Improving Oxygen Transfer efficiency in a Chemical manufacturing plant
Background
A mid-size chemical manufacturing company situated in Madhya Pradesh was facing efficiency issues in improving oxygen transfer efficiency in its ETP, such as low efficiency, biomass suspension, and diffuser dysfunction. Despite maintaining a good overall diffused aeration system, their biomass was not developing, and MLVSS was very low.
As a result, the client incurred high CAPEX due to unnecessary diffuser replacements and remained non-compliant with regulatory COD/BOD limits.Facing challenges in improving oxygen transfer efficiency and facing high energy costs? Let Team One Biotech help.
ETP details:
The industry had primary treatment, biological treatment, and then a tertiary treatment.
| Flow (current) | 750 KLD |
| Type of process | ASP |
| No. of aeration tanks | 1 |
| Capacity of aeration tanks | 1150 KL |
Challenges:
| Parameters | Avg. Inlet parameters(PPM) | Avg. secondary system outlet parameters(PPM) |
| COD | 18000 | 6000 |
| BOD | 8500 | 2800-3000 |
| TDS | 30000 | 2500 |
Problem Statement:
The client observed persistently low dissolved oxygen (DO) levels in the aeration tank despite extended blower run-times and increased air supply. This resulted in:
- Sub-optimal biological treatment
- Elevated energy costs
- Occasional odor issues and inconsistent COD/BOD reduction
A preliminary diagnosis indicated biofilm accumulation and diffuser fouling, affecting fine bubble formation and limiting oxygen dispersion.
Our Approach
Team One Biotech initiated a comprehensive on-site audit including:
Diffuser Health Check
- Inspected diffuser membranes for fouling
- Identified scaling and microbial slimes affecting pore performance
Baseline Monitoring
- DO levels across the tank: <1.5 mg/L
- Specific Oxygen Uptake Rate (SOUR): <15 mg O₂/g VSS/hr
- Blower energy use: ~65 kWh/day
- OTE Baseline: Estimated OTE was 12%
Microbial Evaluation
- Floc structure was loose, with filamentous dominance
- Low settleability (SVI > 200)
To implement a cost-effective, eco-friendly bioremediation strategy that:
- Enhances the degradation of formaldehyde and glutaraldehyde.
- Restores biological treatment efficiency.
- Achieves compliance with CPCB norms.
Solution
We proposed a 2-fold intervention:
1.Application of T1B Aerobio Bioculture
- Dose: 10 ppm daily for 10 days, 8 ppm for next 10 days, and 5 ppm for next 10 days, then 3 ppm as maintenance every day.
- Objective: Enrich native microbial diversity and improve biomass quality
2. Aeration System Optimization
- Conducted sequential backflushing of diffusers
- Realigned blower duty cycles with microbial demand using DO automation feedback
Monitored DO, pH, and ORP to ensure a stable environment.
Results:
After 60 days of implementation:
| Parameters | Before intervention | After Intervention |
| DO in Aeration Tank | 1.2 mg/L | 2.8 mg/L |
| SOUR | 1 3.6 mg O₂/g VSS/hr | 22.3 mg O₂/g VSS/hr |
| SVI | 210 mL/g | 120 mL/g |
| COD Reduction | 72% | 87% |
| Blower Runtime | 24 hrs/day | 16 hrs/day |
| Energy Use | 65 kWh/day | 38 kWh/day |
| OTE | 12 % | 21.4 % |
Conclusion
With the combined effect of T1B Aerobio bioculture and technical aeration optimization, the client achieved a 78.3% increase in oxygen transfer efficiency. This translated into:
- Significant energy savings
- Improved microbial activity and settleability
- Stable effluent quality, meeting compliance standards
This case demonstrates how biology-driven solutions, coupled with system know-how, can deliver tangible performance and cost benefits in industrial wastewater treatment.
Ready to optimize your ETP performance? Connect with us today
📧 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!