Wastewater treatment is a critical process for industry and municipal systems. A significant portion of facilities operate with outdated equipment, leading to regular repairs, excessive energy costs, and the risk of non-compliance with regulations.
Steiner Ukraine specialises in the modernisation and integration of turnkey cleaning systems. Below, we outline where problems arise and how to solve them in a way that benefits the company's economy.
Why systems are inefficient
- FOG in food production. Fats and oils form emulsions, settle in pipelines, and reduce the efficiency of pumps and flotation units.
- Workload in the public sector. Excess sludge, peak inflows, and unstable recirculation overload the facilities.
- Outdated blowers. In many cases, old units consume too much electricity and become economically unfeasible: low efficiency under real operating conditions, lack of precise control, frequent downtime.
- Pumping equipment. The market is evolving: modern pumps are more durable and energy-efficient thanks to improved hydraulics, anti-clog impellers, and IE3/IE4 motors. Older models often operate outside optimal points and increase OPEX.
- Lack of automation. Without integrated SCADA/telemetry and online sensors (DO, ammonium, nitrates, TSS), the process is controlled “manually,” which increases the risk of errors and costs.
- Regulations. BOD, COD, TSS, nitrogen/phosphorus forms, and pH are monitored. A violation of even one parameter results in fines and reputational risks.
Modern treatment train (cleaning chain)
- Pre-treatment: screens, grit chambers, grease trap/DAF (especially for food industry wastewater).
- Primary treatment: primary clarifiers (as per scheme).
- Biological treatment: CAS, SBR, MBR, MBBR, IFAS.
- Biomass separation: secondary clarifiers (for CAS/SBR) or membranes in MBR.
- Tertiary/final treatment: filtration, UV/chlorination; if required — sorption, additional nitrogen/phosphorus removal.
- Sludge treatment: thickening → anaerobic digestion (biogas) → dewatering (decanter, screw/belt press) → disposal/beneficial use.
Each stage affects the next: if the pumps ‘sag’ at the inlet or aeration is ineffective, the final stages will not achieve the design quality.
Sludge dewatering — the key to economy
Properly organised dewatering directly affects TCO (total cost of ownership):
- Higher dry solids content (%DS) = lower volume/mass for disposal → reduced logistics costs and disposal fees.
- Less energy for further drying/thermal treatment (less water to evaporate).
- More water is returned to the process thanks to high-quality filtrate/centrate.
- More stable bioprocesses due to uniform sludge removal.
Tools: decanter centrifuges, screw/belt presses (selected according to sludge type); optimized polymer conditioning; automatic control of %DS, filtrate TSS, polymer consumption, and energy use.
What modernisation brings: air blowers, pumps, automation
- Aeration/blowers. Transition to energy-efficient units (including with VFD) and process-based control (DO/ammonium) significantly reduces the energy consumption of the biological stage and stabilizes nitrification/denitrification.
- New-generation pumps. Selection according to duty point, high-efficiency hydraulics, anti-clog impellers, IE3/IE4 motors, variable frequency control → fewer failures, lower losses, and energy savings.
- SCADA and analytics. Online sensors, trends, alarms, and load-based control algorithms reduce the human factor and lower operating costs thanks to stable operation and preventive maintenance.
How this affects TCO
- Energy consumption ↓ thanks to more efficient blowers and pumps and operation at optimum points.
- Service and downtime ↓ — more durable units, predictive diagnostics.
- Reagents are stabilised — more even load on biology.
- Penalty risks ↓ — consistent compliance with standards.
- Human factor ↓ — automation and clear KPIs.
The Steiner Approach
- Wastewater audit and load variability.
- Pre-project and CAPEX/OPEX model with comparison of modernization scenarios.
- Equipment selection and supply: pumps, mixers, DAF, energy-efficient blowers, aerators, thickeners, decanters/presses, automation (leading European manufacturers).
- Integration/SCADA, installation, commissioning, staff training, service.
Conclusion
Problems of wastewater treatment cannot be solved with “patches.” A systematic modernization is needed, in which efficient blowers, modern pumps, automation, and high-quality dewatering together reduce the total cost of ownership (TCO) and ensure stable discharge quality.
Steiner Ukraine offers integrated solutions — from auditing to service — to ensure compliance, reduce costs and increase reliability.
