Treated Waste Water Discharge M/S Arvind Mills Ltd , Santej
Arvind Limited
The Arvind Ltd was established in 1931 and has since grown to become the world’s largest Denim Exporters. Arvind, the flagship company of the Rs 14000 Cr. Lalbhai Group
Having diversified business interest in Textiles, Chemicals, Tele-communication, Heavy Engineering, Water, Wastewater treatment and Patented low cost Evaporation Technology. Arvind Limited
. Turnover : 10000 Cr
. Market Capital : 15000 Cr
. Exports: > 9500 Cr
. Arvind’s having worldwide presence with the offices in New York, London, Germany Mauritius, South Africa, Bangladesh, Delhi, Mumbai, Bangalore and Ahmedabad. LALBHAI Group of Companies Textiles/Yarns/Fabrics/Garment/Industrial Fabrics THE ARVIND LIMITED, DENIM, AHMEDABAD THE ARVIND LIMITED, SANTEJ SHIRTING,KNITS,KHAKHIS,DENIMS THE ARVIND LTD , VOILS, AHMEDABAD ARVIND BRANDS LIMITED ARVIND INTEX AHMEDABAD ASOKA COTSYN AHMEDABAD ASOKA SPINTEX AHMEDABAD ANMOL SPINTEX AT SANTEJ COMPLEX ACHAL SPINNING AT SANTEJ COMPLEX ANVESHAN TEXTILES AT SANTEJ COMPLEX ANKALESH TEXTILES ABEER SPINNING , WEAVINGS SANTEJ COMPLEX ARVIND LTD - ADVANCE MATERIALS, SANTEJ COMPLEX ARVIND-PD COMPOSITES PVT LTD. VADSAR ARVIND-OG NON-WOVEN PVT. LTD, DHOLKA ARVIND LTD-COMPOSITES ARVIND LTD-ANDREW INDIA Engineering & Infrastructure And Environment and Water Treatment ANUP ENGINEERING LIMITED ARVIND ACCEL LIMITED ARVIND ENVISOL PVT. LTD ARVIND`S BRANDS
• Own International Brands : • Licensed International • Flying Machine Brands : • • Excalibur Tommy Hilfinger • Arrow • Newport • • Ruff and Tuff Lee • • Lee Wrangler • US Polo Association • Gant • Izod • Gap ETP Units in ARVIND LTD • DENIM Fabric Manufacturing Unit at Naroda , Ahmedabad having ETP of 9000 M3/Day Treatment Facility. • VOIL business unit at Ankur Division in Ahmedabad city having ETP facility of 3000 M3/Day. • GARMENT Washing Units at Bangaluru of 1000 M3/Day. The Arvind Ltd , Santej • The Arvind Limited , modern and state of art composite textile complex, is set up in 1997, at Village Santej of Gandhinagar District in Gujarat. Total Area is 421 Acres. • Main products of this Textile complex is Shirting fabrics Knit Fabrics Cotton Trousers Fabric. Denim Fabric Waste Water management • Basically this area Khakharia is water scare area and no water was available except bore well water . More over there was no discharge point was available for effluent discharge after treatment. • So being a textile industry and a intensive water usage this complex is planned with the objective of minimizing water consumption by recycling entire effluent, thus the net withdrawal of the water from bore wells is limited to only evaporation losses. Waste Water management
• No discharge point was available for the treated effluents in 1997.Hence , Effluent Recycle Plant has been established to recycle the waste water fit for process reuse , for CPP, cooling tower and also for plantation and gardening in the complex.
• Cost of the ETP Plant is 100 Crores with 45 Acres land area covered in 1997. Waste Water Management
• The textile operations need Process water and produce waste water that is colored , alkaline in nature and having COD and BOD load and is amicable to conventional treatment. • Capacity of waste water Treatment and Recycling Plant designed for the complex is 17000 m3/day. ETP at Arvind Ltd
• Effluent recycling at Arvind is carried- out in three stages viz ; # Physico -Chemical treatment to remove color & Suspended solids. # Biological Treatment -- to remove Organic impurities like BOD & COD # Tertiary Treatment -- For the dissolved solids and colloidal removal , and to make water fit for reuse ETP at Arvind Ltd • Physico - chemical Treatment comprises # Equalization # Neutralization # Coagulation # Flocculation # Clarification • Biological treatment is carried out through # Activated Sludge Process SIZE/ DESIZE H-PLANT BLEACH & MERCERIZING DYEING STREAM
CONCENTRATE
DISTILLATE EQUALIZATION EQUALIZATION EQUALIZATION EQUALIZATION MEE + CRYSTAL. MVR TANK - D TANK - C TANK - B TANK - A
pH CORRECTION pH CORRECTION SALT POWDER FOR RE USE TO DM PLANT PROCESS WATER Gardening TO SBUs FLOCCULATOR FLOCCULATOR RO REJECT PERMEATE For Solution 2 & 3 Rd PROCESS WATER STAGE FOR REUSE RO
REJECT
pH CORRECTION TANK FIRST STAGE REVERSE TO BOILER FEED WASTE OSMOSIS DECANTER SOLIDS P.C-1 P.C-2 SLUDGE THICKENER Sec Clr-II RO PRETREATMENT P.C-3 P.C-4 SECTION PSF CF
TREATED HRSCC Sec Clr-II WATER UNIT TANK TO DM PLANT Aeration Tank -1 & 2 DOMESTIC REJECT PERMEATE STREAM
REVERSE PSF CF OSMOSIS
Sec Clr-II Sec Clr-II BORE WELLS
EFFLUENT RECYCLE PLANT AT AML, SANTEJ Water Quality
• Parameter Raw effluent Treated effluent Recycled PH 10.5 7.0 6.25 • BOD5 500 10 Nil • COD 1500 70 Nil • SS 200 10 Nil • TDS 2000 2500 450 • Color 4500 150 Nil • NH3- N 50 Nil Nil • Oil & Grease 10 Nil Nil Collection and Equalization New Revolution in Colour Removal
• By in house R&D had Developed Bacterial Treatment for Reactive dye removal by specialized facultative Bacteria in Dye effluent , and is Implemented at Santej is giving revolution in Textile effluent treatment . Cost Reduction is 20 Rs/M3. against Chemical Treatment in Present Scenario. ETP-Primary Section Activated Bio Sludge Process ETP Secondary Section ETP at Arvind Ltd • Tertiary Treatment includes # Ultra Polishing Treatment # Pre-Filtration Sand and Catridge Filters # Reverse Osmosis # MVRE and Crystallization for Salt • Number of Stand-by units are provided so that the treated effluent quality remains uniform throughout the year . Ultra Polishing Treatment RO Pre Filtration Section RO Plant at Arvind Ltd Water Management By SCADA - System Specific Water Consumption Pattern
Year Annual Water Source of Annual Water Source of Production Specific Water Consumption Water Consumption Water capacity of the Consumption* (Industrial (Drinking/ other plant (m3 per unit of Process Only use in m3) ^ production) in m3) # 2015-15 7260000 Recycled 108900 Borewell 45000 Based on Fresh MT/Annum water Usage
175 M3/MT
After Recycling
35 M3/MT Ground Water Conservation
Water Actual / Planned Annual Ground Investment made date of completion water saving in m3 conservation project (` Lakhs) implemented
ZLD System May 1998 5800000 10000
Sewage Re-Use August 2016 1452000 1000 Sludge Management
• Sludge is de-watered through Belt Press and Dried and disposed to TSDF site of NEPL , Odhav. RO Reject Management
• Total 94 % Good water is recovered by 3 stage RO system @ 65 Rs/M3 which includes all variable and fixed cost.
• The 6 % Reject is subject to treat in MVRE Plant Total 35 Crore Invested. RO Reject Management
• MVRE Plant includes MVR Evaporator and MEE- Crystallizer for Salt Recovery and Re-use. • The Operation cost is 750 Rs/M3. • The Distilled water is used for Steam generation in Boilers. • The Dry salt is pure, so used in Dyeing process. Total Zero Discharge Cost
• Cost for 94 % Recovery is 65 Rs/M3 • Cost for Reject Management is 750 Rs/M3 • Total cost for Zero discharge is 105 Rs/M3. • Total cost after Salt Recovery Benefit is 90 Rs/M3. Salt Recovery and Reuse
• Resource Recovery : Recovery of salt from RO Reject by new MVR Technology at cost of 35 Cr Rs. • Daily 25 MT/Day Pure Glauber Salt is Recovered. Mechanical Vapor Recompression Evaporation Plants NEW INITIATIVES : Re-Use of sewage
• First Re-use of Sewage had started in Garment Washing units at Bangaluru against Fresh water in 2007 from BWSSB source by KPCB permission . Daily 600 M3/Day treated sewage is used. • In Ankur Division , Ahmedabad is using 1500 M3/Day Raw sewage in January-2016 after in house treatment for textile fabric processing . • New up-coming Arvind Garment Exports Pvt Ltd, Near Dehgam will use 2000 M3/Day Raw sewage of town and after in house treatment will be used in Garment washing. NEW INITIATIVES ; Re-Use of sewage • 1600 M3/day Sewage Effluent generated from 5000 Nos of Arvind & Smart value homes LLP township project with TATA housing near Arvind Santej Plant. used to produce DM water against Raw water presently used in Arvind. This will reduce raw water extraction from Ground to 900 M3/day. • 4000 M3/Day Treated sewage water of Jaspur Sewage Plant ( Ghandhinagar) will be used as Make up water against Ground water From Aug. -2016. Water Foot Print at Santej will be 5 M3/MT. • Rain water Recharge Ponds Major Environmental Project Rain water Recharging Wells
• Two Ground water recharge ponds of Rain in mm. 1200 5700m3 & 9000 m3 capacity are 1000 800 600 excavated in 1999-2000 to protect the 400 200 natural resource. 0 1995 2000 2005 2010 2015
• Rain water recharged
Cu.meter. 70000 Rain Water recharged from 1999-2014 60000 50000 Total 768505 M3 40000 30000 20000 10000 0 1995 2000 2005 2010 2015 Gardening at ETP Green Complex • Total Land 420 Acres • R and B : 190 Acre • Plantation : 150 Acre • Gardening : 50 Acre Glimpses of Santej Textile Complex Thanks