Bisan Chemicals And Engineers Private Limited

MBBR Technology

• Saving of space due to its compactness
• Easy to maintain
• Good for a high volume of load
• Extension and expanding are easy. This made possible by increasing the filling degree of carriers.
• Lower discharge costs
• MBBR is not affected by toxic shock
• Independent process performance because there is no return line for sludge; the MBBR eliminates the return activated sludge (RAS)
• It has high effectiveness of sludge retention time (SRT) which enhances the nitrification process
• Production of sludge is lower
• It does not need recycling of the sludge-like activated sludge system
• MBBR media is installed to retrofit existing activated sludge tanks in order to increase its capacity

A Packaged Effluent Treatment Plant (ETP) is a compact, pre-fabricated, and often skid-mounted or containerized system designed to treat industrial wastewater (effluent) on a smaller to medium scale. Unlike large, custom-built ETPs that require extensive civil work and on-site construction, packaged ETPs are manufactured and assembled in a factory, then transported to the site for quick installation and commissioning.

This "plug-and-play" nature makes them highly appealing for various industries, especially those with limited space, fluctuating needs, or a desire for rapid deployment.

Key Characteristics and Components:

Packaged ETPs integrate various treatment stages, often combining physical, chemical, and biological processes, into a compact footprint. The specific components and processes depend heavily on the type and characteristics of the industrial effluent to be treated (e.g., from pharmaceuticals, textiles, food processing, chemicals, etc.).

Common stages and components found in a packaged ETP:

1. Equalization Tank:

   • Purpose: To collect the incoming effluent, which often varies widely in flow, pH, and concentration of pollutants. This tank homogenizes the wastewater, preventing shock loads to downstream treatment processes.

   • Components: Tank (often FRP, MS, or SS), submersible mixer/agitator, level sensors, transfer pump.

2. Preliminary Treatment (for larger particles):

   • Purpose: To remove larger suspended solids, oil, and grease that could interfere with subsequent processes.

   • Components: Bar screens (manual or mechanical), grit chambers, oil & grease traps/skimmers (belt, disc, or coalescing type).

3. Physico-Chemical Treatment (often integral):

   • Purpose: To remove suspended solids, colloidal particles, heavy metals, and some organic matter through chemical reactions.

   • Components:

     • Flash Mixer: Rapid mixing unit for immediate dispersion of coagulant chemicals.

     • Flocculator: Slower mixing unit to encourage the formation of larger, settleable flocs.

     • Dosing Pumps & Chemical Tanks: For precise addition of coagulants (e.g., alum, ferric chloride), flocculants (polyelectrolytes), and pH-adjusting chemicals (acids, alkalis).

     • Clarifier/Settling Tank (often Lamella Clarifier for compactness): Where the formed flocs settle out by gravity.

     • Sludge Transfer Pumps: To move the settled primary sludge.

4. Biological Treatment (for organic pollutants):

   • Purpose:

A Leachate Treatment Plant (LTP) is a specialized facility designed to treat leachate, which is the liquid that drains or "leaches" from a landfill or waste disposal site. Leachate is formed when rainwater infiltrates through waste, picking up dissolved and suspended solids, organic matter, heavy metals, toxic chemicals, and various other pollutants as it passes through the decomposing waste layers. It's a highly contaminated and complex wastewater stream that poses significant environmental and health risks if not properly managed and treated.

 

Characteristics of Leachate

 

Leachate characteristics vary significantly depending on factors like:

• Age of the Landfill: Younger landfills typically produce leachate with higher concentrations of biodegradable organic matter (high BOD/COD), while older landfills produce more stabilized leachate with lower BOD/COD but potentially higher concentrations of refractory (non-biodegradable) organics, ammonia, and heavy metals.

• Type of Waste: Industrial waste landfills will produce different leachate than municipal solid waste landfills.

• Climate: Rainfall patterns and temperature influence leachate generation and characteristics.

• Landfill Design and Operation: Liner systems, daily cover, and compaction affect leachate quality and quantity.

Common pollutants in leachate include:

• High Organic Load: High Chemical Oxygen Demand (COD) and Biochemical Oxygen Demand (BOD), often with a low BOD/COD ratio in mature landfills (indicating less biodegradability).

• High Ammonia-Nitrogen (NH₃-N): A significant and persistent pollutant.

• Heavy Metals: Lead, cadmium, chromium, nickel, zinc, etc.

• Chlorides and Sulfates: High salinity.

• Refractory Organic Compounds: Humic and fulvic acids, xenobiotic compounds (pharmaceuticals, pesticides).

• Suspended Solids.

• Pathogens.

 

Purpose of a Leachate Treatment Plant

 

The primary purpose of an LTP is to treat leachate to meet discharge standards (e.g., for release into a municipal sewer, surface water, or for reuse) or for safe disposal, preventing:

• Groundwater contamination.

• Surface water pollution.

• Soil contamination.

• Odor nuisances.

• Health risks to humans and ecosystems.

 

Typical Stages and Equipment in a Leachate Treatment Plant (LTP)

 

Given the complex and variable nature of leachate, LTPs often employ a combination of physical, chemical, and biological treatment processes, and sometimes advanced separation technologies.

1. Pre-Treatment / Collection: * Leachate Collection System: Wells, sumps, and pumps to collect leachate from the landfill liner. * Equalization Tank: Crucial for buffering variations in flow and pollutant concentration of leachate, ensuring a more consistent feed to the treatment units. Often includes aeration to prevent anaerobic conditions and reduce odors. * Screens: To remove large debris that might come with the leachate.

2. Physical-Chemical Treatment: (Often used as pre-treatment for biological systems or for specific contaminant removal) * pH Adjustment: Chemical dosing systems (acids or alkalis) to adjust leachate pH, which can be very acidic or alkaline. * Coagulation & Flocculation: Dosing coagulants (e.g., ferric chloride, aluminum sulfate) and flocculants (polymers) to remove suspended solids, colloids, and some heavy metals. * Clarifiers/Sedimentation 

A Zero Liquid Discharge (ZLD) System is an advanced water treatment process that aims to recover and reuse nearly all (or 100%) of the wastewater produced by an industrial plant, leaving behind only a minimal amount of solid waste. The core principle is to eliminate the discharge of liquid effluent into the environment, promoting water sustainability and ensuring regulatory compliance.

 

 

Why Zero Liquid Discharge?

 

ZLD systems are becoming increasingly critical due to several factors:

 

1. Water Scarcity: As fresh water resources dwindle, industries are compelled to recycle and reuse their water to reduce reliance on external sources.

    

2. Stringent Environmental Regulations: Governments worldwide are imposing stricter limits on the discharge of industrial wastewater, especially for industries with highly polluting effluents. ZLD offers a definitive solution to achieve compliance.

    

3.  Cost Savings: While ZLD systems involve significant capital investment, they can lead to long-term operational savings by reducing fresh water intake costs, minimizing wastewater discharge fees, and potentially recovering valuable by-products (e.g., salts).

    

4.  Corporate Social Responsibility (CSR): Companies adopt ZLD to enhance their environmental image and demonstrate commitment to sustainability.

    

5.  Toxic Effluents: For industries generating highly toxic or non-biodegradable wastewater, ZLD is often the safest and most responsible disposal method.

    

 

How a ZLD System Works (Typical Stages)

 

A ZLD system is not a single technology but rather an integrated process combining various advanced water treatment units. The exact configuration depends heavily on the volume and characteristics of the wastewater. A common ZLD approach involves:

 

1. Pre-treatment (Primary & Secondary): * Purpose: To remove larger particles, suspended solids, oils, greases, and initial organic load to protect sensitive downstream membrane and thermal systems from fouling and damage. * Equipment: * Screens: For removing large debris. * Equalization Tank: To balance flow and concentration variations. * pH Adjustment: To neutralize the wastewater. * Coagulation & Flocculation with Clarifier/DAF: To remove suspended solids, colloids, and some heavy metals. * Biological Treatment (Aerobic/Anaerobic ETP): If the wastewater has a significant biodegradable organic load. * Multi-Media Filters (MMF) / Pressure Sand Filters (PSF): For 

An Industrial Wastewater Treatment Plant (WWTP), also commonly known as an Effluent Treatment Plant (ETP), is a facility designed to remove pollutants from industrial wastewater before it is discharged into the environment or reused. For a distillery, this is a critical investment for environmental compliance, resource recovery, and sustainable operations.

 

Why Distilleries Need an Industrial Wastewater Treatment Plant:

 

Distilleries generate significant quantities of highly contaminated wastewater, primarily "spent wash" or "stillage" from the distillation process. This effluent is characterized by:

• High Organic Load (BOD & COD): The sugars, proteins, and other organic matter from the fermentation process result in very high Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD).

• Low pH: Stillage is typically acidic.

• High Solids Content: Contains suspended solids and dissolved solids (TDS).

• High Temperature: Often discharged at elevated temperatures.

• Nutrients: Contains nitrogen and phosphorus, which can lead to eutrophication in water bodies.

• Color and Odor: Can have a strong, unpleasant odor and dark color.

Discharging such untreated wastewater directly into rivers or municipal drains is strictly prohibited and carries severe penalties from regulatory bodies like the Maharashtra Pollution Control Board (MPCB).

 

Goals of a Distillery Wastewater Treatment Plant:

 

1. Meet Discharge Standards: Comply with the stringent effluent discharge norms set by the MPCB (Maharashtra Pollution Control Board) to prevent water pollution.

2. Resource Recovery:

   • Biogas Production: Recover methane-rich biogas from the organic content, which can be used as fuel to power the distillery, reducing energy costs.

   • Fertilizer/Animal Feed: Produce nutrient-rich sludge or concentrated solids that can be used as agricultural fertilizer or animal feed supplements (e.g.,

A Demineralisation (DM) Treatment Plant, also known as a Deionization (DI) Plant, is a water treatment system that removes dissolved mineral salts (ions) from water. The process achieves a very high level of water purity, making it suitable for applications where even trace amounts of dissolved solids can be detrimental.

 

Why Demineralisation?

 

Natural water, including municipal tap water, always contains dissolved mineral salts (like calcium, magnesium, sodium, chlorides, sulfates, bicarbonates, silica, etc.). While generally harmless for drinking, these minerals can cause significant problems in industrial applications:

• Scaling: In boilers, cooling towers, and heat exchangers, dissolved minerals (especially hardness and silica) precipitate out as hard scales, reducing heat transfer efficiency, increasing energy consumption, and leading to equipment damage and premature failure.

• Corrosion: Certain ions (e.g., chlorides, sulfates) can accelerate corrosion of metal surfaces in pipes and equipment.

• Product Contamination: In industries like pharmaceuticals, electronics, food & beverage, and chemical manufacturing, even trace impurities can affect product quality,

1. Primary Treatment: This initial stage physically removes larger solids, grit, and scum from the wastewater. This often involves screening, comminution (grinding), grit removal, and sedimentation in a primary clarifier where heavier solids settle and lighter materials float.

2. Secondary Treatment: This stage focuses on biological treatment to break down organic matter dissolved or suspended in the wastewater. Microorganisms are used to consume these pollutants. Common methods include:

   • Activated Sludge Process: Air is circulated to encourage the growth of bacteria that break down sewage.

   • Trickling Filters: Wastewater is trickled over a bed of media where microorganisms grow and treat the water.

   • Moving Bed Biofilm Reactor (MBBR) / Mixed Bed Bio Reactor (MBBR): This technology uses small plastic carriers within the tank where biomass grows and breaks down pollutants.

   • Membrane Bioreactor (MBR): This combines biological treatment with membrane filtration for higher quality effluent.

3. Tertiary Treatment (Optional but Recommended): This is the highest level of treatment, further purifying the water to make it suitable for reuse or safe discharge. It can include:

   • Filtration: To remove any remaining suspended matter.

   • Disinfection: Using methods like UV light, chlorination, or ozone to kill bacteria and viruses.

   • Nutrient Removal: To reduce levels of nitrogen and phosphorus.

The solids removed during the treatment process are known as sludge, which is then processed separately.

An Oil Water Separator (OWS) is a piece of equipment designed to separate immiscible oil and water mixtures, particularly to remove oil droplets from wastewater or process water before discharge or further treatment. This is crucial for environmental protection, regulatory compliance, and sometimes for oil recovery.

 

Why is Oil-Water Separation Necessary?

 

Oil in wastewater can cause several problems:

• Environmental Pollution: Discharging oil into natural water bodies (rivers, lakes, oceans) can harm aquatic life, contaminate ecosystems, and spread widely, making cleanup difficult.

• Regulatory Violations: Environmental regulations typically have strict limits on the permissible oil and grease content in discharged wastewater.

• Damage to Downstream Treatment Processes: Oil can foul and damage biological treatment systems (e.g., in STPs or ETPs), clog filters, and foul membranes in advanced treatment units (like RO).

• Safety Hazards: Oil spills can create slippery surfaces, fire hazards, and emit volatile organic compounds (VOCs).

• Resource Recovery: In some industries, separating oil allows for its recovery and reuse or resale.

 

Principles of Operation

 

Oil-water separators primarily work on the principle of differences in specific gravity between oil and water, combined with Stokes' Law. Oil is generally less dense than water and will float, while water is denser and will sink.

Stokes' Law states that the settling (or rising) velocity of a particle in a fluid is directly proportional to the square of its diameter and the difference in density between the particle and the fluid, and inversely proportional to the fluid's viscosity. This means:

• Larger oil droplets separate faster.

• Greater density difference leads to faster separation.

• Lower water viscosity (higher temperature) leads to faster separation.

OWSs are designed to create quiescent (calm) conditions that allow enough time for oil droplets to rise to the surface and coalesce, forming a layer that can be skimmed off.

 

Types of Oil Water Separators

 

OWSs come in various designs, each suited for different types and concentrations of oil, and varying flow rates:

1. Gravity Separators (API Separators):

   • Description: These are large, rectangular tanks designed according to American Petroleum Institute (API) guidelines (API 421). They provide a long retention time and laminar flow conditions.

   • Working: Wastewater enters one end, and due to the low velocity, oil droplets rise to the surface and form a layer, while solids settle to the bottom. Scrapers and skimmers collect the oil and sludge respectively.

   • Effectiveness: Primarily effective for separating free oil