Saving OPEX for a reputed Pharma Giant using Bioremediation
Introduction:
The reputed pharmaceutical giant is known for contributing to the global pharmaceutical sector by using bioremediation. This unit is one of the largest Active Pharmaceutical Ingredient (API) producers that manufactures products such as Tamsulosin, Metformin, Esomeprazole, etc. The Unit has a full-fledged Effluent Treatment Plant (ETP) which is a traditional Activated Sludge Process (ASP) system. The unit is committed to treating its industrial wastewater religiously. The unit had an Multi-Effect Evaporator (MEE) installed to treat high COD wastewater stream. Due to the production of multiple pharmaceutical products, the ETP received multiple effluent streams with tough-to-degrade pollutants like toluene, benzene, Metformin, Acetic Acid, Methanol, etc. Due to such high-strength wastewater streams, it was difficult for them to control ETP operations, using bioremediation which led to heavier expenses, specifically on the MEE operation, as it was receiving a heavier load than its designed capacity.
ETP details:
The industry had primary treatment, biological treatment, and then a tertiary treatment.
| Flow (current) | 450 KLD |
| Flow (design) | 500 KLD |
| Type of process | ASP |
| No. of aeration tanks | 3 (in series) |
| Capacity of aeration tanks | 500 KL, 450 KL, 300 KL respectively |
| Retention Time | 67 hours(combined) |
MEE Details:
| Capacity (current) | 12 KLD |
| Current inflow | 10 KLD |
| Inlet COD | 150000 ppm |
| Inlet TDS | 60000 ppm |
Challenges:
| Parameters (PPM) | Avg. Inlet parameters | Avg. Outlet parameters |
| COD | 18000 | 9900 |
| BOD | 5000 | 3000 |
| TDS | 15000 | 9500 |
Operational Challenges:
- The primary treatment system was working at 5% efficiency in terms of COD reduction.
- The biological treatment system was working at an average 45% efficiency in terms of COD reduction.
- They were struggling to effectively treat recalcitrant pollutants such as toluene, benzene, Metformin, Acetic Acid, and Methanol, which compelled them to run the ETP at 10% less hydraulic load.
- A separate high COD stream was directed to MEE, leading to scaling and fouling in MEE.
Volume of stream to MEE: 10 KLD
COD: 150000 ppm
TDS: 80000 ppm
Financial Challenges:
- Urea-DAP consumption: 2160 Kg/month of Urea and 1200 Kg/month of DAP were required to boost the poor biomass in the biological tanks.
- Electricity consumption: Due to high COD effluent, the power requirement went up from a normal 14250 KWH to 20250 KWH monthly.
- Raw Water Consumption: Due to high COD influent, there was a need for higher evaporation, hence around 100000 litres of water was used monthly for MEE.
- Chemical Consumption: Due to high COD inflow in MEE, there was extensive scaling, due to which the MEE needed frequent cleaning with HCL: 22500 kg/month, EDTA: 11250 kg/month.
Extra Costs incurred per month:
| Commodity | Units required | |
| Urea(in Biological tank) | 2160 kg/month | |
| DAP(in Biological tank) | 1200 kg/month | |
| Raw water consumption | 100000 litres/ Month approx | |
| HCL (10 % ) | 5500 kg/month | |
| EDTA | 3200 kg /month | |
| Electricity(MEE) | 20250 KWH/month | |
The MEE cost per liter was coming to Rs. 1820/KL for 10 KLD capacity, while the overall WWTP (Wastewater Treatment Plant) cost to treat 450 KLD effluent swelled to Rs. 200/KLD.
The Approach:
The industry partnered with us to improve the efficiency of their biological units and to reduce operational costs using bioremediation in their WWTP.
We adopted a 3D approach that included:
- Research/Scrutiny:
- Our team visited their manufacturing facility to examine the existing ETP process and scrutinize areas of improvement.
- The visit helped us explore potential ETP optimization strategies in the biological treatment system.
- Analysis:
- We analyzed the previous 3-month cumulative data of their ETP to observe trends in inlet-outlet parameters.
- Innovation (Bioaugmentation):
- After research and analysis, our team curated customized microbial formulations and dosing schedules.
Desired Outcomes :
- Reduction of COD/BOD thereby improving the efficiency of biological tanks.
- Degradation of tough-to-degrade effluents and develop robust biomass to withstand shock loads.
- Reduction in scaling of MEE by reducing COD in biological systems and saving cost using bioremediation.
- Reducing consumption of UREA-DAP.
- Cost saving by treating high COD streams in main ETP.
Execution:
Our team selected two bioaugmentation products:
- T1B Aerobio:
- A blend of specialized microbes that secrete enzymes capable of degrading tough pollutants like toluene, benzene, and Metformin.
- Helps in reducing COD/BOD, stabilizing shock loads, and enhancing biomass stability.
- T1B MacMi:
- A plant-based gel that acts as a nutrient source for bacteria.
- Replaced UREA-DAP to provide essential macro and micronutrients for microbial growth.
Plan of Action:
- Diverting 2 KLD of MEE inlet to the main ETP inlet with COD 150000 ppm.
- Diverting 3 KLD of MEE reject to main ETP inlet with COD 25000 ppm.
- Dosing of T1B Aerobio in all three biological tanks.
- Dosing of T1B MacMi in all three tanks.
Average Inlet COD after the addition of streams: 18406 PPM
Results:
| Parameters | Inlet parameters | Secondary Outlet parameters (ppm) |
| COD | 18406-19000 ppm | 2200 ppm |
| BOD | 9290 to 10000 ppm | 1400 ppm |
Cost Saving :
| Commodity | Units required before treatment | Units required after treatment |
| Urea | 2160 kg/month | 432 kg/month |
| DAP | 1200 kg/month | 240 kg/month |
| Raw water consumption | 100000 litres/ Month approx | 50000 litres/Month |
| HCL (10 % ) | 5500 kg/month | 4000 litres/month |
| EDTA | 3200 kg /month | 2050 litres/month |
| Electricity(Extra) | 675 KWH/day | 478 KWH/day |
The MEE operational cost reduced to Rs. 1220/KLD, and the ETP cost was reduced to Rs. 160/KLD using bioremediation.
Key Achievements:
- 85-89% COD & BOD reduction.
- 20% reduction in ETP OPEX.
- Full-capacity operations restored using bioremediation.
- MEE dependency reduced.
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