Manufacturing Process & Waste Water Treatment in Automobile Industry

2. *Design, development, manufacturing,
marketing and selling of motor vehicles.
* does not include industries dedicated to
maintenance of automobiles.
*India has an annual production of
approximately about 2.3 million units

3. *India’s automobile industry is one of the
most capital-intensive with a big
appetite for re-investment in R&D at
regular intervals
*Production cost per annum in India’s
auto mobile industry is 58000 crore
*Out of which 30% is used for water
consumption

6. *About 148000 litres of water used to make
a car
*About 7600 litres of water used to make
its tires
*100 gallons of water with only a 10-minute
car wash in automobile industry

7. * surface water – 82% of total industrial withdrawals
(in this 82% of surface water-93% of water will be
fresh water)
ground water – 98% of total industrial withdrawals
( in this 98% of ground water- 98% of water will
be fresh water)

9. *Oil, grease, metals which are used
for painting of automobiles
* emission of nitrogen and other
contaminates
* car washing detergents contain
phosphorus

10. Oil, petroleum, toxins _ kill fish, plants,
From automobile industry aquatic life and
even peoples
Trace metals and _ contaminate drinking
Degreasing agents water can cause
illness
Phosphorus and nitrogen _ depletes water of
oxygen, growth of algae
killing fish, aquatic life

11. 1.The chassis production unit
2.The E-coating
3.The surface finish centre
4.The pre-assembly
5.The final assembly line

13. * most challenge work
*An automobile’s body is made
up of aluminium rather than
steel
Reason: the body stiffer and
saves the cars weight
*Around 2000 welds in this
process which only well skilled
workers can perform it

14. *Used to protect by
corrosion
*Submerged in chemical
where it is rotates in 360
degrees to get coated
from inside and outside
*The coating is of:
1.NICKEL
2.MANGANESES
3.ZINC

15. *Build the major
components of car like:
1.doors
2.instrument panel
3.the engine
*Polishes the body and
makes a perfect finish
*Varies chemicals are
used

16. *The final assembly line is divided in 7 units
Unit 1 – installs thin sound proofing sheet (to prevent
noise)
Unit 2 –wiring is done all over the body
Unit 3 –installs strong and stiff instrument panel made
of magnesium
Unit 4 –attaches engine to the chassis and provides
heart to the body

17. Unit 5 –installs the cars windows as well as
windshields
Unit 6 –installation of the seats
Unit 7 –the car’s wheels are mounted

21. - Reverse Osmosis Plant (RO System)
- Water Demineralization Plant
- Industrial Water Softener
- Effluent Treatment Plant (ETP)
- Wastewater Treatment / Recycling Plant
- UV / Ozone System
- Ultrafiltration / MBR

23. SCREENING:
* A screen with openings of uniform size is used to remove large
solids
* maximum 10mm is used

24. REACTION TANK:
* To adjust the PH in the process
* To improve the attraction among fine particles so
that they cometogether and form larger particles
called flocs
* Those flocs are settled out more quickly
PH CONTROL:
* To adjust the PH in the treatment process to
make wastewater PH neutral
* For acidic wastes (low pH): NaOH,
Na2CO3,CaCO3or Ca(OH)2
* For alkali wastes (high pH): H2SO4, HCl

25. CONDENSATION TANK:
* To remove oil and grease which are used in
manufacturing process
* Some chemicals are used to remove those wastes
SEDIMENTATION TANK:
* After primary and secondary treatment of effluent
* Used to increase the removal of solids from effluent
by gravity method
* Here sediment sludge returns into activated sludge
process

27. NEUTRALIZATION TANK:
* To balance the excess acidity in water
* Excessively acid or alkaline wastes should not be
discharged into a receiving stream without
treatment
* Here, organic materials are removed
SAND FILTER:
* To removing most of the solids
* particles are removed by way of absorption
DISCHARGED TANK:
* Here, treated water is discharged

28. Automotive plant water treatment
technologies includes:
1.Microfiltration
2.Reverse osmosis
3.Ultrafiltration

29. *Critical step of treatment applications, including potable
water treatment and industrial and municipal wastewater
treatment
*Acts as both filter and disinfectant
*Requires less than 2 bar pressure
*Physical barrier to a wide range of microorganisms, pathogens
and suspended particles larger than 0.1micrometre

30. *To remove particulates and macromolecules from
water in waste water
*Membranes have a pore size between 100 to 2nm and
require 1 to 10 bar pressure to operate

31. *Membrane with pores of less than 1nm
*Used to separate salts, ions and small organic
molecules from feed water
*Requires high pressure to function it (80 bar)

32. SN ITEMS
Before
Treatment
After Treatment
1 Temperatur
e
250 C to 350 C Not exceed 50 C
above ambient
2 Colour Light yellowish Colourless
3 Odour Present (light) Nil
4 pH NA 6.5 to 8
5 TSS NA <30 mg/l
6 Oil and
grease
NA <10 mg/l
7 BOD NA <30 mg/ltr
8 COD NA 150 mg/ltr

33. *Improved water quality
*Removal of contaminants
*Cost-saving in the long run
*Environmentally friendly
*No shortage of water
*Avoid losing water during a crisis
*Improve taste and water clarity