Filtration Capacity of Vulcan STP

India faces a staggering wastewater challenge, producing over 72,000 million litres of sewage daily while treating only 28% effectively, leading to environmental degradation and health crises costing ₹50,000 crore annually.

In urban and industrial hubs, where water scarcity intensifies operational pressures, advanced sewage treatment system is no longer optional but essential for sustainability. SKF Elixer’s STP Vulcan, a high-capacity wastewater treatment plant, stands at the forefront, leveraging Attached Growth Bioreactor (AABR) technology to deliver superior STP filtration and enable water reuse across applications. This system transforms sewage into a resource, supporting businesses in conserving freshwater and reducing costs.

This blog delves into the filtration capacity of STP Vulcan, its operational mechanics, and why it excels in energy-efficient sewage filtration for Indian contexts. Whether you’re managing a hotel in Goa, an industrial unit in Pune, or a residential complex in Noida, discover how SKF Elixer’s industrial STP solutions in India can optimize your water management.

Understanding STP Filtration and Its Role in Wastewater Management

STP filtration refers to the multi-stage process of removing physical, biological, and chemical contaminants from sewage, measured by parameters like Biochemical Oxygen Demand (BOD) reduction, Total Suspended Solids (TSS) removal, and pathogen elimination.

In India, CPCB norms mandate treated effluent with BOD below 20 mg/L and TSS under 50 mg/L for reuse or discharge. Poor filtration leads to clogged systems, high energy use (₹50,000–₹1 lakh annually in power for a 100 KLD plant), and non-compliance fines of ₹1–5 lakh.

Vulcan STP’s AABR-based filtration excels here, handling inflows of 5–500 KLD with 90–95% pollutant removal efficiency. Using synthetic media for biofilm growth, it degrades organics biologically, producing minimal sludge (50–100 kilograms daily for 50 KLD) and enabling 80–90% water reuse for non-potable needs like irrigation or flushing, saving ₹1–2 lakh yearly in freshwater bills for a 200 KLD setup.

Understanding the Filtration Capacity of Vulcan STP

Vulcan STP’s filtration capacity is defined by its ability to process variable inflows while maintaining consistent outflow quality. Ranging from 5 KLD (suitable for small resorts) to 500 KLD (for large industries), each unit treats sewage through aerobic and anaerobic zones on attached media, achieving:

• Influx Handling: Processes 5,000–500,000 litres daily, with peak load tolerance up to 150% without quality drop, ideal for fluctuating hotel occupancy.
• Filtration Efficiency: Reduces BOD from 200–400 mg/L to <10 mg/L (95% removal) and COD from 500–1,000 mg/L to <50 mg/L, surpassing CPCB standards.
• Pathogen Reduction: Eliminates 99.99% fecal coliform (<100 MPN/100 mL) via biofilm and disinfection, ensuring safe reuse.
• Sludge Yield: Low 0.3–0.5 kilograms per kilogram BOD removed, vs. 0.8–1 in conventional systems, cutting disposal costs by 30% (₹20,000–₹40,000 annually for 100 KLD).

For a 50 KLD Vulcan STP, filtration capacity supports 200–500 users, treating 45,000–48,000 litres daily with oxygen transfer rates of 2–3 kilograms O2/kWh, using 20–30% less energy (₹30,000–₹50,000 yearly savings at ₹5 per kWh).

Vulcan STP Sewage Treatment Technology: The AABR Core

At the heart of STP Vulcan is the AABR system, where wastewater flows over synthetic media (surface area 200–300 square meters per cubic meter), fostering microbial biofilms that degrade pollutants:

1. Preliminary Screening: Removes solids (2–5 kilograms per 1,000 litres), preventing clogs.
2. Anaerobic Zone: Breaks down organics without oxygen, reducing 40–50% BOD.
3. Aerobic Zone: Biofilms oxidize remaining pollutants, with air blowers supplying 1–2 cubic meters per minute, achieving nitrogen removal via nitrification-denitrification (total nitrogen <10 mg/L).
4. Settling and Filtration: Clarifiers separate sludge, with tertiary filters polishing effluent to TSS <10 mg/L.
5. Disinfection: UV or chlorination ensures pathogen-free output.

This technology handles shock loads (up to 200% influx variation), producing odour-free operation and reusable water for cooling towers (saving 50,000 litres daily in factories) or gardening.

Why Capacity Matters in STP Plants: Balancing Inflow, Outflow, and Water Reuse

Capacity directly influences STP performance:

• Inflow-Outflow Balance: Vulcan’s modular design scales inflow (e.g., 100 KLD processes 90,000–95,000 litres outflow daily at 90–95% recovery), preventing overflows costing ₹50,000–₹1 lakh in fines.
• Water Reuse Potential: Treated water meets standards for toilet flushing (saving 40–50% freshwater, ₹1–2 lakh annually for hotels), irrigation (50–100 litres per square meter for landscapes), or industrial cooling (reducing bills by ₹2–3 lakh for 200 KLD).
• Load Fluctuations: AABR stability handles peak inflows (e.g., hospital surges), maintaining filtration efficiency and avoiding sludge bulking that wastes 20–30% capacity in traditional STPs.
• Economic Impact: Optimal capacity cuts energy (0.5–1 kWh per KL treated, ₹50,000 yearly for 100 KLD) and sludge disposal (₹10–20 per kilogram).

For a 100 KLD Vulcan in a residential complex (500 residents), balanced capacity reuses 80,000 litres daily, conserving resources and generating ₹1–1.5 lakh annual savings.

Energy-Efficient Sewage Filtration System in Vulcan

Vulcan prioritizes efficiency:

• Low Power Consumption: AABR’s high oxygen transfer (30–40% efficiency) uses 20–30% less electricity than MBBR systems (0.4–0.6 kWh/KL vs. 0.8–1 kWh/KL), saving ₹30,000–₹50,000 annually for 50 KLD.
• Minimal Sludge: 30% less generation reduces handling costs (₹20,000–₹40,000 yearly).
• Automated Controls: PLC systems optimize aeration, cutting operator needs to 2–4 hours daily (saving ₹50,000 labour).

This makes Vulcan ideal for industrial STP solutions in India, where energy costs escalate operations.

Industrial STP Solutions in India with Vulcan

Vulcan serves key sectors:

• Hotels/Resorts (50– 5–100 KLD): Reuses for flushing/gardening, saving ₹1–2 lakh water bills.
• Hospitals (100–200 KLD): Ensures sterile effluent, complying with rules, avoiding ₹1–5 lakh fines.
• Factories (200–500 KLD): Treats for cooling, reducing freshwater intake by 70% (₹2–5 lakh savings).
• Residential Complexes: 50–500 KLD units fit basements (20–100 square meters), supporting green certifications.

Fully/semi-automatic options include relocatable modules for labor camps.

Why Choose STP Vulcan

SKF Elixer’s Vulcan stands out with:

• Proven AABR: Consistent quality (BOD <10 mg/L), durable Stainless Steel (SS) construction (20+ years).
• Space-Saving: Compact footprint (50% less than concrete STPs).
• Flexibility: Modular, relocatable, scalable.
• Cost-Effective: Low OPEX (30% sludge reduction), enhances eco-reputation.
• Sustainability: Reuses water, produces fertilizer from sludge (₹20,000 value from 50 KLD).

Conclusion

The filtration capacity of STP Vulcan redefines sewage treatment, balancing efficiency, reuse, and sustainability. SKF Elixer’s AABR technology empowers businesses to conserve water and cut costs amid India’s challenges. Embrace Vulcan for a greener operation.

Contact SKF Elixer for tailored solutions.

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