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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
The Company
Olds Products
Mustard Production Facility
Located in Pleasant Prairie, Wisconsin
http://www.oldsproducts.com
Table of Contents
Introduction
-Problem
-Existing Solution
Research and Analysis
Design and Methodology
-Governing Equations
-Economic Analysis
Summation
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
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
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
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
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
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
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
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?
Pressure Filtration
Vacuum Filtration
Harrison pg. 120
K. Bartlett
Forced Filtration
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
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
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”
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
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”
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”
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
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
-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
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.
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
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
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
Total Suspended Solids
Raw Waste Solution
– 19,500 mg/L
Gravity Separated Solution
– 335 mg/L
Unfiltered, Mixed
Gravity Separated,
Aqueous
K. Bartlett
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
Component Testing - HPLC
Nitric Acid
(0.89%)
Acetic Acid
(0.43%)
Unknown
Kira
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
Intelligen SuperPRO Modeling
Mustard
Factory
Separation
Solid
Holding
Aqueous
Holding
Water
Recycling
(Heated)
pH
Adjustment
Land
Application
Disposal to
Pleasant Prairie
System Design
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
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
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
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
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
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
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
Water Recycling
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
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
Secondary Treatment: pH Adjustment
Batch system
1050 HDPE Tank
300 gallon Mild Steel
tank
Automatic pH
controller
Liquid Level Meter to
begin next batch
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
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
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
Disposal Costs
Varying meter sizes
-6” is largest and most
expensive meter
-Flat monthly fee
Largest meter for Lake
Michigan is ¾”
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
Economic Summary
Sustainability
Improves economics of wastewater treatment/removal
Reduces freshwater use
Limits chemical usage for water treatment
Maintains FDA and Organic standings
keepcockecountybeautiful.com
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?
Schedule
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
Table of Contents
Introduction
-Problem
-Existing Solution
Research and Analysis
Design and Methodology
Economic Analysis
Summation
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.
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
Questions?

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Final presentation (1)

  • 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
  • 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
  • 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
  • 37.
  • 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
  • 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
  • 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
  • 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?
  • 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