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Pollution reduction though improvements in ETP operations at M/s Sterling Pigments & Colours, Vapi

Pic: Mixing of lime at M/s Sterling Pigments and Colour after the intervention

Summary of the success

M/s Sterling Pigments and Colours is a micro-scale enterprise in the Gujarat Industrial Development Corporation’s (GIDC) Industrial Estate at Vapi. The company was facing problems with colour in the wastewater even after treatment through its Effluent Treatment Plant (ETP) – a situation which the company’s management and its six employees were eager to improve.

The German consultancy, GOPA Infra visited M/s Sterling Pigments and Colours several times in the course of 2017, to assess and audit the company’s ETP operations, and in order to subsequently develop and suggest improvement measures. With handholding support and encouragement from GOPA Infra and GIZ, M/s Sterling Pigments and Colours learned how to fine tune the coagulation and flocculation processes of the ETP by properly dosing the application of Lime and Ferrous Sulphate (FeSO4). This no-cost intervention led to a significant improvement of the quality of wastewater and even resulted in cost savings for the company.

About the problem

There are more than 1,500 industries from various sectors, such as chemical, paper, dye, drug and pharmaceutical, pesticide, fertilizer, electroplating, etc., located at GIDC Vapi industrial estate. Most of these companies are members of the Common Effluent Treatment Plant (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, however, is very challenging. Hence, pre-treated and more homogenous wastewater streams from discharging companies would greatly help reduce inlet pollution values at the CETP and lead to 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 control board’s compliance norms. The CETP treated effluent is directly discharged to the Daman Ganga River.

Despite being a micro-scale enterprise, M/s Sterling Pigment and Colours came forward with the wish to improve the outlet quality of its ETP’s wastewater. In particular, they wanted to solve operational problems faced during primary treatment of the ETP leading to high levels of BOD, COD, and Colour. 

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 under Indo-German technical cooperation. Jointly with GIDC, the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH 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 companies. In February, May and July 2017, national and international experts visited those companies to collect data and samples in order to do preliminary assessments. Subsequently, a further and more detailed assessment for improvements was undertaken and improvement measure detailed.

Pic: International expert from GOPA and a technical advisor from GIZ discuss findings and possible solutions with M/s Sterling Pigments and Colours

After assessing the issues of the ETP, the team of international consultants suggested some operational changes concerning the adequate dosing of Lime and Ferrous Sulphate which would improve the coagulation and flocculation process in the ETP.

Pic: Mixing arrangement of chemicals at M/s Sterling Pigments and Colours

Efficiency improvement

M/s Sterling Pigments and Colours is a micro-scale industry employing six employees in the GIDC industrial estate Vapi that came forward to be part of the SEIP project in order to improve the outlet quality of its company’s operation wastewater. In particular, Colour was improperly cleared in the primary treatment section, a problem which carried over to proceeding units of the ETP.

The consultants suggested adjusting the dosage of Lime and Ferrous Sulphate in order to improve the coagulation and flocculation processes in the primary treatment stage of the ETP. The coagulation process is used to increase the density of fine and colloidal particles in the effluent so that they can connect with other particles to form bigger sized particles, called flocs

After the successful implementation of the above measure, the company was keen to improve its operations further. As a result, two FRP vessels were installed to accommodate the resins and filters. The costs including material such as pump resins, filters, tanks etc. amounted in 500,000 INR. Wastewater quality improvements were achieved in the form of color reduction by an incredible 94.89%. 

Pic: Lime preparation

Pic: Lime dosing

Pic: FeSO4 preparation for dosing

Pic: FeSO4 dosing

Problems identified

Solutions

Costs

Results

Problems in the coagulation and flocculation process in the primary treatment section of the ETP

Adjust dosing of lime and ferrous sulphate

No cost

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


Savings of 6,000kg of Lime which translating into cost savings of INR 30,000 per year.


Savings of 3,500kg of FeSO4 per year translating in to savings of INR 60,000 per year.


Reduction in sludge translating into savings of INR 35,000 per year.

Yellow/orange colour in primary treated effluent visibly high

Installation of two vessels to accommodate the resins and filters  500,000 INR Reduction of colour by 94.89%

Total costs:

5,00,000

Total savings: 

INR 128,000 per year + + 94.89% colour reduction

Environmental benefits

Economic benefits

Reduction of COD by 16% and BOD by 15%.


Reduction of Colour by 43%.


Reduction of Sludge by 15%.

INR 30,000/ year saving through reduction of Lime.


INR 63,000/year saving through reduction of FeSO4.


INR 35,000 savings through decreased sludge handling and disposal cost.

Pic: Level of Colour before the intervention

Pic: Level of Colour after the intervention

The success – The benefits

What is most striking about this intervention, are the achieved annual savings of INR 128,000 with no investment required. Equally important is the fact that a basic no-cost solution has increased wastewater quality after ETP treatment significantly, thereby contributing to the reduction of environmental pollution.

Before the intervention, there was a general lack of knowledge and awareness regarding saving potentials through more efficient wastewater treatment processes. Knowledge and techniques to properly dose chemicals for wastewater treatment were not available to the company. The fact that improved wastewater management is not merely a good deed for the environment, but also leads to cost savings is being vividly demonstrated by this case example. Cost savings are often a trigger for companies to change their perception regarding environmentally-friendly production, paving the way for further, more large-scale, interventions.

The fact that improved wastewater management is not merely a good deed for the environment, but also leads to cost savings is being vividly demonstrated by this case example. Cost savings are often a trigger for companies to change their perception regarding environmentally-friendly production, paving the way for further, more large-scale, interventions.

Testimonial

“We have drastically improved COD, BOD, Sludge and most importantly color which was my biggest headache to improve upon. All the reductions were achieved just by fine-tuning the dosing which is remarkable. I am thanking GIZ for saving INR 128,000 per year which is a reward for the efforts and also motivational for further tertiary improvement. So, this is my upvote to sustainability.”

Mr. Pratap Patel, Owner of M/s Sterling Pigments and Colours

 

"I am very much amazed after the achievement of results. The colour almost vanished and we have got crystal clear effluent.’’

Mr. Rangaram, ETP Operator &Technician of M/s Sterling Pigments and Colours

 

 

 
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