Flow Chart for Effluent Treatment Plant Design

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
Flow Chart for Effluent Treatment Plant ETP

Effluent Treatment Plant (ETP) – Process Flow Diagram (Chart 2)

SLEffluent Treatment Plant Design ProcessTreatment (Use Chemical/Instrument)Remarks
Step – 1Equalization TankAir and Acid
Step – 2Biological TankBacteria Food [Fertilizer (Urea), Dap]
Step – 3Secondary Clarifier TankWater Separation from Sludge (Live sludge) – [Sludge/clay return to Biological Tank (Activated Carbon/Sludge system)- Bacteria Recycle]Good health conscious
Step – 4EC (Electro Coagulation)Use DC electricity (Water and Sludge breakdown)
  • Hazard Identification
Step – 5Polymer Mixing TankHousekeeping. Polymer Mixing
Step – 6HRSCC (High Rated Solid Clarifier) TankTo assist in creating a safe & healthy workplace. Water and Sludge Separation

(Dead Sludge) –

Chemical Management
Step – 7Sludge Thickening Clarifier TankSludge send to Filter Press.  To aware for safe and healthy environment.

Water send to Sand Filter

Step – 8Water Sand Filter PurificationWater comes from Secondary Clarifier & Sludge Thickening Clarifier.  After Purification, Water will send for final discharge
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
Latest machine in TEXTILE  – 60 to 70 Liters
Corrosive / non corrosive
Flammable / non flammable
Oxidizing – Create rust in metal
Secondary Containment/Abstract MSDS/Labeling/ Storage/Temperature Maintain/RSL/ MRSL
Acetic Acid, Hydrogen Peroxide, Hydrogen Peroxide Killer, Detergent, Dies, Blissing



Environment, Health & Safety committee made up to identify and resolve health and safety issues in the workplace.
The Role of the committee in:
Problem solving

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.


The functions of the Effluent Treatment Plant Design committee in :

  • Fire safety conscious.
  • Housekeeping.
  • Maintaining records and minutes of committee meeting every 3 month.