Over the past two decades process intensification has emerged as a major trend in wastewater treatment and is the key to sustainable wastewater treatment. It is smaller, cleaner, safer and more energy-efficient than conventional treatment. So, what exactly is process intensification, and why is there so much focus on it today? Is it just a fad? Or is it the new normal for wastewater treatment?

Process intensification is not actually a new idea. In fact, it originated in the chemical manufacturing industry. The first formal use of the term was published in a technical journal in Poland in 1971. For that industry, it meant devising a strategy for manufacturing processes, associated equipment and methods that would push a company toward key performance indicators (KPIs) that improved economic growth.

In wastewater, intensifying a process means increasing product mass transfer and throughput. It results in a more sustainable path in times of growth. Critically, it puts a focus on squeezing more out of existing infrastructure to minimize the financial impacts of regulatory changes.

So, why would a public utility be interested in process intensification? Here are some reasons:

• Improving the performance of an existing process.
• Improving the design of a new process.
• Unlocking process capacity, preserving and extending service asset life.
• Promoting environmental sustainability in operations.
• Balancing capital expenditures and operational expenditures.

Combined, these not only make for a more efficient treatment process but better financial outlook for the utility and its rate payers.

The greatest benefits come when the solution is simplistic and practical.

The value to a public utility is about operational efficiency, and efficiency gains to the municipal operator include the following:

• Higher process performance.
• Enhanced process robustness.
• Process redundancy.
• Increased flexibility to address tightening regulations in a sustainable manner.
• A compact process footprint.
• Use and repurposing of existing assets.
• Reduced operational cost (energy, consumables, and labor).
• Improved operational safety.

And you can see these are all signs of efficient operation and wins for any utility manager. Some argue that increased mass throughput is another indicator for measuring process intensification success, but this is still debatable.

One of the main reasons process intensification has gained so much momentum in municipal wastewater treatment in recent years is the number of tools available to measure the impacts. These tools include:

• Mathematically based biological models calibrated to real world data.
• Commercially available high-sensitivity process simulators that allow engineers to study process performance across any range of conditions.
• Maturity of advanced process configurations—particularly for nutrient removal.
• Advanced process controls systems such as ABAC, AvN™, Low DO-SRT, or MOV aeration control.
• High-fidelity digital analytics to support decision-making in real time.
• Advanced analytical methods for testing pollutant levels and the maturity of pilots and demonstrations.

What’s more interesting is when you can see all these tools working together. By bundling the applications of these tools, the benefits of intensifying process can be magnified.

Stantec is excited about the expanded potential for process intensification and is working collaboratively with the Canadian Water Network (CWN) to host a Working Group to connect CWN member municipalities that are researching, trialing, piloting, or curious about how process intensification can be incorporated into their wastewater treatment processes.

The Working Group will aim to create a positive impact on the Canadian water industry by promoting best practices, advancing knowledge, and fostering innovation in intensification technologies and holistic innovative solutions. The Working Group will also provide opportunities for professional development, networking, and recognition for its members.

The primary objective of this Working Group is to foster collaboration, knowledge exchange, and innovation in intensification technologies within the Canadian water industry, and its challenges and opportunities for a sustainable future. It seeks to create a dynamic space that not only connects seasoned experts and immersed operational and engineering expertise within utilities but also acts as a conduit to integrate the perspectives and energy of young professionals and graduates with a passion for process intensification and sustainability.

Stantec is enthusiastic about the potential of this Working Group to advance intensification technologies in wastewater, biosolids, and bioenergy process engineering while nurturing the next generation of industry leaders. Stantec looks forward to collaborating with CWN and industry stakeholders to bring this initiative to fruition.

Please contact Andi Yazdanpanah ([email protected]) if you are interested in joining the Process Intensification working group.

This article was sponsored by Stantec.