why fresh bioculture takes time to show results in ETPs
The ‘Lag Phase’ Dilemma: Why Fresh Bioculture Doesn’t Work Instantly

In the world of biological treatment of wastewater, a common misconception persists: adding fresh bioculture for wastewater treatment guarantees instant results. Many operators expect immediate improvements in COD/BOD reduction or ammonia removal after dosing microbial culture into an underperforming ETP. But when visible results aren’t observed within a day or two, the bioculture for wastewater is often blamed for being ineffective.

Let’s decode this expectation mismatch, delve into a critical microbial phenomenon – the Lag Phase, and understand why even the best pure microbial culture doesn’t deliver overnight miracles. This is backed by operational realities and biological data that matter.šŸ‘‰ Contact us to learn how to optimize your microbial culture application.

Understanding the Microbial Growth Curve

Microorganisms, like all living systems, go through distinct phases of growth when introduced into a new environment:

  1. Lag Phase
  2. Log (Exponential) Phase
  3. Stationary Phase
  4. Decline (Death) Phase

The Lag Phase is the initial stage where no visible growth or activity is observed. However, this doesn’t mean microbes are inactive. During this phase:

  • Microbes adapt to the new environment.
  • Enzymatic systems are adjusted.
  • Gene expression is modified.
  • Cells are gearing up for division, not actively dividing yet.
Ā Why Does the Lag Phase Happen in ETPs?

When fresh bioculture is introduced into the aeration tank or bioreactor, several factors contribute to the length and intensity of the lag phase:

  1. Nutrient Profile Mismatch

Fresh microbes are often grown in optimized lab or fermenter media. When transferred to wastewater:

  • Nutrients may be imbalanced (e.g., low nitrogen or phosphorus).
  • Some carbon sources may be toxic or inhibitory (e.g., phenols, surfactants).
  • BOD:N:P ratio may be non-ideal (target is typically 100:5:1).

Example: If influent COD is 1000 mg/L and TKN is 5 mg/L → BOD: N ratio = 200:1 (far from ideal). This stresses fresh microbes, prolonging the lag phase.

This is why bioculture for removing ammoniacal nitrogen from effluent must be paired with proper nutrient profiling.

  1. Temperature and pH Shocks

Most bioculture strains are cultivated at optimal temperatures (25–35°C) and pH (6.8–7.5). When added to a field ETP:

  • Temperature fluctuations (e.g., influent temp of 18°C in winter) delay enzyme activation.
  • pH shocks (acidic wastewater from dye/textile units) inhibit microbial membrane transport.

Field data:

Fresh bioculture added at 5% v/v. Influent pH = 5.8 → no visible BOD reduction for 3 days. After pH correction to 6.8, activity began within 24 hours.

  1. Toxicity from Heavy Metals or Residual Chlorine

Heavy metals like Cr, Zn, and Cu or residual disinfectants like chlorine can denature proteins and kill cells, especially during initial exposure.

  • Tolerance limit for Cr = <0.5 mg/L
  • Chlorine residuals should be <0.1 mg/L before bio-activation

Example:
In one textile ETP, chlorine carryover from pre-treatment caused 90% loss of viable CFUs in 24 hours. Dechlorination was introduced → lag reduced from 4 days to 1.5 days.

Using anaerobic bioculture suppliers and dechlorination agents can significantly aid this transition.

  1. Low Dissolved Oxygen (DO) Levels

Bioculture organisms (especially nitrifiers) are aerobic. During start-up:

  • Oxygen demand spikes.
  • DO may drop below critical level (<2 mg/L).
  • Lag extends as microbes cannot activate oxidative enzymes efficiently.

Tip:
Maintain DO at 3–4 mg/L during startup even if it means temporary over-aeration.

  1. Microbial Competition and Protozoan Predation

Fresh microbes must compete with native microbes, and also survive protozoan grazing (e.g., Vorticella, rotifers).

  • If sludge age (MLSS age) is >20 days, floc-forming bacteria dominate, and new entrants struggle to establish.
šŸ“Š How to Monitor the Lag Phase in Real Time

Instead of waiting blindly, operators can use data-driven indicators:

ParameterExpected Behavior During LagComment
MLSSLittle to no changeNew cells not dividing yet
MLVSS/MLSS ratioLow (<0.65)High inert fraction initially
SOUR (mg Oā‚‚/g VSS/hr)Flat or very lowMicrobes not metabolizing
COD removal<10–20%Bioculture not active yet
Microscopic ObservationSmall, dispersed cells, few flocsNo protozoa or metazoans yet

Monitoring distribution of microbes in nature under a microscope can help detect early signs of colonization.

ā³ How Long is the Lag Phase?

The lag phase can last anywhere between:

  • 6–24 hours in ideal cases
  • 3–5 days in stressed systems
  • Up to 7+ days in shock-loaded or toxic wastewater
āœ… Strategies to Shorten the Lag Phase
  1. Condition the System First
    • Neutralize pH
    • Eliminate residual chlorine
    • Adjust BOD:N:P ratio
  2. Pre-Activate Bioculture
    • Incubate with actual wastewater and aerate for 12–24 hours before dosing
  3. Gradual Acclimatization
    • Introduce microbes in stages
    • Avoid full load startup
  4. Supplement DO and Nutrients
    • Temporary aeration boost
    • Add Urea/DAP if needed
  5. Use Carriers or Media (optional)
    • MBBR or Biofilm carriers provide protection and surface for colonization
Ā Conclusion: Patience Pays

The lag phase isn’t a failure – it’s a biological necessity. It reflects the intelligent adaptability of microbes to their environment. With the right microbial culture methods, proper planning, real-time monitoring, system conditioning, and application this phase can be shortened, and biological performance optimized.

Next time you add a fresh bioculture, don’t just watch the COD meter. Watch the system parameters, the microbes under the microscope, and give them the right conditions and time.

Because in microbiology – nothing works instantly, but everything works eventually.

šŸ‘‰ Talk to our experts now to enhance your bioculture performance

To know more:

🌐 Visit: www.teamonebiotech.com

šŸ“§ Email: sales@teamonebiotech.com Ā  šŸ“²: 7769862121

šŸ”¹Watch YouTube for our latest insights & innovations!

šŸ”¹Connect with Us on LinkedIn – Stay updated with expert content & trends!

Improving Oxygen Transfer Efficiency in Chemical ETP
Improving Oxygen Transfer efficiency in a Chemical manufacturing plant
Background

A mid-size chemical manufacturing company situated in Madhya Pradesh was facing efficiency issues in improving oxygen transfer efficiency in its ETP, such as low efficiency, biomass suspension, and diffuser dysfunction. Despite maintaining a good overall diffused aeration system, their biomass was not developing, and MLVSS was very low.

As a result, the client incurred high CAPEX due to unnecessary diffuser replacements and remained non-compliant with regulatory COD/BOD limits.Facing challenges in improving oxygen transfer efficiency and facing high energy costs? Let Team One Biotech help.

ETP details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow (current)750 KLD
Type of processASP
No. of aeration tanks1
Capacity of aeration tanks1150 KL
Challenges:Ā 

Parameters Avg. Inlet parameters(PPM)Avg. secondary system outlet parameters(PPM)
COD180006000
BOD85002800-3000
TDS300002500
Problem Statement:

The client observed persistently low dissolved oxygen (DO) levels in the aeration tank despite extended blower run-times and increased air supply. This resulted in:

  • Sub-optimal biological treatment
  • Elevated energy costs
  • Occasional odor issues and inconsistent COD/BOD reduction

A preliminary diagnosis indicated biofilm accumulation and diffuser fouling, affecting fine bubble formation and limiting oxygen dispersion.

Our Approach

Team One Biotech initiated a comprehensive on-site audit including:

Diffuser Health Check

  • Inspected diffuser membranes for fouling
  • Identified scaling and microbial slimes affecting pore performance

Baseline Monitoring

  • DO levels across the tank: <1.5 mg/L
  • Specific Oxygen Uptake Rate (SOUR): <15 mg Oā‚‚/g VSS/hr
  • Blower energy use: ~65 kWh/day
  • OTE Baseline: Estimated OTE was 12%

Microbial Evaluation

  • Floc structure was loose, with filamentous dominance
  • Low settleability (SVI > 200)

To implement a cost-effective, eco-friendly bioremediation strategy that:

  1. Enhances the degradation of formaldehyde and glutaraldehyde.
  2. Restores biological treatment efficiency.
  3. Achieves compliance with CPCB norms.
Solution

We proposed a 2-fold intervention:

1.Application of T1B Aerobio Bioculture

  • Dose: 10 ppm daily for 10 days, 8 ppm for next 10 days, and 5 ppm for next 10 days, then 3 ppm as maintenance every day.
  • Objective: Enrich native microbial diversity and improve biomass quality T1b Aerobio bioculture solution by improving oxygen transfer efficiency

2. Aeration System Optimization

  • Conducted sequential backflushing of diffusers
  • Realigned blower duty cycles with microbial demand using DO automation feedback

Monitored DO, pH, and ORP to ensure a stable environment.

Results:

After 60 days of implementation:

Parameters Before interventionAfter Intervention
DO in Aeration Tank1.2 mg/L2.8 mg/L
SOUR1             3.6 mg Oā‚‚/g VSS/hr22.3 mg Oā‚‚/g VSS/hr
SVI210 mL/g120 mL/g
COD Reduction72%87%
Blower Runtime24 hrs/day16 hrs/day
Energy Use65 kWh/day38 kWh/day
OTE12 %21.4 %
Application results before and after

Conclusion

With the combined effect of T1B Aerobio bioculture and technical aeration optimization, the client achieved a 78.3% increase in oxygen transfer efficiency. This translated into:

  • Significant energy savings
  • Improved microbial activity and settleability
  • Stable effluent quality, meeting compliance standards

This case demonstrates how biology-driven solutions, coupled with system know-how, can deliver tangible performance and cost benefits in industrial wastewater treatment.

Ready to optimize your ETP performance? Connect with us today

šŸ“§ Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Oxygen Transfer Efficiency in wastewater treatment
Oxygen Transfer Efficiency vs. Real-World Conditions: The Hidden Impacts of Diffuser Fouling and Uneven Airflow

In the world of wastewater treatment, Oxygen Transfer Efficiency (OTE) is a critical performance indicator, especially in biological treatment systems where aerobic microorganisms drive the breakdown of organic matter. On paper, system designs often promise high standard oxygen transfer efficiency based on clean-water testing. But in real-world conditions, actual oxygen transfer often falls significantly short — and two often-overlooked culprits are diffuser fouling and uneven airflow distribution.

At Team One Biotech, we help ETPs and STPs uncover these hidden inefficiencies. Contact us today to audit and improve your aeration system’s real-world performance.

Understanding Oxygen Transfer Efficiency

OTE is the percentage of oxygen from the air that actually dissolves into the wastewater. Higher efficiency means better microbial activity, lower energy costs, and more effective treatment. Bottom diffused aeration systems, particularly those with fine bubble diffuser oxygen transfer efficiency, are widely used due to their ability to maximize surface area and minimize energy use.

However, clean-water testing used to estimate standard OTE doesn’t reflect operational realities like biofilm buildup, particulate matter, or operational inconsistencies.

The Silent Saboteur: Diffuser Fouling

Over time, aeration diffusers — especially fine-pore ones — become clogged with biofilms, sludge solids, and inorganic scaling. This fouling:

  • Increases air resistance, reducing overall airflow.
  • Causes larger bubbles, decreasing oxygen transfer surface area.
  • Leads to non-uniform oxygen distribution, harming microbial populations in under-aerated zones.

As a result, a system that once transferred oxygen at 30% efficiency might drop to 15–20%, doubling the energy requirement for the same biological load.

šŸ” Poor sludge management can accelerate diffuser fouling, leading to cascading operational issues.

Tip: Regular diffuser inspection, cleaning schedules, and selecting fouling-resistant materials (e.g., PTFE-coated membranes) can mitigate this loss.

Uneven Airflow: An Invisible Imbalance

Even with clean diffusers, uneven airflow distribution due to pipe layout, blower inconsistency, or back pressure variations can cause:

  • Overaeration in some zones (wasted energy, poor floc formation),
  • Underaeration in others (anaerobic pockets, filamentous growth, odor issues).

This imbalance affects overall oxygen transfer efficiency and biological performance, especially in large or compartmentalized aeration tanks.

The Cost of Ignoring Reality

Ignoring these issues doesn’t just degrade standard OTE — it impacts the entire secondary system:

  • Reduced MLSS activity due to low DO,
  • Increased sludge production from partial degradation,
  • Higher energy bills with little performance gain,
  • Poor compliance with discharge norms due to high BOD/COD.
Real-World Solutions
  1. Flow Balancing: Use air flow meters and control valves to ensure uniform distribution.
  2. Blower Management: VFD-controlled blowers can respond to real-time DO demands, reducing peaks and troughs.
  3. Smart Monitoring: Modern SCADA systems and DO sensors help identify zones of concern early.
  4. Preventive Maintenance: Scheduled diffuser cleaning and aeration audits pay off in energy savings and treatment reliability.
Final Thoughts

It’s time the industry moves beyond theoretical OTE and embraces a ā€œReality-Based Aeration Strategyā€. Understanding and addressing diffuser fouling and uneven airflow are essential for sustainable wastewater treatment — both environmentally and economically.

At Team One Biotech, we specialize in supporting ETPs and STPs in optimizing their biological systems, including audits that uncover hidden losses in aeration efficiency. Let’s not just treat wastewater — let’s treat it wisely.

Reach out to us today to make sure your system isn’t silently losing efficiency — and money.

šŸ“§ Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Seasonal Microbial Shifts Wastewater Treatment
Beating the Seasonal Drift — How a Textile Unit Stabilized ETP Performance with T1B Aerobio Bioculture
 
Background

A mid-sized textile dyeing and processing unit in Gujarat struggled with recurrent seasonal drift in ETP and it’s biological performance. Contact us today to learn how T1B Aerobio can revolutionize your ETP’s performance and help you overcome seasonal challenges effectively.

Despite having a decent system design, they were plagued by:

  • Winter ammonia spikes
  • Monsoon washouts
  • Summer bulking
  • Transitional season shock-loads

These issues led to frequent compliance failures and operational stress.

T1B Aerobio-One Stop solution to seasonal drift:

T1B Aerobio – a blend of robust microbes especially bacteria , is the ultimate Thor’s hammer for seasonal cahllenges in any ETP. With a bank of 76+ different strains , T1B Aerobio was customized according to the challenges face by ETP in every season. It also consist various elements and enzymes which make it more efficient and a single solution for various challenges which no ordinary bioculture/microbial culture can deliver.

T1B Aerobio
ETP details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow150 KLD
Type of processASP
No. of aeration tanks
Capacity of aeration tanks650 KL each
Total RT hours
Season-Wise Breakdown of Challenges & Solutions

šŸŒØļø Winter Challenges (Dec–Feb)

Problems:

  • Nitrifier slowdown → High ammonia (>20 mg/L)
  • Low microbial activity → Increased F/M ratio
  • Reduced floc formation → Poor settling, turbid outlet
Solutions:
  • Pre-winter bioaugmentation with cold-active nitrifiers from T1B Aerobio Bioculture.
  • Increased MLVSS through controlled culture addition
  • Fine-tuned aeration to maintain DO around 3 mg/L
  • Reduced F/M by optimizing sludge wasting
Results:

Ammonia was reduced to <5 mg/L within 10 days. Sludge quality improved, and the outlet was consistently clear.

ā˜€ļø Summer Challenges (Apr–Jun)
Problems:
  • High temperatures → Oxygen depletion
  • DO <1.5 mg/L → Filamentous bulking
  •  anti-filamentous dominant cultures through T1B Aerobio bioculture to suppress filaments
  • Boosted DO levels by adjusting blower run hours
  • Added foam control microbes to reduce surface scum and bulking
Results:

SVI normalized to 95–100 mL/g. Sludge settling and clarity improved; odor complaints dropped significantly.

šŸŒ§ļø Monsoon Challenges (Jul–Sep)
Problems:
  • Heavy rainfall → Dilution & shock load
  • Surface runoff → Toxic load spikes
  • MLSS washed out → From 3500 to 1800 mg/L
  • Sudden pH shifts due to drainage ingress
Solutions:
  • Pre-monsoon culture buildup plan to fortify biomass using T1B Aerbio bioculture’s High-MLVSS variant
  • pH stabilization buffer introduced during heavy rains
  • Equalization tank aeration was increased to handle shock loads better
Results:

MLSS restored to 3100 mg/L within 7 days. COD removal stabilized at 90–92%. No emergency bypass required.

šŸ‚ Transitional Season Challenges (Mar, Oct–Nov)
Problems:
  • Frequent influent variability due to batch changes
  • Occasional toxicity due to dyeing chemical overuse
  • Rapid shifts in temperature and pH → Microbial lag
Solutions:
  • Weekly parameter tracking and real-time microbial health checks
  • Targeted detoxifier blend dosing with Aerobio during chemical overload
  • Gradual culture build-up before full-load restart after holidays
Results:

The biological system became more resilient, absorbing fluctuations without crashing. No major deviations in any parameter

Parameter Snapshot Before vs After Aerbio Intervention
ParameterBeforeAfter T1B Aerobio
(Winter)>20 mg/L<5 mg/L
MLSS (Monsoon)~1800 mg/L~3100 mg/L
SVI (Summer)>160 mL/g90–100 mL/g
COD Removal~78%~92%
Outlet ClarityTurbid frequentlyClear, consistent
Odor ComplaintsFrequentAlmost Nil
Conclusion

Microbial performance doesn’t follow a flat line—it fluctuates with the weather. But with a season-wise microbial management plan, your ETP can remain compliant, efficient, and stress-free year-round.T1B’s Aerbio bioculture adapts where standard systems struggle—empowering your ETP to beat the seasonal drift, naturally.

šŸ‘‰ Contact us to implement a customized, season-wise microbial strategy with T1B Aerobio and keep your ETP biologically stable and compliant—year-round.

šŸ“§ Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Seasonal Microbial Shifts Wastewater Treatment
ETP Performance Drift Due to Seasonal Microbial Shifts
Why Weather Matters More Than You Think in Biological Wastewater Treatment

In the evolving field of biological wastewater treatment, the performance of an effluent treatment plant manufacturer-designed system is often expected to be consistent. Yet, seasonal changes bring unseen forces into play—namely, seasonal microbial shifts.

Yes, the weather outside does impact what’s happening inside your biological tank.

From anaerobic wastewater treatment facilities to residential wastewater treatment systems, the health and efficiency of your microbial workforce are key to sustainability. This article dives into how climate-driven microbial dynamics can cause performance drifts—and how proactive strategies can future-proof your system.

šŸ‘‰ Contact us to know how your ETP can be adapted for every season using customized biological solutions.

The Invisible Workforce Behind ETPs

The core of any biological treatment system is its microbial community in ETP. These microorganisms are responsible for breaking down organic pollutants, converting ammonia to nitrate, and ensuring compliance with regulatory discharge norms.

But just like any workforce, they too have their comfort zones.

Seasonal Microbial Shifts: More Than Just Temperature

Microbes are sensitive to environmental parameters such as:

  • Temperature: Metabolic rates slow down in colder months, especially for nitrifiers.
  • Dissolved Oxygen (DO): Oxygen solubility increases in winter but may be limited due to reduced blower performance or sludge blanket fluctuations.
  • pH & Nutrient Uptake: Seasonal variations in industrial discharge or rainfall can alter pH and nutrient availability, affecting microbial dynamics.
  • Hydraulic Load: Monsoon seasons often increase flow, diluting influent but stressing retention time and contact efficiency.

These subtle shifts can lead to a noticeable drift in performance—sometimes gradual, sometimes sudden.

Microbial Dynamics in Action

Here’s a simplified breakdown of how microbial populations can change across seasons:

  • Winter: Slow growth of nitrifiers (Nitrosomonas/Nitrobacter) → Ammonia carryover risk. Sludge settling improves due to reduced filamentous growth.
  • Summer: Faster BOD removal but potential filamentous bulking due to low DO at higher temps.
  • Monsoon: Washout of biomass and sudden influx of organics or toxins due to surface runoff or diluted effluent—impacting both MLSS in wastewater and treatment efficiency.
What Your Parameters Are Telling You (Seasonal Indicators)
ParameterIdeal RangeSeasonal Variation & What It Indicates
DO (mg/L)2.0 – 3.5<2.0 in summer = filamentous growth; >4.0 in winter with low activity = underperforming bugs
MLSS (mg/L)2500 – 4000Monsoon may dilute or wash out biomass, dropping MLSS suddenly
SVI (mL/g)80 – 120>150 in summer suggests bulking; <70 in winter may indicate compact sludge
F/M Ratio0.2 – 0.4Low in winter due to slow bug activity; high post-monsoon due to fresh organic load
Ammonia (mg/L)<5 (in outlet)Elevated in winter due to slow nitrification; low in summer if nitrifiers are active
pH6.8 – 7.5Rainfall or industrial shifts can push pH outside this range, affecting bug health

By tracking these parameters monthly or weekly, early warnings of microbial stress can be detected and acted upon proactively.

What Can Be Done?
  1. Seasonal Bioaugmentation
    Introducing robust microbial cultures tailored for low-temp or high-load conditions can bridge seasonal performance gaps.
  2. Data-Driven Monitoring
    Trends in DO, SVI, ammonia, and MLSS can forecast seasonal drifts before they become problematic.
  3. Adjust Operating Parameters
    Fine-tune aeration, sludge wasting, or HRT based on seasonal projections for improved biological nutrient removal.
  4. Preventive Culture Dosing
    Pre-dosing before seasonal change (e.g., winter onset or monsoon) can prepare the system for upcoming stress.
Final Thought

Weather is inevitable, but ETP failures are not. Understanding and anticipating microbial behavior shifts with seasons can be the difference between compliance and chaos.

Let’s stop blaming the bugs—and start working with them.

Have you observed microbial shift or performance drift in your ETP system? Let’s connect and explore how tailored microbial strategies can make your system season-proof.

šŸ“§ Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Bioremediation of Aldehyde-Rich Wastewater from a Pharmaceutical Manufacturing Unit
Bioremediation of Aldehyde-Rich Wastewater from a Pharmaceutical Manufacturing Unit
Background

A leading pharmaceutical company situated in Madhya Pradesh in India was facing challenges in treating its aldehyde-laden wastewater, particularly with glutaraldehyde and formaldehyde content.Bioremediation of aldehyde-rich wastewater emerged as a sustainable and effective solution to this issue. Contact Us to learn how we can transform your wastewater challenges into sustainable solutions.

These compounds, used in drug synthesis and as disinfectants, were found to be:

  • Inhibiting microbial activity in their conventional Activated Sludge Process (ASP), a common biological wastewater treatment method.
  • Causing non-compliance with regulatory COD/BOD limits—critical benchmarks in any sewage water treatment process.
  • Producing a persistent pungent odor at the ETP outlet, calling for odour control in wastewater treatment.
ETP details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow (current)900 KLD
Type of processASP
No. of aeration tanks2
Capacity of aeration tanks3180 KL and 2840 KL
Challenges:Ā 
ParametersĀ Avg. Inlet parameters(PPM)Avg. Outlet parameters(PPM)
COD120001500
BOD4500880-500
TDS40001200
Formaldehyde200145
Gluteraldehyde210182
Problem Statement:

Despite having a full-fledged ETP (Equalization → Primary → ASP → Clarifier), the system could not consistently bring down aldehyde levels due to their toxicity to standard microbial consortia. The system experienced:

  • Foaming and poor settling in the aeration tank.
  • Reduced BOD removal efficiency.
  • Increased sludge bulking and filamentous growth—issues typical in inefficient wastewater filtration and sludge management systems.
Objective:

To implement a cost-effective, eco-friendly bioremediation strategy that:

  1. Enhances degradation of formaldehyde and glutaraldehyde.
  2. Restores biological treatment efficiency.
  3. Achieves compliance with CPCB norms.
Solution: Bioaugmentation-Based Bioremediation
Step 1: Selection of Microbial Culture/Bioculture

A customized bio-culture T1B Aerobio blend was developed, containing aldehyde-degrading strains of:

  • Pseudomonas putida
  • Bacillus subtilis
  • Rhodococcus sp.

These microbes had been lab-tested for their aldehyde tolerance and metabolic capabilities..aerobio from t1b

Step 2: Dosing Plan in Full-Scale ETP
  • Initial Loading dose: For 1st 30 days to develop the population of bacteria and generate biomassĀ 
  • Maintenance dose: For the next days and on, to maintain the population of biomass generated.
  • Nutrient balancing (C:N:P = 100:5:1) to promote growth.
Step 3: Acclimatization Phase (2 Days)
  • The culture was activated for two days separately for acclimatization.

Monitored DO, pH, and ORP to ensure a stable environment.

Results:

After 60 days of Bioculture addition/Bioremediation:

ParametersĀ Avg. Inlet parameters(PPM)Avg. Outlet parameters(PPM)
COD12000500
BOD4500280
TDS40001200
Formaldehyde200>15
Gluteraldehyde210>30

60 days of Bioculture addition/ bioremediation of aldehyde-rich wastewater

60 days of Bioculture addition/ bioremediation of aldehyde-rich wastewater

Benefits Observed

āœ… Rapid degradation of aldehydes without secondary pollutants
āœ… Stabilized biomass and improved MLSS/MLVSS ratio
āœ… Significant reduction in foaming and sludge bulking
āœ… Odor control and improved air quality near the aeration tank
āœ… Regulatory compliance achieved within 4 weeks

Conclusion

Bioremediation of aldehyde rich wastewater has proven to be a sustainable and economical solution for treating contaminated wastewater. With careful acclimatization, dosing, and nutrient balancing, the ETP was restored to optimal performance without requiring major infrastructure changes.This highlights the power of using the right wastewater treatment products and techniques to improve residential wastewater treatment systems and eco sewage treatment plants alike.

šŸ“© Contact Us to explore how our waste water engineering solutions can support your sewage treatment plant maintenance needs.

šŸ“§ Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Removal of aldehydes in industrial wastewater and solutions
Aldehydes in Industrial Wastewater: Pollution, Sources & Treatment
Introduction

In this blog, we will explore pollution of aldehydes in industrial wastewater, its impact on the environment, and the methods available for treatment. You’ll gain a clear understanding of what aldehydes are, how they contribute to chemical pollution, and the best practices to treat them effectively in effluent streams. At Team One Biotech, we help industries tackle environmental pollution caused due to aldehydes and related chemical discharge through smart, science-backed wastewater treatment solutions.

šŸ‘‰ Contact us for expert advice on aldehyde removal and advanced effluent treatment systems.

What are Aldehydes?

Aldehydes are a group of organic compounds containing a carbonyl group (C=O) bonded to a hydrogen atom and an R group (which can be hydrogen or an organic side chain). Their general formula is R-CHO, where:

  • R is a hydrogen or carbon-containing group.
  • CHO is the aldehyde functional group.

Common examples of aldehydes include:

  • Formaldehyde (HCHO)
  • Acetaldehyde (CHā‚ƒCHO)
  • Glutaraldehyde (Cā‚…Hā‚ˆOā‚‚)
  • Benzaldehyde (C₆Hā‚…CHO)

Aldehydes and ketones are widely used in manufacturing, pharmaceuticals, and food industries, contributing significantly to chemical industry pollution if untreated. They are known for their reactivity, distinct odors, and broad industrial applications.

How Aldehydes Contribute to Wastewater Pollution

Aldehydes in industrial wastewater, especially at high concentrations, are harmful industrial chemicals that significantly contribute to water pollution. They are toxic to aquatic ecosystems and cause serious chemical effects, posing major environmental risks.Some impacts include:

  • Oxygen depletion: Aldehydes are highly biodegradable and demand large amounts of dissolved oxygen during degradation, leading to lower DO levels.
  • Toxicity to microbes: In ETPs, aldehydes can be harmful to bacteria and other microbes essential for biological treatment, especially nitrifiers.
  • Persistent odor and volatility: Aldehydes like formaldehyde can cause secondary chemical pollution through volatilization.
  • Formation of harmful by-products: Under certain conditions, aldehydes can react with ammonia, chlorine, or other substances adding to chemicals involved in water pollution.
Industries That Release Aldehydes in Industrial Wastewater

Several industrial sectors contribute aldehydes and industrial chemicals that pollute water in effluent streams, either directly or as by-products:

  1. Textile & Dye Manufacturing
    – Formaldehyde-based resins are used for wrinkle resistance and dye fixation.
  2. Paper & Pulp Industry
    – Aldehyde derivatives used in wet strength resins and coatings.
  3. Pharmaceuticals & Chemicals
    – Production of intermediates like formaldehyde, acetaldehyde, and glutaraldehyde.
  4. Leather Tanning
    – Use of aldehyde-based tanning agents.
  5. Cosmetics & Personal Care
    – Preservatives and fixatives may contain low levels of aldehydes.
  6. Disinfectant Manufacturing
    – Glutaraldehyde is used in sanitizers and biocides.
  7. Food Processing (especially flavorings and preservatives)
    – Aldehydes like benzaldehyde used in synthetic flavorings.

These examples highlight the scale of chemical industry pollution and the need for effective regulation and treatment.

Treatment Methods for Aldehydes in Wastewater

Effective treatment depends on the concentration, type of aldehyde, and co-contaminants. The goal is often the reduction of aldehydes and ketones into less harmful substances using a mix of treatment methods:

1. Biological Treatment

Biological treatment is often the core of an Effluent Treatment Plant (ETP), especially for organic pollutants. Aldehydes are biodegradable to some extent, making biological treatment viable — but only if concentrations are not too high.

šŸ”ø a. Activated Sludge Process (ASP)
    • How it works: In ASP, aerobic bacteria in the aeration tank metabolize organic matter. Aldehydes are broken down into simpler compounds like organic acids, COā‚‚, and water.
    • Requirements: Adequate DO (Dissolved Oxygen), stable temperature, and pH (around 6.8–7.5).
Challenges:
    • Aldehydes, especially formaldehyde or glutaraldehyde, can be toxic at high concentrations.
    • They may inhibit microbial activity, especially nitrifiers.
    • Best practice: Use equalization tanks to prevent sudden chemical pollutants in environment spikes
šŸ”ø b. Aerobic Degradation
    • Specificity: Some bacteria (like Pseudomonas, Bacillus, etc.) are specially adapted to degrade aldehydes.
    • Conditions: Requires good aeration and neutral pH.
  • Pros:
    • Low operational cost.
    • Produces minimal secondary pollution.
  • Cons: Not suitable for very high concentrations or highly toxic aldehydes.
šŸ”ø c.Anaerobic Digestion
    • Use case: Rare for aldehydes, but can work in mixed wastewater treatment (especially with long-chain aldehydes).
  • Caution: Anaerobic microbes are more sensitive to chemicals that cause water pollution.
2. Advanced Oxidation Processes (AOPs)

AOPs are highly effective for treating toxic, non-biodegradable, or concentrated aldehydes. They work by producing hydroxyl radicals (•OH) — extremely reactive species that attack and oxidize aldehydes.

šŸ”ø a. Fenton’s Reagent (Fe²⁺ + Hā‚‚Oā‚‚)
  • How it works:
    • Hydrogen peroxide reacts with ferrous iron (Fe²⁺) to generate hydroxyl radicals.
    • These radicals oxidize aldehydes into acids or COā‚‚.
  • Equation: Fe²⁺ + Hā‚‚Oā‚‚ → Fe³⁺ + OH⁻ + •OH
  • Use case: Effective for formaldehyde, acetaldehyde, and glutaraldehyde.
  • Pros: Fast, powerful oxidation.
  • Cons:
    • Requires pH ~3.
    • Sludge generation due to iron salts.
šŸ”ø b. Ozonation
  • How it works: Ozone gas (Oā‚ƒ) is bubbled through wastewater. It reacts directly with aldehydes or generates radicals in water.
  • Reactions:
    • Oā‚ƒ + aldehyde → organic acids + Oā‚‚
  • Pros:
    • Powerful disinfectant.
    • Effective even at low concentrations.
  • Cons:
    • High operating cost.
    • Short half-life of ozone; must be generated on-site.
šŸ”ø c. UV/Hā‚‚Oā‚‚ or UV/Oā‚ƒ Systems
  • How it works:
    • UV light breaks down Hā‚‚Oā‚‚ or Oā‚ƒ to produce hydroxyl radicals.
    • These radicals degrade aldehydes completely.
  • Pros:
    • High removal efficiency.
    • Can achieve near-total mineralization.
  • Cons:
    • Requires UV setup.
    • Higher energy demand.
3. Chemical Treatment

In this method, chemicals are used to neutralize or oxidize aldehydes directly.

šŸ”ø a. Chemical Oxidation
    • Agents used: Potassium permanganate (KMnOā‚„), sodium hypochlorite (NaOCl), chlorine dioxide (ClOā‚‚).
    • Reaction: Aldehyde + Oxidant → Carboxylic acid or COā‚‚
    • Use case: Ideal for small-volume, high-toxicity effluent (e.g., lab or pharma).
  • Pros:
    • Rapid action.
  • Cons:
    • Residual oxidants must be neutralized.
    • Risk of forming additional chemical pollutants in environment (e.g., chloroform with chlorine).
šŸ”ø b. Neutralization
    • Example: Glutaraldehyde can be neutralized with:
    • Sodium bisulfite (NaHSOā‚ƒ): reduces toxicity.
    • Glycine: forms stable, less harmful complexes.
    • Use case: Common in pharma, hospitals, and labs.
  • Pros:
    • Easy to dose.
  • Cons:
    • Only works for specific aldehydes.
    • Generates salt residues.
4. Adsorption Techniques

Adsorption is mainly used as a polishing step or for low concentrations of aldehydes.

šŸ”ø a. Activated Carbon
    • How it works: Porous carbon adsorbs aldehyde molecules from water.
  • Types:
    • Powdered Activated Carbon (PAC)
    • Granular Activated Carbon (GAC)
  • Best for: Trace-level removal in final polishing.
    • Pros:
    • Simple, no chemical use.
  • Cons:
    • Media needs regular regeneration or replacement.
    • Not effective for large volumes or high aldehyde levels.
šŸ”ø b. Ion Exchange Resins / Synthetic Polymers
    • Used for: Specific aldehydes or when very low discharge limits are required.
    • Cost: High, but precise.
5. Membrane Filtration

This method involves physically separating aldehydes using semi-permeable membranes.

šŸ”ø a. Nanofiltration (NF) & Reverse Osmosis (RO)
  • How it works:
    • Pressure is applied to force water through a membrane.
    • Aldehydes and other organics are rejected and concentrated in the reject stream.
  • Pros:
    • High removal efficiency.
    • Produces clean, reusable water.
  • Cons:
    • High CAPEX & OPEX.
    • Membrane fouling risk.
    • Reject stream needs further treatment.
Integration Example in an ETP

If a pharmaceutical plant has glutaraldehyde in its effluent:

  • Equalization Tank – for dilution.
  • Chemical Neutralization – with glycine or bisulfite.
  • Biological Treatment (ASP) – for biodegradation.
  • AOP (UV/Hā‚‚Oā‚‚) – as a polishing stage.
  • GAC Filtration – before final discharge or RO.
Summary Table
MethodBest ForLimitations
Biological (ASP)Low–moderate aldehydesSensitive to toxicity
Fenton / OzoneHigh-concentration aldehydesCost, sludge
Chemical OxidationSmall volumesToxic by-products
AdsorptionPolishing stageMedia replacement
Membrane (RO/NF)Reuse/very clean waterExpensive, complex
Best Practices in ETPs for Aldehyde-Contaminated Effluent
  1. Equalization Tank:
    – To reduce the shock loading of aldehydes on biological systems.
  2. Pre-treatment Unit (AOPs or Chemical Neutralization):
    – Before biological treatment for high aldehyde loads.
  3. Bioaugmentation:
    – Use of aldehyde-degrading microbial strains to enhance biodegradation.
  4. pH and DO Monitoring:
    – Aldehyde toxicity is pH-dependent; maintaining optimal pH (6.8–7.5) helps reduce toxicity.
  5. Toxicity Testing:
    – Regular bioassays to monitorĀ  chemical effects of pollution on microbes
Conclusion

Aldehydes, though small in molecular size, can pose significant environmental challenges if not properly managed in industrial wastewater. As chemical pollutants in environment, they demand robust treatment and monitoring strategies. Integrating pre-treatment, biological processes, and advanced oxidation ensures comprehensive aldehyde removal and compliance with environmental norms.

Industries must also invest in source reduction, green chemistry alternatives, reduction of aldehydes and ketones and ETP upgrades to curb chemical pollution and ensure regulatory compliance.

For expert assistance on treatment solutions or inquiries about the removal techniques of aldehydes in industrial wastewater, Contact Us today!

šŸ“§ Email: sales@teamonebiotech.com🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Implementation of SBR system in a CETP
Implementation of SBR System in a CETP with T1B Aerobio Bioculture
Introduction:Ā 

The SBR system in a CETP situated in Rajasthan handles effluents from over 40 industries in the RIICO sector the system faces difficulty in handling the load of COD above 2000 PPM, owing to discharges from textiles andĀ  chemicals. The SBR system with 4 biological tanks and 4 cycles a day was struggling with its efficiency in termsĀ  of COD reduction, due to which the outlet COD was very high and the load was carried on to the RO, leading toĀ  damage of membranes and high OPEX. Contact us today to learn how we can help optimize your industrial effluent treatment plant (ETP) with customized bioaugmentation solutions.

ETP details:Ā 

The industry had primary treatment, biological treatment, and then a tertiary treatment.Ā 

Flow (current)Ā 2 MLD
Type of processĀ SBR
No. of aeration tanksĀ 4
Capacity of aeration tanksĀ 3 MLD each
Total cycles in 24 hrsĀ 4
Duration of fill and Aeration cycleĀ 1.5 hrs and 2.5 hrs respectively
Challenges:
ParametersĀ Avg. Inlet parameters(PPM)Ā Avg. Outlet parameters(PPM)
CODĀ 3000Ā 800
BODĀ 1800Ā 280-300
TDSĀ 3000Ā 1200
Operational Challenges:Ā 
  • The primary treatment was working at 5 % efficiency in terms of COD reductionĀ 
  • The whole SBR system was lagging in COD degradation efficiency and sustainability of MLVSS as well.Ā 
  • The Carryover COD and unsettled biomass was traveling to RO, damaging membranes.Ā 
The Approach:Ā 

The agency operating the SBR system in a CETP approached us to solve their current issues.Ā Ā 

We adopted a 3D approach that included :Ā 

  1. Research/Scrutiny :Ā Ā 
  • Our team visited their facility during the winter season as they encountered many issues at thatĀ Ā 

Ā  Ā  Ā  Ā  Ā time. Team scrutinized every aspect of the plant to analyze the efficiency of each element.Ā 

  • The visit gave us a complete idea of their processes, current efficiency, trends, and our scope ofĀ Ā 

Ā  Ā  Ā  Ā  Ā work.Ā Ā 

  1. Analysis :Ā 
  • We analyzed the previous 6-month cumulative data of their ETP to see trends in the inlet-outletĀ Ā 

Ā  Ā  Ā  Ā  Ā parameters’ variations and the permutation combinations related to it.Ā 

  1. Innovation :Ā Ā 
  • After the research and analysis our team curated customized products and their dosing schedulesĀ  with formulation keeping in mind the plan of action to get the desired results. This process isĀ  Ā  Ā  Ā  Ā  Ā  calledĀ  bioaugmentation.Ā 
Desired Outcomes :Ā 
  1. Reduction of COD/BOD thereby improving the efficiency of biological tanks.Ā 
  2. Degradation of tough-to-degrade effluents and develop robust biomass to withstand shock loads.Ā 
  3. Ensuring proper settling of Biomass to stop carryover to RO, thereby preventing damage to ROĀ membranes.
Execution:Ā 

Our team selected two products :Ā 

T1B aerobio product

T1B Aerobio Bioculture: This product consisted of a blend of microbes as biocultureĀ Ā 

selected as per our analysis to degrade the recalcitrant COD, and ensure sustainability inĀ Ā 

the SBR system.Ā Ā 

Plan of action:Ā 
  1. We devised a 60 days dosing plan, which was further divided into two phases:Ā 
  • Day 1 to day 30 : Loading dose, to develop the population of bacteria and generate biomass.
  • Day 31 to Day 60: Maintenance Dose, to maintain the population of biomass generated.Ā 
  1. Dosing pattern: We advised dosing in all 4 SBR tanks cycle wise viz. during filling and Aeration, to giveĀ  the bioculture proper mixing and necessary DO.Ā 
Results:Ā 
ParametersĀ Inlet parametersĀ Tank 4 outlet parameters (ppm)
CODĀ 3000 ppmĀ 280-300 ppm
BODĀ 1800 ppmĀ 60-82 ppm

Before and after adding bioculture

The implementation of the bioaugmentation program resulted in significant improvements in the performanceĀ  of biological units in their WWTP:Ā 

  • We were able to achieve around 90 % reduction from their current inlet parameters in COD & BOD,Ā  which was only 70% earlier.Ā 
  • The overall ETP OPEX was reduced by 20%.Ā 
  • The ETP achieved full capacity operations in terms of hydraulic load.Ā 
  • The biological process became more stable and resilient to fluctuations in the influent characteristics.Ā 
  • The RO membrane health was restored and and their damage reduced up to 80%.

šŸ“§ Want similar results for your ETP or STP? Contact us for more Information.

šŸ“§ Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

šŸ”¹ Discover More on YouTube – Watch our latest insights & innovations!-

šŸ”¹ Connect with Us on LinkedIn – Stay updated with expert content & trends!

Scan the code