Midterm ppt

Mustard WasteDesign Midterm Report

http://www.howiamlosingweight.com/wp-content/uploads/2013/09/Mustard-forms.jpg

The “Second Most Ethical” BE Team:Matt Rosen, Ian Melville, Cahner Jennice, Matt Rimer, Kira Bartlett

The Company

Olds Products

Located in Pleasant Prairie, Wisconsin

http://www.oldsproducts.com

Mustard Production

Batch system (seasonal emphasis) - 9000 gallon limit

Two shifts a day (20-24 hours)

Ingredients: mustard seed, vinegar, brine, spices and water

Automatically metered into batch with minor ingredients sometimes added by operator

Slurry is agitated accordingly then pulverized into mustard paste which is then pumped to storage tank to await packaging

Waste Production

Olds Products is subject to the FDA’s cleaning regulations

Machines are cleaned with each flavor change, which is multiple times per day

-Cleaning water must be at least 120 °F

End of week extensive cleaning with hot water and caustic wash

All waste pumped into 6,000 gallon reservoir

The Problem

The Problem

Wastewater cannot be discharged through the sewer system to the Pleasant Prairie municipal treatment plant.

-pH is too acidic (3.3)

-Required pH range: 5.5-9 pH (Kenosha)

-Problems with high salinity and discharge amount

Current Solution - land application method via a third party company

-Expensive! $0.07 per gallon ($200,000 annually)

http://www.wrc.org.za

Land Application

Labor Intensive

Seasonal - Can’t apply to snow or frozen land

Potential Odor near residential areas

Excess nutrient runoff contaminate surrounding water

Needs strict monitoring and precise application

Adds nutrients to depleted soil

Simplest design

Project Goals

Solve immediate problem of waste disposal

-On site treatment

-Make water suitable for off-site treatment

Create/obtain a usable and harvestable byproduct

Create Economic and Sustainable viability

Project Goals

Bioprocess

-Avoid use of chemical reagent to neutralize pH by using a bio-treatment

-Biological treatment of water for recycling throughout facility

Structural

-Incorporate current wastewater reservoir (6,000 gallon tank)

-Design simply & maximize economy of space

Mechanical

-Simplicity and efficiency of design

-Minimize energy usage - strive to be energy neutral

Consideration

Safety

-Working with chemicals and reagents

-Industrial food plant - certain regulations

Ecological

-Impact of treated water products on environment

-Distinct seasonal change in Wisconsin

Ethical

-Company contact is the relative of a team member

Constraints

Geographic: Pleasant Prairie, WI v. Clemson, SC

Budget

Municipal Codes (Wastewater treatment guidelines)

Current operating procedures

Limited information - NO PREVIOUS WASTE ANALYSIS

Overall lack of team experience

FDA regulations

Design Questions

User Perspective:How does it work?

What do I need to do to run it?What is the maintenance/upkeep needed?

Client Perspective:How much will it cost?

What is the system's size?Can it be easily incorporated into other facilities?

Designer Perspective:What is the problem with the waste?

How much waste needs to be processed? At what rate?Is there a maximum start up cost or ROI timeframe?

LITERATURE REVIEW/THEORY/

PRELIMINARY DATA

Separation

Possible Filtration Methods

Gravity Filtration

Pressure Filtration

Centrifugation

http://industrial.centrifugemachinery.com/industrial_centrifuge.jpg

Harrison 120

Gravity Filtration w/o membrane

500mL Waste

Insert mixed waste into conical vessel

24 hours settling time

Settling speed from

Stokes Law

K. Bartlett

Imhoff Cone Separation

70% aqueous solution30% solids

Pressure Filtration

Modeled with vacuum filtration 0.45um filters and 11um filters

Have to backwash a physical filter

dictated by Darcy’s law

K. Bartlett

Centrifugation

Multiple levels of separation - Solids - Oils - Water

Faster separation speed

No filter build-up (no filter)

More advanced build, more energy

http://3.bp.blogspot.com/_xW3FQUQ2DYI/Rp4DF1r_0HI/AAAAAAAAAhY/B5MzdxVSV6I/s400/centrifugation.png

http://www.sigmaaldrich.com/technical-documents/articles/biofiles/centrifugation-basics.html

Coagulation and Flocculation

Assembles smaller suspended particles into larger particles

Easier and faster to separate or filter

Inorganic Coagulants require alkalinity

Organic = Polyamines

Remove salinity and

neutralize pH

http://image.slidesharecdn.com/typesofcoagulants-131004100124-phpapp01/95/types-of-coagulants-3-638.jpg?cb=1380881416

Lab Testing

Electrolysis

http://energy.gov/eere

Zoulias, E., Varkaraki, E., Lymberopoulos, N., Christodoulou C., Karagiorgis, G. (2012) A Review on Water Electrolysis. Centre for Renewable Energy Sources and Energy Efficiency.

Kargi, F. and Arikan, S. 2013. “Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes.” J. Environ. Eng., 139(6), 881–886.

Uses an electric current to dissociate water into hydrogen and oxygen gases.

The electric potential shifts positive ions ( H+) towards the cathode and the negative ions (OH-) towards the anode.

2 H2O(l) --> O2(g) + 4 H+(aq) + 4 e-

2 H2O(l) + 2 e- --> H2(g) + 2 OH-(aq)

2 H2O(l) --> O2(g) + 2 H2(g)

Negative Energy balance

Electrolysis

Graphite Electrode Gas Production at Cathode

Collected the gas produced at cathode

Future testing using Gas Chromatography

pH change from 3.24 to 3.14

K. BartlettK. Bartlett

Component/Property Analysis

Total Suspended Solids

Testing by the Clemson Agriculture Lab

High Performance Liquid Chromatography (HPLC)

Titration

TSS Testing

Unfiltered Solution

– 19.5 g/L

Filtered Solutions

– Gravity Separated

• 0.335 g/L

Unfiltered, Mixed

Gravity Separated, Aqueous

K. Bartlett

Clemson Agriculture LabOriginal Solution

(ppm)Filtered Solution

(ppm)Percent

Reduction (%)Phosphorous 581.82 158.82 72.7

Potassium 335.89 231.2 31.17

Calcium 214.73 104.4 51.38

Magnesium 129.56 92.3 28.76

Zinc 2.56 1.06 58.59

Copper 0.32 0.07 78.13

Manganese 0.85 0.54 36.47

Sulfur 359.889 259.08 28.01

Sodium 2749.7 1118 59.34

HPLC

Nitric Acid (0.9%)

Acetic Acid(0.43%)

Sinapic Acid???

Acetic Acid

Nitric Acid

Lab Solution Comparison

Solution of known acidic components created in lab to determine accuracy of results and compare pure solution to wastewater

Peaks of lab solution coincided with peaks from wastewater

pH of Lab solution was 1.2 significantly lower than the wastewater (3.3)

-Possible Buffers:

Nutrients?

Solids?

Other Acid?

Neutralization (pH increase)pH of original solution: 3.3

Target pH: Between 5.5 and 6.5

Titrations

Used Sodium Hydroxide (NaOH) with both filtered and unfiltered water

Compared use of Sodium Hydroxide to Sodium Bicarbonate (NaHCO3)

Titration Testing

-Titrated with 0.1 Molar Sodium Hydroxide in 50 mL of WasteWater

Non-Filtered Vs. Filtered

51 mL to raise pH to 6= 0.0051 moles and 0.204 grams of NaOH


Titration Testing

Titration Comparison using filtered water

-0.5 M Sodium Bicarbonate vs . 0.1 M Sodium Hydroxide

10.5 mL to raise pH to 6= 0.0053 mols and 0.44 grams of NaHCO3


Antimicrobial Potential

Sinapic Acid

-Phenolic antioxidant: effective against many gram positive and gram negative bacteria

Yellow Mustard

-Sinalbin (4-hydroxybenzyl glucosinolate) --> Benzyl isothiocyanate

->354.77 mg/g freeze dried mustard powder

Oriental Brown Mustard

-Sinigrin (2-propenyl glucosinolate)--> Allyl isothiocyanate

->548.16 mg/g freeze dried mustard powder

Herzalleh and Holley (2012) “Determination of sinigrin, sinalbin, allyl- and benzyl isothiocyanates by RP-HPLC in mustard powder extracts.”

John Abercrombie (Clemson Microbiology Department)

Wastewater Samples:

-Gravity separation (solid & aqueous components)

Original pH and adjusted pH

-Filtered solids from .45 μm membrane

Washed and Unwashed

-TSS solids from 11 μm membrane

Bacteria: P. aeruginosa, P. vulgaris, S. aureus, E. aerogenes, B. subtilis, M. luteus, E. coli, E. faecalis

Antimicrobial Testing

DESIGN METHODOLOGY & MATERIALS

MUSTARD FACTORY WASTEWATER

SEPARATION

AQUEOUS

SOLIDS

ELECTROLYSIS

ANTIMICROBIAL

DISPOSAL VIA TREATMENT PLANT

LAND APPLICATION

BIOLOGICAL TREATMENT

pH ADJUSTMENT

TO MUNICIPAL FACILITY

RECOVERY OF PRODUCTS

GREYWATERRECYCLED

WATER

BIOPESTICIDE

pH NEUTRALIZATION

Preliminary Design

Basic solution

-A pH neutralization system that adjusts the pH of the wastewater to an acceptable level so it can be sent to the municipal treatment facility

Preferred Solution

-Chain of reactor subsystems

-Each branch in the design tree represents a different sub-system that may be implemented into the overall design

-Overall design options vary through multiple possible pathways.

Separation

Gravity Filtration

2-3 10,000 Gallon Tanks

24-Hour Settling Time

Within estimated EPA limits

Gravity Filtration 98% reduction

http://www.industrial-equipment.biz/assets/images/Cone-Tank-Separator.jpg

– Pre-Filter 737 kg solids / day

– Post- Filter 12.7 kg solids/ day

– 724 kg solids filtered off / day


SEPARATION

AQUEOUS

SOLIDS

ELECTROLYSIS

ANTIMICROBIAL


LAND APPLICATION


pH ADJUSTMENT



GREYWATERRECYCLED

WATER

BIOPESTICIDE

pH NEUTRALIZATION

Aqueous

pH Adjustment

Need to decide when to adjust pH

Depends on selected design components

Currently modeling to adjust to pH 6

Chemical Adjustment

Cost

By-products

Chemical pH adjustment

NaOH: Sodium Hydroxide

Acetic Acid Reaction:

CH3COOH + NaOH H20 + CH3COONa (Sodium Acetate)

Nitric Acid Reaction:

HNO3 + NaOH H20 + NaNO3 (Sodium Nitrate)

Chemical pH adjustment

NaHCO3: Sodium Bicarbonate

Acetic Acid Reaction:

CH3COOH + NaHCO3 H20 + CO2 + CH3COONa (Sodium Acetate)

Nitric Acid Reaction:

NaHCO3 + HNO3 H2O + CO2 + NaNO3 (Sodium Nitrate)

Neutralization Cost Analysis

Biological Treatment

Adjust pH and then use biological methods to further treat the water

Could be used to reduce C.O.D, B.O.D, and other inorganic constituents

Biomass production → possible harvestable co-product

Electrolysis

Gas Production at Cathode

Potentially hydrogen gas per theory of electrolysis

Need to test the gas using Gas Chromatography

Potential for slight pH increase

Would need subsequent neutralization

Sample tested reduced pH by 0.1

Acid Extraction and Recovery

Sinapic Acid (>98%: $49.30/g)

Acetic Acid (ACS grade: $0.035/mL) (0.43% of waste solution)

Nitric Acid (ACS grade: $0.224/mL) (0.9% of waste solution)

Extraction Method

Recovery of Products

Pricing from VWR

Water Capture and ReuseGreywater

-Toilets, irrigation

Water Recycling

-Cleaning Production Tanks

Rinsing between flavor changes

End of the week cleaning

Currently using potable city water

-Majority of water usage is for batch making

Currently updating piping & pumps

Reduces amount of wastewater produced


SEPARATION

AQUEOUS

SOLIDS

ELECTROLYSIS

ANTIMICROBIAL


LAND APPLICATION


pH ADJUSTMENT



GREYWATERRECYCLED

WATER

BIOPESTICIDE

pH NEUTRALIZATION

Solids

Antimicrobial/Biopesticide

Antimicrobial or Biopesticide AgentCollect solids to re-sell

Potential Issues with ApplicationNutrient content, SalinityPresence of cleaning agentsOrganic Regulations

Processing, Storage, and Transportation requirements

Further Testing

publish.illinois.edu

Sustainability Measures

On-site treatment

-Eliminate the cost of outsourcing wastewater

-Minimize resources used for disposal/treatment

Biological treatment methods

-Less expensive than chemical treatment

-Naturally occurring process, non toxic


Recycling water back through facility

-Cost effective

-Reduce fresh water used and amount of treatment necessary

Generate coproducts

-Economic sustainability from additional revenue

-Antimicrobial benefits (possibly a more organic/natural option)


Social sustainability

-Recycling/reuse of materials, decrease pollutants

Ethical sustainability

-Meet all guidelines/requirements

Efficiency

-Practical, eco-friendly, cost efficient

Societal issues

-not restricted to specific population http://www.aiche.org


Carbon Footprint

-Minimal fossil fuel carbon emissions

Water Footprint

-Reduce need/use of freshwater

ecology110fra.wordpress.com

Schedule

ReferencesCheng, S. and Logan, B. (2007). Sustainable and Efficient Biohydrogen Production via Electrohydrogenesis. Proceedings of the National Academy of Sciences of the United States of America. vol. 104. no. 47. 18871-18873

Engels, C., Schieber, A., Ganzle, M. (2011). “Sinapic acid derivatives in defatted Oriental mustard (Brassica juncea L.) seed meal extracts using UHPLC-DAD-ESI-MS and identification of compounds with antibacterial activity.” Eur Food Res Technol. 234, 535-542

Harrison, R., Todd, P., Rudge, S., Petrides, D. 2003. Bioseparations Science and Engineering. New York, N.Y.: Oxford University Press.

Herzallah, S. and Holley, R. (2012) “Determination of sinigrin, sinalbin, allyl- and benzyl isothiocyanates by RP-HPLC in mustard powder extracts.” LWT - Food Science and Technology 47, 293-299.

Kargi, F. and Arikan, S. (2013). ”Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes.” J. Environ. Eng., 139(6), 881–886.

Niciforovic, N. and Abramovic, H. (2014) “Sinapic Acid and Its Derivatives: Natural Sources and Bioactivity” Comprehensive Reviews in Food Science and Food Safety 13, 34-51.

Popova, I. and Morra, M. (2014). “Simultaneous Quantification of Sinigrin, Sinalbin, and Anionic Glucosinolate Hydrolysis Products in Brassica juncea and Sinapis alba Seed Extracts Using Ion Chromatography.” Journal of Agricultural and Food Chemistry 62, 10687-10693.

Zoulias, E., Varkaraki, E., Lymberopoulos, N., Christodoulou C., Karagiorgis, G. (2012) A Review on Water Electrolysis. Centre for Renewable Energy Sources and Energy Efficiency. Available at: http://www.cres.gr/kape/publications/papers/dimosieyseis/ydrogen/A%20REVIEW%20ON%20WATER%20ELECTROLYSIS.pdf. Accessed 9 September 2015

http://www.cres.gr/kape/publications/papers/dimosieyseis/ydrogen/A%20REVIEW%20ON%20WATER%20ELECTROLYSIS.pdf

Thank you!

Questions?