AquaInSilico successfully completed a project in partnership with ETSA, a company of the SEMAPA Group. The initiative demonstrated the capabilities of UPWATER™, the digital platform created by AquaInSilico, 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.
The project was both a high-impact technical application and a strategic milestone for AquaInSilico. Launched in early 2025 and supported by the Data4All test bed, it aimed to optimise total nitrogen removal in a complex industrial setting.
What was done
UPWATER™ was used to simulate multiple operational scenarios, providing 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™ made it possible to evaluate eight operational strategies, leading to the identification of the most effective approaches, including:
- Essential control parameters, such as macronutrient concentrations, pH or temperature, to ensure stable nitrification;
- Control strategies, such as regulating aeration based on DO or ammonia concentrations, improving ammonia removal and reducing energy consumption;
- Optimised operating conditions, including flow distribution and carbon dosing, to consistently meet total nitrogen discharge limits.
Using advanced intelligence algorithms, UPWATER™ delivered forecasts and supported preventive actions, helping the plant management team handle the variability typical of industrial effluents caused by changes in production.
Why it matters
This pilot reinforced the value of the collaboration between AquaInSilico and ETSA, demonstrating the adaptability of digital tools in demanding industrial environments and highlighting the role of digitalisation in building a more efficient and sustainable wastewater sector.
“ETSA trusted AquaInSilico, and it was a pleasure to work with a team so genuinely committed to improving sustainability at the Coruche treatment plant. We are proud to demonstrate the potential of UPWATER™ and the broad applicability of our algorithms, which adapted seamlessly to ETSA's operation. Whether in conventional activated sludge systems or advanced technologies such as MBBR reactors, UPWATER™ helps reduce the time needed to identify and overcome process disturbances.”
“The project developed over the past months within the test bed allowed us to quickly and efficiently understand the impacts that changes in the operating parameters of our plant can have — not only on final effluent quality, but also on our operational strategy. Being able to simulate different scenarios through software gives us the advantage of making faster decisions, anticipating potential problems and optimising the plant's energy consumption.”
“This successful demonstration within the Data4All test bed shows how collaborative innovation can turn data into real value for industry and for sustainability. The UPWATER™ pilot with ETSA is a solid example of how AI and digital technologies can improve operational efficiency, reduce environmental impact and support a more resilient and competitive industrial ecosystem.”
About Data4All
Data4All is one of more than 30 national Test Beds approved under Portugal's Recovery and Resilience Plan (PRR). Promoted by INOVA+ and Dectech, the project offers a technology 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 of promoting cooperation between startups and established companies by providing access to industrial infrastructure was achieved with excellent results.
The initiative further strengthens AquaInSilico's ability to demonstrate the adaptability of its digital solutions across different client profiles and operating contexts. The successful conclusion of this project confirms that AquaInSilico is well positioned to support not only urban utilities but also industrial operators, accelerating the transition to smarter and more sustainable wastewater treatment.
About AIS
AIS is a Portuguese deep-tech company and spin-off from NOVA University Lisbon, co-founded with Frontier IP Group. AIS powers UPWATER™ and UPWASTE — AI-powered digital twin platforms for wastewater and organic waste treatment facilities, turning complex biological processes into predictable, efficient and profitable operations.