An overview of a wastewater treatment process aimed at recovering commodity products from industrial effluent without the addition of chemical coagulants.

1. Prepared for:
Presented by:
Chris Miller
DUAL STAGE TREATMENT AND
ADVANCED PRODUCT RECOVERY IN
INDUSTRIAL EFFLUENTS

2. OVERVIEW
• About FRC Systems International
• Dual Stage Treatment and Product Recovery
• Project Profiles
• Q&A

3. ABOUT FRC
• Founded in 1979
• Office Locations
• Toronto, Ontario
• Atlanta, Georgia
• Geraldine, Alabama
• Fayetteville, Arkansas
• Bogota, Colombia
• Over 500 projects in 20+
countries worldwide
• Ability to provide single
products or turn-key solutions

4. Dairy
Meat
Poultry
General
Manufacturing
Fruit/Vegetable
Other Foods
Cosmetics
Chemical/Pharmaceutical
Oil & Gas
Seafood

5. DUAL STAGE
• First Stage
• Product recovery (for sale)
• Reduce downstream chemical use
• Second Stage
• Chemical/physical clarification

6. COMMON DUAL STAGE APPLICATIONS
Animal Proteins {
Poultry processing
Beef processing
Pork processing
Seafood processing
Heavy Oils {
Metals
Manufacturing
Refineries
Misc. { Pulp & paper
Mining
Food Processing { Vegetable oils

7. CATERPILLAR
Winston Salem, North
Carolina
• Truck Axle Manufacturing
• Discharge to POTW
• Design Data:
• Flow: 50,000 gpd
• FOG: 125,000 mg/L
• Petroleum: 32,500 mg/L
• TSS: 10,800 mg/L
• COD: 146,000 mg/L
• Discharge Requirements:
• TSS: <300 mg/L
• FOG: <100 mg/L

8. SINGLE STAGE PROCESS

9. DUAL STAGE PROCESS

10. HIGH-RATE OIL/WATER SEPARATOR
• Removes free and mechanically
emulsified oils
• Rotating skimmer
• Corrugated plate pack

11. SITE PLAN

12. RESULTS
Batch Process:
• System operated as needed
• Recovered oil is filtered and reused in plant
• $10s of thousands of dollars saved on chemical use in DAF
• System achieves discharge requirements
At What Cost?
• Engineering (approx. $50,000)
• Oil/water separator (approx. $150,000)
• Ancillary pumps, tanks, instrumentation, controls (approx. $75,000)

13. FIELDALE FARMS
• Poultry Kill Plant
• Direct Discharge to Local
Stream
Murrayville, Georgia
• Design Data:
• Flow: 2.3 MGD
• TSS: 2,500 mg/L
• FOG: 2,500 mg/L
• BOD: 4,200 mg/L
• Discharge Requirements:
• TSS: <30 mg/L
• FOG: <10 mg/L
• BOD: <30 mg/L

14. PROCESS CALCULATIONS
Hydraulic Surface Loading Rate
Flow rate (feed flow + recycle flow) in gpm
Effective surface area in sqft
(1600 gpm + 240 gpm)
x sqft
= 1 gpm/sqft
Solids Loading Rate
Weight of TSS in feed to DAF in lbs/hr
Free surface area in sqft
(2500 mg/L * 8.34 lbs/gal * 2.3MGD)/24hr/day
x sqft
= 10 lbs/sqft/hr
= 1840 sqft required = 200 sqft required

15. • Angled plates increase
interstitial surfaces to
minimize separation distance
DAF UNIT SELECTION
• Maintains laminar flow
conditions (fluids flow in
parallel layers without mixing)
PCL-90 DAF (x2)
• Effective Area: 1,550 sqft
• Free Area: 87 sqft
• Required Effective Area: 1,840 sqft
• Required Free Area: 200 sqft

16. F-12 PIPE FLOCCULATOR (x2)
Water Inlet
Polymer 2 Mixing
Polymer 1 Mixing
Water Outlet

17. CONVENTIONAL APPROACH
Sludge to
Disposal
Sludge to
Disposal

18. PRODUCT RECOVERY
Cookers
Cookers

19. INSTALLED SYSTEM

20. INSTALLED SYSTEM

21. INSTALLED SYSTEM

22. RESULTS
Recovered Oil & Proteins:
• Approx. 50,000 lbs/day (wet)
• Producing $30K-$40K per week in resale
• $1.5MM - $2MM per year
• Hundreds of thousands of dollars saved on solids disposal per year
At What Cost?
• Engineering (approx. $50,000)
• Recovered product cookers (approx. $250,000)
Time to Payback: <1 year

23. BUNGE
• Oilseed Processing
Morristown, Indiana
• Design Data:
• Flow: 216,000 gpd
• TSS: 19,400 mg/L
• FOG: 120 - 144 mg/L
• Discharge Requirements:
• TSS: <200 mg/L
• FOG: <50 mg/L

24. DESIGN APPROACH

27. RESULTS
Stage One:
• Stable chemical process (acidulation)
• Recovered oil to processing
• Reduced solids loading on DAF
Stage Two:
• Small DAF (9’ x 8’ x 10’)
• Solids separation with very little chemical additives
• TSS & FOG below permit limits

28. TALLOMAN
Perth, Australia
• Rendering Plant
• Design Data:
• Flow: 32,000 gpd
• TP: 150 mg/L
• TKN: 1,280 mg/L
• FOG: 2,860 mg/L
• BOD: 15,925 mg/L
• COD: 30,875 mg/L

29. SYSTEM
• Open tank DAF
• Free area: 48 sqft
• Solids loading: 10 lbs/sqft/hr

30. SAMPLING DATA
FOG
0
1000
2000
3000
4000
5000
6000
7000
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
mg/L
FOG Influent vs. Effluent
FOG In FOG Out
DAF Influent DAF Effluent
Sample 1 1,750 5
Sample 2 1,690 5
Sample 3 1,870 4
Sample 4 1,630 5
Sample 5 6,620 3
Averages 2,953 mg/L 4 mg/L
Avg. 99% Reduction

31. SAMPLING DATA
COD
0
10000
20000
30000
40000
50000
60000
70000
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
mg/L
COD Influent vs. Effluent
COD In COD Out
DAF Influent DAF Effluent
Sample 1 65,600 19,200
Sample 2 9,800 4,900
Sample 3 37,600 7,200
Sample 4 39,600 6,100
Sample 5 38,000 6,600
Averages 38,400 mg/L 6,633 mg/L
Avg. 83% Reduction

32. SAMPLING DATA
BOD
0
5000
10000
15000
20000
25000
30000
35000
Sample 1 Sample 2 Sample 3 Sample 4 Sample 5
mg/L
BOD Influent vs. Effluent
BOD In BOD Out
DAF Influent DAF Effluent
Sample 1 29,800 11,000
Sample 2 9,300 4,700
Sample 3 23,400 5,300
Sample 4 22,700 5,200
Sample 5 20,200 5,100
Averages 22,100 mg/L 5,200 mg/L
Avg. 76% Reduction

33. 30-36%
dry solids in
DAF float

34. RESULTS
Recovered Oil & Proteins:
• Contributes 1.5% - 2% of total plant yield
• Adds $1.5MM - $2MM per year in sellable product
• Dramatically reduces load on lagoon system
At What Cost?
• <$200,000 all in
Time to Payback: <2 months

35. FINAL NOTES
• Consider all inputs and outputs. Is there anything valuable?
• As solution providers it is our job to help project owners find the best
fit for their needs.

36. FRC Systems International, LLC
PO Box 3147 Cumming, GA 30028
(770) 534-3681
www.frcsystems.com
LEARN MORE ABOUT FRC
ONLINE AT
WWW.FRCSYSTEMS.COM
QUESTIONS?