Posted by Katie Anorve-Andress on Wednesday, April 23, 2025
Industrial wastewater treatment is a crucial but often overlooked component in the manufacturing process. The wastewater generated from the manufacturing process is as unique as the products themselves and requires equally unique solutions for treating it. Generally, industrial wastewater is either pretreated and discharged to a local municipal system (pretreatment), or treated to meet levels acceptable for discharge into the environment (direct discharge). In this article, we will explore the ins and outs of industrial wastewater treatment planning and some ways you can adapt to manage the complexities of your unique wastewater stream.
“Industrial Wastewater” isn’t a great description of the wastewater generated from industrial processes. Similar to the wide variety of products generated in manufacturing, each wastewater is similarly unique and each plant or process has its own combination of challenges. Check out the infographic below, which shows the breakdown of wastewater generators by sector. This drill-down can continue down to the facility itself, which is why we focus on finding solutions that will work for each facility, not just the wastewater generated.
Figure 1: A breakdown of permitted wastewater plants into their sources. Figures are listed as percentages. Note that numbers are estimates taken from numerous sources across EPA, WEF, Census, industry reports, and others.
Developing your industrial wastewater treatment plant should consider several aspects of the production process and plant management. Here are four production-related questions that I like to ask when talking to industrial clients:
- Do (or will) dedicated operators staff wastewater treatment?
Especially for pretreatment plants that don’t require a certified operator, it’s common for maintenance staff to manage industrial wastewater processes. This often means someone checks on the plant every few hours and when a production line goes down, all hands are needed to get back up and running as soon as possible, leaving wastewater treatment neglected. In these situations, investing in robust automation is necessary so the plant doesn’t require significant operator intervention. This can look like automatic pH neutralization, pump controls based on level sensors, flow-based chemical addition, and automatic shutdown procedures with the storage space to match. When automating, also remember nothing is 100%. A pH probe is only reliable when it's not fouled, so it should be placed where the flow can provide some cleaning but you may also want to add an auto wash attachment. - What is the production process like?
The production process governs industrial wastewater treatment, so understanding the challenges your operations will impart is crucial to treatment. Are seasonal products made that require entirely different operating conditions? Does the equipment require cleaning? What chemicals are used in that process? Is the wastewater generated continuously, or is it only during certain times? Most of these questions will establish what is needed for equalization before more sensitive operations such as biological treatment and help identify the best fit for treatment technology. - What are the future plans for the facility?
Designing for industrial plants is a delicate balance between a system that isn’t overkill (and over budget) and a system that can handle future production plans. Suppose a facility adds a new manufacturing line. The wastewater plant must handle that extra capacity and any potential new pollutants or changes in the wastewater composition. On the flip side, if production shuts down a line that is no longer profitable, will the plant still run the same on the reduced flow? If the plant wants to develop a water reuse plan, is the wastewater suitable for reuse, or are additional technologies needed? How will the plant be impacted if the water reuse eliminates a significant cooling or dilution source? If a batch process cycles every 8 hours, how much more equalization (EQ) will be needed if batches are pushed to 20-hour cycles? - What’s in the wastewater to be treated? This is incredibly important and probably my favorite aspect of industrial wastewater treatment because the wastewater is so incredibly varied. Understanding the primary pollutants and treatment goals establishes the basis of the design and starts to identify potential treatment options. Food and Beverage wastewater is typically high in Fats, Oils, and Grease (FOG) and Biochemical Oxygen Demand (BOD). Mining waste might require heavy metal removal and high solids. Some wastewater treatment is so complex that it is more cost-effective to haul it offsite for incineration than to develop on-site treatment.
Sometimes, we are lucky, and the wastewater treatment needed is minimal (or nonexistent for a fortunate few). For most industries though, treating wastewater can be complex and will require some creative thinking and collaboration. The first step is an in-depth understanding of the production process and building the wastewater process around it. A design that theoretically removes FOG is useless if it requires continuous adjustment by an operator you don't have. And an anaerobic digester wont live for long if it only gets chemical wash water for half the week. This is why its important to look at not only the wastewater components, but the production process and facility itself to develop a process that not only treats water, but is easy to manage and maintain. Not to mention having the flexibility to work through those "never seen that before" moments!
If you're planning for or struggling with your industrial wastewater, please reach out, I'm happy to help in any way possible!
Katie Anorve-Andress
industrial engineering designer
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Categories: Industrial & Manufacturing
Tagged: Wastewater | Environmental