ndustries that consume large volumes of water are now expected to give every drop back. Stricter CPCB and SPCB norms, rising freshwater costs, and the global shift toward sustainable manufacturing have made Zero Liquid Discharge a non-negotiable for any modern process plant.
Raj Process Equipments & Systems Pvt. Ltd. is among India's most trusted ZLD plant manufacturers, delivering turnkey systems that treat, recycle, and recover industrial wastewater so that nothing leaves the plant as liquid effluent. With 25+ years of process engineering experience and 110+ plant commissionings, we design ZLD systems that don't just meet compliance — they pay back through water reuse, by-product recovery, and energy integration.
What is Zero Liquid Discharge?
Zero Liquid Discharge is an advanced wastewater treatment approach in which 100% of the effluent is treated, purified, and reused within the plant, leaving behind only solids for safe disposal or resale.
A well-designed ZLD plant delivers three outcomes at once:
Clean water returned to the process or utilities loop
Recovered salts and by-products that can be reused or sold
Full regulatory compliance with state and central pollution control norms
For industries facing water scarcity, “no-discharge“ mandates, or the pressure to decarbonise operations, ZLD is the most direct path to a closed-loop, sustainable plant.
Turnkey ZLD Plant Solutions by Raj Process
Every industry produces a different effluent — spent wash from a distillery looks nothing like POME from a palm oil mill or RO reject from a textile unit. That's why we don't sell off-the-shelf packages. Each Raj Process ZLD plant is custom-engineered around your effluent characteristics, recovery targets, steam economy, and site footprint.
We deliver complete EPC scope: process design, basic and detailed engineering, in-house fabrication, supply, erection, commissioning, and post-commissioning support.
Industries We Serve
Distilleries and ethanol plants
Sugar mills and integrated biorefineries
Palm oil mills (POME treatment)
Pharmaceutical and bulk drug units
Specialty and agro chemicals
Textile, dyeing, and printing units
Food and beverage processing
Power plants and refineries
ZLD Process Flow — From Effluent to Reuse
A typical Raj Process ZLD plant moves wastewater through four engineered stages:
1. Collection and Flash Mixing
All effluent streams are routed to a common collection pit, where coagulants such as alum, lime, and polyelectrolytes are dosed to destabilise suspended solids and prepare the stream for separation.
2. Flocculation and Clarification
The dosed effluent flows through flocculation tanks and lamella or tube settlers, where solids are separated. Clarified water then moves to monitoring basins for quality checks before downstream concentration.
3. Evaporation and Concentration
Multiple Effect Evaporators (MEE) — and where energy economics demand, Mechanical Vapour Recompression (MVR) — concentrate the dissolved solids into a thick liquor. The vapours are condensed to recover high-purity condensate suitable for reuse in fermentation, cooling, or boiler make-up.
4. Crystallisation and Drying
The concentrated stream is fed to forced-circulation crystallisers and agitated thin-film or spray dryers to recover salts and produce a dry, handleable solid for reuse or safe disposal.
Why Raj Process ZLD Technology Stands Apart
Handles every effluent type — spent wash, POME, textile dye liquor, RO reject, pharma effluent, sugar mill condensate, chemical waste
Multi-technology integration — evaporation, crystallisation, membrane filtration, and advanced oxidation, deployed in the right combination for each effluent
Compact, modular, skid-mounted designs — units up to 1, 000 KLD available as skids for fast site installation
PLC and SCADA-based automation — fully integrated process control for safe, optimised, low-manpower operation
High recovery rates — typically 95–98% water recovery
In-house fabrication — a key Raj Process advantage; pressure vessels, evaporator bodies, crystallisers, and skids are built in our own Pune facility, ensuring tighter quality control and shorter delivery
Custom engineering — every plant is designed around your specific effluent profile, not retrofitted from a generic package
Specialised ZLD Solutions
1. ZLD for Spent Wash — Distilleries and Ethanol Plants
Spent wash is among the most challenging effluents in industry — high COD/BOD, high TDS, dark in colour, and produced in large volumes. Our integrated ZLD package combines:
Multi-Effect Evaporators (MEE) to concentrate spent wash to 55–60% solids
Spray dryers or rotary dryers to achieve complete drying into a granular solid
Condensate polishing for reuse in fermentation or utility loops
Outcomes: zero liquid discharge, compliance with CPCB and SPCB norms, recovered potash-rich solids for use as soil conditioner or fuel supplement, and full integration with the distillery's steam and water balance.
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