Pollution Control with Profit from Dairy Waste
By Anaerobic Process using UASB

Kerala (Kinfra ETP, Alapuzha MSW) Tamil Nadu (MLD RO  SYSTEM PERUNDRAI, 0.6 MLD RO  SYSTEM, MELVISHARAM, 2.5MLD  RO SYSTEM SIDCO RANIPET, 3.0MLD  RO SYSTEM , RANITECH, 3.0MLD  RO SYSTEM DINDIGAL, MSW PALAVAPURAM, MSW PERUNGADI) Maharshstra (30 MLD STP NANDED, PRIA CETP, PARLI ETP, PARAS ETP, 12MLD CETP, ICHALKARANJI, 1.5 MLD CETP ICHALKARANJI, NBCC MEDICAL COLLEGE  PAREL, VASHI DENTAL HOSPITAL, ANDHERI HOSPITAL, MSW NAVI MUMBAI, MSW PARBHANI, MSW AHMEDNAGAR) GOA - MSW GOA GUJARAT (VAPI CETP, 7.5 MLD WTP PETHAPUR, BARODA Storm water line) MADHYAPRADESH (1.5 MLD CETP PITHAMPUR, Shivpuri STP) RAJASTAN (10 MLD STP Sikar, 8 MLD STP & Drainage Nagaur, 10 MLD STP Barmer, MSW BARMER, MSW PALI, MSW BEAWAR, MSW KOTA, MSW SRI GANGA NAGAR) BIHAR (WATER SUPPLY, KHAGAUL PATNA, WATER SUPPLY,PHULWASARIF ZONE 1&2 PATNA, WATER SUPPLY,PHULWASARIF ZONE  3&4 PATNA) UTTAR  PRADESH (345 MLD STP LUCKNOW, 40MLD STP AGRA, 23 MLD Mainpuri, 43 MLD Jajmau, MSW RAIBARELY, MSW KANNAUJ, MSW ETAWAH, MSW MAINPURI) HARYANA (3.5 MLD STP NARWANA, 40MLD STP ROHTAK, MSW ROHTAK, 6 MLD STP Narnaul NBCC, 5 MLD STP Charkhi-NBCC) NEW DELHI (45MLD  STP FARIDABAD)

UASB SYSTEM
• Upflow fluidised bed single stage reactor with granulation of anaerobic bacteria as media.
• Reactor consists of tank in RCC of 4 to 6 depth and suitably designed diameter.
• Effluent is evenly distributed at bottom and flows up through a bed of anaerobic
sludge during which degradable matter is digested.
• Dissolved organic matter is removed by anaerobic bacteria.
• This is converted to biogas + new cells.
• Gas formed is collected at top portion by gas liquid solid separator.
• Liquid flows out and any sludge is trapped and flows down back to the blanket.

SALIENT FEATURES
• COD Reduction : 80 – 85%
• Biogas generated : 0.5 to 0.55 m3 kg COD reduced
• Detention time : 10-12 hrs
• Organic loading : 4-5 kg/m3
• Anaerobic process thus oxygen from external source not required and no limitation of a transfer of oxygen which is sparingly soluble.
• Higher loading rate, upto 15 kg/m3, thus area requirement drastically reduces.
• Practically no power requirement since no internal mixing /aeration required.
• Generation of methane rich biogas which can be used to generate power.
• Minimal sludge production due to higher sludge retention time.

Cost-Benefit Analysis

INPUT

• COD : 2500 ppm
• FLOW : 1200 m3/day Dairy Waste

COST ANANLYSIS :

 

COST ANANLYSIS :

Annualised capital cost = C [ i(1+i)n]
                                    (1+i)n – 1

                                    = 54 [0.135 (1.135)15]
                                    [ (1.135)15-1]

                                    = 8.50 lakhs
( C = Capital Cost = Rs. 54 lakhs, i = rate of Interest = 13.5%, n = Life of reactor = 15 yrs.)


O & M Cost                 = Rs. 17.5 lakhs /annum
                                    (Manpower + 50 HP+ spare part)

Annualised Cost           = O& M + Annual Capital
                                    = 17.5 + 8.50 lakhs/annum
                                    = Rs. 26.00 lakhs/annum.

RECOVERY : Recovering is worked out based on 24 hrs. operation of dual fuel engine.

Recovery in terms of biogas as        = 1200 m3/d x 2 kg/ m3 x 0.54 m3 biogas/COD destroyed
                                                      generation of power x 0.8 COD destroyed/Kg x 365
                                                      = 3,78,432 m3 of biogas/year
                                                      = 3,78,432 x 1.4 KWH / year
                                                      = 5,29,804.8 KWH /year x Rs. 4.0 /KWH
                                                      = Rs. 21.2 lakhs.


Recovery due to water recycling    = 300 m3/ day x 25 Rs/ m3 x 365
                                                     = Rs. 27.37 lakhs


Payback period                           = Capital cost / (Recovery in terms of electricity & water – Annualised cost)
                                                   = 54 / (27.37 + 21.2 – 26.00)
                                                   = 2.5 years.

 

SOME OF OUR COMPLETED PROJECTS Data

• Mahananda Dairy, Goregaon, Mumbai.

• Gokul Dairy, Kolhapur, Maharashtra.

• National Dairy Development Board, Bangalore.

• Pradeshik Co-Op. Dairy Federation Ltd., Lakhanow, U.P.

• Hassan Dairy, Karnataka.

• Hosakote Dairy, Karnat

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