Rob Herbon - Fremont Industries

1. Water Treatment Optimization
Overland Park Marriott
December 10, 2014

2. WATER TREATMENT
One Size Does Not Fit All!
All Methods are not the same!

4. TOWER INTERNALS

5. PLATE & FRAME HEAT EXCHANGER

6. HEAT EXCHANGER CLEANING

Beer/Mash exchanger cleaning and inspection

Propagation

Fermentation

Mash Cooler

Cookwater Preheater

Counter flow can greatly aid in complete cleaning of heat exchanger surfaces containing biofilms

Biofilms – Consist of bacteria living within a matrix of excreted DNA, proteins, and polysaccharide compounds. This matrix protects the cells from all antimicrobials

7. HEAT EXCHANGER CLEANING

8. WHY TEMPERATURE MATTERS

High temperature may result in damage to yeast cell

Larger the temperature increase, the greater the yeast cellular damage. Increases above 35°C (97°F) may not only increase the cell damage but may result in decrease in the final [EtOH] under some conditions.

Thermal damage results in a reduction (denaturation) of:

Proteins

Nucleic acids

9. HEAT EXCHANGER IN PROCESS

10. SLIMED UP TOWER FILL

11. SLIME BUILDUP

12. Anaerobic Bacteria from Basin

13. SAND FILTER

14. CORROSION CAUSED BY SRB

15. MICROBIOLOGICALLY INDUCED (MIC)

16. pH (Range 0 – 14) “The acidity or alkalinity of a liquid”
Sulfuric Acid RO Cooling Tower
Vinegar City Tap Boiler Caustic

17. RELATIVE ACTIVITY vs. pH
pH %HOCL %HOBR
6 97 100
7 78 98
8 26 83
9 3 33

20. MICROBIO FOULING PREVENTION
Keep System Clean
Eliminate
“Dead Legs”
Minimize Exposure to Sunlight
Employ Effective Biocide Program

21. MICROBIO MONITORING

Visual Inspection

Monitoring Heat Exchanger ΔP and ΔT

Bacteria / Fungi Testing of Tower Water
o
Aerobic/Fungi Paddle Cultures
o
Dip Slides
o
Anaerobic Specific- Bart, SRB, IRB

22. BART ANAEROBIC CULTURES

23. FILLING BART IRB CULTURE

24. AMOEBA FILAMENTS
Laboratory Analysis

25. X-RAY TECHNOLOGY

26. ZERO GRAVITY SYSTEM 2000

27. ZERO GRAVITY 8 POD UNIT

28. SPECIALIZED EVAPORATION
Concentrate Thin Stillage Syrup After De-Oiling from Typical ~36%TS to ~48%TS
Achieve This Evaporation Duty Using Mechanical Vapor Recompression (MVR) Heating with Electrical Power Without Disrupting Thermal Energy Balance of Existing Evaporator Systems
Reduce Water Evaporation Duty and Energy Duty of Dryer by ~40% (per dry syrup solids basis)

29. EVALUATING ZLD
Potential impacts to production
Recycling water to new areas
Biocides limited (Chlorine-ClO2)

30. ZERO LIQUID DISCHARGE
ZLD is somewhat of misnomer; Discharge issues are about the dissolved and suspended solids in the water, not the liquid itself.
ZLD means not allow any waste and/or process water to be discharged from the plant.

31. WHAT ARE THE FINANCIAL INCENTIVES FOR ZERO LIQUID DISCHARGE (ZLD)
Eliminates restrictive operational component from plant
Eliminates discharge fines and possible shutdowns
Enables plant expansion projects
Reduces or Eliminates discharge surcharge (POTW)