Integration of a new plant extension into an existing and operating plant

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.

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.