ReducingReplacing RELIANCE ON MEE in HIGH TDS Effluents
Reducing/Replacing RELIANCE ON MEE in HIGH TDS Effluents

Multi-effect evaporators (MEEs) are widely used in industries dealing with high TDS effluent COD testing. They are highly effective—reducing COD by up to 90–95% even when the TDS of effluent water is extremely high. However, the shine of MEE’s efficiency often masks the significant operational costs that come with it. This blog explores whether MEEs can be replaced or minimized and the role of biological systems in reducing reliance.

This blog explores all sides of this technology and how its usage can be reduced or replaced. Get in touch to learn how innovative bioculture-based treatments can optimize COD reduction and lower operational costs in your effluent systems.

What is an MEE- How it works?

A Multi-effect evaporator (MEE) is an energy–efficient system used to concentrate high-TDS effluents by evaporating water in multiple stages or “effects”. It utilizes steam in the first stage to heat the effluent, causing water to evaporate. The vapor generated is then reused as a heating source for the next stage, progressively reducing energy consumption. This cascading use of steam maximizes thermal efficiency and minimizes operational cost. MEEs are widely used in zero liquid discharge (ZLD) systems, especially in industries with high salinity wastewater. The result is a concentrated brine and distilled water, both of which can be handled or reused appropriately.

Why is MEE in trends?

MEE is one of the most trending technologies in wastewater treatment, owing to its high efficiency in reducing higher levels of COD and tackling tough and toxic effluents with compounds like Cyanide, Toluene, Phenols, and aldehydes. Also, the condensate quality is top-notch. MEE is very popular in industries located near the sea, as it has excellent efficiency up to 98% in effluents with COD up to 150000 PPM and above, and delivers in TDS above 100000 PPM as the sea discharge with higher TDS is permissible.

Technology comes at a Cost

Multiple Effect Evaporator (MEE) systems, while highly efficient in reducing wastewater volume and achieving zero liquid discharge (ZLD), are often cost-prohibitive for many industries. The initial capital investment for an MEE plant typically ranges from Rs 50 lakh to Rs 2 crore, depending on capacity and design complexity.

Operational costs are also steep—electricity and fuel expenses can exceed Rs. 3-5 per liter of treated effluent, especially when steam boilers or thermic fluid heaters are involved. Despite incorporating energy recovery through multiple effects, MEEs still consume 1.2-1.5 kg of steam per liter of evaporated water.

Maintenance adds another layer of expense; anti-scalant chemicals, descaling routines, and part replacements can cost Rs. 5-10 lakh annually for a mid-sized plant. Skilled manpower and automation support further raise the cost.

Additionally, industries must manage the disposal of high-TDS concentrate or salts, which may cost Rs. 2-3 per kg in transport and treatment. Pre-treatment requirements—like neutralization, oil removal, or biological treatment-can add another Rs. 0.5-1 per litre.

While MEE ensures regulatory compliance and high performance, the total cost of ownership makes it unviable for many small and medium enterprises. Hence, despite its technical merits, MEE remains financially challenging, pushing industries to explore cost-effective biological or hybrid solutions.

 

What are the alternatives?

MEEs are known to reduce high COD values in effluents with high TDS values. Hence, it may sound ridiculous, but the best alternatives are BIOCULTURES. Now, the first question coming into the readers’ minds will be Why & How?

Well, let’s first answer Why? There is a certain class of bacteria that survives and thrives in extremely high saline conditions called Halophilic bacteria. These bacteria, when combined with other strains, as biocultures, can effectively work in high TDS effluents and reduce COD with great efficiency.

Now, let’s find out how?

The best way is to gradually divert the primary treated influent stream/inlet stream to MEE to the aeration tank.

Suppose A MEE has a capacity of 30 KLD that treats a stream with COD 75000 and TDS 50000, and the ETP is of 200 KLD that handles an inlet COD of 10000 PPM. In this case, initially, a stream of 5 KLD inlet to MEE can be diverted to the 200 KLD ETP. Then the average COD can be calculated by the below formula:

formula

Hence, the average inlet of 200 KLD ETP after diverting 5 KLD ETP will be approximately 12000 PPM, which can be treated by effective biocultures with strains of halophilic bacteria.

The 5 KLD stream can be increased to 10 KLD and 15 KLD, depending on the performance of the ETP.

How can this strategy be a game-changer?

Well, it is self-explanatory from the above information that diverting the MEE stream can reduce OPEX up to 30-35% straightaway, along with increasing the efficiency of the ETP. However, this strategy is more applicable in industries where sea discharge with High TDS effluent is permitted. But, it is not restricted also; options can be analysed too in other cases.

Technical efficiency and product viability is a must

While, the strategy looks very easy on paper but it is very tough to execute. It requires technical know-how of the whole plant, analysis of trends, and effective identification of strains and its amalgamation into an effective bioculture, its dosing and most important acumen of troubleshooting in real-time as we will be handling a stream which is very toxic , filled with tough-to degrade and shock load inducing compounds.

Team One Biotech is one of the leading Biotech Companies in India, providing advanced microbial solutions like bacteria for ETP treatment and bacteria culture for wastewater treatment.
???? Reach out now to enhance your wastewater treatment efficiency.

???? Email: sales@teamonebiotech.com

???? Visit: www.teamonebiotech.com

???? Discover More on YouTube – Watch our latest insights & innovations!-

???? Connect with Us on LinkedIn – Stay updated with expert content & trends!

Sludge Bulking vs. Sludge Settling Ways to improve wastewater treatment in India
Sludge Bulking vs Settling: Biotech Companies in India

“Our MLSS is quite high, but we are not getting enough settling. “ or “Our biomass development is very good as our MLSS is high, but we have very little BOD/COD reduction”. these statements are often given by EHS managers. However, the concept of MLSS is completely misunderstood; it’s never the quantity of MLSS, it’s always the quality of MLSS. The settling of sludge and BOD reduction always correspond with how good the MLSS is, and not how much it is.

This blog intricately explains the difference between sludge bulking and sludge settling, and which factors are necessary to look out for.

Sludge Settling vs Sludge Bulking:

With the growing awareness of operational efficiency, several biotech companies in India are now addressing sludge bulking challenges through microbial innovation and advanced diagnostics.

Healthy Sludge Settling:

In a well-operating secondary clarifier, biomass flocs are compact, dense, and settle rapidly. The supernatant above appears clear, and the sludge blanket remains stable.

Sludge Bulking:

Here, the sludge appears fluffy, loose, and struggles to compact at the bottom. The supernatant turns turbid, and sludge blankets may rise or disperse.

Parameter Healthy Settling Sludge Bulking
SVI (Sludge Volume Index) 80–120 mL/g >150 mL/g
Sludge appearance Dense, compact flocs Loose, filamentous flocs
Supernatant Clear Turbid
Settling time 20–30 mins >45 mins
Cause Balanced system Filamentous overgrowth, F/M imbalance
Why Good MLSS ≠ Good Settling

Operators often celebrate high MLSS as a sign of strong microbial population. But MLSS is a mass reading-It doesn’t distinguish between healthy floc-formers and problem-causing filamentous organisms.

“ Think of it like body weight: Two individuals weigh the same, but one may be with lean muscle, the other with excessive fat.

In bulking scenarios, the bulk of MLSS is held together by filamentous bacteria-these long, thread-like organisms stretch out of flocs, creating open, web-like structures that trap water and resist compaction.

Reliable biocultures companies have been instrumental in developing floc-forming microbial strains specifically tailored for bulking control.

What Causes Sludge Bulking?
  1. Filamentous Bacteria Overgrowth

Common species: Type 021N, Sphaerotilus, Microthrix parvicella, Thiothrix

These bacteria thrive under specific conditions such as:

Low DO (<1.0 mg/l) – especially at floc centers.

High F/M ratios – excess food leads to dominance of fast-growing filaments

Nutrient Imbalance– N and P deficiency affect floc formation

Surfactants and FOG – common in food, dairy, and textile industries

Hydraulic surges – shock loading from upstream process

Leading microbial companies in India are providing industry-specific solutions for complex ETP issues, helping clients achieve consistent results in variable conditions.

 

  1. F/M Ratio Imbalance

Too much organic load relative to MLSS results in excessive microbial growth, and filamentous bacteria often outcompete floc-formers.

Ideal F/M ratio: 0.2-0.5 kg BOD/kg MLSS/day

Bulking is more likely when F/M > 0.6 or < 0.1, especially during inconsistent feed conditions.

  1. pH and Toxic Shocks

Sudden changes in pH (below 6.5 or above 8.5) , or toxic loads (solvents, phenols, metals) can kill floc-formers and allow filaments to dominate during regrowth. However, Solutions like those from Team One Biotech, a known player among bioculture for ETP STP plant manufacturers, are reshaping how industries manage MLSS health and sludge behavior.

 

Decoding SVI and other key Indicators

Sludge Volume Index (SVI) is the gold standard for assessing settleability.

  • SVI = ( Settled sludge volume in 30 mins, mL/L) / MLSS (g/L)
  • SVI < 100 = Good settling
  • SVI 120–150 → Early warning of bulking
  • SVI > 200 → Severe bulking

Other red flags:

  • Rising sludge in the clarifier
  • Scum layer formation
  • Poor TSS in final discharge
  • Varying DO and pH patterns in aeration tanks
Countermeasures- How to fix Bulking?

In addition to microbial solutions, industrial odor control systems  also play a pivotal role in overall ETP performance and workplace hygiene.

Short-Term Fixes:

  • Chlorination or Peracetic Acid Dosing: Targets filamentous bacteria selectively. Start with 0.5–1 ppm, monitor response.
  • Increase DO Levels: Maintain >2.0 mg/L throughout the aeration tank, especially in large tanks or tanks with dead zones.
  • Sludge Wasting: Reduce SRT (sludge retention time) to control filament growth. Remove excess MLSS.
  • Polymers in Clarifier: For emergency clarity issues, short-term use of cationic polymers can compact sludge.

Long-Term Solutions:

  • Nutrient Balancing: Maintain COD:N:P at approx. 100:5:1. Add urea or DAP if needed.
  • Equalization Tank: Smooth out hydraulic/organic loading rates to the aeration tank.
  • Bioculture Regeneration: Consider seeding with robust floc-forming consortia after bulking episodes.
  • Upgrade Aeration: Switch to fine-bubble diffused aeration systems to improve oxygen transfer.
  • Micronutrient Support: Trace metals like iron, cobalt, and molybdenum support healthy floc formers.

If you’re exploring biocultures for ETP plant manufacturers in India or need effective bacteria solutions for wastewater treatment, Team One Biotech offers proven blends tested across sectors.

Conclusion:

Remember one quote: What settles well, treats well. MLSS and BOD tell only one part of the story – settleability, floc health, and microbial balance complete the picture.

As experts and EHS leaders, we must look beyond the dashboard. A 3500 mg/L MLSS might impress, but if your sludge floats and supernatant clouds, your ETP is already sending you a warning.

Looking for a trusted waste water treatment company to resolve sludge settling problems? Contact Team One Biotech today for tailored solutions and microbial consultation.

???? Email: sales@teamonebiotech.com

???? Visit: www.teamonebiotech.com

???? Discover More on YouTube – Watch our latest insights & innovations!-

???? Connect with Us on LinkedIn – Stay updated with expert content & trends!

Anaerobic Wastewater Treatment: Demystifying Methanogenesis
Anaerobic Wastewater Treatment: Demystifying Methanogenesis

The wastewater treatment world is an unending sea of types of processes and variations. One such process, the anaerobic treatment, holds a prominent and popular reputation due to its low CAPEX-OPEX and generation of byproducts such as methane, which is valuable as well as a clean energy source.

The process that leads to methane production is known as methanogenesis-which is the final and slowest step in the anaerobic digestion chain, where intermediate acids and hydrogen are converted into methane.

However, the process is mostly underperforming in the industries due to its bottlenecks and variable mechanism. This blog helps readers understand the intricacies of methanogenesis and helps understand the concept and mechanism.

In the rapidly evolving landscape of anaerobic wastewater treatment, industries are recognizing the limitations of traditional systems and turning toward advanced, high-efficiency strategies. With increasing load from industrial effluent treatment, especially containing high COD and toxic compounds, the need for anaerobic bioreactor optimization is more critical than ever.

With the increasing demand for bacteria solutions for wastewater treatment, industries are actively seeking partners who understand both biology and process engineering.

Companies like Team One Biotech lead the way among bioculture companies and microbial companies in India, delivering high-performance strains suited for industrial ETPs.

We provide expert consulting and microbial formulations tailored for anaerobic systems. Contact us today to learn more about our solutions and transform your treatment process.

What is Methanogenesis?

Methanogenesis is the last step in anaerobic digestion, where the end products from acetogenesis and acedogenesis process are converted into methane gas and CO2 by methanogenic archaea.

Modern facilities strive for not just compliance but profitability through biogas production efficiency, transforming waste streams into energy assets. The use of engineered microbial consortia, such as T1B Anaerobio, ensures higher methane recovery from wastewater even under challenging conditions like salinity and shock loads.

Core stages of Anaerobic Digestion:

  1. Hydrolysis: Breakdown of complex organics (proteins, carbs, Fats)
  2. Acidogenesis: Fermentation into VFAs (volatile fatty acids), alcohol, H2.
  3. Acetogenesis: Conversion of VFAs into acetate, H2, and CO2.
  4. Methanogenesis: Final step producing CH4 and CO2.

Types of methanogens:

Pathway Microbial Group Substrate
Acetoclastic Methanosaeta, Methanosarcina Acetate → CH₄ + CO₂
Hydrogenotrophic Methanobacterium, Methanococcus H₂ + CO₂ → CH₄

 

These microbes are obligate anaerobes, extremely sensitive to environmental shifts-and incredibly slow-growing.

Why does methanogenesis often fail?

As evident, it is important to have success in all three processes i.e. Hydrolysis, Acidogenesis, and Acetogeneis, before Methanogenesis  to succeed. This requires proper management of pH, temperature, HRT and induction of right biomass. However, in most cases all the three preceding processes are comparatively easier to get executed, it is this methanogenetic process only where most plants struggle due to:

  1. Acid accumulation/VFA Buildup
  • Acidogenesis is rapid, while methanogenesis is slow.
  • Result: VFA overload, which causes pH to drop below 6.8—a toxic zone for methanogens.

 

  1. Toxic Inhibitors

Common industrial effluents contain:

  • Heavy metals (Zn, Cu, Cr)
  • Sulfides
  • Phenols
  • Ammonia >2000 mg/L

These compounds directly inhibit methanogenic enzyme systems.

  1. Salinity and TDS stress

TDS above 15000-20000 ppm imposes osmotic stress, especially on Methanosaeta, which is already slow-growing.

 

  1. Lack of Granular Structure in Reactors

Granules in the sludge allow the methanogens to thrive in micro-environments.

  • Poor granulation = less protection = washout
How to Improve Methanogenesis- Practical Strategies

Improving methanogenesis requires a holistic approach involving operational tuning, microbial reinforcement, and environmental stability.

  1. Maintain Optimal pH: 6.8 – 7.4

Methanogens are extremely pH sensitive; any fluctuation can halt the methanogenic process that leads to unwanted reverses.

  1. Control Organic Loading Rate (OLR)

Gradually ramp up OLR during commissioning, ideal OLR: 1.5-3.5 kg COD/m3/day for stable systems. Overfeeding typically leads to acid overload and ultimately methanogen collapse.

  1. Ensure Adequate Retention Time

The ideal HRT should be between 8-15 days (depending on the substrate). The SRT should be even longer in high-loading systems.

  1. Use advanced Biocultures enriched in Methanogens

Key Traits of Effective Methanogenic Biocultures:

  • Contains both acetoclastic and hydrogenotrophic strains
  • High cell viability in anaerobic, low-oxygen environments
  • Pre-adapted to shock loads, high COD, and salinity

At Team One Biotech, our T1B Anaerobio blend includes halotolerant Methanobacterium and facultative syntrophic partners that stabilize early acid-phase products and prevent VFA accumulation.

  1. Add Conductive Materials (Bio-Stimulation)
  • Use activated carbon, biochar, or magnetite in digesters.
  • These promote direct interspecies electron transfer (DIET), bypassing slower H2 pathways
  • Result: Faster methanogenesis and increased CH4 yield
  1. Control Sulfates and Heavy Metals

 Sulfate-reducing bacteria (SRB) compete with methanogens for substrate.

  • High sulfide also directly poisons methanogens
Key Indicators of Methanogenesis Health
Parameter Healthy Range
pH 6.8 – 7.4
VFA/Alkalinity ratio <0.3
ORP -300 to -400 mV
Biogas CH₄ content >60%
Foaming Minimal (indicates balance)
Gas production rate Steady increase or plateau
Methanogenesis is Fragile, but Fixable

Methanogenesis is the most sensitive yet rewarding step in anaerobic treatment. It’s where the “waste” becomes “resource,” and the environmental liability transforms into a clean, combustible asset.

But to get there, industries must move beyond legacy systems and general-purpose biology.

They must:

  • Understand the microbial bottlenecks
  • Deploy engineered or acclimated methanogens
  • Support them with pH buffering, controlled feeding, and granular retention

Only then can your anaerobic system realize its full potential — both in COD removal efficiency and renewable methane production.

Conclusion:

Achieving high COD removal technology performance depends heavily on maintaining organic loading rate control, optimal pH, and reducing VFA accumulation. Furthermore, granular sludge formation enhances microbial retention and process stability, which is vital in high-strength wastewater treatment systems.

Through targeted bioaugmentation for anaerobic digestion, enriched with salinity resistant methanogens, it’s now possible to manage volatile environments and optimize yield. These microbial consortium for ETP solutions include both acetoclastic and hydrogenotrophic archaea, enabling efficient conversion pathways and reduced inhibition.

One promising method includes introducing conductive material in digesters, which boosts DIET and facilitates faster VFA to methane conversion. This, combined with proper HRT/SRT balance and T1B Anaerobio application, unlocks new levels of process performance.

As we progress towards zero-waste water solutions and advanced ETP solutions, methanogenesis is no longer just a biological reaction—it’s a cornerstone of sustainable industrial practice.

In recent years, several biotech companies in India have made significant strides in anaerobic treatment technologies, offering customized microbial formulations.

Team One Biotech is one of the leading Biotech Companies in India, providing advanced microbial solutions like bacteria for ETP treatment and bacteria culture for wastewater treatment.
???? Reach out now to enhance your wastewater treatment efficiency.

???? Email: sales@teamonebiotech.com

???? Visit: www.teamonebiotech.com

???? Discover More on YouTube – Watch our latest insights & innovations!-

???? Connect with Us on LinkedIn – Stay updated with expert content & trends!

Scan the code