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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Bioculture-Based Treatment of Recalcitrant COD
Bioculture-Based Treatment of Recalcitrant COD in Pharmaceutical Effluents
Introduction

It often happens that an Effluent Treatment Plant’s (ETP) chemical oxygen demand (COD) degrading efficiency becomes stagnant at a certain point. Despite trying multiple wastewater treatment methods and technologies, breaking this threshold remains a challenge. The real culprit behind such scenarios is the presence of recalcitrant COD in pharma effluents.

Pharmaceutical wastewater, in particular, presents high COD and BOD challenges due to persistent Active Pharmaceutical Ingredients (APIs), solvents, and excipients that resist biological treatment. Conventional systems often struggle to meet regulatory compliance, making microbial culture-based treatment a promising alternative. This blog explores treatment efficiency, plant configurations, cost analysis, and pilot project insights for implementing enzyme-based bioculture in pharma effluent treatment.

To learn more about effective solutions for reduction of recalcitrant COD reduction in Pharmaceutical Effluents, feel free to contact us.

1. Understanding Bioculture-Based Treatment for Pharma Effluent
How Biocultures Work?

Microbial culture is a specialized microbial consortia capable of degrading recalcitrant COD through enzymatic breakdown. They work via:

✅ Advanced oxidation processes – Breaks complex organic compounds into biodegradable intermediates. 

✅ Co-Metabolism – Uses an additional carbon source to enhance pollutant degradation. 

✅ Biofilm Formation – Protects microbes from toxic compounds and improves stability in treatment systems.

Targeted Degradation of Recalcitrant COD Components
Pharma Compound Common Source Microbial Strains Used Enzymes Involved Degradation Pathway
Paracetamol Painkillers Pseudomonas putida, Bacillus subtilis Amidase, Laccase Amide hydrolysis to p-aminophenol, oxidation
Ibuprofen & Diclofenac NSAIDs Sphingomonas sp., Rhodococcus sp. Dioxygenases, Hydrolases Hydroxylation & carboxylation of aromatic rings
Ciprofloxacin & Ofloxacin Antibiotics Acinetobacter sp., Pseudomonas aeruginosa Monooxygenases Quinoline ring cleavage
Erythromycin & Azithromycin Macrolide Antibiotics Bacillus licheniformis Esterase, Oxidase Ester bond hydrolysis, oxidation
Estradiol & Progesterone Hormones Comamonas testosteroni, Mycobacterium sp. Hydroxylase, Dehydrogenase Steroid ring hydroxylation
Chloramphenicol Antibiotics Pseudomonas fluorescens Reductase, Hydrolase Nitro group hydrolysis
Azo Dyes (Erythrosine, Tartrazine) Coloring Agents Pseudomonas aeruginosa, Shewanella oneidensis Azoreductase Azo bond cleavage
Nonylphenols, PEGs Surfactants Sphingomonas sp., Pseudomonas sp. Oxidase, β-Oxidase Oxidation of alkyl chains
2. Treatment Systems Configurations Using Biocultures
Plant Design for Pharma Wastewater Treatment Process
Stage 1: Pre-Treatment (Equalization & Primary Treatment)

Objective: Remove suspended solids, neutralize pH, and reduce initial COD load.

✅ Equalization Tank – Balances flow & pH (6.5–7.5).
✅ Coagulation-Flocculation – Removes large particulates (e.g., PAC or FeCl₃).
✅ Screening & Oil Removal – Eliminates large solids and oil residues.

Stage 2: Advanced Biological Treatment with Microbial Culture

✅ Moving Bed Biofilm Reactor (MBBR) or Sequential Batch Reactor (SBR) – Bioculture for STP wastewater treatment. 

✅ Optimized Microbial Seeding – Customised culture for targeted degradation. 

✅ Retention Time: 24–36 hours for reaction time.

Stage 3: Advanced Oxidation Processes & Membrane Filtration 

✅ Fenton’s Process / Ozonation – Further breaks down recalcitrant COD. 

✅ Membrane Bioreactor (MBR) or Reverse Osmosis (RO) – Final purification.

Stage 4: Sludge Management & Water Reuse

✅ Dewatering & Sludge Handling – Using filter press or centrifugation. 

✅ Effluent Recycling – Treated water reused for lagoons wastewater treatment.

3. Pilot Project Insights: Real-World Applications
Case Study 1: Antibiotic Manufacturing Effluent Treatment

???? Location: India | COD Level: 10,000 mg/L

✅ Solution: Bioculture companies for wastewater treatment (Acinetobacter sp. & Pseudomonas sp. in MBBR). 

✅ Result:

  • COD reduced by 85% (Final COD: <500 mg/L).
  • Reduced toxicity – No microbial inhibition observed.
Case Study 2: NSAID (Ibuprofen & Diclofenac) Removal

???? Location: Europe | COD Level: 8000 mg/L
✅ Solution: SBR + Microbial Culture Companies in India (Rhodococcus + Sphingomonas). 

✅ Result:

  • COD reduced by 90% (Final COD < 250 mg/L).
  • High removal of Ibuprofen (96%) & Diclofenac (89%).
4. Cost Analysis of Bioculture-Based Treatment
Cost Component Estimated Cost (₹/m³) Description
Bioculture Seeding ₹3–6 Initial inoculation for microbial growth
Reactor Operation (MBBR/SBR) ₹15–20 Aeration, energy, and microbial maintenance
AOP (Ozonation/Fenton’s Process) ₹8–12 Advanced oxidation for recalcitrant organics
Membrane Treatment (RO/MBR) ₹12–18 Filtration and final polishing
Total Treatment Cost ₹38–56 per m³ Cost-effective compared to ZLD (₹80-100 per m³)
Key Takeaways:
  • Bioculture-based treatment reduces overall cost by 30–50% compared to purely chemical or ZLD systems.
  • Lower sludge production compared to coagulation-based treatments.
  • Faster startup time (2–3 weeks) compared to conventional activated sludge.
Conclusion: The Future of Biocultures in Pharma Effluent Treatment

???? Bioremediation companies in India offer a sustainable & cost-effective solution for treating recalcitrant COD in pharma effluents.
???? Bioculture companies in India can provide enzyme-based bioculture tailored for specific APIs, ensuring high pollutant removal.
????  Integrating biocultures with advanced oxidation & MBBR/SBR technology enhances efficiency & meets regulatory standards.

If you’re looking for expert guidance or customized solutions for your ETP, our team is here to help!

Contact us today for a consultation or to learn more about how we can support your effluent treatment needs!

???? 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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