This document outlines a thesis project studying effluent treatment plant (ETP) processes for tanneries in Hazaribagh, Bangladesh. The objectives are to study wastewater quality, installation and operating costs of different ETPs, and develop a theoretical cost-effective ETP model. The methodology includes laboratory experiments to test wastewater parameters and an industrial data analysis of ETP costs. Preliminary results found that biological treatment processes had higher installation costs but lower operating costs than chemical treatment. The thesis will conclude by recommending an optimized ETP design for tanneries based on the analysis.

1. CHE 400
Thesis I & II
Suman Sarkar
0802019
1
STUDY OF DIFFERENT TYPES OF ETP PROCESSES AND TO
DEVELOP A THEORETICAL COST EFFECTIVE MODEL OF
EFFLUENT TREATMENT PLANT (ETP) FOR TANNERIES OF
HAZARIBAGH

2. Supervisor
Dr. Easir Arafat Khan
Assistant Professor
Department of Chemical Engineering, BUET
2

3. Outline
• Background
• Objective
• Methodology (Experimental/ Simulation Principle-
Procedure)
• Results and Discussion
• Conclusion & Recommendation
3

4. Background
:
4
In developing countries like Bangladesh water pollution
due to industrial wastewater is a serious concern. Most
of the industries in Bangladesh do not treat their
wastewater properly and let it go to the river which
cause the pollution of river water. These untreated
wastewater has very bad effect on agriculture, aquatic
plant, fish and human health.
Tanneries in Hazaribagh cause massive pollution to
Buriganga and nearby areas of Hazaribagh.

5. Objectives
5
 To study the wastewater quality of several industries
and compare with national standards
 To study installation & operating cost and efficiency
of different ETP
 Compare the ETPs based on installation & operating
cost and efficiency and develop a theoretical cost
effective model of ETP for Tanneries of Hazaribag

6. Methodology
6
 Laboratory experiment (BOD, COD, DO, TDS, pH
measurement)
 Industrial data analysis (cost analysis)

7. 7
Lab Experiment
 BOD5 measurement:
 Chemical procedure
 BOD5 = DO5 – DO1
 COD measurement:
 Chemical procedure
 Heating and instrumental measurement

8. 8
Lab Experiment cont’d
 Direct instrumental measurement:
DO
TDS
pH

9. Lab Experiment cont’d
9
Aeration
(BOD5 )
Heating
COD

10. 10
Lab Experiment cont’d
DO pH
TDS

11. Lab Experiment cont’d
Paramet
ers
Chemica
ls
Industry Paint Industry DOE
Waste
water
Treated
water
Waste
Water
Treated
water
pH 3 7.3 6.93 7.03 6 - 9
BOD5 450 ppm 38 ppm 250 ppm 16 ppm 50 ppm
COD 1200 ppm 172 ppm 670 ppm 46 ppm 200 ppm
TDS 4288 ppm 1900 ppm 1130 ppm 870 ppm 2100 ppm
DO 0 5.35 ppm 0 6.1 4.5 - 8
11

12. Parameter Tannery Effluent Department of
Environment
(DOE)
pH 3.88 6 - 9
BOD5(mg/l) 1454 50
COD(mg/l) 3386 200
TDS(mg/l) 14572 2100
DO(mg/l) 0.0 4.5 - 8
Cr(ppm) 987 0.5 (0.1 for Cr6+)
12
Lab Experiment cont’d

13. Industry of
Chemicals
Paint Industry
No. of Employee 4 6
Working Shifts 1 3
Working Hours 8 24
Liquid effluent
discharge (m3/d)
8 120
Point of discharge Unused open land Pond
13
Industrial data analysis

14. Fixed Cost Annual
variable cost
Chemicals Tk. 1300000 Tk. 800000
Paint Tk. 3050000 Tk. 6200000
14
Cost analysis

15. Chemical
s
Industry Paint Industry
Chemical
Process
Biological
Process
Chemical
Process
Biological
Process
Operating
Cost
Tk.
121000
Tk. 78000 Tk.
3550000
Tk.
1252000
Installatio
n Cost
Tk.
410000
Tk.
740000
Tk.
1150000
Tk.
1650000
15
Cost analysis cont’d

16. 16
Cost analysis cont’d

17. Cost analysis cont’d
17

18. Cost analysis cont’d
18
 Installation cost of Biological treatment process
units were larger than Chemical treatment process
units
 Operation cost of chemical treatment process was
larger than biological treatment process

19. Cost analysis cont’d
19

20. Cost analysis cont’d
20
 Paint Industry produces 10 times more effluent
than Chemicals Production Industry
 The ratio of cost of
Material supply = 1.78:1
Consultancy-commissioning-supervision = 1.67:1
Civil work = 4.8:1
Total fixed cost = 2.346:1

21. 21
ETP Model
 Presence of Cr
 Cr neutralization methods
 Adsorption
 Sawdust

22. 22
ETP Model cont’d

23. Conclusion & Recommendation
23
 BOD, COD, TDS, DO, pH of treated water will
reach DOE specification
 Cr removal will not reach DOE specification
Conclusion

24. 24
Conclusion & Recommendation cont’d
 Lab experiment
 Low cost adsorbent having optimum pH 2.5 – 3.5
 Presence of alkalinity, chloride, oil and grease,
phenol compounds, sulfide etc.
 Sludge management
Recommendation

25. END
of
Thesis I & II
25

26. CHE 408
Process Design Sessional I & II
Suman Sarkar
0802019
26
Design of Natural Gas Processing with Hysis
simulation

27. Supervisor
Dr. Dil Afroza Begum
Professor
Department of Chemical Engineering, BUET
27

28. Outline
• Objectives
• Project definition
• Available Process
• Design Basis
• Process Block Diagram
• Process Flow Diagram (PFD)
28

29. Outline cont’d
29
• Comparison between raw & products gas
• List of Major Equipments
• Individual Major Equipment Design
• Mechanical Design
• P&I Diagram
• Overall Economic Analysis

30. Objectives
 Ensuring more efficient and profitability Design
 Improving plant control, operability
 Reducing human error and time requirement
 Eliminating process bottle necks and minimizing
process network
30
By hysis simulation:

31. Project definition
:
31

32. Project definition cont’d
• Location- Golapgonj, Sylhet
• Capacity-550 MMSCFD
• Raw materials-Raw Natural Gas From 3
Producing Gas Wells, DEAmine Solution, TEG.
• Utility- Cooling water, Electricity (2 MW Capacity),
Natural Gas.
32

33. Available Process
33
• Gas Sweetening
 Solid Bed Sweetening Process: Molucular Sieves
 Aquasorption Process (Wash Water Process)
 Selexol Process
 Chemical Absorption Process(MEA,DEA,TEA
Processes)
 The Holmes-Stretford Process

34. 34
Available Process cont’d
• Gas Dehydration
 Absorption Process(Methanol, Glycol Process)
 Adsorption Process (Solid Dessicants, Alumina,
Silica Gel, Molecular Sieves)

35. Design Basis
35
Climate Condition:
Ambient Temperature-
Max- 35oC Min-12oC
Design max temp- 40oC Min temp-5oC
Annual Avg. Atmospheric pressure-0.11 MPa
Annual Avg. relative Humidity- 80%
Wind Velocity-52 miles/hr
Rain- Annual avg Rainfall- 2850 mm

36. Process Block Diagram
36

37. PFD (Hysis Simulation)
:
37

38. 38
Comparison Between Raw Natural gas
& Product gas
Raw Natural Gas
Components Composition
Methane 0.8634
Ethane 0.0574
Propane 0.0088
i-Butane 0.0007
i-Butane 0.0005
n-Pentane 0.0005
n-Hexane 0.0003
H2O 0.0467
Nitrogen 0.0018
CO2 0.0204
Components Composition
Methane 0.930973
Ethane 0.053632
Propane 0.000658
i-Butane 0.000022
i-Butane 0.000014
n-Pentane 0.000007
n-Hexane 0.000002
H2O 0.000101
Nitrogen 0.002029
CO2 0.012562
Product Gas

39. List of Major Equipments
39
Equipment Name Quantity
Designation in the
HYSYS Simulation
Compressor 1 K-100
Heat Exchanger 2 E-100, E-102
Absorber 2 T-100, T-102
Separator 3 V-100, V-101, V-104
Pump 2 P-100, P-101
Storage Tank 1 V-106
Stripper Column 2 V-102, V-103
Stabilizer Column 1 V-105

40. 40
Design Parameter
Separator Diameter: 8.12 ft
Minimum Separator height: 40.6
Thickness of the Separator: 3.3 ft
Gas-Liquid Separator

41. 41
Design Parameter cont’d
Pump (P-100) of Dehydration plant
Total frictional loss:
2.44 ft
Total head: 43.11 ft
Power requirement:
17.1hp
Material: cast iron
RPM: 1750
Flow capacity: 770GPM
(max)
Impeller size: 11-3/4”
Weight: 255 lbs
Price: $ 4662.00
Specification of pump:

42. Mechanical Design of Separator
42

43. 43
P & ID Diagram
Figure: P & I diagram for gas liquid separator

44. P & ID Diagram cont’d
44

45. 45
Overall Economic Analysis
 Equipment Cost at Present(2014)- $1.088 million
 Total Capital Investment - $ 6.12 million
 Total Annual Expenses- $ 13.24 million
 Net Profit After Tax(15%)- $ 15.4 million
 Pay back period – 3 year 11 month
 Salvage value- $ 0.532 million
 Depreciation- $0.765 million/year
 IRR i% = 24.58 %
 ERR i% = 19.67%
 Project life – 20 years

46. THANK YOU
46