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

The Common Effluent Treatment Plant (CETP) situated in Rajasthan handles effluents from over 40 industries in the RIICO sector. Equipped with SBR system in CETP technology, the system faces difficulty in handling the load of Chemical Oxygen Demand (COD) above 2000 PPM, owing to discharges from textiles and chemicals. The SBR wastewater treatment system, with 4 biological tanks and 4 cycles a day, was struggling with its efficiency in terms of COD reduction, resulting in high outlet COD levels. This excess load was carried over to the Reverse Osmosis (RO) system, leading to membrane damage and increased operational expenses (OPEX).

To explore effective solutions for optimizing wastewater treatment and improving COD reduction efficiency, you can reach out to Team One Biotech

ETP details:

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

Flow (current)2 MLD
Type of processSBR
No. of aeration tanks4
Capacity of aeration tanks3 MLD each
Total cycles in 24 hrs4
Duration of fill and Aeration cycle1.5 hrs and 2.5 hrs respectively
Challenges: 
Parameters Avg. Inlet parameters(PPM)Avg. Outlet parameters(PPM)
COD3000800
BOD1800280-300
TDS30001200
Operational Challenges:
  • The primary treatment was working at only 5% efficiency in terms of COD reduction.
  • The entire SBR process was lagging in COD degradation efficiency and sustainability of Mixed Liquor Volatile Suspended Solids (MLVSS).
  • Carryover COD and unsettled biomass were traveling to RO membranes, causing severe damage.
The Approach:

The agency operating the CETP wastewater treatment plant approached us to solve these pressing issues.

We adopted a 3D approach:
  1. Research/Scrutiny:
    Our team visited their facility during the winter season as they faced many challenges. We scrutinized every aspect of the plant to assess the efficiency of each component.
  2. Analysis:
    We analyzed six months of historical data to identify trends in wastewater treatment parameters, including BOD removal efficiency, COD degradation, and total dissolved solids (TDS) reduction.
  3. Innovation:
    Based on our findings, we developed a bioaugmentation strategy by selecting customized products and designing a targeted dosing schedule.
Desired Outcomes:
  • Significant COD and BOD reduction, improving the efficiency of biological treatment systems.
  • Degradation of hard-to-treat industrial effluents and formation of stable biomass to handle shock loads.
  • Enhanced biomass settling, reducing carryover COD and preventing RO membrane damage.
Execution:

Our team selected two products :

T1B Aerobio Bioculture: This product consisted of a blend of microbes as bioculture selected as per our analysis to degrade the recalcitrant COD, and ensure sustainability in the SBR system in CETP. 

Plan of Action:
  1. We devised a 60-day dosing program, divided into two phases:
  • Day 1 to Day 30: Loading dose to accelerate microbial population growth and generate biomass.
  • Day 31 to Day 60: Maintenance Dose, to maintain the population of biomass generated.
2. Dosing Strategy:
  • Dosing was carried out in all 4 SBR aeration tanks during filling and aeration cycles to ensure optimum microbial activity.
Results:
ParametersInlet parametersTank 4 outlet parameters (ppm)
COD3000 ppm280-300 ppm
BOD1800 ppm60-82 ppm

diagram of before and after bioculture, SBR system in CETP
The implementation of bioaugmentation program by SBR system in CETP resulted in significant improvements in the performance of biological units in their WWTP:

✅ Achieved 90% COD and BOD reduction, compared to the previous 70% efficiency.
✅ Reduced CETP operational expenditure (OPEX) by 20%.
✅ Increased ETP capacity utilization to handle full hydraulic load.
✅ Improved biological process stability, making it more resilient to influents fluctuations.
✅ RO membrane health restored, reducing damage by 80%.

Conclusion:

The successful implementation of bioaugmentation with T1B Aerobio Bioculture led to an efficient, cost-effective, and sustainable wastewater treatment system. By enhancing COD degradation efficiency, reducing BOD levels, and improving biomass stability, the CETP wastewater treatment achieved outstanding results. This highlights the importance of biological wastewater treatment solutions in optimizing industrial effluent treatment processes.

 Discover how T1B Aerobio Bioculture can help you today!

Struggling with high COD levels in your wastewater treatment system? Contact us today to know more about how T1B Aerobio Bioculture can help you today!

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effluent treatment plant
Enhancing effluent treatment efficiency at a Nylon tyre cord company

Industry Overview

A leading manufacturer of Nylon Tyre Cord Fabric (NTCF) and Nylon Filament Yarn (NFY) in India. The manufacturing process generates waste water containing high BOD COD and complex organic pollutants, requiring an advanced effluent treatment system or compliance with environmental norms. 

To learn how our solutions can help optimize wastewater management and ensure regulatory adherence, contact us today.

ETP Overview

 The company operates a 650 KLD effluent treatment plant (ETP) with the following aeration tank capacities:

  • Aeration Tank 1: 450 KL
  • Aeration Tank 2: 800 KL
  • Aeration Tank 3: 400 KL

The wastewater treatment system includes equalization, primary treatment, biological treatment (aeration tanks), secondary clarification, and waste management through sludge treatment.

Challenges Faced by the ETP

  1. Frequent Upsets Due to Multiple Waste Water Streams 

The industry has multiple waste water streams, including:

  • ✅ Process wastewater treatment from Nylon production – Contains high COD, phenols, and recalcitrant organics.
  • ✅ Dye and finishing waste water – High in sulfates, surfactants, and residual dyes.
  • ✅ Boiler & cooling tower blowdowns – High in TDS and scaling compounds.

These varied streams led to fluctuations in pH, organic load, and microbial inhibition, making biological treatment inconsistent.

  1. Filamentous Bacteria Growth Leading to Bulking & Poor Settling 

The aeration tanks experienced frequent filamentous bacterial overgrowth, leading to:

  • ❌ Sludge bulking – Poor settleability in the secondary clarifier.
  • ❌ Reduced oxygen transfer – Filamentous microbes formed a mat, lowering aeration efficiency.
  • ❌ High MLSS but poor COD removal – Inefficient microbial metabolism caused high effluent COD.
  1. High COD and BOD in Final Discharge
    • COD levels >1200 mg/L after biological treatment (well above discharge limits).
    • BOD levels exceeded 250 mg/L, indicating poor organic degradation.
    • Fluctuations in ammonia and nitrate levels due to microbial stress.

Solution: Implementation of Our Customized Bioculture for Effluent Treatment System

To address these challenges, a customized culture solution was implemented in three stages:

  1. Bioaugmentation with Specialized Microbial Strains We introduced a high-performance microbial culture consortia designed to degrade recalcitrant organics and control filamentous growth.
Pollutant / Issue Targeted Bioculture Strains Mode of Action
High COD from dyes & finishing Pseudomonas putida, Bacillus subtilis Produces oxidative enzymes to break down complex organics.
Phenolic compounds & nylon by-products Acinetobacter sp., Comamonas testosteroni Uses phenol hydroxylase to degrade toxic aromatics.
Surfactants & residual oil Sphingomonas sp., Rhodococcus sp. Breaks down surfactants & hydrocarbons.
Filamentous bacterial overgrowth Bacillus licheniformis, Nitrosomonas sp. Competes with filamentous microbes & improves sludge settling.
Ammonia & nitrate fluctuations Nitrobacter sp., Paracoccus denitrificans Enhances nitrification & denitrification for ammonia removal.

Dosage Strategy:

  • First 10 days: Shock dosing of bioculture for STP wastewater treatment (10 ppm/day) to quickly establish microbial dominance.
  • Post-10 days: Maintenance dosing (2–3 ppm/day) for stable microbial activity.
  1. Process Optimization in Aeration Tanks
    • Dissolved Oxygen (DO) Optimization: Increased DO from 1.5 mg/L to 2.5 mg/L by fine-tuning aeration rates.
    • MLSS & SRT Adjustments: Maintained MLSS at 3500–4000 mg/L for optimum microbial growth.
    • Sludge Recycle Ratio: Adjusted to 60% return rate to prevent sludge bulking.
  1. Enhanced Settling & Clarifier Performance
    • The addition of floc-forming microbes (Bacillus sp.) improved sludge compactness, reducing SV30 from 200 ml/L to 80 ml/L.
    • Sludge volume index (SVI) improved from >250 mL/g to <120 mL/g, indicating better sludge settleability.

Results Achieved

Parameter Before Treatment After Bioculture Implementation Reduction %
COD in Effluent 1200 mg/L 180 mg/L 85%
BOD in Effluent 250 mg/L 35 mg/L 86%
Phenol Concentration 45 mg/L 5 mg/L 88%
Filamentous Bacteria Issue Frequent sludge bulking Fully controlled –
Dissolved Oxygen (DO) 1.5 mg/L 2.5 mg/L –
Sludge Settling (SVI) >250 mL/g <120 mL/g 52% Improvement

Key Benefits for the Industry 

✅ Consistent Compliance with Environmental Norms

  • Effluent quality now meets CPCB discharge limits (COD < 250 mg/L, BOD < 30 mg/L).

✅ Reduced Operating Costs

  • Lower aeration energy costs due to improved oxygen transfer efficiency.
  • Reduced chemical usage (e.g., less need for coagulants & antifoam).

✅ Stable ETP Operation with No More Upsets

  • Bioculture created a robust microbial ecosystem that handled stream variations effectively.

✅ Improved Sludge Management

  • Better settling resulted in less sludge disposal & reduced maintenance costs.

Conclusion 

The implementation of our customized bioculture solution successfully transformed the effluent treatment system at Century Enka Ltd., Bharuch. By addressing COD BOD problems, filamentous bacterial issues, and inefficient aeration, the plant achieved stable treatment performance, reduced operational costs, and regulatory compliance. 

Are you looking for expert solutions in effluent treatment and sustainable wastewater management?

Contact us to know more about how our customized bioculture solutions can help!

Email: sales@teamonebiotech.com

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Wastewater treatment plant for integrated textile industry
Effective Wastewater Treatment Plant for an Integrated Textile Industry in India
Introduction:

The Integrated Textile Industry is a leading cloth manufacturing company that involves denim production, cotton apparel manufacturing, and is also involved in the pulping of raw materials and paper manufacturing. With a strong commitment to environmental sustainability, the Integrated Textile Industry operates a waste water treatment plant (WWTP) at its textile manufacturing facility to treat the industrial effluent generated during its textile production processes.

However, the industry faced challenges in meeting the effluent discharge limits for certain pollutants, including the presence of components from reactive dyes, high chemical oxygen demand (COD), elevated biochemical oxygen demand (BOD), higher levels of color, and effluent temperature reaching up to 50°C. To address these challenges, the industry implemented a bioaugmentation program at its effluent treatment plant (ETP), which resulted in significant improvements in the wastewater treatment process and compliance with regulatory standards for industrial effluents.

Effluent Treatment Plant (ETP) Details:

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

Flow 500-600 KLD
Type of process MBBR
No. of aeration tanks 2 (in parallel)
Capacity of aeration tanks 650 KL each
Total RT hours
Challenges:
Parameters Inlet parameters  Outlet parameters (Secondary System)
COD 13,000 to 10000 8500 to 6800 
BOD 4000 to 2500 2800 to 1650
Colour 750 to 900 Hazen 560 to 700 Hazen
  • The primary treatment system was working at 20-30% efficiency in terms of COD reduction.
  • The biological treatment was working at an average of 10-15% efficiency combined in terms of COD removal.
  • The system was struggling to effectively treat pollutants originating from reactive dyes and to reduce color contamination in the textile effluent.
  • The mixed liquor suspended solids (MLSS) were very low, and the microbial population in the biological treatment tanks could not develop due to the high wastewater temperature of 50°C.
  • The conventional MBBR waste water treatment plant was not efficient enough to consistently meet the stringent effluent discharge standards set by local environmental regulatory agencies.

As a result, the textile manufacturing company faced the risk of non-compliance, which could lead to regulatory fines, reputational damage, and environmental pollution.

The Bioaugmentation Approach:

The Integrated Textile Industry partnered with us to enhance the efficiency of their biological units. They had two aeration tanks in parallel, equipped with diffusers, handling a daily wastewater flow of 500-600 KLD.

Bioaugmentation is a biological wastewater treatment technique that involves adding specifically selected microorganisms, such as bacteria and enzymes, to improve the biological degradation of pollutants in a waste water treatment plant. The team conducted a comprehensive wastewater assessment to analyze the industrial effluent characteristics and the WWTP’s operational parameters, identifying the best bioaugmentation strategy for this textile effluent treatment plant.

Based on the assessment, a customized bioaugmentation program was designed and implemented. The microbial cultures were carefully selected to target organic pollutants, particularly contaminants from reactive dyes in the industrial effluent stream. Thermophilic bacteria were introduced to withstand high-temperature wastewater conditions and enhance the biological treatment process.

The bioaugmentation process was seamlessly integrated into the existing wastewater treatment process, and the performance of the WWTP was monitored over the next three months.

Improved Effluent Quality After Bioaugmentation:

Parameters

 Inlet Parameters (ppm)

Outlet Parameters (After Bioaugmentation) (ppm)
COD (Chemical Oxygen Demand) 13,000 to 10,000 2,500 to 1,800
BOD (Biochemical Oxygen Demand) 4,000 to 2,500 800 to 650
Color (Hazen Units) 750 to 900 150 to 300
Results and Benefits of Bioaugmentation in Wastewater Treatment:

The implementation of the bioaugmentation program resulted in significant improvements in the performance of biological units at the wastewater treatment plant:

✅ Achieved around 80-84% reduction in COD & BOD levels in the treated industrial effluent.
✅ Attained 80-85% color removal efficiency, demonstrating visible improvement in effluent clarity.
✅ Enhanced microbial population growth in biological tanks, even at higher wastewater temperatures.
✅ The biological treatment system became more stable, reducing process fluctuations caused by influents variability.
✅ Increased plant reliability, ensuring consistent compliance with regulatory discharge limits.
✅ Reduced operational costs through optimized biological treatment efficiency.

The successful bioaugmentation application has helped the Integrated Textile Industry maintain regulatory compliance, improve wastewater treatment plant performance, and support their commitment to sustainable textile manufacturing.

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Chemical Industry Effluent Treatment with T1B Aerobio Bioculture
Introduction:

Effluent treatment is an essential process for the chemical manufacturing industry as it is a significant source of industrial wastewater pollution. Chemical industries produce a wide range of chemicals, and the effluent wastewater from these industries can contain a variety of pollutants that need to be treated before discharge into the environment. Biological wastewater treatment of effluent with bioculture for wastewater treatment is an effective and eco-friendly method for treating industrial effluent from the chemical sector.

A chemical processing industry located at Amaravati MIDC industrial area was perturbed by surging Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (BOD), and Total Dissolved Solids (TDS) levels. Our client had an activated sludge process (ASP) wastewater treatment plant, which had 4 aeration tanks in series. The industrial effluent contained high levels of chemical pollutants such as phenol, formaldehyde, ammonia, and heavy metals like lead, cadmium, and chromium. The industry used microbial culture for effluent treatment to reduce effluent parameters. However, it was incompetent at treating wastewater discharge, which could not meet the Pollution Control Board (PCB) wastewater treatment guidelines.

The initial approach: After a complete study of the effluent treatment plant (ETP) through a questionnaire, an on-site effluent assessment, and discussions with the EHS (Environmental Health & Safety) team, our experts identified numerous challenges to be addressed:

Main Issues:
  • High COD levels in wastewater
  • High BOD levels in wastewater
  • High Total Ammoniacal Nitrogen (TAN) in effluent
Effluent Treatability Study:

Before planning a wastewater treatment scheme, it is crucial to perform an industrial wastewater treatability study to understand the characteristics of industrial effluent and devise an appropriate biological wastewater treatment regime specific to the chemical industry wastewater. Team One Biotech provided the sample for a pilot-scale wastewater treatment trial, which is a laboratory-scale effluent treatment study that confirms the suitability of the bacterial consortium for wastewater treatment present in our product and its development in the effluent stream. These trials were specifically designed to provide a clear indication of whether the microbial solution for wastewater treatment can grow in a given type of effluent without compromising the pollutant reduction efficiency.

Microscopic analysis reports of the sample revealed satisfactory bacterial growth in industrial effluent. Understanding and developing methodologies for the treatment of chemical industry wastewater is necessary due to the scarcity of freshwater resources. The four main constituents in pharmaceutical plant wastewater treatment that regulators are generally concerned with are Total Organic Carbon (TOC), Total Nitrogen (TN), Total Phosphorus (TP), and Total Suspended Solids (TSS).

Treatment Regime Using T1B Aerobio:
T1B Aerobio: A Complete Solution for Industrial Wastewater Treatment

Our team of researchers developed this unique biotech formulation for effluent treatment, T1B Aerobio, which has proven to be extremely beneficial in solving the most challenging industrial wastewater treatment problems over the years. T1B Aerobio is a microbial consortium for wastewater treatment, isolated from nature. The microbes secrete effective biodegrading enzymes, which are completely natural and safe for humans, plants, and animals. These microbes are highly efficient in degrading organic pollutants in wastewater, refractory wastewater contaminants, and toxic industrial effluents even under high TDS levels.

Our team of experts planned to move ahead strategically for maintaining transparency in effluent treatment implementation between us and the industry. Initially, there was a laboratory-scale study, followed by a pilot plant study to build the client’s confidence in our biological wastewater treatment technology. Finally, the treatment was implemented on the actual industrial wastewater treatment plant (WWTP).

Execution:
Plant Optimization:

Team One Biotech recommended some changes in the effluent treatment plant design for the smooth functioning of the biological treatment process.

Initial Dosing Plan:

We planned a 60-day dosing schedule with a higher microbial culture dosing in the first month and a maintenance dose in the second month.

Observation:

We observed that after adding T1B Aerobio, it significantly reduced the COD in industrial wastewater, BOD in chemical effluent, and TAN levels in wastewater. The table below shows the reduction:

Day 1 Day 15 Day 30 Day 45 Day 60
COD ppm 25000 14084 8015 2045 243
BOD ppm 10000 4049 2510 804 110
TAN ppm 450 358 190 98 44
Results:

We observed:

  • 99% reduction in COD levels
  • 99% reduction in BOD levels
  • 90% reduction in TAN levels
  • Achieved the desired Mixed Liquor Volatile Suspended Solids (MLVSS): Mixed Liquor Suspended Solids (MLSS) ratio of 0.7
  • Maintained the required Food to Microorganism (F/M) ratio
  • Improved overall effluent treatment plant efficiency
Conclusion:

The use of T1B Aerobio for industrial wastewater treatment in the chemical manufacturing sector proved to be an effective and eco-friendly method. The efficiency of the effluent treatment plant (ETP) improved significantly, stabilizing the biological wastewater treatment process quickly. The treated effluent successfully met the Pollution Control Board (PCB) compliance standards for wastewater discharge norms.

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Commisioning of ETP of a petrochemical industry
Restart and Commissioning of ETP of a Petrochemical Industry
Introduction: 

This petrochemical industry in West Bengal has a full-fledged Activated Sludge Process (ASP) system with two aeration tanks in parallel. This Effluent Treatment Plant (ETP) experienced shock loads and frequent upsets due to multiple streams and high Polycyclic Aromatic Hydrocarbons (PAH) in the effluent. Maintenance of a good biomass in the aeration tanks along with sustainability in shock loads was a challenge as the upsets were highly shock-inducing.

ETP Details:

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

Previous Capacity
Flow (current) 450 KLD
Flow (design) 450 KLD
Type of process ASP (parallel tanks)
Capacity of AT-1 350 KL
Capacity of AT-2 350 KL
Retention Time 37.33 hours(combined)
Challenges: 
Parameters (PPM) Avg. Inlet parameters  Avg. Outlet parameters (MBR Outlet)
COD 4000-8000 3200-6000
BOD 2600-5800 1200-3800
TDS 7000 1000
PAH 1450 1000
Operational Challenges:
  • The primary treatment was working at 5% efficiency in terms of COD reduction.
  • The biological treatment worked at an average 20-25% efficiency in terms of COD reduction.
  • They were struggling to control the higher PAH levels, and it was inducing shock loads, as explained earlier.
The Approach:

The industry partnered with us to commission their Upflow Anaerobic Sludge Blanket (UASB) and Aeration Tank with increased capacity and restart the ETP at its full capacity in terms of hydraulic load.

We adopted a 3D approach that included:

Research/Scrutiny:

Our team visited their facility to go through the process of the new Effluent Treatment Plant (ETP) and to scrutinize the value-addition factors.

Analysis:

We analyzed the 3-month cumulative data of their ETP to see trends in the inlet-outlet parameters’ variations and the permutation combinations related to it.

Innovation:

After the research and analysis, our team curated customized products and their dosing schedules with formulation, keeping in mind the plan of action to get the desired results.

This process is called bioaugmentation.

Desired Outcomes:
  • Development of strong biology to withstand shock loads and prevent upsets.
  • Making ETP more efficient regarding COD/BOD and PAH degradation.
  • Reduction in FOG (Fats, Oils, and Grease).
Execution:

Our team selected the product:

For Aeration Tank:
  1. T1B Aerobio: consists of blends of several strains of aerobic and facultative microorganisms, usually bacteria, along with key trace elements on a complex inert media.
For Oil/Grease Trap:

2. T1B FOG BioBloc:

  

Our plan of action included:
  • The addition of T1B Aerobio was also done every day with a reduction in the dosing every 10 days.
  • A total of 150 kgs of T1B Aerobio was used for 60 days of treatment.
  • T1B FOG BioBloc was placed at the O/G trap for FOG reduction.
  • 4 blocks of T1B FOG BioBloc were used for 60 days.
Results:
Parameters
Parameters (PPM) Avg. Inlet parameters  Avg. Outlet parameters (secondary clarifier outlet)
COD 4000-8000 1200-2300
BOD 2600-5800 500-850
TDS 7000 1000
PAH 1450 321

The implementation of the bioaugmentation program resulted in significant improvements in the performance of biological units in their Wastewater Treatment Plant (WWTP):

  • The COD/BOD degrading efficiency increased from 20% to 70% in the biological system.
  • PAH was also getting degraded up to 77%.
  • MLSS (Mixed Liquor Suspended Solids): MLVSS (Mixed Liquor Volatile Suspended Solids) ratio was optimized.
  • Biomass in the ASP system displayed great stability even during shock load situations.

This sustainable wastewater treatment approach has helped the industry optimize effluent quality, enhance microbial community stability, and ensure compliance with environmental standards.

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Saving operational expenses for pharma business using bioremediation
Saving OPEX for a reputed Pharma Giant using Bioremediation
Introduction: 

The reputed pharmaceutical giant is known for contributing to the global pharmaceutical sector by using  bioremediation. This unit is one of the largest Active Pharmaceutical Ingredient (API) producers that manufactures products such as Tamsulosin, Metformin, Esomeprazole, etc. The Unit has a full-fledged Effluent Treatment Plant (ETP) which is a traditional Activated Sludge Process (ASP) system. The unit is committed to treating its industrial wastewater religiously. The unit had an Multi-Effect Evaporator (MEE) installed to treat high COD wastewater stream. Due to the production of multiple pharmaceutical products, the ETP received multiple effluent streams with tough-to-degrade pollutants like toluene, benzene, Metformin, Acetic Acid, Methanol, etc. Due to such high-strength wastewater streams, it was difficult for them to control ETP operations, using bioremediation which led to heavier expenses, specifically on the MEE operation, as it was receiving a heavier load than its designed capacity.

ETP details:

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

Flow (current) 450 KLD
Flow (design) 500 KLD
Type of process ASP
No. of aeration tanks 3 (in series)
Capacity of aeration tanks 500 KL, 450 KL, 300 KL  respectively
Retention Time 67 hours(combined)
MEE Details:
Capacity (current) 12 KLD
Current inflow 10 KLD
Inlet COD 150000 ppm
Inlet TDS 60000 ppm
Challenges:
Parameters (PPM) Avg. Inlet parameters  Avg. Outlet parameters 
COD 18000 9900
BOD 5000 3000
TDS 15000 9500
Operational Challenges:
  • The primary treatment system was working at 5% efficiency in terms of COD reduction.
  • The biological treatment system was working at an average 45% efficiency in terms of COD reduction.
  • They were struggling to effectively treat recalcitrant pollutants such as toluene, benzene, Metformin, Acetic Acid, and Methanol, which compelled them to run the ETP at 10% less hydraulic load.
  • A separate high COD stream was directed to MEE, leading to scaling and fouling in MEE.

Volume of stream to MEE: 10 KLD
COD: 150000 ppm
TDS: 80000 ppm

Financial Challenges:
  • Urea-DAP consumption: 2160 Kg/month of Urea and 1200 Kg/month of DAP were required to boost the poor biomass in the biological tanks.
  • Electricity consumption: Due to high COD effluent, the power requirement went up from a normal 14250 KWH to 20250 KWH monthly.
  • Raw Water Consumption: Due to high COD influent, there was a need for higher evaporation, hence around 100000 litres of water was used monthly for MEE.
  • Chemical Consumption: Due to high COD inflow in MEE, there was extensive scaling, due to which the MEE needed frequent cleaning with HCL: 22500 kg/month, EDTA: 11250 kg/month.
Extra Costs incurred per month:
Commodity Units required
Urea(in Biological tank) 2160 kg/month
DAP(in Biological tank) 1200 kg/month
Raw water consumption 100000 litres/ Month approx
HCL (10 % ) 5500 kg/month
EDTA 3200 kg /month
Electricity(MEE) 20250 KWH/month

The MEE cost per liter was coming to Rs. 1820/KL for 10 KLD capacity, while the overall WWTP (Wastewater Treatment Plant) cost to treat 450 KLD effluent swelled to Rs. 200/KLD.

The Approach:

The industry partnered with us to improve the efficiency of their biological units and to reduce operational costs using bioremediation in their WWTP.

We adopted a 3D approach that included:

  1. Research/Scrutiny:
    • Our team visited their manufacturing facility to examine the existing ETP process and scrutinize areas of improvement.
    • The visit helped us explore potential ETP optimization strategies in the biological treatment system.
  2. Analysis:
    • We analyzed the previous 3-month cumulative data of their ETP to observe trends in inlet-outlet parameters.
  3. Innovation (Bioaugmentation):
Desired Outcomes :
  1. Reduction of COD/BOD thereby improving the efficiency of biological tanks.
  2. Degradation of tough-to-degrade effluents and develop robust biomass to withstand shock loads.
  3. Reduction in scaling of MEE by reducing COD in biological systems and saving cost using bioremediation.
  4. Reducing consumption of UREA-DAP.
  5. Cost saving by treating high COD streams in main ETP.
Execution:

Our team selected two bioaugmentation products:

  1. T1B Aerobio:
    • A blend of specialized microbes that secrete enzymes capable of degrading tough pollutants like toluene, benzene, and Metformin.
    • Helps in reducing COD/BOD, stabilizing shock loads, and enhancing biomass stability.
  1. T1B MacMi:
    • A plant-based gel that acts as a nutrient source for bacteria.
    • Replaced UREA-DAP to provide essential macro and micronutrients for microbial growth.

                                       

Plan of Action:
  • Diverting 2 KLD of MEE inlet to the main ETP inlet with COD 150000 ppm.
  • Diverting 3 KLD of MEE reject to main ETP inlet with COD 25000 ppm.
  • Dosing of T1B Aerobio in all three biological tanks.
  • Dosing of T1B MacMi in all three tanks.

Average Inlet COD after the addition of streams: 18406 PPM

Results:
Parameters Inlet parameters  Secondary Outlet parameters (ppm)
COD 18406-19000 ppm 2200 ppm
BOD 9290 to 10000 ppm 1400 ppm 
Cost Saving :
Commodity Units required before treatment Units required after treatment
Urea 2160 kg/month 432 kg/month
DAP 1200 kg/month 240 kg/month
Raw water consumption 100000 litres/ Month approx 50000 litres/Month
HCL (10 % ) 5500 kg/month 4000 litres/month
EDTA 3200 kg /month 2050 litres/month
Electricity(Extra) 675 KWH/day 478 KWH/day

The MEE operational cost reduced to Rs. 1220/KLD, and the ETP cost was reduced to Rs. 160/KLD using bioremediation.

Key Achievements:

  • 85-89% COD & BOD reduction.
  • 20% reduction in ETP OPEX.
  • Full-capacity operations restored using bioremediation.
  • MEE dependency reduced.

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Challenges faced in Adhesive effluent treatment with shock load
Adhesive Effluent Treatment with Shock Load Challenges
Introduction:

The adhesive effluent treatment from a manufacturing industry contains a variety of pollutants, depending on the type of adhesives being manufactured (e.g., water-based adhesives, solvent-based adhesives, hot-melt adhesives, or reactive adhesives). The main pollutants typically found in industrial wastewater treatment for the adhesive industry include:

An adhesive manufacturing plant in Pune with an overall capacity 750 KLD effluent treatment plant (ETP) faced issues due to the presence of certain contaminants such as:

  • VOCs (Volatile Organic Compounds): Benzene, Ethyl Acetate, Acetone, etc. (from solvent-based adhesives).
  • Resins & Polymers: Acrylic resins, epoxy resins, polyurethanes, or other polymeric residues.
  • Unreacted Monomers: Styrene, vinyl acetate, acrylates, formaldehyde, etc., which are organic but difficult-to-degrade pollutants contributing to outlet contamination and lower efficiency in COD removal along with imposing shock loads.
Plant Details:
Flow Rate 750 KLD
Inlet COD:  8000-1000 ppm
Inlet TDS 6000 PPM
Aeration Tank 1 Capacity 800 KL
Aeration Tank 2 Capacity 350 KL
COD reduction efficiency of secondary system 40%-50%
Research and Analysis:

The plant’s Effluent Treatment Plant (ETP) was comprehensively evaluated to diagnose wastewater treatment challenges through site visits. Key issues identified were:

  • High COD levels caused by organic pollutants and chemical residues.
  • Frequent upsets due to shock loads from multiple industrial effluent streams.
  • Poor microbial performance in the biological treatment system.
  • Unsustainability and low MLVSS (Mixed Liquor Volatile Suspended Solids), leading to inefficient biodegradation of industrial effluents.
Innovation:

T1B Aerobio: Enhancing Biological Treatment Performance

T1B Aerobio is a specially formulated biological treatment solution powered with 76+ robust bacterial strains designed to degrade complex organic compounds in adhesive industry wastewater. Its high-performance microbial strains secrete enzymes that efficiently break down tough-to-degrade contaminants that indigenous microbes fail to degrade.

Execution:
Plant Optimization:
  • Adjusted Return Activated Sludge (RAS) and Waste Activated Sludge (WAS) to enhance the secondary biological treatment system efficiency.
Dosing Regime:

A 60-day microbial dosing schedule was implemented:

  • Phase 1 (Days 1-30): High initial dose to establish a dominant biological culture for effective COD degradation.
  • Phase 2 (Days 31-60): Maintenance dosing to sustain color removal and COD reduction.
Monitoring Parameters:
  • COD and BOD (Biochemical Oxygen Demand) levels.
  • Sludge Volume Index (SVI) and sludge settling characteristics.
Observations:

The addition of T1B Aerobio resulted in significant improvements in adhesive effluent treatment. Key observations are summarized below:

Parameter Day 1 Day 15 Day 30 Day 45 Day 60
COD (ppm) 10,000 7,500 4,700 2,500 945
BOD (ppm) 4,300 2,800 1,200 850 400
SVI (mL/g) 20 25 32 35 40
Results:
  • COD Reduction: Achieved a 91% reduction in COD levels by Day 60, ensuring compliance with environmental discharge standards.
  • BOD Reduction: Achieved a 90% reduction in BOD levels, meeting wastewater discharge norms.
  • Improved Sludge Settling: Optimized Sludge Volume Index (SVI) values, leading to better sludge compaction and reduced carryover.
  • Shock Load Management: Frequent ETP upsets were effectively controlled.
Conclusion:

The application of T1B Aerobio significantly improved the performance of the adhesive industry’s effluent treatment plant (ETP). Enhanced biological treatment facilitated the degradation of hard-to-degrade organic pollutants, stabilized microbial activity, and maintained ETP efficiency under shock load conditions.

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phenol management for industries
Phenols in Industrial Effluents: Challenges and Solutions

Phenol in industrial effluents are among the most challenging and hazardous compounds to manage. Industries such as Pharmaceuticals, Agrochemicals, Organic Chemicals, and Textiles generate wastewater containing high concentrations of phenols. Despite having well-equipped wastewater treatment plants (WWTPs), 60% of industries still struggle with phenol management, leading to increased CAPEX, OPEX, and regulatory non-compliance.

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Phenols pose significant environmental and health risks. If consumed, they can be highly toxic, making their proper management critical. Efficient waste recycling strategies and robust water treatment plant projects are essential to tackling phenol contamination effectively.

What Are Phenols?

Phenol in industrial effluents are organic compounds characterized by a hydroxyl group (-OH) attached to an aromatic benzene ring. While they occur naturally in plants, they are also synthetically produced and widely used in various industrial processes.

Industries with Phenol Presence
  • Petrochemical Industries
    • Origin in Crude Oil: Phenols naturally occur in crude oil due to the decomposition of organic matter over time.
    • Formation During Refining: Processes like catalytic cracking, hydrocracking, and thermal cracking can produce phenolic compounds as byproducts.
  • Chemical Industries
      • Use in Plastics: Phenolic resins, formed from phenol and formaldehyde, are used in molded products, laminates, and coatings.
      • Use in Resins: Phenolic compounds play a crucial role in epoxy resin production, used for coatings and adhesives.
      • Byproduct Formation: Chemical reactions involving phenols often generate phenolic byproducts and contaminants in wastewater.
      • Incomplete Purification: Poorly optimized purification steps can lead to residual phenols in final products and wastewater.
  • Textile Manufacturing
    • Dyeing: Phenolic compounds act as dye carriers, mordants, and fixatives.
    • Printing: Used in textile printing pastes and inks.
    • Finishing: Added to textiles for flame retardancy, water repellency, and antimicrobial properties.
  • Pharmaceutical Industries
    • Drug Synthesis: Phenolic compounds serve as precursors in the synthesis of active pharmaceutical ingredients (APIs).
    • Formulation: Used as stabilizers, preservatives, and antioxidants.
    • Biopharmaceutical Production: Support cell culture growth and therapeutic protein production.
  • Agrochemical Industries
    • Pesticides: Enhance pesticide effectiveness and stability.
    • Herbicides: Found in products like glyphosate and 2,4-D.
    • Fungicides: Used in copper-based compounds and phenylphenol derivatives.

Industry-Wise Effects on Effluents
Petrochemical Effluents
  • Contain phenolic compounds from process streams, cooling water, and liquid discharges.
  • Contributing factors: process water, spills, and leaks.
Textile Effluents
  • Dyeing and Printing Chemicals: Phenolic-based dyes, carriers, and auxiliaries add to phenol in industrial effluents.
  • Process Wastewater: Dye baths and printing solutions release phenolic compounds.
Pharmaceutical Effluents
  • Chemical Synthesis: Generates phenolic byproducts and impurities.
  • Purification & Isolation: Incomplete purification results in phenols in waste streams.
  • Formulation & Packaging: Phenolic preservatives may leach into solutions.
Agrochemical Effluents
  • Phenols originate from reaction byproducts, incomplete purification, and waste disposal.
  • Manufacturing & Formulation: Used in raw materials and solvent applications.
  • Application & Spraying: Pesticide use contributes to phenol dispersal via drift, runoff, or volatilization.
Estimation of Phenol Concentration in Effluents

Industries typically follow six methods:

  • Colorimetric Methods
  • High-Performance Liquid Chromatography (HPLC)
  • Gas Chromatography (GC)
  • Titration Methods
  • Enzymatic Assays
  • Immunoassays

The choice of method depends on factors like concentration range, sample matrix, sensitivity, equipment availability, and regulatory requirements. Validation ensures accuracy and reliability.

phenol management for industries

Bioremediation: The Antidote for Phenols

Bioremediation utilizes microorganisms to degrade pollutants through enzymatic action.

Key Microbes and Enzymes for Phenol Degradation
  • Phenol Hydroxylase: Converts phenol to catechol (Pseudomonas species).
  • Catechol 1,2-Dioxygenase: Cleaves catechol into muconic acid (aromatic compound degraders).
  • Phenol Monooxygenase: Hydroxylates phenol to hydroquinone (Acinetobacter, Bacillus, Rhodococcus).
  • Hydroquinone 1,2-Dioxygenase: Converts hydroquinone into intermediate products (Burkholderia, Alcaligenes).
  • Phenol Oxidase: Oxidizes phenolic compounds to quinones (Bacillus subtilis, Bacillus licheniformis, Bacillus pumilus).
  • Laccase: Oxidizes phenols and non-phenolic substrates (Streptomyces, Enterobacter).
Best Treatment Methods for Phenol Degradation

1. Activated Sludge Process (ASP)

  • Maximizes phenol degradation in a biological treatment tank using specific microbial cultures.
  • Frequently used in wastewater treatment plants to remove phenolic contaminants efficiently.

2. Biofilters

  • Media Bed: Uses organic materials like compost or synthetic media to support microbial growth.
  • Microbial Action: Bacteria and fungi metabolize phenols into less harmful compounds.
  • Pollutant Removal: Effluent passes through biofilters, reducing phenol concentration.
  • Aeration & Moisture Control: Optimized oxygen and moisture levels enhance microbial activity.
  • Applied widely in effluent treatment plant manufacturers and wastewater treatment companies in India.
Conclusion:

Phenol in industrial effluents remains a significant challenge for industries, requiring advanced treatment solutions to mitigate environmental and regulatory risks. Bioremediation, particularly through activated sludge processes and biofilters, provides an effective, eco-friendly solution for phenol degradation, ensuring compliance and sustainability.

For industries investing in water treatment plant projects, domestic waste management, and waste recycling, adopting innovative phenol degradation techniques is crucial for sustainable industrial operations.

Are you looking for a reliable wastewater treatment solution?
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