EnviroChemie Develops Future-Proof Solutions for Eliminating APIs from Pharma Wastewater

Rossdorf, Germany: – Industrial water treatment specialist EnviroChemie GmbH is developing safe, adaptable and future-proof multi-stage wastewater treatment solutions to remove elusive drug residues from pharmaceutical wastewater.

These customized solutions provide a vital advantage for pharma companies struggling to identify the most effective treatment technologies for removing trace levels of active pharmaceutical ingredients (APIs). This challenge is compounded by ongoing changes to regulatory requirements, making adaptability essential for long-term compliance.

Evolving Regulatory Demands

The issue is illustrated by the case of a major German-based producer of generic medicinal products that is now required by authorities to pre-treat its production wastewater before discharge to the municipal wastewater treatment plant.

Current regulations stipulate that residual API concentrations must be reduced to below 3 µg/L before discharge.

However, expectations are tightening. The customer anticipates future limits requiring API concentrations below 0.5 µg/L – around 15% of the current threshold – meaning any solution must be capable of significantly higher removal efficiency.

A Complex and Variable Treatment Challenge

Developing the optimal treatment approach is made more difficult by:

• A very wide spectrum of APIs produced, with frequently changing production campaigns
• The risk that advanced chemical processes used to degrade persistent molecules may themselves create toxic transformation products requiring further removal

EnviroChemie’s objective was therefore to develop a reliable, robust and adaptable process that could remove all relevant APIs while also preventing and eliminating any toxic by-products formed during treatment.

A Broad Toolbox of Advanced Treatment Technologies

Having impressed the customer with its open and technology-neutral approach, EnviroChemie was commissioned to develop the process engineering concept.

The team evaluated a broad range of solutions, including chemical–physical, biological and membrane-based treatments. For advanced oxidation processes (AOPs), EnviroChemie leverages multiple proven technologies rather than relying on a single method, including:

• Ozone oxidation
• UV / hydrogen peroxide
• Fenton Reaction, an especially powerful oxidative technique for degrading toxic, refractory and persistent organic pollutants

Their multi-stage treatment strategy offered a compact and flexible solution that can be adapted to a wide variety of pollution scenarios.

Developing a Tailored Multi-Stage Solution

Working collaboratively with the client, EnviroChemie proposed a combined process using Biomar® MBR membrane biology followed by Envochem® AOP ozone treatment.

The concept was verified through an extensive test programme at the EnviroChemie Technical Center, which spent eight weeks analyzing 20 different APIs in representative process wastewater samples.

Key findings included:

• Significant fluctuations in wastewater composition between samples
• Several APIs were biodegradable
• Non-biodegradable APIs were reliably eliminated via ozone oxidation
• Residual API concentrations below 3 µg/L could be achieved consistently
• Residual API levels below 0.5 µg/L were attainable by adjusting ozone dosage

EnviroChemie also performed PEC/PNEC analyses to assess potential environmental impact from direct or indirect discharge. Results were favorable, but further genotoxicity testing (Umu Chromotest) was conducted to verify that no toxic degradation products were being formed. These tests confirmed that the treated wastewater is genotoxically safe.

Ensuring Long-Term Safety and Compliance

Thanks to close collaboration between the pharmaceutical producer and EnviroChemie’s experts, a robust and future-proof wastewater treatment process was successfully developed – one capable of meeting current limits and adaptable to stricter regulations.

Pilot plant trials established the design parameters for scaling the system to industrial capacity, with accompanying analyses confirming reliable API elimination and the absence of harmful transformation products.

About EnviroChemie

EnviroChemie GmbH has established a reputation for reliable and innovative technology for water and wastewater treatment and water recycling, specializing in developing and implementing tailor-made for customers.

This engineering and service company was founded in 1976 and offers a holistic range of “Made in Germany” branded products and services based on chemical-physical, biological and membrane filtration processes, whose pedigree relies on its long list of research achievements and patents.

EnviroChemie adopts a partnership approach in which client specialized needs and characteristics form the basis for individual design, planning, engineering, building and commissioning of water and wastewater treatment plants and water recycling. In terms of plant operation, EnviroChemie offers comprehensive services, operation management, contracting and water treatment chemicals.

With more than 30,000 plants sold worldwide, EnviroChemie can apply unrivalled experience to continuous development of innovative and reliable industrial water and wastewater technologies.

EnviroChemie is a member of the EnviroWater Group, a network of companies that specialize in a broad range of solutions for sustainable water treatment. This in turn is a leading group component of German-based Skion Water, which is a technology and solution provider, as well as a plant manufacturer, in both municipal and industrial water and wastewater technology.

Further information at: www.envirochemie.com

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EnviroChemie is a leading expert in holistic industrial water management, primarily serving industries across Europe. Partner with EnviroChemie for innovative, eco-friendly solutions tailored to your needs.