Prepared for:

Presented by:

Chris Miller

DUAL STAGE TREATMENT AND

ADVANCED PRODUCT RECOVERY IN

INDUSTRIAL EFFLUENTS

OVERVIEW

• About FRC Systems International

• Dual Stage Treatment and Product Recovery

• Project Profiles

• Q&A

ABOUT FRC

• Founded in 1979

• Office Locations• Toronto, Ontario

• Atlanta, Georgia

• Geraldine, Alabama

• Fayetteville, Arkansas

• Bogota, Colombia

• Over 500 projects in 20+

countries worldwide

• Ability to provide single

products or turn-key solutions

Dairy

Meat

Poultry

General

Manufacturing

Fruit/Vegetable

Other Foods

Cosmetics

Chemical/Pharmaceutical

Oil & Gas

Seafood

DUAL STAGE

• First Stage

• Product recovery (for sale)

• Reduce downstream chemical use

• Second Stage

• Chemical/physical clarification

COMMON DUAL STAGE APPLICATIONS

Animal Proteins {

Poultry processing

Beef processing

Pork processing

Seafood processing

Heavy Oils {Metals

Manufacturing

Refineries

Misc. { Pulp & paper

Mining

Food Processing { Vegetable oils

CATERPILLARWinston Salem, North Carolina

• Truck Axle Manufacturing

• Discharge to POTW

• Design Data:• Flow: 50,000 gpd

• FOG: 125,000 mg/L

• Petroleum: 32,500 mg/L

• TSS: 10,800 mg/L

• COD: 146,000 mg/L

• Discharge Requirements:• TSS: <300 mg/L

• FOG: <100 mg/L

SINGLE STAGE PROCESS

DUAL STAGE PROCESS

HIGH-RATE OIL/WATER SEPARATOR

• Removes free and mechanically

emulsified oils

• Rotating skimmer

• Corrugated plate pack

SITE PLAN

RESULTS

Batch Process:

• System operated as needed

• Recovered oil is filtered and reused in plant

• $10s of thousands of dollars saved on chemical use in DAF

• System achieves discharge requirements

At What Cost?

• Engineering (approx. $50,000)

• Oil/water separator (approx. $150,000)

• Ancillary pumps, tanks, instrumentation, controls (approx. $75,000)

FIELDALE FARMS

• Poultry Kill Plant

• Direct Discharge to Local

Stream

Murrayville, Georgia

• Design Data:• Flow: 2.3 MGD

• TSS: 2,500 mg/L

• FOG: 2,500 mg/L

• BOD: 4,200 mg/L

• Discharge Requirements:• TSS: <30 mg/L

• FOG: <10 mg/L

• BOD: <30 mg/L

PROCESS CALCULATIONS

Hydraulic Surface Loading Rate

Flow rate (feed flow + recycle flow) in gpm

Effective surface area in sqft

(1600 gpm + 240 gpm)

x sqft= 1 gpm/sqft

Solids Loading Rate

Weight of TSS in feed to DAF in lbs/hr

Free surface area in sqft

(2500 mg/L * 8.34 lbs/gal * 2.3MGD)/24hr/day

x sqft= 10 lbs/sqft/hr

= 1840 sqft required = 200 sqft required

• Angled plates increase

interstitial surfaces to

minimize separation distance

DAF UNIT SELECTION

• Maintains laminar flow

conditions (fluids flow in

parallel layers without mixing)

PCL-90 DAF (x2)

• Effective Area: 1,550 sqft

• Free Area: 87 sqft

• Required Effective Area: 1,840 sqft

• Required Free Area: 200 sqft

F-12 PIPE FLOCCULATOR (x2)

Water Inlet

Polymer 2 Mixing

Polymer 1 Mixing

Water Outlet

CONVENTIONAL APPROACH

Sludge to

Disposal

Sludge to

Disposal

PRODUCT RECOVERY

Cookers

Cookers

INSTALLED SYSTEM

INSTALLED SYSTEM

INSTALLED SYSTEM

RESULTS

Recovered Oil & Proteins:

• Approx. 50,000 lbs/day (wet)

• Producing $30K-$40K per week in resale

• $1.5MM - $2MM per year

• Hundreds of thousands of dollars saved on solids disposal per year

At What Cost?

• Engineering (approx. $50,000)

• Recovered product cookers (approx. $250,000)

Time to Payback: <1 year

BUNGE

• Oilseed Processing

Morristown, Indiana

• Design Data:• Flow: 216,000 gpd

• TSS: 19,400 mg/L

• FOG: 120 - 144 mg/L

• Discharge Requirements:• TSS: <200 mg/L

• FOG: <50 mg/L

DESIGN APPROACH

RESULTS

Stage One:

• Stable chemical process (acidulation)

• Recovered oil to processing

• Reduced solids loading on DAF

Stage Two:

• Small DAF (9’ x 8’ x 10’)

• Solids separation with very little chemical additives

• TSS & FOG below permit limits

TALLOMANPerth, Australia

• Rendering Plant

• Design Data:• Flow: 32,000 gpd

• TP: 150 mg/L

• TKN: 1,280 mg/L

• FOG: 2,860 mg/L

• BOD: 15,925 mg/L

• COD: 30,875 mg/L

SYSTEM

• Open tank DAF

• Free area: 48 sqft

• Solids loading: 10 lbs/sqft/hr

SAMPLING DATAFOG

0

1000

2000

3000

4000

5000

6000

7000

Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

mg

/L

FOG Influent vs. Effluent

FOG In FOG Out

DAF Influent DAF Effluent

Sample 1 1,750 5

Sample 2 1,690 5

Sample 3 1,870 4

Sample 4 1,630 5

Sample 5 6,620 3

Averages 2,953 mg/L 4 mg/L

Avg. 99% Reduction

SAMPLING DATACOD

0

10000

20000

30000

40000

50000

60000

70000

Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

mg

/L

COD Influent vs. Effluent

COD In COD Out

DAF Influent DAF Effluent

Sample 1 65,600 19,200

Sample 2 9,800 4,900

Sample 3 37,600 7,200

Sample 4 39,600 6,100

Sample 5 38,000 6,600

Averages 38,400 mg/L 6,633 mg/L

Avg. 83% Reduction

SAMPLING DATABOD

0

5000

10000

15000

20000

25000

30000

35000

Sample 1 Sample 2 Sample 3 Sample 4 Sample 5

mg

/L

BOD Influent vs. Effluent

BOD In BOD Out

DAF Influent DAF Effluent

Sample 1 29,800 11,000

Sample 2 9,300 4,700

Sample 3 23,400 5,300

Sample 4 22,700 5,200

Sample 5 20,200 5,100

Averages 22,100 mg/L 5,200 mg/L

Avg. 76% Reduction

30-36%

dry solids in

DAF float

RESULTS

Recovered Oil & Proteins:

• Contributes 1.5% - 2% of total plant yield

• Adds $1.5MM - $2MM per year in sellable product

• Dramatically reduces load on lagoon system

At What Cost?

• <$200,000 all in

Time to Payback: <2 months

FINAL NOTES

• Consider all inputs and outputs. Is there anything valuable?

• As solution providers it is our job to help project owners find the best

fit for their needs.

FRC Systems International, LLC

PO Box 3147 Cumming, GA 30028

(770) 534-3681

www.frcsystems.com

LEARN MORE ABOUT FRC

ONLINE AT

WWW.FRCSYSTEMS.COM

QUESTIONS?