Wastewater Treatment for Distillery
Effective Wastewater Treatment for Distillery in Amravati, Maharashtra

Introduction:
The Integrated Distillery, a prominent food processing unit, specializes in producing whiskey and rum. Dedicated to environmental sustainability, they operate a wastewater treatment plant (WWTP) to manage the industrial effluent generated during production. However, the distillery faced challenges in consistently meeting discharge limits for specific pollutants, particularly due to the seasonal operation of their effluent treatment plant (ETP). To overcome these issues, they implemented a bioaugmentation program, resulting in substantial improvements in treatment efficiency and regulatory compliance.

 ETP details:

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

Flow (current) 1200 KLD
Flow (design) 1500 KLD
Type of process ASP
No. of aeration tanks 2 (in series)
Capacity of aeration tanks 2000 KL each
RT 37-39 hours(each)

 

 Challenges:

The primary and biological treatments were significantly underperforming, leading to inefficiencies:

Parameters Inlet parameters Outlet parameters
COD 4,000 to 6,000 3500 to 5780
BOD 2000 to 3100 1500 to 2600
  • The primary treatment was working at 5 % efficiency in terms of COD reduction
  • The Biological treatment was working at an average 8 to 10% efficiency in terms of COD reduction.

They were struggling to effectively treat pollutants which compelled them to run the ETP at 40% less hydraulic load. The FOG in the effluent was uncontrolled as there was a high accumulation in pipes and equipment also which was the reason for higher CAPEX and OPEX. The conventional ASP treatment process was not efficient enough to consistently meet the stringent discharge limits for these pollutants set by local regulatory agencies. As a result, the industry faced the risk of non-compliance, which could lead to fines, reputational damage, and environmental impact.

Another main reason of the inefficiency was the seasonal operation of the ETP due to which the biomass which would have developed in course of its operation died completely due to lack of activity.

Our Approach:
The industry partnered with us to improve the efficiency of their biological units. They had a total of 2 aeration tanks, which were in series. With a total daily flow of around 1200 KLD. Our team conducted a visit to understand the process of the ETP and the timing of 3 months during its operation was selected.

After analysis, it was decided that the commissioning procedure would be followed where the flow rate will be gradually increased starting from 500 KL/day to achieving a full capacity of 1500 kl/day in order to generate healthy biomass via Bioaugmentation. Bioaugmentation is a process that involves adding specifically selected microorganisms, such as bacteria or enzymes, to enhance the biological treatment process in a WWTP. The team conducted a thorough assessment of the effluent characteristics and the WWTP’s operational parameters to identify the most suitable bioaugmentation approach.

Based on the assessment, a customized bioaugmentation program was designed and implemented at the industry. The selected microorganisms were carefully selected to target the organic pollutants The bioaugmentation program was integrated into the existing treatment process, and the performance of the WWTP was closely monitored for the next 3 months.

The program aimed to:

  1. Enhance COD/BOD degradation
  2. Optimize hydraulic load
  3. Develop resilient biomass to handle shock loads

Execution:
Following the analysis, we introduced T1B Aerobio, a formulation of facultative microbes that secrete enzymes to break down COD, BOD, and FOG. A three-month dosing schedule was established.

Reduces aeration processing in Wastewater treatment. Improves functioning & efficiency of biological units in WTP. Useful in activated sludge process bioreactors & biodigesters

Results:

 

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

  • We were able to achieve around 80 to 89 % reduction from their current outlet parameters in COD & BOD
  • Biomass was developed with MLVSS values between 2800-3200.
  • The bioaugmentation program also resulted in other operational benefits for the industry.
  • The ETP achieved full capacity operations in terms of hydraulic load.
  • The biological process became more stable and resilient to fluctuations in the influent characteristics.
  • Increased plant reliability and reduced operational costs.

Are you facing similar challenges in industrial wastewater treatment? Explore the potential of bioremediation, and connect with our technical experts today:

+91 8855050575 / sales@teamonebiotech.com

Transforming wastewater treatment in paper manufacturing industries: Replacing Ammonium Phosphate and Phosphoric Acid with T1B MacMi

Introduction:  

The Integrated Paper and Pulp Industry is a leading paper manufacturing company involved in pulping of raw materials and paper manufacturing. The company is currently located in Dahej, Gujarat. With a strong commitment to environmental sustainability, The Integrated paper and pulp industry operates an industrial wastewater treatment plant (WWTP) to treat the effluent generated during its production processes.

They were using very high amounts of Ammonium Sulphate and Phosphoric Acid to meet their nutritional requirements and maintain MLVSS. To address these challenges, the industry implemented a bioaugmentation program at its WWTP, which resulted in significant improvements in the treatment process and compliance with regulatory standards.

Details provided for Effluent Treatment Plant (ETP):

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

Flow    4500-6000 KLD
Type of process ASP
No. of aeration tanks 7 (in series)
Capacity of aeration tanks 100 KL (1 and 2 ), 400 KL(3), 1800 KL(4,5,6,7)
Total RT 31.2 hours

Findings and Challenges:

Parameters Inlet parameters Outlet parameters
COD 3,000 to 5,000 800 to 500
BOD 1000 to 1800 400 to 150
MLVSS (avg.) 6500 5679

To maintain the performance of the ETP, especially the biological tank the MLVSS levels are necessary to be maintained. However, it required a very high amount of ammonium sulphate and phosphoric acid viz. 700 kgs and 300 kgs per day respectively. Such a huge amount imposed a very high cost as well as the chemical consumption had high chance of going on with unwanted reactions in ETP, especially with lignin streams.

The Approach:

The industry partnered with us looking for a common solution that can serve as a replacement for Ammonium Sulphate and Phosphoric acid that can reduce the cost and should be Organic. Our team of experts went through the complete past 3 months’ data of ETP to analyze the trends. After conducting the visit, Team One Biotech suggested implementing T1B MacMi for wastewater treatment.

 The Solution: T1B MacMi

  • Organic, plant-based bio cultures replace conventional nitrogen and phosphorus sources.
  • Eliminate the need for urea, DAP, ammonium sulphate, phosphoric acid, and other chemicals.
  • Single source of Nitrogen, Phosphorous, Potash, Calcium, Magnesium, Copper, and other micro and macronutrients.
  • Promote biological wastewater treatment through specialized microorganisms.

Results:

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

  • 98% reduction in ammonium sulphate and phosphoric acid consumption
  • Maintained MLVSS levels within desired ranges
  • 60% reduction in nutrient costs and 30% reduction in overall operating expenses (OPEX)

Are you facing similar challenges in industrial wastewater treatment? Explore the potential of T1B MacMi and connect with our technical experts today:

+91 8855050575 / sales@teamonebiotech.com

Bioremediation in a Lake- a Tourist Hotspot

Introduction:

The lake is present in one of the popular cities of India and is itself a tourist hotspot. Hundreds of tourists visit the lake which is know for its scenic beauty and being one of the centres of attractions, the lake is surrounded by food parks, amusements, restaurants etc. However, during past few months the lake water suddenly started stinking and developed a lot of algae. Since, the lake was under the management of local municipal corporation. They employed physical cleaning along with installation of fountains of aeration but it was of no use. The odour was getting worst day by day thereby causing drop in the number of tourists and impacting the local tourism in terms of economy.

The municipal corporation then approached Team One Biotech to get the proper solution for the deteriorating conditions of the lake. We took a sample of the lake water and analysed it at our R&D lab.

Lake Details:

  • Capacity: 300 Million Litres
  • Area: 47 acres
  • Diameter: 30 sq meters
  • COD: 168 ppm
  • BOD: 87 ppm
  • Ammoniacal Nitrogen: 52 ppm
  • Algae: High Concentration

 

Findings and Challenges:

The COD, BOD and Ammoniacal Nitrogen were found to be high in concentration than the discharge limits. Also due to higher amount of AN, the algae growth was increasing rapidly made the water look greenish. Septic like odour was also present, though its source wasn’t initially clear, so we tried to find out any ingresses in the lake. We found that there was an ingress through an overflowing line of sewage nearby causing the lake water to smell and further deteriorating its quality.

The Approach:

After complete study of the lake through on-site visits, water sample analysis and  discussions with lake management and municipal corporation, we concluded that the sewage ingress and lack of management in terms of cleaning especially control on waste disposal.A Wastewater Microbiome Analysis (WMA) was carried out before providing a detailed techno-commercial offer. WMA reports of the sample revealed satisfactory growth and development of the microbes in the lake as well as gave us a complete analysis on the exact product and strategy to be employed for effective bioremediation.

Performance Evaluation:

The performance of our solution in lake was evaluated based on various parameters such as chemical oxygen demand (COD), biological oxygen demand (BOD), ammoniacal nitrogen, algae reduction, odor removal and color improvement . The results showed that the ETP was able to achieve the desired effluent quality as per regulatory standards.

The Entire bioremediation program ran for 6 months.

We designed a bioaugmentation and bioremediation programmme which was divided into three parts.

  1. T1B Lake Cleaner:  We planned a 180-day dosing schedule. It included strategic incorporation of T1B lake cleaner. Initially the first 4 weeks were crucial and therefore dosing was kept high to naturally increase the population of healthy microbes. Next 4 weeks and on the amount decreased & the primary agenda for dosing was to maintain a constant population of microbes in the system.
  2. Physical Cleaning and restrictions on waste disposal: Regular cleaning on lake water from non-biodegradable waste was setup. Strict restriction on waste disposal were also implemented with cooperation from Municipal corporation.
  3. Monthly monitoring of data and site inspection: Reports of the parameters were sent to us and was scrutinized by T1B to analyse the performance of the product and explore the areas of troubleshooting. On-site inspection was also initiated every fortnite to monitor odor and algae reduction.

Results and discussions:

  • We observed 75% reduction in COD and 76% reduction in  BOD and and 78.84 % reduction in TAN levels after 180 days.
  • Odour was completely eliminate.
  • Algae concentration became NIL.
  • Tourist footfall increased.

Connect with our experts:

+91 8855050575/sales@teamonebiotech.com

API CASE STUDY – Wastewater Treatment in multinational API pharmaceutical company

Introduction:

API and bulk drug manufacturers generate a considerable amount of wastewater through their manufacturing, washing, and cleaning processes. One Indian multinational pharmaceutical company encountered significant challenges in managing the high organic load produced from their manufacturing processes, specifically at a factory located in Gujarat GIDC, where they manufacture multiple APIs.

Details provided for Effluent Treatment Plant (ETP):

  • Primary, Biological and Tertiary systems, with RO & MEE.
  • The activated sludge process (ASP) has one anoxic tank and 3 aeration tanks in series.
  • Flow: Around 125 m3/day
  • Inlet COD: 18,000 to 22,000 ppm
  • COD outlet after biological treatment: 9000 to 17000 ppm

Findings and Challenges:

  • Despite the high amount of MLSS & MLVSS in all aeration tanks, COD, BOD, and Ammoniacal Nitrogen levels consistently exceeded discharge limits.
  • The EHS department of the industry faced pressure to maintain parameters according to PCB norms.
  • The implementation of an MBR after the ASP process, as recommended by some consultants, failed to produce satisfactory results.

The Approach:

The solution offered by Team One Biotech is a comprehensive strategy for improving the biological treatment of wastewater generated by API and bulk drug manufacturers. This strategy includes the use of robust microbial consortia and the implementation of various processes and technologies to optimize the performance of the Effluent Treatment Plant (ETP). Some specific solutions offered by Team One Biotech include:

1. Introduction of T1B Aerobio: Team One Biotech devised a 60-day dosing schedule that incorporated T1B Aerobio strategically. This microbial product was used to raise the population of healthy microbes naturally and sustain a consistent population within the system.

2. Increase in Flow rate: Team One Biotech aimed to achieve a flow rate of 225 m3/day by the 60th day. They gradually increased the flow rate on a weekly basis, starting from an initial flow rate of 120 m3/day. This increase in flow rate was achieved without compromising on the outlet parameters.

3. Wastewater Microbiome Analysis (WMA): Team One Biotech conducted a WMA to understand the current biological health of the plant. This analysis helped identify deficiencies in the appropriate biomass in the biological units and provided insights for developing effective solutions.

4. Implementation of MangEfficient microbes: Team One Biotech incorporated their MangEfficient microbes into the strategy for the API bulk drug Pharma unit. These microbes were used to enhance the treatment process and improve wastewater quality.

5. Elimination of shock loads: Team One Biotech eliminated shock loads by transitioning to a continuous flow rate, avoiding any abrupt or sudden changes in the biological process. This helped maintain consistent performance of the ETP.

6. Reduction in COD, ammonical nitrogen, and electricity usage: The solution provided by Team One Biotech resulted in more than 80% reduction in COD values, more than 70% reduction in ammonical nitrogen, and savings in terms of electricity usage.

Results:

  • We observed 85.8% reduction in COD and 75% reduction in TAN levels after 60 days and today the COD is in the range of 500 to 450 ppm in their biological outlet.
  • MLSS lowered from earlier 18000 ppm to around 8000 to 10,000 ppm in all the 3 tanks.
  • Use of MBR and the electricity to run the same, was eliminated.
  • Improved the flow rate by 12% without compromising on the outlet parameters.

Six Months Progress:

  • Eliminated shock loads by continuous feed
  • Carries out WMA to understand their current biological health
  • Introduced T1B Aerobic considering the plant conditions and their current process

After six months of monitoring, it’s evident that the outlet from the biological units consistently decreased despite fluctuating incoming loads. This consistent outcome suggests that our resilient microbial consortia effectively controlled all biological units.

Client Testimonial:

 “When we partnered with this T1B team, we were not really sure about the output, though we were confident that they would make some positive impact, but we didn’t anticipate the extent of the success we would achieve. We were struggling with low ETP performance & high cost in terms of electricity and solid handling not realizing the full potential of our Effluent Treatment Plant. Their team came in with a clear, well-thought-out strategy covering all aspects of the ETP in terms of performance, process and savings.

The results speak for themselves — more than 80% reduction in COD values, more than 70% reduction in ammonical nitrogen and saving in terms of electricity & solid handling. I wholeheartedly recommend their services to any business looking to revamp their digital marketing strategy and see real, quantifiable results.”

Are you facing similar challenges in industrial wastewater treatment? Explore the potential of bioremediation, connect with our technical experts today:

+91 8855050575 / sales@teamonebiotech.com

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