MMA CETP MAHAD 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 Savitri River & 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