Improved COD Removal Efficiency in a CETP Using T1B Aerobio Cultures

Introduction:

A Common Effluent Treatment Plant (CETP) is designed to collect, treat, and discharge effluents from multiple industries. Treating CETP effluent is particularly challenging due to the complex mix of organic and inorganic compounds, heavy metals, and pollutants. The use of bio cultures for CETP wastewater treatment offers a sustainable, cost-effective solution to these challenges.

One of our CETP clients in Gujarat (GIDC) received effluents from diverse sources, including textile, chemical, dyes, intermediate, and food industries. These effluents exhibited high levels of COD (Chemical Oxygen Demand), BOD (Biological Oxygen Demand), and color. The CETP, with a capacity of 100 MLD, utilized SBR technology for wastewater treatment.

ETP Flow chart:

• Treatment Process: Primary treatment → SBR-based biological treatment.
• Setup: 10 SBR tanks, each processing 10 MLD of effluent.
• Flow Rate: 10 MLD
• COD Levels:

1. Inlet COD: 1500 to 2200 ppm
2. Outlet COD (post-SBR): 500 to 700 ppm

Challenges:

• The CETP sought to improve COD removal efficiency and reduce effluent color levels.
• It required robust and active bacterial cultures for CETP treatment to handle shock loads during peak seasons and maintain performance during winters.
• Stabilizing the system’s biomass and enhancing its resilience were key objectives.

The approach: It was decided that we go ahead with one of their worst performing SBR tank.  After conducting a lab base trail and WMA, we went ahead with our techno-commercial offer for 10 MLD for one of their SBR. (Please Note: The lab trial carried out is specifically designed to provide a clear indication of whether our microbial consortia can grow in their effluent along with some reduction in the pollution parameters. WMA shows the health of the current biomass which tell us a lot in terms of the biological efficiency and future direction)

 Steps Taken:

• Assessment of Active Microbes: Analyzed the current status of active microbes and the overall biological efficiency of the system.
• Lowering MLSS (Mixed Liquor Suspended Solids): Reduced MLSS levels from 4000+ ppm to around 2000 ppm to enable faster stabilization of T1B Aerobio cultures.
• Bioaugmentation with T1B Aerobio Cultures: Introduced robust microbial consortia into the SBR system, gradually establishing a strong microbial population.

Dosing Schedule:

• Total Dosing: 900 kg of T1B Aerobio cultures over 2 months.
• Phase 1 (Month 1): Higher doses to establish microbial activity.
• Phase 2 (Month 2): Maintenance dosing to sustain efficiency.

Results and discussions:

• The bioaugmented SBR had better reduction in terms of COD removal more by 25 to 40% as compared to their other SBR tanks.
• The biomass in the SBR tank was much more stable and robust as compared to biomass in other tanks as per the Wastewater Microbiome Report “WMA” as below.

What is Wastewater Microbiome Analysis (WMA)?

 Microscopic analyses of any biological system should be a critical component of any ongoing daily, weekly, or monthly monitor and control programs in your WWTP.

WMA helps you to correlate the health of the system, any changes in floc structures, higher life forms, oxygen penetration, filamentous identification, polysaccharide coating of the bacteria, and suspended solids can be determined by using a high-end microscope and examining the biomass. WMA can help not only show exactly what the health of the system is at a given time but can also help predict which direction the plant is headed if used regularly. It can also help prevent critical upsets, or can also be used as an early warning and help avoid costly chemical consumption

Key Components of WMA:

1. Floc Analysis

• Floc Size Distribution: Determines the settleability of sludge. Ideal floc sizes range from 100 to 5000 µm.
• EPS/Slime Analysis: Evaluates the floc-forming properties of bacteria, which are critical for stable treatment processes.
• Sludge Age Analysis: Assesses the biological health of the plant using parameters like SRT and MCRT.
• Oxygen Penetration: Analyzes oxygen availability within flocs, ensuring aerobic conditions for microbial activity.

2. Filamentous Biomass Analysis

• Identifies harmful filaments (e.g., Nocardia) that can cause foaming or bulking.
• Staining methods like Neisser and Gram staining help classify filaments.

3. Higher Life Form Analysis

• Identifies protozoa, metazoa, and other organisms that indicate system health and sludge age.

Basic WMA findings

From the microscopic images of bioaugmented SBR (with T1B Aerobio cultures) and non-bioaugmented SBR (without T1B Aerobio cultures) it can be clearly seen the number, size, structure of sample of sludge from treated SBR shows better quantifiable microbial activities then non treated SBR which can also be seen from the better reduction in terms of COD.

Looking to improve your CETP performance? Choose T1B Aerobio cultures for robust, efficient, and eco-friendly wastewater treatment. Contact us today to transform your effluent management system!

Phosphorus Removal from a Sewage Treatment Plant using T1B STP Bio culture

Introduction: Sewage treatment plants (STPs) play a crucial role in maintaining the environmental quality of water bodies. The excessive presence of phosphorus compounds in sewage can lead to the uncontrolled growth of algae, disrupting aquatic ecosystems and depleting healthy flora and fauna. To address this challenge, innovative and eco-friendly solutions like biological treatment with bio-culture for phosphorus removal have gained prominence. One of our clients in Pune was facing persistent issues with high phosphorus levels in wastewater. Their treatment system utilized an activated sludge process (ASP).

STP Flow chart:

• Treatment Process: Primary treatment → Biological treatment → Tertiary treatment
• Flow Capacity: 500 m³/day
• Inlet Phosphorus: 50 ppm
• Outlet Phosphorus: 40 ppm

Challenges:

The sewage treatment plant faced several challenges, including:

1. High phosphorus levels in treated sewage, exceeding permissible discharge limits and threatening downstream water bodies.
2. Operational inefficiencies due to excessive phosphorus loads, adversely affecting overall treatment performance.
3. Compliance issues with local environmental regulations, posing risks of fines and reputational damage.
4. A need for improved efficiency in aeration tanks to enhance phosphorus removal efficiency and reduce odour.

Approach:

The biological treatment system exhibited limited efficiency, achieving only 15%-20% phosphorus reduction. Conventional ASP processes struggled to treat organic pollutants and phosphorus effectively, making it difficult to meet stringent discharge standards. The client sought a solution that could optimize the treatment process while ensuring compliance with regulatory norms.

Solution:             

T1B STP Bio-culture, a specialized solution for biological phosphorus removal (EBPR), was introduced. Its unique formulation with polyphosphate-accumulating organisms (PAOs) enabled the efficient removal of phosphorus through intracellular storage.

Steps Taken:

1. Biocultures Integration: T1B STP Bio-culture was introduced into the aeration tanks. This bio-culture consisted of PAO bacteria adapted to thrive in the plant’s treatment conditions.
2. Monitoring and Adjustment: Continuous monitoring of phosphorus levels, pH, temperature, and dissolved oxygen ensured optimal conditions for PAO activity. A 60-day dosing plan was implemented, with a higher dose in the first month and maintenance doses in the second month.
3. Process Optimization: The treatment parameters were fine-tuned to support PAO growth, including adjustments to dissolved oxygen, pH, and temperature.

Observation:

We observed that after the addition of our cultures, The phosphorous level was significantly reduced.

 Results:

The use of T1B STP Bio-culture for sewage treatment delivered significant improvements:

1. Phosphorus Reduction: Achieved an 80% reduction in phosphorus levels.
2. Odour Control: Reduced odour by 90%, enhancing the surrounding environment.
3. Regulatory Compliance: The plant consistently met the discharge standards for phosphorus removal, alleviating environmental and regulatory concerns.
4. Operational Efficiency: Optimized treatment processes resulted in fewer operational disruptions and higher overall efficiency.

 Conclusion:

The introduction of T1B STP Bio-culture provided an effective, eco-friendly, and sustainable solution for phosphorus removal from sewage. The plant’s efficiency improved significantly, ensuring compliance with pollution control norms and stabilizing overall operations.

By adopting this innovative biological treatment method, the sewage treatment plant set a benchmark for efficient and environmentally responsible wastewater management.

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.

 Challenges:

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

• 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.

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.

Findings and Challenges:

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