Wastewater Treatment Plant for the Pharmaceutical Industry

Wastewater treatment in pharmaceutical industries presents unique challenges due to wastewater contaminant nature, non-biodegradable and potentially hazardous compounds, and stringent regulatory requirements.

Source: M. Hassan et al., Removal of antibiotics.., Environ. Eng. Res., 26(1): 190405, 2021.

Based on our more than a decade of experience, some common problems in wastewater treatment plants for pharmaceutical industries and their potential solutions are as follows:

1. Presence of Pharmaceuticals and Active Pharmaceutical Ingredients (APIs)

Problem: Pharmaceuticals and APIs can be present in wastewater in high concentrations, posing a risk to the environment and public health.

Solution: Implement advanced treatment processes like activated carbon adsorption, Advanced Oxidation Processes (AOPs), and membrane filtration, such as Reverse Osmosis (RO), to remove pharmaceuticals and APIs effectively. AOPs such as ozonation or UV/H2O2 treatment to break down complex organic compounds before biological treatment is an economical solution.

Additionally, consider source control and process optimization to reduce the introduction of problematic chemicals into the wastewater.

Source: J. O. Eniola et al., A review on conventional.., J. Clean. Prod., Vol. 356, 131826, 2022.

2. High Variability and Fluctuations

Problem: Wastewater composition can vary significantly in pharmaceutical plants due to batch processes and changing production schedules.

Solution: Implement advanced process control and monitoring systems to adapt to changing conditions. Buffer tanks and equalization basins can help smooth out variations in flow and composition. Stay updated on emerging contaminants, conduct research, and adapt the new treatment processes accordingly. Pilot new treatment technologies before implementation.

Source: A. Turolla et al., Antibiotic resistant bacteria.., Chemosphere, Vol. 191, 761-769, 2018.

3. High Chemical Oxygen Demand (COD) and Biochemical Oxygen Demand (BOD)

Problem: Pharmaceutical wastewater typically has a high COD and BOD, which can overload biological treatment systems.

Solution: Optimize and upgrade biological treatment processes, such as activated sludge or sequencing batch reactors, and consider using pretreatment methods like chemical coagulation, flocculation, and primary sedimentation to reduce organic load. Adjust the nutrient levels to maintain the appropriate Carbon:Nitrogen:Phosphorus (C:N:P) ratio for biological treatment. Use chemical dosing or the Biological Nutrient Removal (BNR) processes.

Source: E. Płuciennik-Koropczuk et al., New Approach in COD.., Water, 11, 148, 2019.

4. Heavy Metals and Hazardous Chemicals

Problem: Some pharmaceutical processes involve the use of heavy metals and hazardous chemicals, leading to the presence of toxic substances in wastewater.

Solution: Implement chemical precipitation, ion exchange, or adsorption processes to remove heavy metals and hazardous chemicals. Proper containment and disposal of sludge are also crucial. Further, use bioremediation techniques like acclimatization of microbial communities to specific compounds.

Source: M. Ahmed et al., Recent developments in hazardous.., npj Clean Water, 12, 2022.

5. Chlorinated Solvents and Volatile Organic Compounds (VOCs)

Problem: Solvents and VOCs are common in pharmaceutical manufacturing and can be challenging to treat.

Solution: Employ advanced air stripping or activated carbon adsorption to remove volatile contaminants from wastewater. Consider recycling solvents where feasible to reduce the generation of such wastewater.

Source: Y. Li et al., Reversible Absorption of Volatile.., ACS Omega, 6, 1, 253–264, 2021.

6. High Salt Content

Problem: Some pharmaceutical processes involve salt utilization, leading to high salinity in wastewater.

Solution: Use reverse osmosis or electrodialysis to desalinate wastewater and recover valuable chemicals. Adequate pretreatment will prevent membrane fouling. Minimize salt usage in pharmaceutical processes whenever possible.

Source: N. A. A. Qasem et al., Removal of heavy metal.., npj Clean Water, 4:36, 2021.

7. Microbial Contamination and Pathogens

Problem: Pharmaceuticals may contain bacteria, viruses, or other pathogens, posing a risk to human health and the environment.

Solution: Incorporate disinfection methods such as Ultraviolet (UV) disinfection, chlorination, or ozonation to eliminate the microbial contaminants from wastewater. Further, implement tertiary treatment processes like advanced biological treatment, such as activated sludge with extended aeration and nitrification-denitrification, to remove residual microorganisms. Monitoring effluent for antibiotic resistance genes can also be valuable.

Source: A. S. Adeleye et al., Abundance, fate, and effects.., J. of Haz. Mat., Vol. 424-B, 127284, 2022.

8. Resource Recovery

Problem: Valuable resources, such as solvents, water, and energy, can be wasted in pharmaceutical wastewater treatment.

Solution: Implement resource recovery technologies like solvent recovery plants, anaerobic digestion for biogas production, heat recovery systems, and water recycling to minimize resource consumption and reduce operational costs.

Invest in green technologies, reuse/recycle water where possible, and explore ways to reduce the environmental footprint of wastewater treatment. Further, focus on energy-efficient treatment technologies, process optimization, and resource recovery to reduce operational costs. Explore opportunities for on-site renewable energy generation to offset energy consumption.

Source: Saltworks Technologies, via Wikimedia Commons.

9. Sludge Management

Problem: Pharmaceutical wastewater treatment generates sludge that may contain hazardous substances.

Solution: Opt for safe disposal or treatment of sludge, such as incineration, co-processing, or landfilling, depending on the composition and regulatory requirements. Explore opportunities for sludge valorization if feasible.

Source: G. Wang et al., Study on optimization.., Sci. of The Total Env., Vol. 739, 140166, 2020.

10. Monitoring and Data Management

Problem: Accurate monitoring and data management are crucial for efficient wastewater treatment.

Solution: Invest in real-time monitoring systems and data analytics tools to optimize treatment processes, identify issues promptly, and make informed decisions for process improvement. Flexible treatment systems can better adapt to changing conditions.

Source: Z. Yang, Low-cost and rapid sensors.., Nat Water, 1, 405-407, 2023.

11. Regulatory Compliance

Problem: Stringent regulations govern the discharge of pharmaceutical wastewater, and non-compliance can result in fines and legal issues.

Solution: Stay updated with local, state, and central regulations and work closely with regulatory agencies to ensure compliance. Regular monitoring and reporting are essential.

Source: C. Gadipelly et al., Pharm. Ind. Wastewater.., Ind. Eng. Chem. Res., 53, 29, 11571–11592, 2014.

12. Operator Training and Safety

Problem: Inadequate training and safety measures can lead to accidents and operational inefficiencies.

Solution: Provide comprehensive training for plant operators and maintain strict safety protocols to prevent accidents and ensure smooth wastewater treatment plant operation.

Source: A. S. Oberoi et al., Insights into the Fate and.., Env. Sci. & Tech., 53, 13: 7234–7264, 2019.

Successful wastewater treatment in pharmaceutical industries requires a holistic approach combining physical, chemical, and biological treatment methods and a commitment to regulatory compliance and sustainability. Collaboration with environmental experts like EnviroChem Services and regulatory agencies is essential to address these challenges effectively.