removal of organic load andgeneration … of organic load andgeneration of biogas from dairy ... it...
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REMOVAL OF ORGANIC LOAD
ANDGENERATION OF BIOGAS FROM
DAIRY WASTE WATER JANANI.R1, JAYAKEERTHANA.E2, GNANAPRAGASAM.G.G3
1,2UG STUDENTS, 3SENIOR ASSISTANT PROFESSOR
DEPARTMENT OF CIVIL ENGINEERING
IFET COLLEGE OF ENGINEERING, VILLUPURAM.
ABSTRACT The dairy industry plays a vital role among all food industries. It is used to manufacture the dairy products like milk,
cheese, butter, ghee etc., so, it produces more amount of wastewater which contains large organic load. 2.5-3.0 liters of
wastewater is produced per liter of milk processed in the dairy industry. An experimental investigation was carried out to
remove the organic load and generate biogas (methane) by anaerobic treatment (mixer reactor) with varying percentage of 10%,
25%, 50%, 75% and 100%. From that 75% of wastewater treated with anaerobic bacteria, results maximum reduction of COD
and biogas generated with an average of 0.35m3/day.
Keyword: organic load, anaerobic treatment, COD, biogas
1. INTRODUCTION
In India, farmers directly distributed the
milk to the consumers whereas the remaining part of
the milk processed in dairy industries to manufacture
various types of milk products. In dairy industry, the
process of starting, equilibrating, stopping and
rinsing of the production units produces some
amounts of wastewater. More amount of wastewater
is produced from the cleaning operations, while the
milk converted into different types of dairyproducts
by specific production process and cleaning
operations. In an intermittent way, dairy processing
effluents are generated and the effluents flow rates
will change significantly. The quantity of the product
content in the dairy industry wastewater at a given
time changes with the application of another
technology cycle in the processing line. Average of
2.5-3.0 liters of wastewater produced from the dairy
industry for per liter of the milk processed. Generally
dairy waste water sludge contains large quantities of
fat, inorganic salts, casein, and lactosebesides
detergents, sanitizers etc., used for washing. The
valuable nitrogen and phosphate present in the dairy
sludge when compare with conventional mineral
fertilizers nutrient content of potassium is low.
Compared to municipal sludge, dairy sludge has
considerably more fertilizers value.The process
involves in the dairy products produces wastewater,
the composition of this wastewater is mostly suitable
for the biological wastewater treatment. Aerobic
process consumes more volume of electricity for the
treatment of dairy wastewater. To overcome the more
energy consumption and to remove more amount of
organic load anaerobic technology is recommended
for the dairy wastewater treatment. Anaerobic
technology used for the treatment of dairy wastewater
to remove the organic load by converting COD into
bio-gas. Biogas is used for the production of
electrical and thermal energy.
2. SOURCE OF WASTEWATER
Following are the sources of wastewater
from dairy industry:
2.1 Milk receiving
Milk is received by tank and truck. After the
usage of milk, washing can be done. Hence, the
wastewater produced by washing of storage tank,
washing of pipe line and sanitizing. Wastewater
consists of milk wastes, milk solids, detergents and
sanitizers.
2.2 Whole milk products
More amount of wastewater is produced
from the cleaning operations, while the milk is
converted into different types of dairy products by
specific production process and cleaning operations.
Wastewater contains organic loads and inorganic
loads due to the process of washing and milk
processing units. In developing countries, the main
problem of pollution can be caused by spoilage of
milk.
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2.3 Cheese/whey/curd
Wastewater is mainly produced from the production
of whey (liquid by-products from cheese),wash
water, curd particles etc., the whey and wash water
from cottage cheese results more fine curd particle
compared to other chesses. If mechanical washing
process is used, the amount of fine particle in the
wash water will increaseautomatically. Because
manual washing process did not result much fine
particles in the wash water.
2.4 Butter/Ghee
Wash water from butter processing unit
containing buttermilk. Skim milk powder can be
produced by skim milk and buttermilk in the factory
itself. The skim milk powder may be shipped to
another dairy food plant tank truck. The potential
waste load can be reduced by the continuous butter
production process material. By eliminating the
buttermilk production and the washing steps.
2.5 Milk powder
By cleaning and emission of CO2 and CO
during the drying process consumes high energy. It
caused severe environmental problems.
2.6 Condensed milk/cream/khoa
The production of condensed milk, cream
and khoa consumes more energy during the
evaporation process. It also results environmental
problems. The coagulated milk and fine particle of
cheese curd are the main suspended solids which are
produced by milk processing units.
Table 1 Waste production data
Reference 1 2
Avg Range Avg Range
Wastewater
Production
2300 120-
12000
2300 100-
7000
BOD 7 0.2-
70.2
5.6 0.2-7.2
SS 2.1 0.07-
10.6
Nitrogen 0.16 0.002-
0.42
Phosphorus 0.011 0.007-
0.14
Table 2 Volume of wastewater and BOD
production from the different types of dairy
product
Type of
product
Wastewater
volume
BOD
Avg Range Avg Range
Milk 3150 100-
5000
4.1 0.20-
7.6
Condensed
milk
2110 1000-
2700
7.5 0.22-
13.5
Butter 810 0.84
Milk
powder
3600
1400-
5900
2.1
0.02-
4.6
Cottage
cheese
6000 800-
12400
34.0 1.30-
71.2
3. CHARACTERISTICS OF WASTEWATER
Dairy wastewater contains detergents, milk
wastes, milk solids and cleaning water. The
characteristics of wastewater consist of high
concentrations of organic, inorganic and nutrient
contents. High salinity levels in wastewater due to
salting activities of the cheese production. Acids,
alkali with a number of active ingredients, and
disinfectants, as well as a significant microbiological
load, pathogenic viruses and bacteria are present in
the wastewater.
Parameters Units Guideline value
pH - 4-12
SS mg/l 24-5700
BOD mg/l 450-4790
COD mg/l 80-95000
Nitrogen mg/l 15-180
Phosphorus mg/l 11-160
Oil and grease mg/l 10
Coliform
bacteria
MPN/100ml 400
Magnesium mg/l 25-49
Potassium mg/l 11-160
Chloride mg/l 48-469
Calcium mg/l 57-112
4. ANAEROBIC TECHNOLOGY
Anaerobic technology is a biological method
of treatment of wastewater. It involves in the process
of methane production (CH4). The micro-organisms
involves in this process is called anaerobic bacteria,
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because these bacteria does not requires oxygen to
survive. The anaerobic process involves four process.
They are as follows:
Hydrolysis
Acidification
Acetogenesis
Metanogeneza
The anaerobic process removes the bulk of
COD from the wastewater by converting it into
biogas (= methane + carbon dioxide) at low costs.
4.1 Benefits of anaerobic technology
It can be used to reduce the
uncontrolled emissions of methane
(CH4) as the waste breaks down.
It is used to produce the renewable
energy which displaces fossil fuel
energy.
It recovers the energy from organic
waste and produces a material which is
suitable for land spreading.
4.2 Combining aerobic and anaerobic biological
cleaning of wastewater
Figure 1: combination of aerobic and anaerobic
process
Anaerobic process of waste water cleaning results
Sludge production is nearly 70% less
After floatation 80% COD still in the
wastewater, which is converted into methane
and it is used as energy.
Energy consumption for the process of
anaerobic is less when compared to aerobic
process.
4.3 Energy efficiency
Dairy wastewater cleaning by anaerobic
technology generates on an average of 2m3 of biogas
per m3, which replaces about 1.2 liters of fuel oil.
80% of excess sludge volumes are reduced by
reduces their disposal costs. The excess sludge
contains high concentration of calcium and
phosphates which is created in the anaerobic plant.
High phosphate content in the sludge is used as
fertilizer.
Whey is the by-product of cheese, which
produced 40m3 of biogas by anaerobic process (40m3
of biogas is converted into 6.5 KWh/Nm3 biogas by
thermal value of biogas). Hence, per tonne of whey
produces 260KWh of thermal energy.
5. EXPERIMENT
5.1 Study site
Present study was carried out at Aavin Co-
op Milk Producers’ Federation Ltd., Villupuram,
India. To release the treated effluent a seasonal drain
was located near the complex.
5.2 Volume of the effluent
In dairy industry, the milk processes is
nearby about 4500-5000liters/day. Volume of
effluent discharged from dairy products
manufacturing is about 20,000liters/day.
5.3 Analysis of dairy effluent
a. pH
b. COD (chemical oxygen demand)
c. Bio-gas
The effluents from dairy were analyzed with respect
of the given parameters.
5.4 Methods of sampling
Daily samples from Aavin industry were
collected in plastic bottles. Samples are first rinsed
with distilled water in the laboratory and then rinsed
with effluent at the sampling site. From the plant,
samples of inlet were collected and an outlet sample
was collected from the mixer reactor.
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5.5 Module making of mixer reactor
Treatment of wastewater done by anaerobic
process (mixer reactor). Module making of mixer
reactor can be done by using water bottles 20 liters,
pipe, ¾ PVC pipe, volve, t-valve, funnel and tyre
tube, PVC pipe cap.
Figure 2: Module of a reactor
5.6 Analysis of samples
Sample of inlet and outlet can be analyzed
after the treatment process.
5.6.1 Analysis of samples by varying the
percentage
Table 3 shows results of COD for various
percentage of wastewater treatment
Percentage of
wastewater
treated (%)
COD (mg/l) Biogas
generatio
ns
(m3)
Inlet Outlet
10 504.2 201.7 0.25
25 463.8 208.7 0.23
50 728.7 327.9 0.36
75 894.5 358.9 0.45
100 710 390.5 0.36
5.6.2 Analysis of samples by increasing its pH
From table 3, taking the percentage of
wastewater which produces more biogas. Increase its
pH for 3 times and determine its COD after the
treatment process.
75%
of
waste
water
pH COD (mg/l) Biogas
generations(m3) Inlet Outlet
6.8 894.5 358.9 0.45
6.9 894.5 305.7 0.451
7.0 894.5 208.2 0.453
5.6.3 Analysis of samples by treating it for 2days
75% of waste water can be treated in the
mixer reactor for 2days. Biogas and COD
determination can be carried for 24, 36 and 48 hours
intervals.
75%
of
waste
water
Time
interval
(hours)
COD (mg/l) Biogas
generation
(m3)
Inlet Outlet
24 894.5 358.9 0.45
36 894.5 278.4 0.452
48 894.5 201.3 0.453
5.7 Results
Present study showed that at inlet effluent
analysis COD value ranged from 400mg/liter to
900mg/liter and average value has 650mg/liter. The
analysis of COD at outlet sample showed variation
from 200mg/liter to 400mg/liter. The study showed a
total reduction of COD of 78 percent. The
fluctuations in percentage COD reduction between
inlet and outlet samples are graphically depicted in
below figure 3, figure 4 and figure 5.The gas
generation fluctuated between 0.23m3/day to
0.46m3/day with an average of 0.35m3/day. The
fluctuations in gas generation are graphically shown
in figure 6.
Figure 3: percentage of COD reduction for
various percentage of waste water
40
45
50
55
60
65
70
0 50 100 150
% o
f C
OD
red
uct
ion
% of waste water treated
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Figure 4: percentage of COD reduction at time
intervals
Figure 5: percentage of COD reduction at
different pH values
Figure 6: Biogas generation
6. Conclusion:
Effluent from the dairy can be treated by
anaerobic technology which is cost effective. It also
produces biogas. Biogas is considered as renewable
natural gas. Biogas can provide number of social and
environmental benefits and it is an cost effective
substitute for fuel wood. Anaerobic technology is
secured process for generating biogas.
7. References:
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50
60
70
80
0 20 40 60
% o
f C
OD
red
uct
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Time (hr)
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75
80
6.7 6.8 6.9 7 7.1
% o
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OD
red
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pH value
50
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65
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75
80
0.448 0.45 0.452 0.454
% o
f C
OD
red
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Biogas (m3)
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