Established Innovation in Treatment of Food …...5/5/2016 1 Innovation in Treatment of Food Processing Wastewater Karen Mancl, PhD Professor Food, Agricultural & Biological Engineering,

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Innovation in Treatment of Food Processing Wastewater

Karen Mancl, PhD

Professor Food, Agricultural & Biological Engineering, OSU

Wastewater Treatment

• Established technologies

• Domestic wastewater

Wastewater Treatment

• Established technologies • Domestic wastewater

Discharge to City Sewer?

Domestic Sewage Food Processing Wastewater

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Discharge to City Sewer?

Different from sewage

• 5 times stronger

• 100 times more grease

Food Processing Wastewater

Discharge to City Sewer?

Different from sewage

• 5 times stronger

• 100 times more grease

Food Processing Wastewater

Must change the wastewater

• Expensive

• Not very effective

Change treatment technology?

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Change the treatment technology

Sand Bioreactor System

• Effective

• Low-cost

Designed to treat food processing wastewater

Whitewater Processing

• Kopp Family Business

– 4th generation

– 110 employees

– 7000 turkeys per day

Whitewater Processing

• Kopp Family Business

– 4th generation

– 110 employees

– 7000 turkeys per day

– Contacted OSU in 2000

Ohio EPA orders – Abandon old ponds

Discharging Pipe Storage Pond Lagoon

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Options

• Connect to city

• City of Harrison – 10,000

people

Differences

Pollutant Domestic

wastewater

Slaughterhouse

wastewater

Organic matter (BOD5) 200 800

Suspended solids 150 600

Ammonia 20 40

Fat, oil & grease 2 200

Options

• Connect to city

• City of Harrison – 10,000

people

• 20 year cost $12.5 million

Why so expensive?

• City uses a mechanical,

aeration plant

• Wastewater has too much

• Fat

• BOD5

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Mechanical Treatment Why my lab?

• Innovation in wastewater treatment

• Food, Agricultural & Biological Engineering

• Small flows

• Agricultural wastewaters

Industry open to new options

Lawsuit Close

Regulators open to new

options

Protect environment

Retain Jobs

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Develop & build

full-scale system

Dr. Karen Mancl

Professor Food, Agricultural &

Biological Engineering

Ryan Kopp

Owner, Turkey Slaughterhouse

Secondary Treatment

Sand bioreactor

Before & After Microbial Biofilms

sand

air

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Biofilm

25 26 Gaur, Cai, Mancl, and Tuovinen. 2010.

Sand Treatment

Microorganisms

Organic matter & ammonia is their food

Sand Treatment

Create ideal environment for microorganisms

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Sand Treatment

Create ideal environment for microorganisms

Surface to attach to

Air

Water

Food

sand 土壤 Pore space

sand

土壤 土壤 Pore space

sand

B

I

O

F

I

L

m

Waste

water

土壤 土壤

air

Organic matter

CO2

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土壤 土壤

air

Organic matter

CO2

Ammonia

air

土壤 土壤

air

Organic matter

CO2

Ammonia

air

nitrate

CBOD5

0

5

10

15

20

25

30

35

40

45

50

July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar

30-day limit CBOD2013 2015

Ammonia

0

1

2

3

4

5

6

7

8

9

10

July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar

30-day limit Ammonia

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Before & After

Since 2012 – full-scale system meets all regulatory discharge standards

Fat, Oil and Grease Removal

Influent Effluent

FOG FOG

Sept. 6, 2012 212 Not detected

Oct. 30, 2012 139 Not detected

Nov. 19, 2012 189 Not detected

Dec. 19, 2012 374 Not detected

Jan. 9, 2013 80.8 Not detected

Feb. 13, 2013 168 Not detected

Feb. 27, 2013 273 Not detected

Mar. 27, 2013 42.4 Not detected

Options

• City of Harrison

• Annex

• Sewer extension

• Pretreatment

• Surcharge

Decentralized

• Sand bioreactor

• Onsite construction

• Discharge permit

Costs

Connect to City

• $12.5 million

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Costs

Connect to City

• $12.5 million

New System

• $2.6 million

Costs

Connect to City

• $10.56/1000 gal

• Plus pretreatment

New System

• $3.90/1000 gal

• No pretreatment costs

DAF

Why costs so low?

Simple to build Easy to operate

• Low electricity

• No sludge

• 1 full-time operator

Liners with underdrain

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Media Layers of sand, coarse sand &

pea gravel

Construction

• Easy

• Local force labor

• Purchased construction equipment

• Local aggregate company

Restaurants

Food processors

Resorts

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Conclusions

• Sand Bioreactors

• Best option for food processing wastewater

• Local jobs

• Saved money

• Protects stream

setll.osu.edu