NEWS - We #StandForWater, for a sustainable, resilient
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EDITION 21 | JULY 2021
Nijhuis Saur Industries
NEWS
“W e # S t a n d F o r Wa t e r, f o r a
sustainable, resilient and
inclusive future
“
Project in the spotlight: ANOPC/Petrojet
“ E g y p t o n t o p o f t h e Mid dle Ea st ma rk e t:
Petrojet awarded Nijhuis Saur Industries the order to design
and build a unique WWTP for a new hydrocracking complex”
A contribution from Nijhuis Industries | Saur Industrie | Econvert | Unidro
#NijhuisSaurIndustries #StandForWater #ItsAllAboutThePeople
2
Nijhuis Saur Industries NEWS
#ItsAllAboutThePeople
Dear valued clients and business partners,
After almost 1.5 years of lock-down waves, and despite the fast-spreading delta virus, we are
finally seeing the first signs of a world that is opening-up once more. During the past period,
health and safety has been, and will remain our first and top priority.
As the situation is still very fragile, we need to stay flexible and adapt to the highly dynamic and
sometimes unpredictable future as our team has been doing successfully since the pandemic
occurred. We sincerely hope that you are keeping well during these challenging times!
As we have experienced ourselves first-hand, the personal and human interaction has been truly missed,
such as meeting our beloved families, friends, valued clients, business partners and our continuously
expanding team around the globe.
However, during these challenging times, the global water sector and our colleagues of Saur have worked
hard to secure access to clean water and sanitation, thereby helping vital industries to protect their water
sources with adaptable solutions to secure a more sustainable, resilient, and inclusive future.
#StandForWater impact
To protect our water resources, the Saur Group actively promotes their mission to engage with all our
stakeholders to #StandForWater. The newly formed Nijhuis Saur Industries team, consisting of Nijhuis
Industries, Saur Industrie France, Econvert and Unidro, is celebrating their first anniversary. Solid
synergies are being found from the combination of complementary technologies, client portfolios, industrial
knowledge, and geographical presence, all with the aim and ambition of helping our clients to reduce,
reuse and recover water, energy, and resources.
Shifting gears from compliance to ‘reduce, reuse and recover’
Most industries have successfully reduced their water footprint and focus to keep
their cost low. However, climate change and water scarcity (often on the back of
tighter environmental regulations) are now requiring a fundamental change. To
protect our precious water sources, a mind-shift is needed towards the proactive
adoption and integration of reuse solutions and/or the recovery of energy and
valuable resources from reclaimed water.
Gain exclusive insight into the latest industrial water projects
So, what does it mean to #StandForWater? What drives CEO’s, CTO’s, Engineers and Operators
at industrial production sites to prioritise water management, bearing in mind that water is a ‘license to
operate’? In this edition of Nijhuis Saur Industries NEWS, we are demonstrating the huge impact of our
#StandForWater mission, and how you can benefit from our 118 years of extensive experience.
When partnering with Nijhuis Saur Industries, our clients enjoy the Value-Added benefits of working with
a partner who offers a one-stop-shop water management portfolio, and is a lifetime project partner, due
to our commitment to successfully continuing our innovation and implementation of water reuse,
resource recovery and digital services.
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
3
Water & Energy
#ItsAllAboutThePeople Prepare for the future: delivering water-
Our successful and innovative on-demand
approach has been recognised Anticipating the growing demand for clean water is
once again, as Global Water the root cause of our #StandForWater mission. As an
Intelligence awarded us with the integrated water cycle solution provider, we combine our
Industrial Water Plant of the Year 2021 (L’Oreal leading technologies into affordable, sustainable, and
Warsaw Water Recycling Station) and Desalination resilient solutions.
Plant of the Year 2021 (as being Dissolved Air
Flotation technology supplier for the Keppel Marina East Supported by our unique "Customer For Life”
Desalination Plant). approach, integrating consultancy, the best available
technology, operation & maintenance, and continuous
Our team has also been awarded with innovation, we support our clients by solving their water
the prestigious Dutch Innovation Award challenges and deliver water-on-demand.
(‘Achterhoek Open Innovatieprijs’) for
MediOxi, a highly innovative solution We sincerely hope you will stay safe and healthy.
to remove medical residues and To obtain more information about the unique set of
micropollutants from hospital wastewater. technologies, systems, solutions, or any of our added-
value services we offer, do not hesitate to contact one
Lastly, I would like to express my gratitude to an amazing of my colleagues, myself, or meet us during one of our
team, our valued clients, and business partners. Without organised in-person or digital events!
them, my name would never have been mentioned
by Global Water Intelligence in the top 20 most
transformative leaders in the water industry.
One of the secrets of successfully bringing innovations to
the market is the ability of our strong and global team to
collaborate closely together with our public and private
clients, science, universities, and technology partners.
This enables the development of adaptive, flexible and
circular solutions, contributing to the Sustainability
Menno M. Holterman
Development Goals and a more and a more
President and CEO Nijhuis Saur Industries
sustainable and resilient future.
Email: menno.holterman@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
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13
Meat, Fish and Agricultural:
Content and project
Unique technology
reduces heat and energy
consumption of Dutch
poultry slaughterhouse
highlights
19
Pharma, Cosmetic, Healthcare/l
Advanced treatment
technologies meet
simplified construction
methods to remove API's
12
Meat, Fish and Agricultural:
North-American meat
23
Paper and Pulp:
cutting facility reduces
75% COD reduction, water
surcharges and labour
reuse and energy recovery
costs with a new WWTP
at European recyclable
board company
43
Commercial Buildings:
Global bank extends
operation contract
following successful
cooling tower upgrade
40
Holiday and Leisure:
How ‘smart’ water reuse
protects Stonehenge and
reduces ground water
25
abstraction Heavy Industries:
Supply and support of a
modular MBR solution for
temporary use at
European refinery site
31
Potable Water and Sewage Treatment:
Municipal and Industrial pilot
plants and full-scale
innovations in the spotlights
33 34 35 36
11
Food, Beverage, Dairy:
Chilean wine producer
solves operational
challenges with Nijhuis
Saur Industries DAF
24
Paper and Pulp:
By Outsourcing their WWTP
operations, a banknote
facility is now meeting its
discharge consent
News colophon
Text Contributors | Nijhuis Saur Industries team
14
Meat, Fish and Agricultural:
Text Editors | Steven Nieuwboer, Purnima van Elst Plant refurbishment
reduces OPEX at a duck
Photography | Nijhuis Saur Industries team meat processing plant
Do you have a question or request more information? Fish processing plant
WWTP under construction
for Australis Seafoods, one of
Please send a mail to news@nijhuisindustries.com the leading companies in the
chilean salmon industry
or take a look on our website:
www.nijhuissaurindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
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09
Food, Beverage, Dairy:
New wastewater treatment
for large dairy plant in
Germany
15
Meat, Fish and Agricultural:
16
Pharma, Cosmetic, Healthcare: ‘Creating Perfection’ -
Nijhuis Saur Industries is State-of-the-art water
proud to congratulate treatment plant is critical to
L’Oréal as winner of the Russian Egg Producer
GWI Awards
21
Pharma, Cosmetic, Healthcare:
Pharmaceutical wastewater
treatment: end of pipe
or essential part of the
production process?
30
Heavy Industries:
Ready to go on tour to
ORLEN, Poland?
08
Food, Beverage, Dairy:
One of the world’s largest
FMCG companies has
upgraded their existing
wastewater treatment plant
Textile Industry:
Wastewater treatment
plant for Misr. Spain in
26
Egypt Heavy Industries:
Fresh/ demineralised water
treatment systems are
in commissioning for a
Floating Liquefied Natural
Gas Project
28
Heavy Industries:
The main EPC contractor
Petrojet has awarded
Nijhuis Saur Industries the
water treatment order
First aid / Refugee camp:
Waste to clean energy to
facilitate the generation of
biogas for cooking and other
10
Food, Beverage, Dairy:
key energy needs
New dairy wastewater
treatment successfully
provides clean water
Desalination Plant:
High Rate Concrete i-DAF
38
Leache treatment from waste for Marina East Desalination
Advanced clean water plant in Singapore
solution in construction
for Italian leachate and
digestate facilitye
27
Heavy Industries:
New condensate water
treatment system W2E
06
plant, as part of the flue Innovation - Water Reuse
gas treatment upgrade Freshwater sources are running out,
balancing local water demand is the
way to go
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
6
Innovation - Water Reuse
Circular Economy examples
“Freshwater sources are running out,
balancing local water demand is the way to go”
Freshwater sources in several regions around the world are running out or will run out soon. Water
is necessary to ensure an improved quality of life due to the impact of climate change and other
environmental issues. However, in a future world in which the water sector delivers ‘Water-on-Demand’
solutions, in combination with new technologies and new business models, the balance between demand
and supply should be in harmony. The reuse of water from industrial wastewater has attracted particular
interest to improve environmental and business image perspectives.
Let’s start from the beginning: what is water reuse?
Water reuse, also known as water recycling, is the process by which wastewater from a variety of sources is treated
to be reused for beneficial purposes. Instead of discharging water into rivers (which ultimately ends up in the sea)
water recycling will retain water in the area where it was originally used and keep the local water supply at the desired
‘on-demand’ level.
Why apply water reuse?
To cope with water stress, authorities are imposing
increasing water restrictions and more stringent
regulations. As a result, water will become more
valuable and its price will increase. Moreover, when
an industrial facility reaches its production limitation
due to shortages of fresh water supply, it is no
longer a choice but a necessity to reuse ‘waste’
water to continue production growth.
“
Some typical cases to consider water reuse:
• Production limitations due to water shortage.
• Meet Corporate Social Responsibility goals to
reduce the water footprint.
• Reduce water disposal costs and/or meet
“Every drop of water counts,
effluent disposal limits. whatever the original source,
providing on-demand water quality
• Reduce the impact of drought by reusing
sewage wastewater.
• Decentralised circular water management for
residential areas.
conforming to the highest industrial
hygiene and safety standards.”
“
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
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Innovation - Water Reuse
Circular Economy examples
Water Reuse Technology Solutions
in a nutshell
Depending on the application, technologies can either be applied to industrial wastewater, ground water,
cooling water, condensate water treatment or decentralised sewage water and sanitation treatment.
• BIOCTOR-MBR • MLD/ZLD - Evaporation
A sludge water separation system through membranes, A smart combination and selection of various solutions
using flat plate or hollow fibre membranes modules for such as evaporation, crystallization, membrane and EDR
wastewater. This can be part of tertiary treatment, start solutions towards minimum and zero liquid discharge.
of pre-treatment for the membranes including CIP and This is sometimes necessary to cope with the brine
flush water recovery. generated from reverse osmosis, minimising brine for
disposal.
• NMS-UF - Ultrafiltration • AECO-CIP - CIP Recovery
This unit is a superior barrier for viruses and bacteria The AECO-CIP recovery is a system to treat spent CIP
removal and a solid pre-treatment for reverse osmosis. solutions (i.e. hot soda based). This unit enables the
reuse of spent CIP fluids and (hot)water.
• NMS-dNF - Direct Nanofiltration
• NMS-EDR - Electrodialysis Reversal
This step is considered the finest step, combining two
The Nijhuis EDR unit removes all kinds of dissolved
steps in tandem, ultra and micro filtration. This unit can
materials, such as salts. The unit can be adjusted to
be implemented to remove colour, bacteria and viruses
remove the salts with electricity and uses a reduced
for drinking water and wastewater applications.
amount of chemicals.
• NMS-RO - Reverse Osmosis
This is the last membrane step before disinfection for Let #NijhuisSaurIndustries implement
producing high quality process, or even potable, water. your water reuse solution to reduce your
The unit removes dissolved components, such as ions,
water footprint!
heavy metals, TOC and viruses.
Contact Thijs Wolbrink for more information about ‘Water Reuse’: thijs.wolbrink@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
8
Light Industries
Food, Beverage and Dairy
One of the world’s largest FMCG companies has upgraded their
existing wastewater treatment plant with Nijhuis Saur Industries’
intelligent dosing control to meet environmental goals
A Fast-Moving Consumer Goods multinational has upgraded their wastewater treatment plant in South East
Europe with an innovative technology installation by Nijhuis Saur Industries. Already using one of the most
technologically advanced and environmentally friendly production plants, the client contacted Nijhuis Saur
Industries in 2019 to discuss how to meet their environmental goals. After the first consultative report, the
existing treatment process was optimised with intelligent dosing control to reduce chemical costs by up to
30%.
In 2019, the factory team contacted Nijhuis Saur Industries to discuss an upgrade of the existing wastewater treatment
system in order to fulfil the company’s sustainability goals. The Nijhuis Saur Industries team started developing a plan
to meet the client’s expectations. The first step to optimise the existing treatment process was by introducing Intelligent
Wastewater Chemical Dosing – i-DOSE.
Intelligent Dosing Control From pilot to reuse request
The “i-DOSE” is a solution that can be installed on any new The second part of the production facility’s cooperation
or existing chemical pre-treatment process, and provides with Nijhuis Saur Industries came in January 2020, when
a real-time control for chemical treatment of wastewater, the client asked Nijhuis to find a solution to reduce the
significantly reducing wastewater operational costs (e.g., effluent Cl (chlorine) level in order to meet more and
chemicals, aeration, energy). The system also allows more restrictive discharge parameters. The most suitable
facilities to be operated at a maximum performance solution to achieve the necessary Cl reduction was a
with reduced operator presence due to the intelligent membrane technology. In the summer of 2020 Nijhuis
dosing philosophy. Prior to a permanent installation of installed a state-of-the-art pilot system consisting of MBR
the i-DOSE, the client wanted to test the equipment’s biological treatment, nanofiltration, and a reverse osmosis
efficiency, so a rental solution was installed on a temporary polishing step.
basis.
The pilot trials were concluded in early 2021 with a positive
The local engineering team installed, commissioned the outcome. Shortly after, the client submitted a request for
i-DOSE, and trained the operators on how to use the device, quotation for a full-scale water reuse system upgrade to the
whilst thereafter offering 24/7 support. After 5 months of existing WWTP which Nijhuis Saur Industries is currently
testing with extremely positive chemical reduction results, generating for submission.
Nijhuis Saur Industries was pleased to receive an order
from the client to buy the i-DOSE.
The permanent solution is now working seamlessly,
reducing chemical consumption by up to 30%, whilst
also dramatically reducing the labour time of the client’s
operators.
#ItsAllAboutThePeople
Contact Marcin Wielgopolan for more information about the project: marcin.wielgopolan@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
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New wastewater treatment for large dairy plant
in Germany
At the end of 2020, a "Greenfield" wastewater pre-treatment plant from Nijhuis Saur Industries was
commissioned and has been operating at the premises of a German dairy factory ever since. The project
aims to ensure the long-term discharge of wastewater into the local municipal sewage treatment plant,
whilst also reducing wastewater discharge costs for the dairy factory.
Ensure production expansion possibilities and comply with discharge conditions
The new wastewater pre-treatment will both allow the potential for future production expansion possibilities, and
will comply with the discharge conditions of the local municipal sewage treatment plant. Furthermore, since a large
quantity of the wastewater will be treated via the new pre-treatment plant, the local municipal sewage treatment plant
will benefit as well. The new pre-treatment system ensures a reduction of COD and TSS which has a positive impact
on the biological system of the municipal sewage treatment plant, reducing the power consumption of the aeration
system.
In the new pre-treatment plant, a large part of the
PROJECT IN A NUTSHELL TO #StandForWater:
pollution is removed from the wastewater by a
chemical-physical process. The so-called "flotation Customer: Milk factory
sludge" is energy-rich and can even be used to Industry: Dairy
produce biogas in the digestion system of the local Location: Germany
municipal sewage treatment plant. Approximately Flow: 2600 m3/d
2,600 m3 of wastewater per day will be treated at the BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
Dairy site via a filter, a balancing tank and will then flow Reduce wastewater discharge costs / Comply with
to the Nijhuis Dissolved Air Flotation system, which will discharge conditions.
treat a volume flow of approx. 95m³/h. Ensure availability of future production expansions.
Nijhuis Saur Industries’ expertise in flotation for excess
solids removal before biological treatment.
CUSTOMER FOR LIFE APPROACH:
• Contract type: Design, Build
• Added value services: Delivery, installation,
commissioning, training on site and monitoring
• NSI one-stop-shop portfolio solutions: filter, balance
tank, flocculator, DAF
• Project commissioning: 2020
#ItsAllAboutThePeople
Contact Christophe Lodde for more information about the project: christophe.lodde@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com
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New dairy wastewater treatment successfully
provides clean water
The new Nijhuis Saur Industries installation at Danone Nutricia site in New Zealand marks the second
successfully completed dairy wastewater project in collaboration with local NZ partner Filtec Ltd (the first
being Mataura Valley Milk, completed back in 2018). The PFR/IPF system supplied by Nijhuis is installed in
a new wastewater treatment plant built by Filtec.
The system is mainly designed to remove the suspended solids content (TSS) in the raw effluent coming from the dairy
factory. Thus, also helping to reduce discharged COD/BOD concentrations. The treated effluent from the flocculation-
flotation system is transferred to the client’s new biological treatment system, starting with the anoxic tank followed by
an aerobic pond and secondary clarifier. The plant is designed to treat on average 30 m3/h, and is now fully functioning
after being commissioned in 2020.
PROJECT IN A NUTSHELL TO #StandForWater:
Customer: Danone Nutricia BENEFITS / REDUCE-REUSE- CUSTOMER FOR LIFE APPROACH:
Industry: Dairy RECOVER IMPACT: • Contract type: Design, Build
Location: New Zealand Primary treatment system for a • Added value services: Delivery,
Flow: 30 m3/h new wastewater treatment plant. installation, commissioning, training on
Minimal treatment footprint with site and monitoring
in-line flocculant dosing through • NSI one-stop-shop portfolio
pipe flocculator technology. solutions: balance tank, flocculator, DAF
Nijhuis expertise in flotation for • Project commissioning: 2020
excess solids removal before
biological treatment.
#ItsAllAboutThePeople
Contact Duane Schlicht for more information about the project: duane.schlicht@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com11
Chilean wine producer solves operational
challenges with Nijhuis Saur Industries DAF
pre-treatment
The Viña Santa Rita winery in Palmilla, Chile, struggled during the past year with operational problems of their
pre-existing DAF pre-treatment, and the filtration of solids. To solve this situation, Nijhuis Saur Industries
was asked to design a solution to continuously achieve environmental compliance, to avoid exceeding
the discharge limits (and thus avoiding possible penalties), whilst also avoiding operational issues in the
future. Ultimately, the new state-of-the-art treatment facility installed by Nijhuis Saur Industries helps the
winery plant to keep its focus on their core business, and reduces their total environmental footprint.
The Solution
PROJECT IN A NUTSHELL TO #StandForWater:
The Nijhuis Saur Industries treatment facility has been
operating since 2020, and treats the wastewater via a Customer: Viña Santa Rita
design consisting of a balance tank, flocculator, and Industry: Winery
dissolved air flotation system. The flocculator adds Location: Palmilla, Chile
chemicals into the water to enhance and secure a Flow: 500 m3/d
better separation of solids and undissolved fats within
the dissolved air flotation unit (DAF). With the addition BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
of dissolved air into the DAF unit, suspended solids Avoid operational issues and reduce OPEX.
and undissolved fats are floated as a top layer within Continuously meeting the discharge limits and
the flotation unit, and are removed via a scraper environmental compliance.
system. Clean water then flows to a sewer connection.
Contributing to clean water to the Colchagua Province
Nowadays, approximately 500 m3 per day of pre-
treated water is discharged into the Palmilla sewer, and in Chile.
therefore contributes to providing cleaner water to the
CUSTOMER FOR LIFE APPROACH:
Colchagua Province, O'Higgins Region in Chile.
• Contract type: Design, Build
• Added value services: Delivery, installation,
commissioning, training on site and monitoring
• NSI one-stop-shop portfolio solutions: balance tank,
flocculator, DAF
• Project commissioning: 2020
#ItsAllAboutThePeople
Contact Tamara Sepulveda for more information about the project: tamara.sepulveda@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com12
Light Industries
Meat, Fish and Agricultural
North-American pork meat cutting facility
reduces surcharges and labour costs with a
new wastewater treatment facility
A large pork processing facility in the U.S. has contacted Nijhuis Saur Industries as a wastewater treatment
expert to help them reduce their wastewater surcharge and labour costs. Their facility operates from
Monday to Saturday, based on an 8-hour working cycle. With a flow of around 19,000 gallons per day
(around 70 m3/d), the wastewater was previously treated with basic technologies. To reach the effluent
parameters of13
Unique technology reduces heat and energy
consumption of Dutch poultry slaughterhouse
A large-scale poultry slaughterhouse in the Netherlands is the first company in the Netherlands to use a
unique technology, AECO-FAT, from Nijhuis Saur Industries to remove fat from process water and make it
suitable as biofuel in a hot water boiler. The poultry slaughterhouse uses the energy that is released in this
process for in-house use. As a result, the client benefits from significantly reduced gas consumption and
associated operating costs.
Nijhuis Saur Industries' AECO-FAT technology works as following: a specially developed flotation installation removes
the fat from the process water and then refines it into three streams; solid matter, clean water and fat. The fat is cleverly
separated in such a way that it can be easily burned in a hot water boiler as a sustainable energy source. Via this
way, the client makes an important contribution to the regional circular economy. In addition, Nijhuis Saur Industries
can help to implement the correct burner and boiler combination to burn the fat in a sustainable way.
In addition to a reduction in gas consumption, PROJECT IN A NUTSHELL TO #StandForWater:
the technology also has other advantages. For Customer: Largest poultry slaughterhouses in the
example, less chemicals are needed for water Netherlands
purification, and the poultry slaughterhouse has to Industry: Poultry slaughterhouses
discharge less sludge, both of which reduce CO2 Location: The Netherlands
emissions. After application abroad, this unique Flow: 1-1.5 m3 biofuel per day
technology has now been applied at full-scale in
BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
the Netherlands for the first time.
More than 50% reduction of chemical use for the current
The technology is also interesting for the recovery chemical/physical installation.
of fat from wastewater flows generated by other More than 50% reduction of the produced sludge.
companies in the food and beverage industry. In
Reduction of the energy costs (natural gas saving).
addition, a food producer may sell the fat from the
process water as a sustainably recovered product Sustainable solution, reducing the CO2 footprint.
to customers in the region. Contributing to corporate social responsibility, reduction
of environmental footprint and sustainability
requirements.
CUSTOMER FOR LIFE APPROACH:
• Contract type: Design and Build AECO-FAT system
• Added value services: Design, Engineering, Project
Management, Manufacturing, Delivery, Installation,
Commissioning, Training
• NSI one-stop-shop portfolio solutions: Fat-flotation,
disconnector, decanter, boiler
• Intelligent services: i-MONITORING
• Project commissioning: 2020
#ItsAllAboutThePeople
Contact Johan Hekkenberg for more information about the project: johan.hekkenberg@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com14
From consultative study to operation:
Plant refurbishment reduces OPEX at
a duck meat processing plant
A large agrifood cooperative with a duck meat processing plant located in France needed a wastewater
treatment plant upgrade. Nijhuis Saur Industries (Saur Industrie) has been responsible for the O&M of
the existing treatment plant for several years, and when the time came in 2018 to refurbish the existing
equipment, this pre-existing relationship turned into a real joint-partnership.
The customer set some very ambitious requirements for the project, and challenged Nijhuis Saur Industries
on the current O&M contract in a tough competition. However, Nijhuis Saur Industries’ existing knowledge
of the system enabled a study to highlight several plant optimisation options that would yield promising
results on operational expenses, energy savings and sludge reduction. As a result of this study, Nijhuis
Saur Industries was successfully able to meet the customer’s ambitious technical and financial targets,
resulting in the successful award of the project.
Previous situation
The relationship between the client and Nijhuis Saur
Industries was started around 2007, and was further
enhanced when a new clarification plant was installed in
2013. Nijhuis Saur industries has also operated the pre-
treatment, biological treatment and sludge management
system of the duck meat processing plant for the most
recent years. The biological treatment consists of a
continuous system. As the wastewater contains a high
amount of fat, a fat treatment unit is installed. Next to
the wastewater treatment plant, the on-site fresh water
intake plant is operated and maintained as well.
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com15
Conclusion of the study and new situation
The expert team from Nijhuis Saur Industries saw several options to upgrade the fat treatment equipment into a new
system, to install a new sludge treatment system, and to cover the storage of sludge. With a ROI of up to 4 years, the
client decided to tender the project equipment.
After tendering, Nijhuis Saur Industries was successfully selected again against 2 serious competitors to design,
purchase and install the new equipment, alongside a renewal of the operational contract for 5 years. The total project
value equalled a total amount of €1.5 million. In addition, the NEXTEP monitoring tool from Saur Industrie ensures
that the client has 24/7 insight into the plant status. The tool helps the client to improve economic and environmental
performance.
The plant refurbishment is now under construction and is expected to be finalised Fotoat the end of Summer 2021.
After start-up, a fulltime Nijhuis Saur Industries operator will operate the plant. In addition, in case of any
emergency, a service line is 24/7 available for the client to prevent any wastewater treatment plant problems which
might affect the production process of the duck meat processing facility.
PROJECT IN A NUTSHELL TO #StandForWater:
Industry: Duck Meat processing
Location: France
Flow: 315,000 m3 per year / 2 tons COD per day
BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
Reduce sludge and energy costs after consultancy works.
24/7 monitoring with the NEXTEP monitoring tool from
Saur, improving energy and environmental performance.
Nijhuis Saur Industries expertise in operating duck meat
processing plants.
CUSTOMER FOR LIFE APPROACH:
• Contract type: Design-Build for plant refurbishment +
Operate-Maintain contracts
• Added value services: Delivery, installation,
commissioning, operation and monitoring
• NSI one-stop-shop portfolio solutions: fat treatment
system, sludge treatment system, plant optimisation
• Project commissioning: 2021
#ItsAllAboutThePeople
Contact Mathieu Puerta for more information about the project: mathieu.puerta@saur.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com16
Watch the movie!
‘Creating Perfection’ - State-of-the-art water
treatment plant is critical to Russian
Egg Producer
JSC “Roskar Poultry Farm” is a modern and dynamic Russian enterprise with advanced equipment for
producing high-quality egg and poultry meat products. To fully demonstrate the ‘Creating Perfection’
slogan of Roskar, a state-of-the-art water treatment facility has been designed and built by Nijhuis Saur
Industries to generate clean effluent to meet the stringent river discharge requirements. To achieve the
highly stringent environmental protection goals, Roskar explored the water treatment market and selected
Nijhuis Saur Industries as their main solution-provider for the complete wastewater treatment facility.
About the plant
With a production capacity of approximately 3 million eggs per day, around 2000 m3 per day of wastewater needs to
be treated. To the meet the stringent river discharge requirements, a system consisting of curved screen, flocculation,
flotation unit, biological treatment, and polishing step has been designed. Besides that, the plant is equipped with an
intelligent dosing control system (i-DOSE), ensuring a stable dosing of chemicals for the water treatment system to
avoid overdosing.
PROJECT IN A NUTSHELL TO #StandForWater:
Via this intelligent system, the client saves Customer: Roskar
by reducing both chemical costs, and the Industry: Poultry / Egg production
amount of required operational attention. Location: JSC Poultry farm Roskar
Due to the solid and reliable water Flow: 2000 m3 per day
treatment plant, Roskar can maintain their
BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
core focus of producing high quality egg
Reduction of the environmental footprint, meeting the highly
products, making the water treatment
stringent environmental protection goals of Roskar.
an integral part of their egg production Complete water treatment facility, including pre-treatment, biological
facility. and polishing, meeting the stringent river discharge requirements.
Smart intelligent dosing control, reducing chemical costs and
The positive results of the Nijhuis Saur operationl attention.
Industries and Roskar’s cooperation CUSTOMER FOR LIFE APPROACH:
resulted in the launch of a joint reference • Contract type: Technology Design and Build of a Wastewater
video. treatment plant
• Added value services: Design, Engineering, Project Management,
This underlies the statement that Manufacturing, Delivery, Installation, Commissioning, Training
• NSI one-stop-shop portfolio solutions: : Screening, Flocculator,
‘Creating Perfection’ starts with building
Flotation, Nitrification/Denitrification, Sand Filter, Carbon Filter, UV
a successful business case whilst also disinfection
working on a sustainable and resilient • Intelligent services: i-MONITORING
future at the same time. • Official start date: Summer 2018
#ItsAllAboutThePeople
Contact Dmitry Molokanov for more information about the project: dmitry.molokanov@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com17
Light Industries
Pharma, Cosmetic and Healthcare
Nijhuis Saur Industries is proud to congratulate
L’Oréal as winner of the Global Water
Intelligence Awards
ORLEN
On JunePo ndnie S.A wastewater treatment plant in Trzebinia
2łud, L’Oréal and Nijhuis Saur Industries proudly received a Global Water Intelligence award in the
category ‘Industrial Project of the Year’. Nijhuis Saur Industries designed and built the turnkey installation
of the L’Oréal Warsaw Water Reuse Station. Established in 2006 by Global Water Intelligence, the awards
recognise the most important achievements in the international water industry across several categories.
These help to highlight and to demonstrate initiatives in the water, wastewater and desalination sectors
that are moving the industry forward through improved operating performance, innovative technology
adoption and sustainable financial models.
According to CEO Menno M. Holterman from Nijhuis Saur Industries: “We greatly appreciate the trust and confidence
from L’Oréal to work with us on these landmark projects, and like to thank the Global Water Intelligence Readers
for their votes. Both industrial water reuse, and desalination, will play a very important role in the future, and we are
proud to help set new standards and inspire the world to work with our experts to solve their water challenges.
Last but not least, it’s a great achievement of our team for their dedication, passion, perseverance and knowledge.
The team sets new standards and inspires our valuable customers to work with us to solve the ever-demanding water
challenges and contribute to the circular economy and a more sustainable and resilient future, which fits our purpose
as a group to #StandForWater.”
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com18
About the Industrial Project of the Year
The Industrial project of the year, commissioned in
2020, represents the most impressive technical and
environmental achievement in the field of industrial water
and wastewater.
L’Oréal Warsaw Water Reuse Station, Poland
What is it?
A 400 m3/d wastewater treatment and water reuse plant
commissioned for cosmetics giant L’Oréal in Warsaw,
Poland.
Who was involved?
Nijhuis Saur Industries delivered the €4.3 million design
build project and was involved in the turnkey installation
and commissioning. 3D technology was used for
project execution and implementation, without stops in
production, and L’Oréal’s staff operate the plant with the
support of Nijhuis.
What makes it special?
With Poland facing increasingly more frequent drought periods, L’Oréal’s Warsaw site has slashed its water consumption
in half by reusing approximately 75,000 m3 of water annually. An array of Nijhuis processes are employed, including
flocculation & flotation, a membrane bioreactor, sludge treatment, and a reverse osmosis system.
The produced clean water is reused for co-production processes. Inspired by the ‘Water Loop factory’ concept, part
of L’Oréal’s sustainability strategy, this project proves that the environmental footprint of cosmetics production
can be significantly reduced. With exceptional white walls and a glass façade, the design was an integral part of
this plant’s implementation, perfectly complementing the aesthetics of the Warsaw site. Another unique feature of
this plant is the Nijhuis i-DOSE system, an intelligent chemical dosing system. While conventional dosing pumps are
set on a fixed setting, often leading to overdosing chemicals during strong fluctuations in effluent quality, the Nijhuis
i-DOSE uses real-time online analysis of multiple wastewater quality parameters to adapt the chemical consumption
to the actual pollution load.
By optimising the chemical usage, the i-DOSE system increases the efficiency of the pre-treatment system which
reduces the power consumption in subsequent treatment phases. Therefore, the plant is not only achieving economic
and environmental gains by minimizing chemical costs, but also through power savings. Adding to these gains,
operation time and labour load are also reduced since it is a fully automated system.
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com19
Advanced treatment technologies meet
simplified construction methods to remove
Active Pharmaceutical Ingredients (API)
ORLEN Południe S.A wastewater treatment plant in Trzebinia
Nowadays, industrial and municipal customers are continuously searching for solutions to meet their
sustainable goals, to lower their environmental footprint, and to combine productivity and energy
efficiency, whilst also ensuring minimum life-cycle costs. As a combination, these issues continue to pose
a challenge to companies that strive to balance their economic and sustainability goals. By overcoming
these challenges, a growing number of global customers are successfully extending utility infrastructure
lifetimes, improving sustainability, and reducing operational costs through the implementation of
innovative and flexible water treatment designs.
Active Pharmaceutical Ingredients (API) ingredients, a modular building construction with
The pharmaceutical and healthcare industry is not advanced purification processes combines the best of
an exception to this trend. They produce wastewater both worlds. In this way, local legislation and a short
which can contain Active Pharmaceutical Ingredients project time-scale can both be achieved.
(API). These APIs are not fully, or sometimes even partly,
degradable by conventional purification processes. One of the latest Nijhuis Saur Industries project examples
Besides, the pharmaceutical and healthcare companies is the installation of a modular and prefabricated
deal with variations in production levels calling for water treatment facility.
flexibility in the volumes of the wastewater generated
from production. This installation will enable a global pharmaceutical
company in Europe to comply with local legislation
Modular construction with advanced purification and internal environmental standards. The APIs will be
processes degraded before discharging into the municipal sewer.
To meet the growing demand from end-clients for water Ozonation was chosen as the preferred technology within
treatment suppliers to both construct and engineer the total scope of Nijhuis Saur Industries’ supply, which
flexible treatment facilities, together with treating includes Design, Build, Operation and Maintenance
challenging components with often limited degradable of the wastewater treatment plant.
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com20
Simplified civil construction and reduced installation and commissioning time
Nijhuis Saur Industries’ modular solutions not only simplify civil construction requirements, but also reduce the installation
and commissioning time on site (including reduction of NOx and CO2 emissions). Each module is manufactured,
pre-assembled and tested at our state-of-the-art production facility. Modular plants enable the minimum footprint to be
used, and can be easily relocated or extended thanks to their modular design. Further benefits of modular construction
include allowing global multinationals to relocate production facilities during their economic lifetime, allowing them to
react far quicker and at a much lower cost to changing local requirements, changing demands and regulations.
The units are based on a simple design requiring
minimal installation time. Built to be robust and reliable
for monitoring conditions, the systems can also be
custom-made to suit particular requirements, and
to achieve environmental compliance within a limited
time scale. The solution is adjustable to variations in
the industrial activity, representing a ‘plug and play’
principle to enable clients to achieve their sustainability
goals.
The main advantages of this modular build system PROJECT IN A NUTSHELL TO #StandForWater:
over a conventional civil installation are:
Industry: Pharmaceuticals
Flow location 1: max. 30 m3/d | flow location 2: 85 m3/day
• Flexibility: Provides a better programme guarantee
by minimising seasonal weather influences on site. BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
• Environment: Reduce concrete constructions Reduction of API’s, reducing the impact of API’s on
and on-site NOx and CO2 emissions the environment.
• Time & Schedule: Reduced installation Reduction of on-site construction time, due to modular
and commissioning time; the ‘plug and play’ prefabrication.
connections between the modules require only a Clean water for discharge to the municipal water
few days on site. treatment plant.
• Reducing risk: construction methodology CUSTOMER FOR LIFE APPROACH:
enables installation to be completed in a dedicated • Contract type: Design, Build, Operation and
production facility, whilst pre-delivery testing Maintenance of two API removal plants
improves reliability on start up. • Added value services: Design, Engineering, Project
• Health & Safety: Simplifying permitting Management, Delivery, Installation, Commissioning,
Training, Operation
procedures and reduced manhour presence.
• NSI one-stop-shop portfolio solutions: Curved
• Multiple Use: Process water, wastewater, clean screen, balance tank, MicroOxi Technology in modular
water and reuse applications. systems (ozone system 360 g/hr), UV technology
• Project commissioning: 2020
#ItsAllAboutThePeople
Contact Gert-Jan Oude Egberink for more information about the project: gert-jan.oudeegberink@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com21
Pharmaceutical wastewater treatment: end of pipe
or an essential part of the production process?
Behind the scenes of a 20-year-old wastewater treatment facility
Years ago, a wastewater treatment was seen as an ‘end of pipe’ solution and a costly investment. Nowadays,
an investment in a wastewater treatment plant is a solution to maintain environmental compliance and
production performance for years to come. An excellent example of such a ‘customer-for-life’ project
is the installation of a complete water treatment solution, located in the basement of the Polish Poznan
production hall for a pharmaceutical client. More than 20 years after first operating, the client came back
to Nijhuis Saur Industries with a request to modernise the installation, and for it to be adapted to the
increased flows.
The first installation for the pharmaceutical industry
The installation that was completed 20 years ago was one of the first projects for Nijhuis Saur Industries in the Polish
pharmaceutical sector. At that time, pharmaceutical wastewater in Central Europe was typically treated in a different
way: due to the (relatively) small amount of wastewater, any issues relating to decentralised treatment on site were
typically resolved by sending the wastewater directly to sewer for treatment at the local municipal sewage treatment
plant. However, this client had a visionary mindset, dictated by environmental concern. By striving to achieve the
highest environmental standards, and establishing cooperation with Nijhuis Saur Industries, a precedent was set
that proved to be an indication of the direction of future industry development.
Design challenges
The implementation of the project 20 years ago presented Nijhuis Saur Industries with the need to face and solve three
completely different challenges and problems. In 2000, the construction of a free-standing wastewater treatment plant
at the pharmaceutical plant was impossible due to the problem of obtaining a building permit. The second challenge
was that the implementation of a wastewater treatment plant was the first project of its kind for the pharmaceutical
company, and it was necessary to find a way to effectively treat wastewater from the production of creams heavily
contaminated with greasy substances. The study and analysis of pharmaceutical residues in the treated wastewater
was the third challenge – no laboratory in Poland undertook this task.
Applied solutions
The innovative implementation required the wastewater treatment
installation to be located in the basement of the existing production hall.
To arrange the low and narrow rooms of the basement for the needs of an
efficient installation was a challenge, requiring the Nijhuis Saur Industries
team to have specialist knowledge and experience. All elements of the
installation, such as the filter, flocculation, flotation and sludge dewatering,
were disassembled and transported via an elevator to the sub-zero level,
before then being completely reassembled.
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com22
Ensure production expansion possibilities and comply with discharge conditions
The new wastewater pre-treatment will both allow the potential for future production expansion possibilities, and
will comply with the discharge conditions of the local municipal sewage treatment plant. Furthermore, since a large
quantity of the wastewater will be treated via the new pre-treatment plant, the local municipal sewage treatment plant
will benefit as well. The new pre-treatment system ensures a reduction of COD and TSS which has a positive impact
on the biological system of the municipal sewage treatment plant, reducing the power consumption of the aeration
system.
Modernisation after several years learn about current needs and problems, and to offer
Nowadays, the client is a global, innovative, research- service support. The cooperation between the client
driven healthcare company with a mission to help people and Nijhuis Saur Industries is a model example of a
achieve more, feel better and live longer. The company relationship based on mutual trust.
is guided by three priorities – innovation, achievement,
and trust. In 2020, the dynamic development of This shows once again, even after 20 years, that a
the company brought new challenges related to wastewater treatment is not an end-of-pipe solution,
production, which had previously been only gradually but it is an essential part of a pharmaceutical
increasing. facility to keep life-cycle cost as low as possible,
and to achieve environmental compliance.
Following a plant audit, Nijhuis Saur Industries
PROJECT IN A NUTSHELL TO #StandForWater:
developed a concept for the modernisation of the fatty
wastewater pre-treatment plant in order to double the Industry: Pharmaceuticals
efficiency. Modernisation works to the wastewater Location: Poland
supply line, and updating of chemical reagent
lines was carried out. Due to the addition of new BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
components, it was also necessary to design and Reduce environmental footprint and reduce discharge
costs.
commission a new electrical panel. Engineers from the
Local operation and commissioning team, helping the
local Polish team carried out the commissioning of the client since 2000 to keep the life-cycle cost as low as
installation, consisting of stages such as the electrical possible.
installation, electrical start-up, mechanical start-up, Nijhuis Saur Industries expertise in pharmaceutical
hydraulic start-up and technological start-up. plants with a reliable plant operation since 2000.
Customer for Life example CUSTOMER FOR LIFE APPROACH:
• Contract type: Design-Build for plant complete plant +
The Nijhuis Saur Industries team in Poland regularly
plant modernisation
contacts installed base customers - over the last decade • Added value services: Delivery, installation,
they have reached all recipients of their treatment commissioning, operation and monitoring
plants in Poland. A personal visit to each plant has • NSI one-stop-shop portfolio solutions: filter,
demonstrated a real commitment to cooperation with flocculation, flotation and sludge dewatering
all former clients, whilst providing the opportunity to • Project commissioning: 2020 and 2021
#ItsAllAboutThePeople
Contact Marcin Polit for more information about the project: marcin.polit@nijhuisindustries.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com23
Light Industries
Paper and Pulp Water & Energy
75% COD reduction, water reuse and energy
recovery at European recyclable board company
As part of their sustainable responsibility plan, a European fibre-based packaging plant has installed a new
wastewater treatment facility from Econvert, enabling water reuse and energy recovery. At this production
facilities in the Netherlands, waste paper and cardboard is received and recycled into solid board packaging.
Controlling the complete process from recycling to carton board production they maintain a high standard
of quality and sustainable performance. The new treatment facility compliments this and is based on an
8-year rental contract, helping them to reduce discharge costs, meet their environmental goals and reduce
water pollution by up to 75%.
Based on the two different water streams, the mill intends to reuse as much wastewater as possible. “When there is
residual water, a location can only contain a certain amount of water. Whatever you take in, you must discharge”, the
Plant Director said. “We are taking our responsibility and have decided to treat the wastewater in a better way.”
Econvert consulted with the client over the design PROJECT IN A NUTSHELL TO #StandForWater:
and installation of an Econvert-IR® reactor. “It is better
to obtain knowledge from someone who can help Industry: Solid board packaging
us improve the process of sustainability, rather than Location: the Netherlands
trying to figure this out by ourselves”, according to Flow: max. 70 m3/h | Biogas: Max. 80 m3/h | COD: max.
the Managing Director. After the wastewater has been
BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
pre-treated with dissolved air flotation, the gas-tight
Econvert-IR® converts the BOD in the wastewater into Reduction of the environmental footprint and reduction
biogas before discharging the treated stream to sewer. of COD resulting in savings on discharge costs.
Recovery of biogas and water.
A positive collaboration
According to the Managing Director: “It was a positive High-level anaerobic expertise from Econvert, supporting
collaboration, with a great transfer of knowledge. the process operators on a daily basis.
Combing Econvert’s expertise with ours ensures the
best solution. That is exactly what we were looking for CUSTOMER FOR LIFE APPROACH:
in a partnership to jointly work on the best solution.” • Contract type: Design and Build of an 8year rental
anaerobic treatment plant
#ItsAllAboutThePeople • Added value services: Design, Engineering, Project
Management, Delivery, Installation, Commissioning,
Contact Pascal Telaar for Training
more information about • NSI one-stop-shop portfolio solutions: Econvert-IR®
the project: ECO (ECO reactors are standardized prefabricated plug-
p.telaar@econvert.nl and-play solutions)
• Project commissioning: 2020
Watch the movie!
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.com24
By Outsourcing their WWTP operations to the
expert team in Saur Industries, a leading
Integrated banknote manufacturing facility in
France is now meeting its discharge consent
With a long history in the banknote industry, the integrated banknote manufacturing facility has internationally
recognised expertise in the field of banknote production. It is the only central bank in Europe to incorporate
both a paper mill and printing works. Due to this special manufacturing process, the wastewater contains
hard nitrogen which requires a reliable treatment process and expert operations. As the client was failing
to meet their consent parameters they required immediate assistance. After success in the tendering
process, Saur Industries now operates and maintains the plant to ensure the client meets the discharge
limits.
The existing treatment facility receives the wastewater
PROJECT IN A NUTSHELL TO #StandForWater:
from the banknote manufacturing process into a
coagulation, flocculation and settling stage. After pre- Industry: Banknote paper production
treatment, the water flows into the biological treatment Location: France
process. Due to the difficult nature of the wastewater, Flow: 2400 m3 per day / 1.5 tons TOC per day
specifically the hard nitrogen, the biological system
needs to be in perfect condition to meet the effluent BENEFITS / REDUCE-REUSE-RECOVER IMPACT:
parameters. As the client couldn’t change their Reduce client’ manpower, with O&M expertise at
production method to reduce the impact of the hard the same time.
nitrogen, the wastewater treatment plant needed to 24/7 monitoring with the NEXTEP monitoring tool
deal with it. As this needs a high-level of technological from Saur to meet the discharge limits, providing
expertise, the client went to the market for help. peace of mind.
Nijhuis Saur Industries expertise dealing with hard
Saur Industries was successful in the tender due to
nitrogen levels.
the trust established during the tendering phase in
our industrial expertise, technical knowledge and our CUSTOMER FOR LIFE APPROACH:
proposed added-value solutions. One of which, the • Contract type: Technological studies, Operate-Maintain
NEXTEP monitoring tool helps the client to daily contract
monitor their 2400 m3 per day of wastewater. • Added value services: Operation and monitoring
An experienced Saur Industries operator helps the • NSI one-stop-shop portfolio solutions: Monitoring
client from Monday to Friday, with the support and tool, based on existing pre-treatment, aerobic biological
back up of Saur Industries global leading experts treatment and sludge treatment
to ensure the performance of the plant has • Project commissioning: 2021
been maximised and the discharge parameters are
constantly met.
#ItsAllAboutThePeople
Contact Jean Francois Mialon for more information about the project: jean-francois.mialon@saur.com
#StandForWater Nijhuis Saur Industries NEWS I www.nijhuissaurindustries.comYou can also read
