Industry Background and Problems
The chemical processing industry encompasses a vast array of sectors—including petrochemicals, speciality chemicals, fertilizers, and pharmaceuticals—where water acts as a key raw material, solvent, coolant, and cleaning agent. Due to the diversity of processes, the industry generates a wide spectrum of wastewater streams containing high levels of organic pollutants, acids/alkalis, heavy metals, solvents, oils, and complex toxic compounds. Untreated or poorly managed water can result in fouling, corrosion, process disruptions, product contamination, and costly equipment failures.
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Increasingly stringent environmental and regulatory standards demand that chemical plants reduce the discharge of total dissolved solids (TDS), hazardous organics, and priority pollutants while optimizing water consumption and promoting circular use. Variable wastewater composition—combined with risks of toxicity, pH fluctuation, and high volume—requires treatment systems that are robust, flexible, and adaptable to changing conditions. Facilities also face the imperative to minimize operational costs, achieve near-zero liquid discharge (ZLD), and contribute to sustainable water management practices.
Our Approach to Solving the Problems
Sarvo specializes in designing and operating tailored water and wastewater treatment solutions for chemical processing clients. Our systems begin with a comprehensive site and effluent audit—analyzing pollutants, flow rates, utilities, and discharge norms—to engineer an optimal mix of physical, chemical, and biological treatment steps. Pre-treatment employs advanced multi-stage filtration, clarification, and softening to eliminate solids, oils, and hardness. Chemical dosing precisely controls pH, prevents corrosion, and eliminates scaling, with real-time monitoring for quality assurance. Biological processes (activated sludge, MBR) reduce BOD/COD and degrade complex organics, while tertiary polishing (ultrafiltration, reverse osmosis, AOP, evaporation/crystallization) enables high recovery, minimizes environmental discharge, and meets ZLD goals. Automation and AI-powered sensors ensure process stability and compliance while reducing manual intervention. Sarvo’s modular, scalable solutions also support resource recovery (water, salts, solvents) and integrate easily with new or existing infrastructure.
Key Points
About Our Tech in Pointers
- Multi-stage treatment trains combining physical, chemical, and biological steps for robust pollutant removal.
- Advanced membrane systems (UF/RO) for high water recovery and ZLD compliance.
- Automated chemical dosing and pH adjustment for corrosion and scaling control.
- Biological reactors and MBRs for efficient organic degradation and COD/BOD reduction.
- Real-time monitoring and AI analytics to optimize treatment, lower OPEX, and ensure compliance.
- Modular, scalable plants for flexible integration and future expansion.
- Resource recovery options (water, salts, solvents) for circular water management.
- Designed for reliable performance under fluctuating loads and compositions.
Relevant Technologies
Multimedia filtration, clarification, softening, and pre-treatment
Chemical dosing (pH, corrosion/scaling inhibitors, coagulants)
Activated sludge, MBR, and biological reactors
Ultrafiltration (UF), Reverse Osmosis (RO)
Advanced Oxidation Processes (AOP, ozonation)
Evaporation, crystallization, and ZLD systems
Instrumentation, remote monitoring, and AI automation
Customer Case Study: PG Technoplast, Bangalore
Sarvo designed and commissioned a comprehensive effluent treatment system for PG Technoplast, an automotive paint shop and chemical processing unit in Bangalore. The wastewater contained high loads of suspended solids, chemical contaminants, and paint shop effluent characteristics.
The treatment train includes chemical coagulation, flocculation, and sedimentation followed by ultrafiltration and reverse osmosis membranes to achieve high-quality water reuse suitable for the cooling tower and process water requirements. The RO reject is concentrated in an MVR evaporator system with a centrifuge for sludge dewatering, delivering a full Zero Liquid Discharge (ZLD) solution.
This system maximized water recycling, reduced wastewater volumes, and ensured compliance with discharge norms while lowering overall treatment costs through automation and energy-efficient designs.
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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.