TREATMENT FLOW CHART: DAF, UASB FOLLOWED BY ASP & FILTERS
Ms Bhole Baba Milk food Industries Ltd. is situated at
khair road, Aligarh
The Dairy handle
about 10-lac litre of milk every day. Depending on the season, major
differences occur in the quantities of milk received from cooperative milk
federation and in the use of butter, butter oil and milk powder. The value
added products manufactured will be Casein,Milk Protien
Concentrate,Lactose-Both Food &Pherma,Demineralised Whey Protien,Whole Milk
Powder,Skimmed Milk Powder, & White Butter In Bricks Form, with future
planning to produce processed Cheese/Mozerella.
Generation
of Waste Water:
Waste water is generated mainly from Receiving Station,
Bottling plant, Cheese Plant, Butter Plant, Casein Plant, Condensed Milk Plant,
Dried Milk Plant, Ice Cream Plant, Water Softening units, Cooling towers,
Bottle and can washing sections and Various CIP systems,
Normally it is Cleaning of floors, equipment, etc., and
domestic waste from the dairy and staff quarters.
The unit will release an amount of estimated 10-lac litre
of effluent every
BASIS
& DESIGN DATA:
The designing of the plant
is based on the basis of parameters of generated effluent from similar type of
plant, which engaged in processing of milk and manufacturing Pure Ghee &
Milk powder.
CHARACTERISTICS
OF GENERATING EFFLUENT WATER:
The
values of incoming wastewater at ETP is as under:
|
S.No.
|
Parameter
|
Unit
|
Value
|
|
1.
|
pH
|
|
6.0 – 10.5
|
|
2.
|
Total Suspended Solids
|
Mg/l
|
1500.0 – 2000.0
|
|
3.
|
B.O.D.
|
Mg/l
|
1500.0 – 1800.0
|
|
4.
|
C.O.D.
|
Mg/l
|
2500.0 – 3500.0
|
|
5.
|
Oil & Grease
|
Mg/l
|
150.0 – 250.0
|
|
6.
|
Rated capacity of ETP
|
KL/Day
|
1,000.0
|
What is Upflow
Anaerobic Sludge Blanket?
Upflow anaerobic
sludge blanket, or UASB, is a form of anaerobic (oxygen-free) digester used in
wastewater treatment. It is a methane-producing digester which uses an anaerobic
process and forming a blanket of granular sludge and is
processed by anaerobic microorganism.
UASB was developed in
1970s by Letinga in the Netherlands. It is essentially a suspended growth system in which proper hydraulic retention time (HRT) and organic
loading rate (OLR) is maintained in order to facilitate the dense
biomass aggregation known as granulation.
In the UASB process, the whole waste is passed through the
anaerobic reactor in an upflow mode, with a hydraulic retention time (HRT) of
only about 8-10 hours at average flow. No prior sedimentation is required. The
anaerobic unit does not need to be filled with stones or any other media; the
upflowing sewage itself forms millions of small "granules" or
particles of sludge which are held in suspension and provide a large surface
area on which organic matter can attach and undergo biodegradation. A high solid
retention time (SRT) of 30-50 or more days occurs within the unit. No mixers or
aerators are required. The gas produced can be collected and used if desired.
Anaerobic systems function satisfactorily when temperatures inside the reactor
are above 18-20°C. Excess sludge is removed from time to time through a
separate pipe and sent to a simple sand bed for drying.
The design of UASB pond is a function of:
The design of UASB pond is a function of:
§ COD input of
wastewater
§ Flow of wastewater
§ Organic loading
rate
§ Hydraulic retention
time
These are the 4 top applications of the UASB reactors:
o
Breweries
and beverage industry
o
Distilleries
and fermentation industry
o
Food
Industry,Dairy, Slaughter Houses.
o
Pulp
and paper
Together, these four industrial sectors account
for 87% of the applications. However, the applications of the technology are
rapidly expanding, including:
1. treatment of
chemical and petrochemical industry effluents
2. textile
industry wastewater
3. landfill
leachates
4. Conversions in
the sulfur cycle and removal of metals.
BHOLA BABA DAIRY GAS PRODUCTION & POWER GENERATION:
STREAM
–I :
Process Flow= 900 KLD having COD 3300ppm
Influent COD@ 3300 ppm = 2970 Kg
COD removed in a day (60% reduction) = 1782 kg
Bio
gas produced @ 0.1 cu mtr per kg of COD removed = 178.2 cu mtr per day.
Capacity
of gas holder:
Provide a gas holder of 200 cu mtr capacity.
POWER
GENERATION:
The bio gas produced in UASB process should be utilized
for production of electric power. The amount of electric power generated shall
be as under:
Bio Gas production = 178.2 cu mtr /day
Methane content (65.75%) = 117.16 cu mtr
Calorific value =28.9 MJ/N.cu mtr
Energy content 117.16x28.9x273/(273+30)=3050.85 MJ/Day
Generator efficiency--- 30%
Electricity generated =0.3x3050.85x1000000/3600x1000
=
254.23
Electric power generated = 254.23x0.04167=10.59 kw say 10 kw
= 1.25x 10=
12.5 kva.
STREAM
–II :
Mother Liquor= 100 KLD having COD 3,28,000 ppm will be
fed to the UASB reactor separately from the 900 kLD flow.
Influent COD@ 3,28,000 ppm = 32800 Kg
COD removed in a day (60% reduction) = 19680 kg
Bio
gas produced @ 0.1 cu mtr per kg of COD removed = 1968 cu mtr per day.
Capacity
of gas holder:
Provide a gas holder of 2000 cu mtr capacity.
POWER
GENERATION:
The bio gas produced in UASB process should be utilized
for production of electric power. The amount of electric power generated shall
be as under:
Bio Gas production = 1968 cu mtr /day
Methane content (65.75%) = 1293.96 cu mtr
Calorific value =28.9 MJ/N.cu mtr
Energy content 1293.96x28.9x273/(273+30)=33692.92 MJ/Day
Generator efficiency--- 30%
Electricity generated =0.3x33692.92x1000000/3600x1000
=
2807.74
Electric power generated = 2807.74x0.04167=116.99 kw say110 kw
= 1.25x 110=
137.5 kva.
TOTAL KW= 10+110 = 120 KW
We can go for a gas engine of capacity 65 KW If any gas is left , it will be flared or supplied
to staff quarters. Before the gas can be supplied, it has to be scrubbed in a
scrubber.
Capacity
of gas holder:
Provide a gas holder of 2200 cu mtr capacity.
CLARIFIER
UASBR
PANEL BOARD
DAF AND INTAKE
FILTERS
SCRAPPER IN CLARIFIER
FILTERS
DIFFUSERS IN AERATION TANKS
AIR BLOWER
AERATION TANKS
GAS PIPES IN UASBR
OPENING IN UASBR
GAS HOLDER
BIRDS EYE VIEW OF THE PLANT
FLARE STACK FOR GAS FLARING
LABORATORY ROOM
VIDEO OF THE PLANT
Our Project photo and Video in
our facebook page https://www.facebook.com/envoprojects
Some Of the UASB Projects
|
NAME
OF COMPANY
|
SCOPE
OF WORK
|
Year
|
HMA
FROZEN FOOD EXPORTS,AGRA
|
SLAUGHTER
HOUSE ETP WITH UASB,450KLD
|
2007
|
AL
HAMD FROZEN FOODS, ALIGARH
|
ETP
PROJECT, 200 KLD UASB
|
2004
|
Bhola baba Dairy Ind Limited,Aligarh
|
1 MLD ETP with UASB
|
2007
|
SARASWATI
SUGAR MILLS,HARYANA
|
Suger
mill ETP Project,UASB,500KLD
|
1998
|
Namaste
India Dairy, Kanpur, UP
|
1MLD
DAIRY ETP Project with UASB
|
2010
|
Malhotra
Gelatine and Bones,Unnao
|
Rendering
plant ETP Project with UASB,1MLD
|
2010
|
AOV
Exports, Unnao,UP
|
Slaughter
House ETP Project with UASB,750KLD
|
2010
|
Mash
Agro Pvt Ltd, Unnao
|
Slaughter
house ETP with UASB, 1 MLD
|
2013
|
Rustam
Foods, Unnao, UP
|
Slaughter
house ETP with UASB, 1 MLD
|
2013
|
Al
Laham Food Exports,Khurja,UP.
|
Slaughter
House ETP with UASB,750 KLD
|
2014
|
Al Huda Frozen Foods, Khurja
|
Slaughter
House ETP with UASB,750 KLD
|
2014
|
Al
Halal Foods (Link Lock Company),Aligarh
|
Slaughter
House ETP with UASB,1 MLD
|
2016
|
Al
Ammar Exports, Aligarh
|
Slaughter
House ETP with UASB,600 KLD
|
2016
|
Agrotec
Foods Ltd, Kanpur
|
Food
processing waste, 200 KLD,UASB
|
2015
|
Bholebaba Dairy,Kanpur
|
500KLD
DAIRY ETP Project with UASB
|
2016
|
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