Mustard design final presentation

Mustard Waste Treatment Design Final Report

Matt Rosen, Ian Melville, Cahner Jennice, Matt Rimer, Kira Bartlett

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

The Company

Olds Products

Mustard Production Facility

Located in Pleasant Prairie, Wisconsin

http://www.oldsproducts.com

Table of ContentsIntroduction

-Problem

-Existing Solution

Research and Analysis

Design and Methodology

-Governing Equations

-Economic Analysis

Summation

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

-Minor ingredients added by operator

Waste Production

Machines are cleaned with each flavor change

-Multiple cleanings per day

-Cleaning water heated to 120 °F

Periodic caustic wash

All waste pumped into 6,000 gallon reservoir

The Problem

http://www.wrc.org.za

Unable to discharge wastewater through sewer system

Complaints from Pleasant Prairie municipal water treatment plant

-pH is too low (3.3) with a required pH range between 5.5-9 pH (Kenosha)

-Discharge volume is too high

Current Solution - Land Application

Waste Solids sprayed or injected on farmland

$200,000 annual cost

supernovatrucking.com/index.php?option=com_content&view=article&id=11&Itemid=10ohioline.osu.edu/aex-fact/0707.html

Project Goals

Solve immediate problem of waste disposal

Create/obtain a usable and harvestable byproduct

Create Economic and Sustainable viability

-Design simplicity

-Water capture and reuse

Constraints

Geographic: Pleasant Prairie, WI v. Clemson, SC

Company Budget

Municipal Codes (Wastewater treatment guidelines)

Current operating procedures

Limited information - No previous waste analysis

FDA and Organic regulations

ConsiderationsSafety

-Working with chemicals and reagents

-Industrial food plant - FDA and organic regulations

Ecological

-Impact of treated water products on environment

-Distinct seasonal change in Wisconsin

Ethical

-Company contact is the relative of a team member

Design QuestionsUser 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?

Pressure Filtration

Vacuum Filtration

Harrison pg. 120K. Bartlett

Forced Filtration

Gravity Separation

Centrifugation

Imhoff Cone Separation:70% aqueous solution

30% solids

Sedimentation

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

Coagulation and Flocculation

Assembles smaller suspended particles into larger particles

Easier and faster to separate or filter

Neutralize surface charges

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

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

Electric potential shifts positive ions (H+) towards cathode and negative ions (OH-) towards anode

Theoretical pH increase

Negative Energy balance

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)

Kargi and Ariken, 2013. “Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes”

Electrolysis: Lab Testing

500 mL setup

9 V current

pH change from 3.24 to 3.14

Tested using Gas Chromatography-20.6% H2

-1.03 moles H2 per 2,000 gallons

K. Bartlett

K. Bartlett

Hydrogen Fuel Cell

Combines hydrogen and oxygen to produce electricity

Reaction in single fuel cell typically produces about 0.7 volts

Electrochemical process - low emissions

2 H2 --> 4 H+ + 4 e-

O2 + 4 H+ + 4 e- --> 2 H2O

2 H2 +O2 --> 2 H2O

fuelcells.orgLin, 2000. “Conceptual design and modeling of a fuel cell scooter for urban Asia”

Scale-Up & Design Considerations

2,000 gallons per dayElectrolysis: 267.5 kJ/day

Hydrogen Fuel Cell: 245.1 kJ/day (max) → 30.3 kwh/year

132.4 kJ/day (practical) → 11.5 kwh/year

Improve Electrolysis Efficiency

Different type of Hydrogen Fuel Cell

Corrosive PropertiesKabza, 2015. “Fuel Cell Formulary”Kargi and Ariken, 2013. “Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes”

Sodium Hydroxide (NaOH):

Sodium Bicarbonate (NaHCO3):

Acetic Acid NaOH + CH3COOH H20 + CH3COONa (Sodium Acetate)

Nitric Acid NaOH + HNO3 H20 + NaNO3 (Sodium Nitrate)

Acetic Acid NaHCO3 + CH3COOH H20 + CO2 + CH3COONa

Nitric Acid NaHCO3 + CH3COOH H20 + CO2 + NaNO3

Chemical pH Adjustment

42 mL of 0.1 M NaOH to reach ph of 6= 0.0042 Moles of NaOH= 0.168 Grams of NaOH

12 mL of 0.5 M NaHCO3 to reach ph of 6= 0.006 Moles of NaHCO3 = 0.504 Grams of NaHCO3

Titration Testing

42 mL of 0.1 M NaOH to reach ph of 6= 0.0042 Moles= 0.168 Grams

53 mL of 0.1 M NaOH to reach ph of 6= 0.0053 Moles= 0.212 Grams

Titration Testing

Potential Antimicrobial Properties

Antimicrobial properties cited due to sinapic acid conjugates

Primary Testing: Clemson Microbiology Department

Secondary Testing: Home-scale testing

Inconclusive Results

Popova and Morra. 2014. Simultaneous Quantification of Sinigrin, Sinalbin, and Anionic Glucosinolate Hydrolysis Products in Brassica juncea and Sinapis alba Seed Extracts Using Ion Chromatography.

Primary Antimicrobial Testing

Gravity Filtered Solids(original pH)

Gravity Filtered Aqueous(original pH)

Re-suspended solids from TSS testing (.11 μm filter)

Re-suspended filtered solids with DI water (.45 μm filter)

I. Melville

I. Melville

I. Melville

Secondary Antimicrobial Testing

TSS SolidsBacteria from Mouth

Filter SolidsBacteria from Mouth

TSS Solids (Shoe) Filter Solids (Floor) TSS Solids (Face)

K. Bartlett K. Bartlett

K. Bartlett K. Bartlett K. Bartlett

Biological Treatment

Yeast - Torula (Candida Utilis)

Yeast glucose utilization C6H1206 + 6O2 → 6CO2 + 6H2O + 16-18 ATP

Initial COD estimates: 18 g/L

Theoretical COD Reduction of 53% in 24 hours

COD 18 g/L 9.5 g/L

Postma, Kuiper, Tomasouw, Scheffers, and Dijken. 1989. Competition for Glucose between the Yeasts Saccharomyces cerevisiae and Candida utilis.Wongkarnka, 2005. The application of aerobic yeast for treatment of high strength food processing wastewater containing furfural. iSee Systems Stella Model

Total Suspended Solids

Raw Waste Solution– 19,500 mg/L

Gravity Separated Solution– 335 mg/L

Unfiltered, Mixed

Gravity Separated, Aqueous

K. Bartlett

Clemson Agriculture Lab

Component Testing - HPLC

Nitric Acid (0.89%)

Acetic Acid(0.43%)Unknown

Kira

Advanced Filtration and Drying

Cost of machinery and installation between $70,000 and $80,000 (quoted by M.W. Watermark and Kontek Ecology)

Semi Automatic systems would need trained operators

Future costs of equipment maintenance and replacement parts

Disposal cost of solid waste

Intelligen SuperPRO Modeling

Mustard Factory

Separation

Solid Holding

Aqueous Holding

Water Recycling (Heated)

pH Adjustment

Land Application

Disposal to Pleasant Prairie

System Design

Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application


Primary Treatment Stage

Largest Volume of Treatment

Gravity Separation

Stokes Law: *

V = Settling Velocity

μ = viscosity of liquid

ρp= Density of Particle

ρf= Density of Fluid

g= gravity

R= particle radius

ts = settling time

h= height of separation tank

v = settling velocity

ts = 15 hours

19,500 mg/L -> 335mg/L

98% Reduction in TSS

724 kg solids separated per dayDr. Muhammad Tahseen Aslam - Settling of solids in raw wastewater

Gravity Separation

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

plastic-mart.com/tech_drawings/norwesco/10000%20Gallon%20X%2030%20Deg%20Cone%20Bottom%20Tank.pdf

Total System Cost: $40,000

cdf1.com/technical%20bulletins/Polyethylene_Chemical_Resistance_Chart.pdf

Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application

Solid mix held in holding tank prior to transportation

Utilizes existing 6,000 gallon tank


Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application


3,000 gallons a day

Land Application system already in place

Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application


10,000 gallon capacity

Fully Insulated

Two outlet streams-Water Recycling-pH Adjustment

Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application


Used for rinsing tanks between batches

50/50 split of recycled water and city water

Water Recycling

Water Recycling

Low pH beneficial for cleaning process

Two Week Cycles

Decreases water use, discharge and related expenses-Water use: -1,700,000 gallons per year

-Water expenses: -$4,500 per year

Recycled water meets FDA and organic standards if it does not contact actual food product

Solid Solution

Aqueous Solution

Original pH

Neutral pH

Interview with M. Freedman, October 15, 2015

Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application


Secondary Treatment Stage

Chemical adjustment using %25 NaOH

Secondary Treatment: pH Adjustment

Batch system

1050 HDPE Tank

300 gallon Mild Steel tank

Automatic pH controller

Liquid Level Meter to begin next batch

pH Adjustment

Utilizes 25% Sodium Hydroxide Solution by weight- Reduces freezing point, safety hazards, and corrosiveness to system.

Batch System- Accounts for fluctuations of influent waste

- Effluent quality is critical

- NaOH system handling is important for safety

Secondary Treatment: pH Adjustment

Cost of 25% Sodium Hydroxide = $2.22/Gallon

Amount NaOH needed to adjust 1000 Gallons = 12.72 Kilograms

= 2.64 GallonsWITH RECYCLING TECHNIQUES :

Waste Treated per Day = 2000 GallonsNaOH Needed Daily = 5.3 GallonsNaOH Needed Yearly = 2260 GallonsExtra 5000 Gallons every two weeksNaOH Cost per year = $5000

Waste Treated per Day = 7000 GallonsNaOH Needed Daily = 18.5 GallonsNaOH Needed Yearly = 6714 GallonsNaOH Cost per year = $15,000

Mustard Factory

Separation

Solid Holding

Aqueous Holding


pH Adjustment

Land Application


Daily discharge reduction by 8,000

gallons

Disposal Costs

Varying meter sizes-6” is largest and most expensive meter-Flat monthly fee

Largest meter for Lake Michigan is ¾”

Economic Advantages

Water Recycling Advantages-Reduction of water usage saves $4,500 per year

-Reduction in treated water saves $10,000 in NaOH costs per year

Simplicity of design-Low maintenance and repair cost

-Low labor requirement

Re-use old equipment wherever possible to subsidize costs

Economic Summary

Sustainability

Improves economics of wastewater treatment/removal

Reduces freshwater use

Limits chemical usage for water treatment

Maintains FDA and Organic standings

keepcockecountybeautiful.com

Design QuestionsUser 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?

Schedule

Summation

Problem: pH and Waste Volume

Solution:-Gravity Separation

-pH Adjustment

-Water Recycling

-Disposal

Economics: Saves around $50,000 annually after first year

Sustainability: Water recycling reduces water consumption

Table of Contents

Introduction

-Problem

-Existing Solution

Research and Analysis

Design and Methodology

Economic Analysis

Summation

ReferencesCheng, S., 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.

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

Kabza, Alexander. 2015. “Fuel Cell Formulary.” Zentrum für Sonnenenergie- und Wasserstoff-Forschung Baden-Württemberg.

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.

Kemker, C. 2013. pH of Water. Fundamentals of Environmental Measurements. Available at: http://www.fondriest.com/environmental-measurements/parameters/water-quality/ph/#p8. Accessed 7 September 2015.

Lin, Bruce. 2000. “Conceptual design and modeling of a fuel cell scooter for urban Asia.” Journal of Power Sources 86: 202-213.

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.

Postma, E., Kuiper, A., Tomasouw, W., Scheffers, W., Dijken, J. 1989. Competition for Glucose between the Yeasts Saccharomyces cerevisiae and Candida utilis. Applied and Environmental Microbiology 55(12): 3214-3220.

Wongkarnka, Monchai. 2005. The application of aerobic yeast for treatment of high strength food processing wastewater containing furfural. Iowa State University: Retrospective Theses and Dissertations. Paper 1821.

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%20W ATER%20ELECTROLYSIS.pdf. Accessed 9 September 2015.

Acknowledgments

Michael Freedman, Olds Products - Company Contact

Dr. Caye Drapcho, Clemson University - Project Advisor

Ning Zhang, Clemson University - Lab work assistance

John Abercrombie, Clemson University - Microbiology Lab work assistance

Dr. David Freedman and Rong Yu, Clemson University - Gas Chromatography Assistance

Dr. Terry Walker, Clemson University - Project Consulting

Tom Jones, Clemson University - Project Consulting

Questions?