Industry Background and Problems
The refinery and petrochemical industry plays a vital role in the global energy and manufacturing ecosystem by processing crude oil and natural gas into fuels, chemicals, plastics, and other essential products. These processes generate complex wastewater streams characterized by high chemical oxygen demand (COD), total suspended solids (TSS), oil and grease, hydrocarbons, heavy metals, and toxic compounds. Effluent streams typically originate from desalting, catalytic cracking, cooling tower blowdown, and wash water, demanding stringent treatment before discharge or reuse.
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Discharging untreated or partially treated effluents leads to severe environmental impacts, regulatory non-compliance, hefty fines, and operational risks. Water scarcity and cost pressures further incentivize reducing freshwater consumption by maximizing treated water recycle within plants. Challenges for wastewater management include treating highly variable, toxic, and oily streams with tight volumetric constraints and achieving zero liquid discharge (ZLD) while managing residual solids safely.
Our Approach to Solving the Problems
Sarvo offers end-to-end, customized water and wastewater solutions for refinery and petrochemical clients, addressing their unique process and environmental challenges. Our modular treatment trains integrate advanced oil-water separation, chemical coagulation and flocculation, pH correction, and sophisticated biological treatment including membrane bioreactors (MBR) for effective COD and TSS reduction. Multi-stage filtration, ultrafiltration (UF), reverse osmosis (RO), and electrodeionization (EDI) systems provide high-quality water for process reuse and boiler feed.
To meet zero liquid discharge goals and minimize environmental footprint, Sarvo deploys energy-saving Mechanical Vapor Recompression (MVR) evaporation systems paired with crystallizers and sludge handling equipment for concentrate management. State-of-the-art process control, AI-driven monitoring, and automation optimize performance, compliance, and energy efficiency. Sarvo’s solutions help refineries dramatically reduce freshwater intake, comply with stringent Central Pollution Control Board (CPCB) and international standards, and sustain cost-effective operations.
Key Points
About Our Tech in Pointers
- Integrated, customized effluent treatment trains designed for high oil, organic, and toxic pollutant loads.
- Advanced oil-water separators and chemical-physical units for rapid removal of free and emulsified oils.
- Biological treatment via MBR and other biotechnologies for COD and organic load reduction.
- High-purity water production with UF, RO, and EDI suitable for boiler feed and process reuse.
- Energy-efficient MVR evaporators and ATFD units for zero liquid discharge and minimal waste.
- Automated systems with AI-based optimization and real-time process monitoring.
- Scalable, modular plants enabling phased implementation and retrofit.
- Safe sludge dewatering, drying, and disposal mechanisms compliant with hazardous waste norms.
Relevant Technologies
Oil-water separation and dissolved air flotation (DAF)
pH adjustment, coagulation, and flocculation
Membrane Bioreactors (MBR), Moving Bed Biofilm Reactors (MBBR)
Ultrafiltration (UF), Reverse Osmosis (RO), Electrodeionization (EDI)
Mechanical Vapor Recompression (MVR) evaporation & Agitated Thin Film Dryers (ATFD)
Advanced oxidation processes and chemical dosing
PLC/SCADA control and AI analytics
Sludge dewatering, centrifuges, and drying beds
Customer Case Study: IFFCO Refinery, Bangalore
Sarvo Technologies successfully delivered an integrated wastewater treatment plant for the IFFCO petrochemical refinery in Bangalore, meeting stringent environmental and operational requirements. The system treats complex refinery effluents including cooling tower blowdown, boiler blowdown, and process waters with high oil and organic content.
The treatment train combines oil-water separation, coagulation/flocculation, ultrafiltration (UF), reverse osmosis (RO), and Biological treatment via Membrane Bioreactors (MBR) to achieve high-quality effluent suitable for recycling within the plant. A state-of-the-art Mechanical Vapor Recompression (MVR) evaporator with an Agitated Thin Film Dryer (ATFD) enables zero liquid discharge by concentrating and drying process rejects, significantly reducing wastewater volume.
Automated process controls and AI-driven monitoring ensure minimal manpower, reduce energy consumption, and maintain robust adherence to Central Pollution Control Board (CPCB) norms. The plant significantly decreases freshwater intake and waste disposal costs, exemplifying Sarvo’s commitment to sustainable and high-performance solutions in refinery and petrochemical water management
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Ready to conduct a refinery wastewater treatment feasibility study or learn about our rapidly deployable equipment rental options? Contact us today.