1

GRASIM Industries, Nagda

A Practice School Station of

BIRLA INSTITUTE OF TECHNOLOGY and

SCIENCE,PILANI.

[JULY 2023]
Group Members:

Name of Students ID

1. Siddhant Sharma 2021A2PS2133P

2. Anisha Saini 2021B1TS2072P

3. Aayushman Singh 2021B5A11315P

4. Jatin Rawat 2021B1TS2080P

5. Yatin Kumar Sahu 2021A2PS2607P

 2

TABLE OF CONTENTS

Chapter no. Chapter Name Page no.

Acknowledgement 3
Abstract 4
1 Overview of Grasim Industries 5-15
1.1 List of all the Plants across India 7
1.2 History 8-9
1.3 Major Commodities they Produce 10-11
1.3.1 Viscose Staple Fiber 10
1.3.2 Textile Business 10
1.3.3 Chemical 10
1.3.4 Cement 10-11
1.3.5 Insulators 11
1.4 CSR initiatives undertaken by Grasim Industries 12-13
2 Working in Grasim Industries, Nagda 14-25
3 Manufacturing of Viscose Staple Fibre 26-29
3.1 Efficiency of Biological Reactors 30-41
3.1.1 Introduction: Biological Reactors 30
3.1.2 Types of MBR Systems 31
3.1.3 Advantages of an MBR 31-32
3.1.4 Classification of Biological Reactors 32-41
4 Wastewater Chemical Treatment 47-48
4.1 Neutralization 42-43
4.2 Precipitation 43-44
4.3 Coagulation 44-46
5 A few strategies for increasing the efficacy
of wastewater treatment 46-49
5.1 Reduction and advanced Oxidation Process (AOP) 46-48
5.2 Demineralization \ Ion Exchange Method 48-49
5.3 Adsorption via chemi 49
6 COD and BOD Levels for June 2023 50
7 Role of Artificial Intelligence in ETP 51-53
8 Analysis of the potential environmental
impacts of effluent discharge 54-59
8.1 Other Method 57-59
8.1.1 Titration Methods 57-58
8.1.2 Reagent Methods 58-59
8.2 Conclusion 59
8 Reference 60
 3

Acknowledgement

We have dedicated considerable efforts to this project, but its realization

would not have been possible without the generous support and assistance
from numerous individuals and organizations. We wholeheartedly express our
sincere appreciation to all of them. Our profound gratitude goes to Mr. Arun
Maity and Mr. Anil Vijay for their invaluable guidance, unwavering
supervision, and the vital information they provided throughout the project.
Their support played a crucial role in its successful completion. We would
also like to extend our heartfelt thanks to our parents and the members of our
team for their kind cooperation and encouragement, which greatly
contributed to the successful culmination of this project. Additionally, we
wish to convey our special appreciation and thanks to the team at Grasim
Industry, Nagda, for their attentive assistance and time. We are immensely
grateful to all the respondents with whom we had the opportunity to interact
during our project work. Without their support and cooperation, we would
not have achieved the successful outcome of this project. Lastly, we feel a
deep sense of indebtedness to all those individuals and organizations who
directly or indirectly provided assistance in the triumphant completion of this
project.
 4

Abstract

The majority of river basins are facing or have already experienced severe
water scarcity due to the combined impacts of agricultural expansion,
industrialization, and urbanization. The performance of state-owned sewage
treatment plants responsible for treating municipal wastewater, as well as
common effluent treatment plants handling effluent from small-scale
industries, does not meet the prescribed standards. Consequently, the treated
effluent from these plants is often unsuitable for household use, and the reuse
of wastewater is predominantly limited to agricultural and industrial
purposes. It is a matter of great concern to us that the development of
innovative technologies for treating wastewater from various industries
remains a pressing issue. While numerous research papers have addressed
wastewater pollution control studies, there is a scarcity of research focused
on treating wastewater specifically from steel industries, particularly
regarding the design of industrial effluent Treatment Plants (ETP) systems.
 5

Overview of Grasim Industries

Grasim, Nagda is the world’s largest producer of spun-dyed specialty fibre. It

produces a wide range of VSF to suit customer needs in terms of length, denier and
colour. It is the world's first viscose plant to have Zero Liquid Discharge Plant.

Grasim is India's pioneer in VSF — a man-made, biodegradable fibre that is fast

emerging as a sustainable alternative to cotton. A versatile fibre, VSF is used in
apparel, home textiles, dress materials, knit wears and non-woven applications.
Our Birla Cellulose range of fibres can be used in their original form, or can be
blended with all natural and synthetic fibres for enhanced comfort and feel.

Starting production in 1954 at our Nagda facility, the business has grown steadily
over seven decades. The Pulp & Fibre Business derives its competitive edge from
its integrated business model, with captive raw materials - dissolving grade wood
pulp, caustic soda, carbon-disulphide, power generation and steam.
VSF Capacity stands expanded to 824KTPA post brownfield expansion at Vilayat
and debottlenecking at three sites.
 6

Recent Milestones:-
2012 – Acquired assets of Terrace Bay, a paper grade mill, in a JV with Group
company Thai Rayon, in July 2012(with Grasim holding a 40% stake and the
remaining 60% held by Thai Rayon Public Company Ltd.)
2011 – Acquired Domsjo Fabriker AB (Domsjo), Sweden, in a joint venture with
Group Companies.
2010 – Consolidation of the cement business under UltraTech Cement Limited.

Brief Financial Analysis of Grasim Industries

As of 2022 the revenue generated is of Rs 75073 Cr and the profit being Rs 1886
Cr.
There are a total of 24390 Employees in the industry and the Market Capitalization
of the company is about 48648 Cr.
 7

List of all the Plants across India

● Vikram Woollens, Madhya Pradesh

● Epoxy, Vilayat

● GPF, Kolhapur, Maharashtra, Maharashtra

● Halol, Gujarat

● Nagda, Madhya Pradesh

● Indian Rayon, Veraval, Gujarat

● Rishra, West Bengal

● Rishra, West Bengal (insulators)

● Kharach, Gujarat

● Century Rayon, Shahad, Maharashtra (CTIL)

● Renukoot, Uttar Pradesh

● Harihar, Karnataka

● Rehla, Jharkhand

● Ganjam, Odisha

● Veraval, Gujarat

● Karwar, Karnataka

● Balabhadrapuram, Andhra Pradesh

 8

HISTORY
On August 25, 1947, Grasim Industries Ltd. was formally established. The
company began producing fabrics in Gwalior in 1950 using imported rayon
made of synthetic materials. At Nagda in Madhya Pradesh, they started
producing VSF in 1954. They established the Engineering Division for
VSF's plant and machinery in 1962. They opened a composite textile plant in
Haryana's Bhiwani in 1963. They started producing rayon in 1968 at
Mavoor, Kerala.

The company started producing rayon grade caustic soda for VSF
manufacture at Nagada in 1972.The company's first cement facility, Vikram
Cement, opened in 1985 near Jawad in Madhya Pradesh.They started up
Vikram Ispat, the third-largest gas-based sponge iron factory in India, in
1993. They also established Birla Consultancy & Software Services to offer
IT consulting services and to build software. Two new greenfield cement
facilities were opened by the firm in 1995: Grasim Cement in Rawan,
Chattisgarh, and Aditya Cement in Shambhupura, Rajasthan.

Following a partnership with Lawson Software (USA), the business

established the Lawson Competency Centre as a section of Birla
Consultancy & Software Services, the software arm of Grasim, in the year
2000. The corporation split off its consulting and software service divisions
in 2001 to become Birla Technologies Ltd. Four ready-mix concrete plants
with a combined aggregate capacity of one million cubic meters were put
into operation.The business expanded its ownership of L&T by 10% in
October 2002, bringing their total investment to 15.3%. In order to produce
the "Grasim" and "Graviera" labels, the company sold its Gwalior textiles
unit in 2002. The textile operations were then consolidated in Bhiwani.
Additionally, the business amalgamated with Dharani Cements Ltd.

The firm bought the majority share in UltraTech CemCo Ltd (now UltraTech
Cement Ltd) in the year 2004. Together with Tembec Inc., the company
 9

bought Canada's St. Anne Nackawic Pulp Mill in 2005. The business
established Birla Jingwei Fibers Company Ltd. as a joint venture in 2006.
Additionally, they bought a VSF factory in China.

The company finished its ongoing cement expansions in 2009–10 and put
the 3.1 million TPA grinding capacity at Kotputli, Rajasthan, into service.
The company separated its sponge iron division through a slump sale on
May 22, 2009. With effect from October 1, 2009, Samruddhi Cement Ltd.
(Samrudhi), a subsidiary of the company, received the company's cement
operations under the terms of the agreement. Samruddhi Cement Ltd. and
UltraTech Cement Ltd. merged concurrently with effect from July 1, 2010.

The company purchased a 1/3 share in Aditya Holding AB, a major

producer of specialised pulp used in the production of VSF, during the
2010–2011 fiscal year. Domsjo Fabriker AB (Domsjo), a Swedish company,
was acquired by Aditya Holding AB for an enterprise value of Swedish
Kroner (SEK) 2.12 Billion (about Rs 1,570 crore). The purchase of ETA Star
Cement Company LLC, which included a 2.3 million TPA clinker factory
and grinding units of 2.1 million TPA in the UAE, 0.4 million TPA in
Bahrain, and 0.5 million TPA in Bangladesh, was finalised by UltraTech in
September 2010.

UltraTech now has direct access to the markets in the Middle East and
surrounding areas thanks to this acquisition. Due to this acquisition,
UltraTech now has an additional 52 million TPA of capacity. Aditya Birla
Power Ventures Ltd was bought by the company in August 2011, making it a
subsidiary of the original business. At a cost of Rs 1,700 crore, the business
is constructing a 120,000 TPA Greenfield VSF plant in Vilayat, Gujarat.

Additionally, a brownfield expansion at Harihar (Karnataka) will increase

capacity by 36,500 TPA at a cost of Rs 449 crore. The company will also
build a Caustic Soda facility at Vilayat with a capacity of 182,500 tonnes as
part of their aim to resource de-risk vital inputs.
 10

Major Commodities they Produce

● Viscose Stable Fiber

○ Grasim is the largest producer of Viscose Filament Yarn in India.
Raysil, viscose filament yarn, is a versatile fashion yarn manufactured
from premium and imported wood pulp. It is 100% biodegradable and
eco-friendly, giving a feather-light feel, vivid colours, and a natural
luster.
○ Grasim Industries Ltd is the No. 1 VSF producer in India and has been
manufacturing the world-class Viscose Staple Fibre for more than
seven decades across four plant locations. VSF is a regenerated
cellulose fibre made from wood pulp, a sustainable natural resource
and is biodegradable and eco-friendly. Moved up the VSF share in the
overall Fibre market share from 3.5% to 5% in the last four years.
● Textile Business
○ Established in 1949 as a textile unit, Jayshree Textiles is a producer of
premium textiles (linen fabric, linen yarn, and worsted yarn) in the
linen and wool business in India. Through brand Linen Club, Grasim
Industries Ltd has significantly revolutionised the Indian textile
market by popularising linen in India across a wide customer base.
The integrated linen factory is equipped with state-of-the-art facilities
in spinning, weaving and finishing systems from Switzerland and
Italy.
● Chemicals
○ Grasim Industries Ltd is the largest caustic soda producer in India
with significant integration and a capacity of 1,147 KTPA. The largest
end-consumers are alumina, textiles, and others. Net sales in Caustic
Soda surpassed the 1-million-tonne mark during the year – a new
benchmark set by any Indian company. Total Caustic Soda capacities
are set to increase from 1,147 KTPA to 1,457 KTPA by FY21.
● Cement
○ UltraTech is today the 3rd largest cement company in the World,
excluding China with a consolidated capacity of 102.75 million tonnes
per annum of grey cement (including 4.00 million tonnes per annum
 11

under commissioning) and the largest manufacturer of grey cement,

ready-mix concrete and white cement in India.
○ UltraTech is India’s No. 1 cement and concrete brand. UltraTech has
an operational presence in five countries (India, UAE, Bahrain,
Bangladesh and Sri Lanka).
○ In India, UltraTech’s distribution network comprises a network of 49
cement plants, over 100 ready mix concrete plants, more than 650
warehouses and more than 200 railheads. UltraTech services 20,000
orders of different order sizes on a daily basis through a mix of
logistical modes comprising rail, road, and sea.
● Insulators
○ Aditya Birla Insulators is the largest electrical insulator manufacturer
in India and ranks among the top four insulator manufacturers in the
world. It produces the broadest range of insulators in India, including
insulators for transmission lines and substations up to a voltage level
of 1200 kV and equipment and railways. Its total installed
manufacturing capacity is 56,400 TPA with specialisation in both
ceramic and composite insulation. The company established Aditya
Birla Power Composites Limited, a joint venture with Germany's
Maschinenfabrik Reinhausen GmbH, in 2019 to establish a
state-of-the-art CHCI manufacturing facility in Halol, Gujarat, India.
 12

CSR initiatives undertaken by Grasim Industries

Corporate Social Responsibility (CSR) may be defined as the creation of a positive

social impact through philanthropic, environmental, community-based, and other
initiatives undertaken by an organisation in furtherance of ethical or strategic
purposes.

Section 135 of the Companies Act, 2013, mandates that an organisation with an
annual turnover of INR 1000 crore or more, a net worth of at least INR 500 crore,
or a net profit of INR 5 crore or more, shall contribute at least 2% of its average net
profits in the previous 3 years towards CSR activities.

It is pertinent to note that, more than a legal obligation, CSR activities are a way of
giving back to the community at large.

As a responsible organisation, Grasim Industries is committed to serving the

community at large, drawing inspiration from Shri GD Birla's understanding of the
concept of trusteeship-based management.

Notably, the Aditya Birla Centre for Community Initiatives and Rural
Development, led by Ms. Rajshree Birla, channels Grasim's CSR activities by
providing strategic direction and insights.

For her exemplary work serving society, Ms. Rajshree Birla was awarded the
Padma Bhushan in 2011.

Grasim has been serving Nagda for more than seven decades and has given n
impetus to several socio-economic reforms in the region; some of them are as
follows:

(a) COVID Relief: Grasim Industries played a proactive role in handling the
pandemic situation by providing gloves, hand sanitizers, can sanitizers, 10,000 face
 13

masks, 50 oximeters, and other important supplies to the Nagar Palika. The relief
material was worth around 10 lakh rupees.

(b) Grasim Jan Seva Trust runs the Indu Bhai Parikh Memorial Hospital, a 150-bed
hospital with modern facilities, at Nagda. The hospital annually caters to 1.4 lakh
people belonging to 350 villages.

(b) Grasim manages 3 schools catering to 4200 students, of whom 50% come from
vulnerable sections of society.

(c) Construction of 4 dams on Chambal, catering to the needs of 2,00,000 people in

addition to satisfying the water requirements of the Railways.

(d) Grasim Industries works closely with government departments, like District
Rural Development Authorities, Health Department, Village Panchayats, the
District Animal Husbandry, Agriculture, and Horticulture departments, etc., and
supports their initiatives pertaining to community development.
 14

Working in Grasim Industries, Nagda

INDUSTRIAL DISCIPLINE:

Safety: Free of all the risks and hazards.

Concern: GRASIM prioritizes the health and safety of its employees .

Approach of the industry : It has a World Class Manufacturing concept

(WCM-1997) which places it at par with the global standards.

Certified by:

It has following certificates to its name :

1. ISO 9001-Quality management system

2. ISO 14001-Environmental management system
3. ISO 18001- also called OHSAS 18001 Occupational Health and Safety
4. SA 8000- Social Accountability

Heinrich Triangle (330 rule): Heinrich's law is a theory of industrial safety that is
based on probability. According to this law, the number of accidents decreases as
the severity of the accidents increases. However, it is important to note that this
law is not without controversy.

While it is true that minimising the number of minor incidents can reduce major
accidents, this is not always the case. In fact, some experts argue that this approach
can lead to a false sense of security.

It is worth noting that Heinrich's law is often used to analyse workplace safety. The
law states that out of every 330 accidents, 300 are just near miss cases, 29 are
minor accidents, and only one is a fatal injury. These incidents can include near
misses, accidents, fires, and other workplace hazards.

Despite its limitations, Heinrich's law has been an influential theory in the field of
industrial safety. It has been used as a starting point for many safety programs and
guidelines, and has led to improvements in workplace safety across many
industries.
 15

CAPA:

Corrective and Preventive Action. Loses include man and material , work loss,
skill loss. Safety is the legal requirement.

Do’s: 1.Helmet 2.Safety shoe 3.Carry no flammable material 4.Follow walk

paths, traffic signals 5.Safety goggles, dust mask & ear plug wherever needed.
6.Away from all chemicals, do not touch unless permitted, using appropriate PPEs
7.Be away from rotating parts and overhead equipment activities. 8.Follow
instructions of escorts 9.Handrails on stairs

Don’t s: 1.Loose clothes 2. Bidi/ Cigarettes/Matchbox/Gutkha pouch/Drugs. 3.

Photography and video without prior permission 4. Entry into prohibited
/cordoned off areas 5 Crossing of railway track during movements indicated by
railway siren & red lamp 6. Crossing near mobile equipment 7. Avoid using
mobile phones while walking on road, in critical areas & at height In case of
Emergency or Fire: 8. Code of Siren –Intermittent sound for Emergency &
Continuous for all clear 9. Just move to nearby SAFE ASSEMBLY POINT and
stay there till All Clear signal 10. Move perpendicular to the direction of gas
leakage as indicated by work sock. 11. Emergency contact numbers as below

Department service⇒ Local telephone number Fire Fighting : 101, 116, 5140
Safety : 117, 5140 Ambulance : 118

Visibly alerting people:

1. Safety reminder – Red colour flash lights

2. Road safety
3. Colour coding and direction of flow
4. Safe chlorine handling ( TLV – threshold limit value)
5. Good practice and safe chemical handling
6. Emergency preparedness
7. Barricade.
 16

GOOD QUALITY FIBRE:

G-10 Fibre Quality Parameters:

1. Spinning faults ( 2 or more filaments fuse)

2. Shirley faults

3. Denier

4. Denier % CV

5. Length

6. Conditioned tenacity

7. Colour/ whiteness

VISCOSE FIBRE PLANT (Power control-1):

Started before independence.

Turnover: 15,000

TPD 1, 56, 000

TPA 4,600

Employees 495Staff

Fibre: It’s a filament.

Ex: Cotton, Lenin, Silk, Wool – natural fibres

• Polyester, Nylon, Carbon, Acrylic –artificial fibres

• Viscose Fibre is a man-made fibre produced from wood.

• Soft wood: contains resin and calcium in less quantities.

 17

• Hard wood: contains resin and calcium in high quantities.

Reactions:

Viscose + Spinning bath -----> Fibre + Na2SO4 + CS2 + water + H2SO3,

H2S

Spinning: Change in form. (Chemical bonding) After spinning Staple fibre

division (related to length of the fibre)

Length of the filament may vary from 30 mm to 120 mm

GCF- GRASIM continuous Filter. In filtration process the material goes

through GSF 1, GSF 2

VISCOSE REACTION:

(C6H9O4-OH) n + n NaOH (C6H904-ONa) n + n H2O

Cellulose Alkali Alkaline Cellulose (C6H9O4-ONa) n + n CS2 -

(C6H9O4-ONaCS2) n Alkali Sodium Cellulose Xanthate

EXCEL FIBRE PLANT (Power Control-2):

Products: Excel Fibre

Standards: ISO 9000, OHS, MS 18001, EMS 3001, SA 8000

Man power:

ENGINEERS: 20
 18

CONTRACT LABORERS: 70

CONTRACT WORKERS: 120

Raw Materials: Pulp, NMMO,

PG Department: EXCEL FIBRE DEPT

DESCRIPTION OF THE PROCESS:

Pulper- A uniform proportion of NMMO and pulp is blended together. The mixing
time is critical. It takes about 30-35 minutes and produces approximately 2000 ltrs
of cellulose. For the mixture, the ratio is also significant. It is transferred from the
pulper to the hopper for measurement.

WFE (Wiped Film Evaporator):The main phase in fibre synthesis is called the
WFE (Wiped Film Evaporator). It is the centre of the manufacturing facility. It
transforms the material into a 600–700 psi viscous liquid dough from pulp. This
technique recovers 64% of the NMMO. It happens in a 650 mm/Hg vacuum.

PROCESS OF SPINNING:

The mixture serves as the spinning process' raw material. After the mixture has
gone through filters, this procedure occurs. They go via a water filter. NMMO is
recovered using the leaching process.

Jet room: The hub of the spinning process is the jet room. It comprises of
ring-shaped structures with roughly 6000–7000 holes that are 60 microns in size.
This room is where the fibre is transformed into filaments.

Squeezing process: Water is added to the filaments before they are squeezed
between two cylindrical rollers that have a vacuum system built into them. This
causes the filaments to adhere to the outer surface of the rollers. They are set up in
 19

a different order. The filaments are cleaned of a solution of water and NMMO.
This method eliminates the residual NMMO.

AFTER-TREATMENT- The residual NMMO is removed from the mixture by

passing it through rollers after being washed with ordinary water. The filaments
are run through chlorine in the bleach wash zone to make them more white.

Soft Finish Zone:To boost its OPU (Oil Pickup Unit), the filaments are then
combined with soft finish.

The water is subsequently removed from the filaments, leaving them with a water
content of 11–12%, by passing them through dryers operating at 120–30°C. The
procedure of bailing is then applied to the filaments.

BALING PRESS-In order to lessen the fiber's density and make it more
transportable, the fibre is compressed into a cuboidal shape.

CS2/H2SO4 PLANT (Power Control-3):

CS2 Plant:

This plant produces carbon disulfide. Each of the 16 furnaces generates 5

Tonnes each day.

Charcoal (cylindrical shape) and molten sulphur are the raw materials used.
 20

The first phase in the combustion process is the burning of charcoal. A

14-meter-long bed is made from burned charcoal.

This is an endothermic reaction. The bed is heated for two days using the
power source before the process begins.

Graphite electrodes and transformers are positioned in a pattern at the top and
bottom of the structure.

Sulphur will fall into the bed due to the force of gravity.

Condensers are used to transform the gaseous CS2 that is produced during
the manufacturing process into the liquid form.

There are two condensers for each furnace in series.

Condenser 1: Normal water is used to lower down the temperature

Condenser2: Cold water is used which is at a temperature of 5- 6 O C

There is one REFINERY ARRANGEMENT that involves repeatedly heating

and condensing CS2 in order to get rid of the sulphur fumes and H2S that are
produced by the reaction.

At this point, the produced CS2 is transferred into storage tanks where it is
kept in liquid form.
 21

SO2 & H2SO4 Plant:

❖ There are 4 Sulphuric acid plants which individually produce 90 tonnes

per day.

❖ DCDA stands for "Double Contact Double Absorption," which describes

the method that is utilised in the production of H2SO4.

❖ Raw materials used are Sulphur in liquid form and Oxygen in dried form.

❖ S + O2= SO2

❖ This reaction is a highly exothermic reaction. The heat generated is used

to produce steam.

❖ Steam jacketed lines are used to keep sulphur in molten form. 12

❖ Furnace temperature is maintained at 1000O C.

❖ Excess reactant Oxygen is used for controlling the reaction.

❖ SO2 + Excess oxygen SO3

❖ Catalyst V2O5 is provided through 5 beds, each having capacity 250 kg.

❖ The temperature will drop from 1000o C to 500 o C.

❖The absorption of SO3 takes place in two different tanks called the Initial
Absorption Tank (IAT) and the Final Absorption Tank (FAT), and in both
tanks there is a flow of countercurrent.
 22

❖ In both the tanks, the reaction taking place is as follows: H2SO4 + SO3
H2S2O7 (Oleum)

❖ After dilution Oleum is converted to H2SO4

❖ The Oxygen is taken from air for this process, so it is sent through
DRYING TOWER to remove water vapour.

❖ In the furnace H2SO4 (liquid form) flows from top to bottom and gases
flow from top to bottom to top

.❖ HGF (hot gas filter) is a bed of Quartz crystal that removes dust particles
from air.

❖ FBME (fibre bed mist eliminator) is used to remove water vapour from
oxygen, SO2, SO3.

❖ Fleming’s process : SO3 + H2O H2SO4 This reaction is highly

exothermic and uncontrollable
 23

Flow Process :

1. Sulphur pit –molten sulphur.

2. The blower should draw in oxygen.

3. The drying towers remove oxygen from the air.

4. The subsequent stage is to heat the HGFs of the furnace using diesel as the
heating source. The flow of hot gases continues for at least 48 hours, or until
the temperature reaches 150 to 200 degrees Celsius. After then, the flow of
diesel should be stopped, and the flow of molten sulfur should be started.

5. After being burned with oxygen, sulphur is sent to the BOILER, and then it
is sent to the BYPASS TOWER.

6. The BYPASS TOWER has two different inlet lines: one contains gas that
is 500 degrees Celsius, and the other has gas that is 1000 degrees Celsius.
The temperature of the mixture that results from combining the two is 650
degrees Celsius.

7. The following stage is the CONVERTER, which consists of four to five

beds of catalyst and subsequently sends the product to the Initial Absorption
Tower.

8. It comprises of a circulation tank along with control valves that regulate

the concentration as well as the quantity of acid that is contained in the tank.
The set point for the strength is between 98.5 and 99.5.

9. The final absorption tower also participates in the same manner as the
others.
 24

10. There is one plate heat exchanger, often known as a PHE, for the purpose
of heat exchange. It is arranged with fire bricks inside of it. • Excel fiber is
the third generation of optical fiber, while VSF is the traditional type. • Pulp
and NMMO (n-methyl morphine oxide) are the two raw materials that are
used. • At the excel fiber facility, the production of fiber takes only 5–6
hours, whereas the production of VSF takes 48 hours.

THERMAL POWER PLANT:

• Water that has been demineralized at the DM PLANT (and hence contains
no rust) is next heated in a BOILER.

• After that, it is delivered to the DEERATOR, which is a device that

separates gases from water. In order to prevent the water inside this tank from
turning into steam, the pressure is kept at 110 Hg/mm at all times.

• After that, it is processed by the FP, and after that, it is processed by the
ECONOMIZER. This area has a pressure that is kept at 66 kilogrammes, and
waste gases are routed through an economizer in the form of a pipe for the
purpose of heat exchange.

• After that, it goes through the boiler's WATER WALLS before going into
the STEAM DRUM of the boiler. This is where the temperature is changed.
Following this, the steam travels via the SUPER HEATER, and then it is sent
to the TURBINE. The pollutants in the steam are removed in the STREAM
DRUM of the BOILER, which is located within the BOILER. The RPM of
the TURBINE is set to 1000.

The following are the steps that take place during the energy conversion:
 25

1.Thermodynamic Forces The Energy of Mechanisms Electrical Energy

2.When the TURBINE is rotated at 126 spins per hour at a pressure of 60

kilogrammes, this plant is capable of producing 30 megawatts (MW) of
power.

3.The frequency is 50 hertz, and the voltage is 6.6 kV.

4.EXCITER is utilised in the construction of the Initial Voltage.

 26

3. Manufacturing of Viscose Staple Fibre

Introduction to Viscose Staple Fibre:
Viscose Staple Fibre (VSF), also known as rayon, is a type of man-made fiber
that is derived from natural materials. It is a versatile and widely used fiber in
the textile industry due to its desirable properties and wide range of
applications. Viscose staple fibre is made from cellulose, which is obtained
from wood pulp or other plant-based sources.It is considered a sustainable
and eco-friendly fiber because it is made from a renewable resource and is
biodegradable. VSF offers various desirable properties such as fluidity, lustre,
softness, drape, and comfort, making it suitable for a wide range of garments.
It is particularly known for its excellent feel against the skin and its ability to
create soft drapes.

Originally, viscose was referred to as "artificial silk" due to its resemblance to

silk and its lustrous appearance. Later on, it was named rayon to highlight its
brightness and structural similarities to cotton. Viscose falls into the category
of manufactured regenerated cellulose fibers, which means it is neither
entirely natural (like cotton, wool, or silk) nor fully synthetic (like nylon or
polyester). Instead, it occupies a middle ground between these two categories.

Viscose staple fiber is composed of natural cellulose polymers, typically

derived from cotton linters or wood pulp. The raw material is often sourced
from spruce and pine trees. The staple fiber form refers to fibers that are
relatively short in length, as opposed to continuous filaments. VSF staple
fiber contains around 11-13% moisture and a finishing agent to enhance its
properties.
 27

Additionally, viscose staple fibre can be easily blended with other fibers such
as cotton, polyester, or wool to enhance its properties or create unique fabric
blends. It can be dyed in a wide range of colors and exhibits good color
retention. Viscose staple fibre is also known for its versatility, as it can be
used in various textile applications, including apparel, home textiles, and
non-woven products.

As of the business year 2019, Grasim Industries, a company involved in the

production of VSF, is undergoing a capacity expansion at one of its plant
locations. This expansion aims to increase their current capacity from
566,000 metric tonnes per annum (KTPA) to 788,000 KTPA.

Processing Steps Involved in

Manufacturing of Viscose Staple Fibre:
 28

● Steeping: Cellulose pulp is immersed in 17-20% aqueous sodium

hydroxide at a temperature of 18-25°C in order to swell the cellulose
fibres and to convert cellulose to alkali cellulose

● (C6H10O5)n + n(NaOH) ⟹ (C6H9O4ONa)n + nH2O

● Shredding: The pressed alkali cellulose is shredded mechanically to

yield finely divided; fluffy particles called crumbs. This step
provides increased surface area of alkali cellulose, thereby
increasing its ability to react in the steps that follow.

● Ageing: The viscose solution is allowed to age or ripen for a specific

period of time. During this aging process, the viscose undergoes
chemical changes that improve its spinning properties and result in
better-quality fibers. The alkali cellulose is aged under controlled
conditions of time and temperature (between 18 and 30°C) in order
to depolymerize the cellulose to the desired degree of
polymerization. In this step the average molecular weight of the
original pulp is reduced by a factor of two or three. Reduction of
cellulose is done to get a viscose solution of right viscosity and
cellulose concentration.

● Xanthation: The alkali cellulose is further treated with carbon

disulfide to create a yellow-orange solution called cellulose
xanthate. This reaction is known as xanthation and involves mixing
the carbon disulfide with the alkali cellulose under controlled
conditions. In this step the aged alkali cellulose crumbs are placed in
vats and are allowed to react with carbon disulphide under
controlled temperature (20 to 30 °C) to form cellulose xanthate.

● Dissolving: The yellow crumb of cellulose xanthate is dissolved in

aqueous caustic solution. Because the cellulose xanthate solution (or
more accurately, suspension) has a very high viscosity, it has been
termed “viscose”.
 29

● Ripening: The viscose is allowed to stand for a period to “ripen”.

Two important processes occur during ripening: Redistribution and
loss of xanthate groups. The reversible xanthation reaction allows
some of the xanthate groups to revert to cellulosic hydroxyls and
free CS2. This free CS2 can then escape or react with other hydroxyl
on other portions of the cellulose chain. In this way, the ordered, or
crystalline, regions are gradually broken down and a more complete
solution is achieved. The CS2 that is lost reduces the solubility of
the cellulose and facilitates regeneration of the cellulose after it is
formed into a filament.

● Filtering: The viscose is filtered to remove undissolved materials

that might disrupt the spinning process or cause defects in the rayon
filament

● Degassing: Bubbles of air entrapped in the viscose must be

removed prior to extrusion or they would cause voids, or weak
spots, in the rayon filaments.

● Spinning: Production of Viscose rayon filament

● The conversion of the viscous solution into the solid fiber is

generally referred to as spinning. The spinning of viscose fibre
consists of extrusion, coagulation, stretching, and take-up or
collection.

● Drawing and Drying: The washed and bleached viscose fibers are
then drawn to align the individual fibers and improve their strength
and uniformity. Drawing involves passing the fibers through sets of
rollers at different speeds. After drawing, the fibers are dried to
remove moisture and prepare them for further processing or
packaging.
The rayon filaments stretch while the cellulose chains are still relatively
mobile.
 30

Efficiency of Biological Reactors

Introduction: Biological Reactors

A "bio-reactor" or "biological reactor" refers to a system that utilizes

microorganisms to break down contaminants present in water. These
bioreactors are commonly employed in wastewater treatment processes. The
contaminated water is circulated within an aeration basin, where
microorganisms break down organic substances, leading to the formation of a
sludge that can be disposed of or recycled. Another type of bioreactor
employs a rotating biological matrix, where microorganisms grow on a
rotating matrix within the reactor. Additionally, there are bioreactors that use
a packed bed approach, where a tank is filled with a support medium that
offers a large surface area for microbial growth.
Among the various types of bioreactors, membrane bioreactors (MBRs) are
specifically utilized for wastewater treatment. An MBR serves as the initial
stage in a biological process, employing microbes to degrade pollutants,
which are subsequently filtered through a series of submerged membranes.
MBRs combine suspended growth biological treatment methods, typically
activated sludge, with membrane filtration equipment, such as low-pressure
microfiltration (MF) or ultrafiltration (UF) membranes. These membranes
effectively separate solid particulate matter from the liquid phase. To
generate activated sludge, secondary and tertiary clarifiers are employed in
the process.
 31

There are two types of MBR systems:

1. Vacuum (or gravity-driven) systems are immersed and typically use hollow
fibre or flat sheet membranes fitted in either the bioreactors or a subsequent
membrane tank.
2. Pressure-driven systems: These are in-pipe cartridge systems that are
positioned outside of the bioreactor.

Advantages of an MBR:
1. It is typically 30-50% smaller than a conventional active sludge operation
of comparable size.

2. The technique also yields high effluent quality, capable of meeting the
most demanding water quality standards.

3. It has a modular design that facilitates expansion and configuration

flexibility.

4. Reducing the need for downstream disinfection.

 32

Classification of Biological Reactors:

There are five classifications depending on various factors and bioreactor

needs, methods, and so forth.

I.Biological reactors are easily categorized into three types depending on

their oxygen and stirring requirements.

1. Non-stirred, non-aerated bioreactors: These are used to produce traditional

products such as wine, beer, and cheese.

2. Non-stirred aerated reactors: These are quite unusual.

 33

3. Stirred and aerated reactors: These are commonly employed for the
generation of metabolites that necessitate the growth of bacteria that demand
oxygen. This type of bioreactor is used in the majority of contemporary
approaches.

Bioreactors are categorized into three kinds based on their way of operation.

1. Batch reactors: These are typically employed when a corporation want to

manufacture a variety of products using various reactants and reactor settings.
They will subsequently be able to use the same equipment for these reactions.
Colorants and margarine are two examples of processes that utilize batch
reactors.A typical batch reactor is made up of a tank in which chemical
reactions take place. An agitator and an internal heating or cooling system are
also included in these tanks. Tank capacities range from one to 15,000 litres.
 34

2. Fed batch: During culture, one or more nutrients (substrates) are fed
(provided) to the bioreactor, and the product(s) remain in the bioreactor until
the conclusion of the run.Fed-batch fermentation is used in the accumulation
of non-growth-associated products, such as antibiotic synthesis, where a high
concentration of cells is required prior to the switchover of the cells'
metabolism for product generation in the stationary phase.The key benefits of
the fed-batch fermentation operation system are control of microbial growth
rate, bioactive metabolites, and oxygen transfer limiting by inlet feeding rate.
 35

3. Continuous:The primary distinction between batch and continuous culture

is that batch culture is a closed system that performs fermentation with a
fixed amount of nutrients, whereas continuous culture is an open system that
does fermentation continually.Continuous reactors (also known as flow
reactors) transport material in the form of a continuous stream. Continuous
feed of reactants into the reactor results in a continuous stream of product.
Continuous reactors have the potential to be many times more productive
than batch reactors. This is partially because the reactor does not have to be
shut down as frequently, and it is also because the growth rate of the bacteria
in the reactor can be more readily controlled and optimized.

Based on the method of microbial growth, bioreactors can be classified into

two types:
Suspended-growth bioreactors: In suspended-growth bioreactors,
microorganisms are kept in suspension by continuously mixing the reactor
through pneumatic aeration or mechanical agitation. Within these bioreactors,
the microorganisms form floc particles ranging from 50 to 200 µm in
diameter. These floc particles are conglomerates of microorganisms held
together by polysaccharides and proteins.
 36

The aquaculture industry considers two main configurations of

suspended-growth bioreactors:
a) Sequencing batch reactors (SBRs): SBRs operate through several stages as
follows:

Fill stage: The SBR is filled with "dirty" wastewater, which may be pumped
or allowed to flow by gravity. Bioflocs from the previous batch cycle are
already present in the bioreactor.
Reaction stage: The "dirty" wastewater is mixed with the existing bioflocs
until specific treatment objectives, such as achieving more than a 90 percent
reduction in nutrients, are met.
Settling stage: The mixing cycle is stopped, allowing the bioflocs to settle out
of the quiescent water column.
Decantation stage: Treated "clean" wastewater is extracted from the
bioreactor while leaving the settled bioflocs behind.

b) Membrane batch reactors (MBRs):The operation of a

membrane batch reactor is similar, but instead of using settling
and decantation stages, the well-mixed bioflocs and treated
wastewater are separated from each other using a membrane
or filter.
 37

1. Immobilised cell bioreactors: Cell immobilisation is a biotechnology

technique in which cells, such as animal and plant cells, are immobilised by
fixing them in a suitable matrix.Immobilised cell systems are relevant to
fermentation because of the advantages that immobilised cells have over
freely suspended cultures in terms of reactor performance, easy separation of
the biomass from the liquid and easy product recovery, and specific
metabolic improvements or products created during immobilisation.
Large scale immobilised bioreactors are utilised for commercial metabolite
production. They are as follows:
 38

Moving bed or moving bed biofilm reactor

(MBBR)
 39

2. Fibrous bed

3) A packed bed refers to a container, such as a hollow tube, pipe, or vessel,

that is filled with a packing material. This packing material can consist of
small objects like Raschig rings or a specifically designed structured packing.
Packed beds may also include catalyst particles or adsorbents such as zeolite
pellets or granular activated carbon.
The main purpose of a packed bed is to enhance contact between two phases
in a chemical or similar process. Packed beds find applications in various
processes, including chemical reactors, distillation processes, scrubbers, and
even heat storage in chemical plants. In heat storage applications, for
instance, hot gases are allowed to escape through a vessel packed with a
 40

refractory material until the packing becomes hot. Subsequently, air or

another cool gas is circulated through the hot bed, pre-heating the air or gas.

4. Membrane BioReactor:MBR processes can produce effluent of high

quality enough to be discharged to the coastal, surface, or brackish
waterways or to be reclaimed for urban irrigation. Other advantages of MBRs
over conventional processes include small footprint, easy retrofit, and
upgrading old wastewater treatment plants.

IV. Based on the microbial agent used, bioreactors can be categorized into
two types:
Those based on living cells: These bioreactors utilize living cells as the
microbial agent for various processes. The cells can be immobilized or freely
suspended within the reactor.

Bioreactors employing enzymes: In these bioreactors, enzymes are used as

the microbial agent instead of living cells. Enzymes play a crucial role in
catalyzing specific biochemical reactions.
V. Based on the process requirements, bioreactors can be classified as
follows:
Aerobic bioreactors: These bioreactors facilitate aerobic fermentation
processes. They require adequate provisions for sterile air supply and
mechanisms for stirring and mixing the medium and cells. Two common
types of aerobic bioreactors are:

a. Stirred tank bioreactor: This conventional mixing reactor is typically

constructed from glass or stainless steel. The stirrer can be positioned at
either the top or bottom of the reactor. The dimensions of the reactor depend
 41

on the amount of heat that needs to be removed. Baffles in the center of the
tank prevent vortex formation and ensure effective mixing of the ingredients.
Continuous stirred-tank reactors (CSTRs) are a common example of this
type.

b. Air lifts: These bioreactors are either closed-type or batch reactors. In

some cases, continuous flow reactors are also employed.

Anaerobic bioreactors: These bioreactors are designed for anaerobic

fermentation processes, where aeration is not necessary except during the
initial preparation of inoculums. Once fermentation begins, the gas released
from the media provides sufficient mixing. In enzyme production, strict
anaerobic conditions are required for recovery, as the presence of oxygen can
adversely affect enzymatic activity.

Solid-state bioreactors: Solid-state fermentation (SSF) is a method used in

various industries, such as pharmaceuticals, food, and textiles, to produce
metabolites using a solid support instead of a liquid medium. SSF involves
the growth of microbes without a free-flowing aqueous phase. Solid-state
bioreactors, such as rocking drums, stirred aerated systems, and rotating
drums, are commonly used in SSF processes. SSF offers advantages such as
lower water usage and higher volumetric productivity compared to
liquid-based fermentation methods.
 42

4. Wastewater Chemical Treatment

Chemicals are employed in a variety of wastewater treatment techniques to
improve water quality. Chemical unit processes are chemical processes that
cause chemical reactions and are used in conjunction with biological and
physical cleaning processes to achieve specific water standards.
Chemical treatment employs methods that involve the addition of chemicals
or other chemical reactions to remove or convert pollutants.
The most typical examples of wastewater treatment are precipitation,
adsorption, and disinfection:

● Neutralization

● Chemical Precipitation

● Coagulation and Flocculation

● Reduction and Advanced Oxidation Process(AOP)

● Ion Exchange

● Chemical Adsorption

Neutralization
When a waste stream is discovered to be dangerous due to corrosivity,
neutralization is the primary treatment method. It is utilized as a
pretreatment system prior to biological, chemical, and physical
treatment operations.

It is the process of changing the pH of water by adding an acid or base

based on the target pH and process requirements. Some activities, such
as boiler operations and drinking water requirements, require pH 7
neutral water.
 43

Wastewater is often regarded as neutralized

● if it causes minimal harm to metals

● concrete, or other materials
● has little impact on fish and aquatic life, and has no impact on
biological matter, i.e. biological treatment systems.

Parameters which affect Neutralization

● pH

● Acidity/Alkalinity

● Hardness

● Buffers

Precipitation
Precipitation is a method of eliminating dissolved metals from hazardous
effluent. A precipitation reagent is used to turn the dissolved metal into solid
particles. A chemical reaction happens when dissolved metals solidify.
 44

To remove the particles from the mixture, filtration can be utilized. The
efficiency of the process is determined by the metals present, their
concentration, and the reagent utilized.

In hydroxide precipitation, for example, calcium or sodium hydroxide is used

as a reagent to produce solid metal hydroxides.

Coagulation
Because the settling velocity of very small suspended particles in wastewater
is relatively low, sedimentation cannot remove them.Fine colloidal or
scattered particles carry electric charges and move in a state known as
Brownian Motion.

Using coagulation and flocculation, very small suspended particles can be

eliminated by increasing their size. Certain chemical compounds are added to
the wastewater, resulting in the formation of a gelatinous precipitate known
as Floc after complete mixing. They then settle after passing through a
sedimentation tank.
 45

It takes place in very fast rapid mix or flash mix basins.A quick mix basin's
principal duty is to spread the coagulant so that it contacts all of the
wastewater.

Coagulation Principle
Individual particles mix in coagulation. When a coagulant is employed in
water, it produces a spongy gelatinous precipitate that absorbs and binds tiny
sized particles in the water. The entire process results in bigger particles that
are heavier and settle more easily.

Common Coagulant Properties

● React Quickly

● Electrolyte

● React in larger pH range

● High variance ions for high efficiency

Various compounds have been utilized as coagulants over the years.

The most common examples are:

● Alum (Al₂(SO₄)₃)

● Ferrous Sulfate (FeSO₄.7H₂O)

● Lime (Ca(OH)₃)

● Ferric Chloride (FeCl₃)₉

● Ferric Sulfate(Fe₂(SO₄)₃)
 46

A significant portion of the job focuses on wastewater treatment to

guarantee that the environment is harmed as little as possible.

Aside from the ways of wastewater treatment indicated above, there are
also approaches to improve the effectiveness of the treatment with
the necessary modifications.

A few strategies for increasing the efficacy

of wastewater treatment:

1. Reduction and Advanced Oxidation Process(AOP)

In this procedure, an oxidizing agent is provided during chemical
oxidation such that electrons flow to the pollutants from the oxidant,
causing structural changes in the pollutant and making it less
damaging. AOPs rely on the generation of highly reactive hydroxyl
radicals (•OH) in situ. These reactive species are the most powerful
 47

oxidants in water, capable of oxidizing practically any component

present in the water matrix, frequently at a diffusion-controlled
reaction speed.

This approach has the following advantages:

1. It aids in the removal of organic molecules generated as a result of

chemical oxidation.

2. Chlorinated pesticides are eliminated effectively from wastewater.

3. It destroys pharmacological compounds in water, such as antibiotics

or cytostatic medicines.

4. Disinfection can be performed in some AOP designs, making these

AOPs an integrated solution to some water quality problems.

5. Because H2O is the entire reduction product of •OH, AOPs do not

theoretically introduce any additional harmful chemicals into the
water.

The disadvantages of this strategy are as follows:

 48

1. The main disadvantage of this technology is that it is quite expensive

due to the continual input of expensive chemical chemicals for the
operation.

2. The procedure is technically difficult.

3. Unsuitable for huge amounts of water and only viable at the end
stage (i.e. after primary and secondary treatment).

Moving on to another technique,

2. Demineralization/Ion Exchange Method

This technique is used to soften hard water containing calcium and
magnesium ions. The cleaning process is less effective when the
water is hard.

Positively charged sodium ions are liberated in hard water in the form
of brine solution (NaCl + water) in this process. Sodium ions take
the place of hard calcium and magnesium ions.
 49

This approach has the following advantages:

1. There is no penetration of substances into the soft water.

2. Heavy metals can be recycled.

3. It is a highly effective method of water softening.

Adsorption via Chemi

Chemi Adsorption refers to the process of adsorption that occurs as a result
of the creation of a chemical bond between the adsorbent and the material.

This differs from physical adsorption, in which adsorption takes place.

Because of the Van der Waals forces between the adsorbent and the material.

In chemical wastewater treatment, activated carbons are utilised as

adsorbents.They bind to soluble components in water that were not
eliminated during the previous phases of treatment.

Colorants used in textile dyeing, as well as medicinal residues such as arsenic

and heavy metals, are examples of compounds that can be eliminated using
this procedure.
 50

COD and BOD Levels for June 2023

❖ The maximum limit for COD level in Grasim Industries, Nagda is 250
cpm.
❖ The maximum limit for BOD level in Grasim Industries, Nagda is 30
cpm.
❖ Generally COD ∝ BOD.
 51

ROLE of ARTIFICIAL
INTELLIGENCE in ETP
Prediction of effluent concentration in a wastewater
treatment plant using machine learning models
The integrated treatment of food waste and wastewater has been identified as
an effective method of waste management. However, high levels of food
waste can lead to a concentrated amount of total nitrogen (T-N), negatively
impacting the quality of effluent water in conventional wastewater treatment
processes. This study aimed to establish two machine learning models,
artificial neural networks (ANNs) and support vector machines (SVMs), to
predict 1-day interval T-N concentration of effluent from a wastewater
treatment plant in Ulsan, Korea. Daily water quality data and meteorological
data were used to evaluate the performance of both models in terms of the
coefficient of determination (R2), Nash-Sutcliff efficiency (NSE), and
relative efficiency criteria (drel). Sensitivity analysis and model parameter
optimization were conducted using Latin-Hypercube one-factor-at-a-time
(LH-OAT) and a pattern search algorithm. Results showed that both models
effectively predicted T-N concentration of effluent in 1-day intervals. SVM
model demonstrated higher prediction accuracy in the training stage and
similar results in the validation stage. Sensitivity analysis demonstrated that
the ANN model was superior in predicting T-N concentration in 1-day
intervals due to its ability to establish a cause-and-effect relationship between
T-N concentration and input values. This study suggests a robust nonlinear
time-series modeling method for predicting water quality in integrated food
waste and wastewater treatment processes.FOR MORE INFORMATION
REFER TO
https://www.sciencedirect.com/science/article/abs/pii/S1001074215001278
 52

Forecasting of Wastewater Treatment Plant Key

Features Using Deep Learning-Based Models:
Wastewater treatment plants (WWTPs) can benefit from accurate forecasting
of key features, which can help with process design, system reliability, cost
reduction, and overall optimization. Deep learning technologies, particularly
proven data-driven soft-sensors, can be used for WWTP applications to
tackle non-linearity and the dynamic nature of environmental data. This study
aims to forecast WWTP key features, including influent flow, influent
temperature, influent biochemical oxygen demand (BOD), effluent chloride,
effluent BOD, and power consumption, using six deep learning models based
on long short-term memory (LSTM) and gated recurrent unit (GRU)
technologies. The models include traditional LSTM and GRU, exponentially
smoothed LSTM, and adaptive versions of LSTM and smoothed LSTM. The
smoothed LSTM technique is expected to reduce the outlier effect and
improve forecasting accuracy, while adaptive deep models enhance the
capabilities of LSTM to follow future data trends accurately and quickly. We
compared the performance of our models with Bi-directional LSTM
(BiLSTM) and the seasonal decomposition using local regression. We used
historical records from a coastal municipal WWTP in Saudi Arabia to verify
the effectiveness of our models. Our proposed models provide promising
forecasting results without requiring assumptions on data distributions. In
terms of efficiency, GRU-based models converge faster than LSTM-based
models. In terms of accuracy, the LSTM soft-sensor shows overall optimal
results for all key features, followed by the exponentially-smoothed GRU and
LSTM. However, the adaptive models achieved the lowest forecasting
performance compared to other models. These findings will benefit
practitioners in achieving data-driven WWTP management.FOR MORE
INFORMATION REFER
TOhttps://ieeexplore.ieee.org/abstract/document/9222127
 53

Comparative study on total nitrogen prediction in

Effluent treatment plant and effect of various feature
selection methods on machine learning algorithms
performance
Predicting wastewater characteristics in wastewater treatment plants
(WWTPs) can reduce the number of samples needed, as well as energy and
costs. To improve prediction accuracy, Feature Selection (FS) methods are
used in the pre-processing stage. This study evaluates the impact of seven FS
methods (filter, wrapper, and embedded methods) on predicting total nitrogen
(TN) in the WWTP influent flow. Four scenarios based on FS
recommendations were defined and compared using three supervised
Machine Learning (ML) algorithms: Artificial Neural Network (ANN),
Random Forest (RF), and Gradient Boosting Machine (GBM). Input
parameters, including daily time-series data for pH, DO, COD, BOD, MLSS,
MLVSS, NH4-N, and TN concentrations, were used. The dataset was divided
into train and unseen test datasets, and the performance of all models was
evaluated based on Root Mean Square Error (RMSE), Mean Absolute Error
(MAE), and correlation coefficient (R2). Results show that scenario IV,
suggested by Mutual Information, including NH4-N, COD, BOD, and DO,
produced the best results compared to other FS methods. Furthermore,
decision tree algorithms (RF and GBM) showed better performance than the
neural network algorithm (ANN). GBM effectively predicted the dataset
patterns and produced the best performance on the unseen dataset,
demonstrating the effectiveness of this state-of-the-art ML algorithm for
predicting wastewater components.FOR MORE INFORMATION REFER
TOComparative study on total nitrogen prediction in wastewater treatment
plant and effect of various feature selection methods on machine learning
algorithms performance - ScienceDirect
 54

Analysis of the potential environmental impacts of

effluent discharge.

To ascertain whether or not the effluent discharge is threatening to the

environment, it is necessary to mimic the environmental conditions and
analyse the potential consequences of the discharge. For this, several
methods are adopted, the most common of which is mimicking
environmental conditions using fish ponds.

1) In this method, the fish pond is maintained close to the present

environmental conditions, and a sample size representative of
the marine life present in the nearby area is the unit of analysis.

2) Having treated the wastewater in the sedimentation tank, a part of it,

proportional to the discharge and the size of nearby water bodies, is sent
to the fish pond, where the levels of various substances present in the
effluent and the effluent's properties such as temperature, etc. are
measured.

3) If a significant amount of damage is observed to the fish pond or the

fish present inside, the effluent is further treated to remove the
damage-causing substances or properties.

4) Here, not only the damage arising out of the quantities of substances
present in the effluent is seen, but the damage arising out of the effluent's
attributes such as relative density, temperature, etc. can also be seen.

5) The method is important in community medicine as well, considering

that industrial discharge and its effects on marine life have also affected
the nearby human population. Some noteworthy instances include the
Minamata disease, caused by the consumption of
methylmercury-poisoned fish, and the Itai-Itai disease, arising out of the
 55

consumption of Cadmium-contaminated paddy and water. It is

noteworthy that heavy metals are among the most common
contaminants in water.

6) The method is also useful as it can also be used to study ecology by

knowing the interdependence of various marine lifeforms on each other,
thereby letting us know the significance and functions of each trophic
level in sustaining the marine ecosystem. Furthermore, this lets us
understand the impact of marine life on other ecosystems, such as the
organisms dependent on water bodies and the organisms present in the
water bodies.

7) To make sure that the method is effective, several factors have to be

effectively modelled.

(a) The fish pond should have conditions representative of the nearby
water bodies.

(b) The fish varieties chosen must be such that they experience effects
similar to humans when exposed to pollutants such as biological
pollutants (pathogens), organic pollutants, chemical pollutants, and other
pollutants such as temperature, etc. Some fish variants are unaffected by
certain kinds of bacteria as they enter a symbiotic relationship with such
variants of fish. However, such bacteria affect humans, so this should be
kept in mind. For instance, though E. Coli exists as a symbiote in the
human intestine, its excess can cause bloody diarrhoea, kidney failure,
etc. However, fish variants are in a symbiotic relationship with E. Coli
and only experience its indirect effects, such as increased BOD
(Biological Oxygen Demand) in the water body. Also, E. Coli seldom
has a direct effect on fish, as fish variants are usually not warm-blooded.
Therefore, the indirect effects should be closely monitored.
 56

(c) The fish population should be large enough so that it constitutes an

effective sample size.

(d) The effects of the effluent's attributes as pollutants should also be

considered. For example, if the effluent's discharge temperature is
high, it may contribute to thermal pollution.

8) Sometimes, fish ponds are also used to remove certain

pollutants present in the effluent. For instance, in China, fish
are used to control algal growth arising from eutrophication.

9) Phytoplankton, though not fish, can also be used to produce oxygen

if there's not enough margin for planting trees near the industrial plant
if the industrial expansion is not in compliance with the current
emission norms (it may have been in compliance with the earlier
norms before the expansion).

Thus, fish pond analysis is a cost-effective method to ascertain the

environmental consequences of effluent discharge.

Figure-1: Schematic Diagram (SEDIMENTATION TANK)

 57

Other Methods

To assess the potential environmental impacts of effluent discharge, some other methods are also
employed. Out of the available methods, a choice is made based on considerations such as the
nature of the industry, its scale of production, its location, the cost of determination, etc.

Some of the methods employed are as follows:

1. Titration Method

In this method, the effluent is titrated so as to ascertain the amount of impurities or

harmful substances present in the effluent. Sometimes, the titrations themselves are used
to remove the harmful substances.

For Instance, EDTA (Ethylenediaminetetraaceticacid) is used to remove Lead (Pb) from the
effluent.
Lead is highly toxic. Its upper prescribed level in drinking water is 50 parts per billion
(ppb). Lead poisoning affects the kidney, liver, reproductive system, etc.

The titration results in the formation of a coordination compound. Due to being hexadentate,
EDTA is an excellent chelating agent. It forms a stable complex upon its reaction with Lead,
thereby preventing
Lead poisoning.

Not only is the titration used to ascertain the amount of lead, but it is also used to
remove Lead from the effluent, if its amount is found to be above the tolerable limit.

Similarly, in conductrometric titrations, the effluent is tested for its conductivity, thereby
giving an idea of the nature and the amounts of various substances present, thereby
facilitating the ascertainment of the potential environmental impacts of the effluent’s
discharge.
 58

To ensure that the titration process is effective, an appropriate type of titration must be chosen,
depending on the nature of the suspected harmful substances. Furthermore, an effective indicator
must be chosen, and the endpoint must be carefully determined so as to accurately estimate the
amount of the harmful substance.

Note: Depending on the nature of the harmful substances, different titrants may have to be
used, which may render the method expensive.

2. Reagent Method

This method is subtly different from the Titration method. It also involves the addition of
substances to remove, nullify or modify the harmful substances or attributes present in the
effluent. However, here, the ascertainment of the harmful properties or substances is not
necessarily done by the titration method.

To confirm the presence of the harmful substances, appropriate reagents are added so as to
cause observable changes in the effluent or its properties, thereby facilitating the
ascertainment of the potential environmental impacts. This method is also used to treat the
effluent, if it contains harmful substances or properties.

For instance, living systems are sensitive to pH variations and can sustain themselves within a
narrow pH range. Despite the wastewater having been treated in the prior stages, the effluent
may have an unsafe pH. Its nature can be ascertained by pH-sensitive indicators. E.g., Methyl
Orange turns red in acidic medium. Having determined
the effluent’s nature, its environmental impacts can be predicted. Furthermore, reagents such as
mild bases can be
added to alter the pH.

To ensure the method’s effectiveness, effective reagents must be added to confirm the presence of
the harmful
 59

substances and properties. Furthermore, effective reagents must be chosen to treat the effluent, if
required.

Note: Depending on the nature of the harmful substances and their properties, different reagents
may have to be used, which may render the process expensive.

Conclusion

In conclusion, it may be said that since the wastewater is treated before being discharged so as to
retain any useful or reusable substances it may contain, and primarily to minimise the negative
environmental consequences its discharge may have, it is required to implement cost-effective
methods to assess the potential ill-effects and take appropriate measures to manage them. Doing so
ensures sustainable development and ensures that no living organism is harmed, considering that
the lifeforms are interdependent for sustenance. The choice of method rests on several
considerations, such as the nature of the industry, its scale of production, its location, and the
associated expenses, etc.
 60

5. References
https://www.cdc.gov/ecoli/index.html
https://www.nationalgeographic.org/activity/
save-the-plankton-breathe-freely/
https://www.kanazawa-med.ac.jp/~pubhealt/c
admium2/itaiitai-e/itai01.html
https://www.env.go.jp/en/chemi/hs/minamata
2002/ch3.html
https://deq.utah.gov/water-quality/e-coli-faqs
https://www.envirotech-online.com/news/water-wastewater/9/breaking-news/fish-used
-to-improve-water-quality- in-china/8498
https://www.ncbi.nlm.nih.gov/books/NBK565883/
https://www.sciencedirect.com/topics/
chemistry/conductometric-titration
https://pubchem.ncbi.nlm.nih.gov/co
mpound/Methyl-orange
https://www.google.com/finance/quot
e/GRASIM:NSE?hl=en
https://www.grasim.com/about-us/stor
ies/grasim-csr-commitment-to-nagda
https://www.adityabirla.com/media/st
ories/75-glorious-years-of-grasim
https://sites.google.com/a/stu.ximb.ac.
in/grasim-industries/home/history
https://www.grasim.com/about-us/pla
nts
https://www.grasim.com/about-us/plants/nagda

https://indiancompanies.in/grasim-industries-limited-adithya-birla/
https://www.ndtv.com/business/stock/grasim-industries-ltd_grasim/reports
https://www.ndtv.com/business/stock/grasim-industries-ltd_grasim/reports-a
uditor-report
https://www.indiantextilemagazine.in/grasim-industries-terrace-bay-acquisiti
on-really-strategic-move/
https://indiancompanies.in/companies-by-number-of-employees-in-india-list /