Effective Wastewater Treatment in Speciality Agrochemical Industry
Effective Wastewater Treatment in Speciality Agrochemical Industry
Introduction:

The agrochemical industry generates a significant volume of industrial wastewater due to continuous cleaning, washing, and multiple manufacturing processes. An Indian multinational agrochemical company faced a major challenge in handling a high organic load generated from its production operations. One of its plants, located in Gujarat GIDC, manufactures multiple agrochemical products and was struggling to maintain wastewater parameters within Pollution Control Board (PCB) discharge norms. For expert solutions on managing industrial wastewater effectively, contact Team One Biotech today.

ETP Flow Chart:

The Effluent Treatment Plant (ETP) consists of Primary, Biological, and Tertiary systems, integrated with Reverse Osmosis (RO) and Multiple Effect Evaporator (MEE). The activated sludge process (ASP) includes three aeration tanks in series and one anoxic tank positioned before the aeration units to enhance biological treatment efficiency.

Flow Parameters:

Flow: 200 m3/day
Inlet COD: 14,000 to 17,000 ppm
Inlet Ammoniacal nitrogen: 280 to 320 ppm
COD outlet after biological treatment:   9000 to 12000 ppm
Ammoniacal Nitrogen after biological treatment 220 to 270 ppm

Challenges:
 Despite maintaining high MLSS and MLVSS levels in all aeration tanks, the plant continued to record elevated COD, BOD, and Ammoniacal Nitrogen values, exceeding PCB discharge standards. The EHS department faced pressure to stabilize the biological process and meet environmental regulations. Some consultants even suggested incorporating a Membrane Bioreactor (MBR) after the ASP process, but it failed to deliver the expected COD and BOD reduction.

The Approach:
 After a detailed evaluation using Team One Biotech LLP’s WWTP evaluation form, on-site 

inspection, and extensive discussion with the EHS team, it was concluded that the main issue was the absence of an effective microbial consortium in the biological treatment system. Additionally, multiple waste streams entering the ETP from various production campaigns further disturbed microbial stability. To address this, Team One Biotech performed a Wastewater Microbiome Analysis (WMA) and Effluent Treatability Study. These scientific evaluations helped determine the adaptability and growth of microbial cultures in the effluent, confirming that bioremediation could significantly reduce COD, BOD, and TAN levels.

Performance Evaluation:
 The ETP performance was analyzed based on key parameters — Chemical Oxygen Demand (COD), Biological Oxygen Demand (BOD), Total Suspended Solids (TSS), pH, and Dissolved Oxygen (DO). Results revealed that with proper bioremediation and ETP optimization, the plant could achieve effluent quality within regulatory discharge limits.

Implementation Strategy:
 The bioremediation program spanned over 60 days, where Team One Biotech bioaugmented all biological tanks, excluding the MBR. Interestingly, the MBR was later removed from the process, as the required output was achieved without it. The implementation was structured into three focused stages:

  • Plant Optimization: The influent flow rate was stabilized to prevent biological shock. Earlier, the flow fluctuated with production, which hampered microbial activity. It was converted to a continuous flow pattern for steady biological treatment performance.
  • T1B Aerobio Dosing: A 60-day dosing plan was executed with T1B Aerobio, a proprietary microbial formulation. The first four weeks included high dosing to increase microbial population density, followed by maintenance dosing for biomass stability.
  • Flow Rate Enhancement: The treatment capacity was gradually increased from 120 m³/day to 225 m³/day by the 60th day, maintaining consistent outlet quality.
Results and Discussions:


 After 60 days, the plant achieved remarkable success: a 91% reduction in COD and 75% reduction in Total Ammoniacal Nitrogen (TAN). The COD levels decreased from ~15,000 ppm to ~500–450 ppm at the biological outlet. MLSS levels dropped from 18,000 ppm to 8,000–10,000 ppm, indicating improved biomass efficiency. The removal of the MBR system and its associated power consumption resulted in significant cost savings. Furthermore, the plant’s flow rate improved by 12%, and the RO membrane life increased due to reduced organic load. After a 3-month optimization phase, the use of RO was discontinued entirely, reflecting stable and sustainable ETP performance.

These outcomes demonstrate how Team One Biotech’s microbial bioremediation solutions effectively enhance industrial wastewater treatment efficiency and ensure compliance with PCB discharge norms. The project highlights how advanced biological treatment systems and ETP optimization strategies can reduce costs, improve environmental sustainability, and extend system life.

If you wish to improve your industrial wastewater treatment, achieve high COD and BOD reduction, and ensure sustainable ETP operations, connect with Team One Biotech LLP today. As one of the leading biotech companies in India, we provide a sustainable product range across multiple verticals, including probiotics for aquaculture, biofertilizers and plant growth promoters, eco-friendly cleaning solutions, animal probiotics, and on-site consultation for biocultures for ETP and STP.

Email:  sales@teamonebiotech.com

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industrial holidays Anaerobic Wastewater Treatment in Industries
The effect of industrial holidays on ETP health

The ecosystem of industries is complex as well as consistent. However, shutdowns due to festivals, season, operational failure, or force give a halt to the whole system. Although mostly planned, these industrial holidays are intended to give relief, but deep down in the concrete basins of effluent treatment plants brews a storm of crisis, whether it may be in the primary, secondary, or tertiary systems.

Looking for expert solutions to manage ETP shutdown challenges? Contact Us today for tailored advice and services!

And if we focus on the secondary system, the microbial population gets the worst hit. This blog focuses on what happens inside the secondary system during an industrial holidays, its effects, precautions, and prevention.

The living Microbial world of ETP:

The secondary system is like a society where microbial populations i.e, bacteria, fungi, yeast, metazoans etc. thrive on:

Food: Readily biodegradable organic matter.

Shelter: Biofilms, flocs, or suspended habitats.

Environmental Comfort: pH, temperature, DO, and nutrients in a narrow optimal range.

Maintaining microbial diversity and stability is crucial for consistent ETP performance.

Microbial Starvation- A Hidden Shutdown Crisis

A 10-15 day shutdown without influent feed creates what we call a starvation phase in the bioreactor. The period can trigger several microbial stress responses:

Autolysis Begins:
  • Without food, heterotrophic bacteria begin digesting their own cellular reserves.
  • When reserves run out, cell walls rupture, releasing intracellular enzymes and ammonia into the mixed liquor.
Shift in Community Structure:
  • Fast-growing, high-COD degraders die off first.
  • Resilient microbes like filamentous bacteria and nitrifiers may survive longer, but their metabolic activity drops drastically.
Dissolved Oxygen (DO) Becomes Redundant:


  • With no substrate to oxidize, aeration continues but becomes wasteful.
  • High DO levels can paradoxically stress certain facultative anaerobes used to fluctuating oxygen levels.


MLSS/MLVSS Decline:
  • The Mixed Liquor Volatile Suspended Solids (MLVSS)- the biologically active portion of MLSS drops due to decay.
  • Settling characteristics deteriorate, and the SVI (Sludge Volume Index) can spike due to deflocculation.
Recovery is Not Instant – The Myth of “Rest and Run”

When production resumes, many assume the ETP will bounce back like a machine switched on. But biological wastewater treatment systems have no reset button.

Lag Phase in COD Reduction
  • Microbial populations take time to rebuild numbers and enzyme systems.
  • Expect 2-5 days of poor performance and higher COD/BOD in the outlet, especially in systems with no pre-seeding plan.
Sludge Age Misbalance
  • Sludge that has aged during the shutdown may have lost its settling efficiency.
  • Decayed sludge may also release toxins and nutrients, creating internal loading.
Shock Loads on Restart
  • Sudden reintroduction of full-strength effluent can lead to shock loading.
  • This exacerbates foaming, odor, and even system upset.
Preventive Measures

ETP health during shutdowns doesn’t have to be a gamble. Here are proven strategies, drawn from both research and field practices.

1.Feed Synthetic System:
  • Use glucose, molasses, milk whey, or diluted Urea/COD substitutes to mimic organic load at low levels (10-20% of actual COD).
  • Feed once or twice daily to maintain microbial respiration and floc integrity.\
2.Aerate intermittently:
  • Continuous aeration is wasteful. Instead, apply 4-6 hours/day intermittent aeration to maintain DO and prevent anoxic.
3.Monitor pH and ORP
  • During starvation, microbial metabolism can skew pH or ORP. Keep these in range to avoid unfavorable drift.
4.Bioaugmentation on Restart
  • Introduce high-count commercial biocultures tailored to your effluent type. This accelerates recovery.
  • Use starter cultures or preserved sludge from pre-holiday if available.
5.Sludge Management 
  • Remove aged or decaying sludge before shutdown. 
  • During long holidays, periodic recirculation or RAS/WAS adjustments prevent septic conditions.
Maintaining ETP Efficiency During Industrial Holidays with Bioculture Support

When industrial units pause operations during holidays, the ETP treatment process often slows down due to the absence of organic load. Microbes inside the aeration tank gradually lose activity, leading to poor degradation once the plant restarts. That’s where a bioculture for ETP operations becomes critical — it revitalizes the microbial community, improves resilience, and stabilizes performance without costly chemical interventions.

During downtime, parameters like ETP sludge volume, dissolved oxygen, and pH can fluctuate drastically. A pre-dosage of selected microbial strains helps maintain a balanced environment and prevents sludge bulking or odour generation. When operations resume, the system achieves faster recovery and reduced start-up lag.

To ensure long-term system reliability, work with trusted ETP plant manufacturers in India who understand the importance of integrating biological solutions into design. Many modern ETP and STP systems now include dedicated dosing points for microbial formulations and smart monitoring dashboards that track ETP standard parameters such as BOD, COD, TSS, and MLSS.

Whether you operate a textile, chemical, or food processing unit, maintaining your ETP treatment plant during holidays means safeguarding compliance and avoiding post-shutdown surges in effluent load. Explore how Team One Biotech’s Bioculture Solutions ensure consistent ETP water treatment efficiency even under variable operating conditions.

For more insights on biological treatment technologies, check out our detailed blog on What Are Biocultures for Wastewater Treatment — A Complete EHS Guide and a practical case study Bioculture for ETP- How a Textile Unit Stabilized ETP Performance with T1B Aerobio . Both resources complement this article by showing how bioculture for ETP transforms operational challenges into measurable efficiency gains.

Conclusion:

Industrial holidays are an unavoidable part of operations across industries such as textiles, pharmaceuticals, and chemicals and can’t be avoided but the problems related to it in an ETP can surely be avoided by taking the right steps, proper planning, and taking proactive measures.Investing in bioaugmentation, sludge handling, and strategic aeration ensures microbial resilience during shutdowns.

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

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Toxic Shockwaves Travel Through ETPs How to Deal
How Toxic Shockwaves Travel Through ETPs: A Deep Dive into Impact, Zone-Wise Failure, and Recovery

A sudden or abrupt change from regular mechanisms, schedules, habits, or play is detested everywhere, right from living to non-living beings and from nature to industries or the metropolis.  These sudden changes sometimes come with the signs of change that, if identified at the right time, either prevent or make one prepare. But not all thunders come up with lightning.

Here, as we talk about wastewater treatment in ETPs, shock loads remain one of the most common and feared issues.With the onset of shock loads or the sudden introduction of a toxic system with lethal compounds leads to complete disarray in the system, and the whole microbial population gets attacked and damaged and it a tough task to reboot it and get it back to its normal stage.

However, if we know how toxic shockwaves in ETP travel in different systems and what signs the system produces before and during the onset, we can empower us to control this unwanted phenomenon.???? Need expert support in handling or preventing toxic shockwaves in ETP? Contact our team at TeamOne Biotech for consultation, solutions, and support.

Let’s explore the shockwave travel mechanisms, early signs of warning, zone-wise failure and how to recover.

What is Toxic Shock ?

A sudden short-terms ingress of physical or chemical conditions that disrupts routine mechanisms an d disrupts microbial populations.

The Culprits: Common Toxic Agents:

  • Heavy metals (e.g., Cr⁶⁺, Zn²⁺, Cu²⁺): Inhibit enzymes and damage membranes.
  • Phenols and aromatic solvents: Disrupt cell walls, denature proteins.
  • Quaternary ammonium compounds (QACs): Destroy microbial membranes.
  • Strong acids or alkalis: Denature enzymes and destroy extracellular polymeric substances (EPS).
  • High TDS or salts: Cause osmotic shock, dehydration of microbial cells.
  • Temperature spikes: Above 40°C can be lethal to most ETP microbes.

A high COD  is not always directly proportional to toxicity. Even in a batch with COD of 2000 ppm, a 50 ppm phenol will cause disruptions.

How do toxic shockwaves in ETP travel through each zone?

1.Anaerobic Zone:

The anaerobic digestors or UASB reactors break down organics into methane or carbon dioxide by acidogenic and methanogenic bacteria.

The Effect of Toxic Shock:

Methanogens are more prone to shock as they are highly sensitive to pH shifts, metals, and aromatic solvents. A toxic load here may: 

  • Kill methanogens outright, collapsing methane production.
  • Lead to accumulation of VFAs (volatile fatty acids), crashing the pH below 6.5.
  • Result in black sludge, gas bubbles, and floating scum layers.
Indicators:

  • Drop in biogas flow rate (if monitored).
  • pH drop in digester effluent.
  • Sulphide-like odor and gas toxicity.
  • Foaming or bubbling at inlet distribution zones.
Recovery Options :

  • Stop influent flow immediately
  • Neutralize VFAs to bring pH back to 7.2 to 7.6
  • Inoculate with fresh anaerobic bioculture.
  • Feed diluted influent after 3-5 days of stabilization
2.Anoxic Zone: The Invisible Impact Zone

The function of the anoxic zone is highly dependent on nitrifying and denitrifying bacteria. 

The Effect of Toxic Shock:

Denitrifiers are facultative—more robust than methanogens—but still impacted by solvents, surfactants, and metals.

  • Nitrate remains unreduced.
  • Partial reduction leads to nitrite accumulation, which is also toxic.
  • Disruption in redox balance halts nitrogen removal.
Indicators:

  • Rising NO₃⁻ or NO₂⁻ in secondary-treated water.
  • No bubbles or gas generation from the anoxic tank surface.
  • Slight odor of chlorine or nitric oxide due to nitrite oxidation.
  • No apparent foaming or color change—this failure is usually silent.
Recovery Options :

  • Supplement the carbon source ( eg, methanol or acetate ) to restart denitrification.
  • Check and adjust DO and ORP to stay below 0.3 mg/L and -100 to -300 mV, respectively.
  • Restart mixing gently—denitrification is sensitive to turbulence.
3.Aerobic Zone: 

Aerobic microbes (heterotrophs, nitrifiers) oxidize organics and nitrogen, producing CO₂, nitrate, and water.

The effect of Toxic Shock:

It is comparatively easier to identify shocks easily in Aerobic Zones:

  • Increase in soluble COD and turbidity due to Cell lysis.
  • Release of ammonia and phosphates into the water.
  • Poor settling followed by clarifier overflows due to the disintegration of flocs.
  • Pathogen population surge due to collapsed microbial competition.
Indicators:

  • Septic-like: conditions-black, greasy foam with foul smell.
  • A sharp increase in SVI.
  • Filamentous and Nocardia become prominent.
  • Sudden DO depletion even with aeration on.
Recovery:

  • Stop the influent
  • Maintain DO at 3-4 mg/l
  • Slowly start the hydraulic load with 25-30% for the first 5-6 days and then gradually increase.
  • Waste heavily to remove lysed or decayed biomass.
  • Start adding bioculture with robust and shock-tolerant bacteria.
System-Wide Effects Ripple effects:

Secondary Clarifier:

  • Overloaded with dispersed solids → turbid effluent.
  • Sludge blanket floats or rises.
  • Polymer usage increases for sludge settling.
Sludge Dewatering:

  • Decayed biomass becomes non-dewaterable.
  • Centrifuges and belt presses clog easily.
  • Sludge has high moisture content and low calorific value.
Tertiary Treatment:

  • UF/RO membranes foul rapidly with organic colloids.
  • Sand filters choke with fine, dispersed flocs.
  • Chemical dosing (PAC, alum) surges.
Recovery Timeline Framework

PhaseActionTypical Duration
Initial ArrestStop feeding, start aeration, dose buffers0–24 hours
StabilizationAdd bio-culture, monitor parameters1–3 days
Gradual LoadingResume with diluted or treated influent4–7 days
Full RecoveryReturn to design load with full microbial function7–15 days
Conclusion:

AN ETP is like a living ecosystem with uncertainties. If we can find our early warning signs, we can prevent the discrepancies arising due to toxic shock waves in ETP. Although it is a very tough scenario to tackle but if prevented in time, the chances of vulnerability become very less. 

???? Facing recurring issues or need expert intervention? Reach out to TeamOne Biotech — your partners in effective wastewater treatment and process recovery.

???? 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!

Removal of aldehydes in industrial wastewater and solutions
Aldehydes in Industrial Wastewater: Pollution, Sources & Treatment
Introduction

In this blog, we will explore pollution of aldehydes in industrial wastewater, its impact on the environment, and the methods available for treatment. You’ll gain a clear understanding of what aldehydes are, how they contribute to chemical pollution, and the best practices to treat them effectively in effluent streams. At Team One Biotech, we help industries tackle environmental pollution caused due to aldehydes and related chemical discharge through smart, science-backed wastewater treatment solutions.

???? Contact us for expert advice on aldehyde removal and advanced effluent treatment systems.

What are Aldehydes?

Aldehydes are a group of organic compounds containing a carbonyl group (C=O) bonded to a hydrogen atom and an R group (which can be hydrogen or an organic side chain). Their general formula is R-CHO, where:

  • R is a hydrogen or carbon-containing group.
  • CHO is the aldehyde functional group.

Common examples of aldehydes include:

  • Formaldehyde (HCHO)
  • Acetaldehyde (CH₃CHO)
  • Glutaraldehyde (C₅H₈O₂)
  • Benzaldehyde (C₆H₅CHO)

Aldehydes and ketones are widely used in manufacturing, pharmaceuticals, and food industries, contributing significantly to chemical industry pollution if untreated. They are known for their reactivity, distinct odors, and broad industrial applications.

How Aldehydes Contribute to Wastewater Pollution

Aldehydes in industrial wastewater, especially at high concentrations, are harmful industrial chemicals that significantly contribute to water pollution. They are toxic to aquatic ecosystems and cause serious chemical effects, posing major environmental risks.Some impacts include:

  • Oxygen depletion: Aldehydes are highly biodegradable and demand large amounts of dissolved oxygen during degradation, leading to lower DO levels.
  • Toxicity to microbes: In ETPs, aldehydes can be harmful to bacteria and other microbes essential for biological treatment, especially nitrifiers.
  • Persistent odor and volatility: Aldehydes like formaldehyde can cause secondary chemical pollution through volatilization.
  • Formation of harmful by-products: Under certain conditions, aldehydes can react with ammonia, chlorine, or other substances adding to chemicals involved in water pollution.
Industries That Release Aldehydes in Industrial Wastewater

Several industrial sectors contribute aldehydes and industrial chemicals that pollute water in effluent streams, either directly or as by-products:

  1. Textile & Dye Manufacturing
    – Formaldehyde-based resins are used for wrinkle resistance and dye fixation.
  2. Paper & Pulp Industry
    – Aldehyde derivatives used in wet strength resins and coatings.
  3. Pharmaceuticals & Chemicals
    – Production of intermediates like formaldehyde, acetaldehyde, and glutaraldehyde.
  4. Leather Tanning
    – Use of aldehyde-based tanning agents.
  5. Cosmetics & Personal Care
    – Preservatives and fixatives may contain low levels of aldehydes.
  6. Disinfectant Manufacturing
    – Glutaraldehyde is used in sanitizers and biocides.
  7. Food Processing (especially flavorings and preservatives)
    – Aldehydes like benzaldehyde used in synthetic flavorings.

These examples highlight the scale of chemical industry pollution and the need for effective regulation and treatment.

Treatment Methods for Aldehydes in Wastewater

Effective treatment depends on the concentration, type of aldehyde, and co-contaminants. The goal is often the reduction of aldehydes and ketones into less harmful substances using a mix of treatment methods:

1. Biological Treatment

Biological treatment is often the core of an Effluent Treatment Plant (ETP), especially for organic pollutants. Aldehydes are biodegradable to some extent, making biological treatment viable — but only if concentrations are not too high.

???? a. Activated Sludge Process (ASP)
    • How it works: In ASP, aerobic bacteria in the aeration tank metabolize organic matter. Aldehydes are broken down into simpler compounds like organic acids, CO₂, and water.
    • Requirements: Adequate DO (Dissolved Oxygen), stable temperature, and pH (around 6.8–7.5).
Challenges:
    • Aldehydes, especially formaldehyde or glutaraldehyde, can be toxic at high concentrations.
    • They may inhibit microbial activity, especially nitrifiers.
    • Best practice: Use equalization tanks to prevent sudden chemical pollutants in environment spikes
???? b. Aerobic Degradation
    • Specificity: Some bacteria (like Pseudomonas, Bacillus, etc.) are specially adapted to degrade aldehydes.
    • Conditions: Requires good aeration and neutral pH.
  • Pros:
    • Low operational cost.
    • Produces minimal secondary pollution.
  • Cons: Not suitable for very high concentrations or highly toxic aldehydes.
???? c.Anaerobic Digestion
    • Use case: Rare for aldehydes, but can work in mixed wastewater treatment (especially with long-chain aldehydes).
  • Caution: Anaerobic microbes are more sensitive to chemicals that cause water pollution.
2. Advanced Oxidation Processes (AOPs)

AOPs are highly effective for treating toxic, non-biodegradable, or concentrated aldehydes. They work by producing hydroxyl radicals (•OH) — extremely reactive species that attack and oxidize aldehydes.

???? a. Fenton’s Reagent (Fe²⁺ + H₂O₂)
  • How it works:
    • Hydrogen peroxide reacts with ferrous iron (Fe²⁺) to generate hydroxyl radicals.
    • These radicals oxidize aldehydes into acids or CO₂.
  • Equation: Fe²⁺ + H₂O₂ → Fe³⁺ + OH⁻ + •OH
  • Use case: Effective for formaldehyde, acetaldehyde, and glutaraldehyde.
  • Pros: Fast, powerful oxidation.
  • Cons:
    • Requires pH ~3.
    • Sludge generation due to iron salts.
???? b. Ozonation
  • How it works: Ozone gas (O₃) is bubbled through wastewater. It reacts directly with aldehydes or generates radicals in water.
  • Reactions:
    • O₃ + aldehyde → organic acids + O₂
  • Pros:
    • Powerful disinfectant.
    • Effective even at low concentrations.
  • Cons:
    • High operating cost.
    • Short half-life of ozone; must be generated on-site.
???? c. UV/H₂O₂ or UV/O₃ Systems
  • How it works:
    • UV light breaks down H₂O₂ or O₃ to produce hydroxyl radicals.
    • These radicals degrade aldehydes completely.
  • Pros:
    • High removal efficiency.
    • Can achieve near-total mineralization.
  • Cons:
    • Requires UV setup.
    • Higher energy demand.
3. Chemical Treatment

In this method, chemicals are used to neutralize or oxidize aldehydes directly.

???? a. Chemical Oxidation
    • Agents used: Potassium permanganate (KMnO₄), sodium hypochlorite (NaOCl), chlorine dioxide (ClO₂).
    • Reaction: Aldehyde + Oxidant → Carboxylic acid or CO₂
    • Use case: Ideal for small-volume, high-toxicity effluent (e.g., lab or pharma).
  • Pros:
    • Rapid action.
  • Cons:
    • Residual oxidants must be neutralized.
    • Risk of forming additional chemical pollutants in environment (e.g., chloroform with chlorine).
???? b. Neutralization
    • Example: Glutaraldehyde can be neutralized with:
    • Sodium bisulfite (NaHSO₃): reduces toxicity.
    • Glycine: forms stable, less harmful complexes.
    • Use case: Common in pharma, hospitals, and labs.
  • Pros:
    • Easy to dose.
  • Cons:
    • Only works for specific aldehydes.
    • Generates salt residues.
4. Adsorption Techniques

Adsorption is mainly used as a polishing step or for low concentrations of aldehydes.

???? a. Activated Carbon
    • How it works: Porous carbon adsorbs aldehyde molecules from water.
  • Types:
    • Powdered Activated Carbon (PAC)
    • Granular Activated Carbon (GAC)
  • Best for: Trace-level removal in final polishing.
    • Pros:
    • Simple, no chemical use.
  • Cons:
    • Media needs regular regeneration or replacement.
    • Not effective for large volumes or high aldehyde levels.
???? b. Ion Exchange Resins / Synthetic Polymers
    • Used for: Specific aldehydes or when very low discharge limits are required.
    • Cost: High, but precise.
5. Membrane Filtration

This method involves physically separating aldehydes using semi-permeable membranes.

???? a. Nanofiltration (NF) & Reverse Osmosis (RO)
  • How it works:
    • Pressure is applied to force water through a membrane.
    • Aldehydes and other organics are rejected and concentrated in the reject stream.
  • Pros:
    • High removal efficiency.
    • Produces clean, reusable water.
  • Cons:
    • High CAPEX & OPEX.
    • Membrane fouling risk.
    • Reject stream needs further treatment.
Integration Example in an ETP

If a pharmaceutical plant has glutaraldehyde in its effluent:

  • Equalization Tank – for dilution.
  • Chemical Neutralization – with glycine or bisulfite.
  • Biological Treatment (ASP) – for biodegradation.
  • AOP (UV/H₂O₂) – as a polishing stage.
  • GAC Filtration – before final discharge or RO.
Summary Table
Method Best For Limitations
Biological (ASP) Low–moderate aldehydes Sensitive to toxicity
Fenton / Ozone High-concentration aldehydes Cost, sludge
Chemical Oxidation Small volumes Toxic by-products
Adsorption Polishing stage Media replacement
Membrane (RO/NF) Reuse/very clean water Expensive, complex
Best Practices in ETPs for Aldehyde-Contaminated Effluent
  1. Equalization Tank:
    – To reduce the shock loading of aldehydes on biological systems.
  2. Pre-treatment Unit (AOPs or Chemical Neutralization):
    – Before biological treatment for high aldehyde loads.
  3. Bioaugmentation:
    – Use of aldehyde-degrading microbial strains to enhance biodegradation.
  4. pH and DO Monitoring:
    – Aldehyde toxicity is pH-dependent; maintaining optimal pH (6.8–7.5) helps reduce toxicity.
  5. Toxicity Testing:
    – Regular bioassays to monitor  chemical effects of pollution on microbes
Conclusion

Aldehydes, though small in molecular size, can pose significant environmental challenges if not properly managed in industrial wastewater. As chemical pollutants in environment, they demand robust treatment and monitoring strategies. Integrating pre-treatment, biological processes, and advanced oxidation ensures comprehensive aldehyde removal and compliance with environmental norms.

Industries must also invest in source reduction, green chemistry alternatives, reduction of aldehydes and ketones and ETP upgrades to curb chemical pollution and ensure regulatory compliance.

For expert assistance on treatment solutions or inquiries about the removal techniques of aldehydes in industrial wastewater, Contact Us today!

???? Email: sales@teamonebiotech.com???? Visit: www.teamonebiotech.com

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Implementation of SBR system in a CETP
Implementation of SBR System in a CETP with T1B Aerobio Bioculture
Introduction: 

The SBR system in a CETP situated in Rajasthan handles effluents from over 40 industries in the RIICO sector the system faces difficulty in handling the load of COD above 2000 PPM, owing to discharges from textiles and  chemicals. The SBR system with 4 biological tanks and 4 cycles a day was struggling with its efficiency in terms  of COD reduction, due to which the outlet COD was very high and the load was carried on to the RO, leading to  damage of membranes and high OPEX. Contact us today to learn how we can help optimize your industrial effluent treatment plant (ETP) with customized bioaugmentation solutions.

ETP details: 

The industry had primary treatment, biological treatment, and then a tertiary treatment. 

Flow (current)  2 MLD
Type of process  SBR
No. of aeration tanks  4
Capacity of aeration tanks  3 MLD each
Total cycles in 24 hrs  4
Duration of fill and Aeration cycle  1.5 hrs and 2.5 hrs respectively
Challenges:
Parameters  Avg. Inlet parameters(PPM)  Avg. Outlet parameters(PPM)
COD  3000  800
BOD  1800  280-300
TDS  3000  1200
Operational Challenges: 
  • The primary treatment was working at 5 % efficiency in terms of COD reduction 
  • The whole SBR system was lagging in COD degradation efficiency and sustainability of MLVSS as well. 
  • The Carryover COD and unsettled biomass was traveling to RO, damaging membranes. 
The Approach: 

The agency operating the SBR system in a CETP approached us to solve their current issues.  

We adopted a 3D approach that included : 

  1. Research/Scrutiny :  
  • Our team visited their facility during the winter season as they encountered many issues at that  

         time. Team scrutinized every aspect of the plant to analyze the efficiency of each element. 

  • The visit gave us a complete idea of their processes, current efficiency, trends, and our scope of  

         work.  

  1. Analysis : 
  • We analyzed the previous 6-month cumulative data of their ETP to see trends in the inlet-outlet  

         parameters’ variations and the permutation combinations related to it. 

  1. Innovation :  
  • After the research and analysis our team curated customized products and their dosing schedules  with formulation keeping in mind the plan of action to get the desired results. This process is            called  bioaugmentation. 
Desired Outcomes : 
  1. Reduction of COD/BOD thereby improving the efficiency of biological tanks. 
  2. Degradation of tough-to-degrade effluents and develop robust biomass to withstand shock loads. 
  3. Ensuring proper settling of Biomass to stop carryover to RO, thereby preventing damage to RO membranes.
Execution: 

Our team selected two products : 

T1B aerobio product

T1B Aerobio Bioculture: This product consisted of a blend of microbes as bioculture  

selected as per our analysis to degrade the recalcitrant COD, and ensure sustainability in  

the SBR system.  

Plan of action: 
  1. We devised a 60 days dosing plan, which was further divided into two phases: 
  • Day 1 to day 30 : Loading dose, to develop the population of bacteria and generate biomass.
  • Day 31 to Day 60: Maintenance Dose, to maintain the population of biomass generated. 
  1. Dosing pattern: We advised dosing in all 4 SBR tanks cycle wise viz. during filling and Aeration, to give  the bioculture proper mixing and necessary DO. 
Results: 
Parameters  Inlet parameters  Tank 4 outlet parameters (ppm)
COD  3000 ppm  280-300 ppm
BOD  1800 ppm  60-82 ppm

Before and after adding bioculture

The implementation of the bioaugmentation program resulted in significant improvements in the performance  of biological units in their WWTP: 

  • We were able to achieve around 90 % reduction from their current inlet parameters in COD & BOD,  which was only 70% earlier. 
  • The overall ETP OPEX was reduced by 20%. 
  • The ETP achieved full capacity operations in terms of hydraulic load. 
  • The biological process became more stable and resilient to fluctuations in the influent characteristics. 
  • The RO membrane health was restored and and their damage reduced up to 80%.

Want similar results for your ETP or STP? Contact us for more Information.

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 / Issue Targeted Bioculture Strains Mode of Action
High COD from dyes & finishing Pseudomonas putida, Bacillus subtilis Produces oxidative enzymes to break down complex organics.
Phenolic compounds & nylon by-products Acinetobacter sp., Comamonas testosteroni Uses phenol hydroxylase to degrade toxic aromatics.
Surfactants & residual oil Sphingomonas sp., Rhodococcus sp. Breaks down surfactants & hydrocarbons.
Filamentous bacterial overgrowth Bacillus licheniformis, Nitrosomonas sp. Competes with filamentous microbes & improves sludge settling.
Ammonia & nitrate fluctuations Nitrobacter sp., Paracoccus denitrificans Enhances 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

Parameter Before Treatment After Bioculture Implementation Reduction %
COD in Effluent 1200 mg/L 180 mg/L 85%
BOD in Effluent 250 mg/L 35 mg/L 86%
Phenol Concentration 45 mg/L 5 mg/L 88%
Filamentous Bacteria Issue Frequent sludge bulking Fully controlled –
Dissolved Oxygen (DO) 1.5 mg/L 2.5 mg/L –
Sludge Settling (SVI) >250 mL/g <120 mL/g 52% 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

Visit: www.teamonebiotech.com

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

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

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