DAIRY ETP ONE MLD CAPACITY UASB BHOLA BABA DAIRY ALIGARH

DAIRY EFFLUENT TREATMENT PLANT (ETP) ONE MLD CAPACITY.BHOLA BABA DAIRY ALIGARH, 2007

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:

§  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

Effluent Treatment Plant- Case Study Bone Rendering Plant

Dear Sayeed,

Thanx for the info. I hope you continue to send such valuable info which slips my eye

pls note following points please.

1. The process you sent is primary treatment which is to be followed by MBR or Constructed WETLAND which we have not provided anywhere yet.

In The primary Treatment,  we have not provided UASB.  And then the foaming problem is the biggest.We have not found a solution to the foaming problem yet.

in the flow chart :

2.Balance Tank :We have a balance tank and using lime there to balance pH. NaOH is already coming mixed with water, so no need to add additional NaOH

3. DAF Unit: we are already using Ferrous sulphate, sulphuric acid and PAC there (Polymer) in  DAF.  Dosing is yet to be optimised. 

4.Denitrification:It is done in UASB tank.UASB is missing in Ashrafi and is to be added.We can convert the existing collection tank after DAF into Anaerobic condition by closing the open Top..In Malhotra,we are going for UASB tanks.

5.Nitrification: It is done in the Aeration tank.We have found an anti foaming agent from Ion Exchange by the name INDOFOAM1500, let us try that.Silicone defoamer is not working.We have not found a solution to the foaming yet..We have not used phosphoric acid in the aeration tank.This is a new info.We will try concentrated phosphoric acid when we visit kanpur this time insha Allah.

6.Ultra filtration:In its place we are using Pressure Sand filter.

These primary treatment units are to be followed by a MBR unit or a  Constructed Wet lands unit .After this water can be reused.... ZERO Discharge.

Thanx again for sending such a beautiful article.

Saleem Asraf Syed Imdaadullah,
Mobile: +919899300371
ENVO PROJECTS
New Delhi, India
Web Site :
www.envoprojects.in
www.saleemindia.blogspot.com
Follow me on Twitter : www.twitter.com/saleemasraf

Adapting UASB technology for sewage treatment

Adapting UASB technology for sewage treatment in Palestine and Jordan [research article]

March 3, 2008 · No Comments

High rate anaerobic technologies offer cost-effective solutions for "sewage" treatment in the temperate climate of Palestine and Jordan. However, local sewage characteristics demand amendments to the conventional UASB [upflow anaerobic sludge blanket] reactor design. A solution is found in a parallel operating digester unit that stabilises incoming solids and enriches the UASB sludge bed with methanogenic activity. The digester operational conditions were assessed by operating eight CSTRs [continuous stirred tank reactors] fed with primary sludge. The results showed a high degree of sludge stabilization in the parallel digesters at SRTs [ solids retention times] 10 and 15 days at process temperatures of 35 and 25°C, respectively. The technical feasibility of the UASB-digester combination was demonstrated by continuous flow pilot-scale experiments. A pilot UASB reactor was operated for 81 days at 6 hours HRT [hydraulic retention time] and 15°C and was fed with raw domestic sewage. This period was subsequently followed by an 83 day operation period incorporating a parallel digester unit, which was operated at 35°C. The UASB-digester combination achieved removal efficiencies of total, suspended, colloidal and dissolved CODs of respectively 66, 87, 44 and 30%. Preliminary model calculations indicated that a total reactor volume of the UASB-digester system corresponding to 8.6 hours HRT might suffice for sewage treatment in Palestine. [author abstract]
Source article:  Mahmoud, N., Zeeman, G. and  Lier, J.B. van (2008). Adapting UASB technology for sewage treatment in Palestine and Jordan. Water science & technology—WST  ; vol. 57, no. 3 ; p 361–366. doi:10.2166/wst.2008.100

Saleem Asraf Syed Imdaadullah
Mobile : 9899300371
311/22,Zakir Nagar,New Delhi-110025
email: saleemasraf@gmail.com
BLOG: http://saleemindia.blogspot.com

UASB DESIGN PARAMETERS

UASB Design
In general, there are two ways to design an UASB reactor
If input COD: 5,000 - 15,000 mg/l or more, the design method should be used based on Organic Loading rate, (OLR) If input COD < 5000 mg/l, the design method should be calculated based on velocity.


Some H2S gas can pass the GSL separator and accumulate above the water level in the top of the reactor. This will be oxidized to sulphate by oxygen in the air to form Sulphuric Acid that will in turn cause corrosion of both concrete and steel. Below the water level: Calcium Oxide, (CaO), in concrete can be dissolve with by Carbon Dioxide, (CO2), in the liquid in low pH conditions. To avoid these problems, the material used to construct the UASB reactor should be corrosion resistant, such as stainless steel or plastics, or be provided with proper surface coatings, (e.g. coated concrete rather than coated steel, plastic covered with impregnated hardwood for the settler, plastic fortified plywood, etc).
Operation
Operation criteria: The optimum pH range is from 6.6 to 7.6 The wastewater temperatures should not be < p =" 350"> 20oC) and sometimes the start-up can take up to 3 – 4 months. In start-up process, hydraulic loading must be Ј 50% of the design hydraulic loading.
The start-up of the UASB reactor can be considered to be complete once a satisfactory performance of the system has been reached at its design load.

VIDEO