ACKNOWLEDGEMENT

We would like to acknowledge PROF.G.PRABHAKAR Guide and

professor of the Department of Chemical Engineering, SRI VENKATESWARA
UNIVERSITY COLLEGE OF ENGINEERING, TIRUPATI, for his guidance
during the course of this project. We are indebted to our guide for his advice given
at each and every stage during the course of the dissertation work.
We express a special word of thanks to Prof. B.SARATH BABU and Prof.
P.AKHILA SWATANTRA Head of the department of Chemical engineering, Sri
Venkateswara University College of Engineering, Tirupati.
We are very glad to express our thanks to MR.N.GOPINATHA RAO- HOD-
ENVIRONMENT DEPARTMENT, ARBL who guided and shared his innovative thoughts with us
during the internship.
We are thankful to MR.M.PRASAD –PROJECT GUIDE who guided in such a way that which
enhanced our knowledge and we are thankful for the support and guidance.
We are thankful to MR.VENU, AMARA RAJA BATTERIES LIMITED, for their help to carry out this
project at AMARARAJA BATTERIES LIMITED, KARAKAMBADI.

A.S.P.DEEKSHITH (Roll No.:11401003)

M.S. PADMAJA (Roll No.:11401035)
N.R.BALAJI (Roll No.:11401038)
V.DEEPAK SUBRAMANYAM (Roll No.:11401066)

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CONTENTS:

S.No NAME OF THE TOPIC PAGE NUMBER

1. AMARA RAJA GROUP-AN OVERVIEW 1-9

2. AMARA RAJA BATTERIES LIMITED 10-12

(ARBL)

3. PRODUCTION AND PROCESSING IN 13-21

INDUSTRIAL BATTERY DIVISION

4. WATER 22-24

5. INTRODUCTION TO WASTE WATER 25-40

6. PRESENT STUDY 41-43

7. RESULTS 44-47

8. BIBLIOGRAPHY

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1. AMARA RAJA GROUP - AN OVERVIEW

1.1 INTRODUCTION

The Amara Raja group is an Indian conglomerate company with its corporate office at
Anna Salai, Chennai. The group has presence in industrial and automobile batteries, packaged
foods and beverages, electronics products manufacturing, infrastructure sector, power system
production and fabrication of sheet metal products and fasteners. The Amara Raja group is better
known for its automotive battery brand “AMARON” which is the second largest selling
automotive battery brand in India today. Amara raja group employs a work force of over 7000
employees and has international joint venture alliance with Johnson Controls Inc. Amara Raja
batteries figures in Asia’s “Best under a Billion” 2010 list of companies compiled by Forbes
magazine.

Amara Raja believes in influencing and improving the quality of life by building
institutions that provide better access to better opportunities, goods and services to people all the
time. With innovative engineering, research and design, Amara raja has grown with partnerships
and information sharing with world leaders.

1.2. PROFILE OF THE AMARA RAJA COMPANY

Dr. Ramachandra N. Galla has started his career as an Electrical Engineer in US Steel
Corporation and then moved on to Sargent & Lundy, USA as a Consulting Engineer for the
Designing of Nuclear & Coal Fired Power plant. He initiated various projects in these
corporations & mastered the ropes of this competitive business in a very short time. However, he
soon discovered that his natural inclination was serving his country and as a logical sequel he
gravitated towards Chittoor. Dr.Galla laid the foundation of Amara Raja Batteries in 1985 closer
to Tirupati. With his intense zeal and highly focused approach, he propelled Amara Raja
Batteries in the top league of battery companies in India.

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 Dr.Galla obtained his Bachelor and Master Degrees from Sri Venkateswara University, &
Roorkee University, (now upgraded to IIT), respectively and also holds M.S. Degree from
Michigan State University. Dr. Galla has been bestowed with Honorary Doctorate degrees from
Jawaharlal Nehru Technical University, Hyderabad & Sri Venkateswara University, respectively,
in2008 & 2007.

Dr. Galla has established various charitable trusts like Krishna Devaraya Educational &
cultural association (KECA), Rajanna Trust, Mangamma & Gangul Naidu Memorial Trust. He is
dedicated to rural development and improving economic conditions of farmers in Chittoor
District, Andhra Pradesh. KECA which was established in 1975 provides scholarship to the poor
and needy students to pursue their higher education.

1.3. Key Milestones of Amara Raja Group

 Designed and implemented the most advanced battery manufacturing facility in India in
1991-92
 Received the ISO-9001 Certification in February 1997
 Crossed 100 crore turnover mark in March 1997
 Commissioned in-house plastics and tool room section in August 1997
 Installed latest air pollution control equipment in April 1999
 Received the QS-9000 Certification in May 19999
 Launched Amaron Hi-Life (automotive batteries for the replacement market) in January
2000
 Implemented the ERP system in March 2000 for enhanced operational efficiencies and
closer integration of expanding operations and spread of business
 Launched Amaron Pit shops- exclusive state-of-the art showrooms for Amaron in July
2000
 Launched Amaron Shield inverter batteries in July 2001
 Launched Brute motive power batteries in September 2001
 Launched new corporate logo in September 2001
 Commissioned Phase-1 of fully integrated automotive battery in Tirupati, September
2001

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  Received the ISO 14001 Certification for EMS in May 2002
 Received the ISO/TS 16949:2002 in the year 2004 for ARBL
 Received the ISO/TS 16949:2002 in the year 2006 for ARBL
 Commissioned SMT (Surface Mount Technology) Machine at AREL Diguvamagham in
2006
 Commissioned extruder plant at MPPL, Petamitta in the year 2007
 Commissioned VHT project in GFL with a view to export Fruits & vegetables to Japan in
2007
 Laid Foundation stone for establishing Two wheeler battery plant on 10 April 2007
 Launched Power Zone Batteries brand on May 2007
 Commissioned Beverage plant in GFL on 21 April 2008

1.4. Awards Received by Amara Raja Group

 Best Industry round Performance award in 1998 by FAPCCI

 Entrepreneur of the year award to Mr. R.N. Galla, chairman & Managing Director in
1998 by HMA
 Business Excellence Award in 1999 by industrial Economist
 Udyog Rattan Award in 1999 by the institute of Economic studies
 Most Significant Automotive product of the year in December 2000 by overdrive (India’s
leading auto magazine). This honor is in recognition of Amaron technological superiority
and innovative product features, which have created new standards for automotive
batteries in India.
 ‘Excellence in Environmental Management’ in June 2002 by Andhra Pradesh pollution
control board
 Amara Raja received 5 Awards at the Mumbai Advertising club Awards 2003 for the
Amaron Hi-Life advertising campaign of the year Award, Advertiser of the year Award
and 2 silver and 1 Gold Abby in other categories.
 Amara Raja received Best 5S practices implementation award from CII, southern region
 MPPL Received award in recognition of excellence in cleaner production Technologies
and adoption of climate change mitigation measures from AP pollution control Board.

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  Employee Branding Awards: “Award for Best HR strategy in line with Business’’ and
“Award for continuous innovation in HR strategy at work’’.
 Amara Raja power systems Ltd (ARPSL) has won the prestigious IEEMA SME Quality
Award, the highest award constituted by IEEMA for Excellence in Quality systems for
2010.
1.5 The Associate Amara Raja Group of Companies
 AMARA RAJA BATTERIES LIMITED (ARBL)
 AMARA RAJA POWER SYSTEMS PRIVATE LIMITED (ARSPL)
 MANGAL PRECISIONS PRODUCTS PRIVATE LIMITED (MPPL1)
 MANGAL PRECISIONS PRODUCTS PRIVATE LIMITED (MPPL2)
 AMARA RAJA ELECTRONIC PRIVATE LIMITED (AREPL)
 GALL FOODS PRIVATE LIMITED (GFPL)
 AMARA RAJA INFRA PRIVATE LIMITED (ARIPL)

Amara Raja Batteries Limited (ARBL)

Amara Raja Batteries Limited (ARBL) was established in the year 1985 as private
limited and then converted into public company in the 1990.The company is currently poised on
a healthy growth curve since its inception. Amara Raja Batteries has a strategic tie up with
Johnson control Inc. USA, who owns 26% stake in this company. Johnson Controls is a Fortune
500 company and also the largest manufacturer of lead acid batteries in North America and a
leading global supplier to major automobile manufacturers and industrial customers. BL has
demonstrated its commitment to offer optimum system solutions of the highest quality. It has
become the largest supplier of standby power systems to core Indian utilities such as the Indian
Railways, Telecommunications, Electricity Boards and Major power generation companies in
India.

Amara Raja has always offered time tested world class technology and processes
developed on international standards-be it high VRLA systems like Power Stack and Power Plus
or the recently launched high performance UPS battery –KOMBAT and Amaron hi-life
automotive batteries that are products of the collaborative engineers at Johnson Controls Inc. and
Amara Raja. Amara raja entered into an agreement with Honda, Japan for the development of

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VRLA motor cycle batteries and Amara Raja is the first supplier of the batteries for India’s first
micro hybrid vehicle of Mahindra & Mahindra.

Amara Raja Power Systems Pvt. Ltd [ARPSL]

Amara Raja Power Systems Pvt. Ltd was incorporated in 1984 and was co-promoted by
AP ELECTRONIC DEVELOPMENT CORPORATION [APEDC].By virtue of APEDC’s
equity participation, ARSPL has become a deemed Public Limited company as per section 43(A)
of the companies Act. ARPS (P) is engaged in the manufacture of uninterruptible Power Systems
(UPS), Battery Chargers (BC) and Inverters. The company had a technical collaboration with
HDR Power System Inc. USA. The operations of the firm are highly satisfactory. The present
credit rating of the company is ‘A’.

Product(s): Conv. Chargers, Switch Mode Rectifiers (SMR) & Integrated Power Supply System
(IPS).

Customers: Telecom, Railways, and offshore platforms.

Mangal Precision Products Private Ltd (MPPL1)

Mangal Precision Products Private Limited was incorporated in the year 1990 for manufacture
of MS Cabinets, trays, UPS, Battery Chargers, Inverters, etc. and to manufacture small battery
parts. It is having all the sheet metal processing machinery starting from sheet cutting to final
painting with punching, bending, phosphate and power coating processes. The Plant is located at
Tirupati and is registered as an ancillary unit to ARBL and ARPSL. The operations of the
company are brisk and satisfactory.

Mangal Precision Products Private Ltd (MPPL2)

Mangal Precision Products Private Limited was started in the year 1996-97 to produce battery
components like copper connectors, copper inserts, hardware required by ARBL & ARPSPL.
The unit is located at Petamitta village, Puthalapattu Mandal, Chittoor District, AP at a distance
of 65 kms from Amara Raja Group of Companies, Karakambadi. To develop backward villages,
ARBL, CMD located the unit in Petamitta and provided an employment to nearly 35 persons. It
will also produce quality hardware for Automobile manufactures coming up near Madras. The
unit is having required machinery and equipment like power press break, mechanical press, cold

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forging machine, thread forming machine, lathe, drilling, trapping machine etc. to produce the
above components. These components are electroplated and dispatched to ARBL and ARPSL.

Amara Raja Electronics Private Limited (AREPL)

Printed circuit Boards (PCB) assembly on job work basis for Amara Raja Power Systems
Pvt. Ltd., Tirupati. Populated Printed Circuit Board assembly for sale to Original Equipment
Manufacture [OEM].

Galla Foods Pvt. Limited

 . Tropical fruits pulp and concentrate(Used for-ice cream, Confectionery, Beverages and
juices)
 Fresh fruits (Mango-Artificial ripening chamber) (Table variety for Exports only)

Activities:

 Fruit juice extraction

 Treatment
 Concentration
 Sterilization
 Packing in Aseptic condition

Amara Raja Infra Private Limited (ARIPL)

Amara raja group entered into a new business venture like infra & civil construction and
it was established on 29th May, 2008. ARIPL is a part Amara Raja Group of companies & taking
responsibility of internal Civil constructions, Electrical projects & infra development across the
Amara Raja Group.

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Amara Raja Industrial Services Pvt. Ltd (ARISPL)

After a recent launch of Infrastructure Company ARIPL by Amara Raja last year (2008),
this year (2009) Amara Raja ventured into another business of industrial services. This company
will focus on facility management, property management and other hospitality related services.

2. AMARA RAJA BATTERIES LIMITED (ARBL)

Amara Raja Batteries Limited Company comprises three major divisions such as:

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 (i) Industrial Batteries Division [IBD]
(ii) Automotive Batteries Division [ABD]
(iii) Small Batteries Division [SBD]

2.1. Industrial Batteries division [IBD]:

ARBL is the first company in India to manufacture valve regulated Lead-acid

(VRLA) batteries and (also named as sealed Maintenance Free batteries) with GNB
industrial battery Co. U.S.A. for manufacturing Valve regulated lead acid (VRLA)
batteries. Amara Raja Batteries Limited was established in the year 1985 as private
limited and then it has been shaped into a public limited company. The company was
located at the karakambadi village, Renigunta Mandal.
India is one of the largest and fastest growing markets for industrial batteries in the world
and Amara raja is leading the front, with an 80% market share for standby VRLA
batteries. Amara raja has become the benchmark in manufacturing industrial (VRLA)
batteries. It is also having the facility for producing plastic components required for
industrial batteries.

The major application of VRLA batteries are given in the following.

 Power Plants
 Process & Service industry
 Railways
 Telecommunications
 Uninterruptible Power supply (UPS) systems
 Electronic private Automatic Branch Exchange [EPABX]
 Defense [onshore & offshore wireless communications, cellular radios]
 Motive Power, etc.
 Kombat: UPS, EPBX, Emergency lighting, SPV, Fire alarm, security systems, etc.
 Brute: Forklifts, Pallet trucks, Stackers, Platform trucks.
 Genpro: Generators starting
 Quanta: Bank, Insurance, Finance, Healthcare, Education, IT enabled services, Industry,
etc.

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Customers:

Amara Raja Batteries being the first entrant in this industry had the privilege of
pioneering the VRLA technology in India. With the requisite approvals and
manufacturing facilities, Amara Raja has established itself as a reliable supplier of high
quality products to the major segments like Telecom, Railways and power control.

2.2. Automotive Battery Division (ABD):

Amara Raja batteries Limited inaugurated its new automotive plant at the
karakambadi in Tirupati on September 24th, 2001. This plant is part of the most
completely integrated battery manufacturing facility in India with all critical components,
including plastics sourced in-house from existing facilities on-site. This gives Amara
Raja complete control over inventory and product quality. In this project, Amara Raja’s
strategic alliance partners Johnson Controls, USA have closely worked with their Indian
counterparts to put together the latest advances in manufacturing technology and plant
engineering. It is also having the facility for producing plastic components required for
automotive batteries.

Products:

 Amaron Fresh batteries

 Amaron Hi-way truck batteries
 Amaron Harvest tractor batteries
 Amaron PRO
 Amaron Hi-life batteries for Automobiles
 Amaron Shield for Inverters
 Amaron GO batteries
 Amaron Black
 Power Zone

Customers:

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 ARBL has prestigious OEM clients like FORD, General Motors, Daewoo Motors,
Mercedes-Benz, Daimler Chrysler, Maruthi, Premier Auto Ltd and recently acquired a
preferential supplier alliance with Ashok Leyland, Hindustan Motors, Telco, Mahindra &
Mahindra and Swaraj Mazda. The company entered the replacement battery segment with
the launch of Amaron Hi-life auto batteries.

3.PRODUCTION AND PROCESSING IN INDUSTRIAL

BATTERY DIVISION

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 In Industrial Batteries Division (IBD), the production of batteries is done by various
processing steps followed by the other. The manufacturing steps are shown below in flow sheet and
are given detailed:-

Figure 3.1: The flow chart showing the manufacture of Lead Acid batteries in IBD

3.1.Grid Casting:

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 Melt the Pure Lead bars (99.9%) dropped into the lead pot which is maintained at a temp
of 280 0c. The dust fumes released inside the pot are extracted through Dust Fume Extractors.
The molten metal is pumped to the ladle by solenoid valve which flows through a series of grid
casting molds. The grids are designed in such a way that molten metal gets converted into grids.
During the process of grid casting, common deviations or defects observed are:

(i) Variation in thickness (ii) Shrinkage

(iii) Miss trimming (IV) Blow holes

(v) Flashes (VI) Wire missing

3.2. Oxide Plant:

Pure lead (99.97%) is used to prepare oxide powder using the Barton pot process,
where the lead ingots were melted and oxidized in the presence of air. The process parameters
that are maintained during the preparation of oxide powder are:

 Melting pot temp : 665±15 0F

 Reactor pot preheating temp : 425±15 0F
 Normal operation temp : 715±15 0F
 Reactor motor load : 35 to 45 0F
 Bag house temp : 200±20 0F

The lead ingots are melted with the help of heaters. The molten lead is fed into the reactor
pot and is broken up into droplets by revolving paddle. A stream of air is blown over the droplets
which oxidizes the lead. The resulting oxide powder is carried by air stream into the cyclone
where the powder further disintegrated and is moved to bag house (silos) which consists of
number of filters. Silos are used to store the lead oxide. Each silo has the capacity of 25 ton.

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 Figure 3.2: The process flow chart in oxide plant

3.3. Ox-Master Plant:

In Ox-Master the paste mixture is prepared which is applied over the grids prepared from
the grid casting section. The paste mixture is prepared in a batch reactor where the input to the
reactor is located in the Ox-Master plant. Demineralized water, Lead oxide powder, H2SO4are
fed to the reactor. The mixture is allowed to mix evenly for some time. Then the mixture is used
as pasting line over the grids and thus plates are prepared.

3.4. Pasting lines:

Grids were made to pass through with help of conveyor. The paste mix pastes over the
grids as the grids passes along with the conveyor. The paste is applied through the grid structure
by paste feed roller that is located in upper orifice plate. The bottom orifice plate rollers trowel
the paste on the underside of grid. After stacking, the stacked plates were transferred to curing
and drying ovens. Before that the plates are to undergo aging period. Ensure that the plates
should have undergone aging for 24 hours (+ve plates).

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 Figure3. 3: The flow chart showing pasting process on the grids

3.5. Curing and Drying:

Curing and Drying is one of the critical processes in tailoring the electrode plates
and is done at different stages with varying curing conditions. It is carried out to impart cohesion
and adhesions are imparted to the active material prior to formation. Adhesion is dependent upon
the strength of the bond, which is formed between the paste and the grid. These essential
properties are the best accomplished by conducting the curing procedure in the following
sequence:

 Steaming period: Steam is applied to equalize the moisture content in all the
plates and it supports for the development of lead sulfates.
 Low humidity treatment to affect oxidation of free lead.

Drying process is to bring down the water content (moisture) to the low level for the
active material to have good stability. During the process physical, chemical and morphological
changes take place within the active material.

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3.6. Assembly:

The tailored electrode plates of positive and negative are selected and grouped
alternatively and each process is discussed in the following sub sections. The process of
assembly of the lead acid battery is shown as flowchart in the following figure:

Figure 3.4: The flow chart showing the process of assembly

3.6.1. Group stacking:

Bottom shield is placed in the fixture, this prevents the plate damage. First an unwrapped
negative plate is placed in the fixture. Then a half-length separator is placed on the negative
plate.

 The separator is shared by activating the cutter blade after getting the pre-defined length.
 Then positive plate is placed and separator is folded over this plate. Place the half-length
separator on the last positive plate and then place unwrapped negative plate on the top of
the half-length separators, complete the stack.

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  Shields are provided on positive plates to avoid direct contact between positive and
negative plates.

3.6.1.1. Group burning:

 Aligning of bus bars with lugs is called group burning.

 By using the protection of jigs, these combinations can be shield rightly.
 Adjust the oxy-acetylene gas torch for neutral flame and length of inner core is 2.5 cm.
 Positive strap is burnt first as if requires more time for cooling.
 The molten metal is stirred with them.
 The post protection jigs are chilled with demineralized water and then they were
removed.

3.6.1.2. Group strapping:

 Plates were strapped on strapping machine with poly-propylene. These straps held the
stacks together.

3.6.1.3. Group Insertion:

 The strapped plates are inserted into jars/containers shield in wrapped form on the plates
before insertion.

3.6.2. Heat Sealing:

The cover is placed over the jars such that the posts can slide inside the bushing. The
heaters are maintained at a temperature of range 440-480 0F. First take 10 seconds for melting
and other 10 seconds for welding them together. The covers must be positioned so that the
polarity marking on the cover corresponds to proper post/bushing location.

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3.7. Formation:

The cells or batteries are placed in tub and packed with PPCP spacers and strapped with
metallic bale. The cells are connected in series using cable connectors and bolts.

Figure 3.5: The flow chart showing the formation process of Lead Acid Batteries

3.7.1. Acid filling:

At first the volume vessel is filled up to the present volume. The cycle starts by pulling
the vacuum in the battery until present vacuum level is reached. Then the acid is transferred from
volume vessel to the expansion vessel. The venting valve provided on top of the machine will
open and because of vacuum in the battery causes an air stream which will force down the acid

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into the battery. If there is still electrolyte in expansion vessel another vacuum pulse will be
pulled.

Specific gravity of H2SO4is 1.257 ± 0.005 H2SO4 is chilled to100 C and filled. Funnel is
installed on cell to be filled and must not be removed until the formation discharge. Once the
funnel has been secured, place the filling hoses from the jar into the funnel tubes. Soaking time is
20-75 min. Fill the tubes with water before connecting them for first charge. Water regulates the
temperature during formation temperature of cell (electrolyte) should be between 40-650c during
formation change maximum of 108 cells be formed on any given circuit.

The first charge is 60 hour with a rest period for 10-15 min and then formation and
discharge of 10hr. The capacity verification is done at the end of the 10th hour and the cells that
are showing voltage more than 1.75V should be considered acceptable. During capacity
discharge, water is added the bank current shall be monitored and recorded for every 2hr once
the discharged has started it will continue until a reading at 90% capacity is taken. The vent plug
is fixed without silicon sealant within 1hr from the start float charge. Recharge the battery for
10hrs (10%) and then 12hrs (3%). The float voltage of the cell or battery is 2.25V and time is
around 12hrs.

During the cell cleaning all the inter connections are removed and the cells were flushed
with fresh water. They are cleaned with is propyl alcohol and the petroleum jelly is applied to
post and ensured that there is no water residue.

3.8. Finishing & Dispatching:

The vent plug is and sealant compound is applied to it. Resin is applied for IP series cells.
Screen printing of the cell details is done on the vertical side of the tray. Boost charging is done
if required before going for dispatch. If the cells are stored for more than 30 days, boost charging
is required i.e. charge at 3% for 24 hrs and the rest the cells for about 30 min. the capacity
discharge is done for 10 hrs.

In dispatching the cells were packed and the necessary accessories required for
functioning of the cells is supplied to the customer. The accessories include connectors, bolts,
washers, cables etc.

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 4. WATER

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 Water is essential for life. People, animals, and plants all need water to live and to
grow. On worldwide basis the amount of fresh water available is approx.8300 m3 per person per
year. However, neither the population nor the availability of fresh water is uniformly spread
across the globe.

Water in our body has a very important role and an excellent water circulating system is
established in our digestive tract. The human body consists of around 65% water and if we lose
3% of it, we will have symptoms of dehydration. If we lose 10~15% of it, body conditions get
affected.

Usually adults drink around 2~2.5 liters of water every day, but in our body
approximately 6~7 liters of water is circulated in our digestive tract to digest and absorb the
nutrients of foods.

In 1970, the clean water Act provided 50 billion dollars to cities and states to utilize
waste water, this act helped control water pollution from industrial and municipal areas. In 1972
the clean water Act was passed by the government, each state had to comply with the set
required standard from government and follow the guidelines to control water pollution. Our
Government can’t do it alone.It is up to us as human beings to be aware, informed and educated
.We must become familiar with our local water resource by being educated and learn who, what,
when , where, why and how to dispose certain chemicals, car oil, fertilizers, pet waste, leaves,
and grass clipping out of the gutters and storm drains. These are just few requirements that are
necessary to prevent water pollution .We can also protect ourselves by learning which is most
beneficial home water filter to use for certain type of minerals that comes from our water supply.
We as human beings need to take responsibility for our own actions on health, and ocean life to
help prevent to add to the event.

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4.1 Total availability of water on the earth

Figure 4.1: Total availability of water on the earth

4.2 Percentage of Drinking water on the earth

Only a small percentage of water is suitable for humans to drink. Not all of the water in
the ground and in lakes and rivers is easy to reach or clean enough to drink. Ice caps and glaciers
are certainly hard to use for humans, plants, and animals. Some work is being done to take the
salt out of ocean water (desalination of water), but that is an expensive process. The drinking
water percentages: 0.419% total and 2.799% grand total.

4.3 Water usage in industries

Industrial water use includes water for such purposes as processing, washing, and cooling
in facilities that manufacture products.

Major water-using industries

 Steel industries.
 Chemical and allied products
 Paper and allied products
 Petroleum refining

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4.4. Effluent waste water Recycling

Reusing water provides at least three important benefits: it reduces the demand for clean
water, reduces the quantity of wastewater requiring treatment, and reduces the amount of treated
wastewater discharged back into the environment. Some industries have been particularly
effective in reusing water. They reuse process water for washing and cleanup rather than using
clean water.

Some municipalities reuse treated and disinfected wastewater for irrigation. Using the
same water more than once in the same or alternate forms—is the third conservation practice that
helps prevent water pollution. For example, paper recycling helps prevent water pollution by
lowering the demand for raw timber, allowing more trees to remain on the mountainside for
stabilizing the soil, cooling tributary waters, and otherwise benefiting water quality.

Recycled paper is also easier to pulp than timber. It takes less energy, less water, and
fewer chemicals to create recycled paper than it does to create paper from raw wood.

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 5. INTRODUCTION TO WASTE WATER TREATMENT
Wastewater Treatment is one of the most important services a municipality may provide
and one of the least viable. Wastewater or sewage water is the byproduct of many uses of water.
There are the household uses such as showering, washing, laundry and of course flushing the
toilet. Additionally, companies use water for many purposes including processes and cleaning or
rinsing of parts. After the water has been used, it enters the wastewater stream, and it flows into
the wastewater treatment plant. Rapid development of industry and society led to serious
environment problems such as contamination of groundwater and surface chemical treatment
with organic compounds coming from agriculture (pesticides, herbicides, etc.) or inorganic
compounds in industries(pigments, heavy metals, etc. ).

5.1 What is Waste Water???

Natural water in contact with foreign matters during either industrial process or domestic
use becomes polluted. Such polluted water is termed as waste water.

Every day, 2 million tons of sewage and industrial and agricultural waste are discharged
into the world’s water (UN WWAP 2003). The UN estimates that the amount of wastewater
produced annually is about 1,500 km3, six times more water than exists in all the rivers of the
world (UN WWAP 2003).

5.2 Sources of Waste Water

Wastewater can originate from many sources such as homes, businesses and industries.
Storm water, surface water and ground water can enter the wastewater collection system and add
to the volume of; wastewater. The source of wastewater will determine its characteristics and
how it must be treated. For example, wastewater from homes and businesses (domestic
wastewater) typically contain pollutants such as fecal and vegetable matter, grease and scum,
detergents, rags and sediment. On the other hand, wastewater from an industrial process
(industrial wastewater) may include; toxic chemicals and metals, very strong organic wastes,
radioactive wastes, large amounts of sediment, high temperature waste or acidic/caustic waste.

DEPT. OF CHEMICAL ENGG. SVUCE 25

 Wastewater could even come from streets and parking lots during a rainstorm (storm
wastewater) that could contain motor oil, gasoline, pesticides, herbicides and sediment.

5.3 Effects of Discharged Waste Water into the Environment

Wastewater can potentially contain any disease causing organism, or pathogen, that the
people contributing waste to the collection system are infected with common diseases caused by
water borne pathogens include typhoid, hepatitis, cholera, dysentery and polio. If pathogens are
discharged without treatment into the natural environment, they will pose a danger to anyone that
is exposed to them. For this reason, one of the primary goals of wastewater treatment is to
disinfect the effluent before it is discharged.

Most living organisms live in a narrow pH range that is near neutral. If an effluent has a
pH that is higher or lower than that of the receiving water, the organisms in the receiving water
may be killed off. In addition, if the pH of the influent coming into a wastewater treatment plant
changes rapidly and significantly, the plant treatment processes may be disrupted.

Figure 5.1: Discharge of untreated industrial waste water into a river

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5.4 Types of Waste Water

1. Domestic waste water (sewage)

2. Process waste water (effluent)

1. Domestic Waste Water

Waste water discharged from residence and from commercial, institutional, and similar
facilities. Wastewater is usually treated by supplying oxygen so that bacteria can utilize the
wastewater contents as food. In general it is considered as:

Wastewater + oxygen treated wastewater + new bacteria

The nature of domestic wastewater is so complex that it precludes its complete analysis.
However, since it is comparatively easy to measure the amount of oxygen used by the bacteria as
they oxidize the wastewater, the concentration of organic matter in the wastewater can easily be
expressed in terms of the amount of oxygen required for its oxidation. Thus if for example, half a
gram of oxygen is consumed in the oxidation for each liter of a particular wastewater, then we
say that this wastewater has an ‘Oxygen Demand’ of 500 mg/l, by which we mean that the
concentration of organic matter in a liter of the wastewater is such that its oxidation requires 500
mg of oxygen.

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 Figure 5.2 : Common steps for sewage treatment

Figure 5.3: Composition of domestic waste water

2. Process Waste Water

Industries require large quantities of water, which gets contaminated during the various
industrial processes. The contaminants include acid, caustic, dissolved solids, toxic metals, metal
compounds and color. Studies conducted by the CPCB (Central Pollution Control Board) reveal
that about 13000 million liters of waste water is generated daily, of which only 60% generated
from large and medium industries is treated.

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 Industrial waste water usually contains specific and readily identifiable chemical
compounds. Water pollution is concentrated within a few subsectors, mainly in the form of toxic
wastes and organic pollutants. Out of this a large portion can be traced to the processing of
industrial chemicals and to the food products industry. Most major industries have treatment
facilities for industrial effluents but this is not the case with small-scale industries, which cannot
afford enormous investments in pollution control equipment as their profit margin is very
slender. The effects of water pollution are not only devastating to people but also to animals,
fish, and birds. Polluted water is unsuitable for drinking, recreation, agriculture, and industry.

5.5. Waste Water Treatment Methods

Treatment methods are two types. They are

A. Unit operations

B. Unit processes

A. Unit operations

Methods of treatment in which the application of physical forces are predominate are
known as unit operations. Ex:-Screening, Filtration, Sedimentation, Adsorption, Clarifier,
Settling tank.

5.5.1. Screening

Screening is employed for removal of suspended solids of various sizes. Screen openings
range in size depending on their purpose, and cleaning of screens is done either manually or
mechanically. Screenings are disposed off by burial, incineration, or anaerobic digestion.

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 Figure 5.4: Screening process.

5.5.2. Filtration

The process of removing solids by passing water through bars, screens, and filters that
allow the water but not the solids to pass. Filtration also occurs in nature as water passes through
vegetation or percolates through the soil.

5.5.3. Sedimentation

Sedimentation is utilized in waste water treatment to separate suspended solids from the
waste water. Removal by sedimentation is based on the difference in specific gravity between
solid particles and bulk of the liquid, which results in settling of the suspended solids.

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 Figure5.5: Sedimentation Tank

5.5.4. Adsorption

Adsorption technology can remove organic materials from wastewater that resist removal
by biological treatment. These resistant, trace organic substances can contribute to taste and odor
problems in water.

Figure 5.6: Adsorption

5.5.5. Clarifier or settling tank

Clarifier also known as a settling tank, removes solids from wastewater by gravity
settling or by coagulation. Tanks designed for the Physical separation of wastewater floatable
solids and settle able solids. The clarifier separates the treated slurry from clean water. The
sludge settles down and treated water at the top flows down to the cooling tower from where is
cooled and recycled. .

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 Figure 5.7: Clarifier

5.5.6. Filter press:

Sludge from the sludge tank will be pumped to the Filter Press equipment for dewatering
purpose. Dewatering is accomplished by pumping a slurry or sludge into chambers.

(A) Surrounded by filter membranes.

(B) As pumping pressure is increased the filtrate is forced through the accumulated filter
cake.

(C) Filter until the chamber is full of solid filter cake. The chambers are formed by two
recessed plates held together under hydraulic pressure.

(D) Moves the follower.

(E) Against the stack of filter plates.

(F) Closing the press. The ram continues to apply sealing pressure of sufficient force to
counteract the high internal compaction pressures.

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 Figure 5.8: Filter Press Equipment

B. Unit processes

Methods of treatment in which the removal of contaminants is broad about by chemical

or biological reactions are known as unit processes.

UNIT PROCESS

Chemical unit processes Biological unit processes

Treatment methods in which the removal or Treatment methods in which the removal or
conversion of constituents is brought about conversion of constituents is brought about by
by the addition of chemical or by other biological activity are known as Biological unit
chemical reaction are known as Chemical processes.
unit processes.
Ex: disinfection, oxidation, precipitation. Ex: activated sludge, trickling-filter.

Table 5.1: Difference between Chemical and Biological unit processes

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5.6. Waste Water Treatment Levels and Processes

Effluent can be treated in a number of different ways depending on the level of treatment
required. These levels are known as preliminary, primary, secondary and tertiary. The
mechanisms for treatment can be divided into three broad categories: physical, chemical and
biological, which all include a number of different processes. Many of these processes will be
used together in a single treatment plants.

Table 5.2: Wastewater treatment levels and processes

Figure 5.9: Flow diagram for wastewater treatment levels

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5.7. AQUEOUS EFFLUENT TREATMENT PLANT (ETP)

Waste water treatment plants are very essential at different places. Now-a-days
installation of waste water treatment plants has become obligatory for industries, commercial
places or residential complexes where a large volume of waste water is discharged every day.
The installation of wastewater treatment plant separates all contamination from the waste water
and makes it safe to release in the waste bodies or in the environment.

Common Effluent Treatment Plant

Figure 5.10: Effluent Treatment Plant

5.7.1 Effluent:

Industrial effluents are liquids or water carrying wastes discharged from various
processes in industries. Wastewater or other liquids, partially or incompletely treated waste water
flowing from a reservoir, basin, treatment processes or treatment plant.

Influent:

DEPT. OF CHEMICAL ENGG. SVUCE 35

 Wastewater or other liquids flowing into a reservoir, basin, or treatment plant. Influent is
the raw material that has been collected and conveyed to the plant for treatment. It includes all
the water and debris that entered the collection system.

5.7.2. Treatment in ETP

The removal of excessively accumulated matter from the waste water is known as
treatment. Treatment facilities incorporate numerous processes which in combination achieve
the desired water quality objectives. These processes involve the separation, removal and
disposal of pollutants present in the wastewater. The treatment of wastewater is accomplished
by 4 basic methods or techniques.

1. Physical

2. Mechanical

3. Biological

4. Chemical.

1. Physical methods of treatment include the use of tanks and other structures designed to contain
and control the flow of wastewater to promote the removal of contaminants.

2. Mechanical treatment techniques involve the use of machines, both simple and complex in
design and operation.

3. The action of bacteria and other micro-organisms are biological methods of treatment, which
play a vital role in the removal of pollutants which cannot be effectively achieved by other
means.

4. Chemical treatment methods enhance the efficiency of other process operations and provide
specialized treatments as a result of their addition at various treatment stages.

5.7.3. The Need for Waste Water Treatment

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 When untreated wastewater accumulates and is allowed to settle, the decomposition of
the organic matter contained in it will lead to the unhygienic conditions include the production of
malodorous gases. In addition to the untreated waste water contains numerous pathogenic
microorganisms that dwell in the human intestinal tract. Waste water also contains nutrients,
which can stimulate the growth of aquatic plants, and may contain toxic compounds or
compounds that potentially may be mutagenic or carcinogenic. For these reasons, the immediate
and nuisance-free removal of waste water from its sources of generation, followed by treatment,
reuse or disposal into the environment is necessary to protect public health and the environment.

5.8.Waste Water Treatment in Amara Raja Batteries Limited

The waste water of Amara raja Batteries Ltd, treated by using three individual effluent
treatment plants at three divisions(IBD, SBD, ABD) of production for process waste water and
cooling water (effluent water).

5.8.1. Sources of Effluent Water in Industrial Battery Division (IBD) Production:

DEPT. OF CHEMICAL ENGG. SVUCE 37

 Figure 5.11: The flow chart showing the sources of Effluent Water

5.8.2. Effluent treatment plant observation in IBD

All the collected waste water from the different sources of plant is sent into the settling
tank. A batch containing 30000 liters of effluent water is sent to the reaction tank. Initially pH of
the effluent is maintained at required level by addition of lime to the effluent and stirring it with
a stirrer. After maintaining the pH at required level adds the chemicals like lead precipitator,
coagulant to the effluent. The flocculent solution is prepared and is poured slowly into the
reaction tank. After reaction of the effluent with the added chemicals the lead present in the
effluent gets precipitated and settles down to the bottom of the reaction tank. Then the treated

DEPT. OF CHEMICAL ENGG. SVUCE 38

effluent is pumped to the clarifier. The clarifier tank contains two wells separated by walls. The
treated effluent is pumped to the center well where the minute lead particles if any settle to the
bottom of the clarifier. Settling of micro particles takes place in the clarifier. Then the treated
effluent is sent to the collection tank where it is stored. At last the treated effluent is passed
through the Multi Grade Filter (MGF).

5.8.3. Environmental regulations (Effluent parameters):

Effluent parameters are to be brought below the levels mentioned below:

Table5. 3: environmental regulations of effluent parameters

Parameter Concentrations not exceed, mg/lit

(except for pH)
pH 6.5-8.5
Suspended solids 50
Lead 0.1

5.8.4. Preparation of solutions:

 Preparation of lead precipitator solution:

3kg of lead precipitator is added to 20lit of water for a batch size of 30000lit of effluent.

Table 5. 4: Composition of lead precipitator

Chemical compound name Composition

Calcium hydroxide, Ca(OH)2 >46%
Magnesium hydroxide, Mg(OH)2 <2.5%
Calcium carbonate, CaCO3 <1.5%
Sodium carbonate, Na2CO3 >50%

 Preparation of lime solution:

DEPT. OF CHEMICAL ENGG. SVUCE 39

 Prepare 10%Ca (OH)2 solution by adding 20Kg lime to 200 lit water

 Preparation of coagulant solution:

2kg of coagulant (aluminum sulfate (or) alum) is added to 25lit of water for a batch size of
30000lit of effluent.

 Preparation of hydro flock solution:

50gram of hydro flock (poly electrolyte) is added to 50 lit of water for a batch size of
30000lit of effluent.

5.8.5. Procedure for IBD-ETP

 The effluent waters from the different sources are collected into the collection
tank.
 Mix effluents for 15-20 minutes for obtaining uniformity of effluents before
transferring into the reaction tank
 Before adding the chemicals into the reaction tank we need to check the pH range
of the effluent to be treated.
 If the pH of effluent is below 7.5 then add 10% lime slowly or if it is more than
9.0, add slowly dilute hydrochloric acid / dilute sulfuric acid to maintain pH
between 8.5 to 9.0
 Mix effluents for 20 minutes.
 Add lead precipitator solution prepared and mix it for half an hour.
 Add coagulant solution prepared and mix it for half an hour.
 Add poly electrolyte solution prepared and mix it for twenty minutes
 Because of addition of the coagulant, flocculent solution lead particles gets
precipitated and settles to the bottom of the reaction tank.
 The treated water is pumped to the clarifier tank; over flow water from the
clarifier tank is collected into clarifier collection pit.
 After that collected pure water is sent to the multi grade filter (MGF), effluent
from MGF will be collected for analysis.

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  Take the sample of treated effluent from MGF is sent for qualitative analysis, if
the results are not meeting environmental regulations, take back to the reaction
tank and the procedure is repeated, else the purified water is collected in the
storage tank or send to gardening.
 Sludge present at the bottom of clarifier is pumped out through pumps and is sent
to filter press.
 The sludge cake formed is removed periodically from filter press, weighed,
packed in to polyphone bags and sent to central scrap yard.

COLLECTION COLLECTION
TANK 1 TANK 2

REACTION REACTION
TANK 1 TANK 2

CLARIFIER

TANK
CLARIFIER
COLLECTION PIT

FILTER
PRESS
MULTI GRADE
FILTER
SLUDGE
CAKE
OUTLET
WATER
Figure 5.12: Flow chart for effluent treatment plant in IBD

6. PRESENT STUDY

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 An attempt has been made to find an alternative scheme of waste water treatment from
battery industry in the present study.

Industrial procedure comprises of adjustment of pH, precipitation with the help of a

precipitator, coagulant and a flocculator. Filtration and then disposal . The precipitation is the
key step in this scheme, causing the lowering of free lead that would otherwise cause undesirable
effects to the environment, humans and animals. A mixture of Calcium Hydroxide, Magnesium
Hydroxide, Sodium Carbonate and Calcium Carbonate is used as the precipitating agent, Alum is
used as the coagulant and a proprietary flocculent are currently being used.

An adsorption procedure, in place of precipitation, to take out the free lead from the
effluent is studied in this work. A dispensable ash available in the same industry is tried to check
the suitability of the material for lead adsorption. This, it is thought, would reduce the usage of
chemicals and also will be a partial solution to the disposal of the ash.

Hence, the objective of the present study is

a) To check the feasibility of adsorption as an alternative to precipitative removal of free

lead
b) To identify the appropriate level of pH for adsorption
c) To find time of contact for the attainment of equilibrium and
d) To find the impact on coagulant requirement, for post precipitation / adsorption step.

Reagents Used :

10 % Ca(OH)2 solution (10gram of lime are added to 100 ml water )

Lead precipitator (1.35 g of Ca (OH)2, 0.075 g of Mg(OH)2, 0.045g of CaCO3,1.5 g

Na2 CO3 dissolved in 20 ml of water)

Coagulant (2g of aluminum sulfate added to 25ml of water)

Flocculating Agent (0.01g of hydro flock (poly electrolyte) in 100ml of water)

DEPT. OF CHEMICAL ENGG. SVUCE 42

6.1. METHODOLGY

In the industry, effluents generated at various points of battery manufacture are collected
into a storage tan and are then subjected to treatment to reduce the free lead content of the
composited effluent.

In the first set of experiments, a 100 ml of sample of the composited effluent is checked
for its pH, which is then adjusted to the desired level using lime solution or dilute HCl /H2SO4 .
0.05 g of waste ash are added, the mixture agitated for a specified time, 0.01 ml of 0.075 weight
percent alum (coagulant) solution is added , the mixture is again stirred 10 minutes, 0.2 ml of the
flocculating solution are added, the mixture is homogenized and is filtered. Then the free lead
content and total dissolved solids and conductivity meter are estimated using Atomic Absorption
Spectrometer and a conductivity an instrument , respectively. All the quantities of reagents, the
procedure are the same as that adopted by the industry, excepting for replacement of
precipitation with adsorption. A sample with precipitation is also run for the purpose of
comparison.

Second set of experiments is a repetition of the above procedure, but the time of agitation

Percentage removal of lead = (Co – Cf) x 100 / Co

Co and Cf are the initial and final lead content in the sample.

Table6.1: Parameters Studied:

pH 2.2, 4.0, 6.1, 7.5, 10.3, 11.8, 12.5

Agitation Time (min) 15,30,45,60
Amount of Coagulant, ( ml of 0.075 wt percent) 0.03,0.05

Collect the effluent into beakers Collect the effluent into beakers

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Add lime solution or dilute H2SO4 Add lime solution or dilute H2SO4
solution and stir it well for attaining solution and stir it well for attaining
required pH required pH

Add lead precipitator solution and stir it Add fly ash and stir it for optimum
for 15 minutes time

Add coagulant solution and stir it for ten

Add coagulant solution and stir it for ten
minutes
minutes

Add hydro flock(poly electrolyte) solution

and allow to settle for five minutes. Add hydro flock(poly electrolyte) solution
and allow to settle for five minutes.

Neutralize the effluent water by using

lime solution or dilute H2SO4 solution Neutralize the effluent water by using
lime solution or dilute H2SO4 solution

Filter the treated effluent by filter paper,

collect sample for finding of TDS, %lead Filter the treated effluent by filter paper,
removal collect sample for finding of TDS, %lead
removal

Figure 19: Flow sheet comparing experimental procedure and industrial procedure

7.RESULTS
7.1.Effect of variation of pH:

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 Data collected in the first set of experimentation intended to study the pH
suitability is tabulated in table. 7.1 and figures 7.1and 7.2
Table 7.1 Percentage removal of Lead – pH Variation
S.no Initial pH before pH pH after TDS Conductivity % removal of
pH treatment after neutralization (ppm) (µS) lead
treatment
1 2.3 9.5 8.8 8.0 1621 3140 99.08
(Industry)-
Reference
2 2.3 2.2 3.3 8.4 1859 3710 99.07
3 2.3 4.0 6.0 8.2 1408 2810 98.11
4 2.3 6.1 6.4 7.8 1959 3910 98.8
5 2.3 7.5 6.3 7.7 1772 3540 98.51
6 2.3 10.3 8.9 8.0 2030 4060 99.06
7 2.3 11.8 11.6 6.6 2490 5010 98.92
8 2.3 12.5 12.5 8.35 3860 7700 98.8

9000
8000
7000
6000
5000
ph vs tds
4000
3000 ph vs conductivity
2000
1000
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Fig7.1: pH vs TDS and Conductivity

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 99.2
99
98.8
98.6
98.4
98.2
98
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Fig 7.2:pH vs %lead removal

As can be seen from the table and plots, lead removal comparable to that of the
industrial practice is observed at pH levels of 2.2 (acidic condition ) and 10.3 (alkaline
condition). While the conductivity and TDS levels at pH of 2.2 are close to those realized in the
current practice, the same were a little away at a pH of 10.3. The data clearly indicates that
adsorption, in place of precipitation, is a viable option and that adsorption is worth probing
further.
Experiments was repeated with the pH levels found suitable earlier, and the data are
shown in Table 7.2. pH adjustment to make the treated effluent suitable for disposal is omitted.
It is found that the performance of the adsorbent could be repeated , with the effluent taken in
alkaline condition. So, further study was continued with the effluent taken at around 10.0 pH.

Table 7.2: focused study on pH vs % lead removal

S.No Initial pH before Lime pH after TDS Conductivity %lead
pH treatment added treatment (PPM) (mS) removal

1 1.75 9.5(arbl) 0.6 9.1 1918 3.83 100

2 1.75 10.1 0.65 8.4 1959 3.91 100
3 1.75 1.75 0 3.6 1888 3.77 28.57

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7.2. Effect of variation of time of stirring and volume of coagulant:
Further, study to identify the contact time for adsorption and also the effect
of coagulant was carried out and the outcome is shown table. 7.3

Table 7.3: % Removal of lead vs time of stirring and volume of coagulant

The variation of time and the amount of coagulant are resulting in subtle variation in the
three major goal parameters – lead content, TDS and Conductivity and the study needs to be fine
tuned and refined to identify the exact levels of suitability. A 15-minute contact time and
coagulation with 0.03 ml volume appear to be good enough for lead removal.

DEPT. OF CHEMICAL ENGG. SVUCE 47

Conclusion:

Feasibility study to replace precipitation with adsorption, using an internally

available waste ash is conducted and it is indicated, in all the studies that said process
modification is promising. Preliminary experiments suggested that 0.5 g of adsorbent per
liter of effluent, an agitation time of 15 minutes and the same coagulation as is practiced
now are suitable conditions.

DEPT. OF CHEMICAL ENGG. SVUCE 48

BIBLIOGRAPHY:

1. Introduction to waste water management

---Environmental finance center

2. Clean water

---KENNETH.M VIGIL

3.Domestic waste water treatment in developing countries

---DUNCAN MARA

4. Waste water treatment

---HLTHMAN (volume 20)

5. Adsorption Performance of fly ash for removal of lead

--- Satya Vani yadla, V.Sri Devi and M.V.V. Chandana Lakshmi.

6.Lab manuals of Amara raja batteries limited.

DEPT. OF CHEMICAL ENGG. SVUCE 49

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