Task
For a facility in the German sugar industry, ALMAWATECH expanded an existing anaerobic wastewater treatment plant to add an additional treatment capacity of 45 metric tons of COD per day. The goal was to permanently eliminate the previous practice of temporarily storing beet washing water in open storage ponds and to ensure highly efficient wastewater treatment available year-round.
Design data
Waste water volume:
- 220 m³/h
- 45 metric tons of CSB per day
Solution & implementation
ALMAWATECH handled the complete process design of the plant for a wastewater inflow of up to 220 m³/h and COD loads of up to 45 t/d, including heat balance calculations and process calculations.
Anaerobic Core Process Technology
- New methane reactor (Gas Mixed Reactor, GMR) with a gross volume of approximately 5,300 m³, steel construction, central gas injection for circulation, and a circulating sludge withdrawal system
- Connection and retrofitting of the existing reactor to enable parallel operation of both reactors
- Three-chamber degassing vessel with vacuum technology for reliable gas release
- Complete renovation of the sludge thickener, including a new fiberglass-reinforced plastic cover, a new central scraper, and a refurbished exhaust air system with a biofilter
Heating Concept: A two-stage preheating system for the energy-efficient utilization of existing waste heat using multiple plate heat exchangers.
Gas Utilization and Safety Technology
- Gas compressor station for feeding sewage gas into the plant network
- Refrigeration Dryers and Condensate Management
- Safety flare for the emergency combustion of excess sewage gas, including noise abatement measures
- Overpressure and underpressure protection for the reactor in accordance with recognized regulations
Chemical Station and Automation: Dosing system for nutrients (phosphoric acid) and defoamers, fully automated and integrated into the central process control system, including measurement, control, and regulation technology, switchgear, and operator training.
Similar projects
Similar projects
Sugar Industry, Southern Germany, ALMA BHU GMR
High-performance anaerobic wastewater treatment plant with a capacity of 45 metric tons COD/day. Includes a new methane reactor (ALMA BHU GMR, approx. 5,300 m³), a two-stage heat recovery system, and fully automated gas utilization. Result: over 95% COD removal with stable plant operation year-round.
Sacher, Austria, ALMA NeoDAF
ALMAWATECH built a compact, turnkey flotation plant in the ALMA module for the long-established company Sacher. The pre-assembled ALMA NeoDAF enables particularly fast installation and commissioning and offers high efficiency and sustainable wastewater treatment while requiring minimal space.
Dairy Southern Germany, ALMA BioFil Compact
Vapor water treatment using biofiltration with a capacity of 600m3/d for a dairy in southern Germany. The vapor condensate is produced during the production of whey and lactose powder.
Eisbär Eis GmbH, Germany, ALMA NeoDAF HDED
We had the opportunity to supply and install our ALMA NeoDAF flotation system with a capacity of 16 m³/h as part of the construction of a new wastewater treatment plant for an ice cream manufacturer in northern Germany.
Sugar industry, Chile, ALMA BHU BIO
Construction of a biological treatment stage with sedimentation stage for the treatment of 120 m³/h of wastewater from the sugar industry in Pemuco, Chile.
Sugar factory, Germany, ALMA BHU GMR
Construction of an anaerobic treatment stage or biogas plant for the recovery of energy from waste water from a sugar factory with a hydraulic capacity of 220 m³/h in Germany.
Sugar factory, Poland, ALMA BHU GMR
Construction of an anaerobic treatment stage and a biogas plant to generate energy from sugar production wastewater with a hydraulic capacity of 125 m³/h in Poland.
Sternquell Brauerei GmbH, ALMA Neutra
Treatment of 360m3 of brewery wastewater per day with a pump shaft, solids separator and a neutralization system for Sternquell Brauerei GmbH.
Bäckerei Betz GmbH, Germany, ALMA NeoDAF Blue, grease separator
Treatment of 25m3 of bakery wastewater per day in a grease separator and a flotation plant for Bäckerei Betz GmbH.
Südzucker AG, Ochsenfurt, ALMA BHU GMR, BIO
Treatment of sugar beet wash water in a biogas plant with pre-acidification and a COD load of 45,000 kg COD/d, for Südzucker in Ochsenfurt.