MMA CETP MMA CETP, MAHAD

Seven Billion Dreams. One Planet. Consume with Care Contents • Historical Background of CETP • Effluent characteristics & Challenges of MIDC, MAHAD • Improving Effluent Treatment & Management • Journey towards Sustainability Historical Background…. MMA CETP Mahad  Purpose of Existence  The Mahad Industrial Area came into existence in the later part of eighties to overcome the water pollution related problems of the area.  Tremendous water pollution in surrounding of industrial area and & creek  Thought process developed in early nineties to develop a CETP  However, actual development activity started only in 1998-99.  The treatability studies were conducted in the year 2000 by M/s. Paramount Ltd., Baroda.  The DPR was prepared in Nov. 2000 & technical appraisal done by IIT, Mumbai in 2001.  Primary treatment commissioned in 2003. Although the project execution was delayed due to financial difficulties,  The project was completed and was fully operational only in June 2005. Industry membership status

Large Scale Industries 16 Large Scale Medium Scale Industries 16 Closed & Industries, 12% Temporary Small Scale Industries 40 Closed Industries, 26% Medium Scale Total 72 Industries, 12% Green 28 Green Small Scale Industries, 21% Closed/Temp. Closed 35 Industries, 30% TOTAL 135 Category wise distribution of Industries Industries Small Medium Large Total Chemicals 66 15 9 90 Pharmaceutical 1 1 3 5 Dyes & Dye Intermediate 2 2 0 4 Textile 2 0 2 4 Pigment 0 0 1 1 Paper 0 0 1 1 Packing 1 0 0 1 Engineering 3 2 0 5 Others 23 1 0 24 Total 98 21 16 135 • Historical Background of CETP • Effluent characteristics & Challenges of MIDC, MAHAD • Improving Effluent Treatment & Management • Journey towards Sustainability Nature of Waste water – MAHAD MIDC

Flow cu. m/d 5500 – 6000 pH 4.5 – 8.5 COD mg/L 4500 – 5500 BOD mg/L 1200 – 1600 TSS mg/L 2000 – 4000 TDS mg/L 10000 – 15000 Design Capacity

Plant Capacity 7.5 MLD Avg. influent qty 6.5 MLD Aeration volume Capacity 11500 Cub Mtr Designed COD 3500 ppm Designed BOD 1000 ppm CETP FLOW DIAGRAM Primary Treatment Secondary Treatment Tertiary Treatment

Lime PAC

Industrial Biotower Effluent Pump Grit Oil pH Flash Pump Equalisation Clariflocculator Feed Biotower Chamber Trap Correction Mixer Sump Grit Receiving Sump with Filtrate Pump Overflow Floating Aerators Polyelectrolyte Centrate SDB

Drying Dewatered Decanter And Sludge Pump Disposal Backwash Polyelectrolyte To MWML Thickener

Pressure Pressure Sand Sand PAC Lime Filter Filter Nutrients Pump Pump

MIDC Reaction Beef extract Disposal Flash Clarifier Sump Clarifier Mixer Flow Pump Distributor Polyelectrolyte Discharge Aeration Tank 1 and 2 To Air with Diffused Aeration saline zone Blower & 9 No floating At aerators ovale Post Commissioning of MAHAD CETP & Performance During 2006 to 2010 Design Inlet Outlet Flow cu.m/d 7500 5500 – 6000 5500 - 6000 pH <4.0 4.5 – 8.5 7.0 – 8.0 COD mg/L 3500 4500 – 5500 1800 – 2500 BOD mg/L 1500 1200 – 1600 120 – 160 TSS mg/L 500 2000 – 4000 < 100 TDS mg/L 2500 10000 – 15000 8000 • Mahad MIDC area was declared in the list of Dirty thirty in world survey report in year 2004 CETP Poor Performance – Environmental Aspects & Impacts . Higher inlet COD along with • Inadequate treatment leading to heavy sludge and dark color. Frequent agitation and public . Operation issues- infrastructure & nuisance from Khadipatta due to staff. obnoxious smell and dark color of effluent in creek. . Bribing to sampling team. • Lost goodwill in society. . Irregular recovery of COD charges. • Frequent breakdown of effluent pipeline due to sludge & . Leakages of storm water through liberation of gases due to damaged pipeline anaerobic conditions resulted chambers resulting high flow to shutdown of whole Mahad MMA CETP and overflow to river. industries many times- Economy loss to industries • Demand for drinking water in Khadipatta. CETP Poor Performance – Aspect & Impact on Environment continued..

• Due to Non-performance of CETP resulted into following… • Discharge line breakage and pollution of water source • Intermittent effluent discharge by MIDC due to villagers agitation • Production loss • Pollution problems in and around MIDC • Sludge accumulation in receiving sump and other equipments like clarifiers and civil tanks. • Implication • Show-cause notice by MPCB • Revoke of Bank Guarantee of Rs. 25.00 lacks • Imposition of Penal charges by MPCB • Serving closure notice to CETP and to all industries • Huge cost of sludge removal and disposal to MWML site • Historical Background of CETP • Effluent characteristics & Challenges of MIDC, MAHAD • Improving Effluent Treatment & Management • Journey towards Sustainability Challenges/Problems

• Very few factories in the MAHAD MIDC area had an ETP with full fledge treatment facilities at the start of the CETP project • Member Industries were ready to pay penalties rather than treating their effluents culture more prevalent. • No Concept of Recycle, reuse by member industries. • Poor Operation & Infrastructure - inefficient aerators and blowers, Poor Laboratory infrastructure for accurate & fast analysis. • High Hydraulic load during monsoon season due to the poor & damaged concrete chamber and old pipelines of incoming effluent. • Frequent breakdowns of Effluent disposal pipelines from CETP to Ovale. • CETP Staff not Competent enough, More prone or get trapped to Bribery leading manipulation of data . • CETP run on contractual . • Poor recovery of treatment charges from industry. Improving Effluent Treatment & Management From 2012 onwards

• Steps taken for improvement of plant Operation & Maintenance • Contractual operation & Maintenance suspended and Society overtook the O & M and all director spend sufficient time for monitoring and day to day work in society. • Replacement of inefficient aerators and blowers by efficient surface aerators, screw compressors and instrumentation. • Up-gradation of Laboratory infrastructure for accurate & fast analysis. • Regular preventive maintenance of plant machinery and sumps. • Restructuring and strengthening of Civil structures. • Installed online monitoring system on influent and treated effluent Improving Effluent Treatment & Management continued…

• Appointment of qualified staff & Training to staff for their skill improvement. Improvement of pay-package, incentives , stern action against employees who were indulged in malpractices. • CETP started focuses on how to manage and monitor the different units/industries of ETP, Improved Competence of their field staff and Laboratory staff on how to collect, sealing and preserve samples from different units of ETP and send it to the laboratory for analyzing, which parameters have to be analyzed, how frequent sample has to be taken from different industries etc, • With consistent follow-ups by CETP and rounds of meetings, several member industries developed plans, constructed and enhanced treatment facilities in their ETPs. Improving Effluent Treatment & Management continued…

• Knowledge Development of Effluent Treatment - The CETP arranged several workshops and Seminars for the Member industry owners and management, where representatives from ETP designers and suppliers provided know-how and latest technological solutions to those who already have an ETP and facing problems regarding operating and monitoring ETP and also to member industries who are intending to install new treatment facilities in their own industry. • Arranged internal visits to the best performing industries in terms of Effluent treatment management. Improving Effluent Treatment & Management.. Contd…

• Determining effluent characteristics – Monitoring individual industries ETP/ Zone wise performance. ( As Guided by Dr. Rakesh Kumar, NEERI) • The CETP has been assisting these member industries by reviewing and monitoring the operating efficiency of ETPs and also providing support in ETP management to improve efficiency and where possible try to reduce the running costs of the ETP. • Visit of Executive committee member during night vigilance sampling to support sampling chemist in case of disputes/resistance for taking sample and also if required calling local MPCB officer to witness the facts. • Deputed 24 hours monitoring duty of sampling chemist if industry is not cooperating and discharge high COD effluent. • Valuable contribution of founder Members Mr. Suresh Bhonsle ,Mr. Mohanti & Mr. J.Z. Patil • Appointment of technical consultant Mr. Hemant Rane . Improving Effluent Treatment & Management continued…

• Turning Point • During Dec- 2014 , Executive Body, CETP took vital decision to evaluate individual ETP performance by doing Stage-wise sampling and analysis. • This resulted into identifying of poor performing & defaulter industries. • These industries pressurized for the up gradation of ETP Management systems in their Units. • Most of the identified and defaulter industries improved their performance. This resulted into substantial reduction in Organic load . • CETP Management has taken stringent actions on industries who has still remain defaulters and name of such industries notified to MPCB for further actions. • Within six months CETP inlet COD drastically reduced from the range of 1500 to2000 ppm to 700 to 900 ppm ( April 2015 onwards) • Since last one year treated effluent norms maintained as per consent limit Improving Effluent Treatment & Management.. Contd…

• Weekly Executive body meeting to review MMA CETP performance and resolve operation and sampling team issues. • Calling defaulting industry in weekly executive body meeting and, taking action plan for improvement, in case repeated violation reporting to MPCB for further action • Joint Analysis In case of deviation/difference in MMA CETP and member industry reading - Giving chance for Joint analysis of sealed sample and consider that analysis for billing purpose. • Appointment of ISO consultant to implement Quality management systems, Environmental & legal compliance, Health & safety practices. • Incentive scheme for best performance of staff through performance appraisal system. • Involvement of Sr. NGO Dr. Patwardhan for their valuable inputs. Management

Built up strong team to combat the pollution

• Executive Committee Members-11 • Technical Committee-4, • Sampling & Vigilance team-4, • General Manager-1 • Plant Operations’ Manager-1, • Mechanical Engineer-1 • Environmental Officers- & Chemists – 8, • Operators-11, • Technicians-4, • Senior Account-1, • Office staff-3, • Operation Helpers ( from surrounding villages) --30 Improved performance from year 2015

• Effluent color Almost colorless. • Inlet COD 700 to 900 ppm • Inlet BOD 100 to 150 ppm • Outlet COD 190 to 250 ppm • Outlet BOD 50 to 90 ppm Incoming Effluent Color before & and after Effluent Color Before & After at bio-tower Effluent Color Before & After at Disposal point Disposal point down stream Average Stage Vise COD Reduction year 2015

1800

1600

1400

1200

1000 In let eff. COD mg/lit

800 A.Primary COD mg/lit

600 Secondary COD mg/lit

400 Tertiary COD mg/lit 200

0 JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC Average Stage Vise BOD Reduction for year 2015

600

500

400

300 Inlet eff. BOD mg/lit

200 A.Primary BOD mg/lit

Seconday BOD mg/lit 100 Tertiary BOD mg/lit 0 JAN FEB MAR APR MAY JUN JUL AUG SEPT OCT NOV DEC MPCB RESULT FOR YEAR 2015 OF CETP 400

350

300

250

200 MPCB Results year 2015 150 BOD outlet

100 MPCB Results year 2015 50 COD outlet

0

1/5/2015 2/9/2015 3/2/2015 5/5/2015 6/8/2015 8/3/2015 8/5/2015 9/7/2015

2/16/2015 4/20/2015 1/15/2015 1/26/2015 3/16/2015 3/30/2015 4/13/2015 5/18/2015 5/30/2015 6/18/2015 6/29/2015 7/13/2015 7/20/2015 7/27/2015 8/17/2015 8/27/2015 9/18/2015 9/28/2015

10/12/2015 12/29/2015 10/26/2015 11/16/2015 11/30/2015 12/14/2015 MPCB RESULT FOR YEAR 2016 OF CETP

300

250 240 240 224 216 208 208 210.4 200 192 192 200 184

150 MPCB REPORT 2016 OUT LET BOD MPCB REPORT 2016 OUTLET COD 100 90 90 90 80 80 72 70 73.2 60 50 50 50

0 ROLE OF MEMBER INDUSTRIES IN IMPROVING CETP PERFORMANCE • Few of Large scale & RED category Industries upgraded their ETP by using new technology like MEE, RO, aeration systems and thus started recycle and re-use of effluent in their own plant/ processes resulted organic Load as well reduced the hydraulic load to CETP. • Member industries started fall in line as per direction given by Hon. High Court i.e synchronization of products • Few of the Industries adapted the Waste to Wealth concept and thus converting their wastage in to the by-product and reusing in-house or selling as byproduct to the other need industries for their actual uses. This lead to reduction in TDS levels • The industry like H. acid manufacturer which was using spent acid for the isolation, generated gypsum and iron oxide sludge is selling to the cement and still manufacturing industries. Key of success

• Timely Repairs of damaged chambers on effluent collection lines by MIDC to avoid storm water leakage and to reduce hydraulic load on CETP. • MIDC Focused on preventive maintenance of effluent lines from CETP to Ovale. • Executive engineer MIDC has always played vital role between Khadipatta public and CETP body to improve communication and relations. • Actions considered and improvements made as per guidelines of Dr. Rakesh Kumar from NEERI during DPR to do the backward integration of incoming COD load. • With the support of local MPCB officer and MMA CETP joint visits are conducted to Defaulting units. • Quarterly review meetings with Local Govt. authority , SRO & RO- MPCB, NGO to review public complaints due to pollution problems in MIDC and Khadipatta and to tackle the issues at local level. Action Taken in 2014-2016

 First in to Install Online monitoring system as per CPCB guidelines.

 Modified the Laboratory by providing/up-grading the testing equipments with qualified chemists.

 Segregation of MIDC residential colony sewage with separate line and connecting directly to aeration for Bio-Mass seeding.

 Nine number of sumps have been constructed at different location in order to monitor the pollution levels.

 Treatability study of incoming effluents in context to change in the characteristic of the incoming effluent

 Enhancing the operation and monitoring by integrating the advanced instrumentation.

 First in Maharashtra (2nd in India) to qualify for IMS certification for effective implementation of QMS , Environment, Health & safety for efficient quality operations. (ISO-9001:2008, ISO-14001:2004 & OSAH-18001:2007) certificate is granted by ICS certification body

Social Activities

A. Providing drinking water to Khadipatta Villages through MIDC and reimburse 90% payment. B. Financial help to schools for e-learning. C. Provided free mobile hospital facility to all villages in Mahad. Permanant Mobile hospital Seva to surrounding Villages & Adivasi Vadi Areas for Mahad Taluka Permanant Mobile hospital Seva to surrounding Villages & Adivasi Vadi Areas for Mahad Taluka Permanant Mobile hospital Seva to surrounding Villages & Adivasi Vadi Areas for Mahad Taluka Impact of best MMA CETP performance • Villages covered in ecosensitive zone passed resolutions to delete their name from the ecosensitive zone list and supported for expansions and inviting for new industries. • Surrounding peoples started involving in various industrial welfare programs. • Due to scientific approach and best performance of CETP students from various universities approaching for academic project work under guidance of our tech experts e.g. recently Mr. Amit Late from MPCB FO has been published his research paper on process of Sodium sulphate recovery in the international conference of Water Environment, Energy & Society at Bhopal. • Started giving respect to industry Support Required from MPCB/MIDC for Sustainable Development of Industry

 ECO sensitive zones to be reconsidered to enhance the Industrial growth in Mahad MIDC.  For the Development of the Mahad Industrial area permission to new in coming industries.  Additional /standby disposal line required from Village Muthavali to Ovale village and extension of the line to the saline zone as per reports given by NIO. Proposal is under process with MIDC but need to speed up Video Clip

VID-20160302-WA0002.mp4 Future plans.. Journey towards Sustainability A. Treatability study with new MBR technology to increase MMA CETP capacity for industrial growth. B. Provide support for sewage treatment of Birawadi village. C. Set up compost plant in MMA CETP for canteen waste disposal of all industry and other biodegradable waste in surrounding. D. CSR activities for surrounding villages. OUR GOALS

Continuously achieve MPCB prescribed norms 1 2 Conservation of the natural resources 3 Work to achieve the Golden point 4 for balancing of ECO system 5 Safe planet for coming next Generation 6 Provide Green environment to the society

Seven Billion Dreams. One Planet. Consume with Care

• Backup slides

We work together

Action Taken in 2010-2015 • Installed high efficient aeration system by providing 9 Nos. of aerators (Total 270 H.P.)with cost of Rs: 65 lacs, • Revamping of Chemical dosing system with cost of Rs: 15 to 20 lacs, • Civil work of receiving sump’s pump house & sump enclosed wall jacketing with cost of Rs: 15 lacs, to arrest the leakages of receiving tanks. • Modification of Bio Tower, Flocculater & Scrappers in Primary & Secondary clarifiers with cost of 4.5 lacs, • Revamping of sand filters with cost of Rs: 2.5 lacs, • Replacing old pipe lines with cost of Rs: 5lacs, • Segregation of low COD effluent of 2.5 MLD & feeding to tertiary treatment . • Installed 2 number of sound proof and energy efficient air blowers of 37kv each of Atlas Copco make. In this case we save 30-40% energy of air blowers in Jun 2014 • Dissolved oxygen level increased from 0.7 to 1.5 ppm. • Improved F/M Ratio from 1.5 to 0.9 • Optimized the Dosing Pumps capacities in Chemical House to improve the Physico Chemical Treatment in Jan2015 • Replaced old inefficient pumps by Screw Pumps in Primary & Reaction Clarifiers and Sludge Thickener for de-sludgeing Success story of Industries

PHOTO GALLARY: ETP, MEE & Spray Dryer Crocodile at the CETP Disposal point