Replacing Urea-DAP in a Textile Industry

Introduction:

We, at Team One Biotech LLP, help industries achieve sustainability goals with our biological wastewater treatment solutions, offering natural replacements for chemicals like urea-DAP and other nutrients.

In this success story, we are going to walk through the treatment efficiency and results achieved using SustainX for a leading textile company located at Dabhasa, GIDC, Gujarat. If you want to know more, feel free to contact us. 

The industry happens to be one of the most compliant and efficient in terms of textile wastewater treatment, they had a very good ETP mechanism and trained staff. However, they had a huge consumption of UREA-DAP, leading to high OPEX, also they used to experience sudden spikes in Ammoniacal nitrogen values during winters.

ETP Flow chart:

Primary- Biological and Tertiary systems, with RO & MEE. The activated sludge process (ASP) has 3 aeration tanks in series and one anoxic tank before the aeration tanks. 

Challenges:

Why traditional nutrients are inefficient in ETPS:

The commonly used urea and DAP are often overused in industrial treatment plants and they limit bioavailability for microbes. This results in poor nutrient uptake in biomass and limitations in COD and nitrogen removal causing ammonia spikes disturbing overall textile wastewater treatment systems.

1.The F/M ratio was low due to heavy consumption of UREA-DAP, leading to higher OPEX.

2.Sudden spike in ammoniacal nitrogen levels, especially in winters, due to non-consumption of ammonia from these fertilizers.

3.Saturation in COD is degrading efficiency.

The Scrutiny:

After a complete study of the plant through our WWTP evaluation form, on-site visits, and discussions with the EHS team, we concluded:

1.The F/M ratio gets lower if we stop urea-DAP addition.

2.The spike in ammoniacal nitrogen was due to the higher concentration of non-available nitrogen in the aeration tank, which was not absorbed by the biomass.

3.The indigenous microbial population was only performing at 60% efficiency in terms of COD reduction due to lower nutrient absorption despite a heavier dosage of UREA-DAP.

The Approach:

How T1B SustainX Works Better Than Urea-DAP:

SustainX is enriched with the naturally derived formulations comprising organic carbon and essential nutrients. It accelerates microbial metabolism and enhances organic waste degradation. Its unique formula helps eliminate side effects of urea and DAP and stabilizes the ammonical nitrogen. SustainX has proven benefits of optimising F/M ratio.

1. Product Selection:

T1B SustainX—The natural replacement of UREA—DAP.

Natural powdered blend with a well-balanced 

• C:N:P ratio, which will work in most scenarios.

• Rich in organic carbon, bioavailable nitrogen, and phosphorus.

• Contains natural trace elements and other nutrients essential for healthy biomass development.

• Supports both aerobic and anaerobic microbes.

2.Dosing Schedule:

A dosing schedule was fixed for 60 days initially as follows:

3.The Execution:

The product was then dosed as per the efficiency of each aeration tank in series:

Results and discussions:

• We observed a 94.5 % reduction in COD and a jump of 8% in efficiency from earlier values.
• F/M ratio optimized to 0.234 , a rise of 64% was observed.
• Use of MBR and the electricity to run the same was eliminated. 
• Improved the flow rate by 12% without compromising on the outlet parameters. 

📧 Email: sales@teamonebiotech.com

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