BiOWiSH™ Aqua Benefits• Reducessludgeproductionand
handling
• Increasesplantcapacitybyreducingcontacttime(capitalavoidance)
• Eliminatesodorousemissions
• Deliverssubstantialenergysavingsduetoreducedaeration
• Minimizesneedforchemicaladditives
• Stabilizesandimprovesplanttreatmentperformance
• Lowershydrogensulphide,ammoniaandnitratelevels
• Pre-treatsinfluentincollectionsystems
• 100%naturalandnon-toxic
Available Sizes• 100g/3.5oz
• 1kg/2.2lb
Industrial Waste Water Treatment
Case Study
Synthite Industries, India
Executive SummarySynthiteiswidelyacclaimedastheleaderintheSpiceOleoresinindustrywithover30%shareoftheglobalmarket.Thecompany’seffluenttreatmentplant(ETP)inKerala,Indiadealswithchallengingcircumstances:effluentvariessubstantiallyonadailyandoftenhourlybasisduetothewidevarietyofrawmaterialsprocessedinthefactory.
InMay2009,SynthiteandIWA/EnvironmentbeganacollaborativepilotprojecttoadoptBiOWiSH™asatechnologicalplatformtoimprovetheplant’seffectivenessintreatingeffluent.In110days,theprojectachievedthreeremarkableperformanceoutcomes:
1.Reducedaerationenergyconsumptionby30%;and
2.Completelyeliminatedtheuseofchemicalsforsettlingsolids;and
3.Renderedtheplanttotallysludge-free.
CollectivelytheseresultshavereducedtheannualoperatingcostoftheplantfromRs.1,343,000(US$28,600)toRs.717,000(US$15,270)–anannualcostreductionofalmost50%.
ThebenefitstoSynthiteextendbeyondsimpleeconomicmeasures:theplant’sperformancehasbeentotallystablesinceJune2009;finaleffluentisconsistentlybeatingthestandards;andoperatorinterventionhasbeencompletelyeliminated.
TheseresultsareaconsequenceofatransformationinthebiologyofSynthite’sETPprocess.TheplantnowreliesonBiOWiSH™andisnolongersolelydependentonbiomasstotreateffluent.
“In less than 3 months we achieved stability and chemical-free operation in our ETP. We’ve saved money on energy and
chemical costs, and no longer have solid waste. BiOWiSH™ is phenomenal. The results were simply beyond our expectations!”
– Mr. George Paul, Director, Synthite Industries
Biological Help for the Human Race™
Biological Help for the Human Race™
BackgroundLocatedatKolencheryinthestateofKerala,SouthIndia,Synthiteisamultimilliondollarenterpriseandthepreferredsupplier-partnertoleadingflavorhousesworldwide,withpresenceinEurope,AsiaandLatinAmerica.
ThecompanymanufacturesawidespectrumofSpiceProductsincludingOleoresins,EssentialOils,NaturalFoodColors,HealthIngredients,HerbExtracts,OrganicExtracts,FairTradeExtracts,FloralConcretes,AbsolutesandSpices–whole,groundandcrushed.
Synthite’sETPprocessesaround100KLofeffluentperday.Theplant’svisiblestateofgoodmaintenancereflectsSynthite’sattitudeofcaretowardstheenvironment.Eventhearchitectureisharmonizedwiththelandscape–thehillycontoursofthesitehavebeencleverlyusedtominimizelifts.
TheETPisdesignedtoprocesseffluentthroughfivestages:chemicalsettling,aerobictreatment,anaerobictreatment,finalaerobictreatmentandfiltration.Thetreatedeffluentisusedforirrigationonthefactory’sgrounds.
Anaerobic digestion is a bacterial process that is carried out in the absence of oxygen. The process can either be thermophilic, in which sludge is fermented in tanks at a temperature of 55°C, or mesophilic, at
a temperature of around 36°C. On the other hand, Aerobic digestion is a process that occurs in the presence of oxygen. Under aerobic conditions, bacteria consume organic matter and convert it
into carbon dioxide. The operating costs are usually much greater for aerobic digestion because of the energy used by the equipment needed to add oxygen to the process.
Biological Help for the Human Race™
The Issues
Energy Consumption
TheETPemploystheactivatedsludgetechnologytotreatSynthite’sproductioneffluent.LikeallactivatedsludgesystemsSynthite’sETPalsorequiredasubstantialenergyinputforaerationtosustainthemicrobialpopulationofthesystem.AnnualcostsforaerationenergypriortoimplementingBiOWiSH™amountedtoRs.7.88lakhs(US$16,780).
ETP Process Instability
Oleoresinsareproducedfromchilies,garlic,greentea,onions,rosemary,pepper,andahostofotherspices.Factoryproductionvariesfromdaytodayandoftenfromhourtohour.EffluentsreceivedattheETPvaryincolor,turbidityandpH–oftenseveraltimesinaday.
PriortoimplementingBiOWiSH™theETPoperatorshadtotrackpHvaluesonanhourlybasisandmakecorrespondingadjustmentstolimedosage.ThismanualanderrorproneprocesswasneededtocontrolpHwithinthenarrowrangethatoptimizedchemicalsettlingofsolids.AnylapseinpHmeasurementorlimedosagewouldimmediatelyimpactsettlingandgenerateveryundesirableeffectsonallofthedownstreamprocesses.
SynthitewasunderstandablyverykeentofindasystemthatwouldmanagethenutrientloaddespitesubstantialinfluentpHvariations.
Hazardous Waste
Theuseoflime,alumandpolyelectrolytechemicalsattheplanttransformedSynthite’ssludgefromapurelyorganicwastetoasubstancedesignatedasahazardouswaste.Insteadofbeingasubstancesuitableforuseasafertilizer,Synthite’ssludgewassubjecttoseveralonerousregulatorycontrolsandneededdiligentmanagementoversight.
The SolutionInearlyMay2009,IWA/Environment(theauthorizedBiOWiSHTechnologiesdistributorinIndia)approachedSynthite’smanagementwithaproposal:ReduceoperatingandenvironmentalcostsoftheETPbyimplementingtherevolutionaryBiOWiSH™technology.
IWA/Environmentproposedatwo-stageproject:(1)reduceaerationandcaptureenergysavingsand(2)eliminatechemicaluse.
“We wanted to eliminate the application of chemicals because that was a key source of plant instability. Anytime we got the pH wrong it would take days to recover from the spike in suspended solids.”
- Mr. B Shanavas, Engineering Manager, Synthite Industries.
Biological Help for the Human Race™
The Results
Aeration energy reduced by 30%
Shortlyaftertheimplementationbegantheprojectteamstartedtoprogressivelyreduceaeration.Onthe84thdayoftheimplementationtheplantwasoperatingitsaeratorsona30minuteon/30minuteoffcycletocaptureastunning50%reductioninaerationenergyconsumption.
Sincetheconclusionoftheproject,Synthitemanagementhasoptedtokeepaerationlevelsat70%oftheoriginalbaselinefigureastheyarecontinuingtomakechangestotheplant’sstandardoperatingprocedures.TheintentionofSynthitemanagementistoeventuallyrecoverthefull50%savingsthatwasachievedduringtheproject.
No more chemicals
Onthe90thdaydosageoflime,alumandpolyelectrolytewereturnedoff.Since10thAugust2009therehasbeennodosingofchemicalsandtheplant’sfinaloutputhasconsistentlyoutperformedtheregulatorystandardsforfinaldischarge.
No more sludge
BeforeimplementingBiOWiSH™theETPgenerated10m3ofsludgeeachday:4m3atchemicalsettlingand6m3ofbio-solids.Theplanttodaygenerateszerosludge.Sludgehasbeencompletelyeliminatedbytwomechanisms:thehighspeedactionofBiOWiSH™digested6m3andtheremaining4m3wastransferredtotheAnaerobicDigesterwhereitiscompletelyconsumed.
Measurable commercial benefits
Cost ElementBaseline Annual Cost Annual Cost Reduction
Rs. Lakhs US$ Thousand Rs. Lakhs US$ Thousand
AerationEnergy 7.88 16.78 2.36 5.03
Chemicals 4.95 10.54 4.95 10.54
SludgeHandling 0.60 1.28 0.60 1.28
BiOWiSH™Investment 0.00 0.00 (1.65) (3.51)
TOTAL 13.43 28.60 6.26 13.33
“Synthite’s leaders approved a pilot project when others in India were understandably reluctant to be pioneers with BiOWiSH™. Their willingness to experiment has delivered stellar results – unprecedented
stability, substantial recurring cost savings and a complete elimination of bio-solid sludge.” – Mr. Itty Varugis, IWA/Environment
Biological Help for the Human Race™
Key Success Factors
Ground Breaking Technology
Byaccelerateddigestionofwastethroughahigh-speedprocess,BiOWiSH™completelyalteredtheSynthiteplant’srelianceonbiomassfornutrientremoval.
Furthermore,sinceBiOWiSH™performedconsistentlyundervaryingeffluentpHlevelstherewasnofurtherneedforerror-pronemanualpHinterventions.
TheentireresultwasachievedwithoutanyalterationofSynthite’splantinfrastructure.BiOWiSH™istrulyabreakthroughtechnology:highlyflexibletoadapttoanyexistingplantinfrastructure,toleranttoawiderangeofoperatingconditionsandfundamentallytransformativeofatreatmentplant’sbiology.
Openness to Change
Synthite’sopennesstonewtreatmenttechnologyhasbeenakeyfactorinthesuccessoftheproject.LikemostETPs,theSynthiteplantreliedheavilyonbiomasstocompletethewastetreatmentprocess.PlantmanagementwaswillingtoshiftparadigmsandembracethenewBiOWiSH™technology.
Collaboration
TheBiOWiSH™implementationwasamanagedprocesswithtreatmentoutcomesateachstageoftheprocessdiligentlymonitoredonadailybasis.SynthiteandIWA/Environmentcollaboratedtoassessprogress,anticipateissuesandestablishcountermeasures.
IWA/EnvironmentprovidedtechnicalassistanceandadvicetoSynthiteplantmanagementallthroughouttheprojectwithfullsupportfromtheBiOWiSHTechnologiesheadofficeteam,ensuringproperdosingtechniquesandprecautionarymeasureswereinplaceaswellaspreparingplantpersonnelonwhattoexpectateverystageofthetrial.
“The BiOWiSH™ trial went smoothly and the results were remarkable. Superior product performance, the ability to work on varying pH levels, as well as a very good plan and support system provided
by IWA/Environment contributed to the success of the project.” – Mr. B Shanavas, Engineering Manager, Synthite Industries.
Biological Help for the Human Race™
The detailed implementation program
Day1:TheprojectteambeganimplementationofBiOWiSH™attheSynthiteETPon13thMay2009. BiOWiSH™ AquawasmixedintosolutionandmeteredintotheSecondaryCollectionTanktoachievethefollowingdosingrates:
Day1:20mg/l
Day2:10mg/l
Day3:10mg/l
Ongoing(daily):1mg/l
Day20:TheimplementationofBiOWiSH™radicallychangedthebiologyoftheETP.Inamerethreeweeks theplant’sbiologyhadbeenshiftedfromarelianceonbiomasstousingBiOWiSH™todigestnutrients.
Day32:Theplantconsistentlydemonstratedstablenutrientremoval.Internalmeasuresshowedtheidealoutcomeofprogressiveimprovementinateachstageoftheeffluenttreatmentprocess.Throughouttheplantandeveninthesludgedryingbeds,smallbubblesofgaswerevisible.ThisistypicalbehaviouroftheBiOWiSH™biologywhichconvertsasubstantialportionofwasteintofinalendcompoundsofcarbondioxide,nitrogengas,oxygenandwater.
Day 20 Day 27 Day 34
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
Oil & Grease
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Chem
ical Settling
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
Oil & Grease
‐
1,000
2,000
3,000
4,000
5,000
6,000
Equalization Tank
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters Before Treatment
BOD
COD
TSS
Oil & Grease
Day 1 Day 20
Biological Help for the Human Race™
Day38:Aerationdrivemotorswereswitchedofffor30minutesinevery4.5hourcycle.Theplant’soutputremainedunaffectedandstablenutrientremovalcurvesweresustained.Inthemeantime,itwasbusinessasusualattheshopfloorwithawidedailyvariationinproductioneffluent.
Day48:StoppedreturningsludgeatAerators1and2.Undernormalcircumstancesthisactionisanunthinkablelossofbiomassandeffluenttreatmentcapability.WithBiOWiSH™theplant’sperformanceremainedabsolutelystableandnutrientremovalcontinuedtoshowtheclassicformofprogressiveremovalthroughthedownstreamETPprocesses.
Day89:Totallyeliminatedbio-solidsludge.PartlybyBiOWiSH™digestingnutrienttoinertendproductsandpartlybytransferringtheresidualsludgetotheAnaerobicDigesterforcompleteconsumption.
Day90:Completelyeliminatedchemicalsettling:TheprojectteaminstalledaseconddosagedeviceattheEqualizationTankusingthesamedosagetableasthefirstphaseimplementation.
Day110:Completelyeliminatedallsludge.ThesludgedryingbedsatSynthitehavebeenidlesinceandthelandformerlyoccupiedbythebedshasbeenre-formattedforalternativeuse.
Sludge Volume
050
100150200250300350400450500
21.5.
09
28.5.
094.6
.09
11.6.
09
18.6.
09
25.6.
092.7
.099.7
.09
16.7.
09
23.7.
09
30.7.
096.8
.09
13.8.
09
20.8.
09
27.8.
093.9
.09
Aerator 1 DischargeAerator 2 DischargeSTP Aerator
Chemical SettlingStopped on Day 90
Day 34 Day 41 Day 48
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Chem
ical Settling
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Chem
ical Settling
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
‐
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Equalization Tank
Chem
ical Settling
Second
ary Co
llection Tank
Aerator 1
Aerator 2
Sewage Co
llection Tank
Anaerob
ic Filter
Aerator 4
Stagewise Parameters After Treatment
BOD
COD
TSS
Biological Help for the Human Race™
About BiOWiSH™ AquaTheresultofover18yearsofresearchanddevelopment,BiOWiSH™isapowerfulblendofbiocatalyststhatbreaksdowncomplexorganicmoleculestohelpeliminatewaste,reduceodors,improvesoilfertilityandenhancewaterquality,amongotheruses.100%naturalandnon-toxic,BiOWiSH™issafeforeverydayuseinawiderangeofconsumerandindustrialproducts.Ithasbeenproventosolveproblemsinenvironmentalmanagement(includingwastewater,solidwaste,soilandwaterremediationandindustrialemissions),aswellasagriculture.BiOWiSH™productsareusedextensivelyandavailableinAsia,Australia,Europe,NorthAmericaandLatinAmerica.
DevelopedspeciallyfortheWastewaterTreatmentindustry,BiOWiSH™ Aquaacceleratesthebiologicalremovalofnutrients,pathogens,suspendedsolidsandothercontaminantsfromwastewater.
Contact DetailsFormoreinformationonthiscasestudy,pleasecontact:
Deep Rekhi
IWA/EnvironmentChennai,IndiaP:+919840710027E:[email protected]
B. Shanavas
SynthiteIndustriesLtdKolencherry,IndiaP:+914843051295E:[email protected]
CSWT14MA11INT
Biological help for the human race
BiOWiSH™isaregisteredtrademarkofBiOWiSHTechnologiesInc.
www.biowishtech.com
