Dairy Effluent Treatment by Anaerobic Digestion

1. Eco Sensitive Maverik Approach
for the Dairy Industries
By

2. About Us
• Maverik Inc. is multifaceted company involved in the business
of water treatment, waste water treatment and effluent
treatment projects. Its activities include Engineering,
Designing, manufacturing, marketing and servicing. We
execute the projects on turnkey basis.

3. About Dairy Effluent Generation
• The dairy industry is one of the most polluting of industries,
not only in terms of the volume of effluent generated, but
also in terms of its characteristics as well.
• A chain of operations involving receiving and storing of raw
materials, processing of raw materials into finished products,
packaging and storing of finished products, and a group of
other ancillary operations (e.g., heat transfer and cleaning)
will produce wastewater.

4. • In the dairy industry, some amount of wastewater gets
produced during starting, equilibrating, stopping, and rinsing
of the processing units. However, a majority of wastewater
gets produced during cleaning operations, especially between
product changes when different types of products are
produced in a specific production unit and clean-up
operations. Dairy processing effluents are generated in an
intermittent way and the flow rates of these effluents change
significantly. The quality and quantity of the product content
in the dairy wastewater at a given time changes with the
application of another technological cycle in the processing
line.
About Dairy Effluent Generation

5. Sources of Waste Water
DAIRY PROCESS SOURCES OF WASTE
Preparation Stages
1) Milk receiving/ storage
2) Pasteurization/Ultra heat
treatment
• Poor drainage of tankers
• Spills and leaks from pipes
• Foaming
• Spills from storage tanks
• Cleaning operations
• Liquid losses
• Foaming
• Recovery of downgraded
product
• Cleaning operations
• Deposits on surface of
heating equipment.

6. 3) Homogenisation
4) Separation/Clarification
Product Processing Stage
5) Market milk
• Liquid losses/leaks
• Cleaning operations
• Foaming
• Pipe leaks
• Product washing
• Sludge removal from clarifier
• Damaged milk packages
• Overfilling
• Poor drainage
• Cleaning of filling machinery
• Leaks
• Cleaning operations
Sources of Waste Water

7. 6) Cheese Making
7) Butter Making
8) Milk powder manufacture
• Overfilling vats
• Incomplete separation of
whey from curd
• Using salt in cheese making
• Product washing
• Vacreation( reduced pressure
pasteurization using stream)
and salt use.
Spills of powder handling
• Start up and shut down losses
• Plant malfunction
• Stack losses
• Cleaning of evaporators and
driers
• Bagging losses
Sources of Waste Water

8. Sources Of Effluent Generation from Various
Units of Milk Operation
CLARIFICATION/STANDARDIZATION
STORAGE TANK
RECEIVING
PASTEURIZATION
HOMOGENISATION
DEODORISATION
STORAGE TANK
PACKING
STORAGE
TRANSPORTATION
DS WW
DS WW
DS WW
DS WW,CW,ST
DS WW
ST, DS WW
DS WW
DS WW
DS WW
EF
EF
EF
EF
EF
EF
EF
EF
EF
EF
DS-Detergents and Sanitizing Agents, WW-Wash Water, ST-Steam, CW-Cooling Water.

9. Characteristics of Waste Water
• Dairy wastewater contains milk solids, detergents, sanitizers,
milk wastes, and cleaning water.
• It is characterized by high concentrations of nutrients, and
organic and inorganic contents.
• Salting activities during cheese production may result in high
salinity levels.
• Wastewater may also contain acids, alkali with a number of
active ingredients, and disinfectants, as well as a significant
microbiological load, pathogenic viruses, and bacteria.
• Other wastewater streams include cooling water from
utilities, storm water, and sanitary sewage.

10. Parameters UNITS GUIDELINE VALUE
pH - 4-12
Suspended solids mg/l 24-5700
BOD5 mg/l 450-4,790
COD mg/l 80 - 95000
Total nitrogen mg/l 15-180
Total phosphorus mg/l 11-160
Oil and grease mg/l 10
Total coliform bacteria Mpn/100ml 400
Magnesium mg/l 25-49
Potassium mg/l 11-160
Chloride mg/l 48-469
Calcium mg/l 57-112
BIS Guidelines of Parameters

11. Requirements for Anaerobic Digestion
Unlike aerobic wastewater treatment systems, the loading rate of anaerobic
reactors is not limited by the supply of a reagent, but by the processing
capacity of the microorganisms. Therefore, it is important that a sufficiently
large bacterial mass is retained in the reactor. For low rate systems the latter
is achieved by applying a sufficiently long retention time. For high rate
systems the retention of biomass is increased in comparison with the
retention of the liquid. The following conditions are essential for high rate
anaerobic reactors
• A high concentration of anaerobic bacterial sludge must be retained under
high organic (>10 kg/m3 /day) and high hydraulic (>10 m3 /m3 /day)
loading conditions.
• Maximum contact must occur between the incoming feedstock and the
bacterial mass.
• Also minimal transport problems should be experienced with respect to
substrate compounds, intermediate and end products

12. Prevailing Anaerobic Technologies in India
• Conventional Anaerobic Digester
• Anaerobic Contact Digester
• Anaerobic Fixed Film Reactor
• Up-Flow Anaerobic Sludge Blanket(UASB) Process
• Two Phase / Hybrid Reactor
• Combined - Anaerobic & Aerobic Process
Modified
Technology of
UASB Provided
by Maverik

13. Treatment Methodology
• The manufacturing activities in a dairy are of the “batch” type, i.e. one
batch of milk is processed, the equipments is drained, thoroughly
cleaned and the next batch is taken for processing. As a result, the flow
of waste water form a dairy comes in slugs. This fact should be taken
into account in designing a waste water treatment plant to handle
dairy waste water.
• The amount of water used in a dairy (and hence the volume of waste
water produced) depends on its availability. However, an average value
of waste water generated ranges between 4 to 8 liters of milk
processed. The bulk of water consumption goes toward cleaning of the
equipment and floor washing. The average characteristics of dairy
waste are: 5 day 200 C, BOD 1200 mg/l, COD 1800 mg/l, suspended
solids 600-800 mg/l, oil and greases 200-900 mg/l. The ratio of
COD:BOD is favorable for applying biological methods of treatment
preceded by some form of pretreatment such as flow equalization and
oil and grease removal

14. • Biological methods of treatment include: (i) non-mechanized
methods such as a anaerobic treatment, aerobic ponds and
combination of these two and (ii) mechanical methods such as
trickling filters, aerated lagoons and activated sludge process
based on extended aeration. In large dairies, it is possible to use
the anaerobic process such as anaerobic filter or Upflow
anaerobic sludge blanket (UASB) process.
• The organic impurities in dairy waste are easily biodegradable
and hence, can be conveniently subjected to biological
treatment. In view of high BOD value of the raw waste, it is
possible to digest the whole waste anaerobically after reducing
its oil and grease contents. Anaerobic treatment reduces the
oxygen demand of the waste water by 70%-80% and results in a
sizable reduction of power consumption for subsequent aerobic
treatment. In addition, the gas produces by a anaerobic
digestion can be used as a source of energy.
Treatment Methodology

15. Comparison of Performance
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Organic in
Waste Water
Anaerobic
Treatment
Aerobic
Treatment
Input
> Effluent
> Sludge
> Methane
> CO2

16. We Offer End 2 End Solutions
• Maverik is your ideal partner for delivering impact. We provide a one stop solution
by partnering with you across the entire spectrum of services required to execute
waste management projects. We provide…
Consultancy
Design the most
efficient plant for
your requirement at
your site
Engineering,
Procurement &
Construction (EPC)
Construct plant on
a turn key basis
Operations and
Maintenance (O&M)
Operate the plant
and provide designed
output
Customized Solution
Provide your desired
output - fuel, fertilizer,
& electricity - through
customized design
End Produce Sales
Support
Monetize all
produce from the
plant through
marketing services

17. Modified UASB Technology - Our Forte’
• The digester is specially designed to process different types of substrates; be it
liquid, semi solid or solid, it works on the basic principles of UASB technology
• The digester is compatible with numerous raw materials viz. animal dung, poultry
manure, food, vegetable & fruit waste, slaughterhouse waste, starch, dairy &
distillery waste water, sugar mill press mud, sisal unit effluent, De Oiled Cake,
molasses, human waste, Sewage Waste Water, etc. To name a few
• The main difference between a regular UASB reactor and the MUASB digester is
the acceptance of biodegradable solid contents along with liquids in the range of
0.1% to as high as 10%. The digester can be constructed in a variety of ways with
a floating dome or with fixed dome with separate balloon storage. It is capable of
taking multiple feed stocks with high SRT. Because of high SRT, the most of the
influent solids are digested within the reactor and converted into biogas. And the
yield of Biogas is higher than any other technologies

18. Benefits of Our Technology
Benefits of Anaerobic Treatment
• Low production of stabilized sludge
• Very low nutrient requirements
• Little if any energy requirement
• Production of biogas
• Reduction of green house gas emissions
• Very high loading rates (up to 35 kg COD.m-3.day -1)
• Relatively simple in operation and maintenance

19. Modified UASB Digester

20. Why Anaerobic Technology?
• High efficiency for the removal of organic matter as well as for the
nutrients.
• High treatment efficiency for biodegradable sludge
• Reduction of greenhouse gas emissions through methane recovery
• Minimal energy requirements
• Relatively short detention time (due to the relatively small volume
of the tanks)
• Biogas production (it is additional benefit)

21. Anaerobic digestion provides a variety of benefits. The environmental
benefits include:
• Odors are significantly reduced or eliminated.
• Flies are substantially reduced.
• A relatively clean liquid for flushing and irrigation can be produced.
• Pathogens are substantially reduced in the liquid and solid
products.
• Greenhouse gas emissions are reduced.
• And finally, nonpoint source pollution is substantially reduced.
Benefits of Anaerobic Technology

22. On the economic side, additional benefits are provided.
• The time devoted to moving, handling, and processing manure is minimized.
• Biogas is produced for heat or electrical power.
• Waste heat can be used to meet the heating and cooling requirements of the
dairy.
• Concentrating nutrients to a relatively small volume for export from the site can
reduce the land required for liquid waste application.
• The rich fertilizer can be produced for sale to the public, nurseries, or other crop
producers.
• Income can be obtained from the processing of imported wastes (tipping fees), the
sale of organic nutrients, greenhouse gas credits, and the sale of power.
• Power tax credits may be available for each kWh of power produced.
• Greenhouse tax credits may become available for each ton of carbon recycled.
• Finally the power generated is “distributed power” which minimizes the need to
modify the power grid. The impact of new power on the power grid is minimized.
Benefits of Anaerobic Technology

23. Bio Gas from Anaerobic Treatment
Process of Waste Water
Never Ending Source of
Power, Fuel & Fertilizer

24. Real Time Applications of Biogas
CBG
POWER
THERMAL
BIO GAS STORAGE
BALLOON

25. Vihar Pancholi,
(CEO)
Maverik Inc.
2, Giribaug Society,
Behind Centre Point,
R.C. Dutt Road,
Alkapuri, Vadodara – 390 007
Gujarat. INDIA.
Phone:+91-265-234 3010
Cell # +91 989 806 2970
email: vihar@maverikgroup.biz
Contact: