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Improvements in Effluent Treatment Plant operations in the textile company M/s Faze Three Ltd. in GIDC Industrial Estate of Vapi, Gujarat

Primary Clarifier at Faze Three Ltd. with increased capacity 

Summary of the success

M/s Faze Three Ltd. is a large-sized textile company situated in the Gujarat Industrial Development Corporation’s (GIDC) Industrial Estate at Vapi. Despite the fact that the company fulfilled the inlet standards for the pre-treated wastewater discharged from its premises through the Effluent Treatment Plant (ETP) as per the norms set by the Common Effluent Treatment Plant (CETP) at Vapi, the company decided to further improve the operations of their ETP.  

Under the the “Sustainable and Environment-friendly Industrial Production (SEIP)” project of the Indo-German Development Cooperation, the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH engaged the German consultancy, GOPA Infra to provide solutions for improvement of selected ETPs in the Vapi industrial estate so as to reduce overall pollution load from the industrial estate. M/s Faze Three Ltd. was one such industry taken up under the SEIP project for its improvement. The German consultants visited M/s Faze Three Ltd. several times in the course of 2017, to assess and audit the company’s ETP operations, and to subsequently develop and suggest improvement measures. With handholding support and encouragement from GOPA Infra and GIZ, M/s Faze Three Ltd. replaced their ETP’s Primary and Secondary Clarifiers with equipment of higher capacity. The improvement achieved has been significant: the reduction of pollution parameters such as Suspended Solids (SS), Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (BOD), Total Dissolved Solids (TDS) and colour was achieved. 

About the problem

At the GIDC’s Vapi industrial estate, there are more than 1,500 industries from various sectors, such as chemical, paper, dye, drug and pharmaceutical, pesticide, fertilizer, electroplating etc. Most of these industries are members of the CETP of Vapi which has a capacity of 55 MLD. Due to the large volume and diversity of wastewater, the treatment of the effluent at the CETP has been very challenging. Hence, it has become very important for more homogenous wastewater streams discharged from the industries to reduce inlet pollution values at the CETP to ensure its improved operation.

The CETP is experiencing difficulties in treating effluent parameters, such as Colour, COD, BOD, TDS, TSS, Ammonical Nitrogen, Phenol etc. and is at the borderline of meeting the pollution board’s compliance requirements. The CETP treated effluent is directly discharged to the Daman Ganga River.

Despite the fact that M/s Faze Three Ltd. met all the CETP inlet norms, the industry wanted to improve the quality of the wastewater they discharge to CETP. In particular, they faced operational problems of the ETP during the primary and secondary clarification processes which led to improper settling of solids and subsequently to carry-over of Suspended Solids (SS) into next treatment units. 

Actions initiated

To systematically improve the situation, the Industrial Estate Vapi of the Gujarat Industrial Development Corporation (GIDC) was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” project of the Indo-German Development Cooperation. Jointly with GIDC, GIZ has been implementing the SEIP Project at Vapi since 2016.

Under SEIP, the German consultancy Gopa Infra was hired to assess the operations of 10 ETPs installed at chosen industries. In February, May and July 2017, the national and international experts visited those companies to collect data and samples in order to do preliminary assessments. Subsequently, further more detailed assessment for improvements was undertaken and improvement measure detailed.

Whilst the detailed assessments are still ongoing, some suggestions on improvements were already given during the initial site visits. The textile company, M/s Faze Three Ltd, is one of the companies that has already acted on the suggestions of the consultants, and installed new Primary and Secondary Clarifiers at their ETP. 

International expert from GOPA and a technical advisor from GIZ discuss findings and possible solutions with M/s Faze Three Ltd. 

ETP inlet at M/s Faze Three Ltd.

The Results

In the clarification process at the ETP of the industry, Suspended Solids did not settle properly. The carryover of the Suspended Solids resulting from this caused problems in subsequent treatment stages of the ETP. The German consultants suggested to improve the settling process in the clarifiers by increasing the capacities of the Primary and Secondary Clarifiers from 64m3 to 164 m3, and from 58m3 to 153m3 respectively. The measure led to significant improvements in pollution parameters, such as SS, COD, BOD, TDS and colour.

Problems identified

Solutions

Cost 

Results

Problems in the settling of solids in the ETPs clarification tanks due to insufficient capacity of clarifier tanks.

Increase of capacity of Primary Clarifier from 64m3 to 164 m3.


Increase of capacity of Secondary Clarifier from 58m3 to 153m3.

 1 million INR capital and installation cost

Improvement of water quality parameters, such as SS, COD, BOD, TDS and colour. 

Total cost: 1 million INR (capital and installation cost)

Environmental Benefits

Reduction of SS by 56% and TDS by 30%

Reduction of COD by 35% and BOD by 34%

Reduction of Colour by 30%

Before

After

The Success!..The benefits!!

Repeated interactions with SEIP’s project team as well as the international and national team of experts convinced M/s Faze Three Ltd. about the ETP improvements expected from the implementation of the suggested measure. One initial hurdle which consisted of space constraints was overcome by choosing compact clarifier models. M/s Faze Three Ltd. is very satisfied that the one-time investment would give them continuous improvement in the ETP’s operation. 

Before the intervention, there was a general lack of knowledge and awareness regarding the topic of wastewater treatment, its economic and environmental benefits, as well as on technologies and techniques available. Whilst many companies were apprehensive before the implementation of the measures, the readiness for change towards more sustainable methods as well as the openness for and the trust in new technologies and techniques substantially increased after the successful intervention. M/s Faze Three Ltd. representatives said that they would do the investment again. As a matter of fact, M/s Faze Three Ltd. is now looking into conducting a pilot study for tertiary treatment through Reverse Osmosis (RO) and Ultrafiltration (UF) to further improve the quality of their treated wastewater. 

Testimonials

Mr. Anand Sreeraj, Plant Head, Faze Three Ltd. 

The improvements which we implemented at our Primary and Secondary Clarifiers are giving us better results. We are now able to maintain 25 % MLSS in the aeration tank. Due to this improvement, the quality of the water that we are discharging to the CETP is much improved. We are now also planning to install Tertiary Treatment, such as RO or UF.

 

 

Mr. Bheemanna Chikkerur, Admin Head, Faze Three Ltd. 

Frequent interactions with the German experts and the GIZ-Vapi-team led to improvements in SS and Colour removal by increasing the capacity of the Primary and Secondary Clarifiers. Faze Three Ltd. is keen to do more for environmental improvement.

 

 
SEIP

Mr. Anand Sreeraj, Plant Head, Faze Three Ltd. 

The improvements which we implemented at our Primary and Secondary Clarifiers are giving us better results. We are now able to maintain 25 % MLSS in the aeration tank.  ...

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