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Henan Suijing Environmental Protection Technology Co., Ltd
Date: 2025-12-23Read: 1
Application Case of Online Monitoring System for Qinghai Pharmaceutical Wastewater Treatment Station
1、 Project Background and Requirements
A large pharmaceutical enterprise in Qinghai Province, with core business covering chemical raw materials, formulation production, etc., generates a large amount of industrial wastewater during the production process, mainly including chemical synthesis wastewater, extraction and refining wastewater, fermentation wastewater, equipment cleaning wastewater, and domestic sewage, which are uniformly collected into the self built sewage treatment plant in the factory for treatment. The wastewater industry of this enterprise is unique, containing residual drug active ingredients, high concentrations of COD, ammonia nitrogen, total phosphorus, suspended solids, and small amounts of heavy metals (such as total arsenic and total lead). Some of the wastewater has high salt content, high toxicity, and is difficult to degrade. If it is not treated and discharged in accordance with standards, it will not only pollute the sensitive water environment in Qinghai (such as the Huangshui River Basin), but also violate environmental regulations and the requirements of the "Regulations on Water Pollution Prevention and Control in the Huangshui River Basin of Qinghai Province".
Due to the insufficient ability of existing laboratory operators to understand the core principles, parameter settings, precise operation, and troubleshooting of new equipment, if directly put into use, problems such as non-standard operation, large data deviations, and rapid equipment wear and tear may occur, which cannot meet the requirements of efficient testing business. Based on this, the enterprise entrusts equipment suppliers to arrange technical engineers to provide on-site customized training services, ensuring that laboratory personnel fully master equipment usage skills and guarantee the rapid deployment of new equipment in practical applications.
2、 Basic Training Information
Training target: 10 core testing personnel in the laboratory, including 3 equipment administrators (all with basic water quality testing experience, without GNST-SC1000 operation foundation)
（1） Overall system architecture
The system adopts a three-level architecture of "on-site monitoring layer data transmission layer central control management layer" to achieve closed-loop management of the entire process of pharmaceutical wastewater treatment water quality indicators from real-time collection to intelligent regulation: ① On site monitoring layer: Deploy multi parameter online monitoring equipment (including COD, ammonia nitrogen, total phosphorus, suspended solids, etc.) pH、 Dissolved oxygen detector, equipped with automatic sampling device, customized pretreatment module and dedicated sensor, responsible for real-time detection of water quality indicators in various links; ② Data transmission layer: Through industrial Ethernet+4G dual-mode transmission, it ensures stable uploading of data in complex industrial environments in the factory area, supports breakpoint continuation, and meets the HJ/T 212 environmental protection data transmission standard and the docking requirements of Qinghai Province ecological environment monitoring platform; ③ Central control management: Build an intelligent monitoring platform to achieve real-time data display, trend analysis, abnormal alarm, report generation, and linkage control of sewage treatment processes.
（2） Key point deployment
Based on the process flow of pharmaceutical wastewater treatment station (classified collection pretreatment anaerobic aerobic deep treatment discharge), monitoring equipment is accurately deployed at the core nodes to achieve full process coverage: ① Pre treatment unit: regulating tank inlet (monitoring COD, suspended solids, determining influent water quality load), high salt wastewater pretreatment outlet (monitoring salt content related conductivity indicators, evaluating pretreatment effect); ② Biochemical treatment unit: anaerobic tank inlet and outlet (monitoring COD, evaluating anaerobic degradation effect), aeration tank inlet and outlet (monitoring COD, ammonia nitrogen, dissolved oxygen, regulating aeration intensity), secondary sedimentation tank outlet (monitoring suspended solids, total phosphorus, evaluating sedimentation effect); ③ Deep processing unit: filtration system outlet (monitoring suspended solids, pH, ensuring effluent accuracy); ④ Discharge outlet: Total discharge outlet (monitoring COD, ammonia nitrogen, total phosphorus, suspended solids, etc.) pH， Ensure compliance with emission standards and upload data synchronously to the Qinghai Province Ecological Environment Monitoring Platform. Each monitoring device at each point is equipped with anti-corrosion and anti vibration protective enclosures, suitable for the humid and corrosive gas environment of sewage treatment plants.
（3） Core equipment parameters
The core parameters of the selected online monitoring equipment are accurately adapted to the monitoring needs of pharmaceutical wastewater treatment: ① Monitoring parameters and ranges: COD (0-2000mg/L), ammonia nitrogen (0-50mg/L), total phosphorus (0-10mg/L), suspended solids (0-100NTU), pH (0-14), dissolved oxygen (0-20mg/L); ② Measurement accuracy: COD ± 5% FS, ammonia nitrogen ± 5% FS, total phosphorus ± 5% FS, in compliance with industrial wastewater detection standards; ③ Measurement cycle: The minimum measurement cycle is 30 minutes, and it can be adjusted from 1 to 9999 minutes to cope with the variable composition of pharmaceutical wastewater; ④ Calibration cycle: adjustable at any interval from 1 to 99 days, reducing maintenance costs; ⑤ Operating environment: temperature+5~40 ℃, humidity ≤ 90% (non condensing), suitable for normal temperature conditions in Qinghai Plateau; ⑥ Output function: Supports RS-232, RS485, 4-20mA signal output, can be directly connected to the central control platform and Qinghai environmental protection supervision platform; ⑦ Protection function: It has abnormal alarm and power-off data retention function, automatically restores working status after power outage and incoming call, ensuring monitoring continuity.
（4） Preprocessing module adaptation
In response to the characteristics of residual drug active ingredients, high suspended solids, and high salt content in wastewater from pharmaceutical companies, the monitoring equipment is equipped with customized pretreatment modules: a two-stage filtration device (coarse filtration+fine filtration) is used to first remove large suspended particles through 5 μ m coarse filtration, and then remove small impurities through 0.45 μ m fine filtration to avoid blocking the detection channel; Add a pre-treatment and inactivation unit for drug active ingredients to eliminate the interference of residual drugs on detection accuracy; Equipped with high-pressure automatic backwashing function, regularly clean the filtering components to ensure stable pre-treatment effect, suitable for pharmaceutical high load and complex sewage monitoring needs.
（5） Training adaptation adjustment (supplement)
Considering that the operators of sewage treatment plants and laboratories lack the ability to understand the core principles, parameter settings, and troubleshooting of pharmaceutical wastewater online monitoring equipment, the enterprise entrusts equipment suppliers to conduct customized on-site training: ① Training objects: 10 core personnel from sewage treatment plants and laboratories, including 3 equipment administrators (all have basic sewage treatment experience but no foundation in online monitoring equipment operation); ② Training equipment: GNST-SC1000 practical prototype and consumables for detecting core parameters such as COD and ammonia nitrogen; ③ Training focus: targeted content such as equipment calibration, pharmaceutical wastewater pretreatment operation, elimination of drug residue interference, abnormal data judgment, equipment anti-corrosion maintenance, etc., to ensure that personnel fully master equipment usage skills.
3、 Implementation of core processes and functions for online monitoring
（1） Automated implementation of full process monitoring
The system implements a fully automated monitoring process without the need for manual supervision: ① Automatic sampling: monitoring equipment at each point automatically collects water samples according to preset cycles, with a precise sampling volume controlled at 50mL to ensure detection representativeness; ② Pre treatment: After two-stage filtration and drug inactivation pretreatment, the water sample enters the detection unit to remove interference factors; ③ Detection and analysis: Based on different parameter characteristics, multi parameter synchronous detection is completed through corresponding detection technologies such as spectrophotometry and electrode method. The digestion unit precisely controls the temperature and duration for COD and total phosphorus detection; ④ Result output: The detection data is displayed in real-time on the local touch screen of the device and uploaded to the central control platform and Qinghai Province ecological environment monitoring platform through a dual-mode transmission channel, with a data transmission delay of ≤ 3 seconds.
（2） Data transmission and platform management functions
1. Data transmission: Adopting a dual-mode transmission mode with industrial Ethernet as the main and 4G as the backup, supporting data encryption transmission to prevent information leakage and ensure stable data upload in complex network environments of sewage treatment stations, in compliance with HJ/T 212 environmental protection data transmission standards. 2. Core functions of the platform: ① Real time display: The central control platform dynamically displays multi parameter water quality data and equipment operation status (such as calibration status and cleaning status) of each monitoring point, using line charts and bar charts to present data change trends and intuitively reflect the sewage treatment effect; ② Abnormal alarm: preset warning values for various parameters (such as COD ≥ 80mg/L, ammonia nitrogen ≥ 8mg/L) and exceedance values (in accordance with the first level standard limits of the pharmaceutical industry). When the data reaches the warning threshold, the platform immediately triggers an audible and visual alarm and pushes a text message warning to the management personnel's mobile phones, marking the abnormal points and exceedance values. The response time is ≤ 5 minutes; ③ Data traceability: Automatically store historical detection data (storage period ≥ 1 year), support accurate queries by time, location, and parameters, and can generate detection reports that meet Qinghai's environmental protection regulatory requirements and export them; ④ Equipment management: The platform can remotely set equipment calibration and sampling cycles, monitor equipment failure status in real-time, and generate maintenance reminders.
（3） Linkage control and process optimization
Intelligent linkage between the system and sewage treatment process system to improve treatment efficiency and compliance rate: ① Inlet load regulation: Based on real-time COD data at the inlet of the regulating tank, the inlet flow rate is automatically adjusted to avoid high load impact on the biochemical system; ② Biochemical process regulation: Based on COD, ammonia nitrogen, and dissolved oxygen data in the aeration tank, automatically adjust the speed and aeration amount of the aeration fan to optimize the microbial reaction environment; ③ Accurate dosing control: Based on the total phosphorus data at the outlet of the secondary sedimentation tank, the dosage of flocculants and phosphorus removal agents is automatically calculated, and the dosing rate is adjusted by the linked dosing pump to avoid chemical waste; ④ Emergency response: When there is a warning of parameter exceeding the standard at the main discharge outlet, the discharge valve will be automatically closed, and the sewage will be returned to the regulating pool for reprocessing. At the same time, emergency response reminders will be pushed to ensure that the effluent is stable and meets the pollution prevention and control requirements of sensitive areas in Qinghai's water environment.
4、 System operation guarantee and maintenance
（1） Daily maintenance standards
Based on the humid, corrosive, and highly suspended environmental characteristics of the sewage treatment plant and the climate characteristics of the Qinghai Plateau, a targeted maintenance plan is formulated: ① Daily: inspect the operation status of the equipment through the central control platform, check the remaining amount of reagents and the pressure of the pretreatment module (to determine whether the filtration is blocked), and clean the surface water stains and corrosive substances of the equipment; ② Weekly: Disassemble and clean the pre-treatment filtration module and sampling port to avoid drug residue and suspended solids blockage; Complete equipment calibration according to platform reminders to ensure detection accuracy; ③ Monthly: Conduct a comprehensive inspection of equipment sealing performance, data transmission stability, and replace expired reagents; Check the heating performance and electrode status of the digestion unit; ④ Quarterly: Conduct third-party comparison and verification of test data to ensure accurate and reliable test results; Synchronize and check the effectiveness of the linkage control function to ensure the accuracy of process regulation.
（2） Emergency handling of faults
Establish a rapid response mechanism for common faults in online monitoring: ① Sampling blockage: The equipment automatically triggers a backwash program. If the cleaning is ineffective, the platform pushes a fault warning, and maintenance personnel arrive within 1 hour to disassemble and clean it; ② Calibration failed: The platform prompts that the calibration solution is invalid or the sensor is abnormal. Replace the calibration solution and recalibrate. If it is invalid, replace the sensor; ③ Data transmission interruption: automatically switch to 4G backup transmission, while troubleshooting Ethernet faults to ensure uninterrupted uploading of environmental protection data to the Qinghai Province ecological environment monitoring platform; ④ Detection accuracy deviation: Review the preprocessing process and digestion parameters, recalibrate the equipment, and contact supplier technical support if necessary; ⑤ Equipment corrosion: Regularly inspect the protective casing and seals of the equipment, replace them promptly if corrosion is found, and avoid damage to the core components of the equipment.
5、 Application effectiveness
1. Significant improvement in compliance control accuracy: Real time monitoring of the entire process of pharmaceutical wastewater treatment has been achieved, with data lag time reduced from the traditional 4 hours to 3 seconds, and water quality anomaly warning response time ≤ 5 minutes, effectively avoiding the risk of excessive discharge. Since the operation of the system, all indicators of the effluent from the sewage treatment plant have steadily reached the first level standards of the pharmaceutical industry, COD、 The average emission concentrations of ammonia nitrogen and total phosphorus were controlled within 32mg/L, 3mg/L, and 0.25mg/L, respectively, which were better than the preset control standards and successfully passed the special verification of Qinghai Province and the Huangshui River Basin.
2. Significant cost reduction and efficiency improvement achievements: Through the intelligent linkage dosing system, the consumption of coagulants and phosphorus removal agents is reduced by 30% compared to traditional manual dosing, saving approximately 150000 yuan in annual chemical costs; Accurately regulating aeration and inlet load, reducing energy consumption of equipment such as fans and pumps, and saving approximately 100000 yuan in electricity bills annually; Reduce the workload of manual sampling and testing, streamline 2 testing positions, and save approximately 140000 yuan in labor costs annually; After process optimization, the sewage reuse rate has been increased to 25%, saving about 8000 tons of water annually, which meets the requirements of water resource conservation and utilization in Qinghai Province.
3. Compliance and management upgrade: Establish a complete pharmaceutical wastewater treatment monitoring data traceability system, automatically generate testing reports that meet Qinghai's environmental protection regulatory requirements, and achieve "full traceability" of data throughout the process; The central control platform realizes the visualization management of the entire sewage treatment process, providing reliable data support for process optimization, improving the level of operation and maintenance refinement, ensuring the continuous and stable operation of the sewage treatment station, maintaining the enterprise's environmental credit rating, and establishing the green development of Qinghai's pharmaceutical industry.
