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:redhex@vsnl.com

B. Shanavas

SynthiteIndustriesLtdKolencherry,IndiaP:+914843051295E:shanavas@synthite.com

CSWT14MA11INT

Biological help for the human race

BiOWiSH™isaregisteredtrademarkofBiOWiSHTechnologiesInc.

www.biowishtech.com