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From the Engineering Department of
© 1997 WaterSmart Environmental,
Engineering Data Sheet
Effective Date: August 15, 2000 WSE Publication No. 599
© 2000 WaterSmart Environmental, Inc.
Process: Zero Discharge Dairy Farm Waste Treatment
While producing 6.5-7.0 gallons of milk per day the average cow also generates 8-10 gallons of wastewater and 14 pounds of solid waste. Odorous and expensive to dispose of, these wastes are a significant management burden on the farm and the environment.New technology can now change the way operators view waste treatment. WaterSmart Environmental’s cutting edge and modern SuperAnaerobicDigesterTM
Treatment Process not only provides highly efficient and cost-effective treatment of cow wastes, it goes a step further and converts one of the by-products of that treatment, biogas, into a usable, and sustainable fuel source. With this modern SuperAnaerobicDigesterTM
Process, the burden of concentrated waste treatment becomes a huge and fully sustainable and continuing asset to the farmer.Each SuperAnaerobicDigesterTM process treatment plant is totally energy independent as the waste itself generates
far more energy than is required for treatment. The excess energy produced may be sold and used as a primary fuel (methane gas) or converted into electricity. The General Design Data table below and the charts on page 2 show the quantities of energy that cow wastes can produce. In order to design equipment is supplied to capture ammonia-nitrogen, phosphorus, and potassium nutrients as liquid fertilizer. The fully treated effluent is recycled as potable livestock drinking water. The residual sludge qualifies as Class A Biosolids thus enabling its beneficial use as a soil conditioner or as an organic fertilizer. The attached process engineering drawing No. S-5060 shows a dairy farm treatment plant. Standard designs to 100,000 standing head are available.
The United States Environmental Protection Agency has designated WaterSmartEnvironmental, Inc. as an "Ag-STAR Ally" for its groundbreaking technology. For more information on becoming an AgSTAR Partner or Ally telephone the AgSTAR Hotline at 1-800-95AgSTAR.
General Design Data - AgSTAR
Average weight of all cows: 1,300 pounds each
Total wet waste factor: 8.0%
Average wet waste = 1,300 x 0.08 or 104 pounds per day
Total solids = 13.5% of average wet waste or 104 x 0.135 = 14.0 pounds per
Volatile solids = 75% of total solids or14.0 x 0.75 = 10.5 pounds/day
Average volatile solids reduction = 92.5%
Volatile solids methane yield = 12.0 cubic feet per pound of volatile solids removed
Volatile solids removed = 10.5 x 0.925 = 9.71 pounds per day
= 9.71 x 12.0 = 116 cubic feet/day
Approximate methane conversion factor is: 12 CFH = 1 kW
Waste-generated biogas per standing head measured in cubic feet per hour (CFH) and cubic meters per hour (m3/h). The appropriate kilowatt sized gas
generator is also shown
Standing Head100 200 300 400 500 600 700 800 900 1,000
CFH 483 967 1,450 1,934 2,417 2,900 3,383 3,868 4,350 4,833
m3/h 13.7 27.4 41.1 54.8 68.5 82.2 95.9 110 123 137
kW 40 80 120 160 200 240 280 320 360 400
Standing Head1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
CFH 4,833 9,666 14,500 19,332 24,166 29,000 33,832 38,664 43,498 48,332
m3/h 137 274 411 826 685 822 1,237 1,652 1,511 1,370
kW 400 800 1,200 1,600 2,000 2,400 2,800 3,200 3,600 4,000
Standing Head10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000
CFH 48,332 96,664 145,000 193,000 242,000 290,000 338,000 386,000 435,000 484,000
m3/h 1,370 2,740 4,110 5,480 6,850 8,220 9,590 10,960 12,330 13,700
kW 4,000 8,000 12,000 16,000 20,000 24,000 28,000 32,000 36,000 40,000
Dairy Waste-To-Energy…no land disposal of
manure…zero liquid discharges
Made possible by theSuperAnaerobicDigester™
Optimized Anaerobic
Treatment Process© 2001 WaterSmart Environmental, Inc.
No Lagoons. All liquid and solid wastes are continuously
treated, not stored.
Existing lagoons may be decommissioned.
Animal deads are processed and added to the waste feedstock rather than rendered.
Eliminates all potential for surface runoff and groundwater pollution.
No Land Disposal of Solids
or Liquid Manure. Dairy waste solids and liquids are
continuously treated by anaerobic digestion and converted into methane gas, carbon dioxide gas, organic fertilizer, and liquid fertilizer concentrate.
Animal deads are ground and added to the digester as organic wastes.
No Liquid Discharges. The digester effluent is highly purified by
reverse osmosis (RO) treatment. The RO concentrate contains ammonia
nitrogen orthophosphates, and potassium salts, the main components of liquid fertilizer.
The RO permeate is continuously recycled for livestock drinking water.
Total Treatment Design.
Solids (Digestate)Composition.
Grit and sand. Insoluble Sulfides of Cadmium, Calcium,
Copper, Iron, Lead, Manganese, Trivalent Chromium, and Zinc.
Approximately 1-1-1 NPK (Nitrogen, Phosphorus, and Potassium)
Qualifies as Class “A” Biosolids in compliance with 40 CFR Part 503
Also Qualifies as Organic Fertilizer
Solids Management. May be used as livestock bedding
material since it is pathogen free. May be sold to the marketplace as an
organic fertilizer commodity. May be sold to the marketplace as a soil
conditioner or soil amendment.
Liquid Streams. Liquid fertilizer concentrate. Reverse osmosis permeate.
Liquid Fertilizer
Concentrate.
Contains about 20-10-10 NPK in a concentrated water solution.
Contains trace amounts of aluminum, magnesium, and sodium salts
Reverse OsmosisPermeate.
Total dissolved solids < 50 mg/L Total coliform count < 1MPN/100 mL BOD < 1 mg/L COD < 1 mg/L TOC < 1 mg/L TSS < 1 mg/L NPK < 10 mg/L
Liquids Management. Liquid fertilizer concentrate may be
directly used by the farmer for routine crop nutrient requirements.
Liquid fertilizer may be sold to the marketplace as a commodity.
Reverse osmosis permeate water is continuously recycled as livestock drinking water.
Other Co-Products. Methane gas. Carbon dioxide gas.
Co-Product Methane. Is compressed, dried, and stored at 300
psig for site use and for generation of electricity.
Compressed methane may also be sold as CMG (compressed methane gas) or LMG (liquefied methane gas).
Generated electricity may be used at with excess sold to utility grid.
Co-Product Management. No release of methane gas to the
environment. No release of carbon dioxide gas to the
environment. No gas releases accomplish a 500%+
reduction in greenhouse gas effect.
Complete Odor Control. No liquid or solid manures are ever land
applied to create odors. Odors within enclosed livestock barns are
controlled by continuous use as power plant combustion air thereby achieving complete thermal oxidation. Odors are therefore destroyed rather than discharged to the environment.
Co-ProductCarbon Dioxide.
Is compressed, dried, purified, and liquefied for sale to the marketplace as a commodity.
Meets food and medical grade quality.
The SuperAnaerobicDigester™ Process
Is the only process that combines:
Two-phase Anaerobic Digestion Thermophilic Bacteria Staged Phase Treatment Fixed Growth Media Flow Recirculation pH and Temperature Control Essential Nutrient Addition
Bacteria Can Produce FuelFrom Liquid & Solid
Wastes. Solid waste landfills biologically generate
methane gas (called biogas) as clear evidence of the ability of bacteria to produce fuel.
Biogas is a mixture of carbon dioxide and methane gas. It has a heating value of about 25,000 kJ per cubic meter.
Biogas can be used as a primary fuel or to
generate electricity.
Wastewater TreatmentPlants Use Bacteria.
Almost all wastewater treatment plants use bacteria to treat the water.
Aerobic plants use aeration. They consume about 8,000 kJ per kg COD (Chemical Oxygen Demand) removed.
WaterSmart’s OAT™ anaerobic plant generates about 22,000 kJ/kg COD for an energy improvement of about 30,000 kJ/kg COD.
Wastes That Can BeConverted Into
Biogas. Municipal
Wastewater Landfill Leachate Chemical
Manufacturing Pulp & Paper Mills Sugar Mills
Palm Oil Mills
Breweries & Distilleries
Fish & Food Processing
Agricultural Solid Wastes
Cardboard & Sawdust
Ethanol Plants Rubber
Plantations
...More Eligible Wastes. Animal Feed Lot Wastes Dairy & Cheese Production Fruit & Vegetable Canning Pharmaceutical Wastes Rendering Plants Textile Manufacturing Municipal & Industrial Digester Sludge Food and Green Wastes Municipal Solid Wastes
A Renewable And AlternativeEnergy Source.
These many wastes are generated each and every day in the normal course of living.
The routine treatment or disposal of wastes is tremendously expensive.
The SuperAnaerobicDigester™ process, however, makes their treatment or disposal profitable, an extremely pleasant surprise.
Excess Energy Produced. The SuperAnaerobicDigesterTM process uses
some of the methane it generates to heat the wastewater being treated.
The excess methane can be sold, used to operate pumps, or generate electricity.
The excess green power electricity can be used by the treatment plant, sold to the local electric utility, or even to a distant business or city through the Internet.
Positive Return On
Investment. When one generates a profit from the
treatment of wastes, a positive return on investment (ROI) always results.
Rather than a burden on society, wastes may now be viewed as an asset--an incredible reversal of common perception.
Wastewater treatment plants of the
anaerobic digester design can now pay for themselves!
Energy Costs. Wastewater treatment is very expensive, particularly
because of energy costs which increase at 3-5% every year.
A typical biological wastewater treatment plant uses about 8,000 kJ per kg COD (Chemical Oxygen Demand) removed.
WaterSmart’s SuperAnaerobicDigesterTM process can produce up to 22,000 kJ/kg COD removed, for an energy improvement of about 30,000 kJ per kg COD.
Capital Equipment Costs. Are also very expensive, on the order of
US$2K+ for every kg of COD treatment capacity.
If ammonia, nitrate, phosphorus, or heavy metal removals are required, the associated costs are much higher.
WaterSmart’s Anaerobic Treatment Plant costs about half as much as other anaerobic systems treating the same amountof COD or Volatile Solids.
Environmentally FriendlyAnd Sensible.
Korea’s Sudokwon Landfill, the world’s largest, has the motto: “Don’t Waste Wastes.”
We share that view and believe wastes should be converted into something useful, like fuel or electricity, if it can be done so safely and economically.
In so doing, waste volumes are greatly reduced to better manage the environment for ourselves and the next generation.
Odors?Absolutely
None! All treatment is carried out in closed
vessels
Hydrogen Sulfide is removed from produced biogas.
All gasses are captured and used or
recycled. None escape.
Environmental Damage?
Absolutely None! No emissions to atmosphere.
Heavy metals removed as insoluble sulfides.
Organic constituents removed to innocuous levels.
Effluent contains nutrients which are
beneficially recycled.
Beneficial Co-ProductsIn addition to methane gas, the digester process generates other useful and profitable co-products. Carbon Dioxide Organic Fertilizer Liquid Fertilizer Concentrate Reverse Osmosis Permeate Water
Greenhouse Gasses A methane powered generator or gas turbine
will discharge EPA permissible amounts of carbon dioxide when producing electricity.
If a fuel cell is used to make electricity, no carbon dioxide is discharged.
No methane is ever discharged to the environment.
Noise…
Practically none!The loudest component is a biogas
powered generator or turbine --similar to a truck
engine.Noise producing equipment can easily be
enclosed for noise attenuation.
Sludge 0.01 pounds of solids produced for
every pound of BOD removed—about 25% that of competitive anaerobic treatment plants!
The SuperAnaerobicDigesterTM process sludge qualifies as Class “A” Biosolids that can be sold as fully certified organic fertilizer.
Single Vessel Design.Carbon Dioxide outlet Methane outlet
97% CO2
85-95% CH45-15% CO2
Vertical circular insulatedprocess vessel with dome cover
Acidogenic stage isolation wall
0-3% N2
+ H2S
0-1% H2S
Static water level
Liquid outlet
Methanogenic stage isolation wall
Phase partition wall
1st stage acidogenic digester
2nd stage acidogenic digester
Headworks. After trash removal: Grind or comminute the raw wastewater. No primary treatment required. Biosolids may be ground and added. Organic wastes may also be added. Liquid organic wastes may also be added. Green Wastes may also be added. Food wastes may also be added.
Sophisticated DesignBut Easy To Operate.
Automatic controls simplify routine plant operations.
Close process control translates into a high degree of treatment efficiency.
Minimal plant operator skill required.
Digester Upgrades Available.
Existing anaerobic digesters may usually be upgraded to the digester process thus saving project site construction and piping costs.
A complete upgrade to the digester process can increase the digester capacity 10 times.
Beneficial use or sale of the produced methane, electricity, Class A biosolids, reverse osmosis permeate water, and carbon dioxide makes the upgrade a positive ROI.
Summary. Wastes can be beneficially converted into fuel or
electricity. An efficient anaerobic treatment process results in
a positive return on investment. The SuperAnaerobicDigester™ process is the
most efficient anaerobic treatment available. SuperAnaerobicDigester™ plants are smaller,
less expensive, do not smell, and generate a profit.
Reverse Osmosis permeate can be continuously recycled for livestock drinking water
For Project FeasibilityStudies and Proposals
Contact: WaterSmart Environmental, Inc.
POC: Chuck Steiner @ 913-428-7520
Fax: 913-428-7520
email:
Website: www.watersmart.com
