Sludge in pharma aeration tank digested & activated by MiCroBial Aqua

Background –

Smruthi Organics is one the famous pharmaceutical company manufacturing active pharmaceutical ingradients located in Solpaur MIDC, Maharashtra.The company follows a proactive approach to Environmental compliance and boast of a zero discharge ETP in our main manufacturing facility. The company has a dedicated team to take actively manage Environmental, Health & Safety policies to assure excellence in addition to compliance.

Objectives –   

Objectives of validation program was listed given below,
1) Develop biological activity in aeration tank 1st and 2nd.
2) Reduce sludge quantity existing aeration tank 1st which was not working existingly.
3) Develop MLSS in aeration tank 1st & 2nd with nitrification and denitrification process.
4) Develop biomass in aeration tank and activate biological process

Before Biological Treatment –

As per the first meeting observation before starting biological treatment, earlier scenario was given below,
1) No biomass and biological activity present in aeration tank 1st & 2nd
2) Sludge was floating on the surface of aeration tank 1st & 2nd
3) About 40% of sludge was found in aeration tank along with bad odor and organic matter which was observed dead, no aeration and          no biological activity
4) As observed, there was no MLSS, Nitrification and Denitrification process in aeration tank and clarifier respectively

Implementation Protocol – 

• On first day effluent from collection tank of optimum PH was taken into aeration tank 1st to fill the aeration tank and started aeration tank continuously for get sufficient DO in aeration tank.
• PH & DO of aeration tank was monitored regularly and adjusted both parameters to its optimum PH of 7-7.5 & dissolved oxygen 1-2 mg/l, biological treatment started when optimum conditions received.
• Daily flow of effluent was adjusted to specific flow so that biological process wont have shock loading of organic matter.
• The activation tank was filled with 100 liters of fresh water and mixed with 800 gm of MiCroBial Aqua and kept it for 24 hrs.
• Aeration was provided in activation tank to provide oxygen. After activation, dosing started into inlet point of aeration tank 1st.
• Dosing Tank of 100 liter capacity used during activation of MiCroBial Aqua product. 800 gm of product was mixed with 90-100 liter of fresh water and kept it for 24 hrs activation.
• Two tank were used to activate the product. One tank was used for activation of product and second tank was used to dose activated solution directly into inlet point of aeration tank.
• Both, activation and dosing tank were washed regularly during application of MiCroBial Aqua product.
• Additional aeration was provided to tank to activate the microbes along with optimum temperature

Optimum Conditions –

We had provided optimum condition to the aeration tank that will help to bacteria to survive and work efficiently so that there will be good reduction percentage in organic matter and pollutants. Following were the optimum conditions that we provided.

DO – 2-3 mg/l in aeration tank 1 and 2.
PH – In between 7-7.6.
HRT – min 24 hrs 
COD: BOD ratio – 2:1.
MLSS – There was no MLSS in aeration tank.
Aeration was provided 24 hrs to provide O2 to the microbes for aerobic digestion.

Results –

After about 8 weeks of addition of MiCroBial Aqua product into aeration tank, implementation team observed significant improvement in biomass ( sludge volume) and water quality in aeration tank. Improvement in aeration tank after MiCroBial Technologies treatment were listed below,
1) We observed good sludge reduction in aeration tank
2) Thick layer of sludge floating on surface of aeration tank was reduced to very good extend and converted to thin layer of sludge that indicated sludge quantity was reduced by biological mechanism.
3) Initially color of effluent was dark red wine color which was changed to brownish green color & ultimately to brownish black.
4) There was good development of MLSS in aeration tank,MLSS testing was done in lab and it was found as per below

     a) MLSS in aeration tank – 3700 mg/l
     b) MLSS in aeration tank – 2200 mg/l

Optimum concentration of MLSS in aeration tank should be 3000-4000 mg/l. so we were maintaining it thru return activated sludge from clarifier 1st and 2nd. Good sludge settling was observed in clarifier, settling sludge was increased due good biomass development.

 

Conclusion –

The result of validation program demonstrate the effectiveness of MiCroBial Aqua in degradation of sludge in aeration tank. MiCroBial Aqua microbes were able to degrade the sludge and converting it to the biomass, liquifying the dead organic matter. MiCroBial Aqua helps the system to activate the aeration tank and generate biomass. Currently aeration tank is fully activated and having good biological activity helping in reducing different parameters and improving water quality.