Infrastructure, Networks & Equipment

    Industrial WWTP Companies

    Industrial wastewater plant builders handling complex effluent from manufacturing, mining, energy, and chemical sites.

    183 providers

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    EMS Industries Ltd logo

    EMS Industries Ltd

    United Kingdom

    EMS are a UK based manufacturer of positive displacement ram pumps and grit removal solutions used traditionally in the wastewater industries but also in the food waste (AD) sector. EMS Industries was established in 1995 and has since grown into a world-renowned name for providing robust, reliable products which have provided our substantial client list with many years of trouble free service. All EMS products are designed, manufactured and tested in our Stoke on Trent operational facilities where we can also offer additional services including spare parts, service and repairs, installation, commissioning, operator training packages and full CAD and 3D modelling services. As a framework provider to some of the major UK utility companies, we ensure that our products meet with all current legislation and continually strive to provide innovative products to the market place.

    Treatment Process Technologies
    ERG (Air Pollution Control) Ltd logo

    ERG (Air Pollution Control) Ltd

    United Kingdom

    ERG (Air Pollution Control) Limited is the leading supplier of wastewater odour control units (OCUs) for the UK Water Industry and increasingly supplies odour control systems around the world. In addition, ERG can provide specialist advice and solutions to assist in achieving IED compliance for relevant odour assets. In the past 10 years, we have provided over 200 OCUs and count all the UK water companies and major main contractors among our clients. So, whether you are looking for a large, multi-stage chemical scrubbing system, an environmentally friendly bio-trickling filter or bio-scrubber system, a simple but efficient activated carbon or dry media system, an Odorgard™ from ERG Hygrade, or even an RTO (Regenerative Thermal Oxidiser) system, ERG can develop a tailor-made solution to suit. All ERG Odour Control Systems are: Purpose-designed by our process engineers to eliminate the cocktail of inlet odours to the required standard. Optimised to give the best value capital and running costs. Built and tested to current BS EN and WIMES specifications. Guaranteed to achieve the required discharge odour concentration and supported by our skilled and experienced maintenance team. Minimising non-compliant emissions to atmosphere by regular, planned maintenance protects your reputation and saves you money. Our maintenance department can help keep your air pollution and odour control systems running effectively and at the lowest operating costs. Our specialist engineers are experts in maintaining most types of odour and air pollution control equipment and always work to the highest safety standards. We often save clients many thousands of pounds by repairing and enhancing dilapidated air pollution and odour control equipment. We are a framework supplier for odour control maintenance to Southern Water, Scottish Water and Thames Water, regularly maintaining more than 120 sites.

    Treatment Works Products/Services
    FLI Precast Solutions logo

    FLI Precast Solutions

    United Kingdom

    FLI Precast Solutions (formerly FLI Carlow) provide design, engineering and manufacturing services for the off-site manufacture of specialist concrete infrastructure and attenuation systems. Our markets include Water, Wastewater, Energy and Storm Attenuation in the UK & Ireland and bespoke projects globally. SERVICES INCLUDE Design, engineering and manufacturing services for the off-site manufacture of specialist concrete infrastructure and attenuation systems. Design to national and international water industry standards and our semi-precast modular designs make us the industry leader in off-site concrete engineering and manufacture. By early involvement and integrating with our clients’ design teams we can accelerate and improve design optimisation and reduce cost. The value is in the solution, and off-site manufacturing and fabrication leads to higher efficiencies and lower risks and costs. Framework agreements enable us to add more value through collaboration, innovation, economies of scale, supply chain partnering and cost management. Our products and designs are engineered to provide solutions to many challenges facing our clients: water retention, water storage, water conveyancing, water management, water treatment, fire-resistance criteria, chemical resistance parameters, infrastructural products, retaining walls, coastal erosion, decorative walls, to name a few. We are a solutions provider using innovative off-site concrete engineering and our industry leading semi-precast modular designs. The company is part of the FLI Group which is a diversified group of companies providing environmental solutions, services and technologies to private and public sector customers in the UK, France, Ireland and throughout the world. PRODUCTS INCLUDE Service reservoirs Process settlement tanks (PST / HST / FST / etc) Storm & attenuation tanks (network or site based) Process structures (ASP / TSR / GAC / RGF / etc) MCC service foundations Bund wall system Chambers Channel & lids Comms chambers Multi-purpose chambers Bespoke culverts Holding tanks Barriers Demountable fence supports (international airport approved) Ballast blocks Dry flow channelling Foundation bases Blast fence supports

    Precast Concrete
    Concrete Works
    Gardner Denver Ltd – Robuschi logo

    Gardner Denver Ltd – Robuschi

    United Kingdom

    In a competitive and evolving global market, our long history of supplying aeration equipment in wastewater treatment plants that best meets customer specific requirements, makes Robuschi a trusted and reliable partner for the environmental industry. Cost-effective solutions for new plants or refurbishments of existing installations are a major focus of our product excellence and application expertise. Therefore, as a global supplier of environmental solutions, we lead the market in developing innovative technologies that support our customers in reducing life cycle costs, increasing efficiency, meeting legal requirements and, finally, improving the quality of product or services they want to provide to their own customers. In wastewater treatment plants, power consumption mainly comes from aeration machines. Robuschi supplies PD blowers and screw blowers, able to provide significant energy saving, depending on plant configuration. Additionally the Robox Energy combines the technological advantages of Robuschi screw compressor and permanent magnet motor with Smart Process Control tool to halve wastewater treatment plant running costs. Ecological sustainability is part of the Robuschi strategy, focusing on promoting environmentally friendly promoting, enhancing energy saving and protecting natural resources.

    Treatment Process Technologies
    Gearing Recruitment Solutions (GRS Ltd) logo

    Gearing Recruitment Solutions (GRS Ltd)

    United Kingdom

    Gearing Recruitment Solutions (GRS Ltd) is a leading technical recruitment agency with over 20 years of experience in the industry. Our team of experts specialises in providing white-collar permanent and freelance recruitment solutions for construction and water industries. We have supported large tier one M&E contractors through to local regional-based businesses in construction, ensuring that the companies we partner with share similar values and principles to us. This ensures that the candidates we place have the best opportunity to progress and develop in their careers. In the water industry, we have extensive experience in MEICA engineering for large industrial contracts and have recruited for top Tier 1 civils and infrastructure companies within construction, maintenance, and consultancy engineering. We have also partnered with large and regional MEICA contractors to provide recruitment solutions for AMP frameworks across the UK, including Thames Water, Southern Water, Severn Trent, United Utilities, and Scottish Water. Our recruitment services include positions such as: M&E Construction: Senior Appointments/Directors M&E Operations Manager Mechanical Project or Contracts Managers Electrical Project or Contracts Managers M&E Estimators, M&E Quantity Surveyors M&E Supervisors M&E Managers for main contractors Water: Directors Framework Managers Proposal Managers/Estimators, MEICA Managers MEICA Project Engineers Mechanical Supervisors Electrical Supervisors Quantity Surveyors Design Engineers/CAD Commissioning Engineers Process Engineers Health & Safety Sub Agents Civil Engineers At GRS, we pride ourselves on our honesty, true partnership, passion for our sector, and a continuous ambition to improve our technical knowledge. This allows us to perfectly position ourselves to cover all of your recruitment needs.

    Recruitment
    Greenbank Group logo

    Greenbank Group

    United Kingdom

    A specialist engineering company with a global customer base. Greenbank provides a wide range of products and services to companies operating across a number of industries and is now establishing itself in the clean and wastewater sector. For many years the company has utilised the unique properties of volcanic basalt for lining products used in heavy industries such as power generation and minerals extraction. In partnership with Czech firm Eutit, the company has also been pioneering the use of basalt in the renovation and restoration of sewer systems in central European following a series of successful projects in Prague. As a result of devastating floods, the city’s sewer system was extensively rebuilt and upgraded with basalt being used in a number of key locations to provide a new level of security to the system. More than a decade on, the new system continues to perform well and has set a standard that’s now been followed in other European cities. Well suited for the most demanding of applications, thanks to the partnership between Greenbank and Eutit, a wide range of basalt solutions are now available in the UK market. These include products and systems that bring a wide range of benefits to the industry, including: Basalt tiles that can also be used to line existing brickwork, a more cost-effective solution than full replacement, and their reduced drag co-efficient means improved flow – in effect a smaller-diameter pipe or tunnel lined with basalt can carry a higher volume of water than a larger one with traditional brick surfaces. The effective life expectancy of basalt-lined sewer systems is between 100 and 200 years, thanks to their excellent resistance to abrasion and chemical damage – as well as the rigours of high-pressure water jetting that’s often used to clear unwanted blockages. For larger round or ovoid systems, basalt can be used in the lower sections to deal with the wear and tear with concrete upper sections to provide optimum life performance. Alternatively, steel pipes lined with basalt can be produced up to 3000mm diameter producing a lighter therefore lower cost installation option to thick wall concrete. Ease of installation and reduced maintenance costs make basalt ideal for bottom gutters, branch pipes and tubes and slip-resistant elements for walkways, and Greenbank can also supply bespoke-shaped tiles to meet the unique requirements of individual clients. With manufacturing facilities in Derbyshire and Nottinghamshire, supported by the additional capacity and expertise provided by the latest addition to the group, Franklyn Yates Engineering, Greenbank is well placed to react quickly and efficiently to the needs of new and existing clients.

    Gurney Environmental Ltd logo

    Gurney Environmental Ltd

    United Kingdom

    Gurney Environmental is a well established provider of systems and technologies used in the treatment of water and wastewater. From water supply to water re-use, we have designed and developed innovative, low cost and sustainable systems for the water and wastewater industries. Low CAPEX plus low OPEX equals low TOTEX. True sustainability is the benchmark for success with Gurney. We offer unique water and wastewater treatment systems, equipment and design including zero-to-low energy www and reservoir destratification systems. Our experience and knowledge of the water and wastewater treatment industries has successfully helped a wide variety of clients including major landowners (such as the Crown Estate) and many of the UK’s water utility companies. Our systems are today recognised internationally with a growing number of foreign municipals. Gurney has a total commitment to quality. Our systems and solutions represent the finest in long-term value, which is why we place such a strong emphasis on equipment with sturdy construction and fewer moving parts. Our commitment to a low total life cost is a key part of a commitment to quality.

    Treatment Process Technologies
    Haigh Environmental Company Ltd (Part of the Haigh Group Ltd) logo

    Haigh Environmental Company Ltd (Part of the Haigh Group Ltd)

    United Kingdom

    Suppliers of FujiClean Sewage Treatment Systems & Manufacturers of Inlet Screeners Haigh Environmental is part of the Haigh Group Ltd, an established provider of specialist water and waste services in the UK, employing around 120 people. Providing next-generation water treatment solutions that protect our waterways for future generations is at the heart of our business. Driven by impact, not profit, we pride ourselves on our open-minded, transparent approach, taking a long-term view on the right solutions for our clients and local communities. We supply a range of screens and package water treatment plants, including the pioneering FujiClean system – with excellent results across all relevant metrics. Simplicity is at the heart of our value proposition. As a response to increased environmental permit requirements, complex solutions have emerged across the water industry in a piecemeal fashion, often leading to non-standardised, expensive and over-engineered systems. Working together with utility companies, contractors and communities, we are leveraging the expertise of our experienced team to offer practical, cost-effective and standardised alternatives to septic tanks and conventional chemical dosing treatment options.

    Designers
    Accreditations
    Hewitech UK Ltd logo

    Hewitech UK Ltd

    United Kingdom

    Hewitech UK Ltd operate in the Stormwater, Wastewater and Cooling Towers markets in the UK Hewitech  design, manufacture and supply a comprehensive range of products for use in the wastewater, stormwater retention and infiltration, and cooling tower industries. Our structured media filters for biological wastewater treatment applications are suitable for both municipal and industrial waste and potable water, with our products being used for: BOD treatment and nitrification in trickling filters (NTF) Submerged aerated filters (SAF) Biologically activated fixed film filters (BAFF) Primary sedimentation through lamella, in new and existing applications. Hewitech’s SuDS systems for stormwater retention and infiltration are the strongest available in the stormwater market, proven by rigorously testing for long term performance. While our comprehensive range of plastic media fill, air louvres and drift eliminators have the high module strength, thermal efficiency, and excellent material temperature performance to meet all cooling tower applications. Our product range includes: HewiFILL HewiPIER HewiTUBE Variobox Hewitech work closely with consultants, designers, architects and engineers to ensure smooth design and install on all projects.

    Stormwater Storage
    Hydro International logo

    Hydro International

    United Kingdom

    Hydro International, a CRH company,  provides advanced products, services and expertise to help municipal, industrial and construction customers to improve their water management processes, increase operational performance and reduce environmental impact. Hydro International can help water companies meet their AMP and environmental obligations, including the reduction of sewer overflows and the Water Industry National Environment Programme (WINEP). Hydro International provides total solutions for Inlet Works, Combined Sewer Overflows (CSOs), Stormwater Management, Flood Warning and Prevention, and Water Resource management, from design to supply and installation through to ongoing preventative maintenance, servicing and emergency repair.  These solutions include: Hydrometric data collection, monitoring analysis and reporting for river level, reservoir, network and weather. Continuous water quality monitoring for compliance with Section 82 of the Environment Act. Water resource analysis and consultancy. Stormwater management solutions, including options for Sustainable Drainage Systems. (SuDS) and Smart Maintenance. CSO event duration monitoring. CSO and storm tank treatment and screening. Passive flow controls for flood prevention schemes, SuDS, CSOs and WwTWs. Inlet works screening and grit removal solutions. Sludge screening. Dropping sewage or water safely from height. Hire, repair and maintenance of inlet works screens and screenings handling equipment

    Networks - Sewerage
    Asset Maintenance & Rehabilitation
    PBJ Engineering Services Ltd logo

    PBJ Engineering Services Ltd

    United Kingdom

    Do you need Thermal Hydrolysis Plant operational support, training and maintenance? Does your critical water process equipment require contract support and safety assurance? Visualise your assets and maintain operational efficiency through our 360 degree image capture. Invest in your operations through our professional training and technical support services. PBJ Engineering delivers a range of services to support your wastewater treatment and process facilities – we specialise in THP systems and Steam Boiler services, including CEA and BOAS accreditation.  Our team is available nationally to support you, on a contract, project or emergency basis. Supporting your facility and team with a programme custom designed to your needs, typically includes elements of: Whole System Contracts Consultation and Best Practice Commissioning and Maintenance Optimisation and Monitoring Refurbishment and Rebuild Component Fabrication and Supply Training for BOAS and CEA accreditation Some of our typical on-site activities include full capabilities in; Thermal Hydrolysis Plants Steam Boilers Sludge Dewatering Processes Water Treatment Coil and Heat Exchangers Pumps Our ancillary support services includes; 360O Image Capture – Virtual Plant Training and Maintenance Boiler Log Books – Custom design & print Boiler House design – Advice and guidance Equipment – Hire services and component spares Our priority is the safety of all personnel and the operational efficiency of your facilities.  We work with you and your team, to maintain and support your infrastructure – protecting your people, investment and optimising your asset performance. Our team is qualified with CITB / SMSTS, Achilles, and CEA / BOAS. Project involvement includes: Thames Water: Basingstoke THP (commissioning, operation, training, optimisation, maintenance) Beckton THP (energy surveys) Chertsey THP (operation, training, optimisation) Crawley THP (commissioning, operation, training, maintenance, part supply) Crossness THP (operation, optimisation, energy reduction, training, energy surveys) Longreach THP (operation, training, optimisation) Oxford THP (operation, optimisation, fault finding) Riverside THP (water treatment installation, design, energy surveys) Severn Trent: Finham THP (operational support) Strongford THP (operation, training) Southern Water: Goddards Green THP (operational support & performance monitoring) Others: Nestles – Trowbridge – steam boiler operational contract (24 hour call out) Heathrow airport – hot water boiler – scale cleaning

    Renewables & Energy Management
    Asset Maintenance & Rehabilitation
    PLR Building Services Ltd logo

    PLR Building Services Ltd

    United Kingdom

    Here at PLR Building Services, our team brings extensive experience in the water industry, specialising in top-tier electrical installation work for framework companies across the utility companies. Our primary focus is on ensuring compliance with regulatory requirements for water systems. We offer a comprehensive electrical design package and project management services. Our team is equipped with the latest health, safety, and electrical qualifications to meet all your project requirements efficiently. As a NICEIC approved contractor, we excel in both new systems installation and the refurbishment of existing installations. Water treatment Wastewater treatment Sludge treatment Pumping stations Reservoirs Inspection Testing Electrical Design Project managing

    Contractors
    Water Pumping Stations
    Technocover Ltd logo

    Technocover Ltd

    United Kingdom

    Technocover is an approved ISO 14001:2004 Environmental and ISO 9001:2008 Quality Accredited Company, dedicated to the Design, Manufacture, Installation and Maintenance of Physical Security Access Solutions for protection to all industrial sectors. Our extensive in-house design and manufacturing facilities are home to well established research and development unit and comprehensive testing facility. Our commercial offices incorporate our design team who utilise the latest computer aided design technology and work alongside our dedicated planning section who oversee everything from surveying, scheduling and contract reviews, to the management of framework agreements. We have been designing and manufacturing innovative steel products since 1993. In that time, through organic growth, planned expansion and acquisition, we have gained a reputation as the UK’s leading supplier of Physical Steel Security Access Products. We have a range of aperture security solutions for virtually every application, establishments in the UK and overseas have sought our expertise in providing security products for asset protection. We operate a Total Service Philosophy and can handle complete projects from site survey to final installation, whether for new or refurbishing projects, the adaptability of our galvanised steel access products means the most complex design criteria can be met. Our range of high quality access products offer custom built operational and security solutions to prevent unauthorised persons gaining access, securing key assets against all levels of trespass, malicious vandalism, theft, extortion, contamination or terrorism. Many of our access system products have been tested and approved by the Loss Prevention Certification Board (LPCB)  to LPS 1175 issue 5 or above, Security Rating Levels 2, 3, 4 or 5. Frameworks We hold both exclusive and shared framework agreements with most of the major UK water companies. Framework Security items include: LPCB Level 2 Universal Gas Cylinder Clamps LPCB Level 3 Mesh Cage Systems LPCB Level 3 Flush Access Covers LPCB Level 4 Upstand Access Covers LPCB Level 4 Padlockable Access Doors LPCB Level 4 Key Entry Doors LPCB Level 4 Enclosures/Kiosks/Cabinets LPCB Level 4 Walk-In Modular Buildings LPCB Level 4 Window Bar Sets LPCB Level 5 Louvres

    Security Solutions
    Asset Maintenance & Rehabilitation
    Total Automation & Power logo

    Total Automation & Power

    United Kingdom

    Total Automation & Power (TAP) is a formal joint venture between Cougar Automation Ltd and Technical Control Systems Ltd. Formed in 2005, it has delivered hundreds of projects worth tens of millions of pounds. Current water and wastewater frameworks include Severn Trent, Thames, Welsh & Yorkshire Water. Working with TAP is just like working with a single company. Every project has a dedicated project manager who coordinates all the work and gives you a single point of contact. You place a single order for all of your electrical and control system design, supply and installation so you can concentrate on delivering your project without having to worry about placing and managing separate orders for MCCs, a control system and electrical installation. Unlike separate orders, both companies stand behind the whole scope and unlike a contract/sub-contract arrangement we don’t mark up each other’s price. Projects are easy to manage, secure and competitively priced. Supporting clients from initial concept design stage through to on-site commissioning, TAP collaborates with clients at every stage to evaluate designs to optimise TOTEX outcomes. When you choose TAP as your partner you get an unrivalled combination of expertise: Control System, SCADA & PLC expertise from Cougar Automation in six regional offices throughout the UK. MCC, low voltage assembly and panel expertise from Technical Control Systems’ manufacturing facility in Leeds.

    Networks - Sewerage
    Asset Maintenance & Rehabilitation
    Veolia Water Technologies UK logo

    Veolia Water Technologies UK

    United Kingdom

    Veolia Water Technologies (VWT) provides an unrivalled combination of capabilities in the UK for the treatment of water, wastewater, sludge and odour. VWT provide turnkey solutions from feasibility studies, design and build and supply and installation of packaged treatment solutions, through to the extension or refurbishment of existing water and wastewater facilities. The company’s investment in Research & Development focuses on developing the most innovative solutions for its municipal and industrial clients, while at the same time considering the environmental challenges being faced. VWT’s goal is to develop sustainable and technologically superior solutions that balance the demand for efficient and cost effective technology whilst protecting the environment by looking at energy consumption, carbon emissions, odour pollution and safe guarding water quality. With over 125 years of experience in the UK, VWT is able to draw upon an unsurpassed knowledge of traditional and innovative solutions in order to meet the demands of both industrial and municipal clients. Performance is measured by the global satisfaction of VWT’s customers. Their technical creativity is reflected by a prestigious track record of extensive references in the UK and across the world supported by operational experience. A partnership with VWT provides the unique benefits of technical excellence, innovation, reliability and a trusted partnership. VWT offers a range of proprietary technology for applications to treat Drinking Water, Wastewater, Sludge Treatment, Odour Treatment and Industrial Effluents.

    Treatment Works Products/Services
    Asset Maintenance & Rehabilitation
    Waterco logo

    Waterco

    United Kingdom

    Waterco are engineering and environmental consultants providing design and consultancy services relating to water, drainage and flood risk. We have expertise in engineering and environmental disciplines and are supplemented by a network of specialist independent consultants with extensive experience in major development projects throughout the UK. Our focus is on achieving the optimum solution for our clients, meeting their objectives and adding value to their projects. We have gained a reputation for a friendly, professional and flexible approach since our establishment in 1990. Our Services Water industry infrastructure and non-infrastructure projects Pipelines & Sewerage Water & Wastewater Treatment & Systems Pumping Stations Contingency Planning Security Assessments Asset Management Surge Analysis Hydraulic Modelling Flood Risk Assessment Breach Analysis Coastal & Shoreline Analysis Surface Water Management Sustainable Drainage Systems Natural Flood Management/Catchment Approaches Clients and Partners Our clients and partners include water companies, consultants and contractors. Incorporating their experience and knowledge, we investigate and develop practical designs, to help deliver cost-effective solutions. Geographic Coverage We undertake projects all across the UK, with many of our reporting services being desk-based, travelling to site visits and meetings as required. We have also been involved in international projects such as a major development in Lekki, Nigeria. Accreditations We currently have an ISO 9001 : 2015 accredited Quality Management System; have a BS8555 : 2003 certified Environmental Management System; have design approval in the Water Industry Registration Scheme (WIRS); have maintained Investors in People recognition since 2011 and operate an ICE approved training scheme.

    Designers
    WEW Engineering Ltd logo

    WEW Engineering Ltd

    United Kingdom

    WEW Engineering Ltd is a specialist Consulting Engineering design and management firm focused on sustainable, energy-efficient water and wastewater treatment, including waste-to-energy projects, both industrial and municipal. The company is run by its three founding shareholders, Seamus Crickley, Henk van der Puil, and Tony Mahon, supported by a team of talented engineers and CAD technicians. Our highly professional team comprises specialist Water Chemists, Chartered Engineers, Master Planners, Field Specialists, and 3D CAD Designers. In-house water engineering specialities include chemistry and process design, with integrated mechanical electrical instrumentation and automation engineering services, all available for each project. We are recognised as international experts in this area of Engineering practice. WEW Engineers have been applying cutting-edge technologies in the Water, Energy and Wastewater sectors, both Municipal and Industrial, for over 45 years.

    Project Planning & Surveying
    Contractors
    Wilson Power Solutions Ltd logo

    Wilson Power Solutions Ltd

    United Kingdom

    Powering and Transforming Sustainable Water Infrastructure Our transformers play a crucial role in the water sector, ensuring the smooth operation of wastewater treatment works (WwTW), sewage treatment works (STWs), and water treatment works (WTW). By adjusting voltage levels to power water pumps, motors, and other equipment, they ensure optimal performance across all systems. In addition to voltage regulation, transformers guarantee reliable power delivery to critical water infrastructure, preventing service downtime, such as water distribution and water treatment. Moreover, Transformers like Wilson e4 contribute to increased energy efficiency by optimising power usage, reducing energy losses, and supporting sustainable practices in water utilities. We understand the main challenges in the water market sector: Energy efficiency aims to reduce costs and minimise environmental impact. Grid stability is crucial, and transformers safeguard a steady power supply for water infrastructure and seamless service delivery Ageing infrastructure requires urgent upgrades with modern transformers enhancing efficiency and reliability, minimising the risk of outages or failures. We are a leading provider of transformer solutions, including in the water sector. With decades of expertise, we deliver tailored, reliable, high-quality transformer systems for water treatment plants, wastewater facilities, and critical infrastructure.

    Power Supply

    Industrial Wastewater Treatment Plant Design: Load Characterisation, Process Selection, and Discharge Compliance

    Industrial wastewater treatment plant (IWTP) design begins with comprehensive effluent characterisation: flow measurement (instantaneous, average, peak hour, and total daily), BOD5 and COD (including COD:BOD ratio indicating biodegradability - below 2 indicates readily biodegradable, 2 to 5 is moderately biodegradable, above 5 indicates recalcitrant compounds), suspended solids, nutrients (TN, TP), pH range (typically 4 to 11 for industrial), and specific contaminants (heavy metals, hydrocarbons, solvents, priority substances). Design flow for plant sizing is typically 1.5 to 2.0 times average daily flow for biological processes and 2.5 to 3.0 times average daily flow for physical-chemical processes to accommodate peak hydraulic loads without process upset.

    Process selection follows contaminant type. High-BOD organic wastewater (food and beverage, pulp and paper, brewing): aerobic activated sludge (conventional or sequencing batch reactor, SBR) or anaerobic digestion at above 2,000 mg per L COD for energy recovery. High-nitrogen effluents (fertiliser, food processing): nitrification-denitrification with anoxic zones (Modified Ludzack-Ettinger, 4-stage Bardenpho). Heavy metals: chemical precipitation at optimum pH, coagulation-flocculation, and sludge dewatering. High TDS brines: ZLD by crystalliser or evaporation. Hydrocarbon-contaminated: air flotation (DAF at 30 to 50 microns bubble size) for oil removal plus biological treatment for dissolved fraction. MBBR and MBR are increasingly preferred for brownfield retrofit where footprint is constrained.

    Regulatory compliance is driven by discharge consent conditions: direct discharge to surface water (permit from Environment Agency in UK, state NPDES permit in US) specifies limits for BOD, SS, COD, ammonia, pH, and sector-specific pollutants. Discharge to sewer (trade effluent consent from water company or industrial pretreatment permit in US) specifies limits upstream of the municipal WWTP. Non-compliance penalties: Environment Agency prosecutions lead to fines of $10,000 to $1M plus remediation costs; US Clean Water Act violations up to $37,500 per day per violation. Environmental management systems (ISO 14001) reduce non-compliance risk by formalising effluent monitoring, permit condition tracking, and process control responses.

    Frequently Asked Questions

    What industrial effluent requires its own treatment plant?

    Industries with wastewater that cannot be discharged directly to sewer without pretreatment include: food and beverage (high BOD, typically 1,000 to 10,000 mg per L vs 250 to 500 mg per L sewer limit); electroplating (heavy metals and cyanide, above trade effluent consent limits); pharmaceutical (active pharmaceutical ingredients, solvents); petrochemical (hydrocarbons, TPH); tanneries (chromium, high TDS); semiconductor (metals, fluoride, IPA); and landfill (high COD, ammonia, variable heavy metals). Most water companies set trade effluent consent limits triggering pre-treatment: BOD above 500 mg per L, SS above 500 mg per L, pH outside 6 to 10, specific substances (chromium, cyanide, mercury) above agreed limits. Failure to treat before discharge is an environmental offence under Water Industry Act 1991 in the UK.

    What is the difference between aerobic and anaerobic wastewater treatment?

    Aerobic treatment (activated sludge, biofilm systems) uses oxygen-consuming bacteria to oxidise organic compounds to CO2, water, and new biomass. Achieves BOD removal above 95 percent, producing sludge at 0.3 to 0.5 kg dry solids per kg BOD removed. Requires continuous aeration (energy 0.5 to 1.5 kWh per kg BOD at 2 to 4 mg per L dissolved oxygen). Anaerobic treatment (UASB, EGSB, anaerobic lagoon) degrades organics without oxygen, producing biogas (60 to 70 percent methane, energy value 22 MJ per m3) and much less sludge (0.05 to 0.10 kg DS per kg COD). Economic for COD above 2,000 mg per L where biogas revenue offsets capital cost. Anaerobic is cost-effective at large scale and high-strength waste; aerobic follows as a polishing step to achieve discharge standards (aerobic effluent BOD below 20 mg per L vs anaerobic effluent BOD 100 to 500 mg per L).

    How do you meet zero liquid discharge for industrial wastewater?

    Zero Liquid Discharge (ZLD) eliminates all liquid effluent from a facility, recovering water for reuse and concentrating dissolved solids to a solid or paste. The treatment train: (1) Conventional pretreatment (coagulation, biological treatment) to remove organics and suspended solids; (2) Reverse osmosis to recover 70 to 80 percent of water at low energy cost (3 to 6 kWh per m3); (3) Brine concentration by High-Efficiency Reverse Osmosis (HERO, pH 10 to 11 to prevent scaling) or Mechanical Vapour Recompression (MVR) evaporator to 15 to 20 percent TDS (energy 10 to 20 kWh per m3 of water recovered); (4) Crystalliser to produce dry salts for disposal or sale (energy 50 to 80 kWh per m3 of final brine). ZLD capital cost is $2M to $50M for 1,000 to 10,000 m3 per day; applicable where discharge prohibition, water scarcity, or salt value (lithium, sodium sulphate) justifies the capital and operating cost.

    How is industrial wastewater sludge managed?

    Industrial wastewater sludge composition and quantity depend on the treatment process: chemical precipitation sludge contains metal hydroxides (heavy metals, up to 25 percent dry solids metal content) and must be characterised as hazardous if TCLP metals exceed thresholds. Biological sludge from activated sludge contains 60 to 80 percent volatile solids and 1 to 3 percent total solids in secondary clarifier underflow. Sludge handling sequence: thickening (gravity belt or drum thickener, from 0.5 to 3 to 4 to 6 percent DS), dewatering (belt press to 15 to 25 percent DS, screw press to 20 to 30 percent DS, centrifuge to 20 to 35 percent DS), and disposal (landfill for hazardous, anaerobic digestion then land application for non-hazardous biological sludge, incineration for pharmaceutical or contaminated sludge). Disposal cost: industrial hazardous sludge $200 to $600 per tonne, non-hazardous $50 to $150 per tonne.

    Case Study·Pharmaceutical manufacturing
    Challenge

    A pharmaceutical API manufacturer in the East Midlands discharged a mixed effluent stream (6,000 mg per L COD, pH 4 to 9 swing, trace solvents including acetonitrile and THF) under a water company trade effluent consent with a COD limit of 500 mg per L. Solvent spikes caused consent breaches and the water company had issued a formal notice under Water Industry Act 1991 Section 125.

    Approach

    Installed a two-stage treatment plant: neutralisation tank with automated pH dosing followed by UASB reactor achieving 70 percent COD removal, then a 4-stage Bardenpho activated sludge system for polishing to below 200 mg per L COD. Solvent segregation and batch neutralisation upstream eliminated pH swings. Solvent recovery by distillation was installed on high-strength solvent streams to reduce load to the IWTP.

    Outcome

    Effluent COD consistently below 300 mg per L over 24 months of operation. No consent breaches in the period following commissioning. Biogas from the UASB (280 m3 per day at 65 percent methane) was captured and used in the site boiler, displacing 3,500 GBP per month of natural gas. Sludge production from biological treatment was 60 percent lower than a fully aerobic alternative due to the anaerobic pre-stage.

    Questions to Ask Shortlisted Providers

    1. 1

      Have you characterised our effluent across the full range of production campaigns, not just during steady-state, and what is your design basis for peak hydraulic and peak load events?

      Industrial effluent variability is the single biggest source of IWTP underperformance. A plant sized for average conditions will fail during peak production campaigns or solvent changeover events. Ask for the design peak factor (typically 1.5 to 3 times average flow, 2 to 5 times average COD load) and how the plant manages these events without consent breach.

    2. 2

      What is the biodegradability of our specific compounds and does your process design account for any recalcitrant or inhibitory substances?

      Standard biological treatment fails for effluents with COD:BOD above 3 to 4, or for effluents containing compounds toxic to biological treatment such as antibiotics, heavy metals, or chlorinated solvents. If your effluent contains these, biological treatment must be pre-treated or supplemented with advanced oxidation. A designer who quotes biological treatment for a solvent-heavy effluent without toxicity testing is under-scoping the problem.

    3. 3

      What trade effluent consent limits apply to our discharge point, and have you confirmed with the receiving water company that the proposed plant design will consistently meet those limits?

      Trade effluent consents are site-specific and water-company-specific. Some consent limits include time-averaged limits and instantaneous never-to-exceed limits. A plant design should demonstrate, by treatability testing and modelling, that it meets both the average and the worst-case instantaneous limits. Consent breaches attract surcharges or formal notices under Water Industry Act 1991 Section 125 and can lead to supply termination.

    4. 4

      What sludge quantity and classification do you expect, and have you confirmed disposal routes and costs for the specific sludge composition?

      Industrial sludge disposal cost depends heavily on hazardous waste classification. Heavy metal precipitation sludge from electroplating is hazardous waste at 300 to 600 GBP per tonne. Biological sludge from a food-industry IWTP may be non-hazardous at 50 to 100 GBP per tonne. An IWTP design without confirmed sludge disposal route and cost can produce a plant that is technically compliant but economically unviable.

    5. 5

      What online monitoring and automated response does the plant include to detect and prevent consent breaches before effluent leaves site?

      Online COD monitors, TOC analysers, and pH sensors on the effluent channel provide early warning before discharge to sewer. An automated emergency diversion to a holding tank prevents consent breaches during process upsets. Ask specifically whether the plant includes a consent-compliance monitoring system and an automated response to detected limit exceedances.

    What Drives Cost in This Category

    Effluent COD concentration and biodegradability

    Capital cost of an IWTP scales approximately with organic load. A plant treating 100 m3 per day at 1,000 mg per L COD (100 kg COD per day) costs 200,000 to 600,000 GBP. The same flow at 5,000 mg per L COD costs 800,000 to 2,000,000 GBP due to larger reactor volumes, more sludge dewatering capacity, and additional treatment stages. Non-biodegradable COD requiring advanced oxidation adds 50 to 200 percent to capital cost.

    Trade effluent surcharge avoided

    Water companies in the UK charge trade effluent surcharges proportional to the strength and volume of discharge above standard consent strength (Mogden formula). A 100 m3 per day discharge at 2,000 mg per L COD and 500 mg per L SS may attract annual trade effluent charges of 30,000 to 80,000 GBP. An IWTP reducing discharge COD to 200 mg per L and SS to 100 mg per L can reduce trade effluent charges by 70 to 85 percent, with payback of 3 to 7 years on capital investment.

    Sludge disposal cost

    Sludge disposal is typically 20 to 40 percent of IWTP operating cost. Chemical precipitation sludge from electroplating is hazardous waste at 200 to 600 GBP per tonne, contributing 50,000 to 200,000 GBP per year for larger sites. Biological sludge from food industry IWTPs is non-hazardous at 50 to 120 GBP per tonne. Sludge dewatering with a centrifuge or belt press (capital 50,000 to 300,000 GBP) reduces disposal volume by 5 to 10 times.

    Energy cost for biological treatment

    Aerobic biological treatment requires aeration at 0.5 to 2.0 kWh per kg BOD removed. For a 1,000 kg BOD per day IWTP, annual aeration energy costs 50,000 to 200,000 GBP at 0.15 to 0.20 GBP per kWh. Anaerobic pre-treatment at COD above 2,000 mg per L reduces net energy cost by recovering biogas energy and reducing aerobic treatment load by 60 to 80 percent.

    Key Regulations & Standards

    Water Industry Act 1991 -- Trade Effluent Consent

    Under Water Industry Act 1991 Section 118, any non-domestic discharge to the public sewer requires a trade effluent consent from the sewerage undertaker. Consent specifies maximum flow, strength limits (COD, BOD, SS, pH, specific contaminants), and timing restrictions. Discharge without consent or in breach of consent conditions is an offence under WIA 1991 Section 118(5), punishable by fine up to 20,000 GBP per incident in magistrates court or unlimited fine at Crown Court.

    Environmental Permitting Regulations 2016 -- Direct Discharge to Surface Water

    Industrial facilities discharging treated effluent directly to surface water require an environmental permit from the Environment Agency under EPR 2016. The permit specifies discharge limits aligned with Water Framework Directive receiving water quality standards. Non-compliance triggers permit review, enforcement notices, and prosecution. Large discharges are subject to WFD objectives for achieving Good Ecological Status, which may require more stringent limits than technology-based standards.

    EU Industrial Emissions Directive 2010/75/EU (retained in UK)

    The IED applies to large industrial installations above specified capacity thresholds for energy, chemicals, waste management, and intensive agriculture. IED requires application of Best Available Techniques for pollution prevention including wastewater treatment. BAT Conclusions for relevant sectors specify minimum wastewater treatment performance and monitoring requirements. IED installations must comply with Environmental Permit conditions incorporating BAT-based effluent limits.

    COSHH Regulations 2002 -- Hazardous Effluent Handling

    IWTP operators handling industrial wastewater containing hazardous substances (solvents, acids, alkalis, heavy metals) must conduct COSHH assessments for operator exposure risk. Confined space entry into IWTPs requires a confined space permit under the Confined Spaces Regulations 1997. Chemical storage for treatment reagents (coagulants, acids, anti-scalants) requires risk assessment, appropriate PPE, and emergency spill response procedures per COMAH 2015 where threshold quantities are exceeded.