DSTSPL Continuation Sheet

TECHNO COMMERCIAL PROPOSAL

For

EFFLUENT TREATMENT PLANT

(Based on Preliminary Process, Anaerobic Process & Aerobic
Process Followed by Sludge Dewatering Process)

For

M/s. NATURE DELIGHT DAIRY & DAIRY PRODUCTS

PVT LTD., INDAPUR

For

Treatment of 1000 m3/d of Dairy Effluent

Submitted By
Diligent Solutions Technology Services Pvt. Ltd.
7, Chintamani Apartments, Plot 16,
Chintamani Society, S. No. 25/4,
Karvenagar,
PUNE 411 052
Telefax: 020-25454446
E Mail: [email protected]

Date –19/12/2019, Revision: 02

DSTSPL Continuation Sheet

INDEX

Section I Introduction to UASB Process

Section II Design Data

Section III Process Description

Section IV Scope of Supplies

Section V List of Exclusions

Section VI Battery Limits

Section VII Utilities

Section VIII Commercial Terms and Conditions

DSTSPL Continuation Sheet
Section I
Introduction to UASB – Process

The heart of the UASB system is the anaerobic reactor based on Upflow Anaerobic Sludge
Blanket process. The reactor consists of a large corrosion resistant tank which incorporates a
unique 3-phase settler called as GLSS, to separate the sludge, biogas and effluent. The settler is
located at the top of the reactor and is designed for specific COD reactor loadings and hydraulic
throughput.

A flow distribution network is located at the base of the reactor. This network is designed to
distribute the flow evenly throughout the bottom of the reactor. This eliminates short - circuiting
and promotes the proper formation of the sludge flocs which is a critical factor in reactor operation.
The distribution network is designed to facilitate easy cleaning, thereby eliminating potential
plugging problems.

New bacterial cells formed in the reactor aggregate into tiny flocs with extremely good settling
characteristics. The biogas produced by the bacteria in the form of small bubbles rises upward
through the sludge bed / blanket zones and provides a natural mixing action. When the biogas
reaches the top of the reactor, it is removed by gas collectors. A gas-free zone above the collector
makes possible the settling of finely dispersed solids to the reactor bottom.

SALIENT FEATURES OF THE UASB PROCESS

• High treatment efficiency in terms of BOD & COD reductions in single stage
• Very low or practically nil energy requirements
• Ability to withstand organic and hydraulic shock loadings
• Low nutrient requirements
• Production of Biogas with high percentage of methane which can be converted into an useful
energy resource viz. Heat, Electricity, etc.
• Low space requirements due to higher organic loading rates
• It is a high rate process i.e. It can operate at high volumetric loading
• Low production of stabilized excess sludge with very good dewatering characteristics
• Low operation / maintenance costs since very few moving parts
• Sludge can be stored for extended periods of time (bacteria go dormant)
DSTSPL Continuation Sheet
ADVANTAGES OF THE UASB PROCESS OVER
CONVENTIONAL ACTIVATED SLUDGE PROCESS

The “ UASB ” process has been recognized and accepted world wide as the “ Most Cost
Effective ” process, due to following direct and inherent advantages, as compared to traditional
conventional system i.e. Activated Sludge Process :

♦ Higher efficiency and working results.

♦ Compact reactor, hence space reduced to a large extent.

♦ Very low power consumption (mainly required for feed pumps only).

♦ Stable process

♦ Production of stabilized excess sludge is low with very good dewatering characteristics.

♦ Low nutrient requirement, as bacteria retain Nitrogen & Phosphorus and there is no
destruction of cells.

♦ Resistant to shock loadings

♦ Methane rich biogas is produced as a by-product which can be effectively used either for
domestic or industrial purposes.

♦ Volumetric loading rate is high. .

♦ In case of power failure or long shut down, the bacteria go into dormant stage and plant can
be restarted to take full load within short period.

♦ Since the anaerobic digestion takes place in a closed reactor, there is no foul smell in
surrounding area and in the vicinity of E.T.P. Further, the nuisance due to flies, mosquitoes
etc, is totally eliminated.

♦ “UASB” process eliminates large number of pumps / blowers / aerators etc. hence operating
and maintenance cost reduces to a large extent.

The system proposed by us has many advantages over the Conventional Activated sludge
treatment scheme. These are as follows:
1. The total capital cost of UASB followed by Extended aeration is substantially less
than the Conventional Activated sludge process.
2. The operating electrical power requirement of the UASB + Extended Aeration is
about 50% of that of the conventional ASP.
3. The excess sludge generation in the UASB + Extended Aeration is negligible as
compared to the conventional ASP.
DSTSPL Continuation Sheet

Section II
Design Data

Raw Effluent Characteristics:

The Preliminary Process, Anaerobic Process & Aerobic Process followed by Sludge Dewatering
Process is designed on the basis of the following characteristics of raw dairy effluent as furnished
by you as indicated below in Table 1.

Table 1 - Raw Effluent Parameters (At the inlet of Inlet Channel)

Parameter Value
Flow, m3/day 1000
pH 9 – 11
BOD, mg/l 1500 – 2000
COD, mg/l 3000 – 4000
TSS, mg/l 300 – 400
TDS, mg/l 1000 – 1800
Chloride, mg/l 300 - 400
Sulphate, mg/l 600 - 700
Temperature, deg C 30 – 40
Oil & Grease, mg/l 100

Treated Effluent Characteristics:

The anaerobically treated effluent Ex – UASB process will have characteristics as mentioned
below in Table 2
Table 2 – Ex UASB Process

Parameter Value
pH 6.5 – 7.5
BOD Reduction 85 %
COD Reduction 80 %
Biogas Production Co-efficient 0.35 - 0.40 m3/kg CODr
Total Biogas Production 900 m3/ day Max.
BOD, mg/l 225
COD, mg/l 600

The anaerobically treated effluent will be further subjected to Aerobic Process. The treated
effluent parameters after Aerobic Process shall be as indicated below in Table 3.
DSTSPL Continuation Sheet

Table 3 – Ex Aerobic Process

Parameter Value
pH 7.0 – 8.5
BOD, mg/l < 30
COD, mg/l < 100
TSS, mg/l < 100
TDS, mg/l < 2100
O & G, mg/l < 10

PROCESS DESIGN CONSIDERATIONS

♦ Effluent Treatment Plant is designed for the dairy plant effluent and will consists of
Preliminary Process, Anaerobic Process & Aerobic Process followed by Sludge Dewatering
Process.

♦ The preliminary process includes fat removal, screening, collection, oil & grease removal,
equalization, flash mixing & primary clarification.

♦ The Anaerobic Process includes Buffering (acidification), neutralisation, UASB Process

and Biogas Handling System & Hopper Bottom Settling Tank. The Aerobic Process
includes Aeration & Secondary Clarification & Treated Effluent Tank. The Sludge
Dewatering Process includes Sludge Drying Beds.

♦ As the pH of the effluent available at the inlet is in between 9.0 – 11.0 then either alkali or
acid will have to be used for neutralization during process stabilization and commissioning
and the consumption of the same can be reduced gradually. We propose dosing tanks for
dosing of alkali or acid by gravity to the buffer tank.

♦ The treated effluent parameters Ex – Aerobic Process will be guaranteed for the raw effluent
parameters mentioned above in the Table 1.

ECONOMICS OF BIOGAS UTILIZATION

COD Load : 3000 kg/d Max.
Gas Production Co-eff. : 0.35 - 0.40 m3/kg CODr
Total Biogas Production : 900 M3/d Max.
Calorific Value Of Biogas : 6000 Kcal/m3
Total Calorific Value : 5.40 X106 K-Cal.
DSTSPL Continuation Sheet
Section III
Process Description

The following section provides a brief description of the process flow diagram and the unit operations
involved in the proposed treatment:
The raw effluent from the dairy plant will enter into Inlet channel to remove free floating fat
manually. The effluent from inlet channel will enter into Screen Chamber which is provided with one
coarse screen and one fine screen. Coarse material & fine solids in the effluent will be removed
periodically from the screen chamber. The effluent from screen chamber will enter into Collection
Tank from where it will be pumped to Equalisation Tank, where any hydraulic as well as organic
variations will be dampened. Coarse bubble diffusers will be provided for complete mixing of the
contents of the Equalization Tank.
The equalised effluent will be then pumped to Flash Mixer. A flash mixer is provided with an
agitator. Chemicals will be dosed in the flash mixer from the Dosing Tank by using dosing pump. The
effluent from flash mixer then flows by gravity in Primary Clarifier where free floating solids will be
removed by skimmer and settled suspended solids will be pumped for dewatering and disposal on to
the Sludge Drying Beds while the filtrate will be taken back to the equalization tank.
The clarified effluent will enter into Buffer Tank where alkali or acid will be dosed by gravity from
Dosing Tanks if required. Buffer Tank is designed for a specific HRT considering the recycle of the
treated effluent to maintain certain pH of the effluent entering UASB Reactor and also to maintain
certain feed upflow velocity in the UASB Reactor for mixing purpose.
The effluent from buffer tank will then be pumped by using pumps to the proposed UASB Reactor
through a series of distribution pipes. The multiple distributions ensure a uniform flow of liquid
throughout the sludge blanket making maximum use of available high bacterial population. The liquid
rises to the top of UASB reactor along with the biogas generated and also some sludge particles.
A unique three phase separator separates out the biogas, liquid and the sludge particles. The biogas is
allowed to leave through collecting domes and is carried through a gas header, foam trap, sediment trap
to gas flare for ultimate flaring to atmosphere. The liquid overflows through the gutters and the
suspended solids then separated are allowed to settle down in the sludge blanket thereby retaining
valuable bacterial population (attached to the suspended solids).
The anaerobically treated effluent from UASB Reactor shall then enter by gravity into Hopper Bottom
Settling Tank for settling of any suspended solids carryover from UASB System. The settled sludge
will be pumped back to the buffer tank while the overflow from the hopper bottom tank will enter by
gravity into Aeration Tank. The aeration is achieved by means of fine bubble diffusers which also help
in the complete mixing of the contents of the aeration tank. The activated sludge generated from the
aeration tank will be settled in the Secondary Clarifier. A part of the settled activated sludge is
recycled back to the aeration tank by using pumps for maintaining a desired MLSS concentration,
while the excess sludge is pumped onto the Sludge Drying Beds for further dewatering while the
filtrate will be taken back to the equalization tank.

The treated effluent from secondary clarifier will be collected in a Treated Effluent Tank from where
it can be discharged for final disposal or for the gardening purpose.
DSTSPL Continuation Sheet
Section IV
Scope of Supplies
1. CLIENT’S SCOPE
Civil Works:
Sr. No. Unit Specifications Quantity
1. Inlet Channel & Screen 1 No.
Chamber
Length, m 21.0
Width, m 1.0
SWD, m 1.0
Free Board, m 0.3
MOC RCC

2. Collection Tank 1 No.

Length, m 5.25
Width, m 5.25
SWD, m 3.0
Free Board, m 0.3
MOC RCC with pipe railing

3. Equalization Tank 1 No.

Length, m 13.0
Width, m 13.0
SWD, m 3.0
Free Board, m 0.3
MOC RCC with pipe railing

4. Primary Clarifier 1 No.

Diameter, m 12.0
SWD, m 3.0
Free Board, m 0.5
MOC RCC

5. Buffer Tank 1 No.

Length, m 13.0
Width, m 4.3
SWD, m 3.0
Free Board, m 0.3
MOC RCC with pipe railing
DSTSPL Continuation Sheet

6. UASB Reactor 1 No.

Diameter, m 14.6
SWD, m 6.0
Free Board, m 0.5
MOC Foundation with RCC Raft, PCC Raft, Rubble
Soling & Compacted Sand Filling and
Superstructure in RCC with 1 m wide walkway
around the reactor with Pipe Railing of 1m
height and Drain Channel around the reactor and
connecting gutter to buffer tank

7. Hopper Bottom Settling 1 No.

Tank
Length, m 16.0
Width, m 1.75
SWD, m 3.0
Free Board, m 0.5
MOC RCC with pipe railing

8. Aeration Tank 1 No.

Length, m 16.0
Width, m 16.0
SWD, m 3.0
Free Board, m 0.5
MOC RCC with platform, ladder & pipe railing

9. Secondary Clarifier 1 No.

Diameter, m 9.0
SWD, m 2.5
Free Board, m 0.5
MOC RCC

10. Treated Effluent Tank 1 No.

Length, m 13.0
Width, m 13.0
SWD, m 3.0
Free Board, m 0.3
MOC RCC with pipe railing

11. Sludge Drying Beds 6 Nos.

Size, m 7.0
Total Height, m 1.0
MOC RCC with sand & gravel media filling
DSTSPL Continuation Sheet

12. Other Foundations for a. Feed Pumps, Dosing Pumps & Dosing Tanks 1 Lot
b. Air Blowers
c. Foam Trap, Biogas Flare
d. Cable trenches, pipe supports
e. Inserts required in civil structures

13. MCC/ Lab Room and 1 No.

chemical storage room

2. DSTS PVT. LTD’S SCOPE

A. New UASB System, New Biogas Handling System:
Sr. No. Unit Specifications Quantity
1. UASB System comprising of: Reactor Dia.14.6 m x 6.0 m SWD 1 Lot
a. Influent Header In M.S of suitable size
b. Bottom Distribution System HDPE - 10 kg/cm2
c. Three Phase Settler MSEP
d. Supporting Structure MS with anticorrosive painting
e. Distribution Line Valves As per Design
f. Baffles, Effluent Gutters etc. In MS
g. Sampling Ports Suitable size
h. Inspection Manhole 1 Lot.

2. Biogas Handling System comprising of: 1 Lot

a. Foam Trap
b. Sediment Trap
c. Flame Arrestor
d. Gas Flare System without Ignition
System
DSTSPL Continuation Sheet

B. Mechanical Bought Outs & Instrumentation:

Sr. No. Unit Specifications Quantity
1. Bar Screens (Coarse 10 & Fine Screens) 2 Nos.
Length, m 1.0
Depth ,m 1.0
Bar Space opening Coarse 10 mm, Fine 5 mm
Cleaning Mode Manual
MOC MSEP

2. Air distribution grid in Equalization Coarse Bubble diffuser grid, 1 Lot

Tank & Sludge Tank HDPE, 6 kg/cm2

3. Equalization Tank Feed Pump 1 No.

Flow Rate, m3/hr 60.0
Head, MWC 10.0
Motor Rating / Speed 7.5 HP / 2900 RPM
Type Horizontal Centrifugal Non Clog
MOC- Body/Impeller C.I./SS 304

4. Flash Mixer Feed Pump 1 No.

Flow Rate, m3/hr 42.0
Head, MWC 10.0
Motor Rating / Speed 5.0 HP / 2900 RPM
Type Horizontal Centrifugal Non Clog
MOC- Body/Impeller C.I./SS 304

5. Flash Mixer 1 No.

Tank Size L.(m) x W (m) x Ht. (m) 1.0 x 1.0 x 1.0
MOC MSEP

6. Agitator in the Flash Mixer 1 No.

Rating, HP 0.5
Type Turbine Type Impeller
MOC SS 304

7. Chemical Dosing System for Flash

Mixer
Dosing Tank 1 No.
Capacity, lit 500.0
MOC HDPE
Dosing Pump 2 Nos.
Pump Capacity, LPH 0 - 250 LPH, 0.5 HP, PP (1 +1)
Agitator in Dosing Tank 0.5 HP, SS 304 1 No.
DSTSPL Continuation Sheet

8. Primary Clarifier Mechanism 1 No.

Diameter, m 12.0
MOC MSEP

9. Primary Clarifier Sludge Drain Pump 1 No.

Flow Rate, m3/hr 17.0
Head, MWC 10.0
Motor Rating / Speed 1.5 HP / 2900 RPM
Type Horizontal Centrifugal Non Clog
MOC- Body/Impeller C.I. / SS 304

10. Dosing Tanks for Acid & Alkali 2 Nos.

Capacity, lits 500.00 (1 Each)
MOC HDPE

11. UASB Reactor Feed Pump 1 No.

Flow Rate, m3/hr 60.0
Head, MWC 15.0
Motor Rating / Speed 7.5 HP / 2900 RPM
Type Horizontal Centrifugal Non Clog
MOC- Body/Impeller C.I./SS 304

12. Air Blowers in Aeration Tank 2 Nos.

Flow, m3/hr 575.0 (1+1)
Head, m 5.0
Rating, HP 15.0 HP
Type Twin Lobe Roots
MOC C.I.

13. Diffusers for Aeration Tank 1 Lot.

Type Fine Bubble Tubular Retrievable
Size 90 mm dia. x 1000 mm long
MOC EPDM

14. Secondary Clarifier Mechanism 1 No.

Diameter, m 9.0
MOC MSEP

15. Sludge Recycle Pump 1 No.

Flow Rate, m3/hr 42.0
Head, MWC 10.0
Motor Rating / Speed 5.0 HP / 2900 RPM
Type Horizontal Centrifugal Non Clog
MOC- Body/Impeller C.I./SS 304
DSTSPL Continuation Sheet

16. Process Piping, Valves and Fittings Piping- M.S. Class B / UPVC 1 Lot.
within battery limits Valves- C.I Butterfly Wafer

17. Liquid Flow Meter 2 Nos.

Location Flash Mixer & UASB Feed
Pumps Delivery
Range 0 – 42 & 0 – 60 m3/hr
Type Full Bore Electro Magnetic

18. Level Switches for Pumps operation 1 for each Tank Location 2 Nos.
Location Flash Mixer & UASB Feed
Pumps

19. Pressure Gauges 1 Lot.

Location Pump Delivery
Range 0 - 4 kg/cm2

C. Electricals:
a. Control Panel Non- Draw Indoor Type.
b. Local Push Button Station for all Drives.
c. Associated Cabling and Earthing.

Notes:
1. Client to supply one point power connection at ETP during construction, erection and
commissioning.

2. DSTSPL will provide the drive ratings with individual connected and operating load.
DSTSPL Continuation Sheet

MAKES OF MAJOR MECHANICAL, BOUGHT OUTS, INSTRUMENTATION &

ELECTRICALS ITEMS

Sr. ITEM MAKE

No.
1. Centrifugal pumps Johnson / Kirloskar
2. Motors Siemens / Kirloskar / Crompton
3. Dosing Pumps Milton Roy / Prominent / E dose
4. Air blowers Kay / Everest / Usha
5. Diffuser Scogen
6. Primary & Secondary Clarifier, Flash DSTSPL
Mixer, Agitator
7. Foam Trap, Sediment Trap, Biogas DSTSPL
Flare
8. MS Piping Jindal / TATA / PRAKASH
9. HDPE Piping Godavari / Supreme
10. UPVC Piping Supreme/ Astral
11. Butterfly & Check Valves Normax / Intervalve / Delvel
12. Flow meters Adept / Forbes Marshall / E&H / Eq.
13. Level Switches Pune Techtrol/ Eq.
14. Pressure gauges Wika / H Guru
15. Cables Polycab / Finolex
16. Structural steel Jindal/ SAIL/ Eq.
17. Electrical switchgear Siemens / L&T/ Schneider
18. Electrical Components in MCC Panel Siemens
19. LPBS Hansu Control
DSTSPL Continuation Sheet

Section V
List of Exclusions

In addition to the scope of supply mentioned under SECTION IV (1.CLIENT’S SCOPE),

following facilities are to be provided by the Dairy.

1. Site Clearance, Site Development, motorable access to the site, consolidation of soil if
required, fencing and gate, internal roads and pathways.

2. Supply of required quantity of power at one point at ETP during construction, erection
and commissioning.

3. Supply of water required during construction, commissioning and for operation, at battery
limit specified by DSTSPL.

4. Laboratory chemicals, lab equipment and testing facilities.

5. Civil works as mentioned in the scope of supply. DSTSPL will provide general
arrangement drawings for civil works while structural drawings will be in client’s
scope.

6. Chemicals, Lube Oil, nutrients, seed sludge and necessary man power required for
stabilization of process and commissioning of plant.

7. Lodging and Boarding facilities alongwith communication facilities such as phone, fax,
email will be provided at free of cost to the supervisors, engineers deputed by DSTSPL
for supervision on civil works, erection and commissioning.
8. Secured space / godown for storage of material and hardware and also security for Plant
& Machinery, equipment etc.

9. Necessary facilities for unloading of plant, machinery, equipment etc to be provided.

10. All statutory approval from local authorities.

11. Biogas piping exceeding above 10 meters from the cut-of battery limit of DSTSPL
towards utilisation if required.

12. Disposal of free & skimmed fat & oil, skimmed oil & grease, dried sludge cakes from
SDB’s. Treated effluent pumping required for disposal.

13. Items not included in the DSTS Pvt. Ltd.’s scope of supply if any.
DSTSPL Continuation Sheet
Section VI
Battery Limits

1) INLET (From Client)

Water : Necessary quantity of water before mobilization of site and during

construction and operation and to inlet of Foam Trap and Dosing
Tanks with required pressure.

Power : Necessary and required power supply during construction and

operation at ETP.

Effluent : At the inlet of Inlet Channel with characteristics as outlined in

Table 1 of Design Data.

Chemicals / : As per requirement

Seed sludge

2) OUTLET (From DSTSPL’s Plant)

Biogas : From UASB Reactor to Biogas Flare located within 10 m.

Treated : At the inlet of Treated Effluent Tank

Effluent

Excess : Pumping to Sludge Drying Beds

Aerobic
Sludge

Primary : Pumping to Sludge Drying Beds

Sludge
DSTSPL Continuation Sheet

Section VII
Utilities

A. Area Required

App. 2200 - 2800 m2

B. Power

Operating Load - 45.00 HP

Connected Load - 60.50 HP

C. Chemicals / Nutrients and Seed Sludge

Lime / Caustic - App. 500 kg/day

OR
HCl Acid - App. 500 lit/day

PAC / Alum - App. 300 lit /day

Anaerobic Seed Sludge - App. 250 m3 (Only one time)

Aerobic Seed Sludge - App. 30 m3 (Only one time)

Notes:

1. The anaerobic & aerobic seed sludge requirement will be one time during process stabilization
and commissioning.

2. The acid & alkali requirement will be worked out as per actual field conditions & after knowing
the acidity and alkalinity of the effluent.

3. Depending upon the N & P content available in the raw effluent, nutrients in the form of DAP &
Urea are required for the process, which can be dosed manually into the buffer tank and aeration
tank as per requirement. The PAC / Alum requirement will be worked out as per actual field
conditions.
DSTSPL Continuation Sheet
Section VIII
Commercial Terms and Conditions

1. Validity:
Our offer is valid upto 30 days from the date of submission, and thereafter subject to the revision
confirming in writing.

2. Price:
Our price for the scope of supplies as defined in SECTION IV under “2. DSTS PVT. LTD.’S
Scope” and including design, engineering, detail engineering, supply, erection and
supervision on commissioning except civil works, shall be as indicated below

Sr. No. Item Price, Rs. Lakh

1. Design and Engineering, UASB System, Biogas Handling

System, Mechanical Boughtouts, Electricals and 79.00
Instrumentation, Erection and Commissioning

TOTAL 79.00

(RUPEES SEVENTY NINE LAKH ONLY)

GST : Extra at 18 %
P & F, Transport & Insurance : Extra at actuals

CLIENT SCOPE: COMPLETE CIVIL WORKS. TOTAL CIVIL

UNIT VOLUME – APP. 4500 M3

3. Terms of Payment:

30 % - Overall Interest free advance alongwith technically and commercially clear

purchase order.

60 % - On prorata basis against agreed billing schedule against proforma invoice.

10 % - After successful commissioning

4. Delivery Completion Period:

The supply, erection and commissioning of the plant will be completed within 4 - 6 months
period after completion of civil works from client.