CRUX Biotech 1700 KLD UF RO Water Treatment Plant Case Study
CASE STUDY
1700 KLD UF + RO1 + RO2 Water Treatment Plant
CRUX Biotech India Pvt. Ltd., Nandigama,
Andhra Pradesh
Grain-Based Distillery |
16.761197°N, 80.148811°E
1700
KLD Capacity
90%
Recovery
2
RO Stages
Project Team
Design & Calculation
Mr. Rohit Shinde
Drawing & Documentation
Mr. Rohit Shinde
Manufacturing
Shankar & Team
Installation & Commissioning
Deepak & Team
Material Management
Tanuja Jagtap
Project Execution
Mukesh Fulore
1 │ PROJECT OVERVIEW
| Client | CRUX Biotech India Pvt. Ltd. |
|---|---|
| Site Location | Nandigama, Andhra Pradesh (16.761197°N, 80.148811°E) |
| Industry | Grain-Based Distillery |
| Executed By | BlueMaarlin Environmental Pvt. Ltd. (BMEPL) |
| System | Ultrafiltration (UF) + Two-Stage Reverse Osmosis (RO1 & RO2) |
| Feed Source | CPU (Condensate Polishing Unit) & ETP Treated Water |
| Design Tool | AutoCAD Plant 3D |
| Design Capacity | 1700 KLD (70.23 m³/hr peak flow) |
| Target Recovery | 90% overall water recovery |
2 │ Client Requirements
CRUX Biotech operates a grain-based distillery in Nandigama, Andhra Pradesh, generating approximately 17,00,000 litres of process condensate and effluent daily across multiple distillation units. The treated water from the CPU and ETP still contained residual TDS, organics, and dissolved salts that prevented direct process reuse.
- High-recovery water recycling system downstream of CPU and ETP treatment
- Energy-efficient, low-maintenance solution suitable for a remote location in Andhra Pradesh
- Full process automation to minimise operator dependency
- 90% overall water recovery aligned with Zero Liquid Discharge (ZLD) objectives
- Consistent permeate quality despite variable feed characteristics from distillery operations
- Low initial capital investment with long-term membrane longevity (target: 3+ years)
Feed Water Quality (Design Basis)
| Parameter | Value | Unit |
|---|---|---|
| TDS | 730 | mg/L |
| BOD | 2,144 | mg/L |
| COD | 3,446 | mg/L |
| TSS | 94 | mg/L |
| pH | 3.5 – 4.0 | — |
| Temperature | ~39 | °C |
3 │ CHALLENGES
Technical Challenges
- Designing a two-stage RO system to achieve 90% overall recovery while limiting individual membrane flux rates to protect longevity
- RO2 challenge: achieving 60–64% recovery at higher flux rates; resolved by integrating a booster pump between RO2 stages
- Managing fouling and scaling risk from grain-based distillery effluent with aggressive antiscalant and antioxidant dosing schemes
- Ensuring 3+ year membrane life while operating at elevated pressures with high-rejection Toray 8040 elements
Site & Logistics Challenges
- Remote site in Nandigama, Andhra Pradesh — all equipment, materials, and skilled teams mobilised from Pune/Nagpur
- Compact plant footprint requiring precise 3D layout engineering using AutoCAD Plant 3D to fit UF, RO1, RO2, and CIP skids
- Tight project schedule requiring parallel manufacturing, procurement, and site civil preparation activities
- Coordination with Lars Enviro (P&ID authority) and end-client across multi-disciplinary teams
- Developing fully automated operation (Aster UF Matic + RO Matic MCC panels) without cost escalation
4 │ ENGINEERING & DESIGN APPROACH
Based on the feed water parameters, BlueMaarlin's design team — led by Rohit Shinde — adopted a three-stage treatment philosophy: Ultrafiltration (UF) for suspended solids and turbidity removal, followed by a two-stage Reverse Osmosis system (RO1 + RO2) to maximise water recovery. The entire plant was modelled using AutoCAD Plant 3D to ensure accurate piping isometrics, equipment placement, and clash-free layout before fabrication commenced.
Design Rationale
- UF selected with HITEC PES membranes (100KD MWCO, 50 LMH flux) for reliable suspended solids removal protecting downstream RO membranes
- RO1 designed at 72% recovery (inlet 70.23 m³/hr, reject 19.66 m³/hr redirected to RO2) using 78 Toray TM20D-400 elements in 13 × 6E housings
- RO2 designed at 60–64% recovery (inlet 19.66 m³/hr, final reject ~7.2 m³/hr)
- CNP booster pump (CDLF 12-3) integrated between RO2 stages
- Both RO high-pressure pumps fitted with VFDs for energy optimisation and flow control
- CIP system with Kirloskar SS316 pump and 3000L HDPE tank for periodic membrane cleaning
Water Balance (Design)
| Stream | Flow Rate (m3/hr) | Note |
|---|---|---|
| UF Feed | 77.0 | From CPU + ETP treated water |
| UF Permeate | 70.23 | Feeds RO1 (90% UF recovery) |
| UF Reject | ~7.7 | Backwash / drain |
| RO1 Permeate | 50.57 | Product water |
| RO1 Reject | 19.66 | Feeds RO2 |
| RO2 Permeate | 12.46 | Product water |
| RO2 Reject | ~7.2 | Final reject / ZLD feed |
| Total Product | ~63.0 | 90% of UF feed recovered |
5 │ ULTRAFILTRATION (UF) SYSTEM
| Component | Specification |
|---|---|
| Membrane Make | HITEC |
| Model | EDMT-EM-81XVI-MBM100KD |
| Membrane MOC | PES (Polyethersulfone) |
| MWCO | 100 kDa |
| Membrane Area | 81 m2 per module |
| No. of Membranes | 19 Nos. |
| Flux Rate | 50 LMH |
| UF Recovery | 90% |
| End Cap MOC | PPGF (Polypropylene Glass Filled) |
| Backwash Pump | Kirloskar DBXE 125/32-94 – 248 m3/hr, 25m, 30 kW |
| Transfer Pump | Kirloskar DB32/26xe — 9.5 m3/hr, 15m, 1.5 kW |
| Basket Strainer | BMEPL SS304, 150 micron, 80 m3/hr, 120NB |
| Acid Dosing | Positive Metering PP pump, 375 LPH, 3.5 kg/cm2 |
| Alkali Dosing | Positive Metering PP pump, 276 LPH, 3.5 kg/cm2 |
| Hypochlorite Dosing | Positive Metering PP pump, 370 LPH, 3.5 kg/cm2 |
| Dosing Tanks | Plasto HDPE/PP, 100L each (Acid, Alkali, Hypo) |
| UF Skid | MS Epoxy Coated (BMEPL) |
| Piping | Astral UPVC SCH40 |
| Auto Butterfly Valves | Aira CI, 4" and 8" (Pneumatic) |
6 │ REVERSE OSMOSIS — STAGE 1 (RO1)
| Component | Specification |
|---|---|
| RO Membrane Make | Toray |
| Model | TM20D-400 |
| Size | 8040 (8" × 40") |
| Membrane Housing | UKL FRP, 8040, 6 Elements/vessel, 300 PSI |
| No. of Housings | 13 Nos. → 78 Total Membranes |
| Raw Water Pump | Kirloskar DB50/16x6-78 — 70 m³/hr, 3 kg/cm², 9.3 kW |
| High Pressure Pump | CNP CDL 85-40 — 70.5 m³/hr, 9.3 bar, 30 kW, VFD |
| Cartridge Filter | BMEPL SS304, 5 micron, 30" × 30E, 100NB |
| Recovery | 72% (RO1) |
| Feed Flow | 70.23 m³/hr |
| Permeate | 50.57 m³/hr |
| Reject to RO2 | 19.66 m³/hr |
| Acid Dosing Pump | Positive Metering PP, 11 LPH, Electronic (Edose) |
| Antiscalant Pump | Positive Metering PP, 6 LPH, Electronic (Edose) |
| Antioxidant Pump | Positive Metering PP, 6 LPH, Electronic (Edose) |
| Dosing Tanks | Plasto HDPE, 100L each (3 nos.) |
| Pressure Gauges | Baumer SS, 0–7 kg/cm² and 0–21 kg/cm² (20 nos.) |
| Pressure Switches | Danfoss KP35 (Low), KP36 (High) |
| Solenoid Valve | Aira/Uflow SS, NC, 80NB |
| RO1 Skid | MS Epoxy Coated with CIP provision (BMEPL) |
| Piping | Astral UPVC SCH40; HP lines SS304 |
7 │ REVERSE OSMOSIS — STAGE 2 (RO2)
| Component | Specification |
|---|---|
| RO Membrane Make | Toray |
| Model | TML20D-400 |
| Size | 8040 (8" × 40") |
| Membrane Housing | UKL FRP, 8040, 5 Elements/vessel, 450 PSI |
| No. of Housings | 5 Nos. → 25 Total Membranes |
| Raw Water Pump | Kirloskar DBXE 32/16-78 — 20.5 m3/hr, 3 kg/cm2, 3.7 kW, CF8M |
| High Pressure Pump | CNP CDLF 20-12 — 20.5 m3/hr, 12 bar, 15 kW, SS316, VFD |
| Booster Pump | CNP CDLF 12-3 — 11 m3/hr, 2.5 bar boost (inlet 11 bar) |
| Recovery | 60–64% (RO2) |
| Feed Flow | 19.66 m3/hr (RO1 Reject) |
| Permeate | ~12.46 m3/hr |
| Final Reject | ~7.2 m3/hr |
| Dosing Pumps | Acid & Antiscalant — PP, 4 LPH each (4 nos.) |
| Dosing Tank | Plasto HDPE, 100L |
| Pressure Switches | Danfoss KP35 / KP36 |
| Solenoid Valve | Aira SS, 50NB |
| RO2 Skid | MS Powder Coated with CIP provision (BMEPL) |
| Piping | Astral UPVC SCH40; HP lines SS316 |
8 │ CIP SYSTEM & ANCILLARY EQUIPMENT
| Component | Specification |
|---|---|
| CIP Pump | Kirloskar DBXE 50/16-78 — 62.5 m³/hr, 40m, SS316 |
| CIP Tank | Plasto HDPE, 3000L, Vertical Cylindrical |
| CIP Cartridge Filter | BMEPL SS316, 5 micron, 30" × 24E, 100NB |
| Conductivity Meters | Aster CT650, 0–2000 ppm, Field Mount — 4 nos. |
| pH Meters | Aster PO650, Meter + Sensor, Relay Output — 2 nos. |
| ORP Meter | Aster PO650-ORP, Relay Type — 1 no. |
| Mag Flow Meters | Aster MSRL Electromagnetic — 11 nos. |
| Level Transmitters | Forbes Marshall Ultrasonic — 3 nos. |
| Temp Transmitter | Forbes Marshall — 1 no. |
| DP Switches | Danfoss — UF, RO1, RO2 (3 nos.) |
| Level Switches | Aster, 5m cable, Low Level (8 nos. for dosing tanks) |
| Rotameters | Aster Polycarbonate, Flanged — 2 nos. |
| Control Panel | Aster — UF Matic + RO Matic (RO1 & RO2), Pre-programmed MCC |
| Air Compressor | For pneumatic butterfly valves — continuous operation |
| SDI Kit | Aster with 50 pcs filter paper — 1 no. |
9 │ OPERATIONAL DATA — LIVE SHIFT READING
The following data was recorded during a live shift reading at the CRUX Biotech plant, confirming the system is operating in close alignment with design parameters.
| Date | 13 May 2026 |
|---|---|
| Shift | G |
| Operator | M. BalaBhaskar |
UF System — Shift Performance
| Parameter | Reading | Unit |
|---|---|---|
| Running Hours | 05:00 | hrs |
| UF Feed (Flow Meter) | 254748 → 255130 = 382 | m³ |
| UF Permeate | 226877 → 227221 = 344 | m³ |
| UF Reject | 38 | m³ |
| UF BW Feed | 9358918 → 9358941 = 23 | m³ |
| UF BW Reject | 26764 → 26795 = 31 | m³ |
| UF Recovery | 90 | % |
RO1 System — Shift Performance
| Parameter | Reading | Unit |
|---|---|---|
| Running Hours | 04:00 | hrs |
| RO1 Feed (Flow Meter) | 201031 → 201256 = 225 | m³ |
| RO1 Permeate | 50439 → 50591 = 152 | m³ |
| RO1 Reject | 60907 → 60989 = 82 | m³ |
| RO1 Recovery | 67.5 | % |
RO2 System — Shift Performance
| Parameter | Reading | Unit |
|---|---|---|
| Running Hours | 04:00 | hrs |
| RO2 Feed (Flow Meter) | 62563 → 62643 = 80 | m³ |
| RO2 Permeate | 13370 → 13418 = 48 | m³ |
| RO2 Reject | 25347 → 25380 = 33 | m³ |
| RO2 Recovery | 60 | % |
Ancillary Transfers — Same Shift
| Stream | Reading | Volume (m³) |
|---|---|---|
| CT Blowdown | 25692 → 25746 | 54 |
| RO Permeate Transfer | 135905 → 135905 | 0 (Pump not running) |
| RO2 Reject Transfer | 16116 → 16166 | 50 |
| UF Permeate Transfer | 85749 → 85895 | 146 |
| Air Compressor | Running Hours | 08:00 hrs |
10 │ RESULTS & ACHIEVEMENTS
90%
Water Recovery
122 Nos
Total Membranes
Full
Automation Level
- 1700 KLD UF-RO system successfully commissioned at CRUX Biotech, Nandigama — operational and performing to design specifications
- 0% overall water recovery achieved from CPU and ETP treated water, enabling near-ZLD operation at the grain-based distillery
- Reliable permeate quality maintained consistently using Toray high-rejection RO membranes (TM20D-400 & TML20D-400)
- Live shift data confirms UF at 90% recovery, RO1 at 67.5%, RO2 at 60% — well within design parameters
- Fully automated plant operation via pre-programmed Aster MCC (UF Matic + RO Matic) — minimal operator intervention required
- Innovative two-stage RO design with inter-stage booster pump protects membrane flux rates while achieving maximum recovery
- Robust CIP system (Kirloskar SS316 pump, 3000L tank) ensures sustained membrane life — targeted at 3+ years
- AutoCAD Plant 3D engineering ensured clash-free layout, accurate piping, and smooth on-site installation by Deepak's team
- Remote site in Andhra Pradesh successfully handled through meticulous planning and procurement by Tanuja Jagtap and Mukesh Fulore