Appendix 1 - Annex A - Process Design Report

APPENDIX 1 - ANNEX 1
Project: “Mainstreaming Climate Change Adaptation

through Water Resource Management in Leather
Industrial Zone Development”
(GEF ID 5666; SAP ID 150052)
“Common Effluent Treatment Plant for Sialkot
Tannery Zone”
March, 2018
Process Design Report

(Revision 02)
Project:
“Mainstreaming Climate Change Adaptation through Water Resource

Management in Leather Industrial Zone Development”
(GEF ID 5666; SAP ID 150052)
Common Effluent Treatment Plant

For
Sialkot Tannery Zone

(Revision 02)
March, 2018
A project of:
United Nations Industrial Development Organization (UNIDO)
Common Effluent Treatment Plant for Sialkot Tannery Zone
CONTENTS
LIST OF ANNEXURES .........................................................................................................................II
LIST OF TABLES ............................................................................................................................... III
LIST OF FIGURES ............................................................................................................................. IV
ACRONYMS ..................................................................................................................................... V
SALIENT FEATURES ........................................................................................................................ VII
1.1 GENERAL .............................................................................................................................. 1
1.2 TREATMENT CONCEPT ......................................................................................................... 2
1.3 THIS REPORT ........................................................................................................................ 2
CHAPTER 2: REVIEW OF AVAILABLE DATA ...................................................................................... 3
2.1 STZ PRODUCTION DATA ....................................................................................................... 3
CHAPTER – 3: INFLUENT AND EFFLUENT ........................................................................................ 6
3.1 WASTEWATER QUANTITY AND CHARACTERISTICS ............................................................. 6
3.2 REVISED WASTEWATER DESIGN DATA ................................................................................ 9
3.3 EFFLUENT REQUIREMENTS ................................................................................................ 12
CHAPTER 4: ALTERNATIVES ANALYSIS .......................................................................................... 13
4.1 SEGREGATION OF WASTEWATER CONVEYANCE SYSTEM ................................................. 13
4.2 OPTIMUM MODULAR APPROACH ..................................................................................... 13
4.3 TREATMENT TECHNOLOGY ................................................................................................ 14
4.3.1 Treatment System Objectives ........................................................................................ 14
4.3.2 General Selection Criteria for Wastewater Treatment System ..................................... 14
4.3.3 Treatment System Requirements for CETP.................................................................... 15
4.3.4 Evaluation of Alternate Preliminary Treatment Processes ............................................ 16
4.3.5 Evaluation of Alternate Primary Treatment Processes .................................................. 18
4.3.6 Evaluation of Alternate Biological Treatment Processes ............................................... 19
4.3.7 Comparative Analysis of Alternate Treatment Processes .............................................. 22
4.3.8 Comparative Analysis of Alternate Treatment Technologies in Combinations ............. 24
4.3.9 Evaluation of Alternate for Aeration System and Sludge Dewatering........................... 27
4.4 KEY TREATMENT SYSTEM COMPONENTS AND FACILITIES ................................................ 27
CHAPTER 5: DESIGN OF WATER LINE ............................................................................................ 29
5.1 BAR RACK FOR ULTIMATE FLOW ....................................................................................... 30
5.2 FINE SCREENS ..................................................................................................................... 31
5.3 VORTEX TYPE GRIT CHAMBER............................................................................................ 32
5.4 OIL & GREASE SEPARATOR................................................................................................. 33
I
5.5 EQUALIZATION TANK # 1 WITH SULPHIDE CATALYTIC OXIDATION – BEAM HOUSE

EFFLUENT ...................................................................................................................................... 33
5.6 EQUALIZATION TANK # 2 – TANNING & POST TANNING EFFLUENT ................................. 35
5.7 COAGULATION AND FLOCCULATION ................................................................................. 35
5.8 PRIMARY SEDIMENTATION TANK ...................................................................................... 36
5.9 AERATION TANK ................................................................................................................. 38
5.10 SECONDARY SEDIMENTATION TANK ................................................................................. 42
5.11 ADVANCED CHEMICAL OXIDATION ................................................................................... 43
CHAPTER 06: TERTIARY TREATMENT ............................................................................................ 45
6.1 RAPID SAND FILTERS .......................................................................................................... 46
6.2 LOW PRESSURE MEMBRANE TREATMENT ........................................................................ 47
6.3 LOW PRESSURE VACUUM EVAPORATION ......................................................................... 49
CHAPTER 7: DESIGN OF SLUDGE LINE ........................................................................................... 50
7.1 COMBINED SLUDGE THICKENERS ...................................................................................... 50
7.2 SLUDGE DEWATERING ....................................................................................................... 51
7.3 SLUDGE DISPOSAL .............................................................................................................. 52
CHAPTER 08: PRELIMINARY PROJECT COST.................................................................................. 53
8.1 CAPITAL COST..................................................................................................................... 53
8.2 OPERATION AND MAINTENANCE COST ............................................................................. 53
8.3 COST ESTIMATE FOR TERTIARY TREATMENT..................................................................... 54
CHAPTER 09: HUMAN RESOURCE REQUIREMENTS FOR OPERATION AND MAINTENANCE ........ 55
9.1 PLANT OPERATING HOURS ................................................................................................ 55
9.2 SHIFT TAKE OVER PROTOCOL ............................................................................................ 55
9.3 STAFF TRAINING ................................................................................................................. 56
LIST OF ANNEXURES
Annexure I: “Basic Information and Guidelines for Segregation of Streams in Sialkot Tannery
Zone” ........................................................................................................................................ 58
Annexure II: UNIDO Documents .............................................................................................. 70
Annexure III: Drawings ............................................................................................................. 74
Annexure IV: Punjab Environmental Quality Standards for Municipal and Liquid Industrial
Effluents ................................................................................................................................... 78
Annexure V: Schedule of Plant ................................................................................................ 82
Annexure VI: Motor List ........................................................................................................... 98
II
LIST OF TABLES
Table 1: Number and Type of Tanneries to be established in STZ ............................................ 3
Table 2: Area Allocated for Amenities ....................................................................................... 5
Table 3: Planned Production Capacity for STZ ........................................................................... 5
Table 4: Calculated Wastewater Quantity, Pollution Load and concentration based on
maximum production capacities and emission factors ............................................................. 7
Table 5: Average Concentrations of Tannery Wastewater computed using Emission Factors . 8
Table 6: Concentrations of tannery wastewater, domestic sewer and combined effluent ...... 8
Table 7: Adopted Design Values for CETP.................................................................................. 9
Table 8: Average Values of Pollution Load Discharged (Conventional Process) - UNIDO ....... 10
Table 9: Concentration Estimation based on Loads per Ton of Production – Phase I ............ 11
Table 10: New Estimated and Adopted Raw Effluent Design Data – Phase I .......................... 11
Table 11: Summary of Key Parameters; Punjab Environmental Quality Standards (PEQS) -
2016 ......................................................................................................................................... 12
Table 12: Treated Effluent Requirements ............................................................................... 14
Table 13: Screening of Preliminary Treatment Technologies: Screen ..................................... 16
Table 14: Screening of Preliminary Treatment Technologies: Grit Chamber .......................... 17
Table 15: Screening of the Primary Treatment Technologies ................................................. 18
Table 16: Screening on the Basis of Desired BOD Removal Efficiency .................................... 23
Table 17: Screening on the Basis of Ability to Treat High Strength Wastes and Resistance to
Shock Loads .............................................................................................................................. 24
Table 18: Comparative Analysis of Various Treatment Technologies ..................................... 24
Table 19: Comparative Analysis of Aeration System ............................................................... 27
Table 20: Comparative Analysis of Sludge Dewatering ........................................................... 27
Table 21: Summary of Wastewater Design Data for Phase I of STZ ........................................ 29
Table 22: Design Criteria and Unit Dimensions for Bar Rack ................................................... 30
Table 23: Screen Chamber Design Details ............................................................................... 32
Table 24: Design Criteria and Design of Vortex Grit Chamber ................................................ 32
Table 25: Design of Equalization Tank for Beam House Effluent ............................................ 34
Table 26: Design of Equalization Tank for Tanning & Post Tanning Effluent .......................... 35
Table 27: Design of Coagulation Flocculation Unit .................................................................. 35
Table 28: Primary Sedimentation Tank Design ........................................................................ 37
Table 29: Biological Process Parameters adopted for Aeration Tank Design ......................... 38
Table 30: Design Parameters Adopted for Aeration Tank Design ........................................... 39
Table 31: Design Check Parameters ........................................................................................ 39
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Table 32: Design of Aeration Tanks ......................................................................................... 40

Table 33: Pre-selector Design .................................................................................................. 40
Table 34: Design of Aeration System ....................................................................................... 41
Table 35: Design Criteria of Secondary Sedimentation Tank .................................................. 42
Table 36: Design of Secondary Sedimentation Tank ............................................................... 42
Table 37: Chemical Oxidation Tank with Neutralization Tank ................................................. 43
Table 38: Capacities of Tertiary Units ...................................................................................... 45
Table 39: Influent Data and Design Criteria for Rapid Sand Filters ......................................... 46
Table 40: Design of Rapid Sand Filters ..................................................................................... 47
Table 41: Required Quality of Reclaimed Water ..................................................................... 47
Table 42: Energy Consumption, Product Recovery, and Removal Efficiencies of Different
Residual Particulate Matter Removal Operations ................................................................... 48
Table 43: Primary Sludge Thickener (Picket Fence Type) ........................................................ 50
Table 44: Sludge Conditioning Tank and Filter Press ............................................................... 51
Table 45: Landfill Area Requirement for CETP Sludge Disposal .............................................. 52
Table 46: Capital Cost for Single Module of CETP (4,000 m3/day) .......................................... 53
Table 47: Annual Operation and Maintenance Cost ............................................................... 53
Table 48: Unit O&M Cost for Wastewater Treatment............................................................. 54
Table 49: Staffing Requirement & Recommendation .............................................................. 55
LIST OF FIGURES
Figure 1: Layout of Sialkot Tannery Zone .................................................................................. 4

Figure 2: Available Biological Methods for Wastewater Treatment ....................................... 19
Figure 3: Available Combinations of Biological and Physico-chemical Methods for
Wastewater Treatment............................................................................................................ 25
Wastewater Treatment; black cross, eliminated option due to non-compliance with effluent
standards; grey cross: eliminated due to too high space requirements. ................................ 26
Figure 5: Simplified Scheme of Treatment Options ................................................................. 26
NEC Consultants (Private) Limited IV

ACRONYMS
STZ Sialkot Tannery Zone

STAGL Sialkot Tannery Association (Guarantee) Limited Company
EIA Environmental Impact Assessment
ACO advanced chemical oxidation
BLC-CTPKT British Leather Centre – Clean Technology Program for Korangi
Tanneries
CMAS Complete Activated Sludge
UNIDO United Nations Industrial Development Organization
CETP Common Effluent Treatment Plant
HRT Hydraulic Residence Times
PEQS Punjab Environmental Quality Standard
CSA Climate and Social Assessment
TSS Total Suspended Solids
COD Chemical Oxygen Demand
BOD Biochemical Oxygen Demand
Cr Chromium
S2- Sulphide
NH3-N Ammonium Nitrogen
TKN Total Kjeldahl Nitrogen
TN Total Nitrogen
Cl Chloride
SO4 Sulphate
pH Potential of Hydrogen
SS Suspended Solids
UASB Up flow Anaerobic Sludge Bed
RBC Rotating Biological Contactors
RO Reverse Osmoses
MBR Membrane Bioreactor
CEPT Chemically Enhanced Primary Treatment
O&M Operation & Maintenance
RCC Reinforced Cement Concrete
PST Primary Settling Tanks
PE Polyvinyl Ethylene
MLSS Mixed Liquor Suspended Solids
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VSS Volatile Suspended Solids

SRT Solids Retention Time
RSF Rapid Sand Filter
F:M Food over Micro Organism Ratio
TDS Total Dissolved Solids
VI
SALIENT FEATURES
Project Name Establishment of Combined Effluent Treatment Plant

(CETP) for Sialkot Tannery Zone, Pakistan
Client UNIDO
Location Sialkot Tannery Zone, Airport Road, Sialkot
Type of Wastewater Tannery Wastewater
Quantity of Wastewater Initial Phase: 4,000 m3/day.
Quality of Wastewater BOD5@20oC = 1,600 ppm, COD = 4,400 ppm, TSS = 2,500
ppm
Applicable Standards Punjab Environmental Quality Standards - 2016, ‘Inland
Water Discharge Limits’
Treatment Technology Activated Sludge Treatment System with Chemically
Enhanced Primary Treatment (CEPT)
Key Components Water Line
 Prescreen Chamber
 Screen Chamber
 Detritor Grit Chamber
 Equalization Tank with Catalytic Sulphide Oxidation
 Coagulation and Flocculation Tank
 Primary Sedimentation Tank
 Aeration Tank (Activated Sludge Process)
 Secondary Sedimentation Tank
 Advanced Chemical Oxidation
 Final Neutralization
Sludge Line
 Sludge Thickening
 Sludge Conditioning Tank
 Sludge Dewatering (Belt-Press Type Sludge Filter)
Area Required Initial Phase requirement is 3.0 acres
Estimated Tentative Capital PKR 300 Million for initial phase
Cost
Tentative Annual Operation PKR 141.2 Million/year for initial phase + PKR 16.96
and Maintenance Cost Million Annual Depreciation.
Energy Requirement 598 KW for initial phase
VII
CHAPTER – 1: INTRODUCTION
1.1 GENERAL
The town of Sialkot is located about 130 km from Lahore, in the province of Punjab.
Currently, there are 250 tanneries located in 10 different clusters, scattered all
around Sialkot city and suburbs. These scattered tanneries are unable to meet the
international standards which are becoming more and more stringent with the
passage of time. Meeting the international standards needs proper infrastructure
which is not possible to be extended to each tannery in scattered locations all
around the city. The foremost and critical requirement for international trade and
exporting leather goods is the environmental and social compliance.
Relocation of the tanneries to a more spacious location with appropriate

infrastructure for efficient and cost effective treatment of solid and liquid wastes has
thus become a prerequisite for survival and growth of this vital export-oriented
sector of the country’s economy and for protecting the region’s agriculture and
health.
Based on these factors, it is planned to shift the tanneries at a dedicated tannery

zone away from the main city. The proposed Sialkot Tannery Zone (STZ) is a project
initiated and managed by Sialkot Tannery Association (Guarantee) Limited Company
(STAGL). The STAGL has been established as a special initiative of the Sialkot Tannery
Association and, Government of Punjab. Sialkot Tannery Association (Guarantee)
Limited is registered under section 32 of the Companies Ordinance 1984 (XLVII of
1984) to develop focused industrial growth in Sialkot by developing international
standard Tannery Zone in the region. The company is limited by guarantee having
share capital.
STZ with an area of 392 Acres will provide a central place for various scattered
tannery clusters of Sialkot and the surrounding areas. It shall mitigate the
environmental pollution in the city. It will be an international standard industrial
zone equipped with all facilities & infrastructure like roads, sewerage, water supply,
drainage, effluent treatment plants and others. (Ref: EIA of STZ, 2011)
STAGL is supported by UNIDO, which is working on a GEF funded project entitled:

‘Mainstreaming Climate change Adaptation through Water Resource Management in
Leather Industrial Zone Development’, has intended to implement a project of
Combined Effluent Treatment Plant (CETP) for the STZ.
A result of these joint efforts was the Technical Report depicting Conceptual Design
of the Common Effluent Treatment Plant, prepared by UNIDO in 2015. On the basis
of this report, to fulfill the requirements of the project, UNIDO seeks the services of
consultants for detailed designing and supervision of the implementation of CETP for
STZ.
1
1.2 TREATMENT CONCEPT
The concept of the CETP is to have the pre-treated wastewater collected from all the
units located within STZ to a common facility for treatment to comply with PEQSs.
1.3 THIS REPORT
In this report a process design for the CETP is presented, based on consideration of
both wastewater characteristics, opportunities for cost reduction and design criteria.
In Chapter 2 summary of available data is presented, after which the wastewater

data is presented in Chapter 3. In Chapter 4 a brief of various alternatives is
discussed. A design, which always should be the logical result from the combination
of wastewater characteristics and the design criteria, which themselves are by and
large defined by the effluent requirements, follows in Chapter 5 and 6. In chapter 7,
tertiary treatment is discussed and chapter 8 and 9 deals with cost estimates and
human resource requirements for CETP.
This version of the report is for review and comments on the local and international
level. As soon as the process design of CETP concludes, CETP hydraulic profile will be
developed on the basis of the definitive process design and accordingly, will be
documented as a Chapter in the final report.
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CHAPTER 2: REVIEW OF AVAILABLE DATA
The Sialkot Tannery Zone is just initiated and still relocation of tanneries in the zone is yet to
get pace. Therefore, data required for CETP design in terms of quality and quantity is to be
extracted from Secondary Sources. Basically the planning documents of the proposed zone,
Environmental Impact Assessment (EIA - March 2011) of the Sialkot Tannery Zone Project
and Climate and Social Assessment Study (CSA – February 2015) are the main documents for
development of CETP design data. At the same time, information provided by the
Management of Sialkot Tannery Association (February 2017) regarding Size and production
of Sialkot Tanneries is used to verify and update the production statistics.
Secondly, the Technical Report prepared by UNIDO (May 2015) addressing the conceptual
design of CETP STZ was also used to arrive at a safe conclusion.
Layout of the proposed Sialkot Tannery Zone is shown in Figure-1. A brief of the data is
presented in the following sections of the report.
2.1 STZ PRODUCTION DATA
Total area of proposed STZ is 160.175 hectares. As per the latest data of STZ, a total
of 554 industrial are planned to be located in the zone. The details are as follows:
Table 1: Number and Type of Tanneries to be established in STZ

(Ref: February 16, 2017, STZ Meeting)
No. of
# Process
Tanneries
1 Raw to Wet blue or Finish 60
2 Wet blue to Finish 244
3 Wet blue to Crust 150
4 Finish goods factories (leather garments & gloves manufacturers) 100
Total No. of Units 554
The area covered by these Units will be 112 Hectare. Out of 112 Hectares, area
reserved for processing units is 83 Hectares. Another 48 Hectares are reserved for
various purposes as per following details.

Figure 1: Layout of Sialkot Tannery Zone

Table 2: Area Allocated for Amenities
# Land use Area (Hectare)

1 Waste Management Facility 13.18
2 Roads 30.44
3 Parks 4.92
Total 48.54
As per surveys carried out in 2000 and accordingly, production planned for STZ in
2014, following production figures were finalized;
Table 3: Planned Production Capacity for STZ
Surveyed in Planned for

No. of
# Process Year 2000 STZ in 2014
Units
(Kg/day) (Kg/day)
1 Raw to Finish 88,108 153,626
2 Raw to Wet Blue 7,240 12,624
3 Raw to Crust 20,520 35,779
Subtotal 115,868 202,029 60
4 Wet Blue to Crust 50,079 87,317 150
5 Wet Blue to Finish 48,020 83,727 244
Subtotal 98,099 171,044 394
6 Finish Goods Factories (Leather garments & 100
gloves manufacturers)
Total 213,967 373,073 554
The surveyed carried out in Year 2000 among 189 tanneries located in Sialkot showed
that about 4.5 tons of Hides/Skins are being processed per hectare of land. The same
ratio has been used to finalize the design production of STZ for 83 Hectares allocated
to processing tanneries.
The Zone is planned for processing of about 1,400,000 sft per day, although current
production in Sialkot is about 700,000 sft/day.
It is estimated in the Master Plan that about 13,500 work-force will be available in
the STZ.
5
CHAPTER – 3: INFLUENT AND EFFLUENT
3.1 WASTEWATER QUANTITY AND CHARACTERISTICS
Production data, as discussed in chapter 02 is used in estimation of quantity and

quality of the effluent to be discharged from STZ. Unit Pollution Loads as provided in
following International Documents are used for computations purpose. Data thus
generated is compared with other similar cluster data (Korangi tannery cluster) to
arrive at a safe conclusion;
1. UNIDO Publication ‘The Scope for Decreasing Pollution Load in Leather

processing’ Prepared by j. Ludvik – August 2000,
2. International Environment Commission (IUE-1995), and
3. British Leather Centre – Clean Technology Manual – Part B; Tannery Effluent
Treatment and Available Technologies. BLC-CTPKT, 2002.
It shall be noted that all aforesaid references presents unit pollution loads more or
less in the same ranges.
6
Table 4: Calculated Wastewater Quantity, Pollution Load and concentration based on maximum production capacities and emission factors
Maximum Pollution Load - Range (Kg/day)

3
Production Wastewater (m /day)
Process
Capacity 2-
(Kg/day) TSS COD BOD Cr S NH3-N TKN Cl SO4
Range Average
Raw to Finish 153,626 5,223 - 8,603 6,913 12,751- 22,890 22,276- 35,488 7,681 - 13,212 461 - 1,075 615 - 1,383 615 - 922 1,782 - 2,750 21,047 31,032 7,989 - 16,899
Raw to Wet Blue 12,624 328 - 505 417 972 - 1,717 1,528 - 2,348 530 - 871 25 - 63 50 - 114 47 - 69 134 - 201 1,666 - 2,424 530 - 1,073
Raw to Crust 35,779 1,181 - 1,896 1,538 2,970 - 5,260 5,188 - 8,086 1,789 - 3,005 107 - 250 143 - 322 143 - 215 415 - 640 4,902 - 7,227 1,861 - 3,936
Subtotal 202,029
Wet blue to Crust 87,317 611 - 1,135 873 87 - 175 873 - 1,048 262 - 437 9 - 35 - 9 - 17 17 - 44 262 - 524 349 - 786
Wet blue to Finish 83,727 670 - 1,340 1,005 84 - 335 837 - 1,005 251 - 419 8 - 33 - 8 - 17 17 - 42 251 - 502 335 - 754
Subtotal 171,044
Total 373,073 8,013 - 13,479 10,746 16,864- 30,376 30,702- 47,974 10,514 -17,944 611 - 1,457 808 - 1,818 821 - 1,240 2,365 - 3,677 28,128- 41,710 11,063- 23,447
Concentrations Range (mg/l) 1,569 - 2,827 2,857 - 4,464 978 - 1,670 57 - 136 75 - 169 76 - 115 220 - 342 2,617 - 3,881 1,030 - 2,182
7
On the basis of these computations, average quantity of wastewater (10,746 m3/day)

is multiplied by minimum and maximum pollution loads. An average of both is also
depicted in the Table-5.
Table 5: Average Concentrations of Tannery Wastewater computed using Emission Factors
Tannery Wastewater Concentration

Parameter
Unit Range Average
Q m3/day 8,013 - 13,479 10,746
pH - 7-8 8
Temp °C 30 30
TSS mg/L 1,569 - 2,827 2,198
COD mg/L 2,857 - 4,464 3,661
BOD5@20°C mg/L 978 -1,670 1,324
Cr mg/L 57 - 136 96
2-
S mg/L 75 - 169 122
NH3-N mg/L 76 - 342 209
TKN mg/L 220 - 342 281
-
Cl mg/L 2,617 - 3,881 3,249
SO4 mg/L 1,030 - 2,182 1,606
Remaining wastewater from commercial and institutional establishments is

estimated on the basis of standard value of 75 litres/capita/day. Calculating the
quantity for 13,500 work-force it will be about 1,012.5 m3/day. Domestic
characteristics are taken as high strength sewer characteristics (Ref: Metcalf and
Eddy). Combining the Industrial and domestic wastewater the outcome is presented
in the Table-6.
Table 6: Concentrations of tannery wastewater, domestic sewer and combined effluent
Parameter Unit Tannery Wastewater Domestic Sewer Combined Effluent

3
Q m /day 10,746 1,012.5 12,000*
pH - 8 7 7-8
Temp °C 30 30 30
TSS mg/L 2,198 400 2,043
COD mg/L 3,661 800 3,414
BOD5@20°C mg/L 1,324 350 1,240
Cr mg/L 96 0 88
8
Parameter Unit Tannery Wastewater Domestic Sewer Combined Effluent

S2- mg/L 122 1 112
NH3-N mg/L 209 45 195
TKN mg/L 281 70 263
Cl mg/L 3,249 90 2,977
SO4 mg/L 1,606 50 1,472
Rounded off to 12,000
These values are further compared with the similar cluster’s data obtained from
Korangi Tannery Cluster, presented hereunder. Adopted design values are rounded
off figures with nominal safety margin to remain in line with the similar data.
However, SO4 values are taken lower than the Korangi value due to the fact that in
Korangi, brackish ground water (due to proximity of ocean) is being used in
processes, containing high SO4 concentrations, which is not the case in Sialkot.
Table 7: Adopted Design Values for CETP
Adopted Design
Parameter Unit STZ Effluent CETP - Korangi
Values
Production Tons/day 458 373
Q m3/day 12,000 13,500 12,000
pH 7-8 7-8 8
Temp °C 30 30 30
TSS mg/L 2,043 2,000 2,100
COD mg/L 3,414 3,570 3,600
BOD5@20°C mg/L 1,240 1,390 1,400
Cr mg/L 88 6.2 100
2-
S mg/L 112 N/T 200
NH3-N mg/L 195 N/T 200
TKN mg/L 263 300 300
Cl mg/L 2,977 N/T 3,000
SO4 mg/L 1,472 2,210 1,500
3.2 REVISED WASTEWATER DESIGN DATA
In accordance with the aforementioned data, a detailed process design report was
prepared in March 2017 and submitted to the UNIDO and STAGL for review and
comments. After review of the report, UNIDO experts emphasise on the need of
9
fresh production data from the STAGL. Subsequently, on October 19, 2017, STAGL
held a meeting to review the availability of fresh production data. After a thorough
discussion with the stake holders, technical consultants and UNIDO expert, STAGL
recommended the following revised data to be adopted as design parameters for the
first phase of CETP design:
1. The CETP will be established on modular approach and the first module will be
for the treatment of 4,000 m3/day of tannery effluents.
2. Effluents from industries will be in two separate channels – “Chrome free” from
beam-house operations 1,500 m3/day and 2,500 m3/day from tanning & post
tanning operations.
3. It was also decided that CETP will have separate sulphide oxidation for Beam-
house effluents. For tanning liquors STAGL will arrange Chrome Recovery Units
either within individual tanneries or on cluster level.
4. It was also deliberated that the CETP design will be replicable for rest of the two
or three modules.
In the light of above discussion and conclusion on the wastewater quantity following
estimations are made for the pollution concentration for Phase I of the project.
Table 8: Average Values of Pollution Load Discharged (Conventional Process) - UNIDO
Tanning & Post

Parameter Unit Beam House
Tanning
3
Wastewater m /ton 17.0 23.0
BOD, total kg/ton 53.0 15.5
COD, total kg/ton 144.5 43.5
TSS kg/ton 99.0 17.0
TN kg/ton 12.5 2.3
Sulphide kg/ton 6.5 -
Chloride kg/ton 112.0 57.5
Chromium kg/ton - 5.0
SO4 kg/ton 21.0 60.0
Beam house operations: soaking, liming, deliming & bating
Tanning & post tanning operations: tanning, post tanning & finishing
10
Table 9: Concentration Estimation based on Loads per Ton of Production – Phase I
Tanning & Post

Tanning
3
Wastewater* m /day 1,500 2,500
BOD, total mg/L 3,118 674
COD, total mg/L 8,500 1,891
TSS mg/L 5,824 739
TN mg/L 735 98
Sulphide mg/L 382 -
Chloride mg/L 6,588 2,500
Chromium mg/L - 217
SO4 mg/L 1,235 2,609
* MoM_19Oct2017_NEC_STAGL_UNIDO
Table 10: New Estimated and Adopted Raw Effluent Design Data – Phase I
Combined Raw Adopted Design

Parameter Unit
Effluent Values
3
Wastewater m /day 4,000 4,000
BOD, total mg/L 1,590 1,600
COD, total mg/L 4,370 4,400
TSS mg/L 2,646 2,500
TN mg/L 337 335
Sulphide mg/L 143 143
Chloride mg/L 4,033 4,000
Chromium mg/L 136 140
SO4 mg/L 2,094 2,100
The new design values are representative of the untreated combined raw effluent
from tanneries’ operations. While, in accordance with the discussion above, the
beam house effluent will be transported separately and primarily treated for
sulphide removal. Similarly chrome tanning effluent will first go through chrome
recovery unit. The two primarily treated streams will then be combined and treated
for BOD, COD and TSS removal as conventionally.
11
3.3 EFFLUENT REQUIREMENTS
The Punjab Environmental Quality Standards (PEQS)-2016, pertaining to the

wastewater under study in this report, are summarised in Table-11.
Table 11: Summary of Key Parameters; Punjab Environmental Quality Standards (PEQS) -
2016
Parameter Unit Value

COD mg/L 150
BOD5@20°C mg/L 80
TSS mg/L 150
NH3 mg/L 40
Sulphide mg/L 1
It shall be noted that the treated wastewater through most efficient biological
treatment process will treat the wastewater in conformance to all PEQS except TDS
and its constituent Chlorides and Sulphates. These details will be presented in
Chapter 4 and 5 of this report.
However, to further treat the water to bring down the TDS limits, high cost
technologies would be required, such as Membrane Filtration, etc. This aspect has
been discussed in detail in Chapter 6 of this report.
12
CHAPTER 4: ALTERNATIVES ANALYSIS
Alternative analysis has been done for the following three important decisions:
1 Segregation of wastewater conveyance system

2 Optimum modular approach
3 Selection of appropriate technology
4.1 SEGREGATION OF WASTEWATER CONVEYANCE SYSTEM
A separate report has been prepared to discuss and finalize the various alternatives
pertaining to segregation of conveyance system in STZ. The report has been
submitted to UNIDO and STAGL and duly finalized after a detailed deliberation in the
Month of July 2017. For ready reference the said report is attached as Annexure-I
with this document.
4.2 OPTIMUM MODULAR APPROACH
It is obvious that starting with the operational functioning of the estate, the
wastewater flows and pollution loads would keep on increasing with time, as the
individual production units come into operation one by one, and it would take
certain period of time, till all the individual industrial units in the estate are operating
at their full capacities and, consequently, the ultimate wastewater flows and
pollution loads are being generated by estate. This period to the full development
may be in years. Keeping this aspect in view, commonly the CETPs are not
constructed at their ultimate design capacity at the start and are rather executed in
phases, commensurate with the actual growth of the flows and pollution loads from
the estates, as established by actual time-to-time monitoring. This course is adopted
primarily to avoid the waste of facilities and equipment, owing to their prolonged
disuse and useless maintenance expenses, during the periods of their disuse, both
leading to the wastage of the financial resources. In such cases, the capacity of the
CETP, to be executed at the start, may range from 25 – 50% of the ultimate capacity,
depending upon the assessment of the growth patterns during initial stages of the
development.
Implementation of STZ is just initiated and relocation of industrial units is yet to gain
pace. Industrial estates in Pakistan may take 10 to 15 years to reach the optimum
occupancy. It would be advisable to construct the CETP in modules as per increase in
occupancy level.
Alternative 1 could be the construction of complete plant having capacity of 16,000

m3/day. Though in cost terms, it will be cheaper due to use of ‘common walls’
approach in construction of various units. Similarly, mechanical equipment, electrical
and instrumentation will also become cheaper. On the other hand, almost 70 - 80 %
of the tanks and equipment will remain unused for many years resulting in complete
damage of assets within three to four years.
13
As Alternative 2, it would be better to start with 25 % of capacity for at least next 4

to 5 years and then add another 25 % and so gradually reach 100 % capacity in next
15 years. This will not only save the finances but also allow the possibility of
adjusting and modifying the design in the forthcoming modules.
However, the STAGL management has decided to construct first module of CETP
having a capacity of 4,000 m3/day and subsequent modules will be planned after
reviewing the actual occupancy and growth rate of industries in STZ
4.3 TREATMENT TECHNOLOGY
4.3.1 Treatment System Objectives
As already established in Chapter 3, the CETP shall be intended to bring the values of
wastewater BOD, COD, SS and oil & grease within the limits set by National
Environmental Quality Standards for Inland Waters, as promulgated under Pakistan
Environmental Protection Act, 1997. However, removal of chromium present in the
wastewater shall be carried out within the industries.
Table-12 presents the design influent concentrations for BOD, COD and SS,
applicable PEQS values, design effluent concentrations and respective required
treatment efficiencies.
Table 12: Treated Effluent Requirements
Design
PEQS Value (mg/L) Concentrations Required
(mg/L) Treatment
Parameter
Efficiency
Into Inland Into Sewage
Into Sea Influent Effluent (%)
Waters Treatment
BOD5 @20°C 80 250 80 1,600 80 95
COD 150 400 400 4,400 150 96.6
TSS 200 400 200 2,500 200 92
COD removal, by any biological treatment, would not exceed about 1.6 to 1.8 times
the amount of BOD removed. The design effluent concentration for COD is
established on the assumption that the ratio of biodegradable/bioeliminable COD to
BOD shall be of the order of 1.6. Residual COD exceeding the limits will be treated by
additional treatment unit.
4.3.2 General Selection Criteria for Wastewater Treatment System
The wastewater treatment facilities shall be selected after taking due consideration
of the pertinent technical, operational and economic factors, limitations and
constraints. The key factors, which govern the choice of the treatment system, are as
follows:
14
 Nature and Strength of Wastewater: The applicable physical, chemical and

biological treatment processes are primarily governed by the nature of pollutants
to be removed and their strengths in the wastewater. The treatment system
selected shall ensure the required pollutant removal efficiencies.
 Physical Constraints: Physical constraints, principally being the area available and
the topography of the plant site with reference to the system hydraulic
requirement, govern the selection of treatment technology.
 Cost: The system selected should be the least cost alternative, keeping in view
both capital as well as operational costs, within the range of technically feasible
options.
 Operational Skills: Skills required for the routine operation and maintenance of
the treatment system should be available locally, with only a minimum of
training. The proposed system shall have relative ease of operation and
maintenance.
 Mechanical Equipment: The selected system shall be such that minimum

mechanical equipment needs to be provided. Unnecessary mechanical
equipment shall be avoided. The system shall be designed such that maximum of
the mechanical equipment is from local manufacture.
 Nuisance: The degree of color, odor and noise shall be below the nuisance
threshold, especially, with reference to the proximity of the treatment system to
the build-up areas.
4.3.3 Treatment System Requirements for CETP
The principal pollutants to be removed are BOD, COD and SS. It implies that a
combination of physical and biological treatment processes shall be required. The
ratio of COD-to-BOD is such that the removal of BOD, by biological treatment, would
not bring the COD within the PEQS limits and advanced/tertiary treatment will be
needed.
In the case of Sialkot Tannery Zone, tannery wastewater treatment may call for a
sequence of anaerobic /chemically enhanced Primary Treatment - aerobic
treatment, which is known to be rather effective in the removal of high organic
pollutants.
Therefore, biological treatment technology with various combinations will be further

evaluated for wastewater treatment.
 Evaluation of alternate biological treatment processes unit for selection of the

most appropriate one for CETP is made in Section 4.3.4.
15
 Sludge, produced by removal of suspended solids by physical or biological

processes, shall need to be treated, for rendering it suitable for transportation
for disposal or reuse, as the case may be. The suitable sludge treatment for CETP
is laid down in Section 4.3.5.
4.3.4 Evaluation of Alternate Preliminary Treatment Processes
Mainly preliminary treatment process system consists of following:
 Screening
 Grit removal
Following Table-13 and 14 provides a detail comparative analysis of preliminary

treatment for Sialkot Tannery Zone CETP in consideration with local conditions:
Table 13: Screening of Preliminary Treatment Technologies: Screen
Large Small
Selection of Screens Remarks Justification
Solids Solids
 Easy operation and
maintenance.
 High skill labor not
Bar Screens (Coarse) High Low 
required.
 Efficient in removing
large solids.
maintenance.
Mechanically Cleaned Fine Bar Screens High High 
required.
 Efficient in removing
small solids.
 Complex operation and
maintenance.
Rotary Screens High High   High skill labor required.
 Very efficient in
removing small solids.
 Complex operation and
maintenance.
Disc Screen High High   High skill labor required.
 Very efficient in
removing small solids.
16
Table 14: Screening of Preliminary Treatment Technologies: Grit Chamber
% Removal % Removal
Selection of Grit
of 0.3 mm of 0.2 mm Remarks Justification
Removal Unit
Particle Particle
maintenance.
required.
 Simple construction
Horizontal Grit
 Large footprint
Chamber without 90 90 
Mechanical Aid  Head loss is excessive
 Channels without
effective flow control will
remove excessive
amounts of organic
material
 High skill labor required.
 Do not require flow
control because all
bearings and wearable
moving mechanical parts
are above the water line.
 Minimal head loss
Detritor  Large footprint than
95 90 
(Mechanical) vortex type.
 Removal system removes
large quantities of
organic material
 In shallow installations
the rake arm of scraping
mechanism can create
agitation of settled grit
 Remove a high
percentage of fine grit
 Small footprint
 Minimal head loss
Vortex Grit  Energy efficient and
Chamber 95 95  require less power as
(Mechanical) compared to detritor.
 Feasible for small flows
 Modifications in the
system are difficult at a
later stage
17
4.3.5 Evaluation of Alternate Primary Treatment Processes
A brief description of primary treatment technologies is as follows:
 Plain Sedimentation: Sedimentation tanks are large circular basin with retention
time of not less than 1.5 hours to hold water under quiescent conditions. No
agitation helps to remove settleable solids under their own weight or gravity. In
plain settling no chemical aid is provided. Requires slow loading rates, produce
less sludge and consumes less energy. However due to low loading rate, large
surface area is required.
 Chemically Enhanced Sedimentation: In this process, chemicals namely

coagulants are first added which help solids particles to come closer and make
flocs. Flocculants are also used sometime to strengthen the flocs bond. In this
way the weight of the flocs is increased and the gravity settling time is reduced.
Chemical aid reduces the loading requirement and higher surface loading rates
can be achieved. However the sludge quantity is increased substantially because
of the formation of chemical sludge.
 Dissolved Air Flotation: in this process, air is dissolved in wastewater under a

certain pressure. This pressurized liquid-water is then released at atmospheric
pressure level in the flotation tank. The released air forms tiny bubbles which
adhere to the suspended matter causing the suspended matter to float to the
surface of the water where it may then be removed by a skimming device.
The loading rates are much higher than the gravity settling types but high
amount of air is required, hence increasing energy requirement of the system.
The sludge quantity is also increased because of the chemical sludge. Increased
number of equipment, hence maintenance requirement is more. Skilled labour is
required to operate the system.
Table 15: Screening of the Primary Treatment Technologies
Primary Treatment *TSS Energy

Foot Print Upkeep Remarks
Technologies Removal (%) Required
Plain Sedimentation 50 – 70 Low High Low 
Chemically Enhanced Low to
80 – 90 Low Medium 
Sedimentation medium
Dissolved Air Flotation Medium
80 – 95 Low High 
to high
* Treatment of Tannery Wastewater: Naturgerechte Technologien, Bau-und Wirtschaftsberatung (TBW) GmbH,
Frankfurt (Germany), April 2002
18
4.3.6 Evaluation of Alternate Biological Treatment Processes
4.3.6.1 Screening Process for Treatment Technology Selection
At the first step all available and applicable treatment technologies are brought
under review. Generally following biological treatment technologies are available for
industrial wastewater treatment:
Figure 2: Available Biological Methods for Wastewater Treatment
Biological Methods of
Wastewater Treatment
Aerobic Anaerobic
Suspended Growth Attached Suspende Attached

Growth d Growth Growth
Activated Sludge Lagoon Trickling Completely Packed

Filter Mixed Bed
Aerated
RBC Lagoons Fluidized
Conventional Oxidation Bed
Pond
Extended Facultative Fluidized Expanded

Lagoons Bed Bed
High Rate Sludge

Blanket
Contact Stabilization
Sequencing Batch
Reactor
Above mentioned technologies are listed in simplified form as below:
■ Aerobic
 Oxidation Ponds
 Trickling Filters
19
 Aerated Lagoons
 Activated Sludge
 Rotating Biological Contactors
 Membrane Bioreactors
■ Anaerobic
 Anaerobic Ponds
 Up flow Anaerobic Sludge Bed (UASB)
A brief description of these processes is as follows:
 Oxidation Pond System: Oxidation ponds are large shallow basins, in which raw
wastewater is treated entirely by natural processes, involving both algae and
bacteria. They are the most important method of wastewater treatment in hot
climates. However, since the rate of unaided oxidation is slow, large areas are
required for their construction. Their specific advantages are simple operation
and reduced sludge management problem.
 Tricking Filter Process: In this process, the settled wastewater is allowed to trickle
down over a circular deep bed of coarse aggregates filter or plastic media filter.
The microbial film, developed on the surface of filter media over time, treats the
wastewater. A part of this film, washed away by the hydraulic action of trickling
wastewater, is separated in secondary clarifier, in form of humus sludge,
disposed of after sludge treatment, or returned for digestion into the UASB
reactor, if applicable.
 Aerated Lagoons: Aerated lagoons are completely mixed basins, with detention
periods ranging from 2 to 6 days, in which wastewater is generally treated on
flow through basis (without solids recycling), with forced aeration. The aerobic
suspended biological flocs, responsible for the waste conversion, closely
resemble to that of activated sludge process. Area requirements are in between
those of the oxidation ponds and activated sludge process.
 Activated Sludge Process: Activated sludge process is the biological treatment, in

which aerobic microorganisms present in wastewater, use the colloidal and
dissolved organic matter of the wastewater, for their multiplication and growth,
with the help of oxygen thus converting them into readily settleable biomass.
Generally, the required oxygen supplies are maintained by forced supply of air to
the wastewater in the aeration tank. The aerated effluent is then allowed to pass
through a secondary settling tank to separate the biomass or the “activated
sludge”. A part of the "activated sludge" is recycled to the aeration tank to
maintain optimum microorganism concentrations. The remaining secondary
sludge is removed from the system periodically; dewatered and dried; and
disposed off.
20
 Rotating Biological Contactors (RBC): Rotating Biological Contactors (RBCs) are

mechanical secondary treatment systems, which are robust and capable of
withstanding surges in organic load. An RBC unit comprises a series of closely
spaced "circular disks" normally made from a plastic material. The disks are
partially submerged in the sewage and are slowly rotated through it.
The rotating disks support the growth of bacteria and micro-organisms present in
the sewage, which breakdown and stabilize organic pollutants. To be successful,
micro-organisms need both oxygen to live and food to grow. Oxygen is obtained
from the atmosphere as the disks rotate. As the micro-organisms grow, they
build up on the media until they are sloughed off due to shear forces provided by
the rotating discs in the sewage.
 Membrane Bioreactor (MBR): The term membrane bioreactor (MBR) defines a

combination of an activated sludge process and membrane separation. The MBR
process can be employed in activated sludge processes, using the membranes as
liquid-solid separation instead of the usual settling. Suspended solids can be
removed completely and bacteria-free treated water produced. The sludge
concentration and hydraulic loading rates are considerably higher than in
conventional treatment.
Pre-treated, screened influent enters the membrane bioreactor, where

biodegradation takes place. The mixed liquor from the bioreactor is withdrawn
and pumped along submerged or semi-cross flow filtration membrane modules.
 Upflow Anaerobic Sludge Bed (UASB): UASB technology, normally referred to as

UASB reactor, is a form of anaerobic digester that is used in the treatment of
wastewater. The UASB reactor is a methanogenic (methane-producing) digester
that evolved from the anaerobic clarigester (digester + clarifier).
UASB uses an anaerobic process whilst forming a blanket of sludge in the lower
parts of the tank. Wastewater flows upwards through the blanket and is
processed by the anaerobic microorganisms. The upward flow combined with the
settling action of gravity suspends the blanket. The blanket begins to reach
maturity at around 3 months after start-up.
Biogas with a high concentration of methane is produced as a by-product, and

this may be captured and used as an energy source, to generate electricity for
export and to cover its own running power.
 Anaerobic Ponds: Anaerobic ponds are normally used to treat high strength
concentrated industrial waste and no oxygen is present in the pond. All the
biological activity is anaerobic decomposition. These ponds are 8 to 12 feet deep
and are anaerobic throughout. Scum forms on the top of the most anaerobic
ponds. This scum stops air from mixing with the wastewater. The gases that are
produced by the anaerobic bacterial action cause odor problems.
21
4.3.7 Comparative Analysis of Alternate Treatment Processes
All of these technologies are screened for applicability in the specific Sialkot Tannery
Zone conditions. Following is a comparative analysis of above treatment systems,
with respect to their suitability for CETP of STZ:
■ Step 2: Screening on the basis of desired BOD removal efficiency (%)
 Anaerobic Ponds: Maximum BOD removal efficiency percentage of Anaerobic

Ponds as reported in the literature is 70%. In STZ conditions, neither removal of
organic pollutants could be achieved, at the desired level, through this
technology nor is the required area available. Therefore this technology could
not qualify for further screening.
 Rotating Biological Contactors: For RBCs also, maximum BOD removal efficiency
as reported in literature is 85%, therefore the technology could not be applicable
in STZ conditions.
 Oxidation Pond System: For Oxidation Pond also, maximum BOD removal
efficiency as reported in literature is 90%, therefore the technology could only be
applicable as pretreatment unit in STZ conditions. Moreover, these ponds need
very large areas, for their construction. In STZ conditions, the area requirement is
of the order of 50 -60 acres. The pond area required, to achieve the desired
treatment efficiency, in case of CETP, is far in excess of the available area. This
option therefore cannot be considered at all.
 Aerated Lagoons System: For Aerated Lagoons also, maximum BOD removal
efficiency as reported in literature is 90%, therefore the technology could only be
applicable as pretreatment unit in STZ conditions. Moreover, Aerated Lagoons, in
comparison with the activated sludge and trickling filter process, need more
area. Estimated area requirement for the STZ case is about 30 - 45 acres which is
2 - 3 times of those required for activated sludge (conventional) or trickling filter
process. In any case, the area required for CETP, to achieve the desired
treatment efficiency, is more than that available.
 Upflow Anaerobic Sludge Bed (UASB): For UASB also, maximum BOD removal
efficiency as reported in literature is 80 - 90%, therefore the technology can only
be applicable as pretreatment unit in STZ conditions. Anaerobic treatment
processes in comparison to aerobic treatment processes, except for oxidation
ponds systems, are highly energy efficient, particularly in hot climates.
In aerobic biological systems, such as, activated sludge and aerated lagoons
processes, energy is required for artificial aeration of wastewater. In case of
activated sludge process, energy is also consumed in sludge recycling process.
For trickling filters, hydraulic energy is needed to rotate the rotary distributor by
pressurized feeding of the influent and recirculation wastewater to it.
Introduction of an anaerobic treatment reduces the overall operational cost of
the biological treatment, because lesser amount of organic matter is to be
22
degraded by the subsequent aerobic process. Various alternate types of

anaerobic wastewater treatment processes are available. Most of these
processes have come up recently as a result of the extensive research, which is
still going on. UASB Reactor is the most common one.
Table 16: Screening on the Basis of Desired BOD Removal Efficiency
Maximum BOD
# Treatment Technologies Removal Efficiency Remarks
Reported
1 Oxidation Ponds 90 
2 Trickling Filters (Two Stage + recycling) 95 
3 Aerated Lagoons 90 
4 Activated Sludge 95 
5 Anaerobic Ponds 70 
6 Membrane bioreactors 98 
7 Rotating Biological Contractors 85 
8 Up flow Anaerobic Sludge Bed (UASB) 80 
■ Step 2: Screening on the basis of ability to treat high strength wastes and
resistance to shock loads
 Trickling Filter Process: The principal advantages claimed for attached growth
processes, like trickling filters, over the activated sludge process include less
energy requirement and better sludge thickening properties; whereas the
disadvantages often cited are poorer effluent quality and greater sensitivity to
lower temperatures. In most cases, the reaction rates for soluble industrial
wastewaters are relatively low and hence filters are not economically attractive
for high treatment efficiencies. Reported BOD removal efficiencies for industrial
wastewaters range from as low as 10% to most of them lying below 60%.
Another problem associated with trickling filters is breeding of filter flies
(psychoda), which is a nuisance for plant area as well as the surrounding
communities.
 Activated Sludge Process: This process is in fact the most commonly employed
treatment process worldwide for the removal of BOD from the domestic as well
as from a variety of individual and combined industrial wastewaters, because of
its operational flexibility and its capability to furnish higher removal efficiencies
in varying conditions with suitable level of process control, besides other
comparative advantages.
23
 Membrane bioreactors: A latest type of Activated Sludge Process with

combination of membrane technology also qualifies the required parameters for
selection for STZ CETP.
Table 17: Screening on the Basis of Ability to Treat High Strength Wastes and Resistance to
Shock Loads
# Treatment Technologies Sensitivity Remarks

1 Trickling Filters (Two Stage + recycling) High 
2 Activated Sludge Process Moderate 
3 Membrane bioreactors Moderate 
Results of aforesaid discussion are presented in the Table-18.
Table 18: Comparative Analysis of Various Treatment Technologies
Maximum
Tentative Area
BOD Removal Sensitivity to
# Treatment Technologies Requirement
Efficiency Shock Loads
(acres)
Reported
1 Anaerobic Ponds 70
2 Rotating Biological Contractors 85
3 Oxidation Ponds 90
4 Aerated Lagoons 90
5 Up flow Anaerobic Sludge Bed (UASB) 80
6 Trickling Filters (Two Stage + recycling) 95 25 - 35 High
7 Activated Sludge 95 15 - 20 Moderate
8 Membrane Bioreactors 98 10 - 15 Moderate
4.3.8 Comparative Analysis of Alternate Treatment Technologies in Combinations
Treatment may also be performed in combined treatment steps. Regarding the

treatment in combined systems, the following systems may be observed.
After preliminary treatment (reception, screening, sand trap), the following

treatment alternatives are possible:
for primary or first-step treatment, there may be
− anaerobic lagoon
− chemically enhanced primary treatment (CEPT) or
24
− upflow anaerobic sludge blanket (UASB) system

− alternatively, there may be no first-step treatment
These treatment steps may be seen as a total treatment, followed by advanced

chemical oxidation (ACO) or a second treatment step before ACO may be included.
This second treatment step may consist of:
− oxidation pond
− aerated lagoon
− activated sludge system
− membrane bioreactor
The various options are schematically represented in Figure-3.

Wastewater Treatment
(none)
(none)
oxidation
pond
anaerobic
preliminary lagoon aerated ACO
treatment lagoon
CEPT
activated
sludge
UASB
MBR
With regards to the estimated efficiencies of the first treatment step, it may be
noted that a second treatment step is absolutely necessary in order to comply with
the effluent standards. For this reason, the option “no treatment” should be left out
of the options for the second step. In view of the limited space available, the
hydraulic residence times (HRT) that are normally applied in the various systems
may prove helpful in deciding for the best combinations for further study. It may be
noted that with a HRT of more than 5 to 7 days, the system under study may be
considered too large for application in the CEPT. In Figure-4, the indicative HRTs of
the various systems are presented. They will lead to exclusion of a number of
systems from the scheme.
25

Wastewater Treatment; black cross, eliminated option due to non-compliance with
effluent standards; grey cross: eliminated due to too high space requirements.
(none)
(none)
oxidation
pond HRT 20 d
anaerobic
preliminary lagoon aerated
HRT 4 d A
GCA O
C
treatment lagoon
HRT 7 d
CEPT
HRT 1.5 h activated
sludge HRT 1 d
UASB
HRT 8 h
MBR
HRT 0.5 d
The elimination of a number of options leads to a more simple scheme for treatment
options, which is shown in Figure-5.
Figure 5: Simplified Scheme of Treatment Options
(none)
activated
preliminary sludge
CEPT AA
G CC
O
treatment
MBR
UASB
MBR is very expensive technology in Pakistan’s local context. It will be 2.5 times
higher than Activated Sludge System in terms of Capital Cost and about 1.5 times
higher in terms of O&M Cost.
Considering the high Sulphate concentration in tannery wastewater which are more
than 2,100 mg/L in this case and corresponding COD:Sulphate ratio which is about
2.1, it will be high risk to opt for the UASB technology. As the desired concentration
for UASB is less than 1,000 mg/L and COD:Sulphate ratio is 3:1, therefore, it is
expected that emissions of Hydrogen Sulphide will be generated which are fatal for
the human life.
■ Selected Biological Treatment Process
On the basis of afore-stated comparative analysis of anaerobic and aerobic

treatment processes, the Activated Sludge Process is the only suitable secondary
processes for the CETP and is selected for detailed design. The primary treatment
will comprise of physico-chemical treatment, like coagulation/flocculation followed
by sedimentation.
26
4.3.9 Evaluation of Alternate for Aeration System and Sludge Dewatering
Following Table-19 and 20 provides a detail comparative analysis of Aeration System

and Sludge Dewatering for Sialkot Tannery Zone CETP in consideration with local
conditions:
Table 19: Comparative Analysis of Aeration System
Selection of Aeration System Efficiency Labor Skill Maintenance Remarks

Surface Aerators 1.5 lb O2 per kWh Moderate Moderate 
Fine Bubble Diffusers with Blower 4.9 lb O2 per kWh High Very High 
Jet Aeration System with Blower 3.9 lb O2 per kWh High Moderate 
Table 20: Comparative Analysis of Sludge Dewatering
Selection of Sludge Area Environmental

Efficiency Labor Skill Maintenance Remarks
Dewatering Requirement Nuisance
Sludge Drying Beds Low Low Low Very High Very High 
Sludge Filter Press
High Moderate Moderate Low Low 
(Belt Type)
4.4 KEY TREATMENT SYSTEM COMPONENTS AND FACILITIES
In light of the above discussion, following are the key components of treatment
system and facilities proposed for CETP.
■ Water Line
o Beam House Effluent
 Screen Chamber
 Grit Chamber
 Equalization Tank with Catalytic Sulphide Oxidation
o Tanning & Post Tanning Effluent
 Screen Chamber
 Grit Chamber
 Equalization Tank
27
o Combined Effluent
 Coagulation and Flocculation Tank

 Aeration Tank - Activated Sludge Process
 Secondary Sedimentation Tank
 Advanced Chemical Oxidation
 Final Neutralization
■ Sludge Line
 Sludge Thickeners
 Sludge Conditioning Tank
 Sludge Dewatering (Belt-Press Type Sludge Filter)
Details of each aforesaid unit are discussed in Chapter 5 and Chapter 6 of this report.

CHAPTER 5: DESIGN OF WATER LINE
In the following sections detailed design of CETP will be presented. Table-21 depicts the
Wastewater data used for designing of the CETP.
Table 21: Summary of Wastewater Design Data for Phase I of STZ
Tanning & Post

Tanning
Wastewater flow m3/day 1,500 2,500
Peak Factor - 2.50 2.50
Peak Rate m3/hr. 156.25 260.4
TSS mg/L 5,824 739
COD mg/L 8,500 1,891
BOD5@20°C mg/L 3,118 674
Cr mg/L 0 217
S2- mg/L 382 0
TN mg/L 735 98
Cl mg/L 6,588 2,500
SO4 mg/L 1,235 2,609
The targeted effluent characteristics shall be in conformance to PEQSs of Pakistan:
Water line of the proposed CETP will be consisting of the following components:
 Pre-screen Chamber #1 for Beam House Effluent

 Screens #1 for Beam House Effluents
 Grit Chamber #1 for Beam House Effluents
 Pre-screen Chamber # 2 for Tanning and Post Tanning Effluent
 Screens # 2 for Tanning and Post Tanning Effluents
 Grit Chamber # 2 for Tanning and Post Tanning Effluents
 Equalization Tank # 1 with Catalytic Sulphide Oxidation for Beam House Effluent
 Equalization Tank # 2 for Tanning and Post Tanning Effluent
 Wastewater Pumping Station
 Coagulation Flocculation Tank
 Aeration Tank – Extended Activated Sludge System
 Secondary Sedimentation Tank – Extended Activated Sludge System
 Tertiary Treatment Unit

Description of each aforesaid component with its design and basis of design is
presented in this chapter. However, details regarding hydraulic profile are presented
in the Chapter 7 of this report.
5.1 BAR RACK FOR ULTIMATE FLOW
It is recommended that the Pre-Screen Chamber shall be provided for the ultimate
flow of 6,000 m3/day for beam house and 10,000 m3/day for tanning and post
tanning effluents, so that future Phases could start directly from here.
The chambers are provided to act as a receiving structure for the wastewater from
the industrial estate. It will receive wastewater for screening through RCC sewers.
The design criteria and the unit dimensions are provided in the Table-22.
Table 22: Design Criteria and Unit Dimensions for Bar Rack
Tanning & Post

Tanning
Wastewater flow
Maximum m3/day 4,500 – 6,000 7,500 – 10,000
Peak Factor - 2.50 2.50
Peak Flow m3/hr. 470 – 625 781 – 1,040
Design of Pre-Screen Chamber
Retention time seconds 15 10
Length m 1.5 1.5
Width m 2.0 2.0
Water Depth m 0.9 0.96
Mechanical Bar Rack
Numbers Nos. 2 + 1 Standby 2 + 1 Standby
3
Capacity, each m /hr. 235 – 313 390 – 520
Clear spacing b/w bars mm 20 20
Screen angle degree 60 60
Screen channel width m 0.60 1.00
Approach velocity m/sec 0.650 0.650
Depth of flow m 0.25 – 0.33 0.25 – 0.33
In case of complete accidental shutdown of CETP, the chamber will also act as the
bypass structure so that all the effluent can be bypassed directly to the ultimate

disposal point. For this purpose the chambers will be equipped with a penstock,
each, at the inlet point.
After Bar Screen, all the subsequent units are designed for Phase I of the CETP
having average capacity 4,000 m3/day.
5.2 FINE SCREENS
From the coarse screen chamber, the wastewater will flow into the fine screen
channel which will be provided with mechanically & manually cleaned screens. The
wastewater has to be screened in order to remove the large floating constituents
present in it. At the top of the screening channels, RCC platforms, of adequate space,
shall be provided for manual cleaning of the screens, operation of the sluice gates
and other purposes. The screenings shall be disposed to the landfill site along with
dewatered sludge. For safe operation, 1 + 1 screens for each wastewater stream
shall be provided, each capable of handling the full flow.
Two numbers of screening channels for each stream of wastewater in parallel will be
constructed. The channels shall be of rectangular geometry in plan. One of the
channels will be equipped with mechanically operated coarse screens. While the
other will be equipped with manually cleaned screens as standby operations. Two (2)
sluice gates at inlet and outlet of each screen channel are also provided to take any
channel out of operation for maintenance purpose. Under normal operating
conditions, the wastewater will flow through all channels.
Following are the key components of the Screen Channel:
 Two Screening Compartments (RCC), in parallel, with 1 Penstock (CI) each, at its
inlet and outlet to the common Influent & Effluent Chamber, in order to bring
any of the compartments out of operation
 One mechanically cleaned Screen in one of the two channels.
 One manually cleaned screen to act as standby.
 Two Operating Platforms constructed 1 each in the 2 Screening Compartments,
at level of top of screens, in order to receive screenings, for their subsequent
transfer to the ground level
 Common Effluent Chamber (RCC)
 One effluent pipes (RCC), to the Grit Chamber.
 Access Walkways
 Monkey Ladders (SS)
Table-23 presents the design criteria for mechanically cleaned screen chambers
adopted for the Project:

Table 23: Screen Chamber Design Details
Tanning & Post

Tanning
Wastewater flow
Average m3/day 1,500 2,500
Peak factor 2.50 2.50
Peak flow m3/hr. 156.25 260
Mechanically Cleaned Screen
Type reciprocating rake bar screen
Numbers Nos. 1 + 1 Standby 1 + 1 Standby
Screen bar width mm 15 15
Screen bar depth mm 75 75
Clear spacing b/w bars mm 06 06
Screen angle with horizontal degree 60 60
Screen channel width m 0.60 1.00
Approach velocity m/sec 0.65 0.65
Depth of flow m 0.30 0.30
5.3 VORTEX TYPE GRIT CHAMBER
The screened wastewater will pass through grit chamber prior to entering the
respective equalization tanks. Grit removal is essential for safe operations of pumps
and to avoid overloading of the aeration tanks with inert inorganic material.
The grit chamber is designed on a loading rate of 0.02 – 0.04 m3/m2/sec for effective
grit removal. The design criteria and unit dimensions are given in Table-24.
Table 24: Design Criteria and Design of Vortex Grit Chamber
Tanning & Post

Parameters Unit Beam House
Tanning
Sewage Flows
average flow m3/d 1,500 2,500
peak factor 2.50 2.50
3
peak flow m /hr. 156.25 260
Design Criteria
Type Vortex Vortex

Tanning & Post

Parameters Unit Beam House
Tanning
maximum overflow rate m3/m2/sec 0.025 0.040
HRT seconds 60 60
Design
Numbers nos. 1 + 1 Standby 1 + 1 Standby
Diameter m 1.50 1.50
It should be noted that for each module one number vortex grit chamber is
proposed as duty. For ultimate capacity two numbers are proposed as standby. One
of the standby will be constructed during Phase I and other will be constructed in
Phase III of the CETP.
Each vortex grit chamber is equipped with:
 Motion unit
 Central shaft with paddles
 Air lift for extraction of grit
 Coaxial gearmotor
5.4 OIL & GREASE SEPARATOR
After degritting, the effluent shall pass through the oil separator. It is a packaged
device to remove oil from water. The separated oil is collected inside the separator
unit while the wastewater is directed to the effluent line. The flow capacity of oil
separator for beam-house effluent is 43 Lt/sec, and for tanning & post tanning
effluents is 72.2 Lt/sec.
5.5 EQUALIZATION TANK # 1 WITH SULPHIDE CATALYTIC OXIDATION – BEAM

HOUSE EFFLUENT
Bea house wastewater, after passing through respective grit chambers will enter into
the designated Equalization Tanks. These tanks will equalize the characteristics and
flow for onward treatment processes. This is necessary because of the expected
large fluctuations in the quantity of the wastewater. It is expected that a substantial
number of the industrial units will be working in one shift only. Therefore, for a 24
hours smooth biological treatment process, continuous supply of wastewater is
essential. The equalization tanks will also act as a reserve buffer for storage and
onward unhindered supply of wastewater to the biological reactors.
Other main function of this equalization tank is to provide sulphide elimination by

catalytic oxidation. Table-25 presents design of the equalization tank # 1.

Table 25: Design of Equalization Tank for Beam House Effluent
Parameter Unit Phase I

Influent Data
Inflow m3/d 1,500
Sulphide mg/L 362
Design Criteria
Residence Time Hrs. 24
Oxygen requirement kg O2/ kg S 2.0
3
Dose of catalyst gm-MnSO4/m 20
Sulphide in effluent mg/L 1
Design
Total Volume required m3 1,500
Number of Tanks nos. 01
Length x Width m 23.80 x 21.00
Depth m 3.0
Minimum Free Board m 0.5
Aeration
Theoretical Oxygen requirement kg-O2/day 1,144
Standard oxygen requirement kg-O2/day 2,400
3
Air requirement Nm /hr. 1,500
Mixing device Self- Aspirating Submersible Jet
Aerator
Number Nos. 02
3
Capacity, each m /hr. 750
Pressure Head atm. 0.350
Wastewater Pumping
Type Dry Mount, Non Clog, Open Impeller
Number Nos. 1 + 1 Standby
3
Discharge m /hr. 75.0
Chemical Dosing
MnSO4 Dosing Tank No. 1
Dosing Pumps No. 1 + 1 Standby
It is expected that influent will contain a concentration of 365 mg/L of Sulphide

which will be controlled through catalytic Oxidation of Sulphide in presence of
Manganese Salt. Equalization tanks will be equipped with Jet Aerators for Mixing and
Catalytic Oxidation of Sulphide. Dosing tanks along with pumps will be associated
with the Equalization Tank.

5.6 EQUALIZATION TANK # 2 – TANNING & POST TANNING EFFLUENT
Tanning & post tanning wastewater, after passing through respective grit chambers
will enter into the designated Equalization Tanks. These tanks will equalize the
characteristics and flow for onward treatment processes. This is necessary because
of the expected large fluctuations in the quantity of the wastewater. It is expected
that a substantial number of the industrial units will be working in one shift only.
Therefore, for a 24 hours smooth biological treatment process, continuous supply of
wastewater is essential. The equalization tanks will also act as a reserve buffer for
storage and onward unhindered supply of wastewater to the biological reactors.
Table-26 presents design of the equalization tank # 2.
Table 26: Design of Equalization Tank for Tanning & Post Tanning Effluent
Parameter Unit Phase I

3
Inflow m /d 2,500
Residence Time Hrs. 24
Design
Total Volume required m3 2,500
Number of Tanks nos. 01
Depth m 3.0
Minimum Free Board m 0.5
Mixing
Mixing device Submersible Mixers
Number Nos. 05
Wastewater Pumping
Type Dry Mount, Non Clog, Open Impeller
Number nos. 1 + 1 Standby
3
Discharge m /hr. 125
5.7 COAGULATION AND FLOCCULATION
The wastewater from the equalization tanks # 1 and equalization tanks # 2 shall be
pumped to Coagulation Flocculation Unit of the CETP. Alum will be used as
Coagulant and Poly electrolyte Flocculants will be used for proper flocs formation.
Details are as under:
Table 27: Design of Coagulation Flocculation Unit

Description Unit Value

DESIGN DATA
Average Wastewater Flow m3/day 4,000
Peak Pumping Rate, combined m3/hr. 200
pH of incoming wastewater - 8.00
Temp of incoming wastewater °C 30.0
Type of Coagulant - Alum
Flash Mixing Tank
Turbine & Propeller
Type of Mixing Device -
Mixers
Contact Time minutes 1.0
3
Volume of Tank m 3.30
Liquid depth m 1.25
Flocculation Tank
Type of Mixing Device - PADDLE MIXER
Residence Time for Paddle Mixing min 20
Volume of Tank, Required m3 66.67
Numbers of Tanks nos. 1.0
Liquid Depth m 3.00
Length / Width of tank, each m 5.40
Volume of Tank, provided m3 68.7
5.8 PRIMARY SEDIMENTATION TANK
The flocculated wastewater shall enter Primary Sedimentation Tank under gravity.
Quiescent conditions will ensure the settling of > 80% of suspended solids in the
Tank. Details are as follows:
Chemically enhanced primary wastewater treatment, the second step in the

wastewater treatment process beyond the preliminary treatment of headwork’s,
involves the physical separation of suspended solids from incoming sewage flow
using Primary Settling Tanks (PST). In PST, suspended solids are allowed to settle via
gravity under quiescent condition.
Settled sludge is collected and removed through an opening provided in the sludge
hopper at bottom whereas clarified wastewater is collected through overflow weirs.
It is perceived that the system will give 85% TSS, 30% BOD & 40% COD removal
efficiencies.

Table-28 presents influent characteristics and design criteria used for design of new
PSTs along with design summary for existing units.
Table 28: Primary Sedimentation Tank Design

INFLUENT CHARACTERISTICS
Average Flow m3/day 4,000
Peak Pumping Rate m3/hr. 200
Biochemical Oxygen Demand, Total mg/L 1,473
Chemical Oxygen Demand, Total mg/L 4,051
Total Suspended Solids mg/L 2,537
EFFLUENT CHARACTERISTICS
Biochemical Oxygen Demand, Total mg/L 1,031
Chemical Oxygen Demand, Total mg/L 2,430
Total Suspended Solids mg/L 380
DESIGN CRITERIA
Surface Settling Rate-Average Flow m3/m2/day 30
Surface Settling Rate-Peak Flow m3/m2/hr. 1.29
Output Sludge Concentration kg/m3 35
type of coagulant chemical Alum Sulphate
dose of coagulant chemical mg/L 200
Dose of PE Flocculent g/m3 3
DESIGN OF SEDIMENTATION TANK
Number of Tanks nos. 1.0
Geometry of the Tank Circular
Internal Tank Diameter m 14.10
Surface Area, Provided m2 156
Side Liquid Depth m 3.00
Bottom Slope m 12.0
Hydraulic Retention Time
Average hrs 2.6
Peak hrs 2.2
SLUDGE PRODUCTION


Total Sludge production by weight kg/day 9,264
SS sludge kg/day 8,624
Alum sludge kg/day 600
PE sludge kg/day 12
Volume of sludge m3/day 264
Numbers of primary sludge pumps nos. 1 + 1 Standby
3
Capacity of Pump, each m /hr. 35.0
5.9 AERATION TANK
In aeration tanks, microorganisms under aerobic condition convert the dissolve and
colloidal organic matter in wastewater to mineralized products. One Aeration Tank
will be provided which shall receive screened, equalized, grit-free and 70%
suspended solids removed wastewater from the primary sedimentation tank under
gravity.
The current worldwide practice is to base the design of activated sludge process on
Solids Retention Time (SRT) and Mixed Liquor Suspended Solids (MLSS). Same is
adopted for the project. Values of solids retention times (SRT) and mixed liquor
suspended solids (MLSS) concentrations, for CMAS process, as suggested in literature
and as adopted for the project are given in the Table-29.
Secondary sludge produced in terms of volatile suspended solids (VSS) is computed

by accounting for the following component contributions:
 Heterotrophic biomass
 Biomass cells debris
 Influent non-biodegradable volatile suspended solids (nbVSS)
Secondary sludge produced in terms of suspended solids (SS) is computed by

accounting for the following component contributions:
 Heterotrophic biomass
 Biomass cells debris
 Influent non-biodegradable volatile suspended solids (nbVSS)
 Influent Inert suspended solids
Following are the values of different biological parameters adopted for the process
design:
Table 29: Biological Process Parameters adopted for Aeration Tank Design

Biological Process Parameters Unit Value

Design Wastewater Temperature – Minimum (Winter) – TMIN °C 20
Biomass Yield Coefficient – Y VSS/bCOD 0.30
Biomass Decay Coefficient @ 20 °C (1/d) – KD-20 1/d 0.12
Biomass VSS/SS Ratio – FVS 0.85
Biomass Cell Debris Fraction – FD VSS/VSS 0.15
Biomass Max Specific Growth Rate @ 20°C – GM-20 1/d 1.05
Half-Velocity Constant – KS mg-bCOD/L 20
Table-30 presents other design parameters, their typical ranges and the values
adopted for the aeration tank design.
Table 30: Design Parameters Adopted for Aeration Tank Design
Parameter Unit Design Values

Wastewater flow
Daily Design Flow m3/d 4,000
Principle Design Parameters
bCOD/BOD5 Ratio – FU 1.70
VSS/TSS Ratio in Influent to Aeration Tank 0.80
nbVSS/VSS Ratio in Influent to Aeration Tank 0.28
Solids Retention Time – TC d 20
MLSS (mg/l) – XL-SS mg/L 4,000
Following are the key secondary design parameters which are computed for the
proposed design and checked against the literature-reported values:
Table 31: Design Check Parameters
Parameter Unit Value

F:M Ratio 1/d 0.25
BOD Loading kg-BOD/m3-d 0.7
Hydraulic Retention Time – TD h 40
MLVSS mg/L 1,951

On the basis of above presented design parameters and wastewater characteristics

with a safety factor (+10%), design of the Aeration Tanks is presented in the Table-
32.
Table 32: Design of Aeration Tanks
Parameter Unit Design Values

Design Flow
Daily Design Flow – Q m3/d 4,000
Peak Design Flow – QP m3/h 200
Aeration Tank Dimensions
Number of tanks nos. 02
3
Volume of tanks m 10,400
Liquid Depth m 6.00
Length x Width m xm 36.0 x 24.0
2
Surface area of tank, each m 864
Free Board @ no-flow Conditions m 0.75
Total Sludge Production – PX-TSS kg/d 2,072
Total Sludge Production – PX-VSS kg/d 1,011
Recirculation Ratio - 0.60
3
Volume of Sludge Recycled m /day 2,400
3
Sludge Wasting Rate m /day 165
Number of sludge recirculation pumps nos. 2 + 2 Standby
Capacity of sludge recirculation pumps m3/hr. 60
A pre-selector will be provided for return sludge before mixing in the aeration tank,
details are presented in the Table-33.
Table 33: Pre-selector Design
Influent Parameter Unit Value

Peak pumping rate, Qpeak m3/min 3.33
Peak Sludge Recycling Flow m3/min 2.0
Total inflow to Pre-selector m3/min 5.33

Design criteria
Retention Time min 30
Design
Number of selectors nos. 02

Influent Parameter Unit Value

Side liquid depth m 4.00
Width of selector, each m 4.00
Length of selector, each m 5.00
Volume, total m3 160
■ Design Basis for Aeration System
Aeration is an integral part of activated sludge system. Various types of equipment

are available to supply air required by the system viz. mechanical surface aerator,
aspirating aerators and diffused aerators. Diffused aeration system is adopted for
supply of air due to its higher oxygen transfer efficiency.
The design of aeration system is presented in Table-34. While designing the aeration
system biomass growth and other factors are considered at maximum design
temperature.
Table 34: Design of Aeration System
Aeration Requirement Unit Value

Theoretical daily O2 requirement kg-O2/day 6,000
Operating O2 Concentration in Reactor mg/L 2.00
Saturation of O2 for tap water at 20°C mg/L 9.08
Altitude Correction Factor – FA 0.975
Salinity Correction Factor – b 0.85
Field Sat. O2 Conc. – Cs mg/L 9.02
O2 Transfer Correction Factor for Waste – a 0.6
O2 Req. @ Stand. Cond. – No [ N/aDF ] kg-O2/day 11,986
Standard daily O2 requirement kg-O2/hr. 250
3
Total Air Flow m /hr. 14,218
Blowers Details
Number of Blowers 2 + 1 Standby
3
Blower Capacity, each (@ 70% eff.) Nm /min 170
Blower Pressure atm. 0.45
Mode of Aeration Jet Aeration
Numbers of Recirculation pumps Nos. 02
Capacity of Recirculation pumps m3/hr. 650 - 860

5.10 SECONDARY SEDIMENTATION TANK
The effluent from aeration tanks will flow to the sedimentation tank, where mixed
liquor is allowed to settle under dormant condition. Settled sludge is removed from
bottom whereas clarified wastewater is recovered from weirs. Settled sludge will be
returned to the aeration tank through opening at bottom of the tank. Table-35
presents influent characteristics and design criteria used for design of sedimentation
tank.
Table 35: Design Criteria of Secondary Sedimentation Tank
Process Parameters Unit Range Value

Wastewater flow
Average Wastewater Flow m3/day 4,000
Peak hourly flow m3/hr. 200
MLSS in Aeration Tank mg/L 4,000
Recirculation ratio - 0.6
Design Criteria
Overflow Rate – Peak Flow m3/m2-hr <1.0 0.50
Solid Loading – Peak kg-SS/m2-hr 2–3 3.0
Diameter of Inlet Drum % >20 15
Surface area for sedimentation tank was calculated for each loading rate. Solid
loading rate governed the area requirement. The design of sedimentation tank is
presented in Table-36.
Table 36: Design of Secondary Sedimentation Tank
Design Unit Value

Number of units - 02
Diameter of tank m 16.5
2
Surface Area (Provided) m 214
Bed Slope 1:12
Free Board (minimum) m 0.50

5.11 ADVANCED CHEMICAL OXIDATION
The wastewater discharged from SST will still have COD greater than the PEQS
values. Therefore, a chemical Oxidation unit will be required to bring the COD to the
required limits. The details are presented in the Table-37.
Table 37: Chemical Oxidation Tank with Neutralization Tank
Description Units Value

Influent Parameters
Daily Wastewater Flow m3/day 4,000
3
Peak Pumping Rate m /hr. 200
Influent Chemical Oxygen Demand mg/L 570
Effluent COD mg/L 150
Chemical Oxidant
Name of Chemical Fenton’s Reagent
Typical Dosing Rate
Fe gm/gm COD rem. 30
H2O2 gm H2O2/gm Fe 15
Reaction Time H2O2 minutes 45
Removal Efficiency % 74%
Design of Chemical Oxidation
Fe Dosing
Chemical Consumption of Fe kg/hr. 2.78
Mixing time minutes 1.0
Flash Mixing Tank
Length x width mxm 1.65 x 1.65
3
Volume m 3.33
-1
Velocity Gradient sec 500 - 1500
Design of Tank for H2O2 Dosing
Volume of reactor, Required m3 150
Length x width mxm 7.0 x 7.0
Chemical Consumption
H2O2 Consumption kg/hr. 41.7
H2O2 (50% Solution) Liters/hr. 69.5


Design of Neutralization Tank
Design Criteria
Retention Time minutes 10
Design of Tank @ Peak Flow
length m 4.40
Width m 2.65
3
Volume, provided m 33.8

CHAPTER 06: TERTIARY TREATMENT
The treated wastewater will be in conformance to all PEQS except TDS and its constituent
Chlorides and Sulphates. To further treat the water to bring down the TDS limits is possible
through Membrane Filtration. It would be advisable to install Rapid Sand Filters before the
Low Pressure Membrane Treatment. At the same time, the concentrate (Reject) which will
contain very high ppm of TDS will also be required to pass through some evaporation
process to extract salt from it. Therefore, bringing the TDS below 3,500 ppm treated
wastewater could be discharge into the inland water.
This scheme will have very high capital and operational cost. It is advisable to design tertiary
treatment after at least one year of CETP smooth and stable operations. At that time various
options shall be studied for reused of treated wastewater such as;
1. Further treatment with domestic sewer of Sialkot City,

2. Recycle in the soaking process,
3. Reuse in irrigation or greening of STZ through cultivation of salt tolerant species of
plants,
4. Use in the composting of Solid waste, etc.
After having one year’s data based precise information on treated water quality will enable
designer to choose any option from the aforesaid alternatives or select proper membranes
for RO treatment. In the following section, a conceptual design and cost estimate has been
presented to support the decision making process.
The proposed membrane treatment will comprise the following:
 Rapid Sand Filtration/Activated Carbon Filtration

 Low pressure RO Unit
 Vacuum evaporation
Table 38: Capacities of Tertiary Units
Recovery Product Total Product

Description Feed water (m3/hr)
(%) (m3/hr) (m3/hr)
Capacity of single train (consisting pretreatment followed by RO membrane)
Pretreatment 167 100 167 Total feed to RO
RO System 167 60 100 100
Total 100
Concentrate that will be taken to Vacuum Evaporation 67
Details of Sand Filters are presented hereunder:

6.1 RAPID SAND FILTERS
Wastewater from Neutralization Tank will flow into Rapid Sand Filters for further
polishing. The design criterion of filter is presented in Table-39.
Table 39: Influent Data and Design Criteria for Rapid Sand Filters
Parameters Units Range Value

Influent Characteristics
Daily Wastewater Flow m3day 4,000
Peak Flow m3/hr. 200
Influent Suspended Solids mg/L 200
Influent BOD Concentration mg/L 80
Influent COD Concentration mg/L 150
Temperature °C 20
Design Criteria
Filtration Rate
Average flow condition m3/m2.hr 5 – 10 7
Peak flow condition m3/m2.hr ≤ 10 8
Backwash Rate m3/m2.hr 45 – 75 45
Water Depth above media mm > 1000 1,000
Viscosity m2/s 9.42E-07
SS Removal Capacity kg/m2 2.5 – 4.5 4.0
Filter Media
Clean Silica Sand
Uniformity Coefficient 1.40
Shape Factor 0.75
Porosity 0.40
Size (2mm for Single Bed) mm 0.80
Depth of Bed mm 1,000
Anthracite
Shape Factor 0.60
Porosity 0.56
Size mm 0.80

Parameters Units Range Value

Depth of Bed mm 750
Gravel (Provided As Support Medium)
Shape Factor 0.73
Porosity 0.50
Size mm 25
Depth of Bed mm 150
Design of gravity filter is presented in Table-40;
Table 40: Design of Rapid Sand Filters
Parameters Unit Value

Filter service time hrs 2.7
Surface area, required m2 25
Number of filters - 1 + 1 Standby
Tank diameter m 5.70
Surface area, provided m2 25.5
Total depth m 3.90
Backwash time min 30
Treated water tank would serve as source water for filter backwash. The backwash
pump shall be connected to the electrically operated valves installed at inlet and
outlet of filter to facilitate automatic backwash.
6.2 LOW PRESSURE MEMBRANE TREATMENT
The wastewater from the RSFs will be pumped to the RO unit for further treatment.
The required quality of treated water to used in agriculture or can be discharged to
irrigation canal is shown in the Table-41.
Table 41: Required Quality of Reclaimed Water

Ammonia mg/L --
Arsenic mg/L 0.10
Bicarbonate (HCO3) mg/L --


BOD5 mg/L 30
COD mg/L --
Cadmium mg/L 0.01
Chromium mg/L 0.1
Chloride mg/L --
Calcium mg/L --
Lead (Pb) mg/L 5.0
Magnesium mg/L --
Nitrate mg/L --
Nickel mg/L 0.2
Sulphate mg/L --
TSS mg/L 30
TDS mg/L < 500
Total Hardness mg/L --
Turbidity NTU --
Zinc mg/L 2.0
Coliform -- 23/100ml
Chlorine (Residual) mg/L <1
pH -- 6-9
Temperature C --
Selection of appropriate membrane will be done as per the criteria shown in the
Table-42.
Table 42: Energy Consumption, Product Recovery, and Removal Efficiencies of Different
Residual Particulate Matter Removal Operations
Factors Reverse osmosis

Membrane Driving Force Hydrostatic pressure difference
Typical pore size (µm) Dense (<2nm)
Typical operating range 0.0001 to 0.001
Selected for influent TDS range > 2000 mg/L
Typical constituents removed Very small molecules, color, hardness, sulfates,
nitrate, sodium and other ions
Operating pressure 16 bars
Energy consumption 3 – 10 kWh/m3
Product recovery 70 – 85 %

Simulation of selected RO membrane is done with the help of ROSA a purpose built
Software.
6.3 LOW PRESSURE VACUUM EVAPORATION
The concentrate having very high ppm of TDS will be taken to the evaporator for
extraction of salt. Vacuum evaporator will be selected for 50 m3/hr flow and 17,000
ppm TDS.

CHAPTER 7: DESIGN OF SLUDGE LINE
This chapter presents the Design of the Sludge Line of CETP for Phase I for total capacity of
4,000 m3/day. Sludge line shall consist of following units:
 Combined Sludge Thickener

 Inline Sludge Conditioning
 Sludge Belt Press
Description of each component with its design and basis of design is presented in the
following sections.
7.1 COMBINED SLUDGE THICKENERS
There will be two main sources of sludge generation in the CETP; the Primary and
the secondary sedimentation tanks. Both the sludge will be taken to Combined
Sludge thickened. From the thickener the sludge will be conditioned inline and finally
to Filter press for dewatering. Details of thickening unit are presented hereunder:
Table 43: Primary Sludge Thickener (Picket Fence Type)

Primary Sludge
Load kg-SS/d 9,236
Volume m3/day 264
Percent Solids % 3.5
Secondary Sludge
Load kg-SS/d 2,072
3
Volume m /day 207
Total Sludge
Load kg-SS/d 11,309
3
Volume m /day 471
Design Criteria
Overflow rate m3/m2-d 10
2
Solid loading rate kg-SS/m -d 64
Design of Tank
2
Surface area, required m 176.7


Geometry of the tank CIRCULAR
Internal tank diameter 15.00
2
Surface area, provided m 176.7
Side liquid depth m 3.00
Bottom slope 1 : 10
Volume of tank m3 596
Retention time hrs. 30.4
Output Sludge Characteristics
Output sludge concentration 5.5
Solid capture efficiency % 85
Output sludge amount kg-SS/day 10,178
3
Output sludge volume m /day 186
7.2 SLUDGE DEWATERING
The thickened sludge from combined sludge thickener will be conditioned with
Polyelectrolyte inline through inline mixer or orifice plate, before final dewatering.
The details are provided in the Table-44.
Table 44: Sludge Conditioning Tank and Filter Press

3
Thickened Sludge Volume m /day 186
Total sludge dewatering time hrs. 10
Sludge Filter Press
Number of filter press nos. 1 + 1 Standby
3
Capacity of filter press m /hr. 20
Operating hours hrs. 9.35
Filter Press Feed Pumps
Number of pumps nos. 1 + 1 Standby
Capacity of pumps m3/hr. 20
Operating duration hr. 9.35
Dewatered Sludge Characteristics
Output sludge concentration % 15 – 20
Solid Capture efficiency % 90
Output Sludge Amount kg-SS/day 9,206
3
Output Sludge Volume m /day 46 – 60


Polyelectrolyte Dosing
Chemical dose kg PE/ton SS 5.0
Tentative dose kg PE/d 50.89
Tentative dose (@ 5%) Liters PE/d 110
7.3 SLUDGE DISPOSAL
The dewatered sludge from filter press will be disposed of into designated landfill.
The landfill site is proposed and shown alongside the CETP site. The type of landfill
proposed is “Area/Mount type” as the ground water table during rainy seasons is up
to 1.52m (5 ft.) as provided by STAGL.
The required area for the landfill for disposal of CETP sludge is anticipated to be
27,000m2 (6.67 acres), mainly because of the restriction of mount height of not more
than 3 meters.
Table 45: Landfill Area Requirement for CETP Sludge Disposal

3
Dewatered Sludge Volume m /day 46 – 60
Dewatered Sludge Amount kg-SS/day 9,206
Total sludge dewatering time hrs. 10
Area of Landfill
Landfill Life years 5.0
Total volume of sludge to be disposed in 5
years m3 108,000
Depth of Mount m 3.0
Compaction % 25
3
Volume after compaction m 81,000
Area required m2 27,000
Area required Acre 6.67

CHAPTER 08: PRELIMINARY PROJECT COST
8.1 CAPITAL COST
Table-46 presents estimated and tentative capital cost for single module of CETP,
having capacity of 4,000 m3/day.
Table 46: Capital Cost for Single Module of CETP (4,000 m3/day)
Amount
# Description
(Million Rs.)
1 Civil Works Including Building, Roads and Yard Piping 200.00
2 Mechanical Works including Machinery, Equipment with Allied Piping 80.00
3 Electrical Works Including External Illumination 15.00
4 Contingency 5.00
TOTAL 300
 The prices presented above are tentative and preliminary in nature. Precise
costing will be furnished in ‘Engineers Estimate’ along with the tender
documents.
 It should be noted that the above mentioned capital cost estimates for civil
works are based on structural design taking into account a normal bearing
capacity of 1.85 kg/cm2 at 1.5 meter depth
 Estimates are based on the market rates prevailing in the month of December
2017. USD conversion rate is taken at Rs. 110 / USD.
8.2 OPERATION AND MAINTENANCE COST
Table-47 presents annual operational and maintenance cost of CETP.
Table 47: Annual Operation and Maintenance Cost
Amount
# Description
(Million Rs.)
A Operations and maintenance items
1 Human Resource 10.00
2 Chemical 42.00
3 Energy 80.00
4 Sludge Disposal 7.00
5 Maintenance 1.20

Amount
# Description
(Million Rs.)
6 Laboratory Cost 1.00
Sub - Total - A 141.2
B Depreciation cost (using straight line depreciation)
1 Civil (based on 25 years span) 8.00
2 Mechanical (based on 10 years span) 8.00
Electrical (based on 25 years span for cables and 10 years span
3 0.96
for equipment)
Sub - Total - B 16.96
Grand Total (A+B) 158.16
Rounding Off, Say 158
Table 48: Unit O&M Cost for Wastewater Treatment
# Description Rs./Unit
1 O&M cost Rs./m3 of wastewater 118
2 O&M cost Rs./gallon of wastewater 0.53
 The prices presented above are tentative and shall be considered as reference only.
 Only depreciation cost is added, other financial costs (capital cost refund, bank
charges, currency devaluation margin, etc.) are not included.
8.3 COST ESTIMATE FOR TERTIARY TREATMENT
The initial estimates show that the capital cost of Tertiary Treatment system will be
about PKR 100 – 115 million. And annual operating cost will be around PKR 90/m 3 of
wastewater. This is in addition to the aforesaid costs of secondary treatment.

CHAPTER 09: HUMAN RESOURCE REQUIREMENTS FOR OPERATION AND
MAINTENANCE
This component of operation and maintenance mechanism presents the chain of command,
number of personnel required to run the plant and specific recommendations for staffing
including specific man-hours, job responsibilities according to qualification, experience
necessary for proper operation of each unit operation and process.
9.1 PLANT OPERATING HOURS
The plant, under normal course of operation, shall run for 24 hours a day, in
following three shifts:
Shift-1 (Morning) 0800 to 1600 (08:00 AM to 04:00 PM)

Shift-2 (Evening) 1600 to 2400 (04:00 PM to 12:00 PM)
Shift-3 (Night) 2400 to 0800 (12:00 PM to 08:00 AM)
9.2 SHIFT TAKE OVER PROTOCOL
Following are some protocols that shall be followed while shift take over:
 The predecessor shall hand-over all log books of operation and maintenance data
to the successor.
 The predecessor shall inform the successor of any accidents that has occurred
during the preceding shift.
 The predecessor shall inform the successor of any mechanical and electrical
equipment and instrument malfunctioning that has occurred during preceding
shift.
 The predecessor shall inform the successor of the status of chemical supplies, if
needing refill, required by the wastewater treatment processes.
Table 49: Staffing Requirement & Recommendation
# Category Staff (No.)

Management and Office Staff
1 Plant Manager (Environmental Engineer) 1
2 Administration & Purchase Officer 1
3 Accountant 1
4 Office Attendants 1
5 Janitors for Plant Building 1

# Category Staff (No.)

Laboratory Staff
7 Chemist 1
8 Assistant Chemist 1
7 Laboratory Attendant 1
Operation Staff
9 Senior Operators 2
10 Operators’ Helpers 3
11 Laborer and Coolies 2
Maintenance Staff
12 Mechanic 1
13 Mechanic Helper 1
14 Electrician 1
15 Electrician Helper 1
16 Equipment Cleaners 1
17 Janitors 2
Miscellaneous
18 Tractor-Trolley Drivers 1
19 Gardener 1
20 Security Guards 2
Total 26
9.3 STAFF TRAINING
Plant staff shall be trained on all the relevant issues relating to plant operation &
maintenance and data documentation. Frequency of these trainings can be
established according to the need. Consultants, trainers and people from different
agencies working on these issues can provide in-house trainings to the relevant staff.
Staff should be provided training in the following key areas:
 Wastewater Treatment Processes

 Wastewater Treatment Processes Operating Principles & Controls
 Wastewater Treatment Processes Trouble Shooting
 Sludge Collection & Handling
 Wastewater Treatment Plant Startup & Shutdown Procedures
 Mechanical & Electrical Equipment and Instrumentation Handling & Maintenance
 Operational and Maintenance Data Log Books Preparation and Upholding
 Occupational Health & Safety
 Operating Data Reporting and Analysis
 Technical Records & Report Composing / Documentation
 Computer Proficiency Development / Enhancement

ANNEXURES

Annexure I: “Basic Information and Guidelines for

Segregation of Streams in Sialkot Tannery Zone”

Project: “Mainstreaming Climate Change Adaptation
through Water Resource Management in Leather
Industrial Zone Development”
(GEF ID 5666; SAP ID 150052)
“Common Effluent Treatment Plant for Sialkot July 26, 2017
Tannery Zone”
Basic Information and Guidelines for Segregation of Streams in

Project:
“Mainstreaming Climate Change Adaptation through Water Resource

Management in Leather Industrial Zone Development”
(GEF ID 5666; SAP ID 150052)
Common Effluent Treatment Plant

For
Basic Information and Guidelines for Segregation of Streams in Sialkot

Tannery Zone
July 26, 2017
A project of:
United Nations Industrial Development Organization (UNIDO)

CONTENTS
1.1 GENERAL INTRODUCTION

1.2 REQUIREMENT OF SEGREGATION
1.3 AVAILABLE OPTIONS FOR SEGREGATION
LIST OF TABLES:
Table 1: Anticipated Chromium content in the CETP Sludge

Table 2: Decision Support Framework
LIST OF FIGURES:
Figure 1: Stream Segregation within Tanneries

Figure 2: Illustration for Option 2
Figure 4: Egg-Shaped Sewer to maintain self cleansing velocity in large variations in flow

1.1 GENERAL INTRODUCTION
The town of Sialkot is located about 130 km from Lahore, in the province of Punjab.
Currently, there are 250 tanneries located in 10 different clusters, scattered all
around Sialkot city and suburbs. These scattered tanneries are unable to meet the
international standards which are becoming more and more stringent with the
passage of time. Meeting the international standards needs proper infrastructure
which is not possible to be extended to each tannery in scattered locations all
around the city. The foremost and critical requirement for international trade and
exporting leather goods is the environmental and social compliance.
Relocation of the tanneries to a more spacious location with appropriate

infrastructure for efficient and cost effective treatment of solid and liquid wastes has
thus become a prerequisite for survival and growth of this vital export-oriented
sector of the country’s economy and for protecting the region’s agriculture and
health.
Based on these factors, it is planned to shift the tanneries at a dedicated tannery

zone away from the main city. The proposed Sialkot Tannery Zone (STZ) is a project
initiated and managed by Sialkot Tannery Association (Guarantee) Limited Company
(STAGL). The STAGL has been established as a special initiative of the Sialkot Tannery
Association and, Government of Punjab. Sialkot Tannery Association (Guarantee)
Limited is registered under section 32 of the Companies Ordinance 1984 (XLVII of
1984) to develop focused industrial growth in Sialkot by developing international
standard Tannery Zone in the region. The company is limited by guarantee having
share capital.
STZ with an area of 392 Acres will provide a central place for various scattered
tannery clusters of Sialkot and the surrounding areas. It shall mitigate the
environmental pollution in the city. It will be an international standard industrial
zone equipped with all facilities & infrastructure like roads, sewerage, water supply,
drainage, effluent treatment plants and others. (Ref: EIA of STZ, 2011)
STAGL is supported by UNIDO, which is working on a GEF funded project entitled:

‘Mainstreaming Climate change Adaptation through Water Resource Management in
Leather Industrial Zone Development’, has intended to implement a project of
Combined Effluent Treatment Plant (CETP) for the STZ.
A result of these joint efforts was the Technical Report depicting Conceptual Design
of the Common Effluent Treatment Plant, prepared by UNIDO in 2015. On the basis
of this report, to fulfill the requirements of the project, UNIDO seeks the services of
consultants for detailed designing and supervision of the implementation of CETP for
STZ. Services of NEC Consultants (Pvt.) Ltd are taken by the UNIDO as per a
predetermined TOR and subsequent contract.
As per the TORs, NEC is supposed to provide the following:

‘Provide basic information and guidelines for STZ management for segregation of the
streams in the tannery/STZ in order to reduce volume of sludge contaminated with
chromium. ‘
Accordingly, this report is focused on the essentiality for segregation of tannery

wastewater streams and available options:
1.2 REQUIREMENT OF SEGREGATION
It should be noted that characteristics of wastewater discharged from different

process (Soaking to Finishing) streams of leather processing are different. They have
different pH and chemical compositions. Segregation of these streams is essential
because of following three main reasons;
1 Discharge of liming effluent, containing substantial quantities of Sulphide, when

mixed with tanning effluent having pH of 4 -5, results in release of H2S gas which
is fatal to human life. As reported by International literature, it is the most
significant cause for the fatal accidents in tanneries.
2 Discharge of tanning and post tanning effluent contains significant quantity of

Chromium Sulphate. This Cr2SO4 settles in the primary settling tank of any
WWTP/CETP, whenever, it gets higher pH (more than 8). Primary Sludge thus
produced contains significant quantity of Chromium content in it. Disposal of
chrome containing sludge becomes problematic due to following two reasons:
a. Environmental laws: At present, available environmental laws in Pakistan do

not directly address sludge and solid waste discharges. However, it is
anticipated that gradually with the due passage of time such laws will also be
developed and enforced. It should also be noted that International laws and
certifications such as LWG also consider chrome containing sludge as
Hazardous waste. Therefore, it is very important for any new tanning zone or
even individual tannery to consider this aspect very seriously.
b. Health and safety issues. Although the major quantity of Chrome is in the
form of trivalent Chromium, but different environmental conditions such as
high temperature can change it into Hexavalent Chromium which is
reportedly carcinogenic.
Sludge having nominal content of chrome can be safely disposed in any landfill site
or alternatively can be fed to composting unit for conversion as fertilizer.

3 Chromium Sulphate is an expensive resource which shall not be wasted into the
drains and logically shall be recovered and reused.
In specific case of Sialkot Tannery Zone, based on the data provided in February
2017, following are the expected quantities of Chromium in the wastewater:
Table 1: Anticipated Chromium content in the CETP Sludge
# Parameter Unit Quantity
1 Wastewater quantity m3/day 3,000

2 TSS mg/l 2,100
3 Chrome concentration mg/l 100
4 Expected Sludge from the Primary Settling Tank Kg/Day 4,725
6 Chrome content in the Primary Sludge Kg/Day 280 - 300
7 Chrome % in Primary Sludge % 6 - 6.4
8 Full Scale CETP 12,000
9 Chrome content in primary Sludge in Full Scale Tons/Day 1.1 – 1.2
Even if the primary sludge is mixed with the secondary sludge and other sludges like
alum etc, even then it will be more than 3 % of the total sludge. This high content of
chromium will definitely hinder the final disposal or utilization of sludge.
Aforesaid three points, made it absolutely necessary to make such arrangement that
following targets can be achieved:
1 100 % fool proof system to avoid mixing of tanning and post tanning effluent
with liming discharge. It will eliminate the risk of H2S production and subsequent
accidents.
2 Recovery of Chromium from wastewater and ultimately from sludge.
1.3 AVAILABLE OPTIONS FOR SEGREGATION
It shall be mandatory in each tannery to have a segregated system of streams as per

following scheme:
1 Separate line for Liming discharges

2 Separate line for tanning and post tanning discharges
Subsequently, following options are available for further treatment and conveyance
of wastewater:

 Option 1:
This option will have the following essential components; (Figure 1, illustrates
the scheme)
 Recovery of chrome through Installation of Chrome Recovery Plants in each

wet-blue processing tannery,
 Catalytic Oxidation of Liming Discharge within each Tannery,
 Mixing of Post CRRP effluent and Post Liming Oxidation effluent with all other
wastewater streams in a common channel equipped with screen. Final
discharge into a common channel towards CETP for complete treatment.
Figure 1: Stream Segregation within Tanneries
Ref: Introduction of Treatment of Tannery Effluents – UNIDO – 2011
 Option 2:
Following essential components will be the part of this option.
 Separate line from tann-yard of each tannery to common CRRP at CETP site
 Separate line from beam house to the CETP site for common Catalytic
Oxidation.
 Post CRRP and Post liming oxidation effluents mixed in the CETP treatment
scheme

 Option 3:
 Recovery of chrome through Installation of Chrome Recovery Plants in each

wet-blue processing tannery. Conveyance of this chrome free effluent mixed
with other finishing effluent to CETP Site.
 Separate line from beam house to the CETP site for common Catalytic
Oxidation.

All above options are workable and will necessarily achieve the desired targets.
Selection of any one option from the aforesaid three options shall be based on the
enforcement authority of industrial by-laws entrusted to STAGL management. To
support the decision, a framework summarizing the important factors is presented in
Table 2:
Table 2: Decision Support Framework
# Description Option 1 Option 2 Option 3

1 Segregated Streams within Tannery Yes Yes Yes
2 Segregated Streams at Cluster Level No Yes Yes
3 Common Chrome Recovery Plant at Zone Level No Yes No
4 Chrome Recovery Plant within Tannery Yes No Yes
5 Catalytic Oxidation of Liming effluent within Tannery Yes No No
6 Chrome free Sludge Yes Yes Yes
7 H2S Elimination Yes Yes Yes
8 Disposal of nominal chrome sludge in landfill Yes Yes Yes
Use of nominal chrome sludge as fertilizer after
9 Yes Yes Yes
composting
10 Cost of CRRP to be borne by: Tannery STZ Tannery
11 Cost of Liming effluent Oxidation to be borne by: Tannery STZ STZ

# Description Option 1 Option 2 Option 3

Higher Nominally
12 Cost of conveyance system Minimum than other higher than
options option 1
13 Vigilance Requirement from STZ Very High Minimum Moderate
14 International Certification (LWG) fulfillment Yes Yes Yes
15 Acceptable to UNIDO Yes Yes Yes
16 Local Laws compliance Yes Yes Yes
If STAGL can locate all the wet blue processing tanneries in one sector nearest to the
CETP, than option 3 would be the best option. Installation of CRRPs in each tannery
with a separate line for tanning and post tanning effluents to the CETP site and a
separate line for beam-house discharge to the CETP Site may be the best choice.
All the other tanneries which are not involved in the wet-blue processing can use a
single conveyance system upto the CETP site.
If relocation of Wet-blue processing tanneries is not possible, than the option 1

would become the best option.
If STAGL foresees weak implementation authority to oversee the individual

tanneries, than option 2 is the best fool proof option.
In addition to above mentioned recommendations regarding segregation of Streams,

it should also be noted that as per International BEST PRACTICES, a properly
designed closed conveyance system having sufficient self cleansing velocity shall be
designed and installed. An ideal profile of the conveyance system is the so called
egg-shaped sewer:

Figure 4: Egg-Shaped Sewer to maintain self cleansing velocity in large variations in flow
69
Annexure II: UNIDO Documents

■ “The Scope for Decreasing Pollution Load in Leather Processing, August 9, 2000
70
■ Emission Factors for the Calculation of the Wastewater Quantity and Quality of the Leather
Manufacturing Process
71
72
■ Pollution levels per ton from other types of hides processed (British Leather Company
Document)
■ Distribution of effluent pollution according to the different stages of conventional leather

processing in kg/t rawhides (salted weight) (British Leather Company Document)
73
Annexure III: Drawings
74
Process Flow Diagram
75
Layout Plan

Master Layout Plan
77
Annexure IV: Punjab Environmental Quality

Standards for Municipal and Liquid Industrial
Effluents
78
79
80
81
Annexure V: Schedule of Plant

Wastewater Pump for Beam House Effluent (WP01)
Equipment Wastewater Pumps (WP01)

Location Equalization Tank Beam House
Numbers 02 (01 operating + 01 standby)
Pump
Medium Tannery Wastewater
Heavy-duty (horizontal, direct-coupled /vertical, pedestal
Pump Type mounted dry- pit), single-suction, centrifugal, CW rotation,
Centrifugal
Capacity 75 m3/h
Head 08 m
Free Pass 80 – 100 mm
Guaranteed Duty Point (GDP) is between 80% and 120% of
Efficiency the flow rate at the Best Efficiency Point (BEP).
Pump Casing Cast Iron and shall comply with BS EN 1563 / EN-GJS-700-2
Cast S.G. Iron and shall comply with BS EN 1563 / EN-GJS-
Casing Wear Ring
450-10
Impeller
700-2
KSB, Flygt, Bedford Pumps, Torishima, Flowserve, Goulds,
Make
Sulzer Pumps or approved equal
Motor
Make SIEMENS, ABB or approved equal
Phase/Voltage 3/400 V
Frequency 50 Hz
Efficiency Motor efficiency shall comply with the requirements of IEC
60034 - 30 high efficiency Class IE2.
IP 55
Insulation Class F
Wastewater Pump for Tanning and Post Tanning Effluent (WP02)
Equipment Wastewater Pumps (WP02)

Location Equalization Tank Tanning and Post Tanning
Pump
Heavy-duty (horizontal, direct-coupled /vertical, pedestal
Pump Type
mounted dry- pit), single-suction, centrifugal, CW rotation,
82
Centrifugal
Capacity 125 m3/h
Head 08 m
Free Pass 80 – 100 mm
Guaranteed Duty Point (GDP) is between 80% and 120% of
Efficiency the flow rate at the Best Efficiency Point (BEP).
Pump Casing Cast Iron and shall comply with BS EN 1563 / EN-GJS-700-2
Casing Wear Ring
450-10
Impeller
700-2
KSB, Flygt, Bedford Pumps, Torishima, Flowserve, Goulds,
Make
Sulzer Pumps or approved equal
Motor
Make SIEMENS, ABB or approved equal
Frequency 50 Hz
Efficiency Motor efficiency shall comply with the requirements of IEC
60034 - 30 high efficiency Class IE2.
IP 55
Insulation Class F
Coarse Screens (01)
Equipment Mechanical Coarse Screens (CS) Beam House

Location Coarse Screen Chamber
Clear spacing b/w bars 20 mm
Height of Screen 1500 mm (Will be Finalized)
Screen angle with 600
horizontal
Screen Chamber width 600 mm
Approach velocity 0.65 m/sec
Water depth 300 mm
Material Stainless Steel 316
Make Sun Engineers, Ovivo, ESTRAUGA, COSME or approved
equivalent.
83
Coarse Screens (02)
Equipment Mechanical Coarse Screens (CS) Tan House

Location Coarse Screen Chamber
Height of Screen 1500 mm (Will be Finalized)
horizontal
Water depth 300 mm
equivalent.
Fine Screens (01)
Mechanically Cleaned Mechanically Operated rake type

Equipment
Fine Screens (FS 01) Beam House
Location Fine Screen Chamber
Screen bar depth 75 mm
horizontal
Water depth 300 mm
equivalent.
Fine Screens (02)
Mechanically Cleaned Mechanically Operated rake type

Equipment
Fine Screens (FS 02) Tan House
Location Fine Screen Chamber
Screen bar depth 75 mm
84

horizontal
Water depth 300 mm
equivalent.
Vortex Grit Chamber
Vortex grit chamber with grit conveyor, pumps and

Equipment
classifier
Location Grit chamber
Max overflow rate 0.025 and 0.040 m3/m2/sec for Beam House and Tanning &
Post Tanning respectively.
HRT 60 seconds
Mechanism Automatic Grit Removal Mechanism
Oil and Grease Separator (01)
Equipment Oil and Grease Separator Beam House

Location Oil and Grease Chamber
Max overflow rate 45 liters/sec
Mechanism Automatic Oil and Grease Removal
Oil and Grease Separator (02)
Equipment Oil and Grease Separator Tan House

Location Oil and Grease Chamber
Max overflow rate 75 liters/sec
Mechanism Automatic Oil and Grease Removal
Jet Aerator (JA01)
Equipment Jet Aerator (JA01)

Location Equalization Tank Beam House
Numbers 02
Type Submersible Ejector Shaft
Air Discharge (each) 18 Nm3/min
Pumping Head 4.0 m
Make Flygt or approved equivalent.
85
Submersible Mixer
Equipment Submersible Mixer

Location Equalization Tank Tanning and Post Tanning Effluent
Tank
Length 33.15 m
Width 25.5 m
Depth 3.0 m
Medium Tanning and Post Tanning Effluent
Density 1,000 kg/m³
Mixer
Numbers 05
Material (Shaft & Propeller) SS 316
Material (Flange, Nuts & SS 316
Bolts)
Make Flygt, SERECO or approved equal
Geared Motor
Make SEW, Flender or approved equal
Frequency 50 Hz
IP 68
Insulation Class F
Mixer Coagulation Tank (MCT)
Equipment Mixer Coagulation Tank (MCT)

Location Coagulation Tank
Type Turbine Propeller Mixers
Numbers of Tank 01
Length 1650 mm
Width 1650 mm
Water Depth 1250 mm
Density 1000 Kg/m³
Agitator
Numbers of Agitator 01
Agitator type Top Entry, Turbine 6 Blades with 45˚ with Agitator Shaft
INVENT, Flygt, SHARP MIXER, SERECO, ABS, KSB,
Make
LIGHTNIN or approved equal
Material (Shaft & Propeller) SS 316L
Material (Flange, Nuts & SS 316L
Bolts)
86
Geared Motor
Frequency 50 Hz
Velocity gradient 1500/sec
IP 65
Insulation Class F
Accessories Oil level glass etc.
External Finish Epoxy coating on gear box
Miscellaneous
Foundation plate SS 316 plate
Mixer Flocculation Tank (MFT)
Equipment Mixer Flocculation Tank (MFT)

Location Flocculation Tank
Type Paddle Mixers
Numbers of Tank 01
Length 5600 mm
Width 5600 mm
Water Depth 3250 mm
Density 1,000 Kg/m³
Agitator
Agitator type Top Entry, Paddle Type
INVENT, Flygt, SHARP MIXER, SERECO, ABS, KSB, LIGHTNIN
Make
or approved equal
Bolts)
Geared Motor
Frequency 50 Hz
Speed of rotation (output) 10-15 rpm
IP 65
Insulation Class F
Miscellaneous
87
Mixer Pre-selector Tank (MPT)
Equipment Mixer Pre-selector Tank (MPT)

Location Pre-selector Tank
Type Turbine Propeller Mixers
Numbers of Tank 02
Length 5000 mm
Width 4000 mm
Water Depth 4000 mm
Density 1000 Kg/m³
Agitator
Make
or approved equal
Bolts)
Geared Motor
Frequency 50 Hz
Speed of rotation (output) 50 rpm
IP 65
Insulation Class F
Miscellaneous
Mixer Chemical Oxidation Tank (MCOT)
Equipment Mixer Chemical Oxidation Tank (MCOT)

Location Chemical Oxidation Tank
Type Turbine 6 Flat Blades, Vain Disk
Numbers of Tank 01
Length 7000 mm
Width 7000 mm
Water Depth 3100 mm
Density 1000 Kg/m³
88
Agitator
Make
or approved equal
Bolts)
Geared Motor
Frequency 50 Hz
Velocity gradient 100/sec
IP 65
Insulation Class F
Miscellaneous
Sludge Scraper for Primary Sedimentation Tank (PSCR)
Equipment Sludge Scraper for Primary Sedimentation Tank (PSCR)

Location Primary Sedimentation Tank
Numbers 01
Type Peripheral Driven Rotating Half-Bridge Type Scraper
Tank diameter 13100 mm
Side Liquid Depth 3.0 m
Bed Slope 1:12
Free Board (Minimum) 0.50 m
Make (Motor) Flender, SEW or approved equal
Central Support Unit
Type Ball type turntable
Main Components Stainless Steel
Make Ovivo, Hambaker Adams, Varis Engineering, ESTRAUGA,
Landustrie, COSME, or approved equivalent.
Scum Removal Tray
Main Components Stainless steel
Ovivo, Hambaker Adams, Varis Engineering, ESTRAUGA,
Make
89
Sludge Scraper for Secondary Sedimentation Tank (SSCR)
Equipment Sludge Scraper for Secondary Sedimentation Tank (SSCR)

Location Secondary Sedimentation Tank
Numbers 02
Type Peripheral Driven Rotating Half-Bridge Type Scraper
Bed Slope 1:12
Scum Removal Tray
Main Components Stainless steel
Sludge Scraper for Picket Fence Sludge Thickener (PFST)
Equipment Sludge Scraper for Picket Fence Sludge Thickener (PFST)

Location Sludge Thickener
Numbers 01
Type Peripheral Driven Rotating Full-Bridge Type Picket Fence
Sludge Scraper
Bed Slope 1:8
90
Aeration System for Aeration Tank

Jet Aerators (JA03)
Recirculation Pumps (RP01)
Air Blower (BL01)
Aeration Tank Dimension

Length 36000 mm
Width 24000 mm
Water Depth 6000 mm
Depth 6750 mm
Equipment Recirculation Pumps

Numbers 02
Pump Type Horizontal, Centrifugal, Dry Mounted
Make KSB, Goulds, Sulzer or approved equal
Efficiency >75%
Pumping Capacity 870 m3/h (approx.)
Head 6.0 m
Frequency 50 Hz
Equipment Air Blower
Type Positive Displacement Air Blowers
Make Dresser Roots, Kaeser, Robuschi or approved equal
Material Cast Iron
Aeration Capacity 170 Nm3/min
Differential Pressure 0.7 bar
Phase/Voltage 3/380
Frequency 50 Hz
Calculated Lifetime 100,000 hrs
Equipment Jet Aerator
Numbers 2
Type Jet Aerators with Nozzles
Make Arbiogaz, Mixing Systems, or approved equal
Material Body: Stainless Steel
Bubble Type Fine bubble
Differential Pressure 0.7 bar
Transfer Efficiency >25 %
91
Primary Sludge Pumps
Equipment Primary Sludge Pumps (PSP)

Location Primary Sedimentation Tank
Each Pump
Medium Tannery Wastewater Sludge
Type Horizontal, Dry Mounted, Screw Centrifugal Impeller
Capacity 35 m3/h
Head 10 m
Sludge Type 3% Solid contents
Pump casing Cast iron (EN-JL 1040, GG25, ASTM A 48 Class 40B)
Rotor 1.4301 / 304 SS, Chrome-plated tool steel
Protection Over Pressure and Dry Run Switch
Make Hidrostal, Vaughan Triton Pumps or approved equal
Each Motor
Make SIEMENS, ABB, Flender or approved equal
Frequency 50 Hz
IP 65
Insulation Class F
Secondary Sludge Pumps
Equipment Secondary Sludge Pumps (SSP)

Location Secondary Sedimentation Tanks
Each Pump
Capacity 60 m3/h
Head 10 m
Each Motor
Frequency 50 Hz
IP 65
Insulation Class F
92
Thickened Sludge Pumps
Equipment Thickened Sludge Pumps (TSP)

Location Primary Sludge Thickeners
Pump
Capacity 20 m3/h
Head 10 m
Each Motor
Frequency 50 Hz
IP 65
Insulation Class F
Sludge Belt Filter Press
Equipment Sludge Belt Filter Press (SFP 01)

Numbers 02 (01 Operating + 01 Standby)
Type Belt Press
Make European / North American Brand or approved equal
Loading Sludge Rate 20.0 m3/hr
Input Sludge Concentration 5%
Output Sludge 15 – 20 %
Concentration
1. Washing Water Pump
Essential Component
2. Air Compressor
K-Polymer Dosing Pumps
Equipment K-Polymer Dosing Pumps (DP)

Location K-Polymer, Chemical Dosing Tanks
Numbers 03 (2 operation + 1 standby)
Pump
Medium K-Polymer
Pump Type Diaphragm with controller
93

Capacity 100-150 lit/h
Head Minimum Head Required
Motor
Frequency 50 Hz
IP 65
Insulation Class F
A-Polymer Dosing Pumps
Equipment A-Polymer Dosing Pumps (ADP)

Location A-Polymer, Chemical Dosing Tanks
Pump
Medium A-Polymer
Capacity 5-15 lit/h
Motor
Frequency 50 Hz
IP 65
Insulation Class F
Alum Dosing Pumps
Equipment Alum Dosing Pumps (ADP)

Location Alum, Chemical Dosing Tanks
Pump
Medium Alum
Motor
Frequency 50 Hz
IP 65
Insulation Class F
94
Hydrogen Peroxide Dosing Pumps
Equipment Hydrogen Peroxide Dosing Pumps (HDP)

Location Hydrogen Peroxide, Chemical Dosing Tanks
Pump
Medium Hydrogen Peroxide (50% Solution)
Motor
Frequency 50 Hz
IP 65
Insulation Class F
Ferric Chloride Dosing Pumps
Equipment Ferric Chloride Dosing Pumps (FDP)

Location Ferric Chloride, Chemical Dosing Tanks
Pump
Medium Ferric Chloride (40% Solution)
Motor
Frequency 50 Hz
IP 65
Insulation Class F
Manganese Sulphate Dosing Pumps
Equipment Manganese Sulphate Dosing Pumps (MDP)

Location Manganese Sulphate, Chemical Dosing Tanks
Pump
Medium Manganese Sulphate
95
Capacity 5-50 lit/h

Motor
Frequency 50 Hz
IP 65
Insulation Class F
Sodium Hydroxide Pumps
Equipment Sodium Hydroxide Dosing Pumps (DP)

Location Sodium Hydroxide, Chemical Dosing Tanks
Pump
Medium Sodium Hydroxide
Motor
Frequency 50 Hz
IP 65
Insulation Class F
HCl Dosing Pumps
Equipment HCl Dosing Pumps (DP)

Location HCl, Chemical Dosing Tanks
Pump
Medium HCl
Motor
Frequency 50 Hz
IP 65
Insulation Class F
96
Dissolved Oxygen Meter
Equipment Dissolved Oxygen Meter

Location Aeration Tank, Equalization Tank Beam House
Numbers 03
DO Meter
The aim of dissolved oxygen measurement is to keep the
waste treatment process functioning properly and to hold
the dissolved oxygen level within an acceptable range and
avoid conditions detrimental to the process. The equipment
shall be controlled by the PLC system.
Specific Requirement
Meter shall be of the floating ball type. Measurement range
0-10 mg O2/l.
Accuracy of ±0.1 on oxygen content. Accuracy on zero ± 0.1

ppm.
pH Meter
Equipment pH Meter
Equalization Tanks, Mixing Tank, Flocculation Tank, Aeration
Location
Tank, Chemical Oxidation Tank, Neutralization Tank
Numbers 08
pH Meter
Online pH measurement, range pH 2-12. Accuracy of meter ±
Specific Requirement
pH 0.1.
97
Annexure VI: Motor List

Power Total Working Daily
Equipment Working Standby
(kW) kW Hours kW/h
Wastewater Pumps Beam
House (Capacity 75 m3/hr & 1 1 3.7 3.7 20 74.0
Head 8 m)
Wastewater Pumps Tan House
(Capacity 125 m3/hr & Head 1 1 4.0 4 20 80.0
8m)
Coarse Screen Beam House
2 1 0.75 1.5 24 36.0
(Clear spacing 20 mm)
Coarse Screen Tan House (Clear
2 1 0.75 1.5 24 36.0
spacing 20 mm)
Fine Screen Beam House (Clear
1 1 0.75 0.75 24 18.0
spacing 06 mm)
Fine Screen Tan House (Clear
1 1 0.75 0.75 24 18.0
spacing 06 mm)
Vortex Grit Chamber (Beam
House) Sand Classifier + Sand 1 1 1.65 1.65 24 39.6
Trap
Vortex Grit Chamber (Tan
House) Sand Classifier + Sand 1 1 1.65 1.65 24 39.6
Trap
Oil and Grease Separator Beam
1 1 0.18 0.18 24 4.3
House (Capacity 45 liters/sec)
Oil and Grease Separator Tan
1 1 0.37 0.37 24 8.9
House (Capacity 75 liters/sec)
Jet Aerator (Submersible
Ejector Shaft for Beam House 2 0 37 74 24 1,776.0
18 Nm3/min each)
Submersible Mixer (Volume of
5 0 2.5 12.5 24 300.0
tank 2,536 m3)
Mixer for Coagulation Tank
1 0 0.18 0.18 24 4.32
(Volume of tank 3.40 m3)
Mixer for Flocculation Tank
1 0 1.5 1.5 24 36
(Volume of tank 101.9 m3)
Mixer for Pre-Selector Tank
2 0 3 6 24 144
(Volume of tank 80 m3)
Mixer for Chemical Oxidation
1 0 1.5 1.5 24 36
Tank (Volume of tank 152 m3)
Sludge Scraper for PST
1 0 0.25 0.25 24 6
(Diameter of tank 13.1 m)
Sludge Scraper for SST
2 0 0.25 0.5 24 12
(Diameter of each tank 16.5 m)
98
Power Total Working Daily

Equipment Working Standby
(kW) kW Hours kW/h
Sludge Scraper for Picket Fence
Sludge Thickener (Diameter of 1 0 0.37 0.37 24 9
tank 15.0 m)
Recirculation Pumps for
Aeration Tank (Capacity 870 2 0 30 60 22 1,320
m3/h and Head 6.0 m)
Blower for Aeration Tank
(Capacity 170 Nm3/min and 2 1 245 490 20 9,800
Differential Pressure 0.7 bar)
Primary Sludge Pumps (Capacity
1 1 4 4 24 96
35 m3/h)
Secondary Sludge Pumps
2 2 9.3 18.6 22 409
(Capacity 60 m3/h)
Thickened Sludge Pumps
1 1 3 3 10 30
(Capacity 20 m3/h)
Sludge Belt Filter Press
1 1 2.2 2.2 10 22
(Capacity 20 m3/h)
K-Polymer Dosing Pumps 2 1 0.026 0.052 10 1
A-Polymer Dosing Pumps 1 1 0.026 0.026 20 1
Alum Dosing Pumps 1 1 0.026 0.026 20 1
Hydrogen Peroxide Dosing
1 1 0.026 0.026 20 1
Pumps
Ferric Chloride Dosing Pumps 1 1 0.026 0.026 20 1
Manganese Sulphate Dosing
1 1 0.026 0.026 20 1
Pumps
Sodium Hydroxide Pumps 1 1 0.026 0.026 20 1
HCl Dosing Pumps 1 1 0.026 0.026 20 1
kW/day 14,359
kW/hour 598
99

Appendix 1 - Annex A - Process Design Report

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Appendix 1 - Annex A - Process Design Report

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APPENDIX 1 - ANNEX 1

Project: “Mainstreaming Climate Change Adaptation

Process Design Report

“Mainstreaming Climate Change Adaptation through Water Resource

Common Effluent Treatment Plant

Process Design Report

5.5 EQUALIZATION TANK # 1 WITH SULPHIDE CATALYTIC OXIDATION – BEAM HOUSE

NEC Consultants (Private) Limited III

Table 32: Design of Aeration Tanks ......................................................................................... 40

Figure 1: Layout of Sialkot Tannery Zone .................................................................................. 4

NEC Consultants (Private) Limited IV

STZ Sialkot Tannery Zone

NEC Consultants (Private) Limited V

VSS Volatile Suspended Solids

Project Name Establishment of Combined Effluent Treatment Plant

Relocation of the tanneries to a more spacious location with appropriate

Based on these factors, it is planned to shift the tanneries at a dedicated tannery

STAGL is supported by UNIDO, which is working on a GEF funded project entitled:

1.2 TREATMENT CONCEPT

1.3 THIS REPORT

In Chapter 2 summary of available data is presented, after which the wastewater

NEC Consultants (Private) Limited 2

2.1 STZ PRODUCTION DATA

Table 1: Number and Type of Tanneries to be established in STZ

NEC Consultants (Private) Limited 3

Figure 1: Layout of Sialkot Tannery Zone

NEC Consultants (Private) Limited 4

Table 2: Area Allocated for Amenities

# Land use Area (Hectare)

Table 3: Planned Production Capacity for STZ

Surveyed in Planned for

3.1 WASTEWATER QUANTITY AND CHARACTERISTICS

Production data, as discussed in chapter 02 is used in estimation of quantity and

1. UNIDO Publication ‘The Scope for Decreasing Pollution Load in Leather

Maximum Pollution Load - Range (Kg/day)

On the basis of these computations, average quantity of wastewater (10,746 m3/day)

Table 5: Average Concentrations of Tannery Wastewater computed using Emission Factors

Tannery Wastewater Concentration

Remaining wastewater from commercial and institutional establishments is

Table 6: Concentrations of tannery wastewater, domestic sewer and combined effluent

Parameter Unit Tannery Wastewater Domestic Sewer Combined Effluent

Parameter Unit Tannery Wastewater Domestic Sewer Combined Effluent

Table 7: Adopted Design Values for CETP

3.2 REVISED WASTEWATER DESIGN DATA

Table 8: Average Values of Pollution Load Discharged (Conventional Process) - UNIDO

Tanning & Post

Table 9: Concentration Estimation based on Loads per Ton of Production – Phase I

Tanning & Post

Combined Raw Adopted Design

3.3 EFFLUENT REQUIREMENTS

The Punjab Environmental Quality Standards (PEQS)-2016, pertaining to the

Parameter Unit Value

1 Segregation of wastewater conveyance system

4.1 SEGREGATION OF WASTEWATER CONVEYANCE SYSTEM

4.2 OPTIMUM MODULAR APPROACH

Alternative 1 could be the construction of complete plant having capacity of 16,000

As Alternative 2, it would be better to start with 25 % of capacity for at least next 4

4.3 TREATMENT TECHNOLOGY

4.3.1 Treatment System Objectives