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A PRESENTATION ON

MECHANICAL, BIOLOGICAL AND


CHEMICAL PLANT
BY
V. ADITYA SHANMUKHA (13021A2505)
SK. INJU REHAMAN (14025A2551)
VIZAG STEEL PLANT
(RASHTRIYA ISPAT NIGAM LIMITED)
Visakhapatnam steel plant (VSP), the first coastal based steel plant of
India.
VSP has an installed capacity of 3 million tonnes per annum of liquid steel
and 2.656 million tonnes of saleable steel.
VSP has become the first integrated steel plant in the country to be
certified to all the three international standards for quality (ISO-9001), for
environment management (ISO- 14001) & for occupational health &
safety (OHSAS-18001).
MAJOR DEPARTMENTS AT VIZAG STEEL
PLANT
COKE OVENS AND COAL CHEMICALS PLANT
SINTER PLANT
BLAST FURNACE
STEEL MELT SHOP AND CONTINUOUS CASTING
LIGHT & MEDIUM MERCHANT MILL
WIRE ROD MILL
MEDIUM MERCHANT AND STRUCTURAL MILL
SECTIONS OF COKE OVENS AND
COAL CHEMICALS PLANT
COKE OVEN BATTERIES
COAL CHEMICAL PLANT
1. EXHAUSTER HOUSE. 8. BENZOL DISTILLATION PLANT
2. AMMONIUM SULPHATE PLANT. 9. HYDRO REFINING
3. M.B.C PLANT. 10 EXTRACTIVE DISTILLATION.
4. TAR DISTILLATION PLANT.
5. P.C.L.A
6. NAPHTHALENE FRACTION CRYSTALLIZATION.
7. BENZOL PLANT.
INTRODUCTION- MBC PLANT
MBC stands for Mechanical, Biological and Chemical plant. It takes in
effluent water from various sections and treats it and discharges it into
sea.
Steel plant use a tremendous amount of water for various purposes like
sintering mills, coke plants, blast furnaces, chemical processes etc.,
From all these processes, waste water is generated in huge quantity
containing Phenols, Cyanides, Oil & grease materials, solids etc.,
Different technologies can be employed to treat these effluents including
physical, chemical and biological treatments. MBC is one of such
treatment unit which is considered to be efficient to remove many
impurities from the waste water.
SOURCES OF EFFLUENTS
Excess flushing liquor from battery (w1).
Blow down water from pump house (w2).
Spillage generated in Benzol distillation plant (w3).
Spillage generated in tar plant.
Effluent collected in phenolic water pump houses.
Coke oven gas coming from batteries is quenched by flushing
liquor from 2000of to 176of. this flushing liquor is an aqueous
ammonical solution, from which ammonia vapors are
separated and water is sent for treatment (w1).
From the pump house ,contaminated cooling water used in
primary gas coolers is sent to MBC for treatment(w2).
Effluent generated in benzol distillation plant, tar distillation
plant are sent for treatment (w3)
WHICH ARE THE POLLUTANTS
Ammonia or Ammonium salt
Phenol & Phenolic compounds
Cyanides
Thiocyanates
Tar & oil.
Because of their adverse effect on land and water and
ultimately on the living kingdom. Also they disturb the ecology
EFFECTS OF POLLUTANTS

PHENOL
Produce unpleasant odors & taste during chlorination.
Toxic to marine life.
Having strong bactericidal action.
CYANIDE & THIOCYANATE
These have lethal and toxic effect on ecology.
EFFECTS OF POLLUTANTS

AMMONIA
It is toxic to fish and other aquatic life.
It is corrosive.
Cause undesirable algae growth.
Cause the formation of nitrates & nitrites.
PROCESS
The different methods used for the treatment of effluent in
MBC are Mechanical, Biological & chemical.
Heavy particles, tar & oil are removed by mechanical &
chemical methods.
Organic toxic compounds are removed by biological method.
The capacity of the MBC plant in VSP is 120 m3 per hour.
The plant consists of three stages namely Mechanical stage,
Biological stage and Chemical stage.
PROCESS FLOW DIAGRAM
Effluent from
Contaminated Cooing BDS(W3) Fe-Sulphate
Water(W2)

Flash
Unit Oil Flotator H3PO4
Tar Settling Tank
Effluent after Heat Exchanger Pre-Aerator
NH3 Averaging Tank
Column(W1)
T19 / 20
Treated Effluent
Al- Sulphate
Sand Filter 1st stage
Flocculant

Clarifier T18 2st Stage


Activated Charcoal

Soda Ash

4th Stage
Clarifier
3rd Stage
Clarifier
All Inputs are collected, mixed with air in Pre-Aerators and
distributed in Tar Settling Tanks (TST).
TST works in parallel. Heavy matter and tar settle in TST and
the settled effluent overflow to collecting tank.
From collecting tanks effluent is pumped to Oil Flotators via
Pr. tanks for oil removal. Two Oil Flotators can work in series
or parallel. Oil is removed by froth flotation mechanism.
From Oil Flotators effluent overflow to Equalizing tanks by
gravity. Here P2O5 is added and pumped to 1st stage
Aerotanks for Phenol degradation.
In 1st Stage degradation of Phenol take place due to bio-
oxidation by activated sludge.
Effluent Overflow from 1st stage to intermediate collecting
tank from where it is again pumped to 2nd stage Aerotanks.
Cyanide and Rhodamides are decomposed here by similar
action like 1st stage.
Effluent from 2nd stage overflow to intermediate collecting
tank and from there it is pumped to new MBC.
Two Air blowers pumps ambient air into the system as a
source of Oxygen.
TOXIC
ELEMENTS ENZYMES CARBOHYDRATES
FROM &
CONTAINING
BACTERIA ENZYMES
C, H2 , O2 , N2,P

HOW DOES
BACTERIA WORK
CHARACTERISTICS OF BACTERIA CONSUMED
DEPEND ON VARIOUS BY
PARAMETERS SUCH AS TEMP., pH, BACTERIA
CONCENTRATION & DISTRIBUTION
OF DIFFERENT ELEMENTS ETC.
DOMINANT MICRO-ORGANISM IN
ACTIVATED SLUDGE PROCESS

ACHROMOBACTER
ALCALIGENES
COMOMONAS
FLAVOBACTERIUM
PSEUDOMONAS
THIOBACILLUS
ZOOGLOEA
EFFLUENT QUALITY AT DIFFERENT STAGES OF MBC PLANT.
Sl Parameter Unit Inlet After 1st After 2nd
Stage Stage
01 Phenol PPM 400 3-5 1
02 Cyanide PPM 20 12 1.5-3.5

03 Thiocyanate PPM 400 350 10


04 Free NH3 PPM 250 90-100 80-100
05 Total NH3 PPM 600 500 500
06 Tar & Oil PPM 500 30-35 25
07 TSS PPM 100 200-300 150-200
08 BOD PPM - 1000 150

09 COD PPM 2500 1200 300


10 PH 7-9 7-9 7-9
SL RESIDENCE TIME IN Minimum

01 PREAERATOR 15 min.

02 TAR SETTLING TANK 6 Hrs.

03 OIL FLOTATOR 1 Hrs.

04 AVERAGING TANK 16 Hrs.

05 1st STAGE AEROTANK 20 Hrs.

06 2nd STAGE AEROTANK 25 Hrs.


SL TECHNOLOGICAL PARAMETERS

01 Air Flow to PREAERATOR 15- 20 Nm3 / Hr

02 Air Flow to AVERAGING 30 Nm3 / Hr of


TANK Effluent.

03 Air Flow to 1st & 2nd 50 Nm3 / Hr of


AEROTANKS Effluent.

04 Qty. of Sludge Recycle to 30%


Aerotanks.
After completion of 2nd stage aeration, treated water enters the 3rd
stage aeration tanks through an intermittent storage tank
3rd stage aeration tanks are in series (5 tanks) connected with S
shaped overflow pipes.
Here effluent is treated from ammonia, nitrites and nitrates
To ensure nitrification, soda ash solution is added maintaining a P H of 7
to 8
The effluent is passed through 2 clarifiers in parallel and sludge
settled is recycled back to the aeration tanks ( recycling activated
sludge).
The overflow water collected in intermediate storage tank enters 4th
stage aeration tanks (2no.s) intended for decrease in cod
Biosorption technology is used
Activated carbon solution is pumped for this purpose
Effluent from stage 4 enters into clarifiers and sludge settled is
recycled back( activated sludge)
The overflow enters into a storage tank where flocculant and
alum solutions are added for flocculation and coagulation purpose
Chemically treated water enters clarifiers and overflow water
through an intermittent tank passes through rapid pressure sand
filters where any suspended solids are removed and is stored in a
storage tank and discharged at constant flowrates.
SALIENT FEATURES OF MBC PLANT

Reduction of ammonical nitrogen to 50 ppm.


Reduction of free cyanide to 0.20 ppm.
Removal of color of the treated effluent.
Reduction of hydrogen sulphide.
Reduction of cod to 250 ppm.
SALIENT FEATURES OF MBC PLANT

Simultaneous bio-oxidation of ammonia (both nitrification &


de-nitrification), cyanide, thio-cyanide & H2S with residual
phenol in a single stage.
Use of activated charcoal treatment after biological treatment
to reduce color & cod of the effluent.
Final control of suspended solids in effluent after pressure
sand filter.
Entire treatment is based on activated sludge process.
ANY
QUIRIES?
THANK YOU

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