INDUSTRIAL TRAINING REPORT

HUBERT ENVIRO CARE SYSTEMS PRIVATE LTD

Submitted by M. Vidhya - (2010215006) P. Sivasakthi- (2010216030) V. Manikandan-(2010215031) M. Sree prathima Devi-(2010215005) in partial fulfillment for the award of degree Of MASTER OF ENGINEERING in ENVIRONMENTAL ENGINEERING & ENVIRONMENTAL MANAGEMENT

FACULTY OF CIVIL ENGINEERING ANNA UNIVERSITY: CHENNAI-600 025 JUNE 2011

ACKNOWLEDGEMENT

First of all, We would like to solicit sincere thanks to our Director Dr.A.Navaneetha Gopalakrishnan, Professor, CES, Anna University, Chennai for his encouragement, guidance and suggestion to undertake this industrial training as a part of our course. We express my sincere thanks to my course coordinators Dr.S.Amalraj,& Dr.R.Kanmani, lecturer, CES, Anna University, Chennai for encouraging us to undergo industrial training. We are very grateful to Dr.J.R.Moses CEO of Hubert Enviro Care Private Limited for granting permission to undergo training in the industry. We wish to extend my immense pleasure and deep sense of gratitude to thank Dr.Rajkumar Samuel, Technical director of Hubert Enviro Care Private Limited who helped me to know much information about the industry in all aspects amidst their busy schedule. We would also like to thank all the staff members of the Hubert Enviro Care Private Limited rendered their help and support throughout the period of training.

1.INTRODUCTION: Hubert Enviro Care Private Limited (HECS) is Indias one of the Leading Environmental Management solutions provider and serving as a catalyst to the cause of environmental preservation in the Industrial and Domestic Sectors. Hubert Enviro care private limited established in the year of 1997. This company is located in Ashok Nagar, Chennai. Nature of the business is manufacturing and service providing. Manufacturing includes sewage treatment plants, water treatment plants, Rain water harvesting system and also offering consultancy, Plant operations, and Plant maintenance services. They provide EPC Turnkey Supplies, Analytical Services, Operation & Maintenance Services and Consultancy Services. About 500 number of people working in this company. The activities of the company are briefed as follows. Turnkey Supply Services: Technology & Engineering division of this company offers concept development, design, engineering, detailed engineering fabrication, erection, testing and commissioning of Effluent Treatment Plants, Sewage Treatment Plants, Water Treatment Plants, Incinerators, Softeners, Gas scrubbers, DM Plants, RO Plants, Desalination Evaporators, Waste Water Evaporators, Solar Water Purifiers. Analytical Services: The laboratory of this company at Chennai offers all Analysis of Air, Noise, Water, Light and Solids analysis in Physio-Chemical and Microbiological parameters as per BIS / Pollution Control Board standards. Operation & Maintenance Services: The Operation and Maintenance team provides Operation & Maintenance services for all Engineering products like Effluent treatment plant, Raw water treatment, Boilers, with compliance of design standards and statutory compliances. Consultancy Services: The Consultancy division of this company offers Consultancy services in Feasibility studies, Treat ability studies, Environmental impact assessments, Environment Management Plan, Risk analysis, Environmental audit, ISO 14000, etc. and obtaining Approval from Pollution Control Board / Ministry of Environment Forest. Currently Hubert Enviro Care Limited have constructed and is maintaining numbers of STPs, ETPs and RO plants for clients in and around Chennai and some of these plants have been

visited and we had hands on experience about the design, construction and operation of the plants. The following plants have been visited and the details are listed. 1. RO plant at Koyambedu Bus Stand, Chennai 2. STP and ETP at Cavin Kare Pvt Ltd in Guindy, Chennai 3.STP at Express Avenue. 4.STP and ETP at TIDC, Ambattur 5. STP at MIOT Hospital, Chennai.

2.1.RO PLANT AT CMBT LOCATION: The RO site that we visited is located in the Koyambedu CMBT. PURPOSE: To provide or supply drinking water in and around CMBT and nearby places. INTRODUCTION: Reverse osmosis is a process in which water is separated from dissolved salts in solution by filtering through a semi permeable membrane at a pressure greater than the osmotic pressure caused by the dissolved salts in the waste water. With existing membranes and equipment operating pressures vary from atmospheric to 1000 lbf/in2. Reverse Osmosis has the advantage of removing dissolved organics that are less selectively removed by other demineralisation techniques. The primary limitations of reverse osmosis are its high cost and the limited operating experience in the treatment of domestic waste waters. The basic components of a reverse osmosis unit are the membrane, a membrane support structure, a containing vessel and a high pressure pump. Cellulose acetate and nylon have been used as membrane materials. Four types of membrane support configurations have been used: spiral wound, tubular and hollow fibre configurations. The spiral wound configuration is the most successful for use with water/domestic wastewater effluents. Reverse osmosis units can be arranged either in parallel to provide adequate hydraulic capacity or in series to effect the desired degree of demineralisation.

A very high quality feed is required for efficient operation of a reverse osmosis unit. Membrane elements in the reverse osmosis unit can be fouled by colloidal matter in the feed stream. Pretreatment of a secondary treated water by chemical clarification and multimedia filtration and ultrafiltration is usually necessary. Also, the removal of iron and manganese is sometimes necessary to decrease scaling potential. The pH of the feed should be adjusted to a range of 4.0-7.5 to inhibit scale formation. Regular chemical cleaning of the membrane elements(about once a month) is necessary to restore the membrane flux.

UNITS AND PROCESSES INVOLVED IN THE RO PLANT AT CMBT AND THEIR PURPOSES: RAW WATER COLLECTION TANK: The raw water is collected through borewells and stored in the collection tank. IRON REMOVING FILTER: The ground water contains high content of iron. Removal of iron is necessary to decrease the scaling potential. DUAL MEDIA FILTER: A sand-anthracite filter or dual media filter or multimedia filter is primarily used for the removal of turbidity and suspended solids. Dual media filters provide very efficient particle removal under the conditions of high filtration rate. Inside a sand-anthracite filter is a layered bed of filter media. Filter size is upto 10-20 microns. ANTISCALANT DOSING TANK AND ACID DOSING TANK: Antiscalants are proprietary mixtures of various molecular weight polycarboxylates and polyacrylates. Antiscaling agents are added inorder to prevent scales formation in the operating vessel. Acid is added for pH correction. Hydrochloric acid (HCl) and acetic acid can be used. But HCl is avoided now. CARTRIDGE FILTER:

Cartridge filters are preferable for systems with contaminations lower than 100 ppm, that is to say with contamination levels lower than 0.01% in weight. Cartridge filter can be surface or depth-type filter: depth-type filters capture particles and contaminant through the total thickness of the medium, while in surface filters (that are usually made of thin materials like papers, woven wire, cloths) particles are blocked on the surface of the filter.

2.2 SEWAGE TREATMENT PLANT (STP) AND EFFLUENT TREATMENT PLANT (ETP) AT CAVIN CARE 2.2.1. Location Sewage Treatment plant and Effluent treatment plant are located in Cavin Kare Pvt Ltd with a capacity of 100 m3/ day. Cavin Kare Pvt Ltd is a food processing industry which is located in the heart of Chennai. The sewage waste from canteen and bathrooms and effluent waste from the industry including chemical waste from Labs has to be treated. For the purpose of treating this sewage and effluent waste a separate sewage treatment plant and an effluent treatment plant have been installed. The function of the STP is to treat collectively the waste from the Canteen, toilets, water closets, sinks, showers and other sanitary and kitchen fitments and ETP is installed to treat the waste from chemical labs. The treated water from the plants is used for gardening purposes. 2.2.2. Components and Functions of STP The parts of the STP are,

2.2.2.1. Anaerobic Chamber Raw wastewater is initially received into the anaerobic chamber. Approximately 30 - 50% of the suspended solids settle out in this chamber where they undergo anaerobic digestion. The anaerobic digestion process is carried out by microorganisms which have the ability to feed, grow and multiply in the absence of free oxygen. In addition, settled sludge and skimmed material returned from the clarification chamber are further digested in this chamber. The plant is sized to enable these microorganisms to maintain a sufficient population naturally without the need for the addition of proprietary biological products. 2.2.2.2. Aerobic Chamber

The partially treated wastewater, still containing the colloidal and dissolved solids which represent approximately 65% of the pollution loading, flows from the anaerobic chamber to the aerobic chamber. Air is introduced to the liquid in this chamber by means of a compressor and diffusers, maintaining aerobic (free dissolved oxygen) conditions. The oxygen enriched effluent flows about packs of submerged media having a large surface area on which bacteria and other microorganisms thrive, forming a biological film. These microorganisms have a different growth process to those in the anaerobic chamber in that they utilise the dissolved oxygen in the effluent, while consuming the dissolved and colloidal organic matter as food to create new cell growth and stable oxidised products. The air pattern causes the liquid in the chamber to pass through the media in a discreet flow pattern and to have intimate contact with the microorganisms. The process differs from ordinary suspended growth systems in that it is more stable and also allows the growth of sub-surface anaerobic microorganisms beneath the surface film of aerobic microorganisms. This allows anaerobic bacterial action to check the media growth, thereby reducing the biological sludge accumulation. Nevertheless, as the thickening of material on the media occurs, some sloughing off will take place. The multiple compartment design of the aerobic chamber ensures that no short-circuiting can occur, preventing the possibility of partially treated wastewater passing to the clarification chamber. The diffused aeration system allows the air to be introduced below the media packs. Basically the reaction in the aerobic chamber converts the dissolved and non-settle able (colloidal) solids into carbon dioxide and a biological floc, which, under quiescent conditions, will settle.

2.2.2.3. Clarification Chamber Following aeration, effluent flows into a circular hopper bottomed clarification chamber, where the biological floc (or sludge) settles under quiescent conditions. Settled sludge from the bottom of the chamber and floating material are returned to the anaerobic chamber. From the clarification chamber, the effluent is drawn off below surface level and flows through the chlorinator to the disinfection chamber. This continuous return of sludge to the anaerobic chamber ensures continuous fluid movement in the plant even with zero inflow and keeps the system "live" during periods of extended vacancy

2.2.2.4. Disinfection Chamber The discharge from the clarification chamber passes through an automatic gravity chlorinator. The chlorinator is calibrated for above normal water usage. Chlorine stocks are provided to cover maximum usage with built in safety factors to cover all foreseeable circumstances between the service periods. The disinfection chamber is designed to provide a minimum of 30 minutes contact time between the effluent and chlorine to ensure achievement of bacterial die-off

2.2.2.5. Pumpout Chamber After disinfection, the treated effluent enters the pumpout chamber. The submersible pump in this chamber is automatically controlled by a level switch to operate and shut down as the level of the effluent rises and falls.

2.2.2.6 Filter Beds

2.2.2.7 Sludge Drying Beds Sludge drying beds are used to dewater sludge. It can handle sludge quantity of 1080 lit. After drying, sludge is removed and used as a soil conditioner.

2.2.3. Components and Functions of ETP There are several components in ETP. i.e 1.Collection tank 2.Flash Mixer(Naocl,Alum) 3.chlorine contact tank 4.Activated carbon Filter 5.Pressure sand filter 6.Sludge Drying beds 2.3. STP AT EXPRESS AVENUE: There are two STP units at Express avenue TANKS Collection tank Aeration tank Clarisettler tank Sludge holding tank Soft water tank Filter feed tank Softener feed tank STP 1 44 90 44 39 112 45 112 STP 2 51 53 24 24 75 27 75

2.4 STP & ETP AT TIDC, AMBATTUR: Location: Ambattur Plant visited: ETP, STP INTRODUCTION: TIDC, located at ambattur is the unit for the manufacturing of metal chains used in automobiles. PRODUCTS MANUFACTURED: Metal chains used in vehicles GENERATION OF WASTES: There are both effluent treatment plants & sewage treatment plants preset in TIDC industry, Ambattur. The effluent treatment plant is developed to treat the effluent released from the manufacturing of metal chains for automobiles. The effluent generated are Caustic Soda, Soda ash, emery sand wastes. The Sewage treatment plant is for biological treatment of wastewater from canteens, restrooms, etc. SEWAGE TREATMENT PLANT: STP unit consists of a collection tank, upflow anaerobic sludge blanket reactor, aeration tank, clarifier and sludge drying bed.

Collection tank:

The collection tank is of the capacity of 35.85 m3. It consists of wastewater from canteens, restrooms etc. The wastewater is pumped into the collection tank by means of a pump. Upflow anaerobic sludge blanket reactor:

In the upflow anaerobic sludge blanket (UASB) process, the wastewater to be treated is introduced in the bottom of the reactor. The wastewater flows upward through a sludge blanket composed of biologically formed granules. Treatment occurs as the wastewater comes in contact with the granules. The gases produced under anaerobic conditions cause internal circulation, which helps in formation and maintenance of the biological granules. The capacity of

upflow

anaerobic

sludge

blanket

reactor

is

49500

lit.

Aeration Tank: The water from UASB reactor flows into the aeration tank of volume 122500 lit, in which an aerobic bacterial culture is maintained in suspension. The wastewater is aerated by means of diffused air aeration system, consisting of blowers. The reactor contents are referred to as Mixed Liquor. The conversion is as follows, COHNS + O2 + nutrients
(organic matter) bacteria

CO2 + NH3 + C5H7NO2 + other end products

(new bacterial cells)