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In response to the changing wastewater conditions in the Höchst industrial park, its owner, Infraserv Höchst, implemented a new wastewater treatment system as well as a nitrification system as countermeasures, thereby ensuring that the companies located there can treat their production wastewater in a safe and environmentally sound manner. At almost every stage of the project, Siemens can provide technical support for the most advanced wastewater treatment systems. Due to the constantly changing conditions of wastewater at the site, it was necessary to introduce a new wastewater purification system; therefore, Infraserv’s water treatment experts decided to launch this project. Two insulin factories have also started production there; their output is biodegradable wastewater with a high chemical oxygen demand (COD). This wastewater cannot be treated directly by Infraserv’s central wastewater treatment system, as the system has already reached its maximum capacity. Comprehensive pretreatment capable of reducing COD: Currently, an anaerobic pretreatment unit (APU) and a nitrification pretreatment unit (NiPU) are used to pre-purify wastewater from the pharmaceutical industry. In the APU, insulin-containing wastewater needs to be treated through an anaerobic process. Here, the pollutants in water are converted into biogas, along with a small amount of organisms and excess sludge. This biogas is a bio-desulfurized gas, which consists of 80% methane. Engines of the three block-type thermal power plants that can drive the system. Therefore, this unit operates using a completely independent power source and also feeds electricity into the Infraserv network. Infraserv Höchst has signed a contract with Siemens’ process experts to plan the system. Prior to this, Infraserv and Siemens had already carried out experimental cooperation aimed at selecting the optimal process type and designing the system. As the overall planner for the anaerobic pretreatment unit, Siemens is responsible for planning at all stages, from test supervision in the technical center to pre-final/final design, from detailed design to assembly and commissioning support. Siemens designed the system and carried out the experimental tests required for process adaptation. Therefore, proof can be provided in advance to confirm that the selected process type is capable of meeting the requirements for reducing COD. In addition, through experimental testing, all project-specific characteristics, such as the acceptable levels of toxic components, met the experimental requirements. Through collaboration with Infraserv, Siemens has developed a solution designed to make full use of the excess heat generated during the process, to generate electricity from the biogas produced, and to produce almost no excess sludge. This adaptation process is automated, and the use of Simatic PCS 7 helps to achieve reliable process control in complex systems. Biological oxidation: Under stress-free conditions, the wastewater discharged from the APU can flow into the NiPU, where ammonium compounds are oxidized; subsequently, together with the remaining COD, they undergo nitrification through an aerobic activated sludge process. The wastewater generated by NiPU is fed back into the existing central wastewater treatment plant. This device has sufficient removal capacity to handle the nitrate components in NiPU during the initial high-load phase. Wastewater generated by complex systems in the pharmaceutical industry can be pre-treated by using an ammonia pretreatment unit (APU) and a nitration pretreatment unit (NiPU). The new NiPU building implements the measures adopted by the industrial park owner, Infraserv Höchst, in order to meet the wastewater treatment requirements of modern complex systems. After numerous preliminary tests, Infraserv chose to use the biological nitrification process type. It took two years from the initial research to the debugging phase; in just two years, the development of this system was completed. From the analysis of specific requirements in 2003, through comparisons of various technical approaches, conceptual design, experimental verification of the full-scale system, traditional testing, and the authorization to proceed as per regulations, the system was put up for bidding in the summer of 2005, implemented, and debugged on schedule. As the builder of the factory, Infraserv Höchst was responsible for tasks such as the planning of building technology, the purchase and installation of all packaging units, as well as the commissioning and operation of these units. Siemens is responsible for the overall planning of mechanical equipment/pipes during the front-end and implementation phases, as well as the electrical engineering components. Siemens’ field devices were first installed for wastewater treatment in the Höchst industrial park. The technical expertise of the on-site team, especially during the process development phase, laid a solid foundation for the successful partnership between Infraserv and Siemens in the subsequent period. Similar to the case of APU, NiPU also uses Simatic PCS 7 to control its processes. Integrated into the overall control system of the wastewater treatment plant. All processes can be controlled from a control center just one mile away or locally. Long-term access to clean water: Both systems are operating perfectly and meet the requirements for purification performance. Integrating APU and NiPU together into the existing central wastewater treatment system ensures the long-term and effective treatment of wastewater in complex industrial systems. (end)