• AQUAFLOW SYSTEMS is one of the leading EPC(Turnkey)

Contractors for the Design, Drawing, Construction , Supply, erection

and commissioning of Water, Effluent, Sewage, Leachate, Common
Effluent treatment plants and Multiple Effect Evaporation Systems in
all over India on Turnkey Basis.

• We offers turnkey solution to all water/waste water treatment needs

right from the process design, detailed engineering, construction,
supply, erection, commissioning and Operation & Maintenance
services on Turnkey basis
• 1. EXISTING CETP SYSTEM.

• 2. CURRENT STATUS OF THE CETP.

• 3. REVAMPING OF THE EXISTING CETP SYSTEM.

• 4. IMPLEMENTATION OF ZLD FOR ACHIEVING THE NORMS.

• The textile park CETP was built in 2007 with the capacity of
450KLD (100KLD DYE BATH & 350 WASHINGS) and not in
operation from last 10 years.

• The present system containing the following components:

• Collection and conveyance
• Pre-treatment system
• Biological system
• Filtration system
• Solar Evaporation system.
• The water is mainly used for application of chemicals on to the fibres and
rinsing of the final products. The waste water generation from the
process will be sent to CETP through two streams. One is Dye bath
effluents and second one is washings and it will be collected in two
separate collection tanks for further treatment.

Dyebath Collection tank Washing effluents collection tank

• DYE BATH EFFLUENTS:
• COLLECTION & EQUILIZATION
• NEUTRALIZATION, FLOCCULATION (LIME & FERROUS
SULPHATE)
• CALRIFICATION & FILTRATION
• WASHING EFFLUENTS:
• COLLECTION & EQUILIZATION
• NEUTRALIZATION, FLOCCULATION (LIME & FERROUS SULPHATE)
• PRIMARY CALRIFICATION
• BIOLOGICAL TREATMENT & FILTRATION
• SLUDGE DEWATERING SYSTEM:
• SLUDGE COLLECTION
• FILTRATION
• SLUDGE DRYING
OBSERVATIONS AND SUGGESTIONS IN THE CETP FOR
RECONDITIONING

Sl.No OBSERVATIONS SUGGESTIONS

1 Lot of debris, dust and septic water Remove the all debris, dust and septic water
observed in the dye bath effluent collection from both collection tanks.
sump as well as washings collection sump.
2 Floating aerator is in damaged condition in There is no use for existing floating aeration
the dye bath effluent collection tank. There system and it is to be removed from the sump.
is no floating aeration system in the We have to establish aeration grid system by
washing collection sump. using twin lobe air blowers for both effluent
collection sumps (dye bath and wash water
effluents).
3 Ferrous sulphate dosing and Lime dosing Gear box and motors are to be changed. Total
system shafts and blades are ok but gear no. of motors and gear boxes are 4nos.
motors are corroded.
4 Feed pumps are in damaged condition for Feed pumps to be provided for each sump for
dye bath and wash water effluents. one pump. Existing pumps can be used for
standby.
 OBSERVATIONS AND SUGGESTIONS IN THE CETP FOR
RECONDITIONING

Sl. No. OBSERVATIONS SUGGESTIONS

5 Primary clarifloculator mechanism for wash Change the clarifloculator mechanism
water system is in damaged condition. with new one.
6 Mechanical aerators are rusted and also in Establish new aeration grid system by
damaged condition. using twin lobe blowers with fine bubble
diffusers

7 Multi Grade Sand and Activated Carbon Change the media for both sand filter and
Filters are ok but exhausted the Activated carbon filters.
carbon media.
8 There is no sand media in the filter beds. Top-up the sand media in the filter beds.
9 All pumps, motors and Panel board are in Need to be reconditioning and
idle condition for fast ten years. replacement is required wherever
necessary.
 IMPLEMENTATION OF ZLD

• VARIOUS TREATMENT TECHNOLOGIES ARE AVAILABLE FOR

ZERO LIQUID DISCHARGE:

• 1. Segregation of High and Low TDS waste stream based ZLD.

• 2. MBR based ZLD.
• 3. Thermal Evaporation for salt crystallisation based ZLD.
• 4. NF Brine Reuse based ZLD.
• 5. Treated Brine reuse based ZLD.
INLET CHARACTERISTICS:

Dye bath
S.No Parameter Unit Wash water Effluent
Effluent

1 pH - 12 8.0 -10.0
2 Suspended Solids mg/l 200 200-300
3 COD mg/l 1,200 1500-1750
4 BOD mg/l 500 500-600
5 TDS mg/l 10,000
5000-6000
S.No Parameter Unit Outlet value

1 pH - 6.5-7.5

2 Suspended Solids mg/l < 30

3 COD mg/l < 250

4 BOD mg/l < 30

Segregation of High and Low TDS waste stream based ZLD

PRIMARY TREATMENT

SECONDARY TREATMENT

TERTIARY TREATMENT

SLUDGE HANDLING SYSTEM

• BAR SCREEN CHAMBER- Floatable solid material shall be removed with the
help of screen

• COLLECTION/ EQUALIZATION TANK- Homogeneous condition of effluent

can be maintained.

• Addition and mixing of coagulants.

• PRIMARY CLARIFIER For removal of the suspended solids in the effluent by

using Clarifier.
AERATION TANK

SECONDARY CLARIFIER
• It is a activated sludge process with suspended growth system.

• BOD/COD reduction can be achieved by virtue of aerobic microbial activities.

• Oxygen will be supplied through fine air bubble diffusers with the help of twin
lobe air blowers.

• Efficiency is 90%
• It is a gravity separation for removal of
suspended and colloidal materials.

• Finally sludge will be settled in the

hopper bottom.
MULTIGRADE SAND FILTER

ACTIVATED CARBON FILTER

ULTRA FILTRATION SYSTEM

REVERSE OSMOSIS SYSTEM

MULTIPLE EFFECT EVAPORATION SYSTEM (MEE)

AGITATED THIN FILM DRIER (ATFD)

• MGF: It is used to remove the suspended solids in the feed
effluent. The water percolates through the bed of graded
pebbles and sand where the solid particles get retained on
the sand and clear water withdrawn from the outlet of the
filter.

• ACF: It is used to remove the organic matter, dissolved

chlorine and odour. Water percolates through a bed of
granular activated carbon and gets filtered (adsorption).
• This system is dead end filtration system with Hallow Fiber Membrane.
• Rejects only generated during back flushing.
• The ultra filtration membranes are with small pore size (0.01 microns) and used to
remove the suspended solids, bacteria, colloids, proteins and carbohydrates.
• System Recovery: 90%
• Unlike UF system, the feed water is separated into two
streams, one with low TDS and the other containing rejected
salts (High TDS).

• The RO membranes are spiral wound and have small pores of

size 0.0001 micron which do not allow ions to pass through.

• The system recovery: 70-75%

• RO REJECTS AS A FEED (3-5%) TO MEE FOR FURTHER
CONCENTRATION

• The RO rejects water is concentrated in a multiple effect

Evaporation system around to 35- 40% TDS. The dry saturated
steam is used as heating medium. The system has 4 to 5 effects
operating under vacuum and the vapours from the last effect
are condensed to produce the process condensate.
MEE CONCENTRATE LIQUID (35-40%) FEED TO ATFD FOR
GETTING THE FLOWING POWDER.

• The thick liquor with 35- 40% TDS is treated in drying section
with ATFD to produce solid (salts with 5 to 10 % moisture) for
disposal. The steam condensate can be re use.
• REVAMPING OF SYSTEM COST OF Rs. 65 Lakhs
• UPGRADATION OF EXISTING SYSTEM TO ZLD: Rs. 15 crores
• OPERATION AND MAINTENANCE COST:
• FOR EXISTING SYSTEM: Rs. 25 Paisa per litre
• TOTAL COST FOR THE MONTH:
• FOR ZLD:
• TOTAL COST FOR THE MONTH:
S.No Description Qty Unit Unit Rate Total
1 Design, drawings for refurbishment 1 No 2,00,000.00 2,00,000.00
2 Effluent feed pump for dye bath effluents 1 No 60,000.00 60,000.00
3 Effluent feed pump for wash water effluents 1 No 75,000.00 75,000.00
4 Dosing pumps for both dye bath and wash water tanks 2 Nos 35,000.00 70,000.00
5 Gear boxes for stirrers 2 Nos 1,50,000.00 3,00,000.00
Twin lobe air blowers for dye bath and wash water effluent collection
6 2 Nos 2,00,000.00 4,00,000.00
tanks
7 Twin lobe air blowers for wash water aeration tank 2 Nos 3,00,000.00 6,00,000.00
8 Air diffusers – coarse bubble diffusers 40 Nos 4,000.00 1,60,000.00
9 Air diffusers – Fine bubble diffusers 45 Nos 5,500.00 2,47,500.00
10 Filter feed pump for dye bath 1 No 65,000.00 65,000.00
11 Filter feed pump for wash water 1 No 85,000.00 85,000.00
12 Filter press 1 No 6,00,000.00 6,00,000.00
13 Filter press feed pumps 2 Nos 85,000.00 1,70,000.00
14 Air grid distribution pipe lines with accessories 1 Lot 3,50,000.00 3,50,000.00
Pipe, fittings and valves for entire Dye bath and waste water CETP
15 1 Lot 4,50,000.00 4,50,000.00
system
16 Activated carbon filter 1000 Kgs 150.00 1,50,000.00
17 Quartz sand 1000 Kgs 17.50 17,500.00
18 Sand filling in the sludge drying beds 1 Lot 2,00,000.00 2,00,000.00
19 Electrical cables and miscellaneous 1 Lot 4,00,000.00 4,00,000.00
20 Filter press flat form and shed 1 No 5,50,000.00 5,50,000.00
21 Reconditioning of the system and Commissioning of the plant 1 No 9,50,000.00 9,50,000.00
22 Minor Civil works 1 No 2,00,000.00 2,00,000.00
23 Plant Operation 1 Month 2,00,000.00 2,00,000.00
TOTAL 65,00,000.00