Trying to build a modular plant that mostly runs itself
I am working with a small team on whether a treatment plant can be built more like a standardised product than a bespoke project. First application is reclaimed and STP water to cooling tower makeup spec for data centers.
Physical side: a common chassis carrying the controls, electrical, pumping, and container interfaces. The treatment modules inside get selected per site based on feedwater chemistry. The chassis stays the same everywhere, the modules change.
Controls side monitors feedwater chemistry, conductivity, pressure and flow, membrane differential pressure, permeate quality, energy consumption, chemical consumption, and equipment health. The longer-term intent is that operating data from every deployment feeds back so we get better at predicting fouling, scheduling maintenance, dosing, and energy optimisation. AI proposes, PLC decides, hardware responds. No model in the safety path.
We are early enough that finding the problems now is worth more than finding them later.
What I would like to know:
a. What are we likely to underestimate about feedwater variability?
b. At what point does modularisation stop being practical and turn into a custom build with extra steps?
c. How predictable is fouling in real reclaimed-water systems? Predictable enough to schedule against, or not really?
d. What would stop this from running with minimal on-site intervention, and what would you insist on having in a design like this before you'd trust it?
Not looking for validation. If you have operated these systems and think this is a bad approach, that's the most useful thing I could read today.
Happy to go into more detail with anyone who's run reclaimed water systems.