B

Brewery W
Waste
t WWater
t
Treatment
Agenda

 VE/ VWS
 Financial concerns
 Specific design issues for Breweries
 Technological solutions
 Energy production
 Operational experience
Veolia
V li Environnement
E i t & VWS
Veolia Environnement

 VE: the world’s leading

g environmental services company
p y
¾ Global revenue in 2007 : €32.6 billion
¾ More than 300,000 employees worldwide
Veolia Water Solutions & Technologies

 Technical subsidiary of Veolia Water and world leader

in water treatment solutions

 In the UK: >500 employees, >100 in servicing activities

 Comprehensive range of technological

solutions and associated services

Fi
Financial
i l Concerns
C
Financial Pressure

 Competitive market

 Focus on productivity

 Utility costs

 Water costs

 Manpower
Utility Costs

Electricity fluctuations Gas fluctuations

Wastewater Costs

 Typical medium sized brewery load

¾ COD 12,000 kg COD per day
¾ SS 3 000 kkg SS per d
3,000 day
¾ Flow 3,000 m3 per day

 Mogden formula
¾ Potential cost p
per annum - £1,800,000
, ,
Potential Savings - Discharge Costs

 Discharge to sewer post treatment

¾ Anaerobic treatment to reduce COD by 80%
- Reduce costs by ~ £ 900
900,000
000
¾ Full treatment discharge to sewer
- Reduce cost byy ~ £1,400,000
 Discharge to river
¾ IPPC permit costs ~ £20,000
- Reduce discharge costs by ~ £1,750,000
S
Specific
ifi Design
D i Issues
I for
f Breweries
B i
Brewery Specific Issues

 Beers spills
 Yeast spills
 Temperature
 Caustic
 Sulphate
 Space
Specific Design Issues

 Wastewater composition
¾ COD, SS, Ca, SO4, toxic components
 Buffering, pre-treatment (SS removal).
 COD reduction rates in the anaerobic step can vary
(50-90%), dependent on the type of raw material and
nature of the wastewater.
 Discharge requirements / water reuse / closed cycle
The Solution

Can be one or a combination of the following;

 Full or partial treatment

 Pre-treatment/ conditioning
 Anaerobic Treatment
 Aerobic Treatment
 Tertiary Treatment
T h l i l Solutions
Technological S l ti
Bioconversion

 Aerobic - reduce COD /

BOD concentration by micro
organisms in the presence
of oxygen

 Anaerobic - reduce COD /

BOD concentration by micro
organisms
g in the absence of
oxygen
BOD Conversion - Anaerobic/Aerobic

A
Anaerobic
bi A bi
Aerobic
80% Biogas 45%CO2

5%Wastewater
18%Wastewater

2%Biomass
50%Biomass

BOD CH4+CO
CO2+Biomass
Bi BOD 02
BOD+0 H2O+CO
O CO2+Biomass
Bi
Process Comparison

A
Anaerobic
bi A
Aerobic
bi

Low High
Energy consumption
Biogas production Air input
0,07-0,1 kWh/kg COD 0,7-1 kWh/kg COD

Low High
Sludge production
0,01-0,05 kg/kg COD 0 2 0 6 kg/kg COD
0,2-0,6
Value Disposal costs

Surface area High rate Low rate

Compact design Big footprint
Aerobic Processes – Activated Sludge

 Activated sludge
¾ Large Aeration Tank
¾ Air supplied by blowers and
diffusers
¾ Final settlement tank

 Can achieve very high

quality effluent
Aerobic Processes – Bio-towers

 Bio-towers
¾ Fixed media
¾ Lower power consumption
¾ Intermediate settlement

 Typically used as a pre-

treatment stage
Anaerobic Technologies

Various types available

 EGSB - Expanded granular sludge bed reactor
 UASB - Upflow Anaerobic sludge blanket
 Continuous stirred tank reactor CSTR
¾ mainly agricultural and sewage sludge
 Anaerobic filter AF
 Hybrid reactor
 Fluidised bed FBR
Anaerobic Treatment

 Biobed® EGSB reactor

¾ Small footprint, relatively low
height (14m)

 Unique three-phase
separator
t
¾ Ensure retention of biomass

 Conditioning Tank
¾ Wastewater conditioning
Biobed® EGSB reactor

Biogas

Effluent

Sludge bed

Influent
Biobed® EGSB reactor
Overview of Full Treatment Plant

Biogas to 
Brewing & 
Brewing & Boilers/CHP
Treated 
Packaging 
Wastewater
Wastewaters

Balance Tank Clarifier
Activated Sludge

Screens Sand Filter

Biobed® 
Anaerobic 
Reactor Pressed 
Sludge

Divert Tank Sludge 
Dewateringg
E
Energy P d ti
Production
Bio-Energy Production

 Biogas from Anaerobic Treatment

 Typical biogas production rate 0.43 m3/ kg COD removed
 Generally methane content 70 - 80%
 Methane production rate 0.35 m3/ kg COD removed
 H2S proportional to sulphate in the feed
¾ Caustic scrubber
¾ Biological scrubber
Biogas Benefits

Financial benefit input variables

Import power inc CCL 7.5 p/kWh
Boiler fuel inc CCL 2 p/kWh
Biler efficiency 80%
Cost of CHP fuel 0 p/kWh
ROC 4.00 p/kWh
single ROC = 1, double = 2 2

Value of
displaced Value of heat
Heat (water at import power produced per ROC value per Total output
Power kWe 90C) kW per hour hour hour value per hour

12te COD day, 80%

reduction 499 638 £37.43 £15.95 £39.92 £93.30
Sit Experience
Site E i
Reference – Royal Brewery, Manchester

 Requirements
¾ Turnkey wastewater treatment plant
for cheaper sewer discharge
 Treatment
¾ Screen
Screen, balance and divert tanks
¾ Anaerobic and aerobic treatment
¾ DAF and Sand Filter
 Benefits
¾ Biogas used in site boilers
¾ Provide
P id significant
i ifi t savings
i iin
wastewater disposal costs
¾ No client staffing required
Average Wastewater Properties

 Water:Beer ratio of 3.3:1

 Flow
¾ Daily 2,269 m3
¾ Hourly 95 m3
 COD
¾ Concentration 4,450 mg/l
¾ Load 10,500 kg/day
 TSS
¾ 830 mg/l
g
¾ 1,900 kg/day
 Temperature 28oC
Operational Experience

 Spillage's do occur

 Communication between
plant operators and
brewery critical

 Optimisation
O ti i ti off plant
l t
operation
 0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22-Feb-06

06-Mar-06

18-Mar-06

30-Mar-06

11-Apr-06

23-Apr-06

05-May-06

17-May-06

29-May-06

10-Jun-06

22-Jun-06

04-Jul-06

16-Jul-06

28-Jul-06

09-Aug-06

21-Aug-06

02-Sep-06

14-Sep-06

26-Sep-06
Actual Plant Feed Data

08-Oct-06

da te
20-Oct-06

01-Nov-06
Feed Data

13-Nov-06

25-Nov-06

07-Dec-06

19-Dec-06

31-Dec-06

12-Jan-07

24-Jan-07

05-Feb-07

17-Feb-07

01-Mar-07

13-Mar-07

25-Mar-07

06-Apr-07

18-Apr-07
Daily Flow

30-Apr-07
Daily COD load

12-May-07

24-May-07
 Temperature

15.0
20.0
25.0
30.0
35.0
40.0
22/02/2006

08/03/2006

22/03/2006

05/04/2006

19/04/2006

03/05/2006

17/05/2006

31/05/2006

14/06/2006

28/06/2006

12/07/2006

26/07/2006

09/08/2006
Temperature Profile

23/08/2006

06/09/2006

20/09/2006

04/10/2006

Date
18/10/2006
Temperature

01/11/2006

15/11/2006

29/11/2006

13/12/2006

27/12/2006

10/01/2007
IC Feed

24/01/2007

07/02/2007

21/02/2007
Discharge

07/03/2007

21/03/2007

04/04/2007

18/04/2007

02/05/2007

16/05/2007
 0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90 0
90.0
100.0
24/02/2006

24/03/2006

24/04/2006

24/05/2006

24/06/2006

24/07/2006

24/08/2006

24/09/2006

24/10/2006

24/11/2006

24/12/2006
Anaeraobic Reactor COD removal Efficiency

24/01/2007

24/02/2007
Anaerobic Reactor SCOD Efficiency

24/03/2007

24/04/2007

24/05/2007
 mg/l

0
50
100
150
200
250
300
3 0
350
400
22/02/2006

08/03/2006

22/03/2006

05/04/2006

19/04/2006

03/05/2006

17/05/2006

31/05/2006

14/06/2006

28/06/2006

12/07/2006

26/07/2006

09/08/2006
Final Effluent Quality

23/08/2006

06/09/2006

20/09/2006

04/10/2006

18/10/2006
Final Effluent Discharge

01/11/2006

15/11/2006

29/11/2006

13/12/2006

27/12/2006

10/01/2007
Filterd COD

24/01/2007

07/02/2007

21/02/2007

07/03/2007
Total COD

21/03/2007

04/04/2007
SS

18/04/2007

02/05/2007
Cesu Alus - Latvia

 Design Input
¾ Flow 600 m3/day
¾ COD 6,000
6 000 mg/l/l - 3,600
3 600 kkg/day
/d
¾ TSS 210 kg/day
 Other requirements
¾ Readily expandable
¾ Large
g ppeaks in load
 Performance
¾ pH 6.0 – 10.0
¾ COD < 1,500 mg/l
¾ TSS < 500 mg/l
Cesu Alus - Latvia

 System Design
¾ Pre-treatment
¾ B l
Balancing
i ttankk
¾ Conditioning tank
¾ 4 Modular plants (each 50 m3
capable of processing 1 te COD/
day)
¾ Flash
Fl h aeration
ti
Reference – Coors Brewery, Tadcaster

 Requirement
¾ Turnkey wastewater treatment plant
for discharge to river Wharfe
 Treatment
¾ Screen, balance and divert tanks
Screen
¾ Anaerobic and aerobic treatment
¾ DAF and Discfilter
 Benefits
¾ Biogas used in site boilers
¾ Removal of wastewater disposal costs
¾ No client staffing required
Design Wastewater Properties

 Flow
¾ Daily 1,323 m3
 COD
¾ Load 6,243 kg/day
 TSS
¾ Load 1,642 kg/day
 Temperature 28oC
Actual Effluent Feed Data

Coors Feed Data kg SCOD per day flow m3/day

7,000

6,000

5,000

4,000

3,000

2,000

1,000

0
01-Apr-08 01-May-08 01-Jun-08 01-Jul-08 01-Aug-08 01-Sep-08 01-Oct-08 01-Nov-08 01-Dec-08
Temperature Profile

Balance tank Final effluent

Temperature profile
40.0
35.0
30.0

25.0

20 0
20.0

15.0
10.0

5.0
0.0
01-Apr-08 01-May-08 01-Jun-08 01-Jul-08 01-Aug-08 01-Sep-08 01-Oct-08 01-Nov-08 01-Dec-08
Final Effluent Quality

Final Effluent
100.0
90.0
80.0
70.0
60.0
50.0
40.0
30.0
20.0
10.0
0.0
01-Apr-08 01-May-08 01-Jun-08 01-Jul-08 01-Aug-08 01-Sep-08 01-Oct-08 01-Nov-08 01-Dec-08
Conclusion

 Brewery waste water is

readily treatable on site

 Anaerobic treatment
provides significant benefits
against aerobic treatment

 Brewery operation is
inextricably linked to the
treatment plant performance