American Meat Institute

Conference on Worker Safety, Human

Resources and the Environment
Kansas City, Missouri
Brian Mulini, !"E"
Brian Bakke, !"E"
H#R En$ineerin$, Inc"
March %&, %&'(
Wastewater Design &
Best Practices
)vervie*
+ Waste*ater , *hat are *e treatin$
+ !reliminary -reatment
+ Anaero.ic -reatment
+ Aero.ic -reatment
+ /itro$en Removal
+ !hos0horus Removal
+ -ertiary -reatment
+ BOD
5
+ TSS
+ FOG
+ TKN
+ Phosphorus
+ Proteins
+ Fats
+ Carbohyrates
+ Partia!!y"Digeste
Fee
+ #anure
+ $rine
What %re We Treating&
O'
O'
What are We -reatin$1
+ Slau$hterhouse
, !roteins 2.lood, meat, etc"3
, 4at
, !artially di$ested feed from stomachs and intestines
, Manure from 0ens
, 5rine from 0ens, kidneys, .ladders, etc"
+ !rocessin$
, !roteins
, 4at
, Car.ohydrates
+ Animal 4eedin$ )0erations
, Manure
, 5rine
, Some uneaten feed 20rotein, car.s, fat6oil3
What -y0e of 4ood is Bein$ -reated1
()a*p!e Protein Fat Carbohyrates
S!aughterhouse


Processing
+ +a*s So*e So*e ,-ro* the pic.!e !i/uor0
+ Bacon 1itt!e ,-ro* the pic.!e !i/uor0
+ Coo.e Sausage 1itt!e
+ Chic.en"Frie Stea.s ,-ro* the breaing0
'enering
'eay"to"(at Foos So*e So*e ,noo!es2 sauces2 seasonings2 etc30
!retreatment Can Shift -y0e of 4ood
+ #A4 reduces fat and some 0rotein
+ 4erric 0retreatment $reatly reduces .oth fat and
0rotein
+ Many car.ohydrates
, 7o into 8true solution9
, 5naffected .y 0hysical or chemical 0retreatment
#etermine Waste :oads from 4ood
+ !rotein B)#
;
< -K/ ="%; &">
+ 4at B)#
;
< 4)7 2 '"?@ 3
+ Car.ohydrate B)#
;
<
-otal B)#
;
, !rotein B)#
;
, 4at B)#
;
Why is -y0e of 4ood Im0ortant1
+ Anaero.ic Slud$e !roduction
+ 0H Bufferin$
, !roteins make their o*n alkalinity
, 4ats and car.s reAuire alkalinity for .ufferin$
+ /utrient ReAuirements
, !roteins are a com0lete food source
, 4ats and car.s are deficient in nutrients and
micronutrients
+ #ifferent !hysical Characteristics
, 4ats may coat media, float
Fat Protein Carbs
4 455 " 6 7 " 5
S*ine 4arms are Sli$htly #ifferent
+ S*ine farm *aste is similar to human *aste *ithout
the dilution *ater
+ Birtually everythin$ has .een throu$h di$estive or
urinary tract
+ !i$s have utiliCed much of readilyDdi$esti.le food
2ener$y3, leavin$ less easilyDdi$esti.le to treat
What is Eour #ischar$e ReAuirement1
+ Munici0ality
, :imits s0ecific to system
, Surchar$es
+ :and A00lication
, A$ronomic rates
+ #irect #ischar$e
, Effluent $uidelines
, /utrient limits
P'(T'(%T#(NT
Screenin$
+ Remove solid materials, 0revent avoida.le B)#
and -SS
+ -y0esF
, Static Screens
, Bi.ratin$ Screens
, Rotary Screens
, Channel Screens
7ravity Clarifiers
Removal
BOD 68"98:
TSS 98"78:
TKN 48"68:
FOG 58";8:
#issolved Air 4lotation
Removal
Without
Chemicals
With
Chemicals
BOD 98"78: ;8"<8:
TSS 58";8: =8"<8:
TKN 68"98: 78";8:
FOG 58"=8: =8">8:
%N%('OB?C T'(%T#(NT
Anaero.ic -reatment , A Marvelous -ool
+ Reduce CB)#
;
.y >;DG&H
+ Reduce -SS .y ?&D>&H
+ Bio$as 0roduced containin$ ?I@H
+ Acce0t6treat shock or$anic loads
+ Serves as eAualiCation
+ Accom0lishes *ith minimal ener$y reAuired and
minimal slud$e 0roduction
Anaero.ic #e$radation of )r$anic Materials
Acid-Forming
Bacteria
Methane-Forming
Bacteria
Co*p!e)
Organics
Organic
%cis
#ethane @
CO6 @ s*a!!
a*t5 Ce!! #ass
Waste Conversion
(minimal energy lost,
minimal BOD reduction)
Waste Stabilization
(waste energy converted to
methane energy, big BOD
reduction)
Anaero.ic -reatment -echnolo$ies
+ :o* Rate
, Anaero.ic la$oon
+ Medium Rate
, Anaero.ic contact system
, Anaero.ic SBR
+ Hi$h Rate
, 50flo* Anaero.ic Slud$e Bed 25ASB3
, Anaero.ic filtersJ u0flo*, do*nflo*, e0anded .ed
, Hy.rids
Anaero.ic -reatment Com0arison
Low Rate Medium Rate High Rate
ProcessA'eactor 1agoon
Contact
process %SB' $%SB Fi!ters
1oaing2
!bs BOD5A4888 -t
9
Aay
45 B 98 ;8 B 4;8 ;8 B 9=5 C4;8 4;8 " ;65
+'T2 ays
955 B 45 4 B 48 855 B 48 8565 B 455 855 B 658
S'T2 ays
un.nown2
but !ong
C68 C98 C488 98"488
In summary, anaerobic lagoon is lightly loaded with a long detention
time and sludge age and all the more robust for it
Covered Anaero.ic :a$oon
Stor* Water Co!!ection
Synthetic or
Natura! CoDer
Periphera! Biogas
Co!!ection
#esi$n Considerations 6 Common )0eratin$
!ro.lems
+ Solids Accumulation
, 4)7 at la$oon K (;& m$6:
, !revent sand, mud, $rit, 0aunch manure, 0en *aste,
truck .eddin$, etcL kee0 out of la$oon
, Measure60lot $rease cover and settled slud$e
thickness S0rin$, Summer and 4all
, Remove slud$e every 4all to maimiCe active volume
, K ';H of WAS di$ests in la$oon, serves more for
thickenin$J remove WAS sent 'D%M6year
#esi$n Considerations 6 Common )0eratin$
!ro.lems 2cont"3
+ Anaero.ic -em0eratures
, Ideally G;N4
, Can $o as lo* >%D>=N4, or lo*er for shorter 0eriods
+ Chemicals
, ChloridesF sudden s*in$s of O ',%&& m$6: may
disru0t anaero.ic treatment
+ !rocessin$ 0lants *ith .rine chills, 0ickle liAuors
+ Beef 0lants *ith .rine hide curin$
#esi$n Considerations 6 Common )0eratin$
!ro.lems 2cont"3
+ Chemicals 2cont"3
, Sulfates6Sulfides
+ Sulfates ty0ically from *ater su00ly
, 4erric sulfate in 0retreatment
, !rocessin$ mucosa
, -annery *aste*ater
+ Sulfates in anaero.ic influent reduced to hydro$en sulfide
, Reduces methane $eneration
, At hi$h concentrations can .e toic to methano$ens
P Rule of thum. , C)#FS K IF'
, Most in effluent, .ut released in .io$as 2de0endin$ on 0H and
tem0erature3
, 4or every %= m$6: H
%
S in the liAuid, 'H in $as 0hase 2(;EC3
, 4or each ' m$6: sulfide in effluent, reAuires % m$6: of dissolved
oy$en to oide .ack to sulfate
, Can use ferric6ferrous to tie u0 sulfide
#esi$n Considerations 6 Common )0eratin$
!ro.lems 2cont"3
+ Chemicals 2cont"3
, Quaternary Ammonium Com0ounds 2Quat3
+ Inhi.itory levels at ;D'; m$6: active in$red"
, MacronutrientsF nitro$en, 0hos0horus, 0otassium
, Micronutrients
+ Co.alt, co00er, man$anese, moly.denum, nickel
2&"' m$6: deficient3
+ Iron 2'"& m$6: deficient3
Meat !rocessin$ !lant
Anaero.ic :a$oon Effluent
(&
I&
;&
=&
?&
>&
G&
'&&
&
;&&
'&&&
';&&
%&&&
(
6
I
6
&
?
I
6
'
;
6
&
?
;
6
%
?
6
&
?
?
6
>
6
&
?
>
6
'
G
6
&
?
G
6
(
&
6
&
?
'
'
6
'
'
6
&
?
'
%
6
%
(
6
&
?
%
6
(
6
&
>
(
6
'
=
6
&
>
I
6
%
?
6
&
>
=
6
>
6
&
>
?
6
%
&
6
&
>
>
6
(
'
6
&
>
'
&
6
'
%
6
&
>
'
'
6
%
(
6
&
>
'
6
I
6
&
G
%
6
'
;
6
&
G
(
6
%
G
6
&
G
;
6
'
&
6
&
G
=
6
%
'
6
&
G
>
6
%
6
&
G
G
6
'
(
6
&
G
'
&
6
%
;
6
&
G
'
%
6
=
6
&
G
'
6
'
?
6
'
&
%
6
%
>
6
'
&
I
6
'
'
6
'
&
;
6
%
(
6
'
&
T
e
m
p
e
r
a
t
u
r
e

(

F
)
C
B
O
D

(
m
g
/
L
)
CB)# m$6l Bolatile Acids -EM! 2R43
Micronutrient
Addition
'eactions to upsets2 not
causesF
+ Drop in biogas
prouction
+ 1ow p+
+ ?ncrease in O'P
+ +igh Do!ati!e acis
+ ?ncrease
aciFa!.a!inity ratio
?- per-or*ing poor!y2
chec.F
+ New p!ant operations2
!i.e processing *ucosa
+ Te*perature
+ Guats
+ Suen ch!orie swings
+ Nutrients an
*icronutrients
%naerobic 1agoon Operating Prob!e*s
%('OB?C 1%GOON T'(%T#(NT
Aerated :a$oons6Basins
+ +yrau!ic an S!uge etention
ti*e 4"5 ays
+ Detention ti*e2 not o)ygen
trans-er rate ictates siHe
+ %s CBOD
5
rops2 TSS c!i*bs ue
to *icroorganis* growth
%Dantages
+ Si*p!e to operate
+ No s!uge to han!e
+ BOD reuction
+ 58: in winter
+ S=5: in su**er
+ ConDert anaerobic
e--!uent to aerobic
+ Nitri-y N+
9
uner
certain conitions
DisaDantages
+ (!ectrica! energy re/I
+ TSS increase
+ Nitri-ication re/uires
+ 1onger etention ti*e
+ Te*peratures C 58JF
+ S*a!! in-!uent -!ows
re/uire Dertica!"wa!!
tan.s
%erate 1agoonsABasins
%CT?K%T(D S1$DG( B N?T'OG(N '(#OK%1
Activated Slud$e !rocess
%eration
C!ari-ication
Bio*ass
'ecyc!e
Bio*ass
Waste
Activated Sludge is lie a loo! with no beginning and no end
+ Continuous or se*i"continuous
B CBOD o)iation
B Nitri-ication
+ 'epresents *ost wie"sprea
use in *eat an pou!try
inustries
+ ConDersion into sett!eab!e
so!is
+ DeDe!op iea! bio*ass
+ Ba!ance o- -!oc an -i!a*ent"
-or*ing organis*s
?n-!uent
(--!uent
B)# )nly Activated Slud$e
+ #esi$n !arameters to consider
, #issolved oy$en su00ly , Maintain %"& m$6: #)
, Alkalinity , Maintain 0H ="; , ?"G
, #etention6contact time , I to > hours
, Mied :iAuor Concentration , %,&&& to (,&&& m$6:
, )y$en 50take Rate , I& to ;& m$6:6hour
, Slud$e a$e , ' to ( days
, -em0erature ran$e , '& to (& de$" C"
Consu*esF
454 g O
6
A g BOD
-y0ical Meat Industry Activated Slud$e
Aeration Basin
4inal
Clarification
RAS
WAS
Anaero.ic :a$oon
Anaerobic Inluent Anaerobic !luent
Por"#$ee Poultr% Meat Proc& Por"#$ee Poultr% Meat Proc&
CBOD
5
,*gA10 4688"4988 ;88"4<88 ;88"4;88 688"788 458"658 458"658
TKN ,*gA10 468"988 ;8"4<8 58"458 448"6=8 55"4;8 75"495
NitrateANitrite ,*gA10 L758 L758 L758 858 858 858
Phosphorus ,*gA10 68"58 45"98 68"75 4<"75 4955"6= 4<"78
BODFNFP
488F48F45;= 488F48F45;= 488F48F958 488F;8F48 488F58F48 488F78F47
Ammonia /itrification
+ %Dste0 conversion
, Ammonia to /itrite D /itrosomonas
, /itrite to /itrate D /itro.acter
+ #esi$n !arameters to consider
, #issolved oy$en su00ly , Maintain %"& m$6: #)
, Alkalinity , Maintain 0H ="; , ?"G
, #etention6contact time , I to %I hours
, Mied :iAuor Concentration , (,&&& to ;,&&& m$6:
, )y$en 50take Rate , I& to ;& m$6:6hour
, Slud$e a$e , > to '; days de0endin$ on tem0erature
, -em0erature ran$e , '& to (& de$" C"
Consu*esF
755= g O
6
A g N+
7
"N
=547 g %!. CaCO
9
A g N+
7
"N
-raditional /itrification6#enitrification
65: O
6
65: O
6
78: Carbon
,BOD0
78: Carbon
,BOD0
;8: Carbon
,BOD0
;8: Carbon
,BOD0
'itriication(Aerobic
)enitriication(Ano*ic
+&,- g .
/
#g 'H
+
(' o*idized
0&,(1 g C.)#g '.
0
(' reduced
-&2+ g CaC.
0
#g 'H
+
(' o*idized
recover 0&,- g CaC.
0
#g '.
0
(' reduced
2 mol 'itrite
3'.
/
(4
2 mol 'itrite
3'.
/
(4
2 mol 'itrate
3'.
0
(4
5 mol 'itrogen 6as
3'
/
4
2 mol Ammonia
3'H0# 'H+ 74
Autotro8hs
Heterotro8hs
=5: O
6
=5: O
6
/itro$en Removal !rocesses
+ Sin$le Sta$e /itrificationD#enitrification
+ Simultaneous6Com.ined /itrification #enitrification
+ SeAuential B)#D/itrificationD#enitrification
+ Biolo$ical )0tions
, Sus0ended 7ro*th
, 4ied Biofilm
/itro$en Removal !rocesses D Classic
Toned
Wuhrman
Ludzac"(!ttinger
Modiied Ludzac" !tinger
3ML! Process4
$arden8ho
3+ stage Phoredo*4
Ste8 Feed
Ti!*ann W'P2 1os %nge!es
(--!uentF
N+
7
"N M 4 *gA1
TN M 48 *gA1
/itrif6#enitrifF U?&H -/ Removal
#oi-ie 1uHac."(ttinger ,#1(0 syste*
Aeration
Basin
4inal
Clarifiers
RAS 2'Q3
WAS
Anoic
Basin
Mied :iAuor Return 2IQ3
2nitrate source3
4rom
Anaero.ic
:a$oon
TN
200 mg/L
TN
40mg/L
Car.on
Alkalinity
0%
20%
40%
60%
80%
100%
0 2 4 6 8 10
Recycle Rat! (R"# $ %L##)
#enitrification vs Recycle
/itrif6#enitrifF =D> m$6: Effluent -/
Aeration
Basin
4inal
Clarifiers
RAS 2'Q3
WAS
Anoic
Basin
Mied :iAuor Return 2IQ3
2nitrate source3
4rom
Anaero.ic
:a$oon
7"Stage Barenpho syste*
TN
200 mg/L
TN
7 mg/L
Car.on,
Alkalinity
!ostDAnoic
Basin
Reaeration
Basin
Car.on
TN
40 mg/L
!ork !lant , Effluent /itro$en
0
5
10
15
20
25
30
35
40
45
50
1-Nov-08 3-Jan-09 7-Mar-09 9-May-09 11-Jul-09 12-Sep-09 14-Nov-09 16-Jan-10
T
o
t
a
l

N
i
t
r
o
g
e
n
,

m
g
/
L
Effluent -/
Probably lost nitrification
Sitched from Final
!larifier
to "F Membranes
Influent -K/ avera$ed 'GG m$6l
Simultaneous /itrification6#enitrification
+ Biolo$ical 0rocess occurrin$ concurrently in same
reactor
+ Relies on dynamic .alance of #)6B)#6/H
(
+ 5tiliCes control of aeration .y #) or ammonia
concentration
+ Reduces oy$en reAuirements and recovers
alkalinity
+ -otal nitro$en removal
Simultaneous /it6#enit
65: O
6
78: Carbon
;8: Carbon
'itriication(Aerobic
)enitriication(Ano*ic
2 mol 'itrite
3'.
/
(4
2 mol 'itrite
3'.
/
(4
2 mol 'itrate
3'.
0
(4
5 mol 'itrogen 6as
3'
/
4
2 mol Ammonia
3'H
0
# 'H
+
7
4
Autotro8hs
Heterotro8hs
=5: O
6
0&+0 g .
/
#g 'H
+
(' o*idized
/&2(0&1 g C.)#g '.
0
(' reduced
,&- g CaC.
0
#g 'H
+
(' o*idized
recover /&09 g CaC.
0
#g '.
/
(' reduced
/itro$en Removal Simultaneous
S$R
.*idation )itch
$iodenitro
: C%clic Aeration
;wo <one Activated
Sludge with ). Control
(--!uentF
N+
7
"N M 7 *gA1
TN M ; *gA1
Simultaneous /it6#enit
S/#
Basin
4inal
Clarifiers
RAS 2'Q3
WAS
4rom
Anaero.ic
:a$oon
Car.on
Alkalinity
!ost
Aeration
/H( 6 #)
Control
+ Target e--!uent N+
9
in -irst stage
+ Target DO in -irst stage 8584"8545 *gA1
+ Denitri-ication epenent on DO contro! an BOD aDai!abi!ity
Potentia! %Dantages
+ (!i*ination o-
separate tan.s2
interna! recyc!e
+ Si*p!er process
esign
+ 'euction o- carbon2
o)ygen2 energy2 an
a!.a!inity
consu*ption
Potentia! DisaDantages
+ 1i*ite contro!!e aspects
o- the process
+ F!oc siHes
+ ?nterna! COD storage
+ DO pro-i!e within -!oc
+ S!ower Growth 'ates
+ 1arger Tan. SiHes
+ S!uge bu!.ing2
-i!a*entous bacteria
growth
+ Co*p!e) instru*entation
Si*u!taneous NitADenit
Anammo
65: O
6
78: Carbon
'itriication(Aerobic
)enitriication(Ano*ic
2&90 g .
/
#g 'H
0
(' o*idized
= g C.)#g '.
/
(' reduced
0&2 g CaC.
0
#g 'H
0
(' o*idized
2 mol 'itrite
3'.
/
(4
2 mol 'itrite
3'.
/
(4
2 mol 'itrate
3'.
0
(4
5 mol 'itrogen 6as
3'
/
4
2 mol Ammonia
3'H
0
# 'H
+
7
4
Autotro8hs
Heterotro8hs
78"58: O
6
=5: O
6
;8: Carbon
#efinition
#evelo0ed in Euro0e
Bactera
+ Autro0hic , 5se C)
%
as Car.on
&r!'t( C!)*t!)+
+ Anaero.ic6Anoic
+ -em0erature %&D(;NC
+ Bery slo* $ro*ers ,
, :on$ slud$e a$e O (& days
+ /H
I
U F /)
%
D ratio V ' F '"(%
, 0H 2neutral ran$e3
, /itrite 2maintain at KI& m$6:3
, 4ree Ammonia 2maintain at K'&
m$6:3
+ )nce 7ro*n Bery Sta.le D Can
.e stored for months *ith no
food"
Anammo !roviders
+ !aAues BB
, 50flo* $ravity se0aration
+ Anita Mo
-M
.y Beolia Water -echnolo$ies
, !lastic .iofilm carriers
, Similar to MBBR
+ #EM)/
W
.y World Water Works
, WAS cyclone se0aration
, SBR reactor
Anammo 2#EM)/
W
3
)0erational !hiloso0hy
4 process cyc!e o- the
D(#ON inDo!Des 7 ti*e"
contro!!e phasesF
+ %eration phase
+ Fi!! A 'eact phase
+ Sett!ing phase
+ Discharge phase
Stanar (--!uent
>8: re*oDa! N+
7
"N
48: prouction NO
9
"N
<8: re*oDa! TN
4ull Scale )0eration
+ Re$ular sam0lin$
+ SensorsF 0H, #), conductivity,
/H
(
D/
+ Re$ular )0eration
, #) ran$e of &"(D&"I m$6:
2durin$ aeration 0hase3
, 0H ty0ically ?"&
+ Avoidance nitrite accumulation
+ #o*ntimes
#EM)/
W
#esi$n ReAuirements
+ !retreatment
, Most B)#, -SS removed
, !reDstora$e tank 2=D'% hrs HR-3
+ #esi$n 0arameters
, -otal6solu.le C)#, -K/, /H
(
D/, Alkalinity, !)
I
D!,
-SS, -em0erature, 0H
, 4lo* 2aver6ma3J slud$e 0rocessin$
+ -ank reactor
, )0erates as SBR, .ut can .e continuous flo*
#EM)/
W
MaXor Com0onents
See S!uge %eration
Syste*
?nstru*ents &
Contro!s
Tan.
B!owers Decanter #i)er Cyc!one
Com0arison
N6
C.
/
emissions > +&- t C./#t '
NO9
C(source
/&0 lb
Methanol#lb '
N+7
!nerg% 2&/- "Wh#lb '
Nitri-icationADenitri-ication
N6
C.
/
reduction (=&+ t C./#t '
NO6 A N+7
C(source
= lb
Methanol#lb '
N+7
!nerg% =&,= "Wh#lb '
D(#ONN"syste*
#emon Results D Sidestream
+eie!berg2 Ger*any
46;2888 ga!AayO 42988 *gA1 TN
P+OSP+O'$S '(#OK%1
Biolo$ical !hos0horus Removal
+ Many !rocess )0tions
+ Anaero.ic Tone key to 0rocess
, 7ro* !hos0horus Accumulatin$ )r$anisms 2!A)s3
+ -y0ically achieves K'"& m$6:
+ Hi$h influent Sol B)#6! is reAuired
, car.on6B4A addition via fermentation
+ !rocess sta.ility is key" Conditions that favor the
ri$ht !A) 0o0ulations are need to .e understood
Biolo$ical !hos0horus Removal
%!*,e* (-.+tage) Bar*e)p(!
/CT
%!*,e* /CT
012 (0rg)a
1)tat3e
2r!ce++)
(--!uentF
TP M 4 *gA1
OP M 855*gA1
Chemical !hos0horus Removal
+ Chemical )0tions
, 4erric Salts 24erric Chloride, 4errous Chloride3
, Alum
, Sodium Aluminate
, :ime
+ ReactionF 4eCl
(
Y !)
I
4e!)
I
Y (Cl
+ #osa$eF -heory F ;"%I l.s 4eCl
(
6 l. !
ActualF '&"I> l.s 4eCl
(
6 l. !
RateF ("' $allons (&H 4eCl
(
6 l. !
-y0ical Chemical -reatment )00ortunities
Primar% Secondar% ;ertiar% Polish
Solids
Processing
T('T?%'P T'(%T#(NT
-ertiary -reatment
+ -reatment 7oal , Remove additional -SS, -/, -!
not ca0tured in secondary treatment 0rocesses"
+ Sim0le -SS Removal
, -ertiary Clarifier
, Cloth 4ilter #isk
, Sand 4ilter
+ More Com0le
, Mem.rane Bioreactor
, 5ltra 4iltration
, R)
TN 'e*oDa!
+ Bio!ogica!!y %ctiDe Fi!ter ,B%F0
+ Sub*erge Bio-i!ter
American Meat Institute
Conference on Worker Safety, Human
Resources and the Environment
Kansas City, Missouri
Brian Mulini, !"E"
Brian Bakke, !"E"
H#R En$ineerin$, Inc"
March %&, %&'(
Guestions&
Wastewater Design &
Best Practices