Article On Effluent Treatment in Bulk Drug Industry

Vol. 3 (3) Jul Sep2012 www.ijrpbsonline.
com 1095
International Journal of Research in Pharmaceutical and Biomedical Sciences ISSN: 2229-3701
___________________________________________Research Article
Study on treatment process of effluent in Bulk drug industry
NV. Srikanth Vuppala
1
, Ch. Suneetha
2
and V. Saritha
3

1
Basic Science Department, Aditya Engineering College, Kakinada, Andhra Pradesh, India.
2
Department of Environmental Sciences, Acharya Nagarjuna University, Guntur,
Andhra Pradesh, India.
3
Department of Environmental Studies, GITAM University, Visakhapatnam, Andhra Pradesh,
India.
_____________________________________________________________________________________
ABSTRACT
Drug industry is one of the major industries causing water pollution. In India, Drug industry generates about
Gallons of waste water processed depending upon the process employed and product manufactured. Considering
the increased demand for Drugs, the Drug based industries in India is expected to grow rapidly and have the waste
generation and related environmental problems are also assumed increased importance. Poorly treated waste
water with high levels of pollutants caused by poor design, operation or treatment systems creates major
environmental problems when discharged to surface water or land. Considering the above stated implications an
attempt has been made in the present project to evaluate one of the WWTP for Drug industry. The waste water is
treated in two units based on characteristics namely LTDS (Unit-I), it is a common ETP process and HTDS (Unit-II) is
Multiple evaporating system (MEE). Samples were collected from six points; Raw effluent [P-1], Oil and grease trap
[P-2], Equalization tank [P-3], Aeration tank 1 [P-4], Aeration tank 2 [P-5] and Secondary clarifier [P-6] to evaluate
the performance of WWTP. Parameters analyzed for evaluation of performance of WWTP are COD, BOD5 at 20
C, TSS, TDS, oil and grease, Chloride and Alkalinity. Mass balance of COD, TSS and TDS was performed to find the
fate of pollutants in WWTP. Parameters like pH and oil & grease were used to access the suitability of secondary
effluent for reuse in irrigation. The COD, BOD5 at 20 C and TSS removal efficiency of WWTP were 96%, 95%and
94%respectively, which are in acceptable range for Disposal in to marine.

INTRODUCTION
In view of high cost of conventional wastewater
treatment systems there is an increasing need to
develop low cost methods of treating wastewater
particularly that of municipal and industrial origin.
Rapid industrialization has resulted in the rise of
pollution. To counter the above shortcoming and to
preserve the high quality of the environment new
concept so called Cleaner Production for waste
minimization is being introduced, technology
designed to prevent waste emission at the source of
generation itself (Uwadiae et al 2011). Developing
low cost technology for wastewater treatment offers
an alternative and has been found to be most effective
for treatment of domestic and industrial wastewater,
particularly for those situated in the tropical and
subtropical regions (NgMiranda et al., 1989; Puskas
et al., 1991; El-Gohary et al., 1995; Rosen et al.,
1998). Technologically because of the simplicity of
waste stabilization ponds even affluent nations,
which can afford the luxury of expensive wastewater
treatment, are planning to use more and more low
cost treatment technologies (Khan and Ahmad, 1992;
Junico and Shelef, 1994).
Environmental degradation is an escalating problem
owing to the continual expansion of industrial
production and high-levels of consumption. A
renewed dedication to a proven strategy to resolve
this problem is needed. Cleaner Production is one
such strategy, which can address this problem. It is a
preventive environmental management strategy,
which promotes eliminating waste before it is created
to systematically reduce overall pollution generation,
and improve efficiencies of resources use. (Hashmi
Imran 2005).
Wastewater pollution is the main issue of this sector.
In pharmaceutical industries wastewater is mainly
generated through the washing activities of the
equipment. Though the wastewater discharged is
small in volume, is highly polluted because of
presence of substantial amounts of organic pollutants
(Overcash, 1986). Solid waste usually comprises of

Vol. 3 (3) Jul Sep2012 www.ijrpbsonline.com 1096
expired or rejected medicines, spent solvents,
packaging material and damaged bottles. Level of
wastewater pollution varies from industry to industry
depending on the type of process and the size of the
industry (Garcia et al., 1995).
Hence Effluent Treatment Plants or ETPs are used by
leading companies in the pharmaceutical and
chemical industry to purify water and remove any
toxic and noneffluent-treatment-plant toxic materials
or chemicals from it. These plants are used by all
companies for environment protection.
Hetero Drugs Ltd, established in April 1993 and its
new branch established in 2004 at surveyNo.150/2,
N. Narasapuram (Vill) , Nakkapally ( Mandal),
Visakhapatnam ( Dist) 531081,A.P.India, Hetero
labs is involved in the manufacture of a range organic
intermediates, active pharmaceutical intergradients (
APIS) and drug products .Hetero labs has chosen to
walk the path of discovery and innovation in health
sciences .the company is vertically integrated with a
presence across the pharmaceutical value chain,
producing and delivering safe, innovative and highly
quality finished dosage forms, active pharmaceutical
ingredients and biotechnology products, which are
famous across the globe. It had the two decades of
experience in producing safe pharmaceutical drugs
and it is moving successfully in achieving its core
purpose to help people lead healthier lives. The
major researches of the company include the areas
study concentrated on latest features and the methods
followed in building a health environment. The
objective of this work is to Evaluation of pollution
parameters of wastewater from drug based industry
and check whether the treatment units are working
with designed efficiency or not. Within this view, the
experimental work has been designed and is
presented here with.

METHODOLOGY
Effluent Treatment Processes in Hetero Drugs
Waste water treatment aims at the removal of
unwanted components in waste waters in order to
provide safe discharge into the environment. This can
be achieved by using physical, chemical and
biological means, either alone or in combination. A
treatment plant is like an assembly in a factory where
the various steps in purification are arranged in such
a sequence that the quality of the output of one step is
acceptable in the next step. Physical treatment
methods such as screening, sedimentation, and
skimming remove floating objects, grit, oil and
grease.
Chemical treatment methods such as precipitation,
pH adjustment, coagulation, oxidation, and reduction,
remove toxic materials and colloidal impurities.
Finally, dissolved organics are removed by biological
treatment methods. Tertiary treatment methods are
used for further purification and for reuse of treated
wastewater for various purposes. In this drug industry
the treatment of waste water is done by two methods
based on the characteristics of raw effluent from
processing units, they are LTDS (Low Total
dissolved solids) and HTDS (High Total Dissolved
solids). The LTDS treatment is done by common
effluent treatment process in three stages i.e.,
primary, secondary and tertiary treatments. (UNIT-I)
The HTDS treatment is done by Multiple Evaporator
effect. In this treatment of process the effluent comes
from the processing units is tend to sent in to multiple
evaporating effect. The treatment is done in
particular stages, consists of Screening, Grit, oil &
Grease chamber, Equalization cum Neutralization
Tank, Flash Mixer, Flocculator, Aeration Tank, MEE
Feed Tank, Stripper column and Evaporators.( UNIT-
II). The effluent is characterized by evaluation of
concentrations of TSS, PH, and conductivity before
sending in to treatment process, based on the results
if the TSS is less than 15,000 mg/L, considered as
LTDS and if the effluent TSS is greater than15, 000
mg/L considered as HTDS. Then the inlet of waste
water is opened and sends to the required process
Unit-I/ unit-II.
For HTDS the important parameters to be considered
are PH, TDS, TSS, COD, and BOD. The important
parameters to be considered for LTDS are DO,
MLSS, BOD, SVI (Sludge Volume Index).
The waste water which is treated and stored in
Effluent Treatment Tank may send to RO plant for
further treatment , this water is used for irrigation,
cleaning purposes, etc., else send to disposal in to
marine.

Monitoring of WWTP and its performance
evaluation
Samples were collected from WWTP at different
sampling points of WWTP and characterize for
parameters BOD, COD, pH, TSS, TDS, Alkalinity,
Oil & grease etc. Overview of WWTP and location
of sampling points is given in Section

Sampling procedures
The reliability of the results of analysis of waste
water samples depends up on the proper collection of
a true representative sample from a large volume of
waste water. The sample after collection was
transported to the laboratory in a preserved condition.
So that it will represent fairly and accurately
conditions when the sample was collected.

Sampling Schedule and frequency
Grab samples were collected for every three days in a
week from WWTP. Six sets of samples comprising of

Raw effluent [P-1]
Oil and grease trap [P-2]
Equalization tank [P-3]
Aeration tank 1 [P-4]
Aeration tank 2 [P-5]
Secondary Clarifier [P-6] (Figures 1 6)
Were collected and analyzed for the parameters
shown in Table. Samples for BOD, COD, Chlorides
and Solids etc were analyzed in accordance with the
procedure laid down in Standard Methods for the
Examination of Water and Wastewater (APHA 1996)

Instruments used for measurement of different
parameters
S.
No
PARAMETERS MEASUREMENTS
1. pH pH meter
2. BOD
Bio-Chemical oxygen
Demand

Titrimetric Method
3. TCOD
(Total Chemical Oxygen
Demand)

Closed reflux method
4. Chlorides Argentometric Method
5. Total Solids
Total Dissolved Solids
Total Suspended Solids
Drying Oven
Drying Oven
Drying Oven
6. Alkalinity Titrimetric Method
7. Acidity Titrimetric Method
8. Oil & grease Partition Gravimetric
Method

RESULTS AND DISCUSSION
Samples were collected from six points. Sampling
points are Raw effluent [P-1], Oil & grease Trap [P-
2], Equalization tank [P-3], Aeration Tank 1 [P-4],
Aeration Tank 2 [P-5] & Secondary Clarifier [P-6] to
evaluate the performance of WWTP.

Effluent characteristics
The physio-chemical characterization of effluent
from equalization tank is given in Table - 1. The key
pollutants in the wastewater from pharmaceutical
based drug industry are organic compounds and
suspended solids and biogeneous elements.
Biodegradability may be estimated on the basis of
ratio between BOD
5
& COD. BOD
5
: COD ratio
obtained from the literature data In the present case
BOD
5
: COD [691/1300] was found to be 0.53, which
indicate that most of the organic compounds in the
wastewater from pharmaceutical based drug industry
should that are easily biodegradable.

Suspended solids in wastewater from WWTP was
found to be 687 mg/L. Suspended solids in
wastewater from pharmaceutical based drug industry
originates from coagulated effluent of chemicals
from drug processing units.

Table 1: Characterization of effluent from
Equalization Tank of Drug based Industry
S.
No.
Parameters Concentration
1 pH 6.8
2 BOD5 at 20 C [mg/L] 620
3 TCOD [mg O2/L] 1290
4 TS [mg of TS/L] 1956
5 TSS [mg of TSS/L] 686.7
6 TDS [mg of TDS/L] 1237
7 Chloride [mg Cl-/L] 108
8 Alkalinity [mg
CaCO3/L]
460
9 Oil & grease [mg/L] 16

Standards for Waste Water Quality

#Thesestandards shall beapplicablefor industries, operations or processes other than thoseindustries.
Operations or process for which standards havebeen specified in Scheduleof theEnvironment Protection Rules 1989.

S. No. Parameters Collection site Frequency Standards Inlet Standards Outlet
1 pH Inlet & outlet Daily 9.5-11.0 6.5-8.5
2 BOD mg/l Inlet & outlet Daily 1500-2000 100 max
3 COD mg/l Inlet & outlet Daily 4000-5000 250max
4 TDS mg/l Inlet & outlet Daily 2000-3000 2100 max
5 TSS mg/l Inlet & outlet Daily 1000-1500 100 max
6. Suspended solids Inlet & outlet Daily 600 100 max
7. chlorides Inlet & outlet Daily 250 1000 max
8. Alkalinity Inlet & outlet Daily 200 600 max
9. Oil & Grease Inlet & outlet Daily 60-80ppm 10max

WWTP & ASP Performance
Wastewater from pharmaceutical based drug industry
was treated by Activated Sludge Process (ASP).
Sequence of operations is explained in methodology.
The performance of WWTP is evaluated by
parameters TSS, TDS, COD, BOD, Oil & grease etc.
The data given in Table: 1 9.

pH
The use of acid, alkali, cleansers in the
pharmaceutical based drug industry typically results
in highly variable wastewater pH values. Literature
data indicated that pH value ranged between 6.2-8.2
with an average of 6.56 (P-1) - 8.04 (P-6). The pH
value is increased from acidic to base. The present
pH is quite favorable for the ASP process

Sampling
points
Dec-24
th
Dec-27
th
Dec-
30
th

Jan-3
rd
Jan-7
th
Jan-
10
th

Jan-13
th
Jan-
16
th

Mean S.D
P-1

6.8 6.2 6.9 6.5 6.5 6.7 6.6 6.3 6.56 0.24
P-2 6.9 6.5 7 6.7 7.1

6.8 7.1 6.3 6.80 0.29
P-3 7.1 7.3 7.2 7.1 7.5 6.8

7.5 7.1 7.20 0.23
P-4 7.8 7.9 8.1 7.5 7.8

7.5 7.9 7.8 7.79 0.20
P-5 7.8 7.9 8.2 7.8

8 7.7 7.9 7.8 7.89 0.16
P-6 7.9 8

8.2 8 8.1 8.2 8 7.9 8.04 0.12

BOD
Data presented in Table 2 shows variation of BOD
5

at different sampling points. BOD
5
in raw effluent
was found to be average 690.25 and after final
treatment in secondary clarifier it is found that the
BOD value is 34.25 (mg/L) gives consolidated
information in the characteristics of six sampling
locations of WWTP.

Table 2: BOD
5
at 20C (mg/L)
Sampling
points
Dec-24
th
Dec-29
th
Dec- 3
rd
Jan-8
th
Jan-13
th
Jan- 18
th
Jan-23
rd
Jan-28
th
Mean S.D
P-1 704 698 617 681 694 693 727 708 691 32.49
P-2 615 647 598 635 678 587 591 637 624 31.51
P-3 605 605 560 590 598 565 580 621.6 591 21.16
P-4 340 210 212 230 205 200 190 200 224 48.55
P-5 210 199 185 174 198 168 170 170 184 16.24
P-6 25 32 48 28 27.5 41 29 43.5 34 8.64

TCOD
Data presented in Table 3 shows the monthly
variation of TCOD at different sampling points.
TCOD in the raw effluent was found to be 1304.38
mg/L (average), which is reduced to 43.49 mg/L
(average value) after secondary clarifier.

Table 3: TCOD (mg/L)
Sampling point Dec-
24
th

Dec-
27
th

Dec-30
th
Jan-3
rd
Jan-7th Jan-10
th
Jan-13
th
Jan-16
th
Mean S.D
P-1 1277 1310 1297 1318 1305 1278 1317 1333

1304 19.62
P-2 1246 1287 1260 1244 1270 1267 1274 1269

1265 14.32
P-3 1220 1188 `1190 1211 1145 1045 1202 1223

1178 59.13
P-4 613 642 525 530 610 690 649 650

614 58.64
P-5 490 654 518 517 534 528 546 518

538 49.54
P-6 41 44.7 40 41.7 47 51 43 39.5

44 3.93

Total solids
variation of Total solids at different sampling points.
Total solids in the raw effluent was found to be 3647
mg/L (average P-1), which is reduced to 1125 mg/L
(average value) after secondary clarifier.

Table 4: Total solids (mg/L)
Sampling points Dec-
24
th

Dec-
27
th

Dec-
30
th

Jan-3
rd
Jan-7th Jan-
10
th

Jan-
13
th

Jan-
16
th

Mean S.D
P-1 3740 3510 3746 3640 3548 3576 3752 3670

3648 95.36
P-2 3280 3440 3600 3450 3466 3310 3666 3650

3483 146.11
P-3 1980 1980 1960 2180 1990 2079 2060 2037

2033 72.96
P-4 1880 1700 1850 2120 1990 1950 1960 1950

1925 121.30
P-5 1780 1675 1856 1870 1795 1798 1850 1870

1812 65.88
P-6 1080 1240 1120 1056 990 1276 1100 1140

1125 94.05

TDS
variation of Total Dissolved solids at different
sampling points. Total solids in the raw effluent was
found to be 1615 mg/L (average-P1), which is
reduced to 974 mg/L(average value) after secondary
clarifier.

Table 5: TDS (mg/L)
Sampling points Dec-24
th
Dec-27
th
Dec-30
th
Jan-3
rd
Jan-4
th
Jan-10
th
Jan-13
th
Jan-16
th
Mean S.D
P-1 1690 1590 1530 1690 1668 1656 1578 1519

1615 69.87
P-2 1247 1150 1250 1310 1290 1199 1180 1266

1237 55.43
P-3 1038 1060 1190 1120 1222 1126 1156 1232

1143 70.98
P-4 1055 1023 1060 1070 1212 1105 1121 1150

1099 60.90
P-5 990 1002 1010 1018 1188 1110 1188 1100

1076 82.30
P-6 986 990 998 986 990 975 890 980

974 34.78

Total Suspended Solids
Data presented in Table 6 shows the variation in
TSS. TSS (2249 mg/L) in raw effluent was reduced
to 52.75 mg/L after entrapment in secondary clarifier.
Gradual decrease in TSS was observed in all tanks.
Recycling of sludge and oxidation of substrate are the
primary factors contributing to TSS in aeration tank.
Figure 4.6 represent concentration of solids at various
sampling points. In the present case, no primary
treatment is provided, so whatever removal is there
i.e. because of secondary clarifier. A certain fall of
concentration of TSS at sampling points P-4 & P-5
was observed which is due to oxidation of substrate
and production of biomass.

Table 6: Total Suspended Solids (mg/L)
Sampling
points
Dec-24
th
Dec-27
th
Dec-30
th
Jan-3
rd
Jan-7th Jan-10
th
Jan-
13
th

Jan-16
th
Mean S.D
P-1 2050 1966 2436 2180 2350 2280 2272 2460 2249 175.51
P-2 2010 1940 2400 2012 2299 2100 2005 2420 2148 194.14
P-3 735 675 645 700 705 670 683 710 691 27.90
P-4 650 635 610 667 654 540 546 630 579 101.92
P-5 210 240 310 280 298 286 243 246 264 34.37
P-6 48 54 62 42 70 59 42 45 52 10.26

Chlorides
Table 7 represent the concentration of chlorides at
different sampling points. The concentration of
alkalinity in raw effluent was 141 mg/L ( average P-
1), as the effluent treated with chemical treatment
unit the concentration reduced to 112mg/L(P-$). At
the end of the treatment unit concentration reduced
to72mg/L. (P-6)

Table 7: Chlorides (mg/L)
Sampling
points
Dec-24
th
Dec-27
th
Dec-30
th
Jan-3
rd
Jan- 7th Jan-10
th
Jan-
13
th

Jan-
16
th

Mean S.D
P-1 156 164 128 145 135 129 139 132

141 13.11
P-2 145 154 112 130 121 120 117 129

129 14.43
P-3 137.6 137 159 128 118 132 110 120

130 15.12
P-4 124 100 115 115 104 127 103 112

113 9.81
P-5 111 99.5 120 113 98 103 99 98 105 8.39

P-6 76 65.6

87

85 45.9 60 87 77 73 14.73

Alkalinity
Table 8 represent the concentration of alkalinity at
different sampling points. If alkalinity is not removed
before discharge in to aeration tank, it can interfere
with the biological life in the surface water and create
unsightly films. The concentration of alkalinity in
raw effluent was 438 mg/L, as the effluent treated
with chemical treatment by adding the base unit the
concentration reduced to 434 mg/L. At the end of the
treatment unit concentration reduced to 411 mg/L.

Table 8: Alkalinity (mg/L)
Sampling
points
Dec-
24
th

Dec-27
th
Dec-30
th
Jan- 3
rd
Jan- 4
th
Jan-
10
th

Jan-
13
th

Jan-16
th
Mean S.D
P-1 469 433 448 458 437 449 445 460

438 13.52
P-2 457 428.9 439 428.5 432.9 445 440 456

437 9.07
P-3 456 421 418 433.6 426.7 443 438 453.5

434 14.05
P-4 408 398.9 416 373 399 437 435 452

414 27.37
P-5 400 394 410 413 338 436 435 428

419 17.57
P-6 393 390 412 411 331 399 411 411.5

411 11.40

Oil & Grease
Table 9 represent the concentration of oil & grease
at different sampling points. If grease is not removed
before discharge of treated wastewater, it can
interfere with the biological life in the surface water
and create unsightly films. The concentration of oil &
grease in raw effluent was 25 mg/L, as the effluent
passes through oil & grease trapping unit the
concentration reduced to 16 mg/L. At the end of the
treatment unit concentration reduced to 9 mg/L.

Table 9: Oil & grease (mg/L)
Sampling
points
Dec-24
th
Dec-27
th
Dec-30
th
Jan- 3
rd
Jan- 4
th
Jan-
10
th

Jan-
13
th

Jan-
16
th

Mean S.D
P-1 27 23 22.6 27 23.9 26.9 23 25 25 1.94
P-2 15.6 17 16.8 13 18 18.5 17.5 14 16 1.95
P-3 13.9 12.5 13.8 12.9 15 17 12 13 14 1.61
P-4 12 11.7 11.7 11.9 9.8 12.5 11 12.6 12 0.90
P-5 11 11.4 10.9 11 9.5 11.5 10.8 10 11 0.68
P-6 7.9 10 9 8.5 9 10 9 9 9 0.70

CONCLUSIONS
The present study has been carried out in M/S.
HETERO drugs. The bulk drug industry discharges
effluents like acid, alkali effluents and gaseous
emission, the present study is aimed on effluent
treatment process, the effluents discharged during
manufacturing of drugs process is collected and
treated by mechanical, chemical and biological
methods in effluent treatment plant which worked
under Environmental Health and Safety
Department. The characteristics parameters
analyzed are PH, TSS, TDS, BOD, COD, Alkalinity,
Chlorides, Oil and Grease.
After going through all the waste handling
procedures in this organization one can come to a
conclusion that environmental health and safety
department is also considered as a production
department and it is having equal importance with all
other departments. Environmental policies are strictly
followed and implemented the industry. The
techniques here used are latest in the present world
and only very few industries are using the same
procedures to treat the effluent.
Two units are installed for treatment of effluent i.e.,
common effluent treatment plant and MEE (Multi
Effect Evaporation system), which is famous in food
industry, is accordingly modified for treatment of
effluent and there are re- using the generated
condensate for cooling towers, which is helping in
saving of plenty of water.
The treated waste water which is generated from unit
I (treatment plant) is collected and stored in treated
effluent tank and then disposed in to marine through
pipe lines in to sea, the dry sludge generated from
unit II (MEE) collected in gunny bags and disposed
safely. Every treatment phase of this effluent
treatment process (ETP) has its unique removal
capacity, and the treated water of treatment plant met
the effluent discharge standards and also fulfills the
4Rconcept called Reduce, Reuse, Recycle and
Replenish (Desitti et al., 2011).

Fig. 1: Sampling point Raw effluent collection
Sump [P-1]

Fig. 2: Sampling point Oil and grease trapping
unit [P-2]

Fig. 3: Sampling point Equalization tank [P-3]

Fig. 4: Sampling point Parallel arrangement of
two aeration tank (P4, P5)

Fig. 5: Sampling point Secondary clarifier [P-6]


Fig. 6: Sludge drying beds

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