For Hosur's industries, zero liquid discharge (ZLD) is increasingly a business requirement as well as a regulatory one. Electroplating, surface finishing, chemical and some electronics units operate under ZLD conditions, and global automobile and electronics customers expect their suppliers to manage water responsibly. With water scarce and tanker costs high, recovering every litre also pays off directly. Intellect Aqua designs, upgrades and operates ZLD systems for Hosur industries.
Whether you need a new ZLD plant, an upgrade or a team to operate it, we cover the full scope from effluent treatment to evaporation and solids handling.
Why ZLD Matters in Hosur
- Compliance: Plating, finishing and chemical units often have ZLD in their consent conditions.
- Customer requirements: OEM supplier audits increasingly examine water use and discharge.
- Water cost: Recovered water replaces expensive tanker and borewell water.
- Lake and river protection: Local water bodies are already under pressure.
How a ZLD System Works
1. Segregated Pre-Treatment
For plating units, chrome, cyanide and general rinses are treated separately first — chrome reduction, cyanide destruction and metal precipitation. See ETP for Hosur.
2. Combined ETP
Equalisation, neutralisation, clarification and, where needed, biological treatment.
3. Tertiary Treatment and UF
Sand, carbon and ultrafiltration protect the membranes.
4. Multi-Stage RO
RO recovers most of the water for reuse in rinsing, washing and cooling.
5. Evaporation
RO reject is concentrated in an MVR or MEE evaporator; condensate is reused. MVR is often attractive in Hosur where steam is not readily available.
6. Drying and Solids Handling
The concentrate is dried; metal-bearing solids are handled as hazardous waste through authorised channels.
Designing ZLD That Runs
- Every stream characterised, including concentrated baths
- Segregation designed in from the start
- RO recovery set with a safety margin against scaling
- Evaporators sized for real reject volumes
- Full mass balance shared before you invest
- Operators trained and daily logs set up at commissioning
Controlling ZLD Costs
Evaporation is the costliest stage. We maximise RO recovery, recover rinse water close to the source with counter-current rinsing and drag-out recovery where suitable, segregate low-TDS streams, and choose MVR or MEE based on your energy costs.
Reducing Waste at Source
The cheapest effluent is the one you never create. In plating lines, counter-current rinsing, drag-out tanks and better bath maintenance can reduce rinse water volume significantly. We review your processes as part of the feasibility study and suggest practical changes that shrink the ZLD plant you need.
ZLD Feasibility Study
Our study covers effluent characterisation, source reduction options, treatment scheme, mass balance, equipment list and layout, utility needs, capital cost and monthly running cost.
Upgrading Existing Plants
If your plant runs below design recovery, membranes foul quickly or the evaporator cannot keep up, we audit every stage and prepare a fresh mass balance.
Records for Compliance and Audits
We set up daily logs for flow, recovery, chemical use, evaporator operation and hazardous waste so your plant can show consistent performance to regulators and customers.
Reusing Recovered Water
Recovered water from RO and evaporator condensate is often better quality than the borewell or tanker water many Hosur units buy. It can be reused for plating rinses, component washing, paint shop pre-treatment, cooling towers and boiler make-up after polishing. We design the reuse network along with the ZLD plant — storage, pumps and distribution lines — so recovered water actually reaches the process instead of being wasted. For many units, this reuse is what makes ZLD economically sensible.
Choosing the Right ZLD Scheme
There is no single ZLD design that suits every unit. A small plating shop with low volumes may need compact segregated treatment and a small evaporator, while a large auto component plant with mixed effluents needs a full ETP, multi-stage RO and a larger evaporator. Some units can reduce the load by collecting concentrated wastes separately for authorised disposal. We compare options on capital cost, running cost, space and reliability, and recommend the scheme that fits your volume, chemistry and budget.
Operation and Maintenance
Our O&M contracts include operators, membrane cleaning, chemical management, evaporator monitoring, spares and daily logs. See our AMC service.
Why Hosur Industries Choose Intellect Aqua
- Experience with plating, automobile and engineering effluents
- Complete scope from segregated pre-treatment to evaporator
- Honest mass balance and running-cost estimates
- 15+ years of industry experience and 700+ projects
Areas We Serve
We build and upgrade ZLD systems across Hosur and Krishnagiri district — SIPCOT Phase I and II, Mathigiri, Zuzuvadi, Bagalur, Alasanatham, Shoolagiri, Krishnagiri and Bargur.
We also build ZLD plants in Chennai, Ranipet, Salem and Coimbatore.
Request a ZLD Feasibility Study
Share your processes, effluent volume and current setup. We will prepare a report with source reduction options, mass balance and cost estimates.