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How To Make Industrial Biological Waste Water Treatment Successful

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Written by- Rasa Bihari Mishra | +91 84696 27669 | rbm.innovations@gmail.com

Waste Water Treatment is a necessity. Why?

Because most of the Industries generate Waste Water. And all of them are loaded with the pollutants and can pollute the environment. So you can’t dispose off the waste water without making them harmless to the Environment. The only solution is to treat the waste water effectively. When it comes to waste water treatment it must be Efficient.

Anaerobic Biological Waste Treatment

Aerobic Biological Waste Treatment

Efficient Treatment

Efficient waste water treatment helps in achieving the business objectives like: –

-You must be able treat the waste water effectively in order to comply with the pollution control requirements. It’s a must.

-The treatment facility must be Efficient enough to take care of the variations in the waste water getting generated.
-You need to introduce new products and new technologies for business growth. The waste water treatment must not be a constraint.

-And above all the Treatment cost must be minimum without compromising with the treatment efficiency.

You can treat the waste water using different Treatment Technologies. But when it comes to Industrial Waste Water Treatment the situation becomes difficult. Why?

Because the industrial waste water treatment is difficult. Different treatment technologies are available. But it’s tough to meet the treatment objectives. Here the Biological Waste water treatment comes to the picture. In most of the cases it can meet the treatment objectives effectively.

-It can treat large volume of waste water. It can handle variations in the quantity and characteristics very well.
-The Treatment consists of natural processes. Hazardous substances are not used. The treatment processes are environment friendly.

-The Treatment cost is less as compared to other Treatment Technologies No wonder most of the waste water treatment facilities employ Biological Treatment. But the Biological Treatment has got some limitations especially with the difficult to treat waste water.

Unless you do something about overcoming the limitations you can’t make it successful. But before getting into the details let’s know how Biological Treatment works.

How Biological Treatment Works

Biological treatment utilizes the power of microorganisms. Microorganisms are tiny organisms so small that you can’t see them with your naked eye. You’d need amicroscope to see them. The microorganisms eat away the pollutants present in the waste water. The pollutant molecules undergo biochemical processes inside the cells of the microorganisms and get converted into environmentally harmless products.

Biological treatment can be broadly divided into two categories:

Anaerobic biological treatment works in the absence of air. These micro- organisms can’t survive in the presence of oxygen. You need to ensure the absence of oxygen by carrying out the process in closed condition. Anaerobic Biological Treatment generates Biogas. The microorganisms break down the carbon compounds into Carbon Dioxide and Methane. You can use the methane in the Biogas generated during anaerobic biological treatment as fuel and save on your energy cost.

Aerobic Biological Treatment works in the presence of air. These microorganisms need oxygen to survive. So you need to maintain a minimum dissolved oxygen level by supplying air. The microorganisms break down the carbon compounds into Carbon Dioxide and water and make them harmless to the environment. But here you need to spend in energy cost in order to supply air.

Limitations of Biological Treatment

A wide variety of both aerobic and anaerobic treatment technologies are available. All of them have got their own plus and minus points. But as we’ve discussed earlier the biological treatment has limitations.

Very High Dissolved Salt Concentration

Some waste water have high level of dissolved solids – both salts and other compounds. And when the salt concentration is very high, the microorganism can’t survive due to the osmotic effects. It’s very difficult to treat this type of waste water.

Non biodegradable molecules

Anaerobic Biological Waste Treatment Aerobic Biological Waste Treatment The presence of non biodegradable molecules in the waste water makes it very difficult to use biological treatment as the microorganism can’t consume them. In addition to it these molecules inhibit their growth resulting in drastic reduction in the treatment efficiency.

Toxic Compounds in Waste Water Streams

The presence of toxic substances can kill or drastically affect the microorganisms. These compounds are toxic to the microorganisms and destroy the cellular mechanisms in them. It results in total breakdown of the treatment system. Industry professionals, research organisations and innovators are putting in massive efforts to overcome the limitations of biological waste water treatment. Newer technologies and processes are being developed.

Let’s see what options are available to us.

Get rid of the Non-biodegradable and Toxic Compounds. Ensure that the waste water is free from non biodegradable and toxic substances. It’s important. Why? Because as we’ve already discussed the non-biodegradable and toxic compounds have severe effect on the microorganisms.

Segregate the Waste Water Streams

To start with it’s better to avoid the waste water streams containing non biodegradable and toxic compounds in the biological treatment facility. You can segregate the waste water streams based on their characteristics. It’s better to separately collect the difficult to treat streams so that they can be handled separately.

Optimize the Primary Treatment

Primary waste water treatment utilizes many techniques like Waste Stream Neutralization, Flocculation, Clarification, Chemical Precipitation and so on. During these processes many pollutants get in solubilized. In fact proper selection of Primary Treatment can reduce the pollutant load significantly. And if it results in the removal of the non-biodegradable and toxic compounds the waste water treatment becomes costeficient.

Use Non Biological Treatment Technologies for Partial Treatment You can think of Non-Biological Treatment technologies only when nothing works. Because they’re economically not at all attractive. But because of their non biological nature they’re effective in treating the waste streams which biological treatment finds difficult.

It’s better to use these technologies for the partial treatment. It’s easier to treat the waste water partially and It results in lowering down the treatment cost. Partial treatment helps in making the waste water streams suitable for biological treatment.

Acclimatization of the Biomass

Different types of microorganisms take part in biological treatment processes. Their growth as well as performance depend on many physical and chemical parameters. Fortunately biology has many ways to adjust to the environment. And these micro creatures learn how to deal with the day to day variations in waste water characteristics. When the only food available for them is those unpalatable compounds – the only option remains for them is to use them in order to survive. And they develop the internal biochemical mechanism in them to metabolize the non-biodegradable and toxic molecules. This is what is biomass acclimatization. Systematic procedures are available to achieve effective biomass acclimatization in the waste water treatment facilities. It results in significant improvements in the treatment efficiency.

Specially Developed Microorganisms

Microorganisms are different. Some microorganisms can eat away difficult to treat pollutants with ease while others find it difficult to even survive. What if you’re able to develop these super microorganisms? It’ll solve much of your treatment problems. Isn’t it?

We’ve already discussed how biomass acclimatization results in improving the microorganisms. But there’s another extremely powerful way to achieve far better results. You can use the power of advanced technology to develop the internal biochemical mechanisms of the microorganisms very fast.

The idea here is to select and develop the microorganism and convert them into super organisms capable of eating non biodegradable and extremely toxic compounds.

These technologies can make it happen in days, which the nature takes years to accomplish. They can be developed for different pollutants. You can augment the biomass of your waste water treatment plant with suitable super microorganisms and achieve incredible results.

Other Technical Innovations

Optimization of waste water treatment technologies is a knowledge intensive initiative. Looking to the wide variations in the waste water quantities and characteristics a number of Technical Innovation Initiatives are being applied.

Some of ideas being tried are:

-Maintaining Very High Active Biomass Concentration has got it’s own advantages. It’ll not only make the treatment faster and better but also treat the difficult to treat pollutants in a much better way.

-High pressure Aerobic Treatment technologies are taking the advantage of higher dissolved oxygen concentration to intensify the processes.
-Innovative systems are done to utilize different types of microorganisms in an optimized way to make the Treatment Effective.

-Developing highly dense biomass granules are helping in enhancing the treatment efficiency significantly.

-Effective usage of membranes in the waste water treatment process is resulting in major improvements.

How to Make Biological Treatment Efficient

It’s not enough to have a well designed biological waste water treatment facility. Why? Because unless you operate the treatment facility efficiently neither you’ll be able to comply with the pollution control requirements nor control the waste treatment cost.

Variations in Waste Water Quantity and Characteristics
When it comes to waste water treatment the operation is challenging. Day to day operations of your manufacturing facility results in large variations in the quantity and characteristics of the waste water streams. There’s another more important aspect. In today’s competitive business environment process improvements have become common. I order to retain the leadership position in the market you’ve to introduce new products and implement improved manufacturing processes. And you’ve to expand and modify the manufacturing facility.

All these initiatives are no doubt essential for business sustainability. But there’ll be large impact on the waste generation. And you won’t like your waste water treatment facility to be a constraint. Isn’t it?

So you need to ensure that your waste water treatment facility is properly designed. But first you need to decide on the waste treatment processes. Here the Treatability Study comes to your help.

Treatability Study

Treatability Study is very effective in selecting the right waste water treatment technologies. Here you do the laboratory experimentations to see which treatment processes are working and which are not. In case of biological treatment you can check the effect of the actual waste water on the microorganisms. Whether the microorganisms are able to treat the waste streams? It helps in optimizing the treatment processes for the actual waste water.

Waste Water Treatment Pilot plant

Testing the waste water in the laboratory for the treatability provides wealth of information so that you can select the right treatment processes and design an efficient waste treatment plant. But when it comes to deal with the daily variations in the quantity and characteristics of the waste water streams, you need something similar to your waste water treatment plant. So that you can experiment at small scale. Here a well designed waste water treatment pilot plant becomes much helpful.

Let’s Conclude

As we’ve already discussed an integrated approach is essential to make the biological waste water treatment successful. The manufacturing processes have significant impact on the quantity and characteristics of the waste water. That’s why close coordination between the production, process development, process engineering and environmental functions becomes necessary.

The integrated environmental management need to include:
-Detailed study of the manufacturing processes with respect to the waste water generation is necessary. You can conduct Treatability Study which will be of great help in designing, expanding, and modifying the waste water treatment facility.

-Regular monitoring of the waste water generation and the operation of the treatment facility is essential.

-A well designed waste water treatment pilot plant can help you achieve major improvements. It’s necessary to prepare the organization for the future.

-You can initiate an Integrated Evaluation and Enhancement study to Optimize the Environmental Management system.

-Conducting periodic Technical Training Programs can help in making the industry professionals knowledgeable. It’ll help them in not only operating the plant efficiently but also making significant contributions in the organizational growth.

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Process Industry

How To Make Industrial Crystallization Efficient

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By- Mr. Rasa Bihari Mishra | +91 84696 27669 | rbm.innovations@gmail.com

Think of the solid products you’re using in daily basis like sugar or common salt. They’re different. One substance is organic while the other is inorganic. But there’s one similarity. How? Because both of them are manufactured using Crystallization process. In fact most of the solid products especially those which are made in Chemical, Pharmaceutical, and other Process Industries are manufactured by using Crystallization process. Crystallization is the most used Separation Process to Recover Solid Products from the Solution.

That’s the reason why it becomes necessary to make the industrial Crystallization processes efficient.

Crystallization Process
The aim of the crystallization process is to recover the product from the solution selectively. Why?
Because the product is there in dissolved condition along with other undesirable compounds. That’s why selective separation becomes necessary to get rid of the undesirable compounds.
Crystallization takes the advantage of reducing the solubility of the product by changing the physical and chemical parameters. The solution gets supersaturated and the product becomes insoluble and comes out of the solution leaving behind the undesirable compounds. So you get the solid product in pure form.
Sometimes people prefer to call it precipitation

especially when the process happens due to the reactions. In industrial crystallization once the crystallization is over slurry forms. The slurry consists of the product solids suspended in the solvent. Of course the solvent is no longer pure now. Many compounds are dissolved in it. The product solids are separated by using filtration or centrifugation. But still the solid particles are coated with the filtrate loaded with undesired compounds. So the solid particles are washed with suitable solvent to remove the filtrate and make the products pure.

The washed solids are in wet condition. They’re not free from the solvents. So drying operation is necessary to remove the solvents and make them dry. A wide variety of crystallization processes are used in the industry. These are nothing but using various ways to make the solution supersaturated. Because they use different supersaturation methods to reduce the solubility of the product in the solvent. Since the supersaturation methods are different it’s better to evaluate them separately.

Cooling Crystallization
The solubility of the substances depend on the tem- perature. The solubility of most of the compounds are lower at lower temperatures. So when you cool the solution it gets supersaturated and the products get crystallized out. You need to effective heat transfer process to lower down the temperature. And hence efficient heat transfer system is important here.

Cooling crystallization process is used for a wide number of products. Both continuous and batch mode of operations are utilized. A wide number of technologies are in operation.

Evaporative Crystallization
The solubility of a chemical compound in a solvent is constant at a certain temperature. When you remove the solvent by evaporation the solution gets concentrated. As the quantity of product dissolved in the Solution depends on the quantity of solvent, the solution gets supersaturated. And the product get insolubilized and crystallize out of the solution.

You need to use Evaporation system to evaporate the solution. And that’s why efficient evaporation system becomes necessary. Evaporative crystallization process are used in many places. Both continuous and batch mode of operations are utilized. A wide number of technologies are available to select from. Usage of Precipitants The solubility of chemical compound changes drastically when they get interacted with different types of chemical substances. We call them Precipitants. Some precipitants react with the product molecules. Some precipitants form adduct with the product molecules. Some precipitants alter the solubility of the product molecule significantly by common ion effect. Precipitant addition results in significant reduction in the solubility. The solution gets supersaturated and the products get crystallized out. With batch manufacturing processes you need to use mixing vessel with good agitation to avoid dead zones for making the process efficient.

pH Adjustment
Most of the chemical compounds become electrically neutral at certain pH based on the presence of acidic and basic groups in the molecule. At that pH the solubility of the compounds become minimum. That’s what is gainfully utilized in many crystallization processes.

You need to add suitable acid or alkali to take the pH of the solution to the Isoelectric point, where the product molecule becomes electrically neutral. Because of significant reduction in the solubility of the product molecule, the solution gets supersaturated and the product gets crystallized out.

With batch manufacturing processes you need to use mixing vessel with good agitation to avoid dead zones and achieve uniform pH in the crystallizer. It helps in making the process efficient.

Anti-Solvent Addition
The solubility of chemical compounds depend on the type solvents in which the molecules are dissolved. Solvents are different as far as their ability to dissolve the compounds in them is concerned. When you mix certain solvents in which the product molecules have no solubility or very less solubility, the overall solubility situation changes drastically. We call these solvents to be Anti-Solvents.

You need to ensure that the solvents you are using for precipitation are miscible in the solvent in which the product is dissolved. Then only the process will be effective. When you add suitable anti solvents (water included) the product solution the solubility of the product decreases resulting in supersaturation. So the product gets crystallized out. With batch manufacturing processes you need to use mixing vessel with good agitation to avoid dead zones and uniform solvent concentrations for the precipitation process to succeed.

Sometimes no single supersaturation method becomes effective. In that case you may have to use multiple supersaturation techniques in order to make the crystallization processes efficient.

Before getting into the details of how we can enhance the crystallization operation, let’s understand what really happens inside the crystallizer. Two major events happens which decide the outcome of the crystallization process.

-Crystallization Nucleation

-CrystalGrowth
Let’s discuss about them…

Crystallization Nucleation
When you make the solution – in which your product is dissolved – supersaturated, the product starts getting insoluble. In the initial phase of supersaturation some crystals or precipitates come out of the solution. We call them nuclei and the process crystallization Nucleation. In that initial phase the size of the solid particles are smaller. In fact with time the size increases. That’s what happens in the next phase of the crystallization process-crysta growth.
Crystal Growth
Once nuclei forms in the crystallization process, the insoluble products coming out of the solution start getting deposited on them. When the crystallization rate is not very high this results in crystal growth and you get crystals of proper size and shape.

Sufficient time for crystal growth helps in the process.
But when the supersaturation rate is very high the situation becomes different. There’s not enough time for crystal growth. It results in small crystals of improper size and shape. And when the supersaturation rate is so high that the crystallization is instantaneous, only nuclei forms. That’s why it results in the formation of products of amorphous nature. As we have discussed above in order to improve the crystallization efficiency you need to focus on nucleation and the crystal growth. Optimize the Supersaturation The crystallization process solely depends on the supersaturation. Supersaturation decides the outcome of crystallization. Irrespective of what you are doing for making the solution supersaturated, the rate and extent of supersaturation need to match with the requirements.

The importance of IIOT for the food and beverage industry

Product Yield and Quality
When you talk about the product yield and product quality in crystallization process the situation becomes challenging. Why? Because the Crystallization is a selective process. You’re separating the products from the solution in solid form selectively. You want the products but not the impurities.

When you reduce the product solubility to a very extent you may be able to achieve high product yield. But if the undesirable compounds get crystalize out of the solution the product quality will suffer. So here the selectivity matters.

So you need to optimize the solvent as well as supersaturation methods to achieve both high product yield and improved product quality. If consider the product quality many quality attributes depends on the rate of super saturation. Again the rate of supersaturation will depend on the supersaturation method. So you need to go for detailed optimization considering all the technical and business aspects. The idea is to match the manufacturing process with the customer requirements efficiently.

Let’s Conclude
As we have discussed crystallization is one of the most important separation process to get the products in solid form. That’s why it’s extensively used in Chemical, Pharmaceutical and other Process Industries.
In order to make the manufacturing efficient you need to optimize the separation processes. But the processes are interdependent. That’s why an integrated approach becomes effective. And so close coordination between the production, process development, quality, process engineering and sales & marketing functions becomes necessary.

-Detailed Evaluation and Monitoring of the Manufacturing Processes are important.

-Carrying out Detailed Mass and Energy Balance Study can help

-You can initiate an Integrated Technical Evaluation & Enhancement to Optimize
the Separation Processes.

-Conducting periodic Technical Training Programs can help in making the industry professionals knowledgeable. It’ll help them in not only operating the plant efficiently but also making significant contributions in the organizational growth.

In today’s competitive business environment it’s essential to give utmost importance to the improvement initiatives and finding creative solutions to industrial problems. Implementing Technical Innovations in a structured way can help a lot.

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Process Industry

INDUSTRIAL WASTE WATER TREATMENT

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Article written by- Rasa Bihari Mishra | rbm.innovations@gmail.com | +91 84696 27669

About author: R B Mishra is a Consultant to Chemical, Pharmaceutical, & Other Process Industries. He provides End to End Technical Support to Help the Industries Maximize the Profitability and achieve Sustainable Business Growth. It helps them to take their businesses to the Next Level.

Rapid industrialization is a boon to the modern world. The contributions of the industries are immense. They’re helping in enhancing the prosperity level, poverty eradication, employment generation, improving the quality of our lives, and what not. Everywhere industrialization is adding tremendous value.

But the coin has sides. Every good thing has some bad attributes. Industrialization is not different. Why?

Because industries generate waste. Of course some industries generate more whereas some generate less. The wastes of some industries are more harmful to the environment while the wastes of some others have less environmental impact.

Irrespective of the quantity and characteristics of the wastes different industries are generating all of them are harmful to the society. The harmful wastes are nothing but the pollutants and they pollute the environment if not checked. The only solution is to do something to avoid the exposure of the pollutants to the environment.

But how to do that?

The solution has two parts. The first initiative is to avoid waste generation. However it’s not always possible to avoid waste generation completely. The idea is to minimize the waste generation.

You can’t avoid the waste generation completely. But you must avoid the adverse environmental impact at any cost. That’s why it’s essential to go for effective waste treatment. By using suitable end of the pipe treatment technologies you can make the wastes harmless to the environment and comply with the pollution control requirements. If you closely study the details of the wastes generated, you’ll observe that the liquid waste – waste water – forms the major part. And it’s really a challenge to treat waste water. When you talk about the waste water treatment the characteristics of the waste streams become important.

HRS Hot Water Systems

Waste Water Characteristics of Different Industries

Industries are different. Their products are different. The raw materials they use are different. And above all the manufacturing processes used by different industries are different.

But if you study the usage of raw materials you’ll find one interesting fact. Most of the industries are using water for manufacturing their products. Once you use water in the manufacturing processes there’ll be waste water generation. Of course if the water you use gets incorporated in your products then it’ll be a different story. That’s why most of the industries generate waste water. Of course the characteristics of the waste waters will be different. In fact what we’re Interested in is the pollutants level and how difficult it’s to treat the waste water. Equally important is the cost of waste water treatment. In order to make the treatment technologies effective you need to study the waste water details meticulously.

As for example the food industries generate a lot of waste water. Though the pollutants level in the waste water is very high, they’re biodegradable and non toxic. So in most of the cases biological treatment becomes effective.

Treatment Process

Selecting the right waste water treatment process has two aspects.

l It’s necessary to achieve proper treatment to make the waste water harmless to the environment.

l The treatment process must be technically feasible and economically viable.

The quantity and characteristics of waste streams vary a lot. And which treatment process will work for which waste water is not certain. It makes the selection of treatment processes challenging. It’s always better to test the treatment processes in the laboratory.

Industrial Scale Up-Chemical, Pharmaceutical, & Other Process Industries

A well designed Waste Water Treatability Study can help you select the right treatment process.

Waste water treatment process has three stages.

l Primary Treatment

l Secondary Treatment

l Tertiary Treatment

Primary Treatment to Start with The waste water treatment starts with primary treatment. The major aim of the Primary Treatment processes is to make the waste water suitable for the Secondary Treatment.

Screening

The screening process is to remove the bigger particles from the waste water streams. Both fine and coarse screens are used to get rid of fine as well as coarse particles. It’s necessary to avoid problems in the later stages.

Equalisation of Waste Streams

In order to make the treatment effective, you need to collect the waste water streams for a predetermined period of time and mix them properly before you think about the treatment. This process is called ‘Equalization’. It acts as a buffer against the fluctuations in quantity and characteristics of the waste water streams.

Neutralisation

Most of the waste water streams generated in the industries are either acidic or basic in nature. Every treatment process has got its own optimum pH to be effective. That’s why it becomes necessary to adjust the pH using suitable acid or base. The selection of the right neutralising agent (acid or base) is critical for the effectiveness of the primary treatment. You can neutralise the waste water batch wise or by using continuous mode.

Get rid of the Suspended Solids

The waste water streams may contain fine suspended solids difficult to remove by screening. In addition to it initial operations -equalisation and neutralization -may generate suspended solids further. Suitable coagulating and flocculating agents are added to help the suspended particles come together and make bigger particles (Flocs).

Based on the characteristics of the suspended particles, either they will settle down or float up. Settling or floatation unit operations make the waste water free from the suspended solids based on the type of the solids. You can also use the filtration process to get rid of the solids and clarify the waste water.

Chemical Precipitation to remove soluble pollutants

Use of suitable chemical precipitating agents to precipitate out the soluble pollutants help. The type and quantity of precipitating agents depends upon which pollutants you want to get rid of and to what extent. The precipitating agents react with the soluble pollutants and make them insoluble. Once they become insoluble, you can remove them as you do with suspended solids.

Secondary Treatment

The Secondary Treatment processes do the major treatment of the waste water. The major aim of the Secondary Treatment processes is to make the waste water pollutants free.

Biological Treatment

In most of the cases Biological Treatment is used as main waste water treatment. Why?

Because it’s the most economical way to treat the waste water and comply with the pollution control norms. It’s the microorganisms who do the main job in biological treatment. They eat away the pollutants and make them harmless to the environment.

That’s why most of the Waste Water Treatment plants have Biological Treatment facility. It helps in making the treatment process cost-effective.

You can divide the biological treatment process into two categories.

Anaerobic Biological Treatment It works in the absence of air (oxygen). You need to ensure the absence of oxygen by carrying out the process in closed condition. The microorganisms break down the carbon compounds into Carbon Dioxide and Methane. You can use the methane generated during anaerobic biological treatment as fuel and save on your energy cost.

Aerobic Biological Treatment It works in the presence of air (oxygen). As oxygen is essential in this process, you need to maintain a minimum dissolved oxygen level by supplying air. The microorganisms break down the carbon compounds into Carbon Dioxide and water and make them harmless to the environment. But here you need to incur some cost in order to supply air.

Advanced Oxidation Technologies

Though biological treatment is the most economical there are limitations. Biological treatment processes are not effective especially when the waste water contains nonbiod-egradable and toxic compounds. In those situations non-biological treatment processes help.

Advanced Oxidation Processes can be used where biological treatment is ineffective. You can choose out of different types of advanced oxidation technologies available. Almost all advanced oxidation technologies utilize the power of hydroxyl radicals reactive enough to oxidise the pollutants. The way to generate hydroxyl radicals varies from technology to technology. Detailed parameters of your waste water streams will decide which technologies are right for you.

Wet Air Oxidation

You can choose Wet Air Oxidation process effectively when the waste water is not suitable for biological treatment. It’s a type of non-biological treatment process suitable when the quantity of waste water is high. In wet air oxidation process air (source of oxygen) is used under high temperature and pressure in the presence of a suitable catalyst to oxidise the pollutants. A lot of work is going on to develop improved catalysts for enhancing the treatment efficiency and reducing the temperature and pressure requirements. Of course the temperature and pressure requirements depends on the type of pollutants present in the waste water.

Tertiary Treatment

The Tertiary Treatment processes do the final treatment of the waste water. The major aim of the Secondary Treatment processes is to make the waste water totally harmless to the environment and suitable for disposal.

Final Filtration

Various fine filtration processes are used to clarify the waste water and make it completely free from suspended particles. In many waste treatment plants Sand Filters are used.

Activated Carbon Treatment

Activated Carbon Treatment is very effective in removing various types of pollutants from the waste water. Difficult to treat pollutants get adsorbed on to the surface of activated carbon. It’s very effective when the pollutants level is low. That’s why it’s used for final treatment before disposal. In most of the waste water treatment plants granular activated carbon is used.

Special Treatment

Different waste waters have different characteristics. Sometimes there are some pollutants which are difficult to treat effectively with common treatment processes. But it’s essential to make the waste water pollution free.

In those situations special treatment processes are used to get rid those difficult to treat pollutants. Of course the special treatment processes vary from waste water to waste water. Technical feasibility and economical viability decide which process to select.

Zero Liquid Discharge (ZLD)

In some industrial situations waste water discharge is not allowed. Or you are interested in using the water in your waste streams in order to deal with water scarcity. Whatever be the reason you can use Zero Liquid Discharge (ZLD) Technologies. Here the waste water is concentrated by using membrane filtration and evaporation processes. The concentrated waste water is dried to get the solid waste. The solid waste is disposed off by incineration or landfill. Whereas the water recovered from the ZLD process gets utilized in the manufacturing processes.

Let’s Conclude

Industrial Waste Water Treatment is critical for saving our environment from adverse impacts. The Treatment starts with Waste Stream Characterization and Segregation. Designing the Waste Treatment Process and the Facility is based on meticulous study of Waste Stream details. Treatability Study helps a lot in selecting the right Treatment process. The waste water treatment comprises of Primary Treatment, Secondary Treatment, and Tertiary Treatment. When you talk about the Secondary Treatment processes there are Biological and Non-Biological treatment Technologies.

However in order to make the Waste Water Treatment Cost-Effective you need to make Biological Treatment successful. Here Specially Developed Microorganisms and Engineering Innovations can add value.

Integrated Optimization of the Waste Water Treatment System along with adopting Technological Innovations can help you in achieving the Pollution Control Objectives.

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Process Industry

BPCL in the process to acquire stake in Bharat Oman Refineries

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The Board of Directors of Bharat Petroleum Corporation Limited (BPCL) at the meeting held on 17th December 2020 has accorded its approval for acquisition of 36.62% of equity shares in Bharat Oman Refineries Ltd (BORL) from OQ S.A.O.C. (formerly known as Oman Oil Company S.A.O.C) subject to the finalization of definitive agreement between parties, the approval of the competent authorities and completion of Regulatory and other requirements.

The Board of Directors has also approved the proposal to approach Government of Madhya Pradesh (GoMP) for acquiring 269,00,000 warrants held by GoMP in BORL.

BORL was incorporated on 25th February, 1994. The Authorised share capital of BORL is Rs. 7000 crore and paid up share capital is Rs. 2426.83 crore. BPCL holds 63.38% of the paid up share capital of BORL and OQ S.A.O.C holds 36.62% of the paid up share capital. The revenue from Operations of BORL for the financial years; 2019-20 was Rs. 41,940.96 crore, 2018- 19 was Rs 31,597.59 crore, 2017- 18 was Rs 31,287.48 crore.

BORL has a refinery of 7.8 MMTPA capacity at Bina, Madhya Pradesh, Crude Oil import / supply system consisting of a Single Point Mooring System, Crude Oil Terminal at Vadinar, Gujarat and 937 KMs long cross country crude oil pipeline from Vadinar to Bina.

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Process IndustryUpdates

Global Leader in Manufacturing Paddy Processing Plant & Machinery, Waste Water Treatment Plant & Entire range of Mineral Water Plant

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SKF ELIXER – DHANYAMITHRA

This state-of-the-art super-efficient, multi utility drier has Auto-control of air and temperature for uniform drying and total automation for easy operation and maintenance. Wholly made of stainless steel and maintenance free, it incorporates hot air technology for indirect heating for uniform drying to produce hygienic and quality rice.

Its futuristic design, minimal power and fuel consumption (paddy husk/firewood/agro waste) have made it a favorite of rice millers world over! DHANYAMITHRA ensures uniform drying and hence reduces losses during further processing. The paddy is safe and fit for even long-time storage. Paddy is usually harvested at 20-25% moisture content while 14% or less is considered safe for storing grains. Hence paddy drying is very essential and the need of the hour for a successful rice miller. It would bring in multiple benefits.

Today, the ultra-modern ORYZA, the grain processing plant and DHANYAMITHRA, the drier, are considered as the best in their category globally and exported to Nigeria, Brazil, Vietnam, Pakistan, Bangladesh et al.

SKF VULCAN STP

SKF VULCAN STP ( Sewage/Effluent/Waste Water) Treatment Plants Today, STP (Sewage Treatment Plant) has been made mandatory for every hotel, hostel, hospital, industry et al by the State & Central Government. SKF VULCAN is the first corporate company to introduce wholly Stainless Steel, Plug & Play STP into the market. Our SKF VULCAN STP costs far less than the conventional plant. It provides for quick installation. It is corrosion & maintenance free. What’s more, the output water from the Vulcan STP can be easily converted into 100% pure and safe, hygienic Mineral Drinking Water by installing an Elixer RO plant! Every Flat, Hostel, Hospital, Hotel, Industry et al should have an STP installed so that all waste water is treated before discharge to leave behind us a ‘clean & green earth’ for our future generation to prosper.

AROMA COFFEE DRIER

The next successful product launched by SKF is Aroma Coffee Drier. The unprecedented features like ultra-modern design, state – of the – art technology. Wholly Stainless-steel body, incorporating auto – control for hygienic products, have made this the favorite of Coffee Growers globally. Aroma, the coffee drier, has become the favorite of Coffee planters in India.

ELIXER MINERAL WATER PLANTS

The tremendous success in the designing, manufacturing and marketing of grain processing plants, especially paddy, coffee beans et al, made SKF the global leader. Mr. Achar, the visionary he is, with decades of investment in R and D decided to foray into the field of water purification. He realized that most of the bottled drinking water is just pure clean tap water. He launched Elixer brand of Mineral Water Plants to provide 100% pure, mineral drinking water from one’s own source! Everyday millions of empty plastic bottles pollute the environment. It can only be imagined how much damage this will cause to the environment in the next one decade alone. To save the Earth, this indigenous solution can provide you bacteria free pure drinking water at the tap of a button without any plastic.

The dissolved fluoride, sodium, arsenic, lead, insecticides, pesticides besides bacteria & virus in the contaminated water can cause various health issues. They can damage the kidneys, immune and nervous systems, blood circulation and even retarding the physical and mental development in children. The high-end RO/UV/UF technology, incorporated in Elixer Mineral Water Plants, removes all contaminants, retains the essential minerals and brings the TDS, PH level to that of mineral water to give 100% pure drinking water. And what’s more at the most affordable rate too, just One Rupee for One Liter .

Get more products information in next edition of Industrial Outlook
Email: mktg@skfeleixer.in / mktg@skfgrainstech.com

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Process Industry

SKF Group of companies, continuously working towards MAKE IN INDIA initiative and achieving a milestone YOY

by Industrial Outlook
written by Industrial Outlook

Mr. G. Ramakrishna Achar 
Managing Director | SKF Elixer India Pvt. Ltd

The dynamic and visionary Managing Director of SKF Group of companies, Mr. G. Ramakrishna Achar, hailing from Gangolli, Kundapur, in Karnataka, is the inspiration behind the phenomenal growth of the group. In 1987, Mr. Achar founded SKF Industries, in a hired shed, in Moodbidri, with an initial capital of INR. 25,000. 

Beginning with the manufacturing of Rice Cookers, the company grew exponentially, thanks to Mr. Achar’s entrepreneurship and vision, and today the company has an annual turnover of INR. 2000 million and an infrastructure of INR. 500 million with a highly experienced, dedicated and a professional team of technical, administrative and marketing personnel. The company has had the distinction of designing and manufacturing for the first time in India, a 1000 ton/day capacity Paddy Boiler- cum-Drier plant. SKF has more than 4000 installations all over India and Abroad, the latest being in Costa Rica. It is a remarkable achievement, considering Mr. Achar has done all of it from a remote village of Bannadka, near Moodbidri, Mangalore. This is truly a MAKE IN INDIA initiative years back. Innovation, Flexibility and Complete Solutions have ensured continuous improvements in quality and performances of the equipment. 

SKF ELIXER – ORYZA

This plant enables the miller to produce any type of rice, as per the market demands at the most economical rate. Steamed rice is in great demand in the market today because of fast food in vogue globally. SKF ORYZA Classic plant is built wholly of stainless steel, and produces the most hygienic, world class steamed rice. 

Majorly five types of rice are processed in India – Raw rice, Steamed rice, Half boiled rice, Basmati rice and Full – boiled (Sella) rice. SKF Oryza can process and produce all these five types of rice of the best quality as it incorporates total PLC automation. Oryza is highly efficient and guarantees the best quality of output and reduces the brokens in further processing, thereby increasing the yield of head rice. The return on investment could be as low as 6 months.

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Process Industry

Our commitment for quality and best service praxis, making us most loving boiler manufacturing in India.

by Industrial Outlook
written by Industrial Outlook
Mr B Nagarajan Managing Director

ASHWINI ENGINEERING INDUSTRIES is India’s leading boiler manufacturing company, which deals with different kinds of boilers and its components. It was established by four technocrats, who had served in the design department of a renowned boiler manufacturing company. They are the senior most (Active) in the Boiler Industry today.

Manufacturing Facility

This is the group company of ARK Engineering & Power Consultants (P) Ltd., which is dealing with power plant consultancy and Boiler detailed engineering services. Hence, ASHWINI has a strong design base. With expertise in fields like performance engineering, commissioning, performance testing and troubleshooting. The company not only aims at selling products to its clients but also to go out of its way and provide any technical assistance they might require at any point of time. Executed 125+ Power plant consultancy projects and successfully commissioned for the Multinational / Corporates, which includes SAINT GOBAIN GYPRO LTD, JINDAL SAW GROUP, JAIN IRRIGATION, LALBHAI GROUP, VEDANTA GROUP, GE-TRIVENI, CLARIANT, APOLLO TYRES, ACC, etc

Ashwini has a very high level of technical knowledge, manufacturing, and management capabilities to supply, timely delivery, best quality, and reliable products to cater to the customers’ needs. Ashwini purchased the main manufacturing unit of Veesons Energy System Pvt. Ltd. which had supplied 5000+ boilers in India. Moreover, leading technical experts are deployed in different departments such as Proposal & Estimation, Performance Engineering, Detailed Engineering, Commissioning, Performance Testing, and Troubleshooting. It has its own design team having a group of designers who are senior most (Active) in the Boiler Industry today. Furthermore, the Erection and After Sales department is headed by an official who has vast experience in this field.

The highest level of financial discipline is being maintained without any fund or non-fund based liability with any bank as on today. Our bankers are Indian Overseas Bank, Cantonment, Tiruchirappalli. Our finances are sound to execute different projects.

ASHWINI is located in Trichy, which is one of the biggest fabrication hubs in India due to the presence of BHEL (High-Pressure Boiler Manufacturing Unit) and its ancillaries. Hence the skill sets such as high-quality IBR Welders, Fitters, etc., are available in abundant and can be easily accessible to manufacture high-quality boilers.

Above all, our customers are our pride who reposed their faith in us, and we have admirably discharged our responsibility most honestly and professionally, earning the goodwill of all the clients.

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Process Industry

The opportunities for new business in the food process industry; and SS Milling helping in their business

by Industrial Outlook
written by Industrial Outlook
Mr. Dhruv Khandelwal
Managing Director – SS Milling & Engineering Co.
Milling Technologist – Swiss School of Milling, Switzerland
Msc International Business and Management, University of Manchester, UK

There are a lot of business opportunities present in the food processing industry of india. The food habits of the indian people have changed drastically in the last few years.
From the traditional wheat & rice Milling to oats, maize, quinoa milling etc, the whole dynamic has changed.  The demand for grains other than wheat and rice has increased a lot over the last few years.
We feel there is a major untouched area in our industry which needs to be exploited.

We as technical consultants of this industry for over 36 years, can design the plants of these various grains according to the clients market demand in a flexible way so that any fluctuation in the market doesn’t affect the mill production.
We provide high technology machinery which helps our clients achieve the maximum results without any hindrance. With an extensive knowledge & experience of the Milling Industry we provide solutions for the new upcoming multigrain value addition sector. 

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Process Industry

Food Industry one of the emerging market in India

by Industrial Outlook
written by Industrial Outlook

Food is very essential and considered to be an inherent factor and strong backbone of any countries economic growth. In India, the food industry is estimated to be USD 543 Bn in FY 2020 at CAGR growth of 14.6%. 

The diversity in Indian culture and changing needs of customers create further complexity in the food production and distribution system in the country. A number of changes are shaping the Indian food landscape with disruptions in business models of companies, in terms Current State of Food Ecosystem Cultivation Agri- logistics Communication Product and Service Flow Future State of Food Ecosystem Food Service Food Retail of their interaction with consumers and responsiveness to their needs. While packaged food is the fastest growing segment posting a double digit growth yoy, currently only ~10% of agri-produce is being processed in India.

Food Ecosystem in India

India is the 7th largest country  with an area of 31.7mn square kms, the 2nd most populous country and the 2nd largest producer of food in the world. The task of ensuring that the food produced reaches 1.2 Bn Indians is complex and involves a number of stakeholders. About 210mn farmers and agriculture labourers cultivate various crops which they harvest and sell in Agriculture Produce Market Committee (APMC) markets or ‘mandis’. There are 2,477 APMCs and 4,843 sub- market yards  regulated by the respective states in India. Multiple levels of value addition activities are undertaken on the agri-produce in a food processing plant, which in turn produces the packaged and processed food products. There were 38,608 registered food processing units in FY 15. Distribution in India involves serving a large fragmented base of kirana shops. There are 14,000 organized retail outlets concentrated largely in urban areas. Unorganized retail consists of 12-14mn  stores spread over 5,000 towns and 600,000 villages across India. The diversity in Indian culture and changing needs of customers creates further complexity in the food production and distribution system in the country.

Key Segments in the Food Value Chain

Key highlights of Food processing industry

  • The Processed food market is expected to grow to $543 bn by 2020 from $322 bn in 2016, at a CAGR of 14.6%
  • Food processing has an important role to play in linking Indian farmers to consumers in the domestic and international markets
  • The Ministry of Food Processing Industries (MoFPI) is making all efforts to encourage investments across the value chain
  • The industry engages approximately 1.77 million people in around 39,319 registered units with fixed capital of $29.2 bn and aggregate output of around $144.6 bn
  • The key sub-segments of the Food Processing industry in India are: Dairy, Fruits & Vegetables, Poultry & Meat processing, Fisheries, Food retail etc.
  • Egg production of around 88.1 billion during 2016-17 and total fish production in 2016-17 was 11.41 million tonnes
  • Food Retail market is majorly dominated by Food Grocery (growing at CAGR 25%) and Food Services (growing at CAGR 15%) segments

Food Producer

FDI Facts For Food Processing Industries.

  • $9 bn inflows from FDI in food processing industries during April 2000 – March 2019
  • $328 bn FDI equity inflows over April 2014 – March 2019
  • 22% Share in total FDI inflows

India’s food ecosystem offers huge opportunities for investments with stimulating growth in the food retail sector, favourable economic policies and attractive fiscal incentives. The Government of India through the Ministry of Food Processing Industries (MoFPI) is also taking all necessary steps to boost investments in the food processing industry. The government has sanctioned 42 Mega Food Parks (MFPs) to be set up in the country under the Mega Food Park Scheme. Currently, 17 Mega Food Parks have become functional.

By 2020, Indian Food and Retail market is projected to touch $828.92 bn, while the dairy industry is expected to double to $140 bn.

100% FDI in the food processing sector in India is permitted under the automatic route.

100% FDI in food processing is allowed through government approval route for trading, including through e-commerce in respect of food products manufactured or produced in India.

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Process Industry

Rapid industrialization, Increasing Demand for Heat Exchangers

by Industrial Outlook
written by Industrial Outlook

The demand for heat exchangers is anticipated to grow, owing to numerous factors such as increase in number of food industries, rise in demand for energy, surge in number of chemical industries, and others. Furthermore, there is a significant increase in CO2 emissions because of energy generation from coal. Due to which the government of India has aimed to reduce its dependence on coal and move toward a sustainable solution-generation of energy from nuclear power. Generation of the energy from nuclear power increases the adoption of heat exchangers. However, the rise in fouling problems have increased the maintenance cost for end-user industries, which is anticipated to hinder the market growth. On the contrary, the automobile industry is growing at a considerable pace, which is anticipated to create lucrative growth opportunities during the forecast period. Aluminum-based heat exchangers are mainly used in automotive applications as it offers advantages such as light weight, excellent corrosion resistance, high thermal conductivity, and others. 

Heat exchangers play an important role in the food industry, as they are used for the production of fruit pulp, food paste, juices, hazelnut pastes, yogurts, and others. Furthermore, many industries in India have adopted high-end energy-saving heat exchangers to mitigate the issue of their loss, owing to rise in the cost of energy, which significantly drives the growth of the market.

Heat Exchanger Market in India by Type. 

Shell & Tube segment is anticipated to grow at the fastest rate as well as gain a dominating share .

Key Highlights of the India Heat Exchangers Market:

● Based on type, the shell & tube segment is expected to gain dominant share 33.2% 

● Based on end-user industry, oil & gas is expected to experience rapid growth with a rate of 9.2% 

● Based on the material of construction, carbon steel heat exchangers are projected to grow at the highest CAGR of nearly 8.9%, in terms of revenue, during the forecast period. 

● A comprehensive analysis of the factors that drive and restrain the heat exchangers market growth is provided 

● An extensive analysis of various government policies provides insights that are expected to allow companies to strategically plan their business moves

● The qualitative data in this report aims at the market dynamics, India heat exchangers market trends, 

● The developments in the India heat exchanger industry are also studied 

● The quantitative data provides the India heat exchangers market size in terms of revenue

Heat Exchangers Production in India is Cheaper

Global Heat Exchangers Market Outlook 

Global heat exchanger market is expected to witness significant growth during the forecast period owing to increasing investments in various industries including marine, food process equipment, power generation, oil & gas, power generation and food & beverages. The Asia 

Pacific region is dominating the heat exchanger market, due to increasing investments in chemical industries and increasing power generation capacity in countries like China, Japan and India. Hence, the growth of manufacturing, chemical, and construction industries in Asia-Pacific is expected to dominate the market growth during the forecast period. According to the World Nuclear Performance Report 2018, published by the World Nuclear Association, four reactor construction projects have been commissioned by 2017 with a capacity of 4298 MW from countries such as India, Bangladesh and South Korea, which signifies a huge contribution from Asia-Pacific countries which drives the market demand for the heat exchange market. Hence, the global heat exchanger market generates a significant demand across verticals of industries for application of heat exchanger which brings the market growth during the forecast till 2023.

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