Final Presentation of Senior Design Project

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/AAAA
AAAAAhY/B5MzdxVSV6I/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 H2O(l) --> O2(g) + 4 H+(aq) + 4 e-
2 H2O(l) + 2 e- --> H2(g) + 2 OH-(aq)
2 H2O(l) --> O2(g) + 2 H2(g)
energy.gov/eere
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 H2O
2 H2 +O2 --> 2 H2O
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 + CH3COOH H20 + CH3COONa (Sodium Acetate)
Nitric Acid NaOH + HNO3 H20 + NaNO3 (Sodium Nitrate)
Acetic Acid NaHCO3 + CH3COOH H20 + CO2 + CH3COONa
Nitric Acid NaHCO3 + CH3COOH H20 + CO2 + NaNO3
Chemical pH Adjustment

20. Titrated 50 mL of Filtered waste with 0.1 Molar NaOH and 0.5 Molar NaHCO3
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. -Titrated 50 (mL) of Filtered and Unfiltered waste with 0.1 Molar Sodium Hydroxide
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 C6H1206 + 6O2 → 6CO2 + 6H2O + 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

27. Clemson Agriculture Lab
Original Solution
(ppm)
Gravity
Separated (ppm)
Percent
Reduction (%)
Phosphorous 581.82 158.82 72.7
Potassium 335.89 231.2 31.17
Calcium 214.73 104.4 51.38
Magnesium 129.56 92.3 28.76
Zinc 2.56 1.06 58.59
Copper 0.32 0.07 78.13
Manganese 0.85 0.54 36.47
Sulfur 359.889 259.08 28.01
Sodium 2749.7 1118 59.34

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

30. Intelligen SuperPRO Modeling

31. Mustard
Factory
Separation
Solid
Holding
Aqueous
Holding
Water
Recycling
(Heated)
pH
Adjustment
Land
Application
Disposal to
Pleasant Prairie
System Design

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%20B
ottom%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 GallonsWITH 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
NO RECYCLING TECHNIQUES :
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?