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5/5/2016
1
Innovation in Treatment of Food Processing Wastewater
Karen Mancl, PhD
Professor Food, Agricultural & Biological Engineering, OSU
Wastewater Treatment
• Established technologies
• Domestic wastewater
Wastewater Treatment
• Established technologies • Domestic wastewater
Discharge to City Sewer?
Domestic Sewage Food Processing Wastewater
5/5/2016
2
Discharge to City Sewer?
Different from sewage
• 5 times stronger
• 100 times more grease
Food Processing Wastewater
Discharge to City Sewer?
Different from sewage
• 5 times stronger
• 100 times more grease
Food Processing Wastewater
Must change the wastewater
• Expensive
• Not very effective
Change treatment technology?
5/5/2016
3
Change the treatment technology
Sand Bioreactor System
• Effective
• Low-cost
Designed to treat food processing wastewater
Whitewater Processing
• Kopp Family Business
– 4th generation
– 110 employees
– 7000 turkeys per day
Whitewater Processing
• Kopp Family Business
– 4th generation
– 110 employees
– 7000 turkeys per day
– Contacted OSU in 2000
Ohio EPA orders – Abandon old ponds
Discharging Pipe Storage Pond Lagoon
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4
Options
• Connect to city
• City of Harrison – 10,000
people
Differences
Pollutant Domestic
wastewater
Slaughterhouse
wastewater
Organic matter (BOD5) 200 800
Suspended solids 150 600
Ammonia 20 40
Fat, oil & grease 2 200
Options
• Connect to city
• City of Harrison – 10,000
people
• 20 year cost $12.5 million
Why so expensive?
• City uses a mechanical,
aeration plant
• Wastewater has too much
• Fat
• BOD5
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Mechanical Treatment Why my lab?
• Innovation in wastewater treatment
• Food, Agricultural & Biological Engineering
• Small flows
• Agricultural wastewaters
Industry open to new options
Lawsuit Close
Regulators open to new
options
Protect environment
Retain Jobs
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Develop & build
full-scale system
Dr. Karen Mancl
Professor Food, Agricultural &
Biological Engineering
Ryan Kopp
Owner, Turkey Slaughterhouse
Secondary Treatment
Sand bioreactor
Before & After Microbial Biofilms
sand
air
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7
Biofilm
25 26 Gaur, Cai, Mancl, and Tuovinen. 2010.
Sand Treatment
Microorganisms
Organic matter & ammonia is their food
Sand Treatment
Create ideal environment for microorganisms
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Sand Treatment
Create ideal environment for microorganisms
Surface to attach to
Air
Water
Food
sand 土壤 Pore space
sand
土壤 土壤 Pore space
sand
B
I
O
F
I
L
m
Waste
water
土壤 土壤
air
Organic matter
CO2
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土壤 土壤
air
Organic matter
CO2
Ammonia
air
土壤 土壤
air
Organic matter
CO2
Ammonia
air
nitrate
CBOD5
0
5
10
15
20
25
30
35
40
45
50
July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar
30-day limit CBOD2013 2015
Ammonia
0
1
2
3
4
5
6
7
8
9
10
July Aug Sept Oct Nov Dec Jan Feb Mar Apr May June July Aug Sept Oct Nov Dec Jan Feb Mar
30-day limit Ammonia
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Before & After
Since 2012 – full-scale system meets all regulatory discharge standards
Fat, Oil and Grease Removal
Influent Effluent
FOG FOG
Sept. 6, 2012 212 Not detected
Oct. 30, 2012 139 Not detected
Nov. 19, 2012 189 Not detected
Dec. 19, 2012 374 Not detected
Jan. 9, 2013 80.8 Not detected
Feb. 13, 2013 168 Not detected
Feb. 27, 2013 273 Not detected
Mar. 27, 2013 42.4 Not detected
Options
• City of Harrison
• Annex
• Sewer extension
• Pretreatment
• Surcharge
Decentralized
• Sand bioreactor
• Onsite construction
• Discharge permit
Costs
Connect to City
• $12.5 million
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Costs
Connect to City
• $12.5 million
New System
• $2.6 million
Costs
Connect to City
• $10.56/1000 gal
• Plus pretreatment
New System
• $3.90/1000 gal
• No pretreatment costs
DAF
Why costs so low?
Simple to build Easy to operate
• Low electricity
• No sludge
• 1 full-time operator
Liners with underdrain
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Media Layers of sand, coarse sand &
pea gravel
Construction
• Easy
• Local force labor
• Purchased construction equipment
• Local aggregate company
Restaurants
Food processors
Resorts
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13
Conclusions
• Sand Bioreactors
• Best option for food processing wastewater
• Local jobs
• Saved money
• Protects stream
setll.osu.edu