Fertiliser Production

Key problems include managing high-strength nutrient loads, heavy metals, salts, and variable wastewater volumes. The industry faces pressure to minimize freshwater consumption amid rising water scarcity while ensuring zero or minimal environmental discharge that can impact soil and water bodies. Operational efficiency, cost control, and regulatory compliance remain major priorities amidst increasingly stringent environmental standards.

Sarvo’s Comprehensive Water Solutions

Sarvo delivers end-to-end, customized water and wastewater treatment solutions tailored for fertiliser manufacturing units. Our robust treatment trains include advanced physical, chemical, and biological treatment processes suitable for handling high nutrient loads and complex wastewater matrices. We utilize pH adjustment, coagulation-flocculation, sedimentation, and nutrient removal technologies (e.g., denitrification, phosphorus precipitation) to reduce contaminant loads.

Sarvo’s membrane filtration systems, including ultrafiltration (UF) and reverse osmosis (RO), enable removal of dissolved solids and recovery of clean water for reuse in plant processes. For zero liquid discharge (ZLD) goals, we deploy energy-efficient Mechanical Vapor Recompression (MVR) evaporators combined with drying systems to safely concentrate and dispose of residual solids.

Our solutions integrate automation, PLC/SCADA controls, and AI-driven monitoring to optimize treatment efficiency, reduce chemical and energy consumption, and maintain compliance with pollution control norms. Modular designs offer flexibility to suit various plant scales and facilitate future expansion with minimal downtime.

Key Technology Highlights

• pH neutralization and chemical coagulation for solids and precipitable nutrient removal.

• Biological nutrient removal and treatment for nitrogen and phosphorus reduction.

• Ultrafiltration (UF) and Reverse Osmosis (RO) for dissolved solids removal and water polishing.

• Mechanical Vapor Recompression (MVR) evaporators and drying units for Zero Liquid Discharge (ZLD).

• Automated control systems with AI analytics ensuring operational stability and energy efficiency.

• Modular and scalable plant configurations adapting to individual site needs.

• Safe sludge management and compliance with hazardous waste guidelines.

Customer Case Study: IFFCO Fertiliser Plant, Bangalore

Sarvo provided a complete water and wastewater treatment solution for IFFCO’s fertiliser manufacturing facility in Bangalore. The project addressed the treatment of high-strength wastewater including process effluent, cooling tower blowdown, and boiler blowdown uploads.

The integrated system comprised advanced coagulation/flocculation units, biological treatment technologies, and membrane filtration (UF & RO) to achieve stringent discharge norms and produce high-quality recycled water for reuse in boiler feed and cooling processes. Sarvo also implemented an energy-efficient Mechanical Vapor Recompression (MVR) evaporator with Agitated Thin Film Dryer (ATFD) technology to achieve Zero Liquid Discharge by concentrating and drying rejects, minimizing waste disposal volume and cost.

This turnkey plant is equipped with advanced automation and AI-driven process optimization, ensuring compliance with Central Pollution Control Board (CPCB) norms while enhancing water security and reducing the environmental footprint. Sarvo’s solution significantly lowered operational expenses and freshwater intake, exemplifying sustainable industry practices in fertiliser production wastewater management