Water, Waste Water Treatment and Re-usein the Beer-, Malting and Beverage Industry
Thijs WolbrinkDavid Parocki
March 2009
2 Basis for WWTP and Re-use: Ultrafiltration Membranes Process Water Production Concepts (well / city / surface) Waste Water Treatment Concept: Effluent Polishing Waste Water Treatment Concept: Norit MBR-technology Introduction MBR Applications and Implementations Norit Water Audit Case Studies (Process Water Prod. / Effluent Polishing / MBR) References Process Water/Water re-use in B&B Water qualities and quantities statements
Contents
MicroFiltration10 um 100 nm
UltraFiltration100 - 10 nm
NanoFiltration10 - 1 nm
ReverseOsmosis< 1 nm
colloids virusescolourhardness pesticides saltswater
giardacryptobacteria
colour hardnesspesticidessaltswater
colloidsviruses
saltswater
colourhardnesspesticides salts
water
Basis for WWTP and Re-useNorit Ultrafiltration Membranes (0)
Early 1990s X-FlowHollow Fibre Membrane CapillaryPolyEtherSulfon
XIGA-technology
ID : 0,8 mmID : 1,5 mm
Potable Water / Process WaterWell Water / Surface Water
Basis for WWTP and Re-useNorit Ultrafiltration Membranes (1)
2000 Acquisition Stork FrieslandTubular MembranePVDF-membrane (Polyester support)
Aquaflex-technology
ID : 5,2 mmID : 8,0 mm
Process Water / Re-useSurface Water / Waste Water
Basis for WWTP and Re-useNorit Ultrafiltration Membranes (2)
Norit Solutions for the B&B-Industry (1)
brewery / factory
customers existing WWTP
raw wastewater
surface watercity water
effluent
discharge
effluent polishing
polishing
re-useprocess- and / or productwater
ground water
polishing polishing
MBR
Norit Solutions for the B&B-Industry (2)
Process- and/or Brew Water Production Concepts NanoFiltration/Reverse Osmosis (Well Water) Ultrafiltration + Activated Carbon (City Water) Ultrafiltration + NanoFiltration (Surface water)
Waste Water Treatment and Re-Use Concepts Effluent Polishing Membrane Bio Reactor (MBR)
Why additional polishing Full re-use at proces and bottle cleaning requires
drinking water standard!
Ultra Filtration permeate is excellent basis for re-use Free of suspended solids and turbidity Free of bacteria and virusses
However, only UF on WWTP-effluent is not givingdrinking water RO removes residual COD/BOD and salts ClO2 gives primary desinfection GAC removes residual ClO2 and organics UV gives final desinfection
New Greenfield BreweryOptimal re-use = 1.6 hl/hl
5.4 m hl/y Beer
13.6 m hl/y Waste water
Total 17.3 m hl/y Water 4800 m3/day 200 m3/h
3650 m3/day 157 m3/h
WWTPwith UF-airliftRO
City water 100 m3/h
Re-use water 120 m3/h
UF-permeate to discharge 0 m3/h !!!
75%
ClO2GACUV
RO-waste 40 m3/h
8.6 m hl/yPotable
treatment80%
80 m3/h
Conventional system
AT CT
aeration tank clarification tank
AT CT M
membrane unit
Concepts - Effluent Polishing (1)
Based on X-Flow Hollow Fiber Capillary UF Membrane
PolyEtherSulphon ID = 0,8 mm Effluent polishing
Concepts - Effluent Polishing (2)
AT CT
aeration tank clarification tank
AT M
side-stream
Concepts Membrane Bioreactor (2)
Membrane Bioreactor
Based on X-Flow Tubular UF Membrane
PVDF ID = 8 mm
Conventional System
Concepts Membrane Bioreactor (3)
Bioreactor
Feed pumpCrossflow UF
PermeateMembrane
Circ. pump
Excesssludge
SYSTEM CONCEPTS
Crossflow MBR
SYSTEM CONCEPTS
AirLift
continuousair injection
Concepts Membrane Bioreactor (4)
MBR vs Conventional treatment:Conventional: MBR: Low MLSS * (3-5 g/l) High MLSS * (10-20 g/l) Low age activated sludge High age activated sludge Only floc forming bacteria All kind of bacteria survive Only fast growing bacteria Fast and slow growing bacteria
high sludge production less sludge production Few component-specific bacteria Many component-specific bacteria Sludge carry-over No sludge carry-over Effluent polishing required High quality filtrate Large footprint Smaller footprint
* MLSS = Mixed Liquid Suspended Solids
Concepts Membrane Bioreactor (5)
BUFFERBUFFERTANKTANK
OPTION
BIO REACTORANAEROBIC
UF-PERMEATETANK
WASTEWASTEWATERWATER
Greenfield
BIO REACTORAEROBIC
Applications and Implementation (1)
Existing Anaerobic plant
BIO REACTORAEROBIC
UF-PERMEATETANK
BUFFERBUFFERTANKTANK
WASTEWASTEWATERWATER
Existing
BIO REACTORANAEROBIC
Applications and Implementation (2)
Existing Anaerobic/Aerobic plant
UF-PERMEATETANK
BUFFERBUFFERTANKTANK
WASTEWASTEWATERWATER
Existing
BIO REACTORANAEROBIC
BIO REACTORAEROBIC
Applications and Implementation (3)
BASIS UF-Permeate:SS = 0No bacteria/viruses
CIP water
BREWERYBREWERYBREWERY QUALITYQUALITYQUALITY
Dilution for chemicals ? l/hr.
Flush/cleaning water
Process water
Rinsing of Crates ? l/hr.Rinsing of Bottles ? l/hr.Cleaning of Floors ? l/hr.
Pasteurizers ? l/hr.Bottles ? l/hr.Buildings ? l/hr.Boiler Feed Water ? l/hr
? l/hr.
WATERAUDIT
WATERWATERAUDITAUDIT
UF-PERMEATETANK
QUANTITYQUANTITYQUANTITYBEVERAGEBEVERAGEBEVERAGE
Norit Water-Audit (1)
WATER AUDITWATER AUDITWATER AUDIT Selection of Polishing
Activated Carbon: removal of organics (colour, smell, taste) Reverse Osmosis: removal of salts / softening UV-desinfection: bacteria and virus barrier Ion exchange: removal of ions/softening Combinations of above technologies or others
Norit Water-Audit (2)
General Water consumption of a breweryhl water / hl beer
BW brewing; 1,2
BW Process cleaning; 0,7
SW Bottle / kegs cleaning; 0,8
Plant water (service); 0,4
Demin water (boiler feed); 0,1
Flush water; 0,8
200,8Rince/concentrate from RO/IEXFlush water
1004,0Total
2,50,1Boiler feedDemin water
100,4General / servicePlant water
200,8Botte / kegs cleaningSoft Water
17,50,7Process cleaning
301,2BrewingBrewing Water
%hl/hlUseWater type
New Greenfield Brewery5.4 m hectolitres / annum
5.4 m hl/y Beer
16.2 m hl/y Waste water
21.6 m hl/y Water
6000 m3/day 250 m3/h
4500 m3/day 187 m3/h
Basis for design; 4 hl water / hl beer
Where to re-use?
BW brewing; 1,2
BW Process cleaning; 0,7SW Bottle / kegs cleaning; 1,2
Plant water (service); 0,8
Demin water (boiler feed); 0,1
n.a.n.a.0,6Rinse / concentrate from RO / IEXFlush water
0,9
0,1
0,4
0,2
0,2
0
hl-reuse
24%3,8Total
100%0,1Boiler feedDemin water
100%0,4General / servicePlant water
25%0,8Botte / kegs cleaningSoft Water
25%0,7Process cleaning
Not1,2BrewingBrewing Water
Re-usehl/hlUseWater type
New Greenfield Brewery24% re-use = 2,85 hl / hl34
5.4 m hl/y Beer
14.9 m hl/y Waste water
17.3 m hl/y Water 4800 m3/day 200 m3/h
4150 m3/day 173 m3/h
WWTPwith UF-airlift
WWTP; Waste water treatment plant Anaerobic, Aerobic, Airlift Ultra FiltrationRO; Reverse Osmosis Final removal COD
RO
City water 178 m3/h
Re-use water 58 m3/h
UF-permeate to re-use 77 m3/h
UF-permeate to discharge 96 m3/h
75%
flush
Potabletreatment
80%
15.4 m hl/y
Where to re-use?Re-use 54% = 1.6 hl / hl
BW brewing; 1,2
BW Process cleaning; 0,7SW Bottle / kegs cleaning; 1,2
Plant water (service); 0,8
Demin water (boiler feed); 0,1
n.a.n.a.0,3Rinse / concentrate from RO / IEXFlush water
0,9 1,9
0,1
0,4
0,2 0,8
0,2 0,7
0
hl-reuse
23% 57%3,5Total
100%0,1Boiler feedDemin water
100%0,4General / servicePlant water
25% 100%0,8Botte / kegs cleaningSoft Water25% 100%0,7Process cleaningNot1,2BrewingBrewing Water
Re-usehl/hlUseWater type
Additional polishing: - ClO2, - GAC, - UV
Re-use water 120 m3/h
Case Study
Process-water reuse for Maltery Eemshaven
The treatment capacity of the plant is 65 m3/h The maltery processwater will be reused for more than
80% after treatment (other 20% allowable discharge onsurface water)
The plant consists of a Norit MBR system followed byActivated Carbon filtration and UV disinfection
The produced processwater has a waterquality accordingto Dutch drinking water requirements
Case Study
Process-water reuse for Maltery Eemshaven
FIT
PT
M01
02
03
04
05
06
07
14
Polymeer dosering
08
0910
12
13
11
11
09
0815
10
12
13
11
09
0816
10
12
13
11
09
0817
10
12
13
18
19
20
21 22 23
33
12
13
11
25
26
272829
30
UV-desinfectie
Natronloogdosering(Optie)
31
2432
POMPPUT 2m3
34 35
36
37
BLOWER
KONTAKTTANK300 m3BIOREACTOR
1730 m3
BIOREACTOR 1730 m3
BUFFERTANK1500 m3
CIPTANK2 m3
PERMEAATTANK25 m3
UF/CF-unit
UF/CF-unit
UF/CF-unit
UF/CF-unit
BLOWER
BLOWER
CIRC. POMP
VOEDINGSPOMP
CIP POMP PERMEAATPOMP
CIRC. POMP
CIRC. POMP
CIRC. POMP
DECANTER
TRANSPORTSCHROEF
CONTAINER15 m3 (20TON)
SLIBVOEDINGSPOMP
SCHUIM-LANSEN
AKTIEFKOOLFILTER
AKTIEFKOOLFILTER
Case Study
Process-water reuse for Maltery Eemshaven
124Sludge content g/l (MLSS)
0,350,45Operational costs / m3
500750Sludge production kg ds/day
350900Square meters m2 (layout)17405200Bioreactor m3
MBRConventional system
Case Study
Process-water reuse for Maltery Eemshaven
55 + 1065M3/hFlowEffluent (after AC)InfluentUnitParameter
Reasons for Holland malt to choose Norits MBR
Proven technology Robust system Simple process set-up Small footprint Low chemical usage Low sludge production Operational costs: 0,3-0,4/m3 (exclusive depreciation/interest)
Case Study
Process-water reuse for Maltery Eemshaven
Facts and Figures: Client : Boon Rawd Brewery, Khon Kaen, Thailand Raw Water Source: Tertiairy Effluent NMT Technology : SF-XigaUF-RO-UV Effluent : acc. to EU potable water legislations Capacity : 100 m3/h for re-use OPEX : 0,20-0,30 euro/m3
Case Study
Waste-water reuse for Boon Rawd Brewery
Project start : July 2006Start-up : March 2007
Treated Water Purposes: Dilution water for the preparing of Chemical
Cleaning Solutions Cleaning of crates Cleaning of floors, walls and buildings Other cleaning purposes Other water purposes
Case Study
Waste-water reuse for Boon Rawd Brewery
Facts and Figures: Client : Martens Brewery, Bocholt, Belgium Raw Water Source: Brewery Waste Water NMT Technology : Crossflow MBR phase 1 and RO-UV phase 2 Effluent : acc. to EU potable water legislations Capacity : 30 m3/h for re-use in phase 2 OPEX : 0,30-0,40 euro/m3
Case Study
Waste-water reuse for Martens Brewery
Project start : July 2006Start-up phase 1 : July 2007Start-up phase 2 : 2009-2010
Treated Water Purposes in Phase 2: Dilution water for the preparing of Chemical Cleaning
Solutions Cleaning of crates Cleaning of floors, walls and buildings Other cleaning purposes Other water purposes
Case Study
Waste-water reuse for Martens Brewery
Facts and Figures: Client : Cerveceria Polar, Caracas, Venezuela Raw Water Source: Brewery Waste Water NMT Technology : Airlift MBR and RO Effluent : potable water quality Capacity : max. 70 m3/h for re-use OPEX : 0,30-0,40 euro/m3
Case Study
Waste-water reuse Polar Brewery Caracas
Project start : February 2008Start-up : December 2008
Treated Water Purposes Dilution water for the preparing of CIP
Solutions Cooling Pasteurization Steam production Other water purposes
Case Study
Waste-water reuse Polar Brewery Caracas
Facts and Figures: Client : Unicer Brewery - Porto Raw Water Source: Biological Treated Effluent NMT Technology : SF + XIGA UF + UV Effluent : free of SS, bacteria and virusses Capacity : 45 m3/h (re-use 30 m3/h) OPEX : 0,47 euro/m3
Example of a successful integration of conventionaland membrane technology for water reuse accordingto customers specifications
Case Study
Waste-water reuse Unicer Brewery
Facts and Figures: Client : Obolon Maltery - Ukraine Raw Water Source: Raw waste water Maltery NMT Technology : Crossflow MBR Effluent : Free of organics, bacteria and virusses Capacity : Initial 63 m3/h (extension 100 m3/h) OPEX : 0,3-0,4/m3
Case Study
Waste-water reuse Maltery Obolon
Facts and Figures Client: Bavaria, Lieshout (the Netherlands) Raw Water Source: Well Water Capacity: 250 m3/h Process: De-Ironing + NanoFiltration Hardness Product water: 1-2 DH Bacterial and Virus Free OPEX: 0,35/m3
Case Study
Process Water Production Bavaria
Facts and Figures Client: Heineken, Den-Bosch (the Netherlands) Raw Water Source: Well Water Capacity: 540 m3/h Process: Anaerobic NanoFiltration Lime dosing Hardness Product water: 2 DH Bacterial and Virus Free OPEX: 0,4/m3
Case Study
Process Water Production Heineken
Facts and Figures Client: Zujiang Brewery, China Raw Water Source: City Water (unsafe) Capacity: 120 m3/h Process: XIGA-UF Hardness Product water: 8 DH Bacterial and Virus Free OPEX: 0,2/m3
Case Study
Process Water Production Zujiang Brewery
Facts and Figures Client: Coca-Cola Wakefield, U.K. Raw Water Source: City Water Capacity: 400 m3/h Process: AC + XIGA-UF Bacterial and Virus Free OPEX: 0,3-0,4/m3
Case Study
Process Water Production Coca-Cola
CUSTOMER CAPACITY PURPOSE TECHNOLOGY--------------------------------------------------------------------------------------------------------------
Kanes Foods 40 m3/h WWTP MBR Cerestar 70 m3/h WW-reuse UF-RO LambWeston&Meijer 50 m3/h WW-reuse UF-RO-UV Pasfrost 20 m3/h WW-reuse UF-RO Frosta Elbtal 66 m3/h WW-reuse UF-RO Paulaner Brauerei 15 m3/h WW-reuse UF-RO-UV Cargill Corn 35 m3/h WW-reuse MBR Polar Cerveceria 50 m3/h WW-reuse UF-RO Holland Malt 65 m3/h WW-reuse MBRAC-UV IFBM/MAGB 3 m3/h WW-reuse MBRAC Unicer 45 m3/h WW-reuse SF-UF-UV Boon Rawd Brewery 100 m3/h WW-reuse SF-UF-RO-UV Obolon Maltery 100 m3/h WW-reuse MBRAC Martens Brewery 30 m3/h WW-reuse MBRROUV Polar Cerveceria 100 m3/h WW-reuse MBR-RO
References Wastewater treatment and re-usein Food, Beer & Beverage industry
CUSTOMER CAPACITY PURPOSE TECHNOLOGY --------------------------------------------------------------------------------------------------------------
Zhujiang Brewery 120 m3/h bacterial barrier UF Quingdao Brewery 80 m3/h process water RO Koninghoeve Brewery 20 m3/h softened water RO Bavaria Brewery 180 m3/h softened water NF Bavaria Beverage 65 m3/h softened water NF Danone Bierun 30 m3/h bacterial barrier UF Menken/Coca Cola 120 m3/h bottling water RO-AC-UV Coca Cola Wakefield 400 m3/h bacterial barrier AC-UF Danone Warsaw 30 m3/h bacterial barrier UF Heineken Den Bosch 540 m3/h softened water anaerobic NF Suzhou Brewery 120 m3/h bacterial barrier UF-AC-ClO2 Bavaria Brewery 80 m3/h softened water NF Refresco/Coca Cola 80 m3/h bottling water RO-AC-UV Brasserie dOrval 12 m3/h softened water RO Westmalle 40 m3/h bacterial barrier UF
References Water Treatmentin Food, Beer & Beverage industry
Norit Membrane Technology can treat all kind of water sources
Norit Membrane Technology can produce out of all kind of water sources all water qualities needed by combination of membrane- and conventional technologies
Norit Membrane Technology can find an economical attractive solution for all kind of water house keepings in all kind of Industries
Water Qualities and QuantitiesStatements
No doubts. Norit. Just Proof.
Thank you for your attention