This six-part series captures the journey of validating Cyclor® Turbo in North America—from early concept through full-scale implementation. 

In Part 1, we explored why local validation matters when introducing new biological treatment technologies into the market. Read here: Bringing Cyclor® Turbo to North America – Part 1: Establishing a Local Reference – Nexom

In Part 2, we explored how the right municipality and facility were identified to reflect real-world operating environments and constraints. Read here: Bringing Cyclor® Turbo to North America – Part 2: Identifying the Right Site – Nexom 

In Part 3, the focus shifts to design— how Cyclor Turbo was adapted to the East St. Paul facility and the key design considerations involved in implementing it within an existing SBR system. Read here: Bringing Cyclor® Turbo to North America – Part 3: Designing for Real-World Conditions – Nexom

In Part 4, the focus shifts to construction— how the Cyclor® Turbo integration design was executed to full scale commissioning within a live treatment environment. 

Sequencing Implementation Without Disruption 

With the design framework established, the next phase for the Cyclor® Turbo improved AGS demonstration at East St. Paul was execution—translating the finalized design into an operational system within an active wastewater treatment plant. This stage required careful sequencing and close coordination with plant operations while maintaining process continuity and site safety considerations. 

Construction planning was structured to minimize disruption to ongoing treatment. Work was sequenced around existing SBR operations, with isolation, decommissioning, and installation activities staged to maintain continuity of service. Modifications to the reactor—including removal of existing components, installation of new aeration systems, influent and effluent distribution elements, and control infrastructure—were executed within the physical and operational limits of the site. 

Specific measures were taken to phase construction while maintaining treatment capacity. Major construction activities were scheduled during the winter low-flow period, allowing the existing treatment processes to continue operating while the retrofit was completed ahead of spring runoff conditions. Most of the work was contained within the SBR basin being converted, minimizing the impacts on the broader treatment system. Only limited shutdowns were required to complete modifications to the influent distribution and blower infrastructure, allowing the facility to maintain normal treatment operations throughout the construction period. 

Coordination with operations staff was central throughout this phase. Because construction occurred within a live facility, daily alignment was required to manage access, maintain treatment performance, and ensure safe working conditions. This collaborative approach ensured that implementation decisions reflected both engineering requirements and operator experience. 

Accelerating Implementation Through Existing Infrastructure 

One of the advantages demonstrated during the East St. Paul project was the ability to move from design through construction on an accelerated schedule. By leveraging existing infrastructure and integrating Cyclor® Turbo within an operating facility, the project was able to progress from detailed design to commissioning within approximately six months. 

While every project is unique, this timeline highlights the potential benefits of upgrading assets rather than pursuing entirely new treatment infrastructure. For municipalities evaluating future capacity expansion or treatment improvements, implementation timelines can be an important consideration alongside process performance and capital cost. 

Preparing for Startup and System Commissioning 

While construction activities were underway, startup planning progressed in parallel. This included the development of commissioning protocols, control system integration, operator training, and preparation of biological startups. Attention was given to preparing the system for cold weather operation and establishing a biological startup strategy aligned with existing site conditions. 

To support the establishment of the Cyclor ® Turbo process, biomass accumulation within the existing SBR was managed in advance of startup by reducing sludge wasting rates. A portion of this accumulated biomass was then used to seed the Cyclor ® Turbo reactor, supporting a controlled transition into biological operation. 

Initial activities focused on system readiness rather than performance. Initial hydraulic commissioning marked a critical milestone, allowing teams to verify hydraulic distribution, aeration performance, instrumentation, and control logic. These activities confirmed that mechanical, electrical, and process systems were functioning as intended before introducing biological startup began. 

This phase of execution established the foundation for stable startup and reliable operation. 

In Part 5, we will explore how Cyclor® Turbo performed during early start‑up, including initial operational observations and system behavior under real-world conditions.