Adhesive Effluent Treatment with Shock Load Challenges
Introduction:
The adhesive effluent treatment from a manufacturing industry contains a variety of pollutants, depending on the type of adhesives being manufactured (e.g., water-based adhesives, solvent-based adhesives, hot-melt adhesives, or reactive adhesives). The main pollutants typically found in industrial wastewater treatment for the adhesive industry include:
An adhesive manufacturing plant in Pune with an overall capacity 750 KLD effluent treatment plant (ETP) faced issues due to the presence of certain contaminants such as:
- VOCs (Volatile Organic Compounds): Benzene, Ethyl Acetate, Acetone, etc. (from solvent-based adhesives).
- Resins & Polymers: Acrylic resins, epoxy resins, polyurethanes, or other polymeric residues.
- Unreacted Monomers: Styrene, vinyl acetate, acrylates, formaldehyde, etc., which are organic but difficult-to-degrade pollutants contributing to outlet contamination and lower efficiency in COD removal along with imposing shock loads.
Plant Details:
| Flow Rate | 750 KLD |
| Inlet COD: | 8000-1000 ppm |
| Inlet TDS | 6000 PPM |
| Aeration Tank 1 Capacity | 800 KL |
| Aeration Tank 2 Capacity | 350 KL |
| COD reduction efficiency of secondary system | 40%-50% |
Research and Analysis:
The plant’s Effluent Treatment Plant (ETP) was comprehensively evaluated to diagnose wastewater treatment challenges through site visits. Key issues identified were:
- High COD levels caused by organic pollutants and chemical residues.
- Frequent upsets due to shock loads from multiple industrial effluent streams.
- Poor microbial performance in the biological treatment system.
- Unsustainability and low MLVSS (Mixed Liquor Volatile Suspended Solids), leading to inefficient biodegradation of industrial effluents.
Innovation:
T1B Aerobio: Enhancing Biological Treatment Performance
T1B Aerobio is a specially formulated biological treatment solution powered with 76+ robust bacterial strains designed to degrade complex organic compounds in adhesive industry wastewater. Its high-performance microbial strains secrete enzymes that efficiently break down tough-to-degrade contaminants that indigenous microbes fail to degrade.
Execution:
Plant Optimization:
- Adjusted Return Activated Sludge (RAS) and Waste Activated Sludge (WAS) to enhance the secondary biological treatment system efficiency.
Dosing Regime:
A 60-day microbial dosing schedule was implemented:
- Phase 1 (Days 1-30): High initial dose to establish a dominant biological culture for effective COD degradation.
- Phase 2 (Days 31-60): Maintenance dosing to sustain color removal and COD reduction.
Monitoring Parameters:
- COD and BOD (Biochemical Oxygen Demand) levels.
- Sludge Volume Index (SVI) and sludge settling characteristics.
Observations:
The addition of T1B Aerobio resulted in significant improvements in adhesive effluent treatment. Key observations are summarized below:
| Parameter | Day 1 | Day 15 | Day 30 | Day 45 | Day 60 |
|---|---|---|---|---|---|
| COD (ppm) | 10,000 | 7,500 | 4,700 | 2,500 | 945 |
| BOD (ppm) | 4,300 | 2,800 | 1,200 | 850 | 400 |
| SVI (mL/g) | 20 | 25 | 32 | 35 | 40 |
Results:
- COD Reduction: Achieved a 91% reduction in COD levels by Day 60, ensuring compliance with environmental discharge standards.
- BOD Reduction: Achieved a 90% reduction in BOD levels, meeting wastewater discharge norms.
- Improved Sludge Settling: Optimized Sludge Volume Index (SVI) values, leading to better sludge compaction and reduced carryover.
- Shock Load Management: Frequent ETP upsets were effectively controlled.
Conclusion:
The application of T1B Aerobio significantly improved the performance of the adhesive industry’s effluent treatment plant (ETP). Enhanced biological treatment facilitated the degradation of hard-to-degrade organic pollutants, stabilized microbial activity, and maintained ETP efficiency under shock load conditions.
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