1. INTRODUCTION With the increased industrialisation and urban areas, the pollution levels are increasing day by day.

Central Pollution Control Board has established some norms / regulations to control the emissions, effluents into the surrounding environment. If untreated effluents are allowed to drain off, the water bodies are no where to use. 1.1 Significance Proper treatment of effluents is necessary for many reasons such as: a. To avoid odour and unpleasant smells in and around the premises b. To protect the aquatic life from the effluent constituents c. To safeguard the water and soil in the surrounding environment d. To have cleaner environment for comfortable life in the vicinity of industries

2. PROCESS DESCRIPTION The effluent treatment plant design is based on the quality/quantity of different effluent streams from the plant and to the disposal practice of the treated effluent (as per the State Pollution Control Board norms). 2.1 Sources of Effluent Various effluent generating sources from prawn processing section are raw material washing, floor cleaning, foot dips, packing section and Regeneration Water. Regeneration water is segregated and collected separately. Neutralised regeneration waste water is directly pumped into final collection tank and mixed with other treated waste water.

2.2 Characteristics of Raw Effluent Raw effluent generated is at the rate of 250 m3/day with the following characteristics. pH Total Suspended Solids Total Dissolved Solids Biochemical Oxygen Demand Chemical Oxygen Demand : : : : : 6.5 to 7.5 600 - 900 mg/L 2500 mg/L 1500 mg/L 3200 mg/L

2.3 Characteristics of Treated Effluent The final treated water will have the following characteristics: pH Total Suspended Solids Total Dissolved Solids Biochemical Oxygen Demand Chemical Oxygen Demand 2.4 Chemistry of Biological Reaction The coagulation of non-settleable colloidal solids and the stabilisation of organic matter contributing to BOD are accomplished biologically using variety of microorganisms, principally bacteria. The microorganisms convert the colloidal and dissolved carbonaceous organic matter into various gases and into cell tissue. Because cell tissue has a specific gravity slightly greater than water, the resulting tissue can be removed from the treated liquid by gravity settling. The conversion of organic matter into gases facultatively using suspended growth or attached growth systems. In aerobic conversion a part of the organic matter is converted to end products and other part to obtain the energy for the synthesis of new cells and hence the growth. The growth pattern consists of the following three phases: : : : : : 6.5 -9.5 < 100 mg/L < 2100 mg/L <100 mg/L < 250 mg/L

i)

The log growth phase: There is always an excess amount of food surrounding the microorganisms and the rate of metabolism and growth is only a function of the ability of the microorganisms to process the substrate.

ii)

Declining growth phase: The rate of growth and hence the mass of bacteria decreases because of limitations in the food supply.

iii)

Endogenous growth phase: The microorganisms are forced to metabolize their own protoplasm without replacement, since the concentration of available food is at minimum. During this, a phenomenon known as lysis can occur in which, nutrients remaining in the dead cells diffuse out to furnish the remaining cells with food.

In most biological treatment systems, these three processes occur simultaneously.

In the activated sludge treatment, biological growths are created which absorb organic matter from the wastes and convert in into simple end products like C02, H2O, NO3 etc., by means of oxidation enzyme systems in the presence of oxygen. External aeration activates the sludge and encourages the growth of an active culture of aerobic organisms.

The main features of activated sludge treatment are: To Clarify the effluent by absorbing majority of the colloidal and suspended solids on the surfaces of the sludge particles. To oxidize the organic matter.

In

activated

sludge

process,

aerobic

and

facultative

bacteria-Pseudomonas,

Achromobactor, Flavobacterium, Nocardia, Mycobacterium, Nitrosomonas & Nitrobactor, Protozoa and rotifers etc., play the most I mportant role.

In the Activated Sludge Process, the bacteria are the most important microorganisms, because they are responsible for the decomposition of organic material in the influent. In the reactor or mixed liquor tank, a portion of the organic waste matter is used to obtain energy for the synthesis and the remainder of the organic material into new cells. While bacteria are the microorganisms that actually degrade the organic waste in the influent, the metabolic activity of other microorganisms is also important in the activated sludge system. For example, protozoa and rotifers act as effluent polishers. Protozoa consume dispersed bacteria that have not flocculated and rotifers consume small biological flow particles that have not settled.

2.5 Design Criteria for the Effluent Treatment Plant

i)

Equalisation / Neutralisation Tank Flow, m3/day Detention time, hr 250 7

ii)

Aeration Tank BOD, kg/d MLSS, mg/L F/M, kg BOD / kg MLSS / d Oxygen provided, kg O2 / kg BOD 375 3500 0.22 1.5

iii)

Clarifier Flow, m3/day Hydraulic loading rate, m /m /d Percent recycle capacity, %

3 2

417 67 ( Permissible upto 72) 67

iv) Sludge Drying Beds Sludge consistency, % Drying period, d 1 10

2.6 Design Details of Effluent Treatment Plant

a) Bar screen chamber Length of the Chamber Width of the Chamber Depth of the Chamber b) Oil and Grease Trap Length of the trap Width of the trap Depth of the trap 3.0 m 1.5 m 1.0 m LD 1.0 m 0.75 m 0.3 m LD

Proper inlet and outlet arrangements were made. c) Collection cum Equalization Tank Length of the Tank Width of the Tank Depth of the Tank d) Anaerobic Filter Length of the Tank Width of the Tank Depth of the Tank e) Aeration Tank Length of the Tank Width of the Tank Depth of the Tank f) Secondary Clarifier Length of the Clarifier Width of the Clarifier Depth of the Clarifier 2.5 m 2.5 m 4.2 m TD 18.0 m 9.0 m 3.5 m TD 7.25 m 5.5 m 2.5 m TD 7.5 m 5.5 m 4.5 m TD (1.75 m LD)

Hopper is provided with bottom 0.4 x 0.4 m and slope 45o.

g) Sludge Drying Beds 3 Nos. Length of each bed Width of each bed Depth of each bed 5.0 m 3.0 m 0.8 m TD

h) Final Collection Tank Length of Tank Width of Tank Depth of Tank 3.0 m 3.0 m 2.0 m LD

2.7 Various Units and Operations Involved a. Bar Screen Chamber The waste water passes through bar screen chamber where the large floating matter will be arrested through the screens. b. Oil and Grease Trap The oil and grease and any other fatty content in the effluent will be trapped. The oil-free effluent will overflow to the collection cum neutralisation tank. c. Collection cum Equalization Tank Generally in all the effluent treatment plants, the flow into the plant will be varied from time to time and from day to day. To avoid the shock loads on to the processing units, the effluent will be collected in a collection tank and gradual out flow will be allowed. d. Anaerobic Filter The effluent from collection tank uniformly pumped in to anaerobic filter where the effluent under goes anaerobic decomposition in the obscene of oxygen and BOD will be reduced by 30% 40%.

e. Aeration Tank The partially treated effluent from anaerobic filter over flows into the aeration tank where it undergoes biological treatment with the help of microorganisms. The organic matter present in the waste water is degraded by the microorganisms. 2 Nos. 10.0 HP floating aerators are provided to supply the necessary oxygen to the microorganisms for biological activity. Required quantities of nutrients are to be added if necessary in aeration tank to activate growth of the microorganisms. Desired Mixed Liquor Suspended Solids (MLSS) at the rate of 3000 mg/L is to be maintained by recirculating the part of the settled sludge from the secondary clarifier. The overflow of the aeration tank shall enter the clarifier by gravity. f. Secondary Clarifier

The overflow from the aeration tank will be fed to secondary clarifier. The settled sludge will be collected in hopper bottom. Part of this settled sludge will be re-circulated to aeration tank to maintain MLSS in the aeration tank through re-circulation pumps. The remaining portion will be send to sludge drying beds for sun drying. The overflow from the clarifier is fed to the final collection tank. g. Sludge Drying Beds The excess sludge from secondary clarifier will be fed into sludge drying beds where the sludge will be dewatered. The dried out sludge can be used as manure.

h. Final Collection Tank The treated effluent from secondary clarifier will be collected in final collection tank and pumped to the Activated Carbon Filter and followed by Pressure Sand Filter for further polishing the treated water. The final treated effluent meets the prescribed standards of APPCB and used onland for irrigation.

3. STARTUP PROCEDURE To achieve the desired MLSS in the aeration tank and quality of final treated effluent, proper startup procedure should follow. Variations from the procedure may be adopted where necessary. 3.1 Pre-startup Please ensure the following before going for startup: a. All civil structures and pipelines should be leak proof b. All mechanical connections should be done properly. c. Check for lubrication d. Fill the aeration tank with fresh water

3.2 Bio-mass Development a). Anaerobic Filter The bio-mass required for anaerobic reaction in anaerobic filter will form a thin layer of biomass around the media slowly and it may take 25 30 days to get the optimum results in the process. b) Aeration Tank About 400 kg of cow dung should be added to the aeration tank water initially to build-up the bio-mass. The cow dung mixed water should be aerated for 2 to 3 days by agitation to develop the desired MLSS without any addition of effluent into it. Nutrients mixed water containing Urea (10 kg) and Di-ammonium Phosphate (DAP 5 kg) will be added gradually to this in these days. On fourth day, effluent will be added gradually in a phased manner and 100 % waste water flow can be achieved in a week. During this process, the overflow from the aeration tank will be passed to secondary clarifier and the settled biomass collected in the secondary clarifier hopper bottom should be recirculated to aeration tank

continuously. MLSS analysis should be done continuously in this period. Chemical Oxygen Demand and Biochemical Oxygen Demand analysis should be done for the supernatant. 3.3 Addition of Chemicals About 4 5 kg per day of de-chlorinating chemical to be dosed into the equalization tank. Small doses of urea and DAP also dosed into aeration tank if necessary.

4. OPERATION & MAINTENANCE 4.1 Normal Operation In normal conditions for smooth operation of treatment plant, the following conditions can be adopted. a) Collection/Equalization The raw effluent passes through bar screen chamber after removing the large floating matter will enter the oil & grease trap where top oil/fatty layer if any will be trapped and fed to the collection tank. Transfer pumps (one is standby) provided will pump the effluent uniformly to biological system.

b) Biological System In anaerobic filter the effluent undergoes anaerobic decomposition in the obscene of oxygen and BOD will be reduced around 30%-40%. In aeration tank, the effluent will be aerated with 2 nos of 10.0 HP aerators. The dissolved oxygen content should be maintained at least 1.0 mg/L. The mixed liquor from the aeration tank over flows to secondary clarifier by gravity. The settled sludge in the bottom of secondary clarifier will be re-circulated to aeration tank to maintain required MLSS. The supernatant from the secondary clarifier will be sent to final collection tank for further usage. This treated effluent will confirm to the A.P. Pollution Control Board norms. To this treated

effluent, chemical analysis viz., pH, total dissolved solids, total suspended solids, chemical oxygen demand, biochemical oxygen demand and oil & grease should be done regularly. c) Sludge handling The sludge settled at the bottom of the clarifier has to be either recycled back into the aeration tank or has to wasted on the sludge drying beds. i) Sludge recirculation In general, the return sludge pumps should be set so that the return flow is approximately equal to the percentage ratio of the volume occupied by the settleable solids from the aeration tank effluent to the volume of the clarified liquid (supernatant) after settling for 30 min in a 1000 mL graduated cylinder. This ratio should not be less than 15 percent at any time. For example, if the settleable solids occupied a volume of 300 ml after 30 min of settling, the percentage volume would be equal to 42.9 percent (300 ml / 700 ml x 100). If the plant flow is 80 m3/d, the return sludge rate should be 1.24 L/s i.e. 107.0 m3/d.

ii) Sludge wasting Sludge is wasted when the solids concentration in the aeration tank exceeds the desired level of 3500 mg/L. The excess sludge (settled) in the secondary clarifier will be pumped to sludge drying beds by sludge pump provided. The dried out sludge in these drying beds can be used as manure for the garden. 4.2 Routine Maintenance of ETP The following procedure are necessary for routine operation and maintenance of effluent treatment plant. a. Clean oil & grease trap regularly. b. Clean weir and remove solids. c. Remove accumulations of debris and scum from inlet channel and outlet weir every day.

d. Keep daily record of dissolved oxygen in the aeration tank, MLSS concentration. If any unusually high or low values are found, take corrective measures. e. Clean all vertical walls and channels by squeegee on daily basis. f. Hose down and remove waste water spills without delay. deterioration of paint. h. Prepare lubrication chart for mechanical equipment. i. Drain aeration tank annually to inspect under water portions of the tank, piping, etc. Replace or repair all defective parts. Patch the defective portions and repaint all clean metal surfaces as required. j. l. Observe sludge return and adjust the flow rate as required from laboratory tests. Check electrical motors for overall operation, bearings condition and voltage and current (Amperes) twice a day. m. Drain clarifier annually to inspect underwater portion of structure & mechanism and patch defective areas. Inspect mechanical equipment to wear and corrosion and apply protective coating. n. Inspect sludge collection and other equipment annually for indication of corrosion, leakage and corrective measures. k. Determine sludge level and adjust waste sludge pump as necessary. g. Inspect gratings and exposed metal during daily cleanup for signs of corrosion and

4.3 Abnormal Operation 4.3.1 Draining aeration tank If the aeration tank is to be emptied, the content has to be taken on the sludge drying beds to remove the suspended solids.

4.3.2 Draining collection tank Depending on the solids accumulated in the equalisation tank, this has to be cleaned occasionally and whenever necessary.

5. OPERATIONAL PROBLEMS & TROUBLE SHOOTING The operators concerned record their observations, day to day performance including the flow, analysis of raw and treated effluent etc., in a logbook. Any abnormal observation is brought to the concerned person in charge. a) Collection /Equalization facility The function of this unit is collection and flow equalization. The pump capacity will be higher than the rate required and hence it may need throttling to ensure an uniform load to the biological units. b) Biological Treatment Since toxic compounds are not expected from the waste water streams, no process problem is anticipated in the aerobic system. For the growth of microorganisms, nutrients like nitrogen & phosphorous are essential. Deficiency may result in poor performance of the aeration system, for which sufficient nutrient addition is the remedy. I) Aeration tank The operator watches for changes in the physical appearance of the system and relates those changes to the performance of the system. Observations can direct the operator towards making more specific control tests that will indicate process demands and determine the type and extent of control adjustments that are needed. The general appearance of the aeration tank contents has to be observed to determine if there is any unusual colour or foam formation.

i) Mixed liquor colour Healthy sludge shows a light brown colour. A dark blackish colour may indicate anaerobic conditions caused by low oxygen or an improper discharge of sludge in the aeration tank. This may require a check of influent flow in the aeration tank. If this condition persists for longer period and affects the quality of treated waste water, the feed to aeration tank has to be stopped and sludge from the tank has to be partially wasted. ii) Fresh white foam A modest accumulation of white foam is usually a good sign of well operated system that is producing good effluent.

iii) Thick billowing white foam Thick billows of white sudsy foam may indicate that the sludge age is too low and requires an increase by reducing the sludge wasting rate. Stop sludge wasting to the beds.

iv) Thick dark tan foam A dense and some what greasy and scummy layer of deep tan foam covering the surface of the aeration tank may indicate an old sludge or one that is over oxidised. To eliminate this, gradually increase the sludge wasting rate. Trends are watched until the difficulties are overcome and process is restored to proper balance. Measure the MLSS concentration in the aeration tank and gradually waste the sludge and observe the changes. v) De-flocculation & Low pH of MLSS Low pH of MLSS (pH below 6.7) is an indication of nitrification or acid wastes reaching the plant. Control measures includes increasing sludge wasting, lime addition or proper control of influent.

II) Clarifier If the effluent is clear, it shows that the prevailing control practices are adequate. If the effluent is turbid contains noticeable solids or the quality deteriorates steadily, operating variables have to be reviewed. i) Bulking of sludge Bulking normally is attributed to the presence of filamentous microorganisms. Many factors have been blamed for the development of bulking sludge like shock loading, ineffective aeration, nutrient imbalance and too low sludge age. Check the waste water characteristics to estimate the loading. Stop sludge wasting to sludge drying beds if the wasting is in operation. Small dosage of chlorine at times reduces the bulking of sludge.

ii) Turbid Effluent (Pin Floc in Effluent) Turbid Effluent may be due to excessive turbulence in the aeration basin or overoxidized sludge. This problem is easily overcome by reduced aeration or agitation, increased sludge wastig or decreased sludge age. Turbid effluent may also be the result of anaerobic conditions in the aeration basin. this can be easily solved by increasing aeration. Often toxic shock loading may cause turbid effluent. Microscoplc examination of MLSS will certainly show inactive protozoa. Reseeding from another plant may be necessary. Enforcement of industrial waste pretreatment must be done.

iii) Rising of sludge At times large masses of sludge will raise to the settling tank surface, burst and spread over the surface. If aeration is sufficient to produce nitrates in the aeration tank and dissolved oxygen level in the clarifier is not high enough denitrification may result. The oxygen associated with nitrate is removed and the remaining nitrogen gas rises to the surface

carrying solids with it. When floating sludge appears in quantity on the clarifier, stop the feed and continue sludge recycling till the flocs gradually disappear.

SHUTDOWN PROCEDURE

a) Seasonal / Major Shut Downs When the production plant is down for the annual shut down, the nature of the waste water will be different. With cleaning of the equipment and process area the probability of a waste water having higher concentrations of polluting parameters is more during the first few days. Similarly also during the restart up period the concentrations of the polluting parameters may be high. Hence it is achieved to introduce the waste water into biological units at a low rate to avoid shock load. It will be advantageous to carryout maintenance work of effluent treatment plant during the shutdown period to avoid another shut down exclusively for effluent treatment plant. Before restarting the effluent treatment plant all the precautions taken during the pre-startup should be observed. The aerator in the aeration tank has to be operated without feed for few days to create aerobic conditions.

b) Minor Shut Downs If there is a power failure (for more than 8 hours) at the treatment site, the manufacturing process being operative, the effluent feeding from the equalisation tank to the aeration tank should be stopped. Waste water in the equalisation tank should be aerated for 2 to 3 hours before reintroducing to aeration tank.

7) ANALYSIS PROCEDURES Analysis procedures are given in Appendix A 7.1 Analysis Frequency The following is the frequency of analysis suggested for knowing the condition of treatment and to maintain the log sheet of the treatment plant. These schedules should be scrutinised from time to time and modified as and when necessary.

SCHEDULE OF CONTROL TESTS SOURCE Inlet to anaerobic filter Inlet to aeration tank From Equalization tank From Aeration tank Clarifier outlet PARAMETER p , COD, BOD pH, COD, BOD pH, COD, BOD, TSS, TDS, O & G. and residual chlorine MLSS & DO. pH, COD, BOD, TSS, TDS, O & G. and residual chlorine
H

FREQUENCY Every day Every day Every day Every shift Every day

This schedule should be scrutinized from time to time and modified as and when necessary.

I. pH

For most practical purposes the pH of aqueous solutions can be taken as negative logarithm of hydrogen ion activity. pH values from 0 to 7 are diminishingly acidic, 7 to 14 increasingly alkaline and 7 is neutral. The pH of natural water usually lies in the range of 4.4 to 8.5. Its value is governed largely by the carbon dioxide/bicarbonate/carbonate

equilibrium. It may be affected by humic substances by changes in the carbonate equilibria due to the bio-activity of plants and in some cases by hydrolyzable salts. The effect of pH on the chemical and biological properties of liquids makes its determination very important. It is used in several calculations in analytical work and its adjustment is necessary for some analytical procedures.

The determination of pH conventional chemical means is not practicable and the equilibria which are involved depend to some extent on temperature. The precise accepted scale of pH must therefore be based on an agreed primary standard. The colourimetric

indicator methods can be used only if approximate pH values are required.

The pH determination is usually done by electrometric method which is the most accurate method and free of interference.

Electrometric Method: The pH is determined by measurement of the electromotive force of a cell comprising an indicator electrode (an electrode responsive to hydrogen ions such as glass electrode) immersed in the test solution and a reference electrode (usually a mercury calomel electrode) contact between the test solution and the reference electrode is usually achieved by means of a liquid junction, which forms a part of the reference electrode. The emf of this cell is measured with pH meter. This is a high calibrated in terms of pH. II. TOTAL SOLIDS (TS) Principle: impedance electrometer

Total solids are determined as the residue left after evaporation of the unfiltered sample. Procedure: 1. Take an evaporating dish (made up of silica, porcelain or platinum) of at least 100 ml capacity. Ignite at 550 + 50C in a muffle furnace for about an hour, cool in a desiccator and weigh.

2. Evaporate 100 ml of unfiltered sample (or more in case the solids are less than 250 mg/L) in the evaporating dish on a water bath or a hot plate having temperature not more than 98C.

3. Heat the residue at 103-105 C in an oven for one hour and take the final weight after cooling in a desiccator.

Calculation: A-Bx1000 x 1000 ----------------V

Total Solids (mg/L)

Where A = Final weight of the dish in g B = Initial weight of the dish in g V = Volume of sample taken in ml

III.TOTAL DISSOLVED SOLIDS (TDS)

Principle: Total dissolved solids are determined as the residue left after evaporation of the filtered sample. Procedure: 1. Take an evaporating dish (see Total Solids determination) and ignite it at 550 + 50C in a muffle furnace for about an hour, in a desiccator and weigh. 2. Filter the sample through glass fiber filter paper applying the suction. 3. Evaporate 100 ml of this filtered sample (or more in case the solids are less than 25 mg/L) in the pre-weighed evaporating dish on a water bath or a hot plate having temperature not more than 98C. 4. Heat the residue at 103-105 C in an oven for one hour and take the final weight after cooling in a desiccator. Calculation TDS (mg/L) = Where A = Final weight of the dish in g B = Initial weight of the dish in g V = Volume of sample taken in ml A-Bx1000x1000 -------------------V

IV. TOTAL SUSPENDED SOLIDS (TSS)

Determine total suspended solids as the difference between the total solids and total dissolved solids.

TSS = TS-TDS

V. DISSOLVED OXYGEN (DO)

All living organisms are dependent upon oxygen in one form or the other to maintain the metabolic processes that produce energy for growth and reproduction. Aerobic processes of great interest for their need for free oxygen. Dissolved Oxygen (DO) is also important in precipitation and dissolution of inorganic substance in water. The solubility of atmospheric oxygen in fresh water ranges from 14.6 mg/L at 00 to about 7.0 mg/L at 350 under one atmospheric pressure. Since it is poorly soluble gas its solubility directly varies with the atmospheric pressure at any given temperature.

Principle: Oxygen present in sample rapidly oxidizes the dispersed divalent manganous hydroxide to its higher valency which precipitates as a born hydrated after addition of NaOH and Kl. Upon acidification, manganese reverts to divalent state and liberates iodine from Kl equivalent to the original DO content. The liberated iodine is titrated against Na 2S2O3 (N/80) using starch and an indicator.

Interference:

Ferrous ion, ferric ion, nitrate, microbial mass and high suspended solids constitute the main sources of interfernce. Apparatus: 1 BOD bottles 300 ml capacity 2. Sampling device for collection of saple Reagents: 1. Magnesium Sulphate: Dissolved 22.5 g MgSO4. 7 H2O and dilute to 1000 ml. Filter if necessary. This solution should not give colour with starch when added to an acidified solution of Kl. 2. Alkali iodide-azide reagent: Dissolve 500 g NaOH and 150 g Kl or 135 g. Kl dilute to 1000 ml. Add 10 g NaN3 dissolved in 40 ml distilled water. This solution should not give color with starch solution when diluted and acidified. 3. Sulphuric acid: H2SO4 conc. 1ml is equivalent to about 3 ml alkali-iodide-azide reagent. 4. Starch indicator: Prepare paste or solution 2.0 g L.R. grade soluble starch powder and 0.2 g salicylic acid as preservative in distilled water. Power this solution in 100 ml boiling water. Allow to boil for few minutes, cool and then use. 5. Stock Sodium thiosulphate 0.1N: Dissovle 24.82 g Na2S2O3, 5H2O in boiled water and dilute to 1000 mL. Prepare by adding 5 mL chloroform per litre. 6. Standard Sodium thiosulphate 0.025 N: Dilute 250 mL stock Na2S2O3. Preserve by adding 5 mL chloroform per litre. (This solution will have to be standardized against standard dichromate solution for each set of titrations). Procedure: 1. Collect sample in a BOD bottle using DO sampler.

2. Add 2 mL MnSO4 followed by 2 mL of alkali-iodide azide reagent. The tip of the pipette should be below the liquid level while adding these reagents. Stopper immediately. 3. Mix well by inverting the bottle 2-3 times and allow the precipitate to settle leaving 150 mL clear supernatant.

4. At this stage, add 2 mL conc. H2SO4. Mix well till precipitate goes into solution. 5. Take 203 mL in a conical flask and titrate agianst Na2S2O3 using starch as an indicator. When 2 mL alkali-iodide-azide reagent is added to the sample in (2) above 4.0 mL of original sample is lost. This 203 mL taken for titration will correspond to 200 mL of original sample. 200 x 300 (200-4) = 203 mL

Calculations DO, mg/L = mL of titrant used

VI. BIOCHEMICAL OXYGEN DEMAND (BOD)

Principle:

Biochemical Oxygen Demand (BOD) is defined as the amount of oxygen required microorganisms while stabilising

by

biologically decomposable organic matter in a waste

under aerobic conditions.

A mixed group of organisms should be present in the sample; if not, the sample has to be seeded artificially. Temperature is controlled at 20C. The test is conducted for 5 days as 70 to 80% of the waste is oxidized during this period.

Interferences: Ferrous ion, Ferric ion, nitrite, microbialmass and high suspended solids constitute the main sources of interference. In addition, lack of nutrients in dilution water, lack of an acclimated seed organisms and presence of heavy metals or other toxic materials such as residual chlorine are other sources of interference in this test.

Apparatus: 1. BOD bottles 300 ml capacity 2. Incubator to be controlled at 20C + 1C.

Reagents: 1. Phosphate buffer: Dissolve 8.5 g KH2PO4, 21.75 g K2HPO4, 33.4 g Na2PO4.7H2O and 1.7 g NH4Cl in distilled water and dilute to 1000 ml. Adjust PH to 7.2. 2. Magnesium Sulphate: Dissolve 22.5 g MgSO4.7H2O and dilute to 1000 ml. 3. Calcium chloride: Dissolve 27.5 g anhydrous CaCl2 and dilute to 1000 ml. 4. Ferric chloride: Dissolve 0.25 g FeCl3,6H2O and dilute to 1000 ml. 5. Sodium sulfite solution 0.025 N: Dissolve 1.57 g Na2SO3 and dilute to 100 ml. Solution should be prepared freshly.

6. Manganese sulphate: Dissolve 480 g tetrahydrate manganous sulphate and dilute to 1000 ml. Filter if necessary. This solution should not give colour with starch when added to an acidified solution of KI. 7. Alkali iodide-azide reagent: Dissolve 500 g NaOH and 150 g KI or 135 g. KI dilute to 1000 ml. Add 10 g NaN3 dissolved in 40 ml distilled water. This solution should not give colour with starch solution when diluted and acidified. 8. Sulphuric acid: H2SO4 conc. 1 ml is equivalent to about 3 ml alkali-iodide-azide reagent. 9. Starch indicator: Prepare paste or solution of 2.0 g L.R. grade soluble starch powder and 0.2 g salicylic acid as preservative in distilled water. Pour this solution in 100 ml boiling water. Allow to boil for few minutes, coll and then use. 10. Stock sodium thiosulphate 0.1N : Dissolve 24.82 g Na2S2O3 5 H2O in boiled distilled water and dilute to 1000 ml. Preserve by adding 5 ml chloroform per litre. 11. Standard sodium thiosulphate 0.025 N: Dilute 250 ml stock Na2S2O3 preserve by adding 5 ml chloroform per litre. (This solution will have to be standardized against standard of dichromate solution for each set of titrations).

Procedure: 1. Fill a jar with tap water and aerate for 3-4 hours. 2. Add 1 ml/L each of buffer phosphate, magnesium sulfate, calcium chloride and ferric chloride solutions to the aerated water. Mix the water well. 3. Add 1 ml/L of seed to the dilution water. Seed can be prepared by adding an equal quantity of water to a fresh sample from the aeration tank. Mix completely by thorough shaking. 4. Wash the BOD bottles with tap water and shake out the rinsed water completely. 5. Blank, three dilutions of the sample depending on the COD values (In some cases 4

dilutions also). COD mg/L 1000-2000 Direct pipetting to 300 ml BOD bottle (ml) 0.5, 1.0, 1.5

500-1000 200 - 500 100 - 200 <100

1.0, 1.5, 2.0 1.5, 3.0, 6.0 3.0, 6.0, 15.0 6.0, 15.0, 30.0

Exact dilutions of waste water and no. of dilutions will be known with experience and knowing the strength of the sample. 6. Make up with dilution water, shake out any air bubbles and stopper bottle. Store bottle in a water bath for 5 days at 20C or 3 days at 27C. After 5 days/3 days: 7. Add 2 ml of manganous sulphate solution followed by 2 ml of iodide-azide reagent well below the surface of liquid in the bottle. Stopper with care to exclude air bubbles and mix by inverting bottle several times. Repeat the shaking second time when the

precipitate has settled down. 8. Remove stopper and immediately add 2 ml of conc. H 2SO4, restopper and mix gently inversion. Iodine should be uniformly distributed throughout the bottle. 9. Decant 203 ml of liquid from bottle into a conical flask, titrate with 0.025N sodium thiosulphate (Na2S2O3) upto pale yellow colour, add a few drops of starch indicator and titrate upto end point (blue to colorless).

Calculation: BOD (mg/l) Where a = vol. of thiosulphate used for blank b = vol. of thiosulphate used for sample  This calculation is valid when the sample is taken directly in the bottle VII. CHEMICAL OXYGEN DEMAND (COD) = (a-b) x vol. of BOD bottle -------------------------------(ml of sample)

Principle: The organic matter gets oxidized completely by K2Cr2O7 in the presence of H2SO4 to produce CO2 + H2O. The excess K2Cr2O7 remaining after the reaction is titrated with Fe (NH4)2 (SO4)2.

The dichromate consumed gives the O2 required for oxidation of the organic matter.

Interference:

Fatty

acids, straight chain aliphatic compounds, chlorides nitrates and iron are the

main interfering radicals.

Apparatus:

1. Reflux apparatus consisting of a flat bottom 250 to 500 ml capacity flask with ground glass joint and a condenser with 24/40 $ joint.

2. Burner or hot plate with temperature regulator.

Reagents:

1. Standard potassium dichromate 0.250N: Dissolve 12.259 g K2Cr2O7 dried at 103C for 24 Hrs. In distilled water and dilute to 1000 ml. Add about 120 mg sulphamic acid to take care of 6 mg/L NO2-N.

2. Sulphuric acid reagent: Add 22 g Ag2SO4 to 9 lbs conc. H2SO4 or 10 gms to 1000 ml conc.H2SO4 and keep over night for dissolution.

3. Standard ferrous ammonium sulfate 0.1 N: Dissolve 39 g Fe(NH4)2(SO4)2,6H2O in about 400 ml distilled water. Add 20 ml conc. H2SO4 and dilute to 1000 ml.

 For standardization of ferrous ammonium slphate, prepared as above, use 10.0 ml std. K2Cr2O7, acidify by adding 10.0 ml H2SO4 and titrate with ferrous ammonium sulphate to be standardized using ferroin indicator. Calculate normality.

4. Ferroin indicator: Dissolve 1.485 g 1, 10- phenanthroline monhydrate and 695 mg FeSO4.7H2O and dilute to 100 ml with distilled water.

5. Mercuric Sulphate: HgSO4 crystals, analytical grade.

Procedure: 1. Wash 250 ml COD reflux bottle with tap water and then rinse with DM water. 2. Pour 20 ml of sample. For blank, pour 20 ml of DM water. 3. Put 0.4 g of mercuric sulphate (HgSO4) in COD flask. 4. Add 5 ml of conc. H2SO4 in flask. 5. Add 10 ml of 0.25N potassium dichromate solution (K2Cr2O7) 6. Slowly add 25 ml of conc. H2SO4, keeping the reflux flask in cold water bath. 7. Mix well. If the colour turns green, either take fresh sample with lesser aliquot or add more dichromate and acid. 8. Add a pinch of silver sulphate. 9. Put some previously washed glass beads in the flask, mix the contents thoroughly by shaking, connect the flask to the condenser and reflux the mixture for 2 hrs.

10. Cool the mixture and wash down the condenser with DM water.

11. Dilute the mixture to about 150 ml with DM water, add 3-4 drops of Ferroin indicator and titrate against 0.1N ferrous ammonium sulphate. End point of titration is the sharp color change from blue-green to reddish brown.

Calculation: C.O.D (mg/L) = (a-b) x N x 8000 ---------------------ml of sample

Where a = ml of FAS used for blank b = ml of FAS used for sample N = Normality of FAS

VIII. OIL & GREASE

1. Principle:

Dissolved or emulsified oil and grease is extracted from water by intimate contact with trichlorotrifluoroethane. Petrol ether (400/600C) or hexane.

2. Interferences : No known solvent will dissolve effectively only oil and grease. Solvent removal results in the loss of short-chain hydrocarbons and simple aromatics by volotilization and heavier residuals of some effluents may contain a significant portion of materials that are not extractable with the solvent.

3. Apparatus: Separating funnel 500 ml or 1 liter capacity. Glass or porcelain dish.

4. Reagents:

A) Hydrochloric Acid : HCl 1 + 1. B) Methyl orange indicator : Dissolve 0.5 g and dilute to 1000 ml with distilled water. C) Trichlorotrifluoethane (Freon or equivalent) : 1,1,2 - trichloro 1,2,2 trifluoroethane, boiling point 47 OC. The solvent should leave no measurable residue on evaporation; distill if necessary, petroleum ether 400/600C or Hexane, can also be used.

5. Procedure:

Take 250-300 ml of the sample in the separating funnel, add 3-4 drops of the methyl orange indicator, acidify using 1:1 HCl such that pH should be 2 or low.

Carefully rinse sample with 100 ml of solvent and shake vigorously for 2 min. However, if it is suspected for a stable emulsion, shake gently for 5 to 10 min.

Let layers separate. Drain solvent layer (top layer) into a pre-weighed dish and evaporate the excess solvent on a water bath. Take the weight of the dish.

6. Calculation: Oil & Grease mg/L = (A-B) x 1000 ---------------------------ml of sample

A B

= final weight of the dish (g). = initial weight of the dish (g).

 Check the purity of the solvent used, by evaporating 100 ml of the solvent in a weighed dish . Apply the correction while determining the oil and grease.

IX. MIXED LIQUOR SUSPENDED SOLIDS (MLSS) Aerobic treatment is dependent on laboratory tests. The results obtained from these tests are most useful when tests are performed daily. The operator can learn from experience the normal range of values for the particular type of activated sludge produced in that specific plant and how plant operation can be adjusted in response to changes in the sludge characteristics.

APPARATUS: 1) Funnel 2) Whatman GF/C papers 3) Drying oven 4) Flask 500 ml

PROCEDURE: Take well mixed sample volume so that will yield approx. 200mg total non-filterable residue. Filter the well-mixed sample. Wash with distilled water twice. Carefully remove filter paper and transfer to aluminum or stainless steel wire gauze as a support. Dry for at least 1 hour at 103 + 20C cool in desiccator and weigh. Repeat the drying cycle until a constant weight. CACULATION: MLSS mg/l = (A B) x 1000 ------------------ml sample

Where

A = Weight of filter paper + Residue B = Weight of filter paper.

CONTENTS 1. INTRODUCTION 1.1 Significance 2. PROCESS DESCRIPTION 2.1 Sources of Effluent 2.2 Characteristics of Raw Effluent 2.3 Characteristics of Treated Effluent 2.4 Chemistry of Biological Reaction 2.5 Design Criteria of the Effluent Treatment Plant 2.6 Design Details of Effluent Treatment Plant 2.7 Various Units and Operations Involved 3. STARTUP PROCEDURE 3.1 Pre-Startup 3.2 Bio-mass Development 3.3 Addition of Chemicals 4. OPERATION & MAINTENANCE 4.1 Normal Operation 4.2 Routine Maintenance of ETP 4.3 Abnormal Operation 4.3.1 Draining Aeration Tank 4.3.2 Draining Collection Tank 5. OPERATIONAL PROBLEMS & TROUBLE SHOOTING 6. SHUTDOWN PROCUDURE 7. ANALYSIS PROCUDURES 7.1 Analysis Frequency APPENDIX A I. pH II. Total Solids III. Total Dissolved Solids IV. Total Suspended Solids V. Dissolved Oxygen VI. Biochemical Oxygen Demand (BOD) VII. Chemical Oxygen Demand (COD) VIII. Oil & Grease IX. Mixed Liquor Suspended Solids 18 19 20 21 21 24 27 30 32 1 1 1 1 2 2 2 4 5 6 8 8 8 9 9 9 10 11 11 11 12 15 16 16

M/s. C.P. AQUACULTURE (INDIA) LIMITED, Tapatopu (V), Kodavaluru (M), Nellore (Dist).

EFFLUENT TREATMENT PLANT OPERATION AND MAINTENANCE MANUAL

UNIVERSAL ENVIRO ASSOCIATES Plot No.62, Aravindanagar, Domalguda, Hyderabad-29. Ph:040-7666901. Fax: 7633361.

APPENDIX A

1 13 25

2 14 26

3 15 27

4 16 28

5 17 29

6 18 30

7 19 31

8 20 31

9 21 33

10 22 34

11 23

12 24

1 13 25

2 14 26

3 15 27

4 16 28

5 17 29

6 18 30

7 19 31

8 20 31

9 21 33

10 22 34

11 23

12 24