ETP Company Surat — South Gujarat
Effluent treatment plant design, supply, and commissioning for Surat's industrial clusters — Sachin and Pandesara textile/chemical GIDCs, Hazira petrochemicals, and food processing — with GPCB-compliant ZLD systems and online monitoring
Industry Overview
ETP Company Surat — South Gujarat
Surat is India's textile capital and one of Gujarat's most industrially significant cities, generating a massive and complex wastewater treatment challenge. Spans Envirotech has served industrial clients across Gujarat — including Surat's textile, chemical, and petrochemical clusters — with ETP, ZLD, and STP systems designed to meet GPCB's stringent compliance requirements.
The Sachin GIDC, Pandesara GIDC, and Icchapor industrial areas host thousands of synthetic textile weaving, dyeing, and finishing units — one of the highest concentrations of textile effluent generators in the world. These units produce highly coloured wastewater with COD 1,500–6,000 mg/L, TDS 3,000–15,000 mg/L from salt-heavy dyebath chemistry, and variable pH from acid dye processes and alkali scouring. Hazira's integrated petrochemical complex — including ONGC, Reliance, and ESSAR installations — generates hydrocarbon-contaminated, high-TDS industrial effluent requiring specialist treatment.
GPCB has been at the forefront of environmental enforcement in India, mandating ZLD for textile dyeing units in Surat progressively since 2015. Units in designated GIDC areas must achieve near-zero discharge, with treated water recycled back into the production process. This has driven significant investment in ZLD infrastructure — and demand for ETP suppliers with proven ZLD expertise in the textile effluent profile specific to Surat's synthetic fabric and dyeing sector.
Industry Challenges
Key Environmental Challenges
Textile Dyeing Effluent — High Colour and TDS
Synthetic textile dyeing at Surat produces effluent with intense colour (ADMI 500–3,000), high COD (1,500–6,000 mg/L), and TDS 3,000–15,000 mg/L from reactive and disperse dyes and sodium chloride/sulphate-based dyebath chemistry. Colour removal requires coagulation-flocculation, ozonation, or electrocoagulation upstream of biological treatment. High TDS complicates downstream RO performance and increases evaporation energy demand.
GPCB ZLD Mandate
GPCB mandates ZLD for textile processing units in Surat GIDCs. Compliance requires a full treatment train: physico-chemical pre-treatment → biological treatment → ultrafiltration → RO → MEE or MVR evaporation → crystallisation. Each stage must be sized and integrated correctly — undersizing the RO or evaporation system typically causes the entire ZLD train to fail compliance within 12–18 months of commissioning.
Hazardous Dye and Chemical Intermediates
Surat's chemical and dye manufacturing units (azo dyes, reactive dyes, pigment intermediates) generate effluent with complex organic compounds that are partially or fully non-biodegradable. COD:BOD ratios below 0.3 indicate poor biodegradability — requiring advanced oxidation processes (Fenton, ozone) or activated carbon adsorption before biological treatment to convert recalcitrant compounds to biodegradable form.
Hazira Petrochemical Effluent
Hazira's refinery and petrochemical complex generates oily wastewater with total petroleum hydrocarbons (TPH), dissolved organics, and process water with high TDS. Treatment requires API gravity separators, CPI/TPI interceptors, DAF with chemical dosing, and biological treatment. Units must also manage cooling tower blowdown, which adds to TDS and water volumes.
Space Constraints in GIDC Plots
Many Surat GIDC industrial plots are compact, leaving limited space for ETP civil infrastructure. ZLD plants with multiple treatment stages — biological reactors, RO pressure vessels, evaporators — must be designed in compact vertical or modular configurations to fit within available footprints without compromising treatment performance.
Online Monitoring and Real-Time Reporting
GPCB requires Online Effluent Monitoring Systems (OEMS) at ETP outlets for industrial units above threshold scale. Systems must measure pH, BOD/COD (surrogate), TSS, TDS, and flow rate continuously, with real-time data transmission to GPCB's server. Installation, calibration, and maintenance of OEMS is now a mandatory part of ETP project scope for most Surat industrial units.
Our Solutions
Tailored Wastewater Treatment Solutions
Textile ZLD System — Complete Design & Build
End-to-end ZLD systems for Surat textile dyeing and finishing units: equalization tank → flash mixer/coagulation-flocculation → DAF → biological treatment (MBBR or AASS) → secondary clarifier → UF membrane → RO → MEE/MVR evaporation → crystalliser. Water recovery >93%. Treated permeate recycled to dyeing process. GPCB online monitoring installed and commissioned.
Colour Removal for Textile Effluent
Specialist colour removal systems using electrocoagulation, ozonation, or chemical coagulation with alum/PAC-anionic polyelectrolyte combination. Typical colour removal >95% from ADMI values of 1,000–3,000 to <50 ADMI in treated effluent. Removes both reactive (water-soluble) and disperse (water-insoluble) dye residuals.
Hazira Petrochemical ETP
Oily wastewater treatment for Hazira complex industries: API/CPI oil-water separation, dissolved air flotation with polyelectrolyte dosing, biological treatment (activated sludge with extended aeration or MBBR), tertiary filtration, and sludge dewatering. Oil content reduced from 50–500 mg/L to <5 mg/L in treated effluent.
GPCB Compliance Support
CTE/CTO documentation preparation, process design reports in GPCB-required format, effluent characterisation data generation, OEMS installation and calibration for real-time GPCB reporting. Post-commissioning compliance monitoring and annual GPCB return support.
MVR Evaporation for OPEX Reduction
Mechanical Vapour Recompression (MVR) evaporators reduce steam consumption compared to conventional MEE systems by 60–70%, cutting ZLD operating costs for high-TDS textile effluent by ₹20–40/m³. Particularly beneficial for Surat textile units running ZLD round the clock with TDS >8,000 mg/L in RO reject.
ETP Audits and Performance Recovery
Independent technical audits of underperforming ETPs in Surat GIDC — identifying design gaps, equipment failures, and operational issues. Prioritised remediation roadmaps with CAPEX estimates and implementation support to bring GPCB consent compliance back on track.
Technologies
Proven Technologies for Your Industry
Benefits
Why Choose Spans for Your Industry
- Specialist ZLD experience for GPCB-mandated textile and chemical units in Surat
- Full GPCB compliance — CTE/CTO documentation, OEMS installation, real-time reporting
- Proven colour removal and TDS management for synthetic textile dyeing effluent
- MVR evaporation for OPEX-efficient ZLD operation
- Turnkey EPC — process design, civil, equipment supply, commissioning
- Compact system design for constrained GIDC plot footprints
- Post-commissioning O&M and annual maintenance contracts
- Gujarat-based site support and rapid response capability
Success Stories
Case Studies
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