ZLD Plant Case Study - Biocon Biologics | Zero Liquid Discharge System

SYNOPSIS

BIOCON Biologics, Malaysia Plant has achieved water conservation and ZLD (Zero Liquid Discharge) objectives with Unique, revolutionary , sustainable, “SCALEBAN” technology without implementing costly conventional technologies available globally.

Background of “SCALEBAN” Project

BIOCON is an Indian company and has a large insulin manufacturing facility in Malaysia. As per DOE (Department of Environment) norms in Malaysia, they were allowed to discharge only 400 m3/ day treated wastewater outside the plant after achieving discharge limit parameters, because of this restriction and
variation in the raw wastewater parameters, they were not able to achieve their full production. Due to this serious issue they were searching for technologies to recycle their 400 m3/day wastewater within the plant to utilize optimum capacity of the plant.

Challenges for BIOCON:

Due to variation in the wastewater parameters, No technology supplier was able to provide a solution to treat their wastewater, as all available conventional technologies are designed on the basis of fixed design wastewater parameters thereby recycling of wastewater project was getting delayed and affecting the plant production.

BIOCON Approach:

During this process of finding a right technology provider, they came across “SCALEBAN” Technology and discussed with our existing clients to gain the confidence on “SCALEBAN” technology.

After verifying the performance of “SCALEBAN” technology, BIOCON Biologics, awarded a contract to “Scaleban” to utilise their 400m3/day high TDS wastewater at 1060TR x 5Nos. Chiller Cooling Towers in place of fresh water for achieving water conservation and ZLD on a sustainable basis. This project was commissioned in the month of August 2021.

"SCALEBAN" water conservation & ZLD Scheme

Achievements of the “SCALEBAN” Project for Biocon

Achieved water conservation and ZLD objectives on a sustainable basis.
Saving in high CAPEX of MEE (Evaporator).
Saving in high OPEX of MEE (Evaporator).
100% saving of fresh water consumption in cooling towers.
Completed project in 6-8 weeks.
Considerable reduction in Carbon footprint.
High COC operations of the cooling tower.
Substantial reduction in cooling tower blowdown quantity.
Zero scale, corrosion and biofouling free operation of the entire cooling tower circuit including chiller condensers.
Maintained chiller approach.
Saving in energy consumption.
No down time of the plant.
By implementing Scaleban technology Biocon contributed in achieving UN
sustainable development goal no. 6,7,13,14.

After successful operation of the “SCALEBAN” project, BIOCON awarded repeat order to “SCALEBAN” for their another facility in Malaysia to utilize 200m3/day utility RO reject in the Chiller and SRP Cooling Tower.

“SCALEBAN” technology is handling total 600m3/day wastewater in all the Cooling Towers successfully and achieving their water conservation and ZLD objectives on a sustainable basis ,also saving equal amounts of fresh water.

In the “SCALEBAN” process we are operating a cooling tower at very high COC (20-25) with wastewater and maintaining 80,000 ppm ;of TDS in cooling tower recirculation water and giving only 15 m3/day concentrated blowdown, which Biocon is handling separately.