Large scale industrial wastewater treatment projects often require a balance between biological process performance, site integration, and long term operational reliability. At this facility, Aerofloat was engaged to design and deliver its largest biological wastewater treatment plant to date, focused on effective nitrogen removal and environmentally responsible discharge.
The system was developed to manage high volume trade waste generated by ongoing production activities. From the initial collection point through to final polishing, every stage of the wastewater treatment system was designed to support compliance, consistent performance, and efficient day to day operation.
A reception and treatment process built for scale
The treatment process begins at a large receival lagoon with a capacity of approximately fifteen megalitres. This stage collects incoming industrial wastewater and provides initial aeration to stabilise water quality before it moves into the main biological treatment sequence.
From this point, high capacity pumps transfer flow into a nitrifying reactor that forms the core of the nitrogen removal process. This reactor was created by converting an existing pond on site, fitted with floating aeration systems, mooring infrastructure, and automated control to maintain precise dissolved oxygen levels.
Biological nitrogen removal through nitrification and denitrification
Within the nitrifying reactor, ammonia is biologically converted into nitrate as part of the first stage of treatment. The process is carefully controlled through automated monitoring and set points to ensure stable and efficient performance.
The next stage directs flow into an anoxic tank, where nitrate is reduced to nitrogen gas in the absence of dissolved oxygen. This denitrification step allows nitrogen to be released safely to the atmosphere, completing the biological cycle and supporting effective industrial wastewater management.
Polishing and discharge through advanced wastewater treatment systems
Following biological treatment, water is directed into a sequence batch reactor that cycles through aeration, mixing, settling, and decanting. Clean water is drawn through an airlock siphon decanter and transferred to an effluent tank for disinfection and final conditioning.
The final stage of the process passes treated water through a series of sand filters to achieve a high level of clarity and quality. This approach ensures the wastewater purification system meets stringent environmental requirements for safe discharge.
Automation and process control for operational confidence
The plant is supported by a central control system that allows operators and process engineers to monitor performance, adjust set points, and review trends in real time. This level of visibility supports informed decision making and consistent operation across both on site and remote support teams.
By integrating advanced control and monitoring technology, the facility operates as a reliable and responsive wastewater treatment system that adapts to changes in flow and load.
Effluent management and sludge dewatering
As part of ongoing effluent management, the biological process generates additional biomass that must be removed to maintain system balance. This is achieved through a belt press that dewaters residual solids, creating the only waste stream that leaves the site.
This dewatering solution supports efficient handling and disposal of byproducts while maintaining overall plant performance and compliance.
Delivering complex water treatment infrastructure at pace
The facility reached operational processing within six months of project award, reflecting a coordinated delivery approach across engineering, supply, and construction teams. This achievement highlights Aerofloat’s capability as a water treatment plant supplier and water treatment plant manufacturer within the Australian industrial sector.
The project demonstrates how industrial water recycling, wastewater screening, and biological treatment processes can be combined into an integrated waste treatment plant that supports both environmental responsibility and production continuity.
A long term asset for industrial wastewater treatment solutions
The completed biological wastewater treatment plant now serves as a critical asset for managing trade waste and complex effluent streams at scale. It reflects a broader shift toward advanced wastewater treatment systems that prioritise sustainability, compliance, and operational resilience.
For Aerofloat, the facility showcases the value of applying proven water purification technology, denitrification processes, and practical site focused engineering to deliver industrial wastewater treatment solutions that perform reliably over the long term.
