ZLD Projects

Ranipet Tannery Effluent Treatment Company Ltd (RANITEC)

Mr. J.K. Dadoo, IAS, Joint Secretary, Department of Commerce & Industry, GoI	Dr. Amarjit Singh, IAS, Additional Secretary, Ministry of Water Resources, GoI
“Very well managed cluster with world class CETP facilities. True Example for Make in India”	“Hats off to the brave team of Shri Hashim and his colleagues for this path breaking work. It was a great pleasure to see Ranitec – the work of good corporate citizens”

Contact details of the CETP:
Ranipet Tannery Effluent Treatment Co. Ltd
Madras-Krishnagiri Bye Pass Road
VC Mottur, Vannivedu Post
Walajah – 632 513.
Telephone: +91-4172-272 653 / 270
Email: tranitec@rediffmail.com
Contact Person: Mr. C.M. Zafarullah, Managing Director, Mob: 94432 66175

PROJECT DETAILS

Ranitec CETP: Leading the Way in Sustainable Effluent Treatment

• About Ranipet's Tannery Cluster-Ranipet, an industrial hub 110 km from Chennai, is home to over 200 tanneries and 51 leather product units, generating an impressive annual export turnover of approximately Rs. 1000 crores.
• Ranitec CETP: A Model of Excellence-Ranitec CETP, the largest tannery effluent treatment plant in Tamil Nadu, treats 4000 m³/day and serves 77 member tanneries. Established in 1995, it has continuously received technical assistance from CLRI, NEERI, and UNIDO. The plant is managed by the Ranipet Tannery Effluent Treatment Company Limited, governed by an elected board of directors from its member tanneries.
• Zero Liquid Discharge (ZLD) Project-In 2008, Ranitec embarked on a ZLD project, positioning itself as a pioneer in sustainable wastewater management. Key components of the ZLD system include:
• CETP Upgradation- Enhanced collection and conveyance lines, new mixing and odor control systems, mechanical screen, pre-settler, and aeration tank, sludge dewatering, softening systems, and improved monitoring.
• RO System- Includes pre-treatment filtration, organic scavenger, ultrafiltration, two-stage reverse osmosis, and automated controls.
• Mechanical Evaporation of RO Reject- Features seven-effect evaporation with thermal vapor recompression and pusher centrifuge for salt separation.
• Salt Disposal Yard -Designed to store generated salt for two years at full capacity.
• Recovered Water Conveyance- Overhead tanks and piping systems to return treated water to tanneries, which are equipped with individual storage tanks.

The ZLD system also integrated effluent from nine tanneries connected to Meltec CETP, which now treats only leather board unit effluent. The Rs. 42 crore project was executed by Hydroair Tectonics PCD Ltd.

Operational Success and Expansion

Commissioned in 2012 and inaugurated by Shri E.M. Sudarsana Natchiappan in 2013, the Ranitec/Meltec ZLD system has been operating successfully. Ranitec has since added an automatic disc filter, upgraded aeration systems, and installed a third-stage High-Pressure RO system to optimize performance. Currently, Ranitec is expanding its capacity from 3000 m³/day to 4000 m³/day with a Rs. 17.84 crore project under the ASIDE scheme, including additional clarifiers, ozone treatment, and UF/RO systems.

Achievements and Training Initiatives

Ranitec CETP was the first leather sector CETP globally to achieve ISO 14001 certification and integrate with Tamil Nadu Pollution Control Board's "Care Air" system for real-time monitoring. CEMCOT has developed a comprehensive training curriculum for the ZLD system, ensuring Ranitec's technical team maintains high operational standards. Regular training sessions and refresher courses are conducted to uphold quality and efficiency.
Explore more about Ranitec CETP's journey towards sustainable and innovative effluent treatment solutions on our website.

Upgradation of ZLD System in Ranitec CETP

Proposal and Approval

In 2018, Ranitec CETP submitted a proposal to the Department for Promotion of Industry and Internal Trade (DPIIT) for the upgradation of its Zero Liquid Discharge (ZLD) system to reduce operational and maintenance (O&M) costs. This proposal was submitted under the Indian Footwear, Leather, and Accessories Development Programme (IFLADP) scheme.

Funding and Implementation

The proposal received approval, with DPIIT agreeing to fund 70% of the project costs. The remaining 30% of the funding was to be equally shared by the Industries Department of the Government of Tamil Nadu and the beneficiary CETP.

Key Components of the Upgradation

The upgradation includes:

- Enhanced ZLD Processes: Incorporating advanced technologies to improve efficiency and reduce costs.

- Cost Reduction Initiatives: Implementation of measures to lower the O&M expenses for the CETP.

- Sustainable Practices: Adoption of eco-friendly and sustainable practices to align with global environmental standards.

Ranitec CETP continues to lead the way in innovative effluent treatment solutions, ensuring environmental sustainability and cost-efficiency for the tannery sector in Ranipet.

The following key components were sanctioned by DPIIT under the IFLADP scheme for the upgradation of the ZLD system at Ranitec CETP, with their respective costs and 100 % completion status:

#	Name of the item as per the DPIIT sanction	Sanctioned cost (In Lakh)
1	Removing and relaying of gravity and pressure manhole in RCC	250
2	Laying of Ductile Iron conveyance lines for transfer of recovered water from CETP to member tanneries	130.78
3	Supply and installation of wireless monitoring system for member tanneries to monitor TDS and flow with cloud server	20.5
4	Conversion of receiving sump pump house into filtrate effluent collection sump	133
5	Construction of equalisation tank size of 42 x 20 x 3.3 m SWD 3.8 m TD, Recirculation pump house of 4 x 3 x 6 m HOS and walkway platform in RCC	103.15
6	Control of odour in the equalisation tank and receiving sump and installation of Vacuum Swing Adsorption (VSA) for generation of pure oxygen	341
7	Upgradation of filter press feed pump with energy efficient pump	26.78
8	Reduction of Hydrogen Sulphide in the pre-aeration tank by using Overall Hydrodynamic Reaction (OHR) aerator	79
9	Improvement of blower efficiency in Aeration Tank I & II	95
10	Conversion of MS Primary clarifier, secondary clarifier and re-activated clarifier mechanism with scrapper in SS 316L	69.5
11	Installation of Air Operating Diaphragm Pumps for chemical dosing	12
12	Extension of Power Control Centre Panel with Building	137.1
13	Sludge extraction pump with lorry and tractor trailer	49
14	Construction of Cable Trench in RCC and cable tray ladder type and supporting in SS 304 including laying of armoured HT / LT LPE Cables	39.41
15	Construction Centralised Control and Monitoring Centre	36
16	Centrifuge for dewatering bio sludge	48.38
17	Improvement of PES UF membrane in to PVDF/Ceramic membrane to reduce backwash process.	210
18	Installation of 600 KLD RO followed by NF	450
19	Construction of De-Nitrification Tank and Nitrification Tank and Fine Screen (250 m3/h)	733.89
20	Installation of 800 KLD Multiple Effect Evaporator with Boiler and ATFD and associated civil works	2265
21	Installation of Ammonia Removal Plant using Hydrophobic membrane, ozone technology for evaporator condensate water	120
22	Installation of Flue Gas Analyser for Boiler	20
23	Construction of wood storage platform	65.89
24	2 Nos for drying of sludge and allied works including capping	504
25	Supply, installation, testing and commission of 4 MW power (1.88MU/PW) solar plant	1779
26	Installation of 1 tonne / h solar steam generation	440
	TOTAL	8158.38

As per the recent order of the DPIIT, GoI, the above project has to be completed in September 2022.

PHOTOS OF ZLD PROJECT