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ON
WATER & EFFLUENT
TREATMENT
AT CFCL
Presented by Praveen Suthar
GET
TOPICS COVERED
RAW WATER SYSTEM
Service Water
Filter Backwash
WATER
Cooling Water
DM Makeup Makeup
Fire Water
WATER CONSUMPTION
PATTERN
WATER CONSUMPTION FOR YEAR 2002-2003
Service Water
4%
Filter Backwash
2%
Fire Hydrants
DM Make Up 7%
10%
RAW WATER SYSTEM
SOURCE OF WATER
The source of raw water for Chambal
Fertilizer and Chemical Ltd is Kalisindh
River.This river is non perennial in
nature.We have installed our pumping
station at a natural build reservoir of the
river which is about 6 km from the
factory.
SCHEMATIC SKETCH SHOWING KALISINDH RIVER AND ITS SURROUNDINGS
KOTA BARAN
ROAD (NH-76)
RIVER
L
ANA
INDH
ARC
KALIS
DAB
CHISA
KHAN KI
TO A
JHOPRI PALAITHA NTA
PROPOSED
I PICKUP WEIR
CAP : 1070 MG
BHATTI PURA
II
CAP : 170 MG
RI
TO
GH
M AD
T
HY
AP
M
RA
DE
AI
III SH
N
HARIPURA
CAP : 991 MG
CA
NA
L
RAW WATER SYSTEM
RAW WATER PUMPING STATION
The pumping station consists of 4 nos of
vertical, turbo, multistage pumps of
capacity 630m/hr and head of 68
MLC.These pumps are installed on the
top of an intake well which is circular
,vertical RCC structure (intake well is
shown in sketch no.1)
RAW WATER SYSTEM
LAYOUT OF PUMPING SATION AT KALISINDH RIVE
PUMP
HOUSE 24 " Supply Header
R.L. 243.75
INTAKE
WELL
R.L. 207.50 M
R.L. 221.65 M
6 Meters
ROCK
R.L. 206.50 M
TUNNEL
2000 MM
R.L. 203.0 M
R.L. 204.50 M
`
RAW WATER SYSTEM
RAW WATER STORAGE FACILITY
The raw water is pumped from Kalisidh
river to the factory through 24 and6
KM CS pipe and stored in two Raw water
reservoirs of capacity 60000m
each.There is also provision of
chlorination of raw water at the entry to
reservoir.
End
WATER PRE-TREATMENT
DRG
WATER PRE-TREATMENT
STEPS INVOLED IN WATER PRETREATMENT
Chlorination
Clarification
Filtration
WATER PRE-TREATMENT
CHLORINATION
The objective of the chlorination of raw water in this plant is to
ensure that organic matter trapped in flocs can not travel
outside the floc, to minimize the bacterial growth during
storage of sludge
When chlorine gas is injected into water, the following chemical
reaction takes place:
H2O + Cl2 = HCl + HOCl
The HOCL being a strong oxidizing agent, oxidizes the organic
matters in water resulting instantaneous death of living matter
thus disinfecting water
In this plant, raw water is chlorinated in the stilling chamber to
ensure that bacterial content is negligible. Dosing rate is set to
ensure that free chlorine is detectable at flash mixer outlet.
WATER PRE-TREATMENT
CLARIFICATION
Suspended solids responsible for the
turbidity and color are characterized by
small size of particles which varies from
0.001 to 100 microns. These colloidal
particles carries a distinct change on its
surface by which it repels the other colloidal
particles and prevent it from
agglomerating. In clariflocculation the
charge of the colloidal particles are
neutralized /reduced so that these can
agglomerate to bigger size and settle down.
WATER PRE-TREATMENT
STEPS OF CLARIFLOCULATION
COAGULATION --A process by which the charge
of the colloidal particles are neutralized or
minimized and make it ready for flocculation
FLOCULATION-A process in which the
neutralized colloidal are agglomerated to-gather
to a size heavier enough to settle down
SEDIMENTATION---A process of settling down of
heavier particles by gravity
WATER PRE-TREATMENT
PROCESS OF COAGULATION AND FLOCULATION
In our plant we use alum /PAC as coagulant.
The active component of alum is aluminum
sulphate. It dissociates in water as follows:
Al2 (SO4) 3 + 6 H2O = 2 AL (OH) 3 + 3 H2SO4.
In the neutral pH range, disassociation
constant of Al (OH)3 is minimum and flocs are
formed. The fine materials in suspension is
trapped in the large pores of the floc. Since
the flocs are large and become heavy, the
flocs containing foreign matter settle down to
the bottom.
WATER PRE-TREATMENT
PROCESS OF COAGULATION AND
FLOCULATION
The reaction between water and aluminum
hydroxide Al (OH3) also produce charge
species such as Al (OH)2+, and Al (O H)4.-
These species thus formed combines with
charged colloidal particles reducing zeta
potential. This results in agglomeration of
the colloidal particles.
In the flocculation zone, the slow moving
paddles bring the flocs together to
agglomerate the flocs and make them
heavier to settle down.
WATER PRE-TREATMENT
FILTRATION
When liquid containing suspended
matters passes through a packed
column containing fine particles of
material inert to the liquid, the packing
traps the suspended matter effecting
the filtration
In our plant gravity sand and dual media
filters are used for filtration of the water
WATER PRE-TREATMENT
PROCESS DESCRIPTION OF WATER PRETREATMENT PLANT
The water treatment plant consists of two streams
of clarifloculator of 800 m /hr and one nos of tube
settler of 400m/hr.The raw water from raw water
reservoir is pumped by the clarifier feed pumps(P-
902) to the stilling chamber. This reduces the
kinetic energy of water in an open tank ensuring
that pressure and flow oscillations applicable at
the discharge of the pump are dampened to
insignificant level. This dampening ensures that
no external disturbance influences formation,
growth and settling of floc in the clarifloculator.
This is of special significance during change of
plant operating load.
DRG
WATER PRE-TREATMENT
HEMATIC OF WATER PRETREATMENT PLANT
RAW
WATER CLARIFIER A
FROM
RESERVIOUR Capacity 1600 M3 BACKWASH PUMP
P-903A/B/C P-5903A/B
FLASH B
MIXER
A CLARIFIER B
S
STILLING FLASH A
CHAMBER MIXER N C
B D
F
I FILTER FILTER FILTER
CHLORINE
L D WATER WATER WATER
PAC TANK A
T TANK B TANK C
E
R
S
PAC DMFI
CHLORINE TO SW II TO CT GP-II
DMFI TO ACT TO UCT TO DMP TO DW TO SW I
DRG
WATER PRE-TREATMENT
PROCESS DESCRIPTION OF WATER PRETREATMENT PLANT
The clarified water from the outer zone of the clarifier
flows to the outer launder of the clarifloculator. Water
from the launder flows to the filters through 22 dia pipe.
A circular baffle plate, projecting 75 mm above the water
levels prevents carry over of scum in to the launder. The
scum retained by the baffle plat is led into a collector and
diverted to a drain.
A skimmer is suspended from the clarifier arm and
transfers the scum to near the baffle plat ereducing the
scope for mixing the scum with the clarified water.
The clear water from the clarifier is filtered by the gravity
sand filters and is stored in the filtered water storage
tank from which it is pumped to different load centers.
DRG
WATER PRE-TREATMENT
PROCESS DESCRIPTION OF WATER PRETREATMENT PLANT
Four nos of concrete filters each having two
beds have been provided for the filtration of
water. The filtered water at the outlet of the
filter is led to the underground covered RCC
tank. The filtered water from this well is
transferred to the three fire cum filter water
storage tanks having 18000 M each. Lower 8 m
of the tank serves as fire water tank and the
region above acts as filter water tank.
Pumps draws the water from the filter water
tanks and supplies to different load centers.
DRG
WATER PRE-TREATMENT
PROCESS DESCRIPTION OF WATER PRETREATMENT PLANT
TUBE SETTLER
The raw water is first received in the stilling
chamber where coagulant is mixed. The thoroughly
mixed water from stilling chamber passes into
flocculators to facilitate flocculation.
The water then enters the tube zone from the
bottom and rises up through the inclined tubes. The
flocs due to density difference will start settling
down. The clarified water will rise upwards and get
collected in uniformly spaced troughs. Clear water
flows to the dual media filter where filtration takes
place. Filter water then flows to filter water well
from which its pumped filter water tanks. The
separated sludge will slide down the tube and will
be drained off by hydrostatic head.
DRG
WATER PRE-TREATMENT
DESIGN WATER QUALITY OF WATER PRETREATMENT PLANT
FILTERED WATER
IN FLOW TO
S.No. CONSTITUENTS UNIT FROM SAND
CLARIFIER
FILTER
1 Total Hardness as C aC o 3 PPM 150.0 150.0
3 CT-I Make up Pump P-0905 A,B/ 2 Nos. 535/520 2.7 ~ 3.7 Cmg
BEACON WEIR M/Hr
4 CT-II Make up Pump P-0906 A,B/ 2 Nos. 310/300 2.7 ~ 3.7 Cmg
BEACON WEIR M/Hr
10 Drinking Water Pump P-015 A,B / 2 Nos. 60/50 M/Hr 9-10 Kg/Cmg
BEACON WEIR
11 Alum dosing Pumps P-011 A,B,C / 3 Nos. 0.5 M/Hr 1.1 Kg/Cmg
SHAPOOTOOLS
WATER PRE-TREATMENT
Blowers
S.No. Blowers Tag No. Quantity Capacity Discharge
Pressure
End
WATER DEMINERALISATION PLANT
WATER DEMINERALISATION PLANT
PURPOSE
DM Plant is designed to produce polished water
suitable for boiler feed.
CATION EXCHANGER
REGENERATION PROCESS
When the resin is exhausted, is regenerated
by using hydrochloric acid or Sulphuric acid
R Ca + HCl - R-H + CaCl2
R Mg + HCl - R-H + MgCl2
DM STORAGE
SBA TANK 1
SAC WBA
DEGASS ED UNIT
ACF UNIT UNIT MIXED
WATER 3 NOS
UNIT 3 NOS 3 NOS BED UNIT
STORAGE
3 NOS 4 NOS
TANK
GP 1
3 NOS
DEGASS ER
TOWER TC
MCF
UNIT
APC PROCESS
SAC 3 NOS
GP - 1
CONDENSATE DEGASSED
STORAGE UNIT
UPC ACF WATER
TANK 2 NOS DM STORAGE MIXED
UNIT S TORAGE
TANK 2 BED UNIT
SC 2 NOS TANK
4 NOS
3 NOS
GP 2
DEGASSER
TOWER
G P -2
APC
PROCESS SAC
DEGAS SED
UPC CONDENSATE UNIT
ACF WATER
STORAGE 2 NOS
UNIT S TORAGE
PW STORAGE
TANK 2 NOS TANK
TANK 1 GP-I
3 NOS
SC
TC
MCF MCF
PW STORAGE
UNITS UNIT
TANK 2 GP-II
3 MOS 3
NOS
WATER DEMINERALISATION PLANT
Stem condensate
DRG
WATER DEMINERALISATION PLANT
DRG
WATER DEMINERALISATION PLANT
PROCESS DESCRIPTION OF CONDENSATE
POLOSING UNIT
The condensate then flows to Strong Acid Cation
exchanger containing strong base cation. In SAC
Ammonia is exchanged with H+ ions of the resin.
The cation unit is designed to handle 87.23
ppm of ammonia as CaCO3
The condensate treated from SAC unit is fed to a
single Degassifier Tower where the carbon
dioxide in the condensate is vented off. The
degassed water after storage is pumped to DM
water storage tank from where it is further
polished by passing it through mixed bed unit.
DRG
WATER DEMINERALISATION PLANT
DRG
WATER DEMINERALISATION PLANT
DRG
WATER DEMINERALISATION PLANT
No. of Nos. 2 2 4 2 2 4
Unit
End
EFFLUENT TREATMENT
PLANT
EFFLUENT TREATMENT PLANT
SOURCE OF EFFLUENT
1. Neutralized effluent from DM Plant
2. ACT#1 / UCT#1 blow down water
3. Side stream filter backwash water from
Ammonia and Urea Cooling Tower
4. Oily water from Ammonia Urea plant
5. Clearate water from Slurry centrifuge
and oily.
EFFLUENT TREATMENT PLANT
DRG
EFFLUENT TREATMENT PLANT
LAYOUT OF EFFLUENT TREATMENT PLANT
Stabilisation Compartment
FLOW METER
Mixing compartments
Mixing Chambers
REGENERATION WASTE FROM DMP
FLOW METER
TO RWR
TO Forest
CLEARATE
PIT TO GB
CLARIFIER BLOWDOWN
CENTRIFUGE
TO HOLDING POND
FLOW METER
EFFLUENT TREATMENT PLANT
PROCES DESCRITION
The neutralized effluent from DM Plant,
cooling tower blow down water from
cooling tower, filter backwash water from
cooling tower, Clearate water from oil
separator enters for the 1st compartment
of the mixing chamber and flows through
other compartment to the stabilization
compartment. The path of the water flow
through mixing chamber is zigzag to
ensure thorough mixing of the different
effluent to form a homogenous mixer.
DRG
EFFLUENT TREATMENT PLANT
PROCES DESCRITION
The mixed effluents there after flows to the
stabilization compartment where the mixed
effluents are stabilized. These influents the
passes for two nos. of mixing compartment
adhere continuous agitation goes on.
There is provision for diluting of the
effluent if required by raw water.
The final neutralized and treated effluent is
pumped to Holding Pond and part of this is
utilized for irrigation network.
DRG
EFFLUENT TREATMENT PLANT
OIL SEPARTATOR
The oil water from Ammonia and Urea
plant of GP1 / GP2 is treated in the oil
separator of ETP. Emulsified oil removed
and solid removal is carried out by
flocculators by dosing alum and
polyelectrolyte. Oily layer from the top is
skimmed out, collected in drum and sold
as used oil. The clear water is taken to
mixing pond.
The capacity of oil separator is 10 m/hr
DRG
EFFLUENT TREATMENT PLANT