As a supplier of holistic industrial wastewater treatment solutions we offer made-to-order and turnkey industrial plants. One example of such is this project in Cambodia from 2024:

A local Cambodian soft-drink bottling company decided to strengthen its market profile by building a new green-field factory in the periphery of the Cambodian capital: Phnom Penh. CUSS GmbH was the partner to realize the according wastewater treatment plant and help protect the local manifold environment by continuously guaranteeing the strict local wastewater effluent discharge values.

NUMBERS & FACTS:

·         Place: Phnom Penh, Cambodia

·         Hydraulic plant capacity: 3050 m³/d

·         Organic Load: 15.000 kg/d (COD)

·         Years of construction: 2023 - 2024

 CONCEPTUAL FORMULATION:

This greenfield project for the construction softdrink bottling factory required precise interaction between the end customer and the general contractor. After several months of preliminary planning, a concept for the wastewater treatment plant was drawn up in line with the customer's requirements while aiming for minimum space requirement. The high organic load of the soft drink wastewater required the construction of an high-load anaerobic reactor with a subsequent aerobic treatment stage in the form of a continuously activated sludge system in form of a aeration tank and a sedimentation tank. The treated wastewater is partially purified via a fine filter and reused for the process water consumers within the wastewater treatment plant in order to further minimize the use of fresh water. Odour emissions are also minimized through the use of a biofilter for exhaust air purification. The biogas produced in the anaerobic process is conditioned in a multi-stage process and is available as fuel for the existing boiler in order to further reduce the primary energy requirement for the superheated steam in the production plant.

The design and construction of the concrete tanks was carried out by the customer, with CUSS GmbH taking on the construction supervision for the installation of the necessary tank nozzles.

The supervisors from CUSS GmbH worked in cooperative partnership together with a Southeast Asian installation company for the mechanical and electrical installation. The complete commissioning and several months of operational supervision, including training of the local operating personnel, were part of the scope of services for this project.

WASTEWATER CONSTITUENTS:

·         Sugar and other easily degradable organics

·         High phosphorous concentration

PROCESS STEPS:

·         Mechanical Pretreatment

·         Calamity tank

·         Equalisation tank

·         Anaerobic Reactor (UASB)

·         Aerobic Reactor (CAS)

·         Biogas Conditioning

·         Sedimentation Tank

·         Waste-Air Biofilter

·         Sludge Dewatering

As a supplier of holistic industrial wastewater treatment solutions we offer made-to-order and turnkey industrial plants. One example of such is this project in Germany from 2019:

A renovation of an effluent treatment plant from a german soft-drink manufacturer was requested due to increased production capacities. After the renovation works, the effluent quality reaches treshold values which allow a direct discharge to the receiving water body – the river Saale. A direct support in terms of consulting was a key tasks besides the technical dimensioning and installation in this project.

NUMBERS & FACTS:

·         Ort: Saxony-Anhalt, Germany

·         Hydraulic plant capacity: 1200 m³/d

·         Organic Load: 5000 mg/l (COD)

·         Year of construction: 2019

CONCEPTUAL FORMULATION:

Primarily, a inventory recording was executed to develop a strategy of renovating the wastewater treatment plant without risking a downtime of production.

The former installed aerobic biological treatment with sequencing batch reactor (SBR) process was changed to a membrane bioreactor (MBR) process by using ultrafiltration modules from a local german manufacturer. This action allowed to keep higher concentration of active biomass inside the aerated tanks and hence increased the biological treatment capacity of the plant. Simultaneously, a solids-free, pristine effluent quality was ensured due to the new membrane technology.

However, pipe routing was conceptualized in a way that a simple change to the old SBR process was still possible if maintenance work needs to be done on the MBR modules without the risk to stop or reduce capacity in production facility.

The rest of the treatment plant was upgraded also next to the change in biological treatment process. A new pretreatment facility in form of a 1mm drum screen was necessary to protect the sensible membranes in the aeration tanks from coarse particles. Next to that, a new aeration system in the equalization tank, as well as new electrical measurement and control technology was implemented where necessary.

The prefabrication of the equipment was done to a large extent in 20’ shipping containers in the production halls of CUSS corporate group. This allowed a fast and precise implementation of the new equipment into the existing treatment plant while minimizing necessary administration and civil works for the customer.

WASTEWATER CONSTITUENTS:

·         Heavily degradable organics in form of sweeteners

·         High organic load

·         Low nutrients concentration

PROCESS STEPS:

·         Mechanical Pretreatment

·         Aeration of Equalisation Tank

·         Conversion SBR to MBR process by using Ultrafiltration module

·         Sludge thickening

As a supplier of holistic industrial wastewater treatment solutions we offer made-to-order and turnkey industrial plants. One example of such is this project in Saudi-Arabia from 2018:

A renowned soft-drink manufacturer consulted CUSS to design and install a new wastewater treatment plant at a greenfield factory in terms of complying with high local environmental standards. A combination of anaerobic and aerobic biological treatment was chosen to decrease overall operational expenditures. Further treatment in terms of ultrafiltration and reverse osmosis allows to use the permeate either for the cooling system or it for irrigation.

NUMBERS & FACTS:

·         Country: Province of Mecca, Kingdom of Saudi Arabia

·         Hydraulic plant capacity: 2500 m³/d

·         Organic Load: 5000 mg/l (COD)

·         Year(s) of construction: 2018

CONCEPTUAL FORMULATION.

To tackle water scarcity in the region of the production plant it was mandatory by local authorities to reuse the produced wastewater to a particular extend. Energy generation in form of biogas production was another additional specification.

To keep the wastewater treatment plant as compact as possible it was decided to install an EGSB (Extended Granular Sludge Bed) high-capacity anaerobic reactor which biologically degrades the unwanted organic load in the wastewater to i.e. the energy source of biogas.

Further treatment takes place in the aerobic membrane bioreactor. A combination of aeration tank and ultrafiltration modules. The permeate from the ultrafiltration is solids-free and only contains very little amounts of organic substances. A further UV-disinfection plant helps to purify the wastewater in terms of microbiological contamination and improves the water quality.

Part of the treated wastewater can now be used to irrigate the company premises. Another 1000 m3/d will be further treated in a reverse osmosis plant from which the filtrated water will then be used in the cooling system of the production plant.

The effluent treatment plant was well designed to cope with future production increases and can be therefore easily extended to an overall treatment capacity of 4000 m3 wastewater per day.

WASTEWATER CONSTITUENTS:

·         High organic load

·         Big pH fluctuations

·         Effluent has cooling water quality

PROCESS STEPS:

·         High capacity anaerobic reactor

·         Sludge Stabilization and dewatering

·         Membrane bioreactor / Ultrafiltration

·         UV disinfection

·         Reverse Osmosis

As a supplier of holistic industrial wastewater treatment solutions we offer made-to-order and turnkey industrial plants. One example of such is this project in Trinidad & Tobago from 2023:

CUSS extensively renewed and expanded an existing wastewater treatment plant for a distillery in Trinidad and Tobago.

The works included:

-          Conversion of the existing but not functioning anaerobic reactor to a CSTR with reliable anaerobic degradation of contaminants

-          The aerobic treatment has been expanded by a selector tank and an aeration basin.

-          A tertiary treatment consisting of sand- and activated carbon filters was implemented.

NUMBERS & FACTS:

·         Place: Laventille, Trinidad & Tobago

·         Hydraulic plant capacity: 350 m³/d

·         Year of construction: 2023

CONCEPTUAL FORMULATION

The wastewater treatment plant already operated by the client could not meet the required wastewater values. CUSS was commissioned to expand the plant and renew it where necessary. In addition to a tender prepared by the client, a visit to the existing plant by a CUSS project engineer was taken as the starting point for the changes made.

Since wastewater from distilleries have very high concentrations of organic material, anaerobic processes are particularly suitable. CSTR technology was chosen because they are operationally stable and uncomplicated to operate. For the solid-liquid separation of the anaerobic sludge-water mixture from the reactor, a belt press and a dissolved air flotation system have been installed. The separated sludge is temporarily stored in a sludge tank and then returned to the reactor.

The anaerobic process keeps operating costs low, as no aeration is required and maintenance is low. Furthermore, biological sludge growth and the associated amount of waste is low. The biogas produced is collected in the gas phase of the reactor and then desulphurised and burnt to avoid the emission of climate-damaging gases such as methane. In the future, there is the option of using the biogas for energy recovery.

The biological load remaining in the wastewater is removed in a downstream aerobic process. This treatment step was optimised with a new selector and aeration tank. In addition, very efficient and quiet rotary lobe compressors were installed.

A sand filter, a post-aeration system and an activated carbon filter are installed as tertiary treatment step. The required effluent values are reliably achieved.

ABWASSERINHALTSSTOFFE:

·         Very high organic load

·         High concentration of solved solids

PROCESS STEPS:

·         Equalisation and neutralisation

·         Anaerobic treatment

·         Aerobic treatment

·         Dissolved air flotation

·         Sand filter

·         Activated carbon filter

·         Sludge dewatering

As a supplier of holistic industrial wastewater treatment solutions we offer made-to-order and turnkey industrial plants. One example of such is this project in Romania from 2021:

In 2016, CUSS built a wastewater treatment plant for a brewery in Sansimion / Romania. The brewery has expanded its portfolio by a production of potato chips. To treat the additional wastewater produced, the plant is being expanded. The chips production is located about one kilometer away from the brewery. In the conceptual design, the current expansion had to be considered and the planned expansion also had to be partially integrated. These two concepts had to be integrated into the existing plant with minimal downtime.

NUMBERS - DATA - FACTS:

· Location: Sansimion / Romania

· Hydraulic capacity of the extension: 250 m³/d

· Organic load: 1200 kg/d (COD)

· Year of construction: 2020/2021

THE TASK

For the additional chips production, the potato wash water is cleaned and then reintroduced into the washing process. The separate process wastewater is mixed with toilet wastewater and then mechanically cleaned of coarse contaminants and then conveyed over one kilometer to the main plant, where it is collected in a tank and further treated.

The new components were selected and designed to sufficiently reduce the contamination in the wastewater, which can then be fed into the existing treatment process without negatively affecting it. An open, automatically controlled gravel filter in concrete design was added to the existing SBR process in the outlet.

The project mainly used proven processes that had to be integrated smoothly into the existing process during plant operation with minimal downtime. This was made possible by close project management and close communication with the customer. Furthermore, the interlocking of the existing control system with the control circuits of the extension was a requirement that had to be considered as a priority. Furthermore, the plant is designed for very low temperatures using insulation and heat tracing to accommodate the climatic conditions in the region. The plant was tailored and designed by CUSS for this specific application. From planning, procurement, and shipping to finally full mechanical, electrical installation and commissioning and training, all the necessary disciplines were carried out by a single source, resulting in an excellent result with which all parties are very satisfied.

WASTEWATER INGREDIENTS:

·         - High load of old fats and solids due to chips production.

·         - High organic load in the form of COD and BOD

·         - High Nitrogen load

PROCESS STEPS:

·         - Mechanical pre-treatment with lamella clarifier

·         - Pumping station with chopper- pumps

·         - Tank for mixing of different wastewater streams

·         - Dissolved air flotation

·         - Dosing stations for chemicals

·         - Sludge dewatering with screw press

·         - Automatically operated gravel filter in open design