Researchers at BITS Pilani, Hyderabad have introduced a low‑energy, three‑stage technology that inactivates 99.9999% of bacteria while reclaiming water and methane‑rich biogas from biopharma effluent. The system is moving toward industrial rollout with vaccine maker Biological E. Ltd., backed by the DST water‑technology initiative.

Key Takeaways

  • Low‑energy three‑stage treatment system
  • >99.9999% bacterial inactivation
  • Water reuse and methane‑rich biogas recovery

Hyderabad – Researchers at BITS Pilani’s Environmental Science and Technology (BEST) Laboratory announced a groundbreaking low‑energy wastewater treatment technology that can disinfect biopharmaceutical effluent while recovering reusable water and methane‑rich biogas. The technology, demonstrated at laboratory scale, is now being advanced for industrial deployment in partnership with Hyderabad‑based vaccine manufacturer Biological E. Ltd., under the Department of Science and Technology (DST) water‑technology initiative.

Biopharma fermentation wastewater is notoriously difficult to treat due to high loads of live production microorganisms, residual antibiotics, and antibiotic‑resistance genes. Current industry practices rely on chemical treatment and steam‑based autoclaving, both energy‑intensive and costly.

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Why This Matters

The BEST team engineered an integrated three‑stage system that combines electrical disinfection, biological treatment, and energy recovery. The first stage employs Pulsed Electric Field (PEF) technology, delivering high‑voltage, short‑duration pulses that cause irreversible electroporation of bacterial cells. This achieves over 99.9999% bacterial inactivation without chemicals or heat.

In the second stage, the disinfected wastewater passes through a Sequencing Batch Reactor (SBR), where naturally occurring microbes degrade organic pollutants, removing more than 90% of the organic load. The resulting water can be further polished via membrane filtration for reuse.

The final stage utilizes the team’s patented Intelligently Stirred Thermophilic Anaerobic Reactor, converting residual sludge into methane‑rich biogas. This biogas can offset a significant portion of the plant’s energy demand, while the treated water supports zero‑liquid‑discharge goals.

"The integration of electrical disinfection with resource recovery sets a new benchmark for sustainable biopharma manufacturing," said Prof. Sankar Ganesh Palani.
Did You Know?: The methane captured from biogas can meet up to 30% of the treatment plant’s energy needs, dramatically lowering operating costs.

Frequently Asked Questions

Q: Can this technology be adapted for other industries?
A: Yes, similar high‑organic‑load sectors such as food processing and chemical manufacturing can benefit from the same approach.

Q: What is the cost implication of adopting this system?
A: While initial capital investment is higher than conventional methods, long‑term savings from energy recovery and water reuse make it economically attractive.