DECLARATION

I have been working my internship experience in A.P.F (Addis Pharmaceutical Factory)

from March, 20/ 2018 to June15, 2019 under the guidance of instructor Brhane(Faculty
mentor) and Mr. Dawit Alem ( Company Advisor).During this internship I have gained
many interesting and useful knowledge including the chemical applications, processes
and control techniques used in the factory.

Approval of the mentor; _____________________

Name of the mentor: _________________________

Signature: __________________

Date of approval: ______________

ACKNOWLEDGMENTS

First and for most, I want to acknowledge the Almighty God for his infinite mercies
without him everything have achieved would be impossible. I would like to give a great
respect and appreciation to the institution for providing these precious opportunities that
enable me familiar with practical skill and us sincerely greatful to my advisor instructor
Brhane for his fruit full advice and encouragement shown in the course to do this project.
In addition I would like to express my gratitude thanks to my supervisor Dawit Alem for
his valuable advice, guidance and encouragement to do this project. Finally I would like
also to express my deepest gratitude to all those A.P.F employees especially for Ato
Akalu Gebre who had helped and given me emotional and motivation to do this project.
Executive Summery

This report& project contains historical background about APF and the various unit
operations and their operating mechanism that performed in APF. This report& project
also contains the challenges that I have faced during designing my report as well as
project, and how I overcome them. I have gained many things in terms of improving my
practical skills, and in terms of upgrading my theoretical knowledge during designing
report and project. And at last it contains recommendation to the company from myself
have seen during performing my report & projection the company.
List of acronyms

APF=Addis pharmaceutical factory

WWT=waste water treatment

HVAC=heating ventilation and air conditioning

GM=General Manager

PC=Product control

QCM=Quality control management

PM=Production manager

HRM=Human resource management

FM=Finance management

MP=Material planning

WHM=Ware house management

MED=Maintenance engineering department

PLC=Private limit company

UIL=University industrial linkage

UIC = University industrial company

AHU= Air handling unit

 PART-1 REPORT

CHAPTER-ONE

INTRODUCTION

1.1 Background

Addis pharmaceutical factory (APF) is one of the greatest pharmaceutical factories in

Ethiopia which is produce many groups of qualified groups’ medicines like syrups, vials,
wet tablets, dry tablets, ointments, ampoules etc. Addis pharmaceutical factory (APF)
was established in 1992 to manufacture medicines with working capacity of 300 million
birr, for the purpose of worldwide market achievement through the port of MASSAWA,
though now this cannot achieve. Despite a gloomy picture of poverty and poor health
services in the country APF plc. is the largest pharmaceutical manufacturing company.
Head quartered at Adigrat town Tigray regional state of Ethiopia which is found 898km
away from Addis Ababa in the direction of north Ethiopia. This town is 2300 meters
above sea level. There is appositive sign or good prospect from government side to the
sector to improve the health situation including pharmaceutical industry such as
government builds health services and health educational institutions and encourages
private investors to involve in the sector by providing different incentives. There are
eleven (11) pharmaceutical factories and have their market share about 30% share of
local market is taken by Addis pharmaceutical factory (APF). Currently APF has been
operating at about 50% production capacity. The plant was constructed and equipped
with high technical production facilities.Why Addis Pharmaceutical factory planted in
Adigrat because?

Air condition of Adigrat is smooth to the Pharmacies (medicines).

Import of raw material to Ethiopia by the Eritrea (red sea) in the short period of time.

The water of Adigrat is comfortable to produce the medicines.

 Some plants are existed in adigrat and in its surroundings for Preparation of different
drugs. E.g endod plant,

1.2 Mission of ADDIS Pharmaceutical Factory (PLC)

 To satisfy customers’ needs by providing quality and effective medicine at afford

able price.
 Generate profit and maximize the wealth of effort endowment in partnership with
other development actors and actively participating in Economic activities that
ensure regional and national development.

1.3 Vision of the company

 To be at a fore front of a Pharmaceutical business in Ethiopia and east Africa.

 Contribute to fight against different diseases with in sufficient supply of
pharmaceutical products in Ethiopia.
 The vision of efforts investment center is to be an exemplary corporate citizen,
able to continually and successfully compete in the global market involved in
sustainable and progressive development.

1.4 Objective of the company

 APF is to facilitate exchange of information and networking among post graduate

students and academics for further research collaboration and networking.
 APF typically features they note academic and industry leaders in hospitality and
tourism as well as referred paper and poster presentation by form participants.

1.5. Raw materials and inputs to the company

The following are the main raw materials mainly used in Adigrat pharmaceutical factory
Plc. for the production of different types of medicine .The different raw materials that are
important for the plant operation are imported from different country. The following table
generalizes the name of different raw materials, the country where they are imported and
the code of imported country from the plant center.
Table 1 Raw material of the company and their imported country

S.N Code of raw material Name of raw material Import country

1 RM 08004 Aerosil

2 RM 08012 Avicel PH 102

3 RM 08085 Dried starch

4 RM 08001 Ethanol

5 RM 01086 Ibuprofen

6 RM 01017 Lactose monohydrate

7 RM 08009 Magnesium stearate

8 RM 01024 Povidine K-30

9 RM 08015 Sodium starch

10 RM 08017

1.6. Main products of the company

 The company has been manufacturing more than 91 high quality pharmaceutical
products of different paretic categories including antibiotics gastro intestinal,
central nervous system drugs, cardio vascular drugs, antibiotic agents. Addis
pharmaceutical factory produces safe, effective and quality drugs and has an
annual production capacity of 1.2 billion tablets, 19 billion ampoule, 10 million
vials, 500,000 capsules, 4million ointment tubes and 9.6 million bottles of syrup.
The company has more than nine production lines and fully equipped laboratories
as well as the capacity to produce tablets, capsules, syrups or suspension, dry
powder for reconstitution, injection vial liquids, injection ampoule, creams and
 ointments. The efficiency the high technical machineries and skilled man power
play important role to the production capacity.
 All type of operation required for the manufacture of Tablets, Capsules, Vials,
Ampoules, Syrups/Suspensions & Ointments for Human use are manufactured
utilizing nine dedicated lines on campaign basis with one product at a time on one
line. The AHU is totally independent of each other to avoid cross contamination.
 Manufacturing processes, raw materials & finished products warehouse and
personnel entry for B-Lactam products is completely segregated with concrete
blocks. Air Handling Units for B-Lactam lines are also exclusively dedicated.
Production of solid dosage forms was started in March 1997. Products are freely
marketed in Ethiopia.
 Installed capacity of the company per year on single shift basis is as following:

- Tablets 650 Million - General Capsules 195 Million

- Ampoules 3 Million - Syrups /Suspensions 1.5 Million

- B-Lac Capsules 65 Million - B-Lactam Vials 5 Million

- Creams/Ointments 2.0 Million

 In line with the company’s policy and to address current public health
challenges, the plant utilization is directed towards enhanced productivity
inclusive of ARVs and latest anti-malarial drugs.

1.7 Main customers of the end users of its products or services of the company

APF is constantly introducing new products following to customer interest’s product

varieties now reached to 91.The factory is now implementing intensive market
penetration with avoidable presses. The distribution is done through domestic
wholesalers, institution buyers and different sales and distribution; Mekelle, Hawassa and
BahirDar. APF productsdistinctive competence of the local pharmaceutical market in the
short future through impact substitution, variety and availability. APF has devoted a
strong commitment to give the highest value to the professional competence and high
caliber presently the manpower mix includes different professionals in all departments
working for value adding and knowledge transfer.

1.8 Number of Workers and their department In APF

The company has a total of 1200 workers from these coverage is increasing through time.

Table 2, No of workers in APF

No Grade No of workers

1 6-8th 28

2 9-10th 190

3 Tvt 62

4 Diploma 120

5 Degree 80

6 Masters and above 6

7 Permanent 560

8 Temporary 150

9 Engineering 4

Total 1200
1.9 Technology and machinery of the company

A. Chemical lab

Frontline ultrasonic cleaner

Water bath

Heater (ceramic plate)

Friability apparatus

M P apparatus

Cyclone mixer

B. Instrumental room

Magnetic stirrer

B O D incubator

Packing conveyor

Refrigerator

Conductivity meter

pH meter

U V spectrometer

Digital disintegration test apparatus

Digital dissolution test apparatus

M V titrate

Polari meter apparatus

Antibiotic zone reader

 Karl Fischer titration

Digital colony

C. Media preparation room

Membrane filters (0.45 mu m.)

Autoclave

Incubator

Vacuum oven

Hot air oven

Coating pan

Fluid bed dryers

D. Sterility chamber

.Leak test of blister, strip & bottles by vacuum

Fritz mill

Sifter

1.10 Main Challenges we have been facing while performing our work task

We have faced some challenges at our working time and place. Some of them are:

 Every factory is designed and erected with cooperation of many engineering

fields like Electrical Engineering, MechanicaEngineering and other Engineering
and related fields, so collecting of data for doing a project is very difficult.
 Bad air condition at that working place
  Lack of information about any design by the Engineers. That means most of the
Engineers thought the company cannot understand and design something as an
engineer but live only to operate the task ordered by the foreigners.
 Unable to get an intended data’s at the intended time
 Misinformation and unwilling to share experiences in some workers
 Unable to get written literatures, books and helpful materials on time
 Absence of internet connection to read literatures.

N.B : The specific problem I have been observed in the company is that Wastage of
powder during capsule filling..

The Measures that have taken in order to overcome these challenges

o In every activity of my internship work and walk of life there were lots of
problems that I should solve and take measures against them. In this practice I had
experienced many problem solving mechanisms and I got strength when I faced a
problem. Some of the measures I took when I came across with expected
problems are as follows:
o I prepare time schedule to follow good progress.
o I made smooth relationship with some persons who have computer access.
o I read more references in order to get acceptable information regarding my
project.
o I goes to wet mixing section every time when necessary even if there is no car.
o I passed it by saying regardless of economy is nothing?
o I gave information about internship program to the company worker who may
concern.
 CHAPTER TWO

OVERALL INTERNSHIP EXPRIENCES

2.1 Why do you select the company?

We select the company because it is near our family’s placement and it also highly
related to our courses. Like chemical and physical process.

2.2 Section of the company that we have worked in and why?

We have seen worked in utility section such as:

 Water and west water treatment sections

 Steam boiler and condenser
 Cooling tower gas compressor
 In the production line

Specific section that we worked in is the reason behind that we have seen utility section
only is that the company workers can’t permit to see the production line.

2.3 Overall Internship Benefits

As the purpose and aim of this industrial internship for the student has a big value in
terms of different field of practical application and others what he is going to get when
he/she is graduated after some year staying in campus then this industrial internship make
the next life of the student easy. Therefore, there some benefits that a student can get
from an industrial internship. And some benefits we got from this internship are:

2.3.1 In Terms Of Improving Practical Skill

Needs experience,flexibility and other different skills. From the internship we have been
working in, we gained the skills how, when, with whom, and in what condition should to
solve the practical problems.

2.3.2 In Terms Of Upgrading Theoretical Knowledge

We have learnt how to visualize my theoretical knowledge, how to relate it with the
practical work of the department should exercise and advantages of the courses in solving
the problems of the company. We were upgrade different things like:

 I had known the effect of maintenance on product quality, service life of the
machine, operator’s safety and productivity.
 Know practically the cause of loss of production due to problem of material
handling.
 Observe how they handle material in each production steps.
 Understanding the obligation and responsibilities of all section of the company.
I.e. the way the organizational goal is achieved.
 Understand motivation methodology to be used for the company workers to
increase the productivity like
 Scaling up workers position based on their performance. Giving learning
opportunity and other responsibilities.

2.3.3 In terms of improving interpersonal communication skills

To develop the communication skills we strive a lot and try to communicate with
operators, day laborers, engineers, and top level managers and hence, we find our self-
good enough in personal interactions. This makes we have a wide knowledge and can
easily communicate with their relatives about the different problems occurred and try to
solve it together.

2.3.4 In terms of improving industrial problem solving capability

We have learnt how to found problem areas, how to get problems how to select specific
problems and how to solve each problem in every systematic way.

2.3.5 In terms of improving team playing skills

The role of team playing is the basic one for productions process of the company in order
to produce the expected product. Having good team playing work in the company can
lead to increase production and productivity of the company as well as improve good
quality of production. I had improved my ability to perform within group how to work
together with other persons peacefully as well as to generate new ideas by discussing
With in groups any, and we have observed that which course in what process

2.3.6 In terms of improving leadership Skills

To be a leader, anyone should participate in every task of the related jobs and there must
be team in the work place of different section or department and the group leader is well
trained in the job by education or practical knowledge. So being a leader is taking the risk
of the job that is done by the group members of the department. Then the place or
position of being a leader has a great responsibility in the work so being leader is being
responsible to each work.

From all these we learnt

 leading the work

 solving the problems faced
 Handling the employees

2.3.7 In terms of understanding about work ethics related issues

As we all know work ethics is the most needed criteria in every work place that
everybody should have in all his/her job activities that he/she gave to the society by
respecting the rules and obligations. We have been guided and obeyed by the rule and
regulation of the company. Some of the work ethics include or to develop strong work
ethics you should:

 smooth relation with partners

 Focus primarily on work related issues.
 Respect what others contribute to the work environment
 Accountable and Responsible
 Being confident and self-motivated to do the tasks responsibly
 Punctuality
 Responsibility
 Transparency
 Honesty
  Loyalty
 Integrity.etc

In general we have gained the advantages of ethical issues in work and we have learnt
how to select that, which ethical issues should participate in what work, and how to
develop and how to fulfill thus ethical issues.

2.3.8 In Terms Of Entrepreneurship Skills

The word entrepreneurship is define as a process of creating new things with value by
devoting the necessary time and effort, assuming the accompanying financial, physic, and
social risk, and receiving the resulting rewards of monetary and personal satisfaction and
independence. Emphasizing the growth of entrepreneurship would not only lead to a new
robust industry of its own but also it is a basis for improving the social and economic
capability of the country. We had a wide range of entrepreneur skills from above skills
including personal traits and management skills. The ability to manage time and people
(both our self and others) successfully.

 The ability to work both as part of a team and independently.

 Able to plan, coordinate and organized effectively.
 How to improve self-motivation and discipline.
 CHAPTER THREE

PROCESS DESCRIPTION

3.1 Overall organization and work flow

The organizational structure of the plant under the plant manager has seven department
managers namely QCM, PM, MED, HRM, FM, MP, and WHM. The plant has four
division in MED, FM and QCM three division in PM and HRM, two division in MP and
WHM. The organizational structure of the plant is depicted as shown in fig below .In
Addis Ababa the suppsitive service department are stationed when performs mainly
marketing and procurement activities. The company APF facilities its work by dividing it
an activity in to different departments each department has its own role to improve the
productivity of the company the work flow of each department is as follows:

Figure 1General organization structure of APF

3.2 Management structure of the company

Production head manager – section manager – The section manager told to the workers
that work on the raw material storage to prepare enough raw materials on the quarantine
area. Then the workers in y-con mixer will be received the raw material and the mix the
powders and send to capsule filing machine. These workers fill the empty capsule by
machine and they send to inspection area. These also inspect by liquid pharaphine. These
also send to blistering machine then it will be cut in to pieces and to storage room

3.2.1 Quality control techniques the factory

The quality control department of the PC pharmaceutical comprises coordinated activities

for quality control of all the entered and raw materials and the manufacturing process
until the production of final product with specified shelf life in appropriate storage
conditions Quality control is consisted of several coordinated activities:

3.2.2 Control of the raw materials, contact and secondary packaging

The control of the active pharmaceutical ingredients, the other compounds and the
contact packaging includes activities for control of their physical and chemical properties
and microbiological characteristics in accordance with the European and international
recognized standards. The secondary packaging should provide sufficient and
understandable information to the medical personnel and patients. These activities are
performed used modern validated instruments and technologies such as: infrared
spectroscopy with narrow Identification area for each container of incoming raw material,
total organic carbon in the water as a medium for pharmaceutical production, gas
chromatography, automatic titration measuring device.

3.2.3 Control of the phase production and control of final products

The products are motored in all the phases of their manufacturing with all their specifics
by phase until the final product is delivering. The activities are performed by employing
modern validated instruments such as high performance liquid chromatography, spectra
photometers connected in inline to dissolution equipment.
3.2.4 Microbiological Control

This is controlling part operates with in the new microbiological laboratory constructed in
compliance with the mast sophisticated CGMP norms. As the part of the biological tests,
the test for absence of bacterial and toxin are performed by modern kinetics turbid metric
methods onto the enter raw materials and the finished product that are specific for sterile
production.

3.2.5 Stability of the Pharmaceutical Finished Products

Samples from the commercially produced batches are stored in special stability rooms in
conditions that simulate the worst case of outdoor conditions at which the products are
exposed during their life cycle until the declared expire date.

3.2.6 Validation activities and monitoring

In the frames of the GMP operation, the following analyses are implementer to:
validation the analytically methods, validation of water systems, compressed air, system,
cleanness of equipment’s.

3.3 Process description of utility

3.3.1 Water treatment plant

This plant is designed to satisfy (produce) the requirement necessary to pharmaceutical

production. Water treatment is carried out with several passages. Water treatment is to
demonstrate the need for treatment of surface.

Water and some ground waters for drinking purposes.

o To introduce the concept of the multiple principles and to describe the more
common and important key processes.
o To describe the function of each treatment process in treating drinking water.
o To describe the function of each treatment process in treating demineralizing
water.
In water treatment plant, the following procedure must be followed for design purpose

 Identifies the water type and amount of impurities available in the water to be
treated.
 Designed the process for the treatment of the identified water to obtain the
required specification.
 Design the equipment necessary for the above processes.

The following key point must be known before design:-

Size

type

Capacity

Mechanism (operation )

Corrosiveness

Control

Water treatment house provides treated water for the boiler and for the production area.

The whole treatment is composed of three processes are:

1) Pre- treatment

2) Potabilization

3) Demineralization

1. Pre- treatment

The raw water coming out from the wall is added with polyelectrolyte, hypochlorite and
coagulant in order to start the growth of floccules. The floccules are then separated from
the water in clarifier and then the water is pumped to couple of and filters.
2. Potabilization

From this basin the water is pumped in to a couple of active carbon filter, at this point the
water is considered to be drinkable. From this basin the water can be for firefighting
purposes, for potable water purpose (pumped) and added with last hypochlorite).

3. Demineralization

The potable water is then pumped and checked in a taste for residual chlorine presence. If
there is necessity of a dosing pump adds chlorine neutralizer in to the line. After the taste
the water arrives of the first cat ion tower with resins, then there is a degassing to tower
and finally to the resin, too. After leaving the tower the water flows through 30 mash
resin trap, to stop any possible resin drainage in to water flow, and then stored in two
containers one is for boiler house and pharmaceutical plant. The raw water that comes
from the underground is pumped by submersible pump. The submersible pump is
installed at 45 m underground connect through electrical cable. It is axial type with 38
impeller, power with electrical motor, upon the rotation of motor sucks the water is pump
it to top with power of 3.7 KW through pipe line that is connected with clarifier. The pipe
diameter is 6 inch and the pump is with the capacity of 3.7 KW power and rotation of
2830rpm.The raw water flow rate is 1.5 lit/sec the water is enter to clarifier.

General process description of water Treatment

1. Clarifier

In this area water comes from the city or the company reaches first portion of the
clarifier. Then the water passes through flow mater which indicates the total quantity of
water transferred in cubic meter be for the raw water, is entered to the first portion of the
clarifier sodium microorganisms. The storage capacity of the first portion is 10m3, in this
portion particles that have a density greater than water is settled, from the first portion of
the clarifier water is transferred to the second portion, then water travels from bottom to
top in the second portion where 30 special plastic filters are installed which are used for
collection of particles and pre filtration water from particles which go escaped for the
first portion, water is transpires to the top by gravity to the final storage tank, clarifier
where minimum and maximum sensor are installed for the detection of water level, for
the operator to transfer the water to sand filters by centrifugal pump.

Figure 2, Clarifier

When how water from to the tanker A. unit reaches to max level since it reaches (water)
above the level the water push to float valve at this time the valve closed to the line (pike)
the flow from tanker A to tanker B, tanker B conation filters so when the water is flow to
that tanker Aluminum sulphate water flow. The filtered water that comes from clarifier
inserted to sand Filter.

When how water from to the tanker A. unit reaches to max level since it reaches (water)
above the level the water push to float valve at this time the valve closed to the line (pike)
from tanker A to tanker B, tanker B conation filters so when the water is flow to that
tanker Aluminum sulphate water flow. The filtered water that comes from clarifier
inserted to sand Filter.
2. Sand filters

Water is transferred from the third portion of the clarifier to sand filters by centrifugal
pumps, the installed numbers of sand filter is 02 and the bed specification is fine sand
before coarse sand, and the water produce potable water, which is used for drinking,
washing an irrigation purposes, then after the water passed the sand fitter, it enters 180
m3 storage tanks.

Table 4 Sand filter arrangement

Material Size Layer thickness Quality

Grit 6-8mm 90mm 100mm

Grit 3-5mm 90mm 100mm

Grit 1-2mm 60mm 150mm

Sand 0.4-0.7mm 500mm 500mm

Back washing procedure of sand filter

Every 15 days sand filters are required to be back washed for minimum of 120 minutes
by pressurized water through using back wash pumps, by pneumatic valves the inlet
would become out let and vice versa for the out let, water should observed physically
takes almost 20 minutes stop the back wash and sand filters are again ready for regular
use. Operation of the control timer is explained sequentially as follows. Operation of the
control timer is explained sequentially as follows.

1) Back wash every two weeks.

2) Before start up, open the manual valves on the back washing line and back washing
pump.

3) Be sure that the back wash water does not enter in to any filter.
4) To start the back washing presses the button MAN for 5 second and then the button
cycle for 2 second on the control timer.

5) After 01 minutes, switch on the back wash pump manually

6) After 15 minutes, switch off the back wash pump.

7) The timer returns automatically on clock position 22 minutes after the start of back
wash cycle i.e. the back wash cycle lasts for 22 minutes.

8) After back washing close all back wash manual valves.

9) The filter is ready for next operation.

N.B Before the water flow into the tanker (180 m3) the dosing pump as sprayed the
hypochlorite solution molder to kill the bacteria growth

Figure 3 Sand filter

3) Carbon filters

The water stored in 180m3 storage tank has chlorine for anti-bacterial and anti –
microbial growth is pumped to carbon filters (carbon fitter A and B), chlorine, odors,
tests, sediments and volatile organic compounds is absorbed removed and precipitates
with active carbon resin and water free from chlorine is pumped to cat ion exchange.

Carbon filter Back wash and sterilized (steam)

Pumps which are used for back washing for sand filters are used for carbon filters, during
back washing inlet becomes out let becomes inlet through pneumatic valves installed on
the line, water from storage tank is pumped in carbon filter for minimum of 30 minutes
and water is inspected physically by collecting in a beaker, once clean water starts
flowing out pumps are switch “ off” and water present in the carbon filter vessel is
allowed to drain out, the drainage is done, steam is injected at a pressure of 8bars for one
hour, for the sterilization of carbon resins, this steam inlet valve is then closed and out let
valves is opened let steam escape, 10 minutes drying time to carbon filter resin is give
and the system is ready for normal operation sequence of operation is followed as such:

 Back wash and sterilize monthly

 To start back washing open the proper manual valves, switch on back wash
solenoid valves by switching on the switches the timer panel and theback wash
pump.
 Be sure that the back wash water does not enter in to any filter
 Be careful that “21/2”drain valve must be partially closed to avoid carbon fall
out
 Back wash for half an hour
 Switch off the pump, solenoid valves and close the manual back wash valves.
 Sterilize average one hour carbon filter with steam at 8 bars until the steam
condensate discharge from the top drain pipe
 Then close the steam supply and drain valves
 The filter is ready for next cycle
Figure 4. Carbon filter

Chlorine neutralization:

Meter collects the sample and checks a gains any chlorine content which is hazardous for
cation exchange before and after reading show the chlorine should i n best condition
should show 0.00 % and should always remain less than 0.01.If the chorine content is
more than 0.1 mg/lt.The setting point of the calorimeter which is 1% dosing pump for
anti injecting at 100% setting of the pump to cat ion exchange is free from chlorine. The
capacity of chlorine neutralize storage tanker is 1000 Lt.

4) Cation exchanger

After the calorimeter water passes through flow meter and enters into cation exchanger
from the top position. It has negatively charged resin which attracts positive charged
particles, present in water, thereby making the water free of p insoluble but caution is
solvable HCL is used for regeneration of caution exchanger. Quantity 650 Lt, color Light
brown code Amberjack 1200 Lt.Then the water filtered flow to Degasser.
5. Degasser-Operation

Water free from positive charged particles enters degasser from top and is sprinkled
where air is entering from bottom through blower this is done to escape any removing
gas.

6. Anion – Exchanger

Water leaving degasser enters anion exchanger where positively charged resin attracts all
negatively charged particles and leaving the water from all such particles charge (positive
or negative) and water becomes dematerialized. NaOH used for regeneration of anion
exchanger. Water leaving anion exchanger passes through 20 μfilter that filtrates size up
to 30 μF.

Table 5 Ion Exchange resins data

7. Mixed Bed Exchanger

These machines are composed of cat ion and anion exchanger together, but have
separation surface either anion or cat ion is on the top and one of them is on the bottom.
This is used to avoid the reaming minerals that are not avoid in the cat ion and anion
exchangers. In the case of mixed bed exchanger there is a polyamine in order to prevent
rusting,
Table 6Mixed beds of regeneration data
Figure 5 Process flow diagram of water treatment plant

3.3.2 Tankers:

There are two tankers in the outside of the water treatment room. Those are boiler tanker
and pharmaceutical tanker. The boiler tanker has a capacity of 8m3, demoralized water to
store. From this tanker water is goes diearter of the boiler by dosing poly amine with
concentration of 2% and the store adjustment is 60%. The capacity of dosing pump is
10Lt/hr. at 10bar in order to prevent the corrosion is the boiler. The pharmaceutical
tanker is also has a capacity of 10m3 of water to store, the water from this pharmaceutical
tanker is enter to mixed bed reactor .

3.3.3 Boiler House

Boiler is a closed vessel in which water or other fluid is heated. The fluid is does not
necessary boil. The heated or vaporized fluid exists the boiler for use in various process
or heating application including water heating central heating, boiler based power
generation, cooking and sanitation. The pure steam generator uses in industrial as heating
mean it has been project and built to satisfy the pharmaceutical industries. The total
capacity hold that inside shell of boiler body is 6476Lt.the steam generator is essentially
composed by,

 Level electrically controlled for minimum and maximum

 Demineralization water pump
 Safety valve, control pressure

The main components in order to produce steam are:

1. Dimineralized water

2. Furnace

3. Condensate

4. Air

As we know the dimineralized water comes from water treatment. And furnace comes
from the tanker that is found behind the boiler house. And the third one, condensate
returns to diaerator from the production.

The main purpose of boiler is:

 To convert water in to steam.

 It is used in steam generators for process steam.
 It is used in steam engines
 It is used in thermal power plant.
  Is to make high pressure steam

3.3.2.1 Furnace flow through the boiler

First furnace enters to the day tanker. Since, a day tanker contains a thermo state that is
heated to the furnace in order to decrease the viscosity after heated the furnace flow to the
burner. The burner is connected with front door .After enter the furnace to the day tanker,
pumped to the burner and enter to the mechanical pump then inserts to the thermostate to
reach maximum temperature (130°C) at this time the furnace becomes atomized. So,
when the furnace passes through the nozzle, the furnace passes through the filter hole.
Because it became highly atomize (pressurized at temperature 130°C.the fuel (spark) tube
are with inner circle tube for passage of fuel gases on the burner. There is a damper that
flow air into the boiler. The air reaches up to inside the boiler hole.When the motor that
found on the burner is start on as soon as the mechanical pump automatically state. At
this time absolve the furnace to the thermostatic.

Figure 6 boiler

As it is stated in the above figure, the combustion has three passages. First passage,
second passage, and third passage. First goes to ward and return back by second holes or
middle holes. And again goes forward by the other or third holes. By this process water in
changed to steam of2500c and 8 bars. This steam is used to produce hot water by shell
and tube mechanism to produce pure steam 121dc temperature and pressure of 3 bars.
Heat is transferred to the water through the tube wall and the fuel gas transfer to the water
almost 75 % on the second tube. Because, the first passage is starting to increase t
gradually.

Methods of Boiler performance test

1). Direct method (input –

2). Indirect method (Heat loss method)

1). Direct method

Where the energy gain of the working fluid (water and steam is compared with the
energy Content of the boiler fuel.

2. Indirect Method

In this method the efficiency is the difference between the losses and the energy input.

3.3.2.2 Flow of water in boiler

The water which enters to the boiler that comes from the diaretor. The diaretor tanker is
put outside of the boiler house and uses the steam heat exchanger. The diarator contains
demineralized water that comes from water treatment. Condensate,that returns from
production.

Separation: The water comes from diarator and pumped by centrifugal pumps type then it
inters in side of the boiler. Examples, if water level is down automatically, absolve the
water from the diaretor.

Heat transfer on boiler:The heat transfer or direction from fuel gas to water due to change
in Temperature (∆T).

Condensate pump

The pump uses to pressure the condensate water to the diarator by means of steam.
Operation: When the condensate water to the pump automatically push to the float valve,
then the valve float above the condensate water on the crank push(upward).then the
diaphragm . At this Time steam insert to the internal part of the pump, the steam by itself
with highly pressurized and pumped the condensate water through one way valve to the
diarator.

Steam is distributed to the following listed below.

Chiller plant

pharmaceutical process

Distillation plant

water treatment plant

Condensate pump

Hot water,heat exchanger and hot sanitary water.

Maintenance of boiler

o Check safety valve, properly closed and opened.

o compressed air filter
o Check de-mineralized water pumping.
o Check the filter of the furnace.
o Level is at very minimum (safety) level.
o Check the internal condensate pump

3.3.3 Compressor House

Compressor:-is a system of producing compressed cleaner air facilitates for the

production process. The Compressor air which produces in the house two atlas copco
machine one for working condition.One for standby. The compressor which inters to
check valve is from the moisture trap to drain process flow sheet as follow. There are two
types of compressor in addis pharmaceutical factory. They are grouped under screw
compressor. These are listed below.
1. RZ.Type is used for water cooling system

2.RT.Type is used for air cooling system.

Figure 7 process flow sheet compressor air

The compressed air is used for:

To open and close pneumatic valves

Cleaning of equipment’s machines

As air supplier to heating ventilation

3.3.4 Chiller House

A chiller is a machine that removes heat from a liquid via, a vapor compression or
absorption refrigeration cycle. This liquid can then be circulated through a heat
exchanger to cool air or equipment as required. As necessary by product, refrigeration
creates waster heat that must be exhausted to ambient or for greater efficiently recovered
for heating process. The chiller house contains the chiller which cools from 10.5to 5.5°C
the chilled water is designed only for HVAC system consumption .In the chiller there is
also the pump set to supply chilled water to HAVC heat exchanger as technical floor.
3.4 HVAC SYSTEM (Heating Ventilation and Air Conditioning System)

The plant (HAVAC) is designed to satisfy the segment necessary to Pharmaceutical

production area. The main objective of the area is in older to get the required
temperature, with the different area of production the plant designed to meet the required
asked for pharmatcall sterilized area and open area.The plant is designed to supply air
from atmosphere to sterilized area through the back filter. The back filter efficiency
98%.The humidity sense device is settled up to maximum relative humidity level of 45%
connected via electronic control to regulation valve on the coiling of the handing unit.
Humidity sensor is regulating the valve on the heating coil of air handling unit.

Filter:in HVAC fundamental components are that actually removes.

The air condition, air (out) from the production and inter the fresh air to production area
must be filtered. There are two types of filters.

1, back filter: - is disposal

2, pre filter:-can be washed to clean the dust collection in it.

When the air insert (pass) through the duct first goes to pre filtered then back filter.

Damper: These are component used to limit the air flow by closing and opening.

Heat Exchanger: Due to the variation of the environmental condition hot water and
chilled water is supplied through coils of pipe to humidity and regulate the temperature of
the air inlet according to specifications controlled.

Fans: The main components of HAVAC which is used to suck in to and out of the room.

3.5 Distillation plant

Distillation operations description: The pharmastical multiple effect stills produce

distilled water for inject able use which meets the requirement of the international
pharmacopeias.
The input of the plant are:

feed water

feed steam

cooling water

The output of the plant are:

distillate

discharge

1. feed water: The feed water is introduced at one point along the column shell. The
column is divided into on upper section and lower section and is immediately heated into
exchanger by the condensate of pure steam by the distillate coming from the last column.
Pressure must be at least two bars more than that of steam quality of feed water
dimineralized and filtered, free of amines, organic matters and silica.

2. Feed steam: The steam must be saturated dry free of oil and impurities which may
scale the exchanger surface, the pressure may be change from 3 to 8 bar. The point is
provided with a safety valve calibrated 9 bar. The steam enters the last column (shell
side) and heats the feed water tube. The feed water evaporates while the steam condenses
and further cools in the heat exchanger and drain as condensate.

3. Cooling water: The cooling water inters the column and further cools distillate which
is cooled and condensed by feed water,

-pressure of cooling water-2bar

-temperature of cooling water-inlet 15c to outlet 80c

-quality of cooling water-softened

Consumption of cooling water-depending on feed steam

4, Distillate: The distilled water is chemically and bacterially pure sterile. Starting with
softened water at 0F hardness it is possible to obtain a conductivity of 1 s/cm, with de-
ionized water the conductivity is normally 0.2-0.5 s/cm.The de-pacification is complete
and PH is near 7.The distilled water is produced at 97 oc atmospheric pressure. The high
quality of the distillate is obtained during the passage from liquid to vapor state per
Heater and final exchangers,

3.6 PROCESS DISCRPTION OF PRODUCTION

The company is manufacture two types of drugs those are lactam and non-bate lactam.

1. Beta lactam: - drug that have developing in the bond of raw material

2. Non beta lactam:-is a drug that has not developing in the bonds of raw material

The bettering is allergic sensitive to same percent due to this reason those product cannot
manifested next each another in order to avoid contamination. General the company has 9
lines of product.

3.6.1 Beta lactam line

3.6.1.1 Capsule line: - Capsule is solid formulation with the powder org ensued in a
gelatin shell. The shell which disintegrated after swallowing serves to mask the tastes of
the active.

Capsules are mostly antibiotics. The raw material products on of capsule are:

225 KG a amoxicillin trihydrate which is active ingredient

33.375 KG magnesium stearate which is in active in gradient

Te-tralin

Doxycycline 102= 92 KG

Caph

Metabolic magnesium stearate= 0.8 KG

Taic = 4.5 KG
Manufacturing capsule line has the following steps:

 Dispensing: Is weighting exact quantity of active and in active raw materials

from the store them in active raw materials lubricant to avoid sticking alidiont
(for proper flow).
 Blending: Is maxing the active and in active raw materials this is per formed in a
double cone until the mixture is uniform by rotating the Y-cone mixture.
 Caps filling: In this the empty caps rose by the pressure and inter to the segment
by the gravity pressure when separated the lower segment and segment and the
powder is filled to the lower segment cap. And reject the caps that are not opened
by any error through the pin and positive presser. Next the caps are closed by the
help of pin and positive pressure and next the powder in the segment in cleaned
by negative pressure.
 Inspection: Is takes place inspection machine the sated negative pressure identify
the underweight and avoid to prepared jar.
 Dudastering: Is to clean the powder on outside of the capsule and to retain the
capsule by pertain to have good for the patient.
 Blistering: First sheet plastic heated up to 130c in order to make mold by the size
of the capsule and increasing the temperate to 180c the mold plastic heated in
order to.
 Sale the plastic with the aluminum
 To write manufacturing date
 Transcribe Bach number using punch and after this the sailed product is chilled
by the chiller in order to avoid fractured. When pulled by the griper and cut by
the required size.

Figure 8 Process flow diagram of capsule line

3.6.1.2 Powder syrup line:-Syrups:-is liquid formulation to be administrated orally. In
addition to the active drug flavoring a gents are added to impart good taste they are sold
in 30- 640 ML bottles.

Syrup production has the following step.

 Drum mix: In this active one in active low materials filled in to drum and the
drum is rotated by electrical power in our to be uniform the mixture.
 Sieve: Is a process for making throughout uniform mixture.
 Double lone mix: Used to mix after in active material like sugar with prepared
mixture.
 Blowing Bottles: Is per from in filling machine the Blower Bottles are come by
the chain and enter to the filling dies by jeniva mechanism and the powered is
filled from the hoper and bottle gets out by other jenive mechanism in to the
chain.
 Capping: The filled Bottle takes cap by the help of jenive mechanism and the
coping process in per formed & get out of by Jenive into the champers.
 Leveling: In this the expire date manufacturing and Bach number are written and
the paper is level to the Bottle properly.

Raw material of syrup 125ml/bottle

- Potassium guaiacum suphonate - sodium benzoate

- Sugar orange oil - bottles 125ml

- Red color for ephedrine – caps

- Tartaric acid - leaflet

- Alcohol - labels to bottles

3.6.1.3 Vial line: - First the bottles are washed in the waling station by demy water and
clean in the cleaning station by using steam. In order to avoid the dusts and small
microorganisms such as bacteria that cannot see be our naked eye. Then, the bottles are
goes to filling station. In order to fill the powder, after that it transferred to coping station
to close by taking a cap. Finally, it moves to labeling room and packed in the pecking
area. The flow sheet of the process is as shown below.

Figure 9 process flow diagram of Vial line

N.B: This line is takes more safety than other lines. Because the medicines produce in
this line are takes by injection that means direct contact with our bloods. So the machine
room and the operators should be clean by demi water and steam in order to prevent
contamination. Be of this the process of this line difficult to see

3.4.2 Non beta lactam line

3.4.2.1 Tablet Line: -Tablets: - are solid from of the drug which, includes, antibiotics,
pain killers and vitamin. Their Weight ranges from 25 to 500 mg.

Tablets are manufactured by the following steps:

Pre pairing binder solution: - is uses Demy water sac rant & methyl proven

 Mixing: - The active and in active wet is in hoper mixer.

 Basket Granulator:- use to move ring type shape
 Drying (FD) ;-Fluid bed drier in this the filtered air is heated by means of heat
Exchanger with steam and the air pass through the basket granulated low material
and the air filtered moisture is obtained.
 Granulation: Grinding to obtain required size.
  Y-cone mixed: Is cone is to mix active and inactive like aerosol and peppermint
ail these row materials are enters in to Y-come by negative pressure and then the
Y-come mixer is rotated to obtained uniform mixer.
 Comprehension: Is to being the powder by completion Machine the powder is
lifted by the lifted by the lift and entered in to the Lie by gravity and their
compressed by the lower and upper punch. The power on the tablet is removed
by negative pressure.
 Coating: Some are full smooch to avoid this problem to pass the Drug to small in
Testing without dissolving in stomach coating solution is perspired and
colodialmias make uniform solution and coated the tablet by the coating
mechanize.

Figure 10, Process flow diagram of tablet line

Raw material of tablet

- Talk - povidone – glue

- Starch - magnesium - carton

-Parastamol - leaflet

3.6.2.2 Syrup Line

Weighting: The active and in active raw material are weighted in weighting machine and
also the sugar is crushed in the grinder machine.
Syrup preparation

In this room there are 7 tankers in the tanker 1 and tanker 2 sugar Solution would be
prepared ,then the sugar solution will be transferred by sugar filter in to tanker 3 and
tanker 4 in tanker 3 and tanker 4 the active and in active raw materials are mix together
with sugar solution . After that it goes to tanker 5 and tanker 6 but tanker 5 and tanker 6
are direct contact with filling machine .The remain tanker 7 is used for suspension.

Washing area: In this area bottles are washed to clean from any dusts. The bottles are

Firstly washed by potable water and dry by compressor; secondly it washed by demi
water and then dries by compressor. After that it goes to filling machine.

Filling area: In this area the prepared syrup solution that are collected in the tanker 5 and
Tanker 6 are filled in to the washed bottles that come from washing area, finally, it goes
to labeling area for same purpose as the dry suspension and then goes to packing area.

Figure 11Process flow diagram of syrup line

3.6.2.3 Ointment Line

First yellow soft paraffin and wool fat (lanolin) well melt in tanker, after that they will
enter to fat heating and melting vessel machine in this machine butyl hydroxynisale and
butyl acid hydroxyl toluene are added ,after you add you will melt them for 1⁄2 hour ,
then will be transferred to preparation tanker. In this tanker until it reaches 50 °C we send
cold water, but if it reaches 50°C we will add lechtamol. After that we close the cold
water and we will mix for 2 hours, then we will send to filling machine, finally we will be
send packing area.
Figure 12 Flow sheet of ointment line

3.7 Waste water treatment

Waste water treatment is one of the most important processes for the Addis
pharmaceutical Factory. Waste water is treated by this manner; first water does a lot of
functions in production and it returns back to primary pound. Then to secondary pound &
it goes in to the tertiary. Then To tertiary pound & later it recycles to the secondary
pound and the tertiary pound .After that by Purifying it in sand fitter it inserts in to first
carbon filter if lefts in to the secondary carbon filter & then for the fourth bound.

After this remove outside as waste.

Figure 13 Waste water treatment cycle in APF

1. Primary pound: - is physical process that non homogeneziable solids and

homogeneziable the remaining effluent.
2. Second ray pound: - is biological process that Remove most of the biological demount
for oxygen.

3. Territory pound: - is physical and biological and chemical than remove nutrients. Like
Phosphorus removes in orgasmic pollutants.

4. Sand filter: - Used to filter zed the waste water which is coming from the secondly
pond treated was the water through different type (size) of sand.

5. Carbon filter: - for the same fashion / procedure/ used to filter zed the waste water
which is coming from the Sand filter through the different size of carbon.

3.8 Material and Energy balance

According to the first law of thermodynamics, energy can neither be created nor
destroyed but it can be change from one to another form. From the first law of
thermodynamics for an open system at steady state has this form.

3.6.1. Energy balance on the boiler

INPUT = OUTPUT

Q – Ws = Δ H + Δ KE + Δ PE

Where:-ws= 0 (no moving part)

ΔPE= 0 (there is no change in length or very small)

ΔKE= 0 (b/c there is no movement or velocity

There for the equation will be reduced to

Q = ΔH, (ΔPE &ΔKE ̴ 0)

Then the energy balance in the boiler will be

Water in =4500 kg/hr. T=250°C & P=8bar

Industrial steam=4500kg/hr.
T=70°C Q = ΔH

ΔH = Ʃ mh – Ʃ mhfg

1 atm = 1.01325 bar ~ 1 bar and 1 atm = 100,000pascal

Then 8 bar = 0.8 Mpas

T = Tsat@ p of 8bar=170.43°c (the saturation temperature is obtained from the steam

table at a given pressure).

If

T<Tsat,,,,,,,,,,,,,,,,, it is compressed liquid.

T = Tsat @ p,,,,,,,,,,,,, it is saturated mixture.

T >Tsat,,,,,,,,,,,,,,,,, it is superheated mixture.

Then it is superheated mixture from the (A – 6) table we obtain the enthalpy is

h=2950kj/k,

And also at T° of 70°c saturated water will be: hfg=2335.3kj/kg

Therefore: Q= ΔH= Ʃ mh – Ʃ mhfg, but mass in=mass out

Q = ΔH = m Ʃ (h-hfg)

ΔH = 4500 kg»hr (2950-2335.3) kj/kg

ΔH = 4500kg/hr. (614.7) kj/kg

Therefore

ΔH=2766150kj/hr, but 1kj=1000j&1hr=3600s

Then,

ΔH= 2766150kj/hr*1000j/kj*1hr/3600s
ΔH=768.375 kW, but there is some heat losses

3.8.1 The energy balance on heat exchanger

This heat exchanger is a double pipe shell and tube heat exchanger is constructed from
stain less steel with k=15.1w/m°c, inner tube di=1.5cm,do=1.9cm and an outer diameter
is 3.2cm.hi=800w/m2°c on the inner surface of the tube ,ho=1200w/m2°c on the outer
surface . For fouling factor Rfi=0.0004m2 °c/w on the tube side and Rfo=0.0001m2 °c/w
on the shell side. With the length of the heat hanger is 1 meter.

Then find Q with the in let 15°c and 85°c on tube side.

First find R

R=1/UA=1/UiAi= Where Ai=πdiL= (0.015m) (1m) =0.0471m2

Ao=πdoL=3.14*0.019m*1m=0.059m2

1/UoAo=1/hiAi+Rfi/Ai+Ln (do/di)/2πkL+Rfo/Ao+1/Aoho

When insert the given value it gives

R= 0.0532°c/w

Then

Q=UiAiΔT=UoAoΔT

Let see on the inner side of the tube

Where Ui=1/RAi

Ui= (1/0.0532*0.0471) w/m2.c

Ui=399.1w/m2 oc

Then Q=UiAiΔT= (399.1*0.0532*70) W

Q=1.486Kw
3.8.2 Material balances

Material balance is apply based on the law of conservation of mass which states that any
matter can be neither created nor destroyed, but can be converted from one form to
another form.

The material balance equation will be:

input + generation– consumption = accumulation + out put

Where:-

Input = enters through the system boundaries.

Generation = produced with in the system.

Output = leaves through the system boundaries.

Consumption = consumed with in system.

Accumulation = build up with in the system.

The following rule is used to simplify the material balance equation:

If the balance quantity is total mass; generation = 0 and consumption =0, expect in
nuclear reactions.

If the balanced substance is nonreactive species:- generation = 0 and

Consumption =0.

For steady state process: - accumulation = zero.

Therefore, the material balance equation will be

Input = output

The material balance has used for:

 To calculate the unknown quantity.

  To know the performance of factory.
 Helps to minimize utility production coast.

Material balance is classified in to two types those are:

 Material balance with chemical reaction.

 Material balance without chemical reaction.

But all the material balance in the factory is without chemical reaction.

3.8.3.1 Material balance for the producation of capsules

Material balance in filling machine

packling

Input

F1=225Kg of Amoxicillin tri hydrate

F2=3.375kg of Magnesium striate

Material balance on double mixer

In the whole process of production of capsules there is no reaction and also the process is
steady state. So that equation will be:

Mass in = Mass out

0.995(F1+F2) = M1
0.995(225+3.375) kg =M1

M1= 227.23 kg

Material balance for filling machine

Mass in = Mass out

0.98(M1) = M2

0.98(227.23 kg) = M2

M2 = 222.68 kg

Material balance for inspection machine

Mass in = mass out

0.9725(M2) = M3

0.9725(222.68 kg) = M3

M3=216.55 kg

Material balance for the blistering machine

Mass in = Mass out

0.97(M3) = M4

0.97(216.55 kg) = M4

M4 = 210.05 kg

3.9 Environmental impact

Addis pharmaceutical factor (APF) has solid and liquid wastes which can pose potential
damage to the environment. Addition of extra material or increase in the concentration to
actual concentration creates the pollution which is direct contact with environment. Addis
pharmaceutical factory (APF) at the moment cannot install complete liquid waste
treatment system due to finical reasons. The industrial operation produces various types
of wastes. Which might have hazardous effect over a period of time to biological life?

 In APF(Addis pharmaceutical factory) the solid wastes can be

removing(removed)using,land filling,incineration methods, means that
incineration, burning solid waste Sanitary land filling (open dumping) throw out
the wastage to the green area especially for water soluble and hazardous solid
wastes. Aside far from a ground water sources should be selected.

The existing waste water treatment plant which treated by:

Primary

Secondary and

Tertiary bond uses sedimentation and neutralization process to minimize the chemical
content of the waste liquid.

The waste water plant which is coming from the production is treated at the territory
bond water treatment and then APF also directly uses to the green area which can effect
environmental protection. Addis pharmaceutical factory (APF) there is also degasser in
waste water treatment (WWT) which is used to remove gases which contain odors. Test
to the environment.APF which is removes the fuel gas (250°C) in boiler to the
environment and which can reduce the concentration of gases which is found on the
atmosphere then which can create the pollution or directly which can damage the
environment. In APF HVAC (air conditioning handling system) which can supply or
exhaust air to production and to the environment. The exhaust air to the atmosphere only
uses pre filter to purify the waste then goes to the atmosphere also create the pollution
also damage the environment. Generally, Addis pharmaceutical factory (APF) which can
cause pollution to the environment directly or indirectly due to the lake of chemical
engineer which is highly related to the controlling of waste water treatment control unit
operation, or environmental engineer which can control at any wastes (solid, liquid , or
gases ) also causes environmental protection.
Finally Addis pharmaceutically factor (APF) which contain many chemicals to convert
the raw material to the finished (final) product the waste removed also direct contact with
environment cause the pollution ( solid , liquid , etc. ).
UNIT FOUR PROJECT WORK ON THE COMPANY (APF)

4.1 Project title: Biological method of wastewater treatment

4.2 Introduction and background

First, waste-water is a combination of water and water carried wastes originating from homes,
commercial and industrial facilities, and institutions. The present study comprises a
comprehensive survey of the various methods and technologies currently used in waste-water
treatment, with emphasis on municipal wastewater. The wastewater discussed in this section is
predominantly of domestic origin. Varying amounts of industrial and laboratory wastewaters
can be collected and treated with the sanitary sewage. The primary purpose of the treatment of
sewage is to prevent the pollution of the receiving waters. Many techniques have been devised
to accomplish this aim for both small and large quantities of sewage. Untreated waste-water
generally contains high levels of organic material, numerous pathogenic micro- organisms, as
well as nutrients and toxic compounds. It thus entails environmental and health hazards, and,
consequently, must immediately be conveyed away from its generation sources and treated
appropriately before final disposal. The ultimate goal of wastewater management is the
protection of the environment in a manner commensurate with public health and socio-
economic concerns. Finally, Biological treatment processes are those that use microorganisms
and remove the nonsettleable colloidal solids and to stabilize the organic matter. There are
many alternative systems in use and each uses biological activity in different manners to
accomplish treatment. 4.3 Statement of the problem APF is one of one of the outstanding
manufactures different quantities of medicine products and from those products the company
mostly produce tablets, syrups and soon. For the Production of those products treated water is
mandatory. However, it countenances product decay in case of production areas due to the
following basis: Lack of treated water in both maintenance and production department. Due
to inconvenience of the workers. Generally, human sanitary wastes, sewerages, industrial
effluents are main causes of water pollution, and conventional methods for waste water
treatment are costly and technically advances. To produce effluent quality of the products the
water must be treated, then to treat the waste our study biological method of treatment is
important and by this method the water pollution will be removed and that human health will
be protected.
4.4 Objective of the study General objectives The general objective of this project is to treat the
waste water in order to protect the human’s health by removing the wastes as possible as, and
it is also used as energy sources and used as a fertilizer. Specific 0bjectives To reuse the waste
water for different purposes. To determine the physic-chemical parameters of waste water
before and after treatments. Removal of soluble organic matter. Stabilization of insoluble
organic matter. Transform or remove nutrients. Remove specific trans constituents. 4.5
Significance of the study As we know in our country treatment methods are traditional or we
can say that there is no treatment process, because the wastes are simply released to the
surfaces. Therefore, this project helps to improve the traditional treatment method to modern
methods. In addition to this it is significant on the following basis: To be Impact on surrounding
positive. Beneficial for agriculture, social, environment and economic sectors. Treatment
and recycling of waste water. Meet water demand without deteriorating the natural system.
4.5 Literature review

4.5.1 Introduction

Wastewater is the combination of liquid or water-carried wastes originating in the sanitary

conveniences of dwellings, commercial or industrial facilities and institutions, in addition to any
groundwater, surface water and storm water that may be present. Untreated waste-water
generally contains high levels of organic material, numerous pathogenic microorganisms, as well
as nutrients and toxic compounds. It thus entails environmental and health hazards, and,
consequently, must immediately be conveyed away from its generation sources and treated
appropriately before final disposal. The ultimate goal of wastewater management is the
protection of the environment in a manner commensurate with public health and socio-
economic concerns. Biological treatment processes are those that use microorganisms to
coagulate and remove the nonsettleable colloidal solids and to stabilize the organic matter.
There are many alternative systems in use and each uses biological activity in different manners
to accomplish treatment.

4.5.2 Nature of municipal waste-water

An understanding of the nature of waste-water is fundamental for the design of appropriate

waste- water treatment plants and the selection of effective treatment technologies. Waste-
water originates predominantly from water usage by residences and commercial and industrial
establishments, together with groundwater, surface water and storm water. Consequently,
wastewater flow fluctuates with variations in water usage, which is affected by a multitude of
factors including climate, community size, living standards, dependability and quality of water
supply, water conservation requirements or practices, and the extent of meter services, in
addition to the degree of industrialization, cost of water and supply pressure. Wide variations in
waste-water flow rates may thus be expected to occur within a community.

4.5.3 Wastewater treatment technologies

Physical, chemical and biological methods are used to remove contaminants from wastewater.
In order to achieve different levels of contaminant removal, individual waste-water treatment
procedures are combined into a variety of systems, classified as primary, secondary, and tertiary
waste-water treatment. More rigorous treatment of waste-water includes the removal of
specific contaminants as well as the removal and control of nutrients. Natural systems are also
used for the treatment of waste-water in land-based applications. Sludge resulting from
wastewater treatment operations is treated by various methods in order to reduce its water and
organic content and make it suitable for final disposal and reuse. This topic describes the various
conventional and advanced technologies in current use and explains how they are applied for
the effective treatment of municipal waste-water.

A. Waste-water treatment methods

As mentioned earlier, waste-water treatment methods are broadly classifiable into
physical, chemical and biological processes. Table below lists the unit operations
included within each category.
 Physical unit operation
 Screening flow
 Communion
 Flow equalization
 Sedimentation
 Flotation Granular-medium filtration
 Chemical unit operations
 Chemical precipitation
 Adsorption
 Disinfection
  Dechlorination
 Other chemical applications
 Biological unit operations
 Activated sludge process
 Aerated lagoon
 Trickling filter
 Rotating biological contactor
 Pond stabilization
 Anaerobic digestion
 Biological nutrient removal

Table 4.1 Waste-water treatment unit operations and processes

Among the first treatment methods used were physical unit operations, in which physical forces
are applied to remove contaminants. Today, they still form the basis of most process flow
systems for waste water treatment. This section briefly discusses the most commonly used
physical unit operations. (a) Screening The screening of waste-water, one of the oldest
treatment methods, removes gross pollutants from the waste stream to protect downstream
equipment from damage, avoid interference with plant operations and prevent objectionable
floating material from entering the primary settling tanks. Screening devices may consist of
parallel bars, rods or wires, grating, wire mesh, or perforated plates, to intercept large floating
or suspended material. The openings may be of any shape, but are generally circular or
rectangular. The material retained from the manual or mechanical cleaning of bar racks and
screens is referred to as “screenings”, and is either disposed of by burial or incineration, or
returned into the waste flow after grinding. (b) Communion Communutors are used to pulverize
large floating material in the waste flow. They are installed where the handling of screenings
would be impractical, generally between the grit chamber and the primary settling tanks. Their
use reduces odors, flies and unsightliness. A communutor may have either rotating or oscillating
cutters. Rotating-cutter communutors either engage a separate stationary screen alongside the
cutters, or a combined screen and cutter rotating together. A different type of communutor,
known as a barminutor, involves a combination of a bar screen and rotating cutters. (c) Flow
equalization Flow equalization is a technique used to improve the effectiveness of secondary
and advanced wastewater treatment processes by levelling out operation parameters such as
flow, pollutant levels and temperature over a period of time. Variations are damped until a
nearconstant flow rate is achieved, minimizing the downstream effects of these parameters.
Flow equalization may be applied at a number of locations within a waste-water treatment
plant, e.g. near the head end of the treatment works, prior to discharge into a water body, and
prior to advanced waste treatment operations. (d) Sedimentation Sedimentation, a fundamental
and widely used unit operation in waste-water treatment, involves the gravitational settling of
heavy particles suspended in a mixture. This process is used for the removal of grit, particulate
matter in the primary settling basin, biological floc in the activated sludge settling basin, and
chemical flow when the chemical coagulation process is used. Sedimentation takes place in a
settling tank, also referred to as a clarifier. (e) Flotation Flotation is a unit operation used to
remove solid or liquid particles from a liquid phase by introducing a fine gas, usually air bubbles.
The gas bubbles either adhere to the liquid or are trapped in the particle structure of the
suspended solids, raising the buoyant force of the combined particle and gas bubbles. Particles
that have a higher density than the liquid can thus be made to rise. In waste-water treatment,
flotation is used mainly to remove suspended matter and to concentrate biological sludge. The
chief advantage of flotation over sedimentation is that very small or light particles can be
removed more completely and in a shorter time. Once the particles have been floated to the
surface, they can be skimmed out. Flotation, as currently practiced in municipal waste-water
treatment, uses air exclusively as the floating agent. Furthermore, various chemical additives
can be introduced to enhance the removal process. (f) Granular medium filtration The filtration
of effluents from waste-water treatment processes is a relatively recent practice, but has come
to be widely used for the supplemental removal of suspended solids from waste-water effluents
of biological and chemical treatment processes, in addition to the removal of chemically
precipitated phosphorus. The complete filtration operation comprises two phases: filtration and
cleaning or backwashing. The waste-water to be filtered is passed through a filter bed consisting
of granular material (sand, anthracite and/or garnet), with or without added chemicals. Within
the filter bed, suspended solids contained in the waste-water are removed bymeans of a
complex process involving one or more removal mechanisms such as straining, interception,
impaction, sedimentation, flocculation and adsorption. The phenomena that occur during the
filtration phase are basically the same for all types of filters used for waste-water filtration. The
cleaning/backwashing phase differs, depending on whether the filter operation is continuous or
semi- continuous. In semi-continuous filtration, the filtering and cleaning operations occur
sequentially. 2. Chemical unit processes Chemical processes used in waste-water treatment are
designed to bring about some form of change by means of chemical reactions. They are always
used in conjunction with physical unit operations and biological processes. In general, chemical
unit processes have an inherent disadvantage compared to physical operations in that they are
additive processes. That is to say, there is usually a net increase in the dissolved constituents of
the waste-water. This can be a significant factor if the waste-water is to be reused. This section
discusses the main chemical unit processes, including chemical precipitation, adsorption,
disinfection, dechlorination and other applications. (a) Chemical precipitation Chemical
coagulation of raw waste-water before sedimentation promotes the flocculation of finely
divided solids into more readily settleable flocs, thereby enhancing the efficiency of suspended
solid, BOD5 and phosphorus removal as compared to plain sedimentation without coagulation.
The degree of clarification obtained depends on the quantity of chemicals used and the care
with which the process is controlled. (b) Adsorption with activated carbon Adsorption is the
process of collecting soluble substances within a solution on a suitable interface. In waste-water
treatment, adsorption with activated carbon a solid interface usually follows normal biological
treatment, and is aimed at removing a portion of the remaining dissolved organic matter.
Particulate matter present in the water may also be removed. Activated carbon is produced by
heating char to a high temperature and then activating it by exposure to anoxidizing gas at high
temperature. The gas develops a porous structure in the char and thus creates a large internal
surface area. (c) Disinfection Disinfection refers to the selective destruction of disease causing
micro-organisms. This process is important in waste-water treatment owing to the nature of
waste-water, which harbors a number of human enteric organisms that are associated with
various waterborne diseases. Commonly used means of disinfection include the following: I.
Physical agents such as heat and light; II. Mechanical means such as screening, sedimentation,
filtration, and so on; III. Radiation, mainly gamma rays; IV. Chemical agents including chlorine
and its compounds, bromine, iodine, ozone, phenol and Phenolic compounds, alcohols etc. (d)
Dechlorination Dechlorination is the removal of free and total combined chlorine residue from
chlorinated waste- water effluent before its reuse or discharge to receiving waters. Chlorine
compounds react with many organic compounds in the effluent to produce undesired toxic
compounds that cause long-term adverse impacts on the water environment and potentially
toxic effects on aquatic micro-organisms. Dechlorination may be brought about by the use of
activated carbon, or by the addition of a reducing agent such as sulfur dioxide (SO2), sodium
sulfite (Na2SO3) or sodium metabisulfite (Na2S2O5). It is important to note that dechlorination
will not remove toxic byproducts that have already been produced. 3. Biological unit processes
Biological unit processes are used to convert the finely divided and dissolved organic matter in
waste- water into flocculent settleable organic and inorganic solids. In these processes,
microorganisms, particularly bacteria, convert the colloidal and dissolved carbonaceous organic
matter into various gases and into cell tissue which is then removed in sedimentation tanks.
Biologicalprocesses are usually used in conjunction with physical and chemical processes, with
the main objective of reducing the organic content (measured as BOD, TOC or COD) and nutrient
content (notably nitrogen and phosphorus) of waste-water. Biological processes used for waste-
water treatment may be classified under five major headings: (a) Aerobic processes; (b) Anoxic
processes; (c) Anaerobic processes; (d) Combined processes; (e) Pond processes. These
processes are further subdivided, depending on whether the treatment takes place in a
suspended growth system an attached growths system or a combination of both. This section
will be concerned with the most commonly used biological processes, including trickling filters,
the activated sludge process, aerated lagoons, rotating biological contactors and stabilization
ponds. (A)Activated-sludge process The activated sludge process is an aerobic, continuous flow
system containing a mass of activated microorganisms that are capable of stabilizing organic
matter. The process consists of delivering clarified waste water, after primary settling, into an
aeration basin where it is mixed with an active mass of microorganisms, mainly bacteria and
protozoa, which aerobically degrade organic matter into carbon dioxide, water, new cells, and
other end products. The bacteria involved in activated sludge systems are primarily Gram
negative species, including carbon oxidizers, nitrogen oxidizers, floc formers and non-floc
formers, and aerobes and facultative anaerobes. The protozoa, for their part, include flagellates,
amoebas and ciliates. An aerobic environment is maintained in the basin by means of diffused
or mechanical aeration, which also serves to keep the contents of the reactor (or mixed liquor)
completely mixed. After a specific retention time, the mixed liquor passes into the secondary
clarifier, where the sludge is allowed to settle and a clarified effluent is produced for discharge.
The process recycles a portion of the settled sludge back to the aeration basin to maintain the
required activated sludge concentration. The process also intentionally wastes a portion of the
settled sludge to maintain the required solids retention time (SRT) for effective organic removal.
To achieve specific effluent goals for BOD, nitrogen and phosphorus, different adaptations and
modifications have been made to the basic activated Sludge design. Aerobic conditions,
nutrient-specific organisms (especially for phosphorus), recycle design and carbon dosing,
among others, have successfully allowed activated Sludge processes to achieve high treatment
efficiencies. A continuous, aerobic biological treatment for wastewater uses a culture of bacteria
suspended in the wastewater in aeration tank to adsorb, absorb and biodegrade (remove) the
organic pollutants. Flocs are formed that may reach 0.1 mm in diameter in the aeration tank.
These are kept in suspension either by air blown in to the bottom of the tank (diffusion air
system) or by mechanical aeration tank. The mixture of activated sludge and the wastewater in
the aeration tank is known as the mixed liquor. Fig 4.3 Activated sludge system of treatment
Process description Compressed air is continually diffused in to the sewage as it flows through
the aeration tank. This provides both a source of oxygen for the aerobic bacterial floc that forms
in the tank and in the turbulence necessarily to bring the waste and the bacteria in to contact.
Aerobic bacteria attack the dissolved and finely divided suspended solids not removed by
primary sedimentation. Some of the floc is removed with the sewage that flows out of the
aeration tank and carried into thesecondary settling tank. Here the floc settles to the bottom of
the tank, and is later pumped back into the aeration tank. (B) Aerated lagoons An aerated
lagoon is a basin between 1 and 4 meters in depth in which waste water is treated either on a
flow through basis or with solids recycling. The microbiology involved in this process is similar to
that of the activated sludge process. However, differences arise because the large surface area
of a lagoon may cause more temperature effects than are ordinarily encountered in
conventional activated sludge processes. Waste-water is oxygenated by surface, turbine or
diffused aeration. The turbulence created by aeration is used to keep the contents of the basin
in suspension. Depending on the retention time, aerated lagoon effluent contains approximately
one third to one half the incoming BOD value in the form of cellular mass. Most of these solids
must be removed in a settling basin before final effluent discharge. (C)Trickling filters The
trickling filter is the most commonly encountered aerobic attached growth biological treatment
process used for the removal of organic matter from waste-water. It consists of a bed of highly
permeable medium to which organisms are attached, forming a biological slime layer, and
through which waste water is percolated. The filter medium usually consists of rock or plastic
packing material. The organic material present in the waste-water is degraded by adsorption on
to the biological slime layer. In the outer portion of that layer, it is degraded by aerobic micro-
organisms. As the micro-organisms grow, the thickness of the slime layer increases and the
oxygen is depleted before it has penetrated the full depth of the slime layer. An anaerobic
environment is thus established near the surface of the filter medium. As the slime layer
increases in thickness, the organic matter is degraded before it reaches the micro-organisms
near the surface of the medium. Deprived of their external organic source of nourishment, these
micro-organisms die and are washed off by the flowing liquid. A new slime layer grows in their
place. This phenomenon is referred to as ‘sloughing’. After passing through the filter, the
treated liquid is collected in an underdrain system, together with any biopasses to a settling
tank where the solids are separated from the treated waste-water. A portion of the liquid
collected in the underdrain system or the settled effluent is recycled to dilute the strength of
the incoming waste-water and to maintain the biological slime layer in moist condition. The
attraction of the standard rate trickling filter are its low power cost and simplicity and with the
appropriate design and suitable biomass carrier material are reliable and needs little
maintenance. Fig.4.1 Wastewater treatment based on a trickling filter system Process
description Bar screens The raw influent first goes through a self-cleaning screen and then into
one end of a shallow and rather fast moving basin so that sand and gravel can settle out. Often
skimmers rotate around the surface of the basin to remove oils that may have been flushed into
the system. The screen removes coarse and floating solids from the sewage. The screen must be
cleaned regularly and the removed solids must be burned, ground and digested, or buried.
Many systems have a grinder known as a communutor used either with or instead of a bar
screen for grinding large particles which might clog the pumps. Grit chamberlogical solids that
have become detached from the medium. The collected liquid thenA chamber in which the
velocity of waste flow is reduced to a point where the denser sand and other grit will settle out,
but the organic solids will remain in suspension. The settled material is buried or used for fill.
Primary settling tank These are usually large tanks in which solids settle out of water by gravity.
Where the settleable solids are pumped away (as sludge), while oils float to the top and are
skimmed off. It operates by means of the velocity of flow is reduced to about 0.005 m so that
the suspended material (organic settleable solids) will settle out. Longer periods usually result in
depletion of dissolved oxygen and subsequent anaerobic conditions. Removal of suspended
solids ranges from 50–65 per cent, and a 30–40 per cent reduction of the five-day biochemical
oxygen demand (BOD) can be expected. Sludge digesters The sludge which settles in the
sedimentation basin is pumped to the sludge digesters where a temperature of 30–35ºC is
maintained. This is the optimum temperature for the anaerobic bacteria (bacteria that live in an
environment that does not contain oxygen). The usual length of digestion is 20–30 days but can
be much longer during winter months. Continual adding of raw sludge is necessary and only
well-digested sludge should be withdrawn, leaving some ripe sludge in the digester to
acclimatize the incoming raw sludge. Drying beds Digested sludge is placed on drying beds of
sand where the liquid may evaporate or drain into the soil. The dried sludge is a porous humus-
like cake which can be used as a fertilizer base. Trickling filters the liquid effluent from the
primary settling tank is passed to the secondary part of the system where aerobic
decomposition completes the stabilization. For this purpose, a trickling filter is used. A trickling
filter is a fixed bed, biological filter that operates under (mostly) aerobic conditions. Pre-settled
wastewater is ‘trickled’ or sprayed over the filter. As the water migrates through the pores of
the filter, organics are degraded by the biomass covering the filter material. The Trickling filter is
filled with a high specific surface area material such as rocks, gravel, shredded PVC bottles, or
special pre-formed filter-material. A material with a specific surface area between 30 and
900m2/m3 is desirable. The filter is usually 1–3 m deep but filters packed with lighter plastic
filling can be up to 12 m deep. Pre-treatment is essential to prevent clogging and to ensure
efficient treatment. The pre-treated wastewater is ‘trickled’ over the surface of the filter.
Organisms that grow in a thin bio-film over the surface of the media oxidize the organic load in
the wastewater to carbon dioxide and water while generating new biomass. Secondary settling
tank With the majority of the suspended material removed from the sewage, the liquid portion
flows over a weir at the surface of the secondary settling tank. Chlorination of the effluent from
the secondary settling tank takes place in accordance with state and local laws. Depending on
the location most laws require that a free available chlorine (FAC) residual (usually 0.2 mg/L) be
maintained after a 30-minute contact period. This contact period is obtained through the use of
chlorine contact chambers which are designed to provide a 30-minute detention time. From the
chlorine contact chamber the treated sewage is normally discharged into a receiving body of
water. (D) Completely mixed anaerobic digestion Anaerobic digestion involves the biological
conversion of organic and inorganic matter in the absence of molecular oxygen to a variety of
end products including methane and carbon dioxide. A consortium of anaerobic organisms work
together to degrade the organic sludge’s and wastes in three steps, consisting of hydrolysis of
high molecular mass compounds, acidogenesis and methanogenesis. Anaerobic digesters are
commonly used for the treatment of sludge and waste-waters with high organic content. The
disadvantages and advantages of a system of this kind, as compared to aerobic treatment, stem
directly from the slow growth rate of methanogenic bacteria. A slow growth rate requires a
relatively long retention time in the digester for adequate waste stabilization to occur; however,
that same slow growth means that only a small portion of the degradable organic matter is
synthesized into new cells. Another advantage of this type ofsystem is the production of
methane gas, which can be used as a fuel source, if produced in sufficient quantities.
Furthermore, the system produces a well stabilized sludge, which can be safely disposed of in a
sanitary landfill after drying or dewatering. On the other hand, the fact that high temperatures
are required for adequate treatment is a major drawback. (E) Biological nutrient removal
Nitrogen and phosphorus are the principal nutrients of concern in waste-water discharges.
Discharges containing nitrogen and phosphorus may accelerate the eutrophication of lakes and
reservoirs and stimulate the growth of algae and rooted aquatic plants in shallow streams.
Significant concentrations of nitrogen may have other adverse effects as well: depletion of
dissolved oxygen in receiving waters, toxicity to aquatic life, and adverse impact on chlorine
disinfection efficiency, creation of a public health hazard, and waste-water that is less suitable
for reuse. B. Application of treatment methods In waste-water treatment plants, the unit
operations and processes described in the previous section are grouped together in a variety of
configurations to produce different levels of treatment, commonly referred to as preliminary,
primary, secondary and tertiary or advanced treatment. 1. Preliminary treatment Preliminary
treatment prepares waste-water influent for further treatment by reducing or eliminating non-
favorable waste-water characteristics that might otherwise impede operation or excessively
increase maintenance of downstream processes and equipment. These characteristics include
large solids and rags, abrasive grit, odors, and, in certain cases, unacceptably high peak hydraulic
or organic loadings. Preliminary treatment processes consist of physical unit operations, namely
screening and communion for the removal of debris and rags, grit removal for the elimination of
coarse suspended matter, and flotation for the removal of oil and grease. Other preliminary
treatment operations include flow equalization, septic handling, and odor control methods.

2. Primary treatment Primary treatment involves the partial removal of suspended solids and
organic matter from the waste- water by means of physical operations such as screening and
sedimentation. Pre aeration or mechanical flocculation with chemical additions can be used to
enhance primary treatment. Primary treatment acts as a precursor for secondary treatment. It is
aimed mainly at producing a liquid effluent suitable for downstream biological treatment and
separating out solids as a sludge that can be conveniently and economically treated before
ultimate disposal. The effluent from primary treatment contains a good deal of organic matter
and is characterized by a relatively high BOD. 3. Secondary treatment The purpose of secondary
treatment is the removal of soluble and colloidal organics and suspended solids that have
escaped the primary treatment. This is typically done through biological processes, namely
treatment by activated sludge, fixed-film reactors, or lagoon systems and sedimentation. 4.
Tertiary/advanced waste-water treatment Tertiary treatment goes beyond the level of
conventional secondary treatment to remove significant amounts of nitrogen, phosphorus,
heavy metals, biodegradable organics, bacteria and viruses. In addition to biological nutrient
removal processes, unit operations frequently used for this purpose include chemical
coagulation, flocculation and sedimentation, followed by filtration and activated carbon. Less
frequently used processes include ion exchange and reverse osmosis for specific ion removal or
for dissolved solids reduction. Fig.4.2 Schematic of a typical wastewater treatment plant In
general, these processes are divided into three stages: preliminary (physical), primary (physical)
treatment and secondary (biological) treatment. Provides a schematic of a typical wastewater
treatment plant. Minimally, wastewater should receive primary (physical removal/settling) and
secondary (biological) treatment, which can be followed by disinfection before discharge. More
advanced processes (advanced or tertiary treatment) may be required for special wastes. When
the effluent from secondary treatment is unacceptable, a third level of treatment, tertiary
treatment, can be employed. There are many basic types of sewage treatment plants employing
both primary and secondary treatment stages that are in use today for treating large quantities
of sewage. Table 4.2 characteristics of wastewater by degree of treatment (mg/L) after
treatment 4.5.4 Characteristics of wastewater Pharmaceutical wastewater is characterized in
terms of its physical, chemical and biological constituent. The strength of waste water is
normally measured using accurateanalytical techniques. The more common analyses used to
characterize waste water entering and leaving a plant are: 1. Biochemical oxygen demand
(BOD): BOD is the amount of dissolved oxygen needed (demanded) by aerobic biological
organisms to break down organic material present in a given wastewater sample at certain
temperature over a specific time period. It is possible to assess the performance of a waste
water treatment plant by measuring the BOD5 of the inflow and the outflow. Many factors can
influence this test, such as temperature of incubation, dilution rate, nitrification, toxic
substances, and nature of bacterial seed and presence of anaerobic organisms. 2. Chemical
oxygen demand (COD): is the total measurement of all chemicals in the wastewater that can be
oxidized. 3. Total organic carbon (TOC): TOC is the measurement of organic carbons present in
wastewater. 4. Total suspended solids (TSS): This is the sum of the organic and inorganic solids
concentrations in waste water and can be subdivided into: a. Suspended solid: represent the
solids that are in suspension in the water. Generally comprised of 70%organic and 30% inorganic
solids and can be removed by physical or mechanical means. b. Organic solids: about 50% of
solids present in pharmaceutical waste water derive from the waste products medicine. c.
Inorganic solids: these substances are inert and are not subject to decay. Include sand. d. PH:
This is the concentration of hydrogen ions in solution and indicates the level of acidity or
alkalinity of an aqueous solution. If the pH of the waste water is outside the range 5-10, there
may be considerable interference with biological processes. e. Total Nitrogen: This refers to the
sum of measurements of total oxidized nitrogen (nitrate and nitrite) and total nitrogen
(ammonia and organic nitrogen). This parameter is a growth limiting nutrient in marine
environments and a limit is specified in the UWWT Regulations for discharges to sensitive water
bodies. 4.6 MethodologyBiological method is used for the treatment of wastewater and from
those aerobic method is the most one. Because aerobic treatment is a good process stability,
high effluent quality and smaller reactor size compared to anaerobic treatment. 4.6.1 Aerobic
method wastewater treatment It is any treatment process that uses aerobes to biodegrade or
remove the unwanted organic or inorganic compounds. The process is used suspended growth
process such as activated sludge process. There are many aerobic bacteria present in an aerobic
wastewater treatment system. Many of these will be able to carry out some of the metabolic
processes needed to treat the waste. From those bacteria zooglia are used. Zooglia Zooglia is a
bacterial generally that grow and form a lot of extracellular material with adherence
characteristics. Zooglia are classed in the Pseudomonad family. These organisms form the basis
of the floc, which is the substance that the other organisms attach to. Without the floc, the cells
would not settle and thus would wash out of the reactor.The floc also serves the purpose of
adsorption of the organic compounds from the water. The main mechanism of contaminant
removal may be the initial adsorption of the compounds into the floc. A lot of the degradation of
the compounds occurs in the floc during and after the activated sludge system. 4.6.2 Activated
sludge system Activated Sludge is a multi-chamber reactor unit that makes use of (mostly)
aerobic microorganisms to degrade organics in wastewater and to produce a high-quality
effluent. To maintain aerobic conditions and to the keep the active biomass suspended, a
constant and welltimed supply of oxygen is required. Activated sludge systems normally make
use of bar screens and/or communions, grit chambers, primary settling tanks, secondary settling
tanks, and digesters, which are operated in the same manner as those of trickling filter systems.
During aeration and mixing, the bacteria form small clusters, or flocs. When the aeration stops,
the mixture is transferred to a secondary clarifier where the flocs are allowed to settle out and
the effluent moveson for further treatment or discharge. The sludge is then recycled back to the
aeration tank, where the process is repeated. Table 4.3 Characteristics of wastewater before
treatment 4.7 Energy and Material balance Material balance In any part of chemical industry,
the raw materials enter as a feed and after the chemical or physical reaction is completed it
gives products. Therefore, it must know the amount the entering and leaving of the process.
Then the amount of the process in any factory will be known by material balance and energy
balance. Law of conservation of mass states that mass can neither be created nor destroyed, but
can be converted from one form to another form. Total mass of input= total mass of outputOr
Raw materials = products + waste products + stored products = losses Determination of
suspended solids for a water sample Volume filtered = 200 mL Filter mass = 1.3255 g Filter after
drying 1.3286 g Suspended solids = (filter + solids) - filter 1.3286 g - 1.3255 g = .0031 g, this was
in 200 mL 0.0031 g / 200 mL x 1000 mg/g x 1000 mL/L SS= 15.5 mg/L Additional to this - put
filter in muffle furnace at 550°C for 4 h. New wt. of filter = 1.3274 g, Determine VSS and FSS FSS
= wt. after furnace - tare wt. = 1.3274 g - 1.3255 g = 0.0019 g in 200 mL = 9.5 mg/L VSS = SS - FS
= 15.5 mg/L - 9.5 mg/L = 6 mg/L Or you can use filter wt. = wt. of filter before furnace - wt. of
filter after furnace = 1.3286 - 1.3274 = .0012 g VSS= 6 mg/L Where SS= suspended solids
VSS=volatile suspended solids FS =filterable solids Determination of the five day BOD BOD
(mg/L) = 𝐷1−𝐷2 𝑃 Where D1=the total dissolved oxygen of the sample D2=the final dissolved
oxygen of the sample after 5 days P = the decimal volumetric fraction of sample used For
example, a sample of 200mL is diluted to 390mL, Then P= 200 390 =0.512 Where D1=300mg/L
D2=390mg/L BOD=300−200 0.512 =195mg/L Note: If no dilution was necessary, then P=1 the
BOD is determined by D1-D2. Determination of COD COD=(𝐴−𝐵)∗𝑁(𝐹𝐴𝑆)∗8000 𝑉 Where
A=Value of titrant used for the sample in mL. B= Value of titrant used for the blank sample in
mL. N (FAS) = Ferrous ammonium normality sulphate (mg/L). V= Volume of a sample (ml) 8000=
Millieqivalent weight of oxygen*100mL/L Let B=900mL A=150mL N (FAS) =0.1N V = 500mL Then,
COD will be calculated = (900−150)∗0.1∗8000 500 COD=1200mg/L Energy balance First law of
thermodynamics, according to which energy cannot be created or destroyed, only modified in
form or they can be converted from one form to another (for example, internal energy stored in
molecular bonds can converted into kinetic energy; potential energy can be converted into
kinetic or to internal energy, etc.). Energy balance is simply the relationship between your
energy input and your energy output. The general energy balance for a process can be
expressed as; Accumulation= input -output + generation – consumption According to the first
law of thermodynamics generation and consumption becomes zero. Accumulation also becomes
zero due to steady state rule. Therefore the above equation is reduced to; Input = output But, in
this treatment method there is no any inputs and outputs energies therefore no energy balance
used. 4.8 Environmental impact analysis In many part of the world country including our
country, health problem and diseases have often been caused by discharging untreated or
inadequately treated wastewater, this discharging is called water pollution. The pollution of
water has a serious impact on all leaving things, can negatively affect the use of water for
drinking, household needs recreation, fishing transportation and commerce. Short summary of
the methodology Bar screen: Removal of coarse and floating solids from the sewage and sand
and gravel can settle out. Grit chamber: A chamber in which the velocity of waste flow is
reduced to a point where the denser sand and other grit will settle out, but the organic solids
will remain in suspension. Primary settling tank: It is a large tank in which solids settle out of
water by gravity. Where the settle able solids are pumped away. In this three process are takes
place; settling, filtering and collecting. Flotation: Used to remove the oils, greases and floatable
solids from the sewage by introducing a fine gas, usually air bubbles. Aeration tank: This
provides both a sources of oxygen for the aerobic bacterial floc that forms in the tank and
turbulence necessarily to bring the waste and the bacteria in to contact. That used to remove
the biodegradable microorganisms and organic solids. Secondary settling tank: In this suspended
material removes from the water. The sludge from secondary settling tank is recycled or
pumped in to primary settling tank to enhance the treatment. Filtration: Used to remove the
undesirable biological contaminants, suspended solids and gases from the water. Ultraviolet
(UV): Used to kill minerals and microorganisms using light. It is safe, clean, and easy to maintain
method of assuring that water is free of bacteria. See the general process: 4.9 Conclusion and
recommendation 4.9.1 Conclusion Generally in this internship program we gain more
knowledge especially when we see in terms of improving our personal skills, we can easily see
the difference between theory and practical work. When you do practical work, you can easily
see each and individual thing so this make better to improve my personal skills and when we see
in terms of upgrading our theoretical knowledge, the knowledge that we know in theory only is
not enough but when you see the theory in practical, it is unforgettable so this makes to
upgrade your theoretical knowledge and when you look in terms of work ethics you learn to be
punctual and to work your work properly. The activities done on each factory helps to see and
to know different things because a lot of activities are done in each day on each factory and we
develop my software knowledge by knowing a software called auto cad, solid work and cattie,
this helps to do part, assembly, and draft and so on we think it is helpful to know this in the
future. And also the mini project helps me to know more things and to read different books so
this helps in the future to take large projects. Wastewater is the combination of liquid or water-
carried wastes originating in the sanitary conveniences of dwellings, commercial or industrial
facilities and institutions, in addition to any groundwater, surface water and storm water that
may be present. Waste-water quality may be defined by its physical, chemical, and biological
characteristics. Physical parameters include color, odor, temperature, and turbidity. Insoluble
contents such as solids, oil and grease, also fall into this category. Chemical parameters
associated with the organic content of waste-water include biochemical oxygen demand (BOD),
chemical oxygen demand (COD), total organic carbon (TOC) and Inorganic chemical parameters
include salinity, hardness, pH, acidity and alkalinity. Bacteriological parameters include
coliforms, fecal coliforms, specific pathogens, and viruses. Biological treatment processes are
those that use microorganisms to coagulate and remove the nonsettleable colloidal solids and
to stabilize the organic matter. A continuous, aerobic biological treatment for wastewater uses a
culture of bacteria suspended in the wastewater in aeration tank to adsorb, absorb and
biodegrade (remove) the organic pollutants. Activated Sludge is a multi-chamber reactor unit
that makes use of aerobic microorganisms to degrade organics in wastewater and to produce a
high-quality effluent. To maintain aerobic conditions and to the keep the active biomass
suspended, a constant and well-timed supply of oxygen is required. Generally, this internship
experience we have got good knowledge by observing the outside environment and the overall
benefits that we gained from this internship experience. 4.9.2 Recommendation The internship
program must participate all parties to meet the goal of this program and the interconnection
among university, government and companies should be strong. The program is the best one,
but needs very much attention specially the participant, company and also much support from
the universities. For instance: The company has some problems especially on the production
process, installation of machines, metal and material wastage. This is as a result of untreated
wastewaters and others. So, to make the company more profitable and increase its capacity,
those problems has to be solved and our study biological method of wastewater treatment is
more necessary. The universities has also some limitations mainly on the relationship between
the companies there is no kinship(relationship), means if the company do not receipt by a
wellthis can affect the students who take the internship program morality. So, this should be
take more attention on the kinship of the company. Even there is no enough library and
internet service in the company the workers are performing their work by reading different
books for helping through manuals. And we were doing our report through sharing through the
previous writing reports. There are no more than two or three educated engineers who have
MSc degree in the department. This can have a great problem because, even all the mechanics
has not god practical knowledge they may not teach us by translating our theoretical knowledge
to that practical skill. But we had been solving any problem by highly asking the engineers and
by asking to each other students who come from universities. 4.9 Reference Badawy M.I.,
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