Advanced Effluent Treatment Solutions for the Textile Industry
Transform textile wastewater liabilities into sustainable competitive advantages through cutting-edge treatment technologies and Zero Liquid Discharge (ZLD) systems
Critical Challenges in Textile Wastewater Management
The textile industry faces unprecedented challenges in wastewater treatment, requiring advanced solutions that address complex effluent matrices and stringent regulatory requirements.
Complex Effluent Matrix
Synthetic dyes, surfactants, salts, heavy metals and recalcitrant organics from desizing, scouring, bleaching, dyeing, printing and finishing processes.
Stringent Discharge Norms
Elevated COD, BOD, TDS and TSS routinely exceed statutory limits, requiring advanced treatment technologies.
Water Scarcity & Cost Escalation
Rising tariffs and unreliable supply threaten production continuity, demanding efficient water reuse systems.
Regulatory Exposure
Inadequate treatment risks penalties or forced shutdowns, making compliance critical for operations.
Circular Economy Mandate
Brands and investors demand traceable water reuse and chemical recovery for sustainable operations.
WTT Integrated Treatment Approach – Deep Technical View
Our comprehensive treatment train combines proven technologies with innovative process optimization to deliver guaranteed performance across all textile applications.
| Process Stage | Core Design Features | Operating Window | Guaranteed KPI |
|---|---|---|---|
| Rotary Brush Screener | 0.5 mm wedge-wire drum, dual nylon brushes, VFD drive | 50 – 1,000 m³/h | ≥ 98% fibre removal, TSS < 100 mg/L to DAF |
| Dissolved-Air Flotation | 45-60 µm micro-bubbles, in-line flocculation (G ≈ 250 s⁻¹) | ≤ 15 m³/m²/h, recycle 12 – 15% | Oil & grease < 5 mg/L, colour reduction 35 – 45% |
| Neutralisation and Cooling | Dual chemical dosing, induced-draft tower | pH 6.8 – 7.2, effluent ≤ 35 °C | Scaling index < 0.6 |
| Hybrid Oxic-Anoxic Biology | Step-feed plug flow, fine-bubble aeration (αSOTE 6% m-depth⁻¹) | MLSS 6-8 g/L, F/M 0.12-0.18 d⁻¹ | COD ↓ ≥ 92%, BOD ↓ ≥ 95% |
| Lamella Settler + Circular Clarifier | 55° PVC lamella, Thompson profile, half-way bridge | Overflow 1.0-1.2 m³/m²/h | Turbidity < 20 NTU |
| Submerged Ceramic MBR | 0.05 µm alumina plates, air-lift scour 0.25 Nm³/m²/h | Flux 22-30 LMH @ 35 °C | Permeate SDI < 3, log-4 pathogen removal |
| Microfiltration + Advanced Oxidation | 0.2 µm PVDF MF + Fenton/ozone (ORP > 850 mV) | Flux 80-100 LMH | Residual colour < 1 Pt-Co |
| Degasser Tower | PP random packing 250 m²/m³ | CO₂ removal > 85% | Alkalinity reduction > 150 mg/L as CaCO₃ |
| High-Recovery RO | Three-stage array, inter-stage ERD, NF pre-pass | Feed TDS 3,000-7,000 mg/L, 85% recovery | Permeate conductivity < 50 µS/cm |
| Brine Recovery | Softening, silica adsorber, colour resin | 15-20% of RO feed | Enables second HR-RO, salt reuse ≈ 1.1 kg/kg |
| Zero Liquid Discharge | MVC evaporator (ΔT 5 °C) + crystalliser | SEC 10-12 kWh/m³ | Liquid purge < 0.5 m³/d @ 5,000 m³/d plant |
| Caustic Recovery (CaRe) | Triple-effect TVR evaporator, mixed-bed polishing | 48 wt % NaOH @ 115 °C | 55-60% NaOH reuse, 12-18 month payback |
Zero Liquid Discharge (ZLD)
MVC evaporator with 84% latent-heat reuse achieving liquid purge < 0.5 m³/d at 5,000 m³/d plant capacity.
SEC 10-12 kWh/m³
Submerged Ceramic MBR
0.05 µm alumina plates with pH 1-13 tolerance, 350°C steam sterilisation, and 10-year warranty.
Flux 22-30 LMH @ 35°C
Caustic Recovery (CaRe)
Triple-effect TVR evaporator with mixed-bed polishing achieving 55-60% NaOH reuse.
12-18 month payback
High-Recovery RO
Three-stage array with inter-stage ERD and NF pre-pass achieving 85% recovery from high-TDS feeds.
Permeate < 50 µS/cm
Treatment Process Flow and Application Nodes
Our integrated treatment train delivers 85-95% water recovery with solid salt cake production for complete resource recovery.
Primary Treatment
Biological Treatment
Advanced Treatment
Final Output
Typical Installations
Dye-houses
250 m³/d
colour < 0.5 Pt-Co, 94% water reuse
Finishing mills
4,000 m³/d
liquid-free discharge, 18% steam saving
Denim units
900 m³/d
indigo solids recovered for pigment resale, 35 t/month NaOH reclaimed
Why WTT Outperforms Conventional Providers
Our advanced technologies deliver superior performance across all key metrics, ensuring maximum return on investment and operational excellence.
| Metric | WTT Performance | Conventional ASP |
|---|---|---|
| Water Recovery | 85-95% | 60-70% |
| Footprint | 0.12 m²/m³/d | 0.18-0.22 |
| Energy (pretreat + RO) | 0.5 kWh/m³ | 0.8 |
| ZLD Energy | 10-12 kWh/m³ | 14-16 |
| Sludge yield | < 0.15 kg DS/kg COD | 0.25-0.35 |
| NaOH Reuse | 55-60% | None |
| Start-up to Compliance | 21 days | 35-45 days |
| Remote diagnostics | Standard | Optional |
40+ Textile References
First-mover ceramic MBR technology
97% Recovery
Patented single-skid HR-RO
Contractual Guarantees
COD ≤ 30 mg/L, colour < 1 Pt-Co
Closed Chemical Loop
ZDHC and GOTS compliant
Specialised Textile Treatment Services
Comprehensive solutions tailored for textile industry requirements with guaranteed performance and operational excellence.
Raw-water Conditioning
Dual-media and zeolite softening, hardness < 2 ppm
Modular ETP Blocks
ISO skids 100 m³/d, expandable in 10% steps without shutdown
Submerged Ceramic MBR
pH 1-13 tolerance, 350 °C steam sterilisation, 10-year warranty
High-Recovery RO and Brine Loop
22% lower osmotic load via NF pre-stage
Zero Liquid Discharge Suites
MVC evaporator with 84% latent-heat reuse
Caustic Recovery (CaRe)
Condensate purity ≥ 80% NaOH, carbonate < 1%
Digital O&M
IIoT sensors, AI aeration control, remote SCADA, 48h spares SLA
Detailed Frequently Asked Questions
Comprehensive answers to technical questions about our textile wastewater treatment solutions.
Ready to Achieve 95% Reuse and Liquid-Free Discharge?
Our senior process engineers will perform a no-cost effluent audit and deliver a guaranteed-performance proposal. WTT – engineering certainty in compliance, cost and circularity for the global textile supply chain.