INDUSTRIAL TRAINING REPORT

AT

NIA CETP
Submitted To: Mayur Sir
College Mentor: Gaurav saxena Sir
Industry Mentor: Karn Patel Sir

Prepared by
PARMAR DHARMESH(16BE01046)

B.TECH CHEMICAL ENGINEERING.

GSFC UNIVERSITY, VADODARA

1
 ACKNOWLEDGEMENT

It has been my upmost privilege to work with NIA CETP. The opportunity of
training here has given me an enriching learning experience, which is a necessity
in our modern world of today. I have been fortunate enough to be trained under
immensely knowledgeable people.
I would first like to extend my thanks to Bakul Brambhatt sir, karn Patel sir
and Mayur sir for helping me out with orientation of my vocational training and
their efforts to make the whole process of my training at NIA CETP Smooth
experience.

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 DECLARATION
I / We------------------------------ , declare, the best of my/ our knowledge, at this
report is a true record of the work I undertook during my industrial training at -----
----------------------------------------------- and has never been submitted for the award
of a Degree in B.Tech (Chemical Engineering) to GSFC University or any other
institution of higher education.

Signature …………………… Date -------------

(_________________ Roll No. -------------) Date --------------

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 CERTIFICATE OF APPROVAL

This industrial training report has been submitted by our approval.

Signature ……………………… Date ……………………

( ------------------- )

Industry Mentor

Signature -------------------- Date ………………

( …………………… )

Faculty Mentor

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 OBJECTIVE OF TRAINING

The objective of training is to acquire practical and field experience along

with the theoretical experience gained by me. Training in field of engineering in
necessary as it provides me with necessary knowledge of the industry and makes
me capable to be prepared to work.

The technology is evolving day by day, and the graduates in field of

engineering should be well versed with technology being used in the industries
today. So to a build better tomorrow, it is imperative that they train the youth in
their respective fields of education.

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 INDEX

Sr. no. Content Page no

1 Introduction of CETP 7

2 Concept of common 8
treatment
3 CETP Categories 10

4 Hydrodynamic Cavitation 11

5 Treatment process 14

6 Baby boiler 15

7 Vaporizer 16

8 Rota flow meter 18

9 Filter press 21

10 Conclusion 24

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 Common Effluent Treatment Plant (CETP)
It is developed by GIDC in the year 1969, is located about 17 Km in the
northwest direction of Vadodara City . Nandesari GIDC estate, with an area
approx. 2.5 sq.km, mainly comprises of chemical industries. It has common
environmental infrastructure facilities like CETP, CHWTSDF (Landfill as well as
Common Hazardous Waste Incinerator).

The industrial statistics of Nandesari Industrial Area is given in following

table.

Type/Sector of Industries Nos

Chemical (Organic & 100
Inorganic)
Dyes Intermediate & 40
Dyes
Pharmaceutical (Bulk 15
Drug and Formulation)
Pesticides (Technical 4
Grade & Formulation)
Others 11

CETP is established by GIDC in the year 1984 for the treatment of mostly
small scale industries. Nandesari Industries Association (NIA) took over operation
and maintenance of CETP in November 1994. The design capacity is 12.5 MLD.
The CETP consists of Collection Sumps, Equalisation tank, hydrodynamic
cavitation unit, filter press, Mixing tank( Rectangular sump).

CETP discharges (2250 KLD) its treated effluent along with treated effluent
from M/s Deepak Nitrate (1300 KLD), M/s Indo Nippon (50 KLD), M/s Ineous ABS
(1000 KLD) into Pumping Station—I at Dhanora Take off Point, ECPL.

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 CONCEPT OF COMMON TREATMENT

The concept of effluent treatment, by means, of a collective effort, has

assumed reasonable gravity by being especially purposeful for cluster of small
scale industrial units. Common effluent treatment plant (CETP) not only help the
industries in easier control of pollution, but also act as a step towards cleaner
environment and service to the society at large. Small scale industries, by their
very nature of job cannot benefit much from economies of scale and therefore
the burden of installing pollution- control equipment, falls heavy on them.
Realising this practical problem, under the policy statement for abatement of
pollution the Govt. felt to extend the scheme for promoting combined facilities
for treatment of effluent and management of solid waste for clusters of small
scale industrial units and also to provide technical support to them. Accordingly,
Ministry of Environment & Forests, Govt. of India, had instructed various State
Pollution Control Boards, to examine the possibilities of establishing CETPs in
various Industrial estates in the respective states.

The concerted approach of joint or common effluent treatment provisions

has many advantages. Wastewater of individual industries often contain
significant concentration of pollutants; and to reduce them by individual
treatment up to the desired concentration, become techno-economically difficult
The combined treatment provides a better and economical option because of the
equalization and neutralization taking place in the CETP.

Other important issues for the merit of common treatment include, scarcity
of land at the industry's level and a comparatively easier availability of
professional and trained staff for the operation of CETP, which can otherwise be
difficult, at the individual industry level. For the regulatory authorities also,
common treatment facility offers a comparatively easier means of ensuring
compliance of stipulated norms. The handling and disposal of solid- waste also
becomes increasingly easier as the infrastructure is created in the project itself.
The concept of common treatment, based on feasibility, should be part of the
new industrial estates as essential component of infrastructure.

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• Advantages of Common Treatment
1. Saving in Capital and operating cost of treatment plant. Combined
treatment is always cheaper than small scattered treatment units.

2. Availability of land which is difficult to be ensured by all individual units in

the event they go for individual treatment plants. This is particularly
important in case of existing old industries which simply do not have any
space.

3. Contribution of nutrient and diluting potential, making the complex

industrial waste more amenable to degradation.

4. The neutralization and equalisation of heterogeneous waste makes its

treatment techno- economically viable.

5. Professional and trained staff can be made available for operation of CETP
which is not possible in case of individual plants.

6. Disposal of treated wastewater & sludge becomes more organised.

7. Reduced burden of various regulatory authorities in ensuring pollution

control requirement.

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 CETP Categories /groups
Homogeneous, in which industries providing similar good are, located in one area,
for instance, tanneries or engineering goods, or pulp and paper, etc. Heterogeneous, in
which industries providing widely divergent goods are placed together, such as
chemical, dairy, food, and fruit processing, tanneries, pulp and paper, pharmaceuticals,
etc.

INLET & OUTLET NORMS OF CETP:

Sr. No. PARAMETER INLET OUTLET UNIT

1 PH 5 to 9 6.5 to 8.5 -
2 Temperature 45 40 °c
3 Colour (pt.co.scale) in - 100 Units
units
4 Suspended solid 600 100 mg/litre
5 Oil & Grease 20 10 mg/litre
6 Phenolic compounds 5.00 1.00 mg/litre
7 Cyanide 0.20 0.20 mg/litre
8 Fluorides 2.00 1.50 mg/litre
9 Sulphides 2.00 2.00 mg/litre
10 Ammonical Nitrogen 50 50 mg/litre
11 Arsenic 0.20 0.2 mg/litre
12 Total Chromium 2.00 2 mg/litre
13 Hexavalent Chromium 1.00 1 mg/litre
14 Copper 2.00 2 mg/litre
15 Lead 0.20 0.2 mg/litre
16 Mercury 0.01 0.01 mg/litre
17 Nickel 5 3 mg/litre
18 Zinc 5 5 mg/litre
19 Cadmium 2 2 mg/litre
20 BOD(5 days at 20°c) 500 100 mg/litre
21 COD 500 250 mg/litre
22 Chloride - 600 mg/litre
23 Sulphate - 1000 mg/litre

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 24 Total Dissolved Solids - 5000 mg/litre
25 Free Ammonia 5.00 5.00 mg/litre
26 Insecticides/Pesticides Absent Absent -

Hydrodynamic Cavitation

• WHAT IS CAVITATION?
Cavitation phenomena was first observed by Osborne Reynolds in 1903. In
his paper which was titled “Experiments concerned with the boiling of water in an
open tube at ordinary temperatures” he explained cavitation as the bubbles of air
and vapour would be carried with great velocity from the low pressure at the
neck, where they formed, into the higher pressure in the wider portion of the
expanding tube; so that the pressure being greater than the Vapour tension,
condensation would ensue and the bubbles would collapse’. The phenomena was
never studied with much interest even though it is occurs in nature.

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 • Theory of HYDRODYNAMIC CAVITATION
At low flowrate, water is everywhere free of cavitation. Velocity is
maximum in the section of minimum area and pressure is then minimum. When
the flow rate is progressively increased, he minimum pressure decreases and
there will be a critical flowrate for which the vapour pressure is obtained at the
throat. At this operating point, cavitation appears in the section of minimum area.
In Figure, two bubbles are clearly visible in the upper part of the Venture. This is
the start of the cavitation state.

If the flow rate through the Venture is further increased, the extent of
cavitation increases. At this point the Calcium hypochlorite (generated inside)
when injected will oxidise the organic matter in exploded bubble and due to the
large surface area available.

The process of bubble generation, and the subsequent growth and collapse
of the cavitation bubbles, results in very high energy densities and in very high
temperatures and pressures at the surface of the bubbles for a very short time.

The overall liquid medium environment, remains at ambient conditions.

Controlled cavitation can be used to enhance chemical reactions due to
disassociation of vapours trapped in the cavitating bubbles.

This principle is used in the mineralization of bio- refractory compounds

which otherwise would need extremely high temperature and pressure
conditions.

By this technology, very difficult waste water generated from H-Acid, Vinyl
Sulphone, 4-NAP, 4- CAP, CPC, Nitro compounds, aniline Nitro compounds,
naphthalene derivatives etc. has also been possible. Phenolic compounds,
ammoniacal nitrogen after treatment are found to be below detectable limits.

The cost of treatment is very low (Rs. 0.08 0.12 per litre depending on the
COD present in the waste water. Waste water containing very high COD (80,000
90,000 mg/L) have also been successfully treated.

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• BLOCK DIAGRAM OF HYDRODYNAMIC CAVITATION UNIT

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 TREATMENT PROCESS

1. The industries book their effluent at the booking office at the CETP. The
waste water from different industries is brought to the treatment plant via
tankers.

2. The tankers is as per the inlet norms, the laboratory issues clearance slip to
the booking office. The tankers then discharges the effluent in to the
designated collection sump.

3. The waste water is collected in the inlet sumps. The waste water is then
pumped through screens and grit chamber to remove solids and grit.

4. From the grit chamber, the waste water flows into the equalization tank
where the waste water equalizes over flow and organic contents.

5. The inorganic effluent comes from the industries through the pipe line into
the equalization tank. After that waste water that to be treated is pumped
in cavitation plant.

6. Where wastewater is treated in cavitation venture pipe and chlorine is

injected to oxidized the organic matter and slurry of lime is also injected to
maintain PH about 7.5 to 8 and after that treated water sent to filter press.

7. The sludge from the filter press is collected directly into the tractor trolley
to be disposed-off in TSDF of NECL, Nandesari.

8. The treated water is collected in blue tank from where it is sent to

rectangular tank after that it is sent to Dhanora station from where through
open channel that treated water dispose in gulf of Khanbhat.

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 BABY BOILER

These Steam generators have water flowing through tubes and hot air is
generated by using pressurized natural gas or any other fuel at bottom. The hot
air thus produced heats the water to convert it into steam. These are vertical in
shape and app. height exclusive of chimney is 5 to 6 foot. Chimney height varies
depending upon the capacity & fuel to be used. These are fitted with water level
Glass, pressure gauges, safety valves & release valves. Rough and tough in
construction has virtually no repairs during very long time of operation. For
efficient working tubes are to be decaled every year.

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 A water softening plant is attached to boiler at feeding end. So that
minimum impurities go to the tubes which ensures better life and less
maintenance of the tubes.

• Operating Condition of Baby boiler

Pressure 125 mbar

Temperature 140 °c
Capacity 600 Kg/hr

Vaporizer

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 Vaporizers are devices which heat and vaporize a working fluid. In many
cases, they are similar to industrial boilers except that they do not build up high
pressures. Vaporizer units are most commonly used for low pressure heat transfer
by incorporating the vaporized stream as the heat exchange fluid. They can also
be used to vaporize liquid fuels or cryogenic liquids.

• Operating Condition Of Vaporizer

Pressure 98 kpa
Temperature 140 °c
Capacity 180 Kg/hr

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 Rota-Flow Meter

A rota meter is a device that measures the volumetric flow rate of fluid in a
closed tube.

It belongs to a class of meters called variable area meters, which measure

flow rate by allowing the cross-sectional area the fluid travels through to vary,
causing a measurable effect.

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• Advantages

1. A rota meter requires no external power or fuel, it uses only the inherent
properties of the fluid, along with gravity, to measure flow rate.

2. A rota meter is also a relatively simple device that can be mass

manufactured out of cheap materials, allowing for its widespread use.

3. Since the area of the flow passage increases as the float moves up the tube,
the scale is approximately linear.

4. Clear glass is used which is highly resistant to thermal shock and chemical
action.

• Disadvantages

1. Due to its reliance on the ability of the fluid or gas to displace the float,
graduations on a given rota meter will only be accurate for a given
substance at a given temperature. The main property of importance is the
density of the fluid; however, viscosity may also be significant. Floats are
ideally designed to be insensitive to viscosity; however, this is seldom
verifiable from manufacturers' specifications. Either separate rota meters
for different densities and viscosities may be used, or multiple scales on the
same rota meter can be used.

2. Because operation of a rota meter depends on the force of gravity for

operation, a rota meter must be oriented vertically. Significant error can
result if the orientation deviates significantly from the vertical.

3. Due to the direct flow indication the resolution is relatively poor compared
to other measurement principles. Readout uncertainty gets worse near the
bottom of the scale. Oscillations of the float and parallax may further
increase the uncertainty of the measurement.

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4. Since the float must be read through the flowing medium, some fluids may
obscure the reading. A transducer may be required for electronically
measuring the position of the float.

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 FILTER PRESS

An industrial filter press is a tool used in separation processes, specifically

to separate solids and liquids. The process uses the principle of pressure
drive,[clarification needed] as provided by a slurry pump. Among other uses, filter
presses are utilized in marble factories in order to separate water from mud in
order to reuse the water during the marble cutting process.

Generally, the slurry that will be separated is injected into the centre of the
press and each chamber of the press is filled. Optimal filling time will ensure the
last chamber of the press is loaded before the mud in the first chamber begins to
cake. As the chambers fill, pressure inside the system will increase due to the
formation of thick sludge.Then, the liquid is strained through filter cloths by force
using pressurized air, but the use of water could be more cost- efficient in certain
cases, such as if water was re-used from a previous process.

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Capacity 1 lakh litre in 2 hours
Area of plate 3600 cm²
Material of filter cloth Polypropylene

• Advantages

1. Simple in construction.

2. Low first cost.

3. Maintenance cost is low.

4. It provides a large filtering area per unit area of floor space occupied.

5. High operating pressures are easily developed.

6. It is possible to alter the capacity.

7. The majority of joints are external, so leakage is easily detected.

8. Flexibility

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• Disadvantages of Plate and Frame press:
1. Labour requirement is very high.

2. Discontinuous in operation. Periodic manual dismantling results in high

wear cloths. So the filter cloth life is relatively short.

3. Not suitable for high throughputs.

4. Presses frequently drip and leak, making housekeeping in the area a

problem.

5. Washing of cake is likely to be imperfect.

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 CONCLUSION
After the completion of the industrial internship, I have enhanced
competency and competitiveness in the respective area. I will try to relate the
experience in the workplace from the knowledge gained in the company under
supervision.

Here I gained the knowledge that can be used for a suitable job without
delay after studies.

I have learned soft skills appropriate to the working environment. With

experience, knowledge & skills acquired during an industrial internship, I will be
better prepared to face working world.

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