Phosphate removal in a chemical manufacturing plant in Madhya Pradesh
Background
A prominent chemical manufacturing unit situated in MP near Ratlam is our existing client to whom we provided technology to treat high COD and TDS effluent. They again approached us due to their experience working with us. They wanted to treat an effluent stream with high phosphate content upto 1500-2000 ppm. They asked us to use their old ETP, revive it , commission and make it efficient for phosphate treatment.
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1st Phase: Scrutiny
Our team of experts visited the factory to introspect and identify scope of improvements.
OLD ETP details:
The ETP had primary treatment, biological treatment (Anaerobic), and then a tertiary treatment.
| Flow (current) | 350 KLD |
| Type of process | UASB |
| No. of UASBR | 1 |
| Capacity of biological tank | 950 KL |
Parameters of the stream with Phosphate:
| Parameters | Avg. Inlet parameters(PPM) |
| COD | 4300 |
| Phosphate Content | 1500-1800 |
| TDS | 3000 |
2nd Phase : The Blueprint
After scrutiny and brainstorming with our R&D, we concluded to transform the old ETP apparatus into an EBPR unit, i.e., Enhanced Biological Phosphorus removal unit, which involves the introduction of PAOs (polyphosphate-accumulating bacteria) into the biological system along with physico-chemical treatment in primary and tertiary systems, respectively, of the old ETP.
ETP process optimization:
An efficient EBPR unit requires anaerobic as well as aerobic system, as in anaerobic the RbCODs get transferred into VFAs, which are then absorbed by PAOs for efficient phosphate uptake, which is dispersed during the anaerobic process. The PAOs then absorb the phosphate rapidly in the aerobic system. Hence, biomass with phosphate-absorbed PAOs is allowed to settle in the clarifier, and then WAS is removed.
In this scenario, the ETP had a UASB system, but no Aeration system, hence:
- We utilized a spare tank of capacity 300 KL located next to USABR, and transformed it into an aeration tank by installing diffusers.
- After our recommendation, the industry installed a 50 KL FRP clarifier after the sedimentation system.
Thus, we converted the old ETP into a facultative EBPR unit with integrated biological phosphorus removal capability.
3rd Phase : Technology and Execution
1. Selecting biocultures:
For UASB:
The perfect solution for an Anaerobic system consists of robust bacteria that can efficiently work in anaerobic conditions, leveraging efficiency in terms of:
- COD reduction
- Biomass Generation
- Methane Generation
- F/M ratio optimization
Here, since our goal was phosphate treatment and reduction, we amalgamated PAOs as well, which made the product extremely effective to be used in the developed EBPR system.
For Aerobic Tank:
Equipped with highly robust and selective strains of bacteria which when combined with PAOs, made T1B Aerobio the best-suited weapons to remove phosphate levels, thereby increasing the efficiency of the EBPR unit.
2.Dosing:
Initially, we provided a dosing schedule for 60 days, in which 1st 30 days was loading dose, with a higher product quantity, and the second 30 days dose was maintenance dose, which was 1/4th of the loading dose.
| Product | T1B Anaerobio | T1B Aerobio |
| Loading Dose | 100 kgs | 60 kgs |
| Maintenance dose | 40 kgs | 20 kgs |
| Point of addition | UASB | Aerobic Tank |
3.Process optimization:
Our target was to achieve MLSS of 3500-4000 in the first 15 days. After that, the WAS was wasted at 15 KLD, and RAS was recirculated at 5 KLD.
Results:
After 60 days of implementation:
| Parameters | Primary Outlet | UASB Outlet | Clarifier Outlet |
| COD | 3900 | 1900 | 800 |
| Phosphate | 1300-1500 | 850-900 | 180 |
| COD Reduction | 10 % | ~ 55 % | 82 % |
| Phosphate reduction % | 8-10% | ~ 65 % | ~85-90% |
Conclusion
With the combined effect of T1B Anaerobio and T1B Aerobio bioculture and process optimization, the client achieved an 85-90 % reduction through the biological system, which further increased after tertiary system. This translated into:
- Improved microbial activity and settleability.
- Stable effluent quality, meeting compliance standards.
- Biocultures are effective in phosphate removal.
This case demonstrates how biology-driven solutions, coupled with system know-how, can deliver tangible performance and cost benefits in industrial wastewater treatment.
👉 Want similar results at your facility? Let’s talk! Contact us now to implement sustainable, biology-based solutions.
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