480 HP The power of an MAN truck
Highly contaminated wastewater is produced whilst refining and painting the surfaces of the vehicles. We make it safe again!
An ever increasing number of companies both at home and abroad are turning to REMONDIS Aqua for efficient and sustainable wastewater management systems. We have listed a selection of references for you to read below.
AkzoNobel Industrial Chemicals b.v., which is based in Amersfoort, produces salt and energy, chlor-alkali products and derivates. It is Europe's largest producer of vacuum salt and a leading supplier of chlorine, caustic lye, hydrochloric acid, ferric chloride and chemicals for processing water. The products have many areas of application and are used by, among others, the detergent, construction, food, paper, aviation, automobile, pharmaceutical, textile and plastics industries.
The composition of the wastewater generated by AkzoNobel's chemical park at Rotterdam Harbour is highly complex due to the production of chlor-alkali products, vinyl chlorides and herbicides at the different business locations on the site. Faced with the prospect of further production challenges in the future and the need for sustainable, state-of-the-art wastewater treatment processes, AkzoNobel decided to look for a competent and expert partner to extend and then manage the facilities on a long-term basis.
By implementing an optimization concept, drawn up to fulfil AkzoNobel's individual requirements, the performance of the two-stage facility (chemical/physical precipitation phase and biological treatment) has been able to be increased. Furthermore, the way wastewater is accepted has become more flexible, the amount of chemicals used has been reduced and less sludge is generated. By implementing REMONDIS' accredited plant operations concept, AkzoNobel now also has access to the company's know-how gained from running numerous industrial wastewater treatment facilities.
Blanke refines, laminates, coats and prints on almost every kind of textile surface and fabric as well as knitted and non-woven goods. Its customers are primarily from the automobile and clothing industries but it also supplies firms in the medical, home textiles and technical textiles sectors.
This renowned textile finishing company operates a wastewater treatment facility for its production wastewater at its plant in Bad Salzuflen. REMONDIS Aqua was commissioned with the task of extending and modernising this facility. Today, we are responsible for the smooth operation of the plant, which treats some 2,500 cubic metres of wastewater every day.
The variable composition of the wastewater has meant that we need to implement special processes, which we developed ourselves and are based on the results of comprehensive studies. Our extensive experience of comparable biological processes was also invaluable here. The production wastewater is now pre-treated biologically before undergoing chemical-physical treatment.
BP Gelsenkirchen GmbH is a joint venture between Deutsche BP AG and the Venezuelan state oil company, Petróleos de Venezuela S.A. Both partners hold a 50% stake in the joint venture, which was established back in 1983.
Within the framework of a company partnership, REMONDIS built an oil sludge treatment plant at BP Gelsenkirchen's Horst site. We provided all of the services involved – from drawing up the concept, to managing and financing the project. The chemical-physical treatment facility has the capacity to process 25,000 tonnes a year. The oil that is recovered is returned for processing and the remaining wastewater is treated.
Before treatment, the liquid and solid elements are first separated from each other. The settled sludge is used, among other things, to produce substitute fuels; the liquid elements undergo further treatment stages, including the use of organic separating agents and splitting up emulsions by reducing pH values.
Deutsche Nickel GmbH can look back on a long and successful history. It has, for example, been processing metals for more than 100 years now at its Schwerte site alone. The company is one of the world's leading producers of materials from nickel and nickel alloys.
REMONDIS Aqua has been responsible for operating the plant's wastewater treatment facility in Schwerte since 2002. Since then, we have upgraded and optimised both its technology and control system. In addition, we have provided a water pollution control officer for Deutsche Nickel GmbH to help the company fulfil its legal obligations.
The production of materials from nickel alloys, non-ferrous metals and stainless steel generates highly polluted wastewater. We use a special process, developed by our own experts, which reliably removes the heavy metals from the water.
DMK Deutsches Michkontor GmbH, the result of a merger between Humana Milchindustrie and Nordmilch, employs approx. 5,500 people and has an annual turnover of around 4 billion euros. Its Altentreptow and Bergen sites generate an annual turnover of approximately 220 million euros.
DMK Deutsches Milchkontor GmbH runs a classic dairy business with cheese production at its Altentreptow site. In 2006, this was then joined by a whey processing plant owned by wheyco GmbH – a company belonging to the DMK dairy corporation. As a result of the expansion of the production site, REMONDIS Aqua was commissioned with the task of extending and operating the wastewater treatment system. In 2008, it was then awarded a second project to build and run a much-needed further extension to the wastewater treatment facility.
Wastewater generated from cheese production and whey processing contains high levels of organic matter – a big challenge for the treatment process. REMONDIS Aqua developed a cost-effective solution: a large percentage of the pollutants are transformed into biogas during the initial treatment phase by using an anaerobic process and then generated into electricity in REMONDIS' own combined heat and power plant. In order to ensure that the energy potential is used in the best possible way, we use the heat generated in the power plant for the treatment process (combined heat and power). In addition, a further procedure was integrated into the system to recover phosphorus, namely our patented REPHOS® process.
At its site in Mönchengladbach, Valensina's subsidiary, FSP Frischsaft FRISCHE Produktions GmbH, produces high quality chilled fruit juices and premium smoothies sold under its Valensina brand.
Valensina GmbH produces and sells a wide range of soft drinks that covers all segments of this market. As the company's business at its site in Mönchengladbach had continued to expand, it needed to increase its production capacity and develop a new concept for the plant's wastewater treatment system.
REMONDIS Aqua's complex anaerobic wastewater treatment system is now being used to ensure that the wastewater is treated in a resource-friendly way: the RE2ENERGY® process guarantees highly efficient levels of treatment and at the same time makes the best possible use of the energy found in the contents of the wastewater. The biogas recovered from the treatment process is a renewable energy and substitutes the natural gas that had previously been used in the production process to generate steam. As a result, FSP has been able to significantly reduce its carbon footprint.
The company in Genthin is a subsidiary of the Hansa Group, an international specialty chemicals company which took over the core of the Henkel plant in Genthin in 2009.
Within the framework of a contracting model concluded with Henkel in 1992, we have been treating the wastewater generated by Henkel's laundry detergent production activities in Genthin since then. In addition to this, the facility is able to accept municipal wastewater and wastewater from other industrial businesses – e.g. from a large laundry company and from companies in the plastics industry. The facility is, therefore, highly efficient and cost effective.
The wastewater at the Genthin laundry detergent plant is generated first and foremost from the production of surfactants. It undergoes ideal treatment at the facility which involves a multi-stage cascading process. Moreover, we recover energy from the waste substances and highly concentrated organic waste streams in a biogas facility.
H. Borgmeier GmbH & Co. KG is a family-run company specialising in fresh poultry products and is located in Delbrück in the Paderborn region. It sells chicken, turkey, duck, rabbit, venison, wild boar, convenience food & sausage products.
H.Borgmeier GmbH & Co. KG was founded by Heinrich Borgmeier back in 1903. Over the years, the company has enjoyed steady growth which meant that it needed a new wastewater treatment concept for its production facilities. At the beginning of the project, the system was expected to treat 400m³ of wastewater per day; the wastewater treatment facility is now able to treat a daily volume of 600m³.
A combination of treatment processes were selected to ensure that the facility always treats the wastewater to the same high standard despite the different qualities of water at the plant – generated on the one hand by the production activities and, on the other hand, by the plant's cleaning activities. The wastewater treatment is carried out using a flotation process which had already been installed. The ensuing main treatment phase is performed in a one-line membrane bioreactor (MBR) facility with immersed ultrafiltration membranes and a sludge treatment stage.
This combination of wastewater treatment technologies saves space, conserves resources and produces water which can be directly discharged.
With over 60 production sites in 33 countries, Jabil Circuit Inc. is one of the leading contract manufacturers in the electronics industry offering complete solutions ranging from production to repair and warranties. One of the company's main areas of expertise is the production of printed circuit boards for OEMs (original equipment manufacturer).
Jabil Circuit India Pvt. Ltd. is a global service provider for electronic components based in Pune, Ranjangaon. REMONDIS Aqua India planned and built a wastewater treatment facility there. REMONDIS continues to be responsible for operating, maintaining and servicing the machinery.
The biological wastewater treatment is carried out in a membrane bioreactor facility. In detail, this involves an activated sludge process followed by membrane filtration in ultrafiltration modules.
LANXESS is one of the leading specialty chemicals companies. It currently employs around 17,500 people in 31 countries and had a turnover of 9.1 billion euros in 2012. The company operates 52 production sites around the world. LANXESS has a workforce of approx. 230 employees at its Indian plant in Jhagadia.
REMONDIS Aqua has been handling the wastewater at LANXESS' production plants in Jhagadia since 2011. LANXESS produces ion exchange resins, rubber chemicals and plastics. The range of services provided by REMONDIS Aqua includes operating, maintaining and servicing the facilities. Thanks to the quality of its performance, LANXESS commissioned REMONDIS to build and operate a further wastewater treatment facility in 2013.
Different wastewater streams from LANXESS' production plants are cleaned together in one wastewater treatment facility. The treatment is based on a three-stage activated sludge process. A second treatment facility using membrane technology treats a further 100 cubic metres of wastewater each day which can then be used for watering the company's grounds.
Wastewater from the food processing industry is primarily contaminated with organic and biological matter. It undergoes the best possible treatment at the Bremerhaven site.
We have been operating a number of different facilities in Bremerhaven together with the city authorities since 2003. These include the central sewage treatment plant which treats both municipal sewage and wastewater generated by the food processing industry located in the fishing port.
The fully biological sewage treatment plant is equipped with state-of-the-art technology. REMONDIS Aqua uses a multi-stage treatment procedure at the plant. The sludge generated by this process is recycled in a modern biogas facility and used to generate energy.
For many years now, Lorenz Snack-World has been one of the leading European producers of snacks with its long-established branded articles such as 'Crunchips', 'Erdnusslocken' or 'Curly Peanuts' and 'Saltletts'. The company has a workforce of around 3,000 employees and sets very high standards when it comes to protecting the environment and conserving natural resources.
Having taken part in a tender, REMONDIS Aqua was able to win over Lorenz Snack-World with its expertise and integrated plant concept. As a result, we now treat the company's production water and recycle any residual waste at our facilities to produce energy.
The existing plants and facilities were integrated into the treatment concept. Since completing the construction work, REMONDIS Aqua has been reliably reaching the treatment targets agreed on – both for the anaerobic pre-treatment of the production wastewater and for the recycling of the organic residual waste. REMONDIS Aqua built a new combined heat and power plant for the biogas produced as a result of the treatment process. The power generated by the unit is fed into the national grid and subsidised in line with the German Renewable Energy Sources Act (EEG).
MAN Truck & Bus AG is the largest company in the MAN Group and one of the leading international manufacturers of utility vehicles. It produces heavy utility vehicles at its main plant in Munich which has a high level of vertical integration.
The production processes used by MAN Truck & Bus AG generate a variety of wastewater streams, some of which are highly contaminated – such as those from its surface refinement and painting operations. This water has to be treated before it can be discharged from the plant. MAN's decision to extend its production plant also meant that its wastewater treatment facilities had to be expanded. REMONDIS Aqua was able to win over the company with its expertise and its comprehensive concept to modernise, extend and operate its wastewater treatment facility.
We treat the wastewater, which contains oil, heavy metals and paint particles, with a variety of technologies, such as modern membrane processes (ultrafiltration) and chemical-physical procedures. In addition, REMONDIS Aqua ensures the facility for producing fully desalinated water runs smoothly.
Oerlemans Foods specialises in growing, producing and supplying frozen vegetables, frozen potato products and frozen fruit.
With an extremely wide range of more than 1,000 premium products, Oerlemans Foods fulfils its customers' specific needs within the international food service, retail and industrial markets. Oerlemans Foods is one of the pioneers in Europe when it comes to organic and bio-dynamically cultivated vegetables, fruit and potato products. Oerlemans Foods exports to more than 50 countries in Europe, the Middle and Far East as well as South and North America.
The wastewater at Oerlemans' two production plants in the Netherlands is treated using an aerobic activated sludge facility with immersed membranes (MBR facility). Both the quantities of incoming wastewater and the substances in the water differ due to the various products that our customer processes throughout the year. Concentrated waste and sludge are collected and then used externally to produce biogas. A completely new facility was built in Broekhuizenvorst; the existing SBR facility in Waalwijk was converted and upgraded. Both facilities are equipped with pre-filtration, intermediate storage and sludge thickening technology.
For over 10 years now, the Oettinger Brewery in Mönchengladbach has been producing a large part of the group's wide range of products. Every year, it makes up to 2.3m hectolitres of drinks.
Looking at its output figures, Oettinger Brauerei GmbH is Germany's biggest beer brand. The company produces and sells a wide range of beers and soft drinks. With the business continuing to grow and wishing to implement more environmentally friendly processes, it decided to have a new resource-friendly concept drawn up for its wastewater treatment processes.
Whilst drawing up the new wastewater treatment concept, priority was put on achieving greater efficiency and process stability combined with greater cost effectiveness. The company opted for REMONDIS Aqua's high-tech process – its RE2ENERGY® process – in which the contents in the wastewater are transformed into biogas in a fully automated anaerobic pre-treatment facility.
For the most part, the procedure involves anaerobic wastewater treatment. Once the solid matter has been removed and the water neutralised, the wastewater undergoes anaerobic treatment in the RE2ENERGY reactor which not only cleans it but also produces biogas. This pre-treated wastewater can then be discharged into the City of Mönchengladbach's sewer system. The biogas is used straight away in the production plant. The plant needs hot water to manufacture its drinks which had previously been produced in a boiler using natural gas. Once the boiler had been upgraded with an additional biogas firing system, the biogas was able to be recycled and used here leading to a reduction in the amount of natural gas consumed by the plant.
Ruhr-Zink GmbH is part of the GEA Group and manufactured zinc and sulphuric acid until 2009. The company has devoted itself to recycling: using a zinc electrolysis procedure, it has processed the largest proportion of secondary input substances from the steel industry than any other business in the world.
REMONDIS Aqua built a wastewater treatment plant at Ruhr-Zink in Datteln back in 1999 that meets all requirements for comprehensively cleaning wastewater strongly contaminated by heavy metals. As the general contractor, we took on the entire management of the project – from drawing up the concept, to financing the project, to ultimately putting the plant into operation. Since then, REMONDIS Aqua has been responsible for the smooth operation of the plant using its own staff and has clearly met the treatment targets at all times.
In the past, Ruhr-Zink used to treat contaminated wastewater with lime in accordance with conventional treatment procedures. This led to large quantities of gypsum waste being generated which was contaminated with heavy metals and which had to be disposed of despite the costly subsequent treatment. Thanks to the special wastewater management and treatment process developed by REMONDIS Aqua, this volume of residual waste has been reduced by 90%. The different kinds of wastewater are first collected separately and later brought together deliberately to make optimum use of their neutralisation potential – without the addition of lime.
Trespa International B. V. develops ideas in the area of architectural materials and is a leading international producer of high quality panels for exterior cladding, decorative façades and interior surfaces.
Trespa® Meteon® is Trespa's leading family of architectural panels. These are decorative high-pressure compact laminate (HPL) with an integral surface manufactured using Trespa's unique in-house technologies: Dry-Forming (DF) and Electron Beam Curing (EBC). Trespa supplies over a million such panels to its customers all around the world every year.
Having carried out some successful trials, REMONDIS Aqua built and now operates an aerobic activated sludge facility with "cross-flow" membranes (MBR facility) to treat the company's production wastewater. The particular challenge here is that the wastewater contains high concentrations of formaldehyde and phenol. The wastewater facility contains extended pre-filtration and sludge thickening technology.
Volkswagen's plant in Pune is the biggest investment ever made by a German company in India. It is the only production plant operated in India by a German car manufacturer and covers the whole of the production chain – from a stamping facility, to a body construction plant, to a paint shop, to the final assembly line.
REMONDIS Aqua (India) Pvt. Ltd. is responsible for treating the wastewater generated by Volkswagen's production plants in Pune. Having concluded a BOT agreement, REMONDIS is in charge of operating, maintaining and servicing the facility.
Using a biological wastewater treatment process with subsequent membrane filtration, the highly contaminated wastewater from Volkswagen's paint shop as well as from its other production processes is cleaned. The treated wastewater can be used to water the company's grounds. The sludge generated by the treatment process is dewatered using a decanter.
The plant in Carcaixent, Spain – in the orange-growing region of Valencia – extracts fructose and produces a variety of flavours for the food and drinks industries.
Wild Valencia is a subsidiary of Rudolf Wild GmbH & Co. KG, a company based in the German city of Eppelheim, and is most well-known for its successful soft drink Capri-Sun. With the business at the plant in Carcaixent, Spain, developing rapidly, the company decided its existing wastewater treatment facility had to be expanded. REMONDIS Aqua built a new facility and is now responsible for its operations management.
The wastewater, which has a high sugar content, undergoes anaerobic and thus energy-saving preliminary treatment. The primary task here is to remove the organic contents. The energy stored in the wastewater can be recovered as biogas. The company benefits as the biogas is used to substitute natural gas in its production processes. A second volume of wastewater, which contains high levels of sulfate, is treated using a high performance aerobic system.