This is an illustrative scenario showing how Reynolds & Bauhm equipment can be configured for this application. Every site has unique requirements — contact us for a solution tailored to your specific wastewater characteristics.
Medium-sized dairy processing plant generating 450 m3/day of effluent with fat 800 mg/L, protein 1,200 mg/L, COD 6,500 mg/L, and variable pH 5-9 due to CIP cycles. Discharge to municipal sewer requires COD <1,000 mg/L and fat <50 mg/L. Client wants to recover fat and protein for biogas valorization.
Step-by-step process configuration from raw wastewater to compliant discharge.
2 mm wedge wire screen removes large solids. Equalization tank with pH monitoring and automated acid/alkali dosing maintains 6.5-7.5 pH range for downstream advanced biological treatment.
Dissolved air flotation with cationic polymer coagulant recovers 85% of fats and proteins as float sludge. Float concentrate at 8% solids pumped to anaerobic digester as biogas feedstock. DAF effluent fat <50 mg/L.
Expanded Granular Sludge Bed reactor converts 70% of organic load to biogas at 35°C. Upflow velocity 4 m/h. Biogas production 1,200 m3/day replacing 40% of natural gas demand. Effluent COD 1,800 mg/L.
Moving bed biofilm reactor with 60% carrier fill removes residual organics. Fine bubble aeration. 12-hour HRT. Final COD <400 mg/L, BOD <80 mg/L. Nitrogen nitrification achieved.
Excess biological sludge dewatered via multi-disc screw press to 20% solids. Combined with DAF float for biogas co-digestion. Dewatering filtrate returned to equalization. Overall energy-positive operation.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
High-rate DAF with fat skimmer, 25 m3/h, cationic polymer dosing, SS construction.
View Equipment35°C anaerobic reactor, 200 m3, granular sludge bed, biogas collection, pH control.
View EquipmentAerobic biofilm reactor, 80 m3, HDPE carriers, fine bubble diffusers, 12h HRT.
View EquipmentMulti-disc press, 80 kgDS/h, 18-22% cake solids, biogas-optimised operation.
View EquipmentRepresentative performance data based on typical operating conditions for this equipment configuration.
Explore the full range of equipment used in this and similar applications.
Discover how these treatment processes connect to form complete wastewater treatment solutions.
Reynolds & Bauhm follows a structured engineering methodology for every project. We begin with detailed wastewater characterisation, process selection based on contaminant profiles, pilot testing where required, and full-scale design with performance guarantees. Our multidisciplinary team of chemical, mechanical, and electrical engineers ensures seamless integration of process, mechanical, and control disciplines.
Comprehensive influent analysis including COD, BOD, TSS, heavy metals, pH, temperature, and flow profiling.
Process flow development with P&IDs, mass balances, and hydraulic modelling validated by CFD where appropriate.
On-site pilot trials validate performance guarantees under actual operating conditions before capital commitment.
FAT, SAT, performance trials, operator training, and handover documentation ensuring operational readiness.
| Pre-Treatment | Screening, grit removal, and flow equalisation |
| Primary Treatment | DAF or lamella clarification for solids and oil removal |
| Secondary Treatment | Biological oxidation (activated sludge, MBBR, or SBR) |
| Tertiary Treatment | Filtration, UV disinfection, or chemical polishing |
| Sludge Management | Thickening and dewatering via belt press or centrifuge |
| Control System | PLC with HMI touchscreen and optional SCADA integration |
| Chemical Dosing | Automated coagulant, flocculant, and pH correction |
| Materials | SS316L, duplex, or rubber-lined carbon steel |
85 – 98% chemical oxygen demand reduction depending on process configuration and influent variability.
90 – 99% suspended solids reduction through combined physical and biological treatment stages.
Tertiary treatment enables up to 80% water recycling for non-potable process applications.
Our engineers will adapt this equipment configuration to your specific wastewater analysis, flow rate, and discharge requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.