OVERVIEW
This case study presents the transformative effects of a digitization and automation project at a plant for a leading pharmaceutical manufacturer in India, aimed at enhancing water management processes. The initiative focuses on improving operational efficiency, reducing costs, ensuring regulatory compliance, enabling scalability, and achieving substantial ESG (Environmental, Social, and
Governance) impact.
PROJECT DESCRIPTION
The project was implemented with the objective of modernizing wastewater treatment operations through advanced digitization and automation techniques. Key components included the deployment of new instrumentation and automated control systems designed to optimize various aspects of water treatment.
CHALLENGES FACING THE PHARMACEUTICAL UNIT
The unit faced several operational challenges due to the stringent demands of ZLD:
- Complex Multi-stage Treatment: Navigating the complexities of ETP, RO, and evaporation stages, which must function flawlessly to avoid production slowdowns due to bottlenecks.
High Operational Costs: Driven by intense energy and chemical usage across the treatment processes.
OBJECTIVES
Enhance Operational Efficiency: Implement real-time monitoring and automated adjustments to streamline operations.
Reduce Costs: Decrease operational expenses by optimizing chemical usage, energy consumption, and sludge generation.
Ensure Compliance: Achieve compliance excellence through precise control and monitoring.
Scalability: Utilize a modular platform capable of expansion across multiple sites.
ESG Impact: Improve environmental sustainability, social responsibility, and governance.
THE SOLUTION
Modular Automation Combined with Digitization
Bio Petro Clean introduced a combination of modular automation systems and the PureBI digital platform, tailored to enhance efficiency and compliance in water and wastewater management.
FAST AND EFFICIENT SETUP
The modular systems were designed for rapid integration, typically deployable within a week, complementing existing infrastructure without disrupting ongoing operations
COST-EFFECTIVENESS AND FLEXIBILITY
The solution, offered as a service, avoids large initial expenditures and adapts to varying operational demands without significant financial outlays. The Automation system optimised plant operations in real-time, directly bringing down the costs of chemical dosing.
HIGH-VALUE DIGITAL INSIGHTS
Advanced Analytics: Leveraging data from diverse sources to provide comprehensive operational insights and actionable intelligence.
Operational Optimization: Enhances process efficiencies across all treatment stages, optimizing chemical use and energy consumption.
Predictive Operational Guidance: Utilizes AI-driven analytics for predictive maintenance and operational troubleshooting.
KEY IMPLEMENTATIONS
1. Instrumentation and Automation
Flow Transmitters: Installed sludge recirculation and aeration inlet lines to control biological treatment processes, leading to better sludge health and reduced sludge production.
Dosing Automation Systems: Automated pumps for HCl, NaOH, Poly, and PAC dosing ensure accurate chemical application, which optimizes pH levels, turbidity, and TSS control while reducing chemical costs.
Sensors and Panels: pH and DO sensors in critical tanks, VFD & MCC panels for electrical control of dosing pumps, and automated sampling systems provide real-time data for precise adjustments.
Control Systems: Automated sampling and analysis systems ensure continuous monitoring and real-time control of water treatment parameters.
2. Instrumentation and Automation
Chemical Costs: There was an 80% reduction in the chemical costs.
Operational Costs: Despite an increase in manpower costs due to third-party O&M contracts, total operational expenses (OPEX) dropped from INR 182.09/m3 to INR 94.78/m3, a 48% reduction.
Energy and Sludge Costs: Notable reductions in steam costs (43%) and sludge costs (88%), contributing to overall cost efficiency.
IMPACT AND BENEFITS
Post-implementation, the unit experienced significant operational improvements:
Enhanced RO Efficiency: Increased by 5%, improving water recovery rates.
Reduced Evaporation Feed: Cut by 10%, lowering energy demands.
Chemical Usage Minimized: Decreased by 60%, optimising resource utilisation and reducing environmental impact.
Operational Cost Savings: Overall operational costs were reduced by 30%, enhancing economic efficiency.
Removing critical bottlenecks: The modular automation package provided on-field savings on chemical dosing and removed process bottlenecks, resulting in higher flow from RO going to the


1. Chemical Cost Savings:
The monthly chemical cost decreased substantially from Sep-23 to Apr-24. The average monthly chemical cost reduction from Feb-24 to Apr-24 was INR 70,000 compared to the previous five months.

2. Cost per Kiloliter
The monthly chemical cost decreased substantially from Sep-23 to Apr-24. The average monthly chemical cost reduction from Feb-24 to Apr-24 was INR 70,000 compared to the previous five months.

3. Steam Consumption:
Steam consumption was reduced significantly after implementing jet cleaning of the MEE, with the lowest consumption recorded in Apr-24.

4. Dissolved Oxygen (DO) Balance After VFD Installation:
Automated blower control through VFDs and DO sensors stabilized DO levels, reducing from an average of 5.8 ppm to 1.8 ppm, leading to better biological sludge characteristics and lower chemical use.

5. Flow to Reverse Osmosis (RO):
The inlet flow to RO systems increased from 12-13 m3/hour to 15-16 m3/hour, enhancing the throughput and efficiency of the RO process.

6. Secondary Clarifier and Tertiary Clarifier Outlet Turbidity:
Improvements in blower automation resulted in better biological process performance, which led to reduced turbidity in the secondary and tertiary clarifiers, improving overall water quality.


ESG IMPACT
Environmental Sustainability: The project significantly reduced chemical usage and optimized energy consumption, thereby lowering the environmental footprint.
Social Responsibility: Improved local environmental conditions by reducing steam usage, which contributes to better air quality and local ecosystem health.
Governance Enhancement: Automated data logging and compliance tracking strengthened regulatory adherence and operational transparency.
FUTURE IMPROVEMENTS AND OPTIMIZATIONS
Operational Excellence: Further increasing RO recovery rates, reducing manpower, parts, and consumables costs, and enhancing the quality of treatment processes.
Environmental Initiatives: Continued reduction of sludge output and the implementation of sustainable energy practices to further improve environmental sustainability.
Advanced Analytical Capabilities: Introducing analyzers for COD, BOD, TN, TP, and ammonia to gain deeper insights and refine control over water treatment processes.
CONCLUSION
The digitization and automation project in water management demonstrated substantial improvements in operational efficiency, cost savings, compliance adherence, and ESG impact. The implementation of advanced instrumentation
and control systems optimized the water treatment process, leading to significant financial and environmental benefits. The scalable nature of the system ensures that these improvements can be replicated across multiple sites, further enhancing the sustainability and efficiency of water management practices.