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Multi Stage Filtration System For Dye Removal And Wastewater Treatment

Abstract: A multi-stage filtration system for dye removal and wastewater treatment, comprising a mesh filtration unit 101 receive wastewater through a collection hopper 103 and remove large solid debris, a cylindrical industrial wastewater storage container 104 regulate wastewater flow rate, a cylindrical absorption unit 105 integrated with flow controllers and pressure gauges for regulating flow and monitoring filtration performance, a cuboidal coagulation and flocculation unit 106 monitoring treatment effectiveness, an electrochemical filtration unit 107 and a flow divider ensures even wastewater distribution, an algae-based bio-filtration unit 108 optimize algal growth and biomass yield, an algal mass collector 109 harvesting mature algae, an automated mechanical harvesting unit 112 to maintain continuous cultivation and biomass removal balance, a UV sterilizer unit 110 eliminating remaining microorganisms and pathogens and a storage container 111 receive purified water.

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
30 May 2025
Publication Number
25/2025
Publication Type
INA
Invention Field
CHEMICAL
Status
Email
Parent Application

Applicants

Marwadi University
Rajkot - Morbi Road, Rajkot 360003 Gujarat, India.

Inventors

1. Karan Ashokbhai Rathod
Department of Chemistry, Marwadi University, Rajkot - Morbi Road, Rajkot 360003 Gujarat, India.
2. Dr. Nishant Ranjan
Department of Mechanical Engineering, Marwadi University, Rajkot - Morbi Road, Rajkot 360003 Gujarat, India.
3. Dr. Mital R Soni
Department of Chemistry, Marwadi University, Rajkot - Morbi Road, Rajkot 360003 Gujarat, India.

Specification

Description:FIELD OF THE INVENTION

[0001] The present invention relates to a multi-stage filtration system for dye removal and wastewater treatment that enhances industrial wastewater treatment by enabling the efficient removal of solid debris, dissolved pollutants, and harmful chemicals in order to improve water quality, and support safe reuse.

BACKGROUND OF THE INVENTION

[0002] The treatment of dye-laden industrial wastewater from industries, requires an efficient multi-stage filtration due to the complex composition of pollutants, including suspended solids, toxic dyes, heavy metals, and organic compounds. Conventional single-step methods often fail to meet environmental discharge standards and are unable to effectively remove all contaminants. Users face challenges such as inconsistent flow rates, ineffective pollutant removal, high chemical usage, and difficulty in monitoring treatment effectiveness in real time. Additionally, the presence of carcinogenic dyes and variable wastewater characteristics complicates treatment processes. A well-structured multi-stage system is essential to address these challenges by offering sequential removal of contaminants, improving efficiency, enabling real-time monitoring, and supporting the reuse of treated water while meeting regulatory compliance.

[0003] Existing devices for industrial wastewater treatment include membrane filtration units, chemical coagulation systems, activated carbon filters, and biological treatment tanks. While these systems offer partial pollutant removal, they often suffer from high operational costs, membrane fouling, limited effectiveness against synthetic dyes, and the need for frequent chemical replenishment. Membrane systems clog quickly with high-solid-content water, and biological treatments are slow and ineffective against non-biodegradable dyes. Additionally, most conventional setups lack integrated monitoring and automated control, making real-time adjustments difficult. These limitations lead to inconsistent purification results and increased labor requirements. As a result, users face challenges in maintaining treatment efficiency, meeting discharge standards, and ensuring sustainable reuse of treated wastewater across varying industrial conditions.

[0004] US6592751B2 discloses a high-rate reactor system, (applying a high superficial velocity), capable of treating partially soluble, complex, high-strength wastewater. The reactor system is configured in multiple stages and has the ability to retain complex insoluble substrates in a wide range of particle sizes in spatially separate stages for sufficient residence time to enable complete degradation. A vertically oriented vessel has neighboring upper and lower chambers, each chamber having a gas retention space and a liquid retention space. A filter chamber has an inlet communicating with the liquid retention space of the lower chamber and an outlet communicating with the liquid retention space of the upper chamber. A gas conduit communicates the gas retention space of the lower chamber with the gas retention space of the upper chamber. A discharge device enables gas to be periodically discharged from the lower chamber to the upper chamber through the gas conduit.

[0005] US9611160B2 discloses a clinical analyser wastewater treatment apparatus is disclosed including a carbonator section. Preferably there is also an anodic oxidation section and a UV oxidation section, as well as a heavy metal removal section. The anodic oxidation section may include a conductive diamond anode. The apparatus may include a measurement device downstream of the carbonator section and a control system to control the operation of the carbonator. The measurement device is preferably a pH sensor.

[0006] Conventionally, many devices are available in the market for water treatment. However, the cited inventions lack to provide integrated, multi-stage treatment with real-time monitoring and automated control. The cited inventions fail to ensure consistent removal of synthetic dyes, heavy metals, and other complex pollutants, leading to operational inefficiencies, increased maintenance, and difficulty in meeting regulatory discharge standards.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that is required to be capable of providing efficient treatment for industrial wastewater, ensuring consistent removal of dyes, heavy metals, and pollutants. The system should support real-time monitoring, automated control, and adaptive treatment responses to enhance efficiency, reduce maintenance, and meet environmental discharge standards effectively.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system that improve the treatment of industrial wastewater by enabling effective removal of solid debris, dissolved pollutants, and harmful chemicals through a multi-stage process.

[0010] Another object of the present invention is to develop a system that ensure stable and controlled flow of wastewater throughout the treatment process for consistent and efficient purification results.

[0011] Yet another object of the present invention is to develop a system that provide real-time monitoring and feedback during each stage of treatment, helping to maintain proper conditions and detect issues early.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to a multi-stage filtration system for dye removal and wastewater treatment that maintains a stable and controlled flow of industrial wastewater throughout the treatment process, leading to consistent and efficient purification and improves the overall effectiveness of the wastewater purification process.

[0014] According to an embodiment of the present invention, a multi-stage filtration system for dye removal and wastewater treatment, comprises of an inclined mesh filtration unit mounted on a supporting frame to receive industrial wastewater through a collection hopper and remove large solid debris, the mesh frame inclination is adjustable via an inclinometer integrated on guide rails to regulate flow rate and debris separation efficiency, a cylindrical industrial wastewater storage container positioned downstream of the mesh filtration unit, a cylindrical absorption unit with an upper activated carbon layer and a lower bio-char layer for adsorbing dyes, organic compounds, and micro-pollutants from partially filtered wastewater, the absorption unit is integrated with flow controllers and pressure gauges for regulating flow and monitoring filtration performance, a cuboidal coagulation and flocculation unit positioned downstream of the absorption unit, having a coagulation tank with precision-controlled dosing pumps for coagulant and flocculant chemicals, an agitator for mixing, a floc settling chamber with a sludge outlet, a pH sensor, and a nephelometric turbidity sensor for monitoring treatment effectiveness, an enclosed reactor chamber housing stacked anode and cathode plates and an electrolyte chamber, an electrical current facilitates oxidation and reduction reactions to break down contaminants, and a flow divider ensures even wastewater distribution across electrodes.

[0015] According to another embodiment of the present invention, the system disclosed herein further comprises of an electrochemical filtration unit comprising an algae-based bio-filtration unit with a transparent bioreactor chamber for cultivating microalgae using partially treated wastewater, integrated with sensors monitoring pH, temperature, light intensity, dissolved oxygen, air diffusers powered by an air pump, and a carbon dioxide injection unit regulated based on real-time sensor data to optimize algal growth and biomass yield, an algal mass collector integrated at the bottom of the algae-based bioreactor for harvesting mature algae, an automated mechanical harvesting unit with biomass concentration sensors, a scraper, a recirculation pump, and a flow return valve, controlled by a microcontroller to maintain continuous cultivation and biomass removal balance, a UV sterilizer unit positioned downstream of the algae-based bio-filtration unit for eliminating remaining microorganisms and pathogens using UV-C light and a storage container is provided downstream of the sterilizer unit configured to receive purified water from the UV sterilizer for accumulation and reuse.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a multi-stage filtration system for dye removal and wastewater treatment.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to a multi-stage filtration system for dye removal and wastewater treatment that offers real-time monitoring and feedback throughout each stage of the wastewater treatment process, which helps to maintain proper operating conditions, and enables early detection of potential issues.

[0022] Referring to Figure 1, an isometric view of a multi-stage filtration system for dye removal and wastewater treatment is illustrated, comprising an inclined mesh filtration unit 101 mounted on a supporting frame 102, a collection hopper 103 mounted on the frame 102, a cylindrical industrial wastewater storage container 104 positioned downstream of the mesh filtration unit 101, a cylindrical absorption unit 105, a cuboidal coagulation and flocculation unit 106 positioned downstream of the absorption unit 105, an electrochemical filtration unit 107, an algae-based bio-filtration unit 108, an algal mass collector 109 integrated at the bottom of the algae-based bio-filtration unit 108, a UV sterilizer unit 110 positioned downstream of the algae-based bio-filtration unit 108, a storage container 111 provided downstream of the sterilizer unit 110 and an automated mechanical harvesting unit 112 downstream the algae-based bio-filtration unit 108

[0023] The system disclosed in the present invention comprises of an inclined mesh filtration unit 101 mounted on a sturdy supporting frame 102, developed to process industrial wastewater. Wastewater enters through a collection hopper 103 at the top, directing the flow onto the inclined mesh screen. As the water passes over the mesh, large solid debris and particles are trapped and retained on the surface. The inclined orientation facilitates debris removal and prevents clogging, ensuring efficient filtration. The large debris are then collected into a vessel arranged underneath the filtration unit 101.

[0024] The mesh frame 102 is mounted on adjustable guide rails, allowing the inclination of the mesh to be modified using an integrated inclinometer, enabling accurate control of the mesh's tilt angle, which influences the flow rate of wastewater passing through the filter. Adjusting the inclination optimizes debris separation efficiency, ensuring effective removal of solids while maintaining appropriate flow conditions.

[0025] The wastewater filtered from the mesh is then transferred to a cylindrical industrial wastewater storage container 104 positioned downstream of said mesh filtration unit 101 to regulate wastewater flow rate. The storage container 104 is a buffer to collect wastewater to regulate wastewater flow rate and prevent surges to subsequent filtration stages.

[0026] To activate the device, the user manually presses a push button which is installed on the frame 102. Upon pressing the button, the circuits within the device gets close, allowing electric current to flow. The push button has an outer casing and an inner arrangement, including a spring and metal contacts. When the button is pressed, the spring-loaded assembly inside is pushes down on. In the default state, the internal contacts are apart, so the circuit is open and no electricity flows. Pressing the button makes the contacts touch each other, closing the circuit and allowing electricity to flow, which activates an inbuilt microcontroller that regulates the further options of the device.

[0027] Upon activation of the device, the microcontroller activates an inbuilt communication module for establishing a wireless connection between the microcontroller and a remote computing unit that is inbuilt with a user-interface and accessed by the user for enabling the user to give input commands to initiate the filtration of the industrial wastewater. The user interacts with the interface through a touch screen, keyboard, or other input methods available on the remote computing unit. The remote computing unit mentioned herein includes, but not limited to smartphone, laptop, tablet.

[0028] The communication module mentioned herein includes, but not limited to Wi-Fi (Wireless Fidelity) module, Bluetooth module, GSM (Global System for Mobile Communication) module. The communication module used in the device is preferably the Wi-Fi module. The Wi-Fi module enables wireless communication by transmitting and receiving data over radio frequencies using IEEE 802.11 protocols. It connects to a network via an access point, converting digital data into radio signals. The module processes TCP/IP protocols for data exchange, interfaces with microcontrollers through UART/SPI, and ensures encrypted communication using WPA/WPA2 security standards for secure and efficient wireless connectivity.

[0029] The microcontroller then actuates flow controllers integrated with a cylindrical absorption unit 105 positioned downstream of the storage container 104 allowing the wastewater to enter the absorption unit 105. The flow controller regulates the flow of wastewater from the storage container 104 to the absorption unit 105 by measuring the current flow using a sensor, which sends signals to the microcontroller. The controller compares this signal with the desired setpoint. In case, there's a difference, it sends a control signal to a valve such as a control valve adjusting its opening to increase or decrease flow. The adjustment of the control valve changes the flow rate, bringing it back to the setpoint.

[0030] The wastewater entering the absorption unit 105 is first passed through an upper layer of activated carbon layer and the passed through a lower layer bio-char absorbing dyes, organic compounds, and micro-pollutants from partially filtered wastewater. The activated carbon layer is used due to the high adsorption capacity of the carbon. When the wastewater is passed through the activated carbon layer, which has a porous structure with a vast surface area, dyes, organic compounds, and micro-pollutants from partially filtered wastewater are attracted and held on the surface of the carbon particles through physical and chemical adsorption, resulting in cleaner water.

[0031] The bio-char, a charcoal-like material produced from organic waste via pyrolysis, is used as a filtration medium for industrial wastewater. The porous structure of the bio-char provides a large surface area for adsorption of pollutants such as heavy metals, organic compounds, and nutrients. When wastewater passes through a bio-char layer, contaminants adhere to the surface of the bio-char through physical and chemical interactions, reducing pollutant levels. Bio-char also helps in removing odors and improving water clarity. Additionally, the bio-char layer immobilizes toxic substances, preventing their release into the environment. After the wastewater is passed through the absorption unit 105, the cleaner water is stored in receptacle positioned underneath the absorption unit 105 for further filtration.

[0032] In synchronization with the absorption of the dyes, organic compounds, and micro-pollutants from partially filtered wastewater, a spectrophotometric sensor associated with the absorption unit 105 is activated by the microcontroller to detect an absorbance peak at around 600 nm(nanometer) associated with azo pigments. The spectrophotometric sensor detects azo pigments around 600 nm by emitting light at this wavelength through the wastewater passing through the absorption unit 105. The pigment molecules absorb specific light due to their conjugated azo groups, reducing the intensity of transmitted light. A detector measures the transmitted light's intensity, and the sensor calculates absorbance using the Beer-Lambert Law. The absorbance value correlates with the pigment concentration. By calibrating the sensor with known standards, it accurately quantifies azo dye levels.

[0033] Based on the detected quantity of azo pigments at 600 nm(nanometer), an AI (artificial intelligence)-driven chemical classification unit is activated by the microcontroller to identify carcinogenic benzidine-based azo dyes. The AI driven chemical classification unit analyzes molecular structures of azo dyes to identify benzidine-based carcinogens. The chemical classification unit extract features such as functional groups, aromatic rings, and specific structural motifs associated with benzidine. Using a trained machine learning protocol on labeled datasets, it learns patterns linked to carcinogenicity. When a new dye is input, the AI evaluates its structural features and predicts its carcinogenic potential, focusing on benzidine-related indicators. Upon identifying carcinogenic benzidine-based azo dyes the microcontroller generates automated warnings recommending safe alternative dye chemicals which is displayed on the remote computing unit of the user.

[0034] Upon collection of the wastewater in the receptacle, a dosing pumps installed between the absorption unit 105 and a cuboidal coagulation and flocculation unit 106 positioned downstream of said absorption unit 105 is actuated by the microcontroller for transferring the wastewater into a coagulation tank associated with the coagulation and flocculation unit 106. The dosing pump operates by using a motor-driven piston, diaphragm, or plunger to deliver water in to the coagulation tank. During the suction stroke, the piston moves back, creating a vacuum that draws water into the pump through an inlet valve. In the discharge stroke, the piston moves forward, pushing the water out through an outlet valve into the coagulation tank.

[0035] As the water is transferred into the coagulation tank, an agitator is actuated by the microcontroller for mixing the drawn water with the coagulant and flocculant chemicals in order to clear the suspended particles from the wastewater. The agitator works by converting mechanical energy from a motor into kinetic energy to produce fluid motion within the coagulation tank. The motor drives a shaft connected to impellers. As the motor turns, the impellers rotate, creating turbulence and flow patterns that mix the coagulant and flocculant chemicals uniformly. Coagulants and flocculants are water treatment agents used to remove suspended particles. Coagulants destabilize and neutralize the charge of suspended particles, allowing them to clump together. Flocculants then bind these smaller clumps into larger masses (flocs) that are settled into a floc settling chamber with a sludge outlet to filter out the settled sludge.

[0036] The coagulation and flocculation unit 106 comprises of a pH sensor, and a nephelometric turbidity sensor for monitoring treatment effectiveness. The pH sensor measures the hydrogen ion concentration in water to determine its pH level using two electrodes to create an electrical circuit. The sensing electrode contains a substance with a known electric potential which is inserted into the solution being tested. The measuring electrode is made of a pH-sensitive glass that reacts to the hydrogen ion concentration in the solution. The glass membrane's buffer solution allows hydrogen ions to enter the membrane, creating a voltage that is measured by the sensor to calculate the pH value.

[0037] The nephelometric turbidity sensor works by emitting infrared light into a coagulation tank. Suspended particles scatter the incident light, and a detector positioned at a 90-degree angle measures the scattered light intensity. The sensor converts this light into an electrical signal, which correlates to the turbidity level, higher particle concentration results in more scattering and a higher reading. The output is calibrated to turbidity units (NTU). This real-time measurement helps monitor water clarity, control treatment processes, and ensure water quality standards are met.

[0038] An ICP-OES (Inductively Coupled Plasma Optical Emission Spectroscopy) and metal ion sensor configured coagulation and flocculation unit 106 to detect elevated concentrations of chromium and copper. ICP-OES detects chromium and copper by nebulizing the water sample into a high-temperature plasma, where the metals are atomized and excited. As the atoms return to lower energy states, they emit characteristic wavelengths of light specific to each element. A spectrometer measures the intensity of this emitted light, which correlates to metal concentration. Elevated levels are identified when emission signals exceed set thresholds. Metal ion sensors, such as ion-selective electrodes, respond to specific metal ions by producing a potential proportional to their concentration. Colorimetric sensors react with metals to produce a measurable color change, triggering automated notifications to the remote computing unit through the communication module, suggesting the use of synthetic tanning agents or eco-friendly mordents.

[0039] Post treatment of suspended particles, an electrochemical filtration unit 107 positioned downstream of coagulation and flocculation unit 106 is activated by the microcontroller where an electrical current facilitates oxidation and reduction reactions to break down contaminants. The electrochemical filtration unit 107 comprising an enclosed reactor chamber housing stacked anode and cathode plates and an electrolyte chamber for producing electrical current in order to initiate oxidation and reduction reactions.

[0040] The electrochemical filtration unit 107 functions by applying an external electrical potential across the electrodes. When connected to a power source, electrons flow from the cathode (negative electrode) to the anode (positive electrode) through the external circuit. Inside the electrolyte chamber, this current drives oxidation reactions at the anode oxidizing contaminants like heavy metals or organic compounds and reduction reactions at the cathode, reducing pollutants or facilitating precipitation. The flow of electrons (current) is thus generated by the applied voltage, enabling electrochemical processes such as contaminant oxidation, reduction, and removal within the reactor.

[0041] In order to treat the bio pollutants, a transparent bioreactor chamber associated with an algae-based bio-filtration unit 108 is activated by the microcontroller for cultivating microalgae using partially treated wastewater. The bioreactor chamber cultivates microalgae by providing a controlled environment optimized for growth. The bioreactor chamber supplies nutrients, light, and carbon dioxide necessary for photosynthesis. The bioreactor chamber maintains suitable temperature, pH, and oxygen levels. Light, often from LEDs or natural sources, stimulates photosynthesis, while aeration or mixing ensures uniform distribution of nutrients and gases. The microalgae grow by converting sunlight and nutrients into biomass. Continuous or batch operation allows for monitoring and adjusting conditions to maximize productivity.

[0042] The suitable environment for cultivation of the microalgae, air diffusers powered by an air pump, and a carbon dioxide injection unit are activated by the microcontroller to provide required conditions. The air pump powers the air diffusers, dispersing fine bubbles that increase dissolved oxygen and facilitate mixing within the bioreactor, supporting microalgae respiration. Simultaneously, the carbon dioxide injection unit delivers precise amounts of carbon dioxide, essential for photosynthesis. Sensors integrated with the algae-based bio-filtration unit 108 monitor dissolved oxygen, pH, and CO₂ levels, providing real-time data to microcontroller. Based on this feedback, the microcontroller adjusts the airflow from the pump and the CO₂ injection rate to maintain optimal oxygen and carbon dioxide concentrations.

[0043] Upon cultivation of algal, an automated mechanical harvesting unit 112 configured with an algal mass collector 109 integrated at the bottom of said algae-based bioreactor is activated by the microcontroller for harvesting mature algae to maintain continuous cultivation and biomass removal balance. The automated mechanical harvesting unit 112 includes several key components. Biomass concentration sensors detect algae density, signaling when to initiate harvesting. The scraper mechanically removes biomass from the reactor surfaces, ensuring continuous collection. The recirculation pump pumps the harvested biomass or culture medium through the system, maintaining flow and preventing settling. The flow return valve directs the recirculated fluid back into the reactor or to a concentration process, enabling efficient biomass separation and reuse. Together, these components automate the harvesting process, optimize biomass recovery, and maintain system efficiency, reducing manual effort and ensuring consistent biomass quality.

[0044] Post cleaning the wastewater through the microalgae, a UV sterilizer unit 110 positioned downstream of said algae-based bio-filtration unit 108 is activated by the microcontroller for eliminating remaining microorganisms and pathogens using UV-C light. The UV sterilizer unit 110 sterilizes water by exposing it to ultraviolet (UV-C) light, which effectively destroys microorganisms. As water flows through the sterilizer chamber, it passes over a UV light source. The UV-C radiation penetrates the cell walls of bacteria, viruses, and algae, damaging their DNA and RNA, preventing replication and rendering them inactive. This process kills or inactivates pathogens without adding chemicals. The UV sterilizer is immediate and chemical-free, ensuring the water is microbiologically safe. The cleaned water is then passed into a storage container 111 is provided downstream of the sterilizer unit 110 configured to store cleaned water for reuse.

[0045] Moreover, a battery is associated with the device to supply power to electrically powered components which are employed herein. The battery is comprised of a pair of electrodes known as a cathode and an anode. A voltage is generated between the anode and cathode via oxidation/reduction and thus produces the electrical energy to provide to the device.

[0046] The present invention, works best in the following manner where the mesh frame 102 mounted on adjustable guide rails with the inclinometer to optimize debris separation. The filtered wastewater moves to the cylindrical storage container 104 for flow regulation, then to the absorption unit 105 through the flow controllers. The absorption unit 105, comprising the activated carbon layer and the bio-char layer, removes dyes, organic compounds, and micro-pollutants. The spectrophotometric sensor detects azo dye absorbance at 600 nm, activating the AI-driven chemical classification unit to identify carcinogenic benzidine-based azo dyes and generate safety warnings. Wastewater collected in the receptacle is transferred by the dosing pump to the coagulation and flocculation unit 106 where the agitator mixes coagulants and flocculants. The pH sensor, nephelometric turbidity sensor, ICP-OES, and metal ion sensors monitor treatment effectiveness and detect heavy metals. The electrochemical filtration unit 107 with stacked electrodes facilitates redox reactions to degrade contaminants. The algae-based bio-filtration unit 108 cultivates microalgae in the bioreactor chamber supported by the air diffusers and the carbon dioxide injection unit, monitored by dissolved oxygen, pH, and CO₂ sensors. The mechanical harvesting unit 112 collects biomass, and the UV sterilizer unit 110 eliminates pathogens. Treated water is stored in the downstream container for reuse.

[0047] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A multi-stage filtration system for dye removal and wastewater treatment, comprising:

i) an inclined mesh filtration unit 101 mounted on a supporting frame 102, configured to receive industrial wastewater through a collection hopper 103 and remove large solid debris, wherein the mesh frame 102 inclination is adjustable via an inclinometer integrated on guide rails to regulate flow rate and debris separation efficiency;
ii) a cylindrical industrial wastewater storage container 104 positioned downstream of said mesh filtration unit 101, wherein a cylindrical absorption unit 105 comprising an upper activated carbon layer and a lower bio-char layer for adsorbing dyes, organic compounds, and micro-pollutants from partially filtered wastewater, wherein said absorption unit 105 is integrated with flow controllers and pressure gauges for regulating flow and monitoring filtration performance;
iii) a cuboidal coagulation and flocculation unit 106 positioned downstream of said absorption unit 105, comprising a coagulation tank with precision-controlled dosing pumps for coagulant and flocculant chemicals, an agitator for mixing, a floc settling chamber with a sludge outlet, a pH sensor, and a nephelometric turbidity sensor for monitoring treatment effectiveness;
iv) an electrochemical filtration unit 107 comprising an enclosed reactor chamber housing stacked anode and cathode plates and an electrolyte chamber, wherein an electrical current facilitates oxidation and reduction reactions to break down contaminants, and a flow divider ensures even wastewater distribution across electrodes;
v) an algae-based bio-filtration unit 108 comprising a transparent bioreactor chamber for cultivating microalgae using partially treated wastewater, integrated with sensors monitoring pH, temperature, light intensity, dissolved oxygen, air diffusers powered by an air pump, and a carbon dioxide injection unit regulated based on real-time sensor data to optimize algal growth and biomass yield;
vi) an algal mass collector 109 integrated at the bottom of said algae-based bioreactor for harvesting mature algae, comprising an automated mechanical harvesting unit 112 with biomass concentration sensors, a scraper, a recirculation pump, and a flow return valve, to maintain continuous cultivation and biomass removal balance;
vii) a UV sterilizer unit 110 positioned downstream of said algae-based bio-filtration unit 108 for eliminating remaining microorganisms and pathogens using UV-C light, wherein storage container 111 is provided downstream of the sterilizer unit 110 configured to receive purified water from said UV sterilizer for accumulation and reuse; and
viii) a microcontroller associated with the device to integrates sensor data from all filtration stages to optimize treatment parameters and eco-friendly alternatives to hazardous substances.

2) The multi-stage filtration system as claimed in claim 1, wherein a user-interface is inbuilt in a remote computing unit accessed by a concerned user, enabling communication between the filtration system and users, configured to transmit real-time information, alerts, and recommendations regarding system operation and wastewater treatment status.

3) The multi-stage filtration system as claimed in claim 1, wherein said absorption unit 105 includes a spectrophotometric sensor detecting an absorbance peak at around 600 nm(nanometer) associated with azo pigments, coupled with an AI (artificial intelligence)-driven chemical classification unit configured to identify carcinogenic benzidine-based azo dyes and generate automated warnings recommending safe alternative dye chemicals.

4) The multi-stage filtration system as claimed in claim 1, wherein said coagulation and flocculation unit 106 further comprises an ICP-OES (Inductively Coupled Plasma Optical Emission Spectroscopy) and metal ion sensor configured to detect elevated concentrations of chromium and copper, triggering automated notifications, suggesting the use of synthetic tanning agents or eco-friendly mordents.

5) The multi-stage filtration system as claimed in claim 1, wherein said algae-based bio-filtration unit 108 includes an optical sensor configured to detect biomass concentration and dissolved oxygen levels, and sudden decreases trigger warnings regarding biocidal agent contamination and automatically adjust wastewater flow to isolate affected batches and recommend eco-friendly dye alternatives.

6) The multi-stage filtration system as claimed in claim 1, wherein said microcontroller integrates sensor data from all filtration stages to generate operational feedback, alerts for hazardous chemicals, and suggestions for optimized treatment parameters and eco-friendly alternatives to hazardous substances.

7) The multi-stage filtration system as claimed in claim 1, wherein a battery is associated with said device for supplying power to electrical and electronically operated components associated with said device.

Documents

Application Documents

# Name Date
1 202521052789-STATEMENT OF UNDERTAKING (FORM 3) [30-05-2025(online)].pdf 2025-05-30
2 202521052789-REQUEST FOR EXAMINATION (FORM-18) [30-05-2025(online)].pdf 2025-05-30
3 202521052789-REQUEST FOR EARLY PUBLICATION(FORM-9) [30-05-2025(online)].pdf 2025-05-30
4 202521052789-PROOF OF RIGHT [30-05-2025(online)].pdf 2025-05-30
5 202521052789-POWER OF AUTHORITY [30-05-2025(online)].pdf 2025-05-30
6 202521052789-FORM-9 [30-05-2025(online)].pdf 2025-05-30
7 202521052789-FORM FOR SMALL ENTITY(FORM-28) [30-05-2025(online)].pdf 2025-05-30
8 202521052789-FORM 18 [30-05-2025(online)].pdf 2025-05-30
9 202521052789-FORM 1 [30-05-2025(online)].pdf 2025-05-30
10 202521052789-FIGURE OF ABSTRACT [30-05-2025(online)].pdf 2025-05-30
11 202521052789-EVIDENCE FOR REGISTRATION UNDER SSI(FORM-28) [30-05-2025(online)].pdf 2025-05-30
12 202521052789-EVIDENCE FOR REGISTRATION UNDER SSI [30-05-2025(online)].pdf 2025-05-30
13 202521052789-EDUCATIONAL INSTITUTION(S) [30-05-2025(online)].pdf 2025-05-30
14 202521052789-DRAWINGS [30-05-2025(online)].pdf 2025-05-30
15 202521052789-DECLARATION OF INVENTORSHIP (FORM 5) [30-05-2025(online)].pdf 2025-05-30
16 202521052789-COMPLETE SPECIFICATION [30-05-2025(online)].pdf 2025-05-30
17 Abstract.jpg 2025-06-18
18 202521052789-FORM-26 [01-07-2025(online)].pdf 2025-07-01