Industry Background and Problems
The automotive industry is a major consumer of water in manufacturing processes such as painting, metal finishing, cooling, and parts cleaning. Water quality and wastewater management have become critical due to stringent environmental regulations and the need to reduce operational costs. Automotive wastewater often contains high concentrations of oils, solvents, suspended solids, heavy metals from electroplating, and chemical residues from paint shops and rinsing operations. These pollutants pose significant treatment challenges and require robust, integrated water management solutions.
Water scarcity and increasing discharge compliance demands further complicate operations, with facilities aiming to recycle and reuse treated water to reduce freshwater intake. The fluctuating nature of wastewater streams, coupled with high organic and inorganic loads, necessitates customized treatment technologies capable of adapting to variable conditions while ensuring consistent, regulatory-compliant effluent quality.
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Our Approach to Solving the Problems
Sarvo offers comprehensive water and wastewater treatment solutions designed specifically for the automotive industry’s complex effluent characteristics. Our modular and scalable systems integrate advanced physical, chemical, and biological treatment technologies, such as oil-water separation, pH adjustment, coagulation/flocculation, activated sludge or membrane bioreactors (MBR), ultrafiltration (UF), reverse osmosis (RO), and zero liquid discharge (ZLD) systems employing Mechanical Vapor Recompression (MVR) evaporators. These technologies collectively ensure removal of oils, heavy metals, suspended solids, and organics.
Our automated control systems and AI-enabled monitoring optimize performance, maximize water recovery, and minimize downtime and operational costs. Sarvo’s solutions enable reuse of treated water for utilities, cooling towers, and certain process applications, ensuring environmental compliance and operational sustainability.
Key Points
About Our Tech in Pointers
- Customized ETPs addressing high oil & grease, metals, and chemical loads typical of automotive effluents.
- Advanced physical-chemical and biological treatment integrating MBBR, MBR, and membrane filtration.
- Ultrafiltration (UF) and Reverse Osmosis (RO) for high purity water recovery targeting reuse.
- ZLD systems with energy-efficient MVR evaporation and drying modules for minimal liquid discharge.
- Automated, AI-driven process control and real-time water quality monitoring.
- Modular, skid-mounted plants offering flexible capacity scaling and rapid installation.
- Comprehensive sludge management solutions including dewatering and safe disposal.
- Proven compliance with local and international environmental standards.
Relevant Technologies
Oil-water separators and flotation systems
pH adjustment, coagulation, and flocculation
Membrane Bioreactors (MBR), Moving Bed Biofilm Reactors (MBBR)
Ultrafiltration (UF) and Reverse Osmosis (RO)
Mechanical Vapor Recompression (MVR) based Zero Liquid Discharge (ZLD)
Sludge dewatering units (centrifuges, filter presses)
PLC/SCADA automation and AI analytics for process optimization
Customer Case Study: JBM India, Pithampur, MP
Sarvo successfully implemented a state-of-the-art Zero Liquid Discharge (ZLD) system at JBM India’s facility in Pithampur, Madhya Pradesh, a leading automotive and automotive component manufacturer. The plant faced complex wastewater streams from paint shops, electroplating, and cooling tower blowdown, containing high levels of heavy metals, oils, suspended solids, and dissolved chemicals.
Sarvo designed and commissioned a multi-step treatment system including chemical precipitation, advanced filtration (UF and RO), and a Mechanical Vapor Recompression (MVR) evaporator to achieve ZLD. The RO reject and concentrate from DM and softener regeneration were efficiently evaporated in the MVR system, significantly reducing wastewater volumes. The concentrate was further dried in centrifuge and drying units to produce dry sludge for safe disposal.
This turnkey project achieved over 90% water recovery for reuse in cooling towers and process needs, ensuring robust compliance with CPCB discharge norms. Automated controls and real-time monitoring ensured operational reliability with minimal manpower, supporting JBM’s sustainability goals and operational efficiencies. The system reduced freshwater consumption and waste disposal costs, enhancing environmental stewardship across their manufacturing operations.
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