On their path to becoming sustainable facilities, it is required that wastewater treatment plants reduce their energy demand, sludge production, and chemical consumption, as well as increase on-site power generation. This study describes the results obtained from upgrading the sludge line of a full-scale wastewater treatment plant over 6 years (2015–2021) using three advanced process control strategies. The advanced process control tools were designed with the aim of (i) enhancing primary and secondary sludge thickening, (ii) improving anaerobic digestion performance, and (iii) reducing chemical consumption in the sludge line. The results obtained show that the use of advanced process control tools allows for optimising sludge thickening (increasing solids content by 9.5%) and anaerobic digestion (increasing both the removal of volatile solids and specific methane yield by 10%, respectively), while reducing iron chloride and antifoam consumption (by 75% and 53%, respectively). With the strategies implemented, the plant increased its potential energy self-sufficiency from 43% to 51% and reduced de-watered sludge production by 11%. Furthermore, the upgrade required a low investment, with a return of capital expense (CAPEX) in 1.98 years, which presents a promising and affordable alternative for upgrading existing wastewater treatment plants.

在成为可持续设施的道路上，污水处理厂需要减少能源需求、污泥产量和化学品消耗，并增加现场发电量。本研究描述了使用三种先进的过程控制策略在 6 年（2015-2021 年）内升级全面污水处理厂的污泥生产线所获得的结果。设计先进的过程控制工具的目的是 (i) 增强初级和二级污泥浓缩，(ii) 提高厌氧消化性能，以及 (iii) 减少污泥管线中的化学品消耗。获得的结果表明，使用先进的过程控制工具可以优化污泥增稠（将固体含量增加 9.5 倍）。5%）和厌氧消化（将挥发性固体的去除率和比甲烷产量分别提高 10%），同时减少氯化铁和消泡剂的消耗（分别降低 75% 和 53%）。随着策略的实施，该工厂的潜在能源自给率从 43% 提高到 51%，脱水污泥产量减少了 11%。此外，升级所需的投资较低，资本支出 (CAPEX) 可在 1.98 年内获得回报，这为现有污水处理厂的升级提供了一种有前景且价格合理的替代方案。该工厂的潜在能源自给率从 43% 提高到 51%，脱水污泥产量减少了 11%。此外，升级所需的投资较低，资本支出 (CAPEX) 可在 1.98 年内获得回报，这为现有污水处理厂的升级提供了一种有前景且价格合理的替代方案。该工厂的潜在能源自给率从 43% 提高到 51%，脱水污泥产量减少了 11%。此外，升级所需的投资较低，资本支出 (CAPEX) 可在 1.98 年内获得回报，这为现有污水处理厂的升级提供了一种有前景且价格合理的替代方案。