The Polish city of Tomaszów Mazowiecki, with its 80,000 residents, faced a pressing issue with its ageing wastewater treatment plant. Originally built in the 1970s, the plant was struggling by the 2000s. Maintenance costs were soaring, energy consumption was high, and meeting effluent quality standards was increasingly challenging.
The Need for Change
The existing system was described as “technologically obsolete,” with outdated aerators consuming excessive energy—about 80% of the total—while providing insufficient oxygen. This inefficiency highlighted the urgent need for a comprehensive overhaul to meet modern standards and improve performance.
To address these issues, the city secured EU funding to revamp the plant. In 2013, the Budimex-Cadagua consortium was awarded the contract to design and build a new chemical and biological treatment facility. A key challenge was designing energy-efficient systems for the new shallow tanks, which were only 3.9 meters deep.
Grundfos’s Role in the Solution
From the outset, Grundfos was integral to the project. The company provided crucial equipment, including pumps, grundfos dosing pumps, booster pumps, and all the necessary components for the bioreactors—such as aeration grids, mixers, and blowers. Additionally, Grundfos was responsible for the design, sub-supply, and assembly of the bioreactors.
The design process was rigorous, utilizing computational fluid dynamics (CFD) modelling and simulations. This advanced technique allowed for the optimization of flow paths, mixing performance, and overall system efficiency, ensuring that the bioreactors would perform at their best.
Impressive Outcomes
The results of the modernization are noteworthy. The upgraded plant now ranks among the few biological treatment facilities in Poland capable of achieving nitrogen levels of 4-5 mg/l and phosphorus levels of 0.4 mg/l in the treated effluent. This performance is a testament to the effectiveness of Grundfos’s equipment and design.
The impact on energy consumption has been substantial. The modernization of the blowers and aeration system alone led to a 50% reduction in energy use. The efficiency of the aeration system is particularly significant, allowing the plant to maintain optimal parameters even during hot weather conditions.
The treated water is discharged into the Pilica River, a major tributary of the Vistula River, flowing through a nature reserve located about 800 meters from the plant. Remarkably, the quality of the treated effluent now surpasses that of the river water, illustrating the plant’s enhanced performance and its positive impact on the local environment.
Conclusion
The transformation of Tomaszów Mazowiecki’s wastewater treatment plant highlights the profound impact of advanced technology and effective partnerships. With Grundfos’s expertise, the plant has not only met but exceeded its treatment goals, setting a new benchmark for wastewater management in Poland.
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