THE LIQUID THAT FUELS TEXAS’S INDUSTRIAL BOOM

Beneath the concrete and steel of Texas’s latest industrial construction site, a hidden river flows. It’s not the kind that carves canyons or floods valleys, but it’s no less vital. In the heart of a massive semiconductor plant, water moves through pipes, filters, and treatment systems, carrying the future of an industry with it. Behind the scenes, the careful management of this invisible river will help determine the plant’s success – and the sustainability of Texas’s industrial future.

THE TECHNOLOGICAL BACKBONE OF A MEGA-FACTORY

In the world of high-tech manufacturing, water is indispensable. Few industries rely as heavily on high-quality water as semiconductor production. In the first major chip factory to be built in the United States, cutting-edge technology meets vast production demands. Even the smallest impurities can disrupt operations, potentially costing millions in downtime, while vast quantities of water are needed daily to maintain the delicate manufacturing processes. Add the broader implications for water management in one of the world’s driest yet most industrialized places to the equation and efficient water use and reuse becomes not only an operational necessity but an environmental imperative.

Enter Veolia, a global leader in water and environmental services. The task: designing a water treatment system that handles the plant’s enormous water requirements sustainably. Veolia’s process design ensures that a significant portion of the treated wastewater is recycled back into the plant. That reduces the strain on local water resources and minimizes the environmental footprint. What water isn’t reused is discharged, carefully treated to meet or even exceed environmental regulations.

A key element of this system is the treatment of sludge – byproducts of the filtration and clarification processes used to purify the water. Deep expertise is needed to get this right. Expertise that ANDRITZ has, based on decades of experience in sludge treatment technologies.

“The flexibility and precision of ANDRITZ’s equipment were essential to meeting the project’s strict requirements,” says John Singleton, SourcingA partnership between ArcelorMittal and ANDRITZ has revolutionized how vehicle components are made, combining innovation with precision to deliver lighter, safer, stronger, and more sustainable parts. Project Leader at Veolia. By reducing the water content of the sludge, the technology cuts down on transportation costs and landfill usage, supporting the plant’s sustainability efforts.

CHALLENGES OF SCALE AND COMPLEXITY

One of the biggest hurdles was the unpredictable composition of wastewater. Industrial wastewater, particularly from a semiconductor plant, contains a mix of chemicals, solvents, and other byproducts, making the composition of the sludge variable and hard to predict. Designing a system that could handle such variability required foresight and flexibility. Veolia’s process needed to be robust enough to handle these fluctuations without compromising performance.

That’s where ANDRITZ’s sludge dewatering technology proved crucial. ANDRITZ state-of-the-art filter presses and screw presses were selected for their ability to adapt to a range of sludge compositions, ensuring that the system could operate efficiently regardless of the waste stream’s makeup. Flexibility was key. 

Beyond the technical challenges, the project was also under significant time pressure. The semiconductor industry moves at a rapid pace, and delays in construction or equipment delivery can have far-reaching effects.

“Schedule was always a concern. Together with ANDRITZ, we managed to minimize the impact of delays, which makes a big difference further downstream,” notes Singleton. 

THE SUSTAINABILITY PAYOFF

While the technical challenges were substantial, the project’s environmental impact may ultimately be its most lasting legacy. The semiconductor industry is known for its high water consumption, and reducing this footprint was a central goal for both Veolia and its partners. Through innovative water treatment and reuse, the project is expected to significantly reduce the plant’s reliance on fresh water, helping to ease pressure on local resources.

“This project is a crucial step toward minimizing water usage while ensuring that our discharge meets environmental standards,” adds Alessandro Artesani, Senior Sourcing Manager at Veolia. The partnership has allowed both companies to innovate in ways that benefit not only the semiconductor plant but the environment as a whole.

A BLUEPRINT FOR THE FUTURE

As the plant moves closer to full operation, the success of this collaboration is already drawing attention. The system developed for the Texas plant could serve as a blueprint for similar projects in other water-intensive industries, offering a scalable solution to the twin challenges of industrial growth and environmental responsibility.

Veolia’s and ANDRITZ’s approach to water treatment in this project reflects a broader trend in the industry: finding ways to support economic development while reducing environmental impact. As water resources come under increasing pressure, particularly in drought-prone regions such as Texas, sustainable water management is becoming ever more important. This is where ANDRITZ comes in and makes an important contribution thanks to its sustainable solutions.