Sewage Treatment Process Control System
Automated treatment process optimization with environmental compliance tracking
Duration
10 months development
Feb 2023 - Nov 2023
Team
8 specialists
Process engineers + Automation
Location
Major City, Eastern India
3 treatment plants
The Challenge
The Regional Wastewater Authority was operating treatment plants with manual process control, leading to inconsistent treatment quality and frequent environmental compliance violations. Operators relied on periodic manual testing, causing delayed responses to process upsets. Energy consumption was 40% higher than optimal due to constant operation of aeration systems. They needed an intelligent control system to optimize treatment processes, ensure compliance, and reduce operational costs.
Process Control Solution
Treatment Process Automation
Stage 1: Primary Treatment
Automated screening and grit removal with flow control
Stage 2: Biological Treatment
Intelligent aeration control based on dissolved oxygen levels
Stage 3: Advanced Treatment
Chemical dosing and disinfection with quality control
Control System Architecture
- PLC-based Control
Allen-Bradley ControlLogix for process automation
- SCADA System
Wonderware InTouch for visualization and control
- Process Instruments
Online analyzers for BOD, COD, TSS, pH, DO
- Variable Frequency Drives
Energy-efficient pump and blower control
Process Optimization Features
- Adaptive Control
Self-adjusting parameters based on influent quality
- Energy Optimization
DO-based aeration control saves 35% energy
- Predictive Maintenance
Equipment health monitoring and failure prediction
- Automatic Reporting
Regulatory compliance reports generation
Environmental Compliance Management
Discharge Standards Monitoring
Compliance Features
Daily, weekly, monthly compliance reports
Instant SMS/email for limit exceedance
Pollution Control Board format exports
Sludge Management Module
Sludge Generation
Primary + Secondary sludge
Digestion Process
Anaerobic digestion period
Final Disposal
Dewatered sludge cake
Results Achieved
Process Improvements
- • Improved treatment efficiency from 75% to 95% BOD removal
- • Reduced energy consumption by 35% through optimized aeration
- • Eliminated compliance violations (100% compliance achieved)
- • Reduced chemical consumption by 25% through precise dosing
Operational Benefits
- • Reduced operator workload by 60% through automation
- • Predictive maintenance reduced equipment failures by 80%
- • Biogas generation provides 40% of plant energy needs
- • Automated reporting saves 20 hours/week of manual work
Client Feedback
"The process control system has transformed our sewage treatment operations. We've achieved consistent compliance with environmental standards while significantly reducing operational costs. The automated control and optimization features have made our plants much more efficient, and the biogas generation has become a valuable energy source. SmartBhujal delivered a comprehensive solution that exceeded expectations."
Optimize Your Treatment Plant?
Achieve environmental compliance while reducing operational costs through intelligent process control and automation. Transform your sewage treatment plant into an efficient, sustainable operation.
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