GROUP MEMBER:

HAMZA FAHIM (EP1642019)

EJAZ KHAN (EP1642014)
AHMAD ALI (EP1642005)
The dairy industry involves processing raw milk into products including
milk, butter, cheese, yogurt, using processes such as chilling,
pasteurization, and homogenization. Typical by-products include buttermilk,
whey, and their derivatives.
Huge amounts of water are used during the process producing effluents
containing dissolved sugars and proteins, fats, and possibly residues of
additives. These effluents have the following characteristics.

 Biochemical oxygen demand (BOD), with an average ranging from

0.8 to 2.5 kilograms per metric ton (kg/t) of milk in the untreated
effluent
 Chemical oxygen demand (COD), which is normally about 1.5
times the BOD level.
 Total suspended solids (TSS), at 100–1,000 milligrams per liter
(mg/l) .
 Total dissolved solids (TDS): phosphorus (10–100 mg/l), and
nitrogen (about 6% of the BOD level).
Cream, butter, cheese, and whey production are major sources of BOD in
wastewater. The waste load equivalents of specific milk constituents are: 1
kg of milk fat = 3 kg COD; 1 kg of lactose = 1.13 kg COD; and 1 kg protein
= 1.36 kg COD. The wastewater may contain pathogens from
contaminated materials or production processes. A dairy often generates
odors and, in some cases, dust, which also need to be controlled.
Hydro-Flo engineers and builds complete solutions to efficiently manage
the wastewater treatment and odor control requirements of the dairy
industry. Our solution includes the following benefits:

 Optimization of use of water and cleaning chemicals with option for

recirculation of cooling waters.
 Segregation of effluents from sanitary installations, processing, and
cooling (including condensation) systems; this would facilitate ability
to recycle the wastewater.
 Energy recovery through use of heat exchangers for cooling and
condensing.
 Use of high-pressure nozzles to minimize water usage.

Dairy wastewater is treated by adjusting pH and using strong coagulant

chemistry to break any emulsions caused by cleaning agents and sanitizers
and to precipitate solids and fats. The chemicals are added to cause de-
emulsification, precipitation, coagulation, and flocculation.
The reuse of wastewater from the dairy industry can also be provided for by
usage of adsorption and membrane separation among other processes.
The color and the odor may be removed completely after activated carbon
treatment. The pretreated water can be passed through a cross flow
reverse osmosis membrane system and the permeate water can then be
reused.

Stage 1 :Emulsion Cracking/pH Adjustment/Precipitation and

Coagulation:
pH is raised (or lowered) to ~8.5 with the pH controller using caustic (or
acid). A coagulant de-emulsifier is added to break any emulsion and cause
precipitation of the solids. A “pin floc” is developed indicating the emulsion
and the suspended solids are precipitated.
Stage 2 - Flash Mix:
The wastewater with it’s precipitated pin floc is introduced to the flash mix
zone where a polymer flocculent is added. This stage maximizes flocculent
dispersion throughout the coagulated wastewater.
Stage 3 - Flocculation:
The wastewater is now introduced to the slow mix zone to agglomerate the
floc into larger particles suitable to be enmeshed with the air bubbles.
Clarifier, Dissolved Air Flotation (DAF):
The flocculated wastewater is introduced into the DAF inlet where the floc
particles are comingled with a pressurized dissolved fine bubble recycle
stream. The floc particles attach to the bubbles and float to the surface
where they are mechanically skimmed into the float scum sludge chamber.
The clarified treated water then exits the end of the DAF and flows
downstream to sewer or further treatment if necessary. The DAF system
bubbles come from a Recycle Air Dissolving system that takes a portion of
treated effluent, pressurizes it and introduces air to be dissolved. The
dissolved air comes out of solution and forms a fine bubble stream when
the pressure is released at the DAF entrance in the presence of floc
wastewater.
DAF Sludge Handling:
The resulting DAF waste scum/sludge is removed from the DAF
automatically as the scum accumulates and is pumped to the sludge
holding tank where it further thickens and accumulates a batch for disposal
or processing in a filter press. The sludge is mixed and conditioned with a
filter aid such as DE to improve porosity and filterability which will improve
cake dryness and prevent premature blinding of the filter cloths.
Sludge Dewatering:
The thickened DAF scum/sludge is allowed to accumulate sufficiently to
provide a full batch for the Filter Press. The filter press is pumped with the
sludge until it is full. The filter press is then emptied of the “cake” which is a
semi solid of approximately 20-35 % solids. Sludge cake is high in solids
and should be disposed of according to environmental regulations.
APPLICATIONS:

 Dairy products companies

 Solid cheese
 Cream cheese
 Sour cream and cottage cheese
 Dry milk
 Sweetened condensed milk
 Ice cream.