CaseStudy:RedhookBreweryPortsmouth,NH

AnaerobicDigestionandBiogasReusePresentedby:AlexRamsey,TietjenHynes,Operations

ProjectEngineer

RedhookBreweryRedhookwasfoundedinSeattle,WAin1981.

Redhookexpandedfromaformertransmissionshoptoanoldtrolleybarn,thenin1994toacustombuilt220,000barrelbreweryintheSeattlesuburbs.

In1996,RedhookexpandedtotheEastCoastwithanewbrewerybuiltwiththesameplansinPortsmouthNH.

CraftBrewAllianceIn2008,RedhookmergedwithrivalWidmerBrothersBrewingfromPortland,ORtobecometheCraftBrewAlliance(CBA).

CBAaddedKonaBrewingCompanytothefamilyin2012,followedbythelaunchofOmissionandSquareMileCider,andpartnershipswithAppalachianMountainBrewing,CiscoBrewing,andWynwoodBrewingfollowed.

OriginalDesignParameters(1996)•  Averageof72,000gpdofwastewater.•  CODconcentrationsaveragearound8,000mg/L,

althoughtheycanreachdoublethat.•  Incomingsolidsaverage1,300mg/Lafter

screening.•  Additionally,thewastewaterpHfluctuates

significantlyfromthecleaningchemicalsinusethroughoutthefacility.

•  Thetemperatureofthewastewatercanalsobevariable,althoughgenerallywithintherequirementsofconventionalwastewatertreatment.

•  Wastewaterisonlygenerated4daysperweek.

Beer

CleaningChemicals

SpentGrain

Hops

Yeast

WastewaterTreatmentPlantAsOriginallyConstructed,1996

1996Installation

InfluentScreen

Pre-assembledanaerobicreactor.

Installedanaerobicconditioningtankandreactor.

Veolia’sBiothaneanaerobictechnologiesAnaerobicGranularSystems

Biobed®AdvancedEGSB

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SS),

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TSSEffluentLimit

HighrateanaerobictreatmentsystemisnotdesignedforTSSremoval

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TCO

D (m

g/l)

Date (week starting)

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TCOD in TCOD eff

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D R

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Date (week starting)

Redhook Weekly Average TCOD

TCOD in TCOD eff TCOD red.

Loadingin2004-2006wasgreaterthanoriginaldesignbasisofanaerobicsystem.

REDHOOKDaily TCOD Loading

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oad

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CO

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Loadingin2004-2006wasgreaterthanoriginaldesignbasisofanaerobicsystem.ThekeydesignparameterforananaerobicsystemisVolumetricLoadingRate.

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WastewaterTreatmentPlant-AsUpgraded2007

12

1.  80,000gallonsofequalization(2tanks)added.Abletosegregateconcentratedflows.

2.  Secondanaerobicreactoradded.TCODreductionhasaveraged81%andSCODreductionhasaveraged92%sincestartup

2007UpgradeInstallationEqualization

TanksConditioning

TankAnaerobicReactors

MechanicalProcessControl

•  Parametersdirectlyinourcontrol:– pH-additionofNaOHorH2SO4

– Flowratetoreactors– Temperature

•  Parametersoutsideourcontrol:–  Influentconcentration– Flowratetotreatmentplant–  Incomingsolidsloading– Chemicaldumping

ProcessControlOtherControlStrategies•  Improvedtesting•  Improvednotification•  Behavioralcontrolsinbrewery•  Communication

BehavioralProcessControls

•  Recipechanges,partnerbrews,andincreasedeffortstoconservebeerandwaterallincreaseoursolidsratio.

•  Makesurewastewaterisinvolvedinallhighlevelconversations.

•  Attempttoharvestsolidsbeforetheygodownthedrainusingsolidstotes,diaphragmpumps,andincreasedlabor

TreatmentPlantPerformance

•  SystemisexcellentatremovingsolubleCOD(SCOD)–average92%removal.BODremovalaverage89%.

•  TotalCOD(TCOD)reductionislowerduetoTSSineffluent–average81%removal

•  Systemisstillnotdesignedtoremovesolids–averageTSSremoval27%.

Evolutionofflowandloadingtoplant

Upgradeof

System

MethaneGeneration140,000CFMofbiogasproducedeachweek,onaverage.Biogasproductionextremelydependentonorganicloading,breweryproductionschedule.90kWgeneratorselectedwithICengineforoptimalturn-down.

ResourceRecovery

CogenerationSystem

Biogasanalysisindicatedupto320ppmofH2Sinthegasstream.Redhookbiogasrangedfrom68-78%methane,dependingonthefeedstockquality.Redhookselecteda90kWgeneratorwithsulfurremoval(activatedcarbon)forbiogasreuse.

CogenerationSystemLiebherr4-cylinderderatednaturalgasengineLeroy-Somer90kWgeneratorset.Dualfuelsystempoweredbyeitherbiogasornaturalgas.Blowertobringlowpressuregasupfrom26mBarto50forcombustion.PackagedsystemwithcontrolsprovidedbyTech3

HeatRecovery

PermitChallenges

•  CityofPortsmouth:(2weeks)•  Foundation•  Plumbing•  Electrical•  Fire

•  State:(2months)•  NHDESrequiredamendedAirResourcespermitbecausesystemispart

ofthePollutionControlsystem.•  CompliancewithTierIIIemissionsismandateddespiteoutput<100kW

•  Other:(10months)Eversource,theelectricalutility,requiredfullInterconnectionStudyandpermitting.BecausetheydidnothaveanyprecertifiedUtilityProtectiveRelaysavailableforsynchronousgenerators,hadtohaveBaslerRelaystudied.

OperatingChallenges

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YTD

SumofAvailablekWHSumofkWHGeneratedSumofTargetkWH(2017)

Earlyproblemswith:•  Automaticgeneratorcontrols

•  Start/stopcontrolbasedontightbiogaspressurerange

•  Analogcontrolofgeneratorrunratebasedonfuelavailability.

•  Faultresetforgeneratorshutdown.•  Warrantyrepairissues

•  Oilpressure•  Jacketwaterpressure•  Turbocharger

•  ConflictbetweenTSSreductionprogramandbiogasgeneration.

Questions?