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Page 1 Siemens Water Technologies
Water Technologies
Strategies for Water Reusein the Food & Beverage Industry
Process ExpoChicago, ILNovember 4, 2011
Page 2 Siemens Water Technologies
Topics for Today’s Presentation
I. Overview
II. In-Plant Cascading Water Reuse
III. Reject Recovery RO’s
IV. Treatment of Plant Effluent Water
V. Summary
VI. Questions
Page 3 Siemens Water Technologies
Water is a Global Crisis in the Making By 2025, Demand for Water Will Exceed Supply
Source: Valmont Water Management Group
Some other analysts put this point 10 years
earlier
Page 4 Siemens Water Technologies
Water Reuse - Overview
Nearly all major Food & Beverage companies have Sustainability goals related to water and energy usage Water Ratio – Water usage per unit of product Energy Ratio – Energy usage per unit of product
Water conservation and awareness should be the initial focus, and then water reuse.
Water Reuse is a key tool for reducing your plant’s water ratio
Page 5 Siemens Water Technologies
Water Reuse - Overview (Continued)
Identifying water reuse opportunities starts with a “Water Balance” of your facility Metering is needed to identify where water is going
and to measure your success
First find your water reuse opportunities that require minimal treatment. These are your “Low Hanging Fruit”: Maximize Condensate Return Empty Container Rinse Water
Any water stream can be reused with enough treatment. The key is to find the right streams and the right solution that will provide an economically justifiable project.
Page 6 Siemens Water Technologies
Topics for Today’s Presentation
I. Overview
II. In-Plant Cascading Water Reuse
III. Reject Recovery RO’s
IV. Treatment of Plant Effluent Water
V. Summary
VI. Questions
Page 7 Siemens Water Technologies
In-Plant Cascading Water Reuse
The easiest and least expensive method of water reuse is capturing water used in the plant before it gets contaminated with other waste streams: Carbon Tower Backwash Multi-Media Backwash Cooling Water for Compressors Empty Container Rinse Water Steam Condensate Discharge from Container Cooler/Warmer Pump Seal Water CIP System Final Rinse Rainwater
Page 8 Siemens Water Technologies
In-Plant Cascading Water Reuse
These water streams are easy to capture and require minimal treatment for reuse
Match the water quality needed with the water streams that
are available. Some possible uses of reuse water include: Irrigation Cooling Towers Crate Washing Warmers/Coolers Toilet Flushing Truck Washing
Page 9 Siemens Water Technologies
Typical Water Treatment System PFD –With Carbon Tower and Multimedia Backwash Reclaim
MultimediaFilters
TreatedWater
Storage
To Distribution
Header
Polishers
City Water
Pumps
CarbonTowers
NanofiltrationOr
Reverse Osmosis
UV
Recirculation
B/W Reclaim
Tank To
Drain
TurbidityMonitor
From Distribution
Header
Cartridge Filter
Backwash Reclaim System
Reject toDrain
Page 10 Siemens Water Technologies
Case Study No. 1: Carbon Tower Backwash Reclaim
Carbonated Soft Drink Plant
Carbon towers are used to treat ingredient water at a soft drink facility
After initial flush to drain, carbon tower backwash water is captured in a 10,000 gallon storage tank.
Collected water is re-chlorinated and filtered by a bag filter and a cartridge filter to capture any carbon fines.
Reuse water is blended back into the incoming city water tank at no more that 10% of total flow.
Saves 10,000 gallons of water for each backwash.
Page 11 Siemens Water Technologies
Rainwater Harvesting – General Guidelines
Use rain water to reduce city water usage in non-critical applications: Irrigation Toilet Flushing Cooling Applications Feed water to in-plant water treatment system
Works best in areas with high annual rainfall
Recommendation: Capture rainwater from the roof rather than parking lots due to oils and other contaminants.
Numerous successful projects in Portland and Seattle areas on commercial buildings. This trend can be applied to industrial facilities as well.
Page 12 Siemens Water Technologies
Rainwater Harvesting – Main System Components
CollectionTank
DayTank
Rain Water
CartridgeFilter
PumpSkid
Water Users
DisinfectionSystem
CityWater
Backup
CoarseFilter System
Controls
Page 13 Siemens Water Technologies
Rainwater Harvesting – Underground Collection Tank
Page 14 Siemens Water Technologies
Rainwater Treatment System – Portland State University – Science and Eng. Bldg.
Page 15 Siemens Water Technologies
Case Study No. 2 - Rain Water Harvesting and Reuse
Carbonated Soft Drink Facility in Asia Rain water is collected, treated, and used to supplement city water.
Rain Water Harvesting & Treatment System
Includes: In-Ground Rain Water Collection Tanks with
Submersible Pumps – (2)
Central Collection Tank – 5,000 Gallons
Transfer Pumps (2)
Multimedia Filter & Bag Filter
Treated rain water goes into their incoming city water tank for treatment by the plant ingredient water
system.
Page 16 Siemens Water Technologies
Topics for Today’s Presentation
I. Overview
II. In-Plant Cascading Water Reuse
III. Reject Recovery RO’s
IV. Treatment of Plant Effluent Water
V. Summary
VI. Questions
Page 17 Siemens Water Technologies
Membrane System Evolution
Timeline for Membrane Filtration:Recovery Rate
1980’s Initial Use of Membranes in Beverage70-75%
1990’s Acceptance of Membrane Filtration75-80%
2000’s Optimization of Membrane Systems80-90%
New Generation of Recovery Technology 90-95%
Future 95+%
Page 18 Siemens Water Technologies
Advantage of using a Reject Recovery RO
90% Recovery
0.1 x
0.9xX GPM
RO plus reject recovery RO
0.8x
0.2x 0.1 x
80% Recovery
0.2 x
X GPM
Standard RO
0.8x
Page 19 Siemens Water Technologies
Typical Water Treatment System PFD –With Reject Recovery RO
MultimediaFilters
TreatedWater
Storage
To Distribution
Header
Polishers
City Water
PumpsCarbonTowers
NanofiltrationOr
Reverse Osmosis
UV
Recirculation
RecoveryRO50%
BreakTank
From Distribution
Header
Reject Recovery RO
Optional Flow Path
Page 20 Siemens Water Technologies
Non-Carbonated Beverage Facility
Case Study Example No. 3 - Reject Recovery RO
Reject water collected from RO and Nanofiltration Units
Recovery RO sized for 90 gpm permeate
Recovery RO cost approximately $100,000
Annual water savings of 20,000,000 gallons
Annual water savings of $120,000 based on $6 per 1000 gallons for incoming water and wastewater treatment
Payback in about one year!
Reject Recovery RO
Page 21 Siemens Water Technologies
Reject Recovery RO’s
Reject Recovery RO’s have become very common in F&B Facilities with membrane water treatment Bottled Water Facilities Carbonated Soft Drink Facilities Non-Carbonated Beverage Facilities Food Production Facilities
Suitability can be limited based on water chemistry. Areas with high silica have limited application.
Don’t run at over 50-60% recovery rate due to high scaling potential. Water chemistry is critical.
Page 22 Siemens Water Technologies
Topics for Today’s Presentation
I. Overview
II. In-Plant Cascading Water Reuse
III. Reject Recovery RO’s
IV. Treatment of Plant Effluent Water
V. Summary
VI. Questions
Page 23 Siemens Water Technologies
Treatment of Plant Effluent Water
The technology exists to treat any Food & Beverage plant wastewater back to potable water quality. If the plant already has a wastewater treatment system, then the economics of water reuse could be much more favorable.
Advancements in membrane technology are making water reuse more viable.
Membrane Bioreactors (MBR) is the leading technology for wastewater reuse.
Page 24 Siemens Water Technologies
Defining Requirements for Water Reuse
Objectives of treatment: To remove contaminates (organics, inorganics, suspended, dissolved) to a quality for beneficial reuse.
Typical Processes:
Removing Organics – Biological Degradation (anaerobic/aerobic), increased use of MBR or UF polishing
Remove Suspended Particles – Clarification and Filtration, increased use of MF and UF membranes
Remove Inorganic Dissolved Constituents - Reverse Osmosis, Microfiltration Softening, Demineralization (increasingly, Integrated Membrane Systems (UF+RO+CDI))
Disinfection (pathogen inactivation) – Chlorine, UV, Ozone
Page 25 Siemens Water Technologies
What is a Membrane Bioreactor?
The substitution of a membrane separation process for activated sludge secondary clarification and tertiary filtration.
Membrane Bioreactor
Page 26 Siemens Water Technologies
MBR
MBR (Membrane Bio Reactor) process uses membranes as an absolute barrier with very small pore size which gives a very clear treated water.
Page 27 Siemens Water Technologies
Water Reuse Solutions
Case Study Example No. 4 – Effluent Water Reuse System
Prescreen
PotableReuse Water
65 GPM
Reject to Drain
Chlorination
F&B PlantWastewaterTreatment(SBR)
IncomingPlant Water
ChlorinatedStorage
To Non-IngredientWater Uses
To Sewer
Reverse Osmosis UltraFiltration
Carbonated Beverage Facility
Page 29 Siemens Water Technologies
Topics for Today’s Presentation
I. Overview
II. In-Plant Cascading Water Reuse
III. Reject Recovery RO’s
IV. Treatment of Plant Effluent Water
V. Summary
VI. Questions
Page 30 Siemens Water Technologies
Water Reuse - Summary
The economics of water reuse can vary widely depending on your circumstances: Cost of water and sewage in your location Availability of water (limitations on production) Volume of water used in your facility Impact of droughts on your region
Public acceptance of water reuse in the Food & Beverage industry is limited. Currently projects are only for non-ingredient applications.
Consider all of your water streams when looking for water minimization and water reuse opportunities (see next slide).
Page 31 Siemens Water Technologies
Water Reuse Solutions (Industrial – F&B) - Summary
Water Sources to be Reused Treatment Reclaimed
Water Users
Carbon Tower B/W Multi-media B/W Cooling Water Container Rinse Water Warmers / Coolers Line Lube CIP Water Pump Seal Water Rain Water Treated Wastewater
Multi-Media Microfiltration Ultrafiltration Reverse Osmosis Membrane Bioreactor Biological Treatment Clarification UV Disinfection Ozonation
Cooling Water Toilet Flushing Irrigation Process Water System Cooling Towers Wash Down Truck Washing Warmers / Coolers Boiler Feed Water
Page 32 Siemens Water Technologies
Water Reuse - Summary
Interest in water reuse is expected to grow dramatically in the near future.
Water reuse opportunities can be simple or quite complicated depending on the application.
Siemens Industry, Inc. can help you identify your potential water savings and reuse opportunities and apply the appropriate solutions.
Page 33 Siemens Water Technologies
Questions?
Page 34 Siemens Water Technologies
Thank You
David BridgersF&B National Account ManagerSiemens Industry, Inc.Water Technologies Business Unit
Atlanta, GAPhone: 770-921-1837Mobile: 404-414-8765E-mail: [email protected]