Introduction
Bio Petro Clean delivered an upgrade project for Spectrum Dyes and Chemicals for their Effluent Treatment Plant. One of India’s leading Disperse Dye Company. Spectrum required a robust and cost-effective solution for the tough Effluent generated during dye manufacturing. The target set was to achieve sustainable output quality and complete compliance with the Pollution Control Board norms. Spectrum ETP receives nearly 4 MLD effluents from its eight major production units.
Issues/Challenges
- Effluent Treatment Capacity was low – Due to inefficient treatment schemes in the ETP, the effluent treatment was ineffective and the ETP was running at 1/4th of the design capacity with tremendous fluctuations.
- Highly fluctuated inlet parameters – Due to fluctuations in COD, BOD, and Ammonia, the existing units were not able to stabilize their performance.
- High TDS – Due to high TDS values 20000+, the biological systems were not able to develop and sustain microorganisms resulting in poor treatment.
- Minimal Automation – Since the site was operating manually, the monitoring was not effective and the chemical dosing was not optimized.
Implementation of BPC Technology
The plant is being operated by BPC’s team along with cutting-edge Biological & Automation technology as well as Monitoring Software. A comparative analysis of the pant before and after the BPC retrofit is given in Table 1.
| After BPC | Proposed/ Under process treatment | |||
| Parameters | Inlet | Outlet | Inlet | Outlet |
| COD (ppm) | 10000 | 2000-2500 | 10000 | <2500 |
| BOD (ppm) | 3000-5000 | <200 | 3000-5000 | <200 |
| DO (ppm) | 2+ | 2+ | ||
| pH | <2 | 6.5-7.5 | <2 | 6.5-7.5 |
| TSS (ppm) | <300 | <300 | ||
| Flow (m3/hrs.) | 167 | 167 | ||
Table 1
BPC proposed a solution for Optimizing Plant operations and it was achieved in different stages:
Stage 1: Getting Chemical Oxygen Demand (COD) below 2500 mg/l and the other parameters like TSS, Ammonia, and Biochemical Oxygen Demand (BOD) under the limit as per the norms.
Stage 2: Complete plant Automation
Stage 3: OPEX Optimization
Completing all the above stages mentioned, we were able to achieve the Outlet Parameters as per the norms with the optimum conditions.
PFD Scheme after implementation of BPC-ACT Technology
The Outlet parameters after the installation of the ACT Bio reactor were as below:
| Date | ACT 1 I/L COD (ppm) | Outlet COD | COD Degradation (%) | BOD (ppm) | Flow (m3/hr) |
| 01-02-2023 | 4353 | 1849 | 58 | 156 | 127 |
| 31-01-2023 | 4950 | 1564 | 68 | 150 | 120 |
| 30-01-2023 | 4923 | 1544 | 69 | 136 | 105 |
| 29-01-2023 | 5029 | 1608 | 68 | 136 | 128 |
| 28-01-2023 | 5154 | 1693 | 67 | 163 | 122 |
| 27-01-2023 | 5083 | 1651 | 68 | 150 | 135 |
| 26-01-2023 | 5611 | 1817 | 68 | 150 | 138 |
| 25-01-2023 | 6077 | 1987 | 67 | 150 | 137 |
| 24-01-2023 | 5531 | 2003 | 64 | 163 | 132 |
System Inlet & Outlet COD
| Outlet COD | |
| Max | 2500 |
| Min | 1200 |
| Average | 1850 |
System Outlet TSS
| Outlet TSS | |
| Max | 250 |
| Min | 150 |
| Average | 200 |
Outlet BOD levels
| Outlet BOD | |
| Max | 190 |
| Min | 140 |
| Average | 165 |
System Inlet flow, Inlet COD, and COD degradation in the System
During the Inlet Shock loads concerning the variable flow rate, the ETP was not performing to satisfactory levels, hence Spectrum Management was looking for a solution that will give sustainable output results during the variable low and high capacities of the inlet flow rate.
After BPC’s ACT implementation: It can be noted in the graph represented below that the COD degradation is very consistent despite an increase in the feed flow as well as fluctuations in Inlet COD values.
Summary and Conclusion
BPC offered a simple yet advanced and efficient solution for upgrading the old/existing ETP to a level that will allow for safe discharge/reuse of treated wastewater.
BPC not only implemented ACT technology at the Spectrum site but also streamlined the process and parameters for the plant which are being maintained as per norms and meeting the guidelines set up by the environmental agencies. Our team on site is constantly working on improving the current process and reducing opex further.
The toughest challenge was to treat the variable inlet stream and the effluent produced from the production units with high TDS and COD values.
BPC also had the limitation of retention time as the retrofit did not add any new volume for the bio. ACT was designed to fit in existing volumes and work effectively with the available retention times.
Spectrum management is pleased with the professional execution of the retrofit and has awarded the OnM of the ETP to BPC for 1 year.
The successful retrofit shows that the BPC-ACT solution can easily be integrated into the currently existing infrastructure, resulting in a more cost-effective manner and environmentally friendly wastewater treatment. The retrofit process is quick and leads to a superior more stable means of effluent treatment.
Optimization Statistics
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From the designers and engineers who are creating the next generation of web and mobile experiences, to anyone putting a website together for the first time.
Digital technology has made our world more transparent and interconnected, posing new challenges and opportunities for every business. As your budget progresses and evolves, continue referring to your SMART objectives. Stay focused and remember your goals – they will always inform what your next step will be!
From the designers and engineers who are creating the next generation of web and mobile experiences, to anyone putting a website together for the first time. We provide elegant solutions that set new standards for online publishing.
As your budget progresses and evolves, continue referring to your SMART objectives. Stay focused and remember your goals – they will always inform what your next step will be!