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ENVIRONMENTAL INFRASTRUCTURE AT VATVA, AHMEDABAD

The Green Environment Services Co-op. Society Ltd.

Office & CETP Site: Plot No.: 244-251, Phase: II, GIDC Estate, Vatva, Ahmedabad 382 445. Phone: (079) 25892283, 25832449, 25832520, 25835652. Fax: (079) 25893614. Web Site: www.gescsl.com E-mail: info@gescsl.com

GESCSL Objectives
GESCSL was formed in 1992 with the main objective to abate pollution and conserve energy and environmental resources to achieve sustainable growth and development in all areas. To achieve this objective approximately a sum of Rs. 100 crore has been spent to set up the following Environmental Infrastructure F ili i and M I f Facilities d Management S Systems Establishment and operation of common facilities for the collection, treatment (CETP) and disposal of industrial effluent in the estate of Vatva having membership of 674 industrial units. Establishment and operation of common secured landfill facility (SLF) for the safe disposal of solid waste being generated by industrial units in Vatva and elsewhere. Organizing joint programmes with academic institutions and industries focusing on energy efficiency, cleaner production practices and environmental awareness.

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COMMON WASTE MANAGEMENT SYSTEMs

The Common Waste Management System in the estate of Vatva consists of the following components Industrial Wastewater Management Internal Collection System Common Effluent Treatment Plant Disposal into Mega Pipeline Solid Waste Management Common S C Secured L dfill Facility (SLF) d Landfill F ilit Spent Acid Management

INTERNAL COLLECTION SYSTEM

No. of industrial units served : 674 Area covered: System Description: Collection of industrial wastewater by gravity into 92 sump rooms. Conveyance of wastewater by gravity from Sump rooms to 7 Pumping stations. Pumping of wastewater from pumping station to CETP for treatment. Monitoring of wastewater quality to assess acceptability. Sampling of discharge of every unit to determine CETP inlet parameters. 13.5 km2.

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COMMON EFFLUENT TREATMENT PLANT

Design Criteria: Flow Rate: pH: TSS: COD: BOD: Land Area: 16000 m3/d 6.5 8.5 600 mg/l 3000 mg/l 1200 mg/l 28000 m2

Treatment Technology: Conventional activated sludge type biological process supplemented by Electro-oxidation. Major Treatment Units: Equalization Tank Electro-oxidation Plant Flash Mixer Flocculator Dissolved Air Floatation Unit Aeration Tank Secondary Clarifiers

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ELECTRO-OXIDATION SYSTEM

AERATION TANK

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ULTIMATE DISPOSAL OF TREATED EFFLUENT

Treated effluent from the Secondary Clarifier is taken to Final Pumping Station from where it is pumped to AMCs mega pipeline carrying the treated effluent to the down stream of Pirana Sewage Treatment Plant through a closed pipeline, where it is mixed with treated sewage of Pirana Sewage Treatment Plant before disposal into River Sabarmati.

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SLUDGE TREATMENT & DISPOSAL

Primary Sludge and Secondary sludge are collected in Sludge Holding Tanks for treatment. Sludge is pumped to Decanters for de watering de-watering. Treated sludge is ultimately disposed to Secured Landfill Disposal Site at Village Vinzol, developed by The Green Environment Services Co. operative Society Limited.

LABORATORY
The CETP has in-house well equipped laboratory. A l i l l b E i Analytical lab: Equipped with hi d i h hi-tech i h instruments f for continuous i analysis of wastewater samples. Microbiological lab: For microbiological testing of Aeration Tank mixed liquor and activated sludge. TOC lab: Equipped with hi-tech TOC Analyzers.

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CETP UP-GRADATION PROGRAMME

The Electro-oxidation Plant based on German technology has been installed and is at present under stabilization and optimization. In the Electro-oxidation Process generation of strong oxidizing agents takes g g g g place in situ under the influence of electric current in a well designed electro cell. These oxidizing agents oxidize as well break up the organic molecules rendering them in the oxidized state and / or converting them in biodegradable form. The effluent after this pre treatment is further treated in CETP where biological processes in the presence of chemical additives degrade the organics at the desired level. Further Proposed Up-gradation Installation of a new Primary Clariflocculator. It will be utilized for imparting physico-chemical treatment to the incoming combined effluent to ensure low levels of suspended solids before it enters Electro-oxidation Plant. This will also help in reducing maintenance and cleaning downtime in the subsequent units. Installation of additional Aeration Tank to achieve longer aeration time, more flexibility in operation and to enhance biological removal of pollutants.

COST OF PROJECT
Initially the common facilities for the collection, treatment (CETP) and conveyance of treated effluent were set up at the cost of Rs. 33.28 crore. The break-up of this cost is as under Internal Collection Systems Treatment units (CETP) Rs. 10.17 crore Rs. 18.00 crore

Conveyance line upto Sabarmati near AMC Pirana STP Rs. 05.11 crore Sub Total p q p Expenditure towards additional equipment installation / modification of new units Phase: I Up-gradation Phase:II Up-gradation Sub Total Total Project Cost: Rs. 74.41 crore Rs. 33.28 crore and Rs. 11.74 crore Rs. 06.70 crore Rs. 22.69 crore Rs. 41.13 crore

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OPERATING COST OF CETP

Rs. 15 18 per m3 of effluent

RATE OF CHARGING
Rs. 20 per kg of TOC p g

SECURED LANDFILL FACILITY

Detailed engineering design, construction and operation are carried out as per the guidelines of CPCB. Initially SLF No. 1 & SLF No. 2 were constructed. Later these two sites were expanded and after full capacity utilization were capped and green vegetal layer was developed. SR. PARTICULARS NO. 1 2 3 4 Development Stage Capacity Period of Operation Total Cost (Rs. in Crore) SLF - 1 Phase: 1 74287 MT SLF - 2 Phase: 2 170004 MT EXPANSION OF SLFs 1 & 2 Phase: 3 128441 MT October 2001 to February 2003 0.81

April 1998 February 1999 to January 1999 to October 2001 0.93 1.66

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SECURED LANDFILL FACILITY

A new Cell (SLF No. 3) was constructed and was put on use in March 2003. Currently this cell is in operation. SR. NO. 1 2 3 4 5 PARTICULARS Development Stage Capacity Commencement of Operation SLF - 3 Phase: 4 675000 MT March 2003

Quantity of S lid W t D Q tit f Solid Waste Dumped as on J l 636319 045 MT d July 636319.045 2010 Total Cost (Rs. in Crore) 11.10

Thus the total capacity created for the safe disposal of solid waste is 1050000 MT with an INVESTMENT of Rs. 14.50 CRORE.

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OPERATING COST OF SLF

Rs. 250 per MT of solid waste.

RATE OF CHARGING
Rs. 400 per MT of solid waste.

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ENVIRONMENTAL MONITORING
We have set up a full fledged Analytical Laboratory equipped with necessary analytical instruments and facilities. Qualified and trained personnel look after th operation of SLF and l b t ft the ti f d laboratory. The monitoring includes the followings Analysis of solid waste received at SLF and leachate. Ambient Air Quality Monitoring Monitoring of Ground Water Quality The Th records of all of the above results are maintained and are made available d f ll f h b l i i d d d il bl to the concerned authorities whenever required.

SPENT ACID MANAGEMENT

(Centralized Industrial Waste Exchange and By-product Recovery Facility)
Spent sulphuric acid is generated in the industrial units involved in the manufacture of dyes, dyeintermediates and other chemicals where sulphuric acid or oleum are used as raw materials. The concentration of sulphuric acid in the spent acid is normally in the range of 10-30%. The individual industries find it difficult to store, handle or treat it effectively. It was therefore decided to establish this facility in f i i i the name of NOVEL S f O SPENT AC MANAGEMENT to carryout the f ACID A AG following activities i i ii Segregation and collection of spent acid received at site in different tanks depending on the concentration of sulphuric acid and other properties. The colour less and concentrated spent acid will be directly supplied to the actual user to utilize it as a raw material in the process or as neutralizing agent in the treatment of wastewater. Part of the spent acid will be supplied to the manufacturers of ferrous sulphate, alum, single super phosphate etc. The relatively dilute and reasonably colourless spent acid will be neutralized using hydrated lime for the production of Gypsum which will be supplied to the cement manufacturing plants. The spent acid having colour and other contaminants will be neutralized with hydrated lime and the resulting sludge will be disposed of into Secured Landfill Facility. The wastewater generated as the filtrate will be treated in the ETP consisting of primary and secondary treatment facilities and the effluent after treatment will be sent to CETP of GESCSL for further treatment and joint disposal.

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SALIENT FEATURES
Total Waste Handling Capacity Average Acid Content Waste to be Reused Waste to be Converted to Gypsum Saleable Gypsum Produced on Neutralization Registered Members Total Project Cost Charging Pattern: 1.5 million liters / day 20 % wt. / wt. H2SO4 0.5 to 0.8 million liters / day 0.4 to 0.5 million liters / day Approx. 300 tones / day

130 (likely to go up to 200) Rs. 30 crore Rs. 400 per MT up to 20 % Acidity Rs. 20 per MT for every 1% acidity exceeding 20%

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ACHIEVEMENTS
The major achievement due to the implementation of the environmental infrastructure projects namely CETP and common SLF in the estate of Vatva is stoppage of discharge of industrial wastewater on land and open drains and prevention of water pollution in this area. This also gave clean and aesthetic look to the estate. The other achievements of GESCSL associated with the establishment and operation of these projects are as under
CETP is certified for ISO 9001:2008, ISO 14001:2004 and ISO 18001:2007 for provisions of services for effluent collection, treatment and discharge. Secured Landfill Facility is certified for ISO 9001:2008, ISO 14001:2004 and ISO 18001:2007 for provisions of services for collection and storage of solid waste.

Winner of Golden Peacock Environment Management Awards 2010 & 2008. Winner of Greentech Gold Award 2008 and Silver Award 2007

ENVIRONMENT EXCELLENCE AWARDs

GOLDEN PEACOCK ENVIRONMENT MANAGEMENT AWARD - 2010

GOLDEN PEACOCK ENVIRONMENT MANAGEMENT AWARD - 2008

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Thank you

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