Orlen Expands WWT Capacity with Nijhuis HR-DAF Technology

Project's context and challenges

The expansion of Orlen’s wastewater treatment facilities marks another important step in strengthening the company’s environmental performance and operational reliability. At the heart of this success is the implementation of the Nijhuis HR-DAF (High-Rate Dissolved Air Flotation) system, delivered by NSI CE, which combines proven engineering with tailored, client-focused solutions.

The project realization faced some challenges from the start: strict Oil & Gas standards, tight delivery timelines, and the need for uninterrupted refinery operations during construction. However, due to the common efforts of dedicated and expert teams involved, the project was completed within the revised deadline and budget. Proactive approach demonstrated by NSI CE team during project execution was highly appreciated by the client.

As part of the order NSI CE team provides also technological support for Orlen for the period of 3 years after take-over, including periodical visits of NSI CE engineer on site.

Сustomer benefits

Technological support

Client is backed up by specialized know-how provided by NSI

Space and cost efficiency

Compact design with lamella plate packages reduces building size and construction costs

Seamless, safe operation

Built with safety in mind, minimizing operator involvement while ensuring reliable performance

Fit-for-purpose engineering

Designed to meet Oil & Gas standards without unnecessary overengineering, keeping the solution cost-effective

Low operating costs

Advanced aeration technology and efficient blowers reduce energy consumption and service needs

Solution

The system operates on two parallel lines, each capable of handling 200–800 m³/h, with a maximum combined capacity of 1,600 m³/h. It ensures reliable, low-maintenance performance with minimal operator involvement.

The HR-DAF system represents the latest achievement in wastewater pre-treatment innovation. Key technological features include:

Lamella plate packs for higher hydraulic capacity and compact footprint.
A patented micro-bubble saturation system ensuring efficient flotation, lower energy use, and reduced operating costs.
Automated pH control and reagent dosing to stabilize water quality before biological treatment.