Upwater® demonstrates its effectiveness in an industrial wastewater facility with ETSA

AquaInSilico has successfully completed a project in partnership with ETSA, a company from the SEMAPA Group. The initiative demonstrated the capabilities of Upwater®, AquaInSilico’s proprietary digital platform, at an industrial wastewater treatment plant located at ETSA’s facilities in Coruche, Portugal, where animal by-products are transformed into feed, proteins, and oils.

This project represented both high-impact technical application and a strategic milestone for AquaInSilico. Launched in early 2025, the project, supported by Portugal’s PRR Data4All testbed, aimed to optimize total nitrogen removal in a complex and variable industrial setting.

At the heart of the project, Upwater® was used to simulate multiple operational scenarios, delivering tailored, data-driven strategies to improve the removal of ammonia, nitrates, and nitrites across different production campaigns. The pilot focused on identifying key performance indicators to ensure robust operation throughout the year.

During the six-month demonstration, Upwater® enabled the evaluation of eight operational strategies, leading to the identification of the most effective approaches, including:

• Key control parameters, such as macronutrient concentrations, pH, or temperature to ensure stable nitrification;
• Control strategies, such as aeration control based on DO or ammonia concentrations, enabling improved ammonia removal while reducing energy consumption;
• Optimized operational conditions, including flow distribution or carbon supply, to consistently meet total nitrogen discharge limits.

By leveraging advanced intelligence algorithms, Upwater® provided predictive insights and supported preventive actions, helping operators manage the typical variability of industrial effluents caused by changes in production.

This pilot reinforced the value of collaboration between AquaInSilico and ETSA, showcasing the adaptability of digital tools in demanding industrial environments and highlighting the role of digitalization in building a more efficient and sustainable wastewater sector.

According to Jorge Santos, CEO of AquaInSilico: “ETSA trusted in AquaInSilico, and it was a real pleasure to work with a team so genuinely committed to improve the sustainability across the wastewater treatment facility in Coruche. We were proud to demonstrate the potential of Upwater® and the broad applicability of our algorithms, which adapted seamlessly to the operation of ETSA. Whether in conventional activated sludge systems or advanced technologies like moving bed bioreactors (MBBR), Upwater® helps reduce the time needed to identify and overcome process disturbances.”

João Oliva, Environmental Technician at ETSA, added: “The project developed over the past few months within the test bed allowed us to quickly and efficiently understand the impacts that changes in our WWTP’s operating parameters can have—not only on the quality of the final effluent, but also on our operational strategy. The ability to simulate different scenarios through software gives us the advantage of making faster decisions, anticipating potential issues, and optimizing the treatment plant’s energy consumption.”

Raquel Sousa, Head of Unit at INOVA+ and Data4All Project Lead, added: “This successful demonstration within the Data4All testbed highlights how collaborative innovation can turn data into real value for industry and sustainability. The Upwater® pilot with ETSA is a strong example of how AI and digital technologies can enhance operational efficiency, reduce environmental impact, and support a more resilient and competitive industrial ecosystem.”

Data4All is one of 30+ national Test Beds approved in the Portugal’s Recovery and Resilience Plan (PRR). Promoted by @INOVA+ and Dectech, the project offers a technological validation ecosystem for startups and SMEs with products and services based on artificial intelligence  and advanced digital technologies. In collaboration with ETSA, under the Sustainability Challenge, the goal to promote the collaboration between startups and established companies by providing access to industrial infrastructure was achieved with great results.

The initiative further strengthens AquaInSilico’s ability to demonstrate the adaptability of its digital solutions across diverse customer profiles and operational contexts.

The successful completion of this project confirms that AquaInSilico is well positioned to support not only municipal utilities but also industrial players, accelerating the transition toward smarter, greener wastewater treatment.