Process innovations and circular strategies for closing the water loop in a process industry

By implementing advanced wastewater treatment technologies coupled with digital tools, high-quality water is produced to be reused within the industry, enhancing process efficiency and closing loops. This paper investigates the impact of three innovation tools (process, circular and digital) in a Solvay chemical plant. Four technologies of the wastewater treatment plant “WAPEREUSE” were deployed, predicting their performance by process modelling and simulation in the PSM Tool. The environmental impact was assessed using Life Cycle Assessment and compared to the impact of the current industrial effluent discharge. The circularity level was assessed through three alternative closed-loop scenarios: (1) conventional treatment and discharge to sea (baseline), (2) conventional and advanced treatment by WAPEREUSE and discharge to sea, (3) conventional and advanced treatment by WAPEREUSE and industrial water reuse through cross-sectorial symbiotic network, where effluents are exchanged among the process industry, municipality and a water utility. Scenario 1 has the lowest pollutants’ removal efficiency with environmental footprint of 0.93 mPt/m³. WAPEREUSE technologies decreased COD by 98.3%, TOC by 91.4% and nitrates by 94.5%. Scenario 2 had environmental footprint of 1.12 mPt/m³. The cross-sectorial symbiotic network on the industrial value chain resulted in higher industrial circularity and sustainability level, avoiding effluents discharge. Scenario 3 is selected as the best option with 0.72 mPt per m³, reducing the environmental footprint by 21% and 36% compared to Scenarios 1 and 2, respectively.