Case Study: 15 KLD STP Plant Installation at Noble Alchem Haryana
Noble Alchem is a chemical manufacturing facility located in Bhiwani, Haryana. As part of its operational expansion, the facility generates a consistent volume of domestic sewage that requires systematic treatment before disposal or reuse. To address this growing need, the management commissioned Netsol Water a trusted Sewage Treatment Plant Manufacturer in Haryana to design, supply, and install a 15 KLD sewage treatment plant using proven MBBR technology.
The objective of this project was clear: treat domestic sewage generated at the facility to meet statutory discharge standards set by the Haryana State Pollution Control Board, reduce dependence on freshwater by enabling treated water reuse, and implement a sustainable, low-maintenance solution that could operate efficiently over the long term.
About the Noble Alchem
Noble Alchem operates as a specialty chemical manufacturer based in Bhiwani, Haryana. The facility runs continuous production processes and hosts a workforce that generates a regular and predictable volume of domestic wastewater daily. As industrial operations grew, so did the need for a structured wastewater management system.
Recognising its responsibilities toward the environment and regulatory authorities, Noble Alchem sought a reliable solution to ensure that all sewage generated within the premises was adequately treated before any form of discharge or reuse. The company also aimed to incorporate water conservation into its sustainability framework by treating and recycling sewage for non-potable applications, thereby reducing its overall freshwater footprint.
Challenges Faced Before STP Installation
Before the installation of a dedicated sewage treatment system, Noble Alchem faced several practical and regulatory challenges that needed to be resolved without delay.
1. Growing Sewage Volume
With an increasing workforce and expanded facility operations, the volume of domestic sewage generated daily had grown steadily, making informal disposal arrangements both inadequate and environmentally irresponsible.
2. Regulatory Compliance Requirements
The Haryana State Pollution Control Board mandates that industrial facilities treat domestic effluents to prescribed quality standards before disposal. Failure to comply can result in penalties and operational disruption. Noble Alchem required a solution that would ensure consistent compliance with these pollution control norms.
3. Water Conservation Targets
Like many industries in the region, Noble Alchem was under pressure to reduce freshwater consumption. Reusing treated sewage for gardening and flushing presented a viable and cost-effective approach but only if the treatment quality was sufficiently high.
4. Space and Operational Constraints
The available area for plant installation within the industrial premises was limited. The solution needed to be compact in footprint, require minimal operator intervention, and remain operationally stable with low maintenance demands over extended periods.
Proposed Solution by Netsol Water
Following a detailed site assessment, Netsol Water a leading STP Plant Manufacturer in Haryana conducted a comprehensive wastewater characterisation study to understand the quality and quantity of sewage generated at the Noble Alchem facility. Based on the findings, the team designed a 15 KLD capacity Sewage Treatment Plant using MBBR (Moving Bed Biofilm Reactor) technology.
1. Design and Technology Selection
MBBR technology was selected for its ability to deliver high biological treatment efficiency within a compact reactor footprint. The system uses plastic bio-media carriers suspended in an aerated bioreactor, which support the growth of a dense biofilm population capable of breaking down organic pollutants at high efficiency. This approach eliminates the need for sludge recirculation, reduces reactor volume, and ensures stable performance even under variable load conditions.
2. End-to-End Execution
Netsol Water executed the project across all stages including detailed engineering design, manufacturing of equipment and structures, supply of all mechanical and electrical components, on-site installation, system integration, and final commissioning. This turnkey approach ensured full accountability and minimised coordination delays between vendors.
As a recognised Sewage Treatment Plant Manufacturer in Haryana, Netsol Water brought both technical expertise and local project management capability to deliver the plant on schedule and within the agreed performance parameters.
Treatment Process and Process Flow
The 15 KLD STP at Noble Alchem follows a multi-stage treatment sequence designed to progressively reduce pollutant concentrations to levels suitable for safe reuse. Each stage plays a specific role in the overall treatment chain.
| Raw Sewage | Domestic sewage from the facility enters the treatment system as raw influent. |
| Screen Chamber | Coarse and fine screening removes large solids, rags, and debris to protect downstream equipment. |
| Equalization Tank | Balances flow rate and pollutant load fluctuations, ensuring consistent feed to the biological stage. |
| MBBR Bioreactor | Core biological treatment stage where biofilm on floating media degrades BOD and COD through aerobic microbial action. |
| Secondary Clarifier | Separates biological solids from treated effluent through gravity settling, producing a clear supernatant. |
| Pressure Sand Filter | Removes residual suspended solids and turbidity through multi-grade sand filtration under pressure. |
| Activated Carbon Filter | Adsorbs trace organics, colour, and odour compounds, producing a clean and odour-free effluent. |
| Disinfection Unit | Chlorination or UV disinfection eliminates pathogenic microorganisms, ensuring safe reuse-grade water quality. |
| Treated Water Tank | Stores treated effluent ready for reuse, with provision for distribution to gardening and flushing points. |
| Reuse | Treated water is distributed for gardening, landscaping, and toilet flushing across the facility. |
Technical Specifications of the 15 KLD STP Plant
| Parameter | Details |
|---|---|
| Plant Capacity | 15 KLD (15,000 Litres per Day) |
| Technology | MBBR (Moving Bed Biofilm Reactor) |
| Application | Domestic Sewage Treatment |
| Automation Level | Semi-Automatic with PLC Controls |
| Reuse Purpose | Gardening and Toilet Flushing |
| BOD Removal Efficiency | >96% |
| COD Removal Efficiency | >92% |
| TSS Removal Efficiency | >96% |
| Design Basis | CPCB / State PCB Standards |
| Structure | MS/RCC, Compact Modular Design |
The plant was engineered with a compact layout to accommodate the available space constraints at the Noble Alchem facility. All components were selected for operational reliability and ease of maintenance, keeping scheduled downtime and operator workload to a minimum. The semi-automated control system reduces human error and allows monitoring of critical process parameters in real time.
Installation and Commissioning Process
Netsol Water's execution team followed a structured project delivery protocol to ensure the plant was installed, tested, and handed over with minimal disruption to the client's ongoing operations.
1. Site Preparation
The installation began with civil preparation of the designated area, including levelling, foundation casting, and tank construction. All civil works were completed in coordination with the client's site team to ensure adherence to layout drawings and safety norms.
2. Equipment Installation and Mechanical Integration
All mechanical equipment blowers, pumps, diffusers, bio-media, and filtration units — was installed sequentially following the approved process flow. Piping interconnections were completed using schedule-rated PVC and MS components, with proper alignment and leak testing at each stage.
3. Electrical Integration
The electrical panel, including starters, MCBs, and control wiring, was integrated and tested. All electrical work was performed in compliance with IS standards to ensure safe and reliable operation.
4. Testing, Trial Run, and Operator Training
Before final handover, the system was subjected to a full hydraulic trial run to confirm flow paths, check for leakages, and validate pump and blower performance. A biological seeding process was initiated to establish the biofilm in the MBBR reactor, followed by a performance trial period. Plant operators from Noble Alchem were trained on system operation, routine maintenance procedures, and troubleshooting protocols.
5. Final Commissioning
Once the plant consistently met the performance targets during the trial phase, a formal commissioning was completed. Documentation including operation and maintenance manuals, as-built drawings, and compliance reports was submitted to the client.
Performance Results After Commissioning
Post-commissioning effluent quality analysis confirmed that the 15 KLD STP at Noble Alchem consistently achieved treated water quality that meets CPCB standards for reuse in gardening and flushing applications.
| Parameter | Raw Sewage | Treated Water |
|---|---|---|
| BOD (mg/L) | 250 – 300 | <10 |
| COD (mg/L) | 500 – 700 | <50 |
| TSS (mg/L) | 200 – 300 | <10 |
The treated water quality achieved by the plant demonstrates a BOD reduction of over 96%, COD reduction exceeding 92%, and TSS removal above 96%. These results are well within the acceptable limits for non-potable reuse applications as specified by regulatory authorities. Noble Alchem can confidently redirect this treated water to its landscaping and flushing systems, reducing its dependence on freshwater supply and lowering associated utility costs.
Benefits Achieved by Noble Alchem
The successful deployment of this Industrial STP Plant by a qualified Sewage Treatment Plant Manufacturer in Haryana has delivered measurable benefits across environmental, operational, and business dimensions.
|
Environmental Benefits Significant reduction in untreated sewage discharge, lower pollution load on receiving water bodies, and a measurable contribution to sustainable wastewater management at the facility. |
Operational Benefits 15,000 litres of treated water made available daily for reuse. Reduced freshwater consumption and lower operating costs through efficient in-house water recycling. |
|
Regulatory Compliance Full compliance with HSPCB discharge norms, eliminating risk of environmental violations and associated penalties. Audit-ready documentation maintained on-site. |
Low Maintenance MBBR technology requires no sludge recirculation and minimal manual intervention. Semi-automated controls reduce operator dependency and ensure consistent performance. |
|
Sustainability Goals Supports Noble Alchem's corporate environmental commitments. Treated water reuse for non-potable purposes aligns with water stewardship objectives and reduces the facility's overall freshwater footprint. |
Long-Term Value Robust construction, quality equipment, and comprehensive operator training ensure reliable plant performance over an extended operational life with predictable maintenance costs. |
Watch the 15 KLD STP Plant at Noble Alchem
Client Feedback
“We approached Netsol Water with a clear requirement a compact, reliable sewage treatment system that would help us meet pollution control board standards without occupying excessive space. The team delivered exactly that. The 15 KLD MBBR-based STP has been performing consistently since commissioning, and the treated water quality has surpassed our expectations. We are now reusing the treated effluent for gardening and flushing, which has noticeably reduced our freshwater consumption. The entire experience from design discussions to on-site installation and training was professional and well-coordinated.”
Management, Noble Alchem, Bhiwani, Haryana
Conclusion
The 15 KLD STP installation at Noble Alchem, Bhiwani, Haryana stands as a well-executed example of how industrial facilities can transition from unmanaged sewage disposal to structured, compliant, and resource-efficient wastewater management. By partnering with Netsol Water a trusted Sewage Treatment Plant Manufacturer in Haryana — Noble Alchem has achieved full regulatory compliance, reduced its environmental footprint, and created a reliable internal water recycling system that delivers tangible operational savings.
The use of MBBR technology ensured that high biological treatment efficiency could be achieved within a compact plant footprint, making the solution well-suited for industrial premises with space limitations. With treated BOD consistently below 10 mg/L and over 15,000 litres of water recycled daily, the plant represents a sound long-term investment in both environmental responsibility and resource conservation.
This project reflects Netsol Water's commitment to delivering technically sound, field-proven wastewater treatment solutions tailored to the specific needs of each client on time, within scope, and to measurable performance standards.
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