One Of Its Kind ETP Based On Anaerobic Technology Treats API Effluent Efficiently
By Dr. Jaideep Dudhbhate
The rapid industrial development and exponential population growth is polluting the environment in an increasing manner, particularly in developing countries, where primarily all efforts are directed towards industrial development. The active pharma ingredients (API) industry, earlier popularly known as bulk drug industry, is a major industrial segment in India. As per a 2011 report, at the current rate of growth India’s domestic pharma market is expected to reach between $49 billion to $74 billion by the year 2020 (India Pharma report Sept. 2011, website: http://issuu.com/focusreports/docs/phex_india_2011).
The wastewaters from API units typically contains variety of chemicals, many of which are also known to be refractory (or difficult to biodegrade). It has been a challenge to the industry to ensure that the treated effluent not only meets the norms but now also be suitable for recycle in process and non-process reuses.
Conventionally, aerobic biological processes have been used along with physico chemical primary and/or tertiary stage. There have been rare instances of use of anaerobic treatment processes as a part of API wastewater treatment process. Also, many such installations were having operational problems and there was a feeling in the industry that the anaerobic biological processes cannot be used for treatment of API effluents.
This could be due to several factors, including:
- Poor performance and past operating problems.
- Odor problems from anaerobic lagoon.
- Concern over sensitivity of microorganisms to toxic materials and pH and temperature changes.
- Lack of understanding of process variables and control.
However, over the last few years several developments have taken place which has resulted in better understanding of anaerobic treatment processes. A.T.E. Envirotech Pvt Ltd, a group company of A.T.E. group, has been providing turnkey solutions for wastewater treatment systems. At its development lab several studies (bench scale as well as pilot scale) has been conducted for use of anaerobic – aerobic biological treatment processes and different treatment solutions have been worked out.
Given below is the case study of an actual operating installation
Background
With a legacy of over 75 years in the generic API industry, this success story belongs to one of the leading international supplier of active pharmaceutical ingredients. With the industry’s broadest portfolio of over 300 API products, this multinational employs over 5,000 professionals at over 20 sites worldwide. This case study depicts how A.T.E. achieved the task of treating the complex API effluent with innovative application of anaerobic-aerobic combination at one of the client’s site in central India.
Challenge
While going for their new factory in central India, client was concerned about the treatability of the complex effluent that was expected to be generated out of this unit. Also the energy cost involved in treating the effluent was a prime concern. One of the renowned project management companies were consultants to the project.
Solution
After a series of discussions with the client and consultant, an anaerobic and aerobic combination was selected. This is considered as a first of its kind solution for pharma effluent treatment.
Result
A.T.E. successfully designed, installed and commissioned a 250 m3/day effluent treatment plant based on anaerobic-aerobic combination.
Following are the advantages of this unique solution for pharma effluent-
- Reduces over 40% COD in anaerobic stage thus reducing the power consumption for aerobic treatment.
- Improves biodegradability of COD entering aeration tank.
- Overall 90% reduction in COD.
About the author:
Dr. Jaideep Dudhbhate is General Manager (Applications and Services) – Wastewater Solutions, at A.T.E. Enterprises Pvt Ltd. He has over three decades of experience in wastewater treatment, spanning a variety of industrial sectors. He has completed over 150 projects and has four patents to his credit, two of which have been commercialized.