EFFLUENT TREATMENT AND ANALYSIS

A Project Report
Submitted in partial fulfilment for the award of the degree
of
BACHELOR OF TECHNOLOGY
In
CHEMICAL ENGINEERING
by
CILAVENI KOMAL KARTHEEK
22011A0833

CARRIED OUT AT:

PATANCHERU ENVIRO TECH LIMITED (PETL)

GUIDED BY:

B. RAMA SREEDHAR REDDY

General Manager
Patancheru Enviro Tech Limited
 DECLARATION

I hereby declare that the mini project entitled “Study about

Patancheru Enviro Tech Limited (PETL) – A Common Effluent
Treatment Plant (CETP)” submitted in partial fulfilment of the
requirements for the award of the degree of Bachelor of
Technology in Chemical Engineering, is a record of original work
carried out by me under the guidance of B. Rama Sreedhar Reddy,
General Manager.
I further declare that this project has not been submitted previously
by me or any other person for the award of any degree, diploma, or
other qualification from any other university or institution.

Date: 27th of May ;2025

Place: Patancheruvu

CILAVENI KOMAL KARTHEEK

(22011A0833)
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY-
HYDERABAD UNIVERSITY COLLEGE OF
ENGINEERING SCIENCE AND TECHNOLOGY
HYDERABAD – 500085

DEPARTMENT OF CHEMICAL ENGINEERING

CERTIFICATE
This is to certify that Cilaveni Komal Kartheek had
successfully completed his role in the “COMMON EFFLUENT
TREATMENT PLANT” at “PAATANCHERU ENVIRO TECH
LIMITED”.
This certificate is issued in recognition of his significant
contributions to the “COMMON EFFLUENT TREATMENT
PLANT” at the “PAATANCHERU ENVIRO TECH LIMITED”.

Dr. K. Vidya
 Head of the
Department
CHEMCIAL
ENGINEERING

PATANCHERU ENVIRO TECH LIMITED

CERTIFICATE
This is to certify that Cilaveni Komal Kartheek had
successfully completed his role in the “COMMON EFFLUENT
TREATMENT PLANT” at “PATANCHERU ENVIRO TECH
LIMITED”.
This certificate is issued in recognition of his significant
contributions to the “COMMON EFFLUENT TREATMENT
PLANT” at the “PATANCHERU ENVIRO TECH LIMITED”.

Sri B. RAMA SREEDHAR REDDY

General Manager
Patancheru Enviro Tech Limited
Patancheruvu

ACKNOWLEDGEMENTS

First and foremost, I am deeply indebted to Shri. Mr. B. RAMA

SRIDHAR REDDY, General Manager for considering and
allowing me to carry out industrial internship under his
esteemed guidance and support, his knowledge and insights
were pivotal to the successful execution of this initiative, he
understands the individual need of his students and generates
thoughtful insight about every aspect of science and
engineering. His expert advice and wisdom helped me to finish
this work and made my study under his supervision enjoyable.
I would also like to acknowledge Mr. [Link] SRIDHAR
REDDY Sir for his enlightening introductory remarks, which
provided a strong foundation for my approach to the project.
I express my sincere gratitude to the prestigious Institution
JNTUHUCESTH for providing the required facilities to carry out
the present work.
Finally, I am really thankful and I express my sense of gratitude
to Dr K. Vidya (HOD -
CHEMICAL ENGINEERING) of JNTUH-UCESTH for giving us the
permission to pursue Industrial Internship here at Patancheru
Enviro Tech Limited.
CILAVENI KOMAL KARTHEEK
 ABSTRACT
This mini project focuses on an in-depth study of Patancheru
Enviro Tech Limited (PETL), a Common Effluent Treatment
Plant (CETP) established to treat industrial wastewater
generated by the diverse industrial cluster located in
Patancheru, Telangana. The region is known for its high
concentration of pharmaceutical, chemical, and dye industries,
which over the years have contributed significantly to industrial
growth but also led to severe environmental degradation,
particularly of water resources.
PETL was set up as a sustainable and centralized solution to
address the collective treatment needs of small and medium-
scale industries that lack the individual capacity or
infrastructure to treat their effluents to acceptable discharge
standards. The CETP receives pre-treated effluents from
member industries and undertakes further treatment through a
systematic sequence of processes including equalization,
neutralization, primary settling, aeration (biological
treatment), secondary clarification, and final disinfection
before discharge. Sludge generated during the treatment
process is handled separately through dewatering and safe
disposal practices.
This project aims to evaluate the operational efficiency,
treatment methodology, environmental significance, and
regulatory compliance of PETL. It also examines the advantages
of centralized effluent treatment in terms of cost-effectiveness,
pollution control, and ease of monitoring. Additionally, the
report discusses key challenges faced by the CETP such as
fluctuating wastewater quality, the need for consistent industry
participation, periodic upgradation of infrastructure, and
adherence to pollution control norms.
The findings highlight that PETL plays a vital role in protecting
local ecosystems and water bodies, particularly the Nakkavagu
stream, from unchecked industrial pollution. While there are
limitations and opportunities for future technological
enhancements, PETL currently represents a practical model for

i
collective environmental management and serves as a
reference point for similar industrial regions across the country.

ii
 TABLE OF CONTENTS
[Link] Title Page
no.
ABSTRACT i
Chapter OVERVIEW OF CETP
1
1.1 INTRODUCTION 1
1.2 PLANT DETAILS 1
1.3 COMPONENETS OF THE PLANT 2
1.3.1 Receiving Sump and Terminal Pumping 2
Station
1.3.2 Primary Treatment Tanks- Equalization Tanks 2
1.3.3 Flash Mixer 3
1.3.4 Clariflocculator 4
1.3.5 Decanter – 1 (Centrifuge) 5
1.3.6 Aeration Tanks 5
1.3.7 Secondary Settling Tanks 6
1.3.8 Decanter – 2 6
Chapter PRIMARY TREATMENT
2
2.1 COMMON EFFLUENT WASTE WATER 7
TREATMENT
2.2 STEPS INVOLVED IN PRIMARY TREATMENT 7
2.3 SLUDGE TREATMENT PROCESS 10
Chapter SECONDARY TREATMENT
3
3.1 STEPS INVOLVED IN SECONDARY 13
TREATMENT
Chapter EFFLUENT ANALYSIS
4
4.1 CHEMICAL OXYGEN DEMAND(COD) 17
4.2 BIOLOGICAL OXYGEN DEMAND(BOD) 19
4.3 TOTAL DISSOLVED SOLIDS(TDS) 21
4.4 OBSERVATIONS 24
Chapter CONCLUSIONS 25
5
 CHAPTER – 1
OVERVIEW OF CETP
1.1 INTRODUCTION
Industrial effluents are discharges from various industries, and
various organic pollutants have been found in different water
resources. They belong to various classes such as pesticides,
fertilizers, hydrocarbons, phenols, plasticizers, biphenyls,
detergents, oils, greases, pharmaceuticals, etc. Hence, industrial
wastewater creates a serious environmental problem. It poses a
danger to water quality when discharged into rivers and lakes.
Moreover, organic and inorganic contaminants are effectively
removed to meet increasingly stringent environmental quality
standards. Here this project will propose an effective way to treat
industrial effluents. Four common ways to treat wastewater include
physical water treatment, biological water treatment, chemical
treatment and sludge treatment. It will overcome the challenges
faced by the wastewater.

1.2 PLANT DETAILS

The concept of Common Effluent Treatment Plant emerged as a
necessity consequent apart from industrial estates, industries have
been established wherever, spreading over the entire area,
including Bollaram, Jinnaram, Pasha Mailaram, Sangareddy, and
other areas, within a radius of [Link] of these industries are
pharmaceuticals and chemical companies. The establishment of
Chemical, Pharmaceutical industries brought a distinction to this
area and has become an address for bulk-drug manufacturers.
Thus, Patancheru is reckoned on the industrial map. Considering the
situation, a full-fledged facility for collection, treatment and disposal
of industrial waste generated in Patancheru industrial area to the
standards prescribed, a common effluent treatment plant, was
promoted in private sector under the name of Patancheru
Envirotech Limited (PETL). The industrial waste from over 200
industries is treated in Patancheru effluent treatment plant.
INLET PARAMETERS UNITS STANDARD ACTUAL
pH 5.5-9.0 7-8
Total Dissolved Inorganic Mg/L 3000
5000
Solids
Chemical Oxygen Demand Mg/L 15000 3500

1
Ammonia(NH3) Mg/L 50 35
Oil and Grease Mg/L 20 10
TABLE -1 Inlet Parameters

1.3 COMPONENETS OF THE PLANT

 Receiving Sump and Terminal Pumping Station
 Primary Treatment Tanks- Equalization Tanks
 Flash Mixer
 Clariflocculator
 Decanter -1 (Centrifuge)
 Aeration Tanks
 Secondary Settling Tanks
 Decanter – 2

Image 1 : OVERVIEW OF CETP

1.3.1 Receiving Sump and Terminal Pumping

Station
Pre-treated effluents received by road tankers are tested /
analysed for inlet standards and unloaded in the sump. The
influents are pumped to Equalization Tanks, to equalize the

2
effluents.
1.3.2 Primary Treatment Tanks- Equalization Tanks
Equalization tanks, also known as balancing tanks or buffer
tanks, are components used in wastewater treatment systems
to provide a consistent and controlled flow of influent to
downstream treatment processes. They play a vital role in
balancing the hydraulic and organic load fluctuations of
wastewater before it enters the main treatment units. The
primary function of an equalization tank is to equalize and
stabilize the flow rate and composition of wastewater.
We have 4 Nos of Equalization Tanks to store the effluents for
about 2-3 days. Equalization Tanks are provided with aeration
grid and air blower to equalize the influents and to strip of any
organic volatile matter. The effluents from equalization tanks
are being pumped to Clari- flocculator / D A F through Flash
Mixer after addition of alum and poly electrolyte. The effluents
do not have similar concentrations at all the time; the pH will
vary from time to time. Effluents are stored from 8 to 12 hours
in the equalization tank resulting in a homogenous mixing of
effluents and helping in neutralization. It eliminates shock
loading on the subsequent treatment system. Continuous
mixing also eliminates settling of solids within the equalization
tank.
1.3.3 Flash Mixer
A flash mixer, is a device used in water and wastewater
treatment processes. It is specifically employed during the
coagulation and flocculation stage to rapidly mix chemicals,
such as coagulants or flocculants, with the water being
treated. The primary purpose of a flash mixer is to promote
the efficient and uniform dispersion of chemicals throughout
the water, ensuring adequate contact and reaction between
the chemicals and the contaminants present. The rapid mixing
action helps in the
destabilization of particles and the formation of flocs, which are
larger, aggregated particles that can be more easily removed
during subsequent treatment steps like sedimentation or
filtration. Flash mixers are essential for achieving optimal
coagulation and flocculation, which result in improved removal
of suspended solids, colloids, and other impurities from the

3
water or wastewater being treated.
Coagulants added to the effluents are:
 Lime: (800-1000 ppm) to correct the pH upto8-9.
 Non-Ferric Alum: (200-300 ppm) to remove colour.
 Poly electrolyte: (0.2 ppm) to settle the suspended matters
& reduce SS, TSS.
The addition of the above chemicals by efficient rapid mixing
facilitates homogeneous combination of flocculates to produce
microflocs.
1.3.4 Clariflocculator
A clarifier, also known as settling tank, is a key component in
water and wastewater treatment systems. Its primary function
is to separate suspended solids and particles from water or
wastewater through the process of sedimentation. The clarifier
operates based on the principle of gravity settling. It provides a
large tank or basin where water or wastewater flows in a
controlled manner. The flow velocity is reduced within the
clarifier, allowing sufficient time for particles to settle due to
gravity. The settled particles, often referred to as sludge or
sediment, accumulate at the bottom of the tank, while the
clarified water is collected from the top or the center of the
tank.
A flocculator is a device or unit used in water and wastewater
treatment processes to promote the formation and growth of
flocs. It is an essential component of the coagulation and
flocculation stage in the treatment process. The primary
purpose of a flocculator is to aid in the aggregation of fine
suspended particles and colloids into larger, settleable flocs.
This process helps facilitate their removal in subsequent
treatment steps such as sedimentation or filtration. Flocculators
typically consist of a series of compartments or chambers
where the water or wastewater flows in a controlled manner.
Within these compartments, gentle mixing or agitation is
provided to promote the collision and contact between
particles, allowing them to adhere and form flocs.

4
In the Clariflocculator the water is circulated continuously by
the stirrer.
 Overflowed water is taken out to the aeration tank.
 The solid particles are settled down, collected separately
and dried; this reduces SS, TSS.
 Flocculation provides slow mixing that leads to the
formation of macro flocs, which then settles out in the
clarifier zone.
 The settled solids i.e., primary sludge is pumped into
sludge drying beds.

1.3.5 Decanter – 1 (Centrifuge)

A decanter centrifuge, also known simply as a decanter, is a
type of centrifuge used for solid- liquid separation processes. It
operates on the principle of sedimentation and centrifugal force
to separate solid particles from a liquid or slurry mixture. The
suspended solids removed in Clari-flocculator / DAF with 1- 2%
concentration is pumped to Primary Decanter. Polyelectrolyte
solution is added to improve separation efficiency.
The decanter centrifuge consists of a rotating bowl, a conveyor
screw and a drive system. The process begins by feeding the
mixture into the bowl through an inlet. Under centrifugal force,
the denser solids in the mixture migrate towards the bowl wall,
forming a solid cake layer. The liquid or clarified phase, with a
lower density, collects in the center of the bowl and overflows
through an outlet. The conveyor screw transports the settled
solids towards the conical end of the bowl, where they are
discharged separately. The clarified water (Centrate) goes to
Buffer Tanks, for further treatment. The sludge cake is collected
in TSDF containers / and disposed to TSDF, Dundigal.

1.3.6 Aeration Tanks

There are 2 nos. of Aeration Tanks, with a capacity of 4,300

5
cum each. 4 Nos. of 50 HP and 6 Nos. of Floating Aerators each
capacity 30 HP. Aeration tanks are key components in
biological wastewater treatment systems. They provide an
environment where microorganisms can thrive and carry out
the process of aerobic biological treatment. The primary
function of aeration tanks is to introduce air or oxygen into the
wastewater to support the growth and activity of aerobic
microorganisms. These microorganisms, known as aerobic
bacteria or activated sludge, utilize the organic matter present
in the wastewater as a food source and convert it into carbon
dioxide, water, and microbial biomass. They contain surface
aerators that distribute air or Oxygen into the waste water
into the waste water to maintain the aerobic respiration
conditions. Oxygen is controlled by checking the DO levels in
Aeration Tanks at regular intervals.

1.3.7 Secondary Settling Tanks

The outlet of the Aeration Tank is connected to Secondary
Settling tanks of diameter 16m, which receives the treated
effluents from Aeration Tank along with the biological sludge in
the form of Suspended Solids. In the activated sludge process,
wastewater is mixed with a population of microorganisms in an
aeration tank, where the microorganisms consume organic
matter and pollutants in the wastewater. After the biological
treatment, the mixture of treated wastewater and activated
sludge flows into the secondary settling tanks. The MLSS
settles at the bottom in the form of sludge. Settled sludge is
re-circulated back to Aeration Tanks to maintain MLSS levels in
the Aeration Tanks. The excess sludge is waste through
Decanter –2.

1.3.8 Decanter – 2
The excess sludge produced in Aeration Tanks is collected in
Secondary Settling Tanks at the bottom, which is sent to
Sludge pit of Decanter, for wastage. The sludge is separated

6
as sludge cake and clarified water in 5 the Decanter. The
clarified water goes back to Aeration Tank and the sludge cake
is transferred to Secured Land Fill Unit. Filter Press is provided
as a standby unit to Decanter during maintenance of the
decante.

7
 CHAPTER -2
PRIMARY TREATMENT

2.1 COMMON EFFLUENT WASTE WATER TREATMENT

Due to presence of different types of contaminants and nature
of contaminants in effluent - physical, chemical, and biological,
the unit operations and processes in wastewater treatment
can also be categorized as such. There are three broad levels
of effluent treatment: primary, secondary, and tertiary.
Sometimes preliminary treatment precedes primary
treatment.

2.2 STEPS INVOLVED IN PRIMARY TREATMENT

The steps involved in the primary effluent treatment physical,
chemical methods. sedimentation, coagulation, flocculation.
Firstly, the waste water from different industry is collected in
one tank by testing the parameters like TDS, pH, etc., is called
as unloading tank. This is the tank where the waste water from
different companies is collected at one place. Then the water
is passed to the Equalization storage tanks. In the PETL,
Patancheru there are four equalization storage tanks of large
capacity in which the waste water is stored.
2.2.1 Equalization and Storage Tanks
A rectangular shaped tanks whose main function is to buffer
i.e. to collect the raw incoming effluent that comes at widely
fluctuating rates and pass it on to the rest of the effluent
treatment plant at a steady flow rate. The internal blowers do
not settle the solids while maintaining the suspension level.
Equalization of wastewater is a vital part of treatment process
management systems and for the minimization and control of
inconsistencies in wastewater. The equalization of
contaminants and flow are engineered to deliver a constant
rate of flow and contaminants to the treatment process. Larger

8
equalization tanks provide a solution that reduces the impact
of batch dumps and unwanted discharges. Aeration Blowers
provide energy to maximize the suspension of solids in the
wastewater to ensure a homogenized waste stream flows into
the treatment system. This equipment has been proven to be
more energy-efficient and has lower maintenance than
mechanical mixing.
2.2.2 Flash Mixer
A flash mixer is a chamber that contains mechanical stirrers,
which is designed to assure fast, thorough, mixing of non-ferric
alum with concentration of 80 ppm, for the purpose of creating
floc. This takes the charge of the effluent into consideration.
After screening out debris and testing the raw water, water
treatment really begins at the flash mix chamber. Here,
chemicals are added to the water, primarily to aid in
coagulation and flocculation. In the flash mixer, the water is
agitated violently for a short period of time before being
released into the Equalization storage tank and flocculation
basin.

2.2.3 Clariflocculator
In common waste water treatment plants, the flocculator and
the clarifier are combined together to achieve economy in

9
construction. The combined unit of flocculator and clarifier is
known as Clariflocculator in waste water treatment process.
Clari-flocculator shall have two concentric tanks with inner
tank serving as flocculation basin and outer tank serving as
clarifier. The treatment chemical like non-ferric alum is used
for coagulating the S.S and the solids are separated. The S.S
removed are collected in the sludge storage tank. The sludge
is sent to decanter -1 for further separation of liquid and solids
in the form of cake.

2.2.4 Decanter – 1(Centrifuge)

A centrifuge is a device that employs a high rotational speed
to separate components of different densities. decanter
centrifuge (also known as solid bowl centrifuge) separates
industries, and solid materials from liquids in the slurry, and
therefore plays an important role in the wastewater treatment,
chemical, oil, and food processing industries.
There are several factors that affect the performance of a
decanter centrifuge, and some design characteristics to be
followed which are dependent upon given applications.
Decantation is pouring away a liquid from solid impurities
which have settled at the bottom of the container. Any
polymer acts as a flocculating agent which separates the
effluent into thick sludge (cake) and clear water.

10
Working of Decanter – 1:
The feed product is pumped into the decanter centrifuge
through the inlet. Feed goes into a horizontal bowl, which
rotates. The separation takes place in the cylindrical part of the
bowl. The fast rotation generates centrifugal forces up to 4000
x g. Under these forces, the solid particles with higher density
are collected and compacted on the wall of the bowl. A scroll
(also screw or screw conveyor) rotates inside the bowl at a
slightly different speed. This speed difference is called the
differential speed. This way the scroll is transporting the settled
particles along the cylindrical part of the bowl and up to the
end conical part of the bowl. At the smallest end of the conical
part of the bowl, the dehydrated solids leave the bowl via
discharge opening. The clarified liquid leaves through a paring
disc (internal centripetal pump). The chemical added to
separate the solid particles from the water is poly-electrolyte or
polymer solution. This solution helps to separate the oil and
grease and other organic contaminants very fast in short period
of time.

2.3 SLUDGE TREATMENT PROCESS:

Sewage sludge is a by-product of treated wastewater. It is
composed of both organic and inorganic materials, a large
concentration of plant nutrients, organic chemicals, as well as
pathogens. Therefore, it is extremely important to properly

11
treat such sludge in order to minimize its environmental
repercussions. Here is a brief over view of the sludge
treatment process to help you gain a better understanding of
the treatment techniques and process requirements:
 Sludge Thickening:
The first step in the sewage sludge treatment plan is called
thickening. In this step, this sewage sludge is thickened in a
gravity thickener to reduce its overall volume, thus enabling
the easy handling of the sludge. Dissolved air flotation is
another alternative that can be used to effectively to thicken
the sludge by using air bubbles to allow the solid mass to
float to the top.

 Sludge Digestion:

After amassing all the solids from the sewage sludge begins
the sludge digestion process. This is a biological process in
which the organic solids present in the sludge are
decomposed into stable substances. This process also helps
reduce the total mass of solids, while destroying any present
pathogens to enable easy dewatering. The sludge digestion
process is a two-phase process. In the first stage, the dry
solid sludge is heated and mixed in a closed tank to enable
anaerobic digestion by acid-forming bacteria. These bacteria
hydrolyse the large molecules of proteins and lipids present
in the sludge and break them down into smaller water-
soluble molecules, which they then ferment into various
fatty acids and methane, after which the methane is
collected and reused to power the digestion tank and
generate power (depending on the quantity retrieved.

 Dewatering:

After retrieving useful gases and other by products, the

remaining sludge is then dewatered before final disposal. In

12
 most cases, dewatered sludge usually contains a significant
amount of water, as much as 70 percent, in spite of its
solidified state. Therefore, it is important to dry and dewater
the sludge beforehand by the help of mobile decanters.
While using sludge- drying beds is the most common way to
carry-out this process, it is extremely time- consuming and
may take weeks before the process is complete. In order to
quicken these processes, waste management plans are also
employing to carry out this process. In fact, centrifugation is
slowly becoming one of the most preferred methods of
dewatering sludge. By passing the sludge through a
centrifuge, it becomes easier to retrieve all the water and
enable easier handling of the solid waste in shorter duration
at reduced costs. Other alternatives include the rotary drum
vacuum filter and the belt filters.

 Disposal:
Once the sludge has been effectively dewatered, it can be
buried underground in a sanitary landfill or can be used as a
fertilizer, depending on its chemical composition. In cases
where the sludge is too toxic to be reused or buried, you can
simply incinerate the sludge and convert it into ash.

13
 CHAPTER – 3
SECONDARY TREATMENT

3.1 STEPS INVOLVED IN SECONDARY TREATMENT

The secondary treatment stage in a Common Effluent
Treatment Plant (CETP) is primarily designed to remove
biodegradable organic matter from the effluent through
biological processes. After primary clarification, where
suspended solids are removed, the effluent enters the
biological treatment unit. Here, processes such as the Activated
Sludge Process (ASP), Moving Bed Biofilm Reactor (MBBR), or
Sequencing Batch Reactor (SBR) are employed. These systems
use aerobic microorganisms to break down dissolved organic
pollutants, with air being supplied to support microbial activity.
The treated water then flows into a secondary clarifier, where
the biomass (sludge) settles out. A portion of this settled sludge
is recycled back into the biological treatment unit to maintain
microbial populations, while the excess is directed to sludge
management systems. Sometimes, disinfection using
chlorination, UV light, or ozonation is carried out to eliminate
any remaining pathogens. The resulting effluent, now
significantly cleaner, is either discharged if it meets regulatory
standards or sent for tertiary treatment for further purification.
3.1.1 Aeration Tanks:
The biological treatment of the wastewater takes place in the
aeration tank. This contains countless microorganisms, such as
bacteria, that are able to break down the colloidal, organic
contaminants dissolved in the wastewater. The bacterial
present in the aeration tank has a life time of 45-60 days during
which they multiply and prolong their survival as a group by
feeding on the organic matter in the effluent. Various
parameters like COD, BOD, TDS, NH3 etc. should be found out
before sending the effluent into aeration tank.

14
The aeration tank present at PETL is of (55 x 22.5 x 3.5) m 3
which can hold a volume of 4770 m [Link] aeration system
is used in PETL which incorporates surface aeration technology.
Aeration brings water and air in close contact in order to
remove dissolved gases and to oxidize dissolved metals,
including iron, hydrogen sulfide, and volatile organic chemicals
(VOCs). This process is typically the first major process at
drinking water treatment plant, and occurs in the secondary
treatment processes of activated sludge treatment in
wastewater treatment plants. An evenly distributed oxygen
supply in an aeration system is essential to effective
wastewater treatment for fostering microbial growth. Keeping
in mind the costs of running the diffusers alone, the diffusion
technique is cost effective compared to surface diffusion. But
the cost of the equipment governing diffusion is very high
compared to surface aeration equipment.

3.1.2 Microbial Needs:

Microorganisms that are natural to the industrial effluent

15
environment play a vital role in the treatment process. The
mixture of microorganisms that come in contact with and digest
biodegradable matter from the effluent is called as Activated
sludge. Beneficial bacteria, protozoa, algae, and fungi feed on
organic material in wastewater, breaking it down. Bacteria
clump together, or floc, forming masses that settle and
separate from wastewater liquids. This settled mass is called
sludge.
The activated sludge is fed into an anaerobic sludge digester
tank where anaerobic microbes digest the bacteria and fungi
present in it in the absence of oxygen. During this process,
gases like methane, carbon dioxide and hydrogen-sulphide are
released. These form the biogas which can be used for cooking.
Bacteria account for 95% of the microorganisms in wastewater.
They are single-celled microorganisms that are classified based
on their response to oxygen. A theoretical requirement of 3500-
4000 ppm of bacteria is required to achieve required outlet
parameters but practically a dose of 6000-8000 ppm of bacteria
is used in order to achieve the required outlet parameters since
in order to consume 100 BOD there is a requirement of 5
Nitrogen and 1 Phosphorus molecules respectively.
 Foods-to-Microorganism Ratio:
If the F/M ratio is too low, nutrient deficiencies can occur. An
environment deficient of phosphorus, nitrogen, and/or sulfur
interrupts the development of the cell wall, creating water
resistance, which results in floc dispersion, sludge bulking, and
foaming. It becomes difficult for nutrients to penetrate the cell
wall. Slime bulking may occur in environments deficient in
phosphorus or nitrogen or high in organic acid The established
food-to-microorganism ratio for a conventional wastewater
treatment plant is 0.5 to 1.0 pounds of COD per day / pound of
MLVSS under aeration. If you're using BOD to estimate the
amount of incoming organics, then use 0.25 to 0.5 pounds of
BOD per day / pound of MLVSS under aeration.
 Retention Time:

16
 The time spent by the effluent in the aeration tank right from
input to output is called retention time. The retention time for
a batch of effluent is 36-48 hours whereas the retention time
for sewage is about 24 hours. During this retention time
microorganisms have a chance of breaking down organic
matter present in the effluent which results in enhancing the
parameters such as COD, BOD, and TDS etc. towards required
ranges.
3.1.3 Secondary Settling Tanks:
Also called as clarifier is a component of modern system of
water supply or wastewater treatment. It allows suspended
particles to settle out of water or wastewater as it flows slowly
through the tank, thereby providing some degree of
purification. They are also used in activated sludge systems for
separating treated water from biomass, settling sludge and
sufficiently thickening it so that when the sludge is returned to
the tank inlet, the concentration levels can be maintained.

17
 CHAPTER – 4
EFFLUENT ANALYSIS
4.1 CHEMICAL OXYGEN DEMAND(COD)
COD stands for Chemical Oxygen Demand. It is a measure of
the amount of oxygen required to chemically oxidize organic
and inorganic compounds in water. COD is used to assess the
overall organic pollution level in water samples, including both
biodegradable and non- biodegradable substances.
Unlike BOD (Biological Oxygen Demand), which measures the
oxygen consumed by microorganisms in the biological
breakdown of organic matter, COD measures the oxygen
demand resulting from both biological and chemical processes.
COD provides a broader indication of the organic and oxidizable
inorganic content in a water sample.
COD is usually reported in milligrams of oxygen consumed per
litre of water (mg/L) or parts per million (ppm). Higher COD
values indicate a higher concentration of oxidizable compounds,
suggesting a higher pollution level in the water sample. By
measuring COD, water resource managers and treatment
facilities can identify the extent of organic pollution and
determine appropriate treatment strategies to safeguard water

quality.

4.1.1 Reagents used for the analysis of COD:

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  Standard potassium dichromate solution (0.25 N):
Dissolve 12.259 g in 1000 ml distilled water.
 Standard ferrous ammonium sulphate solution (0.1 N):
Dissolve 39.214g in distilled water, and 20 ml
concentrated Sulphuric acid. Cool and dilute to 1000 ml
with distilled water.
 Ferroin indicator solution: Dissolve 1.48 g of 1,10
phenanthroline mono hydrate and 695 mg of ferrous
sulphate to 100 ml.
 Sulphuric acid reagent: add 10 gm of silver sulphate to 1
litre of Sulphuric acid.
4.1.2 Procedure for COD:
 Take 20 ml of sample or diluted sample.
 Add 0.4 g of HgSO4.
 Add 10 ml of K2Cr2O7 solution.
 Again add 30 ml of H2SO4 reagent
NOTE: (add 10 gm of AgSO4 to 1 litre of H2SO4) Keep the sample
in COD digester reactor at 150 0 C for one and half hours to two
hours.
 Add 20 ml of distilled water to condenser remove that
sample from COD reactor and cool it for 15 min.
 Titrate with ferrous ammonium sulphate (FAS) using
indicator (ferroin indicator) until the colour changes to
brick red.
4.1.3 Calculation:

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4.2 BIOLOGICAL OXYGEN DEMAND(BOD)
BOD stands for Biological Oxygen Demand. It is a measure of
the amount of dissolved oxygen (DO) that is consumed by
microorganisms in the biological process of breaking down
organic matter in water. BOD is an important parameter used to
assess the organic pollution level and the potential impact of
wastewater or other sources of pollution on water bodies. The
BOD value is most commonly expressed in milligrams of oxygen
consumed per litre of sample during 5 days of incubation at 20
°C and is often used as a surrogate of the degree of organic
pollution of water.
Higher BOD values indicate a higher level of organic pollution in
the water. Clean and unpolluted water bodies generally have
low BOD values, while polluted waters have specifically higher
BOD value BOD of wastewater effluents is used to indicate the
short-term impact on the oxygen levels of the receiving water.
BOD analysis is similar in function to chemical oxygen demand
(COD) analysis, in that both measure the number of organic
compounds in water. However, COD analysis is less specific,
since it measures everything that can be chemically oxidized,
rather than just levels of biologically oxidized organic matter.
The BOD is an important parameter for assessing water quality.
It deals with the amount of oxygen consumption (mg O2 L− 1)
by aerobic biological organisms to oxidize organic compounds.
Sewage with high BOD can cause a decrease in oxygen of

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receiving waters, which in turn can cause the death of some
organisms.
4.2.1 Reagents used for analysis for BOD:
 Sodium thiosulphate solution (0.025 N): Dissolve 6.205 g
of sodium thiosulphate penta- hydrate in distilled water.
Add 0.4 g sodium hydroxide (pellets) and dilute to 1000
ml.
 Starch solution (indicator): Dissolve 2 g lab grade soluble
starch and 0.2 g salicylic acid in 10 ml hot distilled water.
 Alkali azide reagent: Dissolve 500 g of sodium hydroxide
and 135g of sodium iodide (or 700 g of potassium
hydroxide and 150g of potassium iodide) in distilled water
and dilute to 1000ml. Add 10g of sodium azide dissolved in
40 ml distilled water.
 Manganous sulphate solution: Dissolve 364g of manganous
sulphate monohydrate in distilled water and dilute to
1000ml.
 Ferric chloride solution: Dissolve 0.25g of ferric chloride
hexahydrate in distilled water and dilute to 1000ml.
 Calcium chloride solution: Dissolve 27.5g of calcium
chloride in distilled water and dilute to 1000ml.
 Magnesium sulphate solution: Dissolve 22.5g of
magnesium sulphate heptahydrate in distilled water and
dilute to 1000ml.
 Phosphate buffer solution: Dissolve 8.5g KH2PO4, 21.75g
K2HPO4, 33.4g Na2HPO4.7H2O (17.7g of Na2HPO4) and 1.7g
ammonium chloride in distilled water and dilute to 1000
ml, pH should be 7.
4.2.2 Procedure for BOD:
 Take four 300 ml BOD bottles and add 10 ml of samples to
2 bottles and fill the remaining volume with dilution water
 Fill remaining 2 BOD bottles only with dilution water for
blank.

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  Immediately close the bottles when filled and there should
not be any air bubble in the bottle.
 Mark the bottles as blank and sample.
 Incubate one sample and one blank bottle at 20 degrees
Celsius for 3 days.
 Analyze immediately remaining 1 blank and 1 sample
bottle of Dissolved oxygen (DO).
 Analyze incubated bottles for DO after 3 days.
4.2.3 Tests for Dissolved Oxygen (DO):
 Add 2 ml of 36.4% of manganous sulphate (MnSO4, H2O)
solution inserting the tip of pipette tip into the sample
because the drops of solution can allow inserting the
oxygen into the solution.
 Add 2 ml of the alkali-iodide-azide reagent by above
method.
 Allow reacting the solution with the oxygen present in the
sample.
 When precipitates are settled down at the bottom add 2 ml
of concentrated sulphuric acid by placing the pipette tip
very near to sample surface.
 Mix well to dissolve the precipitates.
 Take 20 ml of sample from BOD bottle in to a conical flask.
 Titrate immediately with 0.025 N sodium thiosulphate
solution using starch indicator until blue colour disappears
and note down the burette reading.
 Determine the burette reading for blank in the same
manner.
4.2.4 Calculations:

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4.3 TOTAL DISSOLVED SOLIDS(TDS)
Total Dissolved Solids (TDS) refers to the total concentration of
inorganic and organic substances that are dissolved in a liquid,
typically water. It represents the cumulative content of all
dissolved substances, including minerals, salts, metals, ions,
and small amounts of organic compounds.
TDS is commonly expressed in milligrams per liter (mg/L) or
parts per million (ppm) and is an important parameter in water
quality analysis. The measurement of TDS provides information
about the overall mineral content and dissolved substances in
water, which can have implications for various applications and
processes.
TDS is used as an indicator of water quality and can provide
insight into the general mineral content and level of dissolved
substances in water. High TDS levels may indicate the presence
of minerals, salts, or other contaminants, affecting the taste,
Oduor, and suitability of water for various uses.
4.3.1 Causes of TDS:
 Industrial sewage and waste
 Plankton
 Silt
 Urban runoff
 Road salts during winter
 Pesticides and fertilizers

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In addition to these, TDS can also come from air that contains
nitrogen, sulfur, calcium bicarbonate and other kinds of
minerals, as well as rocks. Water is capable of picking up
copper, lead and other metals as it passes through pipes used
to deliver water to consumers. A water purification system's
efficacy in removing TDS may become weaker over time, so the
quality of membranes and filters should be monitored, and
replacement performed when necessary. Hence, when
inappropriate TDS levels are detected in certain applications,
treatments such as water softening and reverse osmosis should
be implemented immediately. Total dissolved solids are
measured as parts per million (ppm), and standard drinking
water recommends a limit of 500ppm. The lower the TDS, the
better the water quality. For drinking water and fountain
beverages, a TDS of up to 500 is acceptable, but for boiler-
based steam ovens, TDS should be kept very low - less than 100
ppm.
4.3.2 Procedure for Total dissolved Solids:
 Total Dissolved Solids is calculated through Gravimetric
analysis.
 Sample is treated for every 4 hours (before treatment &
after treatment).
 Take 10ml/20ml/50ml of sample, filtrate the sample using
filter paper.
 Add the filtered sample into a ceramic crucible.
 Place the crucible on a heat plate at a temperature of 100-
120 0 C (to remove water content).
 Now place crucible in hot air oven at 180 0C to obtain TDS.
 Adjust the temperature to 500 0 C in digital muffle furnace
to obtain inorganic TDS value.

24
  Cool the crucible using desiccator.

Muffle Furnace and Hot Air Oven

4.3.3 Calculations:

25
4.4 OBSERVATIONS

Results of M/s Patancheru Envirotech Ltd., from January 2009 to

October 2010

Results of STP at Amberpet

26
 CHAPTER – 5
CONCLUSION
Patancheru Enviro Tech Limited (PETL) serves as a vital
environmental safeguard in the Patancheru industrial area, one
of the oldest and most densely industrialized regions near
Hyderabad. Established with the goal of mitigating the
hazardous impact of industrial effluents on the environment
and public health, PETL operates as a Common Effluent
Treatment Plant (CETP) catering to a wide range of industries,
including pharmaceuticals, chemicals, dyes, and other small- to
medium-scale units.
The implementation of PETL has brought about significant
improvements in the management and treatment of industrial
wastewater, especially in a region historically plagued by
severe pollution of water bodies such as the Nakkavagu stream
and groundwater reserves. By centralizing the treatment
process, PETL has not only enabled industries to comply with
environmental norms more effectively but has also reduced the
financial and technical burden on individual units, many of
which lack the capacity for advanced effluent treatment.
Through primary, secondary, and tertiary treatment processes,
including technologies such as Reverse Osmosis (RO), Multi-
Effect Evaporators (MEE), and advanced sludge management
systems, PETL ensures that treated effluent meets or exceeds
the discharge standards set by the Pollution Control Board. The
plant’s operations underscore the importance of technological
integration, scientific monitoring, and regulatory oversight in
achieving consistent environmental performance.
Despite its positive impact, challenges remain. Effective
functioning of PETL depends on regular maintenance, adequate
funding, real-time monitoring of inflows and outflows, and most
importantly, the commitment of participating industries to pre-
treat their effluents before discharging into the CETP. Moreover,
as industrial activity continues to grow, the need for capacity
expansion, energy efficiency, and the incorporation of

27
sustainable resource recovery practices becomes increasingly
critical.
In conclusion, Paatancheru Enviro Tech Limited represents a
progressive step towards environmental responsibility in
industrial development. It serves as a benchmark for other
CETPs across the nation, demonstrating that with proper
planning, cooperation, and technological innovation,
sustainable industrialization is indeed achievable. Continued
investment in infrastructure, regulatory enforcement, and
community awareness will be essential to ensure that PETL
continues to protect the environment while supporting the
region’s economic growth.

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