Water, Waste Water Treatment and Re-use

in the Beer-, Malting and Beverage Industry

Thijs Wolbrink
David Parocki
March 2009

Contents

Basis for WWTP and Re-use: Ultrafiltration Membranes

Process Water Production Concepts (well / city / surface)
Waste Water Treatment Concept: Effluent Polishing
Waste Water Treatment Concept: Norit MBR-technology
Introduction MBR
Applications and Implementations
Norit Water Audit
Case Studies (Process Water Prod. / Effluent Polishing / MBR)
References Process Water/Water re-use in B&B
Water qualities and quantities statements

Basis for WWTP and Re-use

Norit Ultrafiltration Membranes (0)
Micro
Filtration
10 um 100 nm

Ultra
Filtration
100 - 10 nm

giarda
crypto
bacteria

Nano
Filtration
10 - 1 nm
colour
hardness
pesticides

colloids
viruses

colloids
viruses
colour
hardness
pesticides
salts
water

Reverse
Osmosis
< 1 nm

colour
hardness
pesticides
salts
water

salts

salts
water

water

Basis for WWTP and Re-use

Norit Ultrafiltration Membranes (1)
Early 1990s
X-Flow
Hollow Fibre Membrane Capillary
PolyEtherSulfon
XIGA-technology
ID : 0,8 mm
ID : 1,5 mm
Potable Water / Process Water
Well Water / Surface Water

Basis for WWTP and Re-use

Norit Ultrafiltration Membranes (2)
2000
Acquisition Stork Friesland
Tubular Membrane
PVDF-membrane (Polyester support)
Aquaflex-technology
ID : 5,2 mm
ID : 8,0 mm
Process Water / Re-use
Surface Water / Waste Water

Norit Solutions for the B&B-Industry (1)

surface water
city water
ground water
polishing

polishing

polishing

re-use

process- and / or productwater

customers existing WWTP
effluent

raw wastewater

brewery / factory

effluent
polishing

MBR

discharge

Norit Solutions for the B&B-Industry (2)

Process- and/or Brew Water Production Concepts

NanoFiltration/Reverse Osmosis (Well Water)
Ultrafiltration + Activated Carbon (City Water)
Ultrafiltration + NanoFiltration (Surface water)
Waste Water Treatment and Re-Use Concepts
Effluent Polishing
Membrane Bio Reactor (MBR)

Why additional polishing

Full re-use at proces and bottle cleaning requires
drinking water standard!
Ultra Filtration permeate is excellent basis for re-use
Free of suspended solids and turbidity
Free of bacteria and virusses

However, only UF on WWTP-effluent is not giving

drinking water

RO removes residual COD/BOD and salts

ClO2 gives primary desinfection
GAC removes residual ClO2 and organics
UV gives final desinfection

New Greenfield Brewery

Optimal re-use = 1.6 hl/hl
Total 17.3 m hl/y Water
4800 m3/day
200 m3/h

8.6 m hl/y
City water
100 m3/h

Potable
treatment

80 m3/h

5.4 m hl/y Beer

80%

Re-use water
120 m3/h

13.6 m hl/y Waste water

3650 m3/day
157 m3/h

UV

GAC

ClO2
RO
75%

RO-waste
40 m3/h

WWTP
with UF-airlift

UF-permeate to discharge
0 m3/h !!!

Concepts - Effluent Polishing (1)

Conventional system
AT

CT

aeration tank

clarification tank

Effluent polishing
AT

Based on X-Flow Hollow Fiber

CT

Capillary UF Membrane
PolyEtherSulphon ID = 0,8 mm
M

membrane unit

Concepts - Effluent Polishing (2)

Concepts Membrane Bioreactor (2)

Conventional System
AT

aeration tank

CT
Based on X-Flow Tubular UF

clarification tank

Membrane
PVDF ID = 8 mm

Membrane Bioreactor
AT
side-stream

Concepts Membrane Bioreactor (3)

SYSTEM CONCEPTS
Crossflow MBR

Membrane

Excess
sludge
Bioreactor
Feed pump
Circ. pump

Crossflow UF

Permeate

Concepts Membrane Bioreactor (4)

SYSTEM CONCEPTS

AirLift

continuous
air injection

Concepts Membrane Bioreactor (5)

MBR vs Conventional treatment:
Conventional:
Low MLSS * (3-5 g/l)
Low age activated sludge
Only floc forming bacteria
Only fast growing bacteria

high sludge production
Few component-specific bacteria
Sludge carry-over
Effluent polishing required
Large footprint
* MLSS = Mixed Liquid Suspended Solids

MBR:
High MLSS * (10-20 g/l)
High age activated sludge
All kind of bacteria survive
Fast and slow growing bacteria

less sludge production
Many component-specific bacteria
No sludge carry-over
High quality filtrate
Smaller footprint

Applications and Implementation (1)

Greenfield

WASTE
WATER

OPTION

BUFFER
TANK

BIO REACTOR
ANAEROBIC

BIO REACTOR
AEROBIC

UF-PERMEATE
TANK

Applications and Implementation (2)

Existing Anaerobic plant

WASTE
WATER

BUFFER
TANK

Existing

BIO REACTOR
ANAEROBIC

BIO REACTOR
AEROBIC

UF-PERMEATE
TANK

Applications and Implementation (3)

Existing Anaerobic/Aerobic plant

WASTE
WATER

BUFFER
TANK

BIO REACTOR
ANAEROBIC

Existing

BIO REACTOR
AEROBIC

UF-PERMEATE
TANK

Norit Water-Audit (1)

BEVERAGE
BEVERAGE
BREWERY
BREWERY

QUANTITY
QUANTITY
QUALITY
QUALITY

CIP water

? l/hr.

Dilution for chemicals

? l/hr.

Flush/cleaning water
Rinsing of Crates

? l/hr.

Rinsing of Bottles

? l/hr.

Cleaning of Floors

? l/hr.

Pasteurizers

? l/hr.

Bottles

? l/hr.

Buildings

? l/hr.

Boiler Feed Water

? l/hr

Process water

UF-PERMEATE
TANK

BASIS UF-Permeate:
SS = 0
No bacteria/viruses

WATER
WATER
AUDIT
AUDIT

Norit Water-Audit (2)

WATER AUDIT

Selection of Polishing

Activated Carbon: removal of organics (colour, smell, taste)

Reverse Osmosis: removal of salts / softening
UV-desinfection: bacteria and virus barrier
Ion exchange: removal of ions/softening
Combinations of above technologies or others

General Water consumption of a brewery

hl water / hl beer
Flush water; 0,8
BW brewing; 1,2
Demin water (boiler
feed); 0,1

Plant water (service); 0,4

BW Process cleaning;
0,7

SW Bottle / kegs
cleaning; 0,8
Water type

Use

hl/hl

Brewing Water

Brewing

1,2

30

Process cleaning

0,7

17,5

Soft Water

Botte / kegs cleaning

0,8

20

Plant water

General / service

0,4

10

Demin water

Boiler feed

0,1

2,5

Flush water

Rince/concentrate from RO/IEX

0,8

20

4,0

100

Total

New Greenfield Brewery

5.4 m hectolitres / annum

21.6 m hl/y Water

6000 m3/day
250 m3/h

5.4 m hl/y Beer

16.2 m hl/y Waste water

4500 m3/day
187 m3/h

Basis for design; 4 hl water / hl beer

Where to re-use?
Demin water (boiler feed);
0,1
Plant water (service); 0,8

BW brewing; 1,2

SW Bottle / kegs cleaning;

1,2

BW Process cleaning; 0,7

Water type

Use

hl/hl

Re-use

hl-reuse

Brewing Water

Brewing

1,2

Not

Process cleaning

0,7

25%

0,2

Soft Water

Botte / kegs cleaning

0,8

25%

0,2

Plant water

General / service

0,4

100%

0,4

Demin water

Boiler feed

0,1

100%

0,1

Flush water

Rinse / concentrate from RO / IEX

0,6

n.a.

n.a.

3,8

24%

0,9

Total

New Greenfield Brewery

24% re-use = 2,85 hl / hl34
17.3 m hl/y Water
4800 m3/day
200 m3/h

15.4 m hl/y
City water
178 m3/h

5.4 m hl/y Beer

Potable
treatment
80%

Re-use water
58 m3/h

14.9 m hl/y Waste water

4150 m3/day
173 m3/h

RO

UF-permeate to re-use
77 m3/h

75%

flush

WWTP;
RO;

Waste water treatment plant

Reverse Osmosis

WWTP
with UF-airlift

UF-permeate to discharge
96 m3/h

Anaerobic, Aerobic, Airlift Ultra Filtration

Final removal COD

Where to re-use?
Re-use 54% = 1.6 hl / hl
Demin water (boiler feed);
0,1
Plant water (service); 0,8

BW brewing; 1,2

SW Bottle / kegs cleaning;

1,2

BW Process cleaning; 0,7

Water type

Use

hl/hl

Re-use

hl-reuse

Brewing Water

Brewing

1,2

Not

Process cleaning

0,7

25%

100%

0,2

0,7

Soft Water

Botte / kegs cleaning

0,8

25%

100%

0,2

0,8

Plant water

General / service

0,4

100%

0,4

Demin water

Boiler feed

0,1

100%

0,1

Flush water

Rinse / concentrate from RO / IEX

0,3

n.a.

n.a.

3,5

23%

Total

57%

0,9

1,9

Additional polishing:
- ClO2,
- GAC,
- UV

Re-use water
120 m3/h

Case Study
Process-water reuse for Maltery Eemshaven

Case Study
Process-water reuse for Maltery Eemshaven
The treatment capacity of the plant is 65 m3/h
The maltery processwater will be reused for more than
80% after treatment (other 20% allowable discharge on
surface water)
The plant consists of a Norit MBR system followed by
Activated Carbon filtration and UV disinfection
The produced processwater has a waterquality according
to Dutch drinking water requirements

Case Study
Process-water reuse for Maltery Eemshaven
13

Natronloogdosering
(Optie)
12

31

01

20

03
02

34

CIPTANK
2 m3

35

PERMEAATTANK
25 m3

21

25

06

22

23

PERMEAAT
POMP

CIP POMP

11
SCHUIMLANSEN

05
BIOREACTOR
1730 m3

BUFFERTANK
1500 m3

POMPPUT 2m3

KONTAKTTANK
300 m3

07
13

BIOREACTOR
1730 m3

PT

11

VOEDINGSPOMP

UF/CF-unit

AKTIEF
KOOL
FILTER

AKTIEF
KOOL
FILTER

10

09

04

12
36

BLOWER

14 CIRC. POMP

13

08

BLOWER

11
37

UF/CF-unit

09

10
24

12
15 CIRC. POMP

BLOWER

08

32
13

11
UF/CF-unit

UV-desinfectie

10

09
12
19

26

16 CIRC. POMP

08

33
UF/CF-unit

09

SLIBVOEDINGSPOMP

10
12

TRANSPORTSCHROEF

17 CIRC. POMP
30

13

11

DECANTER

29

FIT

28
27

18
CONTAINER
15 m3 (20TON)

Polymeer dosering

08

Case Study
Process-water reuse for Maltery Eemshaven
Conventional
system

MBR

Bioreactor m3

5200

1740

Square meters m2 (layout)

900

350

Sludge content g/l (MLSS)

12

Sludge production kg
ds/day

750

500

Operational costs / m3

0,45

0,35

Case Study
Process-water reuse for Maltery Eemshaven
Design Parameters
Parameter

Unit

Influent

Effluent (after AC)

Flow

M3/h

65

55 + 10

Temperaturen

12-35

12-35

pH

6-8

6-8

TSS

Mg/l

<200

<0,1

COD

Mg/l

1500

<40

BOD

Mg/l

1350

<5

N-kj
PO4-P

Mg/l
Mg/l

50
10

<5
<1

Case Study
Process-water reuse for Maltery Eemshaven
Reasons for Holland malt to choose Norits MBR

Proven technology
Robust system
Simple process set-up
Small footprint
Low chemical usage
Low sludge production
Operational costs: 0,3-0,4/m3 (exclusive depreciation/interest)

Case Study
Waste-water reuse for Boon Rawd Brewery
Facts and Figures:

Client : Boon Rawd Brewery, Khon Kaen, Thailand

Raw Water Source: Tertiairy Effluent
NMT Technology : SF-XigaUF-RO-UV
Effluent : acc. to EU potable water legislations
Capacity : 100 m3/h for re-use
OPEX : 0,20-0,30 euro/m3

Case Study
Waste-water reuse for Boon Rawd Brewery
Treated Water Purposes:
Dilution water for the preparing of Chemical
Cleaning Solutions
Cleaning of crates
Cleaning of floors, walls and buildings
Other cleaning purposes
Other water purposes

Project start

: July 2006

Start-up

: March 2007

Case Study
Waste-water reuse for Martens Brewery
Facts and Figures:

Client : Martens Brewery, Bocholt, Belgium

Raw Water Source: Brewery Waste Water
NMT Technology : Crossflow MBR phase 1 and RO-UV phase 2
Effluent : acc. to EU potable water legislations
Capacity : 30 m3/h for re-use in phase 2
OPEX : 0,30-0,40 euro/m3

Case Study
Waste-water reuse for Martens Brewery
Treated Water Purposes in Phase 2:

Dilution water for the preparing of Chemical Cleaning

Solutions

Cleaning of crates
Cleaning of floors, walls and buildings
Other cleaning purposes
Other water purposes

Project start

: July 2006

Start-up phase 1 : July 2007

Start-up phase 2 : 2009-2010

Case Study
Waste-water reuse Polar Brewery Caracas
Facts and Figures:

Client : Cerveceria Polar, Caracas, Venezuela

Raw Water Source: Brewery Waste Water
NMT Technology : Airlift MBR and RO
Effluent : potable water quality
Capacity : max. 70 m3/h for re-use
OPEX : 0,30-0,40 euro/m3

Case Study
Waste-water reuse Polar Brewery Caracas
Treated Water Purposes
Dilution water for the preparing of CIP
Solutions
Cooling
Pasteurization
Steam production
Other water purposes

Project start

: February 2008

Start-up

: December 2008

Case Study
Waste-water reuse Unicer Brewery
Facts and Figures:
Client : Unicer Brewery - Porto
Raw Water Source: Biological Treated Effluent
NMT Technology : SF + XIGA UF + UV
Effluent : free of SS, bacteria and virusses
Capacity : 45 m3/h (re-use 30 m3/h)
OPEX : 0,47 euro/m3
Example of a successful integration of conventional
and membrane technology for water reuse according
to customers specifications

Case Study
Waste-water reuse Maltery Obolon
Facts and Figures:

Client : Obolon Maltery - Ukraine

Raw Water Source: Raw waste water Maltery
NMT Technology : Crossflow MBR
Effluent : Free of organics, bacteria and virusses
Capacity : Initial 63 m3/h (extension 100 m3/h)
OPEX : 0,3-0,4/m3

Case Study
Process Water Production Bavaria
Facts and Figures
Client: Bavaria, Lieshout (the Netherlands)
Raw Water Source: Well Water
Capacity: 250 m3/h
Process: De-Ironing + NanoFiltration
Hardness Product water: 1-2 DH
Bacterial and Virus Free
OPEX: 0,35/m3

Case Study
Process Water Production Heineken
Facts and Figures

Client: Heineken, Den-Bosch (the Netherlands)

Raw Water Source: Well Water
Capacity: 540 m3/h
Process: Anaerobic NanoFiltration Lime dosing
Hardness Product water: 2 DH
Bacterial and Virus Free
OPEX: 0,4/m3

Case Study
Process Water Production Zujiang Brewery
Facts and Figures

Client: Zujiang Brewery, China

Raw Water Source: City Water (unsafe)
Capacity: 120 m3/h
Process: XIGA-UF
Hardness Product water: 8 DH
Bacterial and Virus Free
OPEX: 0,2/m3

Case Study
Process Water Production Coca-Cola
Facts and Figures

Client: Coca-Cola Wakefield, U.K.

Raw Water Source: City Water
Capacity: 400 m3/h
Process: AC + XIGA-UF
Bacterial and Virus Free
OPEX: 0,3-0,4/m3

References Wastewater treatment and re-use

in Food, Beer & Beverage industry
CUSTOMER
CAPACITY
PURPOSE
TECHNOLOGY
------------------------------------------------------------------------------------------------------------- Kanes Foods
40 m3/h
WWTP
MBR
Cerestar
70 m3/h
WW-reuse
UF-RO
LambWeston&Meijer
50 m3/h
WW-reuse
UF-RO-UV
Pasfrost
20 m3/h
WW-reuse
UF-RO
Frosta Elbtal
66 m3/h
WW-reuse
UF-RO
Paulaner Brauerei
15 m3/h
WW-reuse
UF-RO-UV
Cargill Corn
35 m3/h
WW-reuse
MBR
Polar Cerveceria
50 m3/h
WW-reuse
UF-RO
Holland Malt
65 m3/h
WW-reuse
MBRAC-UV
IFBM/MAGB
3 m3/h
WW-reuse
MBRAC
Unicer
45 m3/h
WW-reuse
SF-UF-UV
Boon Rawd Brewery
100 m3/h
WW-reuse
SF-UF-RO-UV
Obolon Maltery
100 m3/h
WW-reuse
MBRAC
Martens Brewery
30 m3/h
WW-reuse
MBRROUV
Polar Cerveceria
100 m3/h
WW-reuse
MBR-RO

References Water Treatment

in Food, Beer & Beverage industry

CUSTOMER
CAPACITY
PURPOSE
TECHNOLOGY
------------------------------------------------------------------------------------------------------------- Zhujiang Brewery
120 m3/h
bacterial barrier UF
Quingdao Brewery
80 m3/h
process water
RO
Koninghoeve Brewery 20 m3/h
softened water
RO
Bavaria Brewery
180 m3/h
softened water
NF
Bavaria Beverage
65 m3/h
softened water
NF
Danone Bierun
30 m3/h
bacterial barrier UF
Menken/Coca Cola
120 m3/h
bottling water
RO-AC-UV
Coca Cola Wakefield 400 m3/h
bacterial barrier AC-UF
Danone Warsaw
30 m3/h
bacterial barrier UF
Heineken Den Bosch 540 m3/h
softened water
anaerobic NF
Suzhou Brewery
120 m3/h
bacterial barrier UF-AC-ClO2
Bavaria Brewery
80 m3/h
softened water
NF
Refresco/Coca Cola 80 m3/h
bottling water
RO-AC-UV
Brasserie dOrval
12 m3/h
softened water
RO
Westmalle
40 m3/h
bacterial barrier UF

Water Qualities and Quantities

Statements
Norit Membrane Technology can treat all kind of
water sources

Norit Membrane Technology can produce out of all

kind of water sources all water qualities needed by
combination of membrane- and conventional
technologies

Norit Membrane Technology can find an economical

attractive solution for all kind of water house keepings
in all kind of Industries

No doubts. Norit. Just Proof.

Thank you for your attention