International Journal of New Technology and Research (IJNTR) ISSN:2454-4116, Volume-1, Issue-3, July 2015 Pages 46-49 Membrane Bioreactor Coupled with Sequential Batch Reactor: A Supportive Technology in Effluent Recycling Of API Manufacturing Industries Srinivasarao Gangavarapu, Uma Maheswara Rao Ganguru, Sunil Kulkarni, Narasimha MurthyBrahmandam, Srinivasa Anumula membrane separation technology and bio-organic Abstract— Membrane Bioreactor (MBR) combined with combination of a new wastewater treatment technology. By Sequential Batch Reactor (SBR) was operated for treatment of utilizing membrane, MBR separates the activated sludge wastewater generated in a medium scaleActive Pharmaceutical and other biological/Organic matter in wastewater[4]. MBR Ingredients (API) manufacturing unit. Parameters considered process is called as a hybrid system, as it works with to investigate the performance of pilot plant wereChemical Oxygen Demand (COD), Biological Oxygen Demand (BOD) and biological treatment in conjunction with separation. Total Suspended Solids (TSS). However, to support the Operation of MBR with combination of conventional investigation, effluent Total Dissolved Solid (TDS) was also activated sludge system produce high quality treated effluent, characterized. The studies indicated92.3 percent reduction in which can be potentially suitable for recycle [5]. MBR can be COD, 96.0 percent in BOD and 100 percent in TSS, and no operated at sludge concentrations up to 18000 - 19000 mg/l significant effect on TDS reduction was found.The effluents [6]. streams taken up for study were characterized, neutralized, equalized and fed in SBR, which is a fill and draw activated The technology of MBRcan be utilized in biochemical sludge process driven by micro biological mass. The SBR out engineering processes, where it can be employed as lets werereduced73.0, 79.9 and 76.3 percent by load in terms of suspended growth bioreactor (such as; fermentation, COD, BOD and TSS respectively. The SBR outlets were fed in bio-oxidation, nitrification and denitrification)and also for MBR, which is a membrane based reactor, where a further solid liquid separation [7].Lab operated MBR reduction of COD, BOD and TSS by72.0, 79.7 and 100 percent systemconsisting of up flow anaerobic sludge blanket reactor respectively was achieved. After successful pilot studies, it was found that the MBR combined with SBR can be operated shown approximately98% Chemical Oxygen Demand positively for wastewater treatment in API manufacturing (COD)removal and 100% in Total Suspended Solids (TSS) units, where effluent can be recycled after Reverse Osmosis removal inmunicipal wastewater [8].The principle behind (RO) polishing. MBR operation is almost same as activated sludge process, exceptingthat separation the water and sludge through Index Terms— API Unit, BOD, COD, MBR, Re-cycle, SBR, settlement, where the MBR uses the membrane whichis more Wastewater efficient and less in need of oxygen concentration in water [9]. Since past few years, due to several benefits, which I. INTRODUCTION includes excellent permeate quality, low sludge production, Increasing industrialization trend in the worldwide has small foot print, and flexibility in future expansion, raised in generation of industrial effluents inlarge quantities. submerged MBR processes have practiced in domestic and A large number of industrial sectors, and huge amount of municipal wastewater treatment [5] [10]. Application ofMBR production, have usually large changes in product mix, technology for industrial wastewater treatment has also added making difficulty in industrial wastewater treatment [1],[2]. attention because of the strength of theprocess, high organic MBR (Membrane bio-reactor), is an admirable modern loadings and very specific biorefractory. The technical wastewater treatment technology, having several benefits features of the reactor play an important role in solid over conventional activated sludge processes [3]. It is a separation and biomass selection [11]. However, the efficiency in the removalof the organic load determined by Srinivasarao Gangavarapu: Head, API Environment Head, Mylan the type of industrial process that has been employed. Laboratories Limited, Hyderabad, India. The Sequential Batch Reactor (SBR) is a fill and draw Uma Maheswara Rao Ganguru: Mylan Laboratories Limited, activated sludge process. The SBR consisting wastewater Hyderabad, India. Sunil Kulkarni: Head, EHS, APAC, Mylan Pharmaceuticals Private enters partially filled SBR, containing biomass, which is Limited, Global Hyderabad. acclimated to the waste water constituents during preceding Narasimha Murthy Brahmandam:,Head, Corporate Environment, cycles. Once the reactor is full, it behaves like Aurobindo pharmaceuticals, Hyderabad, India. Srinivasa Anumula: Manager, Mylan Laboratories Limited, Hyderabad, India. 46 www.ijntr.org Membrane Bioreactor coupled with Sequential Batch Reactor: A Supportive Technology in Effluent Recycling Of API Manufacturing Industries to Reverse Osmosis (RO) system for further polishing and the a conventional activated sludge system, but without rejects which collects from nozzles send to sludge tank for continuous influent or effluent flow. The aeration and mixing further decanting process. Removal of debris, garbage or any is discontinued after the biological reactions are complete. other solid substances from the influent was achieved by The biomass settles, and the treated supernatant is removed. passing through a fine screen or mesh (1 mm to 3 mm). The Excess biomass is wasted at any time during the cycle[12]. design operational conditions are 3000 to 5000 mg/l MLSS, Wastewater generates from API units is a complex mixture Viscosity less than 100 mPa･ sec and Dissolved oxygen of organic and inorganic substances. Non process wastewater concentration is 1 mg/l or more. is basically characterized by inorganic salts whereas the composition of process wastewater is a mixture of both organic and inorganic constituents including various solvents with varying proportions. However, the composition of wastewater varies from product to product and hence is dependent on the type of product mixture manufactured [1]. Over the above advantage,we made an attempt to operate pilot scale MBR system combined with SBRto treat a medium scale product mix contained API manufacturing industrial effluents. II. MATERIALS AND METHODS: A. Industrial Effluent In the selected API manufacturing unit, the effluents are collected and segregated as high and low concentration streams. If COD >15000 mg/l and TDS (Total dissolved solids)>8000 mg/l, it is considered as high concentration streams. If the effluent stream contains COD of < 15000 mg/l and TDS of <8000 mg/l, it is considered as low concentration streams.The segregation is based on the concentration limits Fig. 1 Schematic of pilot scale plant operated for treatment of of either of the parameters as high or low concentration API manufacturing industrial wastewater. streams. D. Treatment of API effluents Present study is focused on low strength concentration All effluents generated in API manufacturing units are streams. The characteristics of effluents used for treatment is collected in dedicated effluent collection tank before sending tabulated in Table 1. for equalizationwhere the effluents were neutralized (i.e., B. Sequenced Batch Reactor correcting the pH by adding caustic lye solution or HCl) and The SBR, contained 4 numbers of Roller Compacted equalized by blowing air from the bottom of the equalization Concrete (RCC) compartments with holding capacity of 200 tank. The range of pH maintained was 6.5 to 8.5. The KL (Kilo Liter) each, and the compartments are connected to neutralized and equalized effluent fed to SBR, which is a fill a RCC Decant tank with total holding capacity of 50 KL. The and draw activated sludge system, having the facility of SBR compartments are equipped with diffused aeration with equalization, aeration, and clarification. After feeding certain blowing capacity of 450 m3/hr. Supplementation of feed to quantity of effluent, aeration was started and no effluent were SBR done by the feed pump with maximum capacity of 15m3 allowed during this time. MLSS was maintained between per Hour. Followed by the Decant tank, a Lamella settler was 2000 to 4000 mg/l and DO levels are between 1 to 2 mg/l. provided where the overflow feed to the MBR and the sludge Turned off the aeration for at least 2 hours to allow the was collected to the Sludge collection Tank. All the effluents biomass to settle and drawn the clear supernatant from SBR before feeding to SBR were neutralized and equalized in to decant tank. The decant tank overflow collected in lamella dedicated tanks. Schematic of pilot plant is provided as clarifier where effluents clarified extremely. Clarifier outlet Fig.-1. was passed through MBR system where diffuser air of 1.25 to 1.87 m3/min required. Effluent flow quantity was followed as C. Membrane Bioreactor per system design. The entire system and individual units The MBR unit consists of a membrane case consisting performance was investigated with the help of physical, multiple membrane cartridges, which are connected to a chemical and biological parameters in various intervals (i.e., manifold with transparent tubes. The diffuser case has end of the day 1, 2, 3, 4, 5… and 30).Values were considered diffuser pipes inside. Membrane sheets are made from after stabilizing the system. chlorinated polyethylene with nominal pore size of 0.4µm.