By Arun Rao
Thermosag India Pvt. Ltd., an innovative manufacturer in the field of wastewater treatment technologies, is making waves in the industry with its cutting-edge solutions. Specializing in high-speed turbo centrifugal compressors, Thermosag India has established itself as a leader in providing energy-efficient, cost-effective, and highly customizable wastewater treatment systems for various industries, including textiles, chemicals, and pharmaceuticals. The company’s breakthrough technology offers substantial operational savings, improved performance, and lower environmental impact compared to conventional systems.
A Unique Technology for Cost-Effective Wastewater Treatment
One of Thermosag India’s key unique selling propositions (USPs) lies in its high-speed turbo centrifugal compressors, which are designed to handle steam compression at a compression ratio of 1.8-2.0, which is the highest in a single stage for MVR application. This enables system to handle high boiling point elevation and achieve Zero Liquid Discharge (ZLD). Thermosag’s compressors also outperform other alternatives of MVR like blower and fans in terms of Delta T (temperature differential), achieving a remarkable range of 16-20°C, compared to the typical 7 – 9°C in conventional units.
Mr. Avinash Verma, Director of Thermosag India, highlighted the substantial cost benefits associated with their compressors. He stated, “One of the biggest operational costs in ZLD systems is the evaporation cost, which in conventional systems can range from Rs 0.9 to 1.5 per litre. With our compressors, depending on the Total Dissolved Solids (TDS) and Chemical Oxygen Demand (COD) of the effluent, the operating cost reduces significantly to Rs 0.2 to 0.5 per litre.” This reduction in operating costs translates into long-term savings for industrial users, making Thermosag India’s solution highly attractive for industries like textiles, chemicals, and pharmaceuticals.
Efficient Salt Recovery Solutions for the Textile Industry
Another standout feature of Thermosag India’s wastewater treatment solutions is its capability to recover salts commonly used in textile manufacturing. The textile industry, in particular, uses salts like NaCl and Na2SO4 in the processing of yarns and fabrics, which are typically found in the effluents from dyeing and finishing processes. These salts can be valuable, and Thermosag India’s systems not only treat the wastewater but also offer a means of recovering these salts for reuse.
Corrosion-Resistant Equipment and Low-Cost Maintenance
To ensure the longevity and reliability of its wastewater treatment systems, Thermosag India uses titanium, a highly durable and corrosion-resistant material, in its equipment. This is particularly important in industries where harsh chemicals and high salinity levels are present in the effluent. By using titanium, Thermosag India guarantees that its systems remain operational for extended periods, even under challenging conditions, thus reducing the need for frequent replacements and repairs.
In addition to the durability of the materials used, Thermosag India also focuses on offering a low total cost of ownership (TCO) for its customers. “We offer competitive rates for spare parts, and we pride ourselves on providing service within 24 hours,” Mr. Verma explained. “Most challenges faced by plants can be resolved by our engineers over the phone, which minimizes downtime and ensures smooth operation of the plants. Our equipment is rugged and well-suited for the Indian market.”
State-of-the-Art Manufacturing Facility and Quality Control
Thermosag India’s manufacturing facility, based in Ahmedabad, spans over 5,000 square meters and is equipped with the latest CNC machines, including cutting and rolling machines. The company also boasts three cranes with varying capacities, which are used to handle the heavy equipment used in the manufacturing process.
By managing the majority of its production in-house, Thermosag India maintains stringent control over the quality of its wastewater treatment systems. The company fabricates a large portion of its ZLD systems internally and relies on external suppliers only for components such as motors and control panels. This in-house production allows for better oversight of quality control, ensuring that all systems meet international standards and are tailored to meet the specific requirements of each client.
Adapting to Industry Needs: Tailored Solutions for Textile Mills
Thermosag India understands the importance of reliability and robustness in wastewater treatment systems, especially for industries like textile manufacturing, where operations run continuously around the clock. According to Mr. Verma, “Textile mills need rugged and reliable equipment to ensure that there is no disruption in the supply of recycled water.” Thermosag India’s systems are designed to meet these demands, ensuring that they can handle the high volume of wastewater and complex chemical compositions typically found in textile mill effluents.
Overcoming Challenges in Textile Effluent Recycling
Effluents from textile dyeing and processing industries are notoriously difficult to treat due to their high Total Dissolved Solids (TDS) and Chemical Oxygen Demand (COD). Mr. Verma elaborated, “The effluents released by textile dyes manufacturers are some of the toughest to recycle among all industries. The TDS in effluents after Reverse Osmosis (RO) treatment typically ranges between 6-10%, while the COD is around 10,000. In contrast, in factories manufacturing intermediates and dyes, the TDS can be as high as 15-20%, and the COD can range from 50,000 to 100,000.”
Given the complexity of effluents, many textile mills have struggled with the Mechanical Vapour Recompression (MVR) technology which has not proved effective. However, Thermosag India’s MVR solution is designed specifically to handle the challenging effluent profiles found in textile industries. “Our MVR technology is perfectly suited for all industries, including textiles. We have over 25 years of experience in the wastewater treatment sector, and we are convincing textile mills to adopt our MVR systems Or replace their blower with our compressor and also convert their existing MEE system to MVR system by integrating Turbo MVR to their MEE without much of the modifications for operating cost reduction and environmental sustainability,” Mr. Verma said.
Thermosag India’s MVR systems are flexible and can be integrated into existing effluent treatment plants (ETPs) without the need for major changes to the infrastructure. This makes it an attractive option for companies with existing water treatment systems that need to improve performance or increase capacity.
Looking Ahead: Thermosag India’s Commitment to Innovation
“We are committed to offering customized, high-performance wastewater treatment solutions that meet the unique challenges of every customer,” Mr. Verma concluded. “With our expertise, cutting-edge technology, and strong commitment to quality, we are confident that Thermosag India will continue to lead the way in wastewater treatment innovations.”
