UPGRADATION FOR 500KLD & 50 KLD STP PLANTS
HINDUSTAN ZINC LTD - DARIBA ( RAJASTHAN )
Hindustan Zinc Ltd
Location: Dariba Mines, Rajasthan
Project Overview
Hindustan Zinc Ltd. approached Soma Utilities for the upgradation and repair of their existing Sewage Treatment Plants (STPs) of capacities 500 KLD and 50 KLD at Dariba Mines. The primary concern was that the treated outlet water quality was not meeting CPCB discharge norms, leading to compliance and operational challenges.
Existing Issues Identified
After receiving the enquiry, our technical team conducted a detailed site visit and performance audit of both STPs. The following key issues were identified:
1. Improper Operation & Maintenance
- The STPs were not being operated as per design parameters
- Inadequate process control resulted in poor biological treatment efficiency
2. Mechanical & Process Equipment Failures
- Several pumps were underperforming and required replacement
- Air blowers were inefficient and not delivering the required airflow
- Diffusers were choked and damaged, leading to poor oxygen transfer
- Filter media in tertiary treatment units was exhausted and needed replacement
3. Lack of Advanced Tertiary Treatment
Existing treatment scheme was insufficient to consistently achieve CPCB norms Advanced technologies like Ultrafiltration (UF) and Ozonation were not present, which are essential for polishing treated sewage and ensuring consistent compliance
Client Satisfaction
Hindustan Zinc Ltd. expressed satisfaction with the timely execution, technical expertise, and achieved results. The successful upgradation ensured regulatory compliance, operational stability, and long-term reliability of the sewage treatment facilities at Dariba Mines.
Proposed Solution
Based on the findings, Gracelan Utilities proposed a comprehensive repair and upgradation plan:
Corrective measures in plant operation philosophy Replacement of faulty and undersized pumps, air blowers, diffusers, and filter media Design, supply, installation, and commissioning of a UF Plant for advanced tertiary filtration Introduction of an Ozonator system for final disinfection and reduction of residual COD, color, and odor Process optimization to stabilize biological treatment and improve overall plant performance
Scope of Work Executed
After receiving the order, our team mobilized immediately and executed the following:
Repair and replacement of mechanical equipment Restoration of aeration efficiency by installing new diffusers and optimizing airflow Replacement and recharging of filter media in tertiary filters Installation and commissioning of UF Plant Installation and commissioning of Ozonator Trial runs, performance monitoring, and operator training
Results Achieved
Post upgradation and stabilization, both STPs started performing efficiently and consistently. The treated outlet water quality was brought well within CPCB prescribed limits.
Key Outcomes:
- Stable and reliable operation of both 500 KLD and 50 KLD STPs Significant improvement in BOD, COD, TSS, and microbial parameters Treated water quality achieved below CPCB discharge norms Enhanced client confidence in plant performance and compliance
