Cement Industry Effluent Treatment Plant (ETP) — 50 KLD
Specialised ETP Solutions for Cement Plants
Cement industry wastewater typically includes high suspended solids (mill scale, kiln wash), alkaline washings, cooling tower blowdown and process wash water. Our packaged 50 KLD ETP combines robust physico-chemical pretreatment with MBBR biological polishing and downstream filtration — designed for reliable compliance, low footprint and easy operation.
Overview — Cement ETP (5–300 KLD)
Our Cement ETP packages are engineered for:
- Removal of high TSS / solids (kiln dust, mill fines)
- Neutralization of alkaline wash waters and pH control
- Oil separation for workshop washings (where applicable)
- Biological reduction of soluble organics using MBBR
- Polishing for reuse or compliant discharge (sand filter, carbon, UF/RO)
Capacity flexibility: 5 KLD — 300 KLD. Design is finalised after site survey & influent characterization.
Typical Process Flow (Cement ETP)
MBBR offers compact footprint and stable nitrification/denitrification potential — ideal for variable loads and small-to-medium cement operations.
Technical Specifications — 50 KLD Example
| Design Flow | 50 KLD (scalable: 5–300 KLD) |
| Typical Influent | pH 8–12, TSS 500–5000 mg/L (kiln/mill fines), Oil & Grease: 0–200 mg/L (workshop waters), BOD/COD low-moderate |
| Primary Treatment | Screen + Grit + Lamella / Primary Settling |
| Coagulation / Flocculation | Chemical dosing to remove colloidal silica & fine solids |
| Biological Unit | MBBR (media carriers, aeration grid, blowers) |
| Expected Treated Quality | TSS < 100 mg/L (after primary + coagulation) ; final TSS <30 mg/L after polishing; pH 6.5–9; BOD/COD depending on feed & polishing |
| Polishing | Multimedia filter + Activated Carbon; UF/RO for reuse or ZLD feed |
| Sludge Handling | Thickener + Filter Press / Centrifuge (optional) |
| Automation | PLC based control, level/pH/DO monitoring (optional) |
| Civil | Civil drawings & foundations included in turnkey scope |
Final guarantees, power & chemical consumption supplied in proposal after sample analysis and site dimensions.
ZLD Option — RO + MEE / ATFD
For plants aiming zero liquid discharge or maximum reuse, we offer integrated polishing and evaporation solutions:
- UF → RO polishing to remove suspended solids & majority dissolved salts.
- MEE (Multiple Effect Evaporator) or ATFD (Agitated Thin Film Dryer) for brine concentration and crystallization.
- Sludge & salt handling: crystallizer / centrifuge as per project.
Note: ZLD is case-specific. Pilot trials and site studies are mandatory to finalise MEE/ATFD sizing and economics.
Scope of Supply — Typical Turnkey Package
Mechanical
- Lamella clarifier / primary tanks
- MBBR media & carriers, aeration blowers
- Pumps, mixers, DAF / oil separator (if required)
- Filter vessels, activated carbon units
Civil & Fabrication
- FRP / MS fabricated tanks, channels & supports
- Civil drawings & foundation details
- Site erection & supervision
Electrical & Control
- MCC, starters, cabling
- PLC / HMI, sensors (pH, level, DO)
- Instrumentation & commissioning
Key Advantages
- Effective removal of kiln & mill fines using coagulation + lamella settling
- MBBR for compact footprint & low maintenance
- Customisable polishing for reuse or discharge compliance
- Modular skid options for fast deployment
- Full turnkey with civil, electrical & instrumentation
Frequently Asked Questions
A: Yes — pH correction & adequate chemical dosing are part of our design. We neutralize alkali and then proceed to coagulation and settling.
Q: Do you provide mobile/pilot trials for high TSS streams?
A: Yes — jar tests, pilot clarifiers and DAF trials are available prior to full-scale design.
Q: What is the typical commissioning time for 50 KLD?
A: Approximately 4–8 weeks depending on civil readiness and customization.
Request Quotation / Technical Visit
Share: Site location • Daily flow (KLD) • Sample analysis (pH, TSS, TDS, BOD/COD, Oil & Grease) • Consent limits to achieve. We'll provide technical proposal & budgetary estimate.
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