BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

TECHNICAL MANUAL OF BY-PRODUCT PLANT IN COB # 11 COMPLEX

The objective of By-product plant in COB # 11 is to clean the raw coke oven gas generated from
coke oven battery with removal of impurities like tar, ammonia, hydrogen sulphide and naphthalene
to the extent as it can be effectively used as fuel. The impurities thus removed from the system are
separated in the form of saleable products viz. Crude Coal Tar, Ammonium Sulphate, Sulphur (99%
pure) & Naphthalene. The coke oven gas is available at 300C at the outlet of byproduct plant.
The By-product plant consists of following Technological Units.
-

Gas condensation/ Tar separation Plant

Gravel Filter Unit.
Stripper-Deacidifier Unit
Ammonia Scrubber & Ammonium Sulphate Plant
H2S Scrubber & Elemental Sulphur Plant.
Naphthalene Scrubber & recovery unit.
Storage
(a)

Raw Material /catalyst Storage for

(b)

Sulphuric Acid
Solar Oil
Caustic
Catalyst
Finish Product Storage for
-

Coal Tar
Ammonium Sulphate
Naphthalene
Sulphur

The By-product plant is equipped with adequate flexibility from the point of view of design,
operation and maintenance. Adequate standby facilities are ensured for uninterrupted and smooth
operation of the plant.

Page 1

TECHNICAL MANUAL

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Page 2

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

GAS CONDENSATION PLANT, TAR SEPARATION PLANT & GRAVEL FILTER

Coke Oven Gas Circuit
(i)

Coke Oven Gas (COG) generated from battery gets separated from tar & liquor in
downcomer and is sucked by the exhauster through Primary Gas Cooler (PGC) &
Electrostatic Tar Precipitator (E.T.P.). In primary gas cooler, gas is cooled indirectly
first by cooling water followed by chilled water to 20 to 22 Deg C from about 82 0C
(saturated). The primary gas coolers have tubes horizontally placed with certain
inclination in a rectangular vertical box. The Coke Oven Gas flows in the shell side
and cooling water/chilled water flow in the tube side of PGC. Most of the tar-liquor
condensate is separated from C.O.Gas in the PGCs.
Cooling tower & chilled water plant have been installed for catering the requirement
of primary gas cooler and Heat-exchangers of other units. The chilled water plant is
housed in a separate room. Cooling tower & chilled water plant have standby
provision.
System of hot tar-liquor emulsion flushing is there for each PGC for removal of
naphthalene deposit on outside of water tubes. Arrangement of LP steam & Nitrogen
purging to PGC are also made.

(ii)

Electrostatic Tar Precipitator

Electrostatic Tar Precipitators (E.T.P.) is required to remove the remaining tar fog of
gas & the same installed before exhauster. Arrangement for removal of deposited tar in
the ETP tubes is provided. Insulator boxes are provided with electrical heating
arrangement. Inert atmosphere by allowing N2 flow in Insulator boxes is to be
maintained

(iii)

Exhauster
Electric Motor driven exhauster sucks the coke oven gas leaving ETP and discharge
the same with a positive head. The discharge head shall be worked out depending upon
the pressure drops in the downstream equipment and desired pressure (700 mm to
1000 mmWG) of CO Gas at the Battery Limit of By-Product. The temperature of CO
Gas at the discharge of exhauster should be kept minimum. Suction requirement for
upstream of exhauster upto battery is 500 mm WG (indicative).

Tar & Ammoniacal Liquor Circuit

The coke oven gas in Gas collecting main is cooled to 82 0C by spraying
flushing/Ammoniacal liquor. The Ammoniacal Liquor flows in a closed cycle from down
Page 3

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

comer to Solid Decanter; to Tar Decanter, Coal water tank and then back to Gas collecting
main via Ammoniacal/flushing liquor pump. Part of coal water is used for HPLA system in
battery. Excess coal water is sent to Ammonia stripper via Gravel filter.
Major portion of tar content in Coke oven gas is condensed in Gas main by flushing liquor/
Ammoniacal liquor. The tar together with flushing liquor, gas condensate and coal fines
from coke oven flowing through gas collecting main goes to solid decanter. The coal fines
mixed with tar & flushing liquor is known as sludge. The solid decanter serves to separate
sludge from Ammoniacal liquor and tar by settling. Sludge being heavier, settle at the
bottom of solid decanter and sludge is continuously scrapped off by scrapping conveyors
into barrel/ trolley from where it is removed by a dumper/truck. The Ammoniacal liquor and
tar from the decanter overflows into tar decanter. The Ammoniacal liquor from tar decanter
goes to gas mains of battery. Part of this liquor is used for HPLA system also. Surplus
Ammoniacal liquor is generated due to moisture present in the coal. This excess
Ammoniacal liquor is sent to Ammonia stripper via Gravel Filter.
The tar from the tar decanter flows continuously to the Tar Storage Tank for despatch.
Major Technological Equipment/Facilities for Gas Condensation Plant.
This plant comprises of the following major technological equipment
EQUIPMENT
CAPACITY
Primary Gas Cooler
2W+1S
24000
Nm3/Hr
for
Each PGC
Exhauster (650 Kw, 6.6 KV)
1W+1S
47500
Nm3/Hr
Decanter
1W+1S
Flushing Liquor Pumps
2W+1S
525 Nm3/Hr
E.T.P
1W+1S
47500
Nm3/Hr
Centrifugal Pumps for transferring 1 W + 1 S
tar, liquor etc
Tar Storage Tanks
1W+1S
1600 M3
Cooling Tower
2W+1S
Cooling Water Pump
4W+3S
Chilled Water Plant
2W+1S
Chilled Water Pump
1W+1S
Gravel Filter
1W+1S
Heat Exchanger
To prevent gaseous emission from various vessels, tanks equipment & vents, a suitable
pollution control measures are taken.

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BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

AMMONIA & H2S REMOVAL AND RECOVERY SECTION

Ammonia & H2S Scrubbing Unit
Coke oven gas which is pressurized by Exhauster is sent to the inlet of the H 2S scrubber.
The lower section of H2S Scrubber is designed for final cooling stage to remove the
temperature increased in exhauster. By means of a cooling loop comprising of cooling stage
pumps & cooling Heat Exchanger in which circulating liquor is cooled by chilled water &
the gas is cooled to a temperature of 20-220C.
The upper section of H2S scrubber is used to absorb the major amount of H 2S. The
absorption of H2S is performed by using NH3 which is included in the Coke Oven inlet Gas
and which is offered additionally by feeding of ammonia rich solution from ammonia
scrubber & lean solution from Deacidifier.
As the absorption of NH3/ H2S is exothermic in nature, the temperature of the outgoing gas
is not allowed to increase by means of cooling heat exchanger. Further removal of H 2S and
removal of major portion of NH3 is achieved in NH3 scrubbing system by means of stripped
ammonia liquor.
Ammonia stripping & Deacidification Unit
The stripping columns is divided into two parts, free ammonia stripping process takes place
in upper part and in the lower part decomposition of fixed ammonia takes place by means of
caustic solution. The upper part of the column receives the deacidified solution from
deacidifier & coal water (excess flushing liquor) from gravel filter unit after pre heated by
outlet liquor of column. The stripped off NH3 enter the deacidifier.
The deacidifier strips off NH3, H2S, CO2, HCN from the rich solution received from H 2S
scrubber. These vapours from the deacidifier shall enter to the Ammonium Sulphate plant
after proper cooling.
Ammonium sulphate production through Bubbler type saturator route
Ammonia, Hydrogen sulphide gas, CO2 & HCN from deacidifier is led to Saturator where
Ammonia is recovered in the form of Ammonium sulphate. Ammonia and H 2S enters in
saturator from top and bubbles through a bath of mother liquor where a constant acidity is
maintained by continuous addition of sulphuric acid. Sulphuric acid is stored in separate
storage tanks. The sulphuric acid is fed to the saturators by gravity from overhead tank.
Sulphuric acid is pumped to the overhead tank from ground level storage tank. The mother
liquor is kept under constant circulation by centrifugal pumps to maintain uniform bath
acidity and obtain uniform well developed crystals from the Saturator. From the Saturator
the Hydrogen sulphide with HCN & CO 2 enters the acid catcher, where the liquor droplets
Page 5

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

entrained in gas is removed. Ammonium sulphate crystals produced in the Saturator is

ejected out together with mother liquor to the crystal receiving tank. Ammonium sulphate
slurry flows from crystal receiving tank by gravity to the centrifuge continuously for the
separation of mother liquor and salt. Ammonium sulphate from the centrifuge is conveyed
by belt conveyors to the dryer. Drying of ammonium sulphate is carried out in a stainless
steel rotary drier by means of hot air operating with steam and through forced draft fans.
From the drier, spent hot air with entrained dust particles is extracted by suction fan through
cyclone separator and wet scrubbing unit to remove the fine ammonium sulphate salt before
venting to atmosphere. Ammonium sulphate is transferred to the bagging bunker by a bucket
elevator. Dried ammonium sulphate is bagged, weighed in automatic bagging and weighing
machine and then sent to storage or dispatched by rail and road. The provision for both
railway wagon loading and road truck loading are kept. Mechanized system for loading of
bags is provided.
The Saturator, acid catcher and mother liquor tanks is of special steel alloy as per DIN
1.4465 or similar in order to resist corrosion. All process pumps are of Alloy-20
construction.
Sulphur Recovery Unit
H2S/HCN/CO2 vapor coming from drop separator (acid catcher) of saturator enters to
Catalytic Oven Reactor for burning.
The operation of the cracking reactor is characterized by partial burning of sour gas with air
to provide the required temperature for the catalytic cracking stage. Most of the nitrogen
compounds are burnt and reduced to elemental nitrogen and passes the catalyst bed to crack
the remaining ammonia and hydrogen cyanide.
Process gas leaving the catalytical area is post-burnt by providing secondary air, so that the
required ratio of SO2/ H2S is adjusted before the gas is cooled in the waste heat boiler
system (Process Gas Cooler). At the same time the first portion of elementary sulphur is
generated, which is separated in the outlet area of the boiler.
The boiler is used to cool the process gas down to 250 to 280 0C. A partial flow is taken
between the Crack-Reactor and the boiler and mixed with the outlet of the LP boiler to
obtain the correct inlet temperature for the Claus reactor. The boiler is equipped with an
internal sulphur separator, where the liquid sulphur that has been built, is separated from the
process gas.
The process gas leaving the boilers is directed to the first of two claus reactors. Both
reactors are filled with alumina based catalyst. The conversion of sulphur dioxide and
hydrogen sulphide to sulphur takes place by the selected temperature of 2500C.
As the claus reaction is of exothermic natures, the process gas is cooled after the 1st claus
reactor stage in the Sulphur Condenser, followed by a sulphur separator and directed to the

Page 6

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

2nd claus reactor stage. Before the process gas is led into the 2nd claus reactor stage, it is reheated to enter the claus reactor with the required temperature.
The process gas, leaving the 2nd claus reactor stage is also cooled in the sulphur condenser,
released from liquid sulphur in the 2nd sulphur separator and directed as tail gas to the crude
gas main ahead of the primary coolers. By this mode of operation the combined process is
free from emissions.
The following reactions take place during the process.
NH3 + O2 (N2) + H2O
HCN + O2 (N2) + H2O + CO2
H2S + O2 SO2 + H2O
NH3 N2 + (H2)
HCN + H2O N2 + (H2) + (CO)
H2S + O2 SO2 + H2O + 519 KJ
2H2S + SO2 3/x Sx + 2H2O + 147 KJ
H2S + O2 SO2 + H2O + 519 KJ
2H2S + SO2 3/x Sx + 2H2O + 147 KJ
The produced liquid sulphur from the boiler, the sulphur condenser and the two sulphur
separators is led via a sealing pot to a storage tank to process further for producing Sulphur
blocks.
Major Technological Equipment/Facilities
EQUIPMENT
NH3 and H2S Scrubbing Unit
H2S Scrubber
1W
NH3 Scrubber

1W

CAPACITY
47500 Nm3/Hr
Gas Processing
47500 Nm3/Hr
Gas Processing

Enriched water Pumps

1W+1S
Pre Enriched Water Pumps
1W+1S
Internal Cooling Pump
1W+1S
Final Cooling Pump
1W+1S
Enriched water Tank
2W
Heat Exchangers
6W+3S
Ammonia stripping & Deacidification Unit
De acidifiers
1W+1S
Combined Stripper
1W+1S
Deacidifier Discharge pumps
1W+1S
Stripper Discharge Pumps
1W+1S
Stripped water Tank
1W
Stripper water pump
1W+1S
Deacidfier Water Tank
1W
Deacidifier Water Pumps
1W+1S
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BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

Stripped waste Water Tank

Stripped waste water pumps
Heat Exchangers

1W
1W + 1 S
8W+8S

Ammonia Recovery Plant

Saturator with acid Catcher
1W + 1 S
Thickener
1W
Centrifuge
1W + 1 S
Sal conveyor system
1W
Bagging system
1W
Mother liquor pumps
1W + 1 S
Wet Scrubbing system
1W
Seal pot
1W
Sulphur Recovery Unit
Catalytic Oven Reactor
1W
Claus reactors
2W
Process Gas Cooler
1W
Sulphur Condenser
1W
Process Gas Heater
1W
COG Blower
1W + 1 S
Air Blower
1W + 1 S
Vapor Blower
1W + 1 S
Sulphur Storage Tank
1W
Sulphur Drain Pumps
1W + 1 S
Sulphur Solidification Unit
1W
NAPHTHALENE RECOVERY AND REMOVAL SECTION
Naphthalene Scrubber
The Coke oven gas from H2S and NH3 scrubbers is taken to Naphthalene scrubber for
naphthalene recovery to the extent of 0.05 gm/Nm3 max. Most part of Naphthalene in CO
gas is separated out with tar in Hydraulic mains of coke oven battery, Primary Gas Cooler
and the remaining portion in Naphthalene scrubber. The scrubber is packed with suitable
expanded metal packing to provide larger surface area. A measured quantity of makeup solar
oil is added to fresh oil tank and proportionate quantity of Naphthalene rich solar oil is
removed from the bottom section of scrubber to storage tank. Rich solar oil is sent to
Naphthalene stripping section for recovery of naphthalene by steam stripping and to get lean
solar oil for further use in scrubber.
Naphthalene Stripping
A portion of Naphthalene rich solar oil is discharged continuously from the scrubbing unit to
storage buffer tank. The rich solar oil is fed continuously to the Naphthalene Stripper.

Page 8

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

The Naphthalene rich solar oil fed to the Naphthalene stripper where naphthalene is stripped
off by steam. Almost naphthalene free solar oil is taken out from stripping column for reuse
in Naphthalene scrubber after proper cooling.
The vapour coming out from Naphthalene stripper contains Naphthalene with oil & water
vapour which is condensed in water cooled condenser. Naphthalene rich oil getting
separated from water in a separator is allowed to cool in water jacketed Naphthalene tray.
Naphthalene crystallises by indirect cooling. The oil content in the Naphthalene is 1 % max.
Contaminated water from separator goes back to tar separator unit.
Major Technological Equipment/Facilities Naphthalene Scrubbing unit)
EQUIPMENT
Naphthalene Scrubber
Naphthalene Scrubber
1W

CAPACITY
47500 Nm3/Hr
Gas Processing

Solar Oil Circulation Pumps

4W
Enriched Solar Oil Tank
1W
Enriched Solar Oil Pump
1W+1S
Stripped Solar Oil tank
1W
Stripped Solar Oil Pump
1W+1S
Fresh Solar Oil Tank
1W
Heat Exchanger
1W
Naphthalene stripping Unit
Stripper
1W
Wash Oil Stripper
1W
Condenser
1W
Separator
1W
Heat Exchanger
2W+2S
Technological Parameters:
i)

Coke Oven Gas Processing Capacity: 47460 Nm3/hr (Indicative) Including Charging
gas and Tail Gas

ii)
b)
d)

Design Basis: Following overload factors have been considered:

a) Gas Condensation unit consisting of PGC, ETP have 1.15 times of
gas
Processing Capacity.
Exhauster Have 1.15 times of gas Processing Capacity.
c) Other units of by-product plant like H2S, NH3 & Naphthalene Scrubber have
1.07 times of gas Processing Capacity.
Gas Velocity in gas line is 16 to 20 m/sec.

iii)

Raw Coke Oven Gas temperature at inlet of PGC: 82 0C Max.

iv)

Raw Coke Oven Gas Composition & Impurities at the inlet of By-Product Plant
(Indicative):
a) Composition of Raw Coke Oven Gas (% by Volume):
Page 9

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

Hydrogen
: 52-59
Carbon monoxide
: 6-7
Carbon dioxide
: 3-4
Oxygen
: 0.3-0.7
Methane
: 24-28
Nitrogen
: 4-7
CnHm
: 1.5-2.5
b) Impurities of Raw Coke Oven Gas (gm/Nm3):
Tar
: 100-120
Benzol Hydrocarbons
: 30-36
Hydrogen Sulphide
: 3-4
Ammonia
: 10-12
Naphthalene
: 8-10
v)

Impurities in clean Coke Oven Gas (At the outlet of By-Product plant)
Residual Impurities
gm/Nm3
Tar
: 0.02 (Max.)
Hydrogen Sulphide
: 0.80 (Max.)
Ammonia
: 0.03 (Max.)
Naphthalene
: 0.05 (Max.)
Benzol Hydrocarbons
: 28-34

vi)

Quality of flushing Liquor supplied to Coke Oven Battery.

pH
: 9-9.5
Suspended Solids
: <100 ppm
Pressure
: 5-6 kg/cm2
Temperature
: 80-82 0C

vii)

Yield of Finished Products:

Crude Tar
Ammonium Sulphate
Elementary Sulphur
Naphthalene

viii)

ix)

:
:
:
:

Quality of Finished Product:

i Crude Tar:
Moisture Content,
Specific gravity at 40 0C
ii Ammonium Sulphate
ii Sulphur
i
iv Naphthalene

33.83 kg/TDC
15.04 kg/TDC
1.05 kg/TDC
0.11 kg/TDC

:
:
:
:

Less than 4 % (Max)

1.18
As Per IS 826
99 % Purity

Purity of Naphthalene
Content)

:
:
:

1.55 T/Hr
49 Kg/hr
415 Kg/hr

Chemical Consumptions:
i Sulpuric Acid
ii Solar Oil or Wash Oil
iii Caustic Soda

Page 10

(Min.Oil

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

BOD PLANT OF COB # 11COMPLEX

Effluents generated from the Coke Oven and By Product Plant of COB # 11 Complex are treated
at BOD Plant for removal of Ammonia, Phenol, Tar & Oil, Cyanide etc. Treated effluents
discharged into the Reservoir No 2 for internal re-circulation and re-use.
BASIC PRINCIPLE OF THE BOD PLANT:
Physical Treatment
Chemical Treatment
Biological Treatment
(Three Stage Biological System 1 st Stage Activated Sludge Process, Followed by Nitrification and
De-Nitrification Processes)

Page 11

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

BOD PLANT FLOW

DIAGRAM

SLUDGE
RECIRULATIO
N

UNDER
FLOW

TAR/O
IL
SKISKIM
SEPA
EF
SKIMME
MMMED
RATIO
TAR &
FL
D TAR &
N
ED OIL
DISSO
pHN
AMM
EU
TANK EQUALI
OIL
TO
TA SUMPLVED
SATION
ADJU
ONIA
a OIL
NT
SLOP
R/O
TANK
AIR
STRIP
BACTE STME
O
TANK
WITH
FLOAT
NT
PING
IL
RIAL
H
SKIMM
ATION
TANKTOWE
CULTUR
AMM
ER
UNITE
1
R
TREATE
ONIA
MAG BACTERI PREPA
ACI
D
AER
FIXIN
NUT
SETTL NESI AERAAL
SETTL
RATION ATIO
G D
SEWAGE
ING UM TION
ING
RIE
TANK
CULTUR
N
CUM
TREATE
TANKTANKTANKNT
SLUD
TAN
pH
CAR
E
II
II
I
D
GE
K-I
ADJU
SLUDGE
BON
PREPAR
EFFLUE STME
SUMP
RECIRUL
ATE
ATION
EXC
NT
-I THICK
NT
ATION SLUD
TANK
SLUD
SLUD
ESS
OVE
NED
GETANK
GE
GE UND RFL
SLU
SLUD
DRYI
SUMP
THICK ER
GE
NG
DGE
OW
NER
EXC
SUMP
BED
ME -II
FLO
AERA
SLUDGE
DENIT
SETTL
ESS
TH RIFIC
W
TION
ING
FOR
OVE
SLU
AN ATION
TANKTREATE
TANKDISPOS
RFL
DGEIII
III
OL TANK
D

OW

SLUDGE
SUMP-III

AL
EFFLUE
NT FOR
AERATIO
DISPOS
N TANK
AL
1

MAJOR UNITS OF BOD PLANT:

Tar and Oil Separation Unit
Equalization Tanks
Dissolved Air Flotation (DAF) Unit
Skimmed Oil sump
pH Adjustment Tank
Ammonia Stripping Tower
Ammonia Fixing Tank
Page 12

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

Aeration Tank I
Settling Tank I
Aeration Tank II
Settling Tank II
De-Nitrification Tank
Settling Tank - III
Aeration Tank - III
Sludge Sumps
Thickener
Sludge Drying Bed
Chemical House, MCC Room, PLC Room, Office, Laboratory, Chemical Dosing Units
Treated Effluent Collection Sump
Slop Oil Tank
Biological Culture Tank

TECHNICAL FEATURES
Capacity: 40 m3/hr Un-treated Effluents from BPP and COB # 11 and 50 m3/hr Treated Sewage
Water from STP.
TREATMENT SCHEME:
Effluents generated from Coke oven and By-Product Plant (COB#11 complex) contains
pollutants such as Ammonia, phenol, Tar & oil, cyanide etc. Main function of BOD Plant is to
remove tar and oils by physical and chemical systems and subsequent biological degradation of
Phenols , Ammonia and cyanide.
Initially effluents are received in tar & oil separation tank. The capacity of the tank is suitable for
one hour detention period. The effluent collected in this collection sump pumped to subsequent
tar-oil separator. Tar-oil separator unit is provided with skimming facilities. From this unit effluents
flow by gravity to equalization tank.
The equalization tank capacity with residence time of 24 hours for designed flow of 40 m3/Hr. The
equalization tank consists of three compartments, two compartments each having six hours holding
while the third compartment having twelve hours holding capacity. The equalization tank is
provided with necessary tar/oil skimming arrangement, and epoxy painting in the inside faces of
each compartment.
From the equalization tank effluents are pumped to dissolve air floatation unit for removal of
emulsified oils. This unit consists of recirculation pump, air compressor and all other required
accessories. A skimmed tar & oil sump is also provided for collection and storage of skimmed tar &
oil.
Since the skimmed tar & oil contains major portion as water, this skimmed tar & oil is pumped to
slop oil tank for separation of water & tar / oil. In the slop oil tank skimmed tar & oil allowed to
remain for few days for separation of tar and oil. Tar/oil floating on the top surface is taken out
through tapping connection provided for this and sent for secondary use. Water from the bottom of
the tank taken out and sent back to the treatment plant.
From the dissolved air flotation unit effluents flow by gravity to pH adjustment tank. Alkali is
added to raise the pH around 11. This tank is provided with agitator and pH indicating instrument.
pH adjusted effluents are pumped to ammonia stripping tower.

Page 13

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

Stripping of ammonia is carried out in an ammonia stripping tower. The tower is of induced draft
cross flow type and provided with suitable packing, effluent distribution piping, collection basin,
adequate capacity aeration fan and all other accessories.
The ammonia stripped effluents from collecting basin sent to ammonia fixing cum pH
adjustment tank. The residual free ammonia is fixed and pH is brought down to neutral pH by
addition of sulphuric acid. The tank is provided with agitator and pH indicating instrument.
Effluents form ammonia fixing tank are pumped to 1 st stage aeration tank i.e. aeration tank-I. Under
normal operation condition part of treated effluent or treated sewage water is added at the outlet
of ammonia fixing cum pH adjustment tank at the rate of 40 m3/hr before entering into the
biological treatment facilities. The aeration tank-I is aerated along with the return sludge by
mechanical surface aerator. The tank is made of RCC and necessary arrangements are provided in
the tank for receiving the return sludge and required nutrients.
The effluents from aeration tank-I flow to settling tank-I where solid particles are settled out.
Overflow from settling tank-I flow to aeration tank-II whereas the underflow is taken to sludge
sump-I. The settling tank is of RCC construction and
provided with necessary scrapping
arrangement, overflow weir, inlet and sludge outlet pipes, constant bleed arrangement and all other
accessories required. From the sludge sump-I sludge is recirculated to aeration tank 1 and excess
sludge is disposed to sludge thickener inlet.
The aeration tank-II is used as 2 nd stage of the activated sludge process. The tank consists of
aerators and other facilities for receiving the return sludge and required magnesium carbonate
solution. Bacterial culture tanks provided at the platform of aeration tanks.
Effluents from aeration tank-II flow to settling tank-II. The settling tank-II is similar to settling
tank-I. Facilities for collecting settled sludge from settling tank-II and pumping it to aeration tank-II
& sludge thickener inlet, sump is provided.
The nitrified effluents from aeration tank-II flow to nitrification tank. The tank is operated under
anaerobic condition. Requisite quantity of methanol is added as carbon source. Effluents from denitrification tank flow to settling tank-III. The settling tank-III is similar to settling tank-I. Similar
facilities for collecting settled sludge from settling tank-III and pumping it to sludge thickener inlet,
sump, and pumps provided.
From the de-nitrification tank, effluent flow to aeration tank-III, where surface aerators are
provided in the aeration tank to supply required dissolved oxygen in the treated effluent before
disposal.
A sludge thickener is provided for thickening the excess sludge received from different sludge
sumps. The thickener is provided with sludge collection arrangement and all other accessories. The
overflow from sludge thickener is fed at the inlet of aeration tank-I
The underflow from sludge thickener is collected in a thickened sludge sump from where it is
pumped to sludge drying bed unit for dewatering of the sludge.

DESIGN SPECIFICATION:

pH
Temp.
Phenol

Inlet Concentration
7.5 to 9.0
50 - 60 Deg. C
500 mg/l
Page 14

Outlet Concentration
6.0 to 8.0
Ambient Temp
1 mg/l

BY PRODUCT PLANT & BOD

Cyanides
Tar & Oil
Total Ammonia
SS
BOD
COD

TECHNICAL MANUAL

50 mg/l
100 350 mg/l
500 mg/l
-

Page 15

0.2 mg/l
10 mg/l
Ammonical N2 :50mg/l
100 mg/l
30 mg/l
250 mg/l

BY PRODUCT PLANT & BOD

TECHNICAL MANUAL

BOD PLANT FLOW

DIAGRAM

SLUDGE
RECIRULATIO
N

UNDER
FLOW

TAR/O
IL
SKISKIM
SEPA
EF
SKIMME
MMMED
RATIO
TAR &
FL
D TAR &
N
ED OIL
DISSO
pHN
AMM
EU
TANK EQUALI
OIL
TO
TA SUMPLVED
SATION
ADJU
ONIA
a OIL
NT
SLOP
R/O
TANK
AIR
STRIP
BACTE STME
O
TANK
WITH
FLOAT
NT
PING
IL
RIAL
H
SKIMM
ATION
TANKTOWE
CULTUR
AMM
ER
UNITE
1
R
TREATE
ONIA
MAG BACTERI PREPA
ACI
D
AER
FIXIN
NUT
SETTL NESI AERAAL
SETTL
RATION ATIO
G D
SEWAGE
ING UM TION
ING
RIE
TANK
CULTUR
N
CUM
TREATE
TANKTANKTANKNT
SLUD
TAN
pH
CAR
E
II
II
I
D
GE
K-I
ADJU
SLUDGE
BON
PREPAR
EFFLUE STME
SUMP
RECIRUL
ATE
ATION
EXC
NT
-I THICK
NT
ATION SLUD
TANK
SLUD
SLUD
ESS
OVE
NED
GETANK
GE
GE UND RFL
SLU
SLUD
DRYI
SUMP
THICK ER
GE
NG
DGE
OW
NER
EXC
SUMP
BED
ME -II
FLO
AERA
SLUDGE
DENIT
SETTL
ESS
TH RIFIC
W
TION
ING
FOR
OVE
SLU
AN ATION
TANKTREATE
TANKDISPOS
RFL
DGEIII
III
OL TANK
D

OW

SLUDGE
SUMP-III

AL
EFFLUE
NT FOR
AERATIO
DISPOS
N TANK
AL
1

Page 16