Zero Liquid Discharge Plant

Zero Liquid Discharge (ZLD) Plant Manufacturers in India | Raj Process

Advanced Solutions for Wastewater Treatment & Industrial Sustainability. Raj Process Equipments & Systems Pvt. Ltd. is one of the leading Zero Liquid Discharge (ZLD) plant manufacturers in India, delivering world-class turnkey solutions to treat, recycle, and recover industrial wastewater. Our ZLD plants are designed to ensure 100% wastewater recovery, enabling industries to achieve zero liquid discharge compliance while contributing to environmental sustainability and resource optimization.

What is Zero Liquid Discharge (ZLD)?

Zero Liquid Discharge is an advanced wastewater treatment process where effluent streams are treated, purified, and reused, ensuring no liquid waste is discharged into the environment. Industries today face increasing pressure from environmental regulations, water scarcity, and sustainability mandates. ZLD systems provide a closed-loop solution, converting wastewater into reusable water and recovering valuable by-products such as salts and other chemicals.

Turnkey ZLD Plant Solutions by Raj Process

Raj Process offers custom-engineered ZLD solutions tailored for a wide range of industries, including distilleries, sugar mills, pharmaceuticals, textiles, chemicals, food processing, palm oil mills (POME), and power plants.

Key Process Flow

• Collection & Flash Mixing
  • Effluent collected in a common pit
  • Chemical dosing of alum, lime, and polyelectrolytes to coagulate suspended solids
• Flocculation & Clarification
  • Treated water passes through flocculation tanks and lamella/tube settlers
  • Clarified water moves to monitoring basins
• Evaporation & Concentration
  • Multiple Effect Evaporators (MEE) concentrate dissolved solids
  • Vapors condensed to produce pure, reusable condensate
• Crystallization & Drying
  • Recovered salts are crystallized and dried for reuse or safe disposal

Raj Process ZLD Technology Advantages

• Handles Effluents of All Types → Spent wash, POME, textile dye waste, R.O. rejects, pharma effluents, etc.
• Advanced Separation Systems → Uses evaporation, crystallization, and membrane filtration
• Compact Modular Design → Skid-mounted ZLD units available up to 1,000 KLD
• Integrated Process Control → PLC/SCADA-based automation for safe, optimized operations
• High Recovery Rates → Achieves up to 95–98% water recovery
• Custom-Tailored Solutions → Designed to suit industry-specific effluent profiles

Specialized ZLD Solutions

1. ZLD for Spent Wash Drying (Distilleries & Ethanol Plants)

• Integrates Multi-Effect Evaporators (MEE) to concentrate spent wash
• Spray dryers or rotary dryers to achieve complete drying
• Recovered condensate reused in fermentation or process utilities

Benefits: Eliminates water discharge completely, meets stringent CPCB & SPCB norms, integrates seamlessly with ethanol production units.

2. ZLD for POME (Palm Oil Mill Effluent)

• Biological treatment + MEE for volume reduction
• Recover high-quality water for reuse in the milling process
• Enable energy integration by converting residual organics into biogas for captive power

Applications: Palm oil refining units, agro-industries producing high organic wastewater.

3. Sludge Dryer as a ZLD Solution

• Drying Techniques: Paddle dryers, rotary dryers, or flash dryers
• Reduces sludge volume by up to 80%
• Generates solid, dry sludge for safe disposal or reuse
• Minimizes dependence on third-party sludge treatment facilities

Features of Raj Process ZLD Plants

• Capacities: 1 KLD to 10,000 KLD
• High Steam & Power Economy → Integrated energy recovery systems
• Optimized Footprint → Compact designs suitable for space-limited facilities
• Robust Material of Construction → Stainless steel, duplex steel, Inconel, Hastelloy
• Skid-Mounted Options → Easy to transport and install
• Automation → PLC-controlled with real-time monitoring
• Pure Condensate Recovery → For direct reuse in process operations

Benefits of Choosing Raj Process ZLD Plants

• Regulatory Compliance → Meets CPCB, SPCB, and environmental guidelines
• Water Reuse → Saves up to 95% freshwater consumption
• Cost Savings → Reduced waste management and landfill costs
• Energy Integration → Reuse of recovered heat and water
• Resource Recovery → Generates reusable salts and other by-products
• Sustainable Operations → Minimizes environmental footprint and supports net-zero goals

Industries We Serve

• Distilleries & Ethanol Plants
• Palm Oil Mills (POME treatment)
• Pharmaceuticals & Chemicals
• Textiles & Dyeing Units
• Food & Beverage Processing
• Power Plants & Refineries