[Sludge Drying System For CETP Vapi]

PRESENTED BY

[Sachin Ramesh Dhake,DGM, CETP( Vapi ) ]

1 5 . 0 2 . 2 0 1 9 , N E W D E L H I

Capacity :-

Activated Sludge Process (CETP) : 55 MLD (January-1997).

CMEE : 200 KLD (April – 2015).

Spray Dryer : 4 KL/hr (March – 2018).

CETP was designed and built by the National EnvironmentalEngineering and Research Institute (NEERI) in 1997.

Total Area of CETP is 72 Acres in which approx. 45% area coveredwith greenbelt. Total 521 industries are the member of CETP.

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CETP-PROCESS FLOW CHART

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PRIMARY

CLARIFIERS

S.D.B Filtrate Pump

MAIN INLET

CHAMBER

LIME DOSING

COARSE SCREEN

CHAMBER

AUTO SCREEN

CHAMBER

GRIT CHAMBER

EQULISATION TANKS

FLASH MIXER &

FLOCCULATOR

PRIMARY CLARIFIERS

CMEE (200 KLD)

CONDENSATE

CONCENTRATE

AERATION TANKS

SECONDRY CLARIFIERS

FINAL OUTLET

SLUDGE THICNERS

DECANTERS

TIDAL ZONE OF RIVER

DAMAN GANGA

S.D.B Filtrate Pump

Wastewater from GIDC Estate

through under ground pipe line

Sludge Over Flow

Centrate

Cake

WAS

RAS

PROCESS FLOW DIAGRAM OF CETP

CMEE Effluent

storage tank

SPRAY DRYER

(4000 Kg/hr)

Powder/Salt

(to TSDF )

Bagging

Leachate

Sludge to

TSDF for

Land filling

Highly

Concentrated

Waste water

through Tankers

CETP Sludge Generation

In let Suspended Solids :- 400 PPM

Out Let Suspended Solids :- 100 PPM

Quantity Flow :- 55 MLD

Primary SS on Dry basis :- 22 MT

Secondary SS on Dry Basis :- 11 MT

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Decanter Sludge Drying Trials:

Trial: To study the effect of sun drying on moisture contain ofDecanted Sludge. ( Project Initiative by VGEL Technical team.)

Protocol:

Decanted sludge from decanter has been sprayed in 1 – 1.5 ftlayer on PCC surface of Interim sludge storage – 1 on 09/11/2016.

Half of the sludge has been covered with transparent plastic shedwith exhaust fan facility on 13/11/2016.

The Initial moisture/Solid contain in sludge was analyzed.

Alternate day sludge layers are being manually cultivated tochange the drying surface.

Check moisture/solid contain of the sludge every four days.5CETP,VAPI3/4/2019

RESULTS

7CETP,VAPI3/4/2019

SS To Moisture Ratio in sludge

Location Ratio Quantity of Sludge In MT per Day

Primary sludge after Decantation

22:78 100

Secondary sludge after Decantation

18 : 82 61

Sludge after bagging stacking & leaching ( Primary +Secondary)

45:55 73

After Sun drying in 20-30 Day

80:20 33

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Monthly Humidity % of VapiSr. No Month Humidity (%) Sun Shine Hr Temp In °C

01 January 69 270 29

02 February 69 258 29

03 March 69 274 31

04 April 69 274 32

05 May 70 296 34

06 June 80 149 32

07 July 86 73 30

08 August 86 76 29

09 September 83 165 30

10 October 78 240 33

11 November 71 246 33

12 December 69 253 323/4/2019 CETP,VAPI 9

Phase- I Project Construction of CC platform.

Area :- 9000 SQM.

Estimate :- 2.5 Cr

Status :- Completed.

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Lay out Drawing

11CETP,VAPI3/4/2019

Existing Sludge Drying Bed

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Pay Back Calculation Capital Cost :- 230 las

Saving per month :- 12.25 Lacs

Payback period :- 18 month

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Conclusion Total Handling Of sludge per Day :- 130 MT -150MT

Area required with RCC platform :- 9000 SQM

Solid : Moisture Ratio After Sun Drying :- 80:20

Advantage :-

Transportation & Handling cost will be reduced.

Increasing life of TSDF site.

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Proposed project for sludge drying system.

Phase :-II

Construction of Green house shed with Auto turning device.

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Estimate for Phase project –II

Sr.

No.

Particular Cost In Cr.

01 Green house construction. 09 Nos. with

poly carbonate sheet.

9

02 Turning device & Equipment 4.5

03 Mechanize Feeding system 1.5

04 Floor heating system by solar energy 1.5

05 Storage shed of 1800 SQM 2.5

06 PLC & controlling system, exhaust &

Turning device

4.5

Total Estimated Cost Excluding taxes 23.5

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Schematic diagram of Solar Drying System

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Spin Flash Dryer

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Spin Flash Dryer Pilot Trial. Inlet Solid % = 20

Out let Solid % = 80

Drying time ( Contact Time ) = 1.5 hr.

Source of energy

Present by steam with boiler Exhaust.

Proposed energy = hot air by CETP sludge

Cost Evaluation is Under progress.

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Summary

Primary sludge having leaching properties up to 20 % solids concentration.

Secondary sludge having properties up to 18 % solid concentration.

Sun drying system is techno commercially feasible for CETP primary & Secondary sludge.

Suggested to CETP’s for effective sludge drying.

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Contact Details

Mobile No :- 9714004446

Email ID :- ic.cetp@vgelvapi.com

Web site :-htpp// www.vgelvapi.com

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3/4/2019 CETP,VAPI 22