Recalcitrant COD in Pharmaceutical Effluents
Recalcitrant COD in Pharma Effluents: Key Pollutants & Effective Treatment Methods
Understanding Recalcitrant COD in Pharma Wastewater

Pharmaceutical industry effluents contain a mix of organic and inorganic pollutants, many of which contribute to recalcitrant Chemical Oxygen Demand (COD)—a fraction of organic matter that resists biological degradation. These persistent pollutants pose environmental risks and make wastewater treatment challenging. Addressing recalcitrant organic pollutants in industrial wastewaters requires advanced treatment processes that enhance COD removal while ensuring high efficiency in compliance with environmental regulations. To explore effective solutions for recalcitrant COD removal, contact us today.

Key Sources of Recalcitrant COD in Pharma Effluents

Pharma wastewater originates from drug synthesis, formulation, and cleaning processes. The primary contributors to recalcitrant COD include:

Active Pharmaceutical Ingredients (APIs)
  • Antibiotics – Amoxicillin, Ciprofloxacin, Erythromycin
  • Antipyretics & Analgesics – Paracetamol, Ibuprofen, Diclofenac
  • Hormones & Steroids – Estradiol, Progesterone
Solvents & Organic Intermediates
  • Aromatic Compounds – Benzene, Toluene, Xylene
  • Halogenated Organics – Chloroform, Dichloromethane
  • Ketones & Alcohols – Acetone, Isopropanol, Methanol
Surfactants & Preservatives
  • Nonylphenols, PEGs (Polyethylene Glycols) – Found in formulations
  • EDTA (Ethylenediaminetetraacetic acid) – Chelating agent, difficult to degrade
Synthetic Dyes & Excipients
  • Azo dyes, Erythrosine, Tartrazine – Used in coating and formulations
  • Polymers (PVP, HPMC) – Film coating agents
Challenges in Treating Recalcitrant COD in Pharma Wastewater
  • Low Biodegradability – APIs and organic solvents are designed to be stable, making them resistant to biodegradable organic breakdown.
  • Toxicity to Microbes – Many antibiotics and chemicals inhibit microbial activity in biological treatment processes such as treatment with activated sludge.
  • Complex Mixtures – The presence of multiple organic compounds requires a combination of advanced oxidation processes and membrane bioreactors (MBR).
  • Regulatory Compliance – Strict discharge norms (CPCB & local pollution control boards) demand COD removal below permissible limits.
Conclusion

Recalcitrant COD in pharmaceutical effluents is a major challenge due to the persistence of APIs, solvents, and formulation additives. Effective treatment requires a hybrid approach combining oxidation, adsorption, and specialized biological solutions. With growing environmental concerns and stringent regulations, innovative and sustainable treatment processes from leading bioculture companies in India are essential for managing pharma wastewater effectively

Are you looking for a reliable wastewater treatment solution?Contact us now to explore customized strategies for your facility!

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Bioculture-Based Treatment of Recalcitrant COD
Bioculture-Based Treatment of Recalcitrant COD in Pharmaceutical Effluents
Introduction

It often happens that an Effluent Treatment Plant’s (ETP) chemical oxygen demand (COD) degrading efficiency becomes stagnant at a certain point. Despite trying multiple wastewater treatment methods and technologies, breaking this threshold remains a challenge. The real culprit behind such scenarios is the presence of recalcitrant COD in pharma effluents.

Pharmaceutical wastewater, in particular, presents high COD and BOD challenges due to persistent Active Pharmaceutical Ingredients (APIs), solvents, and excipients that resist biological treatment. Conventional systems often struggle to meet regulatory compliance, making microbial culture-based treatment a promising alternative. This blog explores treatment efficiency, plant configurations, cost analysis, and pilot project insights for implementing enzyme-based bioculture in pharma effluent treatment.

To learn more about effective solutions for reduction of recalcitrant COD reduction in Pharmaceutical Effluents, feel free to contact us.

1. Understanding Bioculture-Based Treatment for Pharma Effluent
How Biocultures Work?

Microbial culture is a specialized microbial consortia capable of degrading recalcitrant COD through enzymatic breakdown. They work via:

✅ Advanced oxidation processes – Breaks complex organic compounds into biodegradable intermediates. 

✅ Co-Metabolism – Uses an additional carbon source to enhance pollutant degradation. 

✅ Biofilm Formation – Protects microbes from toxic compounds and improves stability in treatment systems.

Targeted Degradation of Recalcitrant COD Components
Pharma CompoundCommon SourceMicrobial Strains UsedEnzymes InvolvedDegradation Pathway
ParacetamolPainkillersPseudomonas putida, Bacillus subtilisAmidase, LaccaseAmide hydrolysis to p-aminophenol, oxidation
Ibuprofen & DiclofenacNSAIDsSphingomonas sp., Rhodococcus sp.Dioxygenases, HydrolasesHydroxylation & carboxylation of aromatic rings
Ciprofloxacin & OfloxacinAntibioticsAcinetobacter sp., Pseudomonas aeruginosaMonooxygenasesQuinoline ring cleavage
Erythromycin & AzithromycinMacrolide AntibioticsBacillus licheniformisEsterase, OxidaseEster bond hydrolysis, oxidation
Estradiol & ProgesteroneHormonesComamonas testosteroni, Mycobacterium sp.Hydroxylase, DehydrogenaseSteroid ring hydroxylation
ChloramphenicolAntibioticsPseudomonas fluorescensReductase, HydrolaseNitro group hydrolysis
Azo Dyes (Erythrosine, Tartrazine)Coloring AgentsPseudomonas aeruginosa, Shewanella oneidensisAzoreductaseAzo bond cleavage
Nonylphenols, PEGsSurfactantsSphingomonas sp., Pseudomonas sp.Oxidase, β-OxidaseOxidation of alkyl chains
2. Treatment Systems Configurations Using Biocultures
Plant Design for Pharma Wastewater Treatment Process
Stage 1: Pre-Treatment (Equalization & Primary Treatment)

Objective: Remove suspended solids, neutralize pH, and reduce initial COD load.

✅ Equalization Tank – Balances flow & pH (6.5–7.5).
✅ Coagulation-Flocculation – Removes large particulates (e.g., PAC or FeCl₃).
✅ Screening & Oil Removal – Eliminates large solids and oil residues.

Stage 2: Advanced Biological Treatment with Microbial Culture

✅ Moving Bed Biofilm Reactor (MBBR) or Sequential Batch Reactor (SBR) – Bioculture for STP wastewater treatment. 

✅ Optimized Microbial Seeding – Customised culture for targeted degradation. 

✅ Retention Time: 24–36 hours for reaction time.

Stage 3: Advanced Oxidation Processes & Membrane Filtration 

✅ Fenton’s Process / Ozonation – Further breaks down recalcitrant COD. 

✅ Membrane Bioreactor (MBR) or Reverse Osmosis (RO) – Final purification.

Stage 4: Sludge Management & Water Reuse

✅ Dewatering & Sludge Handling – Using filter press or centrifugation. 

✅ Effluent Recycling – Treated water reused for lagoons wastewater treatment.

3. Pilot Project Insights: Real-World Applications
Case Study 1: Antibiotic Manufacturing Effluent Treatment

📍 Location: India | COD Level: 10,000 mg/L

✅ Solution: Bioculture companies for wastewater treatment (Acinetobacter sp. & Pseudomonas sp. in MBBR). 

✅ Result:

  • COD reduced by 85% (Final COD: <500 mg/L).
  • Reduced toxicity – No microbial inhibition observed.
Case Study 2: NSAID (Ibuprofen & Diclofenac) Removal

📍 Location: Europe | COD Level: 8000 mg/L
✅ Solution: SBR + Microbial Culture Companies in India (Rhodococcus + Sphingomonas). 

✅ Result:

  • COD reduced by 90% (Final COD < 250 mg/L).
  • High removal of Ibuprofen (96%) & Diclofenac (89%).
4. Cost Analysis of Bioculture-Based Treatment
Cost ComponentEstimated Cost (₹/m³)Description
Bioculture Seeding₹3–6Initial inoculation for microbial growth
Reactor Operation (MBBR/SBR)₹15–20Aeration, energy, and microbial maintenance
AOP (Ozonation/Fenton’s Process)₹8–12Advanced oxidation for recalcitrant organics
Membrane Treatment (RO/MBR)₹12–18Filtration and final polishing
Total Treatment Cost₹38–56 per m³Cost-effective compared to ZLD (₹80-100 per m³)
Key Takeaways:
  • Bioculture-based treatment reduces overall cost by 30–50% compared to purely chemical or ZLD systems.
  • Lower sludge production compared to coagulation-based treatments.
  • Faster startup time (2–3 weeks) compared to conventional activated sludge.
Conclusion: The Future of Biocultures in Pharma Effluent Treatment

🔹 Bioremediation companies in India offer a sustainable & cost-effective solution for treating recalcitrant COD in pharma effluents.
🔹 Bioculture companies in India can provide enzyme-based bioculture tailored for specific APIs, ensuring high pollutant removal.
🔹  Integrating biocultures with advanced oxidation & MBBR/SBR technology enhances efficiency & meets regulatory standards.

If you’re looking for expert guidance or customized solutions for your ETP, our team is here to help!

Contact us today for a consultation or to learn more about how we can support your effluent treatment needs!

📧 Email: sales@teamonebiotech.com

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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 / IssueTargeted Bioculture StrainsMode of Action
High COD from dyes & finishingPseudomonas putida, Bacillus subtilisProduces oxidative enzymes to break down complex organics.
Phenolic compounds & nylon by-productsAcinetobacter sp., Comamonas testosteroniUses phenol hydroxylase to degrade toxic aromatics.
Surfactants & residual oilSphingomonas sp., Rhodococcus sp.Breaks down surfactants & hydrocarbons.
Filamentous bacterial overgrowthBacillus licheniformis, Nitrosomonas sp.Competes with filamentous microbes & improves sludge settling.
Ammonia & nitrate fluctuationsNitrobacter sp., Paracoccus denitrificansEnhances 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

ParameterBefore TreatmentAfter Bioculture ImplementationReduction %
COD in Effluent1200 mg/L180 mg/L85%
BOD in Effluent250 mg/L35 mg/L86%
Phenol Concentration45 mg/L5 mg/L88%
Filamentous Bacteria IssueFrequent sludge bulkingFully controlled–
Dissolved Oxygen (DO)1.5 mg/L2.5 mg/L–
Sludge Settling (SVI)>250 mL/g<120 mL/g52% 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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Anaerobio Bacteria & Treatment – Microbial Culture, Bio Culture & Product, Digestion, Wastewater, Microorganisms, Baffled Reactors (ABRs), Anaerobic Filter

Team One Biotech’s Anaerobio is a unique combination of anaerobic & facultative bacteria like methanogenic bacteria, acidogenic and acetogenic and hydrolytic bacteria that break down the organic waste sludge in the wastewater treatment process in absence of oxygen.

The microbiome mixture is highly efficacious in reducing organic pollutants and industrial waste materials into methane and reducing the generation of hydrogen sulphide gas thereby increasing the productivity of wastewater treatment plants and furnishing higher output of biogas.

Biomass carryover in an anaerobic digestion process is a widely common concern. It is extremely important that the biomass is healthy with matured flocs. This helps the bacteria to maintain a good sludge blanket inside the reactor. T1B Anaerobio moderates the sludge blanket formation at the bottom of the wastewater tank or clarifier. This allows the removal of small dirt particles, metals, and simpler compounds from the wastewater.

T1B Anaerobio supports all type of anaerobic digesters to control its biomass carryover

T1B Anaerobio | Consortium Of Microbes To Process Anaerobic Digestion, Hydrolysis – Can Be Used In Upflow Anaerobic Sludge Blanket Reactor

 Anaerobic Bacteria – Anaerobic Microbial Culture – Anaerobic Bio Culture – Anaerobic Bio Product – Anaerobic Treatment – Anaerobic Digestion – Anaerobic Wastewater Treatment – Anaerobic Filter – Anaerobic Microorganisms – Anaerobic Baffled Reactors (ABRs) – Microbial Strains – Biodegradation – Bioreactor – Methane Production – Organic Matter Removal – Wastewater Treatment – Microbial Consortia – Biogas – Acidogenesis – Methanogenesis – Hydrolysis – Microbial Community – Biomethanation – Temperature – Alkalinity – Sludge Break Down – Removal Of Organic Volatile Compounds VOC’s – Biogas Production – Acetogenesis – Upflow Anaerobic Sludge Blanket Digestion – UASB – Diverse Range Of Bacteria – Advanced Biochemicals – Hydrogen Sulfide And Methane – Bio Digester – Sludge Blanket – Sludge Wasting – Biomass Carryover – Improve Methane Generation – lower Hydrogen Sulfide Production – Enzyme – Bacteria And Enzyme Production – Bio Enzyme For Biogas – Anaerobic lagoon – EGSB (Expanded Granular Sludge Bed) Reactor – Fluidized Bed Reactors – Breakdown Of Organic Matter In The Absence Of Oxygen – Consortium Of Microorganisms – Renewable Energy – Wastewater Treatment – AD Process – Microbial Digestion – Digestate – Green Energy – Energy Efficiency – AD Technology

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