article on effluent treatment in bulk drug industry

Vol. 3 (3) Jul – Sep2012 www.ijrpbsonline.com 1095

International Journal of Research in Pharmaceutical and Biomedical Sciences ISSN: 2229-3701

___________________________________________Research Article

Study on treatment process of effluent in Bulk drug industry

NV. Srikanth Vuppala1, Ch. Suneetha2 and V. Saritha3

1Basic Science Department, Aditya Engineering College, Kakinada, Andhra Pradesh, India. 2Department of Environmental Sciences, Acharya Nagarjuna University, Guntur, Andhra Pradesh, India. 3Department of Environmental Studies, GITAM University, Visakhapatnam, Andhra Pradesh, India. _____________________________________________________________________________________ ABSTRACT Drug industry is one of the major industries causing water pollution. In India, Drug industry generates about Gallons of waste water processed depending upon the process employed and product manufactured. Considering the increased demand for Drugs, the Drug based industries in India is expected to grow rapidly and have the waste generation and related environmental problems are also assumed increased importance. Poorly treated waste water with high levels of pollutants caused by poor design, operation or treatment systems creates major environmental problems when discharged to surface water or land. Considering the above stated implications an attempt has been made in the present project to evaluate one of the WWTP for Drug industry. The waste water is treated in two units based on characteristics namely LTDS (Unit-I), it is a common ETP process and HTDS (Unit-II) is Multiple evaporating system (MEE). Samples were collected from six points; Raw effluent [P-1], Oil and grease trap [P-2], Equalization tank [P-3], Aeration tank 1 [P-4], Aeration tank 2 [P-5] and Secondary clarifier [P-6] to evaluate the performance of WWTP. Parameters analyzed for evaluation of performance of WWTP are COD, BOD5 at 20° C, TSS, TDS, oil and grease, Chloride and Alkalinity. Mass balance of COD, TSS and TDS was performed to find the fate of pollutants in WWTP. Parameters like pH and oil & grease were used to access the suitability of secondary effluent for reuse in irrigation. The COD, BOD5 at 20° C and TSS removal efficiency of WWTP were 96%, 95%and 94% respectively, which are in acceptable range for Disposal in to marine. INTRODUCTION In view of high cost of conventional wastewater treatment systems there is an increasing need to develop low cost methods of treating wastewater particularly that of municipal and industrial origin. Rapid industrialization has resulted in the rise of pollution. To counter the above shortcoming and to preserve the high quality of the environment new concept so called “Cleaner Production” for waste minimization is being introduced, technology designed to prevent waste emission at the source of generation itself (Uwadiae et al 2011). Developing low cost technology for wastewater treatment offers an alternative and has been found to be most effective for treatment of domestic and industrial wastewater, particularly for those situated in the tropical and subtropical regions (NgMiranda et al., 1989; Puskas et al., 1991; El-Gohary et al., 1995; Rosen et al., 1998). Technologically because of the simplicity of waste stabilization ponds even affluent nations, which can afford the luxury of expensive wastewater

treatment, are planning to use more and more low cost treatment technologies (Khan and Ahmad, 1992; Junico and Shelef, 1994). Environmental degradation is an escalating problem owing to the continual expansion of industrial production and high-levels of consumption. A renewed dedication to a proven strategy to resolve this problem is needed. Cleaner Production is one such strategy, which can address this problem. It is a preventive environmental management strategy, which promotes eliminating waste before it is created to systematically reduce overall pollution generation, and improve efficiencies of resources use. (Hashmi Imran 2005). Wastewater pollution is the main issue of this sector. In pharmaceutical industries wastewater is mainly generated through the washing activities of the equipment. Though the wastewater discharged is small in volume, is highly polluted because of presence of substantial amounts of organic pollutants (Overcash, 1986). Solid waste usually comprises of



expired or rejected medicines, spent solvents, packaging material and damaged bottles. Level of wastewater pollution varies from industry to industry depending on the type of process and the size of the industry (Garcia et al., 1995). Hence Effluent Treatment Plants or ETPs are used by leading companies in the pharmaceutical and chemical industry to purify water and remove any toxic and noneffluent-treatment-plant toxic materials or chemicals from it. These plants are used by all companies for environment protection. Hetero Drugs Ltd…, established in April 1993 and its new branch established in 2004 at surveyNo.150/2, N. Narasapuram (Vill) , Nakkapally ( Mandal), Visakhapatnam ( Dist) – 531081,A.P.India, Hetero labs is involved in the manufacture of a range organic intermediates, active pharmaceutical intergradient’s ( APIS) and drug products .Hetero labs has chosen to walk the path of discovery and innovation in health sciences .the company is vertically integrated with a presence across the pharmaceutical value chain, producing and delivering safe, innovative and highly quality finished dosage forms, active pharmaceutical ingredients and biotechnology products, which are famous across the globe. It had the two decades of experience in producing safe pharmaceutical drugs and it is moving successfully in achieving its core purpose” to help people lead healthier lives. The major researches of the company include the areas study concentrated on latest features and the methods followed in building a health environment. The objective of this work is to Evaluation of pollution parameters of wastewater from drug based industry and check whether the treatment units are working with designed efficiency or not. Within this view, the experimental work has been designed and is presented here with. METHODOLOGY Effluent Treatment Processes in Hetero Drugs Waste water treatment aims at the removal of unwanted components in waste waters in order to provide safe discharge into the environment. This can be achieved by using physical, chemical and biological means, either alone or in combination. A treatment plant is like an assembly in a factory where the various steps in purification are arranged in such a sequence that the quality of the output of one step is acceptable in the next step. Physical treatment methods such as screening, sedimentation, and skimming remove floating objects, grit, oil and grease. Chemical treatment methods such as precipitation, pH adjustment, coagulation, oxidation, and reduction, remove toxic materials and colloidal impurities. Finally, dissolved organics are removed by biological

treatment methods. Tertiary treatment methods are used for further purification and for reuse of treated wastewater for various purposes. In this drug industry the treatment of waste water is done by two methods based on the characteristics of raw effluent from processing units, they are LTDS (Low Total dissolved solids) and HTDS (High Total Dissolved solids). The LTDS treatment is done by common effluent treatment process in three stages i.e., primary, secondary and tertiary treatments. (UNIT-I) The HTDS treatment is done by Multiple Evaporator effect. In this treatment of process the effluent comes from the processing units is tend to sent in to multiple evaporating effect. The treatment is done in particular stages, consists of Screening, Grit, oil & Grease chamber, Equalization cum Neutralization Tank, Flash Mixer, Flocculator, Aeration Tank, MEE Feed Tank, Stripper column and Evaporators.( UNIT-II). The effluent is characterized by evaluation of concentrations of TSS, PH, and conductivity before sending in to treatment process, based on the results if the TSS is less than 15,000 – mg/L, considered as LTDS and if the effluent TSS is greater than15, 000 mg/L considered as HTDS. Then the inlet of waste water is opened and sends to the required process Unit-I/ unit-II. For HTDS the important parameters to be considered are PH, TDS, TSS, COD, and BOD. The important parameters to be considered for LTDS are DO, MLSS, BOD, SVI (Sludge Volume Index). The waste water which is treated and stored in Effluent Treatment Tank may send to RO plant for further treatment , this water is used for irrigation, cleaning purposes, etc., else send to disposal in to marine. Monitoring of WWTP and its performance evaluation Samples were collected from WWTP at different sampling points of WWTP and characterize for parameters BOD, COD, pH, TSS, TDS, Alkalinity, Oil & grease etc. Overview of WWTP and location of sampling points is given in Section Sampling procedures The reliability of the results of analysis of waste water samples depends up on the proper collection of a true representative sample from a large volume of waste water. The sample after collection was transported to the laboratory in a preserved condition. So that it will represent fairly and accurately conditions when the sample was collected. Sampling Schedule and frequency Grab samples were collected for every three days in a week from WWTP. Six sets of samples comprising of



Raw effluent [P-1] Oil and grease trap [P-2] Equalization tank [P-3] Aeration tank 1 [P-4] Aeration tank 2 [P-5] Secondary Clarifier [P-6] (Figures 1 – 6)

Were collected and analyzed for the parameters shown in Table. Samples for BOD, COD, Chlorides and Solids etc were analyzed in accordance with the procedure laid down in Standard Methods for the Examination of Water and Wastewater (APHA 1996)

Instruments used for measurement of different

parameters S. No

PARAMETERS MEASUREMENTS

1. pH pH meter 2. BOD

Bio-Chemical oxygen Demand

Titrimetric Method

3. TCOD (Total Chemical Oxygen Demand)

Closed reflux method

4. Chlorides Argentometric Method 5. Total Solids

Total Dissolved Solids Total Suspended Solids

Drying Oven Drying Oven Drying Oven

6. Alkalinity Titrimetric Method 7. Acidity Titrimetric Method 8. Oil & grease Partition – Gravimetric

Method

RESULTS AND DISCUSSION Samples were collected from six points. Sampling points are Raw effluent [P-1], Oil & grease Trap [P-2], Equalization tank [P-3], Aeration Tank 1 [P-4], Aeration Tank 2 [P-5] & Secondary Clarifier [P-6] to evaluate the performance of WWTP.

Effluent characteristics The physio-chemical characterization of effluent from equalization tank is given in Table - 1. The key pollutants in the wastewater from pharmaceutical based drug industry are organic compounds and suspended solids and biogeneous elements. Biodegradability may be estimated on the basis of ratio between BOD5 & COD. BOD5: COD ratio obtained from the literature data In the present case BOD5: COD [691/1300] was found to be 0.53, which indicate that most of the organic compounds in the wastewater from pharmaceutical based drug industry should that are easily biodegradable. Suspended solids in wastewater from WWTP was found to be 687 mg/L. Suspended solids in wastewater from pharmaceutical based drug industry originates from coagulated effluent of chemicals from drug processing units.

Table 1: Characterization of effluent from Equalization Tank of Drug based Industry

S. No.

Parameters Concentration

1 pH 6.8 2 BOD5 at 20º C [mg/L] 620 3 TCOD [mg O2/L] 1290 4 TS [mg of TS/L] 1956 5 TSS [mg of TSS/L] 686.7 6 TDS [mg of TDS/L] 1237 7 Chloride [mg Cl-/L] 108 8 Alkalinity [mg

CaCO3/L] 460

9 Oil & grease [mg/L] 16

Standards for Waste Water Quality

#These standards shall be applicable for industries, operations or processes other than those industries. Operations or process for which standards have been specified in Schedule of the Environment Protection Rules 1989.

S. No. Parameters Collection site Frequency Standards Inlet Standards Outlet 1 pH Inlet & outlet Daily 9.5-11.0 6.5-8.5 2 BOD mg/l Inlet & outlet Daily 1500-2000 100 max 3 COD mg/l Inlet & outlet Daily 4000-5000 250max 4 TDS mg/l Inlet & outlet Daily 2000-3000 2100 max 5 TSS mg/l Inlet & outlet Daily 1000-1500 100 max 6. Suspended solids Inlet & outlet Daily 600 100 max 7. chlorides Inlet & outlet Daily 250 1000 max 8. Alkalinity Inlet & outlet Daily 200 600 max 9. Oil & Grease Inlet & outlet Daily 60-80ppm 10max



WWTP & ASP Performance Wastewater from pharmaceutical based drug industry was treated by Activated Sludge Process (ASP). Sequence of operations is explained in methodology. The performance of WWTP is evaluated by parameters TSS, TDS, COD, BOD, Oil & grease etc. The data given in Table: 1 – 9.

pH The use of acid, alkali, cleansers in the pharmaceutical based drug industry typically results in highly variable wastewater pH values. Literature data indicated that pH value ranged between 6.2-8.2 with an average of 6.56 (P-1) - 8.04 (P-6). The pH value is increased from acidic to base. The present pH is quite favorable for the ASP process

Sampling points

Dec-24th Dec-27th Dec-30th

Jan-3rd Jan-7th Jan-10th

Jan-13th Jan-16th

Mean S.D

P-1

6.8 6.2 6.9 6.5 6.5 6.7 6.6 6.3 6.56 0.24

P-2 6.9 6.5 7 6.7 7.1

6.8 7.1 6.3 6.80 0.29

P-3 7.1 7.3 7.2 7.1 7.5 6.8

7.5 7.1 7.20 0.23

P-4 7.8 7.9 8.1 7.5 7.8

7.5 7.9 7.8 7.79 0.20

P-5 7.8 7.9 8.2 7.8

8 7.7 7.9 7.8 7.89 0.16

P-6 7.9 8

8.2 8 8.1 8.2 8 7.9 8.04 0.12

BOD Data presented in Table – 2 shows variation of BOD5 at different sampling points. BOD5 in raw effluent was found to be average 690.25 and after final

treatment in secondary clarifier it is found that the BOD value is 34.25 (mg/L) gives consolidated information in the characteristics of six sampling locations of WWTP.

Table 2: BOD5 at 20°C (mg/L)

Sampling points

Dec-24th Dec-29th Dec- 3rd Jan-8th Jan-13th Jan- 18th Jan-23rd Jan-28th Mean S.D

P-1 704 698 617 681 694 693 727 708 691 32.49 P-2 615 647 598 635 678 587 591 637 624 31.51 P-3 605 605 560 590 598 565 580 621.6 591 21.16 P-4 340 210 212 230 205 200 190 200 224 48.55 P-5 210 199 185 174 198 168 170 170 184 16.24 P-6 25 32 48 28 27.5 41 29 43.5 34 8.64

TCOD Data presented in Table – 3 shows the monthly variation of TCOD at different sampling points.

TCOD in the raw effluent was found to be 1304.38 mg/L (average), which is reduced to 43.49 mg/L (average value) after secondary clarifier.

Table 3: TCOD (mg/L)

Sampling point Dec-24th

Dec-27th

Dec-30th Jan-3rd Jan-7th Jan-10th Jan-13th Jan-16th Mean S.D

P-1 1277 1310 1297 1318 1305 1278 1317 1333

1304 19.62

P-2 1246 1287 1260 1244 1270 1267 1274 1269

1265 14.32

P-3 1220 1188 `1190 1211 1145 1045 1202 1223

1178 59.13

P-4 613 642 525 530 610 690 649 650

614 58.64

P-5 490 654 518 517 534 528 546 518

538 49.54

P-6 41 44.7 40 41.7 47 51 43 39.5

44 3.93



Total solids Data presented in Table – 4 shows the monthly variation of Total solids at different sampling points.

Total solids in the raw effluent was found to be 3647 mg/L (average P-1), which is reduced to 1125 mg/L (average value) after secondary clarifier.

Table 4: Total solids (mg/L)

Sampling points Dec-24th

Dec-27th

Dec-30th

Jan-3rd Jan-7th Jan-10th

Jan-13th

Jan-16th

Mean S.D

P-1 3740 3510 3746 3640 3548 3576 3752 3670

3648 95.36

P-2 3280 3440 3600 3450 3466 3310 3666 3650

3483 146.11

P-3 1980 1980 1960 2180 1990 2079 2060 2037

2033 72.96

P-4 1880 1700 1850 2120 1990 1950 1960 1950

1925 121.30

P-5 1780 1675 1856 1870 1795 1798 1850 1870

1812 65.88

P-6 1080 1240 1120 1056 990 1276 1100 1140

1125 94.05

TDS Data presented in Table – 5 shows the monthly variation of Total Dissolved solids at different sampling points. Total solids in the raw effluent was

found to be 1615 mg/L (average-P1), which is reduced to 974 mg/L(average value) after secondary clarifier.

Table 5: TDS (mg/L)

Sampling points Dec-24th Dec-27th Dec-30th Jan-3rd Jan-4th Jan-10th Jan-13th Jan-16th Mean S.D P-1 1690 1590 1530 1690 1668 1656 1578 1519

1615 69.87

P-2 1247 1150 1250 1310 1290 1199 1180 1266

1237 55.43

P-3 1038 1060 1190 1120 1222 1126 1156 1232

1143 70.98

P-4 1055 1023 1060 1070 1212 1105 1121 1150

1099 60.90

P-5 990 1002 1010 1018 1188 1110 1188 1100

1076 82.30

P-6 986 990 998 986 990 975 890 980

974 34.78

Total Suspended Solids Data presented in Table – 6 shows the variation in TSS. TSS (2249 mg/L) in raw effluent was reduced to 52.75 mg/L after entrapment in secondary clarifier. Gradual decrease in TSS was observed in all tanks. Recycling of sludge and oxidation of substrate are the primary factors contributing to TSS in aeration tank.

Figure 4.6 represent concentration of solids at various sampling points. In the present case, no primary treatment is provided, so whatever removal is there i.e. because of secondary clarifier. A certain fall of concentration of TSS at sampling points P-4 & P-5 was observed which is due to oxidation of substrate and production of biomass.

Table 6: Total Suspended Solids (mg/L) Sampling

points Dec-24th Dec-27th Dec-30th Jan-3rd Jan-7th Jan-10th Jan-

13th Jan-16th Mean S.D

P-1 2050 1966 2436 2180 2350 2280 2272 2460 2249 175.51 P-2 2010 1940 2400 2012 2299 2100 2005 2420 2148 194.14 P-3 735 675 645 700 705 670 683 710 691 27.90 P-4 650 635 610 667 654 540 546 630 579 101.92 P-5 210 240 310 280 298 286 243 246 264 34.37 P-6 48 54 62 42 70 59 42 45 52 10.26



Chlorides Table – 7 represent the concentration of chlorides at different sampling points. The concentration of alkalinity in raw effluent was 141 mg/L ( average P-

1), as the effluent treated with chemical treatment unit the concentration reduced to 112mg/L(P-$). At the end of the treatment unit concentration reduced to72mg/L. (P-6)

Table 7: Chlorides (mg/L)

Sampling points

Dec-24th Dec-27th Dec-30th Jan-3rd Jan- 7th Jan-10th Jan-13th

Jan-16th

Mean S.D

P-1 156 164 128 145 135 129 139 132

141 13.11

P-2 145 154 112 130 121 120 117 129

129 14.43

P-3 137.6 137 159 128 118 132 110 120

130 15.12

P-4 124 100 115 115 104 127 103 112

113 9.81

P-5 111 99.5 120 113 98 103 99 98 105 8.39

P-6 76 65.6

87

85 45.9 60 87 77 73 14.73

Alkalinity Table – 8 represent the concentration of alkalinity at different sampling points. If alkalinity is not removed before discharge in to aeration tank, it can interfere with the biological life in the surface water and create

unsightly films. The concentration of alkalinity in raw effluent was 438 mg/L, as the effluent treated with chemical treatment by adding the base unit the concentration reduced to 434 mg/L. At the end of the treatment unit concentration reduced to 411 mg/L.

Table 8: Alkalinity (mg/L)

Sampling points

Dec-24th

Dec-27th Dec-30th Jan- 3rd Jan- 4th Jan-10th

Jan-13th

Jan-16th Mean S.D

P-1 469 433 448 458 437 449 445 460

438 13.52

P-2 457 428.9 439 428.5 432.9 445 440 456

437 9.07

P-3 456 421 418 433.6 426.7 443 438 453.5

434 14.05

P-4 408 398.9 416 373 399 437 435 452

414 27.37

P-5 400 394 410 413 338 436 435 428

419 17.57

P-6 393 390 412 411 331 399 411 411.5

411 11.40

Oil & Grease Table – 9 represent the concentration of oil & grease at different sampling points. If grease is not removed before discharge of treated wastewater, it can interfere with the biological life in the surface water

and create unsightly films. The concentration of oil & grease in raw effluent was 25 mg/L, as the effluent passes through oil & grease trapping unit the concentration reduced to 16 mg/L. At the end of the treatment unit concentration reduced to 9 mg/L.

Table 9: Oil & grease (mg/L)

Sampling points

Dec-24th Dec-27th Dec-30th Jan- 3rd Jan- 4th Jan-10th

Jan-13th

Jan-16th

Mean S.D

P-1 27 23 22.6 27 23.9 26.9 23 25 25 1.94 P-2 15.6 17 16.8 13 18 18.5 17.5 14 16 1.95 P-3 13.9 12.5 13.8 12.9 15 17 12 13 14 1.61 P-4 12 11.7 11.7 11.9 9.8 12.5 11 12.6 12 0.90 P-5 11 11.4 10.9 11 9.5 11.5 10.8 10 11 0.68 P-6 7.9 10 9 8.5 9 10 9 9 9 0.70



CONCLUSIONS The present study has been carried out in M/S. HETERO drugs. The bulk drug industry discharges effluents like acid, alkali effluents and gaseous emission, the present study is aimed on effluent treatment process, the effluents discharged during manufacturing of drugs process is collected and treated by mechanical, chemical and biological methods in effluent treatment plant which worked under Environmental Health and Safety Department. The characteristics parameters analyzed are PH, TSS, TDS, BOD, COD, Alkalinity, Chlorides, Oil and Grease. After going through all the waste handling procedures in this organization one can come to a conclusion that environmental health and safety department is also considered as a production department and it is having equal importance with all other departments. Environmental policies are strictly followed and implemented the industry. The techniques here used are latest in the present world and only very few industries are using the same procedures to treat the effluent. Two units are installed for treatment of effluent i.e., common effluent treatment plant and MEE (Multi Effect Evaporation system), which is famous in food industry, is accordingly modified for treatment of effluent and there are re- using the generated condensate for cooling towers, which is helping in saving of plenty of water. The treated waste water which is generated from unit – I (treatment plant) is collected and stored in treated effluent tank and then disposed in to marine through pipe lines in to sea, the dry sludge generated from unit – II (MEE) collected in gunny bags and disposed safely. Every treatment phase of this effluent treatment process (ETP) has its unique removal capacity, and the treated water of treatment plant met the effluent discharge standards and also fulfills the 4Rconcept called Reduce, Reuse, Recycle and Replenish (Desitti et al., 2011).

Fig. 1: Sampling point – Raw effluent collection

Sump [P-1]

Fig. 2: Sampling point – Oil and grease trapping

unit [P-2]

Fig. 3: Sampling point – Equalization tank [P-3]

Fig. 4: Sampling point – Parallel arrangement of

two aeration tank (P4, P5)

Fig. 5: Sampling point – Secondary clarifier [P-6]



Fig. 6: Sludge drying beds

REFERENCES

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article on effluent treatment in bulk drug industry

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