Single source solution for increased wastewater treatment capacity
Sulzer’s product portfolio supports Italian WWTP with renewal of screening and primary filtration processes
A wastewater treatment plant (WWTP) in the Veneto region of Italy has begun a major refurbishment project that will upgrade the inlet screens, increase primary filtration capacity and replace many pumping assets. Thanks to Sulzer, the scheme will reduce operating costs and enable the plant to handle higher flows experienced during heavy rainfall while reducing the costs for the disposal of screenings.
One of the major challenges facing the wastewater industry is dealing with higher flowrates caused by heavy rain. If the primary settlement system does not have sufficient capacity, the excess has to be stored in storm tanks before being treated after flowrates have dropped. Resolving this issue is difficult because the traditional primary settlement tanks require a large footprint, which is usually not available.
Reducing treatment costs
Sulzer’s Nordic Water brand has decades of experience in designing filtration and screening systems for wastewater applications. Combined with Sulzer’s pumps, the company is very well-placed to deliver the majority of the equipment for the refurbishment.
The inlet screens are the first line of defense for the treatment plant. Making improvements to the capture rate here has a beneficial effect for the rest of the site. In this case, the site has four screens and they will be replaced sequentially so as to avoid any disruption to the operation of the treatment works.
The project will see four Meva Monoscreens installed in place of the legacy equipment. These assets will provide high capture rates and require no wash water while using less than 50% of the energy required by the outgoing screens. The installation includes two MevaPress SWP units, each equipped with a counter pressure screw (CPS-X), which together deliver dry solids content between 40 and 60%.
The new compactor units offer excellent efficiency and the high dry matter content minimizes the disposal costs for the screenings. Equally important, the design of the wash presses makes them insensitive to peak loads, ensuring efficient operation even during times of high flows.
The additional primary filtration capacity will be delivered by 10 Dynabelt filters, which offer a 90% space saving compared to traditional settlement tanks. Their installation requires very little in terms of civil works, and the effectiveness of solids removals enables more efficient downstream biological processes.
Meeting the challenge of CSO discharges
In addition to the screens and filter equipment, Sulzer will also deliver 10 ABS XFP units and several AS and ABS VUPX pumps to replace units that have reached the end of their service lives. Installation of the pre-treatment screens will begin in the first quarter of 2026, with the pumps and Dynabelt filters following on.
Sulzer is unique in its broad portfolio of products that can be delivered by a single source, simplifying the procurement process for the main contractor and the municipality. Supported by numerous reference projects, the benefits of the Meva Monoscreens, MevaPress SWP units, and Dynabelt filters were clearly demonstrated as part of the tendering process.
As part of the installation, Sulzer’s local service center will provide technical support to integrate the controls and remote monitoring systems, ensuring a seamless transition for operating the new equipment. All the new assets will be installed in a staged program to enable the treatment plant to maintain normal operations throughout the refurbishment project.
Once complete, the renovated treatment plant will be able to handle increased flows and minimize operating costs. This is particularly relevant as many treatment plants are trying to find a solution to increased flowrates caused by growing populations and increased rainfall causing combined sewer overflows (CSOs) to discharge into the environment. Sulzer’s expertise and wide range of solutions can support municipalities in achieving their goals of increased capacity and reduced operating costs.
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Meeting the future challenges of water treatment today
Water quality legislation is being tightened globally. The most precious resource on the planet is suffering from contamination and countries around the world are drawing up new regulations to tackle this challenge. It is the responsibility of municipalities to deliver the new standards and, in most cases, that will require additional treatment processes to be implemented.
Three of the major challenges at the forefront of the remodeled legislation are pharmaceuticals, ‘forever chemicals’ and phosphorous. Each one poses a significant threat to water quality and presents a technical problem for those responsible for delivering water to domestic and industrial consumers or releasing it into natural water bodies.
Making polluters pay
Pharmaceutical residues are having a detrimental effect on wildlife and human health, which has led to a revision of European Union (EU) Directive 91/271/EEC. The latest proposals will require producers of pharmaceuticals and cosmetics to pay for the cost of removing micropollutants that come from their products and end up in wastewater, thus implementing the “polluter pays” principle.
Many pharmaceuticals can remain in wastewater throughout the treatment and discharge processes and have been detected in rivers, streams and lakes around the world. Once in the environment, these chemicals can detrimentally affect aquatic wildlife.
Natural and synthetic estrogen compounds are known to cause decreased fertility and other negative reproductive effects in fish. The inhibition of growth and development of secondary sexual characteristics was reported in some species after exposure to a variety of endocrine-active chemicals.
Additional treatment solutions
Furthermore, commonly used antidepressant drugs have been shown to elicit behavioral changes in fish. Antibiotics in the environment lead to the development and propagation of antibiotic resistance, contributing to potential public health concerns. In addition, exposure to antimicrobial ingredients, which are not covered by the current legislation, will exacerbate the global antimicrobial resistance crisis.
Fortunately, filtration technologies exist capable of removing pharmaceutical residues, but there is no ‘one-size-fits-all’ solution, there are several aspects that need to be addressed to achieve the optimal result. Central to these solutions is the use of granular activated carbon (GAC), and in some cases, existing filtration equipment can be upgraded to work with this material and improve performance. If an extra filtration process is required, the additional footprint can be kept to a minimum with the use of continuous up-flow filters.
Forever chemicals
Of equal importance is the growing crisis involving the use of per- and polyfluoroalkyl substances (PFAS), which, due to their persistence in the environment, are often referred to as ‘forever chemicals’. These common materials are widely used in industrial and consumer applications including stain- and water-resistant coatings for fabrics, oil-resistant coatings for paper and cardboard, floor polishes, insecticide formulations and fire-fighting foams.
In the EU, member states will have to ensure they do not exceed stringent levels of PFAS from 2026, but this will require improved monitoring and data collection. The process of removing these chemicals from water supplies can be achieved by a number of technologies including nanofiltration and reverse osmosis, but one of the most cost-effective methods uses granular activated carbon.
Similar to removing pharmaceutical residues, a bespoke approach for each treatment plant is essential to achieving the best results.
Meeting challenging regulations
Finally, phosphorus; an essential nutrient for all living organisms, but its presence in excessive quantities in rivers and lakes poses significant environmental challenges. Phosphorous causes a phenomenon known as eutrophication, which occurs when nutrient levels in a freshwater source become too high, leading to excessive algae growth. This depletes oxygen levels in the water, resulting in hypoxic or ‘dead zones’ where aquatic life cannot survive.
Europe, in particular, has strict regulations aimed at protecting rivers and lakes from eutrophication. The European Union has implemented several directives and regulations to address phosphorus pollution. Countries like the United States have also introduced regulations to limit phosphorus discharges, such as the Clean Water Act, which includes phosphorus limits.
Most large wastewater treatment plants will already have processes in place that can remove a significant portion of the total phosphate content. To achieve better results, either chemical treatments or additional filtration will be required. Lamella plate clarifiers, sand filters and disk filters all offer the ability to meet the most stringent legislation.
As local regulations become tighter on water pollutants such as phosphorous, PFAS and pharmaceuticals, treatment plants will need to upgrade existing processes and install additional equipment to ensure they comply. Fortunately, many of the technologies required have already been developed and proven in hundreds of reference installations and by working with experts in this field, such as Sulzer Nordic Water, treatment plants can stay one step ahead of the legislation.
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Efficient removal of pollutants from wastewater
The DynaSand is a world-leading continuous sand filter designed for exceptional performance in both municipal and industrial water treatment. Trusted globally, DynaSand for a wide range of applications, including:
Solids reduction
Phosphorus and nitrogen removal (denitrification and nitrification)
Pharmaceutical and micropollutant filtration
Ferric and manganese removal
PFAS-removal
Seawater RO pre-treatment
Whether addressing stringent environmental standards or optimizing operations, DynaSand offers unparalleled efficiency and reliability for achieving cleaner, safer water. Click to learn more
Nordic Water DynaBelt™ provides efficient filtration in a compact footprint
Designed to deliver energy efficient primary filtration in a compact package, Nordic Water, a Sulzer brand, has launched its new DynaBelt™ filter for fine filtration. With market-leading capacity, an operator friendly design and smart control features – the DynaBelt is a perfect solution for maximizing the capacity and efficiency of wastewater treatment processes.
Designed for maximum hydraulic flow and occupying just 10% of the space needed for an equivalent sedimentation tank, the DynaBelt offers municipal water treatment works the ability to reliably improve throughput within existing spaces – ideal for facilities in built up areas.
A seamless, auto tensioning belt filter is attached to self-cleaning slave and drive rollers and surrounded by the longest emergency overflow weir on the market. As the filter collects suspended solids and head loss occurs, low consumption internal spray bars activate and water is moved to the integrated backwash system. A highly controlled hot water flush also eliminates fat, oil and grease from the filter without the need for chemicals.
The DynaBelt features a unique sludge discharge roller, which rotates at high speed and creates a partial vacuum. This removes the sludge from the belt into a dedicated compartment separate from the backwash reject water to ensure no dilution occurs. The sludge can then be pumped into storage for further processing. Unlike competitor designs that use energy intensive air knives or blowers, this allows the DynaBelt to consume less than 0.6 kW in operation, providing a large energy cost saving and a sizable reduction in carbon footprint.
It also offers the largest effective filtration area compared to its competitors at 2.7 m2, delivering a 30%-50% average reduction in total suspended solids. Furthermore, three sizes are available to suit different requirements, whether that is pilot schemes, low flow applications or larger systems. DynaBelts can be arranged in parallel to optimize capacity, enabling larger throughput.
User friendliness is another inherent quality of the DynaBelt. Quick connectors allow for a fast belt change, which only needs to be carried out once every one or two years, depending on the application. Lightweight covers mean easy access to the filter belt unit without cranes or tough lifts. The low and compact design of the DynaBelt tank also reduced headroom requirements.
The smart features of the DynaBelt add further benefits for operators. With an integrated human machine interface (HMI) control panel with two variable frequency drives (VFDs), the belt filter can also provide failure validations and notifications to inform maintenance personnel. Operating torque, water consumption, energy usage and head loss detection displays provide ample information daily checks. By specifying the optional 4G antenna, wireless monitoring is also possible, and compatibility is available for a wide range of industrial control systems.
As a Sulzer brand, Nordic Water also offers single source access to a complete range of screening, sedimentation and filtration systems, including the provision of sludge pumps and pipework, further simplifying procurement and future maintenance.
Extended range boosts wash press performance
New high-capacity counter pressure screw reduces screenings volume
Wastewater treatment has many challenges, not least the removal of wipes and rags with a cost-effective and sustainable screening process. Handling this debris efficiently requires robust and reliable equipment, which has been the hallmark of Nordic Water’s Meva product range for decades. The counter pressure screw (CPS), used with the screw wash press, offers excellent dry solids content, optimizing performance and minimizing disposal costs.
Nordic Water, a Sulzer brand, is at the forefront of wastewater product engineering, with a comprehensive range of high-efficiency pumps, mixers, screens, filtration plants and much more. At the treatment plant, the screens and wash presses are the first line of defense for the equipment downstream. Part of the process to remove debris at the inlet involves the screw press, which compacts and dewaters the waste before depositing it in a skip for disposal.
Increased performance
Nordic Water has extended its range of counter pressure screws with the launch of the CPS-X50, which has been designed to handle the full capacity of the SWP 40 wash press. Together they can achieve a dry solids content of 50-60% and the build quality ensures a long service life. It is also possible to specify a long conveyor section to reach storage skips or hoppers for an efficient transport process.
The removal and disposal of screenings from the incoming flow is an important process for any wastewater treatment plant. With an increasing volume of waste, greater pressure is being placed on the equipment and operating costs need to be kept to a minimum. To that end, Nordic Water’s combination of the Meva Screw Wash Press and the Counter Pressure Screw deliver up to 50% less screenings by volume than a traditional pipe system.
The high counter pressure offered by the CPS ensures a longer retention time in the press zone, which provides a greater washing effect. This reduces the organic content of the screenings, an important factor when it comes to disposal. Many countries have imposed increased costs, or even prohibit the disposal of waste with high organic content.
Turnkey solutions
To ensure operators can achieve maximum capacity, the CPS-X50 has a larger diameter screw that is capable of delivering more torque thanks to the larger gear unit, drivetrain and bearings. In fact, this system currently offers the largest capacity of any counter screw equipment on the market.
Specialists from Nordic Water can support customers with all the necessary planning and designs for screenings handling equipment to ensure the most reliable and cost-effective system. Turnkey solutions including controls and connections to surrounding infrastructure ensure minimal disruption and exceptional performance and reliability for years to come.
Learn more about the Meva CPS-X50
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Robots make clean work
Cleaning Lamella settlers the easy way for better performance
Lamella settlement tanks are a compact and simple solution that can enhance water treatment processes within a minimal footprint. To maximize their efficiency, the plates inside the tanks need to be regularly cleaned, and a manual process using pressurized water poses several challenges in terms of operator safety and effectiveness. In response, Nordic Water has developed an automated robot cleaner that ensures this task is completed frequently and safely.
As part of a continuous improvement program, Nordic Water, a Sulzer brand, has made several upgrades to its range of Lamella separators, including the introduction of the CleanBot. Designed to offer an automated cleaning solution for the LPS inclined plate separators, the CleanBot ensures optimum efficiency and performance of sludge settlement.
Improving cleaning processes
Within both water and wastewater treatment plants, Lamella settlement processes are used to remove solids from the water stream. The increased surface area of the Lamella plates enables this process to be achieved in a small footprint, making the tanks ideal for increasing treatment capacity without the need for huge areas of land.
Conventional cleaning procedures for the plate packs include manual spraying with a water hose, using a built-in water spray system. In all these scenarios, the water levels in the settlement tank must be lowered to ensure efficient cleaning. Each option poses its own challenges, but all need the process to be halted while the cleaning is conducted.
Nordic Water’s CleanBot has the solution: an automated process that is completed during normal tank operation, maximizing process efficiency and maintaining personnel safety. The robot resides in a charging station before it is deployed on a pre-timed basis to mechanically clean the plates.
Automation delivers efficiency
The robot is positioned on the rails above the Lamella plates before it lowers the cleaning head between the plates and removes all the solids that has been deposited. After one set of plates has been cleaned, the robot is moved to the next row, and the process continues until all the plate assemblies have been cleaned.
The interval between each cleaning operation can be adjusted as required depending on the application. Trials of the robot have been completed over the last 12 months and now the fully automatic version has been launched to support operators of the LPS tanks and improve their efficiency.
The charging station also houses the control panel and a lifting mechanism to transfer the CleanBot onto the plate rails. If the CleanBot needs to recharge, it returns to the charging station before completing its task.
Niklas Windahl, Product Manager for Nordic Water, comments: “The CleanBot can be retrofitted to existing LPS equipment and enables enhanced performance without the need for pumps or compressed air. Its automatic operation can also allow the sludge separation process to continue uninterrupted and as efficiently as possible with the tank kept in operation.”
Learn more about the Lamella with CleanBot
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Sulzer finalizes Nordic Water acquisition
With the completion of the acquisition of Nordic Water, Sulzer has expanded its offering to the water treatment sector. The deal benefits the customers of both companies and offers a wider range of expertise as well as products to the global market. The synergy between the two companies presents a unique opportunity for these well-respected suppliers to widen the availability of their solutions for more sustainable water treatment processes.
Nordic Water is a leading supplier of screening, sedimentation and filtration equipment to municipal and industrial water treatment plants. With 60 years’ experience in the industry, the company has a large installed base of equipment that will continue to receive industry-leading support as always.
For Sulzer, the deal is an excellent match for the company’s existing portfolio of pumping, mixing, aeration and solids reducing/removal solutions that offer reliability and efficiency to water and wastewater handling applications. Coupled with Sulzer’s global presence and involvement with water treatment projects around the world, the acquisition enables a greater appreciation for Nordic Water products and the improved sustainability they offer.
Jonas Gunnarsson, CEO, Nordic Water, explains: “Our joint history of supporting the water industry and the complementary nature of our businesses will allow us to deliver sustainable products that meet the needs of today without compromising with future generations. We believe in offering high quality products and combined with energy-efficiency, the life cycle cost we will jointly offer our customers is very low. This is a perfect match.”
Soren Jensen, Head of Sulzer’s Water Business Unit, continues: “Nordic Water is a great addition to Sulzer as our strengths are complimentary. They bring extensive expertise, long experience and a wide range of essential water treatment equipment to our already strong water offering. Our combined portfolio will benefit our municipal and industrial water customers worldwide, and together we will be able to open up many new opportunities.”
Sulzer’s acquisition of Nordic Water consolidates the company’s presence in the water sector, expanding the range of products as well as strengthening the knowledge and expertise in the design and delivery of reliable and sustainable solutions for this important market.