Brian Scheffe (bscheffe@h2ok.co.uk)

AECOMIXTM - SOLUTION FOR

COMBINED TREATMENT WASTE

AND WASTEWATER

• Part of Nijhuis Industries, together with Nijhuis Water Technology

& Nijhuis Ozone Solutions

• Long history : >2500 reference plants, > 50 countries worldwide

• High level of process and application knowledge of many industries

• From products to total solutions, including re-use and recovery

• Market leader in DAF systems

• Sales & Service Centers, Poland, Russia, Asia Pacific, China, USA,

Egypt and Latin America

• Nijhuis Industries: 50 million turnover / 250 employees

• Industrial and municipal clients

Nijhuis H2OK

Global Network

Design &

Approvals

Principle

Contractor

Project

Management

Technology

Supply

Mechanical &

Electrical

InstallationOperation &

Maintenance

Planning/

Flood Risk

Assessment

Nijhuis H2OK’s Turnkey Service

• Screening (Drum Filter, Curved screen, Cloth filter, AquaRake,..)

• Gravity separation (API,CPI, NTB, ILS, Hydrocyclone, ..)

• Flocculation, Flotation (PFR, NTR, DAF, DGF, IAF,..)

• Biological (Aerobic & Anaerobic)

• Filtration (Sand, Carbon, MMF, Nutshell, …)

• Oxidation and desinfection (Ozone, UV, AOP)

• Membrane filtration (UF/NF/RO)

• Nutrient recovery (ammonia, phosphorus, fat)

• Anaerobic digestion

• Dewatering systems

Own Techniques / Solutions

• Intensive water use

• High pollution levels divided in 2 categories:

1. Mainly soluble pollutants (breweries and soft drinks)

2. Mixed, including high TSS, FOG

(dairies, confectionaries, fruit and vegetable)

• Typical solutions :

• For 1. : High rate anaerobic : UASB and EGSB/IC type

• For 2. : Pretreatment required before UASB (FOG, TSS removal)

or other solution

The Food & Beverage Industry

This presentation gives an innovative solution for group nr 2

They often also have factory wastes to deal with

Parameter Units Ice cream Chocolate Cheese

COD mg/l 10,000 9,000 4,000

BOD mg/l 6,500 6,000 2,500

TSS mg/l 1,200 1,650 750

FOG mg/l 1,100 700 250

TKN mg/l 80 60 20

Wastewater

Organic Waste

Wastewater and Waste Characteristics

Parameter Units Ice cream Chocolate Cheese

waste

% of flow % 0,8 0,03 20

COD mg/l 400,000 1,350,000 55,000

TSS mg/l 248,000 920,000 2,000

FOG mg/l 40,000 270,000 1,250

Sludge

Digester

Flotation

Screenings

UASB/ ESGBFlotation unitFlocculatorEqualisation

tankFilter

Pre-treatment Decanter

Gas

treatment/use

Cake

Centrate

To

biotreater

Waste

Wastewater chemicals

flocculant

Flow Diagram Conventional Treatment

Sludge

Flotation

Screenings

Flotation unitAecomixEqualisation

tankFilter (option)

Pre-treatment

Gas

treatment/use

Waste

Wastewater flocculant

Biological

treatment

Flow Diagram AecomixTM

• Pre-treatment options: depacking, shredding, pasteurisation

• Excess sludge Biotreater can be added directly or after pre-treatment

• Mixing Aecomix : mechanical or gas-mix

• Dissolved biogas flotation

Both streams combined in 1 process AecomixTM

Parameter Units Ice cream Chocolate Cheese

COD mg/l 13,200 49,000 14,000

BOD mg/l 8,100 30,000 8,000

TSS mg/l 3,200 3,000 1,150

FOG mg/l 1,400 8,800 500

TKN mg/l 80 60 20

The wastewater mixed with factory waste, provides following typical data:

Mixed Substrate for Aecomix

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

0

20000

40000

60000

80000

1 3 5 7 9 11 13 15 17 19 21 23 25

CO

D r

emo

val i

n %

CO

D in

mg

/ldays

COD in mg/l removal

0

1000

2000

3000

4000

5000

1 6 11 16 21 26

CO

D in

mg

/l

days

Case Study – Convectionary Factory - COD Removal

Influent COD and

removal rates

Effluent COD

0.00

0.20

0.40

0.60

0.80

1.00

1 6 11 16 21 26

Fos-

Tac

days

digester 1 digester 2

Fos-Tac measurements

FOS – (Fatty Acids) : TAC – (Total Alkalinity) ratio shows stability and

plant loading.

• Stable anaerobic system with Fos-Tac <0.45

Convectionary Factory - Operational Stability

Dissolved Biogas Flotation

• Biogas solubility is superior to air

• Dissolving is controlled to obtain microscopic gas bubbles

• Flotation requires approx. 15 l/kg solids of gas

• Recycle pump mixes/ dissolves biogas into fluid

• Flocculant dosage : 3-5 g/kg d.s.

• Dry solids float : 5-9 % ds.

• Power consumption Gas flotation : 0.4 kWh/m3 treated

(includes required gas booster pump)

gas

OPEX Comparison

In the OPEX the following is considered for the Aecomix:

• Aecomix concept as described above incl. dewatering

.

Compared to a conventional pre-treatment – UASB – sludge digester :

• A flocculation-flotation system with PAC, NaOH and flocculant

• An UASB reactor

• A digester for DAF sludge + chocolate waste, incl. dewatering

Parameter units Aecomix Conventional

UASB

Power consumption kWh/d 400 450

FeCl3 (40%) kg/d 70

NaOH (33%) kg/d 25 75

Flocculant kg/d 6 3

Operator attention h/d 4 16

OPEX total (excl. manh.) EUR/m3 0.80 1.00

Energy potential biogas kWh/d 6300 6300

• Flocculant dosage : 3-5 g/kg d.s.

• Dry solids float : 5-9 % ds.

• Power consumption Gas flotation : 0.4 kWh/m3 treated

(includes required gas booster pump)

Dissolved Gas Flotation details

Some operating details:

• Mixed Liquor Suspended Solids : approx 6 g/l

• F/M ratio : average 0.23 kg COD/kg MLSS

• Methane content biogas : 60-70%

scada:

Operating Details

Take home message

• Aecomix is a robust and economic solution for food and beverage industries with

substantial amounts of TSS and FOG, such as :

• dairy (cheese), ice cream, confectionary,

• vegetables,

• distilleries

• breweries

• others

• Aecomix is a simple one step solution for factories to deal with their waste and waste water

• Aecomix combines digestion and gas storage in one system

• Aecomix can achieve COD reductions in effluent over 95% (up to 99%)

• Dissolved Gas Flotation is a robust and cost effective S/L separation in Aecomix process

• Aecomix has much lower CAPEX an OPEX (>20%) compared to traditional process and

requires less operator attention, thus making it further economically attractive

References

Biogas Chicken Plant Ukraine

Questions ?

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