Case Study: Stream Ultrafiltration Membranes Delivering Reliable Performance at IGCAR, Kalpakkam for Township STP Water Treatment
- Theway Scholar
- Jan 30
- 3 min read
Introduction
Large institutional townships such as those operated by nuclear and atomic research establishments require highly reliable and safe water treatment systems to support residential, utility, and environmental needs. Treated sewage water must meet stringent quality standards to ensure safe reuse and environmentally compliant discharge.
At Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, treated water from the township Sewage Treatment Plant (STP) required advanced polishing to ensure consistent quality, bacterial removal, and long-term operational reliability. To meet these requirements, IGCAR partnered with Theway Membranes to deploy Stream Ultrafiltration (UF) Membranes. This case study highlights the proven performance of Stream UF membranes in a critical township STP application.
The Challenge
STP-treated water, while biologically treated, often contains residual turbidity, suspended solids, organic matter, and microorganisms that can limit reuse potential. At IGCAR Township STP, the following challenges were identified:
Residual Turbidity & Suspended Solids: STP effluent turbidity varied up to 20 NTU with TSS up to 40 ppm.
Organic Load (BOD & COD): Residual organic matter increased fouling risk and impacted filtration performance.
Microbial Safety: High levels of bacterial removal were essential due to the sensitive nature of the facility.
Operational Reliability: Continuous, trouble-free operation was required for a critical institutional setup.
Long-Term Cost Efficiency: Extended membrane life without replacement was a key operational requirement.
The facility required a robust UF solution capable of delivering consistently high-quality, microbiologically safe treated water.
The Solution: Stream Ultrafiltration Membranes
After detailed technical evaluation, Stream UF Membranes from Theway Membranes were selected for their proven reliability in polishing STP-treated water for reuse and discharge applications.
Key Features of Stream UF Membranes
Advanced Ultrafiltration Technology: Effective removal of suspended solids, organic matter, and microorganisms.
High Bacterial Removal Efficiency: Achieves up to 99.99% bacterial removal, ensuring safe treated water.
Consistent Permeate Quality: Produces low-turbidity, high-clarity water suitable for reuse.
High Fouling Resistance: Maintains stable performance under variable STP effluent conditions.
Long Service Life: Designed for extended operation with minimal maintenance.
Deployment at Cheyyar Cooperative Sugar Mill
The Stream UF system was commissioned in 2023 as a polishing step for the IGCAR Township Sewage Treatment Plant, with a treatment capacity of approximately 0.5 MLD. The system was seamlessly integrated into the existing STP infrastructure.
Key Deployment Details
Location: IGCAR, Kalpakkam
Industry Segment: Atomic Research / Institutional Township
Technology: Stream – Ultrafiltration
Source Water: STP Treated Water
User Application: Sewage Treatment / Polishing
Capacity: ~0.5 MLD
Commissioning: 2023
Results and Impact
Field validation of Stream UF Membranes at IGCAR, Kalpakkam demonstrated consistent and reliable performance over an extended operating period.
Key Results Achieved
Consistent Permeate Quality:
Turbidity: < 1 NTU
Suspended Solids: < 1 ppm
Bacterial Removal: 99.99%Achieved consistently over 25 months, even with feed turbidity up to 20 NTU, TSS up to 40 ppm, and SDI < 6.
Operational Reliability:Stream UF membranes have been operating continuously with no membrane replacement required as of August 2025.
Enhanced Water Safety:High bacterial removal ensured safe treated water suitable for reuse and environmentally compliant discharge.
Minimal Maintenance & Downtime:High fouling resistance reduced cleaning frequency and ensured uninterrupted system operation.
Cost Efficiency:Extended membrane life and stable operation delivered long-term operational cost savings.
Conclusion
The successful deployment of Stream Ultrafiltration Membranes at IGCAR, Kalpakkam demonstrates the effectiveness of Theway Membranes’ UF technology in critical institutional and township wastewater treatment applications. The system consistently delivered high-quality, microbiologically safe treated water while maintaining long-term operational reliability.
By adopting Stream UF membranes, IGCAR achieved enhanced STP performance, improved water safety, regulatory compliance, and sustainable water management. This case study reinforces the suitability of Stream Ultrafiltration technology for sensitive and mission-critical water treatment environments.
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