Treated wastewater is a valuable resource. With advanced scientific techniques, highly treated wastewater can be reused for landscaping, floor washing, toilet flushing, and partially recycled for industrial processes. This reduces stress on natural water resources.
IONICS ENVIRONMENTAL SOLUTION has developed pre-fabricated packaged wastewater treatment plants suitable for sewage and grey water. Due to space limitations in existing buildings, compact and lightweight treatment solutions were engineered.
Innovative technologies such as high-rate clarifiers, coagulation-precipitation with special polymer, self-aerating Biowheel, enzyme-based bacterial augmentation, and bio-media clarification make the plants compact and energy-efficient.
Primary treatment removes suspended solids, floating debris, oil and grease, and equalizes flow. The system includes flocculation and solid clarification using chemical dosing (PAC, caustic soda, polyelectrolyte) and mechanical stirring.
Secondary treatment biologically removes dissolved organic and inorganic compounds. Using aerobic bacteria and attached growth processes, dissolved matter is converted into gases and biomass, which is later settled and removed.
Tertiary treatment removes remaining suspended and dissolved materials through sand and carbon filtration, delivering clean treated water for reuse.
Designed for dyeing and pulping industries, this system uses anaerobic digesters seeded with cattle slurry to establish bacterial growth. Biogas generated during this process can be reused for various applications.
In fluidized bed reactors, cells are immobilized on small particles that move with the fluid. These particles provide a large surface area for microbial attachment and enable efficient transfer of oxygen and nutrients. FBBR systems are ideal for high-viscosity substrates and continuous reaction processes involving gaseous substrates or products. The treatment process consists of four stages: Preliminary, Primary, Secondary, and Tertiary treatment.
In this stage, materials such as polyethenes, paper, fibers, vegetable waste, edible particles, grit, and oil/grease are removed using bar screening chambers and oil-trapping units located in the equalization sump.
Chemical treatment is performed to adjust the pH levels. Chemical dosing is optional and depends on the characteristics of the raw water received.
Removal of organic matter and suspended solids occurs through biological decomposition and clarification using advanced attached-growth biological technology. Biological action takes place in the aeration tank and tube settlers, after which clarified water flows to the chlorine contact tank.
Water from the chlorine dosing tank is allowed to settle in the buffer tank. From the buffer tank, it is pumped through sand and carbon filters for final polishing and treatment.
Treated wastewater is now recognized as a valuable resource. Highly treated wastewater, using advanced scientific techniques, can be reused for applications such as landscape irrigation, floor washing, toilet flushing, and partial process water recycling. This greatly reduces the burden on natural water resources.
Keeping this in view, Ionics Environmental Solution has developed pre-fabricated packaged wastewater treatment plants for sewage and grey water treatment. Space limitations in existing buildings created challenges, leading to the development of compact and lightweight treatment systems.
Innovative techniques such as high-rate clarifiers, coagulation-precipitation with special polymers, self-aerating biowheel attached-growth processes, bacterial augmentation with enzymes, and bio-media clarification have been introduced. These technologies reduce treatment volume, power consumption, and operational costs.
Detailed physical and chemical treatability studies were conducted using organic polymers and reduced inorganic chemicals for different types of sewage and grey water. Based on these studies, a complete treatment scheme has been designed.
Primary treatment aims to remove suspended solids (SS), floating debris, coarse particles, oil and grease, and to equalize flow for uniform loading. This reduces shock loading and decreases aeration power needs in later stages.
The system includes a flocculation chamber and a solid clarifier. Caustic soda, PAC, and polyelectrolyte are dosed uniformly and mixed using mechanical stirring. The solid clarifier uses parallel plate media and a hopper bottom to settle solids effectively.
Secondary treatment biologically removes dissolved organic and inorganic compounds through microorganisms, primarily aerobic bacteria. These microorganisms convert colloidal and dissolved organic matter into gases and biomass. Since the biomass has higher density than water, it settles by gravity.
This process is achieved through an attached-growth system using a mechanical bio-processor. The aerobic condition is maintained by rotating plastic media driven by a geared motor (2.5–3.5 rpm).
The programmed death cell chamber includes floating mesh media for attached growth, with a hopper bottom. In the disinfection chamber, PAC and chlorine are added for precipitation and disinfection, mixed using a mechanical stirrer.
Tertiary treatment removes remaining suspended and dissolved impurities. Water from the disinfection chamber flows to the intermediate tank and is then pumped through sand and carbon filters. The filtered water is collected in the treated water sump.
Ionics provides integrated anaerobic and aerobic treatment systems for wastewater from dyeing and pulping industries. Anaerobic digesters require time for bacterial populations to establish, usually achieved by “seeding” using sewage sludge or cattle slurry.
The digester is filled with cattle slurry, and perforated PVC pipes ensure uniform flow of wastewater. A baffle prevents solid particles from rising, while a horizontal launder collects overflow for the aerobic stage. Biogas generated in this stage is collected and used for various applications.
This treatment plant uses combined biological processes supported by specific bacterial cultures and required chemicals for decolorization. The treated water meets all Pollution Control Board standards.
The Membrane Bio Reactor (MBR) process consists of a suspended growth biological reactor integrated with an ultrafiltration membrane system using hollow fiber membranes. The ultrafiltration system replaces the solids separation functions of secondary clarifiers and sand filters found in conventional activated sludge systems.
Ultrafiltration membranes are immersed in an aeration tank in direct contact with the mixed liquor. A permeate pump creates a vacuum that draws treated water through the hollow fiber membranes. The permeate is then directed to disinfection or discharge facilities.
Intermittent airflow is introduced at the bottom of the membrane module to create turbulence. This scouring action cleans the external membrane surfaces by removing accumulated solids.
Ionics Membrane Bio Reactor technology overcomes the limitations of conventional activated sludge processes, particularly poor sludge settling. MBR enables much higher mixed liquor suspended solids (MLSS) levels, typically between 8,000 and 10,000 mg/L, far above the limits of traditional systems.
Higher biomass concentrations allow highly effective removal of both soluble and particulate biodegradable material. The Ionics MBR system integrates aeration, secondary clarification, and filtration into a single unit, producing high-quality effluent, simplifying operations, and significantly reducing space requirements.