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The impact brew has on poo!
Pretreatment of brewery wastewater to reduce BOD & COD loads prior to sewer discharge, using a new
biological wastewater treatment technology
Presented by:Annie Weidert, BioGill North America
VWEA Industrial Waste & Pretreatment Conference March 4, 2019
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6,000+ craft breweries in the US with an increasing number locating in rural areas and small towns.
This shift has implications for local municipalities as a typical craft brewer discharges >80% of the water it uses into a municipal wastewater treatment system.
Small to mid-sized craft breweries producing <30,000 bbl/yr create high strength wastewater at around 8 gallons per gallon of beer produced (Stier, 2018) with BOD concentrations of 3000-15,000 mg/L.
Why is brewery wastewater a challenge?
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Many local treatment plants built decades ago can now struggle to meet capacity.
When such a treatment plant receives brewery wastewater high in BOD & COD, the facility’s treatment costs go up and its capacity to handle residential wastewater goes down.
Municipalities are recognizing the additional burden breweries can present and are more likely to impose high-strength surcharges and/or load limits.
Why are high-strength surcharges increasing?
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A 5,000 bbl/yr brewery discharges wastewater with BOD load equivalent to ~ 500 residential homes, with levels of solids comparable to 75 residential homes.
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Each gallon of brewery wastewater contains the same BOD loading as 15 gallons of sewage.
Many local utilities are beginning to impose surcharges to recover treatment costs and/or incentivize brewers to improve wastewater practices. Some are imposing strict daily limits, which can limit brewery expansions.
Onsite treatment can make good business sense for the brewery and ease operations for municipal plants.
What are the key drivers for change?
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Installing an onsite treatment system can be difficult to justify when dealing with relatively low flows, given the traditionally high capital costs and operational requirements to run a biological treatment process.
Many smaller breweries have struggled to find cost-effective, low-complexity, highly robust options.
Limited space available, particularly in urban settings, reduces options at many sites.
What are the options?
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Above ground, non-submerged bioreactor technology.
Patented substrate nano-ceramic media, known as “Gills”, provide an enhanced environment for microorganisms to grow as a biofilm.
Single media sheets are looped around a top hanger bar and arranged in series with fixed spacing.
Space inside a looped sheet is exposed to air. Liquid passes between 2 loops creating an anoxic gradient.
Multiple banks of “Gills”, are arranged in a vertical configuration with wastewater fed from a dispersal system located at the top.
New attached-growth technology
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1. Wastewater is pumped to the top from a recirculation tank.
2. Water is dispersed over the Gill media & gravity fed down through the unit.
3. Biomass forms on the Gills.
4. Natural air convection provides oxygen needed for aerobic treatment.
5. Treated wastewater flows out with reduced levels of BOD & COD.
Inside the Bioreactor
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Counter diffusion as oxygen and nutrients come from opposite sides of the hanging “gill” sheet creates diverse regions.
Low sludge yield (0.2-0.3 lb VSS/lb BOD removed)
Air side: Lighter brown aerobic biomass
Water side: Darker anaerobic biomass
Typical BioGill Biofilm Profile Air Side vs. Liquid Side of a Gill
BioGill – Structually Different RegionsStructurally Different Regions
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Case Study # 1: The Coastal Brewing Company - Forster, Australia
Permit Compliance BOD <600 mg/L for sewer dischargeNighttime discharge only
Small Staff Minimized operation & maintenance demands.
Variable Influent Tolerance to fluctuation in wastewater flows & loads due to daily variation in brewery operations
Anticipated growth Scalability to adjust to increased wastewater volumes with increased brewery production.
Pretreatment System Requirements
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The Coastal Brewing Company - Wastewater System Process Flow
Space for future addition of 2 more Towers on existing stands + footprint reserved for an additional 4 Towers
Balance & Discharge Tanks sized upfront for 4X expansion
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The Coastal Brewing Company: Wastewater Process Flow
2m^3 recirc.
tank
2m^3 recirc.
tank
Stage 1 Bioreactor
Stage 2 Bioreactor
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Since commissioning in 2017, the treatment system has consistently achieved compliance.
The Towers have formed a healthy, self-limiting biofilm thereby reducing maintenance demands.
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The Coastal Brewing Company - Results
Influent COD post-brewing event >4000 mg/L
Overall average influent COD 2600 mg/L
Daily flow 1000 gpd
Wastewater:beer ratio 10:1
Design effluent BOD <600 mg/L
Average measured effluent BOD 108 mg/L
Best measured effluent BOD 26 mg/L
Average BOD removal 76%, accounting for periods of recirculated effluent
BOD removal observed following brewing events
90%
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Key Learnings: The Coastal Brewing Company
1. Pre-treatment regulatory compliance continues to be achieved with typically <10 minutes/day operator attention.
2. Rapid restart: Following a 2-month non-production period, the biological treatment system returned quickly to full operation.
3. The system continued to treat to within discharge limits even during an upset event in which batches of extremely high-strength wort were dumped.
4. Benefits of the process design allowing optional recycle from discharge tank to influent equalization tank:• Reduced pH-correcting chemical consumption & costs• Capacity for further treatment/polishing during high load
events.
5. Absence of detectable odor or noise does not disrupt onsite customer events at brewery tasting room.
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Case Study # 2: Woodstock Inn, Station & Brewery
The Brewery• Original 7-bbl brewery; expansion added a 30-bbl brewing system. 7500
bbl/yr current production. Hotel/restaurant onsite.• Brewery wastewater: 2000-4000 gpd, 5 days/week
The Town• Small town (pop. 528) & local POTW• Brewery expansion prompted new permit with BOD limit of 300 mg/L.
The Problem• A newly installed aerated, bioaugmented septic system failed to achieve
discharge requirements for BOD & pH.• Odor issues impacted staff, customers, & neighbors.• Engineering report: misapplied technology for high strength wastewater
pretreatment.• $10,000/month fines for noncompliance ($12/bbl)• Onsite BOD reduction needed to be improved to achieve compliance &
reduce costs.
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Pilot Trial Objectives• Demonstrate BioGill biological treatment
technology capability to reduce BOD loads to <300 mg/L
• Confirm performance model projections and collect data for sizing of a full scale treatment system to replace the existing failed system
Pilot Trial Design• Brewery wastewater sidestream drawn to feed
pilot• Continuous flow, 2-Stage pilot biological
treatment system with 2 bioreactors in series• Phase 1: Feed drawn from primary settling basin
(existing septic)• Phase 2: Feed point moved to draw directly from
160-gal effluent tank in brewery basement.
Woodstock Inn & Brewery
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Woodstock Inn & BreweryPilot Trial Phase 1 Process Layout
Stage 2Bioreactor
Stage 1Bioreactor
500-gal recirculation
tank
500-gal recirculation
tank
30-gal sump
Feed flow rate: 1 gpm
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COD [mg/L]
Woodstock Inn & Brewery – Pilot Trial COD Data, Phase 1
From primary settling basin.
From Stage 2 Bioreactor recirculation tank (same as effluent)
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Woodstock Inn & BreweryPilot Trial Phase 2 Process Layout
Stage 2Bioreactor
Stage 1Bioreactor
500-gal recirculation
tank
500-gal recirculation
tank
30-gal sump
pH adjustment
Feed flow rate: 0.6 gpm
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Feed was highly variable; estimated at minimum 6700 mg/L based on history & spot sampling.
From recirculation tank below Stage 1 bioreactor (partially treated)
From recirculation tank below Stage 2 bioreactor (same as effluent)
Woodstock Inn & Brewery – Pilot Trial COD Data, Phase 2
COD [mg/L]
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Pilot Trial Results:
• 22 kg COD loading (average 6700 mg/L) & 19kg COD removed daily; average COD removal of 86%.
• Effluent BOD measured at 10% of effluent COD (1,008 mg/L COD, 100 mg/L BOD).
• Rapid biomass buildup observed; consistent treatment achieved in <4 day from pilot startup.
Woodstock Inn & Brewery
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Key Learnings: Woodstock Inn & Brewery
1. Consistent COD reductions achieved during both phases of the trial, despite influent variability & minimal equalization in Phase 2.
2. Results validated expected COD reductions as predicted by the manufacturer’s Veltz-based proprietary model and allowed for scale-up to full-scale system design (6 Towers).
3. Value of discussing expected range of results with outsourced laboratories used for BOD data. (For some early samples, BOD was reported as “less than” due to falling outside of quality parameters used by the outside lab.)
4. Final effluent, as reported by the site’s consulting engineer, coagulates & flocculates very well compared to expected effluent from suspended growth or MBBR processes.
5. The installation team shared key learnings about biological wastewater treatment and taught brewery staff basic lab measurements. The collaborative and hands-on approach added to the value of the full scale installation, completed in February, 2019.
6. Odor reduction a key advantage given events held onsite (restaurant, brewpub, special events, hotel/inn).
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160-gal Brewery basement pump
station
160-gal Brewery basement pump
station
Primary settling chamber
Primary settling chamber
Equalizationchamber with mixing
air
Equalizationchamber with mixing
air
Coarse particle screening
Coarse particle screening
Conditioning Tank with pH adjustment,
nutrient dosing
Conditioning Tank with pH adjustment,
nutrient dosing
Biological Treatment (6 bioreactor units)
Biological Treatment (6 bioreactor units)
Secondary clarifier chamber
Secondary clarifier chamber
Effluent pumpingchamber
Effluent pumpingchamber
Discharge to Town Sewer
Discharge to Town Sewer
Existing in-ground septic tankage converted to primary settling, EQ, secondary clarifier, & sludge storage chambers under brewery parking lot
3-Stage Biological Treatment process with 6 BioGill bioreactor units (2 units per stage)
2 Pilot Trial Towers restarted after 18 mo. storage
Average brew day wastewater flow: 2,325 gpd, max 5,580 gpd
5800 mg/L BOD influent to primary treatment
3500 mg/L BOD influent to secondary treatment
<300 mg/L BOD final effluent
Woodstock Inn & Brewery Full Scale Pretreatment System (Feb. 2019)
Full scale treatment system design by Weston & Sampson Engineers, Inc. (Waterbury, VT).
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Wastewater treatment process commissioned in February 2019
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Conclusions
1. In both projects, the expected COD reduction was achieved as predicted by the technology provider’s proprietary model, with COD reductions of up to 90% recorded.
2. This new biological technology has proven particularly effective in reducing soluble BOD found at high levels in brewery wastewater.
3. The technology offers smaller craft breweries a robust, flexible, simple to operate, and scalable pretreatment solution.
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Heinz, M. (2011). Biological wastewater treatment. London: IWA, p. 35.
J Gluck, Steven & Phan, Kevin & Patnode, Caroline. (2018). A solution for onsite treatment of low flow, high BOD brewery wastewater. Proceedings of the Water Environment Federation. 2018. 2282-2294. 10.2175/193864718825136918.
J. Stier, Craft Brewing Conference, Brewers Association, April, 2018.
References
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Any questions?
Annie WeidertRegional Manager – Americas
(414) 344-8381
For technical reports, videos, webinars & case studies, please visit:
biogill.com | brewery.biogill.com
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