Central San’s pilot of Aquasight’s APOLLO™ digital twin cut energy costs, improved chemical efficiency, and flagged maintenance issues early, showing how real-time data can transform wastewater operations.
These are not distant concerns, they’re pressing realities for wastewater utilities today. To stay ahead, utilities need smarter, more predictive tools that move them from reactive operations to data-driven decision-making.
That’s why Central Contra Costa Sanitary District (Central San) partnered with Aquasight to pilot APOLLO™, a digital twin for wastewater treatment that uses live plant data to improve process efficiency, reduce costs, and extend asset life.
Why Wastewater Digital Twins Are Changing the Game
A wastewater digital twin is far more than a SCADA screen. It’s a virtual replica of treatment plant processes that integrates operational data, analytics, and predictive insights into a single platform.
For Central San, the timing was urgent:
Electricity rates in their service area rose significantly over the past five years and could continue increasing in the future.
New Regulatory Limits on the Horizon such as a 40% seasonal reduction in Nitrogen effluent required in the San Francisco Bay Area in 2034.
Capital and maintenance budgets are under pressure from aging infrastructure
The challenge? Improve energy efficiency in wastewater treatment while maintaining compliance and preparing for future regulations.
The Pilot Approach: From Data to Actions
Central San’s Optimization Division responsible for asset management, process innovation, and control systems set clear objectives for the pilot:
Connect APOLLO™ to the plant’s data historian for real-time monitoring.
Visualize trends to support collaborative decision-making.
Identify predictive maintenance needs before failures occur.
Recommend operational changes to optimize chemical use and electricity consumption.
Two process areas were targeted:
Influent Pumping – a major energy consumer, electrical upgrades recently completed and no planned upgrades in the future
Solids Processing – where polymer dosing and equipment health directly impact O&M costs.
Within months, APOLLO™ delivered high-impact results:
Energy Optimization – A revised nighttime pumping strategy cut costs from $50/MG to $35/MG.
Predictive Maintenance Alerts – Detected vibration anomalies and bearing temperature spikes.
Chemical Optimization – Recommended optimal polymer dosages and centrifuge settings.
For plant operators, these weren’t abstract data points, they were clear, actionable steps with the potential to improve performance.
Central San is now considering:
Making energy-efficient pumping strategies standard operating procedure.
Rolling out the solids processing optimization plant-wide.
Integrating APOLLO™’s predictive maintenance insights into their CMMS.
Applying the approach to innovative projects, such as a Membrane Aerated Biofilm Reactor (MABR) pilot.
Key Takeaway for Utility Leaders
Wastewater process optimization with a digital twin is no longer a future concept, it’s a proven, practical strategy.
By combining experienced utility staff with advanced analytics, agencies can unlock:
Lower energy costs
Extended asset life
Reduced chemical usage
Faster, data-backed decision-making
As the sector faces mounting regulatory, financial, and operational challenges, adopting a digital twin for wastewater treatment can help utilities meet today’s needs and prepare for tomorrow’s demands.
Ready to see what a wastewater digital twin can do for your plant?
Schedule a demo of APOLLO™ and explore how to turn your operational data into measurable results.