Chemical Industry Wastewater | Advanced Treatment Retrofit | EPC Delivery

1. Project Overview

The BlueStar (Chengdu) New Materials Wastewater Treatment Upgrade Project is a key environmental retrofit project for a high-end chemical manufacturing facility in China.

The project focuses on upgrading an existing wastewater treatment system to match increased production capacity and stricter environmental discharge requirements. The facility produces high-performance aramid fiber materials, generating complex industrial wastewater containing high COD, high salinity, and refractory organic compounds.

Through targeted process optimization and system retrofitting, the project significantly enhances treatment stability, compliance performance, and operational efficiency.

2. Project Information

3. Client Challenges

The client faced complex wastewater treatment challenges associated with high-end chemical production:

• Highly acidic wastewater requiring multi-stage neutralization

• Refractory organic compounds with low biodegradability

• High COD and high salinity wastewater characteristics

• Strong fluctuations in water quality and flow rate

• Aging treatment system with insufficient capacity

• Increasingly strict environmental discharge regulations

• Requirement for resource recovery and system stability

Core Challenge:
Develop a robust and stable treatment system capable of handling highly variable and complex chemical wastewater while ensuring regulatory compliance.

4. Engineering Solution

SYNERAQUA implemented a multi-stage integrated treatment system combining physicochemical, biological, and advanced treatment processes.

Process Flow

High-Strength Industrial Wastewater → Neutralization Tank → Coagulation & Sedimentation → Hydrolysis Acidification → Biological Oxidation → Secondary Clarification → Discharge

Engineering Concept

• Multi-stage neutralization for strong acidic wastewater

• Enhanced coagulation for suspended solids and COD reduction

• Hydrolysis acidification to improve biodegradability

• Biological oxidation for organic matter removal

• System capacity expansion and hydraulic balancing

• Automated control for stable process operation

5. Scope of Work

SYNERAQUA was responsible for full EPC retrofit delivery, including:

• Existing system evaluation and process redesign

• Neutralization system upgrade and expansion

• Coagulation and sedimentation system installation

• Biological treatment system optimization

• Sludge handling system upgrade

• Electrical and instrumentation system integration

• PLC automation and control upgrade

• Commissioning and performance validation

• Operator training and technical support

6. Key Technologies & Engineering Highlights

High-Strength Neutralization System enables stable pH control for highly acidic industrial wastewater.

Advanced Coagulation Sedimentation Technology improves COD and suspended solids removal efficiency.

Hydrolysis Acidification Enhancement System increases biodegradability of refractory organics.

Biological Oxidation Optimization ensures stable organic load removal under fluctuating conditions.

PLC-Based Intelligent Control System enables fully automated and stable operation of the upgraded plant.

Modular Retrofit Engineering Design minimizes downtime and maximizes reuse of existing infrastructure.

7. Performance Results

• COD Removal Improvement: Significant increase after retrofit

• BOD Removal Efficiency: Improved stability

• SS Removal Efficiency: >50% improvement

• Ammonia Nitrogen Removal: Enhanced performance

• pH Stability: Fully stabilized within discharge range

• System Automation Level: Fully automated operation

• Operational Stability: Significantly improved

8. Project Value

The project significantly enhances the client’s industrial wastewater treatment capability and supports long-term sustainable production.

Key contributions include:

• Ensured compliance with strict environmental regulations

• Increased system capacity and operational stability

• Reduced environmental risk in chemical manufacturing

• Extended service life of existing treatment infrastructure

• Improved efficiency of industrial wastewater management

• Supported green transformation of high-end material production