water waste water treatment & re-use norit 1 & 2[1]

Water, Waste Water Treatment and Re-usein the Beer-, Malting and Beverage Industry

Thijs WolbrinkDavid Parocki

March 2009

2 Basis for WWTP and Re-use: Ultrafiltration Membranes Process Water Production Concepts (well / city / surface) Waste Water Treatment Concept: Effluent Polishing Waste Water Treatment Concept: Norit MBR-technology Introduction MBR Applications and Implementations Norit Water Audit Case Studies (Process Water Prod. / Effluent Polishing / MBR) References Process Water/Water re-use in B&B Water qualities and quantities statements

Contents

MicroFiltration10 um 100 nm

UltraFiltration100 - 10 nm

NanoFiltration10 - 1 nm

ReverseOsmosis< 1 nm

colloids virusescolourhardness pesticides saltswater

giardacryptobacteria

colour hardnesspesticidessaltswater

colloidsviruses

saltswater

colourhardnesspesticides salts

water

Basis for WWTP and Re-useNorit Ultrafiltration Membranes (0)

Early 1990s X-FlowHollow Fibre Membrane CapillaryPolyEtherSulfon

XIGA-technology

ID : 0,8 mmID : 1,5 mm

Potable Water / Process WaterWell Water / Surface Water


2000 Acquisition Stork FrieslandTubular MembranePVDF-membrane (Polyester support)

Aquaflex-technology

ID : 5,2 mmID : 8,0 mm

Process Water / Re-useSurface Water / Waste Water


Norit Solutions for the B&B-Industry (1)

brewery / factory

customers existing WWTP

raw wastewater

surface watercity water

effluent

discharge

effluent polishing

polishing

re-useprocess- and / or productwater

ground water

polishing polishing

MBR

Norit Solutions for the B&B-Industry (2)

Process- and/or Brew Water Production Concepts NanoFiltration/Reverse Osmosis (Well Water) Ultrafiltration + Activated Carbon (City Water) Ultrafiltration + NanoFiltration (Surface water)

Waste Water Treatment and Re-Use Concepts Effluent Polishing Membrane Bio Reactor (MBR)

Why additional polishing Full re-use at proces and bottle cleaning requires

drinking water standard!

Ultra Filtration permeate is excellent basis for re-use Free of suspended solids and turbidity Free of bacteria and virusses

However, only UF on WWTP-effluent is not givingdrinking water RO removes residual COD/BOD and salts ClO2 gives primary desinfection GAC removes residual ClO2 and organics UV gives final desinfection

New Greenfield BreweryOptimal re-use = 1.6 hl/hl

5.4 m hl/y Beer

13.6 m hl/y Waste water

Total 17.3 m hl/y Water 4800 m3/day 200 m3/h

3650 m3/day 157 m3/h

WWTPwith UF-airliftRO

City water 100 m3/h

Re-use water 120 m3/h

UF-permeate to discharge 0 m3/h !!!

75%

ClO2GACUV

RO-waste 40 m3/h

8.6 m hl/yPotable

treatment80%

80 m3/h

Conventional system

AT CT

aeration tank clarification tank

AT CT M

membrane unit

Concepts - Effluent Polishing (1)

Based on X-Flow Hollow Fiber Capillary UF Membrane

PolyEtherSulphon ID = 0,8 mm Effluent polishing

Concepts - Effluent Polishing (2)

AT CT

aeration tank clarification tank

AT M

side-stream

Concepts Membrane Bioreactor (2)

Membrane Bioreactor

Based on X-Flow Tubular UF Membrane

PVDF ID = 8 mm

Conventional System


Bioreactor

Feed pumpCrossflow UF

PermeateMembrane

Circ. pump

Excesssludge

SYSTEM CONCEPTS

Crossflow MBR

SYSTEM CONCEPTS

AirLift

continuousair injection


MBR vs Conventional treatment:Conventional: MBR: Low MLSS * (3-5 g/l) High MLSS * (10-20 g/l) Low age activated sludge High age activated sludge Only floc forming bacteria All kind of bacteria survive Only fast growing bacteria Fast and slow growing bacteria

high sludge production less sludge production Few component-specific bacteria Many component-specific bacteria Sludge carry-over No sludge carry-over Effluent polishing required High quality filtrate Large footprint Smaller footprint

* MLSS = Mixed Liquid Suspended Solids


BUFFERBUFFERTANKTANK

OPTION

BIO REACTORANAEROBIC

UF-PERMEATETANK

WASTEWASTEWATERWATER

Greenfield

BIO REACTORAEROBIC

Applications and Implementation (1)

Existing Anaerobic plant

BIO REACTORAEROBIC

UF-PERMEATETANK



Existing



Existing Anaerobic/Aerobic plant

UF-PERMEATETANK



Existing


BIO REACTORAEROBIC


BASIS UF-Permeate:SS = 0No bacteria/viruses

CIP water

BREWERYBREWERYBREWERY QUALITYQUALITYQUALITY

Dilution for chemicals ? l/hr.

Flush/cleaning water

Process water

Rinsing of Crates ? l/hr.Rinsing of Bottles ? l/hr.Cleaning of Floors ? l/hr.

Pasteurizers ? l/hr.Bottles ? l/hr.Buildings ? l/hr.Boiler Feed Water ? l/hr

? l/hr.

WATERAUDIT

WATERWATERAUDITAUDIT

UF-PERMEATETANK

QUANTITYQUANTITYQUANTITYBEVERAGEBEVERAGEBEVERAGE

Norit Water-Audit (1)

WATER AUDITWATER AUDITWATER AUDIT Selection of Polishing

Activated Carbon: removal of organics (colour, smell, taste) Reverse Osmosis: removal of salts / softening UV-desinfection: bacteria and virus barrier Ion exchange: removal of ions/softening Combinations of above technologies or others

Norit Water-Audit (2)

General Water consumption of a breweryhl water / hl beer

BW brewing; 1,2

BW Process cleaning; 0,7

SW Bottle / kegs cleaning; 0,8

Plant water (service); 0,4

Demin water (boiler feed); 0,1

Flush water; 0,8

200,8Rince/concentrate from RO/IEXFlush water

1004,0Total

2,50,1Boiler feedDemin water

100,4General / servicePlant water

200,8Botte / kegs cleaningSoft Water

17,50,7Process cleaning

301,2BrewingBrewing Water

%hl/hlUseWater type

New Greenfield Brewery5.4 m hectolitres / annum

5.4 m hl/y Beer


21.6 m hl/y Water

6000 m3/day 250 m3/h

4500 m3/day 187 m3/h

Basis for design; 4 hl water / hl beer

Where to re-use?

BW brewing; 1,2

BW Process cleaning; 0,7SW Bottle / kegs cleaning; 1,2



n.a.n.a.0,6Rinse / concentrate from RO / IEXFlush water

0,9

0,1

0,4

0,2

0,2

0

hl-reuse

24%3,8Total

100%0,1Boiler feedDemin water

100%0,4General / servicePlant water

25%0,8Botte / kegs cleaningSoft Water

25%0,7Process cleaning

Not1,2BrewingBrewing Water

Re-usehl/hlUseWater type

New Greenfield Brewery24% re-use = 2,85 hl / hl34

5.4 m hl/y Beer


17.3 m hl/y Water 4800 m3/day 200 m3/h

4150 m3/day 173 m3/h

WWTPwith UF-airlift

WWTP; Waste water treatment plant Anaerobic, Aerobic, Airlift Ultra FiltrationRO; Reverse Osmosis Final removal COD

RO

City water 178 m3/h


UF-permeate to re-use 77 m3/h

UF-permeate to discharge 96 m3/h

75%

flush

Potabletreatment

80%

15.4 m hl/y

Where to re-use?Re-use 54% = 1.6 hl / hl

BW brewing; 1,2

BW Process cleaning; 0,7SW Bottle / kegs cleaning; 1,2



n.a.n.a.0,3Rinse / concentrate from RO / IEXFlush water

0,9 1,9

0,1

0,4

0,2 0,8

0,2 0,7

0

hl-reuse

23% 57%3,5Total

100%0,1Boiler feedDemin water

100%0,4General / servicePlant water

25% 100%0,8Botte / kegs cleaningSoft Water25% 100%0,7Process cleaningNot1,2BrewingBrewing Water

Re-usehl/hlUseWater type

Additional polishing: - ClO2, - GAC, - UV


Case Study

Process-water reuse for Maltery Eemshaven

The treatment capacity of the plant is 65 m3/h The maltery processwater will be reused for more than

80% after treatment (other 20% allowable discharge onsurface water)

The plant consists of a Norit MBR system followed byActivated Carbon filtration and UV disinfection

The produced processwater has a waterquality accordingto Dutch drinking water requirements

Case Study


FIT

PT

M01

02

03

04

05

06

07

14

Polymeer dosering

08

0910

12

13

11

11

09

0815

10

12

13

11

09

0816

10

12

13

11

09

0817

10

12

13

18

19

20

21 22 23

33

12

13

11

25

26

272829

30

UV-desinfectie

Natronloogdosering(Optie)

31

2432

POMPPUT 2m3

34 35

36

37

BLOWER

KONTAKTTANK300 m3BIOREACTOR

1730 m3

BIOREACTOR 1730 m3

BUFFERTANK1500 m3

CIPTANK2 m3

PERMEAATTANK25 m3

UF/CF-unit

UF/CF-unit

UF/CF-unit

UF/CF-unit

BLOWER

BLOWER

CIRC. POMP

VOEDINGSPOMP

CIP POMP PERMEAATPOMP

CIRC. POMP

CIRC. POMP

CIRC. POMP

DECANTER

TRANSPORTSCHROEF

CONTAINER15 m3 (20TON)

SLIBVOEDINGSPOMP

SCHUIM-LANSEN

AKTIEFKOOLFILTER

AKTIEFKOOLFILTER

Case Study


124Sludge content g/l (MLSS)

0,350,45Operational costs / m3

500750Sludge production kg ds/day

350900Square meters m2 (layout)17405200Bioreactor m3

MBRConventional system

Case Study


55 + 1065M3/hFlowEffluent (after AC)InfluentUnitParameter

Reasons for Holland malt to choose Norits MBR

Proven technology Robust system Simple process set-up Small footprint Low chemical usage Low sludge production Operational costs: 0,3-0,4/m3 (exclusive depreciation/interest)

Case Study


Facts and Figures: Client : Boon Rawd Brewery, Khon Kaen, Thailand Raw Water Source: Tertiairy Effluent NMT Technology : SF-XigaUF-RO-UV Effluent : acc. to EU potable water legislations Capacity : 100 m3/h for re-use OPEX : 0,20-0,30 euro/m3

Case Study

Waste-water reuse for Boon Rawd Brewery

Project start : July 2006Start-up : March 2007

Treated Water Purposes: Dilution water for the preparing of Chemical

Cleaning Solutions Cleaning of crates Cleaning of floors, walls and buildings Other cleaning purposes Other water purposes

Case Study

Waste-water reuse for Boon Rawd Brewery

Facts and Figures: Client : Martens Brewery, Bocholt, Belgium Raw Water Source: Brewery Waste Water NMT Technology : Crossflow MBR phase 1 and RO-UV phase 2 Effluent : acc. to EU potable water legislations Capacity : 30 m3/h for re-use in phase 2 OPEX : 0,30-0,40 euro/m3

Case Study

Waste-water reuse for Martens Brewery

Project start : July 2006Start-up phase 1 : July 2007Start-up phase 2 : 2009-2010

Treated Water Purposes in Phase 2: Dilution water for the preparing of Chemical Cleaning

Solutions Cleaning of crates Cleaning of floors, walls and buildings Other cleaning purposes Other water purposes

Case Study

Waste-water reuse for Martens Brewery

Facts and Figures: Client : Cerveceria Polar, Caracas, Venezuela Raw Water Source: Brewery Waste Water NMT Technology : Airlift MBR and RO Effluent : potable water quality Capacity : max. 70 m3/h for re-use OPEX : 0,30-0,40 euro/m3

Case Study

Waste-water reuse Polar Brewery Caracas

Project start : February 2008Start-up : December 2008

Treated Water Purposes Dilution water for the preparing of CIP

Solutions Cooling Pasteurization Steam production Other water purposes

Case Study

Waste-water reuse Polar Brewery Caracas

Facts and Figures: Client : Unicer Brewery - Porto Raw Water Source: Biological Treated Effluent NMT Technology : SF + XIGA UF + UV Effluent : free of SS, bacteria and virusses Capacity : 45 m3/h (re-use 30 m3/h) OPEX : 0,47 euro/m3

Example of a successful integration of conventionaland membrane technology for water reuse accordingto customers specifications

Case Study

Waste-water reuse Unicer Brewery

Facts and Figures: Client : Obolon Maltery - Ukraine Raw Water Source: Raw waste water Maltery NMT Technology : Crossflow MBR Effluent : Free of organics, bacteria and virusses Capacity : Initial 63 m3/h (extension 100 m3/h) OPEX : 0,3-0,4/m3

Case Study

Waste-water reuse Maltery Obolon

Facts and Figures Client: Bavaria, Lieshout (the Netherlands) Raw Water Source: Well Water Capacity: 250 m3/h Process: De-Ironing + NanoFiltration Hardness Product water: 1-2 DH Bacterial and Virus Free OPEX: 0,35/m3

Case Study

Process Water Production Bavaria

Facts and Figures Client: Heineken, Den-Bosch (the Netherlands) Raw Water Source: Well Water Capacity: 540 m3/h Process: Anaerobic NanoFiltration Lime dosing Hardness Product water: 2 DH Bacterial and Virus Free OPEX: 0,4/m3

Case Study

Process Water Production Heineken

Facts and Figures Client: Zujiang Brewery, China Raw Water Source: City Water (unsafe) Capacity: 120 m3/h Process: XIGA-UF Hardness Product water: 8 DH Bacterial and Virus Free OPEX: 0,2/m3

Case Study

Process Water Production Zujiang Brewery

Facts and Figures Client: Coca-Cola Wakefield, U.K. Raw Water Source: City Water Capacity: 400 m3/h Process: AC + XIGA-UF Bacterial and Virus Free OPEX: 0,3-0,4/m3

Case Study

Process Water Production Coca-Cola

CUSTOMER CAPACITY PURPOSE TECHNOLOGY--------------------------------------------------------------------------------------------------------------

Kanes Foods 40 m3/h WWTP MBR Cerestar 70 m3/h WW-reuse UF-RO LambWeston&Meijer 50 m3/h WW-reuse UF-RO-UV Pasfrost 20 m3/h WW-reuse UF-RO Frosta Elbtal 66 m3/h WW-reuse UF-RO Paulaner Brauerei 15 m3/h WW-reuse UF-RO-UV Cargill Corn 35 m3/h WW-reuse MBR Polar Cerveceria 50 m3/h WW-reuse UF-RO Holland Malt 65 m3/h WW-reuse MBRAC-UV IFBM/MAGB 3 m3/h WW-reuse MBRAC Unicer 45 m3/h WW-reuse SF-UF-UV Boon Rawd Brewery 100 m3/h WW-reuse SF-UF-RO-UV Obolon Maltery 100 m3/h WW-reuse MBRAC Martens Brewery 30 m3/h WW-reuse MBRROUV Polar Cerveceria 100 m3/h WW-reuse MBR-RO

References Wastewater treatment and re-usein Food, Beer & Beverage industry

CUSTOMER CAPACITY PURPOSE TECHNOLOGY --------------------------------------------------------------------------------------------------------------

Zhujiang Brewery 120 m3/h bacterial barrier UF Quingdao Brewery 80 m3/h process water RO Koninghoeve Brewery 20 m3/h softened water RO Bavaria Brewery 180 m3/h softened water NF Bavaria Beverage 65 m3/h softened water NF Danone Bierun 30 m3/h bacterial barrier UF Menken/Coca Cola 120 m3/h bottling water RO-AC-UV Coca Cola Wakefield 400 m3/h bacterial barrier AC-UF Danone Warsaw 30 m3/h bacterial barrier UF Heineken Den Bosch 540 m3/h softened water anaerobic NF Suzhou Brewery 120 m3/h bacterial barrier UF-AC-ClO2 Bavaria Brewery 80 m3/h softened water NF Refresco/Coca Cola 80 m3/h bottling water RO-AC-UV Brasserie dOrval 12 m3/h softened water RO Westmalle 40 m3/h bacterial barrier UF

References Water Treatmentin Food, Beer & Beverage industry

Norit Membrane Technology can treat all kind of water sources

Norit Membrane Technology can produce out of all kind of water sources all water qualities needed by combination of membrane- and conventional technologies

Norit Membrane Technology can find an economical attractive solution for all kind of water house keepings in all kind of Industries

Water Qualities and QuantitiesStatements

No doubts. Norit. Just Proof.

Thank you for your attention

water waste water treatment & re-use norit 1 & 2[1]

Documents

hly water

bb water qualities

givingdrinking water

mbr vs conventional

hly waste watertotal

residual clo2

hly beer13

salts clo2