Effluent Treatment Plant Design -ETP, STP, Utility (Water, Electricity, Fuel, Sewerage, Drainage, Chillar, Boiler & Compressor) Management. Air Emission, Sound, Light, Temperature monitoring. Wastage (Hazardous & Non Hazardous) Management. Environment, Health & safety committee members should be available to received workers concern, complaints & recommendations. Receiving, investigating & promptly handling matters and complaints with respect to workplace Environment, health & safety. Making Environment Policy & Procedure. Preparation an ETP Audit Report
Flow Chart for Effluent Treatment Plant ETP
Effluent Treatment Plant (ETP) – Process Flow Diagram (Chart 2)
SL
Effluent Treatment Plant Design Process
Treatment (Use Chemical/Instrument)
Remarks
Step – 1
Equalization Tank
Air and Acid
Step – 2
Biological Tank
Bacteria Food [Fertilizer (Urea), Dap]
Step – 3
Secondary Clarifier Tank
Water Separation from Sludge (Live sludge) – [Sludge/clay return to Biological Tank (Activated Carbon/Sludge system)- Bacteria Recycle]
Good health conscious
Step – 4
EC (Electro Coagulation)
Use DC electricity (Water and Sludge breakdown)
Hazard Identification
Step – 5
Polymer Mixing Tank
Housekeeping. Polymer Mixing
Step – 6
HRSCC (High Rated Solid Clarifier) Tank
To assist in creating a safe & healthy workplace. Water and Sludge Separation
(Dead Sludge) –
Chemical Management
Step – 7
Sludge Thickening Clarifier Tank
Sludge send to Filter Press. To aware for safe and healthy environment.
Water send to Sand Filter
Step – 8
Water Sand Filter Purification
Water comes from Secondary Clarifier & Sludge Thickening Clarifier. After Purification, Water will send for final discharge
Others:
Water Req. for Per kg Fabrics Production:
Water use per kg Fabrics in TEXTILE – 121 to 130 Liters
World wise Standard Data (per kg) – 70 to 80 Liters
PROCESS FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (CHART 3)
Environment, Health & Safety committee made up to identify and resolve health and safety issues in the workplace.
The Role of the committee in:
Inspections
Investigation
Complaints
Problem solving
Communications
Minimising failure rates
The aim of this option is to increase product quality by minimising failure rates.Your products are the figureheads of your company, having a significant impact on your company’s reputation. Minimising failure rates supports your efforts to deliver products of prime quality and should thus be seen as a key strategy for your business success. While most failures occur during the processing, their cause might be found in-house as well as beyond your company’s gates, at your suppliers’ or shipper’s side. Inferior raw material and chemical quality, inadequate handling or unprotected transportation of products are just a few examples.
For an overview of your most frequent failure rates, fill out the table below. Describe to the best of your knowledge the failure, the process and exact location (e.g., which (part of the) machine/process), as well as the cause (see further guidance below the table) and the number of failures. If available, use data from the last fiscal year or the last quarter and state the chosen time-period in the table. Otherwise collect the necessary information. Also try to fill out the total number of failures that occurred during the time-period, which should not simply add up to rows above, but summarise all the failures.
Total number of failures:
For comparability reasons, make sure to use the same time-period (e.g., one fiscal year) for all failures. In case you do not have the information and/or cannot collect it, try to fill out table based on estimates. In this case, mention in the comments line that the figures are based on estimates. Using the generated data will help you to draw a trend line of your performance over different time-periods (benchmark), to identify improvement options and to set targets. With a benchmarking process you can compare your performance internally as well as externally, with industry averages or competitors. To benchmark your performance and see your improvements, use a “failure per unit” ratio. The “unit” should be the unit of production that is most useful for you. Examples could be “kg or m2 of product” or “1 000 units of product”.
Following the identification of failures you should determine their causes, as this allows you to remedy the defects. Next to technical problems with your processing technology, the following causes can be commonly found:
• Poor quality input material delivered from suppliers
• Non-existent quality control of the water supply bases on critical parameters (softness, iron content, colour, buffer capacity, conductivity, etc.)
• Sub-optimised material for your machinery
• Lack of proper training for the employees to locate and fix malfunctions
• Lack of processes and products monitoring (accuracy of the recipe, water solubility, pH, colour, conductivity)
• Absence of written instructions on how to operate the technology
Having identified the causes you should aim to remedy the defects.
As a complementary strategy, you might want to inform the employees involved in processing about the necessity of minimising failure rates. Providing information about the failures and malfunctions that occur is the first step to address these problems. Update your staff about your efforts to reduce the number of failures and publicise the results of your efforts to ensure an ongoing support.
Failure minimisation results in a more efficient production with lower energy, water, raw- and auxiliary material consumption, adequate chemical use and a reduction in the amount of wasted textiles that need to be disposed of.
Following an initial assessment, this option will require investments in both time and money. However, significant savings in materials, energy and water, as well as an increase of product quality can be achieved. Applying measures to improve product quality, the share of second quality or waste products can be reduced by 5% to 35%. Increasing your product quality will also satisfy your customers and open up new business opportunities.
Conclusion
The functions of the Effluent Treatment Plant Design committee in :
Fire safety conscious.
Housekeeping.
Maintaining records and minutes of committee meeting every 3 month.
This environmental legal register summarizes the main environmental legislation as it applies to the activities products and services of the Auto Group. Read more electronic document management system
The objective of this document is to provide guidance to the officials of Auto Group regarding the environmental legislation that may be applicable during the normal execution of their duties. It should be noted that this register is not a compendium of all environmental legislation and officials are advised to obtain clarification from the environmental services directorate regarding environmental legislation should there be any doubt regarding the Auto Group. `Obligation should questions regarding the interpretation of legislation as summarized in this document arise, then the reader is advised to consult the original legislation. Copies of policies, bills, acts and regulations can be obtained from the office of the senior executive (environment): Environmental Management Systems
The inclusion of draft legislation in this register has been kept to minimum in order to maintain the focus of the document on existing legal obligations. This register includes a summary of the main environmental bills and some proposed regulations published before 2011 . The exclusion of policies, white papers and draft bills from this register does not imply that are not applicable or that they may or may not result in additional legal obligations for Auto Group.
Please Take Note:
The facility is in the process of updating its by – laws. Some of the by – laws included in this legal register might have been slightly changed incorporated in to other bylaws.
Emergency Incidents
Section 30 provide for the control of “emergency incident” which could cause potentially serious pollution or detriment to the environment. The responsible party is obliged to remedy the effects of the incident. The relevant authority (the local authority in the first instance) must direct the responsible parties to contain, minimize and remedy the effects of the incident or to undertake these measures themselves and claim responsible costs from the responsible party. A verbal directive must be confirmed in writing within 7 days. A relevant authority must prepare a comprehensive report on the incident and the report must be made available.
Applicability to Auto Group/Required Actions
Auto Group have a dual obligation in terms of this section. In the event of an emergency incident which was potentially detrimental to the Environment, caused by one of Auto Group employees, they have the responsibility to:
Report the incident to the relevant authorities (the provincial environmental authority);
Contain & minimize the effects of the incident and clean up;
Remediate any damage that may have occurred;
Take measures to prevent the recurrence of the incident. In the event that an incident occurs, Auto Group are obliged to direct
Wastewater Disposal – Waste Management No one can establish, provide or operate a waste disposal site without a permit issued by the Minister of Water Affairs and Forestry.This procedure details the system to be followed in order to ensure that all wastewater discharged by the Auto Garments Industry Limited are minimized and managed in an environmentally safe and correct manner in accordance with statutory and company requirements.The site discharges process water to the under ground tank and some of it over flows to drain. Sludge Recycle of ETP
Wastewater Disposal Responsibilities:
No one may dispose of waste or discard it in any other way except at a licensed waste disposal site or at a facility or by a method subject to conditions as the Minister may prescribe. Section 24: Regulations for waste managementIt is the responsibility of the EMR to ensure compliance with this procedure. The EMR has overview management responsibilities for monitoring, controlling and minimizing waster water discharges. It is the responsibility of the EMR to ensure that all personnel in their areas of responsibility are aware of wastewater discharge management provisions and are familiar with this procedure and regulations.
Identification and Characterization:
Provides for the Minister or competent authority at the provincial level to make regulations regarding waste management (see below).
All wastewater discharges must be identified and characterized. This includes storm water discharges also.
A drainage plan must be established and maintained which shows.
The rout of all industrial sewers and storm water sewers
Referenced discharge points/surface drains to sewers
Designated sampling points.
The destination of the industrial and storm water sewers must also be identified and referenced on the plan.
An inventory of all wastewater discharges must be maintained, which cross-references the drainage plan and describes:
Sources of wastewater
Composition of wastewater, including physical parameters such as temperature, PH etc.
Discharge point reference.
Designation. I.e. Trade effluent versus storm water run-off
Quantification and Monitoring of Discharges
In addition, a set of minimum requirements for the management of waste and waste disposal sites (see below).
Trade effluent shall be monitored on a monthly basis and will comprise grab sampling from the designated sampling point, adjacent to off-site discharge. Monitoring parameters will concur with those contained within the Anglican Water Trade Effluent. Discharge consent. The Production Manager may specify further parameters as appropriate. All exceeding must be recorded and corrective action taken as necessary.
Storm water discharges shell is monitored on a bi-annual basis for.
Total petroleum hydrocarbons
Volatile organic
PH in Wastewater Disposal
Suspended solids
The designated sampling point will be used to measure storm water quality.
Managing & Minimizing Discharges
Regulations have been drawn up under the Section 24 regarding refuse removal in the form Auto Group area (see below)
Auto Group have a dual obligation in terms of this section. Auto Group may only dispose of waste at a licensed waste disposal site.
All discharges from the site will be managed so as to minimize quantities and/or environmental impact.
Ways of reducing discharges in both volume and contaminant loading must be identified by:
Identifying alternative processes or substances
Identifying pollution control equipment
Implementing work procedures to control and minimize contaminant loading
The EMR will consult with the Production Manager on any proposals to implement discharge control measures.
No chemicals are to be disposed of down surface water or sewer drains in exceeding of permit limits.
No hazardous materials are to be stored close to storm water drains.
Conclusion
Auto Group are required to provide waste disposal facilities for residents of the municipality. All waste disposal sites run by the Auto Group must be licensed by the Department of Water Affairs and Forestry.The EMR will conduct monthly inspection of the facility to cheek operation practices conform to controlling Wastewater Disposal, these must be recorded in a logbook and any observations documented, together with corrective action. Corrective action which is not immediate (e.g. installation of equipment) must be fully described to include costs responsibilities and dates for completion. Confirmation of completed action must be documented and kept with the logbook. DWAF) any waste disposal facility operated by Auto Group has to comply with the Minimum Requirements
We are blessed with abundant natural fresh water by Wastewater Treatment System. Availability of such fresh water has made things easier for us to do fabric processing businesses in such a small country. However, we use thousand liters of water for dyeing and other purposes every day. The more water we use, the more wastewater or liquid waste is generated from our fabric processing machines every day unlike other wastes. Sludge Recycle of ETP
Textile wastewater (water mixed with different dyes & chemicals) requires systemic treatment by effluent treatment facility. Hence, wastewater is a big issue for any textile industries. We have our own ETP (effluent treatment plant) to treat our wastewater. We are doing the following research & development activities to minimize or reduce wastewater-
Review meeting is held every three month regarding previous decisions and upcoming decisions to make. Our General Manager (GM) advises this meeting. Every waste management related issue is openly discussed and shared. Brainstorming and new idea sharing are done so that corrective actions can be taken in procedure level. We always consider 3R principle (Reduce, Reuse & Recycle) whether we can implement this idea in any aspect of waste management.
Adjusting Liquor Ratio:
Changing Liquor Ratio is another way to save water and chemicals during wet processing which is ultimately Waste or Wastewater Reduction step is taken by our innovative Waste Management Team. Changing Liquor Ratio should be encouraged as it can decrease concentration of dyes & chemicals in the wastewater. Otherwise alternative chemical should be adopted, which requires less Liquor ratio. For example, we use Avitera SE -the dyestuff of Huntsman after Technology Assessment, which is marketed by Huntsman under the logo of Save the Earth. We also use third generation Wash off like Dekol RSA (Resource Saving Agent) and Crosscolor BCSR, which help us to save natural resources like water. We always look for better innovations than the above-mentioned dyestuffs in the market.
Awareness building up can save a lot resources and helps to reduce waste generation. Imparting training program may help workers & employees to be more conscious about resource management & waste management. Ideas should be discussed and shared among workers. Little awareness can save lots of paper, dyes, chemicals & water every day. We have posted awareness building up posters on appliances use, water consumption and energy efficiency in many places of our factory premises so that awareness among the workers can be developed and energy efficiency & better waste management practices may rise thereby.
Proper Metering:
Water is the vital resource for fabric processing. So water consumption should be properly metered. We cannot manage waste consumption without measuring. Total consumption and total disposal of wastewater should be metered. Furthermore, section wise water consumption record should be kept so that assessment and analysis of wastewater can be done properly. We have two inlets for our dyeing section and two flow meters installed on that inlet give us water consumption data.
Fabric processing is a continuous cycle, which involves a lot of chemicals & dyes. A slight change in the fabric recipe can save a lot of chemical/dyes, water and reduce wastewater generation rate. Our production team optimizes the dosage of chemical/auxiliaries by trial and error method. For example, if we use a detergent 1gm/liter, then it is deducted by 10% (.1gm) and some trial batches (by .9gm/liter) are executed. The reports of the batches are reviewed and process designed is Redefined. Dosage Optimization of every chemical/dye is done by this way without deteriorating the quality. Existing process design is re-evaluated if any single process step can be skipped to form new process design which might help to generate less wastewater. our production team re-engineer the process step whether it could be possible to eliminate the rinsing by a single filled wash drain cycle and if it is viable for wastewater reduction. Same importance is given to both energy consumption and natural resources. Our Senior Manager (Production) continuously generates concepts and monitors the overall dyeing process if consumption of dyes & chemicals could be decreased in order to minimize waste water as well. Forming new process design cannot be done in a day or month. Continuous efforts are required for this.
Technology Assessment:
Technological assessment & advancement can help us to save our time, money & resource and generate lesser waste. Existing processing system should be assessed & analyzed if existing machineries can support lowest Liquor Ratio. Old and backdated machineries should be replaced if possible in order to minimize liquid waste or wastewater generation, which is a big issue for textile industries. Our team always looks for any innovations regarding dyestuff, dye auxiliaries that may help to reduce liquor ratio and skip wash cycle, e.t. waste prevention initiative.
Conclusion
If any advanced technology is available in the market, our team tries to figure out the pons & cons and efficiency of that technology and discusses with entrepreneurs about the viability of that Wastewater Treatment System
Segregated wastes are finally disposed of when they are no longer required. Disposal procedure depends on waste category. Some wastes, such as chemical wastewater requires treatment by ETP (Effluent Treatment Plant) and some require simple disposal procedure such as dumping on landfilling site. On the contrary, some other wastes are reused and recycled. In the following tables, we have mentioned all the wastes and their disposal procedures-
Accumulated list of wastes & disposal procedures:
Error is a part of decision or action. Corrective actions must be taken to rectify previous faults or lacking. Slight mistakes or faults in procedure level may hamper total development process. So corrective actions must be implemented properly and regular follow-up is very crucial. In our Review Meeting every waste management procedure is scrutinize thoroughly.
