m3/m2/day
Area of settling Tank = 96/25 = 4m2
Provided polyelectrolyte dosing.
5. Pre-Filtration Tank:
Detention time of 4 hours
Pumping hours = 12
Flow Rate = 48 KLD/12= 4KL/Hr
Volume of Pre- filtration Tank required =4 x 4 = 16KL
6. Dewatering of Sludge:
The settled sludge is disposal as manure by dewatering the sludge using Filter press.
Size = 24” x 24” – 1 No
7. Pumps:
Capacity of 12.5 m3/hr @ 10m head – 8 Nos
8. Pressure Sand Filter
Flow = 48KLD
Considering working hours = 12 hrs
Flow = 4m3/hr
To provide Filter size : 1.5mø – 1 No With sand and gravel media
Flow = 48 KLD

Considering working hours = 12 hrs

Flow = 4m3/hr
To provide Filter size : 1.5mø – 1 No With carbon media
10. Aeration and settling Tank
Providing one day of duration for 48KL. The existing STP facility shall be used for this
purpose.
TREATMENT FLOW CHART

Treatment Units / Treatment flow pattern:-
Paint Booth effluent Floor wash / lapping Coolant effluent
/ Phosphating effluent 100KLD 50 KLD
50 KLD Fine Screen Chamber Fine Screen Chamber
Fine Screen chamber
O/G Trap Stirrer O/G Alum Stirrer Collection Tank - III
Collection Tank-1 / Collection Tank-II/ pH

pH Correction
Correction Reaction Tank
Pumps pH 9.0 Pumps

Pumps
polyplate
Parallel electrolyte
separator polyelectrolyte
Ch chemical Addition
Ultra Filter
Clariflocculator
Motorized
Filter
Filtrate
Pre Filtration Tank
Pressure Sand Filter

Activated Carbon Filter
Aeration Tank
Settling Tank
STP

Figure 5.1 Treatment Units in the ETP
5.4 Treated Effluent Characteristics

The treated characteristics are frequently analyzed on a regular basis, to keep a tab on the
effluent quality. The various parameters under scrutiny are the physical and chemical
characters like pH, COD, Oil and Grease, free ammonia and total nitrogen,
conductivity. These analysis report shown that treated effluent characteristics are very
much conforming to the IS and PCB standards.
The table following table shows the various treated characteristics of two recently
analyses, with the limit and units.
Table 5.3 Treated Effluent Analysis Report

Sl no: Parameters Units IS Result Result
Standard (March-2017) (April- 2017)
1 pH pH 5.5-9.0 7.7 6.4
2 TDS Mg/l 2100 876 1120
3 TSS Mg/l 100 24 32
4 Chlorides Mg/l 1000 520 612
5 Residual free Mg/l 1 - -

chloride
6 Sulphate Mg/l 1000 115 124
7 BOD Mg/l 30 3.0 28
8 COD Mg/l 250 43 146
9 Oil and Grease Mg/l 10 4.8 6
10 Free Ammonia Mg/l 5 4 4
11 Total Nitrogen Mg/l 100 39 56
12 Conductivity µs/cm 2250 1390 1420

CHAPTER 6:
PROPOSED
TREATMENT
UNITS

CHAPTER 6
PROPOSED TREATMENT UNIT
Automotive Axles Ltd is the largest Original Equipment Axle manufacture in the country
and is catering to both Domestic and International market. With the Automobile industry
booming and strong Indian Economy, the Demand for its products has increased
manifold. Also the focus of automobile segment towards manufacture of high tonnage
commercial vehicles for AAL has requires expertise.
In view of the above, the focus is toward in productivity, improve quality with
competitive cost. In order to achieve the ultimate customer satisfaction the plant needs
modernization with the introduction of CNC machines, replacement of special Purpose
Machines, automation, increased capacity of treatment plant and improving other service
related activities. Also all activities will be carried out ensuring minimal environmental
pollution and with all necessary control in place.
Table 6.1 Water Requirement

Sl. No. Source Existing (KLD) Proposed (KLD)
1 Bore well 125 505
2 KIADB 55 55
6.2. Proposed for New Effluent Treatment Plant (200 KLD)

a) Combined Effluent characteristics:-
pH : 6.88
COD : 2000 mg/l
Suspended Solids : 112 mg/l
Oil & Grease : 40-50 mg/l
b) Treated Wastewater Characteristics:-
PH : 6.0-7.0
BOD : < 20 mg/l
Suspended Solids : < 20 mg/l
COD : < 150 mg/l
Oil & Grease : < 10 mg/l
6.3 End use envisaged

The treated wastewater is fit for re-use in Gardening, Flushing Toilets or any
other non-potable uses and organic sludge used as manure.
6.4 The Effluent Treatment Principal

Physico-chemical treatment is applied for the effluent generated from the
engineering shops floor as detailed below for elimination of oil and grease,
metal precipitation and coolant. The treated effluent shall be combined with
treated sewage effluent ultimately for reuse in various non portable
application.
TREATMENT FLOW CHART

Treatment Units / Treatment flow pattern:-
Paint Booth effluent Floor wash / lapping Coolant effluent
/ Phosphating effluent 100KLD 50 KLD
50 KLD Fine Screen Chamber Fine Screen Chamber
Fine Screen chamber
O/G Trap Stirrer O/G Alum Stirrer Collection Tank - III
Collection Tank-1 / Collection Tank-II/ pH

pH Correction
Correction Reaction Tank
Pumps pH 9.0 Pumps

Pumps
Parallel plate separator poly electrolyte

Chemical Addition
Ultra Filter
Clariflocculator
Motorized
Filter
Filtrate
Pre Filtration Tank
Pressure Sand Filter

Activated Carbon Filter

Aeration Tank
Settling Tank
For Future dilution and reuse
STP
Figure 5.1 Flow chart showing the Treatment Units in the ETP
6.5 DESING CALCULATION OF PROPOSED EFFLUENT

TREATMENT PLANT:
1. Design Data:
Combined Effluent characteristics:-
Flow : 200KLD
pH : 6.88
COD : 2000mg/ltr
Suspended Solids : 112mg/ltr
Oil & Grease : 40-50mg/ltr
2 Collection Tank:
A) Collection Tank –I for booth effluent
To equalize the flow parameters and to provide Retention period of 4 hrs of flow.
(Before the effluent enters in to the parallel plate separator)
Pumping hours=12
Flow Rate= 50 KLD/12=4.17 KL/Hr
Volume of Collection Tank Required=4*4.17=16.67 KL
Provide motorized oil and grease trap/skimming tank
Oil and grease trap is provided for the removal of oil only from the process waste
water,
Design Includes
Flow= 50 KLD
Assume detention time= 4 mins

Assume compressed air of= 0.3m³ for 50KLD

Vr= 0.25m/min
The area required for the tank is calculated by using the formula,
A= 0.00622*(Q/Vr)
=0.00622*(50/0.25)
A=1.24m²
Assuming the width as 0.5m, the Length of the tank is

=Surface area/width
=1.24/0.5
=2.5m
Thus, Actual Surface area= 2.5*1.5
=3.75m²
Volume of the Tank=Flow*Detention Time
=50*4
=0.138m³
Hence, minimum depth of the tank= 0.138/1.24
= 0.11m
Provide a minimum depth of 0.5m and a free board of 0.2m
Hence provide oil and grease trap of dimension (2.5*0.5*0.5) m
B) Collection Tank –II for Floor wash/lapping

To equalize the flow parameters and to provide Retention period of 4 hrs of flow.
(Before the effluent in to the Parallel plate separator)
Pumping hours= 12
Flow rate= 100KLD/12= 8.33 KL/Hr
Volume of collection Tank required= 4*8.33= 3.33 KL
water,
Design includes
Flow= 100KLD

Assume detention time= 4 min’s

Vr=).25m/min
The area for the tank is calculated by using the formula,
A= 0.00622*Q/Vr
= 0.00622*100/0.25
A= 2.48m²
Assuming the width as 1.0m, the length of the tank is
= surface area/ width
= 2.48/1.0
= 2.48m
Thus, Actual surface area= 2.48*1.0
= 2.5m²
Volume of the tank= Flow*Detention time
= 100*4
= 0.277m³
= 0.11m
Provide a minimum depth of 0.5m and a free board of 0.2m
Hence provide oil and grease trap of dimension (2.5*1.0*0.5) m
C) Collection Tank –III for coolant effluent

To equalize the flow parameters and to provide retention period of 4 Hrs of flow.
(Before the effluent enters in to the Parallel plate separator)
Pumping hours= 12
Volume of Collection tank required= 4*4.17= 16.67 KL
water.
Design includes

Flow= 50 KLD
Assume detention time= 4 min’s
Vr= 0,25m/min
The area required for the tank is calculated by using the formula,
A=0.00622*Q/Vr
= 0.00622*50/0.25
A= 1.24m²
Assuming the width as 0.5m, the length of the tank is
= Surface area/ width
=1.24/0.5
= 2.5m
Thus, Actual surface area= 2.5*1.5
= 3.75m²
Volume of the tank= Flow*Detention time
= 50*4
= 0.138m³
= 0.11m
Provide a minimum depth of 0.5m and a free board 0f 0.2m
Hence provide oil and grease trap of dimension (2.5*0.5*0.5)m
D) Reaction Tank
De-emulsification of oil and grease by Alum addition and to maintain pH of 0.8.
Pumping hours= 12
Flow rate= 50 KLD/12= 4.17 KL/Hr
Volume of Reaction Tank required= 4*4.17 Kl/Hr
Volume of reaction tank required= 4*4.17= 16.67 KL

3. Parallel Plate Separator
Detention time 2 hours.

To prepare the effluent with lime addition in the flash mixing tank for precipitating
metal sludge.
(Flash mixing size of 1m * 1m)
Pumping hours= 12
Volume of Tank required= 2*16.67= 33.34 KL
4. Clariflocculator Tank
Consider sludge recycling to Aeration tank from settling tank @ 100%
200*2= 400 KLD.
Consider surface loading @ 25m³/m²/day
Area of settling tank= 400/25= 16m²
Provide polyelectrolyte dosing.
5. Pre-Filtration Tank:
Detention time of 4 hours
Pumping hours= 12
Flow rate= 200 KLD/12= 16.67 KL/Hr
Volume of Pre filtration tank required= 4*16.67= 66.68 KL
6. Dewatering of Sludge:
The settled Sludge is disposed as manure by dewatering the sludge using Filter press.
Size= 24”*24” - 1 No.
7. Pumps:
Capacity of 12.5m³/hr @ 10m head – 8 Nos.
Flow = 200 KLD.

Consider working hours = 12 hrs.

Flow = 16.67m³/hr.
To provide Filter size : 1.5m ø – 1 No. With sand and gravel media

Flow = 200 KLD.
Consider working hours = 12 hrs.
Flow = 16.67m³/hr.
To provide Filter size : 1.5m ø – 1 No. With carbon media
10.Aeration and settling Tank

Providing one day of duration for 200 KL. The existing STP facility shall be made use
for this purpose.
6.6 Regulatory Compliance- Legislative requirements

The company is complying with relevant Environment Protection Acts & Rules including
Water [prevention & control of pollution] Act 1974 7 Air [prevention & control of
pollution] Act 1981 and rules.
It valid consents under Water Act, Air Act, & Authorization under Hazardous Waste
Management Rules 1989. Monthly returns as per consent condition are filed regularly.

CHAPTER 7
CONCLUSSIONS
The following conclusions could be drawn from the overall study:
1. It is proposed to have a compact state - the – Art Technology 200KLD capacity
effluent treatment plant including Advance Tertiary is provide so as to reuse, as
well as meeting PCB standards suitable for safe discharge on own land conserve
the water within premises.
2. The treated industrial wastewater is effectively used for gardening
3. Also all activities will be carried out ensuring minimal environmental pollution
and with all necessary controls in place.
4. To establish adequate baseline data against which future performance and change
can be measured.

REFERENCES
 Hammer, Mark J. (1975). Water and Waste-Water Technology. New York: John
Wiley & Sons.
 Kemmer, Frank N. (1979). The Nalco Water Handbook. New York: McGraw-Hill
Book Company.
 Metcalf; Eddy (1972). Wastewater Engineering. New York: McGraw-Hill Book
Company.
 Patterson, James W. (1980). Wastewater Treatment Technology. Ann Arbor,
Michigan: Ann Arbor Science.
 S.K Garg (1999), Environmental Engineering (Vol II), Khanna Publications.
 Rao and Dutta (1987), Wastewater Treatment, II Edition, oxford and IBH Publishing
company Pvt Ltd, India.
 Enviromental Statement Report by AAL.
 Bhole. A.G (1990) “Manual of wastewater Treatment Plant Design”, AICTE Manual,
India.
 Eckenfleder (2000), “Industrial Water Pollution Control”, II Edition, McGraw Hill
Series, Inc., India.

Design Project Report 1

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Design Project Report 1

Hochgeladen von

Copyright:

Verfügbare Formate

An Effluent Treatment Plant In Automotive Axles, Mysuru-A CASE STUDY

Dept. of Studies in Civil Engineering, BIT Page 1

3.5 Monitoring Schedule for Environmental parameters

Dept. of Studies in Civil Engineering, BIT Page 2

Dept. of Studies in Civil Engineering, BIT Page 3

AAL : Automotive Axle Limited

Dept. of Studies in Civil Engineering, BIT Page 4

Dept. of Studies in Civil Engineering, BIT Page 5

Dept. of Studies in Civil Engineering, BIT Page 6

1.1 A Brief History of AAL

Dept. of Studies in Civil Engineering, BIT Page 7

LAND USE Sq.Mtrs

Total land area 202335

Built-up area 39860

open space 76440

1.3 Salient Feature of Plant Site

Maximum Temperature 38ºC

Minimum Temperature 15.9 ºC

Average Rainfall 800 mm

Topography Plain land, gently sloping towards NE

Nearest water Body(River) Kaveri River

Nearest Highway Mysuru Mangalore Highway

Nearest Railway Station Mysuru Railway station- 8 km

Nearest Village Hootagalli 1 km

Nearest City Mysore-10 km

Nearest Airport Mysore-20 km

Dept. of Studies in Civil Engineering, BIT Page 8

5 Front steer Axle-New Product

6 Six rod Bogie suspension- New Product

1.5 Effluent Treatment Plant

Dept. of Studies in Civil Engineering, BIT Page 9

1.6 The Environment Quality Policy Adapted by AAL

 Conserving natural resource by optimal usage and prevention of pollution by adopting

1.6 Objective of the Present Study:

Dept. of Studies in Civil Engineering, BIT Page 10

Dept. of Studies in Civil Engineering, BIT Page 11

2.2 Characteristics of Waste Water

Dept. of Studies in Civil Engineering, BIT Page 12

The pollution characteristics of certain typical Indian industries in table 2.1

2.3 Treatment of Industrial Waste Water

2.3.3 Physical Treatment

Dept. of Studies in Civil Engineering, BIT Page 13

i) Sedimentation:- sedimentation is employed to separate the heavier settle able solids

2.3.4 Chemical Treatment

Dept. of Studies in Civil Engineering, BIT Page 14

vii)Thermal Reduction: - It requires burning and consequent oxidation of some toxic

2.3.5 Biological Treatment:-

Dept. of Studies in Civil Engineering, BIT Page 15

Table 2.1 Characteristics of Wastewater from Selected In India

3 Oil 1.7m3 Tonnes - 200- 200 - - 0.34 High qty of

Dept. of Studies in Civil Engineering, BIT Page 16

2.4 Treatment of Wastewater in AAL

Dept. of Studies in Civil Engineering, BIT Page 17

Dept. of Studies in Civil Engineering, BIT Page 18

Dept. of Studies in Civil Engineering, BIT Page 19

3.2 Noise Pollution Control

SL. NO. Source

 All machineries have been grouted on heavy foundations

Dept. of Studies in Civil Engineering, BIT Page 20

3.3Rain Water Harvesting

Land use Sq.Mtrs

Total land area 202335

Built-up area 39860