Project Overview
The 211 MLD Sewage Treatment Plant at Karanj, Surat demonstrates Enviro’s expertise in combining plant augmentation, advanced nutrient removal, and renewable energy generation within a limited footprint.
Under an EPC + O&M contract for the Surat Municipal Corporation, Enviro expanded and upgraded the existing 140 MLD facility into a modern 211 MLD plant. The project involved:
- Upgrading the original 140 MLD line to Integrated Fixed Film Activated Sludge (IFAS) technology.
- Adding a new 71 MLD Sequencing Batch Reactor (SBR) line with advanced Biological Nutrient Removal (BNR).
- Integrating a 1.0 MWe biogas power generation system, converting sludge into renewable energy.
This approach ensured both quality and quantity upgradation, maximizing output and performance while working within tight site constraints. Augment the existing 140 MLD plant to a total of 211 MLD.
- Upgrade treatment processes for higher-quality effluent, aligned with discharge norms.
- Introduce biogas-based energy recovery to reduce grid dependency.
- Deliver quantity expansion and quality improvement within a minimized footprint.
The Challenge
- Upgrading an operational 140 MLD plant without service interruption.
- Incorporating new treatment units and biogas energy systems into a site with limited space.
- Ensuring reliable integration between the upgraded IFAS line and the new SBR line.
The Solution
Enviro applied a phased and integrated execution strategy:
- Retrofitted the 140 MLD line with IFAS for improved nutrient removal.
- Designed and built a new 71 MLD SBR line to expand total capacity.
- Installed anaerobic digestion and a 1.0 MWe biogas engine to generate renewable energy from sludge.
- Applied careful space optimization and civil modifications to work within the existing footprint.
The Results
- Total capacity expanded to 211 MLD, serving a larger population base.
- Higher effluent quality achieved through IFAS and SBR-based BNR systems.
- Renewable energy generation of 1.0 MWe, reducing operational costs and carbon footprint.
- A successful demonstration of augmenting existing infrastructure with minimal land expansion.
Why It Matters
The Karanj STP project highlights Enviro’s ability to upgrade and expand large-scale municipal plants within existing site limits, while integrating renewable energy systems. It serves as a model for other cities seeking sustainable, high-capacity wastewater treatment solutions.
