Improving Oxygen Transfer Efficiency in Chemical ETP
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 processASP
No. of aeration tanks1
Capacity of aeration tanks1150 KL
Challenges: 

Parameters Avg. Inlet parameters(PPM)Avg. secondary system outlet parameters(PPM)
COD180006000
BOD85002800-3000
TDS300002500
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:

  1. Enhances the degradation of formaldehyde and glutaraldehyde.
  2. Restores biological treatment efficiency.
  3. 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 T1b Aerobio bioculture solution by improving oxygen transfer efficiency

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 interventionAfter Intervention
DO in Aeration Tank1.2 mg/L2.8 mg/L
SOUR1             3.6 mg O₂/g VSS/hr22.3 mg O₂/g VSS/hr
SVI210 mL/g120 mL/g
COD Reduction72%87%
Blower Runtime24 hrs/day16 hrs/day
Energy Use65 kWh/day38 kWh/day
OTE12 %21.4 %
Application results before and after

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

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Oxygen Transfer Efficiency in wastewater treatment
Oxygen Transfer Efficiency vs. Real-World Conditions: The Hidden Impacts of Diffuser Fouling and Uneven Airflow

In the world of wastewater treatment, Oxygen Transfer Efficiency (OTE) is a critical performance indicator, especially in biological treatment systems where aerobic microorganisms drive the breakdown of organic matter. On paper, system designs often promise high standard oxygen transfer efficiency based on clean-water testing. But in real-world conditions, actual oxygen transfer often falls significantly short — and two often-overlooked culprits are diffuser fouling and uneven airflow distribution.

At Team One Biotech, we help ETPs and STPs uncover these hidden inefficiencies. Contact us today to audit and improve your aeration system’s real-world performance.

Understanding Oxygen Transfer Efficiency

OTE is the percentage of oxygen from the air that actually dissolves into the wastewater. Higher efficiency means better microbial activity, lower energy costs, and more effective treatment. Bottom diffused aeration systems, particularly those with fine bubble diffuser oxygen transfer efficiency, are widely used due to their ability to maximize surface area and minimize energy use.

However, clean-water testing used to estimate standard OTE doesn’t reflect operational realities like biofilm buildup, particulate matter, or operational inconsistencies.

The Silent Saboteur: Diffuser Fouling

Over time, aeration diffusers — especially fine-pore ones — become clogged with biofilms, sludge solids, and inorganic scaling. This fouling:

  • Increases air resistance, reducing overall airflow.
  • Causes larger bubbles, decreasing oxygen transfer surface area.
  • Leads to non-uniform oxygen distribution, harming microbial populations in under-aerated zones.

As a result, a system that once transferred oxygen at 30% efficiency might drop to 15–20%, doubling the energy requirement for the same biological load.

🔍 Poor sludge management can accelerate diffuser fouling, leading to cascading operational issues.

Tip: Regular diffuser inspection, cleaning schedules, and selecting fouling-resistant materials (e.g., PTFE-coated membranes) can mitigate this loss.

Uneven Airflow: An Invisible Imbalance

Even with clean diffusers, uneven airflow distribution due to pipe layout, blower inconsistency, or back pressure variations can cause:

  • Overaeration in some zones (wasted energy, poor floc formation),
  • Underaeration in others (anaerobic pockets, filamentous growth, odor issues).

This imbalance affects overall oxygen transfer efficiency and biological performance, especially in large or compartmentalized aeration tanks.

The Cost of Ignoring Reality

Ignoring these issues doesn’t just degrade standard OTE — it impacts the entire secondary system:

  • Reduced MLSS activity due to low DO,
  • Increased sludge production from partial degradation,
  • Higher energy bills with little performance gain,
  • Poor compliance with discharge norms due to high BOD/COD.
Real-World Solutions
  1. Flow Balancing: Use air flow meters and control valves to ensure uniform distribution.
  2. Blower Management: VFD-controlled blowers can respond to real-time DO demands, reducing peaks and troughs.
  3. Smart Monitoring: Modern SCADA systems and DO sensors help identify zones of concern early.
  4. Preventive Maintenance: Scheduled diffuser cleaning and aeration audits pay off in energy savings and treatment reliability.
Final Thoughts

It’s time the industry moves beyond theoretical OTE and embraces a “Reality-Based Aeration Strategy”. Understanding and addressing diffuser fouling and uneven airflow are essential for sustainable wastewater treatment — both environmentally and economically.

At Team One Biotech, we specialize in supporting ETPs and STPs in optimizing their biological systems, including audits that uncover hidden losses in aeration efficiency. Let’s not just treat wastewater — let’s treat it wisely.

Reach out to us today to make sure your system isn’t silently losing efficiency — and money.

📧 Email: sales@teamonebiotech.com

🌐 Visit: www.teamonebiotech.com

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

Aeration Systems for Efficient Biological Treatment
Optimizing Aeration Systems for Efficient Biological Treatment

Effluent Treatment Plants (ETPs) and Common Effluent Treatment Plants (CETPs) play a crucial role in treating industrial and municipal wastewater before its discharge into the environment. The primary treatment of wastewater often involves physical and chemical processes, while the secondary biological treatment stage heavily depends on an efficient aeration system. In this blog, we will discuss the significance of aeration technologies, their alignment with biological treatment, and how to assess the aeration efficiency in ETPs and sewage treatment plants, focusing on biological sewage treatment and aeration systems.

🌐 Visit: www.teamonebiotech.com/contact-us

What is Aeration Essential in ETPs?

Aeration is the process of introducing oxygen into wastewater to support the growth of aerobic microorganisms that break down organic pollutants in the biological treatment process. The key reasons why a well-designed aeration system is critical in effluent treatment plants (ETPs) and sewage treatment plants in India include:

  • Enhanced Biological Degradation – A proper aeration system maintains adequate dissolved oxygen (DO) levels, enabling microbial communities to efficiently degrade organic matter in wastewater treatment projects.
  • Prevention of Septic Conditions – Insufficient aeration efficiency can lead to anaerobic conditions, causing foul odors and incomplete treatment, which can negatively impact sewage disposal methods.
  • Reduction of BOD and COD – A well-functioning aeration system significantly lowers Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD) by enhancing microbial activity.
  • Improved Sludge Settling – Proper aeration technologies prevent the growth of filamentous bacteria, which can cause sludge bulking and poor settling in the clarifier.
  • Energy Optimization – Advanced aeration technologies improve aeration efficiency, reducing energy costs while ensuring superior wastewater treatment.
The Role of Aeration in the Biological Treatment Process


The biological treatment process in ETPs primarily relies on aerobic bacteria to break down organic pollutants. The aeration system facilitates this by:

  • Maintaining Optimal DO Levels – Most aerobic microbes require a DO level of 1.5–3.0 mg/L for effective degradation.
  • Enhancing Microbial Growth and Diversity – Different microbes thrive under well-aerated conditions, ensuring the complete breakdown of organic matter in the effluent treatment process.
  • Supporting Nitrification – Ammonia in wastewater is converted to nitrates by nitrifying bacteria, which require a stable oxygen supply.
  • Ensuring Proper Mixing – Aeration technologies prevent sludge settling, ensuring uniform microbial distribution throughout the effluent treatment plant.

Types of Aeration Technologies Used in ETPs


Different aeration technologies improve aeration efficiency in effluent treatment plants, including:

  • Surface Aerators – Use mechanical action to mix wastewater and increase oxygen transfer.
  • Diffused Aeration Systems – Utilize fine bubble diffusers to enhance oxygen dissolution in biological sewage treatment plants.
  • Jet Aerators – Combine air and liquid to increase oxygen contact time.
  • Hybrid Aeration Systems – Integrate multiple aeration technologies for optimized efficiency and energy savings, ideal for advanced ETPs.
How to Assess if Your Aeration System is Functioning Optimally?


An inefficient aeration system can compromise the biological treatment process and lead to poor effluent quality. Here are key indicators to monitor:

  • Dissolved Oxygen (DO) Monitoring – Regularly check DO levels; if they drop below 1.0 mg/L, microbial activity may be hindered in your ETP plant.
  • Foam and Sludge Observation – Excessive foaming or bulking sludge may indicate an aeration imbalance in your effluent treatment plant.
  • Bubble Size and Distribution – Fine bubbles should be evenly spread across the aeration tank; large or irregular bubbles suggest inefficiencies in diffused air aeration.
  • Air Blower Functionality – Inspect blowers, diffusers, and the air distribution system for blockages or mechanical failures in aeration systems.
  • Energy Consumption Analysis – A sudden increase in energy usage without improved treatment efficiency may indicate poor aeration efficiency.
  • MLSS (Mixed Liquor Suspended Solids) and F/M Ratio – Maintaining a balanced microbial population ensures optimal treatment in ETPs and sewage treatment plants in India.
  • Effluent Quality Check – High levels of BOD, COD, or ammonia in treated effluent signal inadequate aeration.

Best Practices to Improve Aeration Efficiency


To enhance aeration efficiency in effluent treatment plants, consider the following best practices:

  • Regular System Audits – Periodic assessments help detect inefficiencies early, especially in ETP plant manufacturers’ installations.
  • Use of Energy-Efficient Blowers – Advanced blowers optimize air distribution and reduce operational costs in wastewater treatment plants.
  • Optimized Diffuser Placement – Properly placed diffusers ensure maximum oxygen transfer in biological treatment plants.
  • Automated Oxygen Control Systems – Smart control systems adjust oxygen supply based on real-time DO measurements in wastewater treatment projects.
  • Routine Cleaning and Maintenance – Prevent blockages and maintain performance with scheduled maintenance for aeration systems in ETPs and CETPs.
Conclusion:


A well-functioning aeration system is the backbone of the biological treatment process in effluent treatment plants, sewage treatment plants, and biological sewage treatment plants. Regular monitoring and maintenance of aeration technologies ensure optimal performance, energy conservation, and compliance with environmental regulations.
By investing in advanced aeration technologies and conducting periodic system audits, industries can enhance aeration efficiency, reduce ETP plant costs, and achieve sustainable wastewater treatment. For expert assistance in optimizing your ETP’s aeration system and biological treatment process, connect with Team One Biotech. Our customized bioculture solutions and technical support can help you achieve superior treatment efficiency in your effluent treatment plant!

Are you looking for a reliable wastewater treatment solution?
📞 Contact us today to explore customized bioremediation strategies for your industry!
📧 Email: sales@teamonebiotech.com
🌐 Visit: www.teamonebiotech.com/contact-us

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