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Mustard Waste Treatment Design
- 1. Mustard Waste Treatment Design Final Report Matt Rosen, Ian Melville, Cahner Jennice, Matt Rimer, Kira Bartlett http://www.howiamlosingweight.com/wp-content/uploads/2013/09/Mustard-forms.jpg
- 2. The Company Olds Products Mustard Production Facility Located in Pleasant Prairie, Wisconsin http://www.oldsproducts.com
- 3. Table of Contents Introduction -Problem -Existing Solution Research and Analysis Design and Methodology -Governing Equations -Economic Analysis Summation
- 4. Mustard Production Batch system (seasonal emphasis) - 9000 gallon limit Two shifts a day (20-24 hours) Ingredients: mustard seed, vinegar, brine, spices and water -Automatically metered -Minor ingredients added by operator
- 5. Waste Production Machines are cleaned with each flavor change -Multiple cleanings per day -Cleaning water heated to 120 °F Periodic caustic wash All waste pumped into 6,000 gallon reservoir
- 6. The Problem http://www.wrc.org.za Unable to discharge wastewater through sewer system Complaints from Pleasant Prairie municipal water treatment plant -pH is too low (3.3) with a required pH range between 5.5-9 pH (Kenosha) -Discharge volume is too high
- 7. Current Solution - Land Application Waste Solids sprayed or injected on farmland $200,000 annual cost supernovatrucking.com/index.php?option=com_content&view=article&id=11&Itemid=10 ohioline.osu.edu/aex-fact/0707.html
- 8. Project Goals Solve immediate problem of waste disposal Create/obtain a usable and harvestable byproduct Create Economic and Sustainable viability -Design simplicity -Water capture and reuse
- 9. Constraints Geographic: Pleasant Prairie, WI v. Clemson, SC Company Budget Municipal Codes (Wastewater treatment guidelines) Current operating procedures Limited information - No previous waste analysis FDA and Organic regulations
- 10. Considerations Safety -Working with chemicals and reagents -Industrial food plant - FDA and organic regulations Ecological -Impact of treated water products on environment -Distinct seasonal change in Wisconsin Ethical -Company contact is the relative of a team member
- 11. Design Questions User Perspective: How does it work? What do I need to do to run it? What is the maintenance/upkeep needed? Client Perspective: How much will it cost? What is the system's size? Can it be easily incorporated into other facilities? Designer Perspective: What is the problem with the waste? How much waste needs to be processed? At what rate? Is there a maximum start up cost or ROI timeframe?
- 12. Pressure Filtration Vacuum Filtration Harrison pg. 120 K. Bartlett Forced Filtration
- 13. Gravity Separation Centrifugation Imhoff Cone Separation: 70% aqueous solution 30% solids Sedimentation K. Bartlett http://3.bp.blogspot. com/_xW3FQUQ2DYI/Rp4DF1r_0HI/AAAAAAAAAhY/B5MzdxV SV6I/s400/centrifugation.png
- 14. Coagulation and Flocculation Assembles smaller suspended particles into larger particles Easier and faster to separate or filter Neutralize surface charges image.slidesharecdn.com/typesofcoagulants-131004100124-phpapp01/95/types-of- coagulants-3-638.jpg?cb=1380881416
- 15. Electrolysis Uses an electric current to dissociate water into hydrogen and oxygen gases Electric potential shifts positive ions (H+ ) towards cathode and negative ions (OH- ) towards anode Theoretical pH increase Negative Energy balance 2 H2 O(l) --> O2 (g) + 4 H+ (aq) + 4 e- 2 H2 O(l) + 2 e- --> H2 (g) + 2 OH- (aq) 2 H2 O(l) --> O2 (g) + 2 H2 (g) Kargi and Ariken, 2013. “Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes”
- 16. Electrolysis: Lab Testing 500 mL setup 9 V current pH change from 3.24 to 3.14 Tested using Gas Chromatography -20.6% H2 -1.03 moles H2 per 2,000 gallons K. Bartlett K. Bartlett
- 17. Hydrogen Fuel Cell Combines hydrogen and oxygen to produce electricity Reaction in single fuel cell typically produces about 0.7 volts Electrochemical process - low emissions 2 H2 --> 4 H+ + 4 e- O2 + 4 H+ + 4 e- --> 2 H2 O 2 H2 +O2 --> 2 H2 O fuelcells.orgLin, 2000. “Conceptual design and modeling of a fuel cell scooter for urban Asia”
- 18. Scale-Up & Design Considerations 2,000 gallons per day Electrolysis: 267.5 kJ/day Hydrogen Fuel Cell: 245.1 kJ/day (max) → 30.3 kwh/year 132.4 kJ/day (practical) → 11.5 kwh/year Improve Electrolysis Efficiency Different type of Hydrogen Fuel Cell Corrosive Properties Kabza, 2015. “Fuel Cell Formulary” Kargi and Ariken, 2013. “Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes”
- 19. Sodium Hydroxide (NaOH): Sodium Bicarbonate (NaHCO3 ): Acetic Acid NaOH + CH3 COOH H2 0 + CH3 COONa (Sodium Acetate) Nitric Acid NaOH + HNO3 H2 0 + NaNO3 (Sodium Nitrate) Acetic Acid NaHCO3 + CH3 COOH H2 0 + CO2 + CH3 COONa Nitric Acid NaHCO3 + CH3 COOH H2 0 + CO2 + NaNO3 Chemical pH Adjustment
- 20. 42 mL of 0.1 M NaOH to reach ph of 6 = 0.0042 Moles of NaOH = 0.168 Grams of NaOH 12 mL of 0.5 M NaHCO3 to reach ph of 6 = 0.006 Moles of NaHCO3 = 0.504 Grams of NaHCO3 Titration Testing
- 21. 42 mL of 0.1 M NaOH to reach ph of 6 = 0.0042 Moles = 0.168 Grams 53 mL of 0.1 M NaOH to reach ph of 6 = 0.0053 Moles = 0.212 Grams Titration Testing
- 22. Potential Antimicrobial Properties Antimicrobial properties cited due to sinapic acid conjugates Primary Testing: Clemson Microbiology Department Secondary Testing: Home-scale testing Inconclusive Results Popova and Morra. 2014. Simultaneous Quantification of Sinigrin, Sinalbin, and Anionic Glucosinolate Hydrolysis Products in Brassica juncea and Sinapis alba Seed Extracts Using Ion Chromatography.
- 23. Primary Antimicrobial Testing Gravity Filtered Solids (original pH) Gravity Filtered Aqueous (original pH) Re-suspended solids from TSS testing (.11 μm filter) Re-suspended filtered solids with DI water (.45 μm filter) I. Melville I. Melville I. Melville
- 24. Secondary Antimicrobial Testing TSS Solids Bacteria from Mouth Filter Solids Bacteria from Mouth TSS Solids (Shoe) Filter Solids (Floor) TSS Solids (Face) K. Bartlett K. Bartlett K. Bartlett K. Bartlett K. Bartlett
- 25. Biological Treatment Yeast - Torula (Candida Utilis) Yeast glucose utilization C6 H12 06 + 6O2 → 6CO2 + 6H2 O + 16-18 ATP Initial COD estimates: 18 g/L Theoretical COD Reduction of 53% in 24 hours COD 18 g/L 9.5 g/L Postma, Kuiper, Tomasouw, Scheffers, and Dijken. 1989. Competition for Glucose between the Yeasts Saccharomyces cerevisiae and Candida utilis. Wongkarnka, 2005. The application of aerobic yeast for treatment of high strength food processing wastewater containing furfural. iSee Systems Stella Model
- 26. Total Suspended Solids Raw Waste Solution – 19,500 mg/L Gravity Separated Solution – 335 mg/L Unfiltered, Mixed Gravity Separated, Aqueous K. Bartlett
- 28. Component Testing - HPLC Nitric Acid (0.89%) Acetic Acid (0.43%) Unknown Kira
- 29. Advanced Filtration and Drying Cost of machinery and installation between $70,000 and $80,000 (quoted by M.W. Watermark and Kontek Ecology) Semi Automatic systems would need trained operators Future costs of equipment maintenance and replacement parts Disposal cost of solid waste
- 32. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Disposal to Pleasant Prairie Primary Treatment Stage Largest Volume of Treatment
- 33. Gravity Separation Stokes Law: * V = Settling Velocity μ = viscosity of liquid ρp = Density of Particle ρf = Density of Fluid g= gravity R= particle radius ts = settling time h= height of separation tank v = settling velocity ts = 15 hours 19,500 mg/L -> 335mg/L 98% Reduction in TSS 724 kg solids separated per dayDr. Muhammad Tahseen Aslam - Settling of solids in raw wastewater
- 34. Gravity Separation industrial-equipment.biz/assets/images/Cone-Tank- Separator.jpg plastic-mart.com/tech_drawings/norwesco/10000%20Gallon%20X%2030%20Deg% 20Cone%20Bottom%20Tank.pdf Total System Cost: $40,000 cdf1.com/technical%20bulletins/Polyethylene_Chemical_Resistance_Chart.pdf
- 35. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Solid mix held in holding tank prior to transportation Utilizes existing 6,000 gallon tank Disposal to Pleasant Prairie
- 36. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Disposal to Pleasant Prairie 3,000 gallons a day Land Application system already in place
- 38. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Disposal to Pleasant Prairie 10,000 gallon capacity Fully Insulated Two outlet streams -Water Recycling -pH Adjustment
- 39. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Disposal to Pleasant Prairie Used for rinsing tanks between batches 50/50 split of recycled water and city water
- 40. Water Recycling
- 41. Water Recycling Low pH beneficial for cleaning process Two Week Cycles Decreases water use, discharge and related expenses -Water use: -1,700,000 gallons per year -Water expenses: -$4,500 per year Recycled water meets FDA and organic standards if it does not contact actual food product Solid Solution Aqueous Solution Original pH Neutral pH Interview with M. Freedman, October 15, 2015
- 42. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Disposal to Pleasant Prairie Secondary Treatment Stage Chemical adjustment using %25 NaOH
- 43. Secondary Treatment: pH Adjustment Batch system 1050 HDPE Tank 300 gallon Mild Steel tank Automatic pH controller Liquid Level Meter to begin next batch
- 44. pH Adjustment Utilizes 25% Sodium Hydroxide Solution by weight - Reduces freezing point, safety hazards, and corrosiveness to system. Batch System - Accounts for fluctuations of influent waste - Effluent quality is critical - NaOH system handling is important for safety
- 45. Secondary Treatment: pH Adjustment Cost of 25% Sodium Hydroxide = $2.22/Gallon Amount NaOH needed to adjust 1000 Gallons = 12.72 Kilograms = 2.64 Gallons WITH RECYCLING TECHNIQUES : Waste Treated per Day = 2000 Gallons NaOH Needed Daily = 5.3 Gallons NaOH Needed Yearly = 2260 Gallons Extra 5000 Gallons every two weeks NaOH Cost per year = $5000 Waste Treated per Day = 7000 Gallons NaOH Needed Daily = 18.5 Gallons NaOH Needed Yearly = 6714 Gallons NaOH Cost per year = $15,000
- 46. Mustard Factory Separation Solid Holding Aqueous Holding Water Recycling (Heated) pH Adjustment Land Application Disposal to Pleasant Prairie Daily discharge reduction by 8,000 gallons
- 47. Disposal Costs Varying meter sizes -6” is largest and most expensive meter -Flat monthly fee Largest meter for Lake Michigan is ¾”
- 48. Economic Advantages Water Recycling Advantages -Reduction of water usage saves $4,500 per year -Reduction in treated water saves $10,000 in NaOH costs per year Simplicity of design -Low maintenance and repair cost -Low labor requirement Re-use old equipment wherever possible to subsidize costs
- 49. Economic Summary
- 50. Sustainability Improves economics of wastewater treatment/removal Reduces freshwater use Limits chemical usage for water treatment Maintains FDA and Organic standings keepcockecountybeautiful.com
- 51. Design Questions User Perspective: How does it work? What do I need to do to run it? What is the maintenance/upkeep needed? Client Perspective: How much will it cost? What is the system's size? Can it be easily incorporated into other facilities? Designer Perspective: What is the problem with the waste? How much waste needs to be processed? At what rate? Is there a maximum start up cost or ROI timeframe?
- 52. Schedule
- 53. Summation Problem: pH and Waste Volume Solution: -Gravity Separation -pH Adjustment -Water Recycling -Disposal Economics: Saves around $50,000 annually after first year Sustainability: Water recycling reduces water consumption
- 54. Table of Contents Introduction -Problem -Existing Solution Research and Analysis Design and Methodology Economic Analysis Summation
- 55. References Cheng, S., Logan, B. 2007. Sustainable and Efficient Biohydrogen Production via Electrohydrogenesis. Proceedings of the National Academy of Sciences of the United States of America. vol. 104. no. 47. 18871-18873. Harrison, R., Todd, P., Rudge, S., Petrides, D. 2003. Bioseparations Science and Engineering. New York, N.Y.: Oxford University Press. Kabza, Alexander. 2015. “Fuel Cell Formulary.” Zentrum für Sonnenenergie- und Wasserstoff-Forschung Baden-Württemberg. Kargi, F. and Arikan, S. 2013. “Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes.” J. Environ. Eng., 139(6), 881– 886. Kemker, C. 2013. pH of Water. Fundamentals of Environmental Measurements. Available at: http://www.fondriest.com/environmental- measurements/parameters/water-quality/ph/#p8. Accessed 7 September 2015. Lin, Bruce. 2000. “Conceptual design and modeling of a fuel cell scooter for urban Asia.” Journal of Power Sources 86: 202-213. Popova, I. and Morra, M. (2014). “Simultaneous Quantification of Sinigrin, Sinalbin, and Anionic Glucosinolate Hydrolysis Products in Brassica juncea and Sinapis alba Seed Extracts Using Ion Chromatography.” Journal of Agricultural and Food Chemistry 62, 10687-10693. Postma, E., Kuiper, A., Tomasouw, W., Scheffers, W., Dijken, J. 1989. Competition for Glucose between the Yeasts Saccharomyces cerevisiae and Candida utilis. Applied and Environmental Microbiology 55(12): 3214-3220. Wongkarnka, Monchai. 2005. The application of aerobic yeast for treatment of high strength food processing wastewater containing furfural. Iowa State University: Retrospective Theses and Dissertations. Paper 1821. Zoulias, E., Varkaraki, E., Lymberopoulos, N., Christodoulou C., Karagiorgis, G. (2012) A Review on Water Electrolysis. Centre for Renewable Energy Sources and Energy Efficiency. Available at: http://www.cres.gr/kape/publications/papers/dimosieyseis/ydrogen/A%20REVIEW%20ON% 20W ATER%20ELECTROLYSIS.pdf. Accessed 9 September 2015.
- 56. Acknowledgments Michael Freedman, Olds Products - Company Contact Dr. Caye Drapcho, Clemson University - Project Advisor Ning Zhang, Clemson University - Lab work assistance John Abercrombie, Clemson University - Microbiology Lab work assistance Dr. David Freedman and Rong Yu, Clemson University - Gas Chromatography Assistance Dr. Terry Walker, Clemson University - Project Consulting Tom Jones, Clemson University - Project Consulting
- 57. Questions?