In response to a major production increase, Trevi supported Ford Craiova in evaluating, redesigning, and upgrading their wastewater treatment plant. By applying Best Available Techniques and focusing on source reduction, the project delivered a cost-efficient, future-proof installation with a best-in-class water footprint.
Challenge
The planned production increase meant that the existing WWTP could only process 40% of the projected wastewater volume. The plant faced multiple challenges: limited hydraulic capacity, high pollutant loads, particularly from the Paint Shop, and the need to maintain compliance throughout the upgrade process. Additionally, both capital and operational expenses had to remain under control.
Solution
Trevi performed a full scenario analysis, evaluating individual effluent streams and identifying opportunities for source reduction through Best Available Techniques (BAT). Lab trials and cost-benefit studies confirmed which interventions were most effective. By targeting pollution at the source, especially in the Paint Shop, the need for major WWTP extensions was reduced. Trevi then designed a scalable treatment plant using existing infrastructure wherever possible. The upgrades included new buffer tanks for highly loaded wastewater, fluoride-specific dosing in the reactors, and a renovated clarifier. On the biological side, a new feed tank, secondary clarifier and energy-efficient aeration system were added.
Result
The adapted WWTP can now handle the increased volumes without compromising performance. Source-based reductions minimised required investments (CAPEX) and lowered operational costs (OPEX). Water consumption per vehicle was significantly reduced, leading to a best-in-class water footprint of just 0.6 m³ per car.
