Neha Mehendale 1052 MNW

Introduction
y STPs an important requirement y Deal with high BOD of sewage y Preventing adverse impact on water bodies y Energy intensive process

About the organization

y Technogreen Environmental Solutions, Pune y Branches

Technogr een
E nvir onm ental S olutions

Mumbai, Pune, Kolhapur, Nashik, Solapur and Sangli

y Services include Air, Water and Soil Quality Management, Solid and

Hazardous Waste Management

y EIA, Habitat Restoration, Auditing, Biogas Plants, Wastewater

Treatment
y Kirloskar Brothers Ltd. , Mahindra & Mahindra, ITC Ltd., Siemens Ltd.,

Venkateshwara Hatcheries, Bharat Forge

Objectives
y Understanding the process of STP y Energy consumption at the plant y Suggestions for reducing energy costs

Time Line
30th May 4th June 2011 6th June 2nd July 2011 Reporting at Plant and deciding project plan, Plant Visit Study of Sludge Treatment Process and Unit-wise analysis of parameters Data Collection for energy studies Compilation and Analysis Documentation

4th 9th July 2011 11th 16th July 2011 18th 23rd July 2011

Bhairobanala STP, Pune

y Plant capacity: 130 MLD y Input from Kalyaninagar Pumping Station: 30 MLD y Area: 5 Hectare y Activated Sludge process y Plant Commissioned in July 2003

Bhairobanala STP, Pune

y Activated Sludge process y Plant capacity: 130 MLD
Raw Sewage Sump Secondary Settling Tanks Chlorination Tank

Anaerobic Digesters

Aeration Tanks

Primary Settling Tanks

COD and TSS estimation

Unit 1 PST TSS 2 Aeration Tank 3 SST TSS 107 28 73.83% COD TSS COD 515 122 199 60 277.67 38 61 24 46.08% 68.85% 69.35% 60% Parameter COD Inlet (mg/L) 301.34 Outlet (mg/L) 148 Efficiency (%) 50.88%

Standard methods for COD and TSS estimation were used.

Energy Consumption
y Estimate of different forms of energy was made y Electrical y Manual y Mechanical y Information gathered y Details of Electrical Equipment y Staff working at plant y Use of fuel at plant

Energy Consumption
y Electrical Energy

Ep = Pt 3.6 (MJ)
= Power factor (assumed to be 0.9), P= Power of the electrical equipment in kWh T= corresponding hours of electricity operation, 3.6 = energy equivalent 1 kWh

(Waheed et al., 2008)

Energy Consumption
y Manual Energy
i !6

Em ! EiNiTi
i !o

Ei= Energy equivalent for an adult working for 1 hr, Ni= Number of people, Ti= Time spent in Labour

y Mechanical Energy

Ef = 56.31 D (MJ)
56.31 = unit energy value of diesel, MJL-1; D = liters of diesel consumed
(Waheed et al., 2008)

Energy Consumption
Unit Operation Raw Sewage Collection Pre-Treatment Primary Treatment Aeration Secondary Treatment Chlorination Sludge Treatment Other Processes TOTAL Electrical (MJ) 9720.00 233.28 524.88 37091.52 233.28 291.60 4881.77 526.26 53502.59 Manual (MJ) 52.56 52.56 52.56 52.56 52.56 52.56 52.56 52.56 420.46 Mechanical (MJ) 1.15 1.15 64.35 1132.94 1199.59 Total Energy (MJ) 20573.71 546.19 1160.64 78356.88 545.04 668.16 10422.88 2296.48 55122.64

Energy from Biogas

Considered Inlet COD = 350mg/L, For 130MLD plant COD = 45500Kg/day Considering 1.7 Kg COD/ Kg VS and 920 L Biogas/Kg VS (Panter Keith, 2008) Amount of biogas from sludge = (45500/1.7) x (920/1000) = 24623.53 m3/day 1 m3 biogas = 2 KWh (Electrigaz, 2011) Energy from biogas = 24623.53 x 2 = 49247.05 KWh/day Industrial Electricity Cost in Pune = Rs. 5.4/unit (MAHADISCOM, 2011) Energy Savings = 49247.05 x 5.4 = Rs. 2,65,934/day Considering 70% Efficiency of Plant for COD removal, Energy Savings = Rs. 1,86,154/day

Observations
y Current design inconsistent with expansion plan y Faulty analytical procedure y Non-utilization of biogas as energy

Limitations
y Lab equipment failure and power cuts y Unavailability of data y Duration of project

References
y APHA, 1998, Standard Methods for Examination of Water and Wastewater, y y y y

y y

Section 2540 D for TSS and 5220C for COD Bhairoba Nala Plant Layout, 2001, Pune CPHEEO Manual, 1999, Manual on Water Supply and Treatment Electrigaz 2011, Biogas FAQ, Available at <http://www.electrigaz.com/faq_en.htm>, [Acessed on 22/07/2011] H. Singh, D. Mishra, N.M. Nahar, 2002-2004. Energy use pattern in production agriculture of a typical village in arid zone, India - Part I,II and III, Energy Conversion and Management Kansal A., 2011, Lecture notes on Solid Waste Management and Water Quality Management MAHADISCOM 2011, Maharashtra State Electricity Distribution Co. Ltd Bill Calculator, Available at <http://www.mahadiscom.in/>, [Acessed on 22/07/2011]

References
y Middlebrooks E.J., Middlebrookes C.H., Reed S.C., July 1981. Energy

y y

y y y

Requirement for Small Wastewater Treatment Systems, Water Pollution Control Federation, Vol. 53, No. 7, pp. 1172-1197 Mittal, V.K., Mittal, T.K. and Dhawan, K.C. 1985. Research digest on energy requirements in agricultural sector. Panell S. D., 2005, Anaerobic Digestion Options for Industrial Wastewater, Available at <http://pieinternational.com/iwwt/Pannell.pdf>, [Acessed on 25/07/2011] Panter Keith, 2008, Mass and Energy Balances in high solids digestion following thermal hydrolysis pre-treatment, Ebcor Ltd. Vaidya M.V., 2008, PMC STP Audit Report Waheed M.A., Jekayinfa S.O., Ojediran J.O., Imeokparia, 2008. Energetic analysis of fruit juice processing operations in Nigeria, Energy, Vol 33, pp. 35-45