uocument jor Effluent Limitations Guidelines
and New Source Performance Standards for the
MISCELLANEOUS FOODS
AND BEVERAGES
Point Source Category
Prepared by
ENVIRONMENTAL SCIENCE AND ENGINEERING. INC
GAINESVILLE. FLORIDA
FEBRUARY, 1975
^or
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
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DRAFT
DEVELOPMENT DOCUMENT FOR
EFFLUENT LIMITATIONS GUIDELINES
AND NEW SOURCE PERFORMANCE STANDARDS
MISCELLANEOUS FOODS AND BEVERAGES
POINT SOURCE CATEGORY
PREPARED BY
ENVIRONMENTAL SCIENCE AND ENGINEERING. INC.
P. 0. BOX 13454
GAINESVILLE, FLORIDA 32604
FEBRUARY 1975
FOR:
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
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NOTICE
The attached document Is a DRAFT CONTRACTOR'S REPORT. It Includes tech-
nical Information and recommendations submitted by the Contractor to the
United States Environmental Protection Agency ("EPA") 'regarding the sub-
ject Industry. It Is being distributed for review and comment only. The
report 1s not an official EPA publication and It has not been reviewed by
the Agency.
The report, Including the recommendations, will be undergoing extensive
review by EPA, Federal and State agencies, public Interest organizations
and other interested groups and persons during the coming weeks. The
report and in particular the contractor's recommended effluent guidelines
and standards of performance Is subject to change in any and all respects.
The regulations *o be published by EPA under Sections 304(b) and 306 of
the Federal Water Pollution Control Act, as amended, will be based to a
large extent on the report and the comments received on it. However,
pursuant to Sections 304(b) and 30C of the Act, EPA will also consider
additional pertinent technical and economic information which is developed
In the course of review of this report by the public and within EPA. EPA
1$ currently performing an economic impact analysis regarding the subject
Industry, which will be taken into account as part of the review of the
report. Upon completion of the review process, and prior to final pro-
mulgation of regulations, an EPA report will be issued setting forth EPA's
conclusion: regarding the subject industry, effluent limitations guide-
lines and standards of performance applicable to such industry. Judgements
necessary to promulgation of regulations under Sections 304(b) and 306 of
the Act, of course, remain the responsibility of EPA. Subject to these
limitations, EPA is making this draft contractor's report available in
order to encourage the widest possible participation of Interested per-
sons in the decision making process at the earliest possible time.
The report shall have standing In any CPA proceeding or court proceeding
only to the extent that It represents the views of the Contractor who
studied the subject Industry and prepared the information and recommenda-
tions. It cannot be cited, referenced, or represented in any respect in
any such proceedings as a statement of EPA's views regarding the subject
.Industry.
U. S. Environmental Protection Agency
Office of Water and Hazardous Materials
Effluent Guidelines Division
Washington. D. C. 20460
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DRAFT
ABSTRACT
This document presents the findings of an extensive study of the
Miscellaneous Foods and Beverages Point Source Category by Environ-
mental Science and Engineering, Inc., SCS Engineers, Inc., and Environ-
mental Associates, Inc., for the purpose of presenting recommendations
to the United States Environmental Protection Agency for Effluent
Limitations Guidelines, Standards of Performance, and Pretreatment
Standards for the industry for the purpose of implementing Sections
304, 306. and 307 of '.he Federal Water Pollution Control Act, as
ammended.
Effluent Limitation Guidelines recommended herein set forth the degree
of effluent reduction attainable through the application of the Best
Practicable ControV Technology Currently Available (BPCTCA) and the
degree of effluent reduction attainable through the application of the
Best Available Technology Economically Achievable (BATEA) which must
be achieved by existing point sources by July 1, 1977, and July 1, 19C3,
respectively. The Standards of Performance for New Sources (NSPS) re-
commended herein set forth the degree of effluent reduction which 1s
achievable through the application of the Best Available Demonstrated
Control Technology, Processes, Operating Methods, or other alternatives.
Supportive data and rationale for subcategorization of the Miscellaneous
Foods and Beverages Industry and for development of recommended Effluent
Limitations Guidelines and Standards of Performance a>-e contained in
this document.
NOTICE: THl'SE ARE TENTATIVE nECOMMENDATlONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANCE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA,
Hi
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DRAFT
TABLE OF CONTENTS
SECTION PAGE
I CONCLUSIONS 1
II RECOMMENDATIONS
III INTRODUCTION 11
Purpose and Authority 11
Summary of Methods Used 11
Definition of the Industry 13
SIC 2017 Egg Processing 23
SIC 5144 Shell Eggs 29
SIC 2034 Dehydrated Soups 31
SIC 2038 Frozen Specialties 32
SIC 2047 Pet Foods 44
SIC 2051 Bakery Products 59
SIC 2052 Cookies and Crackers 75
SIC 2065 Confectionery Products 80
tSIC 2066 Chocolate and Cocoa Products 100
SIC 2067 Chewing Gum 105
" SIC 2074, 2075, 2076 Vegetable Oil Mills 110
—SIC 2079 Edible Fa: and Oils 131
'SIC 2082 Malt Beverages 149
" SIC 2083 Halt 155
SIC 2084 Mine, Brandy, Brandy Spirits 157
SIC 2085 Distilled, Rectified, Blended Liquors 169
SIC 5182 Bottling, Blending of Wines, Distilled
Liquors 181
SIC 2086 Soft Drinks 181
SIC 2087 Non-Synthetic Flavoring Extracts and
Syrups 187
SIC 2095 Coffee • 196
SIC 2097 Manufactured Ice 204
SIC 2098 Macaroni, Spaghetti, Noodles 210
SIC 2099 Miscellaneous Products 214
Almond Paste 214
Baking Powder 214
Bouillon 216
Bread Crumbs 218
Chicory 221
Chili Pepper and Paprika 223
Desserts, Ready to Mix 226
Honey 228
Molasses and Sweetening Syrups 230
Non-Dairy Coffee Creamer 236
Peanut Butter 240
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DRAFT
TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
Pectin . 243
Popcorn 247
Spices 247
Tea^ 249
Prepackaged Sandwiches 253
Vinegar 255
Yeast 258
IV INDUSTRY CATEGORIZATION 261
Process Variations 261
Vegetable OH Processing and Refining 271
Beverages 274
* Bakery and Confectionery Products 277
Pet Foods 278
Miscellaneous and Specialty Products 279
Raw Material Variations 282
Vegetable Oil Processing and Refining 282
Beverages 284
i Bakery and Confectionery Products 284
Pet Foods 285
Miscellaneous and Specialty Products 286
Plant Age • 289
Plant Size 289
Plant Location 290
Products and By-Products 291
Climatic Influences 291
Seasonal Variations 291
V WASTEWATER CHARACTERISTICS 293
Vegetable 011 Processing and Refining
Subcatcgory A 1 - Oilseed Crushing, Except Olive
011 for Direct Solvent Extraction and Prepress
Solvent Extraction Operations 297
. Snbcotegory A 2 - Oilseed Crushing, Except Olive
Oil, By Mechanical Screw Press Operations 305
Subcategory A 3 - Olive 011 Extraction By
Hydraulic Pressing and Solvent Extraction 306
Subcategory A 4 • Olive Oil Extraction By
Mechanical Scrtw Pressing 306
.,4
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DRAFT
SECTION
TABLE OF CONTENTS
(CONTINUED)
Subcategory A 5 - Processing of Edible 011 By
Caustic Refining Methods Only 308
Subcategory A 6 - Processing of Edible 011s By
Caustic Refining and Acidulatlon Methods 316
Subcategory A 7 - Processing of Edible 011s. By
Caustic Refining, Acidulatlon, Oil Processing, and
Deodorlzation Methods 320
Subcategory A 8 - Processing of Edible 011s
Utilizing Caustic Refining, Oil Processing, and
Oeodorization 322
Subcategory A 9 - Processing of Edible Oils
Utilizing Caustic Refining, Acidulation, Oil Pro-
cessing, Deodorization Methods, and the Production
of Shortening and Table Oils 324
Subcategory 10 - Processing of Edible 011s by
Caustic Refining, 011 Processing, Oeodorization
Methods, and the Plasticizing and Packaging of
Shortening and Table Oils 325
Subcategory A 11 - Processing of Edible Oils by
Caustic Refining, Acidulatlon, Oil Processing:
Oeodorization Methods, and the Plastic1z1ng and
Packaging of Shortening, Table Oils, and Margarine 326
Subcategory 12 - Procession, of Edible Oils by
Caustic Refinery, Oil Processing Method, and
the Plastidzation and Packaging of Shortening,
Table Oils, and Margarine 327
Subctftegory 13 - Plasticizing and Packaging
of Margarine • 327
Subcategory 14 - Plasticizing and Packaging
of Shortening and Tab.le Oils 326
SuUategory 15 - Olive Oil Refining 334
Subcategory A 16 • New Large Malt Beverage
Breweries 334
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DRAFT
TABLE OF CONTENTS
(CONTINUED)
SECTION . PAGE
SubcBtegory A 17 - Old Large Malt Beverage
Breweries 348
Subcategory A 18 - All Other Malt Beverage
Breweries 355
Subcategory A 19 - Halt 355
Subcategory A 20 - Wineries Without Stills 369
Subcategory A 21 - Wineries With Stills 373
Subcategory A 22 - Grain Distillers Operating
Stlllage Recovery Systems 378
Subcategory A 23 - Grain Distillers . 389
Subcategory A 24 - Molasses Distillers 390
Subcategory A 25 - Bottling and Blending of
Beverage Alcohol 396
Subcategory A 26 - Soft Drink Canners 3gg
Subcategory A 27 - Soft Drink Bottling or Combined
Bottling/Canning 402
Subcategory A 28 - Beverage Base and/or Concert-
trit«i 403
Subcatogory A 30 - Instant Tea 407
Subcategory C B - Coffee Roasting Utilizing
Roistar Wet Scrubbtri 412
Subcategory C 9 - Decaffeination of Coffee 414
Subcategory C 10 - Soluble Coffee 416
Subcategory C 1 - Oukery and Confectionery
• Products 4)9
Subcategory C 2 * Cakes, P1es, Doughnuts• and
Sweet Yeast Goods Not Utilizing Pan Washing 421
Subcategory C 3 - Dread and Runs 425
vill
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TABLE OF CONTENTS
' (CONTINUED)
SECTION . pAGE
:•.• -. f . "—•^~
Subcategory C 7 - Cookie and Crocker Manufacturing 427
Subcategory C 12 - Sandwiches
Subcategory 0 1 - Candy and Confectionary 430
Subcategory D 2 - Chewing Gum 432
Subcategory 0 3 - Gum Base 434
-* Subcategories D 5 and 06- Chocolate 436
Subcategory B 5 - Low Meat Canned Pet Food 439
Subcategory B 6 - High Meat Canned Pet Food 440 .
Subcategory 3 7 - Dry Pet Foods 444 .
Subcategory B 8 - Soft-Moist Pet Food 446
Subcategory A 29 - The Production of Finished
Flavors by the Blending of Flavoring Extracts,
Acids, and Colors 448
Subcategory A 31 - Bouillon Products
Subcategory A 32 - Non-Dairy Creamer 453
•
Subcategory A 33 - Yeast 455
Subcategory A 34 - Peanut Butter Plants With
Jar Washing 453
Subcategory A 35 - Peanut Butter Plants Without
Jar Washing 466
Subcategory A 36 - Pectin 455
Subcategory A 37 - Processing of Almond Paste 472
Subcategory 0 1 - Frozen Prepared Dinners 473
Subcategory R 2 - Breaded end Battered Frozen
Products 474
Subcategory B 3 - Frozen Bakery Desserts 477
Subcategory B 4 - Tomato-Cheese-Starch Combinations 479
Subcategory B 9 - Paprika and CM11 Papper 479
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TABLE OF CONTENTS
(CONTINUED)
SECTION pAj£
Subcategory C 4 - Egg Processing 482
Subcategory C 5 - Shell Eggs ' 433
Subcategory C 6 - Manufactured Ice 437
Subcategory 04- Vinegar 490
SubcategoHes E 1 (Molasses, Honey, ard Syrups),
E 2 (Popcorn), and E 3 (Prepared Gelatin Desserts),
E 4 (Spices), E 5 (Spices), E 5 (Dehydrated Soup),
and E 6 (Macaroni, Spaghetti, Vermicelli, and 493
Noodles)
Subcategorles F 2 (Baking Powder), F 3 (Chicory),
and F 4 (Bread Crumbs Not Produced 1n Bakeries) . 492
VI SELECTION OF POLLUTANT PARAMETERS 493
Wastewater Parameters of Pollutional Significance 493
Rational For Selection of Identified Parameters 493
Organics 493
Suspended Solids 494
011 and Grease 454
pH 495
Nickel 49S
Alkalinity . 495
Total 01ssolved Solids 496
Nutrients 496
Color 49fi
Chlorides 497
Temperature 497
Methods of Analysis 497
SolIds 497
pH and Temperature 498
Nitrogen and Phosphorus 496
011 and Grease ' 496
BOD 498
COD 498
Color 498
NH, 498
Chloride 499
TOC TOC 499
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DRAFT
TABLE OF CONTENTS
(CONTINUED)
SECTION
i
VII CONTROL AND TREATMENT TECHNOLOGY
Subcategory A 1 - Oilseed Crushing, Except Olive
Oil for Direct Solvent Extraction and Prepress
Solvent Extraction Operations 518
Subcategory A 2 - Oilseed Crushing, Except Olive
Oil, By Mechanical Screw Press Operations 524
Subcategory A 3 - Olive Oil Extraction 8y
Hydraulic Pressing and Solvent Extraction 529
Subcategory A 4 - Olive Oil Extraction By
Mechanical Screw Pressing 531
Subcategory A 5 - Processing of Edible Oil By
Caustic Refining Methods Only 533
Subcategory A 6 - Processing of Edible Oils By
Caustic Refining and Acidulation Methods 543
Subcategory A 7 - Processing of Edible Oils. By
Caustic Refining, Acidulation, Oil Processing, and
Deodorization Methods 547
Subcategory A 6 - Processing of Edible Oils
Utilizing Caustic Refining, Oil Processing, and
Deodorization 552
Subcategory A 9 - Processing of Edible Oils
Utilizing Caustic Refining, Acidulation, 011 Pro-
cessing, Deodorization Methods, and the Production
of Shortening and Table Oils 559
Subcategory 10 - Processing of Edible 011s by
Caustic Refining, Oil Processing, Deodorizatior
Methods, and the PTasticizinr and Packaging of
Shortening and fable Oils " 561
Subcategory A 11 - Processing of Edible Oils by
Caustic Refining, Acidulation, 011 Processing,
/ Deodorization Methods, and the Plasticizlng and
Packaging of Shortening, Table Oils, and Margarine 565
x1
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TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
Subcategory 12 - Processing of Edible Oils by
Caustic Refinery, Oil Processing Method, and
the Plasticization and Packaging of Shortening,
Table Oils, and Margarine 4 - 572
Subcategory 13 - Plasticizing and Packaging
of Margarine 574
Subcaxegory 14 - Plasticizing and Packaging
of Shortening and Table Oils 580
Subcategory 15 - Olive Oil Refining 582
Subcategory A 16 - New Large Malt Beverage
Breweries 586
Subcategory A 17 - Old Large Malt Beverage
Breweries 600
Subcategory A 18 - All Other Malt Beverage
Breweries 605
Subcategory A 19 - Malt 610
Subcategory A 20 - Wineries Without Stills 616
Subcategory A 21 - Wineries With Stills 630
Subcategory A 22 - Grain Distillers Operating
Still age Recovery Systems 632
Subcategory A 23 - Grain Distillers 650
Subcategory A 24 - Molasses Distillers 664
Subcategory A 25 - Bottling and Blending of
Beverage Alcohol 663
Subcategory A 26 - Soft Drink Canners 664
. Subcategory A 27 - Soft Drink Bottling or Combined
Bottling/Canning 669
Subcategory A 28 - Beverage Base and/or Concen-
trates 677
X11
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TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
Subcategory A 30 - Instant Tea 683
Subcategory C 8 - Coffee Roasting Utilizing
Roaster Wet Scrubbers 690
Subcategory C 9 - Decaffeination of Coffee 692
Subcategory C 10 - Soluble Coffee 698
Subcategory C 1 - Bakery and Confectionery
Products 702
Subcategory C 2 - Cakes, Pies, Doughnuts, and
Sweet Yeast Goods Not Utilizing Pan Washing 708
Subcategory C 3 - Bread and Buns 715
• Subcategory C 7 - Cookie and Cracker Manufacturing 721
Subcategory C 12 - Sandwiches 722
Subcategory D 1 - Candy and Confectionary 726
Subcategory 0 2 - Chewing Gum 730
Subcategory 03- Gum Base 73?
* Subcategories D 5 and D 6 - Chocolate 736
Subcategory 85- Low Meat Canned Pet Food 741
Subcategory B 6 - High Meat Canned Pet Food 744
Subcategory B 7 - Dry Pet Foods 749
Subcategory B 8 - Soft-Moist Pet Food 752
Subcategory A 29 - The Production of Finished
Flavors by the Blending of Flavoring Extracts,
Acids, and Colors 754
Subcategory A 31 - Bouillon Products 761
Subcategory A 32 - Non-Dairy Creamer 766
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TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
f
Subcategory A 33 - Yeast 771
Subcategory A 34 - Peanut Butter Plants With
Jar Hashing 793
Subcategory A 35 - Peanut Butter Plants Without
Jar Washing 795
Subcategory A 36 - Pi:t1n 795
Subcategory A 37 - Processing of Almond Paste 801
Subcategory B 1 - Frozen Prepared Dinners 802
Subcategory B 2 - Breaded and Battered Frozen
Products 808
Subcategcry B 3 - Frozen Bakery Desserts 811
Subcategory B 4 - Tomato-Cheese-Starch Combinations 819
Subcategory B 9 - Paprika and Chili Popper 822
Subcategory C 4 - Egg Processing 824
Subcategory C 5 - Shell Eggs 829
Subcategory C 6 - Manufactured Ice 835
Subcategory 04- Vinegar 837
f
Subcategories E 1 (Molasses, Honey, and Syrups),
E 2 (PopCf •»), and E 3 (Prepared Gelatin Desserts),
t 4 (Spict i, E 5 (Spices), E C (Dehydrated Soup;,
and E 6 (Mac:.ron1, Spaghetti, Vermicelli, and
Noodles) 840
Subcategories F 2 (Baking Powder), F 3 (Chicory),
and F 4 (Bread Crumbs Not Produced in Bakeries) 840
VIII .COST, ENERGY AND NON-WATER QUALITY ASPECTS 641
Cost and Reduction Benefits of Alternative Treat-
ment and Control Technologies 841
x1v
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DRAi
TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
Subcategory A 1 - Oilseed Crushing, Except Olive
Oil for Direct Solvent Extraction and Prepress
Solvent Extraction Operations 843
Subcategory A 2 - Oilseed Crushing, Except Olive
011, By Mechanical Screw Press Operations 853
Subcategory A 3 - Olive Oil Extract!vn By
Hydraulic Pressing and Solvent Extra:tion 858
Subcategory A 4 - Olive Oil Extraction By
Mechanical Screw Pressing 8GO
Subcategory A 5 - Processing of Eaible Oil By
Caustic Refining Methods Only •• 863
Subcategory A 6 - Processing of Edible Oils By
Caustic'Refining and Acidulation Methods 879
Subcategory A 7 - Processing of Edible Oils. By
Caustic Refining, Acidulation, Oil Processing, and
Deodorization Methods "0
Subcategory A 8 - Processing of Edible Oils
Utilizing Caustic Refining, Oil Processing, and
Deodorization 901
Subcategory A 9 - Processing of Edible Oils
Utilizing Caustic Refining, Acidulation, Oil Pro-
cessing, Deodori/ation Methods, and the Production
of Shortening and Table Oils
Subcategory 10 - Processing of Edible Oils by
Caustic Refining, Oi'. Processing, Deodorization
Methods, and the Plasticizing and Packaging of
Shortening .^nd Table Oils
Subcategory A 11 - Processing of Edible Oils by
Caustic Refining, Acidulation. Oil Processing,
Deodorization Method!,, and the Plasticizing and
Packaging of Shortening, Table Oils, and Margarine 936
xv
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DRAFT
TABLE OF COilTCNTS
(CONTINUED)
SECTION PAGE
Subcategory 12 - Processing of Edible Oils by
Caustic Refinery, Oil Processing Method, and
the Plastidzation and Packaging of Shortening,
'Table Oils, and Margarine 950
Subcategory 13 - Plastidzing and Packaging
of Margarine 962
Subcategory 14 - Plasticizlng and Packaging
of Shortening and Table Oils 974
Subcategory 15 - Olive Oil Refining 981
Subcategory A 16 - New Large Malt Beverage
Breweries 988
Subcategory A 17 - Old Large Malt Beverage
Breweries 1005
Subcategory A 18 - All Other Malt Beverage
Breweries 1024
Subcategory A 19 - Malt 1040
Subcategory A 20 - Wineries Without Stills 1053
Subcategory A 21 - Wineries With Stills
Subcategory A 22 - Grain Distillers Operating
Stlllage Recovery Systems 1073
SubcAtegory A 2i - Grain Distillers I"105
Subcategory A 24 - Molasses Distillers H09
Subcavegory A 25 - Bottling and Blending of
Beverage Alcohol
Subcategory A 26 - Soft Drink Canners
Subcotpgory A 27 - Soft Drink Bottling or Combined
Bottling/Canning 1138
Subcatogory A 28 - Beverage Base and/or Concen-
trates 1153
xv1
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DRAFT
TABLE OF CONTENTS
(CONTINUED)
SECTION . PAGE
Subcategory A 30 - Instant Tea 1172
Subcategory C 8 - Coffee Roasting Utilizing
Roaster Wet Scrubbers 1188
Subcetegory C 9 - Oecaffeination of Coffee 1197
Subcategory C 10 - Soluble Coffee 1200
Subcategory C 1 - Bakery and Confectionery
Products 1203
Subcategory C 2 - Cakes, Pies, Doughnucs, and
Sweet Yeast Goods Not Utilizing Pan Washing 1212
Subcategory C 3 - Bread and Runs . 1224
Subcategory C 7 - Cookie and Cracker Manufacturing 1227
Subcategory C 12 - Sandwiches 144f
Subcategory D 1 - Candy and Confectionary 123£
Subcategory D 2 - Chewing Gum 1243
•
Subcategory 0 3 - Gum Base 125P
• SubcategoHes D 5 and D 6 - Chocolate 1267
Subcategory B 5 - Low Meat Canned Pet Food 1295
Subcategory B 6 • High Meat Canned Pet Food 1297
Subcategory B 7 - Dry Pet Foods
Subcategory B 8 - Soft-Moist Pet Food
Subcategory A 29 - The Production of Finished
Flavors by the Blending of Flavoring Extracts,
Acids, and Colors 131C
Subcategory A 31 - Bouillon Products
Subcategory A 32 - Non-Dairy Creamer
XV11
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DRAFT
TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
Subcategory A 33 - Yeast 1357
Subcategory A 34 - Peanut Butter Plants With
Jar Washing 1384
Subcategory A 35 - Peanut Butter Plants Without
Jar Washing 1392
Subcategory A 36 - Pectin 1394
Subcategory A 37 - Processing of Almond Paste
Subcategory B 1 - Frozen Prepared Dinners 1407
Subcategory B 2 - Breaded and Battered Frozen
Products 1417
Subcategory S3- Frozen Bakery Desserts 1419
Subcategory B 4 - Tomato-Cheese-Storch Combinations 1427
Subcategory B 9 - Paprika and Chili Pepper . 1430
Subcategory C 4 - Egg Processing 1434
Subcategory C 5 • Shell Eggs 1444
' "Subcat jory C 6 - Manufactured Ice
Subcategory D 4 - Vinegar 1452
Related Energy Requirements of Alternative Treat-
went Technologies He>4
Non-Water Quality Aspects 1464
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DRAFT
TABLE OF CONTENTS
(CONT'D)
SECTION PAGE
IX EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION
OF THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE-EFFLUENT LIMITATIONS GUIDELINES 1475
Effluent Reductions Attinable Through the Application
of Best Practicable Control Technology Currently
Available for the Miscellaneous Foods and Beverages
Point Source Categories 1476
Identification of The Best Practical Control
Technology Currently Available 1476
Engineering Aspects of Control Technology Costs
of Application 1485
Non-Water Quality Environmental Impact 1485
Factors to be Considered in Applying Effluent
Guidelines 1485
X EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICA-
TION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE-EFFLUENT LIMITATIONS GUIDELINES 1489
Effluent Limitations Attainable Through the
Application of the Best Available Technology
Economically Achievable 1490
Identification of the Best Available Technology
economically Achievable 1490
Engineering Aspects of Control Technology Costs
of Application 1490
<
Non-Water Quality Environmental Impact 1490
Factors to be Considered in Applying Effluent
Guidelines 1490
XI NEW SOURCE PERFORMANCE STANDARDS 1501
New Source Performance Standards for the Miscel-
laneous Foods and Beverages Point Source Category 1501
Pretreatment Considerations 1502
irly
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TABLE OF CONTENTS
(CONT'D)
SECTION PAGE
XII ACKNOWLEDGEMENTS 1505
XIII REFERENCES 1509
XIV GLOSSARY 1529
Conversion Table
Appendix A - Telephone Survey Form 1547
Appendix B - Plant Visitation Form 1549
Appendix C.- Data Handling System 1556
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DRAFT
FIGURES
PAGE
Egg Processing Process Flow Diagram • 25
Shell Egg Process Flow Diagram 30
Process Flow Diagram For Dehydrated Soups 34
Prepared Dinner Plant Simplified Process Flow
Diagram 39
5 Plant G Frozen Bakery Products Plant Simplified
Process Flow Diagram 41
6 Breaded Fish and Shellfish Plant Simplified
Process Flow Diagram 43
7 Process Flew Diagram For Extruded Soft-Moist
Pet Foods 47
8 Process Flow Diagram For Expanded Soft-Moist
Pet Foods 48
9 Process Flow Diagram For Canned Pet Food Ration
Type 52
10 Process Flow Diagram For Canned Pet Food Gourmet
Type b3
11 Process Flow Diagram For Canned Pet Food High
Heat/Fish Type 55
12 Process Flow Diagram For Dry Pet Food 58
13 Bread - Conventional Mix Method Process Flow
Diagram 61
14 Bread - Continuous Mix Method Process Flow
Diagram 64
IS Snack Cake Process Flow Diagram 66
16 Cake Process Flow Diagram 67
17 Snack Pies Process Flow Diagram 69
18 Pies Process Flow Diagram 71
xxl
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DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
..19 Donuts - Cake Type Process Flow Diagram 73
20 Donuts - Yeast Type Process Flow Diagram 74
21 Cookie & Crackers Process Flow Diagram 77
22 Candy Bar Process 81
23 Chewy Candles 64
24 Hard Candy (Hard-Bo1led Sugar) 87
25 Cold Pan Candy B9
26 Hot Pan Candy 90
27 Marshmallow Process 92
28 Lozenges 94
29 Candy Tablets 96
30 Popcorn Balls and Treated Popcorn Products 97
31 Glazed Fruit 99
32 Chocolate . ' 102
33 .Gum Base 107
34 ' Chewing Gum 108
35 A Simplified Flow Diagram For Oilseed Preparation
Before Extraction For A Variety of Oilseeds 119
36 A Simplified Flow Diagram of a Direct Solvent
Extraction Process 121
37 A Schematic Diagram of a Typical Degummlng
Operation 123
38 A Simplified Flow Diagram of Mechanical Screw Press
Extraction 125
XX11
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DRAFT
FIGUkES
(CONTINUED)
NUMBER PAGE
39 Screw Pressing Process For Recovery of 011ve Oil 127
40 Hydraulic Pressing Process For Recovery of
Olive Oil 129
41 Olive 011 Solvent Extraction Process 130
4? Process Flow Diagram of a Typical Edible Oil
Refinery 136
43 A Schematic Diagram of a Continuous Process For
Caustic Refining and Recovery of Acidulatlon
Soaps took 137
44 General Chemical Reactions Associated With the '
Caustic Refining and Acidulation Processes 138
45 A Schematic Diagram for Bleaching Refined Oils 140
46 A Schematic Diagram of a Continuous Hydrogenation
Process 142
47 A Schematic Diagram for a Continuous "Winterlzation"
Process 143
48 A Schematic Diagram for Edible Oil Deodorizing 145
49 A Schematic Diagram for Edible Oil Refinery
Plastlcizlng and Packaging Operations 147
50 A Schematic Diagram of a Continuous Margarine
Plasticizing and Packaging Operation 148
51 Process Flow Diagram Malt Beverage Brewery ISO
52 Packaging Flow Diagram Malt Beverage Brewery 152
53 Spent Grains Recovery Malt Beverage Brewery 154
54 Flow Diagram Malting Process 156
55 Distribution of U.S. Wine Production 1972 158
56 Process Flow Diagram Red Table Wine Production
Without Recovery if Distilling Material 160
XX111
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DRAFT
FIGURCS
(CONTINUED)
NUMBER PAGE
57 Process Flow Diagram White Table Wine Production
Without Recovery of Distilling Material 162
'58 Process Flow Diagram Sparkling Wine Production 164
59 Process Flow Diagram Dessert Wine Production 165
60 Process Flow Diagram Eastern U.S. Winery Operations 166
61 Process Flow Diagram Beverage Brandy and wine Spirits
Production With Complete Recovery of Distilling
Material 166
62 Domestic Distilled Spirits Bottled Output 170
63 Process Flow Diagram Whiskey Distillery 171
64 Process Flow Diagram High Proof Spirits Production 174
65 Process Flow Diagram Feed Recovery System 175
66 Process Flow Diagram Molasses Distillery 177
67 Container Mix in the Soft Drink Industry 179
68 Process Flow Diagram Soft Drink Bottling and
Canning Plant 181
69 Flow Diagram Soft Drink Bottle Washirg Machine 183
70 Process Flow Diagram Bulk Filling So^t Drink Plant 185
71 Standard, Terpeneless and Concentrated Natural
Flavoring Extract Process 187
72 Natural Vanilla Extract Manufacturing Process 189
73 Natural Flavoring Concentrates anJ Powders
Manufacturing Process 190
74 Beverage Concentrate and Syrup Manufacturing Process 192
75 Coffee Roasting Process Flow Diagram 194
xxlv
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
76 Organic Solvent Contact Decaffeinating Process
Flow Diagram 195
77 Liquid/Liquid Extraction Decaffeination Process
Flow Diagram 197
78 Soluble Coffee Process Flow Diagram 199
79 Freeze Drying Process Flow Diagram 200
80 Process Flow Diagram Block Ice 203
81 Process Flow Diagram Fragmentary Ice 206
82 Process Flow Diagram For Macaroni, Spaghetti,
and Noodles 206
83 A Schematic Diagram of Almond Paste Processing 212
84 Baking Powder Process Flow Diagram 214
85 Bouillon Product Manufacturing Process 216
86 Bread Crumbs, Not Made In Bakeries Process Flow
Diagram 217
87 Chicory Process Flow Diagram 219
88 Process Flow Diagram For Paprika Chili Peppers 221
89 ' Prepared Gelatin Dessert Process Flow Diagram 224
90 Horey Process 226
91 Molasses 229
92 Maple Syrup 230
93 Pancake Syrup Process 232
94 Sorghum Syrup 233
95 Liquid Non-Dairy Creamer Manufacturing Process 235
xxv
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
96 Powdered Non-Dairy Creamer Manufacturing Process 237
97 Process Flow Diagram Manufacture of Peanut Butter 239
98 Pectin Manufacturing Process By Alcohol Precip-
itation 242
99 Pectin Recovery By Aluminum Compound Precipitation 244
100 Popcorn Process 246
101 Spice Process Flow Diagram 248
102 Instant Tea Process Diagram 250
103 Sandwich Process Flow Diagram 252
104 Vinegar Process 254
105 Process Flow Diagram Dried Food Yeast 258
107 A Linear Regression Plot of Flow (MGD) Versus Pro-
duction (Ton/uay) For Process Wastewaters Discharged
From Oilseed Solvent Extraction Plants, Subcateoorv
Al. 301
108 A Scatter Diagram Plotting BOD Concentration Versus
Production (Ton/Day) For The Process Wastewaters
Generated From Oilseed Solvent Extraction Plants,
Subcategory Al . 302
109 A Scatter Diagram Plotting COD Concentrations Versus
Production '(Ton/Day) For The Process Wastes From
Oilseed Solvent Extraction Plants, Subcategory Al 303
110 A Scatter Diagram Plotting Concentrations Of Oil
And Grease Versus Daily Production (Ton/Day) For
The Process Wastewaters Discharged From Oilseed
Solvent Extraction Plants, Subcategory Al 304
111 Subcateqory A15, Olive Oil Caustic Refining
Process Model Plant ' 335
112 Subcategory A16, Flow vs Capacity 339
113 Subcategory A16, BOD vs Capacity 340
xxvl
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
114 Subcategory A16, Suspended Solids vs Capacity 341
115 Subcategory A16, Flow Probability Diagram 342
116 Subcateg;...-y A16, BOD Probability Diagram 343
117 Subcategory A16, Suspended Solids Probability
Diagram 344
118 Daily Flow Variability Plant 82A43 345
119 Daily BOU Variability Plant 82A43 346
120 Daily Suspended Solids Variability 347
121 Subcategory A17, Flow vs Capacity 350
122 Subcategory AT7, BOD vs Capacity 351
123 Subcategory A17, Suspended Solids vs Capacity 352
124 Subcategory A17, Flow Probability Diagram 353
125 Subcategory A17, BOD Probability Diagram 354
126 Subcategory AT7, Suspended Solids Probability
Diagram 355
127 Subcategory A18, Flow vs Capacity . 359
128 Subcategory A18, BOD vs Capacity 360
129 Subcategory A18, Suspended Solids vs Capacity 361
130 Subcategory A18, Flow Probability Diagram 362
131 Subcategory A18, BOD Probability Diagram 363
132 Subcategory A18, Suspended Solids Probability
Diagram 364
133 Model Plant For Oeverage Concentrate And Syrup
Manufacturing Process 408
134 Model Plant For Subcategory A30, Instant Tea
Manufacturing Process 411
135 Model Plant For Subcategory A29, Flavoring
Extracts 452
xxvil
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
136 Subcategory A31 -Model Plant, Bouillon Manu-
facturing Process 454
137 Subcategory A32 - Model Plant, Non-Dairy Creamer
Manufacturing 457
138 Pumping Station 505
139 Clarifier Module Plan View 506
140 Clarifier Module Elevation View 507
141 Neutralization System 508
142 Nitrogen Addition System 509
143 Phosphorus Addition System 510
144 Activated Sludge System 511
145 Thick Surface Aerator 513
146 Aerateu Lagoon Cross Section 514
147 Aerobic Digestion Basin 516
148 Vacuum Sludge Filtration 517
149 Flow Measurement Systems 519
150 Sump Decanter System 520
151 Subcategory A 1 - Treatment Alternatives 11-1II 525
152 Subcategory A 1 - Treatment Alternatives IV-V 526
153 Subcategory A 1 - Treatment Alternatives VI-VII 527
154 Subcategory A 1 - Treatment Alternatives VI-VII! 528
155 Subcategory A 5 - Treatment Alternatives II
Through V 544
156 Subcategory A 5 - Treatment Alternatives VI
Through VIII 545
XXV111
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER
PAGE
548
549
553
157 Subcategory A 6 - Treatment Alternatives II
Through V
158 Subcategory A 6 - Treatment Alternatives VI
Through VIII
159 Subcategory A 7 - Treatment Alternatives II
Through V
160 Subcategory A 7 - Treatment Alternatives VI
Through VII 554
161 Subcategory A 8 - Treatment Alternatives II
Through V 557
162 Subcategory A 8 - Treatment Alternatives VI
Through VIII 55
163 Subcategory A 9 - Treatment Alternatives II
Through V 562
164 Subcategory A 9 - Treatment Alternatives VI
Through VIII 5g3
165 Subcategory A 10 - Treatment Alternatives II
Through V 566
166 Subcategory A 10 - Treatment Alternatives VI
Through VIII " Y1 567
167 Subcategory A 11 - Treatment Alternatives II
Through V 570
168 Su5«tegor>-A 11 • Treatment Alternatives VI
Tnrough VIII „-
169 Subcategory A 12 - Treatment Alternatives II
Through V „,.
170 Subcategory A 12 - Treatment Alternatives VI
Through VIII „,
171 Subcategory A 13 - Treatment Alternatives II
Tnrough IV __Q
172 Subcategory A 13 - Treatment Alternatives V
581
xxix
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
.173 Subcategory A 14 - Treatment Alternatives II
Through IV . 584
174 Subcategory A 14 - Treatment Alternatives V
Through VII 585
175 Control and Treatment Plant 82A43 589
176 Control and Treatment Plant 82A16 594
177 Subcategory A 16 - Treatment Alternatives II
Through IV 597
178 Subcategory A 16 - Treatment Alternatives A 16-V
Through A 16-XIII 598
179 Subcategory A 17 - Treatment Alternatives II
Through IV 602
180 Subcategory A 17 - Treatment Alternatives V
Through XIII 603
181 Subcategory A 18 - Treatment Alternatives II
Through IV 607
182 Subcategory A 18 - Treatment Alternatives V
Through VIII 608
183 . Control and Treatment Plant 83A13 611
184 Subcategory A 19 - Treatment Alternatives II
and III 614
185 Subcategory A 19 - Treatment Alternatives IV
VH 615
186 Control and Treatment Plant 84*10 618
187 Control and Treatment Plant 84*09 619
188 Control and Treatment Plant 84*03 620
189 Control and Treatment Plant 84C01 621
xxx
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
190 Control and Treatment Plant 84*02 622
191 Control and Treatment Plant 84*04 623
192 Subcategory A 20 - Treatment Alternatives II
Through VII 627
193 Subcategory A 20 - Treatment Alternatives VIII
Through X 628
194 Control and Treatment Plant 85AO"! 635
195 Control and Treatment Plant 85A02 636
196 Control and Treatment Plant 85A05 637
197 Control and Treatment Plant 85A07 638
198 .Control and Treatment Piu'-t SSA15 639
199 Control and Treatment Plant 85A22 640
200 Control and Treatment Plant 85A27 641
201 Control and Treatment Plant 85A29 642
202 Subcategory A 22A - Treatment Alternatives II
and III 644
203 Subcategory A 22A - Treatment Alternatives IV
Through IX 645
204 Subcategory A 228 - Treatment Alternatives II
and III 646
205 Subcategory A 22E - Treatment Alternatives IV
Through-IX 647
206 Subcategory A 23 - Treatment Alternatives II
Through IV 653
207 Control and Treatment Plant 85C43 657
208 Control and Treatment Plant 85C44 658
xxxl
-------
DRAFT
f NUMBER
v_
209
210
211
212
213
214
215
216
217
,' ''
21 ft
219
220
221
222
223
224
225
FIGURES
(CONTINUED)
Subcategory A 24 - Treatment Alternatives II
Through IV
Subcategory A 24 - Treatment Alternatives VIII
Through IX
Subcategory A 26 - Treatment Alternatives II
Through V
Subcategory A 26 - Treatment Alternatives VI
and VII
Control and Treatment Plant 86A16
Control and Treatment Plant 86A32
Control and Treatment Plant 86A29
Subcategory A 27 - Treatment Alternatives II
. Through V
Subcategory A 27 - Treatment Alternatives VI
and VII
Subcategory A 28 - Treatment Alternatives I, V,
and IX
Subcategory A 28 - Treatment Alternatives II-IV,
VI-VIII, and X-XII
. Secondary Treatment of Instant Tea Process Waste-
water Plant 99T01
Subcategdry A 30 - Treatment Alternatives II, III,
V, and VI
Subcategory A 30 - Treatment Alternatives IV and
VII
Subcategory C 8 - Treatment Alternatives II and III
Subcategory C 8 - Treatment Alternatives IV and V
Subcategory C 9 - Treatment Alternatives II
PAGE
661
662
667
668
670
671
672
675
676
680
681
685
688
689
692
694
Through IV 697
xxx 11
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER
226
227
228
229
230
231
232
233
234
235
236
237 •
238
239
240
241
242
Subcategory C 10 -
and IV
Subcategory C 10 -
Physical -Chemical
Subcategory C 2
Subcategory C 1 -
and IV
Existing Treatment
Subcategory C 2 -
Through V
Subcategory C 2 -
and VIII
Subcategorv C 3 -
III
Subcategory C 3 -
Subcategory C 7 -
Subcategory C 7 -
and VI
Subcategory B 5 -
Through IV
Subcategory B 6 -
Through V
Subcategory B 7 -
Tiirough IV
Subcategory B 8 -
Through IV
Subcategory A 29 -
IV, VI, VII, IX,
Subcategory A 29 -
xr
Treatment Alternatives II
Treatment Alternative III
Treatment of Bakery Wastes
Treatment Alternatives III
Technology - Subcategory C 2
Treatment Alternatives II
Treatment Alternatives VII
Treatment Alternatives II and
Treatment Alternative IV
Treatment Alternative III
Treatment Alternatives II • V,
Treatment Alternatives I
Treatment Alternatives I
Treatment Alternatives I
Treatment Alternatives I
Treatment Alternatives HI,
X
Treatment Alternatives V, VIII,
PAGE
701
703
705
709
711
714
716
719
720
724
725
745
748
751
755
759
760
xxxlll
-------
DRAFT
NUMBER
243
244
245
246
247
248
249
250
251
252
253
254'
255
256
257
258
FIGURES
(CONTINUED)
Subcategory A 31 - Treatment Alternatives II, III,
V, and VI
Subcategory A 31 - Treatment Alternatives IV and
VII
Subcategory A 32 - Treatment Alternatives I! and
V
Subcategory A 32 - Treatment Alternatives III and
VI
Slagelse, Denmark Yeast Plant Treatment System
Control and Treatment Plant 99Y24
Control and Treatment Plant 99Y25
Yeast Plant 99Y20 - Simplified Wastewater Flow
Diagram
Yeast Plant 99Y29 - By-Product Recovery Using
Evaporation
Yeast Plant 99Y20 - Biological Treatment and
Control
Subcategory A 33 - Treatment Alternatives V
Through X, XIV Through XIX
Subcategory A 33 - Treatment Alternatives II
Through IV, XI Through XIII
Subcategory A 36 - Treatment Alternatives III, IV
V, VII, VIII, IX
•t
Subcategory A 36 - Treatment Alternatives VI
and X
Subcategory B 1 - Treatment Alternatives 1
Through IV
Subcategory u 2 - Treatment Alternatives I
Through IV
PAGE
764
765
769
770
778
779
781
782
783
784
789
790
799
BOO
CIO
B13
-------
DRAFT
NUMBER
259
260
261
262
263
264
265
266
267
268
269
?70
271
272
273
274
275
FIGURES
(CONTINUED)
Subcategory B 3 - Treatment Alternatives I
Through IV
Subcategory B 4 - Treatment Alternatives t
Through III
Subcategory C 4 - Treatment Alternative III
Subcategory C 4 - Treatment Alternative V
Subcategory C 5 - Treatment Alternatives II and
III
Subcategory C 5 - Treatment Alternatives IV and
V
Investment and Yearly Costs For Subcategory A 1,
Alt. II. Ill
Investment and Yearly Costs For Subcategory A 1,
Alt. IV, V
Investment and Yearly Costs For Subcategory A 1,
Alt. VI, VII
Investment and Yearly Costs For Subcategory A 1 ,
Alt. VIII
Investment and Yearly Costs For Subcategory A 5,
Alt. II, V
Investment and Yearly Costs For Subcateqory A 5,
Alt, VI, VIII
Investment and Yearly Costs For Subcateaory A 6,
AH. II, V
Investment and Yearly Costs For Subcategory A 6
Alt. VI, VIII
Investment and Yearly Costs For Sulcategory A 7
Alt. II, V
Investment and Yearly Costs For Subcategory A 7
Alt. VI, VIII
Investment and Yearly Costs For Subcategory A 8
Alt. 11, V
PAGE
818
821
330
831
834
836
847
851
855
857
873
878
885
891
898
903
910
XXXV
-------
DRAFT
NUMBER
276
277
272
279
279
280
281
282
283
284
285
286
287
288
289
290
FIGURES
(CONTINUED)
Investment and Yearly Costs For Subcategory A 8
Alt. II, VII
Investment and Yearly Costs For Subcategory A 9-
Alt. II, V
Investment and Yearly Costs For Subcategory A 9
Alt. II, VIII
Investment and Yearly Costs For Subcategory A 10
Alt. II, V
Investment and Yearly Costs For Subcategory A 10
Alt. II, VIII
Investment and Yearly Costs For Subcategory A 11
Alt. II. V
Investment and Yearly Costs For Subcategory A 11
Alt. II. VIII
Investment and Yearly Costs For Subcategory A 12
Alt. II, V
Investment and Yearly Costs For Subcategory A 12
Alt. 11, VIII
Investment and Yearly Costs For Subcategory A 13
Alt. II, IV
Investment and Yearly Costs For Subcategory A 13
Alt. II, V. VI
Investment and Yearly Costs For Subcategory A 14
AH. II, IV
Investment and Yearly Costs For Subcstcgory A 14
Alt. V, VII
Investment and Yearly Costs For Subcategory A 16
Alt. IV
Investment and Yearly Costs For Subcategory A 16
AH. VII
PAGE
914
922
927
934
939
946
952
959
964
970
973
979
984
993
996
31 Investment and Yearly Costs For Subcategory A 16
AH. X 1002
J2 Invcstnent and Yearly Costs For Subcategory A 16
AH. XIII * * 1008
XXXV1
-------
DRAFT
FIGURES
(CONTINUED)
NUMB Eli
293
294
295
296
297
298
299
300
301
302
303 •
304
305
306
307
308
Investment
Alt. IV
Investment
Alt. VII
Investment
Alt. X
Investment
Alt. IV
Investment
AH. VII
Investment
Alt. X
Investment
Alt. XIII
Investment
AH. Ill
Investment
Alt. V
Investment
Alt. VII
Investment
Alt. IV
Investment
AH. VII
Investment
Alt. X
Investment
Alt. Ill
Investment
AH. V
Investment
and
and
and
and
and
and
and
and
and
and
and
and
and
and
and
and
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yc-arly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Yearly
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
Costs
For
For
For
For
For
For
For
For
For
for
For
For
Fcr
For
For
For
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Jubcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
A
17
r;
17
IB
18
18
18
19
•
19
19
20
20
20
22-A
22-A
22-A
PAGE.
1013
1016
1023
1029
1034
1039
1044
1049
1052
1056
1062
1067
1072
1078
1082
Alt. VII 1085
xxxvll
-------
DRAFT
NUMBER
326
327
328
329
330
331
332
333
334
335
336 •_
337
338
339
340
341
FIGURES
(CONTINUED)
Investment and Yearly Costs For Subcategory A 28
Ait. IX
Investment and Yearly Costs For Subcategory A 28
Alt. X
Investment and Yearly Costs For Subcategory A 28
Alt. XI
Investment and Yearly Costs For Subcategory A 28
Alt. XII
Investment and Yearly Costs For Subcategory A 30
Alt. V
Investment and Yearly Costs For Subcategory A 30
Alt. VI
Investment and Yearly Costs For Subcategory A 30
Alt. IV
Investment and Yearly Costs For Subcategory C 8
Alt. Ill
Investment and Yearly Costs For Subcategory C 8
Alt. V
Investment and Yearly Costs For Subcategory C 9
Alt. Ill
Investment and Yearly Costs For Subcategory C 10
Alt. IV
Investment and Yearly Costs For Subcategory C 1
Alt. IV
Investment and Yearly Costs For Subcategory C 2
Alt. V
Investment and Yearly Costs For Subcategory C 2
Alt. VI
Investment and Yearly Costs For Subcategory C 2
Alt. VIII
Investment and Yearly Costs For Subcategory C 3
PAGE
1168
1170
1173
1175
1183
1185
1187
1193
1196
1201
1206
1211
1218
1221
1225
Alt. Ill 1229
AKXlX
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
309 Investment and Yearly Costs For Subcatego'ry A 22-A
AH. IX 1089
310 Investment and Yearly Costs For Subcategory A 22-B
Alt. Ill 1093
311 Investment and Yearly Costs For Subcategory A 22-B
Alt. IV 1097
312 Investment and Yearly Costs For Subcstegory A 22-B
Alt. VII 1101
313 Investment and Yearly Costs For Subcaf>fl?ry A 22-B
Alt. VII " 1104
314 Investment and Yearly Costs For Subcategory A 23
Alt. Ill 1108
315 Investment and Ysarly Costs For Subcategory A 23
Alt. IV 1111
316 Investment and Yearly Costs For Subcategory A 24
Alt. Ill 1115
»
317 Investment and Yearly Costs For Subcategory A 24
Alt. V 1119
318 Investment and Yearly Costs For Subcategory A 24
Alt. VII 1122
319 Investment and Yearly Costs For Subcategory A 24
Alt. IX 1126
320 Investment and Yearly Costs For Subcategory A 26
Alt. Ill 1136
321 Investment and Yearly Costs For Subcategory A 26
Alt. V 1140
322 Investment and Yearly Costs For Subcategory A 26
Alt. VII 1143
323 Investment and Yearly Costs For Subcategory A 27
AH. Ill 1147
3k* Investment and Yearly Costs For Subcategory A 27
AH. V 1151
325 Investment and Yearly Costs For Subcategory A 27
Alt. VII 1155
rxxvlii
-------
DRAFT
NUMBER
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
FIGURES
(CONTINUED)
Investment and Yearly Costs For Subcategory C 7
Alt. IV
Investment and Yearly Costs For Subcategory C 7
Alt. VI
Investment and Yearly Costs For Subcategory D 1
Alt. V
Investment and Yearly Costs For Subcategory D 1
Alt. VI
Investment and Yearly Costs For Subcategory D 2
Alt. V
Investment and Yearly Costs For Subcategory 0 2
Alt. VI
Investment and Yearly Costs For Subcategory D 2
AH. VII
Investment and Yearly Costs For Subcategory D 3
Alt. V
Investment and Yearly Costs For Subcategory D 3
Alt. VI
Investment and Yearly Costs For Subcategory D 3
Alt. VII
Investment and Yearly Costs For Subcategory D 5
Alt. VII
Investment and Yearly Costs For Subcategory D 6
AH. VII
Investment and Yearly Costs For Subcategory D 6
AH. VIII
Investment and Yearly Costs For Subcategory B 5
Alt. IV
Investment and Yearly Costs For Subcategory B 6
Alt. V
Investment and Yearly Costs For Subcategory B 7
Alt. IV
PAGE
1236
1239
1246
1248
1255
1257
1260
1265
1269
1271
1281
1292
1294
1300
1307
1312
XL
-------
DRAFT
FIGURES
(CONTINUED)
NUMBER PAGE
358 Investment and Yearly Costs For Subcategory B 8
AH. IV 1318
359 Investment and Yearly Costs For Subcategory A 29
Alt. IX 1330
360 Investment and Yearly Costs For Subcategory A 29
Alt. X 1332
361 Investment and Yearly Costs For Subcategory A 29
Alt. XI 1334
362A Investment and Yearly Costs For Subcategory A 31
Alt. V 1342
352B Investment and Yearly Costs For Subcategory A 31
AH. VI 1345
363 Investment and Yearly Costs For Subcategory A 31
AH. VII 1347
364 Investment and Yearly Costs For Subcategory A 32
AH. IV 1354
365 Investment and Yearly Costs For Subcategory A 32
Alt. V 1356
365 Investment and Yearly Costs For Subcategory A 33
AH. IV 1362
367 . Investment and Yearly Costs For Subcategory A 33
AH. VII 1367
368 Investment and Yearly Costs For Subcategory A 33
AH. X i 1372
359 Investment and Yearly Costs For Subcategory A 33
AH. VIII 1376
370 Investment and Yearly Costs For Subcategory A 33
Alt. XVI 1382
371 Investment and Yearly Costs For Subcategory A 33
Alt. XIX 1387
372 Investment and Yearly Costs For Subcategory A 36
AH. VII 1404
XL I
-------
DRAFT
(UMBER
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
FIGURES
(CONTINUED)
Investment and Yearly Costs For Subcategory A 36
Alt. VIII
Investment and Yearly Costs For Subcategory A 36
Alt. IX *
Investment and Yearly Costs For Subcategory A 36
Alt. X
Investment and Yearly Costs For Subcategcry B 1
Alt. IV
Investment and Yearly Costs For Subcategory B 2
Alt. IV
Investment and Yearly Costs For Subcategory B 3
Alt. IV
Investment and Yearly Costs For Subcategory B 4
Alt. Ill
Investment and Yearly Costs For Subcategory B 9
Alt. Ill
Investment and Yearly Costs For Subcategory C 4
Alt. Ill
Investment and Yearly Costs For Subcategory C 4
AH. V .
Investment and Yearly Costs For Subcategory C 5
Alt. Ill
Investment and Yearly Costs For Subcategory C 5
Alt. V
Investment and Yearly Costs For Subcategory D 4
AH. V
Investment and Yearly Costs For Subcategory D 4
Alt. VI
Investment and Yearly Costs For Sjbcategory D 4
Alt. VII
PAGE
1406
1409
1411
1416
1422
1428
1432
1436
1440
1443
1447
1451
1459
1461
1463
XUXl
-------
DRAFT
LIST OF TABLES
NUMBER PAGE
1 Miscellaneous Foods and Beverages Industry
Defined By SIC Code 114
2 Egg Products Under Federal Inspection 24
3 Production Of Frozen Food Specialties 33
4 Pet Food Volume 45
. 5 Constituents of Cocoa Nibs 103
6 . The Number of Companies and Establishments
Processing Oilseeds From 1954 To 1974 112
7 Cottonseed Mi 11-Ing Operations By State and Types
of Extractor Methods Utilized 1974 114
8 Extraction of Oil From Oilseeds by Various Processes 117
9 U.S. Domestic Disappearance of Fats and 011s In
Food Products, By Type of Fat or Oil, 1950-72,
l/(Million Metric Tons) 132
10 Production of Major Crude Vegetable Oil In the
United States From 1959-1973 133
11 A Summary of the Number of Edible Oil Refineries
In The United States Lisied By State 134
12 Classification of the Miscellaneous Food and
Beverages Industry By Standard Industrial Classi-
fication Codes 262
13 Recommended Subcategorization of the Miscellaneous
Foods and Beverages Point Source Category 263
14 Edible Oil Process Units 273
15 Process Integration in the Edible Oil Refining
Industry 274
16 Process Units Employed For The Miscellaneous Foods
and Beverages .294
17 Summary of Unit Process Raw Data on Edible 011
Refinery Wastewater Characteristics 298
XLIII
-------
DRAFT
TABLES
(CONTINUED)
PAGE
A Statistical Description of the Wastewater
Characteristics for Solvent Extraction Process
Wastswater 300
19 A Statistical Description of the Wastewater
Characteristics for The Edible Oil Caustic
Refinery Process 309
20 Pollutant Loadings for Caustic Refining Wash Haters 310
21 A Statistical Description of the Wastewater
Characteristics for Edible Oil Refinery Tank Car
Cleaning Operations 312
22 Pollutant Waste Loadings for Edible Oil Refinery
Tank Car Cleaning 313
23 A Statistical Description of the Wastewater
Characteristics for Edible Oil Refinery Storage
and Handling Operations 314
24 Sample Calculations for Determing Total Waste
Loadings for Subcategory A 5 Plants 317
25 A Statistical Descriptions of the Wastewater
Characteristics for the Edible Oil Refinery Soap-
stock Acidulation Process " 318
26 Pollutant Waste Loadings for the Edible Oil
Refinery Acidulation Process 319
27 A Statistical Description of the Wastewater
Characteristics for Edible Oil Refinery Contact
Cooling Tower Slowdown From Barometric Condensers 321
23 A Statistical Description of the Wastewater
Characteristics for Edible Oil Refinery Oil
Processing 323
29 A Statistical Description of the Wastewater
Characteristics for Margarine Processing 32!)
30 Pollutant Waste Loadings for the Processing
of Margarine 330
XL1V
-------
DRAFT
TABLES
(CONTINUED)
NUMBER PAGE
.. 31 A Statistical Description of the Wastewater
Characteristics for Shortening and Table Oil
Packaging Operations 332
32 Pollutant Waste Loadings for Shortening and
Table Oil Processing 333
33 Wastewater Characteristics, Subcategory A 16
(New Large Breweries) 338
35 Wastewater Characteristics, Subcategory A 17
(Old Large Breweries) 349
36 Wastewater Characteristics, Subcategory A 18 357.
37 Analyses of Malting Steep Water Wastes 366
38 Results of Malt Industry Wastewater Survey 367
39 Daily Variability of Malt Waste 368
40 Raw Waste Characteristics During Crushing,
Wineries Without Stills 371
41 Raw Waste Characteristics During Processing,
Wineries Without Stills 372
42 Stillage Characteristics 375
43 Distilling Material Produced Per Ton of Grapes
Crushed 376
44 Stlllage Characteristics 377
45 Process Waste Streams - Grain Distillers With
Stillage Recovery 379
46 Variability in BOD Concentration of Grain Distillery
Evaporator Condensate 381
47 Analysis of Grain Distillery Evaporator Condensate 382
48 Balance Sheet For Grain Neutral Spirits Unit,
Grain Distillery, Subcategory A 22 384
XLV
-------
DRAFT
TABLES
(CONTINUED)
NUMBER PAGE
49 Pollution Load From Week-End Cleanups, Grain
Distillery, Subcategory A 22 385
50 Wastewater Characteristics - Grain Distillery,
Subcategory A 22 387
51 Daily Variations in Raw Waste - Grain distillery.
Subcategory A 22 388
52 Molasses Distillery Waste Streams 391
53 Variability of Molasses Stillage 392
54 Chemical Characteristics of Molasses Stillage -393
55 Ionic Composition of Molasses Stillage 394
56 Raw Waste Characteristics - Rum Distillers 397
57 Daily Waste Characteristics - Soft Drink Canning,
Plant 86A27 401
58 Raw Waste Characteristics, Subcategory A 27 404
59 Summary of Wastewater Characteristics, Subcategory
A 28 406
60 Subcategory A 30 - Summary of Wastewater Character-
istics 410
61 Raw Uaste Summary, Subcategory C 8 - Coffee
Roasting 413
62 Raw Waste Summary Subcategory C 9 - Decaffeination
of Coffee 415
63 Raw Waste Summary, Subcategory C 10 - Soluble
Coffee 418
64 Raw Waste Summary - Cakes, Pies, Doughnuts, and
Sweet Yeast Goods Utilizing Pan Washing 422
65 Raw Waste Summary, Subcategory C 2 - Cakes, P1es,
Doughnuts, and Sweet Yeast Goods Not Utilizing
Pan Washing 424
XLVl
-------
DRAFT
TABLES
(CONTINUED)
NUMBER PAGE
66 Raw Waste Sunroary - Bread and Buns 426
67 Raw Waste Sunmary - Cookies and Crackers 429
68 Raw Waste Sunmary - Candy and Confectionery 431
69 Raw Waste Summary • Chewing Gum 433
70 Raw Waste Summary - Chewing Gum Base 435
71 Raw Waste Summary - Chocolate, With Milk Condensory 437
72 Raw Waste Summary - Chocolate, Without Milk Con-
densory 438
73 Raw Waste Summary - Low Meat Canned Pet Food 441
74 Raw Waste Summary - High Meat Canned Dog and Cat
Food 443
75 Raw Waste Summary - Dry Dog and Cat Food 445
76 Raw Waste Summary - Soft Moist Dog and Cat Food 447
77 Yeast Plant 99Y03 - Unit Operations Wastewater
Characteristics 459
78 Yeast Dewatering Effluent Characteristics,
Plant 99Y03 460
79 Water Usage and Wastewater Characteristics -
Yeast Plants Recycling Separation Water-Plant?
S9Y01 end 99Y05 461
80 Approximate Water Usage Por Operating Day For
Peanut Butter Processing Plant 99P21 464
81 Jar Washer Wastewater Characteristics Plant 99P20 465
82 Occasional Cleanup Wastewater Discharged -
Plant 99P21 467
83 Wastewater Characteristics of Individual Waste
Streams at Plant 99K01 469
xuvu
-------
DRAFT
TABLES
(CONTINUED)
NUMDER PAGE
84 Wastewater Characteristics of Individual Waste
Streams at Plant 99K02 470
85 Summary of Wastewater characteristics, Subcate-
gory A 36 - Pectin 471
86 Raw Waste Summary - Frozen Prepared Dinners 475
.87 Raw Waste Summary - Frozen Battered and Breaded
Specialties 476
88 Raw Waste Summary - Frozen Bakery Products 478
89 Raw Waste Summary - Frozen Tomato-Cheese-Starch
Dishes 480
90 Raw Waste Summary - Chili Peppers and Paprika 481
91 Raw Waste Summary - Egg Processing 484
92 Raw Waste Summary - Shell Eggs 485
93 Raw Waste Summary - Manufactured Ice 489
94 Raw Waste Summary - Vinegar 491
95 Wastewater Treatment Units Used in Treatment Train
Alternatives 502
96 Final Discharge Data for Treatment Systems Handling
Solvent Extraction Process Wastes 522
97 Summary of Treatment Train Alternatives for Sub-
category A 1 523
98 Summary of Present In-Plant Control and Treatment
Technology for the Edible Oil Refining Industry 534
99 Existing Treatment Chain and Major Design Factors
Of Plant 75F-10 for the Biological Treatment
of Edible Oil Refinery Wastes 538
100 Existing Treatment Chain and Major Design Factors
For the Edible Oils-Margarine, Salad Dressing
and Cheese Pretreatment Facilities at Champaign,
Illinois 540
XL v m
-------
DfiAFT
TABLES
(CONTINUED)
NUMBER PAGE
101 Summary of Treatment Train Alternatives 542
102 Summary of Treatment Train Alternatives for
Subcategory A 6 • 546
103 Summary of Treatment Train Alternatives for
Subcategory A 7 551
104 Summary of Treatment Train Alternatives for
Subcategory A 8 556
105 Summary of Treatment Train Alternatives for
Subcategory A 9 . 560
106 Summary of Treatment Train Alternatives for
Subcategory A 10 564
107 Summary of Treatment Train Alternatives for
Subcategory A 11 569
108 Summary of Treatment Train Alternatives for
Subcategory A 12 573
109 Summary of Treatment Train Alternatives for
Subcategory A 13 578
110 Summary of Treatment Train Alternatives 583
111 Waste Treatment Plants Handling Brewery Wastes 590
112 Treatment Plant Design Unit Loadings 593
113 Summary of Treatment Train Alternatives for
Subcategory A 16 596
114 Summary of Treatment Train Alternatives for
Subcategory A 17 601
115 Summary of Treatment Train Alternatives for
Subcategory A 18 606
116 Summary of Treatment Train Alternatives for
Subcategory A 19 613
117 Summary of Treatment Train Alternatives for
Subcategory A 20 625
XL IX
-------
DRAFT
TABLES
(CONTINUED)
PAGE
Summary of Treatment Train Alternatives for
Subcategory A 20 (Non-Crushing Season) 626
119 Treatment System Summary for Subcategory A 22 634
120 Summary of Treatment Alternatives for Subcategory
A 22-A 648
121 Summary of Treatment Train Alternatives for
Subcategory A 22-B 649
122 Summary of Treatment Train Alternatives for
Subcdtegory A 23 652
123 Summary of Treatment Train Alternatives for
Subcategory A 24 660
124 Summary of Treatment Train Alternatives for
Subcategory A 26 666
125 Summary of Treatment Train Alternatives for
Subcategory A 27 674
126 Summary of Treatment Alternatives - Beverage Base
Syrups and/or Concentrates 679
127 Summary of Treatment Train Alternatives - Sub-
category A 30 687
128 Summary of Treatment Train Alternatives 691
129 Summary o Treatment Train Alternatives 696
130 Summary of Treatment Train Alternatives 700
131 Summary of Treatment Train Alternatives -
Cubcategory C 1 707
132 Summary of Treatr.ent Train Alternatives
Subcategory C 2 713
133 Summary of Treatment Train Alternatives 718
134 Sunmary of Treatment Train Alternatives 723
-------
DRAFT
TABLES
(CONTINUED)
NUMBER PAGE
135 Surmiary of Treatment Train Alternatives
Subcategory D 1 729
136 Sunmary of Treatment Train Alternatives
Subcategory D 2 733
137 Sunmary of Treatment Train Alternatives
Subcategory 0 3 735
138 Summary of Treatment Train Alternatives
Subcategory D 5 738
139 Sunmary of Treatment Train Alternatives
Subcategory D 6 740
140 Summary of Treatment Alternatives for Subcategory
B 5 743
141 Summary of Treatment Alternatives for Subcategory
B 6 746
142 Summary of Treatment Alternatives for Subcategory
B 7 750
143 Summary of Treatment Alternatives for Subcategory
B 8 753
144 Summary of Treatment Train Alternatives for
Subcategory A 29 758
145. Summary of Treatment Train Alternatives for
Subcategory A 31 763
146 Summary of Treatment Train Alternatives fo;1
Subcategory A 32 768
K7 Comparison of Nastewater Characteristics and
Spent Beer Reuse 773
148 Summary of ln-Pla;.l Control and Treatment Technology
..for Subcategory A 33 775
149 Summary of End-of-Line Treatment and Control 776
150 Summary of Treatment Alternatives for Subcategory
A 33 787
LI
-------
DRAFT
TABLES
(CONTINUED)
NUMBER PAGE
151 Summary of Treatment Train Alternatives for
Subcategory A 36 - Pectin 798
152 Treatment Unit Chain and Major Design Factors for
Existing Treatment Plant Treating Wastewater from
Frozen Prepared Dinners and Other Specialty Foods 804
153 Reported Performance for Treatment Units Described 807
154 Summary of Treatment Train Alternatives for Sub-
category B 1 809
155 Summary of Treatment Train Alternatives for
Subcategory 8 2 812
156 Treatment Unit Chain and Major Design Factors for
Existing Pre-treatment Plant Treating Wastewater
From Frozen Ba;ery Products 814
157 Summary of Treatment Train Alternatives for Sub-
category 83 817
158 Summary of Treatment Train Alternatives for Sub-
category B 4 820
159 Model Treatment Module Chain and Estimated Pollutant
Removals - Subcategory B 9 825
160 . Summary of Treatment Train Alternatives 828
161- Summary of Treatment Chain Alternatives 833
162 Summary of Treatment Train Alternatives for Sub-
category D 4 839
163 Itemired Cost Summary for Subcategory A 1
Alt. II 845
164 Itsmized Cost Summary for Subcategory A 1
Alt. Ill 846
165 Itemized Cost Summary For Subcategory A 1
Alt. IV 848
166 Itemized Cost Summary for Subcategory A 1
Alt. V ' 850
167 Itemized Cost Summary for Subcategory A 1
Alt. VI 852
til
-------
DRAFT
NUMBER
168
169
170
171
172
173
174
175
176
177
178 .
179
180
181
182
183
TABLES
(CONTINULD)
Itemized Cost Summar Subcategory A 1'
Alt. VII
Itemized Cost Summary for Subcitegory A 1
AH. VIII
Itemized Cost Summary for Subcategory A 3
AK. I
Itemized Cost Summary for Subcategory A 3
Alt. II
Itemized Cost Summary for Subcategory A 3
Alt. Ill
Itemized Cost Summary for Subcategory A 4
Alt. I
Itemized Cost Summary for Subcategory A 4
Alt. II
Itemized Cost Summary for Subcategory A 4
AH. Ill
Itemized Cost Summary for Subcategory A 5
AH. II
Itemized Cost Summary for Subcategory A 5 -
AH. Ill
Itemized Cost Summary For Subcategory A 5
AH. IV
Itemized Cost Summary for Subcdtegovy A 5
Alt. V
Itemized Cost Summary For Subcategory A 5
AH. VI
Itemized Cost Sui.imary for Subcategory A 5
AH. VII
Itemized Cost Summary for Subcategory A 5
Alt. VIII
Itemized Cost Summary for Subcategory A 6
AH. II
PAGE
854
856
859
861
862
864
865
866
868
869
871
672
875
676
877
880
LIII
-------
DRAFT
NUMBER
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
TABLES
(CONTINUED)
Itemized Cost Summary for Subcategory A 6
Alt. Ill
Itemized Cost Summary for Subcatcgory A 6
AH. IV
Itemized Cost Summary for Subcategory A 6
Alt. V
Itemized Cost Summary for Subcategory A 6
Alt. VI
Itemized Cost Surnmary for Subcategory A 6
Alt. VII
Itemized Cost Summary for Subcategory A 6
Alt. VIII
Itemized Cost Summary for Subcategory A 7-
Alt. II
Itemized Cost Summary for Subcatecory A 7
Alt. HI
Itemized Cost Summary for Subcategory A 7
Alt. IV
Itemized Cost Summary for Subcategory A 7
Alt. V
Itemized Cost Summary For Subcategcry A 7
Alt. VI
Itemized Cost Summary for Subcategory A 7
Alt. VII
Itemized Cost Summary For Subcategorv A 7
Alt. VIII
Itemized Cost Summary for Subcategory A 8
Alt. II
Itemized Cost Summary for Subcatcgory A 8
Alt. Ill
Itemized Cost Summary for Subcato
-------
DRAFT
NUMBER
200
201
202
203
204
205
206
207
208
209
210 •
211
212
213
214
215
TABLE3
(CONTINUED)'
Itemized Cost Summary for SubcategoryA 8'
AH. V
Itemized Cost Summary for SubcatcgoryA 8
Alt. VI .
Itemized Cost Sumcary for SubcategoryA 8
Alt. VII
Itemized Cost Summary for SubcategoryA 8
Alt. VIII
Itemized Cost Summary for SubcategoryA 9
AH. II
Itemized Cost Summary for SubcategoryA 9
AH. Ill
•Itemized Cost Summary for SubcategoryA 9
AH. IV
Itemized Cost Summary for SubcategoryA 9
AH. V
Itemized Cost Summary for SubcategoryA 9
AH. VI
Itemized Cost Summary for Subcategory A 9
AH. VII
Itemized Cost Summary For SubcategoryA 9
AH. VIII
Itemized Cost Summary for SubcategoryA 10.
AH. II
Itemized Cost Summary For Subcategory A 10
AH. Ill
Itemized Cost Sumiiary for Subcategory A 10
AH. IV
Itemized Cost Suiwary for Sjbcatcgory A 10
AH. V
Itemized Cost Sunniary for Subcategory A 10
AH. VI
PAGE
909
911
912
915
' 917
913
919
921
923
925
926
929
930
932
933
935
IV
-------
DRAFT
TABLES
(CONTINUED)
NUMBER ' PAGE,
937
538
216 Itemized Cost Summary for Subcategory A !0
AH. VII ,
217 Itemized Cost Summary for Subcatcgory A 10
AH. VIII
218 Itemized Cost Summary for Subcategory A 11 941
AH. II
219 Iten.ized Cost Summary for Subcategory A 11
AH. HI 943
220 Itemized Cost Summary for Subcategory A 11
AH. IV . 944
I
221 Itemized Cost Summary for Subcategory A 11
AH. V • . 945
222 Itemized Cost Summary for Subcategory A 11
Alt. VI 948
223 Itemized Cost Summary for Subcategory A 11
Alt. VII 949
224 Itemized Ccst Summary for Subcategory A 11
AH. VIII . 951
»
225 Itemized Cost Summary for Subcategory A 12
AH. II 954
226 Itemized Cost Summary For Sjbcategory A 12
AH. Ill 955
227 Itemized Cost Summary for Subcateoory A 12
Alt. IV " 956
228 Itemized Cost Summary For Subcategory A 12
AH. V . 958
229 Itemized Cost Sun;uary for Subcategory A 12
AH. VI 960
230 Itemized Cost Summary for Subcatenory A 12
AH. VII ' 961
231 Itemized Cost Sumnary for Subcatenory A 12
AH. VIII 963
LVl
-------
DRAFT
NUMBER.
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
TABLES
(CONTINUED)
Itemized Cost Summary for SubcategoryA 13
AH. II
Itemized Cost Summary for SubcategoryA 13
AH. Ill
Itemized Cost Summary for SubcategoryA 13
AH. IV
Itemized Coot Sunjnary for Subcatecjory A 13
AH.V
Itemized Cost Summary for Subcategory A 13
Alt. VI
Itemized Cost Summary for Subcategory A 14
AH- II
Itemized Cost Summary for SubcategoryA 14
AH. Ill
Itemized Cost Surmary for Succateoory A 14
AH. IV
Itemized Cost Summary for Subcategcry A 14
AH.V
Item'. ?rd Cost Summary for SubcategoryA 14
AH. VI
Itemized Cost Summary For Subcategory A 14
-•AH. VII
Itemized Cost Summary for Subcategory A 15
AH. I
Itemized Cost S unwary For Subcategory A 15
AH. II
Itemized Cost Sunmnry for Subcategory A 16
AH. II
Itemized Cost Summary for Subcategory A 16
AH. HI
Itemized Cost Swnnary for Subcategory A ^
AH. IV
PAGE
966
967
969
971
972
. 975
977
978
980
982
983
986
987
989
991
992
LVI!
-------
DRAFT
NUMBER
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
TABLCS
(COIIT1MUCO)
Itemized Cost Summary for SubcatcgoryA 16
Alt. v
Itemized Cost Surranary for Subcategory A 16
Alt. VI
Itemized Cost Summary for Suucategory A 16
Alt. VII
Itemized Cost Summary for Subcategcry A 16
Alt. VIII
Itemized Cost Summary for Subcategory A 16
Alt. IX
Itemized Cost Summary for Subcategory A 16
AH- X
Itemized Cost Summary for Subcategory A 16
.AH. XI
Itemized Cost Sun.:ary for Subcategory A 16
Alt. XII
Itemized Cost Summary for Subcategory A 16
Alt. XIII
Itemized Cost Summary for Subcateqory A 17
Alt. II
Itemized Cost Summary For Subcategory A 17
Alt. Ill
Itemized Cost Summary for Subcatenory A 17
Alt. IV
<
Itemized Cost Suraiary For Subcateqory A 17
AH. V
Itemized Cost Sunanary for Subcategory A 17
Itemized Cost Sunimary for Subcatugory A 17
Itnrizccl Cost Suiunary for Subcategory A 17
Alt. VIII -
PAGE
994
995
997
999
1001
1002
1004
1006
1007
1010
1011
1012
1015
1016
1017
1020
LVIU
-------
DRAFT
NUMBER
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
TAULES
(COIITI'IUCO)
Itemized Cost Summary for Subcatcgory A 17
AH. IX
Itemized Cost Sunmary for Subcatcgory A 17
AH.X
Itemized Cost Summary for SubcategoryA 18
Alt. II
Itemized Cost Sumnary for SubcategoryA 18
Alt. HI
Itemized Cost Summary for SubcategoryA 18
Alt. IV
Itemized Cost Suiunary for SubcategoryA 18
Alt.V
Itemized Cost Summary for SubcategoryA 18
.AH. VI
Itemized Cost Surrrnary for Sutcategory A 18
AH. VII
Itemized Cost Sonsiiary for Subcategcry A 18
AH. VIII
Itemized Cost Summary for SubcategoryA 18
AH. IX
Itemized Cost Summary For Subcategory A 18
AH. X
Itemized Cost Su:iur,ary for Subcategory A 18
AH. XI
Itemized Cost Summary for Subcategory A 18
AH. XII
Itemized Cost Sunr.iary for Subcatogory A 18
AH. XIII
Itemized Cost Summary for Subcatcgory A 19
AH. II
Itemized Cost Sunsiury for Subcatcgory A 19
Alt. Ill
PAGE
1021
1022
1026.
1027
102B
1031
1032
1033
1036
103V
1038
1041
1042
1043
1046
1047
LIX
-------
DRAFT
c
NUMICR
280
281
282
283
284
285
286
287
288
269
290
291
292
293
294
295
TACLCS
(COIITUIUCD)
Itemized Cost Summary for Subcategory A 19
Alt. IV
Itemized Cost Surmary for Subcategory A 19
Alt.V
Itemized Cost Summary for Subcategory A 19
Alt. VI
Itemized Cost Sumnary for Subcatc-gory A 19
AH. VII
Itemized Cost Summary for Subcategory A 20
AH. H
Itemized Cost Suraiary for Subcategory A 20
AH. HI
Itemized Cost Suinmary for Subcategory A 20
.Alt. IV
Itemized Cost Surma ry for Subcategory A 20
Alt. V
Itemized Cost Snriwiary for Subcategory A 20
Alt. VI
Itemized Cost Sun-nary for Subcategory A 20
Alt. VII
Itemized Cost Summary For Subcategory A 20
AH. VIII
Itemized Cost Suir.mary for Subcategory A 20
Alt. IX
Itemized Cost Sunsmary For Subcategory A 20
AH. X
Itemized Cost Sunmory for Subcategory A 21
AH. II
Itemized Cost Sdiiiiiury for Subcategory A 22-A
Alt. II
Itemized Cost Suiuuary for Subcatogory A 22-A
Alt. Ill
PAGE
1050
1051
1054
1055
1058
1059
1061
1063
1064
1066
1068
1069
1071
1074
1075
1077
-------
DRAFT
NUMBER
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
TABLf.S
(CONTINUED)
Itemized Cost Sum-nary for Subcategory A 22-A
AH. IV
Itemized Cost Suoary for Subcategory A 22-A
AH. V
Itemized Cost Summary for Subcategory A 22-A
AH. VI
Itemized Cost Surcnary for Subcotegory A 22-A
AH. VII
Itemized Cost Summary for Subcategory A 22-A
AH. VIII
Itemized Cost Summary for Subcategory A 22-A
AH. IX
Itemized Cost Summary for Subcategory A 22-B
AH. II
Itemized Cost Sugary for Subcategory A 22-B
AH. Ill
Itemized Cost Summary for Subcategory A 22-B
AH. IV
Itemi/cd Cost Summary for Subcategory A 22-B
AH. V
Itemized Cost Sur:uary For Subcategory A 22-B
AH. VI
Itemized Cost Summary 'for Subcategory A 22-B
AH. VII
Henri zod Ccst Summary For Subcategory A 22-8
AH. VIII
Itemixod Cost Summary for Subcategory A 22-B
AH. Iy
Henri zed Cost Sun;:nar/ for Subcatogory A 2'J
AH. II
Itemized Cost Suoary for Subcategory A 23
AH. HI
PAGE
1079
1080
1083
1084
1087
1088
1091
1092
10*4
1096
1098
1100
1102
1103
1106
1107
LXI
-------
DRAFT
TACLCS
(COIITI'IUCD)
PAGE
312 Itemized Cost Summary for Subcatcgory A 23
AH. IV . 1110
313 Itemized Cost Summary for Subcategory A 24
AH. II 1113
314 Itemized Cost Summary for Subcategory A 23
AH. Ill 1114 ,
315 Itemized Cost Summary for Subcategory A 24
AH. IV 1116
316 Itemized Cost SunTiiary for Subcategory A 24
Alt. V 1118
317 Itemized Cost Summary for Subcategory A 24
AH. VI 1120
318 Itemized Cost Summary for Subcategory A 24
.AH. VII 1121
319 Itemized Cost Su-^ary for Subcategory A 24
AH. VIII 1124
320 Itemized Cost Summary for Subcategory A 24
AH. IX 1125
321 Itemized Cost Summary for Subc.itegory A 25-A
AH. II 1T28
322 Itemized Cost Summary For Subcatccjory A 25-A
AH. Ill 1129
323 Itemized Cost Summary for Subcategory A 25-B
AH. II 1131
324 Itemized Cost Summary For Subcatcgory A 25-B
AH. II . 113?
325 Itemized Cost Summary for Subcatcgory A 26
AH. II 1134
326 Itemized Cost Summary for Subcatcgory A 26
AH. Ill 1135
327 Itc.nizcd Cost Suiwnary for Subcatcgory A 26
AH. IV 1137
LXI!
-------
DRAFT
HUI10CR
328
329
330
. 331
332
3'<3
334
335
336
337
338
339
340
341
342
343
TABLCS
(COIITl/ll'CD)
Itemized Cost Summary for Subcotogory A 26
Alt. V
Hemmed Cost Sugary for Subcategorv A 26
Alt. VI
Itemized Cost Sur.irrary for Subcntegory A 26
AH. VII
Itemized Cost Sundry for Subcategory A 27
AH. II
Itemized Cost Sunnary for Subcategory A 27
AH. HI
Itemized Cost Suirjrciry for Subcategory A 27
Alt. IV
Ite-nizcd Cost Su:nmary for Subcategory A 27
AH. V
Itemized Cost Sugary for Subcategory A 27
AH. VI
Itemized Cost Summary for Subcategory A 27
AH. VII
Itemized Cost Summary for Subcategory A 28
AH. :
Itemized Cost Surcuary For Subcategory A 28
AH. II
Itemized Cost Summary for Subcategory A 28
AH. Ill
Itemized Cosi Suraiary For SubcatCQOry A 28
AH. IV
Itemized Cost Summary for Subcategory A 28
AH. V
Itemized Cost Sugary for Subc-itcgory A 28
AH. VI
Itemized Cost Sun:itary for Subcategory A 28
AH. VII
PACE
1139
1141
1142
1145
1146
1149
1150
1152
1154
1156
1158
1159
1160
1162
1163
1164
LXIII
-------
DRAFT
NWIBCR
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
TABLCS
(COIITinULD)
Itemized Cost Surf-nary for Subcategcry A 28
Alt. VIII
Itemized Cost Sunwary for Subcategory A 28
AH. IX
Itemized Cost Sun;;r,ary for Subcategory A 28
Alt. X
Itemized Cost Sugary for Subcategory A £8
Alt. XI
Itemized Cost S arnia ry for Subcategory A ?8
Alt. XII
Itemized Cost Sugary for Subcategory A 28
Alt. XIII
Itemized Cost Summary for Subcategory A 30
Alt. II
Itemi.-r.d Cost Surra ry for Sutcategory A 30
Alt. Ill
Itemized Cost Surrjy.ary for Subcoteijory A 30
Alt. IV
Itemized Cost Sumnary for Subcategory A 30
Alt. V
Honn.Ted Cost Surrnory For S^lcategory A 30
Alt. VI
Itemized Cost Sugary for Subcategory A 30
AH. VII
Itemized Cost Su^.vary Per S-jLcategory A 30
AH. VIII
Itemized Cost Sur.jiury for Subcategory C 8
AH. II
Heniirt-'ci Cost Sur,:;iury for Subcategory C 8
AH. Ill
Itemized Cost Suiunary for Subcategory C 8
AH. IV
PAGE
',155
1167
1169
1171
1174
1176
1178
1179
1180
1182
T84
1 186
1189
1190
1192
1194
LXIV
-------
DRAFT
Nunro
360
361
362
363
364
365
366
3G7
368
369
370
371
372
373
374
375
TAHLLj
(CONTINUED)
Itemized Cost Summary for Subcatcgory C 8
Alt. V
Itemized Cost Surnrary for Subcategory C 9
Alt. II
Itemized Cost Summary for Subcategory C 9
Alt. Ill
Itemized Cost Suoary for Subcategory C 10
Alt. II
Itemized Cost Su.mary for Subcategory C 10
AH. Ill
Itemized Cost Surr-arv for Subcategory C 10
Alt. IV
Itemized Cost Su-mary for Subcategory C 1
Alt. II
Itemized Cost Su— ary far Subcategory C 1
Alt. Ill
Itemized Cost Sugary for Subcategory C 1
Alt. IV
Itemized Cost Summary for Subcategory C 2
Alt. II
Itemized Cost Surma ry For Subcategory C 2
Alt. HI
Itemized Cost Summary for .Subcategory C 2
Alt. IV
Itemized Cost S'j.r.-nary Tor Subcategory - 2
Alt. V
Itemized Cost Surrr.tfry for Subcategory C 2
Alt. VI
Itemized Cost Sui;;;;iary for Subcategory C 2
Alt. VII
Itemized Cost Suoarv for Subcategory C 2
Alt. VII!
PAGE
1195
1198
1199
1202
1204
1205
1208
1209
1210
1213
1215
1216
1217
1220
1222
.1223
LXV
-------
DRAFT
TAIiLTS
(COiJTlli'JIID)
PAGE
376 Hcmizcd Cost Su.-mary for Subcatcgory C 3
AH- II 1226
377 Itemized Cost Sugary for Subcatecjory C 3
AH. Ill 1228
378 Itemized Cost Summary for Subcategory C 3
AH. IV 1230
379 Itemized Cost Surtr.ary for Subcatogory C 7
AH. II 1232
380 Itemized Cost Su.7T.ary for Subcategory C 7
AH. Ill 1233
381 Itemized Cost Surr.T.ary for Subcategory C 7
AH. IV 1234
382 Itemized Cost Sugary for Subcategory C 7
AH. V 1237
383 Itemized Cost Sun-ary for Subcategory C 7
AH. VI 1238
384 Itemized Cost St;--,-.ary for Subcategory D 1
AH. II 1241
385 Itemized Cost Su--.rr.ary for Subcategory D 1
AH. Ill ' 1242
386 Itc.-.n'zed Cost Sur.rrary For Subcategory D 1
AH. IV 1244
387 Itemized Cost Su::::r,ory for Subcatenory & 1
Alt. V ' 1Z45
388 Itemized Cost Su.r.-iiary For Succategory D 1
AH. VI . 12*7
389 Itemized Cost Sunrciry for Subcatcgory D 2
AH. II 1250
390 Itc:ni:ed Cost Suraary for Subcatcgory D 2
AH. Ill 1251
391 Itemized Cost Sui.::iary for Subcatcgory D 2
AH. IV 1253
LXVI
-------
DRAFT
TAP,LI:S
(COHTJIiULD)
NUMBER PAGC
392 Itemized Cost Suinnary for Subcatccory D 2
Alt. V . 1254
393 Itemized Cost Su^rary for Subcategory D 2
AH. VI 1256
394 Itemized Cost Sun;.T.ary for Subcateqory D 2
AH. VII 1259.
395 Itemized Cost Suoiary for Subcateyory D 3
AH. II 1261
396 Itemized Cost Surmiary for Subcategory D 3
AH. HI 1263
397 Itemized Cost Surr.Tary for Subcategory D 3
398 Itemized Cost Summary for Subcategory D 3
AH. V 1265
399 Itemized Cost Summary for Subcategory 0 3
AH. VI 1268
400 Itemized Cost Sur.-sary for Subcategory 0 3
AH. VII 1270
401 Itemized Cost Summary for Subcategory D 5
AH. II . . 1273
402 Itemized Cost Sunniary For Subcategory D 5
. AH. Ill 1274
403 Itemized Cost Summary for Subcategory D 5
AH. .V 1275
404 Itemized Cost Sur.vnary For Sjbcategory 0 5
AH. V , 1277
405 Itemized Cost Su.rjiiary fcr Subcategory D 5
AH. VI 127".
406 Itemized Cost Summary for Subcategory D 5
AH. VII 1279
407 Itemized Cost bui.jnary for Subcategory D 5
AH. VIII 1282
LXVII
-------
DRAFT
TAI!Li:5
(COIITIIIUCD)
MJI1BCR • PAGE
408 Itemized Cost Sucnary for Subcatcnory D 6
Alt. II " 1284
409 Itemized Cost Smirrary for Subcateyory 0 6
Alt.. HI 1205
410 Itemized Cost Summary for Subcategory D 6
Alt. IV 1286
411 Itemized Cost Surma ry for Subcategory D 6
Alt. V 1288
412 Itemized Cost Summary for Subcategory D 6
Alt. VI 1289-
413 Itemized Cost Surr.r.ary for Subcategory D 6
Alt. VII 1290
414 Itemized Cost Summary for Subcategory D 6
Alt. VIII 1293
415 Itemized Cost Sugary for Subcategory B 5
Alt. II 1296
416 Itemized Cost S'«r.7ary for Subcategory B 5
Alt. Ill . 1298
417 Itemized Cost Summary for Subcategory B 5
Alt. IV 1299
413 Itemized Cost Sumary For Subcategory B 6
AH. II 1302
419 Itemize'} Cost Strawry for Subcategory B 6
Alt. HI " 1303
420 Itemized Cost S'.r.v.ary For Subcategorv B 6
Alt. IV " 1304
421 Itemized Cost Sur.'wry for Subcatogory 6 6
Alt. V 1306
422 Itemized Cost Suraary for Subcategory B 7
AH. II 1309
423 Itemized Cost Sua:iwry for Subcategory B 7
AH. Ill 1310
LXVIIl
-------
DRAFT
NUMBER
424
425
426
427
428
429
430
431
432
433
434
43f.
436
437
438
439
TAIJI.I:S
(COIITIIIULD)
Itemized Cost Surrr-.ary for Sulcatogory B 7
AH. IV
Itemized Cost Si/nary for Subcoteijory B 8
AH, II
Itemized Cost Summary for Subcategory B 8
AH. Ill
Itemized Cost Surmary for Subcategory B 8
Alt. IV
Itemized Cost Surmiarv for Subcategory A 29
AH. II
Itemized Cost Surr-.ary for Subcategory b 29
AH. Ill
Itemi;3d Cost Sunvnary for Subcategory 4 29
AH. IV
Itemized Cost Surr.-.ary for Subcategory A 29
Alt. V
Itemized Cost Su.T.vary for Subcategory A 29
AH. VI
Itemized Cost Summary for Subcategory A 29
AH. VII
Itemized Cost Surmary For Subcategory A 29
AH. VIII
Itemized -Cost Su;:.::;nry for Suboatsgcry A 29
AH. IX
Itemized Cost S'j.'i'jr-ary Fcr Subcategory A 29
AH. X *
Itemized Cost Su,vr?.ry for Subcategory A 29
AH. XI
Itemized Cost Sur,::,:>iry for Subcategory A 31
AH. I
Itemized Cost Suii::wry for Subcategory A 31
AH. II
PAGE
1311
1314
1315
1317
13iy-
1321
1322
1323
1325
1326
1327
1329
1331
1333
1336
1337
LXIX
-------
DRAFT
TAHLL'S
(coinii;yr.u)
i;ui:i!i:n HM.
440 Itemized Cost Surcr.ary for Subcategory A 31
Alt. Ill 1339
441 Itemized Cost Sunrary for Subcateyory A 31
AH. IV 134°
442 Itemized Cost Sur.ir.iary for Subcategory A 31
AH. V 1341
443 Itemized Cost Suraiary for Subcategory A 31
AH. VI 1344
444 Itemized Cost Summary for Subcategory A 31
AH. VII I346"
445 Itemized Cost Surr.T.ary for Subcategory A 32
AH. I 1349
446 Itemized Cost Su~.i-.arv for Subcutegory A 32
AH. II 1350
447 Itemized Cost Surnrcary for Subcategory A 32
AH. Ill "352
448 Itemized Cost Surr.-,;ary for Subcategory A 32
AH. IV . 1353
449 Itemized Cost Sur,-.:rary for Subcategory A 32
AH. V 1355
450 Itemized Cost Sur.mary For Subcategory A 33
AH. II I358
451 Itemized Cost Su;-:r,ary for SubcateQcry A 33
AH. HI ' I360
452 Itemized Cost SL.7iT.3ry For Subcategory A 33
AH. IV . 1361
453 Itemized Cost Su:rn:.iry for Subcategory A 33
AH. V 1363
454 Itc:'iizi!d Cost Su.ir.urv for Subcategory A 33
AH. VI " 1365
455 Itemized Cost Simr.iary for Subcategory A33
AH. VII 1366
LXX
-------
DRAFT
IIUIIK cn
456
457
456
459
460
461
462
463
464
465
466
467"
468
469
470
471
TAI!LLS
(cuminuco)
Itemized Cost Sui.-nory for Subcatcgory A 33
AH. VII! . .
Itemized Cost Sugary for Subcatecjory A 33
AH. IX
Itemized Cost Summary for Subcatogory A 33
AH. X
itemized Cost Surmary for Subcat^gory A 33
AH. XI
Itemized Cost Summary for Subcatcgory A 33
AH. XII
Itemized Cost Suirvr.ary for Subcategory A 33
Alt. XIII
Itemized Cost. Summary for Subcategory A 33
Alt. XIV
Itemized Cost Sugary for Subcategory A 33
AH. XV
Itemized Cost Sn~T,ary for Subcategory A 33
AH. XVI
Itemized Cost Summary for Subcategory A 33
AH. XVII
Itemized Cost Sundry For Subc.itegory A 33
Alt. XVIII
Itemized Cost Su^ir.ary for Subcategory A 33
AH. XIX
Itemized Cost S-jr.n'.ary For Subcategory A 33
AH. XX
Iteinirod Cost Sundry for Subcatcqory A 34
AH. II
Ite:iiizcd Cost Sur.T.ary for Subcategory A 34
AH. Ill
Itemized Cost Suir.nary for Subcateqorv A 35
AH. II
PAGE
1368
1370
1371
1373
1375
1377
1378
1380
1381
1383
1385
1386
1388
1390
1391
1393
LXXI
-------
DRAFT
TARLL3
(COIITJIiULO)
KUMI1CR ' PAGE
472 Itemized Cost Sucrary for Subcatcgory A 35
AH. Ill 1395
473 Itemized Cost Su.rrary for Subcategory A 36
Alt. II 1396
474 Itemized Cost Suiuary for Subcitogory A 36
Alt. HI 1398
475 Itemized Cost Surrrary for Subcategory A 36
Alt. IV 1399
476 Itemized Cost £urr.7.ary for Subcategory A 35
Alt. V 1400-
477 Itemized Cost Sunvr.ary for Subcategory A 36
Alt. VI 1402
473 Itemized Cost Surrary for Subcategory A 36
AH. VII 1403
479 Itenizcd Cost Surrrr.ary for Sutcategory A 36
AH. VIII 1405
480 Itemized Cost Surr."ary for Subcategory A 36
Alt. IX 1408
481 Itemized Cost Summary for Subcategory A 36
Alt. X 1410
482 Itemized Cost Surra ry For Subcategory B 1
AH. II 1413
483 Itemized Cost Su;r;:;;ary for Subcatcqory B 1
AH. Ill 1414
484 Itemized Cost Sugary For Subcateccry B 1
Alt. IV * ' 1415
485 Itemized Cost Su.rjiiary for Suijcntcr'ory B 2
AH. II " 1418
486 Hcmizcd Cost Suii:::ary for Subcatucorv B 2
AH. Ill * 1420
487 Itemized Cost Sundry for Subcategory B 2
Alt. IV 1421
LXXIJ
-------
DRAFT
TARUS
(COIIT1IJUCD)
NUMtiCR
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
I tcmi zed
AH. II
Itemized
AH. Ill
Itemized
AH. IV
Itemized
AH. II
Itemized
AH. HI
Itemized
AH. II
Itemized
. AH. "I
Itemized
AH. II
Item' zed
AH. Ill
Itemized
AH. IV
Itemized
AH. V
Itemized
Alt. II
Itemized
AH. HI
Itemized
AH. IV
Itemized
AH. V
Itemized
AH. II
Cost
Cost
Cost
Cost
Cose
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Summary
Suwary
Summary
Sunmnry
Summary
Surgery
Summary
Su.7rr;ary
*=•"'
Summary
Surr.ary
*r»ry
Suraiary
Sundry
Sunr.'ory
5u:i:;iary
for
for
for
for
for
for
for
for
for
for
For
for
Fcr
for
for
for
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcategory
Subcatcnory
Sulxalegory
Subcategory
B
B
B
B
B
B
B
C
C
C
C
C
C
C
C
C
3
3
3
4
4
9
9
4
4
4
4
5
5
5
5
12
PAGC
1424
1425
1426
1429
•
1431
1433
1435
1437
1439
1441
1442
1445
1446
1449
1450
1453
LXXIII
-------
DRAFT
TAHLL'5 -
(COHil/JUCO)
NUMBER PAGE
504 Itemized Cost Surnnory for Subcatcgory D 4
AH. II . 1454
505 Itemized Cost Suinrary for SuLcategory 0 4
Alt. HI 1456
506 Itemized Cost Summary for Subcatccjory D 4
AH. IV 1457.
507 Itemized Cost. Suoary for Subcategory D 4
Alt. V 1458
508 Itemized Cost Suraiary for Subcategory D 4
Alt. VI 1460-
509 Itemized Cost Sunvnary for Subcategory D 4
Alt. VII , 1462
510 Yearly Electrical Use and Cost Associated
Uith Alternative Treatment designs 1465
511 Recommended Effluent Limitations Guidelines (BPCTCA)
For Vegetable Oil .Voces sing and Refining 1477
512 Recormended Effluent L.iKations Guidelines {BPCTCA)
For Beverages 1478
513 Recommended Effluent Limitations Guidelines (BPCTCA)
Fo.1 Bakery and Confectionery Products 1479
514 Recommended Effluent Limitations Guidelines (BPCTCA;
For Pet Foods ' 1480
515 keconmended Effluent Limitations Guidelines (BPCTCA)
For Miscellaneous and Specialty Products 1481
516 Summary of Investment and Yearly Costs For Treatment
Alternatives (BPCTCA) 1485
517 Recommended Effluent Linn'cations Guidelines (BATEA)
For Vegetable Oil Processing and Refining 1491
518 Recommended Effluent Limitations Guidelines (BATEA)
For Beverages 1492
519 Rer.ommended Effluent Linitations Guidelines (BATEA)
For Bakery and Confectionery Products • 1494
LXXIV
-------
DRAFT
TABLE OF CONTENTS
(CONTINUED)
SECTION PAGE
520 Recommended Effluent Limitations Guidelines (BATEA)
For Pet Food 1495
521 Recormended Effluent Limitations Guidelines (DATEA)
For Miscellaneous and Specialty Products 1496
.522 Summary of Investment and Yearly Costs for Treatment
Alternatives (BATEA) - 1498
uxxv
-------
DRAFT
SECTION I
CONCLUSIONS
For the purpose of developing recommended Effluent Limitations Guide-
lines, this study subcategorlzes the Industry as follows:
VEGETABLE OIL PROCESSING AND REFINING
Al Establishments primarily engaged 1n the production of
unrefined vegetable oils and by-product cake and meal
from soybeans, cottonseed, flaxseed, peanuts, saf flower
seed, sesame seed, sunflower seed by mechanical screw
press operations.
A2 Establishments primarily engaged in the production of
unrefined vegetable oils and by-product cake and meal
from soybeans, cottonseed, flaxseed, peanuts, saff lower
seed, sesame seed, sunflower seed by direct solvent
extraction or prepress solvent extraction techniques.
A3 Establishments primarily engaged 1n the production of
olive oil and by-product cake or meal from raw olives
by hydraulic press and solvent extraction methods.
A4 Establishments primarily engaged 1n the production of
olive oil and by-product cake or meal from raw olives
by mechanical screw press methods.
AS Establishments primarily engaged in the processing of
edible oils by the use of caustic refining methods
only.
A6 Establishments primarily engaged in the processing of
edible oils by the use of caustic refining and acidu-
latlon refining methods.
A7 Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, acidulation, bleaching, deodorization,
winterizing, and hydrogenation.
A8 Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, bleaching, deodorization, winterizing,
and hydroqenation.
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
TJWfoTION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
1
-------
DRAFT
A3 Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, acidulation, bleaching, deodorization,
and the production of shortening and table oils.
A10 Establishments primarily engaged In the processing
of edible oils utilizing the following refinery
methods: caustic refining, bleaching, deodorization.
winterizing, hydrogenation, and the plastidzlng and
packaging of shortening and table oils.
All Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, acidulation, bleaching, deodorization,
winterizing, hydrogenation, and the plastlcizing and
packaging of shortening, table oils, and margarine.
A12 Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, bleaching, deodorization, winterizing,
hydrogenation, and the plasticizing and packaging of
shortening, table oils, and margarine.
A13 Establishments primarily engaged in the processing of
edible oils Into margarine.
A14 Establishments primarily engaged In the processing of
edible oils into shortening and table oils.
A15 Establishments primarily engaged in the refining of
olive oil.
BEVERAGES
A16 Production cf malt beverages by breweries constructed
since January 1, 1950,and with a production capacity
1n excess of 800 cubic meters per day. In addition,
this subcategory includes plant 82A16.
A17 Production of malt beverages by breweries constructed
before January 1, 1900,and with a production capacity
In excess of 2000 cubic meters per day.
A18 Production of malt beverages by breweries not Included
in subcategoMes A16 and A17.
A19 Installations primarily engaged in the production of
malt and malt by-products.
A20 Wineries primarily engaged in the production of wine,
brandy, or brandy spirits, and not operating stills.
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
2
-------
DRAFT
A21 Wineries primarily engaged in the production of wine,
brandy, or brandy spirits, and operating stills.
A22 Distilleries primarily engaged in the production of
beverage alcohol from grains and operating stillage
recovery systems.
A23 Distilleries primarily engaged in the production of
beverage alcohol from grains and not operating still age
recovery systems.
A24 Distilleries primarily engaged in the production of
beverage alcohol by distillation of molasses.
A25 Installations primarily engaged In the blending and
bottling of purchased Mines of spirits.
A26 Installations primarily engaged in the production of
soft drinks; and which package exclusively in cans.
A27 Installations primarily engaged in the production of
soft drinks; and which are not included in Subcategory A26.
A28 Installations primarily engaged in the production of
beverage base syrups, all types
A30 Installations primarily engaged, in the production of
Instant tea.
C8 Installations primarily engaged in the production of
roasted coffee.
C9 Installations primarily engaged in the decaffeination
of coffee.
CIO Installations primarily engaged in the production of
soluble coffee.
Fl Installations primarily engaged in the blending of tea.
BAKERY AND CONFECTIONERY PRODUCTS
Cl Production of cakes, pies, doughnuts, or sweet yeast
goods, separately or in any combination, by facilities
using pan washing.
C2 Production of cakes, pies, doughnuts, or sweet yeast
goods separately or in any combination by facilities
not using pan washing.
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
ITOTfaTION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
C3 Installations primarily engaged 1n the production of
bread related products
C7 Installations primarily engaged In the production of
cookies or crackers separately or In any combination.
C13 Installations primarily engaged In the production of
bread and buns In any combination.
C14 Installations primarily engaged 1n the production of
bread and snack Items, in any combination.
01 Installations primarily engaged 1n the production of
candy or confectionery products separately or In any
combination, except glazed fruits.
D2 Installations primarily engaged 1n the production of
chewing gum.
03 Installations primarily engaged 1n the production of
chewing gum base.
D5 Installations primarily engaged in the production of
milk chocolate with condensory processing.
06 Installations primarily engaged 1n the proauction of
milk chocolate without condensory processing.
PET FOODS
B5 Installations primarily engaged in the production of
canned pet food, lew meat.
B6 Installations primarily engaged in the production of
canned pet food, high meat.
B7 Installations primarily engaged In the production of
pet food, dry.
88 Installations primarily engaged 1n the production of
pet food, soft moist.
MISCELLANEOUS AND SPECIALTY PRODUCTS
A29 Installations primarily engaged in the production of
flavorings, or extracts, separately or In any combination.
A31 Installations primarily engaged in the production of
bouillon products.
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
A32 Installations primarily engaged In the production of
non-dairy creamer.
A33 Installations primarily engaged In the production of
yeast and by-product molasses. If recovered.
A34 The production of peanut butter by facilities using
jar washing.
A35 The production of peanut butter by facilities not
using jar washing.
A36 Installations primarily engaged in the production of
pectin and peel by-products, if recovered.
A37 Installations primarily engaged 1n the production of
almond paste.
61 Installations primarily engaged in the production of
frozen prepared dinners.
B2 Installations primarily engaged in the production of
frozen breaded or battered specialty items, separately
or in any combination.
B3 Installations primarily engaged in the production of
frozen bakery products.
B4 Installations primarily engaged in the production of
tomato-cheese-starch products.
B9 Installations primarily engaged in the production of
chill pepper and paparika, in combination.
C4 Installations primarily engaged in the processing of
eggs.
C5 Installations primarily engaged in the production of
shell eggs.
C6 Installations primarily engaged in the production of
manufactured ice.
C12 Installations primarily engaged in the production of
prepared sandwiches.
Dfi| Installations primarily engaged 1n the production of
vinegar.
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL-REVIEW BY EPA.
-------
TABLE 1A
RECOMMENDED EFFLUENT LIMITATIONS
GUIDELINES
§
BOO
SIACATEGOXV
BPCTCA
Al BATEA
NSPi
BPCTCA
A7 BATEA
NSPS
BPCTCA
A3 BATEA
HSPS
BPCTCA-
A4 BfKEA
NSPS
AS BATEA
NSPS
BPCTCA
A6 BATEA
NSPS
BPCTCA
A7 BATEA
NSPS
8PCTCA
AS B..TCA
NSPS
BPCTCA
A9 BATEA
HSPS
A10 BATEA
NSPS
ss
0
Max. Flax. Max.
30-Day Max. 30-Oay Mix. 30-Day
A»e. Pay Aye. Pay Aye.
(VEGETABLE OIL PROCESSING AMD REFINING)
„ 0.0072 0.018 0.0090 0.023 0.0054
0.0036 0.090 0.0045 0.011 0 0027 •
0.0072 0.018 0.0090 0.023 0.0054
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
r.o
0 035
0.021
0.035
0.067
0.035
0.067
'- h.lJ
0.076
".13
D. 10
0.051
0. It)
0.13
0.073
0.13
3.097
0.048
0.097
0.0
0.0
0.0
o.n
0.0
0.0
0.0
0.0
0.0
0.087
0.052
0.087
O.I/
0.087
0.17
6.32
0.19
O.J2
0.26
0.137
0.26
0.33
0-18
0.33
0.24
0.12
0.24
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.03S
0.017
0.035
0.061
0.030
0.061
~ 0.13 ""
0.063
0.13
0.10
0.051
0.10
0.13
0.073
0.13
0.11
0 056
0.11
0.0
0.0
0.0
0.0
0.0
0.0
O.o
0.0
0.0
0.087
0.043
0.087
0.15
0.075
0.15
"5: 32 '
0.16
0.32
0.26
0.137
0.26
0.33
0.18
0.33
0.27
0.14
0.27
0.0
0.0
0.0 .
0.0
0.0
0.0
0.0
0.0
0.0
0.014
0.0070
0.014
0.021
0.012
0.023
0.051""
0.025
0.051
0.041
0.020
0.058
0.029
P.OSfl ,
0.048
0.024
0.048
ft A
Max.
0.014
0.0070
0.014
0.0
0.0
0.0
0.0
0.0
0.0
o.c
0.0
0.0
0.035
0.017
0.035
0.057
0.030
0.057
0.13
0.062
P-13.,
0.10
0.050
0.10
0.14
0.073
0.12
n.060
0.12
BOD
SUBCATEGORV
BPCTCA
All BATEA
NSPS
6PCTU
A12 BATEA
NSPS
BPCfCA
AD BATEA
NSPS
BPCTCA
A14 BATEA
K;PS
BPCTCA"
A1S BATEA
NSPS
BPCTCA
A16 BATEA
HSPS
6PCTCJI
A17 BATEA
NSPS
flPcTCA
A18 BATEA
NSPS
A19 BATEA
NSPS
Max.
. 30-Oay
Aye.
0.16
0.076
0.16
b.12"
0.060
0.12
0.060
0.030
0.060
0.015
0.0080
0.015
0.0
0.0
0.0
0.28
0.14
0.070
0.55
0.27
NA
0.48
0.24
NA
0.22
0.11
0.11
Max.
PIT.
0.39
0.19
0.39
0.30
0.15
0.30
0.15
0.075
O.IS
0.037
0.020
0.037
0.0
0.0
0.0
0.70
0.35
0.17
1.37
0.67
MA
1.20
0.60
NA
0.55
0.27
0.27
SS
Max.
30-Day
Av«.
0.17
0.087
0.17
0.14
0.072
0.14
0.075
0.037
0.075
0.01S
0.0080
0.01S
Max.
Oar
0.44
0.22
0.44
0.36
0.18
0.36
0.19
0.092
0.19
0.037
0.02
0.037
0.0 0.0
0.0 0.0
0.0 0.0
(BEVERAGES)
0.39 0.97
0.19 0.48
0.097 0.24
o.H
0.38
HA
0.68
0.34
NA
0.13
0.065
0.055
1.90
0.95
M
VW
o.w
HA
0.32
0.16
0.16
DIG
Max.
30-Day Max.
Ave. Day
0.069 0.17
0.03$ 0.087
O.CS9 0.17
0.060 0.1$
0.030 0.07$
0.060 0.15
0.075 0.19
0.037 0.092
0.075 0.19
0.0080 0.024
0.0040 0.012
0.0010 0 024
0.0 0.0
0.0 0.0
0.0 0.0
-
-
-
-------
TABLE 1A (CONT'D)
RECOMMENDED EFFLUENT LIMITATIONS
GUIDELINES
Sz o
-n M
"
«
a —i
m o -•
i/i «-• co
Z m
m -H 3»
o i 30
m 30 m
O ni z
'
30 O 30
-» m
Z S»0
m » o
:orn 3
«— • co m
—ICO
XI O
in CD
<; r» 3>
•-• 3C l/»
m 5 rn
x: z o
o
SU8CATEGOBY
•A20 BPCTCA
BATEA
HSPS
BPCTCA
•A20 BATEA
HSPS
dPCTfA
Wl BATfA
HSPS
flKTM
A22 8ATCA
tlSPS
BPC1CA
«3 BATEA
HSPS
BPCTCA
A24 BATEA
HSPS
OPCTCA
Att OATEA
NSPS
flPCTCA
A26 BATEA
NSPS
PCTCA
A27 BATEA
NSPS
BPCTcR '
A28 BATEA
HSPS
B0(
Max.
30- Day
Ave.
0.77
0.38
0.23
0.28
0.14
0 083
0.0
0.0
0 0
0.76
0.13
0 13
0.054
0.027
0.027
1.2
0.56
O.SB
• 'o.o
0.0
0 0
o.esz
0.026
0.026
0.24
0.12
0 12
0.0050
0.0025
0.0025
)
Max.
Day.
2.30
1.10
0.69
O.B3
0.41
0 2S
0.0
0.0
0 0
0.55
0.32
0 32
0.14
0.62
0.62
3.0
1.5
1.5
0.0
0.0
0 0
0.13
0.065
0.065
0.60
0.30
0 30
0.013
0.0063
0.0063
ss
MM.
30-Day
Ave.
0.11
0.054
0.031
0.41
0.19
0 11
0.0
0.0
0 0
0.37
0.16
0 16
0.077
0.036
0.036
0.69
0.35
0.35
0.0
0.0
0 0
0.030
0.015
0.015
0.14
0.070
0 070
0.0010
0.00050
0.0005
0
Wax.
Max. 30-Day
Day Ave.
0.34
0.16
0.093
l.?0
0.58
0.33
0.0
0.0
0.0
0.80
0 40
0.40
0. 18
0.090
0.090
1.7
0.86
0.66
0.0
0.0
0.0
0.075
0.037
0.037
0.35
0.17
0 17
0.0025
0.0013
0.0013
1 G
Max.
Day. SUKATEGORY
BPCTCA
A30 BATEA
NSPS
C8 BATEA
HSPS
C9 BATEA
NSPS
CIO BATEA
NSPS
Fl BMEA
:;SPS
BPCTCA
Cl BATEA
HSPS
C2 BATEA
NSPS
- — I BPCTCA
C3 BATEA
HSPS
c; B/UEA
HSPS
BOO
MX.
30-Day
Ave.
2.00
1.0
10
SS
hai.
Nix. 30-Day
D«y_ Ave/
5.0 5.5
2.5 1.0
2.5 1.0
0.070 0.21
0.030 0.09
0.030 0.09
0.10
0.10
0.25
0.25
0.0
0.0
0.50
0.25
0.25
0.030
0.030
0.060
0.030
0.030
0.050
o.oso
o.:5
0.25
0.60
0.60
0.0
0.0
(BAKERY AND
1.3
0.6S
0.6S
0.090
0.090
0.18
0.090
0.090
0.13
0.1)
0.070
0.030
0.030
0.10
0.10
0.25
0.25
NM.
OJZ
13.0
2.5
J.S
6.2t
0.09
0.09
0.25
0.25
2.4
0.60
0.60
0 i
Hax.
30-Day
A»e.
0.040
0.020
0.020
6. 10
0.05
0.05
0.16
0.16
0.16
0.0 u.u u.u
0.0 0.0 0.0
0.0 0.0 0.0
CONFECTIONERY PRODUCTS)
0.50 1.3 0.11
0.2S 0.6S 0.04
0.25 0.65 0.04
U.O&
0.03
0.03
0.060
0.030
0.030
0.10
0.050
O.OSO
U.l»
0.09
0.09
A.tt
0.090
0.090
0.25
0.13
0.13
U. JJU
0.020
8.020
.W5
0.020
0 020
.mo
0.030
0.030
6
Max.
Day
0.12
0.06
0.06
0.25
0.13
0.13
0.40
0.40
0.40
.T
0.0
0.0
0.2ft
0.10
0.10
0.090
0.060
0 060
0.12
0.060
0 060
.13
0.080
0.080
» Crushing Season
•• Processing Season
-------
TABLE 1A (CONT'D)
RECOMMENDED EFFLUENT LIMITATIONS
GUIDELINES
i
BOO
SS
ate
BCD
016
30O
SUBCATEGORt
BPCTCA
01 BATEA
NSPS
BPCTCA
02 BATEA
NSPS
BPCTCA
03 BMEA
BPCTCA
K BATEA
NSPS
flf-CTCA ~-
06 BATEA
NSPS
BPCTCA
85 BATEA
NSPS
BPCTCA
85 BATEA
NSPS
BPCTCA
87 BATEA
NSPS
Mix.
30- Day
Ave.
0.15 .
0.075
0.075
0.12
0.030
0.080
0.085
0.030
0.030
0.37
0.075
0.075
0.23
0.045
0.045
0.18
0.09
0.09
0.51
0.76
0.26
0.0046
O.OC23
0.0023
Max.
Day
0.4S
0.22
0.22
0.36
0.24
0.24
0.74
0.090
o.rwo
1.1
0.22
0.22
0.69
0.13
0.11
(PET
0.45
0.23
0.23
1.28
0.64
0.64
0.012
0.0060
0.0060
Max.
30- Day
Ave.
0.07S
0.040
0.040
0.090
0.015
0.045
0.085
0.035
0.035
0.25
0.035
0.035
0.23
0.06
0.06
FCODS)
0.18
0.09
0.09
0.51
0.26
0.26
0.0046
0.0023
0.0023
Max.
Pay
0.22
0.12
0.12
0.27
0.13
0, IJ
0.24
0.1C
0.10
0.75
0.10
0.10
0.69
0.18
0.18
C.45
0.23
0.23
1.28
0.64
0.64
0.01?
O.OOGO
0.0060
Max.
30- Day
Ave.
.
-
.|
0.070
0.010
0.010
0.11
0.010
0.010
0.065
0.033
0.03)
0.51
0.26
0.26
0.003t
0.0016
0.0016
Day' SUBCATEGORT
BPCTCA
88 BATEA
NSPS
BPCTCA
A29 BATEA
NSPS
BPCTCA
0.21 A31 BATEA
0.03 NSPS
0.03 BPCTCA
" 6:33~ A32 BATEA
0.03 NSPS
0.03 BPCTCA"
A33 BATEA
NSPS
BPUCA
0.17 A34 BAUA
O.OhS NSPS
0.085 PC1CA
' 1.J8" A3S BAUA
0. 64 NSPS
0.64 6PCTCA
" O.WBD A36 BATCA
0.0040 NSPS
0.0040
n«.
30-Day Has.
Ave. Day
0.18 0.4S
0.090 0.2)
0.090 0.2)
(MISCELLANEOUS
0.041 0.10
0.02 O.OS
0.012 0.0)
2.34 S.B5
1.09 2.n
1.09 2.7)
0.025 0.063
0.106 0.26S
0.106 0.265
3.73 6.46
1.62 3.24
1.62 3.24
0.0 0.0
0.0 0.0
0.0 0.0
0.0 0.0
0.0 0.0
0.0 0.0
208 417
104 209
104 209
Ha*.
30- Bay
Ave.
Nil.
0*,
Ha*.
30-Riy
Ave.
0.18 0.45 0.028
0.090 0.2: 0.014
0.090 0.2) 0.014
AMD SPEC! AUT» PRODUCTS)
0.012 0.0)0
0.0062 0.016
0.0040 0.010
0.63
0.31
0.31
0.071
C.014
0.014
1.6Z
0.81
0.61
0.0
0.0
0.0 :
0.0
0.0
.o.n .
175.1
8). 4
83.4
1.58
0.76
0.78
0.18
0.035
0.035
3.24
1.62
1.62
0.0
0.0
o.n
0.0
0.0
0.0
350
167
0.63
0.31
0.31
0.043
0.014
0 014
;
0.0
0.0
00
0.0
0.0
0.0
-
Max.
Djy
0.075
0.038
0.038
1.J6
O.f2
0.6?
0.086
0.028
0.078
-
0.0
0.0
0.0
0.0
0.0
0.9
-
-------
TABLE 1A (CONT'D)
RECOMMENDED EFFLUENT LIMITATIONS
GUIDELINES
i
TO
m — ( j»
r> a: 30
m •-• m
•-• in
O ro
i» O *•
Z SO — 4
o xi
m jo O
X m 2
•-« i/> m
Z C Z
— 1 CD O
— I in
23 O
m oo
«= n j»
•-• z «/>
rr 3» m
z z o
tn
CD m «=
-< -a
CD o
BOD
SS
0 1C
SUBCATEGORT
61 BPCTCA
BA7EAV
NSPS
B2
B4
B9
C4
C5
C12
M
BPCTCA
BATEA
HSPS
BPCTCA
BATEA
NSPS
BPCTCA
BSTEA
NSPS
BPCTCA
BAT FA
NSPS
6PCTCA
BATEA
NSPS
6PCTCA '
BATEA
HSPS
BPCTCA
BATEA
NSPi
BPCTCA
BATFA
NSPS
Mil. Max.
30-Day Max. 30-Day
Ave._ Oay_ Ave.
0.78 1.95 0.78
0.39 0.93 0.39
0.39 0.98 0.39
G
0
0
1
0
0
I
1
0
0
0
1
0
0
0
0
0
0
o
0
0
0
.01
.41
.41
.54
.0 0
.0 0
.0 0.
.i 1.
.3 0.
.3 0
.4 5.9 2.
.2 3.0 1.
.2 3.0 1.
.65
.33 '
.33 (
.t 0.
3.8 0.
3.8 0.
.5 3.9 1.
.21 0.63 0.
.21 0.63 0.
.080 0 Z4 0.
.030 0.090 0.
.030 0.090 0.
.0 0.0 0.
.0 0.0 0.
.0 0.0 0.
81
41
41
T
54
54
4
2
2
64
33
33
3
21
21
080
030
030
0
0
0
.060 0.18 0.030
.040 0.12 0.020
.040 0.12 0.020
Ml*.
Pay
0^98
Z.
1.
1.
<*.
1.
1.
b.
3.
3.
1.
0.
0.
0
0
a
7
3
3
94
0
0
6
8
8
3.9
0.63
0.63
0.
0.
0.
0.
0.
0.
0.
0.
0.
24
CM
090
0
0
0
09(1
060
060
Max
30- Day
Ave.
0°.
C.
0.
0.
0.
0.
0.
0.
• 1 .
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
c.
0.
o.
-
IS
12
12
46
23
23
W~
60
BO
4j
22
J
07
07
010
010
0
0
0
Max. 30- Day Ha*.
Day SUSttTE3MY Ave. D*>
0.7} BPCTCA 0.0 0.0
0-37 £1-8 BMEA 0.0 0.0
"•37 NSPS 0.0 3.0
d -T B.'CTCA 0.0 0.0
029 FZ-4 BATEA 3.0 0.0
0.29 N^PS 0.0 0.3
I.I
0.57
0.07
i.O
2.0
1.1
0.54
C.5<
O.J4
0.
-------
DRAFT
SECTION III
INTRODUCTION
PURPOSE AND AUTHORITY
Section 301(b) of the Act requires the achievement by not later than
July 1, 1977, of effluent limitations for point sources, other than
publicly owned treatment works, which are based on the application of
the best practicable control technology currently available as defined
by the Administrator pursuant to Section 304(b) of the Act. Section 301
(b) also requires the achievement by not later than July 1, 1983, of
effluent limitations for point sources, other than oublicly owned
treatment works, which are based on the application of the best available
technology economically achievable which will result in reasonable
further progress towards the national goal of eliminating the discharge
of all pollutants, and which reflect the greatest degree of effluent
reduction which the Administrator determines to be achievable through
the application of the best available demonstrated control technology,
processes, operating methods, or other alternatives, including where
practicable a standard permitting no discharge of pollutants.
Section 304 (b) of the Act requires the Administrator to publish regula-
tions providing guidelines for effluent limitations setting fortn trie
degree of effluent reduction attainable through t!ie application of ~'ie
best practicable control technology currently available and the det,:.j,>
of effluent reduction attainable through the application of the best
control snd procedure innovations, operation methods, and ether alter-
natives. The regulations proposed herein set forth effluent limitations
guidelines pursuant to Section 204(b) of the Act for the Miscellaneous
Food and Beverages Industry. Section 306 of the Act requires the Admin-
istrator to propose regulations establishing Federal Standards of per-
formances for new sources.
SUMMARY OF METHODS USED FOR DEVELOPMENT OF THE EFFLUENT LIMITATIONS
GUIDELINES
The effluent limitations and standards of performance recommended
in this document were developed in the following manner:
1. An exhaustive review of available literature was conducted.
This included searches at the University of Florida, Oregon
State University, University of Tennessee, University of
California, University of Nebraska, and California State
University libraries; the in-house libraries of Environmental
Science and Engineering, Inc., SCS Engineers, Inc., and
Environmental Associates, Inc.; and the libraries of the
Department of the Interior and the Environmental Protection
11
-------
DRAFT
Agency in Washington. Additional literature was obtained
from the California Wine Institute, the National Association
of Chewing Gum Manufacturers, The William Wrigley. Jr.
Company, and from various individuals throughout the mis-
cellaneous foods anoi beverages Industry. Literature searches
Mere also conducted through the following Federal systems:
Compendex, Environ/Prog, SW1RS, WRSIC, MTIS/GRA, and SSIE.
A list of references 1s contained in Section XIII of this
document.
2. Telephone surveys were conducted for 839 plants, and in-
formation concerning production, wastewater characteristics,
and control and treatment technology was obtained. A copy
of the telephone survey form is contained in Appendix A.
3. Information was obtained from questionnaires submitted to
336 plants by various trade associations.
4. On-site inspections were conducted at 264 plants and de-
tailed information concerning process flows, related water
usage, water management practices, and control and treatment
technology was obtained. A copy of the visitation question-
naire form is contained in Appendix B.
5. Sampling programs were conducted at 104 plants to verify the
accumulated data. Sampling procedures were generally con-
ducted in accordance with the methods set forth in the
Handbook For Monitoring Industrial Wastewater ( i ).
6. The data base was handled and summarized on a computerized
system. A discussion of the data handling and reduction
system and a detailed explanation of the algorithms used are
presented in Appendix C.
The reviews, analyses, and evaluations were coordinated and applied to
the fo!lowing:
1. An identification of distinguishing features that could
potentially provide a basis for subcategorization of the
industry. These features included the nature of raw mater-
ials utilired, plant size and age, the nature of processes,
and others as discussed in Section IV.
2. A determination of the water usage and wastewater character-
istics for each subcategory, as discussed in Section V,
including volume of water used, sources of pollution, and
the type and quantity of constituents in the wastewater.
3. An identification of those wastewater constituents, as dis-
cussed in Section VI, which are characteristic of the industry
12
-------
ORAR
and were determined to be pollutants subject to effluent
limitations guidelines and standards of performance.
4. An Identification of the control and treatment technologies
presently employed or capable of being employed by the
Industry, as discussed 1n Section VII, Including the effluent
level attainable and associated treatment efficiency related
to each technology.
5. An evaluation of the cost associated with the application
of each control and treatment technology, as discussed in
Section VIII.
This document is the result of intensive data collection and analysis
conducted over a six month period. It 1s probably the most compre-
hensive coverage of wastewater and wastewater control and treatment
technology existing for the miscellaneous foods and beverages industry.
But it must be noted that the conclusions and recommendations presented .
herein are based on the information available to the study, and in man>
instances on information made available by industry. The amount of
information available was found to be extensive for sevaral of the sub-
. categories defined in Section IV and less extensive for others. In all
cases strong efforts were made to obtain the cooperation of and input
by Industry and other interested parties.
DEFINITION OF THE INDUSTRY
Tht; Miscellaneous Food? and Beverages Industry includes establishments
engaged In the processing of distilled, fermented beverages nonalcoholic
beverages, confectioner products, vegetable oils, and fooo preparations.
More specifically, the industry may be defined as that listed in Table 1.
Ic can be seen that the industry includes an extremely wide range of
products from bagels to beer, from chocolate candy and popcorn balls
to soybean oil. Early in the study several products were eliminated
from further consideration for various reasons. These included the
following:
1. Castor oil and pomace. It was established that castor oil
Is not manufactured as a vegetable oil or by-product cake
and meal In the United States.
2. Coconut, oiticica, palm and palm kernel oil. It was estab-
lished that these oils are not produced in the United States.
3. Tung oil and walnut oil. These oils are neither foods nor
beverages, and no processing plants could be located in the
United States.
13
-------
DRAFT
TABLE 1
MISCELLANEOUS FOODS AND BEVERAGES INDUSTRY DEFINED BY SIC CODE
SIC 2017 Egg processing
1 * Establishments primarily engaged in the drying, freezing,
: and breaking o* eggs.
Egg albumen
Eggs: canned, dehydrated, desiccated, frozen, processed
Eggs: drying, freezing, and breaking
SIC 5144 Egg Packing
/C
.* '"' Establishments primarily engaged in the cleaning, oil
' treating, packing, and grading of eggs.
SIC 2C34 Dehydrated Soups,
_ , . •__ v V. " ^
SIC 2038 Frozen Specialities
i Establishments primarily engaged in freezing and cold pack-
! ing (freezing) food scecialities, such as frozen dinners and
frozen pizza.
Baked goods, frozen: "Native" foods, frozen
except bread and Pies, frozen
bread-type rolls Pizza, frozen
Dinners, frozen: packaged Soups, frozen: except
Food specialities, frozen seafood soups
Frozen dinners, packaged Spaghetti and ."neat balls,
Meals, frozen frozen
Waffles, frozen
SIC 2047 Dog. Cat and Other Pet Food
Establishments primarily engaged in manufacturing dog, cat
and other pet food from cereal, meat, and other ingredients.
These preparations may be canned, froze-i, or dry. This indus-
try also includes establishments slaughtering animals for pet
food. Establishments primarily engaged in manufacturing feed
for animals, other than pets, are classified in Industry 2048.
Bird food, prepared Pet food: canned, frozen.
Dog and cat food dry
Horse meat: canned, fresh. Slaughtering of nonfood
or frozen orimals
14
-------
DRAFT
TABLE 1 'CONT'D)
SIC 2051 Bread and Other Bakery Products, Except Cookies and Crackers
Establishments primarily engaged In manufacturing bread, cakes,
and other "perishable" baker products. Establishments manufac-
turing bakery products for sale primarily for home service de-
livery, or through one or more non-baking retail outlets, are
Included In this industry. Establishments primarily engaged
1n producing "dry" baker products, such as biscuits, crackers,
and cookies are classified in Industry 2052. Establishments
- / producing bakery products primarily for direct sale on the
premises to household consumers are classified in Retail Trade,
Industry 5462.
, . Bagels Bakeries: wholesale.
1 " Bakeries, manufacturing for wholesale and retail
home-service delivery combined
Bakery products "perishable": Bakery products, partially
bread, cakes doughnuts, cooked (not frozen)
pastries, etc. Crullers
Biscuits baked: baking Knishes
powder and raised Pastries: Danish, French,
Bread, Drown: Boston and etc.
other—canned P1es, except meat pies
Charlotte Russe (bakery Rolls (baker products)
product) Sponge goods (bakery
products)
Sweet yeast goods
SIC 2052 Cookies and Crackers
Establishments primarily engaged in manufacturing cookies,
crackers, pretzels, and similar "dry" bakery products. Estab-
lishments primarily engaged in producing "perishable" bakery
products are classified in Industry 2051.
Bake.- products, "dry": Cracker meal and crumbs
biscuits, crackers, Crackers: graham, soda, etc.
pretzels, etc. Hatzoths
Biscuits, baked: dry, except Rusk, machine-made
baking powder and raised Sal tines
biscuit Zwieback, machine-made
Conmunion wafers
Cones, 1ce cream
Cookies
SIC 2065 Candy and Other Confectionery Products
Establishments primarily engaged in manufacturing candy, includ-
ing chocolate candy, salted nuts, other confections and related
15
-------
DRAFT
TABLE 1 (CONT'D)
products. Establishments primarily engaged In manufacturing
solid chocolate bars are classified In Industry 2066 and chew-
Ing gum in Industry 2067. Establishments primarily engaged in
manufacturing confectionery for direct sale on the premises
are classified in Industry 5441, and those primarily engaged
In shelling and roasting nuts are classified in Industry 5145.
Bars, candy: including choc-
olate covered bars
Cake ornaments, confectionery
Candy, except solid chocolate
Chewing candy (not chewing
gum)
Chocolate candy, except solid
chocolate
Confectionery
Cough drops, except pharma-
ceutical preparations
Dates: chocolate covered,
sugared, and stuffed
Fruit peel products: candied,
glazed, glace, and crystal-
lized
SIC 2066 Chocolate end Cocoa Products
Fruits: candied, glazed
and crystallized
Fudge (candy)
Halvah
Licorice candy
Lozenges, candy: non-
medicated
Marshmallows
Marzipan
Nuts, glace
','L'ts, salted or candy-
covered: packaged
Popcorn balls and other
treated popcorn products,
packaged
(J-
Establishments primarily engaged in shelling, roasting, and
grinding cacao beans for the purpose of making chocolate
liquor, from which cocoa powder and cocoa butter are derived,
and 1n the further manufacture of solid chocolate bars and choco-
late coatings. Establishments primarily engaged In manufactur-
ing products, except candy, from purchased chocolate and cocoa
are classified in Industry 2099, and chocolate candy in Industry
2065.
Baking chocolate
Bars, candy: solid choco-
late
Cacao bean products: choco-
late, cocoa butter, and
cocoa
Cacao beans: shelling,
roasting and grinding
for making chocolate
liquor
Candy, solid chocolate
Chocolate bars
Chocolate coatings and syrup*,
made in chocolate plants
Chocolate liquor
Chocolate, sweetened or
unsweetened
Cocoa butter
Cocoa, powdered: mixed
with other substaices--
made in chocolate plants
16
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DRAFT
TABLE 1 (CONT'D)
SIC 2067 Chewing Gum
Establishments primarily engaged In manufacturing chewing gum
J.] or chewing gum base.
Chewing gum Chewing gum base
SIC 2074 Cottonseed Oil Hills
Establishments primarily engaged in manufacturing cottonseed
oil. and by-product cake, meal, and 1 inters. Establishments
primarily engaged in refining cottonseed oil into edible COOK-
ing oils are classified in Industry 2079.
Cottonseed oil, cake and
meal: made in cottonseed
oil mills
SIC 2075 Soybean Oil Hills
Establishments primarily engaged in manufacturing soybean oil,
and by-product cake and meal. Establishments primarily engaged
in refining soybean oil into edible cooking oils are classified
1n Industry 2079.
Lecithin Soybean oil, cake and meal
SIC 2076 Vegetable Oil Mills, Except Corn, Cottonseed, and Soybean
Establishments primarily engaged in manufacturing vegetable
oils and by-prod'uct cake and meal, except corn, cottonseed, and
soybean.Establishments primarily engaged in manufacturing
corn oil and its by-products are classified in Industry 2046,
those which are refining vegetable oils into edible cooking
oils are classified in Industry 2079, and those refining these
oils for inedicinal purposes in Industry 2833.
Castor oil and pomace '" Peanut oil, cake and meal:
Coconut oil made in peanut oil mills
Linseed oil, cake and *• Safflower oil
meal Tallow vegetable
Oils, vegetable: except Tung oil
corn, cottonseed, and Walnut oil, except artists'
soybean materials
OHicica oil
Palm kernel oil V . <•
SIC 2079 Thortening. Table Oils, Margarine and Other Edible Fats and
Oils. Not Elsewhere Classified
17
-------
DRAFT
TABLE 1 (CONT'D)
Establishments primarily engaged In manufacturing shortening,
table oils, margarine, and other edible fats and oils, not else-
where classified, by further processing of purchased animal
and vegetable oils. Establishments primarily engaged in produc-
ing corn ail are classified in Industry 2046.
Butterine Olive oil
Cottonseed oil, refined: Peanut oil, refined: not
not made in cottonseed made in peanut oil mills
oil mills Shortenings, compound and
Margarine vegetable
Nut margarine Vegetable cooking and salad
Oleomargarine oils, except corn oil:"
refined
SIC 2082 Malt Beverages
Establishments prima>-ily engaged in manufacturing all kinds
of malt beverages. Establishments primarily engaged in bottl-
ing purchased malt beverages are classified in Industry 5181.
Ale Halt extract, liquors and
oeer (alcoholic beverage) syrups
Breweries Near beer
Brewers' grain Porter (alcoholic beverage)
Liquors, malt Stout (alcoholic beverage)
SIC 2083 Malt
Establishments primarily engaged in manufacturing malt or malt
, ' by-products from barley or other grains.
Malt: barley, rye, wheat, Malthouses
and corn Sprouts, made in malthouses
Malt by-products
SIC 2084 Wines. Brandy, and Brandy Spirits
Establishments primarily engaged in manufacturing wines, brandy,
and brandy spirits. This industry also includes bonded store-
rooms which are engaged in blending wines. Establishments pri-
marily bottling purchased wines, brandy, and brandy spirits,
but which do not manufacture wines and brandy, are classified
In Industry 5182.
18
-------
DRAR
TABLE 1 (CONT'D)
Brandy Wines: still, sparkling and
Brandy spirits artlftcally carbonated
Storerooms, bended:
engaged in blending
wines
SIC ?085 Distilled. Rectified, and Blended Liquors
Establishments primarily engaged in manufacturing alcoholic
liquors by distillation and rectification, and in manufacturing
cordialsk and alcoholic cocktails by blending processes or by
mixing liquors and other ingredients. Establishments primarily
engaged in manufacturing industrial alcohol are classified in
Industry 2869, and those only bottling purchased liquors in
Industry 5182.
Applejack Liquors: Distilled,
Cocktails (alcoholic beverages) rectified, and blended-
Cordials, alcoholic except brandy
Distillers dried grains Rum
and solubles Spirits, neutral except
Ethyl alcohol for medicinal fruit: for beverage
and beverage purposes purposes
Gin (alcoholic beverage) Vodka
Grain alcohol for medicinal Whiskey: Bourbon, rye,
and beverage purposes scotch type, and corn
SIC 5182 Bottling Purchased Wines, Brandy, Brandy Spirits, and Liquors
SIC 2086 Bottled and Canned Soft Drinks and Carbonated Waters
Establishments primarily engaged in manufacturing soft drinks
(nonalcoholic beverages) and carbonated waters. Establishments
primarily engaged in manufacturing fruit and vegetable juices
are classified in Group 203, fruit syrups for flavoring in
Industry 2087, and cider in Industry 2099. Establishments primarily
engaged in bottling natural spring waters: are classified in
Industry 5149.
Beer, birch and root: bottled Non-alccholic beverages,
or canned bottled or canned
Beverages,non-alcohol1c: bot- Soft drinks, bottled or
tied or canned canned
Carbonated beverages, non-alcoho- Still beverages, r.on-dUnho-
llc: bottled or canned hr'ic: bottled :r canrifd
Drinks, fresh fruit: bottled Water, pasteurized:
or canned bottled or canned
Ginger ale, bottled or canned
Mineral water, carbonated:
bottled or canned
19
-------
DRAFT
TABLE 1 (CONT'D)
SIC 2087 Flavoring Extracts and Flavoring Syrups, Not Elsewhere Classified
Establishments primarily engaged in manufacturing flavoring
extracts, syrups, and fruit juices, not elsewhere classified,
- . for soda fountain use or for the manufacture of soft drinks,
and colors for bakers' and confectioners' use. Establishments
primarily engaged in manufacturing chocolate syrup are classified
in Industry 2066 if from cacao beans and in Industry 2099 if from
purchased chocolate.
Beverage bases
Bitters (flavoring concen
trates)
Burnt sugar (food color)
Coffee flavorings and syrups
Colors for bakers, and
confectioners; use. except
synthetic
Cordials, ncn-alcoholic
Drink powders and concen-
trates
Flavoring concentrates
Flavoring extracts, pastes,
powders, and syrups
Food colorings, except
synthetic
Food giace for glazing
foods (cozeen)
Fruit juices, concentrated:
for fountain use
Fruits, crushed: for
soda fountain use
SIC 2095 Roasted Coffee
Establishments primarily engaged in roasting coffee, and in
manufacturing coffee concentrates and extracts in powdered,
liquid or frozen form, -including freeze-dried.
Coffee extracts
Coffee roasting, except by
wholesale grocers
Coffee, instant and freeze-
dried
SIC 209? Manufactured Ice
Establishments primarily engaged in manufacturing Ice for sale.
Ice plants operated by public utility companies are included
'; In this industry when separate reports are available. When
separate reports are not available, they should be classified
In Major Group 49. Establishments primarily engaged in manu-
facturing dry ice are classified in Industry 2813.
SIC 2098 Macaroni, Spaghetti, Vermicelli, and Noodles
tstabllshments primarily engaged 1n manufacturing dry macaroni,
i ^ spaghetti, vermicelli, and noodles. Establishments primarily
' engaged in manufacturing canned macaroni, spaghetti, etc., are
classified in Industry 2032.
20
-------
DRAFT
TABLE 1 (CONCLUDED)
Macaroni and products, dry:
Including alphabets, rings,
seashells, etc.
Noodles: egg, plain, and
water
Spaghetti, except canned
Vermicelli
SIC 2095 Food Preparations, Not Elsewhere Classified
Establishments primarily engaged In manufacturing prepared foods
and miscellaneous food specialties, not elsewhere classified,
such as baking powder, yeast and other leavening compounds;
chocolate and cc--or products except confectionery, made from
purchase materials; peanut butter; packaged tea including instant;
ground spices; potato, com and other chips; and vinegar and
elder.
Almond pastes
Bakers' malt
Baking powder
Beans, baked: except
canned
Bouillon cubes
Box lunches, for sale off
premises
Bread crumbs, not made in
bakeries
Butter, ladle
Butte1, renovated and
processed
Chicory root, dried
Chili pepper or powder
Chocolate, instant, mfpm
Chocolate syrup; mfpm
Cider
Cocoa, Instant; mfpm
Coconut, desiccated and
shredded
Cole slaw, in bulk
Desserts, ready-to-m1x
Emuls1f1ers food
Fillings, cake or pie: except
fruits, vegetables and meat
Gelatin dessert preparations
Honey, strained and bottled
Jelly corncob (gelatin)
.eavening compound;., prepared
harshmallow creme
Meat seasonings, except
sauces
Molasses, mixed or blended;
mfpm
Pancake syrup, blended and
mixed
Peanut butter
Pectin
Pepper, chill
Pizza, refrigerated: not
frozen
Popcorn, packaged but not
popped
Pork and beans, except canned
Potato chips
Sandwiches, assembled and
packaged: for wholesale
market
Syrups, sweetening: honey.
maple syrup, sorghum
Sorghum, including custom
refining
Spices, Including grinding
Sugar grinding
Sugar, industrial maple:
made in plants producing
maple syrup
Sugar, powdered: mfpm
Tea blending
Tortillas, 1n bulk
Vegetables, peeled or the trade
Vinegar
Ytast
21
-------
DRAFT
4. Non-synthetic food colorings. It was established that guide-
lines for the manufacture of food colorings had been developed
1n the organic chemicals guidelines, Phase II.
5. Baker's Malt. The only known producer of Baker's Malt dis-
continued manufacturing the product several years ago.
6. Food emulslflers processed by organic chemical plants.
Guidelines for these facilities were developed by the
Organic Chemical Industry. Guideline , Phase II. Therefore,
this document will develop recommended guidelines only for
food emulslflers processed by edible oil refining facilities.
7. Butter (ladle, renovated and processed). These products were
determined to have been the subject of effluent guidelines
previously developed for the dairy industry.
6. Baked beans, cole slaw, vegetables peeled fcr the trade,
corn and potato chips, cider, and pork and beans. These
products were established to have been the subject of effluent
guidelines previously developed for the fruit and vegetable
Industry.
9. Jelly corncob (gelatin) and box lunches. These products
could not be established as active industries in th»
United States.
10. Sugar grinding. Other than in sugar refineries which were
subject to previously established guidelines, sugar grinding
could not be defined as an Industry in the United States.
To the original Industry scope as defined by the Environmental Protection
Agency were added several products considered closely related to the
miscellaneous foods and beverages Industry. These additional products
were the following:
1. SIC 5114 Egg Packing. Establishments primarily engaged in
the washing, Inspecting, grading, and packaging of eggs
purchased from laying farms or Independent farmers.
2. SIC 2034 Dehydrated soups. The blending and packaging of
dehydrated soups, and the combining at previously dehydrated
vegetables with various flavorings and protein bases.
3. SIC 2099 Non-Dairy Coffee Creamer.
4. SIC 5132 Bottling purchased wines, brandy, brandy spirits, and
liquors.
1 22
-------
[.RAFT
At. the conclusion of the current study 1t 1s tentatively planned to
de»«iop '•ecommended effluent limitations guidelines for the pro-
dtc'lon of blended flour and hydrolyzed plant protein (hydrolysate)
as an idde.idurn to this document.
SIC 2ul/ - Egg Processing
General - According to the U.S. Department of Commerce ( 2 ), about
12 to" 15 percent of this country's total egg output is processed
Into egg products, and the demand 1s Increasing as the use of specialty
and convenience foods Increases. These products are whole eggs, whites,
or yolks and are in liquid, dried, or frozen form. These egg products
are used directly or in the production of other foods such as in
bakeries. Egg breaking and subsequent processing occurs in approximately
150 plants in 41 states. Nearly one-half of the total annual production
of 393,000 kktj (433,000 tons) occurs in the north central states.
Egg processing occurs in a variety of scales. Plants have from 1 to
at least 13 breaker lines and produce from 5 kkg (6 tons) to 140 kkg
(154 tons) of liquid eog per day. Some processing plants also produce
shell eggs (graded) and some plants receive only liquid egg for further
processing. In plants which break and grade eggs, the majority of the
waste load from the plants is from breaking. In plants which receive
liquid egg for processing, the waste load is significantly lower than
in the plants where the breaking is done.
USDA inspectors are present on a full-time basis of egg breaking plants
to inspect the sanitation practices of the production. It should be
noted that some USDA health regulations, such as frequent cleaning
requirements, add to the waste load of the plant.
Egg processing operations usually operate on an 3 or 24 hour per day
work schedule, 5 or 6 days a week. Egg processing cr'-'jrs year-round,
but more eggs are broken during the spring ind sunder months when the
wholesale prices are the lowest.
Table "2(3) shows the distribution among frozer, dried, and liquid product
produced of the total of shell eggs broker- The large majority of the
dried product is oroduced by a fe.v plants in the north central region.
The liquid and frozen products are produced by the majority of producers
1n all geographical regions.
Description of Process - Eggs for ororessing (breaking stock) come from
several sources. thov.c noted at shell egg handling operations with
cracked, checked, thin, stained, or rough shells are sold to egg
processors, or are transferred to t.he breaking line 1f the plant does
both operations. Another source or breaking stock is supermarkets.
Fresh eggs can only be hel-' for sale for a limited time; unsold eggs
are often sold to egg processors as breaking stock, fionie breaking
stock 1s purchased directly from egg laying farms. The s*.eps in egg
processing ore outlined below and illustrated in Figure 1 .
23
-------
DRAFT
r
TABLE 2
Egg Products under Federal Inspection ( 3 )
Period
Item
Total shell eggs broken
Edible liquid from shell eggs
6/1/7?-
5/30/73
(1.000
kkq)
393
30G
(1,000
tons)
433
337
6/1/73-
5/30/74
(1,000
kkg)
433
341
(1,000
tonsj^
477
37B
broken
Inedible liquid from shell eggs
broken
Liquid egg used in processing*
16.6
18.3
17.7
19.5
Whole
White
Yolk
Total
Liquid product produced
Frozen product produced
Dried product produced
187
117
68
373
118
153
30
206
129
75
411
131
169
33
211
131
72
414
137
166
33
233
144
79
456
151
183
36
* Includes frozen eggs used for processing.
-------
DRAFT
I eO^TINueuS (. CLEANUP,^
:_m~t; I
[ —|
' I
FIGURE 1
EGG PROCESSING PROCESS FLOW DIAGRAM
-------
DRAFT
Delivery and Storage: Delivery of breaking stock and outgoing shipments
of processed eggs are normally made by truck. Since the quality and
product life of eqqs 1s quite temperature dependent, the trucks used
for incoming as well as outgoing shipments are usually refrigerated and
the storage areas are always refrigerated (10° to 13°C). Relative
humidity 1s controlled at 70 to 80 percent in some plants. In many
plants, the loading areas are also refrigerated. Incoming nest run
eggs are usually in cases containing 30 dozen eggs. The cases are
stored on pallets, although some contract shipments utilize steel racks
for shipment and storage of eggs.
Loading and Washing: Flats holding 30 eggs are unpacked from the 30
dozen cases manually. The eggs are Inspected as they are unpacked and
cracked or leaking eggs are put in buckets to be sold as inedibles.
In most plants, the eggs are then automatically vacuum loaded onto a
conveyor which passes through washing machinery Some small plants
transfer the eggs manually onto a conveyor, but this method results in
increased egg breakage. In the washer, the eggs are sprayed, and
sometimes scrubbed by brushes, with a recirculating disinfectant and
detergent solution, the concentration of which is automatically maintained.
Candling follows washing. The eggs are passed over a light sourer:, and
visually inspected. Blood spotted or other inedible eggs are manually
removed. It should be noted that one plant visited did not candle their
eggs before breaking. Some plants reverse these processes, contending
that candling can result in the removal of cracked eggs that would
break In the washer.
Sources of wastewater prior to the breaking of the eggs are:
1. Cleaning of fgg handling equipment
2. Cleaning of floors
3. Overflow and dumping of the egg washwater
Since the shells of breaking stock are less sound than those at shell
egg handling plants, eggs are sometimes broken during unloading, washing,
and candling. Unloading and candling equipment is normally equipped
to catch these broken eggs which then may be sold as Inedibles. However,
some eggs fall to the floor where they must be scraped or mopped up or
hosed into a floor drain. A significant number of eggs are broken during
washing and these go into the washwater, and subsequently into the spwer.
Eqg washing equipment is normally of the recirculating t>pe. The same
uashwater is used over and over with a small quantity of constant over-
flow and make-up. This make-up comes from the water used to rinse the
detergent from the washed eggs.
Breaking and Pasteurizing: Egg breaking Is usually accomplished auto-
matically by machines, normally capable of breaking 0.64 kkg (0.7 tons)
per hour. The eggs are transferred mechanically from candling to the
breakers where the liquid yolks and whites are collected separately or
the whole egg Is collected. Visual inspection of the broken eggs is
also done to eliminate Inedibles. The broken shells are conveyed from
the breaking room to • disposal vehicle by a conveyor such as *n auger.
2C
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DRAFT
The liquid egg 1s conveyed from the breakers into an insnection tank
where odor 1s periodically checked. Next, the liquid is pumped through
a chiller and then into refrigerated holding tanks, l.'hen a holding tank
has been filled with egg yolk or whole egg, the contents are pasteurized.
Conditions used in pasteurizing vary according to the product. For
example, liquid whole eggs are heated for at least 3.5 minutes at not
less than 60°C (14C°F) and then rechilled. Due to the heat sensitive
nature of egg white-:, they must be pasteuriztd at about 56°C (134°F) or
52eC (126°F; using hydrogen peroxide injection. (4)
The sources of.most of the waste load from egg processing plants is the
cleaning of the liquid egg handling equipment. Egg breaking machines
are continually washed with a fin-; spray. The pumps, piping, pasteurizer,
and tanks used in conveying and processing the liquid product are
completely flushed and cleaned every 4 hours. Similarly, equipment used
for the canning, freezing, and drying of eggs is water cleaned and
thus contributes tc the waste stream. Effluent from these cleaning
operations contains the liquid egg product in varying concentrations
plus detergents and disinfectants.
Some egg processing plants receive liquid egg in tank trucks for blending,
freezing, canning, or drying. The wastewater generation in this type
of plant comes only from cleaning the blending equipment, the tank
trucks, and the holding tanks.
Blending: Somr> industrial consumers of processed eggs prefer to
purchase blended frozen or dried '-g products. Blending occurs before
pasteurization and rechilling. The liquid whole egg or egg yolk, or
both, ar« transferred to blending vats where the percent solids is
adjusted. Sugar, corn syrup, occasionally salt, and various other
additives are combined with the liquid egg in assorted combinations
and quantities. After completion of the blending, the product is
transferred to a holding tank and then to the pasteurizer.
Canning and Freezing: If the final product is to be in liquid or
frozen form, the pasteurized liquid yolk, whole egg, or blend is
rechilled and packaged mechanically in 2.3 kg (5 lb) or 4.6 kg (10 lb)
milk-type cartons or 14 kg (30 lb) cans. The packaging room is equipped
with positive flow f11 tared ventilation to prevent contamination of
the pasteurized product. After packaging, the liquid egg may be stored
at 2 to 5°C for up to 1 month before use. Wastewater from the canning
process is normally only generated by the cleanup of the egg dispensing
equipment.
About one half of the total liquid egg production is frozen. Egg whites,
yolks, whole egg, and blends are frozen, normally in 14 kg (30 lb) cans
or 2.3 kg (5 lb) cartons. Freezing causes major changes In the texture
of some egg products and some reduction in bacterial count. However,
the functional characteristics are only slightly affected. Some egg
products are adversely affected by slow rates of freezing; therefore
some producers of frozen products utilize air blast freezing at
27
-------
DRAFT
temperatures as low as -40CC (-40°F). Subsequent storage of the frozen
product is usually at -18e to -23°C (0° to -10eF),
Egg Drying: Dehydrated albumen (egg whites) must be prepared from
desugared liquid egg to -'•event loss of solubility, formation of off-
color and objectionable flavor, and decreased versatility of the dried
product during storage, Bacterial fermentation is the most widely
employed method of glucose removal from eggs. Controlled bacterial
fermentation is a process In which a tank of liquid egg white 1s
inoculated with a culture. After 12 to 24 hours, the albumen 1s
completely desugarsd and is transferred to the drier. Other methods
of desugarlng include tne use of glucose oxidase enzyme or yeast
fermentation. Since the product Is to be dried, almost all of the
liquid egg white can be rinsed from the tank Into the drier. As a
result, the wast? load from this process is quite low.
Egg whites can be either pan or spray dried. Pan drying is a procedure"
in which 0.15 sq m (1.5 sq ft) aluminum trays are covered with a thin
layer of liquid egg white, placed on racks, and run through a heated
tunnel for 24 hours or longer. The resulting egg white solids are
packaged as a flake or granular product or ground and packaged as a
powder. Pasteurization is accomplished by storage of the dried and
packaged product for at least one week at 60°C (140°F).
The majority of all dried egg products are produced by spray drying.
In this process, the liquid egg is atomized into a stream of hot air.
The air used for drying Is filtered and heated to between 120" and 139'C
(250° and 375'F). Because atomization creates a great deal of surface
area, water evaporation is very rapid. The powder formed separates
from the air in the drying Chamber and in a separating device. The
dried product Is removed mecnanically from the dryer, sometimes cooled,
and normally sifted before packaging in 2 or 5 kg boxes, or 45, 70 or
90 kg drums. Dried egg white needs no temperature control during
storage, but other dried egg products are normally refrigerated during
storage. Egg drying equipment 1s normally cleaned semi-annually or
when required by a change in product (for evample, egg yolk to egg white
production).
Inedible Eggs: Eggs classed as Inedibles such as blood spots, cracks,
leaks, and stained eggt are processed separately. Eggs which break on
the floor or grading machinery are normally recovered and also classed
as Inedlbles. Egg albumen 1s sometimes recovered by centrlfuglng from
the shells and 1s included in the product sold as inedible egg. Inedible
eggs are normally frozen in 14 kg cans or dried at plants specializing
in Inedible egg processing. Inedlbles are normally sold to pet food
processors to be used as Ingredients in their products.
Egg Shells: Egg shells ar« a significant source of solid waste from
egg breaking pla.its. These shells are normally spread on fields as
fertilizer, If the location Is such that odors do not cause a problem.
•28
-------
DRAFT
or In a landfill. Experiments have been conducted 1n the utilization
of egg shell wastes as feed for chickens. Despite the high protein
content, a satisfactory method of processing egg shells into feed has
not been developed.
SIC 5144 - Shell Eggs
• General • The fresh eggs available at the wholesale and retail level hove
been washed, Inspected, graded and packaged by shell egg handling firms.
Eggs from processor's laying farms or purchased from independent farmers
are the raw materials for this industry.
In 1972, the total volume of shell egg production v.-as 50 nil!Ion kkg
(70 billion eggs). The gross income of the industry was $1.8 billion.
According to the Bureau of the Census (2 ), an estimated 9,500 shell
egg producers are currently operating. They range in size from family .
businesses to automated operations producing 20 to 80 kkg (several
thousand 30-dozen cases) daily. The top ten egg producing states account
for slightly over one-half of the total shell egg production, California
is the largest producing state with 12 percent of the national total,
and Georgia is second with 8 percent. Six of the top ten states are
located in the south and twr are in the midwest.
Description of the Process - Shell egg grading plants are normally not
located at egg laying farms.
Since cool temperatures improve egg life, the trucks used for hauling
Incoming and outgoing eggs are normally refrigerated. Storage areac are
always refrigerated (10* to 13"C, 50" to 55"F) and sometimes humidity
controlled. In some plants, loading areas are also refrigerated.
Eggs delivered to a grading plant are usually packed In reuseable
• corrugated cases which hold 30 dozen eggs. In some plants which have
contracted suppliers, the eggs are shipped and stored on steel racks.
The eggs in storage are transported on pallets to the loading area of
the process room. The flats of eggs are unpacked manually from the
corrugated cases and Inspected. Broken and obviously damaged eggs are
removed and the sound eggs are normally automatically vacuum loaded
onto a roller conveyor (see Figure 2). On the conveyor, the eggs are
moved through the washer in which tney are sprayed, and sometimes
scrubbed by brushes, with a warm !C-0°C) recirculating detergent and
disinfectant solution, the uoncentratJon of which Is automatically
maintained. As the eggs leave the washer they are dried, given a light.
oil spray to strengthen and prevent drying of the shell during'storage,
and car.c*"!i_d. The eggs are passed over a high intensity light source
and visually Inspected, Blood spots or other inedible eggs are removed
manually.
Sources pf waste'-mtfcr prior to the grading of ihe eggs are as follows:
1. Cleaning of the egg handling equipment
2. Cleaning of floors
29
-------
DRAFT
so
WA
_, INEDIBLg FCCS
1 INEDIBLE EGGS
"
t Mtrni 01 e er.r.*.
'
\
LID
STE
RECEIVING COOLER
*
MACHINE LOADING
\
WASHING
»
OILING
*
CANDLING
1
GRADING
*
PACKING - ONE
DOZEN CARTONS
1
PACKING - SHIPPING
CASES
|
OUT &OING
COOLER
q(-BANUf J
CQNTiNyioys PVE.R- v
FLOW AND DUMPING
CuEANUP ^
|
CLEANUP ,
i
WASTEM
FIGURE 2
SHELL EGG PROCrSS PLOW DIAGRAM
30
-------
DRAFT
3. Overflow and dumping of the egg washwater
Eggs are sometimes broken during unloading, washing, and candling. Un-
loading and candling equipment 1s normally equipped to catch these
broken eggs which then may be sold as Inedlbles. However, some eggs
fall to the floor where th»>y must be scraped or mopped up or hosed
into a floor drain Eggs broken during washing go into the washwater,
and subsequently, Into the sewer. Egg washing equipment 1s normally
of the reclrculatlng type. The same washwater
-------
DRAFT
Also Incorporated Into most blends are various types of soup bases;
e.g.. hydrolyzed vegetable protein. One processor was observed to
manufacture Its own soup base and also to dehydrate from fresh vegetables
a small portion of Us vegetable needs. All other processors contacted
used only Ingredients preprocessed elsewhere.
Process Description. Figure 3 shows a process flow diagram for
a typical dehydrated soup operation. The manufacturing of dry soups
Is essentially a dry Ingredients blending and packaging operation.
All the various dehydrated Ingredients (preprocessed elsewhere) are
taken from dry storage and carefully weighed as per specific formulation.
The Ingredients are dumped directly Into a blender (typically a ribbon
type) and mixed until the dry blend Is homogeneous. Alternately,
some soups, such as onion soup, premix the dehydrated rnlons and soup
base separately to prevent breakage of the onion flakes.
The premlxed soup formulation or base mix 1s transferred to a filling
hopper on a packaging machine. The soup mix (other than onion soup)
is automatically filled (by weight) Into pouches, sealed, cased, *nd
sent to storage. Onion soup, however, 1s filled 1n two steps: b a st-
and onion flakes are filled separately to minimize breaking of tne
dried onion pieces and to assure a consistent ratio of onion to base.
The packages are then sealed, cased, and stored.
Clean-up throughout an operating shift consists of dry methods--sweeping,
brushing, vacuuming. At the end of dally operations, the ribbon blenders
are normally rinsed clean.
The dally e'fluent 1s of a low volume, typically less than several
hundred gallons. Packaging equipment may be steam-cleaned, vacuumed,
or both, but never washed with water. No other water 1s used 1n any
aspects of dehydrated soup (manufacturing.
SiCCode.2038 Frozen Specialties
Frezftn specialties Include such specialties as frozen baked goods,
frozen dinners, frozen pizzas, and other frozen specialties. It does
not include frozen meats, fish, vegetables and fruit except as they
appear at Ingredients to prepared dinners or other frozen specialties.
ilnce production value of frozen specialties has Increased 214 percent
since 1967 and currently constitutes 49 percent of the 1974 value
of all frozen food production, these products were removed from SIC
2037 and given a new Industry Identification, SJC 2038. The value
of production of frozen food specialties in 1974 rose to over two
billion dollars. In 1975, frozen specialties are forecast to Increase
16 percent over the 1974 producticri as illustrated 1n Table 3 .
The Department of Commerce Census of Manufactures, 1972, estimates
there arc 436 plants nationwide tnat process frozen specialties.
The North Central states lead the nation with 140 establishments.
The Northeast Is next with 110 plants, followed by 94 plants in the
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DRAFT
TABLE 3
PRODUCTION OF FROZEN FOOD SPECIALTIES
Year Production in Million Dollars t Increase
1967 947
1970 1401 48
1971 1397 -2
1972 161: 16
1973 1779 10
1974 2028 14
1975 2352 16
33
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DEHYDRATED SOUP
VEGETABLES BASE
ONIONS, CARROTS
PEPPEKS, CELERY
GARLIC, PARSLEY
ETC. . .
FLAVORINGS SALT/SUGAR
OTHER
ADDITIVES
BLENDER RINSE
DRY FRAGMENTS,
SPICES, =*--=--=
POWDERS
FIGURE 3
PROCESS FLOW DIAGRAM FOR
DEHYDRATED SOUPS
. 34
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DRAFT
South and 92 In the West. This location pattern Is due to the fact
that frozen specialty plants desire convenient distribution to major
consumer populations. The major producing states are California,
Illinois, Pennsylvania, New York, Arkansas, and Ohio.
For simplicity, frozen T.V. dinners, meat pies, and other frozen dinners
and main courses may be designated as "Frozen Prepared Dinners."
Frozen prepared dinners represent a substantial sales volume in America's
supermarkets. Specific sales Information is lacking, but the American
Frozen Food Institute (1974). informally estimates that at least three
million T.V. dinners and other frozen main course specialties are
sold dally. The number of processing plants is estimated to be between
40 and 60. This number was derived through analysis of industry organiza-
tion directories and the Standard and Poor index.
The industry is dominated oy about six large corporations. Geographical.
distribution of plants 1s generally in accordance with population
distribution; e.g., plants tend to be located in small communities
because a large force of cheap labor is required to do the hand work
needed in the preparation of ingredients and assembly of the prepared
dinners.
Ingredients usually include meat, fowl, or fish; vegetables; gravies;
and minor additives. In addition, there may be added starches (such
as noodles), grains (such as rice), and a_variety of small dessert
dishes. These ingredients are usually pr*-?repared elsewhere and are
then further processed, cooked, assembled, packaged, and frozen at the
prepared dinner plant. The bulk of the wastes generated originates
from preparation of the ingredients.
"Frozen Bakery Desserts" 1s defined to include frozen cakes, pies,
brownies, cookies, waffles, breakfast coffee cakes, turnovers, and
other desserts. This segment does not include bread or bread-Uke
rolls. The plants are generally large-scale kitchens and most have
national distribution. The magnitude of this industry in terms of
sales and number of plants is not known with exactness. It is estimated
that there are between five and ten million frozen bakery desserts
sold daily in the United States, and that there are approximately
SO to 70 plants manufacturing the bulk of these products. The latter
figure is derived primarily from an analysis of industry organization
yearbooks and Standard and Poor's index. The industry is dominated
by six to eight large corporations whose brand names are household
words.
Frozen "Tomato-Cheese-Starch Combinations" include frozen pizza, lasagna,
ravioli, and other "Italian" specialties made with a tomato, starch,
and cheese base. The magnitude of this segment of the Industry 1s
not known in terms of total production or sales. It is believed that
there may be over 100 plants of various sizes manufacturing frozen
pizza. All those identified discharge wastewater into municipal systems.
.35
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DRAFT
"Battered and Breaded Frozen Specialties" Include many frozen meats,
fish, chicken, and vegetables which are battered and/or breaded.
Onion rings are the most common vegetable Item 1n this segment. Shrimp
and other seafood are also commonly prepared 1n this fashion, as Is
chicken. Generally, the seafood is thawed, washed, dried, dipped
In batter, and frozen without pre-cooking. Vegetables and chicken
follow the same procedure but are cooked before freezing.
As with the other Individual segments of frozen specialty items, there
are no accurate data available defining production volumes and number
of plants manufacturing these Items. Battered and breaded frozen
specialties do, however, occupy a prominent place in the freezer section
of the average supermarket, an*: it is likely that at least several
million pounds a day are sold. All plants identified in this study
that manufacture these items discharge Into municipal systems. Two
plants were investigated, one processing primarily shrimp, and the
other processing primarily onion rings.
Process Description, for Frozen Prepared Dini'.?rs. In many ways, the
unit processes of a prepared dinner plant can be compared to the activities
of an ordinary housewife as she prepares the evening meal for her
family, the only difference being one of scale. Just as the housewife
goes through different steps with each of her ingredients, of cutting,
thawing, cooking, adding spices, etc., and finally assembling them
on the plate to form a complete dinner, the prepared dinner plant
goes through similar steps and finally assembles the dinner on an
aluminum tray for packaging and freezing. The housewife generates
the majority of her wastewater when she discards cooking liquids and
cleans her pots and pans. Similarly, the majority of the wastes from
a prepared dinner plant originates from clean-up of "he vats, kettles,
fryers, mixers, piping, etc., which are used during preparation of
the various components of the final dinner. The major processes as
they are conducted in a typical prepared dinner plant are described
1n the following paragraphs.
Turkeys and chickens arrive plucked, viscerated, and washed. The
birds are placed on verhead meat hooks which travel down a dismantling
line operation. The Jeskinning of the birds is accomplished by the
manual hypodermic Injection of air and subsequent expansion and separation
of the skin away from the flesh. The skin is then peeled off, and
various pieces are cut from the bird as it continues down the lin«.-.
The pieces are placed 1n movable vats and either frozen and stored
for later processing, or moved directly to the Inspection, sorting,
and deboning operation. The chicken is then floured and fried as
whole pieces for later use In prepared chicken dinners or cooked.
If cocked, the cooking operation (for both chicken and turkey) Is
followed by hand trimming from the bone and slicing for later addition
to meat pies or dinners.
Following the hand trimming operation, the bones with adhering flesh
are run through a rotating drum that scrapes and tumbles the meat
36
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DRAFT
from the bones. The meat 1s collected, stuffed into skin \sausage
like), cooked, frozen, and then sliced, making a uniform section of
meat.
Beef and other meat normally arrive at the plant in frozen chunks
and are air thawed, sliced (for dinners) or diced (for Pfes), cooked,
and then moved directly to the assembly area, or they are frozen for
later use. An alternate preparation involves the grinding of the
beef and pressing into hamburger or Salisbury steak patties. Veal
patties are floured. The partial cooking of the meat is usually
accomplished by passing the slices or patties through a long line
of infra-red lamps installed in the roof of the cooking tunnels.
Both sides are cooked by inverting the meat seoment half way through
the tunnel. As the pieces emerge from the brokers, tney fall off
the belt into trays and are carried to the assembly area.
The juices from the meat cooking operations are combined witn flour
and milk to produce the various types of gravies. The gravy is then
pumped to the assembly area, where it is held ready to be sprayed
onto the appropriate section of the T.V. dinner tray as the tray passes
underneath the nozzle.
Vegetables, other than potatoes, usually arrive ^rozen in bulk, u,-e
thawed, run through cluster busters, and are then brought to the assembly
area. The vegetables are placed in "hand pocket fillers" which rotate--
keeping the individual pieces from sticking together—and held unt-1
needed for addition to the tray. Exceptions to the above are those
vegetables which require longer cooking times, e.g., carrots, which
may be partially precooked prior to being brought to the assembly
area. Potatoes are usually prepared from dehydrated potato products.
Water is added to the potato flakes which are then cooked in steam
jacketed kettles, mashed, pumped to stainless steel movable carts,
and wheeled to the assembly area. Other potato varieties, such as
French fries, normally arrive frozen and partially precooked—ready
to assemble without further processing at the frozen prepared dinner
plant.
"Mexican" prepared dinners utilize tortillas, which are normally made
at the plant. The rendering of corn into flat, pliable sheets involves
pumping whole kernels from a storage silo to a grinder which reduces
the corn to the consistency of paste. The paste is then extruded
and rolled into flat sheets, mechanically cut to size and cooked in
vegetable oil. The tortillas are then rolled, stuffed with meat,
and transferred to the assembly area.
Assembly of the commodities that make up the finished product Is perform-
ed along a moving belt assembly line. A hopper, placed at the start
of the line, holds the aluminum trays and drops them one at a time
onto the moving belt. Meat pieces, such as hot dogs, veal patties,
37
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DRAFT
chicken pieces, etc.. are placed on the tray by hand counting the
number of pieces necessary to make up the correct weight. Portions
such as slices or smaller pieces are first hand weighed on scales
placed next to the moving belt and then placed on the tray by hand.
The tortilla products, e.g., tacos. are similarly added to the trays.
Vegetables are added by hand packed fillers which are mechanically
cued to drop a measured portion onto the moving trays. Mashed potatoes
are pumped from their movable carts and are gun Injected, from overhead
extruders, onto the proper section of the tray. The addition of gravies
and butter to the tray 1s performed by overhead "guns" which spray
a preset volume of the liquid onto the vegetables, meat, and potato
portions.
When the complete dinner has been assembled, the trays are mechanically •
covered with foil, sealed, packaged, and transferred to the freezers.
The dinners are then frozen, cased, and stored in refrigerated warehouses-
for shipment to customers.
Figure 4 schematically illustrates the processes described in manufac-
turing frozen prepared dinners. Of course, there are many kinds of
frozen prepared dinner products on the market, and undoubtedly, some
are prepared and assembled differently than the foregoing description.
The reader, however, should have gained a general feel for how most
prepared dinners are processed.
f. Process Description for Frozen Bakery Desserts. Under the process
description for frozen prepared dinners, the a'nalogy was made between
the housewife cooking and baking in her kitchen and the activities
of the large manufacturing plant. The analogy 1s equally valid for
the frozen bakery dessert Industry. Rich ingredients, e.g., butter,
sugar, cream, etc., are purchased In bulk, received, blended under
controlled conditions, further assembled in the final product form.
sometimes baked, packaged, and frozen. All this is accomplished using
large equipment under sanitary conditions with a high degree of quality
control exercised. Just as the housewife may use and "dirty" many
bowls, pans, and utensils on her baking day, so also the frozen bakery
dessert plant must thoroughly clean with hot water all the many mixing
vits, cooking kettles, measuring devices, purrps, piping, etc., which
have come In contact with the ingredients and product. This clean-
up Is continuous during the sMft as different products are manufactured;
e.g.i a section of the plant may run several different kiridi of pies
during a shift, and reaches a peak during the massive final clean-
up at the end of each day's operations.
The process wastewaters thus consist of a mixture of water and the
product ingredients. In this Industry the Ingredients are very "rich,"
e.g., high in carbohydrates, fats, etc., and the resulting waste 1s
high in BOD, grease and oil. etc.
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DRAFT
'-L^_}-L
JH:
^r^ OOiO«
-J IMXIlA
FIGURE 4
PREPARED DINNER PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
39
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DRAFT
Since health standards are strictly enforced, there appears to be
no alternative to the extensive clean-up requirements of these plants
or the resulting strong wastes.
In-plant waste generation can be reduced, however, by separate disposal
a* solid waste of spilled material and sub-standard Ingredients.
Employees must be educated to refrain from discharging such wastes
to the sewer. Figure 5 shows a simplified diagram of unit process
stc;s in a frozen bakery dessert plant.
Process Description for Frozen Tomato-Cheese-Starch Combinations -
All major ingredients are preprocessed elsewhere and arrive at the
manufacturing plant in bulk containers. These ingredients include
tomato paste, cheese, flour, milk, oil, noodles, seasonings, and meat.
Onions and green pepper may be peeled and sliced at the plant, but
the processing of these vegetables 1s a negligible wastewater generator.'
Manufacturing processes consist basically of blending ingredients,
assembling the end product, and packaging and freezing it. Occasionally,
the product may be precooked or baked prior to freezing. Differences
between plants are mainly a function of degree of automation used
versus hand labor. As might be expected, the larger the plant production,
generally i.nt greater the degree of automation.
In pizza manufacturing, the dough 1s mixed separately by combining
flour, baking powder, salt, and suffi' lent water In large mixing vats
to make an elastic dough. The dough is allowed to sit for several
minutes, and then repeatedly machine kneaded. Finally, the dough
is extruded flat on a belt to uniform thickness, and mechanically
cut Into the typical round shape. Meanwhile, the tomato sauce and
spices are being heated and mixed in a separate vat, and the cheese
sauce heated in still another vat. The <;ngred1ents are then combined
mechanically on a moving belt assembly line by use of automatic spray
dispensers which place a measured quantity of tomato and cheese sauce
on each circular doujn segment. Topping ingredients such as meat,
onions, green papers, etc., are then added by hand or machine. The
assembled pizza is wrappad, packaged, and frozen.
Wastewater is generated primarily by clean-up of equipment and spills.
Refrigeration water is generally recycled, but, if not recycled, contributes
a significant volume of clean water to the wastewater. Because process
wastewater is primarily gene: ated by clean-up, it follows that the
wastewater contents consist of the major ingredients used.
40
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DRAFT
INGREDIENTS
STORAGE
SCALING
FIGURE 5
PLANT G
FROZLN BAKERY PRODUCTS PLANT
SIMPLIFIED PROCESS FLOW DIAGRAM
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DRAFT
An efficient plant can hold Us waste of Ingredients to under one
percent of the Incoming Ingredient weight, e.g., loss of le»s than
one pound of tomato paste for every hundred pounds of tomato paste
used.
Process Description for Battered and Breaded Frozen Specialties
Generally, the food item to be battered and breaded has been pre-
processed to some extent prior to arrival at the plant. Typical
preprocessing 1s as follows:
Shrimp - washed and frozen
F1sh - eviscerated, heads and tails removed,
washed and frozen
Heat - slaughtered, dressed, and frozen
Chicken - dressed and frozen
Onions and Mushrooms - washed
Since shrimp 1s the "worst case" for non-vegetable Items, processing
of shrimp is described below and illustrated in Figure 6.
Frozen shrimp are bought 1n bulk, thawed overnight, and processed
the next day. Thawing produces a substantial waste volume since it
1s followed by thorough washing. The shrimp is then shelled, ends
removed, deveined, and washed again. There is equipment to automatically
perform these steps, but in smaller plants they are done manually
by skilled workers. The shrimp are then dried, "butterfiyed" hy machine,
spread on a belt, and conveyed through egg batter. Following battering,
the shrimp are tumbled through a breading machine which coats the
exteriors with bread crumbs and flour. Finally the shrimp 1s boxed
and quick frozen.
Waste generation results from the thawing water, subsequent washings,
and clean-up of equipment and spills. If the shells, heads, and tails '
are Included in the wastewater, they constitute a major organic load
and should be removed as solid waste.
Frozen onion rings are by far the major 1ttm 1n battered and breaded
vegetable specialties. A typical production h
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DRAFT
FROZEN FISH
OR SHELLFISH
FIGURE 6
BREADED PISH AND SHELLFISH PLAKT
SIMPLIFIED PROCESS FLOW DIAGRAM
43
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DRAFT
SIC Code 2047 - Dog and Cat Foods
General - Food products for dogs and cats represent virtually all
Of what Is generally referred to as the pet food Industry. Of the
two major pet foods, cat food represents approximately 20 percent
of the industry tonnage and 30 percent of the retail dollars. Oog
food contributes the remaining 60 percent of tonnage and 70 percent
of retail dollars.
The 1972 Census of Manufacture (2) counts 204 pet food manufacturing
establishments nationwide. California leads the nation with 26 pet
food plants. The Midwest also manufactures a good portion of the
nation's pet food.
At least 90 percent of the dollar sales of pet foods are produced
by plants owned by a few major corporations; many small, fam/ily-ow>ed
pet food operations make up the remaining 10 percent of tne industry.
Table 4 shows pet food production by sales dollars, and pounds solo
from 1969 through 1974 (estimated). This table shows the trend toward
greater production of dry pet food for both cats and dogs and a general
trend toward increased production of all pet fooa.
Raw Ingredients - Pet foods are generally made up af meat and meat
by-products, fish and fish by-products, cereals, and other nutritional
Ingredients which may be received at the plant 1n the form of wet,
dry, or semi-dry products. Proteins and carbohydrates ore principal
constituents, and other diet balancing components are present in varying
concentrations and ratios. The final product 1s marketed 1n three
major styles: canned, dry, and semi-moist.
Ttie variety, style, and form of raw Ingredients used In pet foods
are numerous.
Meats are delivered to the plants fresh In barrels or frozen, typically
in 23 to 46 kg (50 to 100 lb) blocks. The meat may be whole cuts, chopped,
or conroinutod to a particular desired piece size. The meats commonly
used are beef, pork, sheep, horse, poultry, and various types of fish.
These cuts can be either striated muscle tissue or "by-products" (lungs,
tripe, esophagus, gullets, etc.). Poultry products normally are
either finely ground whole carcasses or by-products. F1sh may be
fresh whole, frozen whole, fresh by-products, or frozen by-products.
Other Ingredients used by pet food processors are typically derived
from soybeans, corn, wheat, barley, and oats. Storage 1s normally
In silos for the larger processors but may also be accomplished in
23 to 66 kg (50 to 100 lb) paper or cloth bags. Size reduction Is normally
performed prior to delivery, but grains may also be milled or screened
by the pet food plants. Particle sizes utilized Include whole grains,
cracked grains, grits, m1ds, flakes, and flour.
-------
TABLE 4
PET FOOD VOLUME
RETAIL DOLLAR SALES (MILLIONS) THROUGH U.S. POOD STORES
TYPE
Dog food, dry
Dog food, wet (canned)
Dog food, semi-moist
Cat food,dry
Cat food, wet (canned)
Cat food, semi-rioist
TOTALS
1974*
$2,135
1973
1972
1971
1970
$1,784
$1,481
$1,365
$1,192
1969
$
675
565
265
160
400
70
$ 531
523
214
129
343
44
$ 397
471
174
101
308
JO
5 355
458
152
90
296
14
$ 297
421
128
75
270
1
$ 259
385
108
61
237
$1,050
RETAIL POUND SALES (MILLIONS) THROUGH U.S. FOOD STORES
TYPE
Dog food, dry
Dog food, wet (canned)
Dog food, semi-moist
Cat food, dry
Cat food, wet (canned)
Cat food, semi-moist
TOTALS (in Ibs)
1974*
7, 310
1973
1972
1971
7,044
6,508
6,177
1970
5,768
1969
3,220
2,120
500
420
960
90
2.902
2,254
477
390
963
58
2,591
2,216
407
347
907
40
2,332
2,254
356
309
909
17
2,065
2,254
310
265
873
1
1,848
2,155
265
217
813
5,298
estimated
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DRAFT
Formulations dictate what style, type, and amount of raw Ingredients
are used. Other additives used In these formulations cover a wide
anJ descriptive field; for example, fresh onions, frozen carrots,
dried vegetables, gums and food starches, colors, flavorings, milk-
base products, preservatives, humectants, emu1$1f1ers, sugars and
syrups, vitamins and minerals, and yeasts are often added. In most
cases, these additives are prepared elsewhere, but 1n certain circum-
stances some degree of processing may be needed to prepare Ingredients
for a particular formulation.
Process Description for Soft-Moist Pet Food - There are two styles
of soft-moist pet food, extruded and expanded, each one requiring
a different processing approach. Figures 7 and 8 show typical
soft-moist pet food process flow diagrams for both of the above styles.
The extruded chunk and patty forms can be of similar or identical
formulation. Each contains from ten to thirty percent meat and meat
by-products. Only the package size, shape, and individual product
form are different among the different brands.
The six basic ingredients in extruded chunk and patty-formed products
are soybean meal (and other grains), sugar, fresh meat by-products,
animal fat, preservatives, and humectants. Additionally, minor ingre-
dients such as vitamins, minerals, flavorings, and colorings are normally
used for various reasons (nutritional balance, final product identity,
etc.). All of these materials are typically handled through automatic
mix cycles.
Soybean meal, sugar, fat, propylene glycol, and sorbitol are usually
stored in bulk. Each of the bulk-stored ingredients is located so
that conventional conveying and pumping equipment are used to convey
the Ingredients to a weighscale hopper located above the batch mixer.
Extruded soft-moist can be made in two ways. These are shown as A.
and B. on Figure 7. The first method involves pre-cooking a meat-
preservatives-additives slurry, milling and subsequent addition and
mixing of grains, cooking of the mixture, extruding, further cooling,
and packaging. The secoru method involves the mixing of all ingredients,
a combination cooking-expandlng-extruding step, cooling, and packaging.
In th« first method, known as the meat-slurry method, a selection
of meats and meat by-products (fresh or frozen) Is ground through
a .635 cm (>» in) or smaller plate and conveyed to a cooking tank where
a measured amount of water, sugar, and other additives are brought
together in a specific formulation. The entire slurry is heated with
agitation *ir a predetermined length of time and at a predetermined
temperature The heated meat slurry is usually run through a mill
to further reduce particle size and is introduced into a continuous-
type mixer. Weighed and blended grains are then added to the continuous
mixer. Following thorough mixing, the mass is conveyed through a
46
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DRAFT
A.
B.
EFFLUSNT
FIGURE 7
PROCESS FLOW DIAGRAM FOR
EXTRUDED SOFT-MOIST PET FOODS
47
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DRAFT
jIUEAN^Uf I
SPILJ-AGE
EFFLUENT
FIGURE 8
PROCESS FLOW DIAGRAM FOR
EXPANDED SOFT-MOIST PET FOOD
48
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DRAFT
heat exchanger (for cooling) and extruded into the desired size, shape,
and length. Additional forming (patties, burgers, etc.) is accomplished
after extruding but prior to further cooling.
The extruded and formed product is cooled in a continuous cooler,
wrapped, and packaged.
The second method, shown as B. on Figure 7 , uses a continuous batching
system. This system is considered the most desirable for soft-moist
processing because less labor is used, and the interlocking systems
reduce human error. A typical .45 kkg (one-ton) batch makeup system
for soft-moist consists of:
1. A hopper bin scale which is equipped with a gate
for weighing and collecting all dry ingredients.
2. Hopper bin scale especially designed for weighing
and discharging ground meats.
3. 0.45 kkg (one-ton) stainless steel paddle-type
batch mixer designed for proper mixing of soft-moist
ingredients.
4. An agitated holdinc bin below the batch mixer to
serve as a surge tri and assure a constant and
uninterrupted flsw or material to the extruder
feeder screw.
A typical batch cycle is as follows: soybean meal, sugar, flavorings,
color, and micro-ingredients are fed into the hopper scale, each to
the desired weight, and transferred into the batch mixer below. Pro-
pylene glycol, sorbltol, and fat from storage are then pumped through
meters into the batch mixer. The meters are preset for the desired
volume and stop the pump when the desired volumes in pounds have been
reached. The neat products are then pumped or screw conveyed to the
meat hopper s^.ale above the mixer, where they are weighed and dropped
slowly into the batch mixer.
The mixture becomes very doughy and somewhat sticky. The mixture
is continuously fed into the extruder barrel where live steam is
injected into the mix. The heated mixture is forced through the ex-
truder head under pressure, resulting in:
1. GeUtinization of raw starch.
2. Further reduction of coarse meat fibers, Improving
product appearance and texture.
3. Production of a well-blended, homogeneous chunk
with a meaty appearance.
49
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DRAFT
4. Cooking and pasteurization of the products.
5. Final formation of desired piece size and shape.
Since soft-moist becomes quite soft when heated
and extruded, various techniques 1n die design must
be used to produce smooth, uniform product shapes.
Product temperature varies from 52DC to 163°C (125°F to 325CF).
The extruded product may be further shaped Into patties, burgers,
etc., as desired. The final product 1s cooled in a continuous
cooler, wrapped, and packaged.
The second type Is an expanded soft-moist which contains little or
no meat, but Instead is high in cereals (soy, wheat, corn, oats, etc.) _
which have been cooked during the processing cycle. After cooking,
extruding, and expanding, the product is coated with fat in a revolving.
reel prior to the cooler. This finished product will vary in density
and weight, depending upon ingredients used and formulation.
Figure 8 shows a typical expanded soft-moist manufacturing process.
The ingredients are weighed and mixed in a batch mixer in a manner
similar to that described previously for extruded soft-moist. Prooy-
lene glycol and sorbltol can either be Injected into the mix at the
batch mixer or can be pumped continuously at a prescribed percentage
Into a mixing cylinder which Is a part of the extruder-expander.
From the mixer, the product is typically fed into an extruder barrel
with live steam injection. The steam under pressure moistens and
pasteurizes the product which is in turn expanded while being ex-
truded. No drying of the extruded product Is necessary since the
final moisture content is governed by the amount of water added
in the extruder.
Since fat 1s not added to the mix prior to extrusion, fat and other
liquids are applied to the product externally in a rotary fat appli-
cation reel prior to the cooling process.
When the hot extruded product leaves the extruder/expander and 1s
in the atmosphere a few minutes, its temperature will drop to approx-
imately S6°C (150"F). From this temperature the product is further
reduced to approximately 27°C (80°F) or lower for optimum packaging
anci handling qualities. This final cooling is typically accomplished
1n a horizontal continuous cooler. The product enters the cooler
and 1s spread uniformly to the desired depth over the entire width
of a wire mesh belt. Air drawn into the cooler flows up and around
the chunks or patties, cooling them. Product retention time within
the cooler is regulated by changing the speed of the wire mesh belt.
After proper cooling the product is ready for packaging.
50
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DRAFT
The preservation of both extruded and expanded semi-moist pet food
1s basically accomplished through a reduction of water activity.
Water activity (Aw) is defined as the ratio of the vapor pressure
(P) of water In th~e food to the vapor pressure of pure water (Pp_)
at the same temperature. That is, Aw « P/Pp_. Within the range favor-
able to the growth of mesophllllc micro-organisms Aw 1s practically
independent of temperature. By incorporating an efTective anti-micotic,
heating to destroy vegetative organisms, ana adjusting to an Aw level
of 0.85 or lower, pet food packaged in various types of plastic" wrapping
has proved to have excellent stability.
Process Description for Canned Pet Food - Canned dog and cat food
covers a large variety of styles.Essentially, however, there are
three major styles of canned pet foods—ration, gourmet, and high
meat/fish. Typically, canned ration pet food 1s characterized by
its "meat-loaf" appearance. It is usually a blend of meats, meat
by-products, and cereals. Additionally, vegetables and various vitamins"
and minerals are added to provide desired levels of animal nutrition.
Figure 9 shows a typical process flow diagram for canned ration
pet food. Meat (fish) and meat (fish) by-products, fresh or frozen,
are taken from storage and ground to a desired piece size. Fresh
bones (usually beef) are run through a disintegrator. These are weighed
and conveyed to large agitating cooker-blenders. Additionally, freshly
ground vegetables (onions, carrots, etc.) and other minor ingredients
may be added to the blender. A measured quantity of water is added,
and the entire mixture is agitated while being heated by steam (indirect
or "live" injection). Measured quantities of various grains including
soybean meal, ground corn, wheat, barley, milo, or oats are added
to the cooker-blender, and the mixture Is heated. The product is
pumped to fillers, and the cans are filled, seamed, washed, retorted,
cooled, and packaged.
Canned gourmet pet food is characterized by the presence of "pre-formed"
chunks, p.tties, or meatballs mixed with varying types of gravies
or sauces. Additionally, in some cases, vegetables, "biscuits," or
specialized "bits" may be incorporated. The mix is formulated to
provide a nutritionally balanced diet for dogs or cats, or for a particu-
lar subgrouping by age or condition; e.g., puppies, adult dogs, lactating
bitches, etc. Figure 10 shows a typical process flow diagram for
ct ned gourmet pet foci. Meat (fish) and meat (fish) by-products,
fresh or frozen, are taken from cold storage and ground to the desired
piece size. These are conveyed to a large mixer. Pre-weighed amounts
of grains and minor Ingredients are similarly conveyed into the mixer.
The mass Is mixed for a predetermined length of time resulting in
a product consistency closely resembling "dough." This "dough" is
dumped into an extruder storage bin and the "dough" is extruded as
per specific product requirements. Alternately, steam may be injected
Into the extruder head, and the product may be "expanded." The resultant
pieces aie conveyed directly through drying ovens (drying temperature
51
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DRAFT
MINOR
INGREDIENTS
BONE
STORAGE
DISINTEGRATE
STEAM
WATER
SPILLAGE
CLEAN-UP
GRAINS, PARTICLES
p ^ COOLING
WATER
FIGURE 9
PROCESS FLOW DIAGRAM FOR
CANNED PET FOOD
RATION TYPE
. 52
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DRAFT
MEAT
STORAGE
GRIND
1
MINOR
INGREDIENTS
i
MINOR
INGREDIENTS
MIX
STARCH
WATER
VEGETABLES
(OPTIONAL)
MINOR INGREDIENTS!
SPILLAGE
CLEAN-JP
GRAVY
COOLING WATER
PACKAGE
FIGURE 10
PROCESS FLOW DIAGRAM FOR
CANNED PET FOOD
GOURMET TYPE
S3
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DRAFT
may be as high as 316°C (600°F). The dried chunks are tumble-filled
Into cans, frozen or dehydrated vegetables may be added, and the
containers are topped with hot gravy (starch-water-flavoHng-color-
Ing mlstures). The cans are seamed, washed, retorted, cooled, ^nd
packaged.
Meat (Hr.h) and meat (fish) by-products, fresh or frozen, are taken
from cold storage and ground to the desired piece size and conveyed
to a mixer-blender. Similarly, fresh bone may be disintegrated and
added to the blender. Minor ingredients such as vitamins, minerals,
and flavorings are added as well as any desired slurries of starches
or gums (for thickening) or grains (textured soy products). Typically,
at least 50 percent of the weight is meat and/or fish. The entire
meat mixture may be filled cold at this point or It may be heated
with steam to produce different product characteristics. If the products
are filled "cold," steam-flow must be used on the seamers to achieve
adequate package vacuum. The product is pumped to the filler, and
the cans are filled, seamed, washed, retorted, cooled, and packaged.
All of the canned styles described above are typically pre-cooked
to some extent before being filled, and they are consequently filled
into cans at temperatures above 66°C (150°F). Stew products, how-
ever, are sometimes "cold-fined" so that cooking and sterilization
are both achieved 1n the retorting cycle.
The lethal effect of heat on bacteria is a function of the time and
temperature of heating and the bacterial population of the product.
To design or evaluate an 1n-package heat process, it is necessary
to know the heating characteristics of the slowest heating portion
of the container (normally called the cold zone), the spoilage organism
present, and the thermal resistance characteristic of the spoilage
organisms. The various methods of retorting, cooking, and subsequent
cooling utilize various principles to achieve commercially sterile
products. One of the simplest applications of heating food in containers
1s sterilization of cans in a still retort; that is, the cans remain
still while they are beina heated. In this type of retort,
temperatures above 121 °C (250°F) generally m?> r.ot be used or foods
cook against the can walls. This is especially true of solid-type
products which do not circulate within the cans by convection, but
it also can be a problem with liquid products. Because of r.he temperature
limit and because there is relatively little movement 1n the cans,
the heating time to bring the cold point to sterilizing temperature
1s relatively long; for a small can it 1s about 40 minutes. The cooling
cycle may be accomplished by either carefully flooding the chambers
with cool water or air or by placing the cans 1n cooling canals.
The sterilization time can be markedly -educed by shaking or agitating
the cans during heating, especially wi'.n liquid or semi-liquid type
products. Not only 1s processing time shortened, but product quality
Is Improved. This 1s accomplished with various kinds of agitating
54
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DRAFT
GUMS,
STARCHES
WATER
MINOR
INGREDIENTS
DISINTEGRATE h»-WATER
PARTICLES
COOL ^COOLING WATEFi
FIGUPc 11
PROCESS FLOW DIAGRAM FOR
CANNED PET FOOD
HIGH MEAT/FISH TYPE
1 55
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DRAFT
retorts. The cans rest 1n reels which rotate and thereby stir the
contents. Forced convection within cans also depends upon degree
of can fining, since some free headspace within can< 1s necessary
for optimum food turnover within the cans. In addition to faster
heating, since the can contents are In motion, there 1s less chance
for the product to cook onto the can walls. This permits the use
of higher temperatures than the 121*C (250CF) upper limit for a still
retort and decreases heating times.
Agitation may be of more than one type; for example, cans may be made
to turn end over end or to spin In an axial fashion with their length.
Depending upon the physical properties of the product, one or another
method may be more effective. These substantial reductions in time
with associated quality advantages are not realized in foods that
heat primarily by conduction. These cookers all have as a last step
a cooling chamber which slowly exposes the container to either cool
water or air or both until desired final temperature is achieved.
Continuous retorts (usually of the agitating type) are pressure-tight
and built with special valves and locks for admitting and removing
cans from the sterilizing chamber. Without these, pressure conditions
would not be held constant, and sterilizing temperatures could not
be closely controlled. Another type of continuous pressure retort
which is open to the atmosphere at the inlet and outlet ends is the
hydrostatic pressure cooker.
This type of heating equipment consists essentially of a "U" tube
with an enlarged lower section. Steam 1s admitted to the enlarged
section, and hot water fills one of the legs of the "U" while cool
water fills the other leg. Cans are carried by chain conveyor down
the hot water leg, through the steam zone which may Involve an undulating
path to increase residence time, and up the cool water leg. These
legs are sufficiently high to produce a hydrostatic head pressure
to balance the steam pressure in the sterilizing zone. If a
temperature of 127°C (260'F) is used in the Steril1z1nq zone,
this would be equal .to a pressure of about 1.36 atmospheres, which
would be balanced by water heights of about 16.77 meters (46 ft) in
the hot and cold legs.
As cans descend the not water leg and enter the steam zone, their
Internal pressure increases as food moisture begins to boil. But
this Is balanced by the increasing external hydrostatic pressure.
Similarly, as high pressure cans pass through the water seal and ascend
the cool water leg, their gradually reduced Internal pressure is balanced
ty the decreasing hydrostatic head in this cool leg. In this way,
cans are not subjected to sudden changes In pressure.
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DRAFT
Process Description for Dry Pet Food - As shown in Table 4 , dry
pet food has rapidly Increased Its share of the pet food market in
recent years and now represents approximately half the total pet food
sold by weight.
Figure 12 shows a typical flow diagram for dry pet food manufacture.
Various grains such as soybean meal, corn, wheat, barley, milo, and
oats are measured from storage silos into a large mixer/blender.
Other items such as poultry meal, meat meal, liver meal, etc.. may
also be added as per specific formula. In addHion, micro-ingredienti
such as calcium and potassium additives are introduced into the blender.
Agitation is sufficient to produce a homogeneous blend. The entire
mixture is sent through a hammer-mill. Oversized particles are removed
by screening and recycled to a storage tank where they become an initial'
ingredient and are remilled. The ground fraction of acceptable particle.
size Is conveyed directly to a surge tank.
The mixture at this point may be fed directly into an extruder/expander
or it may be preconditioned with steam. Preconditioning softens the
product and raises its moisture level from a dry range of 12 to 14
percent, to approximately 20 percent. This also aids in gelatinization
during the extrusion process. Additional steam is injected into the
mix at the extruder/expander to raise the moisture level to 22 to
30 percent.
The moist meal is fed into the extruder chamber, which is a stainless
steel tube containing a stainless steel scn>w. Water jackets around
the outside of the extruder maintain proper temperature. Tem-
peratures in the extruder range up to 148.9°C (300"F), and the
product can be in the unit from 30 to 60 seconds. During this time,
the grains and starches are cooked, and all of the Ingredients are
w*ll blended, The product is forced through the extruder die and
cut by a series of whirling knives. Moisture of the product leaving
the extruder 1s 19 to 27 percent.
The moistened and expanded product is conveyed to a drying oven, where
the moisture level is reduced to approximately 10 percent. After
the product leaves the oven, it goes over a series of screens and
then flows tjirough the fat and coating drun. Additional Ingredients
such as flavorings and fat soluble vitamins may be added to tne animal
fat.
The finished product is either stored in bulk for several days or
directly packaged Into desired container sizes.
Because of its low moisture content, dry pet food has excellent shelf
lift without further preservation. Ant1ox1dants and mold-inhibitors
ere sometimes added to the final coating.
57
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DRAFT
DRY STORAGE
(SIl.OS)
MICRO
INGREDIENTS
DRY BLEND^j
STEAM
FAT
VITAMINS
FLAVORS
RECYCLE
"FINE 5"
HAMMERM1LL
SCREEN
SURGE
RECYCLE 'OVERS'
PRE-CONDITION
EXTRU&E/
EX'AND
DRY
COATING
DRUM
BULK
STORAGE
SCREEN
PACKAGE
-STEAM
CLEANUP
FIGURE 12
PROCESS FLOW DIAGRAM FOR
DRY PET FOOD
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DRAFT
SIC 2051 - Bread and Other Bakery Products, Except Cookies and Crackers
Background of the Industry - The bread, cake and related products industry
Includes establishments primarily engaged -in manufacturing bread, cakes,
and other perishable bakery products. This Industry also includes es-
tablishments producing bakery products for sale by home-service delivery
or through one or more non-baking retail outlets.
Bakeries tend to specialize in the products they make with the major
divisions along the lines cf the following: (a) bread iypes and items
such as donuts, snack cakes, snack pies, and sweet yeast goods, and
(b) bakeries which produce primarily full size cakes or pies.
Most bakeries, when baking specialty items such as snack cakes and snack
pies, do not bake larger c?lsi.ii
-------
D.WT
method, accounting for more than 60 percent of all bread made 1r. this
country. This method yields a somewhat coarse and unevenly textured
bread compared to the continuous mix process. The conventional inethoJ
1s described below. Figure 13 presents a typical process flow diagram.
Raw materials used In the baking of bread are purchased in bulk and
1n bins, vats, or bags. Floy requires larger storage facilities than does
shortening, yeast, sugar, salt, and other lesser ingredients. Fruits
used in snack pies or regular pies are purchased frozen and with addition
of sugars and syrups are used as pic fillings. Cthcr ingredients which
are used in lesser quantities, si'Ch as raisins, sesame seed, and rye
meal, are purchased in paper sacks and stored in rooms with temperature and
humidity control .
From its 18,000 to 50,000 kg (1C, 000 to 1)0,000 Ib) storage bins, the
flour is pumped or screw conveyed to a sifter which renoves under. irfiabl?
foreign matter. From the sifter, the flour 1« transferred directly to .
the mixer where ingredients are either added automatically or manLally
depending on the type bread being made. This mix is referred to as 3
"sponge mix" and contains flour, shortening., water, and yeast.
The mixing equipment is cleaned each dsy by scraping the wa^s of the
mixers to remove any dough which moy adhere. Material removed from the
mixers is either used for animal feed or is taken to a sanitary landfill
for disposal. No water is used during the da-iy cleaning process unless
mixing has been completed for the day because the action of water and flou-
together could impede any mixing wMch would occur soon after cleanup.
Water is used tc clean mixers after all mixing has been completed for the
day or during a down day when a major clean-jp of the plant occurs. This
allows the mixers to dry sufficiently before the next day's operation.
Once the sponge mix is completed, the dough is placed into I'.rge greased
troughs. The troughs ar<> rolled into a fermentation room where the
fermenting actlor of the yesst produces carbon dioxide '.vhlch causes
the dough to rise. Tne fermentation room has controlled tt>:nper.'ture and
humidity for optimum results. The dough .-emains in this room for ubnut
five hour;: or until it h.:s risen fully.
When fermentatlor Is completed, the troughs are removed from the room
and the dough beaten down by hand. The trourh
-------
DRAFT
CLEANING
SOLID
WASTE
n
CLEANING
WASTEWATER
FIGURE 13
BREAD - CONVENTIONAL MIX METHOD
PROCESS fLDw DIAGRAM
61
-------
of about 20 minutes. After the second mix, the dough is emptied back
into a greased trough where it remains for an additional 20 minutes.
This is referred to as "floor time" and allows the dough a second rising.
The second mixer is cleaned in a manner similar to the sponge mixer.
When floor time is complete, the dough is emptied into the divider, which
divides the dough into prescribed portions by weight for one loaf of
bread. At the end of each production day, the divider is dry cleaned
to remove excess flour and dough. Useable dough is returned to the
divider hopper for further use. Dough which cannot t/e used is handled
as solid waste.
Once divided, the dough is conveyed a short distance to the rounder. The
rounder is a centrifuge which forms the dough into round shapes and dis-
charges it. The rounder generates a considerable amount of solid waste
which is normally removed by dry cleaning.
The next processing step is called "dry proofing." The rounded dough is-
dropped into pans or into a dry proofer which has captive trays where
it remains at room temperature from 8 to 20 minutes for further rising.
Again, t!ie pans or trays used for dry proofing are usually dry cleaned.
After completing the dry proofing, dough is conveyed to the sheeter.
In the sheeter, the dough is first relied into a pizza-liks shape and
then through a molder to form it into the familiar blunt cigar shape of
a loaf of bread.
After shaping, the dough is put into pregreased pans. If a pullman or
sandwich loaf is to be made, a pan lid will be placed over the pans.
Thi^ creates the familiar square sandwich ''oaf by preventing the dough
fro; rising to form a rounded top. The pans are then conveyed into a wet
proof box and remains there for about 40 to 70 minutes. The wej proofo
box is heated considerably above the room temperature (up to 53 C, 125JF)
and the humidity is increased. This causes the dough to rise and fill the
pans before baking. Hhen removed from the wet proof box, the panned dough
is conveyed to ovens. The bread moves slowly through the ovens where it
bakes for about 20 minutes.
The pans of bread are then conveyed to a depanner which removes the bread
from the pans. This is accomplished by blowing air into the pans to free
the bread. Tne pans then pass under a series of suction cups which lift
the bread out of the pans. The bread is deposited onto a conveyor and the
pans go to a separate conveyor where they are returned to the production
line for further use. Bread pans are seldom washed. Generally they
are regreased and used continuously until the glaze inside the pans begins
to show wear. When this occurs, the pans are sent to a contractor to be
thoroughly cleaned and reglared.
The loaves of bread are air cooled while being conveyed to the packaging
area where they are fed through high speed knife bands which slice the
.62
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DRAFT
bread. After slicing, the bread is automatically bagged and placed on racks
for distribution to the loading and shipping areas. The slicing generates
substantial amounts of crumbs, These, along with raisins from raisin
bread, are swept from the equipment and floor and handled as a solid
waste.
Wet c!eanup methods are used infrequently in most bakeries. During special
cleanup shifts or when a production line is shutdown, equipment and floors
are dry cleaned as thoroughly as possible using air to blow residues
from equipment and brooms and vacuum cleaners to clean the floors. This
is followed by wet cleaning the floors and the mixing equipment. The
floors are cleaned using mops and buckets or scrubbers which vacuums
the water from the floor as it is used. Mops, buckets, and scrubbers are
then cleaned and emptied as needed. Mixers are cleaned using a mixture
of water and mild detergents followed by a thorough flushing with fresh
water.
Description of the Continuous Mix Bread Process - The continuous mix
method of ,-naking bread is used at some bakeries. It produces bread in
lers time than the conventional process; however, the finished product
has an extremely fine texture and is considered less flavorful then bread
made using the conventional process. Figure 14 is a process flew diagram
for this method.
In the continuous method, a slurry of ingredients is produced. The slurry
is much less viscous than the dough produced in the sponge mix for the
conventional process. This slurry is pumped into a refrigerated holding
tank in which it is slowly agitated and sone fermentation takes pla;:e.
The slurry is then transferred to a oremixer where additional flour and
other ingredients are added.
From the premixer, the dough is then pumped through a developer and the
dough is extruded and divided into individual loaf size portions and
deposited directly into pregreased pans. After being deposited in the
baking pans the dough is processed in the same manner as in the conventional
method.
The continuous mix.method eliminates the fermentation time, second mixing,
floor time, dividing, rounding, and dry proof operations of the conventicrj!
mix method.
Mixing equipment is cleaned daily because everything up to the mixer is
liquid in form. The slurry and holding tanks are flushed with fresh
water each day and small utensils are washed continuously. Floors are
cleaned with brooms or vacuum cleaners throughout the area except for the
mixing room which is generally mopped. Because continuous mixing is
primarily liquid, the mixing area is wet and requires frequent mopping.
Description of the Snack Cakes Process •• Snack cakes, which are widely
produced by bakeries, are products requiring special equipment for Its
manufacture and handling, The equipment is designed to make a specific
63
-------
DRAFT
CLEANING
r
t
SOLID
WA.5TE
WASTEWATER
FIGURE 14
BREAD - CONTINUOUS MIX METHOD
PROCESS FLOW DIAGRAM
-------
DRAFT
product. A typical process flow diagram is shown in Figure 15 .
Raw materials for snack cakes Include the basics of flour, shortening,
and sugar, plus minor ingredients such as leavening agents, preservatives,
artificial flavorings and colors, and ingredients for fillings. Storage
of raw materials involves bulk tanks, drums, and bags.
Some ingredients are premixed fn vats or tanks prior to transfer to
a mixer. In the mixer, other ingredients are added and blended into the
batter. The batter is then pumped to a depositor which releases the proper
amount into pregreased baking pans. Snack cakes require a large number
of smaller utensils such as small tubs and beaters for the mixing and
are cleaned frequently. Each time a different line of snack cake is made,
all related mixing equipment must be thoroughly cleaned in the wash room.
This is done using a high pressure spray. Solid waste is in the form of
flour, paper sacks, and other ingredient containers which are discarded
when emptied.
The pans are then .conveyed through an oven for baking. In some plants,
air is bubbled into the batter to aid in the rising process. When baking
is complete, the cakes may be dumped out of the pans for further processing
or may be filled with creme. This filling is accomplished by injecting
the creme using a series of needles, Filled cakes are then dumped from
the baking pans for further finishing or packaging.
Most of the equipment used in producing snack cakes is water cleaned. The
mixing vats, mixers, piping, and depositors are normally washed daily,
or when the cake variety 1s changed. The washing of cake pans is the
source of the strongest wastewater in most bakeries and occurs due to cans
being washed after each use. In-plant studies ( 7 ) at one bakery noted
a BOO of 54,000 mg/1 in the pan wash water. Pans are wash'"J as infrequently
as possible. At least one bakery has completely eliminated pan washing
with a resultant decrease in waste load.
After being dumped from their baking pans, snack cakes pass through a
series of finishing operations. These include slicing, icing, filling,
dusting, and enrobing. These operations generate large amounts of solid
waste and require wet cleaning, [n particular, the enrobing machine,
which coats the entire cake with icing, must be water cleaned and yields
a strong waste stream; however, it may require only infrequent cleaning
depending on its degree of usage. The solid waste generated at these and
other steps in cake baking are often sold as additives for animal feed.
Packaging follows finishing. Snack cakes are automatically wrapped singly,
1n pairs, or in larger groups in plastic wrapping material. They then
pass through a metal detector which removes packages containing metal.
Description of Process • Cakes - The production of full-size cakes is
similar to that of snack cakes, except for the lack of finishing steps
other than icing. Figure 16 illustrates the process flow for cake baking.
65
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DRAFT
CLEANING
£L FAN ING
£J_F_AN I NG
CLEANING
r
PREPARATION
OF FINISHES
PREPARATION
OF FILLINGS
CLEANING
H
— -i
*
SOLID
WASTE
MIXING
1
DEPOSITING
\
BAKING
I
COOLING
i
DUMPING
.
F I NI SH I NG
i
COOL ING
I
PACKAGI NG
i
STORAGE
h CLEANING |
-
CLEANING
_ n
* 1
GREASING
1
| WASHING fc|
1 1
r CLEANING
CLEANING
CLEANING
, »_|
CLEANUP J
WASH CLEANING,,^.
ROOM ~" *"
1
WASTED
FIGURE 15
SNACK CAKt PROCESS FLOW DIAGRAM
66
-------
DRAFT
$ LE_ANINJ
SOLID
WASTE
FIGURE 16
CAKE PROCESS PL3W DIAGRAM
67
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DRAFT
Manufacturers of full sized cakes normally produce a greater variety of
product than do snack cake bakers. This large product variety results
in a frequent (every few hours) change of production from one item to
another. The cleanup of the equipment between products results in larger
volumes (estimate: two to three times) than in snack cake plants which
produce a single product on a given production line. Wastewater Is also
generated during daily mechanical scrubbing of the floors and occasional
mopping of accidental spillages. Cake pans are washed with high pressure
spray in a tunnel type washer with a recirculating reservoir which is
normally emptied and refilled every eight hours.
Solid wastes result from the disposal of ingredient shipping containers,
breakage of the baked cakes, malfunctions of the packaging machinery,
incorrect baking and mixing formulation errors.
Description of Process - Snack Pies - Snack pies are made from refrigerated
dough and contain one or more fruits or other fillings. Snack pies can"
be either baked or fried but are generally baked. The two major elements
of pies are the dough and the filling. Figure 17 illustrates a typical
process flow.
Flour, shortening, sugar, preservatives, flavorings, and additional
ingredients are mixed together. After thorough mixing, the dough is
dumped into a hopper which feeds the dough through an extruder to form sheet:
of dough. This is referred to as sheeting.
When sheeted, the dough is placed on racks and then into a refrigeration
unit for approximately 20 minutes. When refrigeration is complete, the
dough is removed and placed into a second hopper located at the production
line. When the dough is extruded or sheeted a second time, it is the
proper thickness and width and is a continuous ribbon of dough.
Mixers and extruders are cleaned daily by scraping excess dough from their
surfaces. Excess dough which cannot be used further is used as animal
feed or is disposed of as a solid waste. If the production line is
shutdown for an extended period of time, the equipment is thoroughly
washed with water. The production area is dry cleaned then mopped with
mops and buckets as a part of the daily cleanup program.
Fruit used in these pies ib purchased frozen in 14 kg (30 Ib) containers.
The fruit is first cooked in a vat then conveyed to a mixer where additional
ingredients are added for sweetners and for substance to prevent the fruit
from bleeding through the crust. When thoroughly mixed, the fruit is
pumped to the depositor located at a point where the fruit ii added to
the pies.
All related fruit processing »quipment is washed each time a different
variety of fruit is used. Wastewater from this process is from cleanup
water with some solid waste going into the sewer or on the floor.
As the dough is extruded and the ribbon of dough proceeds to the depositor
68
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DRAFT
CLEANING
'—I
CL£*jyj Mi . J
CLEAN1 NT,
_CLEANUP
SOL 10
WASTE
FIGURE 17
SNACK PIES
PROCESS FLOW DIAGRAM
69
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DRAFT
for fruit filling, it is cut to the proper length to include the top
of the pie. When cut, the dough rests on a forming machine which folds
and crimps the pie after it is filled with the fruit filling. Once
formed, the pie Is then Inspected for quality before being conveyed
to the oven or fryer. After baking or frying, the pie passes through
a spray of sugar glare for finishing and is conveyed to the final
Inspection and packaging area. Pies are individually packed in cellophane
or glasene wrappers for distribution.
Cleanup of the production equipment Is generally dry unless the line is
shutdown for an extended period of time. Daily cleanup consists of dry
cleaning the floors and equipment with brushes and brooms. Water is
used for cleaning fruit filling mixer, cooker, and depositor. During down
days, floors may be wet mopped or cleaned with scrubbers, wasted dough
is substantial where the pies are cut, formed, and crimped. Rejected
pies, doughs, and other solid wastes are used as animal feed or go to •
sanitary landfills.
Description of the Pie taking Process - Pie making is very similar to the
process of making snack pies in that dough is mixed, refrigerated, sheeteci,
formed, filled, and baked. After the dough is mixed it is sheeted and
refrigerated once or twice to produce a flaky crust. The dough is put
into a hopper located above the sheeter and then is extruded in continuous
ribbons which are placed on racks and then refrigerated. After cooling,
the dough may be put through a second sheeter. See Figure 10 .
The dough is then conveyed to a point where it is placed over an aHiminun
pie pan and is pressed and formed into the pan. Immediately following
the forming of the dough, the dough-lined pan is trimmed of excess dough
which 1s reused. After the pie is trimmed, it is moved to the filler
where the fruit or other filling is deposited. If a top crust is desir»o,
the unbaked pie is conveyed to a second extruder which extrudes a sheet
of dough over the pie, forms it to the desired shape, and crimps the
The trimmings of dough from both lower and upper crusts arc recycled
used sgaln for pie crusts. The pies arc then placed on a contiguous
conveyor which conveys them through an oven where they are baked. After
baking, the pies are placed on racks and permitted to cool sufficiently
before packaging. .If a finish on the pie crust is desired, a mixture of
sugar and egg white Is sprayed on the crust immediately after baking to
produce a glaze. The pie is then inspected, packaged, and boxed for
distribution.
Fruit used in pie fillings are purchased frozen in 14 kg (30 Ib) containers
and cooked 1n a vat. From the cooking vat, the fruit is pumped to a large
hopper where additional ingredients are added for sweetness and to give
the fruit filling more substance. After being thoroughly mixed, the
fruit is pumped to the filler where it is deposited into the pie shells.
When pies are made with no top crust, the filling, as in creme or leinon
pies, Is deposited after the pie shell has been baked. Additional finishes
or toppings may be applied. The pies are then inspected and packaged in boxes.
.70
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DRAFT
CLEANING
I LLtANlNO
r I
CLEANING
I
MIX
SHEETED
REFRIGERATED
CLEANING
SHEETED
FORMED
r
CLEANING
PREPARATION
OF FILLING
CLEANING
FILLING
— f._7 - CLLEAKJ LNG__ _j
BAKED
CLEANING
SPILLAGE CLEANUP I
[JX.EAN _ING_
I
I
PREPARATION
OF FINISH
SOLID
WASTE
FINISHED |
1 *_ £ UE-A^LLNfi- _J
PACKAGED 1
WA5TSWATCR
FIGURE 10
PIE:
PROCESS FLOW DIAGRAM
71
-------
DRAFT
Cleanup of the pie production area generally follows a daily dry cleanup
routine. The fruit cooking and mixing utensils are cleaned with water
each time a different fruit filling is desired. The fruit mixing area
is generally clean except where spillage may occur and this is removed
by shovels with water being used where needed.
During down days or days when the line is not in production, a major
cleanup of all equipment is done by washing thoroughly with water. The
bulk of solid waste is generated by containers such as cans, cardboard
boxes, and cardboard containers which contained frozen egg whites, frozen
fruit fillings, or minor ingredients. A small amount of dough, flour, and
fruit fillings also contribute to the solid v/aste.
Description of the Cake Doughnut Process - The ingredients for doughnuts
are similar to those for yeast doughnuts" and are stored and handled in
nearly the same manner. The princioal .1ry ingredients are, in so«ie cases,
purchased prefixed, Uater is added to the premix in a large vertical
mixer with recondary ingredients mixed separately and added manually.
Figure 19 illustrates a typical process flow.
Doughnut uatter is transferred to an extruder. This machine forms the
doughnuts and deposits them into the cooking oil. Both the mixer and
the extruder are dry cleaned to the extent possible and then cleaned with
water.
Doughnuts are fried In a hot oil bath. They are conveyed through the oil
cooking on one side. Midway through the oil bath, the doughnuts are
turned over 1n order to cook the other side. Upon completion of frying.
the doughnuts are removed from the oil and conveyed through a spray screen
of sugar glaze. If any finish is required other than sugar glaze, the
doughnuts are reheated by Infra-red lights located above the conveyor
belt while a sprjy of any one of several finishes is applied to the
doughnut. They are then cooled and conveyed to the packaging area where
they '.re inspected and packaged. Packaging is normally in bags or boxe<;
containing a dozen doughnuts,
Wastewater from '.he mixing, finishing, and packaging operations is generated
by the washing or related utensil1; such as mix bowls and oeater blades.
Floor cleaning is done daily using brooms or vaccum cleaners with occasional
wot mopping for spills. During down days or when time permits, the floors
are thoroughly washed with wet mops or with scrubbers, which pick up
the dirty water.
Description of the Yeast Doughnut Process - Yeast type doughnuts are made
using yeast, rather than baking powder, as in the cake type, for leovpning.
Generally, the mix is purchased in bags with all the needed dry iriyredients
blended together as an alternttive and primary method to making doughnuts
from scratch and mixed with only water to complete the dojghnut dou")h. Sec
Flnure 20.
72
-------
DRAFT
CLEANING
I
-| FINISHES r
SOLID
WASTE
CLEANING .
1
T CLEANING ^
WASTEW4TEP
FIGURE 19
DONUTS - CAKE TYPE
PROCESS FLOW DIAGRAM
73
-------
DRAFT
SOLID
W^STE
WASTEWATER
FIGURE 20
DON'JTS - YcAST TYPE
PROCESS FLOW DI4GPAM
-------
DRAFT
The dough is tfitn scaled to verify that the proper amount of water has
been added. After scaling, the dough is fed into a hopper which extrudes
the dough in sheets and the doughnuts are stamped out. Excess dough
is returned to the hopper for further use.
The doughnuts are tnen pic trays which are conveyed to a wet proof
room for about one hour to ,te rising. After completing the wet
proof cycle, the trays are tipped, a-'d the doughnuts fall into the hot
oil bath. Midway through the hot oil bath, the doughnuts are turned over
1n order io cook the other side.
Upon completing the frying period, the doughnuts are removed from the oil
and conveyed for finishing with any one of several finishes, such as
glazing or powdered sugar. Finish and filling equipment is cleaned each
day to prevent clogging of the equipment. Creme fillers generate sub-.
stantial amounts of solid waste and must be cleaned frequently.
When the doughnut has been finished and cooled, fillings may be injected
by needle. After finishing and filling, the doughnuts are then inspected
and packaged in consumer size packages of 6 or 12 doughnuts.
Floors are dry cleaned by sweeping or swept with brooms during normal
daily cleanups. Related equipment for mixing doughnuts is washea at the
end of oach shift to prevent clogging of equipment. Excess dough is
constantly being scraped free of equipment and is handled as solid waste.
SIC 2052 - Cookies and Crackers
General - The cookie and cracker industry is primarily engaged in producing
crackers, cookies, pretzels, and other "dry" bakery products. In 1972,
the industry consumed 1.10 million kkg (1.21 million tons) of flour,
0.32 million kkg (0.35 million tons) of sugar, 0.27 million kkg (0 ">
million tonsjof fats and oils, and 0.05 million kkg (0.055 million :jns)
of other ingredients. There are a total of 311 plants, 40 percent of
which are located in the northeast. The total employment for the industry
is "1,000. According to the Biscuit and Cracker Manufacturers' Association
( 3 ), of the total SI.69 billion value of cookies and crackers shipped
in 1974, large national and regional corporations were responsible for
approximately 70 percent.
According to the Bureau of the Censur ( 2 ), the trends in the cookie
and cracker industry are a decrease in the number cf plants and employees,
and an increase in the quantity and value of products produced. Thus,
the industry is apparently becoming mere automated and consolidated. A
few new cookie and cracker plants are being constructed. These will
rely almost entirely on computer-controlled processing, thus decreasing
the manpower requirements and waste due to human error.
75
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DRAFT
Description of the Cookie and Cracker Process - Process flow diagrams
for cookies and crackers are shown in Yigure 21 • Ingredients used in
large amounts for the manufacture of cookies and crackers are received
and stored in bulk. These include flour, sugar, shortening, invert syrup,
and corn syrup. The flour is sifted before these dry ingredients are
weighed and pneumatically conveyed into the mixers. The liquid ingredients
are metered and conveyed to the mixers.
Ingredients which are used in small quantities are received and stored
on pallets in their shipping containers. These materials are measured,
sometimes prefixed, and added to the mixers manually. Normally, the
only source of wastewater generation from raw materials storage is the
periodic cleaning of the liquid storage tanks.
The mixing operation is normally performed in batches in one or two
stages, or continuously by either a vertical or horizontal mixer. The •
vertical mixer has a series of mixing blades attached to three vertical
arms. The entire mixer can be raised and lowered and is designed for
use with a dough trough which is wheeled unoer the mixer. This mixer is
preferred for use in two-stage mixing processes since the dough from the
first mixing does not have to be added at the second mixing stage.
Horizontal mixers are more common and have a single mixing blade which is
horizontally positioned. The mixing chamber is rectangular with a concave
bottom to allow the mixing blade to incorporate all the ingredients. In
this type of mixer, shortening and sugar are normally added fi"-st, followed
by the liquids, and then the flour. The temperature of the dough is
regulated by adjusting the temperature of the ingredient water.
Batches of dough range from 135 to 450 kg (300 to 1000 Ib), primarily
depending on the capacity of the mixer. In the case of dough which
tends to dry out while standing, batches of less than maximum capacity
are used. According to the Biscuit and Cracker Manufacturers' Association
( 9 ), mixing time ranges from four minuter to one hour, depending on
the product.
In thp plants of the major producers of cookies and crackers, mixing
equipment usually operates continuously five or six days a week. Mixer:
are cleaned out on varying schedules. In near-continuous operations, they
are cleaned on down days. In other situations, mixers are cleaned daily
or between varieties of product. Cleaning consists of scraping the mixers
as clean as possible and then rinsing with hot water. The ingredients
that are scraped out are handled as solid waste, which minimizes the
wastewater load from thir cleaning process.
After mixing, the dough is emptied into a dough trough mounted on casters.
From this trough, the dough is transferred to the forming machinery. There
are five basic types of forming machines as follows:
1. The stiffest dough is formed by a rotary machine. The forming
is accomplished by forciny the 'lough against an engraved
cylindrical die and scraping away the excess with a knife edge.
76
-------
DRAFT
r
~
—
L--
I
r
SOLID
WASTE
COOKIES
M
IXER
HOPPER
FORMING
*
OVEN
*
COOLING OR
CHILLING
JL
ICING OR
ENROBING
(OPTIONAL )
JL
STACKER
PACKAGED
CRACKERS
MIXER
HOPPER
I
SHEETED
L
STAMPER
j_
OVENS
J
_ CLEANUP
CLEANUP
CLEANUP J
FLOOR
CLEANUP
(VACUUM-TYPE
WET AND DRY
SCRUBBERS)
I 1
1
J
H
CLEANUP
r \ F AMI IP
COOLING OR
NG
FLOOR
CLEANUP
(VACUUM-TYPE
WET AND DRY
SCRU3JER3)
_I
SALTINC 3R
O 11. I NG
(OPTIONAL )
J-
WAST£WATF=>
STACKEP
PACKAGES
FIGUPE 21
COOKIE t C3ACKE3S
PROCESS PL:.V D! AGRA
7/
-------
DRAFT
The top surface of the cookie retains the cesign on the cylinder,
as examination of a sandwich or butter cookie will show.
2. Fairly stiff and extensible (stretchable) dough is formed into
sheets and cut into cookies by a cutting machine. All crackers
and some cookies, such as ginge' snaps, are made using this
machine.
3. Bar forming machines use dough which is considerably softer.
These machines extrude .the dough from a die (with a number
of different openings) onto a moving belt which carries them
through the oven. The strips of dough are cut into bars either
before or after baking.
4. The wire cutting machines operate in a manner similar to the bar
forming machines except that as the dough is extruded from the.
die, it is cut into individual cookies with a taut wire. For
most products commonly formed with this machine, such as oatmeal
cookies and vanilla wafers, the cookies drop onto the baking
surface.
5. Deposit forming macnines deposit the dough as individual cookies
without the use of a wire. This method is similar to the cookie
press used by homemakers. These machines are similar enough to
wire cutting machines that a slight modification in formula
permits, for example, oatmeal cookies to be made by the deposit
method.
Pretzels, sugar wafers and ice cream cones utili2e specialized forming
equipment. Pretzels are extruded and cut into sticks or tied by mechanical
equipment. Batter is injected onto plates or matching dies for baking
sugar wafers and ice cream cones.
Wastswater is generated in the forming process during the cleanup of
the machinery. Rotary formers and the nozzles from extruding machines
are commonly water'or steam cleaned in a wash room. Other forming machines
are wet cleaned or dry cleaned in place with compressed air.
The standard oven in the industry is a long (normally 90 m) tunnel oven.
The baking surface is a continuous metal belt. In cracker production,
wire mesh belts are often used in the ovens. Baking time varies from 2
to 15 minutes depending ftn the type of product. Saltines and snack
crackers normally have the shortest baking time. Cookies such as fig
bars and chocolate chip are baked froru seven to eight minutes. No
wastewater is generated as a result of the baking process since the ovens
Jre dry cleaned and wiped down with an organic solvent.
7B
-------
DRAFT
After baking, the product is protected from cold drafts to prevent checking.
Sandwich cookie bases are applied warm thereby reducing product breakage.
For most other cookie and cracker products, ambient air cooling is all that
is required. These temperature control processes do not produce a waste-
water load since the equipment is dry cleaned.
Cracker products are salted and/or sprayed with oil. The salting machinery
is dry cleaned. The oil spraying equipment recirculates the oil it uses
and does not normally require cleaning.
Sandwich cookie bases, marshmallow cookies, sugar wafers and similar
products are iced and/or enrobed (coated) after baking. The icings
and coating are mixed in stainless steel vats and carted or piped to
the appropriate machines. In large more modern plants, the vats and
piping are usually cleaned by a "dean-in-place" (CIP) system which
utilizes pre-rinse, wash, and final rinse cycles. In older plants, the
smaller mixers and other equipment are wet cleaned manually with hoses.
The mixing vats, pipes, aid enrobing equipment are scraped and not
cleaned at the end of each product run, which may occur several times a
day for each line. This is a significant source of waste load within
the cookie production process.
Packaging of the final cookie and cracker products is designed to minimise
breakage and maximize shelf life. According to the Biscuit and Cracker
Manufacturers' Association ( 8 ), both cookies and crackers may be tumble
packed or shingle stacked for packaging. Packaging containers include
bags, overwrapped plastic treys, and cartons. Moisture proof materials
are used to sea! the packaged product. The packaging is performed
mechanically. The equipment is dry cleaned with compressed air weekly.
The steam room and the CIP system are the largest contributors to a
plant's waste load. All equipment associated with icing and enrobing
is cleaned by these methods, and these materials have high concentrations
of sugar and other organic materials.
General cleanuo is a dry process. Wooden floors may be found in some
sections of cookie and cracker plants, evidence that the cleanup processes
in those areas are dry (vacuum and sweeoing). Areas which are subjected
to liquid and semi-liquid spillage are wet cleaned using hoses, mops,
and vacuum-type wet scrubbers.
79
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DRAFT
SIC 2065 Confectionery Products
Background of the Industry - Included 1n this classification are those
establishments primarily engaged in manufacturing candy, Including choco-
late candy, salted nuts, other confections and related products. Confec-
tions have been produced since pre-historic times, however, the extensive
production of refined sugar based candles did not occur until the late
18th century. Candy-making machines were invented during this period and
the Industry has grown steadily since then. Today there are over 2,000
different varieties of confections and an average per capita consumption
of 8.5 kg (18.7 Ib).
The confectionery industry marketed $2,472 million in products in 1972,
an increase of 32 percent compared with 1967. The growth of the industry
will likely continue in the future, but probably at a reduced rate due
to increased raw material costs and a leveling of consumer demand.
In 1972 there were 993 establishments processing confectionery products -
(2); however, of this number only slightly more than one third employed
more than 20 persons. Most of the larger plants are concentrated in
the north central and northeast region, the smaller establishments being
more widely distributed. The following process descriptions concentrate
on the basic production techniques which are common to most of these
varieties.
Description of the Candy Bar Process - Figure 22 shows a typical flow
diagram of a candy bar process.Although the range of candy bar types
is diverse, the manufacture of all bars is basically a single process,
in which there are two stages. In the first stage, the candy nougat or
center is prepared by cooking together varying quantities of sugar, corn
syrup, water, starch, cocoa, milk and other ingredients.' The type of
ingredients utilized depends on the variety of nougat desired. The amount
of moisture removed 1r cooking of the various constituents determines
the density of the finished nougat. One of two types of cooking is generally
employed: 1) Pre-cooking, wMch is usually accomplished in open batch or
continuous- type cookers, and 2) vacuum cookers, which evaporate off excess
moisture from the mixture under vacuum. A combination of both types of
cooking can b>> utilized in a two step operation.
After cooking, the nougat is either cooled and aerated, or blended with
other Ingredients. In the first cese, the nougat mass is cooled, then
subjected to physical working. For lighter, soft nougats, this physical
working is called aeration and is accomplished by some form of pulling
or whipping action, while for hard nougats, kneading is used to work the
mass. In the second case, numerous Ingredients of various kinds may be
added to the nougat to modify its flavor, texture, and appearance. Such
ingredients include vegetable oil, coconut, milk powder, peanuts, and
caramel.
BO
-------
DRAFT
BURNT
PEANUTS
LIQUID
SUGAR
n;ORN
iYRUP
*
— •* COOK
•*-
MISC.
INGREDIENTS
W/
MISC.
EBRIS
ONTAMIN/I
1
^
TED CANC
":
K
BASE
BAR
D-l 1
-J *
FORM
~vx
ENROBE
WASHDOWN
WASHDOWN
* — IHOCOLATt
h1 STORAGE
BLf NO «
COOK
j
f>f\
s
1
COuu _ _
«•
COOLING'
H20
• PRE-PTOCESSEI
, CONT_AMINATTD_CANDY
"
¥
SOLlOS
CHOCOLATE
L WA1HDOWN J JCOJ.ING_H20_ .
EFFLUENT
FIGURE 22
CANDY BAR PROCESS
81
-------
DRAFT
The cooled nougat, or "base bar", 1s then either molded or formed and
cut to size. Two types of molding are utilized for the base bar:
1) A compressed corn starch mold or 2) metal molds, some of which may
be teflon coated. Formed candy nougats may be extruded or passed through
rotating spinners to form candy ropes before cooling and cutting to bar
size. Some candy bar producers utilize various types of nuts in the
base bar production.
Nuts can be added to the nougat before or after forming the base bar.
The nuts, if not previously prepared, are first cleaned of stones,
loose skins and extraneous materials. The nuts are then roasted,
cooled, and sorted or graded. The good nuts are used in the product,
and culls are removed as solid waste material. Peanuts, which are used
mor.t extensively in base bar production, are either sent to grinders for.
peanut butter type bars, or added directly to candy bars in whole or
broken form. If the nuts are processed at the plant, solids resulting
from the cleaning and sorting operations are the primary source of wastes.
The second step, which is not utilized for all candy bars, is to coat
the base bar, normally with chocolate. The coating process is termed
"enrobing". Enrobing is usually a totally automated recirculating
system which coats both the top and bottom of the base bar.
MUk chocolate, which is usually used for enrobing, is prepared by blending
cocoa powder, powdered milk and sugar. After blending these ingredients,
vegetable oils are added to produce liquid chocolate. The mixture is
cooked and then cooled prior to being transferred to heated storage tanks.
Chocolate coatings may be purchased and stored 1n heated tanks prior to
being pumped to the enrobers. Enrobers use warm water jackets to keep
the chocolate fluid. This water 1s continually recirculated in most
Instances.
Whether the candy bars are enrobed or come directly from the base bar
formers, they pass through cooling tunnels. The cooling tunnels utilize
recirculated chill water systems. From the cooling tunnel*, the finished
bars are Inspected and Individually wrapped and packaged.
The ;najor waste water flows originate during washdown operations. Wash-
downs may be in the form of C.I.P. (rlean-in-place) units, which are
used on conveyors, cookers, etc., or from minor cleaning and major wash-
down operations at the end of a processing day. The wastewater from such
washdown operations is high in dissolved solids, detergents, and carbohydrate.
Most plant- recycle the majority of the chill and cooling waters used 1n
their operations. Nevertheless, some plants do discharge some or all of
this non-contact cooling water. These streams contribute significantly to
flow volumes but not to waste loadings. Other small periodic wastewater
discharge result from cleanup of spills, pump seal leakages, steam compen-
sates and other minor sources. Flows varied significantly between plants
depending on plant size, type of product, recirculatlon technique, and
82
-------
DRAFT
washdown procedures from 3,800 I/shift (1,000 gal/shift) to well over
1.3 cu in/shift (350,000 gal/shift). This large range of flows gives
some Indication of the diversity encountered in the candy bar industry.
Description of the Soft and Chewy Candy Process - figure 23 shows the
process flow diagram of a typical soft candy plant. Corn syrup, sugar,
and water are the three major raw materials used 1n the manufacturing
of chewy candies. Dry ingredients, such as cooking starches, cerelose,
and cocoa, can be added to the syrup base. Various blends of the above
constituents are either pre-mixed in slurry tanks prior to cooking, or
in the cooking kettles themselves. After mixing, the syrup is cooked
between 117°C (243°F) and 155°C (34°F). The cooking and mixing area
is termed the "kitchen," and is the location where most of the clean-up
wastewater is generated. The cooking kettles, either batc.h or continuous,
utilize steam for cooki-ng from which the condensate is generally recir-"
culated back to the boiler. Cooking takes from five to ten minutes,
depending on the percentage of moisture desired. Following cooking, which
is closely regulated, the processing steps change somewhat depending
on whether the finished candy is to be a fondant creme, soft or hard
gum, pastille, or jelly.
Fondant cremes, after cooking, are cooled continuously by taking them
from the cooker to a large slowly rotating metal drum cooled internally
by water sprays. The syrup is cooled from 117°C (243°F) to approximately
38°C (100°F) and by means of a scraper knife the syrup is removed from
the drum and discharged into a beater. The quality of the fondant is
largely controlled by the efficiency of the beater which, in addition
to bringing about rapid crystallization, must remove the latent heat by
sufficient flow of water through a cooling Jacket. If the fondant is
allowed to sit, the result 1s normally a rather dense product; a lighter
texture is obtained by the Inclusion of "Frappe." Frappe, or whip, is
prepared by dissolving egg albumen or a substitute in water and then
mixing with sugar/glucose syrup. This mixture is then beaten to a foam
by means of a high speed whisk, either under normal or increased pressure.
Frappe may be used in fondant base in varying quantities depending on the
ultimate density desired.
Lozenges are a combination of corn syrup, sugar, and starch. This com-
bination is heated and mixed or lightly kneaded. Next, rollers are used
to roll out the candy into a sheet approximately 1.3 cm (0.5 in.) thick.
The sheet is fed into lozenge plungers which shape the lozenges to their
circular configuration. During the subsequent inspection, broken and mis-
shaped lozenges are removed and reused in the process. The accepted
lozenges are placed on drying boards and air dried until hard.
Gums, pastilles, and Jellies comprise a large group of soft and chewy
confections. The prime differences between individual products are
the gelatinizing agents used and the moisture content. Most recipes for
gums rely on gum arabic or gelatin as the gelatinizing agent, but certain
83
-------
DSAFT
COOL.I.H G_t_ WA_SHDOWNJ
I
PINISHEP CANDY
1_-£T
- MOGUL
SYSTEM (NJ.O)
CANDY IN T^
MOULDS
CONDIPONING LUBRICATION j
ROOM '
'SWEEPINGS
~*~"t n
EFFLUENT
FIGHP.F ?7
CHEUY CAMDIES
-------
DRAFT
modified starches a-e also used. The syrup mixture is poured in
the gum solution and gently mixed. Flours and coloring are then added
to the mixture prior to deposition in starch molds. With the softer
gums and pastilles, it is usual to include gelatin as well as gum
arable, and the glucose syrup content is therefore higher.
Jellies may be made with the use of agar. gelatin, or pectin as the
gelling agent. Different textures are obtained. Agar produces short
textures, gelatin is inclined to produce toughness, and pectin gives
soft tender jellies with qood keeping properties. Refractometers
are generally utilized for determination of the soluble solids ena point
during cooking. The flavors and coloring are added to the setup kettles
after the cooking process. From the set-up kettles the candy is trans-
ported from the kitthen area to the candy hopper where it is discharged
in measured amounts into starch molds.
The starcn molds are used to form the confection into desired shapes
The starch employed is usually the finest dry corn or maize starch,
which takes the mold imprint in detail and is quick to absorb moisture
from the semi-liquid confectionery. Most plants utilize a fully
mechanized machine known as a "mogul1' or N.I.D. The mogul automatically
prints a tray of starch, which is then moved by conveyor to a multiple
depositor which in turn is fed by a hopper. The depositor works on the
piston principle, supplying precise volumes of liquid candy to each
starch impression. The starci trays are fed into one end of the machine
and, after filling, are removed at the other end and allowea to cool and
set in the conditioning room. After setting, the .confectionery is re-
moved and brushed free of loose starch. Excess starch is then cleaned
and recycled along with makeup starch back through the machine to ref'ill
the starch trays.
The drying (conditioning) room may or may not be heated. Fondants are
usually held for 5 to 16 hr, depending on moisture content, in the
conditioning room at 13 to 16°C (55 to 61°F). The relative humidity is
maintained between 55 and 60 percent. Hard gums are generally dried for
6 to 10 days at 49°C (120°F). Soft gum and pastille drying times vary
between one and seven days. Jellies have higher moisture contents, so
drying times are reduced and vary with desired moisture content. At
six to eight percent moisture a 5 to 3 hr storage is required, while
at 9 to 11 percent moisture a 16 to 24 hr storage is necessary.
After de-molding and cleaning of adhering starches, the candy proceeds
to the coating process. Fondants are generally en-obed with chocolate,
whereas gums and jellies are "sanded." Sandin? is a process whereby
the candy is slightly steamed to make the surfaces sticky thus holding
the crystal-sugar dusting. The sugar coatfd candy Is than subjected
to a slight drying in a warm room prior to packaging.
The main wastewater source emanating from the starch molding/packaging
area is washdown water. Lubricating water and steam condensate from
85
-------
DRAFT
the sanding machine are also two minor sources of wastewater originating
1n this area.
Hashdown from the "kitchen" or cooking area is the primary source
of waste effluent; however, many plants save the initial washdown
of cooking kettles and hoppers to be recycled, after cleaning with
carbon filters.
Description of the Hard Candy Process - There is a wide variety of
hard-boiled sugar confections, all having a basic formulation of sugar
and glucose syrup with color, flavor, and a number of other added
ingredients. Figure 24 shows the flow diagram for a typical hard candy
process. The first step in the hard-boiled sugar operation is pre-
cooking of liquified sugar and glucose until all traces of sugar crystal
are dissolved completely. The candy then goes to a vacuum cooker.
Vacuum cooking takes approximately 10 minutes, depending on the cooking
temperature, which varies between 137° and 143°C (250° and ?90aF). When-
the desired consistency is reached, the syrup may be deposited in
starch board molds analogous to soft and chewy candies, but more
commonly the syrup is taken to the kneading machine (3urk's mixer).
At this point citric acid, colors and flavoring are added, also scrap
candy is sometimes added to form a seed. The kneadin1,] process incorpor-
ates air Into the candy and cools it to the desired texture. Chill
water Is used to keep the kneading table cold co the syrup will solidify.
This water is normally recirculated. After the candy has been kneaded
to the desired texture, it is fed into machines, known as drop rolls,
which press the pliable sugar Into shapes. Alternatively, the pliabie
sugar is supplied to a "spinner," (parallel rollers) which forms it
into a "rope" which 1s then fed into a candy forming machine. This
machine cuts the rope Into small sections and forms the candy Into desired
shapes. Another continuous plant for the production of fruit drops and
similar products uses the principle of pouring the high bodied syrup into
multiple metal nolds where they pass through coolers and then are demolded
on belts.
After the candy has been formed, it is cooled either by a series
of cooling tunnels or by direct air cooling. The candy is then cleaned
and inspected. Some candles Jo not require e cleaning operation
and are iimply sized and inspecteJ prior to packaging.
The major wastewater flow associated with the hard candy proce:s
comes from washrtowns. Another source of wastewater is the vacuum cookers
viliich utilize water to draw off the condcnsate from the cookers when
forming a vacuum. Additionally, water is used to cool compressor^,
condensers and jther machinery. This non-contact cooling water 1s
generally rerirculat.ed.
86
-------
DRAFT
DISCHARGE OR RECIRCULATE
FIGURE 24
HARD'
(HARD-BOILED SUGAR)
67
-------
DRAFT
Description of the Cold Pan Candy Process - Figure 25 shows the flow
diagram for a typical cold pan candy process. A large variety of
confectionery cores can be used for this process. Some of the various
types of cores utilized are jellies, marshmallows, caramels, nuts, and
licorice.
Cold panning is essentially a cold process in which the cores are
rotated in a pan coated internally with a sugar layer. The cores
may be in any shape and are dumped into the pans in measured amounts.
Glucose syrups (60 to 65 percent concentration) are applied alternately
with caster sugar and flavors until the correct size and shape is
obtained. The circular motion of the turning pan causes the cores to
become evenly coated with a wetting agent (glucose syrup) prior to
the addition of sugars. Tne final sugar dustings are with icing
sugar which gives a smooth surface. Following dusting, the candy
is put into trays and allowed to set for 16 to 24 hr in a dry (but
not hot) atmosphere. The candy is then given a luster usually by
the addition of beeswax, carrauba wax, or spermocet. The wax is
usually applied in a molten form, in sufficient quantities to coat
the candy with a thin layer, The candy is then tumbled until a gloss
is obtained.
The major waste source from this process is waslidown water. Flows
from washdown operations have a wide range with observed values from
2000 I/day (500 gal/day) to 40DO I/day (1000 gal/day). Very little
water is utilized in the actual production of the product.
Description of the Hot Pan Candy Process - Hot panning is done in
rotating copper or stainless "steel pans which are provided with some
form of heating, such as steam jac-.ets, direct heating, or injection
of hot air into the pan. Figure 26 shows the flow diagram for * typical
hot pan candy process.
Many types of cores are utilized for this process but mainly they
cons.it of hard candies and nuts. Various types of coatings may be
utilized, i.e. nuts use a gum/syrup or chocolate coating after a
preglaze of gum arable. The coatings are poured onto the cores
while the pan is rotating and a slight heat is being applied. As the
coated cores approach dryness, icing sugar is dusted on and further
applications of syrup and starcn are made. The rotating cores enlarge
gradually with each application of syrup and sugar. The operation
continues until the desired size is obtained. Between wettings, the
confections are continually rolling and rubbing against, one another
and the sides of the pan. This aids in grinding of the high spots
and smoothing the surface. During the last stages of tumbling, colors
and flavorings may be added. Sometimes these additives are dissolved
in the syrup prior to addition to the centers.
38
-------
DRAFT
EFFLUENT
FIGURE 25
COLD PAN CANOY
C9
-------
OftAFT
EFFLUZNT
FIGURE 26
HOT PAN CANDY
an
-------
DRAFT
After the candy has been ouilt up to the desired weight or thickness
it Is transferred to holding trays and taken to conditioning rooms.
The candy remains in the room for approximately 24 hr at a relative
humidity of 45 percent. The candy Is then polished with a coating
of wax, generally beeswax, carnauba or paraffin, and packaged. Waste-
water flows art? the same as the cold candy operations described prev-
iously.
Description of the Marshmallow Process - Figure 27 shows the flow
diagram for the typical marshmallow process. There are many varied
recipes for marshmallow products; however, all contain sugar/glucose
syrups which are aerated with gelatin, egg albumen, Hyforam, or other
whipping agents. The texture and density of marshmallows can be varied
by adjusting the quantity of such constituents as egg albumen and
gelatin or by the inclusion of various gelatinizing agents or gums.
The first step in manufacturing is the weighing out of the various
ingredients before blending. Sugar and glucose are first dissolved
in water and boiled at approximately 112°C (233° F) to the proper
consistency. After cooking, dissolved gelatin and egg albumen are
then added to the syrup which has been cooled to about 71°C (160°F).
This mixture is then beaten to a thick foam. Many types of beaters
are utilized, with the main purpose bein. to incorporate air into
the product. Beating can sometimes be done under pressure to better
control the density of the product.
The marshmallow form is then augered through a scraped surface heat
exchanger wrr.ch cools the product to approximately 61'C (110eF).
Sometimes water cooled surge tanks are utilized for this operation.
The cooling operation generally uses recycled chill water that does
not contact the product. Some wastewater may be derived from this
operation in the form of make up water; however, the waste loadings
are insignificant.
After cooling, the product is formed by pouring into starch molds, by
piping through nozzles, or by extrusion. The last two methods are used
most extensively In the industry. Extrusion of the cooled foam directly
into jars yields marshmallow cream, whereas for marshTOllows, extrusion
is into long "ropes" onto corn starch covered conveyors.
The marshmallow ropes, which may vary in diameter from 1.3 to 2,5 cm
(0.5 to 1 in.), then receive an overhead application of corn starch.
The starch must be dried to a moisture content of 4 to 6 percent and th°
temperature should be below 55°C (100°F). If these conditions a«"e not
met, the marshmallow foam may partially soak Into the starch and cause
a starch crust to form. After extrusion the marshmallow ropes are
conveyed through automatic choppers and cut to designated lengths.
91
-------
DRAFT
SPILLA
__
i
1
1
SPILLAC
ISTARCH a PR
ta|
1
CTAQPW A C
O 1 nn^rl Dl v
4
j PRODUCT
1 (ADDITIVE
i
'PACKAGE MAI
^
^'CONT. PRODI
«L
;e
*
W
COOK
|
COOL £
t
BEAT U
i,
COOL f
1
EXTRUDE
<£>
f
**><•* STARC
t
?_NL. STARC
~ REMOV
Q -.
3M B°
1 "'
•
s -» COOL ST
*
rtWAL
_PACKA
JTT
GE
ASHDOWN, SPILLAGE
i
I
XXtNG H-0, WASHDOWN
DOLING HgO, WASHDOWN
J
rTLE
1
ISM
I
ORE
1
EFPl
r
UENT
FIGURE Z7
MARSHMALLOW PROCCSS
92
-------
DRAFT
The starch covered marshmallows are then conveyed to a humidified
rotating drum. This drum "sets" the marshmallows and helps to prevent
sticking. From this operation the product is conveyed to a starch
removal drum. The removed starch is circulated back through the
process after screening and refining. The product may then go through
a cooling drum where a light application of powdered sugar is applied.
If enrobing w'th chocolate or other coatings is to be done a sugar
application is not employed. Marshmallows then proceed to the packaging
area.
The major wastewater flow originates in the "kitchen" area where
washdowns occur. Virtually no water is used past the cooling steps,
since water in the drying and forming areas would inhibit the quality
of the final product. Dry sweeping, cleaning, and vacuuming is done
in the drying and forming areas.
Most plants have a "cleaning room" which is an additional source of waste
water. This room is used periodically for cleaning equipment and
machinery. Many plants utilize dust collectors in the drying areas
to remove starch and sugars which are suspended in the air. The
collectors are usually dry collection systems, utilized to recover pro-
ducts for recirculation, but wet scrubbers are incorporated for dust
collection in some plants. Effluents from the scrubbers are high in
dissolved solids and add significant short term waste loads.
Description of the Candy Tablets Process - Tablets are a mixture of
flavorings, lubricant, binding, and loose material which have been
stamped or compressed so as to form a hard, cohesive confection which
contains very little moisture. Stamped, or "cut" tablets are termed
"lozenges." A lozenge 1s a sugar dough which has been flavored, cut
to shape, and subsequently dried to remove most of the added water
(see Figure 28 ). Lozenge dough is prepared by mixing together a solution
of gum arabic, gelatin, icing sugar, and flavoring. According to Lees,
( 10 ), efficient mixing is the key to satisfactory production of lozenges,
Mixing times must be standardized to produce homogenized paste without
excessive flavor loss.
When the ingredients are thoroughly mixed, the dough is removed and sent
to the sheeting machine where it is rolled into a continuous smooth
sheet. This sheet is delivered directly to the lozenge-cutting
machine.
The tendency of the lozenges to stick to the conveyor or stamping
machine can be reduced by sprinkling the dough surface with a food
grade dusting powder. Stamped lozenges are then removed and deposited
In one layer on drying trays. The lozenges are then either put into
circulating hot air drying rooms or allowed to air dry until they
are sufficiently hardened. Glazing the lozenges can be achieved by '. ight
steaming and drying.
93
-------
DRAFT
WATER c
(FLAVORING
SUGAR
GELATIN
GUM ARABIC!
BLEND
H CLEAN-UP
-J
MIX
CLEAN-UP
~~ — —
SHEETINC
STAMP
SCRAP
• DRY
STORE
PACK
FIGURF 28
LOZENGES
EFFLUENT
-------
DRAFT
The scrap paste which is left after stamping is then recycled back
to the sheeting machine before excess hardening can occur.
Hashdowns are the primary sources of waste effluents, and are derived
primarily from the blending and mixing areas.
Figure 29 depicts a typical candy tableting operation. Tableting
is essentially a dry process in that ingredients such as powdered
sugar, corn syrup, gelatin, and requisite flavorings are compressed.
The actual production of tablets begins with mixing corn syrup, sugar,
and gelatine in a "masticator." This material is then driad and
transferred to a blender where flavorings and a small amount of water
is added, such that the dry particles will adhere better after passing
through the tablet forming machine. The tablet forming machine molds
the candies under pressures of about 1.9 atm (14 psi) into the desired
configurations. Tablets are then inspected and conveyed to the
packaging area. Rejects are recycled back to the blender to be repro-
cessed.
Any water used in the forming areas would affect the handling of tt-e dry
materials. If machinary is to be deansad, it is removed from the
area and taken to a separate cleaning room. The masticator is the
major piece of machinery that is washed on a daily basis. Cleaning of
floors in the processing area is generally done by vacuuming or sweeping.
Description of the Popcorn Ball and Treated Popcorn Products Process -
There are several varieties of glazed popcorn products. Figure 30 deoicts
a typical flow diagram of a glazed popcorn operation. Corn is brought
in from the field in kernel form, c'eaned, and fed into gas fired corn
poppers. After popping, the corn is passed over shaker screens to remove
to mixers where it is combined with some type of coating.
Popcorn coatings are derived from the cooking of various combinations
of corn syrup, sugar, n<.lasses, and vegetable oil. These ingredients
are first pre-cooked together to blend and liquify the constituents and
the mixture is then cooked to a viscous syrup. Other ingredients, such as,
coconut, margarine or butter, honey, and corn or vegetable oils, may be
added to the syrup.
When the final cooking step is accomplished, the syrup is mixed with
the popcorn in either a continuous or batch process. After mixing the
glazed popcorn is either formed into oopcorn balls or sent to cooling
drums. Two major types of cooling drums are utilized. One type consists
of a rotating wheel which uses baffles to break up the adhering popcorn
as it cools; the other type 1s a large rotating wire mesh screen. Both
kinds of drums employ air injection systems to cool the glazed popcorn.
The glazed popcorn is then separated from clumps and chaff by shaker
95
-------
DRAFT
EFFLUENT
FIGURE 29
CAM1Y TARI.FTS
-------
DPAFT
CLASSES
MISC.
INGREDIENTS
ILL/CE I—
=--~^v---^—J w
WASTE WATET
PHIMAPTLY FPO
WASMDCWN OF
PPOCESSING
AREAS AND
COOLING WATER
IF DISCHAPGED
FIG'JRE 30
POPCORN BALLS AND TREATED POPCORN PRODUCTS
97
-------
DRAFT
screens located at the end of each cooling drum. The finished product
goes into hoppers where it is stored until packaged. Other ingredients,
such as peanuts, may be added to the popcorn at the packaging area.
Wastewaters from the glazed popcorn operation are primarily derived from
washdown operations. The volume of wastewater from washdown comprises
approximately 35 percent of the total flow, with the remainder being
comprised of various cooling water and other non-contact flows. This
percentage will be much higher for washdown flows if cooling waters
are not discharged. With the use of corn and vegetable oils, either
for coating containers to prevent product stickage or in the product
itself, some spillage results. This spillage creates grease and oil
in the washdown waters.
•
Steam rooms are employed in most plants to clean equipment and containers
of adhering syrups and solids. Therefore, the steam rooms are a primary
source of waste effluents which are comprised of detergent, germicide
solutions, corn oil and kernels, peanuts, and molasses and syrups.
Most solid wastes are removed by sweeping prior to washdowns and
separated into edible and non-edible wastes. Edible wastes are sold
for animal feed while non-edible materials are taken to land fill areas
by contractors.
The majority of plants visited during this study recirculate the cooling
and chill waters used in processing. Any water 'iost from cooling oper-
ations would be in the form of overflow or make-up waters.
Description of the Candied. Glazed and Crystallized Fruit Process -
Glazed (candied) fruits and peels are confections~which have had the
water in the product replaced witn a high sugar content syrup. Figure
31 shows the flow diagram for a typical glazed fruit process.
Many makers of glezed fruits first bleach the fresh fruit in a "brine"
solution prior to blanching and addition of flavor and color. Although
processors use various components in somewhat differing ratios, accord-
ing to Soderquist (11 ), a typical brine contains 1.5 percent sulfur
dioxide, 1.5 percent calcium chloride, and l.C percent slaked lime in
a water solution. Fruits may also be stored in brine solutions for
extended periods to insure a continuous production.
Next, the fruits and peels, whether fresh or brined, are "blanched"
or cooked. This is necessary to break down the fruit tissues and to
Improve the penetration of syrups into the product. Futhermore, blanch-
ing helps to remove chemicals from the fruits which have been brined.
Blanching may be accomplished with the use of steam or boiling water.
Times allowed for blanching vary from 2 to 15 minutes depending on the
softness of the fruit.
98
-------
DRAFT
DAMAGED
•c ~
FRUIT
CULLS r
PACKAGE MATERIALS
V
SOLIDS
EFFLUENT
FIGURE 31
GLAZED FRUIT
99
-------
DRAFT
DISSOLVED SOLIDS
PACKAGE MATERTALS
FIGURE 31
GLAZED FRUIT
r.i
-------
DM FT
After blanching, fresh fruits are cooled, whereas brined fruit is
generally leached in water. Water leaching serves the purposes of
removing additional chemicals and cooling the product. The fruit
Is then ready to be immersed in hot sugar syrup in concentrations
between 70 and 80 percent. The amount of sugar transferred into the
fruit 1s of particular significance in connection with the product's
keeping qualities. As reported by Lees ( 10 ) candied fruit should
contain at least 75 percent sugar and candied peel around 65 percent.
Some loss of coloration and flavoring rr.ay occur during brining. This
is artificially restored during the syrup diffusion stage.
The syrup application phase may be repeated several times, following
short drying times, to bring the candied fruits up to desired sugar
concentration levels. The glazed fruits are then sorted and dryed
prior to packaging.
The major wast? loadings are derived from w-ishdowns and dumping of
blanching tanks. If leaching is employed, significant waste loadings
occur in the form of t«-ace minerals such as 502- Brine solutions are
generally reused, but periodically must be dumped resulting in low flow,
high concentration surges.
SIC 2066 - Chocolate and_Cocoa Products
Background of the Industry - This classification includes establishments
primarily engaged in shelling, roasting, ar.d grinding cocoa beans
for the purpose of making chocolate liquor from which cocoa powder
and cocoa butter are derived, and in the further production of solid
chocolate bars and chocolate coatings. The value of shipments from
this industry reached $735 million in 1972, an increase of 41 percent
compared with 1967.
The present technology for the manufacture of chocolate has evolved
over the last 200 yeors, starting with the defat'lng of the cocoa
bean by French and Dutch processors during the late 18th Century.
This and other innovations lead to the preparation of a more palatabla
cocoa powder and the first solid eating chocolate. The present
consumption of chocolate and cocoa in the United States is approximately
300,000 kkg/year, equivalent to about 1.6 kg per person. This consump-
tion represents the processing of over 1.5 million tons of cocoa beans.
The industry is concentrated in the northeastern states arid primarily
in the state of Pennsylvania. Of the 48 plants located throughout
the United States, 30 employ more than 20 persons; however, the majority
of the production is done by e few large manufacturers.
100
-------
DRAFT
Description of the Cocoa and Chocolate Process - Bulk cocoa is
received in this country in e relatively clean and also pre-processed
condition. This pre-processing consists of initial fermentation drying,
and preliminary cleaning of the cocoa beans. The first step of chocolate
manufacture is the further cleaning of this "raw" material. The beans
are passed through screens, brushes, airlifts, and magnetic, separators
to insure the removal of any extraneous material such as grit, sand,
metal, jute fibers, and bean cluster which may interfere with later
processing.
As shown on Figure 32 the next step is the roasting of the beans.
Roasting helps develop the characteristic flavor, color and aroma,
reduce the moisture content, and loosen the shell from the cotyledons
or nibs. The roaster may be of either the batch or continuous type
and depending upon the primary disposition of the beans, i.e., for
cocoa powder, chocolate, or cocoa butter, the temperatures and times
of the rosst may vary considerably.
The beans, the shell now loosened by roasting, are crushed in breaking
rolls so that mainly large pieces of nib and shell arc produced wi':h
a minimum of dust. The mixture of nib and shell is subjected to an air
flow which carries away the shell and dust discharging two main s-'ze
classes of nibs, large and small. The large nibs yield the highest
quality chocolate due to the proportions of cocoa butter, moisture,
shell and garm (Table 5 ). Small nibs may be used in blends or
exclusively for the expeller pressing of cocoa butter. The shel'l is
recovered for use primarily as cattle feed supplement or garden ,nulch.
The reduction of the rib to a fluid state ("liquor" or "paste") is
the next step in the process. Grinding of the nibs in any of a
variety of mills liquefies the fat portion of the nib suspending
the solid cocoa particles in a fluid paste. The nib may be subjected
to the "Dutch Process" which is the alkinization and subsequent
drying of the nib to give a desired color and flavor. The liquor
may be directed to milk chocolate processing or to the pressing
operation. The latter route will be considered first.
As noted in Table 5 , approximately 55 percent of the nib 's made
up of cocoa butter.• Separation of the particles of cocoa matter
and the cocoa butter is effected by subjecting the liquor ";o a
pressing operation. Hydraulic pressing of the liquor yields liquid
cocoa butter and also a press cake of cocoa with a fat content
ranging frdii 1? tip 25 percent, depending on how the cocoa is to be
used. The operation of the presses is completely automatic wherein
the ultimate fat content cf the cocoa cake is controlled by adjustment
of the pressure/time cycle. At the completion of each cycle the
ram travel direction is reversed and the solid cocoa cake is dropped
Into a bin or onto a conveyor for transport to the grinding operation,
101
-------
DRAFT
II
1 1
II
II
II
II
II
II
1 1
1 1
1 1
II
1 1
II
1 1
II
1 1
1 1
1 1
II
1 1
II
M
1 1 BATCH
1 1 MIXER
II 1"
" . *
1 ! HOLDING
II ...y
" 1
1 1 CANNING
II
" 1
i i f
1 ' CAM WASH
1 1 ' i
H <
I ! COOLER
11 i
.
1 1 LABELING
II 1
1 1
V
SOLIDS
(ft/to froa
j
ALMMZATO*
I
I
1
f- — -
1
CLEANING
I
BLENDING
j
WASTING
1
CRACKING
FANNING
1
•l/NB
!.
(P-« COM*
r
— ^- -
WINDING
^.-
MX ING
PICKAGING
EMKNScE
MLX
(Milt Ooeolo*/
r** PT«_O!
1 1
j 1
} i
f CN3CTIOH) i
(Cocoa Bull')
PfttbblNO ' ' MUINO
S^
-------
DRAFT
TABLE 5
CONSTITUENTS OF COCOA NIBS
Moisture
Cocoa Butter
Shell
Germ
2.0 - 3.5 (depending on degree
of roast)
52.5 - 55.5
0.2 - 1.5
0.1 - 1.5 (depending on winnow
setting)
SMALL NIB
Moisture
Cocoa Butter
3.8 - 7.5
35 - 36
103
-------
DRAFT
The cocoa butter expelled from the press may be directed either to the
milk chocolate lin« or Into solid liquid storage.
The reduction of the cocca press cake to a fine, high quality powder
1s accomplished by the cocoa mill which incorporates several processes
in a single unit. Pulverizing of the press cake to a powder begins
by first passing the hard, compacted cake through breaker rollers
and subsequently through hammer mills or peg disintegrators in con-
junction with sifters. The final particle size, however, is dependent
on that achieved during the liquor grinding process. During the
pulverizing of the press cake, set temperature limits are maintained
by cooling air to avoid liquefication of the cocoa butter fraction.
The powder is delivered by an air stream through cooling pipes and
subsequently to a cyclone for separation of the cocoa from the air.
Cocoa powder may be marketed in a pure form or mixed with other in-
gredients to make drinking chocolates. The latter are usually prepared
by mixing with sugar, corn syrup, and flavors under controlled condi-
tions to achieve desired particle characteristics which impart the
qualities necessary for quick dispersion in hot or cold liquids.
In addition to the production of cocoa powder and cocoa butter,
the chocolate liquor may be molded into blocks of unsweetened choco-
late, or processed into milk and sweetened chocolate.
As noted on Figure 32 the production of sweetened chocolate begins with
combining the liquor with additional cocoa butter and sugar. Milk
chocolate is produced by mixing sweetened condensed or dry milk
with the liquor and, in the case of condensed milk, subjecting the mix-
ture to a drying process to drive off the moisture. Chocolate must
be relatively moisture free in that a trace of water can cause stale-
ness and if more than one percent moisture is present it may become
moldy. In addition the presence of moisture renders the product stiff
and difficult to work.
In order to achieve a homogeneous mixture and aid in the development
of a fine texture, the chocolate is passed through a series of water
cooled refining rol.ls before being subjected to period of agitation
in a process known as cohching. Conches of various design function to
produce the final flavor and texture characteristics of the product.
The chocolate is agitated from a few hours up to several days before
removal to liquid storage or molding.
The final step in the manufacture of chocolate is that of molding
it into £he desireci size and shape for distribution. Because of cocoa
butter bloom, air bubbles, and other problems which may occur, molding
is a carefully controlled pro^ss. First the chocolate is brought
to the proper temperature during tempering and injected into metal
molding pans. The filled pans are then passed onto a shaker belt
which functions to distribute the chocolate evenly in the pans and
104
-------
DRAFT
liberate air bubbles. After or during the shaking process,
the pans are passed through a refrigerated chamber to reduce the
temperature of the chocolate under controlled conditions. Once set,
the chocolate is knocked out of the pans and proceeds to some form
of storage or packing.
As previously mentioned ihe presence of water is not compatible with
the production of cocoa products; therefore, the open use of water is
controlled so as to avoid entrainment in the product. Fortunately
the characteristics of chocolate and the high production temperatures
are not conducive to spoilage of the product. This eliminates the
need for continuous use of clean-up or sanitizing water. A variable
amount of wastewater is generated during the periodic cleaning of
holding or mixing tanks, transfer buggies, and molding pans. The
production area floors are also cleaned on a periodic basts, usually
preceeded by dry collection and then mopping, and/or using industrial
floor sweepers. Cocoa butter may often be used as a cleaning solvent
with the later recovery of tne cocoa butter and chocolate material.
The primary source of water is that used for cooling. Cooling water
discharge is quite variable in that it may be recirculated through
a cooling tower for reuse. The cooling water is non-contact and
therefore does not contribute to the strength of the total plant
effluent.
Most large chocolate manufacturers also have a milk condensing plant
for the preparation of sweetened condensed milk for the preparation
of milk chocolate.
SIC 2067 - Chewing Gum
Background of the Industry - This industrial classification includes
those establishments primarily engaged in the manufacturing of chewing
gum and/or chewing gum base. According to the United States Department
of Commerce Census of Manufacturers (2), there were 19 establishments
processing gum in 1972. The majority of these plants are located in
the eastern area of.the United States. The value of products shipped
in 1972 totalled $383 million, an increase of 26 percent over 1967.
The manufacture of chewing gum is most conveniently considered as two
separate industries: 1) the processing of raw latex and additives
into gum base, and 2) th«2 processing of gum base into various styles
of chewing gum. Both processes may occur at a single plant location;
however, they are more cc'inonly separated with a single gum base
plant supplying several chewing gum processors.
105
-------
DRAFT
Description of the Gum Dase Process - Conventional chewing gum base
consists of a combination of natural gum latex, synthetic resins and
rubbers, and plastic;;srs. The highest quality natural gum,
chicle, possesses the ideal characteristics for chewing gum but.
due to fluctuating price and supply, it is most often "extended"
by addition of other natural gums and/or synthetic gums. Various
plasflcisers, e.g., lanolin, oils, waxes, and glycerine may be added
to the gum blend to achieve the desired softness.
As noted on Figure 33, the production of gum base begins with the
grinding cf the crude gums and subsequent filling of the gums into
steam jacketed kettles. Water is added and the gums are preheated
to a state soft enough to allow mixing with agitator blades. After
the gums are mixed to form a homogeneous mass, the mixture is bleached
with a weak solution of sodium hydroxide for spveral hours. The
gum is then subjected to a succession of hot *ater washes for two to
six hours. The wash cycles serve to remove extraneous material as
well as the caustic bleaching solution. The excess water is drained
and the gum is subjected to another cycle of mastication.
After the gum is dried to a three to five percent moisture content,
it is mixed with other natural and synthetic gums and softeners in
heated mixing kettles. The hot mixture is pumped through fine screens
and then through a centrifugal separator to effect a thorougn removal cf
all extraneous material. The gum is subsequently poured into melds
and, when .ool, tha blocks of gum base are reiroved from the molds and
stored for later processing into various chewing gum products.
Wastewater of significant volume and loading is generated by th^es
phases of the process: 1) hot water washing of the gums, 2) contact
cooling water, and 3) daily clean-up of floors and equipment. In
addition, there are wastewater sources of low waste loading (but of
relatively high volume) which include non-contact cooling water and
air scrubber water.
Description of the Chewing Gum Process - The manufacture of chewing
yum is generally quite similar throughout the industry with sliqht
variations employed in processing to achieve product differentiation.
A typical process is shown in cigure 34 . In the first step of manu-
facturing the ground gum base s placed in mixers, vats capable of holding
up to 900 kg (2000 pounds) eacn, equipped with slowly revolving blades.
These mixers blend together gum bass, powdered sugar, corn syrup or
glucose, seed gum, plasticisers, and flavorings. Corn syrup or glucose
additions he>"p sugar and flavorings to amalgamate with the gum base
while keeping the gum moist and pleasant to chew. °owdered sugar is
used as a thickening agent which has an effect on the brittleness or
flexibility of tho final product. As reported by COM (12 ), plasticisers
. 106
-------
CAUSTICS.WASHWATEP
EXTRANEOUS MATERIAL
EFFLUENT
FIGURE 33
GUM BASi:
-------
REPRCCESStO
II
11
II
II
11
souos
PRIMARY SOURCE
nrrr OF SOLID WASTE
FROM FLOOR
SWEEPINGS
PRIMARY SOURCE!
OF WASTE WATER)- -».
FROM FLOOR CLEAN-UP
AND AIR SCRUBBERS
EFFLUENT
FIGURE 34
CHEWING GUM
108
-------
DRAFT
such as glycerin are extensively used to help reduce the viscosity
of the gum base to a desirable consistency and to improve texture.
When the blending is completed, the gum base is "tempered" or pre-cooled
to reduce its temperature. After pre-cooling, the gum is mechanically
kneaded to a smoother and finer texture. The gum then passes to a series
of rollers that produce a sheet of varying thickness; the final thick-
ness of the gum sheet determining the type of gum to be made. Stick gum
comes from the thinnest sheets, candy-coated gum from a thicker sheet,
and bubble or ball gum from the thickest sheets or ropes.
Stick gum, after expulsion from the extruder, then moves to the sheeting
machine. This machine is made up of a series of rollers, each pair
of rollers set closer together to reduce the thickness of the gum
in stages. A light coating of finely-powdered sugar is used as an
adhesion agent to prevent the gum from sticking to the rollers as
well as to enhance the flavor. After passing through the sheeting
machine, the gum is cut into rectangular sheets, approximately 43 by
43 cm (17 by 17 in.), and scored in a single stick pattern. The gum
is then stacked automatically on trays and allowed to "set" in an air
conditioned room for at least 48 hr. Fro- the conditioning room the
gum is taken to specially designed packaging machines which individually
wrap and seal the gum. The individually wrapped gum is then packaged
in multiple-stick packs.
The candy coating process for gums starts with sheets of scored and
flavored gum which are broken into small squares or oblong pellets.
Alternately, ball gum is extended in pencil shape and passed through
specialized forming machines. These different types cf guu pieces
are then placed in panning machines which are simply rotating drums
equipped with blowers so designed as to deliver low humidity air.
A solution of corn syrup and sugar syrjp Is added and the drum is
set in motion until the pieces receive a uniform coating. A small
quantity of flavor is then added and thoroughly distributed. An
addition of finely powdered sugar is made at intervals and partially
coated gum is removed and allowed to season.
A coating is gradually built up .with sugar syrups, starch, and gun
Arabic and dried rapidly by means of the blowers after each application.
A final polish is given to the coated gum by rotating the pieces in
drums lined with beeswax impregnated canvas.
Bubble gum is essentially a plastic base which allows for considerable
expansion when a volume o* air is introduced. The gum base used for
bubble gum is made with various combinations of Jetutong rubber, resins,
and plasticisers. This gum base is then mixed with icing sugar and
glucose syrup in steam jacketed mixing kettles. After mixing, the gum
loaf is fed into an extruder hopper. From the hopper, the loaves are
picked up by two auger-type screws comprising the kneader and forced
under pressure through round holes. These continuous ropes of gum are
109
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DRAFT
then conveyed by rollers to cutters where they are cut into uniform
lengths. Bubble gum may also be formed In sheets and cut to size.
The gum is then put into racks and tempered from one to seven days.
After tempering, the gum is formed into a variety of shapes such as
pencil, kiss, ball, or square. The gum is then lightly coated with pow-
dered sugar, Individually wrapped and boxed.
Wastewcters from chewing gum manufacturing are derived from three
primary sources: washdown, cooling waters, and (if used) air scrubbe-s.
Washdowns are the primary source of waste loading, averaging less than
7500 1/day (2000 gal/day) for stick-gum processing and slightly more
for candy-coated gum. Daily clean-up operations consist mainly of dry
sweeping or scraping and wet mopping with solvent, disinfectant and
water. Very little actual water flushing is done in the plant, except
in certain specified areas. Many plants also utilize automatic
scrubbers for cleaning flocr areas.
Non-contact cooling water is generally recirculated; however, some
plants do discharge some or all of their water. This water, if
discharged, has a negligible '.vaste loading, but may contribute signi-
ficantly to the total flow.
Many plants utilize air scruobers to clean and humidify the air.
The water used in these sc.'ubbers, aue to sugar dust in the air,
may be relatively high in BOD and suspended solids. The flow and
strength of loading will vary with the number and size of air scrubber
and the frequency of discharge.
SIC 2074. 2075. 2076 Vegetable 0;,1 Mills
Mechanical extraction of vegetable oil from seeds originated with the
"stump press" utilized by the Egyptians, Phoenicians, and Chinese.
Dunning (13 ) reports that the process consisted of a burned-out stump
with a heavy pole driven by oxen that rotated upon the seed, thus
crushing the seed and extracting the free oil. The industrial revo-
lution" brought many mechanical improvements, including the invention
of the hydraulic press in 1795. The hydraulic nress remained the major
oil extraction device until the beginning of the present century, at
which time the development of the mechanical screw-press allowed con
tinuous extraction of oil.
Today in the United States, the oilseed crushing industry represents a
major industry utilizing a variety of mechanical and chemical extraction
methods for the removal o. vegetable oils from oilseeds such as soybeans,
cottonseed, flaxseed, peanuts, safflower, and other miscellaneous oilbearing
seeds.
A U.S.O.A. Marketing Research Report (.14 ) states that the marketing
and processing of oilseeds and veoetoble oil has been significantly
afrected by increases in production and an expanding export market over
the past two decades. As a result, the industry has witnessed changes
110
-------
DRAFT
in organizational structure, processing technology, and the size and
number of processing mills. As indicated in Table fi , vegetable oil
production in terms of plant numbers has shown a mixed pattern of growth.
This is best illustrated by the 62 percent increase in the number of
soybean crushing facilities in the last two decades, while cottonseed rrills
decreased by 64 percent during the same period.
Approximately 67 percent of vegetable oil production is used in the
manufacture of shortening, salad and cooking oils, salad dressings,
mayonnaise, and margarine. Refining is usually separated from crushing,
the former preferlng proximity to farm lands and the latter to marketing
areas, and over 70 percent of the final product manufacture occurs at
or near the refineries.
Since World War II, more efficient solvent extraction methods have for .
the mosc part, replaced hydraulic and mechanical screw press methods.
During the same period, other striking technological developments have
included hydrogenation, deodorizing, and plasticizing of oils. These
processes have substantially increased the range of uses of vegetable
oils.
Other important developments in recent years have included an increased
use of safflower and sunflower oils in food products and the development
of meat analogs from oilseed products. The meat analogs, which compete
with lower cost meats such as hamburger, are expected to exert an
increasing demand on vegetable oil production.
The United States Department of Commerce reports ( 15 ) that approxi-
mately 19.4 million K.Kg (21.3 million ton) of soybeans were crushed
at 142 oil mills throughout the country during 1974. Soybean oil mills
are located principally in areas of heavy soybean production or meal
use with the greatest concentration of plants in the Eastern Corn
Belt states of Illinois, Iowa, Minnesota, Missouri, Indiana, and Ohio.
Arkansas and Mississippi represent the other major areas of soybean
crushing in the lower Mississippi Valley. Production data provided
by the National Soybean Processor's Association from J5 plants shows
production ranging from 62 to 2,310 KKg (68 to 2,550 ton) per day
with an average production of 1000 KKg (1100 ton) per day.
The vegetable oil industry is expected to continue the steady growth
shown over the past two decades. Further development of new tech-
nologies are expected and the worldwide demand for oilseed products
continue^ to increase.
Soybean Oil - Smith (16) reports that during the past 40 years soybeans
have made iiore rapid progress in the feed and edible oils industries
than other oilseeds because of their (l) low cost of production (less
thari 10 man-minutes of labor ?»r bushel); (2) adaptability to solvent
extraction processing; (3) economic importance to the feed and edible
oils industries; and (4) demand by foreign markets. The United States
111
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DRAFT
TABLE 6
THE NUMBER OF COMPANIES AND ESTABLISHMENTS
PROCESSING OILSEEDS FROM 1954 TO 1974
Industry and Year Companies
Number
Cottonseed oil mills:
1954 ' 145
1958 125
1953 115
1967 91
1974 74
Soybean oil mills:
1954 55
1958 66
1963 63
1967 60
1974 36
Other vegetable oil mills:
1954 N.A.
1958 38
1963 39
1967 34
1974 N.A.
Establishments
Number
286
214
188
150
102
83
117
102
102
142
46
47
41
N.A.
112
-------
DRAFT
Department of Commerce reports (14 ) that the crushing ?nd solvent
extraction of soybeans alone represented America's number one cash crop
in 1971, producing mere revenue than corn, wheat, or cotton. In addition,
soybeans were the largest single farm export from the United States with
sales abroad in excess of 1.3 billion dollars a year.
Protein rich soybean meal, a by-product in the production of soybean oil,
is a key ingredient in the nation's expanding livestock and poultry
industries. Supplies of soybean meal were more than adequate for
domestic consumption until mid-1972 whsn the United States entered an un-
paralleled soybean and soybean meal supply demand situation. Winner
( 17 j reports that developments su... as (1) unusual'iy large purchases
by Russia; (2) a poor 1972 harvest; (3) curtailment of Peruvian fish
meal production, a protein source for f«ed grains; (4) reduced peanut
meal exports by India and Senegal because of drought and: (5) increasing
worldwide consumption, placed a heavy burden on American farmers and
consumers as prices for these products were propelled from SllS/K.Kg
($130/ton) in mid-December 1972 to more tnan $36?/KKg ($400/ton) by
early June 1973.
Production data provided by the National Soybean Processors Association
(NSPA) from 14 soybean oil mills found typical plants operating in the
range of 450 to 2300 KKg (500 to 2,500 ton) per day. Today 95 percent
of the industry processes soybeans by use of prepress solvent and direct
solvent e>.tract\on methods.
Cottunseed Oil - Cottonseed ranks second in total oilseed production
in the United States with approximately 4.4 million KKg (4.8 million
tons) crushed in 1973. The National Cottonseed Processor's Association
(NCPA) indicates tnat there are 102 active cottonseed crushing plants
in the United States witn the major concentration of production occurring
in the states of Texas (28 plants); Mississippi (18 plants); Arkansas
(9 plants); California (7 plants); and Alabama (6 plants). Production
data provided by the NCPA for five crushing facilities ranged from 230
KKg (250 ton) to 700 KKc (750 ton) per day and averaging about 390 KKg
(430 ton) per day. Table 7 provides a sunmary of the cottonseed
industry listing total numbers of plants per state and the type of
extraction methods used.
Linseed Oil - The crushing of flaxceed to produce inedible linseed oil
was ths third largest oil beating crop produced in 1973 with 0.53 million
KKg (0.58 million ton) produced (about 2 percent of the total oil seed
crushing production). Flaxsesd production is centered in the states of
North Dakota, South Dakotu, and Minnesota which produce about 95 percent
of the nation's crop, with North Dakota alone accounting for about half.
According to the National Flaxseed Producers Association (NFPA), there
are presently a total of six active crushing plants ranging in production
from [50 to 800 KKg (600 to 900 ton) per day. The four largest flaxseed
crashing facilities utilize the prepress solvent extraction process.
Flu/seed crushers also process soybeans periodically depending on the
market value of soybeans.
113
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DRAFT
TABLE 7
COTTONSEED MILLING OPERATIONS BY STATE AND TYPES
OF EXTRACTOR METHODS UTILIZED 1974
Extraction
State
Alabama
Arizona
Arkansas
California
Georgia
Louisiana
Mississippi
Missouri
New Me.vco
North Carolina
Oklahoma
South Carolina
Tennessee
Texas
TOTAL
PERCENT
Number
of Plants
6
3
9
7
7
4
18
2
2
4
4
5
3
28
102
100%
Methods
Mechnical
Hydraulic Screwpress
6
-
3
2
1 4
3
7
- • -
2
3
3
1 4
3
1 10
3 60
2.9% 58.8%
Prepress
Solvent
Extraction
-
3
3
5
-
-
2
2
-
-
-
-
-
4
19
18.6%
Direct
Solvent
Extraction
-
-
3
-
2
1
3
-
-
1
1
-
-
2
20
19.6"
Source: National Cottonseed Producers Association.
114
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DRAFT
Peanut Oil - Peanuts ranked fourth in total oilseed crushing in 1973
and totaled n.Z84 million KKg (0.313 million ton). This represents
less than one percent of the total oilseed crushing production. Infor-
mation provided by the Southeastern Peanut Association indicates that
there are presently eight active peanut crushers located in the States
of Virginia, Alabama, Georgia, and Florida. Daily production at these
facilities ranges from about 100 to 180 KKg (120 to 200 ton) per day.
Sixty-two percent of the industry processes peanuts using prepress
solvent extraction methods with the remainder, usually smaller capacity
operations, using mechanical screw press methods.
Olive Oil - Olives utilized for prodijction of olive oil in the United
States are grown exclusively in California. Of the approximately
12,900 hectares (32,000 acres) of olives harvested annually, about ten
percent are processed for recovery of olive oil.
The production of oliv^ oil can be divided into two product segnents--
virgir. and refined oil. Virgin oil, the finer quality oil, is produced
by mechanical pressing of whole, ripe olives. The poorer quality re-
fined oil is ootainea by the solvent extraction of olive cannery pits,
culls, and from the pressing of low quality, whole, ripe olives. The ex-
tracted oil is then refined and blended with virgin oil. Currently, there
are two major producers of olive oil in the United States. However, there
are numerous "backyard" producers who press out the valuable virgin oil
by any means available.
Virgin oil is in great demand but short supply due to the fact that
roughly 0.9 v^g (one ton) of raw olives is required to produce 100 liters
(30 gallons) of virgin olive oil. The low oil yield is attributaole to
the material makeup of the olive. A goo* quality ripe olive is composed
of about 55 percent water, 2'j percent pomace, and 20 percent oil.
Generally, olive oil is produced between the months of October and June
and continuous production during that period is dependent on the avail-
ability of laborers to harvest the fruit. Although demand for olive oil
exceeds supply, it is unlikely that the number of major producers will
increase since uncertainty of crop yield will continue to cause a reluc-
tance to invest in equipment thereby hindering the production of olive
oil on a large scale.
Miscellaneous Oils - The demand for a variety of other miscellaneous
vegetable oils such as safflower, sunflower, and seasame seed o:'1s has
been increasing in the United States since 1960. The den.and for these
fooa materials has been nust evident in the margarine industry where
food nutritionists and technologists have been utilizing safflower oil
as a source of polyunsaturated vegetable oils, important in controlling
plasma cholesterol levels in the diet. Doty and Lawler (18 ) report
that food use of safflower oil in 1970 totaled 36,000 KKg (40,000 tons)
and industrial use totaled about 9000 KKg (10,000 ton). Results of a
telephone survey durinj tnis study indicated that there presently exist:
115
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DRAFT
two safflower-sunflower seed crushing plants in the United States with one
other under construction. All three facilities are located in California
and utilize both prepress solvent extraction and screw press extraction
techniques.
Description of Oilseed Crushing - The extraction of oil and the production
of meal or cake from oil bearing seeds may be performed by direct solvent
extraction, prepress solvent extraction, mechanical screw press or hydraulic
press operations. As indicated in Table 3 direct solvent extraction is
used primarily in the soybean industry; while prepress solvent extraction
and screw press operations are utilized primarily in the cottonseed, flax-
seed, and miscellaneous industries; and hydraulic press operations in a
small number of old, small capacity plants.
The crushing cf oilseeds by solvent extracn" :*n, prepress solvent extraction,
or mechanical screw press, with minor variations in seed preparation, are
generally similar operations regardless of the seed being crushed with .
one exception—the crushing of raw olives. Therefore, the following
process descriptions will discuss oilseed crushing in reference to the
extraction methods utilized by the major oilseeo industries, while a
separate discussion will be provided for the crushing of raw olives.
Direct Solvent Extraction: Soybeans are commonly processed in the
United States today by the direct solvent extraction method. The manu-
facturing of crude soybean oil involves the .rushing and solvent extrac-
tion of the crude oil from dehulled, conditioned soybean meats. The
important by-products of the process are soybean meal and cakes which
are sold commercially as a protein supplement in feed grains. Other oil-
bearing seeds, such as cottonseed, present problems in that the seeds
tend to disintegrate into fine partic'es, called "fines," which interfere
with the operation of the solvent ret ,ery system. Modern technology,
however, has developed solvent extrat.-.on processes applicable to almost
any type of oilseed. During 1974, 20 percent of all cottonseed processors
utilized the direct solvent extraction process.
Cofield (19 ) reports that 1n general, the initial and operating costs of
a solvent extraction plant are higher than mechanical screw press operations.
More skilled labor 1s required in a solvent extraction plant and a several
hundred metric ton capacity is required for economical operation. Skilled
labor is often difficult to obtain and a large capacity requires large
storage facilities due to the seasonal production of oilseeds. Another
disadvantage of solvent extraction is the nigh cost of the solvent (usually
hexane) and its explosive potential.
The disadvantages and problems of solvent extraction are generally more
than offset by its primary advantage—increased oil yield. Currently,
95 percent of the soybean industry and 38 percent of the cottonseed
Industry use either solvent extraction directly or in combination with
mechanici', jressing.
116
-------
DRAFT
TABLE 8
EXTRACTION OF OIL FROM OILSEEDS BY VARIOUS PROCESSES
011 Extraction Process
Most Cormion Applications
Direct Solvent Extraction
Soybean
Cottonseed
Solvent Extraction With
Prepressing
Cottonseed
Flaxseed
Peanuts
Sunflower Seed
Corn Germ (wet process)
Safflower
Seasame
Mechanical Screwpress
Cottonseed
Peanuts
Olives
Flaxseed
Hydraulic
Cottonseed
Olives
117
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DRA7T
As shown in Figure 35, raw materials arrive at the plant by rail or
trrCK dij are immediately dried and cleaned before storage to eliminate
any fureion matter that could cause combustion, affect oil quality, or
decnricrr*te equipment. Cleaning is accomplished by a combination of
air separators, and magnets.
A pret.'eatment step unique to cottonseed is that of delinting. Brennan
(20 ) reports that any cotton fiber still on the cottonseed after cleaning
is normally removed in two delinting steps, first-cut and second-cut. The
first-cut is a short, high grade fiber used in cotton-felt manufacturing.
The second-cut is usually sold to cellulose manufacturers. The motes, or
remaining fibers, and foreign matter are removed by shaking and are sold
for their cotton content. Cottonseed delinting is also required in prepress
solvent extraction and screw press operations.
All oilseeds must be dehulled to increase the efficiency and capacity of
the solvent extraction operation, and to reduce abrasion of equipment.
Dehulling is normally accomplished in bar or disc huMers or corrugated '
cracking rollers, while screening and air separation are used to isolate
the hulls from the meat. In modern, efficient plants, this operation
creates little if any dust problem. However, in older installations,
particularly in those processing cottonseed, a considerable amount of
dust is created with a resulting loss in product quality and deterioration
of working conditions. Rockwell ( 21 ) reports a number of plants have in-
stalled wet scrubber systems, bag filters, and "cyclones" to reduce air-
borne particulate matter in oilseed preparation areas.
In most cases the hulls are recovered for animal feed or fertilizer.
In some plants, particularly in the peanut industry, the hulls are
incineratea or used as boiler fuel.
Hutchins ( 22 ) reports that the hull -free disintegrated meats are sent
to the "conditioner", usually a vertical stack cooker, where the meats
are heated to 70'C (1589F) maintaining a moisture content of 10 to 11
percent for 15 to 20 minutes. Cooking ruptures oil cells, provides dis-
infection, and stabilizes the enzyme activity of the meats. Conditioned
meats are then processed througn flaking rollers where the meats are
pressed into a flat. flake. Pressed soybean flakes range in thickness
from 0.02 to 0.03 cm (0.008 to 0.012 in.).
The flakes are conveyed from the milling preparation area to the solvent
extraction building housing one of several ..ypes of extractor u'niti.
Although nearly all of the soybean extraction plants in the United State::
now have percolsti.Dii or basket-type extractors, a few immersion types
are still being operated on a small sc?'e. It is not necessary to in-
clude a full description of all commercial extractor units available in
this document; however, adequate descriptions are available from
references: Cofield ( 19 ), Encyclopedia of Chemical Processing C
(23 ), and Langhurst ( 24 J.
118
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DRAFT
RAW MATERIALS
COTTONSEED
CLEANING AND
DRYING
STORAGE AND
WEIGHING
SOYBEANS
PEANUTS
FLAXSEED
SUNFLOWER
AND OTHER
MISCELLANEOUS SEEDS
t'REP
FIRST AND
SECOND CUT
L INTERS
i
'
DISC HULLER
I
HULL
SEPARATION
4
CRUSHING ROLLER
'
COOKER
ARED COTT
1
RECYCLE |
1
UNSEED MEATS
1
^
-•»
ALTERNATIVE
CRACK ING
'
ROLLERS
HULL SEPARATION
COOKER
1
-
FLAKING ROLLER
I
i
i
•«•»
u
J
J
i
^
OREPARED OILSEED
MEATS
DISC HULLER
*
HULL SEPARATION
*
CRUSHING
ROLLERS
*
COOKER
i
PREPARED OILSEED
MEATS
PROCESSING
MECHANICAL
SCREWPRfTSS
OR PRKPPE5S
SXVENT EXTRACTION
SOLVE-MT EXTRACTION
MECHANICAL
SCREWPRESS
OR PREPRESS
SOLVcTNT EXTRACTION
FIGURE 35
A SIMPLIFIED FLUW DIAC-PAM FOR niLStED PREPARATION
BEFORE EXTRACTION FOR '> VARISTY OF OILSEEDS
no
-------
DRAFT
The oil bearing pressed flakos are deposited into steel baskets within
the extractor unit and an organic solvent, usually hexane, Is allowed to
percolate through the flakes sf. a temperature of 48° to 54°C (120° to
130°F) from 25 to 45 minutes.
Solvent extraction removes oil from the meat of oilseeds by the diffusion
of solvent and oil through the ruptured cell walls. Replacing the solvent
outside the cell walls with solvent of lesser oil content prevents the
process from reaching equilibrium, and the process becomes continuous.
The hexane solvent reduces the oil content of the maats to about one percent
or less with the flakes retaining 35 percent of the solvent.
Solvent extraction is accomplished either as a batch or a continuous opera-
tion. Batch methods have the advantages of low initial investment and the
capability of processing relatively small quantities, thus being practical
for the small processor. However, batch processing Involves high labor "costs
and presents danger of flammable and toxic solvent vapor. The latter disad-
vantage has been overcome in recent years by the use of nonflammable tri-
chloroethvlene, and there are some small operations 22 to 27 KKq (25 to 30
ton capacity) which use batch operations. Most commercial operations
use hexane in a continuous operation.
A number of continuous solvent extraction syste.ns are employed by the
oilseed industry, but all use the same basic operations of (1) passing
the solvent over the conditioned, pressed meats to produce the oil-
solvent mixture called miscella; and (2) recc/ering the solvent from
the miscella and the extracted meats. A typical flow diagram of con-
tinuous solvent extraction is presented in Figure 36 .
Kingsbaker ( 25 ) reported that several desolventization methods are used
for recovery of the solvent from the miscella and the extracted meats, with
all having the object of removing the solvent at the lowest possible temper-
ature and recovering the solvent with a minimum of loss. In cottonseed
crushing particular care must be taken to quickly remove the oil from the
miscella to prevent oil damage. This problem is not typical of other oil-
seeds. The recovery of the solvent from the miscella is usually accom-
plished in a long tube evaporator followed by a stripping column. Each
unit evaporator removes approximately 90 percent of the solvent.
The first method of desolventization of .Teats, developed in Germany, is
still used by perhaps a third cf the solvent extraction plants in trie
United States. The method involves passing the meats via a ribbon conve.vor
through a series of steam jacketed Maes called "schneckens.". The schnec .<;
are expensive, difficult to clean, ^nfl less efficient than more modern me* .-s.
The next method of desolventizatlon of meats that appeared in the industry
was the solvent vapor-desolventiziog system. About 99 percent of the
solvent is removed from the meats by passing superheated hexane vapor over
them. The heat from the vapor vaporizes the solvent. A final steam stripping
remove1- the last of the solvent from the meats.
120
-------
PRFPARFO nil
l-EXAhE
SO-VENT
DtSOLV
TO A
(SrmFAN Fl AKFSt (-•-• -- BOILER »
i __
1
m rnn i wTi
BASKET ^ T0«P»
EX1RACTOR ^ NON-CONTACT " '~
A
STEAf
1
ENT I ZER
STEW
SHtNf H.AKb NIJCCLLA » SOLVENT RECOVER
* (CnUDC OIL AM) (I*;-XANE WATER
•IXANC SOLVENT SEPARATOR)
Ml » tl t?C 1
| 1
1
MEAL GRINDING
OF TOASTtO FLAKES
,
COOLJNG-
SHIPPING
1
1
'*-PI
WAS
WAS
Vt
CRUDE M3N-DEGUMMEI
VEGETAS-E OIL
1
TO REFINERY
SOPTNER U— WATER
. ._. . ' <-j rpi v
1
t
SLUDGE
j
1 |
NDN- CONTACT
Y COOLING TOWER
SLOWDOWN AND
BOILER SLOWDOWN
IO7— OOV If
WASTEWATER VOLUME)
1
J* ^ l~*~ CLEANUI
XU^f 1 "ASTEWAT
1
5 *
DISCHARGE TO
SEWER OR
TREATMENT
FACILITY
OILSEED
MEAL
TO
FIGURE 36
A SIHPLIF!CD FLOW DIAGRAMnfA DIRECT SOLVED EXTRACTION PRXESS
-------
DRAFT
The desolventizer toaster Is perhaps the most widely used method of de-
solventlzing meats, particularly in the soybean industry. It consists of
a vertical vessel with steam heated tray sections. The upper trays provide
desolventization by steam sparging while the lower trays provide toasting
by heating the flakes to about 106°C (222"F). The desolventlzed meats are
then cooled, ground, screened and processed as finished meal for animal
feed.
Solvent recovery in every phase or u.ethod of solvent extraction is of
great importance to processors because of the high cost of hexane and its
flammability. Solvent recovery is involved in all of the extraction equip-
ment but is a special problem in the recovery of solvent from the final vent
gas discharge. Various methods employed for this purpose include all adsorp-
tion systems, activated carbon, and refrigerated vent condensers, with the
last being most extensively used.
Modern plants an expect a total loss of hexane of 2 liters (0.5 gal)
or less per KKg (1.1 ton) of seeds processed and a concentration in
the vent of less than 0.9 volume percent air. The total losses in
some plants are considerably higher, as mud) as 4 to 6 1/KKg
(1 to 1.4 gal/ton}. These less efficient plants, besides having the
danger of fire and explosions, will usually face economic problems.
The final product, crude soybean oil, is stored in oil storage tanks
for later shipment via railway tank cars to area edible oil refineries.
Soybean Oil Oegumming: There are a .rge number of solvent extraction
plants in the United States which also process soybean oil for the re-
covery and refining of phcsphatides. This process is generally known
as degurrrr.ing.
Bloomberg ( 26 ) reports that a typical soybean oil will yield a 3.5
percent gum-like material which is 35 percent water and 65 percent
oil soluble; the oil soluble portion will be about one-third oil and two*
thirds acetone-insoluble (lecithin). Lecithin 1s a complex mixture of
phospnatides which consists chiefly of phosphafidyl ethanolamine, phos-
phatidyl serine, and phosphatidyl inositol, combined with various
amounts of other substances such as triglycerides, fatty acids, and
carbohydrates.
A typical plant for degumming soybean oil, operating at 13.6 metric
tons (1.5 ton) per hour, is illustrated in Figure 37 . Oil, containing
3.5 to 4.0 percent guns, is pumped from the crude oil storage tank through
heating coils where it is heated to 59 to 65°C (138 to 149°F); then
through an in-line mixer, about one and one half percent on a weight
basis, of water is added to the crude oil. The oil-water mixture re-
mains in tne hydration tank under continuous mixing for about 45 minutes.
From the hydration tank, the oil-water mixture is pumped to a degumming
centrifuge. The two products are discharged from the centrifuge. De-
gumjned oil, containing about 0.2 to 0.3 percent moisture, goes to a
refining process and lecithin, containing about 35 percent moisture,
122
-------
DRAFT
CRUDE
OIL
TAhK
3.5 TO 4.OX GLMS
WATER AC3ITIQN
1 1/2 WT/WT
HYDRATION
TANK
RESIDENCE TIME
45 WIN
DEGUMMEO OIL
*- TO REFINING
(0.2 TO 0.3k WATER)
LECITHIN
(0.5K WATER)
•FIGURC ;;
A SCHEMATIC DIAGR/\M OF A TYPICAL DEGUMMING OPERATION
123
-------
DRAFT
1s pumped to a vacuum dryer. Dry lecithin, containing about 0.5 per-
cent moisture is discharged from the vacuum dryer. The moisture re-
moved from the wet lecithin amounts to about 227 liters (60 gallons)
per hour, and 1s discharged to a sewer or waste treatment system.
Mechanical Screw Press Operations: The primary emphasis of this de-
scription will focus on the cottonseed Industry as 77 percent of the
processing facilities 1n the United States still use mechanical screw
presses, either for prepressing or complete extraction.
Cottonseed arrives at the plant by rail or truck and 1s stored In large
warehouses. Cottonseed is prepared for pressing by cleaning and sub-
sequent processing through the first and second cut linters (Figure 35 ).
Brennan (TO) reports that the first-cut recovered lint is baled and sold
to cotton-felt manufacturers and the second-cut is sold to cellulose
manufacturers. The delinted cottonseed is then dehulled by cutting
the seeds in bar hullers with the meats being separated from the hulls
by a series of shakers, beaters, and separators. Cottonseed meats are
passed through a crushing roller to flatten the meats into flake form
and to rupture a large number of oil cells. More importantly, crushing
puts the meats into a form that permits uniform treatment of heat and
moisture necessary for preserving good quality oil. Hutchins ( 22 )
reports that after crushing, the meats (30 to 34 percent oil content)
are conveyed into a vertical stack cooker at a temperature of 84°C
(138°F) and a moisture content of 12 percent. Cooked meats are then
discharged into the mechanical screw press or txpeller where about two-
thirds of the oil content is removed and sent to a sump.
Figure ?'j shows a simplified flow diagram for mechanical screw press
extraction. Dunning ( 13) reports that the screw press extractor con-
tains a nain worm shaft that exerts a pressure of 700 to 2,000 atm
(10,000 to 30,000 psi) on the meats being processed; the shaft 1s
selected for the type of seed being processed and the pressure required
by the seed. The particular shaft selectea, however, can have its pres-
sure adjusted for variations in the seeds.
A drainage barrel, consisting of rectangular bars set in a frame, permit?;
drainage of oil from the pressing operation as well as acting as a
filtering media. The spacing of the bars will vary along the length of
the extractor and also according to the type of seed being processed.
The oil from the mechanical extractor Is settled 1n a sedimentation
basin to remove the settleable vegetable solids or "foots", which are
normally about two percent by weight of the meats being processed. The
final unit operation before storage is filtration.
The meat from the mechanical press is in the form of a cake. It may
undergo additional oil removal by solvent extraction, or, if the plant
Is strictly mechanical, it is ground in the meal room. The grinding
-------
MAKEUP I COOLING
WATEB ""i TI-ittEP
M3N-CONTACT WATER OR OIL
IS UC£SJ TO COX SHAFT*
OILSEED M£^
<
HECHANCIAL SCRE* PRESS
UiUJJ-iJJ
SCRE*
CAKE
OIL
SCREENING
TANK
FILTRATION
GRINDING
][
BAGGING.
SHIPPED TO MAWET
TO AN EDIfiCE OIL REFII«RY
C
•;JICAL stt-rw r-r-Tc,5 E5frR/.CT]f)N
-------
DRAFT
operation presents a potential dust problem, particularly 1n the grinding
of cottonseed meal. At this point, ground hulls may be mixed with the
meal for protein adjustment.
Prepress Solvent Extraction Operations: About 19 percent of the cotton-
seed, 50 percent of the peanut, and 50 percent of the flaxseed crush;-
ing industries utilize the prepress solvent extractor method. Typically,
oil seeds are cleaned, cooked, and screw pressed In the same manner as
normal screw press operations where two-thirds of the oil content of the
meats are removed. However, the cooled granulated cake from the screw
press contains about 10 percent oil .(one-third of the oil content of the
seed). This oil Is recovered by the same continuous solvent extraction
process described above. Solvent extraction reduces the oil content of
the cake to less than 0.5 percent and the crude oil is senc to storage.
011ve Oil Processing - Crude olive oil may be produced from whole
ripe olives by the mechanical screw press operation or by hydraulic
press. Cannery crushed whole olives are processed for oil by direct
solvent extraction. The screw press and hydraulic presi produce both
virgin and low grade oils while solvor.t extraction produces only low
grade oil.
Mechanical Screw Press: Figure '„?. illustrates the screw press process
for olive oil produrtion. The whole ripe olives are hopper-fed into
a transport pumo washer for prowasfiino before passing into an air per-
colat'ion washer for f'inal wasr.ing. The clean olives are then trans-
ferred into a hammer mill uy rreiiis of a bucket elevator.
In the hammer mill the olives fall onto a metal screen and are struck
by a rotating drum fitted with steel bar*. The pulverized fruit falls
througn the screen Into an opftn trough which 1s sloped slightly toward
the discharge end. A rotating bar with interspersed, fan-like blades
blends the crushed fruit into'a ncal and conveys it along the trough.
The meal is then transferred into a screw p»-ess with thr resulting
pomaci.' beiig hauled away for fertilizer, while the slurry, composed of
o11i water and flnt p«rt1e1<»s of olives, 15 CentMfuged. Centrlflguatkn
separates the slurry into sludge, oil and r/ater, and fruit water fr«icti
-------
WHOLE RIPE OLIVES
WATER SUPPLY
TRANSPORT
PUMP
WASHER
AIR PERCOLATION
WASHER
MILL
EQUIPMENT
CLEANUP
WATER
SCr-'ET-V, I
MIXIMC
FRUIT
WATER
I FIRST
j CENr«:pijG
J
V
TRUCKED TO _/-'.;
APPLICATION
AWA»-
L'X'j^ TO LArO APUl. 1 CA " 1 t'VJ
. VIRGIN j» i.cw GPAI r ;ML
f'tGUPt 39
SCREW PRESSING PPOCES5 l~ J;^ -EC'J\t^Y CF OlI^ OIL
-------
DRAFT
The oil-water mixture is separated in a polishing centrifuge with the
water being recycled back to the screw press slurry and the oil collected
in storage tanks. Finished oil is tested for taste, odor, and free fatty
acid content to determine if refining is necessary. If the oil proves to
be of high quality, it is retained for blending with refined oil, bottled
as virgin olive oil, or sold in bulk.
Wastewater generated in the screw pressing process consists of periodic
dump 3 of wash tanks, centrifuge effluent, and occasional equipment
dec..,jp.
Hydraulic Press Operations: Figure 40 illustrates the recovery of
olive oil by hydraulic pressing. After crushing in the hamper mill,
the ripe olives are placed in burlap "press bags" which are subsequently
layered into the hydraulic press.
Pressing is carried out in two or more stages, with the first press
(at pressure of asproxirately 20 afn) (300 psi) yielding high grade,
virgin oil. Successive presses at higher pressures yield a lower grade
oil which must be refined. The extracted oil is then centrifuced
to separate fruit water from the oil. Low grade oil goes directly to
refining wnile the virgin oil is bleached by processing the oil tnrougn
a pressure clay filter. The bleached virgin oil is then pumped to
storage tanks.
The porcace remaining in the burlap filter bags contains about ten
percent oil and is mixad with crusned cannery pits and culls for
solvent extraction.
Wastewater generated in the hydraulic pressing process consists of
occasional wasning of the olives prior to pressing ana centrifuge efflut
The Solvent Extraction Process: Figure 41 illustrates the solvent
extraction for olive oil production. Cannery olive pits and culls and
deteriorated, bruised whole olives are manually placed into a hanner mill
and pulverized into wet meal. At this point pomace from the pressing cf
the olive oil may be added to tne rreal , The meal is dried in a rotary >.:'•
to prepare it for extraction. The dried meal is placed into the extractor
where the oil is extracted by a hexane solvent. The hexane is recovered.
the pomace sold for cattle feed, ana the oil recovered for refining. The
only source of wastewater in this process consists of water which drains
out of the fruit during storage.
128
-------
DRAFT
WHOLE R:PE OLIVES
HAMMER
MILL
BURLAP PRESS
BAGS
HYDRAULIC
PRESS
LOW GRADE OIL
TO REFINERY "
POMACE TO REFINING
CENTRIFUGE
VIRGIN OIL
PRESSURE
CLAY
FILTER
WASTE EFFLUENT
(FRUIT WATER)
^ FILTER CAKE
TO SOLID WASTE
VIRGIN OIL
FIGURE 10
HYDRAULIC PRESSING PROCESS FOR RECOVERY OF OLIVE OIL
129
-------
DRAFT
CANNERY OLIVE PITS, CULLS
BADLY BRUISED WHOLE OLIVES
O_WE POM
HAf>WER
MILL
(GRINDING)
HEXANF
RECOVERED
ROTARY KILN
DRYER
MEXANE
EXTRACTION
SEPARATOR
-»• CONSENSER WATER
POMACE TO CATTLE Ft
LOW GRADE OLIVE OIL
FIGURE. O
OLIVE OIL SOLVENT EXTRACTION PROCESS
130
-------
DRAFT
SIC 2079 Shortening, Teble Oils ,_M_argarine And Other Edible Fats And
Oils, Not Elsewhere Cla_ssjfieq
The refining and production of edible oil products from both animal
fats and vegetable oils derived from oilseed products constitutes a
major industry in the United States. The Institute of Shortening and
Edible Oils (ISEO) (27) reports that fats and oils provide about 40 percent
of caloric nutritional needs for the United States. Fat's and oils com-
monly used for table use and cooking purposes are predominately trifatty
acid esters of glycerol, commonly called "triglycerides". Triglycerides
make up approximately 95 percent of the constituents present in crude
vegetable oil. Other principal constituents present include mono- and
diglycerides, free fatty acids, phosphatides, sterols, fatty alcohols,
tocopherols, carotenoids and chlorophyll (color bodies), and vitairins E
and K.
The USDA Foreign Agricultural Service Statistics (28) indicate that
world production of edible oils has been a growing industry for many
years. Prior to World War II, cottonseed was the major oilseed crushed
in the industry, but soybean oil has dominated the American market for
the last thirty years due to its relatively high protein yield. Soybean
oil has been largely responsible for the last decade's increase in
annual world production of vegetable oil from 12.3 to 22 million
metric tons. Table 9 shows the growth m demand for major vegetable
oils and animal fats in the United States over the last two dec^Jes.
Table 10 presents the annual production of the major crude vegetable
oils produced in the United States from 1959 to 1973.
The ISEO (29) reports that there are currently 121 active edible oil
refineries in the United States processing more than 8.2 million metric
tons (9 million tons) of edible fats and oils annually. The largest
concentration of edible oil refineries is in California which as 20
plants; Illinois is second with 15 plants, and Texas is third with 10
plants. Table 11 provides a summary table listing the geographical
distribution of edible oil refining facilities throughout the United
States.
The following process description covers the refining of animal fats
(tallow and lards) ^d crude vegetable oils such as soybean, cottonseed,
peanut, palm, palm .rnal, olive, safflower, and sunflower oils.
Description of Process - A typical, full scale edible cils refinery
usually purchases crude vegetaDle oils from a variety of oilseed crushing
operations and refines the oil into a number of finished products such
as shortening, margarine, salad and cooking oils, salad dressings and
mayonnaise. The principal steps involved in refining edible oils include
(1) storage and handling, including tank car cleaning; (2) caustic
refining; (3) acidulation; (4) bleaching; (5) hydrogenation;
131
-------
TABLE 9 FOOD FATS AND OIL END PRODUCTS
U.S. DOMESTIC DISAPPEARANCE OF FATS AND OILS IN FOOD PRODUCTS.
BY TYPE OF FAT OR OIL, 1950-72 I/ (MILLION METRIC TONS) o
YEAR Soybean Cottonseed Corn Coconut Peanut Palm Palm Kernel Safflower Olive Sesame Total HJ
1950 0.656
1951 0.697
1952 0.867
1953 0.965
1954 C.908
1955 1.047
1956 0.9/8
1957
1958
|P59
1960
1961-
1962
1°63
1964
.041
.281
.431
!366
.279
.4R6
.473
.696
1965 1.701
1966 1.9
-------
1
TABLE 10
PRODUCTION OF MAJOR CRUDE VEGETABLE OIL IN THE UNITED STATES FROM 1959-1973*
MILLION METRIC TONS
(Million Pounds)
Soybean
Crude Oil
Production
Cottonseed
Cnri* W
Production
Peanut
Crwtt Oil
Corn
CrMfc Oil
Production
Linseed Oil
Production
S*fflo»er
Oil
1959
.
(4343)
0.7}
0615)
0.047
(104)
C.U6
(327)
M
M
I960
1.99
M384)
0.81
(1790)
0.038
(83)
o.ioa
(239)
HA
1961
2.01
(4423)
.
(1765)
0.042
(93)
0.152
(335)
HA
0.023
(51)
196?
2 21
0.9'.
(2001)
0.028
(61)
0.166
(366)
0.069
(152)
Vtlties
M - Not Avllttble
Source: F
-------
DRAFT
TABLE 11
A SUMMARY OF THE NUMBER OF EDIBLE OIL REFINERIES
IN THE UNITED STATES LISTED BY STATE
Alabama
Arizona
Arkansas
California
Colorado
Georgia
Illinois
Indiana
Iowa
Kansas
Kentucky
Louisiana
Maryland
Michigan
Minnesota
Missouri
2
2
2
20
1
4
15
3
8
3
1
3
1
1
2
2
Nebraska
New Jersey
New York
North Carolina
Ohio
Oklahoma
Oregon
Pennsylvania
Rhode Island
South Carolina
South Dakota
Tennessee
Texas
Virginia
Washington
Wisconsin
TOTAL
2
8
2
2
5
1
2
1
1
2
2
6
10
3
3
_±
121
134
-------
DRAFT
(6) winterization; (7) deodorization; and (8) plastlciring and packaging.
Figure 42 illustrates a process flow diagram of a typical, full scale
edible oils refining operation.
Storage and Handling: Crude fats and oils arrive at the refinery
receiving area by tank truck or rail car and are pumped to e tank
farm storage area. After use, the tank trucks and rail cars are systema-
tically cleaned with steam or detergents. Tank car cleaning and the
cleanup operations associated with the storage and handling areas con-
stitute a major wastewater discharge from edible oil refineries.
Caustic Refining: There are in use to.-lay several edible oil plants
which use the older methods of bate-' or "kettle" refining of crude
vegetable oils. Sanders (30) reports that economics currently dictates
the use of the continuous caustic refinery process which utilizes
centrifuge separators for the maximum recovery of neutral oils. Figure 43
presents a simplified flow diagram of the caustic refinery process.
The caustic refining process (also termed "saponification") is carried
out by the chemical reactions of a triglyceride (fat) with sodium
hydroxide at a temperature of 60°C (140°F) from one to five minutes.
This chemical reaction is illustrated in Figure 44. Products of the
reaction are alkali salts of the fatty acids whose esters formed gly-
cerides and glycerine.
When the reaction is complete, the caustic solution is centrifuged
to remove the neutral oils from the water solul" sludye or sodium
soaps containing free fatty acias, proteins, c: bodies, and
phosphol ipids. These extraneous mdte'-nals ars on'.y known as
"foots" or "soapstock The neutral, retired are further processed
by a water washing step to remove residual sob, ,at could cause deten-
or:.tv i during later storage or c recess ing. Wa-^r usage for oil washing
is about 10 to 15 percent by wei'jnt of oil.
The washed oil rjst be vacuum dried before storage. This operation
contributes approximately two percent additional water by weight to the
waste load. In addition, clean up operations such as wash-cicwns ,:>r
tanix cleaning produce periodic v.'ater waste loadings.
Soapstock Acidulation: The cc Lely saponified foots or soapstuck
solution is cycled to tin acidi. n tank where excess sulfuric acid is
added to yield free fatty acic- t are recovprable for distillation
purposes for the manufacture o *_ty acid '.1eri vatives. The reaction
follows the general equation si ..'i in Figure 44.
During the processing of soapstock for fatty acid content, waste
water is generated directly from the process itself. Acidulation of a
basic soapstock-water mixture products wastewater not only by neutrali-
zation but also frees water from the soj».ostock mixture. The end result
with respect to waste load is an acid water with a pH of approximately
•135
-------
1
££!»
™1 -
1 f
jzzm.
•
t__ .
r
j
a t«~ i*
1
!
S*VM<'I«:
_ «
*PY
-J
—
-------
DRAFT
18 PERCENT
SODIUM
HYDROXIDE
1 . 5 KG/HR
CRUDE
VEGETABLE
OILS
so KG/HP
PROPORTIONING
PROPOF
SULFUR1C
ACID
PUMPS (p PUMPS O= PUMPS
T
MIXER
2o°C
1-5 MINUTES
3OAPSTOCK
OR
r" FOOTS"
3
CENTRIFUGE
60°C
SOAPSTOCK
ACIDULATION
NEUTRAL OILS
TO
WASHING
47
-------
DRAFT
CAUSTIC REFINING
R-C-O-CH2
Rl-C-OCH2
60'C
NAOH ••• 3 H20
C-H2~OH
-*• C-H
CH2-OH
R-C-OO"NA*
A TRIGLYCER1DE
(CRUDE VEGETABLE OIL )
GLYCERINE
(A NEUTRAL OIL
SOLUABLE IN H20)
SOAPSTOCK OR FOOTS
(A POLAR ALKALI SALT
SOLUABLE IN H20)
ACIDULATIQN
R--C-00 NA*
R2-C-OO~NA'f
SOAPSTOCK
R-C-OOH
Rj-C-OCH
R2-C-OOH
FATTY ACID
SOAPSTOCK>
FIGURE 4-1
GENERAL CHEMICAL REACTIONS ASSOCIATED WITH THE CAUSTIC REFINING AND
AC I DDL .r i ON I:R:CESSF.S
138
-------
DRAFT
1.5 to 2.0. The total volume of water will amount to 65 to 75 percent,
or less, of the soapstock treated. Water from cleanup produces periodic
waste loading.
Bleaching: Bleaching of edible oils 1s usually accomplished by the
adsorption process which consists primarily of the use of bleaching
earth, both natural and activated. A number of refineries use
activated carbon as a substitute adsorbent in place of bleaching earths.
United States refiners usually determine the colors of the lighter
bleached oils and shortenings by matching a 13.3 cm (5.25 in.) column
of the melted fat or oil against red and yellow Lovibond color glasses.
For the darker colored oils a spectrophotometric method has been developed
for the evaluation of oil colors. At the present time both methods are
widely used.
The three bleaching methods commonly used are batch bleaching, continuous'
vacuum bleaching, and a newer development described as countercurren*
vacuum bleaching. All bleaching processes are conducted under vacuun to
protect the oil against oxidation. Some operators add the adsorbent, a
bleaching clay such as Fuller's or diatomaceous earth, at the beginning
of the heating period; others prefer to have ths oil at the bleaching
temperature (usjally 103 to 134=C) before the adsorbent"is added to
facilitate denydration. In bleaching most oils, the cost of the adsorbent
is exceeced by that of the oil lost by retention in the spent adsorbent.
After filtration, the oil ir. usually cooled to a temperature of 54 to
: " (100 to 140CF) before being transferred to storage. Figure 45
;trates a simplified flow diagram of the bleaching process. After
•ation, the ssent filter cake material containing 25 to 1C percent
is usually discarded in either a dry or slurry form. It has not been
.,-iomically feasible in the industry to attempt recovery of the entraines
o-l present in the spent filter cake. However, practices for the recover-/
of this oil nave been developed Dy a few companies. Ths procedure calls
for the spent filter cake to be subjected to a pressurized air flow for
a few minutes until i::ost of the free oil is displaced. Dry stea.T is tncr
introduce into a press chamber from 30 to 45 minutes to renove'the re-
maining oil. In &Qi:ie olants nitrogen is .i
-------
DRAFT
BLEACHING
MATERIAL
(FULLER'S OR
DIATOMACEOUS
EARTH)
•I
REFINED OIL
CONTACT
COOLING WATER
FROM TOWER
BLEACHING
VESSEL
COIL-CLAY SLURRY)
1
FILTER
PRESS
SPENT FILTER
CAKE
REFINED OIL
(TO HYDROGENATION.
" WIMTER1ZAT10N OR
OeOOORIZATON)
GENERAL HOUSEKEEPING
CLEANUP
I
I
STEAM
OIL
RECOVER
T
SOLID WASTE
OIL
I
I
CONTACT
COOLING TOWPP
SLOWDOWN
WASTEWATER
FIGURE 45
A SCHEMATIC DIAGRAM FOR BLEACHING REFINED OILS
140
-------
DRAFT
Waste loadings from the bleaching process are identified as follows:
(1) contact cooling wate" from barometric condenser systems; (?) liquid
waste from the filter cake oil recovery operation; and (3) cleanup
operations.
Hydrogenation: Hardening, or hydrogenation, of an edible fat
consists of the direct Addition of hydrogen to the carbon double
bond of an unsaturated fatty acid chain. Primarily, hydrogenation is,
a means of converting i'>j-'J uls to semi solid, plastic fats suitable
for shortening or margarine manufacture. It also enhances the stability
as well as improving color. Figure 46 illustrates a simplified diagram
of the hydrogenation process. The reaction requires a catelyst wnicn
consists of nickel in a finely divided form, prepared by special methods,
and often supported on a highly porous, inert material, such as
diatomaceous earth. The catalyst is sjspended in the oil during
hydrogenation, a.id at the conclusion is removed by filtration. Although
catalysts decrease in activity with repeated use, a sino'ir charge mey
be used a number of times.
In the usual type of equipment, me hydroqenation reaction is brought
about by agitating the suspension of -atalyst and oil ir. a closed
pressure vessel in an ctmosphere of hydrogen. Agitation serves tne
double purpose of increasing trie solubility of hyd-ooen in oil anc
renewing the oil at the catalyst surface. Th^ rate of hydrogenation
increases with increasing temperature and sressu^e. The romposition
and characte* of the hydrogenate: product n;ay vary accoi o:'ng to tne
positions of the double bonas wr.icn are hydrogena:ed, as well as certcin
isomerizing influences accompanying the reaction, and are nighly ci&-
penoer,t jpon tr.e conditions of nyJrogenation.
The hydrogenation process converts liquid oils to hard or "plastic"
fats, it also improves the resistarce of fats and oils to detei iorafon
through oxidation or flavor reversion. Tne 'nterchangcatil Hty among j
wide variety of fats and oils is largely a result of the contrioution
of the hydrogenation process.
The only wastowater generated from n/drogenation process would be
from periodic cleanup operations.
WinteHzation: The process called "Winterization", a term originatinu
from the fact that initially the process was undertaken in outside
storage tanks during one winter n-jntns, involves removing (pghcr-meltiiiu
glycerides from vegelable oils s(.,::?! as earn oil, soybean oii, and
cottonseed oil. Ac the present time mechanical refrigeration is 'joeo to
crystallize the higher-melting glycerines into a filterable mass, Oil
is either batch or continuously ::rested or certri'fjged to remove the
crystalline solids fron the oil. Winterized oils are processed into
a variety of finished products such as salad oils, and edible oils used
in mayonnaise. Wastewater generation is primarily from genera1
housekeeping cleanup. Figure 47 presents a flow diagram of the winter-
ization process.
141
-------
DRAFT
NICKEL
CATALYST
SUSPENDED IN.
OIL
GENERAL
HOUSEKEEPING
CLEANUP
COMPRESSOR
SPENT CATALYST
(RECOV^HcD BY
SOE PLANTS)
NON-CONTACT
COOL IN TOWER
SLOWDOWN
OIL
WASTEWATER
FIGURE -16
A SCHEMATIC DIAGRAM OF A CONTINUOUS HYDROGENATION PROCESS
142
-------
DRAFT
REFINED DR
BLEAChED CIL
PRECOOLER IZ_-.
CRYSTALIZER
TEMP 7°C
FILTER
REFINED
"WINTERIZED"
OIL
NON-CONTACT
COOLING WATE1?
REFRIGERATION
• STEARINE
GENERAL HOUSEKEEPING
CLEANUP
WASTEWATER
NON-CONTACT
COOLING TOWER
SLOWDOWN
FIGURE 47
A SCHEMATIC DIAGRAM FOR A CCMTINUUiiS "WINTTERIZATION" PROCESS
-------
DRAFT
Deodorization: Edible oils are usually subjected to a steam distillation
process known as deodorization. The purpose of this process is to remove
odoriferous compounds and free fatty acids in order to produce an oil
bland In flavor. Three types of deodorizing equipment are used: batch,
semi-continuous, and continuous. In each, the principles are the same with the
oil held in a vessel under vacuum using stripping steam to affect steam
distillation of the volatiles. A vacuum is generally produced by condensing
steam with water after the steam has been forced through a venturi. The
condensing water is redrculateti back to a cooling tower where heat is
removed and returned to the condensing equipment for further use. Figure
48 presents a simplified flow diagram of the deodoriration process. During
the process, certain fatty materials are concentrated within the stripping
steam and are removed by the barometric condenser water, where they are
eventually deposited on the contact cooling tower grillage and in the tower
basin. Therefore, the contact cooling tow=r presents periodic cleaning
problems which are generally handled manually.
Distillate recovery systems in common use today reduce the rate cf fatty'
material deposition at the cooling tower basin. Distillate recovery is
based on a liquid oil spray condensing the fatty materials before they
reach the barometric condenser. Recovery is on the order of 90 to 95
percent. The recovered distillate is collected in dry form and may be used
or sold as a by-product. The reduction of distillate concentrations of
organic matter to the contact cooling tower has several advanatages:
(1) periods of manual cleanings are reduced; (2) cooling tower waste loadings
are reduced; and (3) odor control is enhanced.
Food Emulsifier Operations: In addition to the previously described pro-
cesses, several manufacturers also produce a variety of food emulsifier
compounds. Production of edible food stuffs requires the use of an emul-
sifying agent in edible form. Items such as dressings, cakes, icings,
etc. are improved by the ability of an emulsifier to hold an oil phase
and a water phase in suspension. In the edible oils industry the production
of food emulsifiers such as mono-and diglyceride compounds fulfills this
need.
The production of mono-and dlglycerides is a result of a chrmical reaction
in whijh excess free glycerine in the presence of a catalyst such as sodium
hydroxide is added into a reaction vessel containing a suitable base oil
(triglycerlde). Under proper temperature and pressure conditions the fatty
acids of the trlglycerides and the hydrohyls of the glycerine exchange
positions to produce a mixture of glycerine, monoglycerides, diglycerideb,
and trlglycerides. At the end of the reaction, excess free glycerine
is "stripped" off using a vacuum system employing an intercondenser to
prevent contamination and loss of glycerine into the barometric condenser
water. In many cases, however, some glycerine escapes Into the condenser
water posing a problem with waste loading at the contact water cooling tower.
144
-------
DRAFT
HYDROGENATED
OIL OR
LIQUID OILS
CONTACT COOL If JG
TOWER WATER
WASTEWATER
OR
LIQUID OIL
FIGURE: 4s
A SCHEMATIC DIAGRAM FOR CCIBL? OIL DEODORIZING
145
-------
DRAFT
Plasticizing and Packaging: The plasticizing and packaging of refined,
hydrogenated (hardened) edible oils into finished products such as
shortening, margarine, or salad dressing are generally processed in
the following manner. Sanders (30) summarizes the plasticizing process
for shortening where the melted blend of refined edible oils are de-
livered from a feed tank through a high-pressure Dump where nitrogen
is added. The blend is then cooled to 18°C (64°F) in about 30 seconds and
is worked gently from one to four minutes during which crystallization
occurs. After crystallization is complete, the blend is allowed to
undergo a sudden decrease in pressure to remove the free nitrogen.
The blend (now shortening) 1s filled into either number 10 cans or 23 kg
{50 Ib) plastic lined boxes and is allowed to "set up" by storage at room
temperature for 24 to 48 hours. Figure 49 Illustrates a typical flow
diagram for a plasticizing and packaging operation.
In general, the packaging of shortenings and other finished products
employ strictly mechanical treatment of oils and their conversion from
large bulk quantities into consumer or commercial sized packages. Con- •
sequently, the bearing these operations have on the waste loading of
wastewater treatment facilities depends primarily on the cleanline-- and "
efficiency of those operations. Cleaning operations, such as sal; 1
packaging, requires larger volumes of water and therefore, contri- more
heavily to waste treatment than a more plastic product such as she. ng.
Margarine production, because of the nature of the product and its ability
to provide a growth medium for bacteria requires considerably more sani-
tation than does the production of shortening. Margarine is by law 80
percent oil and the remainder is water, milk solids, and salt. These
ingredients are creamed and cooled for packaging. As in the packaging of
shortening, general cleanliness has a direct relation to the waste load
imposed. It differs, however, from shortening packaging In at least two
respects: (1) the use of emulsiflers in the product may impose more
severe problems with waste treatment; and (2) the volumes of water needed
Is increased due to the addition of margarine mixing equipment and the
resulting necessity for cleaning. Figure 50 presents a typical flow
diagram of margarine plasticizing and packaging operations.
The plas^dzing and packaging of salad dressings and mayonnaise presents
a variety ,f unique waste loading problems. Dressings are generally an
emulsion of oils and other oil and water soluble ingredients such as cer-
tain vegetables and spices. These ingredients are blended and mechanically
and chemically emulsified to produce a stable product. As in margarine,
the production of salad dressings also supports the growth of certain
pathogenic forms of bacteria. Consequently, CIP (Clean-in-Place) equipment
is wide spread throughout the industry. The production of salad dressings
and mayonnaise requires the use of food emulsiflers (mono- and diglycerides)
as a basic ingredient. The high organic content of food emulsiflers
coupled with their ability to exist in either an oil or a water phase
creates a difficult If not unique waste loading problem for the Industry.
14$
-------
DRAFT
HYDROGENATION
WINTERIZATION
FINISHED
HARDENED OILS
H FILLER
CLEANUP
WATER
PACKAGING j-—
SHORTENING
TABLE OILS
(SALAD OIL.
COOKING GILS)
WAREHOUSE
NON-CONTACT
COOLING
TOWER
SLOWDOWN
CLEANUP
'YASTEWATER
FIGURE 4J
A SCHEMATIC DIAGRAV PQR EDIBLE OIL
REFINERY PLASTICIZINO A^ PACKAGING OPERATIONS
147
-------
DP AFT
REFINED. BLEACHED,
HYDROGENATEO, DEODORIZED,
OIL FTOM STORAGE
PA5TEWIZATJON
<
MILK SUPPLY
XN-PUANT HATE*
SUPPLY
WEIGHING
SCALE
EMULSION
TANK
TEW - 37*C
1
PUMP
PLASTICIZATIQN
(VDTATOR CM1ULEP)
TEMP 7»c
VITAMINS A. D
CQ-ORING. SALT
FLAVORING
EHJLSIFIERS
PACKAGING
15*C
MARGARINE
FIGURE 50
CLEANUP
•ASTEWATER
A SCHEMATIC DIAGRAM OF A CONTINUOUS
MARGARINE PLASTICIZING AND PACKAGING OPERATION
140
-------
DRAFT
SIC 2002 Halt Beverages
There are 104 breweries 1n the United States. According to the Modern
Brewery Age Blue Book (31 ) the 1973 sales for these brewers was 16.2
billion liters (138 million barrels). The total value of shipments
for 1974 was estimated by the Department of Commerce ( 32 ) at 48 billion
dollars. There have been a considerable number of breweries constructed
since 1950. In addition, many breweries constructed prior to 1950 have
undergone major expansion. In general the past 15 years has seen the
number of operating breweries decrease while the size of those operating
has Increased. It would appear that any breweries constructed in the
future will be large and automated. As the 18 year old and over population
group Increases during the decade, the product shipments for the brewing
Industry are expected to grow accordingly.
Description of Process - The malt beverage Industry produces beer, ale, "
and malt liquor by the fermentation of sugars converted from the starch
cf various grains. The basic unit processes Include mashing, brewing,
fermenting, aging and filtering, and packaging. In addition, some
form of by-product recovery is practiced by all brewers. A simplified
process flow diagram for a typical brewery is shown 1n Figure 51. It
should be pointed out that every brewer and, in fact, every Individual
brewery, has features which make 1t unique. For the purpose of this
description, only those process variables which affect wastewater generation
will be discussed.
Mashing: Malt is ground and mixed with water In a mashing vessel. Rice,
corn, and other grain derivatives are similarly ground and mixed, except
that they are brought to a boil. The two mixtures are combined In the
mash cooker, or "mash tun," where the starch from the grain Is converted
by enzyme action Into malt sugar and the proteins are partly degraded
Into amino adds. Upon completion of mashing, the grains solids are
separated from the extract by "lauterlng," by a plate end fratne filter,
or by a grain separator. The extract 1s sent to the brew ktttle. Spent
grains are sold wet or dried to produce marketable animal feed.
Wastes from the mashing process comprise an extremely small part of the
total plant load. They are generated from Intermittent clean-up of
vessels and grain separators. In newer more fully automated plants
vessel clean-up 1$ accomplished b> Clean-In-Place (CIP) equipment. This
procedure Involves an initial hot water rinse, caustic wash, and final
rinse, with the Initial and final rinses being sewered.
Brewing: Once the extract has reached the brew kettle 1t Is boiled and
mixed with hops or hop extract. This boiling destroys the enzymes while
it extracts the resins from the hops which Impart flavor and aroma to the
beer. The hot extract, now called "wort." 1s passed through a hop separator
149
-------
DRAFT
FIGURE 51
PROCESS FLOW DIAGRAM MALT BEVERAGE BREWERY
150
-------
DRAFT
which screens out the spent hops. Insoluble materials which collected
In the brew kettle, now known as "trub," are settled out either 1n the
"hot wort tank" or after cooling. Normally the "wort" is then filtered
with dlatomaceous earth prior to fermentation.
Wastes from the brewing process are spent hops, trub, and filter residue.
Spent hops and trub may be added to the spent grains or sewered. Filter
wastes may be sewered or recovered separately from the spent grains.
Dlatonaceous earth waste 1s filtered to separate solids from the liquid
waste. The liquid 1s then decanted and discharged while the solids are
hauled to land disposal.
Fermenting. Aging, and Filtering: Yeast 1» added to the cooled wort in
fermentation tanks to convert the malt sugar Into alcohol and carbon
dioxide. In addition, an excess of yeast Is produced. About one-fourth
of this yeast may be reused. The carbon dioxide gas may be vented to the
atmospnere or reclaimed for other 1n-plant uses.
Most brewers punp the completely fermented beer Into primary storage tanks.
During this period additional yeasts and Insoluble substances settle out.
In some breweries the partially femented beer 1s pumped to large tanks
for a secondary fermentation and aging period. One variation of the process
allows the yeast to collect in the aging tanks on a bed of beechwood chips.
The chips must be cooked prior to their Initial use. They are then removed
and sterilized before being reused. After aging in primary storage the
beer 1s chilled and filtered with dlatomaceous earth or reusable pads
before final storage. The beer is normally filtered again for clarity
prior to packaging. Some brewers recarbonate at this tine through the •in-
jection of carbon dioxide.
Wastes from fermentation, aging, and filtering Include spent yeast and
spent filter media. Yeast residue from fermentation may be sewered, added
to spent grains, or in some cases evaporated. Filter cake may be ' -(swashed
to decant tanks or to vacuum or pressure filters before discharge *r
those brewers using the beechwood chip process, yeast Is dlfficul
remove because of the large volume of wash water present. A*tsr
these biewers utilize an additional clarification step producing
organic sludge which must be discharged.
Packaging: Malt Beverages are packed in cans, returnable and non-.-. urnable
bottles, and returnable kegs. A packaging flov; diagrar is shown in Figure 52.
Kegs are returned containing some unused beer, which 1s normally discharged
to the sewer. Thn kegs proceed to a washer with a preHnse, caustic, and
final rinse spray cycle. The cleaned kegs are filled and manually cor'
-------
DRAFT
CANS
CAN RINSER I
NON-RETURNABLE RETURNABLE
BOTTLES BOTTLES
_4_ \
BOTTLE RINSER
KEGS
(BOTTLE WASHER
CAN FILLER
J~
H
KEG
SOLIDS
KEG WASHER -H
BOTTLE FILLER
KEG FILLER
PASTEURIZER
LABELLER
COLO STORAGE
I INSPECTION L
» '
REJECTS
CRUSHING
•OLIOS
FIGURE 3-
PACKAGING FLOW DIAGRAM MALT BEVERAGE BREWERY
•ASTEWATCR
BFTLUEWT
15'
-------
DRAFT
Cans are rinsed with clean water to eliminate any dust particles which
they have accumulated. During filling and seaming there Is a beer loss
due to the speed of the line and the configuration to the container.
Canned beer Is usutlly pasteurized, but It may Instead be filtered with
ml 11pore filters or simply kept cold. The cans are Inspected for proper
product level and those rejected are crushed, thereby creating an addi-
tional beer loss.
Non-returnable bottles need only to be rinsed before filling. Returnable
bUtles, however, must be washed, cleaned, sterilized, and rinsed. Labels,
unused product, and other refuse are removed from returnable bottles in
a bottle washer. Basically the washers follow three steps: 1) prerlnsiny,
1n which both the Inside and outside of the bottles are subjected to a hot
spray; 2) soaking, 1n which the bottles are Immersed in a hot caustic
solution; and 3) final rinsing, 1n which caustic carry-over Is removed in. a
fresh water rinse. The pre-rinse and final rinse are normally discharged.
The bottles proceed to the bottle filler where there is some beer loss. .
Prior to shipment the bottles must be labelled and inspected and may be
pasteurized.
Hastes from packaging are an Important factor in total plant load. Beer
loss is generated from keg dumps, bottle and can fillers, and compactors.
These losses are normally sewered although the beer may be collected con-
centrated, and added to spent grains. Returnable bottle washers general?
liquid and solid wastes, the solids being screened and hauled away and
the liquids being sewered.
Spent Grain Recovery: Handling of spent grains from the mashing process
follows one of the tnree following procedures: 1) spent grains may be sold
wet at 80 to 90 percent moisture; 2) spent grains may be screened and pressed
to remove as much moisture as possible, thereby producing spent grain
liquor which must be discharged, and grains at 65 to 70 percent moisture
then fed to gas fired rotary driers to produce animal feed; 3) the grains
may be screened, pressed, and feel to gas fired driers while the spent grain
liquor is concentrated in evaporators to a syrup (20 to 30 percent total
solids) which 1s mixed with the dried grains, Spent hops, trub, and spent
yeast may be added to the grains in any of the above procedures. In addi-
tion, a plant may have all the above capabilities and yet for economic
reasons choose to sell all or some portion of these grains wet. A flow
diagram for a typical spent grains recovery operation 1s shown in Fiqure 53.
Wastes from spent grain recovery form the principal part of the total plant
load. If discharged, the spent grain liquor Is the largest single was*e
source. If the spent grain liquor is recovered iy concentration In evap-
orators, then the evaporator condensate is the major wastewater contributor.
Multiple-effect, vertical tube evaporators are commonly used. Wet scrubber
discharge and periodic cleaning of screens, presses, conveyors, and centri-
fuges will also contribute to the wasteload.
153
-------
D2AFT
SPENT GRAINS
WASTEWATER
EFFLUENT
FIGURE 53
SPENT GRAINS RECOVERY MALT BEVERAGE BREWERY
•ASTEWATER
EFFLUENT
-------
DRAFT
SIC 2083 Malt
The malt Industry consists of 29 malting companies located primarily
1n Wisconsin and Minnesota. Total annual production for 1973 was 128
million bushels (33). Of this total 119 million were used 1n the malt
beverage Industry, 4.14 million were used 1n the distilled spirits In-
dustry, and 3.5 million wtre exported.
Description of Process • Malt 1s a primary raw material for the processes
of brewing and distilling. Fermentation depends upon the action of enzymes,
and the purpose of malting barley 1s to produce those enzymes which bring
about the eventual conversion of starch Into fermentable sugars. Essentially
the process of manufacturing malt from barley consists of steeping, gemin-
ating, and kilning. A flow diagram for the malting.process 1s shown •;,.
Figure 54.
After preliminary cleaning and grading, barley 1s stored 1n grain bins.
Differences 1n types of barley utilized relate primarily to kernal size,
two common designations being two-row and six-row. Once the proper type of
barley has been selected 1t is conveyed to the malt house for steeping.
The barley is placed in large hopper-bottomed steep tanks where it 1s
kept submerged in cool water for 40 to 72 hours. The purpose of this pro-
cess is to Impart moisture to the grain and to remove undesirable colors
and tannins. This Is accomplished by changing the water in the steep tanks
three to four times while compressed air is bubbled through the mixture.
The wastewater discharged during these changes forms the principal part
of the total malt house load.
After steeping, the barley 1s transferred to germinating drums or compart-
ments for a period of four to eight days. It Is during this period that
the formation of enzymes occurs along with the crtatlon of heat and carbon
dioxide. Temperature and humidity controlled air Is forced through the
malt while 1t Is being turned. After a few days additional moisture is
added to accelerate germination, usually by spraying. The portion of this
water which 1s later drained from the germinating drums or compartments
forms the second part of the total wastewater discharge.
The malt Is now ready .'or kilning. During this procedure the malt Is
conveyed to drying floor: where It is kept for three to four days. Furnaces
under the floors provide controlled temperature conditions to dry the malt
to the desired moisture content. The floors are normally situated vertically
so that the malt may be dropped from level to level while the temperature
Is increased. Upon completion of drying the malt Is stored or shipped.
The wastewater effluent from steeping and germinating 1s normally screened
before final discharge. The solid by-product is generally sold as feed.
155
-------
DRAFT
WATER-
COMPRESSED AIR-
WATER SPRAY-
MOIST AIR-
CLEANING
GRADING
STORAGE
STEEPING
GERMINATING
KILNING
MALT STORAGE
SCREEN
-•-SOLIDS
WASTEWATEP EFFLUENT
FIGURE rA
PLOW OIAGFW^ MALTING PROCESS
156
-------
DRAFT
SIC-2084 Mines, Brandy, and Brandy Spirits
According to the Department of Commerce (32) there were 496 bonded wineries
and wine cellars and 49 bottling houses in operation as of June 30. 1373.
The total value of product shipments for these establishments in 1974 was
estimated at $1.06 billion dollars, or about 14 percent of all alcoholic
beverages. Total sales of wine in 1973 were 1.31 billion liters (347
million gallons). Of the total, California produced 69.6 percent, other
states produced 14.5 percent, and 13.9 percent was imported. The distri-
bution of U.S. produced wine by area and type, as reported by the Wine
Advisory Board, (34) is shown in Figure 55.
Beverage brandy production in 1972 was 6.49 million proof gallons, almost
all of which was grape brandy. Severage brandy refers to those fruit
spirits distilled under 170° proof. Neutral brandy refers to those
spirits distilled between 170° and 190° proof. Wine spirits refers to
those fruit spirits distilled over 170° proof. Thus, neutral brandy and
wine spirits are not mutually exclusive classifications. In reporting
the production, withdrawals or stocks of spirits between 170° and 190°
to BATF, producers have the discretion of placing it in the classification
neutral brandy or in the genera] classification "Alcohol and Spirits".
This classification includes other than fruit spirits and since there is
no breakdown of this classification in the BATF reports, the brandy com-
ponent cannot be identified. Tax-free removals of spirits for addition
to wines are reported. Removals under this classification would consist
only of wine spirits. Removals under this classification in fiscal year
1972 totaled 24,419,000 proof gallons. Tax-free removals of "brandy" for
ad. tion to wine totaled 1,000,000 proof gallons. Most or all of this
was produced in California.
The wine industry has maintained a growth rate which averaged
10.7 percent between 1967 and 1972. During the same period per capita
consumption increased 57.1 percent to £.12 liters (1.62 gallons). A
major factor in this increase was the growth of the 21 to 44 age group--
the group associated with higher levels of wine consumption—which will
continue to increase during the 1970's.
Description of Process - Ttie technology of wine making is comprehensive1>
described by Amerine, Berg, and Creuss (35). For the purpose of this
discussion emphasis will be placed only on those process variable directly
affecting wastewater generation. Each and every winery has features
which make it unique. The most conspicuos difference, however, in terms
of wastewater effluent, Is between tnose wineries which do not produce
spirits by distillation and tltcse which do. Table wines (Including
sparkling wines) are produced without the addition of wine spirits.
Wineries producing these form a general classification. These wineries
nay also purchase wine spirits and produce dessert wines. The second
classification includes wineries which produce table wines and dessert
T57
-------
DRAFT
TABLE WINE1
CAt.
DESSERT WINE2
BY TYPE (CALENDAR YEAR 1972!
SPARKLING WINE'
NEW YORK
OTHER
BY 'AREA (FISCAL YEAR 1972)
1 INCLUDES TABLE WINE AND OTHER SPECIAL NATURAl STILL WjrG NOT
OVER IU PERCENT ALCOHOL SY VOLUME.
2INCLUDES DESSERT WINE. VE"?11VJTH A'JD OTHER SPECIAL 'JATURAi. STILL
WINE OVER 14 PERCENT ALCOHOL BY VOLJME.
INCLUDES ALL NATURALLV FERMENTED AND ART1PICALLV CARBONATED
SPARKLING WINES. OTHER SPECIAL NATURAL SPARKLING WINES ARE INCLUDED
FIGURE 55
DISTRIBUTION OF U.b. WI:\'E PRODUCTION 1972
153
-------
DRAFT
wines, but which also produce wine spirits for addition to dessert wines
and/or brandy. It should be noted that wineries in the eastern part of
the U.S. produce only-table wines or if they produce dessert wines,
purchase wine spirits for the addition to dessert wines. In either
case they do not maintain stills. Those wineries producing wine spirits
are located solely in California, and, for the most part, in the San
Joaquin Valley. For this reason the process description will be
divided into two. sections: wineries without stills, and wineries with
stills.
Wineries Without Stills: Products from these wineries are red and white
wines, sparkling wines and dessert wines using wine spirits purchased
elsewhere: The basic unit processes comon to these wineries are:
crushing and destemming, pressing (procedure varies), fermenting, clan'-.
fication, aging, and bottling. In addition, all wineries are faced
with distinct seasonal variations, as are most agricultural food industries.
During the grape crushing season, which lasts approximately six to eight
weeks in September and Octooer, all the fermentable material rust be
fermented. Finishing operations, however, are carried on throughout
the year, thereby creating differing problems in wastewater disposal.
A process flow diagram for the production of red table wine without
recovery of distilling material is shown in Figure 55. After picking,
the grapes are placed in containers and transported to the winery where
they are weighed and dumped into a crusher/stemmer. There are three types
in use: the ••oiler, disintegrator, or Garolla. The Garolla is the only
type from which the steins ana leaves are removed. The juice, skins, and
seed, now known as "must/1 are pu-noed to fermentation vats. Wastes from
crushing and destenining consist of periodic wash downs of the crusher/
stemmer, which are sewered, and steins, which are normally spread on
vineyard property.
Fermentation 1s preceeded by the addition of a small amount of sulfur
dioxide to the must, thereby inhibiting the growth of wild yeast or
bacteria. With tie addition of a pure yeast "starter" the fomentation
process is initiated, and the grape sugars are converted Into roar^y ciua!
parts of alcohol and carbon dioxide. Considerable heat is generated a no'
the vats must be cooled to maintain optinun fermenting conditions. When
the fermenting must has attained the desired amount of color and tannin,
then it is drawn off the porace as "free-run" juice and pumped to a
finishing tank where fermentation may be processed to completion. The
pomace is pressed to extract any remair.'irg liquid. The resulting press-
run may be used fcr the production of less expensive wines or it may bc-
recombined with the "free-run", The pomace is hauled end spread in the
vineyards or dried and sold as feed for poultry. Usually within six
weeks after crushing the fermentation is complete. The liquid, now
called wine, is decanted or "racKod" off the sediment of yeast pulp
end tartaratci known as "lees". This procedure may take place three
or four times. Additional wine may be recovered by passing the lees
through a centrifuge or filter. The sulfur dioxide content is normally
159
-------
S02'
8ENTCNITE
GRAPES
STEMS
CRUSt-ER
STEMMER
MUST
FERMENTER
POMACE
FREE-RUN
JUICE
PRESSED
'POMACE
—
—
PRESS
3-ii TIMES
PRESS-RUN JUICE
1
FINISHING TANKS
WINE
LEES
LESS EXPENSIVE WINE
— CAKE
FILTER
FINING
CAKE
FILTER
REFRIGERATION-
CAKE
FILTER
AGING
ION |
EXCHANGE I
RACK
I
CAKE
FILTER
BOTTLE
FIGURE -^
PROCESS FLOW DIAGRAM RED TARLE WINE PRODUCTION
WITHOUT RECOVERY.OF DISTILLING MATERIAL
WASTEWATER
EFFLUENT
-------
DRAFT
adjusted at this time. Wastewater from fermentation is generated from
wash downs of fermenters, finishing tanks, pomace presses, and lees
filters . Pressed pomace and lees filter cake are normally hauled and
spread in the vineyards.
The wine may now undergo a series of "finishing" operations which vary
from winery to '.vinery. After the first racking a fining agent such
as bentonite clay may be mixed with the wine to encourage the settling
of suspended and colloidal materials. This step would normally be
followed by filtration with filters or plant and frame presses. The
wine must new be aged. This may be done in wooden, stainless steel,
or concrete containers of various sizes. During aging wine is normally
refrigerated to hasten the precioitation of tartarates which might
be desposited after bottling. Since refrigeration is expensive the use •
of ion exchange resins as an alternative has come into limited practice.
In this process potassium and calcium ions are replaced with sodium
or hydrogen ions. Additional racking, filtration, fining, and centri-
fugation may be utiHzed to further clarify the wine. Uniformity of
quality and character are maintained by analyzing and blending the
wine. In every case a polishing filtration is customary shortly before
bottling to insure that the wine is perfectly clear. Wastes from
finishing operations consist of lees from fining vats, centrifuges,
and aging containers. Cake from filters is hauled and spread in the
vineyards.
Bottling, labeling, and casing are the final operations. Most wineries
find it more practical to bottle their own wines, although wine nay be
shippec in tank cars to plants where the only operation is bottling. ThE
bottles are filled and corked under sterile conditions. There is little
spillage involved except in the case of breakage. The wine is inspected
for clarity prior to labeling and casing, and this operation for the
most part, Is entirely automated.
Figure 5? shows a process flow diagram for the production of white table
wine without the recovery of distilling material. Both v/hlte and red
table wine production normally occur in any one winery but th.e processing
operations are different. The white wines are not fermented in the pre:or.ce
of the skins as are the red wines. As a result the tannin and extract
content are lower. It should be noted that either white or red grape;
can be used for the crush. The must from the crusher is allowed to
separate so that the free-run juice may be obtained. It is then sent
to a press, which is most often of cylindrical design, and the re-
maining juice is collected. The pressed pomace, which still contains
some sugar, is hauled and spread in the vineyards. The press-run is
normally utilized for the production of less expensive wine. The free-
run 1s sent to fermentation and innoculatec* with pure yeast. From this
point on the wastewater discharge is similar to that of red wine production.
161
-------
DRAFT
SO-
GRAPES
CRUShER
5TEMM5P
I
MUST
-H
PRESSED
POMACE
PRESS
FREE-RUN
JUICE
PRESS-RUN
JUICE
LESS EXPENSIVE WINE
FINISHING OPERATIONS
SAME AS FOR KED TABLE
WINE PRODUCTION
FIGJRE 37
PROCESS FLCW DIAGRAM WHlTt TA&..S WlKE P
WITHOUT RECDVERY OF OlSTlLlINCi MATERIAL
WASTEWATER EFFLUENT
162
-------
DRAFT
Figure 58 shows a process flow diagram for the production of sparkling
wine. These may be defined as wines which have more than 1.5 atmosphere
pressure at 10CC (50°F). Although there are several methods for the
production of sparkling wines the most common involves the addition
of sugar and yeast to cause a "secondary fermentation" of wine in a
closed container. A common example of one type of sparkling wine 1s
what is known as champagne. To a properly selected and blended wine
or "cuvee", sugar and yeast are added. The moisture is placed in bottles
or tanks for fermentation and storage. After an appropriate time interval
the bottles are "disgorged" or the liquid "transferred" temporarily from
bottle to storage. This procedure allows the removal of yeast which
has accumulated in the bottle. The transferred wine is filtered, placed
back in the bottle, and caseo for storage. If the "bulk" or tank
process is used then two tanks are employed with interconnecting fi'trat^n.
Upon transfer of the fermented wine to the second tank the wine is bottled.
Wastes from sparkling wine production consist of mixing tank cleanup and .
yeast from filtration of fermented wine.
Figure 59 shows a process flow diagram for the production of dessert
wine. These wines contain more than 14 percent alcohol due to tne
addition of fortified spirits. Common examples of this process are
white dessert wine, port or other red dessert wina, and sherry. Fer-
mentation is allowed to proceed to a specified sugar level. The wine
is pumped to fortifying tanks for the addition of wine spirits. Fortified
wine for sherry production may be baked or aged shermat blendeJ with
submerged culture of flor sherry. Fining, filtering, and aging procedures
follow as previously discussed. Wastes from the production of dessert
wine are substantially the sar.e as those from the production of table
wines. Since the two operations normally take place on the sane premises,
the load represents and addition in terms of vessels required for fortifying,
baking, -ind storage, and 1n terms of the associated filtration and wash
downs necessary.
Figure 60 shows a process flow diagram for an eastern winery producing
table,dessert, and sparkling wines. Several basic differences in
eastern and western wineries are aooarerit. The grapes f'-om the east
are the V. labrusca which are lower in sugar content and higher in
acidity tnan tne V._ yinifera grown in California. Preparation tor fermen-
tation generally involves pressing. Grapes for white wines are cold presto
a* they come from the stemmer/crjsher. For this pressing many continuous
and bladder models are being usea. Grapes for red wines are "hot pres:-.co',
i.e. the pulp is heated prior to the loading the p/ess. Amelioration
of up to 35 percent by the addition of dextrose may be required prior
to the fermentation due to the high acidity and low suoar content of the
Juice. In addition, if hot pressing was used, the juice must be cooled
before fermentation starts. After fermentation it Is common practice to
blend 1n up to 25 percent of California wines. Eastern sherry wines are
made by fortifying finished wines and then baking by the Tressler method.
This consists of heating while oxygen is released slowly in the wine.
Another method Involves allowing the sherry" to age in oak barrels.
163
-------
DRAFT
YEAST
BLENDED WINE
OR CUVEE
ilr
SUGAR
MIXING
TANK
TANK BOTTLE
FERMENTATION FERMENTATION
I BOTTLING
TANK «1 J
. > CAKE STORAGE
FILTER —
TRANSFER METHOD
I
BOTTLE METhCD I
TRANSFER TANK
t
DISGORGING *- *•
FILTER
CASE
STORAGE
BOTTLING
F1GURE 38 WASTEWATER
PROCESS FLOW DIAGRAM SPARKLING WINE PRODUCTION
164
-------
DRAFT
WINE FERMENTED
ON SKINS
WINE NOT FERMENTED
ON SKINS
WHITE DESSERT
WINE PRODUCTION
PORT AND OTVER RED
DESSERT WINE PRODUCTION
FORT I FT. CAT U
VrtT
OAK ING
L
FINISHING OPERATIONS
WINE SPIRITS
PRODUCTION
FIGURE •>:
PROCESS FLOW DIAGRAM rCSSERT WINE PRUDUCTION
WASTEWATER
-------
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-------
DRAFT
Sparkling wine production 1s bottle rather than tank fermented and normally
employs the transfer system to clear the bottle of yeast deposits. Waste-
water from eastern wineries 1s generated in a manner similar to that in
western wineries without stills. (For further discussion of wastewater
per unit of production see Wastewater Characteristics, Section V).
Wineries With Stills: Wineries with stills may produce all of the
aforementioned wines in addition to beverage brandy and wine spirits.
A process flow diagram for such a winery with complete recovery of
distilling material is shown in Figure 61 . Only the best wine is
used f;r the production of beverage brandy, whereas wine spirits or
fortirying brandy is made from recovered distilling material .
Beverage brandy is produced from the distillation of wine and normally •
takes place in a continuou: column still. Indirect heat or steam
introduced at the bottom of stripper evaporates the alcohol from the
wine which is introduced near tne top of the column in the counter
current. The vapor leaving the top of the still is condensed to forrr
the spirit. The de-alcoholized residue, known as "stillage", is discharged
from the base of the column. The beverage brandy as it leaves the still
is at 170° proof or less. Additional columns may be added at this tine
to remove the higher alcohols (principally amyl alcohol) which comprise
the fusel oil content of brandy. Removal of aldehydes is also practicec
by the addition of an aldehyde column. Since the aldehydes (chiefly
acetaldehyde) have a low boiling point, they are taken off the top of
the column and the product off the bottom of the aldehyde column. The
brandy is then reduced in proof, aged in wood, and bottled.
Fortifying brandy 1s made by a similar process but by the use of distilling
material such as lees, filter wash, pomace wash, unmarketable standard
wine, and other wine residues. The final product, either wine spirits
or neutral brandy, is distilled from 140° to 190° proof and sold as
such.
A major part of the wastewater from wineries with stills 1s derived
stillage. Since the distillation process depends upon grupe crushing
for its raw mate ial (I.e., either newly fermented wine or distilling
material) the distilling season and stillage generation roughly parallel
the crushing season. During this tine period those California wineries
with stills use a laivl disposal system for stallage wastes. This entail?
pumping the stillage into shallow "checks" or ponds of not more than C.iC"
(four incher) depth for evaporation and percolation. Enough land is
required for separate checks to auco-oojLe at least 7 to 10 Hays of stil'lf,.j?
volume, at which time the original check may be reused after having
dried and being dssced.
16?
-------
PRESSED POMACE
WATER
FINISHED WINE
LEES (FROM FERMENTATION,
FINING. FILTERING, AND
AGING)
CONTINUOUS
COLUMN STILL
ALDEHYDE
COLUMN
BEVERAGE
BRANDY
PRODUCTION
DILUTE
STEMS
| DISINTEGRATOR j
SCALPER
1
(^
DISTILLING
MATERIAL
SOLIDS
STILLAGE
I-C'DS
WINE SPIRITS
PRODUCTION
STORAGE/SHIPMENT
AGE
BOTTLE
FIGURE
WASTE-WATER EFFLUENT
PROCESS FLOW DIAGRAM
BEVEKAGE BRANDY Af:D WI',E SPIRITS PRODUCTION WITH
COMPLETE RECOVERY OF DISTILLING MATERIAL
-------
DRAFT
SIC 2085 Distilled. Rectified, and Blended Liquors
The distilled spirits industry is comprised of those establishments
manufacturing alcoholic liquors by distillation and rectification, and
those manufacturing cordials and liqueurs by blending liquors with
other ingredients. The major products associated with this industry
are whiskey, vodka, gin, rum, cordials, and liqueurs. As reported
by the Distilled Spirits Council of the United States, the relative
proportions of domestic distilled spirits bottled in 1973 are shown
in Figure 62.
Tiie production of distilled liquor was estimated by the Department of
Commerce (2) at $1.9 billion in 1973, with per capita consumption amount-
ing to 2.85 gal (10.6 1) annually. The major producing areas are
Kentucky, Illinois, Indiana, Maryland, Pennsylvania, and Tennessee,
which contain *he majority of the 220 licensed U.3. grain distillers.
The production of rum by molasses distillers occurs principally in
Puerto Rico, with some plants located in the Virgin Islands, Florida,
?nd Massachusetts.
Description of Process - Grain ['i_stille.rs_ - Wide variations in distilled
beverage products can be causea Dy one or more of the following factors:
(1) types of materials and their proportions; (2) methods of material
preparation; (3) selection of yeast types; (4) fermenter conditions;
(5) distillation processes; (6) maturation techniques; and (7) blending
experience. This description, however, will only discuss those varia-
tions germane to a basic understanding of the process and, more
specifically, those variations directly affecting wastev/ater generation.
Figure (63) is a simplified flow diagram for the basic process common
to all grain distillers. The principal steps involved are mashing,
fermenting, distilling, aging, rectifying-hottUng, and feed recovery.
After preliminary grading and cleaning the grain is milled to form a
meal. Milling breaks the oucer cellulose wall around each kernel to
expose more starch surface to the? action of cooking and conversion.
Water is added to the meal and the suspension is fed into a cooker.
Cooking may be carried on under oresiu-ized or atmospheric conditions
in either batch or continuous processes. After partial cooling, the
addition of ground barley malt converts the solubilized starches by
enzyme action into grain sugar. This con/ersion may take place in a
separate vessel called a "converter" in croer to f-ee the cooker for
the next cook. The slurry, at this point called i:n;ash," is further
cooled by vacuum or by tubular heat exchangers and pumped to the
fermenters.
Wastes from the mashing process consist of condensate from pressure
cookers and vacuum coolers in addition to vessel cleanup. For plants
operating in this mode the load comprises about 12 percent of the
169
-------
DRAFT
WHISKEY
53.6* -
MISCHLLANEOUS
1.7X
VODKA
21.6X
CORDIALS. LIQUEURS
6.IX
FIGURE 62
DOMESTIC DISTILLED SPIRITS BOTTLED OUTPUT
170
-------
DRAFT
•M4.T WAIN
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I HFK 1 1 tCM.
1 a IN 1 | BIN
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-------
DRAFT
total plant waste. For plants with atmospheric cookers and shell
and tube mash coolers the load would be lower.
The fermentation process commences with the Introduction of pure cultured
yeast, thus converting the grain sugars into nearly equal parts of ethyl
alcohol and carbon dioxide. Fermenter mash concentration, agitation,
and temperature cause the rate of fermentation to vary between two and
five days. The mash concentration is set between 28 and 40 gallons per
bushel of grain, depending on the amount of "thin stillage" or "back-
set" that is returned from the base of the whiskey separating column
and the amount of water added. In ihe production of "sour mash" whiskey
this concentration, by law, would be greater than 25 percent of the
fermenting mash volume. The fermented slurry, now known as "beer," Is
dropped into a beer well in route to the still.
Wastes from fermentation are small, consisting of fermenter and yes?t
tub cleanup. In most cases the first rinse, which contains considerable*
mash and alcohol, is discharged to the beer well. Sterilization by steam
thus becomes the only discharge and contributes about one percent of the
total plant wasteload.
Distillation involves the separation of alcohol from the de-alcoholized
residue known as "stillage". Although numerous varieties of distillation
exist, for whiskey this is normally accomplished in a continuous whiskey
separating column. Indirect heat or steam introduced at the base of
the column strips the alcohol from the fermented mash introduced near
the top of the still. The vapor leaving the top of the still is condensed
and forms the product. The discharge from the bsse of the column contains
the soluble and suspended substances carried through the process and
from which several useful by-products are derived. The alcohol, at
approximately 115° proof, is stored in a high wine tank, and possibly
run through a dojbler which raises the alcoholic content to approximately
130° proof. The product is then ready for shipment to the cistern tank.
Beer still cleanup and doubler discharge, if not pumped back to the beer
well, constitute the wastes from distilling. These comprise only one
to two percent of the total plant load.
In whiskey production, deionized water is added to the product in the
cistern tank and the mixture is aged in new, white oak barrels with
charred staves ind heading. The total years of storage deoends on
the time it takes to attain the desirable ripeness or maturity. The
three reactions occuring simultaneously in the barrel during aging are
extraction of complex wood constituents by the liquid oxidation of the
original conponents in the liquid and other material extracted from
the wood, and reaction between the various organic substances present
in the liquid resulting in the formation of new congener*. Wastes from
maturation are negligible.
172
-------
DRAFT
If the production of grain neutral spirits is desired, then the product
is pumped from the high wine tank at approximately 105° to 135° proof and
sent through a continuous multi-column still system, thereby by-passing
maturation. Figure (64) illustrates this system, which normally
consists of aldehyde concentrating, rectifying, and fusel oil columns.
The product is first fed to the aldehyde column. The product is then
split into three paths. The main stream (20° to 40° proof) is pumped
to the rectifying column; the heads (aldehydes and esters) are pumped
to the heads concentrating column; and the fusel oil is pumped to the
fusel oil concentrating column. The grain neutral spirits are with-
drawn from the rectifying column at 191° proof.
Wastes from the mulfi-column process comprise two to four percent
of the total plant wasteload. Concentrated heads may be discharged,
burnt as fuel, or returned to fermenters. Fusel oil tails are
discharged to the sewer while fusel oil is sold. Rectifying column
tails maybe sewered or demineralized and used as dilution water. Most
complete distilleries alternate between whiskey or grain neutral spirits
production, and .here is little difference apparent in the resultant
wasteload.
Blending and bottling may take place at a separate facility or as part
of a complete distillery. (A discussion of bottlers is included under
SIC 5132). At a complete distillery the aged product is dumped from
barrels and filtered, with filter media and charcoal residue being
treated as a solid waste. After gauging, the product is final filtered
and the residue sleuced to sewers. The addition of deionized water fixes
the proof, and the product is ready for bottling. Some breakage will
inevitably occur and this also would be sewered. The waste associated
with bottling is probably less than one percent of total distillery
waste.
Several variations exist in the method of recovering whole spent
stUlage. Basically distilleries fall into two categories: 1) those
with no recovery and 2) those utilizing evaporators and dryers for
complete recovery. Only the smallest distilleries practice no stillage
recovery. It is more, economical for these plants to dispose of wet stillage
to nearby farmers for cattle feed than to install a feed recovery system.
These small distilleries have a substantially different wasteload, since
feed recovery is the major contributor to total distillery waste.
Figure 65 illustrates the process flow for a feed recovery system. Since
whole spent stillage is aoproximately five to seven percent solids, feed
recovery is essentially a dewatering process. The first step consists
of passing the whole stillage over a screen. The coarse- solids are re-
tained and sent to a press for further removal of soluable solids. The
press cake, if dried separately on driers, becomes "distillers light
grain." The thin stillage liquid is ncrmally centrifuged to remove
suspended solids then piped to multiDie-effect evaporators where it is
concentrated to a syrup containing about 25 to 35 percent sol Ids. These
V73
-------
IGH WINE TAT*.
HEADS
105°-135" PROOF
HEADS BURNT
HEADS
ALDEHYDE
OXUW
RECTIFYING
CDLUW
?0°-40° PROOF
TAILS TO
SEWER
«0* PROOF
FUSEL OIL
CONCENTRATING
| COLON
FUSEL OIL
FUSEL OIL
COLUMN
PRODUCT
190° PROOF
FIGURE 6*
PROCESS FLOW DIAGRAM HIGH PROOF SPIRITS PRODUCTION
TAILS TO SEWER
-------
DRAFT
WHOLE STILLAGE
DRIED GRAIN
WITH SOLUBLES
WASTEWATER EFFLUENT
FIGURE 65
PROCESS FLOW DIAGRAM
FEED RECOVERY SYSTEM
175
-------
DRAFT
evaporated solubles may be drum dried to produce "distillers dried
solubles," or more commonly dried with press cake in rotary driers
to produce "distillers dark grains."
The major contribution to distillery wasteload is from the feed
recovery system. It can, according to Boruff and BTaine (36), account
for as much as 83 percent of the total distillery waste. The most
significant source of wastewater within the feed recovery system is
the condensate from evaporators. Dust emanating from grain dryers
may constitute a secondary source if wet scrubbers are used, or it
may be eliminated through the use of cyclones.
Description of Process - Molasses Distillers - While the basic process
of molasses distillers is similar to that used by grain distillers,
there exist some variations which warrant discussion. Figure 66 shows
a process flow diagram for a molasses distillery.
Molasses syrup (either case, molasses or citrus molasses) is received
as by-products from the case and citrus industries and stored in large
holding tanks. The molasses is then pumped to tanks where phosphorus
and ammonia nutrients are added no satisfy the nutritional requirements
of yeast fermentation. The amounts of nutrients added depend upon the
grade and purity of the raw molasses.' Hiatt (37) cites instances of
pasteurization of the raw molasses prior to nutrient addition, but exist-
ence of this practice is not evident in the industry at this time. Some
pre-heating of the yeast soed cultures does take place though.i To
eliminate undesirable bacterial contamination the pH is adjusted to be-
tween 4.G and 5.0 through the addition of sulfuric acid. Some distillers
also include the use of antifoamers prior *,o fermentation.
The molasses mixture is seeded with the desired yeist cultures to initiate
fermentation. 'Wh'ile cooling of the molasses to aid fermentation has been
reported, some distillers use a "wild fermentation" process where the
mar.h is inoculated by the yeast that is present in the air and in the
raw material. This takes place in lieu of cooling.-
Followfnc fermentation the "mash" (8 to 12 percent alcohol) is sent
through a multi-column filiation process. . Some experimentation has
been performed attempting to remove the spent yeast cells by centrifu-
gation prior to distillation. Currently, this is not a common practice
in tie industry.) One possible arrangement of the multi-column system is
shown in Figure 66. A separating column removes the alcohol from the
de-alcoholized residue known as ''slops" or "stillage." The vapor leaving
the top of the column is condensed and sent to an aldehyde column. Here
the "heads" (aldehydes and esters) are removed. The product is drawn off
the bottom and sent to the rectifying column where fusel and amyl oils
are separated. The final product is now ready for flavoring, aging, and
176
-------
DRAFT
CITRUS OR BLACKSTRAP
MOLASSES
ALDEHYDES
ESTERS
AMVL ALCOHOLS
FUSEL OILS
WASTEWATER
EFFLUENT
FIGURE 66
PROCESS PLOW DIAGRAM MOLASSES DISTILLERY
177
-------
DRAFT
bottling. By-product fusel oils may be marketed. Aldehydes and esters
may be used for fuel in the distillery.
Sfillage from distillation comprises the major part of molasses distillery
waste. Present methods of stillage disposal vary according to locale.
Puerto R1can distillers discharge their untreated effluents directly to
the ocean. Two of the continental United States molasses distillers prac-
tice periodic evaporation of their slops streams. In these two instances,
the amount of evaporation depends upon the available market for concentrated
molasses slops as feed supplements.
SIC 5182 Bottlers and Blenders of Wines and Distilled Liquors
According to the Bureau of Alcohol, Tobacco, and Firearms (BATF) there are
90 plants in this category, authorized to operate. These plants are dis- "
tributed throughout 25 states with the heaviest concentration in California.
The BATF reports only total bottled output, therefore no breakdown is
available between separate bottlers and bottlers combined with distilleries
or wineries. Production may range up to 13 million proof gallons per year
for the larger plants in this category.
Description of Process - Typical operations in plants from this subcategory
are redistilling, rectifying and bottl^ ~ . As defined in the industry,
rectifying includes mixing, blending, chilling processes. The principal
products of such plants may be wines, i -ies, whiskies, white goods,
cocktails, and cordials. Wastewater f. these plants is negligible, as
documented in Section V.
SIC 2086 bottled and Canned Soft Drinks
The soft drink bottling and canning industry consists of franchised
and independent companies who purchase concentrate or syrup and package
soft drinks. According to the U.S. Department of Commerce, ( Z2 )
soft drink bottlers and canners operate approximately 2470 facilities
with the largest concentration of plants in the southern states.
The National Soft Orifik Association ( 38 ) reported a total wholesale
value of 6.2 billion dollars for product shipped in 1973. P_er capita
to _gfi -Jj_g«J.1.nn s which was divided as follows: 91
_ _..
percent regular and nine percent diet drink. Cola flavored drinks
represented 65 percent of the regular market, with lemon-lime drinks
ranked second at 11 percent. The percentage distribution of package
types is shown in Figure fa/ . It should be pointed out that this
distribution varies widely by local market.
Total sales were marketed as 80 percent packaged and 20 percent bulk.
Packaged product includes all glass containers ind cans whereas
bulk product reaches the consumer via stainless steel pressurized
cannisters of differing sizes classified a? "post-mix" or "pre-mix".
The designation "post-mix" indicates founcain syrup prepared at the
point of consumption, and "pre-mix" indicates a finished beverage
ready to be dispensed. In 1973 "post-mix" accounted for 81 percent and
"pre-mix" 19 percent of total bulk volume.
178
-------
DRAFT
NON-RETUR MABLES
17%
FIGURE 67
CONTAINER MIX IN THE SOFT DRINK INDUSTRY
170
-------
DRAFT
In addition to geographical differences in sales volumes and package
type, there are'definite seasonal variations. During the summer
months of July through September, sales can peak as much as 50
percent above sales during the winter months of January through March.
Peaks in sales are preceded several months by corresponding peaks 1n
production. The value of shipments for the soft drink industry is
expected to maintain a future annual growth rate of 9 to 11 percent
as it has over the past six years.
Description of Process - Soft Drink Bottling and Canning - The term
"soft-drink" refers to those non-alcoholic beverages wnich are normally
flavored, acidified, colored, sweetened, and carbonated. A similar
but non-carbonated product is also packaged but in comparatively small
quantities. Figure 68 is a simplified process flow diagram illustrat-
ing operations in a soft drink bottling and canning plant.
Raw Materials: Soft drink manufacturers must ultimately combine treated
water with finished syrup to form a final product. Finished syrup
received in bulk will already have been flavored, colored, acidified,
and sweetened. This syrup, which is prepared from a proprietary formula
at a corporate bulk syrup plant, is delivered by tank truck to the
bottler. In some cases a flavored, colored, and acidified concentrate
is received and the finished syrup is produced by adding sugar (liquid
or dry) and water to the concentrate. The concentrate may be received
in powder and/or liquid form depending on the type of product. In other
cases all raw materials may be purchased directly from members of
the flavor and extract industry and mixed at the bottling or canning
plant. Under normal conditions, there are no wastes associated with
the receipt of raw materials.
Water Treatment: Soft drink plants routinely treat Incoming city
water. Two degrees of treatment are normally required: water utilized
for bottle washing must be low in hardness; water to be mixed with syruc
must be completely free of any substances which might affect the flavor,
color, and appearance of the final product. A typical water treatment
plant might submit incoming city water to chemical coagulation and
-edimentation in a large reaction tank through the addition of ferrous
sulfate and lime. Water filtration and purification by means of sand,
gravel, and carbon media in addition to chlorination might follow.
Dearfletion and ion exchange units are sometimes utilized. Whatever
the means or degree of treatment, the primary goal is to eliminate
any contaminants destined for product usage. Some plants soften in-
coming city water to be used in bottle washing. This provides for
better wetting and sheeting characteristics, thereby increasing the
ease of caustic removal in the rinse cycles.
Wastewater associated with water treatment will vary widely depending
on incoming water quality and plant operating procedures. As a
general rule, however, these wastes are a small part of the total
pljnt load.
180
-------
DRAFT
SYRUP
WATER SUPPLY
ST3KAOE
CASING
"T— I
._j
INSPECTION
[ LABELING
FIGURE 68
PROCESS FLOW DIAGRAM
SOFT DrtINK BOTTLING AND CANNING PLANT
101
-------
DRAFT
Syrup Preparation and Storage: Syrup received in bulk requires no
preparation. It is typically stored in tanks of approximately 20,000 1
(5,000 gal) until It is ready for use. Separate mixing tanks, however,
are involved in the preparation of syrup from concentrate. These
mixing tanks, which are smaller than the storage tanks, are normally
used to prepare only the amount of syrup to be used in the final product
for tha* day. This means that, if four different products utilizing
concentrates are to be packaged that day, the equivalent of four mixing
tanks is required.
In order to minimize wastes, and to provide ease in handling and
sanitation, stainless steel mixing tanks with cone/dished neaas are
used in the preparation and storage of syrup. Each "flavor cnange"
however, necessitates the removal of residual syrup from the tank
walls. This clean-up constitutes the wasteload from the mixing opera-
tion. Syrup storage tank clean-up also contributes to the total waste-
load, but it is on a less frequent basis.
Container Preparation: The three types of containers associated with
packaged production are cans, non-returnable bottles, ana returnable
bottles. The cans and non-returnable bottles are normally only rinsed
with city water to eliminate particles that may have accumulated during
storage. The returnable bottles may contain leftover materials sucn
as unused product, cigarette butts, mold, and other refuse which are
removed automatically in a bottle washer. These machines must wash,
clean, sterilize, and rinse all bottles. Figure 69 provides an
internal view of one type of washer currently in use.
All bottle washers follow the same basic steps of prerinsing, soaking,
and final rinsing. During prerinsing both the inside anc the outside of
the bottles are subjected to a hot spray, Solids removed at this point
pass first through a ccarse, then through a fine mesh screen before trie
rinsewater is sewered. Recirculated final rinse water is often vised
in the pre-rir,se section. Soaking involves immersing the bottles
for not less than five minutes in at least a three percent alkaline
solution containing 60 percent caustic soda. This occurs in a single
or multi-compartment tank at a minimum of 66°C '150°F). The liquid level
and strength of the solution are checked regularly to maintain soecif'iec
standards. The entire solution is dumped Intermittently, at periods
ranging from six weeks to six months. After intermediate caustic removal
sprays, the bottles undergo a final fresh ^ater rinse. This water, whic'i
contains some carry-over Ctjstic cleansing solution, is sewered if not
reused for pre-rins1ng.
Inspection of soft drink bottling plants confirms that bottle washer
wastes represent the major portion of the total plant load. The
residual drink left in the bottle is the major source of BOD. Suspended
solids from the pre-rinse are inevitably sewered. High alkalinity and
pH result from carry-over detergent in both pre-rinse and final rinse.
132
-------
FINAL RINSE
CAUSTIC REMDVAL
"I SPRAY
PRE-RINISE
/
DIRECTION OF
TRAVEL
BOTTLE
DISCHARGE
HOT CAUT.TIC SOLUTION
WASTEWATER EFFLUENT
FIGURE 69
FLOW DIAGRAM
ORINK BOTTLE WASHING MACHINE
-------
DRAFT
Container Filling: Finished syrup from storage or mixing tanks is
combined in specified proportions with treated water IP the "flow-
mix". This mixture is fed to a cooling-carbonating vessel where it
is chilled and infused with gaseous carbon dioxide. The mixture then
passes to the "filler" where it is introduced into the container. In
some bottling plants an alternate method is used whereby syrup is first
placed in bottles which are then filled with carbonated water. In
either case the container is immediately crowned or capped. The
filled and sealed bottles are passed through a warm water rinse before
inspection, possible labeling, casing, and shipment or storage.
Wastes from container filling result from filler spillage, lost
product associated with flavor changes, and the corresponding clean-
up. A flavor change necessitates flushing the lines from syrup
through the flow-mix, cooling-carbonating vessel, and filler. Chlorine
and treated water, plus any product left in the lines, are then sewered.
The percent of the total plant wasteload contributed by flavor changes
varies according t^ the number of changes made daily and the efficiency
with which each plant eliminates product loss. Filler spillage varies
considerably between bottling and 'anning plants. In a bottling plant
there is little or no spillage while the filler is operating. In a
canning plant, however, there is considerably more product loss in
filling due to the speed or the line and nature of the container. In
a plant which only cans, this loss would be the major source of BOD
wasteload.
Bulk Falling: As part of some plants' total production both pre-mix
and post-mix cannisters are utilized. This operation requires
only that separate syrup and water lines be provided to an area where
the cannisters are filled under pressure. Figure 70 demonstrates
this procedure.
Wastes from bulk filling result from a small amount of residual
product left in the cans by the consumer. Hot water, caustic, and
final water rinse procedures are used to clean the cans.
SIC 2087 Non-Synthetic Flavoring Extracts and Syrups
When used for food purposes a flavoring extract may be generally ae^int-d
(39)as a soljtion in ethyl alcohol of proper strength of the sapid and
odorous principles derived from an aromatic plant, parts of the K1ant,
or essential oil from the plant, with or without coloring matter, con-
forming in name to the plant used in its preparation.
Flavorings derived from parts of aromatic plants are termed natural
flavorings whereas those prepared fron synthetic chemicals, such as
esters, aldehydes, ketones, and others, are considered artificial,
imitation, or synthetic flavors.
184
-------
ORAFT
5YRUP AND WATER
1
FLOW MIX
'
1
!
i
i
COOLEH
CARBONATOR
i
i
PRE-MIX
FILLER
-
i
i
w.
•
CANISTERS S/KUP
\ 1
CANNIS7ER POST-MIX
WASHER * FILLER ~"^
1
1
1
1
L__ _____ ___
__ __..., ____ __.
SHIPNENT
i
CLEANUP
WASTE WATER
EFFLUENT
FIGURE 7P
PROCESS FLOW DIAGRAM BULK FILLING
SOFT DRINK PLANT
MIS
-------
DRAFT
Common flavoring extracts Include vanilla, lemon, clove, cinnamon, orange,
nutmeg, peppermint, and wintergreen. The most common methods for the
preparation of flavoring extracts are steam or water vapor distillation
(with or without vacuum), solvent extraction, and expression.
Flavoring extracts are produced in a wide variety of concentrations and
forms -- extracts, concentrates, powders, emulsions, tablets, and
essences -- with the strength and form depending on the intended use
of the product. Natural flavoring extracts are then blended with other
substances, such as sugar, synthetic flavoring extracts, alcohol, and
food colors, in numerous combinations and proportions to produce finished
specific flavors. The finished flavors are also produced in the same
variety of concentrations and forms as the flavoring extracts. Finished
flavors are utilized in a number of other food related areas, principally
the beverage, baking, confectionery, and frozen desserts industries.
There are approximately 60 companies operating flavor producing plants ir
the United States. While little information is available from the
industry, it would appear that a typical plant produces flavoring extracts
as well as finished specific flavors and possibly spices.
A separate entity of the flavoring extract and syrup industry is the
manufacturing of beverage bases (concentrates and syrups). These bases
are almost exclusively produceo by the major soft drink companies which
utilize them in their soft drink products. There are approximately 22
be/erage base plants operating in the United States.
The demand for flavoring extracts and flavors fluctuates in direct relation
to fluctuations in the beverage, baking, confectionery, and frozen desserts
industries. However, the need for flavoring products probably maintains a
near balance since beverage ard frozen dessert demand is high when
baking demand is low and vice versa v40). In 1973 the value of product
shipments of flavorings accounted for an estimated 1.6 billion dollars
and was expected to rise to 1.7 billion in 1974.
Process DescriptionTStandard. Terpeneless and Concentrated Flavoring
Extracts from Essential Oi1s - Essential oils may be defined as liquids
which occur naturally in many types of plants or which may be reproduced
by a combination of substances in the plant upon reaction with one
another in the presence of water. The preparation of the most common
forms of flavoring extracts from essential oils is illustrated in
Figure 71.
I'.ssential oils are generally purchased and stored in fiber dims, while
alcohol and other solvents are stored in storage tanks. A standard
formula exists for every type of flavoring extract which can be manu-
factured. The preparation of a standard flavoring extract (Figure 71 )
involves a blending process in which a specified percentage by volume
cf the essential oil, alcohol, and water are mixed in tanks.
186
-------
DRAFT
FIGURE 71
STANDARD, TERPENELESS AND CONCENTRATED
NATURAL FLAVORING EXTRACT PROCESS
187
-------
DRAFT
For certain applications, such as in ices and fountain syrups, it is
desirous to produce a more water soluble flavor. Consequently, the
more insoluble components (terpenes) of the oil must be removed. This
can be accomplished by vacuum distillation (Figure 71) or solvent ex-
traction (Figure 71) of the essential oil.
In the vacuum distillation process, steam is used to strip the more
volatile plant oil from the terpenes. The purified oil is then mixed
with dilute ethyl alcohol of proper strength to form the terpeneless
extract.
In the solvent extraction process the solvent dissolves the plant oil
from the essential oil and is drawn off. The solvent is then recovered
from the purified oil which is subsequently mixed with dilute ethyl
alcohol of proper strength to form the terpeneless extract.
Concentrated extracts are produced in the same manner as standard extracts
except the percent by volume of plant oil is considerably increased.
Wastewater generated from the production of these products consists
primarily of internal equipment cleanup when a flavoring change is made.
Process Description-Flavoring Extracts from Direct Solvent Extraction
of Aromatic Plant Tissues - There are few flavoring extracts prepared
from the direct solvent extraction of plant tissue. By far the most
common examcle is the manufacturing of vanilla extract as illustrated
in Figure 72.
Vanilla beans are received and stored in boxes. The vanilla beans taker,
from storage are first chopped before being steeced in an alcohol-water
solution. In order to exhaust the desired material from the bean,
solutions ranging from 35 to 60 percent by volume of ethyl alcohol are
used. The vanilla extract, composed of alcohol, water and dissolved
vanilla flavor, is drawn off through a filter, adjusted to a desired
water, alcohol, and sugar content in storage tanks, and subsequently
bottled.
The alcohol remaining in the chopped beans from the steeping process is
extracted and reused. The beans are discarded as solid waste.
The major wastewater generation is attributable to filter backwash and
to the cleaning of vanilla extract storage tanks when sediment accumu-
lates in the tanks.
Process Description - Natural flavoring Concentrates nd Powders - Flavor-
ing concentrates and powders are deriveo from plant liquor or essential oils.
Fruit liquor is usually used in the case of fruit concentrates and powders
while essential oils are used for spice concentrates and powders.
The typical process flow diagram for the manufacturing of these products
is illustrated in Figure 73 .
188
-------
DRAFT
RAW VANILLA BEANS
CHOPPING
(OPTIONAL)
EXTRACTION
ALCOHOL
RECOVERY
FILTER
FLAVORING EXTRACT
FILTER
BACKWASH
STORAGE
TANK
(CONSTITUENT
ADJUSTfENT)
CLEANUP
WATER
PACKAGING
CLEANUP
WATER
SPENT VANILLA
BEANS TO SOLID
WASTE
WASTEWATER
FIGURE 72
NATURAL VANILLA EXTRACT MANUFACTURING PROCESS
189
-------
DRAFT
FRUITS
WASH WATER
WASTE TISSUE TO
' SOLID WASTE
ESSENTIAL OILS FRUIT
OR LIQUOR
EVAPORATION
VAPOR TO
ATMOSPHERE
CLEANUP
WATER
DEHYDRATION
VAPOR TO
ATMOSPHERE I
WASTEWATER
NATURAL FLAVOR CONCENTRATE
NATURAL FLAVOR POWDER
FIGURE 73
NATURAL FLAVORING CONCENTRATES AND POWDERS
MANUFACTURING PROCESS
190
-------
DRAFT
In order to produce fruit concentrates or powders, fruits are washed and
chopped and the fruit liquor containing water, oil, and fruit particles
is expressed from the chopped fruit. To prepare the fruit concentrate the
liquor is evaporated under vacuum. If powdered flavor is to be produced,
the liquor together with vitamins, sugar, and acid is completely dehydrated.
The production of spice concentrates involves the evaporation of essential
spice oils. The oils are dehydrated for the production of powder.
Wastewater generated from the manufacturing of concentrates and powders
includes fruit wash water, evaporator effluent, and dehydrator effluent.
Process Description - Finished Specific Flavors and Cordials - The manu-
facturing of finished specific flavors and cordials is a blending process
in which natura' and/or synthetic flavoring extracts are blended in nu-*
merous proportions and combinations with other ingredients such as
alcohol, sugar, coloring agents, and water.
If not produced at the plant, flavoring extracts and colors are usually
received and stored in fiber drums. After proper mixing they are packaged
in bulk containers. The finished flavors may be produced in all of the
various forms discussed above.
Cordials are a blend of flavoring extracts, sugar, water, and alcohol.
Cordials are a special case of flavor production in which alcohol
comprises a cons':derab"e ;-r,<"tion of the total product volume.
Wastewater attributable to the oreparation of finished flavors and
cordials consists entirely of cleanup of mixing tanks prior to flavor
changes.
Process Description - Beverage Bases - By far the majority of beverage
bases, botn concentrates anc1 syrups, ire manufactured by major soft drink
companies in plants which produce corccntrates and/or syrups exclusively.
The manufacturing of flavoring concentra:es and syrups is illustrated
in Figure 74 .
The flavoring extracts, a'.ids, treated water, colors, and sugar (except
in concentrate production) ar? proportioned from storage tanks into
large, stainless steel mixing tanks and blended. The product is then
strained through a wire mesh screen and packaged or shipped in bulk by
tank cars or trucks.
The manufacturing of beverage concentrates and syrups in flavoring extract
plants is done on a much smaller scale and excludes water treatment and
container washing. There is also no need for flavoring material storage
as these materials are produced in-house.
The primary sources of wastewater in the soft drink concentrate and syrup
plants are cleanup of mixing tanks prior to flavor changes at the
end of each day; and washing of containers, arums, and tank cars. The
production or beverage bases in flavoring extracts plants would generate
wastewater from cleanup of mix-ing tanks only.
101
-------
DRAFT
SUGAR (SYRUPS ONLY), ACIDS,
COLORS, FLAVORING EXTRACTS
WATER
TREATMENT
MIXING
TANKS
CLEANUP WATER
STRAINING
FILLING
WASHING (DRUMS,
TANK CARS. S &AL.
CONTAINERS)
CLEANUP
WATER
WASTEWATER
FIGURE 74
BEVERAGE CONCENTRATE AND SYRUP MANUFACTURING PROCESS
192
-------
DRAFT
SIC 2095 - Roasted and SoUiblf Coff.e Processing
Genera 1 - Coffee roasting and the production of soluble coffee extracts
occurs in 203 plants distributed throughout the country. According
to the Pan American Coffee Bureau [ /!!), in 1972 043,696 kkg (930,000 tons)
of roasted coffee and 81,048 kkg (89,300 tons) of soluble coffee were
produced with a total value of $2.32 billion. The greatest density
of plants is found along the Atlantic seaboard and in California.
According to the National Coffee Association '42 ), of the 21 million
bags (CO kg each) of coffee that are impo-ted each year, 10 percent
has already been processed, usually into :oluble coffee.
The national Coffee Association further reports that seven large corporations
account for 70 percent of the total production in this country, in the
soluble coffee segment of the industry, two corporations produce 81 percent
of total production.
Coffee is normally sold in a roasted and ground or soluble form. Goth
are available as either regular or decaffeinated types, and soluble coff*?
is produced by spray drying or freeze drying. Some coffee plants produce
all possible combinations of the above forms and types. The Pan American
Coffee Bureau \ 43 ^ indicates that decaffeinated coffee accounts for only
12 percent of all coffee sold; however, 28 percent of all soluble coffee
is made from decaffeinated beans.
Since 1962, the per capita cof'ee consumption in this country has been
declining. However, the National Coffee Association ,'42 ) indicates that
the soluble coffee industry continues to expand and account for a larger
share of the total coffee market each year.
All coffee processing begins with the green coffee bear.. Further proc:-csir.;
will include roasting, possibly preceded by decaffeiration and followed
by extraction and then spray or freeze drying. These processes are describes
in the following subsections. Figure 75 illustrates the basic processes
used in producing roasted coffee.
Description of the Decaffeinatjor. Process - Green coffee beans usually
arrive at the plant-in 60 kg (H2 lb) burlao sacks from which thev are
transferred to a storage hopper. The beans ;re then cleaned by air
levitfltion to remove foreign material and chaff which are lighter thari
the beans. The beans are then either decaffeinated by individual type
or the various types of he^ns are nixed to obtain the desired blend ard
then decaffeinated. If decaffeinated roasted or soluble coffee is desirod.
the caffeine is removed from green coffee beans using the direct solvent
method or the water extraction (liquid/.iquid) method.
In the direct solvent nethod (see Figure 75). caffeine is removed by
contacting the beans with organic solvent, mcst commonly methyl ere chlor-de.
The beans are prewetted by various methods before extraction, o necessary
step tc allow high decaffeination levels. The solvent is drained off and
fresh solvent added until the residual caffeine is at the level desired
103
-------
DRAFT
STORE IN
BURLAP BAGS
1
r
__CHAFF I TRA_SH_ _
SHAKER SCREEN
AIR VACUUM
CAFFEINE
BLOCKS
r
SOLID
WASTE
DECAFFEINATI JN
FOR SOME
PRODUCTS
STORE
1
BL
END
1
ROAST
EFFLUENT
SEE FIGURE
FOR PROCESS FLOW
FOR DECAFFEINAT
WATER
r—L-1
"ET i
! "SCRUBBER [ _^j
WATER !
QUENCH
(AIR-COOL )
MATTER
STONER
SCREEN
STC^E
SOLUBLE
COFFEE
SPRAY, INCORPORATED
IN PRODUCT
1
PACKAG
1
GRI
,
NO
STORE
E
AROMATIZING
AGENT :-
DESIRED
• 1
SEE FIGURE j PACKAGE
STORE
WASTE A A T£i"
GROUND ROASTED
COFFEE
FIGURE 75
WHOLE COFFEE
BEAN
COFFEE
PROCESS FLOW DIAGRAM
194
-------
DRAFT
AIR CLEANED
GREEN BEANS
(SEE FIGURE >
GREEN BEAN
LIQUID
PRE80IL IN
EXTRACTOR TANK
(OPTIONAL)
SOLVENT
RETURN
ADD SOLVENT
STRIP SOLVENT
DECAFFEINATED,
CAFFFTNE IN
BEAN
WATER
STORAGE HOPPER
EVAPORATOR STILL
DEWATEPING
SCREEN
CAFFEINE CAKE
I
HOT AIR DRYER
SOLIDIFY CAFFEINE
INTO BLOCKS
COOLER
BOX (, STORE
CAFFEINE
DRY .CECAF-£INATEC
GREEN BEAN STORAGE
FIGURE 76
ORGANIC SOLVENT CONTACT
DECAFFEINATING PROCESS PLOW DIAGRAM
105
-------
DRAFT
(usually 97 percent of the caffeine is removed). The used solvent is
distilled to recover clean solvent and a crude caffeine residue.
The method of extraction most commonly used in this country by the large
producers of decaffeinated products is called the water extraction or
liquid/liquid extraction method (see Figure 77). In this process, the
caffeine is extracted from the qreen beans in extractor columns with
93UC (200°F) water. Next the extract may be centrifuged tc remove solids.
The caffeine is then selectively transfer-red from the aqueous green
coffee solution stage to the trichlorethylene solvent by counter-current
or rotating disk contactor liquid/liquid extractors. The water extract
is then stripped of its solvent residue and returned to the process
to extract further caffeine. The caffeine contained in the 'richlor-
ethylene can be recoverd by distillation of the solvent, or by lir.uid/ .
liquid extraction with water. The solvent is purified by distillation
and returned to the process. Caffeine may be packed and shipped in its-
crude form or it may be further purified to meet food and drug standards.
The extraction of green beans with recycled water extract continues
until the caffeine level in the green is reduced to the required degree
(usually 97 percent removal), and the beans are then drained, washed
and dried.
In the extraction processes discussed, the decaffeinated beans are
rinsed and dewatered with an auger screw or screen. The beans are thcr
hot air dried, cooled, and stored in preparation for roasting.
Wastewater is generated in the' decaffeinating process primarily from
the washing of the decaffeinated Kear,s, the flushing of the extract
centrifuge and the solvent anc; caffeine separation process. Smaller
amounts of wastewater come from the caffeine solidifying process, storage
of the wet beans and condensate overflow.
Description of the Roasted Coffee Process - Coffee beans are roasted ir
order to develop their flavor. Tnere are eight commonly used shades
or decrees of roasting. Selection of a nrf'cular shade depends en
the type of beans and the flavor desire^
Green coffee beans are normally roasted in revolving metal cylinders,
directly or indirectly heated by gas or =1 fuel oil. Batch roasting
in lots of 230 to 635 kg (500 toJ^OO Ibs) is the mo^e common method.
with end temperatures in the 200J to 220'C (390'' to 42S°F) range at the
end of );he cycle in 8 to 13 minutes^ If a continuous roasting method i-,
used, tne temperature is 260JC (500"F) and the contact time is approxim^t
5 minutes.
The rna^ted hoans are cooled by either wet or dry methods. The roastin:
process ir. turnied ''wet" if it is checked by the spraying of water over
the hot beans (vliilc still ii the roaster). T!iis water is partially
evaporated and partially absorht^ irLo Llie bean. None is discharged
as wastewater. In dry roasting, Jie process is arrested only by air
cooling and by contact with the cooling apparatus.
196
-------
DRAFT
AIR CLEANED
GREEN BEANS
(SEE FIGURE )
EXTRACTORS
BEANS 6 EXTRACT
EXTRACT
CENTRIFUGE
LIQUID/
LIQUID
EXTRACTION
SLURRY
HOPPER
FRACTIONATOR
3) l/l
m o
-H r
c <
xi m
Z 2
SCREENING
n
DEWATERING
SCREEN
jj
SOLVENT AND
CAFFEINE
SEPARATION
-F^^
CAFFEINE CAKE
HOT AIR
DRYER
I
COOLER
T~
I
SOLIDIFY
CAFFEINE
INTO BLOCKS
DRY
DECAFFEINATED
GREEN BEANS
BOX t STORE
CAFFEINE
WASTE
S^LID
WASTE
FIGURE 77
LIQUID/LIQUID EXTRACTION
DECAFFEINATION PROCESS FLOW DIAGRAM
197
-------
DRAFT
Stoning, removal of metal and other foreign material heavier than the
coffee beans, is then performed. Next the beans are stored until
packaged as whole roasted beans or ground, A "granulator" composed of
a series of rollers and often capable of 10 size adjustments, is commonly
used to grind the beans at rates up to 1.8 kkg per hour (2 tons per hour).
The ground roasted coffee is packaged for sale or further processed into
a soluble coffee product.
There is normally no wastewater generated in the production of roasted
coffee unless the plant utilizes a wet scrubber for the stack gasses,
and few coffee roasting plants have wet scrubbers. General plant clean-
up is dry -- usually portable vacuum cleaners and/or brooms.
Description of the Soluble Coffee Process - The fresh grounds are added
to one end of a series of six to eight extractor chambers (see Figure 78),
through which hot water is oassed countercurrent to the grounds. This
countercurrent flow permits the fresh hot water to extract the re-nain-:03
soluble materials from the most spent grounds. The conditions of this
flow are carefully controlled for maximum removal of soluble constituents
and good flavor and quality.
The extract is cooled if it is to be stored before further processing,
and centrifuged or filtered. The liquid extract at this stage is 20
to 30 percent solids. For f>eeze drying, the solids concentration must
be increased to 40 percent. For spray drying, it is economic." 1 ly
advantageous to increase the solids content to the sane 40 percent.
Concentration of the extract to the desired 10 percent solids level
is acconpl-ished by evaporation or freeze concentration.
Spent grounds are carried from the extractor by steam ejection to a
storage tank. In some plants, the grounds are then deposited in a
landfill. In other plants, the grounds are rotary dried or pressed ind
used as fuel for the boilers. The waste from the pressing of the grounds
is a significant source of wastewater as is the intermittent (every 5
to 10 ninutes) cleaning of the centrifuge or filler. Other wostewat.er
sources include the general wasndown of the extractors, sludge from the
centrifuge or filter, the scaling tank, the heat exchanger, and the
holding tank.
Spray Drying and Agglomeration: After concentration (if used), the ex-i-ci.r
is delivered to the atomizing no:rle and spray dried. The dried product
is stored in bulk unf*! it is packaged by automatic or seni-autonatic
machinery. The powdered coffee produced by spray drying is usually
agglomerated by a second pass through part of the drying tower to yie1a
the relatively large "coffee crystals" which are now popular in this
country.
Wastewater is generated in this process step when the equipment is cleaned.
Cleaning is done af. the end of a run which may be as infrequent as monthly.
Freeze Dryinn: Another method of producing soluble coffee is freeze
drying (see Figure 79). In this process, the liqui-* coffee extract
is cooled and concentrated by centrifugation. Following this, it is
frozen, ground, and more water is withdrawn through sublinntion. The
product is then packaged and storsd prior to shipment.
-------
DRAFT
GROUND COFFEE
(SEE FIGURE / )
-SOLJ.D
"WASTE
SEE FIGURE 5
FREEZE DRYING
H
SLUDGE ANC 1
CLEANUP WALTCS
AND CONDENSATE I
SPRAY DRY
AROMAT I ZE
AGGLOMERATE
PACKAGE
STORAGE
-1
CLEANUP
FIGURE 78
SOLUBLE COFFEE PROCESS CLOW DIAGRAM
199
-------
DRAFT
CONCENTRATED
SOLUTION
RECYCLED
EVAPORATOR
EXTRACT FROM
SOLUBLE PROCESSING
COOL
STORAGE
CLEANUP
__
|
CENTRIFUGE
L
AND CLE
FREEZING
GRINDING
SO'EL ; MAT I ON
(
STORAGE
I "IgLT ICE (
1 COFFEE SDLir
.__ AND I
COFFEE SOL~nS \
w ATE_P
AND COFFEE SOLIDS
W A S T 5 '.v A T £ P
FIGURE 79
DRYING PROCESS rLOW DIAGRAM
•200
-------
DRAFT
SIC 2097 - Manufactured Ice
General - Commercial ice producing plants fall within two distinct
product categories - block and fragmentary ice. Block ice is produced
in 136 kg (300 Ib) or 132 kg (400 1b) blocks which are frozen in rec-
tangular cans partially submerged in refrigerated brine tanks. Block
ice is sold whole, divided into 10 to 200 blocks, cut into cubes and
bagged, or crushed and sold as bagged sized ice. Cube ice machines
are sometimes found in ice manufacturing plants, but their low volume
capacity hardly justify their use. Cube and crushed ice finds its
greatest usage in the preserving and serving of foods and beverages,
or distribution to vending machines. Fragmentary ice is produced as
small pieces such as disks, cylinders, and random shapes similar to
crushed ice dnd normally is bagged at the plant. It is often produced
on large capacity units for industrial users sucn as poultry plants,
dairies, chemical plants, ready-mix concrete suppliers, and fish and
seafood transportion.
According to the Bureau of the Census ( 2 ), in 1972 approximately 4.1
million kkg (4.5 million tons) of ice were commercially manufacture'
at some 2,000 plants located throughout the country, with the heaviest
concentration of manufacturers in the Atlanta, Georgia area. Production
at individual plants ranges from 0.45 to 363 kkg (0.5 to 400 tons) per
day; however, typical daily production is in the 45 to 136 kkg ( 50 to
150 ton) range.
Demand for ice fluctuates seasonally, with the highest demand in the
sumner and lowest demand in the winter. Some plants close in the winter
months; others continue to operate with a skeleton crew; and still others
with large storage facilities, sell their product year-round but cease
processing during the winter.
According to the National Ice Association (44 ), approximately 60 percent
of ice manufacturing plants produce both fragmentary and block ice;
25 percent manufacture block ice only, and Ib percent manufacture
fragmentary ice only. Block ice is still the large volume product of
most ice nanufacturers. However, increased efficiency of fragmentary
ice naking machines and decreased demand for block ice has led to
decreased production of block ice and a corresponding increase in frag-
mentary ice. According to the Bureau of the Census ( 2 ), the quantity
of bloc!; ice produced dropped fro.n 4.4 million kkg (4.9 million tons)
in 1967 to 2.2 nillion kkg (2.4 million tons) in 1972. This trend is
expected to continue, resulting in no construction of new block ice
plants. The last known block ice manufacturing plant was built around
1966. The demand for fragmentary ice has been and is expected to continue
to increase substantially, possibly spectacularly. Many manufacturers
have installed fragmentary ice making machines to supplement and/or
to replace block ice making facilities.
Generally, the water us«d to make ice must be potable. It may be supplied
201
-------
DRAFT
by the local water purveyor or a well. Depending on its quality, the
water may be treated by the ice manufacturer.
Description of Process - Block Ice - Municipal water is sometimes not
satisfactory for the production of quality ice. Undesirable water
qualities can result in poor color, residues, and tendencies to shatter
or crack. To obtain clear block ice, it is sometimes necessary to
treat fresh water with lime, sand filters, carbon filters, or reverse
osmosis to remove suspended and/or dissolved solids. According to the
National Ice Association (44), about 60 to 70 percent of the block
ice manufacturers treat their water supply. Sources of wastewater at
this stage of processing include backwash water, precipitate, and brine
from treatment facilities.
Figure 80 illustrates the processing of block ice. The cans in which
block ice is to be frozen are filled from an p'evated can filler. Once
filled, tie cans are placed in agitated brine tanks either singularly .
or in groups. Grouns of cans are held together by grids made of flat
steel with the weight of the grids assisting to keep the cans submerged -
and prevent tipping. The grids also hold the cans apart (seldom over
3 cm) to allow the brine to flow between the cans. Wooden can covers
rest directly over the grids and provide additional weight to hold
the cans in the brine. There is virtually no make-up or blowdown from
brine tanks. Water is kept in the tanks for years, and salt is ar"deJ
once or twice a year. Brine tanks are seldom, if ever, dumped.
During freezing, air miy be used to agitate the fresh water in the cans.
The purpose of this aeration is to aid in foming clear, pure water
crystals by assisting in the rejection of rrost of the impurities
into the core of the ice block. The unfrozen core, consisting of about
10 to 22 ] (3 to 6 gal), is usually pumped oi.t and replaced with fresh
water preferably cooled. According to ASHRAE (45), the block of ic
-------
WATER*
TREATMENT
BACK'./ASH/SLUOGC/BKir.T
WATER*
STORAGE
CANS
FILLED
BRINE
.TANK
CORE PUMPED
6 REFILLED
COMPRESSOR
ANO/CR CONDENSER
COOLING *4TER
DIP
TANK
J_
CORE WATER
OVERFLOW
DUVPED
SNOW AND ENDS
CRUSHER
SS§ENDsl SCORE[
SORTED
CLEANUP
PICKED INTO
BLOCKS
WEIGHED
CLEANUP
RINSE
PACKAGED
CRUSHED ICE
* "AY BE OMITTED
NO SOLID WASTE
»
ICE CUBES
BLOCK ICE
FIGURE 30
PROCESS FL3.V :;
BLOCK ICE
203
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Wastewater from tfie freezinq of block ice comes from core pumping,
water used to cool the refrigeration compressors, dip tank overflow,
and snow from scoring. In some ice plants, compressor cooling water
is routed to the dip tank where it is used to thaw the ice blocks
from the cans. In the dip tank, some chlorides and solids are added
to the wastewater. They are transferred from the brine tank as the
cans are being dipped.
Whole ice blocks are stored in freezer rooms with the bottom layer
held off the floor about 15 cm. A space between the ice blocks and
the side walls of tne storage room is also maintained to promote cold
air circulation around all ice blocks.
Cubes: Cubes prepared from block ice are sawed out of the whole by a
variety of automatic and semi-automatic machines which handle blocks of
11 to 182 kg (25 to 400 Ib). The machines consist of one or two sets
of power operated circular saws operating in two plants successively
and a third large power saw for cutting the indented cubes free of the
block. Ice losses from this type of processing are 30 to 50 percent in
the form cf snow and end pieces. These waste pieces are sometimes used
to precool water which is tc be frozen, but most often are discharged ?.s
wastewater.
Some ice manufacturing plants have small, 225 or 450 kg (500 or 1000 Ib)
per day, cube machines like the cube machines found in hotels and other
commercial establishments. Cube machines are a very small percentage of
most ice manufacturing plants' capacities, and are intended primarily t'cr
retail sales.
Crushed ice: Sizing machines, which have cone into increasing use, consist
of an ice crusher into which blocks of ice are fed. The crushed ice is
delivered into an overhead rotating screen, which separates the broken
pieces into bins containing the desired size(s). These pieces are then
weighed and placed in plastic bags for sale or distribution to retailers.
vending machines, or other larger customers.
Up to 50 or 60 percent of the block ice may be lost in crushing. Particles
less than a specified size cannot be used, and must either be recycled
to manufacturing or melted and discharged as wastewater. A machine has
recently been introduced for use in compressing undersized crushed ice
or snow into blocks. Widespread use of this type of machine could
significantly increase the yield from block ice manufacturing, instead
of wasting the water or recycling the snow and end pieces back to the
product water.
description of Process - Fragmentary Ice - Fragmentary ice differs from
sized ice in that sized ice is made from crushed block ice, whereas frag-
mentary ice is produced when water flows over a freezing surface. One of
five general methods is employed in removing ice from surfaces to which
it has been frozen. These are as follows:
204
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DRAFT
1. Separation from a flexible surface
2. Scraping the ice crystals from a wet direct expansion chilled
surface and pressing the sludge into briquettes
3. Hot vapor heating the surface to release ice frozen by direct
expansion to the inside or outside of tubes
4. Mechanically separating the ice from a direct expansion
refrigeration drum
5. Water defrost of sheets frozen to refrigerated plates ( 45 }.
These processing steps are done in commercial fragmentary ice making
machine^. As indicated in Figure 81 , following removal from the
fragmentary ice machine, the ice is sized by screw conveyors if necessary,
sorted oy size, stored in hoppers or a surge bin, and then packaged
in plastic Dags. Unlike crushed ice, little, if any, ice is less than
the minimum size; accordingly it can all be packaged for sale.
Fragrsntary
-------
WATER*
TREATMENT
ICE
MACHINE**
BULK
STORAGE
SURGE
BIN
jjACKvn ASH/ SLUDGED
BRINE
PACKAG :NG
STORAGE
DJ
. CLEANUP
DI
STRI
BUT
ION
WASTEWATER
•NORMALLY NOT USLD
"THE ICE MACHINE CAN BC ONE OP FIVE TYPES OP FRAGMENTARY
ICE VAKE9S; WITH OP WITHCUT WATER STORAGE 3UILT INTO IT.
NO SOLID WASTE GENERATED.
FIGURE si
PROCESS FL:.> DIA
FRAGMENTARY ICE
206
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DRAFT
SIC Code 2098 -Macaroni. Soagnetti. and Noodles
Spaghetti, •nacaroni, and other related products, known as alimentary
pastes, are made by forming unleavened dough into a variety of shapes,
which are subsequently dried to less than 13 percent moisture. Typically,
these products are made by mixing semolina with water and kneading
the rcs'-'ting dough until homogeneous. The dough is then extruded
or rolled before being cut into the familiar shapes of macaroni products:
spaghetti, macaroni, noodles, shells, elbows, etc. Egg noodles contain
added egg or egg yolk.
According to the Department of Commerce, Census of Manufactures (2)
there are approximately 191 manufacturers spread throughout the nation
which produce macaroni products. The West leads with 64 plants, followed
closeiy by the Northeast with 63 plants. The North Central U.S. has
43 macaroni and spaghetti plants, and the South only 21. The plants
range in size from large corporations to very small, family owned
businesses. Total sales volume is about 400 million dollars, and
production about 910 pillion kilograms annually.
The above figures for number of plants are believed to be misleading,
however, because they include many Italian eating establishments which
manufacture pasta only for their own use. Standard and Poor lists
only 24 companies in this category whicn manufacture on a commercial
scale. Since some of these companies have several plants, it is estimated
that the total number of significant commercial plants in the United
States is between 30 and 40. All plants contacted discharged to municipal
systems.
Process Description. Figure 82 shows a process flow diagram for
a typical macaroni and noodle processor. The basic raw materials
are semolina, durum flour, farina flour, or a combination of these,
and water. Semolina is milled from hard wheat.such as amber duru"..
Size of particles is less important than uniformity. Coarse semolina
is easier to handle, but requires longer mixing times.
Egg products are normally used in certain noodle formulations. In
some cases, frozen pasteurized egg yolks are ussd. Alternatively,
freshly separated egg yolks or dehydrated egg yolk solids may be incor-
porated into the various egg contain!nrj products.
The other major ing-edient common to all pastas is water. Quality
and temperature of incoming water are of special
207
-------
DRAFT
RECVCLE FRAGMENTS
I
WATER
EGG SOLIDS
(OPTIONAL)
VACUUM PUMP COOLING
FIGURE 82
PROCESS FLOW DIAGRAM FOR
MACARONI, SPAGHETTI, AND NOODLES
208
-------
DRAFT
consideration to obtain consistent quality products. Other Ingredients
may Include egg-white solids, onion, garlic, celery, bay leaf, salt
or other seasonings, and disodium phosphate.
Solid and liquid raw materials are mixed together in desired proportions.
On the average, about 30 parts of water by weight are added to 100
parts of solid raw material. The moisture content of the original
semolina varies between 12 and 16 percent.
Mixing methods vary with the type of dough mixer used. The larger
and rore modern facilities utilize continuous dough mixing techniques,
whereas the smaller processors employ batch methods for blending and
mixing. Either process results in a homogeneously kneaded dough of
approximately 30 to 32 percent moisture. After mixing, the dough
is pushed through various shaped dies under high pressures.
In almost all cases, a vacuum is applied to deaerate the dough as
it enters the extruder. This requires extensive cooling water for
proper maintenance and operation of the pumps. This water, while
being non-contact water, is usually combined with remaining plant
effluent, and represents, in many instances, virtually the entire
effluent flow, exclusive of sanitary wastes.
If short macaroni products are to be made, a cutter placed directly
under the die cuts strands into the desired length. The "shorts"
are conveyed directly to the drier. Long spaghetti, macaroni, or
noodle strands are spread manually or mechanically on drying sticks.
After they are cut to an even length, the loaded sticks pass through
a predrier in which approximately s^'x to eight percent moisture Is
extracted in an hour or less time. The goods come out of the predrier
with a moisture content of 22 to 24 percent.
At the discharge from the predrier, there is a recovery zone to insure
equal moisture distribution throughout the product and to prevent
the goods from checking or cracking during the final drying.
The final drier can'be batch or continuous. Batch driers are typically
used when production figures are under 4,545.45 kg (10,000 Ib) per
day. Batch driers in which products circulate in a closed circuit
through different climate zones have proven to be efficient and reliable.
Special equipment is needed to manufacture twisted or stamped goods.
"Pasta Bolognese" is made from a calibrated dough sheet which
209
-------
DRAFT
is extruded from the press. Since twists and stamped goods are
usually made in snail quantities, production costs are relatively
high. They are typically dried in stationary batch driers containing
a number of trays, through which air, heated by coils containing hot
water or low pressure steam, is blown.
Both long and short cut macaroni products are generally dried to about
12 or 13 percent moisture content. Once dried, the products have
excellent preservation qualities.
Short products such as soup pastas, elbows, sea shells, etc., can
either be dried stationary on trays or continuous1./ in drum or belt
driers. Trays are typical for small operations, but continuous systems
were observed for high production levels.
Furthermore, microwave ovens have been recently introduced for the
drying of "shorts." Microwaves selectively heat water with little
direct heating of most solids. Drying is uniform throughout; the
shorts' pre-existing moisture gradients are evened out. This unique
application results in very rapid drying, but requires specialized
equipment and safety devices, formal 24 hour drying cycles were observed
to be reduced to 30 minutes.
In small factories, products art packaged by hand. In larger factories,
long, short, and twisted goods are weighed and filled by semi-automatic
or completely automaf'r. machines into cellophane or plastic bags,
or papa- cartons. Cut corners or "breaks" inherent in the packaging
of "long" items are typically recycled back through the process by
being finely ground and then used as a raw ingredient.
Those plants that utilize frozen egg solids were observed to do in-
pldce cleaning. The resultant waste flows were low (typically less
than 11,340 liters/day (3,000 gal/day)). Similarly, several plants
indicated the use of dried egg solids with all clearjp being performed
with conventional "dry" methods (i.e., sweeping, scraping, rubbing,
etc.).
It is obvious that pasta production is essentially a dry process with
manufacturers avoiding the use of water during processing and cleanup.
The only significant waste volume observed is non-contact cooling
water. The only strong waste from an organic pollutant point of view
is generated by periodic cleaning in special washers of the extrusion
dies, and cleanup of egg product blendinj equipment in noodle manufacturing
operations. In both cases, waste volume is very low.
210
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DRAFT
SIC 2099 Almond Paste Manufacturing
.' Results of this study Indicate there are currently only four active almond
paste manufacturers in the United States. These operations distributed
in the states of New York, New Jersey. Illinois, and California, represent
a relatively minor industry in terms of food production. Several plants
manufacture almond paste in combination with a variety of other nut pro-
ducts such as nut toppings, pastry fillings, icings, glace bases, baker's
specialty items, and other nut pastes. In addition, some facilities manu-
facture almond paste less than 30 days per year. The following process
description was obtained through a plant visitation to one almond paste
manufacturer.
Description of Process - Figure 83 presents a generalized flow diagram
of almond paste processing. Raw almonds (and similar nuts such as pecans.,
walnuts, hazel nuts, cashews, and apricot kernels) arrive at the plant by
truck in boxes and are stored in coolers. The raw almonds are roasted and
placed in a series of initial soak tanks at a temperature of 81 to 92°C
(180 to 200°F) for about 20 minutes. Durst (46) reports that from the
soak tanks, the almonds are blanched to separate the testce ^red skins),
germ (small hearts), and cotyledons (almond halves or split almonds). The
testce and germ are aspirated and separated by screen from the cotyledons.
The cotyledons are inspected and are placed in pregrinding soak tanks at
59 to 72°C (140 to 165°F) for 15 to 20 minutes. After the almond cotyledons
have soaked they are conveyed to a blending hopper where the almonds are
water cooled. At this point ingredients such as sugar and flavorings are
added. The blend is then placed into a grinder which ruptures the fat
v cells causing the mixture to have a pasty consisten;y. The almond paste
is then transferred into a number of soaking units where it is cooked to
a moisture content of 10 to 15 percent. After cooking, the paste is hand
packaged into 227 to 286 gm (8.0 to 10.0 oz) vacuum parked cans or 22.6 kg
(50.0 Ib) plastic lined bakes for institutional use. Substantial packing
care is required to contain the product and prevent oxidation and subse-
quent rancidity of the fat content.
The major scurces of wastewater generation in the manufacturing process
are (1) the initial and pregrind soak tank; (2) daily plant housekeeping
including equipment tleanup and floor washings; and (3) water used to cool
the nuts before grinding.
SIC 2099 Baking Powder
Background of the Industry - Baking powder is produced in at least 28
plants in the United States, most of wh'ch are located in the Chicago
and New York metropolitan areas. Ten manufacturers account for a major
portion of the production of the industry.
Baking powder is produced for use by commercial bakeries as well as by
the individual consumer. Packaging requirements thus range from small
tins to barrels.
v..
'211
-------
ukAFT
INPLANT BOILER
WATER
RAW ROASTED
ALMONDS
INITIAL SOAK TANKS
'C/20 MIN.
PRESSURIZED AIR ^I SKIN PEMQVER
INGREDIENT ADDITION
SUGAR. R.AVORING,
ETC.
INSPECTION
TABLE
HOLDING
BTN
PREGRIND
SOAK
TANKS
BLENDER
HOPPER
GRINDER
COOKERS
HAND
PACKAGING
SOLID WASTE
DAILY PLANT CLEANUP
I
I
WASTEWATER
FINISHED NUT
PASTE PRODUCT
FIGURE 83
A SCHEH4TIC DIAGRAM. OF ALMOND PASTE PROCESSING
212
-------
DRAFT
Description of Baking Powder Processing - A simple process flow diagram
u presented in Figure 84.The basic operations in the production of
bdking powder are dry material transport, metering, blending, mixing,
sifting, and packaging. The hydrophilHc nature of the raw materials
and the final product, and the stringent quality standards for the final
product make 1t Imperative that water be prevented from contaminating
the material handling lines. For this reason, extensive measures are
taken to control humidity and to prevent the use of water in the plant,
except for emergency situations.
The raw materials used (corn starch, bicarbonate of soda, sodium aluminate
sulphate, ana rnonocslclum phosphate) may be delivered and stored either
in bulk or in bags, depending primarily on the size of the plant. In
the larger plants the material is unloaded from railcars or trucks by
air or mechanical transport systems and diverted to dedicated storage
silos. In smaller facilities raw materials are received in palletized
bags which must be mechanically transported to the blending area, opened,
and deposited in storage hoppers. The raw materials are then metered
into the blender in proper proportions. The blended material is trans-
ferred to a surge nopper to await packaging so that a suoreouent batch
may be blended. The material is then sifted to remove foreign materials
and deposited into tne holding hoppers for each packaging line. The
finished product is packaged in the appropriate type and size container,
palletized, and warehoused for future shipment. The entire operation
does not normally require the use of any water eitht for processing
purposes, cleanup, or dust control. In-plant cleanup 1s entirely by
dry methods, i.e., air brushing, foxtail brushes, brooms, and vacuum
systems. Water would be used for cleanup only 1n an emergency situation,
such as after a fire or an accident. The bulk raw material unloading
docks for the air-slide rail cars or trucks and the bagged raw material
unloading and warehousing areas may be hosed by water wash in some plants
1n order to cleanup spills after unloading operations are finished. However,
this cleanup procedure 1s infrequent and undocumented.
Dust from air transport systems is apparently controlled by cyclone
separators, filters, /
-------
DRAFT
RAW MATERIAL UNLOAD i.
-------
DRAFT
Process Description-Bouillon Products - The manufacturing of bouillon
products is basically a four step process as illustrated in Figure 85.
The ingredients used to manufacture bouillon products are purchased
from a number of other food related areas such as the edible oil, spice,
and organic chemical industries. Ingredients are received and stored
in fiber drums, boxes, or plastic bags. It is not uncommon for plants
to produce a portion of the ingredients in-house. Two plants, for
example, are Known to produce their own hydrolyzed vegetable protein.
The various ingredients, including hydrolyzed vegetable protein, salt,
meat extract, fats, spices, and emulsifiers, are proportioned in a
mixing tank. The mixture is dried in an oven and subsequently ground
into a granular form. The granular bouillon is either packaged in jars-
or pressed into cubes.
Wastewater generation in the bouillon process is limited to cleanup
water used to wash mixing tanks, ovens, grinders. The packaging area
is cleaned with air.
SIC 2099 - Bread Crumbs, Not Made in Bakeries
General - The manufacturing of bread crumbs outside of bakeries is a
very limited industry. Four manufacturers of bread crumbs, which are
not primarily bakeries, -.vere contacted. The majority of bread crumbs
appear to be manufactured and packaged for retail sale bv large
bakeries.
Description of the Process - Bread crumb production not in bakeries is
essentially an assembly process. In all of the plants contacted, baked
and ground bread crumbs are the raw material used. These baked crurrr^
are purchased in ?0 to 45 kg (50 to TOO lb) bags from bnkpries. These
bags of crumbs are emptied into a vibrating mixer where they are
blended with the desired combination of spices. From the mixer, the
spiced crumbs are transferred to a holding tank on a conveyor belt.
The crumbs are then gravity fed from the tank to the packaging rnacnim-rv.
The breud crumbs are packaged in 227 gram (8 02) or 4?6 (15 oz) paper
cans. Lids are applied ynd the cans ftre boxer) for storagp and sMpnipr: .
All of the equipment and the floors are dry cleaned, and no water is
used in thi? product. For a schematic representation of the process.
see Figure 06
For all practical purposes, bread crumb processing not in bakeries can
be considered a: a d-y process. There is apparently no process waste-
water d ischarged.
.215
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URAFT
INGREDIENTS
MIXING
TANK
OVEN
DRYING
GRINDING
PACKAGING
CLEANUP
"WATER*
CLEANUP
WATER
CLEANUP
WATER
WASTEWATER
FIGURE 85
BOUILLON PRODUCT MANUFACTURING PROCESS
216
-------
DRAFT
r
SEASONING ADDED
SDL ID
WASTE
FIGURE 06
BREAD CRUMBS. NOT MAD£ IN BAKERIES
PROCESS PLOW DIAGRAM
217
-------
DRAFT
SIC 2099 - Chicory
General - Chicory 1s a flavoring which is blended with coffee. More
chicory is consumed In the South than elsewhere in this country.
Chicory is made from roots of the chicory plant. It is grown in Europe
and is pre-processed prior to importing. The pre-processing consists
of harvesting the roots, cleaning, slicing, and dehydrating. It is
shipped to the United States in burlap bags.
There is only one chicory processing plant in the United States. It
produces approximately 2,270 kkg (5 million Ib) each year. Both the
building and the equipment of the processing plant are relatively old.
Description of the Process - Chicory processing is similar to roasted
coffee processing, as illustrated on Figure 87 . The pre-processed
dehydrated pieces of root are shipped to the plant and stored in burlap
bags. The bags are dumped into a bucket elevator and then a screw
conveyor for transfer to roasting ovens which are similar to roasters
used for coffee.
After roasting a specified time, the oven is fumed off and approximately
4 1 (2 gal) of water per 450 kky (1000 Ib) charge is sprayed onto
the chicory while it is still in the roaster. This water is used to
reduce the potential fire hazard in the roaster. The roasted chicory
is then dumped into an air cooler. There are no liquid drippings rron
this cooler. After air cooling, the chicoi is conveyed to the grinder
where it is ground into specified degrees of granularity and then packed
into polyethlene inner bags and burlap outer bags. Excessively fine
particles are reconstituted and reground.
The bags are stored at the plant until distributed. A relatively low
humidity must be maintained in the packaging and storage areas in order
to prevent "caking" of the chicory. Chicory tends to cake due to the
high sugar content of the material. In that form, 1t is not saleable
and must be reprocessed and repacked.
There is no process water. A minor amount of water Is used for an air-
tooled air conditioner during the summer months and as non-contact cooling
water for a small compressor. None of the equipment requires wet
cleaning; it is wioed Out periodically with rags. General plant cleanup
is dry -- predominately dry brooming. More severe spillage areas m,jy
first be dry broomed; then mechanically scraped and broomed; and possiblv
wet mopped using a conventional mop and bucket. The basement fioor
of the plant was concrete with one floor drain near tl.e back door. The
chicory :s stored on this level, which prevents use of water for cleaning.
The second and third floors of the plant were wood and dM not show
evidence of water application.
210
-------
DRAFT
DBVCL5ANUP
_-N_ONj1C ON TACT
COOLING
MATER
SOL 1 C1
WASTE
FIGURE 07
CHICORY
PROCESS FLOW DIAGRAM
219
-------
DRAFT
SIC Code 2099 - Paprika and Chili Pepper
Paprika and chill peppers are major dehydrated vegetables, aru are
important spices used in many foods. A handful of companies located
in the South and West process these commodities. For the purposes
of this study, three plants were field visited for the collection
of historical data, and composite samples were collected and analyzed
to verify these data.
Paprika and chili peppers are virtually Identical and generally can
only be distinguished by their obvious taste differences. The plants
ere harvested between early October and December. Harvesting is done
mechanically or by hand, depending on the size of field, climatic
conditions, and availability of labor.
Preservation of chilis and paprika is accomplished by standard dehydrating
techniques. Drying is done either on continuous stainless steel belts
or individual tray driers. In either case the original raw moisture
content of the vegetable is reduced to below ten percent by the application
of heat to the sliced, diced, or shredded vegetable. The combination
of heat and moisture reduction preserves the product from bacterial
degradation; these low moisture levels are t.ot conductive to bacteria,
mold, and yeast growths.
Process Description. Figure SO shows a typic?.! process flow diagram
for denydrateo chTTi peppers and paprika. After harvesting, the peppers
are brought to the plant in either large wooden tote bins or in bulk.
Storage is less than 24 hours to prevent any microblal breakdown.
Typically, the chills are conveyed through a dry reel to remove dirt
and debris. They are then dumped directly into a large soak tank
which wets the vegetable and loosens adhering dirt. The chilis are
usually removed from the soak tank by a continuous elevated conveyer
with high-pressure overhead cold water sprays to further clean the
extraneous material.
The soak tanks and water sprays contribute the major volume of wastewater
genrration. The tanks may be dumped several times during the day.
the frequency depending on the condition of the harvested peppers
(mud, vegetable damage, etc.). Tot.e or storage bin washing can also
be a source of significant waste strength.
An inspection typically follows washing at which time lefccts are
removed as culls. The vegetables -jre conveyed directly to either
2?0
-------
DRAFT
-------
DRAFT
a chopper, a sllcer, or a dicer where the entire pod 1s cut. The
various cutting operations contribute a strong concentration of organic
solids (Juices; to the wastestreams due to the macerating of the plant
cells. In addition, these machines are periodically washed to reduce
bacterial contamination. Finely comminuted organic particles enter
the waste flow from these rinsings.
The chopped pieces are coated with fine sulflte sprays to prevent
browning during the dehydration process. These sulflted pieces are
conveyed to either a continuous stainless belt drier or alternately
to wooden trays. If trays are used, then a series of trays are loaded
with even layers of the chopped peppers. When sufficient trays have
been filled, they are placed into a drying tunnel, and warm air Is
Introduced until the desired finished moisture is attained. With
either method of dehydration, final moisture levels of approximately
eight percent are obtained.
The other major source of wastewater Is standard end-of-sh1ft clean-
up, at which time all tanks, conveyors, dicers, etc., are emptied,
opened, and thoroughly washed and sanitized before startup of the
next day's operation.
The dried Hakes may be packaged directly or milled Into fine chill
powder or paprika powder. The milling is done.oy conventional hammermill
and screens; but after the dried pieces are finally ground, they are
added to a type of ribbon blender where water 1n the form of a fine
spray is introduced tc raise the moisture level to ten to twelve percent.
The increased moisture aids in color retention of these ground powders.
The powders are then packaged In the desired container.
Seed recovery 1s an Important by-product of this type of vegetable
operation. Carefully selected flolds of either chilis or paprikas
are identified as being desirable for seed recovery. When these particu-
lar lots are brought into the plant to be dehydrated, the pods are
cracked and core and seed are separated (usually by flotation). The
pods are skimmed from the surface while the seeds are diverted through
a dewflterlng reel. The seeds are sold to a seed company and become
the following year's crop.
Water reuse and recycling was not observed in a typical pepper dehydration.
In some cases the final water sprays became make-up water for the
soak tanks, but the process does not lend itself to water reuse.
222
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DRAFT
SIC 2099 Desserts. Ready-to-Mix (Gelatin)
Background of the Industry - Ready-mix desserts and prepared gelatin
desserts are produced in at least 46 plants 1n the United States with most
Of these facilities located 1n the Mid-west and the Northeast. The
products, directed primarily at the Institutional and Individual consumer,
are marketed 1n nearly Infinite variety of flavors.
Although the Industry has used wet production techniques 1n the past,
technological advances have made dry production techniques virtually
universal in the Industry. These techniques Involve the mixing and
packaging of raw materials and no significant contact with process
water.
Process Description - Ready-mix desserts and prepared gelatin desserts
are manufactured as shown in Figure 89. The basic operations are ary
material storage, transport, screening, metering, blending, mixing,
sifting, and packaging. ~he hydrophillc nature of the raw materials
and the final product in addition to stringent quality standards mane
1t Imperative that water be prevented from contaminating the process
lines. For this reason, extensive measures are taken to control humidity
and to prevent the material from accidentally contacting water.
The raw materials used are generally delivered and stored 1n bags or
cartons. For ready mix desserts these materials may be dextrose, mod-
ified food starch, and/or cornstarch, salt, carrageenan, sodium phosphate,
hydroxylated soybean lecithin, nonfat dry milk, dtrlc add, and miscellan-
eous flavorings and colorings. Prepared gelatin desserts use edible gelatin,
salt, fumaric acid, and miscellaneous flavorings and colorings. Raw
materials are deposited in their designated storage and metering systems.
The various types of desserts are aach preparad in a batch operation. In
larger plants mobile collection hopoers are moved about the facility
collecting screened and metired quantities of Ingredients. When the
desired ingredients are gathered, the hopper Is dischargsd to the mixer.
The prepared gelatin dessert mixing process requires the addition of 3
small amount of wattr (last than one part of water per 600 parts of
product). The water Is incorporated into the product and is not wasted.
The ready-mix dessert process uses no water in the mixing step. This is
the only difference in tne processing of prepared gelatins and ready-
mix desserts.
After mixing the product is stored in a holding hopper until it is packaged
In the appropriate sized container. The product is then warehoused for
future shipment.
233
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DRAFT
BAGGED
RAW MATERIAL.
PROCESS WATER
ADDED ONLY WHEN
GO. AT I IMS ARE
BEING PROCESSED
DEDICATED RAW
MATERIAL DUMP
SCREENING
STORAGE HOPPER
SCALE HOPPER
MOBILE COLLECTION
HOPPER
MIXER
MIXER BATCH
HOLDING HOPPER
PACKAGING
STORAGE
OUST COLLECTION
DUST C01.1.FICTION
DUST COLLECTION
FIGURE 89
PREPARED GELATIN DESSERT PROCESS FLOW DIAGRAM
224
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DRAFT
The only source of wastewater in the processing operation is from the
water washout of mixers to prevent color contamination of the product.
Wash out takes place in a segregated washroom. All other cleanup in
the vicinity of the process line is accomplished by dry means, I.e.,
vacuum cleaners and brooms.
Newer plants are designed to facilitate dry cleaning through provisions
for soft cleaning hoppers, conveyors, and other machinery. Floors and
working surfaces may also be coated to improve dry cleaning efficiency.
Wastewater generation rates from equipment wash out are highly variable
Mixers are washed only when there Is a product change and it happens
that the previous product would cause color contamination of the following
product.
Dust control facilities are required for these plants, however, dry
collection techniques are used exclusively in the plants surveyed.
SIC 2099 Honey
Honey, the oldest known substance used as a food sweetener, was widely
used as such prior to the advent of-refined sugar. Its utilization
today continues as a household condiment and also because of its
hygroscopic characteristics as an ingredient to retard drying in
baked goods. The annual production of honey in the United States
averages 100,000 kkg (110,000 ton). Excluding small farm operations a
total of 16 plants produce the bulk of commercial honey. The value
of honey products in 1972 was S64 million, a 31 percent increase over 1971.
Description of the Honey Production Process - Honey is a natural food,
produced by the honeybee (Apis Mellifera L.), and is available in
various forms, e.g. liquid, comb, cut comb, granulated or finely
crystallized, and creamed. It requires no elaborate processing and
a considerable proportion of the crop passes from the producer direct
to the consumer. However, when honey is to be sold in the retail market,
it usually goes to local producers for packaging. Figure 90 shows a
typical honey process for the retail market.
The honey arrives at the plant already extracted from the cone, unless
comb honey is to be processed. Comb honey, which makes up a small
proportion of the bottled honey, is usually cut and bottled by hand.
Honey which has been extracted from the cone is first stored in heated
tanks at the plant receiving area. Heated storage tanks serve two
purposes: 1) to make the honey less viscous, and 2) to help remove
minute air bubbles entrdpped in the cold honey. The tanks are usually
kept at a temperature between 60"C and 70°C, according to Manley (47).
The storage tanks are generally heated by a recirculatlng hot water
system. Since honey has many flavors and colors, mixing is sometimes
employed in the tanks to produce a more desirable blend. From the re-
ceiving tanks, honey is then pumped to another set of holding tanks called
"filtering tanks." These heated filter tanks are where honey is held
prior to pumping through the filter process.
225
-------
DRAFT
FILTER
WASHDOWN
WATER . BOTTLE
CLEANING WAT?"
IF APPLICABLE
SOLIDS
90
HONEY PROCESS
226
-------
DRAFT
Filter presses employ a series of canvas or textile type screens, through
which the honey 1s forced to remove extraneous material such as wax,
bees wings, and other foreign substances. In some cases, a filter aid,
such as decollte, 1s added to the honey prior to filtering. The presses
are washed daily (outside wash), and are dismantled usually every other
day for a thorough cleaning. From the filter presses, honey can be
returned to storage tanks or directly to filling equipment.
Honey is generally bottled in glass or plastic containers; however, for
bulk purposes tins or paper containers are sometimes utilized. After
bottling and sealing, the containers ar« cleaned of spillage. Depending
on the size of the operation, the clean.ng can either be done manually
by washing and wiping or mechanically with hot water washers. Usually
the use of water in any operation is avoided due to the hygroscopic
tendency of honey.
Honey that is to he sold in granulated form is generally bottled cold.
However, even heatea honey, if allowed to set for a period of time,
will granulate.
Washdowns are the only major source of wastewater in honey manufacturing.
iisually, steam/water hoses are utilized to clean equipment and floors.
Washdown flows, depending on the size of plant or extent of washdown.
seldom exceed 800 I/day (200 gal/day).
SIC 2099 Molasses and Sweetening Syrups
Sweetening syrups and molasses are considered in the Census of Manu-
factures as a single food preparation class and are designated by
SIC product code 20993. Included 1n this group are the producers and/or
bottlers of pancake syrup, sorghum syrup, maple syrup, and molasses.
Together these establishments accounted for $138.8 million 1n ship-
ments 1n 1967.
Maple syrup 1s oroduced 1n 'ie northeastern states from Wisconsin
through New England, with v rmont being the largest producer. The
annual production averaged 4,000 cu m (1.2 million gallon) during the
last ten years and app2ars to have leveled off since 1949. The syrup
has been refined •in essentially the same manner since the local Indians
passed the knowledge on to the white settlers. The manufacture to
date remains a small farm business with only a few establishments
engaged in the packaging of a wholesale product.
Sorghum was first Introduced Into the United States around 1700
primarily as a forage and silage crop. Approximately eight million
hectares (20 million acres) of sorghum are planted yearly. The primary
species of sorghum grown for syrup manufacturing 1s S.. Saccharatum.
which Is grown'prlnarlly in the southern states. In~"l972 the production
of sorghum syrup was reported by Agricultural Statistics to be 27,211 cu m
(7,189,100 gallons).
227
-------
DRAFT
Description of the Molasses Process - Molasses 1s a valuable by-product
of beet and cane sugar manufacturing. "Blackstrap" molasses Is the final
syrup left after repeated crystallizations for the extraction of sugar.
The major portion of molasses produced Is utilized for animal feed,
ethyl alcohol, monosodlum glutamate, and yeast production. Smaller
quantities are used in the manufacture of glycerine, lactic add, acetone,
and syrup.
The molasses obtained in the early stages of sugar production has a
pleasant, palatable flavor and is used in the preparation of edible
molasses. As shown in Figure 91, the edible molasses 1s first heated
and filtered, before being pumped to filling machines which deposit
the molasses into the appropriate container. The containers are then
Inspected, sealed, and rinsed prior to transporting to the labeling
and final packaging area.
The bottling of molasses produces wastewater from two areas: the
periodic cleaning of equipment and the rinsing of the filled bottles.
Due to the limited processing equipment and generally small size
of the operation, the volume of wastewater discharged is not large.
Description of the Maple Syrup Process - Maple syrup is produced from
the sap of the sugar maple tree, Acer Saccharum. which grows in the
north central and northeastern states. During the late winter and early
spring the trees are tapped to draw off the sap. The sap, containing
approximately three percent sugar, is boiled down to a sugar concentration
of 66 percent by the individual farmer prior to delivery to the processor.
The majority of processors are small farm operations; there are only
a limited number of establishments which bottle maple syrup on a large
commercial scale for wide distribution. The following process description,
which is illustrated 1n Figure 92,, Is concerned only with the latter
group of processors.
The syrup 1s received at the plant in drums and subsequently graded
accordfng to color and sugar concentration. The raw syrup is heated
in kettles and then filtered through a medium of dlatomaceous earth. The
filtered syrup..1s filled into the desired container and sealed. The
containers are then washed in either a water bath or spray to remove any
spilled syrup. After washing, the filleo syrup containers are trans-
ferred to the labeling and casing area.
In addition to bottling syrup, the plant may also crystallize maple sugar
for production of various 'ondant creme candies. The discussion of the
candy process has been handled in the section dealing with confections,
SIC 2065. Also, the maple syrup may be carmelized in cooking kettles
to Intensify the maple flavor characteristics. The carmelized syrup
1s reconstituted 1n water and boiled for distribution as maple flavoring.
There are two major sources of wastewater In the maple syrup process:
1) dally cleanup of processing area floors and equipment* and 2) non-
contact cooling water. The cleanup of the floors 1s accomplished
220
-------
DRAFT
EFFLUENT
FI&URE 91
MOLASSES
229
-------
DRAFT
CLEAN-UP
CF
FLOORS,
EQUIPMENT
EXTRANEOUS MATERIAL
CONTAINS? WASHWATER
EFPLUENT
FIGURF 92
MAPLE SYRUP
230
-------
DRAFT
by mopping; the kettles, filters, and other equipment are rinsed with
a small amount of water to maintain cleanliness and efficiency, the total
volume of cleanup water being less then 4,000 I/day (1,000 gal/day).
The discharge of cooling water may rea~.h 20,000 I/day (5,000 gal/day);
however, as it is non-contact, waste leadings are negligible.
Description of the Pancake Syrup Process - The production of pancake
syrups from a sugar base is a relatively uncomplicated process which
requires V:ttle processing prior to bottling. The process, as shown on
Figure 93,begins with dissolving corn and or cane sugar in water
1n heated kettles. Selected flavorings are added to the sugar water
solutions and the liquid is cooked until the desired color and viscosity
characteristics are achieved. Flavorings may be added before the syrup
is pumped to filling machines which deposit the hot syrup into the
appropriate preheated container. The containers are subsequently
capped, rinsed, and transported to the labeling area for final packaging -
preparation.
A continuous flow of wastewater, about 9500 I/day (2500 gal/day) per
line is generated by the container washer. The other significant
source of wastewater is from the daily cleanup of the processing area,
-------
DRAFT
CLEAN-UP
CLEAN-UP
firStf, ^
I
EFFLUENT
FIGURE 93
PANCAKE SYRUP PROCESS
232
-------
DRAFT
EXTRANEOUS _MA TER I_AL_
V
SOLIDS
PERIODIC CLEAN-UP '
CONTINUOUS DISCHARGE
• FIGURE 94
SORGHUM SY9IIP
-------
DRAFT
SIC 2099 Non-Dairy Coffee Creamer
Non-dairy coffee creamer plants produce one of two distinct products --
dry or liquid non-dairy creamer. The main ingredients used in manu-
facturing non-dairy creamer are vegetable oil (usually coconut) and
corn syrup. If the creamer 1s to be a dry product, disodium phosphate
is the only additional Ingredient. On :he other hand, if liquid creamer
1s to be produced, a number of other ingredients such as sodium case-mate,
sugar, mono- and diglycerides, esters of fatty acids, and artificial
flavor and color are added. Liquid creamer 1s commonly packaged in half
ounce, pint, quart, or half gallon containers. Dry creamer is packaged
in jars or in 203 1 (55 gallon) drums for sale to distributors.
Virtually all liquid creamer is produced on a regional basis in multi-
product plants. Products manufactured along with liquid creamer range
from cereals to dessert toppings. Dry creamer is produced by two
companies in two plants which produce solely dry creamer.
The demand for non-dairy creamer Is dependent on price fluctuations in
the dairy ano sugar industries and seasonal changes.
Process Descriptions, Liquid Non-Dairy Creamer - Vegetable oil is received
in railroad tank cars which must be steam heated upon receipt to allow
the oil to be pumped into storage tanks. The other ingredients are re-
ceived in fiber drums, boxes, and bags and are stored dry. While there
is normally no waste generated in the storage of ingredients, occasional
spillage of vegetable oil may occur in transfer from tank cars to storage
tanks.
The manufacturing of liquid non-dairy creamer 1s illustrated in Figure 95.
The Ingredients and water are proportioned Into stainless steel mixing
tanks where they are mix«d at temperatures of approximately 71°C (160°F)
to aid in the molecular blending of the ingredients.
The mixture is pumped from the tanks throug i conventional or flash
pasteurizers. In conventional pasteurization the product must be held
at a temperature of at least 66°C (150°F) continuously for 30 minutes
or 74.5°C (166°F) for 15 seconds, whereas in flash pasteurization the
product 1s pasteurized at 140°C (280°F) for less than one second. The
product, is then homogenized to provide a smooth consistency and avoid
separation of ingredients during ur.e.
The 'liquid creamer is cooled by passing it between stainless plate coolers
and is then pumped into holding tanks before machine packaging into half
ounce, pint, quart, and half gallon containers. The packaged products
are Stored in refrigerated warehouses until shipment to commercial dis-
tributors.
234
-------
DRAFT
CORN
SYRUP
BOILER
NON-CONTACT
SLOWDOWN
FLOOR HOSES
MINOR
INGREDIENTS
VEGETABLE
OIL
MIXING
CIP
PASTEURIZATION
HDMOGENIZATION
PLATE COOLER
HOLDING TANK
PACKAGING
WAREHOUSE
CIP
I
I
CIP '
—1
CIP
CIP
FLOOR I
DRAINS
PLANT EFFLUENT
FIGUIIE 95
LIQUID NON-DAIRY CREAMER MANUFACTURING PROCESS
235
-------
DRAFT
Hastewater generated from the manufacturing of liquid non-dairy creamer
is due solely to cleanup operations. All of the equipment with which
the creamer comes in contact must be thoroughly sanitized to prevent
bacterial growth. The most common sanitation method Is the clean-in-
place (CIP) system which may be automatic, stationary, or portable.
The sequential cycles Involved in the cleanup of liquid creamer equip-
ment are; (1) hot water pre-rinse at approximately 43°C (110°F),
(2) detergent rinse, (3) chlorine rinse, (4) final rinse, (5) sanitiza-
tlon, and (6) air drying. Hosing of floors, primarily in the packaging
area, is a secondary contributor to the waste stream.
Process Description, Powdered Non-Dairy Creamer - The manufacturing of
powdered non-dairy creamer is illustrated in Fiyure 96 . Vegetable oil
and corn syrup are received in railroad tank cars which are heated with
steam upon arrival so that the oil and syrup can be pumped into storage
tanks. Disodium phosphate is stored in separate holding tanks until use.
The corn syrup storage tanks are maintained at a temperature of approxi-
mately 71°C (160°F) so that the syrup will remain fluid. Under normal -
conditions there is no wastewater generated In the storage operations
but an occasional spill of oil, syrup, or disodlum phosphate may occur
during transfer into storage tanks.
The vegetable oil, corn syrup, disodium phosphate, and water are propor-
tioned into stainless steel mixing tanks where^hey are agitated. The
blended product is then passed through a pasteurizer where it is heated
1n coils to a temperature of 70°C (160°F) for a period of 15 minutes.
At this time the product is actually in two phases; oil and liquid-solid.
In order to combine the phases so that separation does not occur during
use. the product is homogenized by pumping It through small diameter
nozzles at approximately 170 atm (2500 psig) to force the molecules in
the mixture together. The liquid mixture is transferred by the high
pressure nozzles into drying boxes where it is dried by blowing hot air
through the mixture. The resulting dry product," with a consistency
similar to diatomaceous earth, then passes through a cooling chamber
before going to the spray drying process. In t^e spray dryer the dry
product is sprayed through nozzles and falls as a fine mist through a
chamber where 1t Is subjected to a stream of steam and then hot air.
This process dries and swells the particles and adds the bulk considered
desirable in the final product. The dry product is then cooled in shaker
coolers and graded for size in a sifter. Particle lumps are disposed as
solid waste, fine particles are recovered and returned to the initial
mixing step, while particles of desired size are packaged in jars or
bulk containers.
Wastewater generated 1n the production of powdered non-dairy creamer
consists of CIP system rinse, sanitizing and caustic wash water (dis-
charged after two washings), floor cleanup of certain areas in the plant,
and a small amount of water from wet scrubbers over the spray dryers.
After the Initial drying of the product all transfers of product to
unit operations are done by vacuum. Since it is undesirable for water
to come in contact with the dry product, all cleanup in these areas
Is done with air.
£36
-------
DRAFT
CORN
SYRUP
L
BOILER
NDN-CQNTACT
SLOWDOWN
OISOOIUM
PHOSPHATE
STEAM, HOT AIR
FLOOR HOSES —»
MIXING
PASTEURIZATION
HOMOGENIZATION
DRYING BOXES
COOLING
SPRAY DRYING
SHAKER COOLERS
I
l
CIP
SYSTEM
WET SCRUBBER
L.
SIFTING
WEEKLY HOSE DOWN
FLOOR DRAINS
PACKAGING
NO>*-CONTACT
PUMP COOLING
WATER
FIGURE 96
POWDERED NON-DAIRY CREAMCR MANUFACTURING PROCESS
WASTEWATL'R
-------
DRAFT
SIC 2099 Peanut Butter
In the United States, peanuts are grown for such products as peanut
butter, candy, and salted and roasted nuts. Surplus peanuts and
those too low 1n quality for food use are crushed for oil and meal.
Total edible peanut consumption has increased about 3 percent annually
in recent years, and the greatest increase in edible usage has been
in the manufacture of peanut butter. Over 63 percent of all edible
peanuts go into peanut butter. Use per person increased from 1.1 Kg
2.5 Ib) in 1950 to 1.6 Kg (3.5 Ib) in 1970, and market outlooks
48 ) indicate consumption will continue tr increase.
In 1970 processors manufactured over 320,000 KKg (350,000 ton) at
115 plants (in 31 states). Woodroof ( 48 ) reports two brands,
of more than 90, produce 58 percent of the peanut butter found on
the market. Over 90 percent of all peanut Nit-.ter is made from
Runner and Spanish type peanuts.
The USDA ( 49 ) defines peanut butter as "a cohesive, comminuted
food product prepared from clean, sound, shelled peanuts by grind-
ing or milling properly roasted, mature peanut kernels from which
the seed coats have been removed and to which salt is added as a
seasoning agent". Texture of the finished product may be smooth,
regular, or chunky, depending on the size of perceptible grainy
peanut particles. Peanut butter types are stabilized or nonstabi-
lized, depending on other added ingredients involved, and are manu-
factured in three grades determined by color, consistency, flavor and
aroma, and absence of defects. The primary use of peanut butter is
in homes and schools, and as an ingredient in a variety of snack
foods.
Process Description - The manufacture of peanut butter is a relatively
simple dry process. No water is added in processing since peanut
butter is immiscible. Figure 97 , a simplified process flow diagram
for the manufacture of peanut butter from shelled peanuts, illustrates
the seven basic process steps of roasting, cooling, blanching, picking
and inspecting, grinding and cooling, salting, and packaging.
The shelled peanuts are received and stored dry in 45.5 Kg (100 Ib)
burlap bags. A mixture of different peanuts is blended and then
transported to roasting by an elevator or similar type conveyor.
Shaker screens may be used to renove fines or other small fragments
at this poini.
Dry roasting is done t>> either batch or continuous methods. In the
batch method, peanuts are heated to 160°C (320°F), and held for 40
to 60 minutes in a revolving oven. Different varieties of peanuts
nay be roasted separately and then blended. An advantage of the
batch method is that special attention can be given batches that
230
-------
DRAFT
SHKLLEP PEANUT
STORAGE
1
I SCREENING
1 ROASTING
<
•"] BLANCHING |
i
r
' 1 INSPECTION
1
SWEETENERS, OTHER 1 GRINDING
| COOLING
1
1 1 fc
AT I ON
| PACKAGING
Fl
FIGURE
FINES
1
SKINS, HEARTS
^
PICK OUTS
BY-PRODUCT REC
CATTLE PEED
INEDIBLE OIL £
CONTINUOUS BLOW
JDVERY
TOCK
DOWN
VACUUM SEAL WATER
JAR WASH
DETERGENT RINSE
BOILER SLOWDOWN
""*
DOR AND EQUIPMENT CLEANUP
97
TO SEWER
PROCESS FLOW DIAGRAM
MANUFACTURE OF PEANUT BUTTER
239
-------
DRAFT
vary In moisture content or other qualities. In the continuous method
peanuts are conveyed through a counter-current stream of hot air.
Continuous agitation provides improved heat transfer, extraction of
moisture and volatiles, and an even and complete color from the center
to the surface of each kernel. Advantages of continuous roasting are
reduced labor and loss due to spills, more uniform roasting, and
smoother plant operations. Continuous roasting is the most common
method used.
Roasting nuts first become dark during the "white roast" as the
skins absorb oil. Then, the peanuts become done or "brown roasted".
Moisture content is reduced from 5 percent to less than 2 percent.
01ly spots called "steam blisters" form on kernel", as volatile com-
ponents are released to the skins as free oil. After roasting, the
peanuts are quickly air cooled using high volume filtered suction
fans to stop further cooking. Wastes to this point consist of floor
wash, and conveyor cleanup.
Shelled peanut kernels consist of two cotyledons (halves), the heart
(germ), and the skin. After cooling, the split peanuts are mechanically
dry blanched or whitened by removing the red skins and hearts. Roasted
peanuts are heated to 138°C (280°F) to loosen and crack the skins.
After cooling, they pass through the blancher continuously where
brushes or rubber belts rub off the skins. By-products recovered in-
clude peanut hearts separated from the cotyledons by screening, and
the skins collected by cyclones. Peanut hearts are bagged and may be
sold for poultry feed, bird feed, or oil recovery. Bagged skins may
be used in cattle feed, oil recovery, poultry house bedding, or floor
sweeping compounds.
The blanched nuts are screened and Inspected manually and electron-
ically. Light or scorched nuts and rocks or other foreign matter
are removed, and the pickout nuts are sold as inedible oil stock.
Grinding is accomplished in two stages to reduce the peanuts to the
desired texture. Constant pressure is applied to produce a uniform
product with little air entrainment. A wide variety of grinding
machinery 1s used 1n the Industry. To avoid overheating, grinding
mills are cooled by a water jacket.
Various ingredients, including about 2 percent salt by weight, are
added before final grinding to improve flavor. Most processors also
add sugar to prevent grittiness. Partially hydrogenated vegetable
oils are commonly added as emulsifiers to prevent oil separation and
improve spreadability. Peanut butter stabilized in this manner may
not legally exceed 55 pvrcent fat content, ( 48 ) including the
natural peanut oil released in grinding. The finished peanut butter
is cooled using votators, a type of heat exchanger, and deaerated
prior to packaging.
240
-------
DRAFT
Blanching and inspection produce no wastewater. Boiler condensate
and cooling water associated with grinding may be sewered or re-
circulated. A small amount of water is used In floor and equipment
washdown.
Peanut butter 1s packed in air tight containers since exposure to
air produces rancidity by auto-oxidation. Package types range from
plastic lined fiber drums to individual servings in flexible plastic.
The most common method of packing for retail trade is in glass jars.
All processors contacted use new glass which is air cleaned prior to
filling, capping, and labeling. Peanut chunks may be added during
filling.
In a few plants it is still economically feasible to reclaim im-
perfectly filled jars. The reclaim operation consists of manually
removing the peanut butter from partially filled or improperly sealed
containers, and collecting it in lined drums for repackaging. Un-
damaged jars are fed to an automatic detergent washer and then re-
filled. Jar washers have prerinse, detergent, and final rinse cycles.
Normally, only the detergent solution is reused.
Unusable cc',tairv_ i become solid waste. Wastewater produced by floor
and equipment washdown is normally sewered. Jar washer discharge is
the major wastestream sewered from packaging.
SIC 2099 Pectin
Pectin is a water soluble substance contained in the peel of citrus
fruits which binds adjacent cell walls in plant tissues and yields
a gel which 1s used in the preparation of fruit Jellies and to some
extent in the pharameceutical industry. The recovery of pectin is
a complex operation which requires a number of processing days. Pectin
is marketed in four standard grades; rapid set, slow set, low methoxyl,
and special formula. There are three known producers of pectin in the
United States and in the course of this study three plants were contacted
and vtsited.
Pectin is produced by two different processes; alcohol precipitation
and precipitation by aluminum compounds. Other than the method of
precipitation, the two processes are similar.
Description of Process - Alcohol Precipitation of Pec.tin - The
production of pectin by alcohol precipitation is 11 lustra ted in Figure
98 Citrus peels are grojnd from raw citrus fruit in-house or purchased
wet or dry in bulk. Thase plants which obtained the peels from raw fruit
In-house generally produce citrus juice and citrus oils 1n addition to
pectin. The processing of wet and dry peels is essentially the same
except that dry peels must be rehydrated prior to processing.
The peels are subjected to a hammer mill and then washed. The insoluble
pectin contained within the oeel is extracted by immersing the peels
in a vat containing hydrochloric add, water, and wood fiber while
steam is injected through the mixture. The combination of live steam
241
-------
DRAFT
jj
.JT^**?- —J^ — - . J WCT M
T
MOUUI • it mil 10.
i—
-L
3AJIH IC««
HI**. *mu j
r—— H
FIGURE 98
PECTIN MANUFACTURING PROCESS BY ALCOHOL PRECIPITATION
242
-------
DRAFT
and acid renders the pectin soluble and the peel and pectin liquor
are subsequently separated by vacuum filtration. The pectin liquor is
passed through a dlatomaceous earth pressure filter to remove Insoluble
Inorganics from the liquor and then cooled. Prior to precipitating by
alcohol, the liquor is concentrated under vacuum to three percent
pectin by weight thereby decreasing the amount of alcohol required for
precipitation. The alcohol removes the water from the liquor leaving
the crude pectin which is separated from the mixture by use of a drain
screw. The pecLin is purified by three successive washings in the
following manner: (1) alcohol and acid wash with six to seven hour
retention time, (2) alcohol wash, and (3) alcohol wash with ammonia added
to adjust the pH to between 4.0 and 5.0. Each of the washings is followed
by a drain screw to recover the spent alcohol. Tne alcohol in the liquid
from the precipitation step and the three washiigs is recovered by
distillation.
The purified pectin is dried in a forced air dryer which removes the
remaining alcohol and decreases the moisture content to between six and
seven percent. The dried pectin is milled to a desired consistency and
blended. Four grades of standard pectin are produced from the blended
product by varying the corn sugar content in each grade.
Wastewater generated in the alcohol precipitation of pectin consists of
the following: (1) alcohol still bottoms, (2) filter sluice from
vacuum and pressure filters, (3) peel washing, (4) weekly caustic
cleaning of the evaporator, and (5) general plant cleanup. Appreciable
quantities of non-contact cooling water and boiler blowdown are also
generated with the total discharge of the plant being 1500 cu m/day
(0.400 HGD).
Process Description - Pectin Recovery by Aluminum Compound Precipitation -
The production of pectin by aluminum compound precipitation is illustrated
in Figure 99. Citrus peels are prepared or received In the sane
manner as previously described. The peels are yround and washed prior
to entering the extraction vats where pectin is extracted from the peel
by the addition of sulfunc acid and the introduction of steam into the
wooden vats. Following a 16 to 20 hour retention time in the vats
the mixture is adjusted for pM and the liquor containing the soluble
pectin 1s separated from the peel by vacuum filtration. The pectin
liquor Is then stripped of insoluble inorganics by pressure filtration
or centrlfugation. Pectin is precipitated from the liquor by the
addition of an aluminum compound, commonly aluminum chloride or sul*ate.
The pectin precipitate and liquor are run through a press which separates
the liquor from the solids containing the soluble pectin. The solid
mass 1s pelletized and the.i rinsed five successive times with the
following sequential rinses; (1) hydrochloric acid-alcohol, {2} alcohol,
(3) citric acid, (4) buffer, and (5) final. The purified pectin is
then drained of excess liquid by a drain screw and prepared for packaging.
The wastestreams generated by the manufacturing of pectin by this process
Include leaching water, spent peel and wastewater, spent filter aid and
sluice water, press wastewater following precipitation, and press water
from pressing of filter cake following sluicing.
243
-------
DRAFT
FIGURE 99
PECTIN RECOVERY BY ALUMINUM COMPOUND PRECIPITATION PROCESS
244
-------
DRAFT
SIC 2099 Popcorn
Popcorn was one of the earliest foods prepared from Indian maize, the native
corn of the Americas. "Flint corn," the most primitive of the commercial
types and the major variety used for popping 1s still much like maize.
According to Agricultural Statistics, there are 19 plants which prepare
popcorn for wholesale distribution which, in 1972, produced 233,883 kkg
(257,271 tons) valued at $16 million. The mid-western states of Illinois,
Indiana, and Iowa account for the majority of production.
Description of the Popcorn Process - The popcorn process starts with the
weighing of the corn as it arrives at the plant from the fields. The corn
arrives slready detached from the cob in dry kernel form. FigurelOO depicts
a typical flow diagram of a popcorn process.
•
After weighing, the corn Is then conveyed to storage bins. From the storage
Mns the corn goes through a screening operation which removes split kernels
and other extraneous material. The whole kernels are then transferred to
another set of hoppers which gravity feed directly into density separators.
These separators are canted shaker type screens which utilize a vibrating
motion to separate the kernel by size. Fine wastes such as "bees wings"
(small varticles from the kernel edges) adhere to the screen and are washed
out daily. This washing of the density separator screens accounts for the
major waste loadings derived from a popcorn operation. Washdown flows frcn
this operation range from a low of 200 I/day (50 gal/day) to a high of 800
I/day (200 qal/day) depending on the number of screens utilized.
The separated corn then goes to a final set of hoppers where it is stored
until packaging. Packaging can be done either in bulk or the more familiar
one to three pound bags. Fumigation with methyl bromide 1s sometimes employed
1n the final holding bins.
All cleaning in a popcorn plant 1s usually done by vacuuming or sweeping
since any water coming in contact with the final product can result in
product damage. Solid waste from screening operations are generally sold
?s animal feed. Packaging wastes are hauled away by contractors to local
disposal sites.
SIC 2099 Spices
Background of the Industry - Spices are produced by approximately 40 manu-
^acturers in the United States. Most of the facilities are concentrated
1n the midwest and northeast. The domestic consumer market 1s dominated
by three companies with strong nationwide positions; however, the total
donwstic and commercial ma-ket is much less concentrated. Plants, 1n
jeneral, process and package spices for both market sectors; however,
most of the smaller companies rely on a few major institutional customers
for most of their work. A typical spice plant processes a large number
of raw spices Into a nearly Infinite variety of final products. Conse-
quently a typical plant may be characterized as being highly flexible In
its material handling processes so that it may readily respond to precise
customer requirements,
245
-------
DRAFT
-. DENSITY
___ WASHING
?8ees WINGS)
SPILLAGE
f_TZ*^"I_~L
>CKAGE MATER1
T
EFFLUENT
FIGURE 100
POPCORN PROCESS
-------
DRAFT
Process Description - The large variety of spices and seasonings received
as raw material are generally in a dried condition and are packaged in
cloth bags or sealed bales. In most plants raw material storage, process
lines, and final product storage areas are climate controlled to prevent
damage from mold, fungus, and condensation. Processing is variable;
however, basic steps include cleaning, sorting and grading, chopping,
grinding, blending and mixing, temporary Intermediate product storage, and
packaging. Rejects and spillage from these operations are primarily cleaned
and removed by dry methods, i.e. foxtail brushes, brooms, vacuum cleaners,
and air brushes. Figure 101 outlines a general process flow schematic for
a typical plant. Final products may be packaged as whole spices, chopped
and blended spices or seasonings, or as ground spices. In most plants
equipment is not dedicated to a single commodity, therefore cleanup is
necessary between product changes. This cleanup, except for the grinding'
mills, is usually dry. Surfaces in many plants have been coated with
silicate based paints to expedite dry cleaning techniques.
The grinding mill, however, must be cleaned with hot water or steam after
certain products, such as black or red pepper, have been ground. This is
necessary to remove oils released by grinding. The mills are removed to
a wash room if hot water or steam clean out is necessary.
Spice plants have a significant dust control problem. Modern facilities
use their air conditioning system filters to renove fugitive particjlates;
however, at least one facility (plant 87E01) uses a wet scrubber and dis-
charges to a municipal sewer. This method of control, however, is not
widely practiced in the industry.
SIC 2099 Tea. Instant and Blended
The development of instant tea In the early 1950's stemmed from attempts
to overcome the perishability of tea leaves, which as a whole are sensitive
to odors, high humidity, and excessive heat. Tea leaves are Imported into
the United States from a number of points in the world, but principally
Ceylon, India, and Kenya. The Department of Commerce (50 ) reports that
i973 Imports of tea leaves totaled 78,600 KKg (86,600 ton). Of this
imported total approximately 70 to 75 percent is utilized in the production
of blended tea while the remainder is processed into instant tea. There
are five companies producing blended ana instant tea in approximately ten
plants. Ir. the course of this study all five companies were contacted,
four plants were visited, and verification samples were taken at three
plants. The industry has provided documentation to the effect that tea
blending is e completely dry process with no wastewater discharge.
The majority of tea plants are located near major ports to facilitate the
receipt of the imported tea leaves. Several of the instant tea manufacture^
produce instant tea in multi-product plants along with such products as
blended tea, soup, salad dressings, instant coffee, and sugar substitutes.
-------
DRAFT
RAW MATERIAL
BAG STORAGE
FIGURE 101
SPICE PROCESS FLOW DIAGRAM
248
-------
DRAFT
Production of blended a'td instant tea remains relatively constant throughout
the year, with the highest demand In the wanner months. The production of
Instant tea Is dependent upon tea crop yield in exporting countries and this
yield can fluctuate drastically from year to year.
Process Description - Instant Tea - Figure 102 illustrates the Instant tea
process.Tea leaves are stored in oil lined wooden tea chests or silos
until processing. The tea leaves, with or without prior blending, are
carefully proportioned with water into an extractor, with the water-tea
ratio being determined by weighing the tea leaves as they enter the ex-
tractor. In the extractor tea leaves and water are boileo for a specified
period of time after which the tea extract is pumped into the first evap-
orator. The wet spent tea leaves are centrifuged and the liquid fractibn
1s pumped into the evaporator while the dewatered tea leaves are used for
composting or cattle feed.
While the tea extract is being evaporated to a specified concentration,
the resulting aromatic tea vapors are passed into an aroma column where
they are condensed and retained for later use in the finished tea product.
The concentrated tea extract is cooled in coils to render tannins and
caffeins insoluble before the extract is passed into gravity clarifiers
from which the clarified tea extract is transferred into the final evap-
orator. Clarifier sludge containing the insoluble tannins and caffeins
is adjusted to an alkaline pH and a catalyst, such as hydrogen perioxide,
is added. The mixture is regenerated within a heat exchanger where the
catalyst aids in breaking down insoluble, long chain hydrocarbon compounds
into soluble, short chain hydrocarbon compounds. The altered mixture is
cooled to render undesirable components insoluble prior tc- Clarification.
The clear tea extract 1s transferred to the final evaporator and the
sludge is recycled to the pH adjustment step.
The clear tea extract contained within the evaporator is concentrated to
a composition of approximately 40 to 45 percent total solids and the
aromatic tea vapors thus generated are returned to the aroma column. At
this point tea vapors (regenerated by heating) from the aroma column and
the concentrated tea extract are mixed to a homogeneous blend in a feed
tank prior to drying in a spray dryer. The blended tea extract is sprayed
in the form of a fine mist from the top of the dryer and while falling
is subjected to a stream of net air. Evaporation of water from the
particles of mist produces soluble powdered tea particles which collect
at the basf of the spray dryer.
Prior to packaging, the "Instant tea" may be blended with sugar, art-
ificial sweeteners, or powdered fruit concentrates to yield various
tea "mixes". The tea or tea mix is packaged in packets, jars, or fiber
drums, depending on whether the final product is for wholesale or
retail use.
Essentially, the only process wa
-------
DRAFT
FIGURE 102
INSTANT TEA PROCESS DIAGRAM
250
-------
DRAFT
waste flow Is attributable to cleanup operations. Daily cleanup gen-
erally consists of an almost continuous floor washdown to remove spills
and leaks from equipment connections.
Since Instant tea manufacturers operate on a 24 hour per day basis, equip-
ment cleanup is generally done once per week and consists of the following
sequential steps: fresh water prerinse, caustic wash, fresh water rinse,
nitric add wash for removal of silica formations, and fresh water rinse.
Process Description - Blended Tea - The blended tea process is a com-
pletely dry process in which tea leaves are received and stored in the
same manner as for instant tea manufacturing. Tea leaves are then tasted
for quality and dry blended in drums prior to being hopper fed into the
packaging line. The crucial step in the blended tea process is the taste
testing of tea leaves from each tea chest to determine which leaves should
be blended together to yield the richest flavor.
SIC 2099 - Pre-packaged Sandwiches
General - Pre-packaged sandwiches for sale off the premises are dis-
tributed primarily from food outlets such as convenience stores and
vending machines. The manufacturers of these sandwiches purchase
processed materials and assemble sandwiches. The sandwiches are old
either frozen or fresh. According to the Bureau of the Census ( ? ),
in 1972, the value of total product shipments of fresh sandwiches
was 565.2 million, a 113 percent increase over the $30.6 million figure
for 1957. Nationwide sales figures were not available for frozen
sandwich production. Plants producing pre-packaged sandwiches are
normally located in major urban areas since that is where most of
their products are consumed.
Description of the Process - Plants producing pre-packaged sandwiches
are essentially assemblers of processed food items (see Figure 103).
Processed meats, cheeses, tuna fish, sandwich spreads, and similar in-
gredients are purchased from a wholesaler and stored in a refrigerated
corler as required. Sliced bread 1s normally delivered each day for
that day's production. In some plants, bread or rolls are baked on
the premises. Meats and cheeses are sliced and the sandwiches are
assembled manually. Some plants purchase canned spreads for the
prepatation of tuna or ham salad type sandwiches. Other olants
produce only sliced meat and/or cheese sandwiches. Still other plants
prepared salad type fillings on the premises, normally in a choppimj
machine, for the preparation of sandwiches. After assembly, the
sandwiches are cello wrapped mechanically and either frozen or distributed
for immediate consumption.
Plants which prepare sandwiches only from processed ingredients generate
wastewater only as a result of the cleaning of utensils in a sink and
cleaning of the floor with a mop and bucket. Firms which prepare salad
type ingredients on the premises will also have wastewater generated
from the washing of the chopping machine and the assorted mixing con-
tainers.
251
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D3AFT
r
SLICED
BREAD
| ' L [
SOLID WASTE
I |
I
I
CLEANUP
SLICED INGREDIENT SANDWICH PREPARATION
PROCESS FLOW DIAGRAM
STORAGE
I —
1
1
1
SLICED
BREAD
CHOPPING 6 MIX
(OPTIONAL)
i
'*
] ASSEMBLED
ING
I 1
I
1
SOLID WASTE
F-ACKAGED
I I
I
I J
CLEANUP WASTEWATE3
SALAD INGREDIENT SANDWICH PREPARATION
PROCESS FLOW DIAGRAM
FIGURE 103
SANDWICH PROCESS FLOW DIAGRAM
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DRAFT
Solid wastes are generated in the slicing and assembly operations and
in toe salad filling preparation. These wastes are disposed of to a
landfill or sold as animal feed.
SIC 2099 Vinegar
The manufacture of vinegar Is one of the most ancient of natural fermenta-
tions which has been used by man; the principle use being a flavoring or
preservative agent in foods. There are currently 94 establishments processing
vinegar, some being independent plants while others are closely tied to the
production of other products. Although distributed throughout the country,
the major concentration of plants is in the eastern states. The value of
shipments in 1971 reached $77.9 million, an increase of over $4.6 million
from 1970 according to the United States Department of Agriculture's
Agricultural Statistics.
Description of Process - Vinegar is defined as a condiment made from sugar
or starch containing materials by alcoholic and subsequent acetic fermenta-
tion. The product is usually classified according to the materials from
which it is made: (1) from fruit juices, e.g., apples, oranges, grapes,
berries, etc.: (2) from starchy vegetables, e.g., potatoes or sweet potatoes;
(3) from nelted cereals; (4) from sugars such as syrup, molasses, honey,
maple skimmings; and (5) from alcohol from yeast manufacture. In the
United States most table vinegar is derived from apples.
The manufacture of vinegar involves two distinct steps: (1) The fermentation
of sugar to ethanol and (2) the oxidation of the ethanol to acetic acid. For
the purpose f this study, only the second step of the process wil1 be con-
sidered in detail. Indeed, in most cases, the raw material for vinegar-
production, i.e., either the fruit for fermentation or the ethanol are
actually the products or by-products of other industries. Fffluent limi-
tations g-jidelines have been, or soon will be, promulgated ior these various
industries, e.g., the production of yeast, apple cider, alcoholic beverages,
fruit juices, etc.
Vinegar production may exist as both a separate industry or as an ancillary
industry and will be charactered herein as an independent process.
As mentioned, the manufacture of vinegar begins with the raw material of
either unfermented fruit or athanol-containing materials. Production Path A
(Figure 104 i starts with the fermentation of cider or fruit juice. The juice
is pumped into fermentation tanks in which the fruit sugars are converted to
ethanol by selected varieties of yeasti, belonging to the genus Saccharomyc_es_.
As the sanitation of these tanks is important tc prevent contamination &y
undesirable organisms, a siynificant quantity of wastewater is generated at
this point by tne washing of the tanks between uses.
253
-------
DRAFT
APPLE CIDER.
rRU!T AND/OR
BY-PRODUCTS
B
FILTER MEDIUM j~"
3--I.1.1.1L'=.~d FILTER
COOLING WATER
CLEANING WATER
«
¥
SOLIDS
SPILLAGE
• •» ii_-« ^m* -w^A
—•!
"EFFLUENT
FIGURF 104
VINEGAR PROCESS
-------
DRAFT
Production Path A, and Path 6 converge at the next step In the process, the
oxidation of ethanol to acetic add which 1s accomplished by the vinegar
bacteria, members of the genus Acetobacter. These organisms are character-
ized by their ability to convert ethanol to acetic acid. The conversion is
accelerated and controlled by the use of a vinegar generator. There are
several types of generators m use, although the design principle remains
the same; I.e., the rate of acetificatlon Is proportional to the amount of
oxygen available for reaction, which in turn is proportional to the surface
area. The reactive surface may be maximized by either of two general
methods: (1) utilizing a fill material such as wood shavings or (2) by
continuous aeration and circulation of the liquid. The generators using a
fill material require periodic cleaning to avoid plugging by the bacterial
growth. This cleaning is, however, not a daily practice and is d.one only
as necessary. The closed system utilizing oxygen injection requires less
maintenance and when operated properly produces vinegar more efficiently "
than the other procedures. Regardless of type, the generators require a
cooling system to maintain the optimum temperature for Acetobacter growth.
The cooling water is non-contact and may be recirculated.
Vinegar produced by the accelerated generator process is often harsh in
flavor and odor and requires aging in wooden tanks to produce an agreeable
flavor and odor, as well as to allow it to clear. A final polishing of the
product is necessary to produce the characteristic sparkling clarity of
most vinegars. This final process may be accomplished by either filtration
or fining. Fining consists of introducing a suspension of clay, casein,
gelatin, bentom'te clay, or other suitable materials and allowing the mixture
to settle. The clear vinegar is then racked. The more common method of
clearing vinegar is that of filtration. The filter system must be cleaned
periodically in order to maintain Its efficiency.
The refined vinegar Is either marketed In bulk or bottled In retail containers
at the plant. In order to prevent the continued growth and subsequent
clouding by the Acetobacter organisms, the vinegar is pasteurized at 60eC ^cr
a few seconds. Pasteurization may fce accomplished in bulk by passing a con-
tinuous stream of vinegar through a steam jacketed tube or plate pasteurizer
and then cooling it In a water cooled unit. Bottled vinegar may be pasteur-
ized by Immersion or by flash pasteurization prior to bottling. The buttled
product 1s subsequently capped, washed and transported to labelling and
casing. During bottling, most of the wastewater is generated by the pasttu'--
ization cooling cycle and the final bottle wash.
The major source of wastewater from the bulk operation Is fron the filtration
system. Periodic cleaning of floors, generators, and bottling equipment aho
contributes variable amounts of wastewater depending upon process and house-
keeping differences. Transient surges of wastewater occur when wooden
storage tanks are drained of the water to keep them from drying out between
uses.
255
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DRAFT
SIC 2099 Yeast
Currently 1n the United States there are 13 active yeast processors
representing four companies producing an estimated 204,000 KKg (250,000 ton)
of yeast annually. The largest producer reports supplying approximately
35 percent of the total market. Production facilities are located near
metropolitan areas 1n the states of New York, New Jersey, Maryland,
Illinois, Missouri, Texas, Louisiana, Washington, and California.
Market demand for yeast products 1s reported (51) to be closely related
to growth in the baking Industry, and is expected to increase slowly in
future years. During the last two years, the industry has witnessed the
closing of one new yeast plant, while another new plant is presently
under construction. Industry trends and economics indicate that new
production plants will be large scale, highly automated facilities.
Background of the Industry - As early as 3500 years ago, man collected
yeast deposits (52) from the surfaces of plant life and consumed them
for medicinal and dietary purposes. Science has since shown that y>,'ast
is high in proteins and vitamins. However, despite its high food value,
yeast is primarily used for fermentation. In the baking industry, yeast
ferments sugar in bread dough producing carbon dioxide gas responsible
for the rising or leavening of bread. In the brewing industry, yeast
ferments or breaks down sugars to alcohol and carbon dioxide.
In the nineteenth century, brewers supplied most of the commercially
grown yeast for the baking industry. During World War I, the scarcity
and high price of grain mashes led to the development of a mathod of
yeast production using molasses as the primary raw material. This process
was highly successful, and with subsequent minor refinements 1s ustd by
the industry today.
Description of Process - The three basic products produced by the yeast
Industry are (1) "bakers compressed yeast" (2) "active dry yeast", and
{3) p/iarn.aceutical dry yeast" (52). The primary product, "bakers
compressed yeast", 1s utilized by large baking companies as a leavening
agent, while smaller .bakeries, blenders of ready-to-bake cake mixes, and
repackagers require the active dry yeast. Pharmaceutical dry yeast, which
represents a small portion of total yeast production, Is used by the
pharamaceutlcal Industry as a protein and vitamin dietary supplement.
The basic raw materials necessary for yea:t growth are cane and beet
molasses, water, chemical sources of nitrogen and phosphorus, and a pure
stock culture of the desired yeast strains. Other requ-lreu production
materials may include sulphuric acid for fermenter pH adjustment,
vegetable oil or chemical defoamers, and small amounts of pUstlclzIng
agents for forming and packaging. Although Individual plants vary accord-
ing to size, age, and water usage, the processing steps and raw materials
256
-------
DRAFT
are virtually identical throughout the industry. Figure 105 presents a
simplified flow diagram for the following basic process steps: (1) molasses
feed wort preparation, (2) stock yeast preparation, (3) fermentation,
(4) yeast cream separation. (5) dewatering and drying, and (6) packaging.
Yeast production begins when the yeast food, called 'feed wort, is prepared
by combining cane and beet molasses, diluting the mixture with water,
and adjusting the pH to 4.5 before sterilization. The mixture is heated
with steam in a high pressure continuous cooker, and after some solid
matter is removed by vibrating screens, the sterilized molasses is fed to
centrifugal clarifiers where additional solids are removed and retained
in the clarifier bowl. The clear wort is pumped to storage tanks. Molasses
provides the primary source of carbon and sugar for yeast food, and supplies
calcium potash, and other elements. The ratio of cane to beet molasses
depends on availability and nutrient content, but a mixture is always used
to provide a balanced yeast diet except that nitrogen and phosphorus must
be added since any molasses is deficient in both.
Clarifier sludge, being mainly inorganic end of little value, is hauled
to landfills or ploughed into agricultural land. Other wastes from fz^d
wort preparation are clarifier, tank, and piping sterilization and cleanup.
Parallel to feed wort preparation, a test take containing sterile
is inoculated with a few cells from pu. > culture of the desired yeast
strain. These grow to a larger mass tnat is transferred to successively
larger vessels until there is a sufficient quantity of stock yeast for
starting growth in the main fermenting tanks. During each transfer, the
contents of the "seed" fermenters are sent to continuous centrifugal sepa-
rators to remove spent nutrients from the stock yeast. Wastes normally
discharged from the culture stages Include water used in sterilizing and
cleaning of tanks and piping, and spent nutrients.
Both stock yeast and feed wort are then delivered to the main fermenters.
Water and stock yeast ar* placed in the sterile tank. Feed wort, nitrogen,
and phosphorus are continuously added as the steadily aerated yeast 1s
allowed to ferment for aoout ten hours. Aqua ammonia and phosphoric acid
are commonly used sources of nitrogen and phosphorus. Foam caused by
aeration is cut back periodically by adding sufficient vegetable oil or
chemical defoamers.
Under ideal conditions the yeast growth is exponential. Since any surplus
nutrients tend to be fermented to alcohol, thus wasting raw materials and
retarding yeust growth, the feed wort and other chemicals are added by
automatic metering equipment at a predetermined, exponential rate. During
growth fermentation, the pnysiological activities of yeast cells cause a
progressive pH decrease. Since yeast grows best in an add medium, pH is
maintained at 4.5 by the addition of aqua ammonia. Because fermentation is
exothermic, cooling water is circulated through coils to maintain an optimum
30°C (85°F) temperature. Near the end of the 12 hour growth stage, the
temperature is further lowered and aeration discontinued to stop growth
and allow the yeast cells to fully mature.
Z57
-------
DRAFT
MOLASSES BLE>eiM
MO STOWAGE
D-
—i
DILUTION ATC
PH AOJUSTVCNT
J
STEAM STER1L12ATJCM
COOCNSATE
CENTRIPudAL
STOCK TEAST, NVTPIEKTS,
PH aJNTRCL.DEFOAMER
--- *. SLUDGE TO DISPOSAL
—•
CETNHIFUGAL
SEPARATION
VACUU*
ML "TAT10N
SPENT BEE"
rtUTRATItX'
ATMOSPHERIC
BO.T CAVING
PACKAGING
PACKAGING
"LAKER OR
PACKAGING
*
OHAWUCPJTICAI. »»v re AST
"OL.N.
^
- AfC
TO SEWE"
FIGURE
PROCESS FLOW DIAGRAM DRIED FOOD YEAST
258
-------
DRAFT
After fermentation, the cream yeast Is separated from the fermented wort
by centrifugal separation. The separated waste resulting from first
separation is called first separator beer. After first separation, the
yeast cream is put through a second and third separation. In each of the
last two separations, the yeast slurry is diluted in a cold water washing
process, and then separated. Wastes from these steps is called second
separator beer and third separator beer. At least two of the largest
production plants use third separator beer as the second separation wash
water. Other discharges from fermentation and separation include fermenter,
centrifuge, and wort tank and piping cleanup.
The process for making bakers compressed yeast, active dry yeast, and
pharmaceutical yeast are identical up to this point.
•
The yeast cream slurry must be filtered and dewatered prior to packaging.
Bakers compressed yeast and active dry yeast are pumped to either recessed-
plate filter presses or a rotating vacuum filter drum. If a filter press
is used, yeast cream is pumped into the filtering compartments and pressure
applied. After opening the press, yeast cake is scraped into stainless steel
carts for delivery to a .nixer. No filter aids are used. If a vacuum filter
is used, a revolving drum covered by a circular band of filter cloth is
evacuated and revolved in a vat of yeast cream. A thin layer of solid yeast
forms on the cloth, and the effluent is discharged from the interior of tne
drum. Potatoe starch may be used as a filter cloth precoat or filter aid,
and is normally reclaimed by settling of the effluent.
Compressed yeast cake is fed to a mixer where it is blended and plasticized
to adjust moisture content and improve extrudability. Plasticizing agents
typically used are vegetable oils, emulsifiers, and shaved ice. After mixing,
bakers compressed yeast is continuously extruded as a ribbon, and cut into
blocks for packaging. Package sizes range from blocks weighing several
ounces to 50 pounds, although l and 5 pound blocks are most common. Bakers
compressed yeast in saleable condition has a 73 percent moisture content,
and must be kept refrigerated until used.
The slurry for active dry yeast is extruded directly after filter pressing.
Then It Is fed into rotary or belt type warm air dryers for 12 hours and
the granular product packaged in filter drums. Active dry yeast contains
only eight percent moisture, and keeps well without refrigeration. Four
parts of active dry yeast equal ten parts of bakers compressed yeast.
The slurry for pharmaceutical dry ypast i- pumped to the vertex of a rotary
double-drum dryer where it is preheated and passed In 6 thin film over
rotating drums heated Internally by live steam. The s1_rry spread on the
drum surface dries and is scraped fo;- conveyor transport to a pulverizer
or flaker. Both powder and flakes are packaged in bags and drums.
Process wastes from yeast drying are filter effluent, spent filttr precoat,
and equipment backflushing and cleanup. Drying and packaging produce onlv
minor wastes from machinery and floor cleanup.
259
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DRAFT
SECTION IV
INDUSTRY SUBCATEGORI2ATION
In the development of effluent limitation guidelines and standards of
performance for the Miscellaneous Foods and Beverages Industry, 1t was
necessary to determine whether significant differences exist which form
a basis for subcategorlzation of the Industry. The rationale for sub-
categorization was based on emphasized differences and similarities in
the following factors: (1) constituents and/or quantity of waste
produced, (2) the engineering feasibility of treatment and resulting
effluent reduction, and (3) the cost of treatment. While factors such
as process employed, plant age and size, and nature of raw material
utilized tend to affect the constituents and quantity of waste produced,
the emphasis herein is not merely on an analyzation of these factors but"
on the resulting differences in waste production, engineering feasibility,
and cost.
The Environmental Protection Agency preliminarily subcategorized the
miscellaneous foods and beverages point source category into the SIC
Codes listed in Table 12. As discussed in Section III, most of these
codes encompass numerous manufacturing processes, and the possibility
that some of the codes could be consolidated was well recognized.
Several factors or elements were considered with regard to identifying
any relevant sutcategories. These factors included the following:
1. Process variations
2. Raw materials
3. Age of plants
4. Size of plants
5. Plant location
6. Products and by-products
7. Climatic Influences
8.- Seasonal variations
After consideration of all of the above factors it 1s concluded that tho
miscellaneous foods and beverages industry should be further divided into
subcategories as given in Table 13. The rationale for the subcategori-
zation is given below.
PROCFSS VARIATIONS
The production of miscellaneous foods and beverages, as indicated 1n
Section III, involves considerable variation In process operations.
These variations, whether caused by the end product desired or other
factors, can result 1n markedly different wastewater characteristics,
applicable control and treatment alternatives, and costs of control
and treatment alternatives. Of all factors considered, process
261
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DRAFT
TABLE 12
CLASSIFICATION OF THE MISCELLANEOUS FOOD AND BEVERAGES
INDUSTRY BY STANDARD INDUSTRIAL CLASSIFICATION CODES
SIC 2017 Poultry and Egg Processing (Egg Processing Only)
SIC 5744 Shell Eggs
SIC 2034 Dehydrated Soups
SIC 2038 Frozen Specialities
SIC 2047 Dog, Cat, and Other Pet Food
SIC 2051 Bread and Other Baking Products, Except Cookies and Crackers
SIC 2052 Cookies and Crackers
SIC 2065 Candy and Other Confectionery Products
SIC 2066 Chocolate and Cocoa Products
SIC 2067 Chewing Gum
SIC 2074 Cottonseed Oil Mills
SIC 2075 Soybean Oil Mills
SIC 2076 Vegetable Oils Except Corn, Cottonseed, and Soybean
SIC 2079 Shortening, Table Oils, Margarine and Other Edible Fats and
Oils, Not Elsewhere Classified
SIC 2082 Malt Beverages
SIC 2083 Malt
SIC 2084 Wines, Brandy, and Brandy Spirits
SIC 2085 Distilled, Recfif-ied, and Blended Liquors
SIC 5'82 Bottling of Purchased Wines, Brandy, Brandy Spirits, and
Liquors
SIC 2086 Bottled and Canned Soft Drinks and Carbonated Waters
SIC 2087 Flavoring Extracts and Flavoring Syrups Not Elsewhere
Classified
SIC 2095 Roasted Coffee
SIC 2097 Manufactured Ice
SIC 2098 Macaroni, Spaghetti, Vermicelli, and Noodles
SIC 2099 Food Preoarations, Not Elsewhere Classified
262
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DRAFT
TABLE 13
RECOMMENDED SUBCATEGORIZATION OF THE MISCELLANEOUS
FOODS AND BEVERAGES POINT SOURCE CATEGORY
VEGETABLE OIL PROCESSING AND REFINING
Al Establishments primarily engaged In the production of
unrefined vegetable oils and by-product cake and meal
from soybeans, cottonseed, flaxseed, peanuts, safflower
seed, sesame seed, sunflower seed by mechanical screw
press operations.
A2 Establishments primarily engaged In the production of
unrefined vegetable oils and hy-product cake and meal
from soybeans, cottonseed, flaxseed, peanuts, safflower
seed, sesame seed, sunflower seed by direct solvent
extraction or prepress solvent extraction techniques.
A3 Establishments primarily engaged in the production of
olive oil and by-product cake or meal from raw olives
by hydraulic press and solvent extraction methods.
A4 Establishments primarily engaged 1n the production of
olive oil and by-product cake or meal from raw olives
by mechanical screw press methods.
AS Establishments primarily engaged 1n the processing of
edible oils by the use of caustic refining methods
only.
A6 Establishments primarily engaged 1n the processing of
edible oils by the use of caustic refining and addu-
litlon refining methods.
A7 Establishments primarily engaged 1n the processing of
edible oils utilizing the following refining methods:
caustic refining, acidulation, bleaching, deodorizatlon,
winterizing, and hydrogenation.
A8 Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, bleaching, deodorizatlon, winterizing
hydrogenation.
A9 Establishments primarily engaged 1n the processing of
edible oils utilizing the following refining methods:
caustic refining, acidulation, bleaching, d«odor1z«t1on,
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TABLE 13
AID Establishments primarily engaged in the processing
of edible oils utilizing the following refinery
methods; caustic refining, bleaching, deodprlzatlon,
winterizing, hydrogenation, and the plasticizing and
packaging of shortening and table oils.
All Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, acidulatlon, bleaching, deodorization,
winterizing, hydrogenation, and the plasticizing and
packaging of shortening, table oils, and margarine.
A12 Establishments primarily engaged in the processing of
edible oils utilizing the following refining methods:
caustic refining, bleaching, deodorization, winterizing,
hydrogenation, and the plasticizing and packaging of
shortening, table oils, and margarine.
A13 Establishments primarily engaged in the processing of
edible oils into margarine.
A14 Establishments primarily engaged in the processing of
edible oils into shortening and table oils.
A15 Establishments primarily engaged in the refining and
processing of olive oil.
BEVERAGES
Alb Production of malt beverages by breweries constructed
since January 1, 1950 and with a production capacity
in excess of 800 cubic meters per day. In addition,
this subcategory includes plant 82A16.
A17 Production of malt beverages liy breweries constructed
before January 1, 1900 and with a production capacity
1n excess of 2i'00 cubic meters per day.
A18 Production of malt beverages by breweries not included
in subcategories A16 and A17.
A19 Installations primarily engaged in the production of
malt and malt by-products.
A20 Wineries primarily engaged in the production of wine,
brandy, or brandy spirits, and not operating stills.
A2) Wineries primarily engaged in the production of wine,
brandy, or brandy spirits, and operating stills.
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TABLE 13 (CPNT'O)
A22 Distilleries primarily engaged 1n the production of
beverage alcohol from grains and operating stillage
recovery systems.
A23 Distilleries primarily engaged in the production of
beverage alcohol from grains and not operating stillage
recovery systems.
A24 Distilleries primarily engaged in the production of
beverage alcohol by distillation of molasses.
A25 Installations primarily engaged in the blending and
bottling of purchased wines of spirits.
A26 Installations primarily engaged in the production of
soft drinks; and which package exclusively in cans.
A27 Installations primarily engaged in the production of
soft drinks; and which are not included in Subcategory A26,
A28 Installations primarily engaged in the production of
beverage base syrups, all types
A30 Installations primarily engaged in the production of
instant tea.
C8 Installations primarily engaged 1n the production of
roasted coffee.
C9 Installations primarily engaged in the decaffeination
of coffee.
CIO Installations primarily engaged in the production of
soluble coffee.
Fl Installations primarily engaged in the blending of tea.
BAKERY AND CONFECTIONERY PRODUCTS
Cl Production of cakes, pies, doughnuts, or sweet yeast
goods, separately or in any combination, by facilities
using pan washing.
C2 Production of cakes, pies, doughnuts, or sweet yeast
goods separately or in any combination by facilities
not using pan washing.
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TABLE 13 (CONT'D)
C3 Installations primarily engaged in the production of
bread related products
C7 Installations primarily engaged in the production of
cookies or crackers separately or In any combination.
C13 Installations primarily engaged in the production of
bread and buns in any combination.
C14 Installations primarily engaged in the production of
bread and snack items, in any combination.
01 Installations primarily engaged in the production of
candy or confectionery products separately or in any
combination, except glazed fruits.
D2 Installations primarily engaged in the production of
chewing gum.
D3 Installations priorily engaged in the production of
chewing gum base.
05 Installations primarily engaged in the production of
milk chocolate with condensory processing.
D6 Installations primarily engaged in the production of
milk chocolate without condensory processing.
PET FOODS
85 Installations primarily engaged in the production of
canned pet food, low meat.
B6 Installations primarily engaged in the production of
canned pet food, high meat.
B7 Installations primarily engaged in the production of
pet food, dry.
88 Installations primarily engaged in the production of
pet food, soft moist.
MISCELLANEOUS AND SPECIALTY PRODUCTS
A29 Installations primarily engaged in the production of
flavorings, or extracts, separately or in any combination.
A31 Installations primarily engaged in the production of
bouillon products.
A3? Installations primarily engaged In the production of
non-dairy creamer.
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TABLE 13 (CONT'D)
A33 Installations primarily engaged in the production of
yeast and by-product molasses, if recovered.
A34 Installations primarily er n the production of
peanut butter by facilities .3 jar washing.
A35 Installations primarily engaged in the production of
peanut butter by facilities not using jar washing.
A36 Installations primarily engaged in the production of
pectin and peel by-products, if recovered.
A37 Installations primarily engaged in the production of
almond paste.
Bl Installations primarily engaged in the production of
frozen prepared dinners.
82 Installations primarily engaged in the production of
frozen breaded or battered specialty items, separately
or in any combination.
B3 Installations primarily engaged in the production of
frozen bakery products.
B4 Installations primarily engaged in the production cf
tomato-cheese-starch products.
B9 Installations primarily engaged in the production of
chili peppar and paprika, in combination.
C4 Installations primarily engaged in the production of
processing of eggs.
C5 Installations primarily engaged in the production of
shell eggs.
C6 Installations primarily engaged in the production of
manufactured ice.
C12 Installations primarily engaged in the production of
prepared sandwiches.
D5 Installations primarily engaged in the production of
vinegar.
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TABLE 13 (CONT'D)
El Installations primarily engaged in the production of
molasses, honey, glazed fruit or syrups, separately
or in any combination.
E2 Installations primarily engaged in the production of
popcorn.
E3 Installations primarily engaged in the production of
ready-mix desserts or gelatin desserts, separately
or in any combination.
E4 Installations primarily engaged in the production of
spices.
E5 installations primarily engaged in the production of
dehydrated soup.
E6 Installations primarily engaged in the production of
macaroni, spaghetti, vermicelli, or noodles, separately
or in any combination.
F2 Installations primarily engaged in the production of
baking powder.
F3 Installations primarily engaged in the production of
chicory.
F4 Installations primarily engaged in the production of
bread crumas
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variation has generally been found most significant in determining sub-
categorization.
The consideration of process variations resulted in the following sub-
categorization:
Vegetable Oil Processing and Refining:
The production of unrefined vegetable oil from soybeans, cotton-
seeds, flaxseeds, peanuts, safflower seeds, sesame seeds, sun-
flower seeds and olives by mechanical screwpress operations.
The production of unrefined vegetable oil from soybeans, cotton-
seeds, flaxseeds, peanuts, safflower seeds, sesame seeds, sun-
flower seeds and olives by direct solvent extraction and prepress
solvent extraction.
Edible oil refining only.
Edible oil refining and acidulation.
Edible oil refining, acidulation, oil processing and deodorization.
Edible oil refining, oil processing, and deodorization.
F.dible oil refining, acidulation, oil processing, deodorization
and the production of shortening and table oils.
Edible oil refining, oil processing, deodorization, and the pro-
duction of shortening and table oils.
Edible oil refinings acidulation, oil processing, deodorization, and
the production of shortening, table oils and margarine.
Edible oil refining, oil processing, deodorization, and the pro-
duction of shortening, table oils, and margarine.
Margarine production only.
Shortening and tabk- oil production only.
Beverages:
Malt beverages.
Malt.
Wineries without distilling operations.
Wineries with distilling operation.
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Grain distillers with stillage recovery systems.
Grain distillers without stillage recovery systems.
Molasses distillers.
Plants primarily bottling wines and distilled liquors.
Soft drink canning plants.
Soft drink bottling, or combined bottling/canning plants.
Plants producing flavor base syrups and/or concentrates.
Roasted coffee.
Coffee decaffeination.
Soluble coffee.
Instant tea.
Tea blending.
Bakery and Confectionery Products;
Bread and bread related products.
Cakes, pies, doughnuts, end sweet yeast goods utilizing pan washing.
Cakes, pies, doughnuts, and sweet yeast goods not utilizing pan
washing.
Cookies, crackers, and other "dry" bakery products.
Candy and confectionery products except glazed fruit.
Glazed fruit.
Chewing gum products excluding the preparation of natural gum base.
Chewing gum base prepared from artificial and natural materials.
Chocolate and cocoa products prepared from cocoa beans.
Pet Food:
Canned pet food.
Dry pet food.
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Miscellaneous and Specialty Products:
Shell egg handling (SIC 5144).
Egg processing (SIC 2017).
Frozei specialties.
Non-dairy coffee creamers.
Production of specific flavors from the blending cf extracts, acids,
and colors.
Manufactured ice.
Bouillon production.
Yeast production.
Peanut butter manufacturing not including jar washing.
Peanut butter manufacturing including jar washing.
Chili pepper and paprika.
Prepackaged sandwiches.
Vinegar.
Molasses, honey, and syrups.
Dehydrated soup.
Prepared desserts, gelatin.
Spices.
Macaroni, spagetti, vermicelli, noodles.
Almond paste.
Pectin.
Baking powder.
Chicory.
Bread crumbs.
The rationale for the above subcategorization due to process variation
1s as follows.
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Vegetable Oil Processing and Refining
Unrefined Vegetable Oil - The production of crude vegetable oil from oil-
seeds involves three distinct processes each resulting in different waste-
water stream loadings. Mechanical screw press operations have been docu-
mented by plant visitations and telephone surveys to have zero discharge
of process wastewater. The extraction processes of direct solvent extrac-
tion and pre-press solvent extraction do contribute an average daily waste-
water flow of approximately 100 cu in/day (0.03 MGD). This wastewater
results from 1) wastewater generated by wet scrubber systems, 2) degumming
operations, 3) steam condensates contaminated by oil, fatty acids or hexane
solvent, and 4) in-plant cleanup resulting from spillage of oil or miscella,
tank leakage or pump failure.
Edible Oil, Shortening, and Margarine - Wastewaters generated from edible
oil refineries, on the other hand, vary greatly with respect to the degree
of process integration existing at each plant. For example, a large fulT-
.scale edible oil refinery may have an entire sequence of operations in
which vegetable oils are transformed into finished products such as
shortening, margarine or table oil. A conventional full-scale operation
would include: 1) storage and handling facilities, 2) caustic refining,
3) soap-stock acidulation, 4) bleaching, 5) hydrogenation, 6) formula bleniiing,
7) winterization, 8) deodorization, and 9) plasticizing and packaging a
number of finished products. In contrast there exists a number of small
scale operations consisting of only tank farm storage and handling facili-
ties with steam or kettle refining. These smaller plants usually sell the
refined oil to other edible oil processors who in turn produce a finished
product.
Due to the variations in plant size and process integration, it was
necessary to adopt a "building block" approach to the assessment of
wastewater loadings within the industry. The eight unit processes listed
in Table 14 have been Identified, each generating a different wastewater
effluent. Table 15 presents a list of the various unit process combi-
nations within the industry and the number of plants utilizing each
combination in the U.S. during 1970.
Three processes are common to about 95 percent of the industry. These
include 1) raw material storage in storage tanks, 2) tank car cleaning,
and 3) caustic refining. Seng (53) reports that as a result of handling
large volumes of edible oils there are erratic flows resulting from
washing and cleaning processes to remove oils and greases that accumulate
due to tank leaks, transfer operations pump failures, and the accumulation
of refuse materials and settled dust. These materials oecome a major
waste load problem when washed into plant storm sewers by rain. Becker
(54) reports that in seme cases the BOD increase as a result of storm
water runoff is considerable.
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TABLE 14
EDIBLE OIL PROCESS UNITS
1. Edible oil refining (i.e., caustic, steam and kettle refining,
and including Intersten'fication rearrangements;
2. Soapstock acidulation
3. Edible oil processing (I.e., bleaching, winterization, and
hydrogenation)
4. Contact cooling tower blowdown from deodorization barometric
condenser systems
5. Tank car cleaning
6. Storage and handling
7. Plasticizing and packaging d-e., shortening and table oils
production)
8. Margarine processing
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TABLE 15
PROCESS INTEGRATION IN THE EDIBLE OIL REFINING INDUSTRY3
Number of Plants Utilizing
Process Integration* Process Integration
1. R 21
2. R 6
3. RP 7
4. ROW 10
5. RDWH 2
6. RDWP 5
7. RDWHP 29
8. RDM 9
9. RDHP 10
10. RDP 5
11. RHP 1
12. DP 2
13. P J.
TOTAL 110
a R = Refine; D = Deoclorization; H = Hydrogenation;
W = Winterize; P = Plasticize
* All plants are assumed to have tank car cleaning and
storage transfer facilities.
Source: 1970 Directory to Edible Oil Refineries
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DRAFT
Tank car cleaning operations are usually adjacent to outdoor tank farm
facilities and may at times contribute to the storage and handling
waste!oad. On the average, about 10 tank cars are washed per week during
the day shift. The wasteload of this operation consists primarily of
bulk oil and detergents flushed out of the tank car by cleaning. Usually
a holding tank is used to recover the bulk oil. The recovered oil is
then pumped to an inedible oil holding tank. Seng (53) reports that
crude oil is treated with caustic and is centrifuged to remove micro-
organisms and soapstock. These "foots" are pumped to an outdoor tank
farm for sale or for acidulation purposes. The refined oil is then
washed and centrifuged. Caustic refining constitutes a continuous
source of process wastewater with a pH value ranging from 10 to 12.
Mater usage for the oil washing process is estimated to be about 10
to 15 percent by weight of the oil processed. The acidulation of soap-
stock or "foots" for fatty acid content produces a continuous wasteload
low in pH (1-5 to 2.0) and higher in organic content. The total water •
volume is estimated to be 65 to 75 percent of the soapstock treated by
weight.
Francois (55) reports that the thermo-comprpssor condensates from the
deodar;zation process constitutes a continuous wasteload high in
organic impurities or "unsaponificable" substances. Certain fatty
acid materials are concentrated within the stripping stream and are
removed by barometric condenser water where they are eventually con-
centrated in the contact cooling tower blowdown.
In general, the steps of bleaching, hydrogenation, and winterization
represent a relatively small wasteload in comparison to the above
defined unit processes. Seng (53) reports that bleaching produces a
wasteload containing a small amount of spent filter material that is
flushed down the sewer during cleanup; a source of suspended solids
found in the wastewater. In the hydrogenation process very small
amounts of nickel catalyst sometimes reach the sewer from cleanup
operations. In the winterization process, the only wastewater that
would result is from general cleanup activities.
Wastewater generation for the plastidzing and packaging of shortening
is quite different from that of margarine processing. In general,
filling rooms that process shortening require much smaller volumes of
cleanup water than do packaging operations that require the maintenance
of bacteria free filling equipment. The packaging of margarine, salad
dressings, mayonnaise, and other milk products capable of supporting
pathogenic bacteria require daily cleaning and sterilization of all
filling equipment. Therefore, margarine processing produces a larger
volume of wastewate- containing high strength disinfectants (chlorine,
detergents) in comparison to shortening and table oil filling rooms.
Beverages
Halt Beverages - The sources of pollutants from the malt beverage Industry
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can be documentated on a plant by plant basis. There are no process
variations justifying further subcategorization of the industry. As
discussed In Section III, one brewing company uses beeehwood chips
during fermentation. The cooking and washing of the chips, as well
as yeast recovery from the chips, creates unit process wastes different
from other brewers.
Malt - All maltsters in the United States process maU by steeping,
germinating, and kilning. Most of the resulting wastewater is associ-
ated with steeping, and all plants use submerged steeping. Process
variation 1s not considered to be a factor for further subcategorization
of the malt industry because of the uniform nature of the process.
Wine, Brandy, and Brandy Spirits - Data and field observations support
the contention that wineries operating stills have considerably higher
wasteloads in the distilling (crushing) season than those who do not
operate stills. Wastewater from stillage represents a 300 percent
Increase over normal wasteloads.
Distilled Spirits - Grain distillers must be subcategorized according
to whether triey do or do not operate stillage recovery systems. Those
plants which do not operate stillage recovery systems generally sell
wet spent stillage as cattle feed and consequently do not generate
a wasteload from stillage recovery (condensate from evaporation).
Molasses distillers stard as a separate subcategory since a majority
neither recover nor sell stillage, but dispose of it directly to the
ocean.
Soft Drinks - There are basically three types of soft drink plants:
1) those that produce only canned drinks, 2) those that produce only
bottled drinks, and 3) those that produce both bottled and canned drinks.
From a process point of view, there is a discrete difference between
bottling and canning operations -- the former Involves bottle washing
while the latter is primarily a mixing-filling operation.
As documented in Section V, the pounds of pollutant per unit of produc-
tion are decidedly less 1n canning plants than in bottling or bottling/
canning plants. This difference is due primarily to the wastewater
generated by a bottle washer processing returnable bottles. This
difference ^n wastewater will vary depending on the percent of returnable
or non-returnable bottles processed.
Therefore, based on process variations, available data justifies two
subcategories of soft drink production: 1) those operations producing
only canned drinks and 2) those operations producing only bottled drinks
and others producing both bottled and canned drinks.
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Coffee - Virtually all production processes are common to all producers
of roasted coffee as a final product. These include: 1) raw material
storage and weighing, 2) air cleaning, 3) blending and roasting, 4)
grinding, and 5; packaging. Coffee roasting requires no process water,
with two exceptions. First, some plants use a water spray to check the
roasting process, but this water is evaporated and incorporated into
the product. Second, a few plants have wet stack scrubbers which
generate small quantities (up to 200 I/day) of wastewater. Cleaning of
all coffee roasting equipment is a dry process.
Decaffeination is a separate step that may or may not exist in soluble
and roasted coffee processes depending on product requirements of the
individual plant. Water is used in the caffeine extraction process and
the rinsing of the decaffeinated green beans. The caffeine extraction
process (including equipment Cleaning) is a significant source of waste-
water volume and concentration. Even though more than one decaffeination
technique is recognized to exist, available wasteload data does not sub-'
stantiate a clear basis for differentiating among the process for effluent
guidelines development purposes.
The :ible coffee process utilizes water to extract the soluble coffee
from .he.- ground roasted coffee. General plant cleanup, extractor equip-
ment leaning, and drying tower cleaning are significant sources of
wastewater volume and concentration. Freeze drying and spray drying
are the normal methods of preparing soluble coffee for marketing.
Available data does not warrant differentiation between the freeze-dried
and the spray-dried product.
Tea - The instant tea manufacturing process is essentially uniform througn-
out the tsa industry. As noted in Section III, one source of process
wastewater generated from instant tea manufacturing is the periodic
dumping of clarifier sludge when regeneration of tea extract from the
sludge becomes minimal. Equipment cleanup water is the major source of
process wastewater. The production of blended tea involves no process
wastewater generafcn and may te designated a dry process. Subcategori-
zation of the tea manufacturing industry to account for process difference:
between instant tea and blended tea production is necessary.
Flavoring Extracts apd Syrups - The processes involved 1n the manufacture
of flavoring extracts and syrups include solvent extraction, distillation,
expression, evaporation, dehydration, and blending. These individual
processes are discussed in Section III of this document. The small
amount of information available from the industry for these products
indicates that most flavoring extract plants perform blending, as well
as several of the extraction processes listed above, and possibly some
dry spice grinding and blending. The one exception to this is the pro-
duction of beverage bases, the majority of which are produced by major
soft drink companies In plants solely manufacturing beverage bases.
Most beverage base plants purchase rather than produce the flavoring
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DRAFT
materials used and the principle process is merely one of blending.
The separation of beverage base plants from flavoring extract plants
is further reinforced by the fact that more wash water is used in the
former.
Bakery and Confectionery Products
Bakery Products - In the production of bread and other baked products,
except cookies and crackers, bread and bun production are virtually
Identical and can be separated from cake and pie production because
bread production requires no filling, icing, enrobing, or other
finishing operations. Additionally, significantly less cleaning of
equipment is necessary. In bread production, pans are rarely, if
ever, wet cleaned. Other equipment is only cleaned weekly.
Cakes, pies, and sweet yeast goods can be produced by methods which may .
or may not require pan washing. This difference plays a major role in
the strength of a plant's wasteload. The BOD of pan wash water has
been reported (7) as high as 54,000 mg/1.
Many processes are common to all cookie and cracker manufacturers.
These include: 1) mixing, 2) baking, 3) cooling, 4) stacking, and
5) packaging. Principal variations in the other processing steps are
the result of the category or style of the end product. The principle
process variations are the forming, oiling, and icing, or enrobing,
procedures. Forming of cookies is usually done by either rotary dyes
cr extruding machines while crackers are formed by sneeting or stamping
the dough. The forming equipment in both cases is dry cleaned with
the exception of rotary formers. This wet cleaning of the rotary formers
is not, however, a significant source of wastewater strength, although
it does contribute a relatively small amount to the volume. Some types
of crackers are sprayed with oil following baking in order to help
improve the flavor. The equipment used for the oil spraying of crackers
Is normally not wet cleaned, and is therefore not assumed to be a con-
tributor to the wasteload. Certain varieties of cookies are either iced
or enrpbed. In the cleaning of this equipment is additional source of
waste. However, virtually all plants produce a variety of cookie and
cracker products and discharge a combined effluent. As a result, avail-
able data does not justify further subcategorization of the cookie and
cracker Industry on the basis of process variations.
Candy Confectionery Products - The candy and confectionery industry pro-
duces a wide range of products and employs a number of different pro-
cessing methods. However, some common denominators in processing lend a
certain amount of homogeneity. The several diverse processes have in
common a "candy kitchen" for the initial preparation of the candy base
and it is at this point that most cleanup water is used and most waste-
water generated, regardless of what later processing is involved in pro-
ducing the final product. Glazed fruit production, however, employs
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processes which generate wastewater with distinct treatment generations.
The glazed fruit process often involves a bleaching of the fruit and
subsequent discharge of sulphur dioxide.
While the production of chewing gum and chewing gum base involves rather
similar processes, sodium hydroxide is used as a bleaching agent in the
preparation of chewing gum bases and presents a pH characteristic which
must be given consideration in treatment.
In the production of chocolate and cocoa products from cocoa beans, the
Incompatability of moisture in chocolate requires a careful control of
the use of open water. However, large volumes of water are used in
several aspects of the process, e.c., cooling water. These establish-
ments characteristically discharge large volumes of water of a relatively
low waste loading.
Pet Foods
The principal variations in pet food processing result from the type of
product being produced. The dry pet food product does not require
processing of fresh and frozen meat and meat by-products. The processing
of fresh and frozen meat and by-products requires an extensive separate
sequence of specialized equipment which may include grinders, screw
conveyors, slurry tanks and interconnecting piping. All of the special
meat handling equipment is a significant source of waste generation duHng
operation and cleanup. In contrast the dry pet food operation is composed
of almost entirely dry ingredients which may require only dry grinding
prior to expanding.
The canned pet food product differs from the dry and semi-moist products
because of the .necessity for the can filling--can washing retort oper-
ation. The canning operation is a signficant source of wastewater volume
in organic pollutant generation.
In terms of processing steps, the soft moist product Hes between the
canned and dry product in terms of number of processing steps and resultant
waste generation. The soft >noist product will normally utilize some fresh
or frozen beef products and by-products and will therefore have a prelimi-
nary meat processing line. In formulation, the soft moist product is
generally similar to the low-meat canned product except for the lower
moisture level and the addition of preservatives. The soft moist product
does not go through a canning operation.
The extruding and expanding operations using soft moist and dry pet food
manufacturing are not major sources of waste generation. Equipment is
typically cleaned daily producing a short-term, high strength waste which
is relatively Insignificant in terms of pollutant generation per volume
of production.
These variations in production processes result in substantially different
waste generations per ton of production, as described in Section V and
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support the subcategorization of the industry into canned, soft moist,
and dry pet food.
Miscellaneous and Specialty Products
Shell Egg Handling and Egg Processing - Shell egg handling and egg
processing are distinct operations in that shell egg handling involves
storage, washing, oiling, handling, and grading of eggs in the shell,
while egg processing utilizes shell eggs as a raw material, whether
broken on the premises or by another processor, and produces dried,
frozen, or canned eggs or albumen. Food and Drug Administration
regulations require that all egg products be pasteurized. The type
of products produced varies widely among egg processing plants and
even within a given plant as a result of changing seasons and demands; •
however, available data on wastewater generation preclude further sub-
categorization.
Frozen Specialties - While many production processes are common to all
frozen specialty manufacturers, variations do occur in some processing
steps as a result cf the style of end product. However, these process
variations are not considered to be of significant magnitude to justify
further subcategcrizatiori of the frozen specialties industry.
Non-Dairy Coffee Creamer - The production of both liquid and powdered
non-dairy creamer nas the following unit processes in common: 1) mixing,
2) pasteurization, and 3) homogenization. Following the homogenizing
of the liquid product, the unit processes differ in that the product
to be powdered is dried while the product to remain a liquid is cooled.
Based on existing evidence, this p-oduction variation does not cause an
appreciable difference in wastewater generated per ton of solid product.
The distinction of solid product is necessary because liquid creamer is
approximately 50 percent water by volume.
Cleanup water from clean-in-place systems is the major source of waste-
water, the quantity and character of which would be the same for both
liquid and powdered.creamer. Consequently process variations do not
substantiate further subcategorization of the non-dairy creamer industry.
Ice Manufacturing - Block and fragmentary ice are produced by signifi-
cantly different processes, as detailed in Section III of this document.
Block ice is produced by partially submerning rectangular cans filled
with water in refrigerated brine tanks. Fragmentary ice is produced
as small pieces, such as disks or cylinders, by machine* especially
designed for that purpose.
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The major volume of wastewater in many block ice plants Is once-through
cooling water discharge. In addition, wastewater may be generated in
the production of block ice from treatment of incoming water, dipping
of the cans to loosen the ice; replacement of the unfrozen core with
fresh water; ice and snow losses; and from scoring, cutting, and crushing.
Conversely, block ice plants that follow good water conservation practices
do not generate these large volumes of wastewater. In fact, some block ice
plants generate less wastewater per kkg of production than fragmentary
ice plants. The quantity of wastewater is dependent upon primarily
plant management rather than process variations.
Fragmentary ice making machines are semi-automatic. Wastewater is
generated from excess water not frozen, defrost water, and blowdown.
The range in quantity of wastewater is relatively narrow, because it
is not highly operator-dependent.
Therefore, although block ice and fragmentary ice processing methods
differ, data indicates no appreciable difference in organic loading,
suspended solids, or potential treatment for the wastewater generated
by the respective processing methods. No further subcategorization of
ice manufacturing is justified.
Yeast - The production processes necessary to produce corcnercially
acceptable yeast are standard throughout the industry. These include:
1) raw material storage and preparation, 2) fermentation, 3) separation
of the mature yeast from residual nutrients, 4) dewatering, and 5)
packaging. Spent beer wash separated from the yeast by centrifugal
methods accounts for over 70 percent of the pollutant loading of com-
bined wastes. Spent nutrients, which may comprise from 15 percent to 50
percent of the total waste volume, depending on dilution water use and
reuse, have a BOD of 2000 to 15,000 mg/1. Although these process vari-
ations cause differences in combined waste volume, no substantial dif-
ferences in waste generation per unit of production were found. Spent
beer is normally discharged to a sewer or pumped to an evaporator for
molasses by-produci: recovery. Yeast dewatering practices, using filter
presses and rotary vacuum filters, constitute the second largest waste
stream in most yeast pla.its. Since there are virtually no differences
in the equipment and procedures used in yeast factories, no basis for
further subcategorization is judged tc exist.
-(
Vinegar - As illustrated in Section III, the process of vinegar pro-
duction is a discreet operation resulting in a wastewater differing
in characteristics from that of other food and beverage processors.
Pectin - As illustrated in Section III, the production of pectin is a
unique process distinctly different from any other in the miscellaneous
foods and beverages industry. This process variation results in a
wastewater with significantly different characteristics as compared to
that of other food and beverage processors.
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ORAFV
Bouillon Products - The process involved in bouillon production is
unique in its simplicity and the fact that equipment cleanup water
Is the only source of wastewater generated in the process.
Peanut Butter - All peanut butter processors roast,.blanch, inspect, and
grind shelled peanuts to produce peanut Lutter. All of these are dry
prtcess steps, although water is used in heating, cooling, and aeration.
In packaging operations, soir.s plants remove the product from partially
fi'lled or improperly sealed jars, and then wash the jars before refilling.
Jar washer discharge is a low volume, concentrated wastestream which
significantly increases plant waste generation per unit of production
when sewered. The increased wasteload from jar washing constitutes a
strong basis for subcategorization of this industry. Other weTtestreams
include floor and equipment cleanup.
Chili Pepper and Paprika - The unit processes employee by the paprika and.
chili pepper industry are generally uniform. New techniques from time
to time have been employee1 to effect reouced volumes and/or strengths of
liquid process wastes. Special efforts have been made on those produc-
tion processes which generate the greatest amounts of pollutants: wash-
ing, fluming, and chopping. It may be concluded that the use cf alternate
process equipment may substantially reduce raw waste generation.
Sines the new technic^es are not entirely proven, they are viewed as
being pollution control options rather than a basis for subcategorization.
Subcategorization on the basis of these new methods is considered to be
inequitable for several reasons: 1) the new techniques are largely still
experimental for most commodities; 2) the magnitude of the new tpchniques'
effect upon raw waste load reduction is still largely undetermined, and
3) the establishment of <* separate (more stringent) subcategory now for
those plants which are attempting pioneering efforts would be unreasonable.
Prepackaged Sandwiches - As described in Section III, the wastewater
generated by the production of prepackaged sandwiches results from the
cleaning of utensils and other equipment, and from floor washing. No
justification for further subcdtegorization of the prepackaged sandwich
industry has been determined to exist.
Baking Powder, Chicory, Bread Crumbs - These processes have been identified
to result in no water use or process wastewater generation and may therefore
be appropriately considered as "dry" operations.
Miscellaneous Products - The preparation and packaging of popcorn, molasses,
the various syrups, honey, prepared gelatin desserts, dehydrated soup, and
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the various macaroni products, while involving diverse operations, is
characterized by low levels of wastewater generation. Therefore, no
further subcategorization of these products is considered justifiable
on the basis of process variations. For the purposes of effluent
guidelines development, these products have been given the designations
El through E6.
RAW MATERIAL VARIATIONS
Vegetable Oil Processing and Refining
Unrefined Vegetable Oils - With the exception of olives, available data
do not justify subcategorization of unrefined vegetable oil production
on the basis of raw materials since most processing plants crush dif-
ferent oilseeds at various times. Raw material and process variation
are to some extent interrelated since processing techniques are often
specially related to the type of oilseed being processed. Solvent
extraction is the most common method used to extract soybean oil v;hile
cottonseed oil is usually extracted by screw press operations.
A significant difference in wastewater characteristics results when olives
are processed for olive oil. As <:ndicated in Section V, a considerably
more concentrated wastc.;tream results from the handling of whole olives
and olive pits as compared to other oilseeds. Therefore, it is necessary
to place the production of olive oil into a separate subcategory from
other oilseed processing. No further subcategorization is justifiable as
a result of raw material variations.
Edible Oil, Shortening, and Margarine - Variations in raw materials offer
no justification for further subcategorization of edible oil, shortening,
and margarine (excluding olive oil). The refining of different oils dee1;
generate different wasteloadings, but a given plant frequently changes
the type of oil being refined and refines more than one type at one time.
As a result, there is no basis for further subcategorization of the
industry on the basis of raw material variations.
However, olive oil refining is done exclusive of other oils and generates
a distinctive wastestream. Therefore, olive oil refining must be con-
sidered as a separate subcategory.
Beverages
Malt Beverages - Raw materials for the brewing industry include malt,
cereal, grains, hops, and yeast. In terms of wastewater generation,
there is essentially no difference in the raw materials utilized within
a brewery. Some breweries use hop extracts instead of hop flowers,
thereby eliminating the spent hop disposal problems, but the disposal
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DRAFT
practice with spent hops is normally the addition of this material to
spent grains. No further subcategorization of the malt beverage
industry as a result of raw material variation is justified.
Malt - Although different types of barley are used for the production of
malt, data presently available does not substantiate any differences in
wastewater generated. No further subcategorization is justified based
on raw material variations.
Wine. Brandy, and Brandy Spirits - Wineries in the western United States
use the V^. Vinifera variety of grape and those in the east utilize the V_.
Labrusca variety!The eastern grape is lower in sugar and higher in
acidity than the western grape. Although eastern wineries practice
amelioration prior to fermentation, there is no data existing to indicate
that the type of grape, per se, creates a difference in wastewater dis-
charged. Therefore, no further subcategorization of the industry as a
result of raw material variations is considered justifiable.
Distilled Spirits - Differences in raw materials contribute to differences
in processes as a rationale for subcategorizing molasses versus grain
distillers. Citrus and blackstrap are used in molasses distilleries
whereas corn, rye, and malt are used in grain distilleries.
It should be mentioned that any grain distiller utilizing a 100 percent
rye mash bill may generate a higher wasteload than that from a straight
whiskey mash bill, although current data does not indicate the justifi-
cation of a separate subcategory for this type of operation.
Soft Drinks - Since diet soft drinks inherently utilize less sugar during
processing than regular soft drinks, lower wasteloads might be expected.
Diet soft drink production, however, is generally less than 10 percent
of the production at any one plant. Available data indicate the waste
characteristics of plants utilizing diet soft drink production to not
be significantly different from other operations. Further subcategori-
zation on the basis of raw material variation is not felt to be justified.
Coffee'- Coffee processors utilize green beans as the basic type of raw
material, with two exceptions. Some producers utilize partially roasted
green beans as their raw material. However, since coffee roasting is a
dry process, this variation does not require further subcategorization.
Second, at least one producer of soluble coffee products imports a coffee
extract from which to manufacture the desired product. This procedure
produces less wastewater than the production of soluble coffee from ground
roasted coffee, but technical deta is not available to support further
subcategorization of the soluble coffee process. Further subcategori-
zation of the coffee processing industry on the basis of raw material
cannot be justified because the industry has adequate control over its
raw material quality and basically the same raw materials are used by all
manufacturers.
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Tea - Raw materials in the tea industry consist of tea leaves imported
?rom various parts of the world. There is no reason to believe, nor do
available data indicate, that there is any difference in wastewater
resulting from the variety of tea leaves utilized. Therefore, no further
subcategorization of the tea industry as a result of raw material vari-
ation is justifiable.
Bakery and Confectionery Products
Bakery Products - All baked goods manufacturers utilize raw materials
such as flour, sugar, shortening, and water. In the production of bread,
these are the only major ingredients. In the production of cakes and
pies, fruit, chocolate, spices, flavorings, and a larger amount of
s.ugar are consumed in addition to those ingredients used for bread pro-
duction. The result of this difference in ingredients is a significant
difference in the wastewater volume and strength generated by the pro-
duction of bread and the production of cake and related products. The .
ingredients used in the production of cake require more frequent wet
cleaning of the equipment associated with their preparation. The large -
amounts of sugar used in cake production also contributes significantly
to the strength of the wastewater discharged.
These variations in raw materials result in substantially different
waste generation per unit of production, and support the recommended
subcategorization of bread vis-a-vis rake products.
All cookie and cracker manufacturing plants utilize the same basic types
of raw materials or ingredients. As detailed in Section III of this
document, these ingredients include flour, sugar, shortening, and
assorted additives, flavorings and colorings. In the production of
crackers, these are the only major ingredients. In the production of
cookies, chocolate is also a major ingredient and a much larger amount
of sugar is consumed per kkg of product. The result of this variation
is undoubtedly a greater wasteload from cookie production than from
cracker production. However manufacturers normally produce both prod-
ucts and discharge a combined effluent. Consequently, no data exists
to support the further subcategorization of the cookie and cracker
industry on the basis of raw material differences.
Candy and Confectionery Products - The refined condition cf sugar and
corn syrup, the major ingredients used in the confectionery industry,
leads to no requirement for pre-cleening or pre-processing. The same
situation is true for chewing gum which uses natural gum base as a
prime ingredient. In contrast, the cleaning of raw materials for gum
base and for chocolate and cocoa products generates wastes of signifi-
cant differences. In general, while raw material variations lend sup-
port to the subcategorization proposed because of process variations,
further subcategorization is not justified.
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DRAFT
Pet Foods
All pet food plants use the same basic types of raw materials or ingre-
dients. As detailed in Section III of this document, these ingredients
fall into the following general categories:
1. Meat and meat by-products,
2. Poultry and poultry by-products,
3. 'Fish and fish by-products,
4. Cereal grain and grain products principally derived from
soybeans, corn, wheat, barley, and oats,
5. Vegetables, fresh, frozen, and denydrated,
6. Sugars and syrups,
7. Gums and food starches,
8. Milk based products,
9. Fats and oils,
10. Minor ingredients such as flavorings, vitamins, minerals,
colors, preservatives, and others.
In general, the raw materials listed above have to some extent been pre-
processed elsewhere prior to arrival at the pet food manufacturing plant.
For example, the meat and meat by-products are typically delivered from
meat-packing plants where the animals have been slaughtered and dressed.
Accordingly, the pet food manufacturer has good control over the quality
and condition of his raw materials. If they do not meet standards- he
may refuse to accept them.
The formulations used by different manufacturers in preparing various
styles of dog and cat food are described in Section III of this docu-
ment. Generally, all or most of the ingredients listed are used to
some extent in each formulation. The principal differences are in the
respective percentages of animal and grain derived ingredients used.
The ratio of meat (fish) to dry ingredients has a profound effect upon
raw waste generation and strength. Results analyzed from twelve canned
pet food plants in Section V show that the organic pol'tutants strength
of the raw wastes generated increases significantly with increase in use
of fresh and frozen meat (fish) and meat (fish) by-products (not including
dry meal). Thus, the data support the subcategorization of the canned
pet food industry into high-meat (fish) and low-meat (fish).
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Miscellaneous and Specialty Products
Shell Egg Handling and Egg Processing - All egg procassors utilize shell
eggs as the predominant raw material, whether broken on the premises or by
another processor. Sugar, salt, and assorted food additives are also
utilized as raw materials by some processors. However, these additional
ingredients do not produce a wasteload which distinguishes plants utilizing
them from plants which process only egg products. The strength and
cleanliness of the eggs' shell also varies. However, insufficient data
"exists for subcategorization on this basis. The chemical composition of
eggs is primarily responsible for the characteristic;; of egg processing
wastewater and consequently for the need for a single egg processing sub-
«gory.
processing plants break (and sometimes pasteurize) eggs for shipmen't
to other processors for pasteurizing, drying, freezing, or canning. How-
ever, available data does not justify a separate subcategory for egg pro-
cessors who do not break eggs.
Frozen Specialties - Frozen baked goods require rich ingredients such as
butter, sugar, cream, etc., and these are purchased in bulk, received,
blended under controlled conditions, further assembled into final product
form, sometimes baked or fried, and packaged and frozen.
The frozen baking dessert plant must thoroughly clean with hot water all
the mixing vats, cooking kettles, measuring devices, pumps, piping, etc.,
which have come in contact with the ingredients and product. This cleanup
is continuous during plant operation as different products are manufactured.
For example, one section of the plant may run several different kinds of
pies during a shift. A peak 1n cleaning is normally reached during tne
massive final cleanup at the end of operation each day.
The ingredients for frozen T.V. di.mers and ethnic foods usually include
meat, fowl, or fish, vegetables, gravies, and minor additives. In
addition, there may be added starrhes (such as noodles), grains (such as
rice), and a variety of small dessert dishes. These ingredients are
usually prepared el severe and are then further processed, cooked,
assembled, packaged, and frozen at the prepared dinner plant. The bulk
of the wastes generated originates from preparation of the ingredients.
Prepared poultry arrives at the processing plant in a form ready for
deskinning and deboning (if desired). Beef and other meat normally arrive
iri bulk. Some vegetables, such as carrots that require a longer cooking
may be partially precooked prior to being brought to the assembly
Potatoes are usually prepared from dehydrated potato products.
The primary wastewater generation results from equipment and container
cleanup, and the differences in ingredients greatly affect the
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DRAFT
characteristics of the wastewaters. Raw material variations further
support the subcategories proposed above for frozen specialties. No
further subcategorization is felt to be justified.
Non-Dairy Coffee Creamer - Raw materials used in the manufacturing of
liquid and powdered creamer are discussed in Section III. The main
difference in raw materials between the two products is the use of
sodium caseinate, mono- and di-glycerides, sugar and fatty acids in
the production of liquid creamer. However, the percent by volume of
these materials in the final product is small and has insignificant
effects on the wastestream. Therefore, raw materials variations do
not necessitate further subcategorization of the industry.
Flavoring Extracts and Syrups - The raw materials used by the flavoring .
extract and syrup industry include whole plants, plant tissues (fruit,
stems, leaves, etc.), essential oils, synthetic flavoring extracts,
alcohol, acids, sugar, solvents, and colors. These materials are
generally used by all flavor producers. The 5xceptions are the beverage
base producers which use only natural and synthetic flavoring extracts,
acids, sugar and colors in their production. The distinct difference
in raw matarial usage further supports the previous subcategorization,
but does not justify further subcategorization.
Ice Manufacturing - All ice manufacturers utilize potable water as their
raw material. It may be supplied by the local purveyor or a well. In
many areas, the water availaote is not satisfactory for the production
of quality ice. Treatment of the incomvg <-;ater may contribute some
additional concentration of minor pollutant parsmetars to the wasteload,
but further subcategorization of \ce manufacturing is not justified by
this difference alone.
Yeast - Cane and beet molasses is the .irirnary row material used in growing
yeast. Differences in such diverse factors as SLga- coi.tent, trace metals,
and minerals, phys-'cal stratification, anino aciV content and mix and
nutrient content may produce daily variations in the totel plant wasteload
due to the controls used in batch processing of yeast. Since all processors
are subject to the same raw material variations, no further subcategorizaf:cn
on the basis of raw materials is justified.
Bouilion Products - The nature of raw materials used in the manufacturing
of bouillon products result in a wastewater high in proteins and thus hi only
biodegradable. Therefore, raw materials usage supports subcategorization
of bouillon products as a discrete suocategory.
Peanut Butter - All processors use shelled peanuts as tue primary raw
material. Small amounts of salt, sugar, stabilizer, and other ingredients.
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DRAFT
are added to improve product quality. Raw material quality may affect
roasting and grinding parameters, but there are no existing data to
document any effect on wasteloads from jar washing and cleanup.
Chili Peppers and Paprika - Paprika and chili peppers, as explained in
Section III, are virtually identical raw products, indistinguishable
except for taste. Some of the contributing variables influencing raw
material quality as it arrives at the processing plant include the
following:
1. Physical quality:
- Dirt and foreign objects - type of soil
- Weather at time of harvest - muddy fields
- Unfavorable climatic conditions - yield decreases
2. Biological quality:
- Climatic influences, drought, etc.
- Insect damage
- Bacterial or mold damage
It is not considered necessary, however, to subcategorize on the basis
of such unpredictable events which would usually be localized in
occurrence. It is concluded that variations in raw product quality
are normal and should be expected from week to week and season to sea-
son. Therefore, the waste management program should be designed with
sufficient flexibility to handle the problems inherent in the industry
due to expected raw product quality variations. It is also suggested
that a processing plant attempt to work out beforehand with its regu-
lating agency an emergency plan to handle a situation where uncontrol-
lable significant deterioration in its raw product quality may cause
subsequent upsets in treatment facilities.
Other variables which influence raw product quality and which are to
some extent under the control of the processor are listed below:
1. Harvest method,
2. Type of container and length of haul,
3. Degree of preprocessing in field, sorting, and
washing.
These variables should be considered when control options are being
considered to help meet the best available treatment limitation for
1983. They are not completely capable of quantitative evaluation
at the present time, but are deemed to represent good engineering
practice and pollution reduction benefits.
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DRAFT
PLANT AGE
The effective age of a processing operation is usually difficult if not
impossible to define — the reason being that there is often little
correlation between the age of a plant building and the age of the
equipment within the building. A processor may constantly replace worn
out equipment with new equipment, or, in some cases, install old equip-
ment in a new building. In general, data is not available or is it
likely to result to support clean differences in waste generation and
treatability within the overall miscellaneous foods and beverages industry
on the basis of plant age alone.
One very notable exception occurs in the malt beverage industry. The
construction of breweries has for the most part occurred prior to 1900 .
or after 1950, with the exception of those built immediately after the
repeal of prohibition. Data indicates that differences in the wastewater-
loading as well as the applicable control and treatment technology, is
significant. Basically, the older breweries were not designed with waste
disposal in mind. Smaller tankage is coi.imoii in the older breweries, thus
providing more surface area, and making cleanup more difficult. Older
mashing vessels do not separate grain as effectively as newer ones, thus
creating additional loads for by-product recovery operations. Intricate
and often unknown plumbing systems make isolation and segregation of
wastestreams economically impractical.
On the other hand, breweries built after 1950 have been increasingly aware
of wastewater disposal. Newer pUnts feature efficiently designed vessels
in conjunction with automated cleanup. Wastes which might be sewered in
an older brewery are reused or added to by-product recovery in the newer
brewery. Plant design in the last few decades has allowed for ease in
waste collection. Wastewater monitoring has identified problem areas and
plant personnel are subsequently trained to be more cognizant of these
problems.
Otherwise, age of plant provides no rationale for further subcategoriraticr
of f.he.miscellaneous foods and beverages industry.
PLANT SIZE
The size of the plant may be significant fr'vn both a technical and econonic
point of view. On the technical side, no correlation to justify a sub-
categorization on the basis of size was found between plant size and either
raw waste characteristics or wastewater volume, except in the malt beverage
industry.
Plant size is more important from an economic viewpoint. Virtually all
in-plant and end-of-pipe waste reduction technology is subject to economy
of scale, and the larger plant will almost always benefit from economy of
scale.
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In the malt beverage industry, .;ize of plant correlates to subcategori-
zation based on plant age. Plants constructed after 1950 have for the
most part been constructed for a production of more than 800 cu m (7000
barrels) per day due to the tendency for demand to be met by large
capacity. It can be expected that this trend will continue and any
future plants will be both large and automated.
Although there is no strict correlation between brewery size and waste
generation, a generalization may be logically made about old, large
breweries. These plants tend to be situated over relatively large areas
with segmented operations occurring in different buildings. The product
must be transferred more frequently and farther; supervision and consoli-
dation of wastes are more difficult. Therefore, size of plant is another
key factor in the subcategorization of breweries, but is not considered
as an element of subcategorization for other products.
PLANT LOCATION
Plant location can be an important economic factor determining the
availability of suitable land, and of municipal treatment facilities.
Other potential effects connected with plant location include the fol-
lowing:
1. Both climate and weather affect end-of-pipe waste treatment
processes. Variations in temperature, rainfall, evaporation
rate, and sunshine can all affect the performance of different
types of treatment systems. This has been taken into account
to the extent possible in the selection of control and treat-
ment alternatives in Section VII. While variation of per-
formance of treatment systems has been recognized, it 1s known
that high loads of pollutant removal efficiency can be main-
tained under variable climatic conditions with proper design,
operation, and maintenance.
2. Availability of solids disposal facilities or marketing op-
portunities near the plant. The cost of solids disposal
(screenings and sludge) varies considerably depending on
local situations.
3. The quality of the receiving water and the state industrial
discharge limitations being imposed. Plants located in areas
designated by a state as being water quality limited generally
have to meet very stringent requirements.
The factors listed above are local in nature and cannot be considered as
factors for subcategorization for industries located throughout the
United States. In general, the technologies developed for reaching the
recommended effluent limitation guidelines set forth in this document are
largely land-independent. Use of land-based treatment measures where
this option exists may in many instances substantially reduce the cost of
effectively achieving the recommended effluent reduction level.
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Of all the products within the miscellaneous foods and beverages industry,
the one most definable by location is wine spirits production. As pre-
viously mentioned, virtually all of the wineries producing spirits are
located in the San Joaquin Valley of California. These factors, however,
merely serve as substantiation of the subcategoriza.tion dictated by pro-
cess variations and do not justify further subcategorization of the
industry.
PRODUCTS AND BY-PRODUCTS
Many of the types of plants discussed in this document produce a variety
of products and by-products -- some change products with the season or
as the market demands, others produce varying styles of the same product.
There is no question that the nature of the products and by-products
produced by a plant usually affects the wastewater of that plant; however,
the subtategories previously developed adequately account for these effects.
No further subcategorization on the basis of products and by-products is-
warranted.
CLIMATIC INFLUENCES
Influences of climate correlate closely with plant location discussed above,
and it is impossible to subcategorize nation-wide industries or the basis
of climate. The location of virtually all wineries with stills is in the
San Joaquin Valley where the climate is relatively dry thereby encouraging
the use of land disposal of wastewater for this previously defined subcate-
gory.
SEASONAL VARIATIONS
The seasonal demand of a number of products in the miscellaneous foods and
beverages industry, e.g., soft drinks, beer, candy has been discussed under
the topic of process variations. Certain raw materials are available on a
seasonal basis. These include various fruits, vegetables, and perhaps
most notably grapes. The availability of grapes restricts the pressing
(crushing) season to a short period of time during the fall of the year.
Since the material for distilling is generating in the pressing season,
distilH-9 takes place at the same time as pressing with a small amount of
time lag. Although this factor doef not directly lead to subcategorizution,
it supports the subcategorization for the distilling industry.
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SECTION V
WATER USE AND WASTE CHARACTERIZATION
The purpose of this section is to identify, for those subcategories
defined in Section IV, the wastewater quantities and constituents which
are characteristic of the subcategory. For each subcategory discussed
herein, a representative model is developed and defined in terms of
wastewater flow and characteristics.
It should be carefully noted that within this document, all pollutant
concentrations and loadings, unless otherwise specified, are in terms
of net units. i.e., do not include pollutants entenng the process
in the fresh water supply.
•
It should also be noted that the raw wastewater flows and character-
istics described for each model plant are intended only to be represent- "
ative of the subcategory, primarily as a basis for developing control
and treatment technology and cost analyses to be developed subsequently
in Sections VII and VIII of this document. These valuer should not under
any conditions be construed as being exemplary nor used as a basis
of pretreatment guidelines for industrial discharges into publicly
owned treatment works.
All pollutant parameters {except oH, color, and temperature) are
ultimately expressed as a ratio of thei> mass in kilograms to a process
unit. The process unit may be kkg or cu m (or in one case proof gaTicns.',
of product or raw material produced or consumed per day. Tabl3 16
defines the process units used for each subcategory.
VEGETABLE OIL PROCESSING AND REFINING
That segment of the miscellaneous foods and beverages industry involved
in the processing and refining of vegetable oil (including the production
of margarine) has been subcategorized into subcategories A 1.through
A 15 (see Table 13 in Section U'.)
Subcategories A 1 through A 4 cover those installations processing un-
refined vegetable oil from various oilseeds and the production of olive
•)il by hydraulic press and solvent extraction in combination, and by
mechanical screw press extraction.
Subcategories A 5 through A lii include those installations engaged in
what can generally be called edible oil refining. The historical dat.i
complied for this study by the Institute of Shortening and Edible Oils
(ISEO) in conjunction with contractor plant visitations and verification
sampling of ten plants represents '.".he most current information available
on the wastewater characteristics of edible oil refineries. Wastewater
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TABLE 16
PROCESS UNITS EMPLOYED FOR
THE MISCELLANEOUS FOODS AND BEVERAGES
SUBCATEGORY
POINT SOURCE CATEGORY
VEGETABLE OIL PROCESSING AND REFINING
AT. A2,
A3, A4
A5 - A12
A13, A14, A15
A16, A17, A18
A19
A20, A21
A22, A23
A24
A25
A26. A27
BEVERAGES
PROCESS UNIT
kkg of oilseed
crushed/day.
kkg of raw olives
crushed/day.
kkg of crude oi1
processed/day.
kkg of finished
product.
cu m of beer
produced/day.
kkg of barley
processed/day.
during crushing, kkg
of grapes crushed/
day; during process-
ing, cu in of wine
produced/day.
kkg of grain
mashed/day.
proof gal Ions of
spirits produced/day.
None.
cu m of beverage
produced/day.
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TABLE 16 (CONT'D)
SUBCATEGORY
A28
A30
C8, C9. CIO
Fl
All Subcategories
BEVERAGES
BAKERY AND CONFECTIONERY PRODUCTS
PET FOODS
All Subcategories
MISCELLANEOUS AND SPECIALITY ITEMS
A29
A31
A32
A33
PROCESS UNIT
cu m of syrup or
concentrate
produced/day.
kkg of Instant
tea produced/day.
kkg of green
coffee beans.
None.
kkg of finished
product/clay
kkg of finished
product/day.
cu m of finished
prod'ict/day.
kkg of granular
bouilIon
produced/day.
kkg of sol id pro-
duct produced/day.
(1) kkg of yeast
packaged/day.
295
-------
DRAFT
TA3LE 16 (CONT'O)
SUBCATEGORY PROCESS UNIT
A34. A35 kkg of peanut
butter produced/
day.
A36 kkg of dry pectin
produced/day.
A37, B1-B4, C6, C12, D4 kkg of finished
?rod'ict/day.
C4, C5 kkg if raw eggs
processed/day.
E1-E6, F2-F4 None.
296
-------
DRAFT
characteristics within the industry vary widely from plant to plant due
to differences in degrees "f process variation, plant size, and the types
of oils processed daily. However, for the most part, process variation
Is the single most important factor in determining the total waste load
for a particular refining operation. The total waste loading for an
edible oils refinery is dependent upon the individual waste load contri-
butions from the various integrated process units within the refinery.
In geneva! terms, large, integrated, full scale refineries produce sign-
nificantly higher wasteloads than small, less integrated operations.
The principle sources of wa^tewater discharge within the industry are
from tne following process units: acidulation; caustic refining;
contact cooling tower blowdown from barometric condensers; tank car
cleaning; storage and handling facilities; margarine; shortening; and
tafe oils packaging; and general cleanup from oil processing procedures
s^cn as hydrogenation, bltdching, deodorization, and winterization.
Figure *2 in Section III presents a schematic diagram of tiie various
waste*at3r flews from individual process units for a typical full
scale, iitssrateci, edible nils refining operation. Table 17 presents
a summary of the waste loading characlensticsof individual unit processes
commonly associated with edible oil refineries as described in Section III.
Due to the high degree of variability in refinery plant size and process
integration, it was necessary to adopt a building block approach for
the formulation of the model plant '-d its associated unit process
waste streams. Model plants wert developed for subcategories A £
through A 14 by combining the wa:,te Ijad for the various unit processes
making up a subcatfegory. For exttnpl? the Subcategory A 5 model plant,
includes the unit processes of caustic refining, tank car cleaning and
storage and handling. A total *aste load for Subcategory A 5 was
derivea by converting a':l unit process vcste loads to a 454 kkg (5'JO icn)
oer day plant and then, by summation of the unit wast^ loads, a i;otal
waste load was assumed for each parameter. The hypothetical model
plants developed utilizing this proceoure arc intc'leJ to be representa-
tive of the subcategory as it presently exists, but cannot be expected
to oe identical to any particular pl^nt. In some us?js che model may
be representative of an act-jal refinery on'iy to a limited extent, but
in all cases the model is considered adequate for the purpose of devel-
oping control and treatment technology (Section VII) and for cost
analyses (Section VIII).
SUBCATEGORY A 1. OILSEED CRUSHING. EXCEPT OLWt 01L. PQR 3IRECT SOLVENT
EXTRACTION />ND PREPRESS SOLVENT EXTvTCTIOh OPERATIONS
A total of six direct solvent extraction plants and two prepress solvent
extraction facilities were visited and verification sampling was con-
ducted at four direct solvent extraction plants.
297
-------
TABLE 17
SUWARY OF UNIT PROCESS RAW DATA ON EDIBLE OIL REFINERY WASTEWATER
CHARACTERISTICS
Unit
Process
Caustic
Refining
Acldulation
Contact Cooling
Tower Slowdown
Oil Processing*
Tank Car
Cleaning
Storage and
Handling
Shortening and
Table Oil
Production
Margarine
Production
Production Flow BOD
KKG/DAY HJ/DAY kg/kkc
Ave. 320
Std. Dev. 221
Ave.
Std. Dev.
Ave.
Std. Dev.
Ave.
Std. Dev.
Ave.
Std. Dev.
Ave.
Std. Dev.
Ave.
Std. Dev.
Ave.
Std. Dev.
486
459
348
264
389
212
167
112
285
80
195
103
112
61
72
145
. 225
148
178
135
25
22
38
32
83
159
75
113
169
139
1.01
1.5H
4.69
5.08
3'.51
0.09
0.23
0.49
0.84
1.36
4.33
0.48
0.75
1.93
4.06
COD
). j<
-------
DRAFT
The principal sources of contact process wastewater generated from
solvent extraction operations include wastewater generated from
soybean oil degumming operations to remove and recover phosphatides
(lecithin); wastewater generated from wet scrubber systems to reduce
air participate emmisslons from mill preparation areas; wastewater con-
taining oil, grease, and solvents, resulting from the extraction of oil-
seeds; steam condensates contaminated by oils, fatty acids, or hexane
solvent; and periodic in-plant floor washing and equipment cleanup
represented by oil or miscellaneous spillage, valve or pump leakage,
etc. In addition to these process wastes, a large number of processors
were observed to combine their process wastewaters with non-contact cool-
ing water from cooling tower and boiler blowdown.
Historical data supplied by the NSPA and the National Cjttonseed Producer's
Association (NCPA) for 18 solvent extraction facilities in cc'nbi nation
with four verification surveys found the following averages for
Subcategory A 1 plants:
Production 780 kkg/day (860 ton/day)
Flow 140 cu m/day (0.037 MGD)
BOD 311 mg/1; 0.058 kg/kkg (0.115 Ib/ton)
COD 619 mg/1; 0.140 kg/kkg (0.281 Ib/ton)
SS 140 mg/1; 0.035 kg/kkg (0.07 Ib/ton)
O&G 253 mg/1; 0.064 kg/kkg (0.128 Ib/ton)
pH 6.2 to 10.4
BOD/COD Ratio 0.50
BOD/O&G Ratio 19.8
Table Id presents a statistical description of the process wastewater
characteristics compiled during the study including mean, standard
deviations, minimum and maximum values.
There was a significant correlation observed in the industry between
the volumes of process wastewater discharged per day and total daily
production as is evidenced in Figure 107. However, there was no corre-
lation indicated between production, BOD, COD, or oil and grease concen-
trations. These data are summarized by the scatter diagrams presented in
Figures 108, 109, and 110.
Total Process Effluent
As indicated in the data presented above, the pollutant concentrations
and waste loadings for solvent extraction nlants are highly variable due
to the following in-plant variations: (1) the amount of wet cleanup
and general housekeeping practices utilized by each plant, (2) the
quality of seed being crushed, and (3) plants that perform soybean oil
degumming periodically in combination with solvent extraction processes.
299
-------
TABLE 18
A STATISTICAL OESCRIPT'ON OF THE WASTEWATER CHARACTERISTICS
FOR SOLVENT EXTRACTION PROCESS WASTEWATfR
VARIABLE
Flow OttDl
Prod, (ton/day)
BOO (ng/l)
SS (rag/1)
C03 (r<3/\)
•FOG (ir.g/1)
BOO (Ib/day)
COO (lb/(H>)
SS (Ib/day)
FOr, (Ib/day)
Ib/Ion-i'OO
kg/krg-EOr
Ib/Un-tOD
kq/H^q-COD
Ib/Ton-SS
liq/kkg-5S
Lb/Ton-FOG
kq/kVg-FOC
BOD/COO Ratio
BOO/FOG Ratio
Flow Ratio
58
58
U9
52
18
«5
49
118
52
fc5
1.9
-g
(IB
(.8
52
52
"5
<-S
UO
37
58
0.01T064
3|l .367307
139.8K16I5
78.Of£"31
176.2ctlU
0.0576C1
C.37CGSU
C.0350C2
O.I27SJ7
0.06<*te
o.sojcio
STANDARD
DEVIATION
0.919112
i28,02«lM
403.98RJ8I
VAAIAHCf
0.00036S
1»5J05.555777
39301.:
3273«7.3J331I
759.7*5755 5772<-«.0025(.5
3237.27«?U2
239110.0'' 1
-------
LEGENDi 1 = OC OBSERVATION. 2 = TWO OBERSVATIONS, ETC.
0.090
0.072
0.05'.
0.036
o.oia
o.o
LINEAR REGRESSION
COEFFICIENT = +0.70
_L
J_
1910
110 470 830 1190 1550
PRODUCTION (TON/DAY)
FIGURE 107 '
ft LINEAR REGRESSION PLOT OF FLOW
-------
CJ
O
300C
2«tOC
ieoo
mo
1300
600
LEGEMD, I = OC OBSERVATION, 2 = TWO OBSERVATION. ETC.
o
30
2 l»
_L
110
830 1190
PRODUCTION (TON/DAY)
1550
1910
A SCATTER DIAGRAM PLOTTING BOO CONCENTRATION VFRSUS PRODUCTION (TON/DAY) FOR TNE PROCESS WASTEWATERS
GENERATED FROM OILSEED SOLVENT EXTRACTION PLANTS, SUBCATEGORY A l
-------
3000 r
LEGEfOi 1 = OE OBSERVATION. 2 = TWO OBSERVATIONS, ETC.
u o
2000 f-
1800 h
1200
600
i
3 •
110 470 830 1190 1550 1910
PROOIICTKIN (TON/DAY)
FICURE 109 •
A SCATTER DIAGRAM PLUTTING COfi CdinLWIKAl IONS VERSUS PRODUCTION (TON/DAY)
FIR THt. PRXESS WA3IT.S FRim OlLbttf) SOLVCNI tXlRACTIOfl PLANTS. SUBCATEGORY Al
-------
5000
400O
U)
in
<
_l
o
3000
2000
1000
LEGEhOi 1 = CTC OBSERVATION. 2 = TWO OBSERVATIONS,
ETC.
l
3
i a
> I I
« 5
I 3 II I IJ
I
i a
i i i i
I
110 470 830 1>90 1550
PRODUC TION (TON/DA Y)
FIGURE 110
A SCATTER DIAGRAM PLOTTIMG CCM^fTRATinNS OF OIL AMD GREASE VERSUS DAILY PRODUCTION (TON/DAY)
fDR THE PROCESS WASTEWATRS DISCHARGED f-ROM OILSEED SOLVEtfT EXTRACTION PLANTS, SUBCATEGORY Al
-------
DRAFT
Model Plant
The model plant for subcategory A 1 is based on the following
assumptions:
1. The model plant is assumed to have a daily •production of
816 kkg (900 ton).
2. The model plant has a flow volume of 0.144 cu m/day
(0.039 MGO).
3. The model plant may or may not have the unit process
of degumming.
4. The model plant may or may not have a wet scrubber
system for removing air particulates.
By converting the data base compiled for this study to a model plant
production of 816 kkg (900 ton) per day by multiplying by a factor of
1.05 (i.e., 816 kkg/780kkg = 1.05), the following wastewater
characteristics were derived for the Subcategory A 1 model plant.
Production 815 kkg/day
Flow 148 cu m/day (0.039 MGD)
BOD 340mg/l; 0.061 kg/kkg (0.122 Ib/ton)
COD 815 mg/1; 0.147 kg/kkg (0.244 Ib/ton)
SS 210 mg/1; 0.038 kg/kkg (0.076 Ib/ton)
04G 380 mg/1; 0.069 kg/kkg (0.138 Ib/ton)
BCD/COD Ratio 0.50
pH Range 6 to 8
SUBCATEGORY A 2 - OILSEED CRUSHING, EXCEPT OLIVE OIL. BY MECHANICAL
SCREW PRESS OPERATIONS
Seven typical n,?chanical screwpress extraction plants (three cotton-
seed crushers and four peanut crushers) were visited in conjunction
with information from the National Cottonseed Producer's Association
and the Southeastern Peanut Association. Only two sources of contact
wastewater were observed. These consisting of 1) contaminated steam
condens-ate from steam cooker operations and 2) wastewaters generated
from infrequent floor and equipment cleanup. Four sources of non-
contact wastewater were observed from the following unit processes:
1) non-contact cooling water circulated through the hollow expeller
worm shaft to keep the oilseed cakes from burning, 2) boiler blow-
down, 3) non-contact'cooling tower blowdcwn (only during the winter
months), and 4) storm water runoff. In general, the resultant con-
tact wastewater generated from screw press operation is less than
4,000 liters (1000 gallons'1 per day. Screw press operations near to
or in conjunction with an edible oils refinery dispose of wastewater
by trucking it to the refinery where the oil is recovered in the
acidulation process. Three plants were also observed to recycle their
wastewater into the boiler feed water. Due to the small volurr.e of waste-
water discharged, it is not necessary to develop a model plant for Sub-
category A 2."
305
-------
DRAFT
SUBCATEGQRY A 3 - OLIVE OIL EXTRACTION BY HYDRAULIC PRESSING AND
SOLVENT EXTRACTION
The process descriptions of the extraction of olive oil by hydraulic
pressing and solvent extraction were presented in Section III. At
present, there is only one plant which utilizes either the hydraulic
press or solvent extraction processes for the recovery of olive oil.
The only source of wastewater generated by the extraction of olive oil
by hydraulic pressing is centrifuge fruit water. Wastewater attribu-
table to solvent extraction consists of a small amount of water which
drains from pits and culls during storage, and an equally small non-
contact condenser water flow. Equipment is wiped clean.
The wastewater from the hydraulic pressing process was determined to
have the following characteristics:
Flow 10.9 cu m/day (0.0029 MGD)
BOD 63,000 mg/1
SS 14,000 mg/1
FOG 3,220 mg/1
pH 5.1
Model Plant
The model plant for this subcategory is plant 79102. Between the months
of October bnd June, the plant generally operates 24 hours per day, sever
days per w.ek with the operating schedula dependent on olive crop yield
and availability of harvesters.
The total plant effluent consists of centrifuged fruit water with the
characteristics listed above.
SUBCATEGORY A 4 - OLIVE OIL EXTRACTION BY MECHANICAL SCREH PRESSING
At present there is only one olive oil manufacturer in the United States
/hich extracts olive oil by the mechanical screw press process. Tin? ex-
traction of olive oi'l by screw press operations produces wastewater fror,
the following sources:
1. Wasning of whole ripe olives prior to pulverizing
2. Centrifuged fruit water
3. Centrifuged sludge
4. General plant cleanup
Fruit Hash Hater
Prior to grinding in the hammer mill the fruit is washed by pump
and air percolation washers. These wash tanks are filled and discharged
306
-------
DRAFT
at least once per day or more depending upon fr:;it condition. The quantity
of wastewater discharged from the washers varies between 19 cu m/day (0.005
MGO) and 38 cu m/day (0.010 MGD).
Centrifuged Fruit Water
The quantity of fruit water generated by the centrifuge is approximately
38 1/min (10 gal/min) for a total centrifuge effluent of 54.5 cu m
(0.0144 MGD). The constituents of the centrifuged fruit water indicate
a BOD concentration of 60,000 mg/1 and a fat content of 25 percent.
Centrifuged Sludge
Approximately 38 cu m/day (0.010 MGD) of centrifuged sludge is generated
from the initial centrifuge following pressing. The pollutant concentra-
tions of the centrifuged sludge were determined to be as follows:
•
BOD 48,000 mg/1
SS 51,000 mg/1
FOG 34,000 ng/1
General Plant Cleanup
Cleanup of equipment is done on an irregular basis with little generation
of wastewater. Due to the irregular nature and inherent variability of
':he cleaning operation, representation of waste flow cannot be reliably
•Jett-rmined. it is, however, reflected \f> J;he total waste discharge.
Total Plant Effluent
-The total effluent from the plant woii'd amount to approximately 114 cu
m/day (0.03 MGD) and would have the following characteristics:
BOD 30,000 mg/1
SS 57,000 mg/1
FOG 20,000 mg/1
pH 5.5
Selection of Model P.lant
The model plant, illustrated in Figure 39 in Section III, processes
44 kkg/day (48 ton/day) of olives. The total plant effluent consists
of the combined waste streams as previously presented. The plant operas
24 hours per day, seven days per week between the months of September
and April except during unpredictable harvesting lulls. The plant's
wastewater has the following characteristics:
Flow 114 cu m/day (0.03 MGD)
BOD 30,000 mg/1
SS 57,000 mg/1
t'OG 20,000 mg/1
pH 5.5
307
-------
DRAFT
SUBCATEGORY A 5-PROCESSING OF EDIBLE OIL BY THE USE OF CAUSTIC REFINING
METHODS ONLY
The individui.1 unit processes characteristic of Subcategory A 5 plants
include: (1) caustic refining operations; (2) general cleanup of
storage and handling facilities; and (3) tank car cleaning operations.
Caustic Refining
A principle source of wastewater generation from Subcategory A 5 refineries
results from the caustic refining of crude vegetable or animal oils.
Wastewater discharged from the washing of refined edible oils will
vary considerably from day to day depending upon the nature of the
crude oil being refined. Seng (53) reported an Illinois caustic refining
operation to have the following average pollutant concentrations:
BOD, 1240 mg/1; COD, 5000 rng/1; suspended solids, 690 mg/1; and ether
solubles, 1800 mg/1. The average waste loads for the Illinois plant
were: BOD, 0.27 kg/kkg (0.55 Ib/ton) COD, 1.1 kg/kkg (2.2 Ib/ton);
suspended solids, 0.15 kg/kkg (0.30 lb/tcn); and ether solubles 0.4
kg/kkg (0.8 Ib/ton). The average flow was recorded as 0.054 cubic
meters per day (0.0144 MGD).
Historical and verification survey data compiled fo- this report from
six edible o^l caustic refining operations found significantly higher
concentrations of BOD, COD, suspended solids, and oil and grease. Mean
concentrations and wasteload valuer, from all data collected were:
Production 353 kkg
Flow 75.7 cu m/day (0.02 MGD)
BOD 6,900 mg/1; 1.01 kg/kkg (2.02 Ib/ton)
COD 14,000 mg/1; 1.8 kg/kkg (3.6 Ib/tcn)
SS 3,700 mg/1; 0.5 kg/kkg (1.0 Ib/ton)
O&G 5,000 mg/1; 0.6 kg/kkg (1.2 Ib/ton)
pH Range /.3 to 11.9
BOD/COD Ratio 0.46
Table 19 provides a statistical description of the data compiled from
six refineries including mean, sample SIZP, standard deviations, minimum,
and maximur.i values. Table 20 presents a summary of caustic refining
waste loadings fran ^the six plants visited and sampled during the course
of this study. As would be expected, calculated correlation coefficient
statistics show a significant correlation between the concentrations
of BOD and COD in the caustic refining wastewater with a calculated BOD-COD
ratio of 0.46. A significant correlation also exists between the kg/kkg
of BOD, suspended solids, and oil and grease. These data indicate that
much of the hexane extractable material exists as oil attached to suspended
solids particles with a specific gravity close to that of water.
Tank Car Cleaning
The cleaning of tank cars to remove residual oil constitutes a major
waste stream associated with all Subcateqory A 5 through A 12 edible
308
-------
TABLE 19
A STATISTICAL DESCRIPTION OF THE H.ASTEWATER CHARACTERISTICS FOR
THE EDIBLE OIL CAUSTIC REFINERY PROCESS
o
5
-n
VAP1A8LE
Flo« (WG01 a
Prod. (lon/a*y) a
BOD (exj/1)
SS fi"j/l)
COC (n^/1)
•ffB (rg/l)
BCO (lb/
-------
Edible
Oils
Refinery
(Process Code)
75R08
75R09
75R15
75R17
75R05
75R06
TAbLE 20
POLLUTANT LOADINGS FOR CAUSTIC DEFINING WASH WATERS
Product ion
(kkq/da>)
424
388
310
245
227
276
Volume
Wastcwater
Discharged
(cu in/day)
29.2
331.6
36.6
54.5
31.5
56.1
BOO
(kg/kkg)
0.39
0.88
0.49
0.28
1.43
2.15
COD
(kg/kkg)
0.99
2.18
2.53
1.11
2.37
0.90*
SS
(kg/fckg)
0.55
0.11
0.38
0.15
0.36
1.46
Oil and
Grease
(kg/kkg)
0.86
0.64
0.28
0.40
O.W
0.75
o
30
* COD sample size was less than BOO sample size.
-------
DP\FT
oil refiii ny facilities. Average concentrations and waste loading of
pollutants froiii six plants were as follows:
Production 184 kkg
Flow 37.8 cu m/day (0.01 MGD)
BOD 2950 mg/1; 0.49 kg/kkg (0.98 Ib/ton)
COD 5850 mg/1 i 1.38 kg/kkg (2.76 Ib/ton)
SS 900 mg/1; 0.19 kg/kkg (0.38 Ib/ton)
O&G 920 mg/1; 0.20 kg/kkg (0.40 Ib/ton)
BOD/COO 0.42
pH Range 5.5 to 11 .9
Table 21 presents a summary table of means, minimums, maximums, sample
size, standard deviations and coefficients of covariance for tank car
cleaning operations from six edible oil refining operations. Table 22
presents a summary table of tank car cleaning wastewater characteristics
for each of the six plants investigated during this study.
Storage and Transfer
Another typical unit process waste load associated with all edible oil
refinery Subcategories A 5 through A 12 is that of wastewaters generated
during cleanup from storage, handling, and transfer areas within the re-
fining plant. Waste loads from these areas are highly variable and are
dependent on general daily cleanup necessitated by accidental spills,
leakage, or pumo failures. Averaged '•/aste load data from three planes
resulted in the following pollutant concentrations.
Production 314 kkg
Flow 75.7 cu m/day (0.02 HGD)
BOD 8, 000 mg/1; 1.4 kg/kkg (2.7 Ib/ton)
COD 21,000 mg/1; 3.8 kg/kkg (7.7 Ib/ton)
SS 5,400 mg/1; C.87 kg/kkg (1.7 It/ton)
O&G 4,200 mg/1; 0.69 kg/kkg (1.4 Ib/ton)
BOD/COD 0.51
pH Range 2.5 to 11.1
Table 23 presents a statistical description of the data compiled for this
study including irean,. standard deviations, minimum, maximum, sample size,
and coefficients of covariance for the three plants investigated.
Refinery Floor Wash
Pollutant waste loadings result from general floor washing operations
necessitated by accidental oil spill:- and pump seal leakages. In general
these cleanup procedures are intermittent, and represent a relatively minor
contribution to the total waste load of Subcategory A 5 plants.
311
-------
TABLE 21
A STATISTICAL DESCRIPTION OF THE WASTEWATER CHARACTERISTICS FOR
ZDIBLE OR REFINERY TANK CAR CLEANING OPERATIONS
VARIABLE
Flott («3\ 36
Prod, (lin/c'tyj 3b
BOO («9/l) i?
SS {rg/l) 35
CCO (*q>l) 36
•FC& Cog/l) 3*
BCD (IbXday) 30
COO (Ib.'day) 3b
SS Mo/tf»y> »5
FOC (lb/4ay) 5=
iD/Tcr.-t.'.'O I-
It: Tor-ton le>
It/Ton-iS 15
3S
3d
36
3J
1C
lb/ Ion-FCC
ECO/COO htlo
BOO/TCG tatu
Flc- Ratio
MEAN
G.C10l2a
lf3.5S2778
K.C33333
STANDA4C
Of VtAtION
o.0oa«it
VARIANCE
J.lStte7
S.IIltll
T33e.au'; 0*0
105. i
67.»-l»79
c.: <• c: 11
r.'« show no reeirri -or significant figures.
MAXIMUM
o.oaeooo
750.003000
1B27S.POOOOO
3S20.000000
HMO.000000
aeub.oooooo
35S2.St7200
752.385200
536.21*700
6.«
25.378337
12. tf>l 69
2.3M20S
1.175602
2.800913
1.(103057
1.1*6667
23.331311
U2.B57I43
COEFF1C1EKT OF
COVARUNCE (t)
JJ.077
67.145
158.S65
100.358
125. e«3
lit.138
122.«07
ltl.508
193.Ota
175.22J
170.7«2
170.742
I7U.73J
I7U.7!B
110.2l«
130.210
ISO.Jfl*
150.!S6
-------
TABLE 22
POLLL'TW HASTE LOADINGS FOR EDIBLE OIL REFINERY TANK CAR CLEANING
o
JO
Edible Oil
Refinery by
Process Code
75T05
75T06
75T08
75T09
75T10
Production
(kkg/day)
68
170
191
127
187
Volume of
Hastewater
Discharged
(cu m/day)
85.4
21.2
44.0
124.9
37.9
BOD
(rng/'l)
1.6
0.37
0.40
0.31
0.13
COD
M/l)
2.7
0.79
1.28
8.07
0.32
SS
(n»9/D
0.26
0.09
0.36
0.21
0.10
Oil &
Grease
(mg/1)
0.27
C.16
0.38
0.68
0.03
-------
TABLE 23
A STATISTICAL DESCRIPTION OF THE WASTEHATER CHARACTERISTICS FOR
EDIBLE OIL REFINERY STORAGE AND HANDLING OPERATIONS
tb/Tc>n-CCO
if »i,-CCO
Ifc/Tgn-FOC
19/kkq-fOC
600/000 DatlO
EOCVFOG Ratio
rtOM Ratio
19
19
19
IS
17
17
21
VARIABLE H NEAJI
Flew (HGD1 21 0.:
Prod. (ton/Ay) ?j
BCO (119/1} 19
55 (iwj/1) 20
COO C^/l) IS
•FOG (rcg/l) 19
E"0 (Ifa/day) 1<>
CCO fib/fair) I*
SS (Ib/sayl '"
FOG rib'fi.if)
11 ' T :'• - E^O
STAMVJID
OCVIAT10N
C.0*1975
VARIANCE
0.00
76(6.09
.i 11 til
166709u»7.oo
3.-3C79?
1 .7 a IS'?
0."71*96
-3a7l5»9.97
1767156.f3
7o.B9
16.72
2n!o3
25.73
6.08
0.01
•OT20.99
ioeoe.39
H1NIWH
o.ooeeoo
tao.eoocoo
70.0000CO
ao.ooroco
130.000000
to.ooooco
iu.Houc.0
0.096730
O.I
O.!9,»003
0. 013741
O.C02U1I
0.29cSCO
O.J0752S
|a.20llC3
• FOG • Fell. Oils, tnc greases.
H » twaber of d«U pclnts
note: Ovipwtcr c*1cuUttons for this Uble show M r«q»r«J for significant figures.
NAXIHJH
0.173000
•98.000000
99000.000000
55600.OOOOCO
126000.090000
56705.000000
1=870.790000
1.0*0000
37.839160
I8.9|«J580
2|.t73a30
10.836715
0.67S676
636.666667
197.701149
COEFFICIENT OF
COVAKIENCE (I)
191.058
?77lfJ7
257.t89
305^710
35P.256
189. D«2
3i2.*65
179,?te
let.001
361.COl
290.«7S
290,«-»5
170.ABB
166.509
-------
DRAFT
Total Processing Effluent
On a dally basis the total waste load from the Subcategory A 5 plants may
be quite variable due to 1) differences in the raw materials processed;
2) the numbers of tank cars washed; and 3) the general cleanup pro-
cedures utilized to clean up accidental oil spills. Data compiled
for caustic refining, tank car cleaning, and storage and handling
indicate that flows and BOO concentrations vary greatly from day
to day as is indicated in the large standard deviations calculated
for these parameters in Table 17.
Model Plant
Based upon the data compiled for this study, a hypothetical model
plant for a caustic refinery operation was formulated. The following
assumption: were made for Subcategory A 5 plants:
1. The model plant is assumed to have a production of 454 kkg
(500 ton) per day.
2. The model plant has separate discharge of process waters
and non-contact cooling water.
3. The model plant has approximately five tank cars washed
per day. Each tank car has a capacity of 68 kkg (75 ton).
4. The model plant has a waste lo:id generated from storage and
handling areas based upon a 4s4 kkg (500 ton) per day
production.
The following pollutant parameter waste loads were calculated for
Subcategory A 5 plants by assuming a linear relationship between
production and wasteload generation. For example, the average
waste loading for caustic refinery from the compiled data base was
as follows:
Suspended Oil and
Production Flow BOD COD Solids Grease
(cu in/day) (kg'kkg) (kg/kkg) (kg/kkg) (kg/kkg)
71.9 1.01 1.81 0.51 0.61
The waste load for a caustic refining operation with e production of
454 kkg (500 ton) per day was then calculated by multiplying each
waste load by afactor of 1.42 (i.e., 454 kkg/320 kkg = 1.42). Thus,
the model plant was assumed to have the following waste load char-
acteristics for caustic refining:
Suspended Oil ar.d
Production Flow BOD COD Solids Grease
(kkg) (cu m/day) (kg/kkg) {ko/kkg}. (kg/kkg) (kg/kkg)
4U4 102 1.43 O7 0.72 6.86
315
-------
DRAFT
Historical and verification survey data compiled for storage and
handling was also converted to a production of 454 kkg (500 ton) per
day by multiplying by a factor of 1.59.
In addition, the model plant was assumed to wash five tank cars daily.
Therefore, tank car cleaning data was converted to a production of
320 kkg (375 ton) per day by multiplying by a factor of 2.05.
The total waste load characteristics for establishments engaged in
the caustic refining of edible oils was then calculated as indicated
in Table 24. Therefore, the wastewater characteristics for the
hypothetical model plant Subcategory A 5 are as follows:
Production: 454 kkg (500 ton) per day
Flow 314 cu m per day (0.033 MGD)
BOO 6,600 nig/1
COO 16,600mg/l
SS 3,600 mg/1
O&G 3,500
pH 5.5 to 11.0
BOD Ratio 4.59 kg/kkg (9.18 Ib/ton)
COD Ratio 11.45 kg/kkg (22.98 Ib/ton)
SS Ratio 2.49 kg/kkg (4.98 Ib/ton)
O&G Ratio 2.39 kg/kkg (4.78 Ib/ton)
5UBCATEGCRY A 6 - PROCESSING OF EDIBLE 01_L_S 3Y THE 'JSE OF CAUSTIC RE'INI1..".
AND ACi::_L|I5TTo!j METHODS'
The major process waste strears associated with Subcategory A 6 plants
arc the sarre as those for Subca jory A 5 with the addition of acldulaticn.
Acidulation
The major waste loading unit process for the edible oil refinery industry
results from the acidulation process for the recovery of fdtty addes
from the soapstock generated by caustic refining. Data collected
from four plants found average pollutant concentrations and waste loaainr.:-
for the acidulation process to be:
Production 486 kkg
Flow 223 cu m/day (0.059 MGD)
BOD 12.000 mg/1; 4.70 kg/kkg (9.39 Ib/ton)
COD 22,000 mg/1; 14.97 kj/kkg (29.94 Ib/ton)
SS 3,800 nig/1; 1.66 kg/idc (3.3 Ib/ton)
O&G 2,500 mg/1; 1.20 kg/kkj (2.40 Ib/ton)
BOD/COD 0.57
pH range 0.6 to J.O
Table 25 presents a statistical description of the data collected
from four refining operations. Ta*>le 26 provides a summary of average
wasteload values calculated for each plant investigated.
316
-------
TABLE 24
SAKPLE CALCULATIONS FOR DETERMINING TOTAL
WASTE LOADINGS FOR SUBCATEGORY A 5 PLANTS
ri~
Unit Process
Caustic Refining
Storage and Handling
Tankcar Cleaning
Total subcategory
AS Plant wasfeload 314.2 4.59 11.49 2.49 2.:
Flow
(cu m/dayj
102.2
132.5
79.5
600
(kg/kkq)
1.43
2.16
1.00
COO
(kO/kkq)
2.57
2.83
6.09
SS
(kq/kkq)
0.72
0.39
1.38
0 & G
(kg/kkq)
0.87
0.41
l 11
o
70
-------
TABLE 25
FIi'U DEvJklPIIOfo OF THE WASTEWAIER CHARACTERISTICS FOR THE
E .iJLE 'JiL REFINERY SiJAf-STUCK ACIDULATION PROCESS
H*?f*3Lr t •"Li* •;!.-..'C.fi.HO VJ'iANCt MINIMUM NJUIHUN
cs..nT:o.t
Fir., •'••-,:) «J .:.c-j«i?& j.miia. :.cc2 c.ccetco C.22S
Prr".:. u'-r/'Jdy} "3 Vs. •»!' = ! <;:i. 1 3c !"»§ 2^tit7'.<»33 i-«.cec;cs it»5.ccc
f -, (-!•)•';' 3: :«:';.-•••:: • j»: *. -tej<^ is:"?-.! 5?. 73 : 7^t.;cc:c: 6^ico.cd*
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f, ... ( .,;!) 35 ; : 7. '. ,t-' ! s J Jt1- ! 5. : Tl7'5 47 '~ ?-? '. 1 . 7C > 273C.C
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r '{'t':i'«l -: :-:-.;i:':'T •:':-.- 1 I** I ft : 3":i ^^\^.••;;•:t
(• ..-: ---T,-J - - 7 - a
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t •••••• r 1 i -' J'1'-- ' * ? •• f> * ^ '1C? -•"
F:,... S4t:c "3 :«:. i.-ri? '.:'.er«:^<» !'.;*£. >2? If.-
:CCO 5t968.COC
cr.cc Jcioco.occ
r:c: 3t57a.c:c
33; : 3°iS5.:e2
J~ti 782Ss..OS
?f?0 3tl-2.«25
*^t(* 2l^2» ^cc
• : ! t 3 s . i s ^
7'C T 203,TI'2
?r?» 1-1. £"^
f; if 3 s . ? i ?
"•: 38 i «. ?Sc
'arJl 3 - . 3 1 f
;i I 1 17. 1 5«
000
'00
:ie
::o
;oa
•:eo
.'•CO
? J 0
36 3
-"GO
P 1 3
3t 2
->KO
fe3
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• T II
•3ftd ^7T ^llltl
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• FOG - Fits. 2>'S, 4'.d tr = -'.*'-
H • Runter tf
-------
TABLE Zc
uR THE
:• 1 ;•:'. REFINERY ACIOuLATION PROCESS
Edi.bie Oil
Refinery by
Process Cede
7E.MC
75A15
75 ACS
T - 1 ~ *-i
/ .'"•.':
Deduction w.i .tt-niti-r RCr
Oi-.ch.ir'jc'i
(• _jt j-'daV .' (illi .Il'.'jy; ;-.j''l;
:T;J 147.6 1
257 51H.5 13
:-«5 171). 7 7
:-'r >fcj.? c
. 2 ^
.43
. C5
. 'M
COO
loa^ll
3.09
59.4
11 .07
10.72
ss
(«"9/l)
0.25
6
0
2
.34
.45
.91
Oil &
Grease
(mg/1)
0.23
5.31
0.04
1.86
-------
DRAFT
Model Plant
The hypothetical model plant described for Subcategory A 6 is assumed
to have a production of 454 kkg (500 ton) per day; to wash five tank
cars per day; and to have a separate discharge of process wastewater
and non-contact water. Jt is essentially the same plant described
in Subcategory A 5 with the addition of the unit process of acidulation.
By converting the acidulatlon data base to a 454 kkg (500 ton] per day
plant and adding this value to the model plant waste loads calculated 'or
Subcategory A 5 refineries, the following wastewater characteristics iw-
derived for Subcategor"/ A ^ refineries.
Production
Flow
BOO
COD
IS
O&G
pH range
BOD '•atio
COO ratio
SS ratio
O&C r.itio
454 kkg (500 ton) per dav
534 CJ m/day (0.141 MM)
7,600 trig/1
21.600 my/!
3,400 pg/1
3,000 r.:'i/ i
0,6 to 3.0
3.95 kg/U-j
2S.41 ku/kkc
4.03 krj/Ug
7.90 lu/tor;
•;C.3i! Ib/tcii;
.06 Ib/ton)
The : fiiji vidual ;m t processes I"-', ill: Lrr.tir-n1; for' tMr i. P'jt ''et i '.a i
ttn.1 .iddition jf '. o jni'; ;.•(•:.•(.;.'...!' ^: j-.-..Jjr;:(T.• or :• i; oil :."-oce::. ••;.
DeodoriCation
The r.antjct
•>q v/ater blj'.»c!OAn rj9"y--3ted fror d(?0'iC'firation
•"ctr''c conO'ji'jer jnits ••»r»-9''?r';' i ™3jcr ::r.tr • LJ'.'. ;i". t.i I.
e load c* -in pd;rlt? O'l '~ef:''•>':•'.'. ''.e''rj'' :.Tr\-n
•it.. rrj"! j'.t. 1'iifininn o: *"•!'•"". .•^••,-> i ~"f ••" !
canoe was from 3.3 to 7.3.
,,», -,,r -,< . -1 _
i . . ,./ i i, L* *
. '!i: ' . ..i •'. .'^
:j, i , i'vj j
• '. C . '' (K' ' ' I ,". .,'*'' ^ d MO "i 1
O&ii
HOLY':-;,:
G..-T
0 . J'L
s'x plants investigated.
I<|L'!;' .'.'7 ;.-»•»?•, "of. .) r. Mti ';t '.:,il ;•• •• •
for ..onl'Kt ui-'cjinj tJwcr &l;r.ji;«i! •"••. .•
Oil ''nicer-.. i nrj
Oil :'rocesri;no include1., fie floo'~ .».i.:.-!n'i and aonpfal cleanup .^asti'-
watc'" ili.Si.'Mr ie> *Vi " '.''c "i.orj-.;; • •' '' , .-. ''-.to1'' ;j t oo , rli-.iv.hing,
320
-------
TABLE J7
A STATISTICAL DCSCRIPT10N OF T||[ WASTEWATER CHARACTERISTICS FOR
;.:~i3LC Ok. RIFINERr rOfiTALT fOOLIW. TOWER BlOWLiQWN FKQH BAROMETRIC CONDENSERS
H^™ ::
:', -:,_' -;1, : ' [,
,''•'• - '.'. , ^ • S
•Fi'1 i 1 -•••!;
fc'.-J Mi 'i •::',} ''
C ' •' 1! i ' ,•'} - *
^ ' , '
i < ! *j • • ** ^
•-'•',' " ' '' -: ~
"
' * '
; 4
*'-"'. *• :
' • w '
1 ' •' •' c-
• ' : •
.•'.-•-- , :
i. 'i: '• Mi" »
t . f . '.a lie
flew -il-.c L-
".:;•, i:*f,.V,Pr> VABU'JLf
". . : 7 7 fl 4 * r-,;5S7?l 5,00
?e5.9:t^l* rtl.-^i"-: "'"7?.?l
^•t; f » P . j i ' *•!,! -?c"7| 2 S 5 1 1 J t 3 i!
73!.!c:5'l l?r?,-e '.;?:« t'71.2k7^t7 7t - ,? ? : r C . - b ' } V i i J - 7 1 1 6
2~- _-^ttCi ^-".~'-ii^- sacc^
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t - . - • • j . i ; : * ; ! > i i
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C17!>.i
CO£FFICI£.NT OF
COVARItNCE (I)
75.930
13 1 - -03
172
ni
130
110
9l>
its
i i ~
ie»
1 S^
156
JiS
115
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1 16
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. 3" 1
. C1'
.722
Carpater ci'.i-UHcrs
-------
DRAFT
and deodorization unit process operations. The wastewaters dis-
charged from the^s operations represent a relatively Minor waste loading
in comparison to the other unit processes previously identified.
The average flow was 26.5 cu m/day (0.007 MGD). Average pollutant
concentrations were calculated as follows:
BOD 1800 mg/1
COD 5000 mg/1
SS 1100 mg/l
O&G 1300 mg/1
pH 7.3 to 13.0
Average waste loadings from oil processing were <;;
(500 ::n) per day plant r,y :he factor^ 1.32 and 1.16, respectively.
The waste loaas fron these jrit orocesses v.-ere then adcred to :.he let;:!
waste!?.5.: 3f trie 4 54 kkq (500 :or; :•<•? day plant cevirii'pd fcr
Subcate'iory A b >-efineries. The follcwin.3 data roDrer.ent; trv. .-.d',*.--
water cnaracteristics of a Suocatego'-y A 7 refmi'Vj ope'-^t'cr con-
sistlr:g of the unit operations of causfii refining, ac'c-ular^or ,
deodocization, c-."d oil processing:
Product -'on
Tl ow
bOU
SS
O&G
pH ranoe
BOD raOc
COD rat:c
bS ratio
O&G ratio
454 kkg
1147 cu •
6. 'IQO ~g
3,1*00 ::iq
1 ,500 :m;
7.3 to 1
lb.i)9 »-..
jb.^1 -. ;,
7.;U i.,:. i
3.-...? k.:,
',!/
' 1
'•'l
;1
•)
k
•
11 I:-., to-
'L Mn;
5 .J'rIUii!-rj C.i
tpriory A 8 is essentially the :..vc js V-ubcati"jory A 7 witM t.'it;
deletion of the unit process of Jciculation. As a result, the -node!
3::
-------
TABLE 29
A STATISTICAL DESCRIPTION OF THE WASTEWATER CHARACTERISTICS FOR
OIL KEFINERY OR PROCESSING**
VARIABLi
N ."EAH
Fiow (."GO) »• O.C3fcb*1.
y.
•J. (ten/day)
(rc/'r,
COU firy.-M
•Ff
^ -
r/Q
Ul ;
fsj
to L'
1 . ,
L i
J-*
i :..
» ...
l: •
k "
2.;:
r;C
•
0 (-c/1)
(lL/;j,i
'": ' -'..)
V ' -
-Lr' .. j
• L ' * - 1 "• n
• . j - y
> • 1 - I rj
:• r-fi "•
; ^,_ J-k -j
'C~C» hi*io
••FOC ftutio
„ ?it -a
FOC = FaU.
1 J "?9 . 1 7 1 i?"
:? I7si.ca35*j
;} 1 C £*.»'. 53!5
is 5 c 7 j . c • o c : :
i , 1 3 3 5 . s : : : : *•
J I 6 7 . . a 1 - : C
13 i e f . r -,:>:-
13 i-.i*-ei :;
i - i i . i *.--.»
i - :.•.-?'.-"
12 ..:-.-•.-:;
13 0 . - - t - J 1
13 C . ; ; i - i 6
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i- i."^7?-fl
t - T .:.::-'-
t ? c . - * '-. ~ \ i
• i i i . •! * ; i J a
!- 25. :/•"='?
Cils, and gresst^.
SIAIiCAHD VARIANCE
DEVIATION
C,CC575i 0.
?5".CC*59" S"760.
J P J 1 . 7 5 t f . C 6 1 « 6 P ? 3 ? I .
l~"S,'»3It50 2'067<)i.
€?!'.57t|fS 67S6>"32.
!£•;>. 3^^161 28S7770.
17S.tUi7tt 3CS39.
3t J . f t 1S52 13rft .
el .J^G^S 3eCS.
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: . * i ^ ? s 3 , c .
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c . •: 7 7 1 :- o c .
C . C ^fibfrG 0.
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j-OiCiie H7«.
2-.8>?63b 616.
0000
95! 5
SSS 7
obb7
57 tS
tf 09
U779
». ! C 9
t-.; r 3
ef 73
C5 1 £
ec » i
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0.
lit.
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c
-------
DRAFT
plant for Subcategory A 8 will have a lov.er waste loading and flow then
Subcategory A 7 plants.
Model Plant
Assuming the sane production rates and assumptions made for Sub-
category A 7 refineries, the model plant for Subcategory A 8 was
calculated to have the following concentration1; and waste loading:
Production
Flow
800
COD
ss
O&G
pH range
BOD ratio
COD ratio
SS ratio
O&G ratio
454 kkg
927 cu m/day (0.245 MGD)
5,750 ma/1
11 ,300 mg/1
3,100 mg/1
1 ,400 mg/i
6 to 9
11.73 kn/kkc (23.46 Ib/ton)
22.99 kg/kku (45.98 Ib/ton)
6.30 kg/kkg (12.60 Ib/ton)
2.81 kg/kkg (5.62 Ib/ton)
SUBCATE3URY A 3 - PROCESSING OF EDIBLE OILr BY THE USE OF CAU:
RF.FINI.'JG, ACIDU'.ATION,
PRODUCTION OF :,HORTENI
OIL °ROCESSrJG, '^EOCORIZATIOiJ AND, THE
.'.G AND TA3LE OILS
Subcategory « 9 is identical to bubcategory A 7 with the addition
of the plastici;ing and packaging oserations associated with a
shortening and tasle oils processing
Shortening and Table Oil Production
Wastewater resulting from shortening ?r,c table oils plasfici zing
and/or packaging operations are pri;nanl-. generated from floor
and periodic eauipment cleanup prccedurc-1;
from these operations repreo-j^t o •••.>! Jti ,
loau'iTj to the total ref-' "ry aff'.jcr;;.
for ti'.ft proojction jt sn: c'liig j-ij Cjbl
in Subcategory A 14 .
Wactev/ater; generated
:•!..• in-, i.-jm ficant -/astr;
verage pollutant oaste loao
oils are avjcu^ea in dcij
Although the model plant for iuncjti.-'-jorv •'• 9 has an additional unit.
procev. v.'a^'.e ^.tceam its tot^l ,-/j-,'.v , oati i •. i)t.:,L>rvr:d to l;e If1','.
concur r. rated tr.an .-Lubcate'jory A :' ju(.' tj :'ie dilution effect attri-
butable to the relatively low waste load contributed by shortening
arid tanlc uil ijrccessin'.;.
-------
DRAFT
Model Plant
The Subcategory A 9 model plant is assumed to be identical to the
Subcategory A 7 model plant with the addition of plasticizing
and packaging of shortening and table oils (i.e., Subcategory
A 14). The shortening and table oils packaging waste loads were
.converted to a 454 kkg (500 ton) per day operation and were added
to the total waste load for Subcategory A 9. The wastev;ater char-
acteristics for Subcategory A 9 plants are as follows:
Production 454 kkg
Flow 1320 cu m/day (0.349 MOD)
BOD 5,900 mg/1
COD 13,500 mg/1
SS 3,000 mg/1
08G 1,500 mg/1
pK range 3 to 9
BOD ratio 17.12 kg/kkg (34.24 lb/ton)
COO ratio 39.15 kg/kkg (78.30 lb/ton)
Sis ratio 8.68 kg/kkrj (17.36 lb/ton)
O&G ratio 4.35 kg/kkg (8.70 Ib/ton)
SUBCATEGORY A 10 - PROCESSING OF EDIBLE OILS BY CAUSTIC REFIM'JG.
(J1L PROCESS!. SECDJttlZATIG||_, -MJ TH£_J>_LA5TIC'_i:i,'ui:ies d 454 kkq (SCO ton) rer >l.i , ;-roa^c'iun *cr both tho re-
finmg operations and the fill my .n,a njctuiijini) ot ihorteninq
jnd tdble o'ls. The .vastewater '_riuir,i(. ten •' k. •• of Suhcdtcgj^y A lo
plants are as follows:
Production 454 kkg
Flow 1101 cu - .j.v. (t;..?9i i-'Cfi)
BOD 5,250 mg.1;
COO 10,400 :rr:.'l
SS 3,000 mg/1
OSG 1,300 I'Kj.M
335
-------
DRAFT
pH range 6 to 9
BOO ratio 12.76 kg/kkg (25.52 Ib/ton)
COD ratio 25.23 kg/kkg (50.46 Ib/ton)
SS ratio 7.14 kg/kkg (14.28 Ib/ton)
O&G ratio 3.23 kg/kkg (6.46 Ib/ton)
SUBCATEGORY A 11 - PROCESSING OF EDIBLE OILS BY CAUSTIC REFINING.
ACIDULATION, OIL PROCESSING, DEODORIZATION. AND THE PLA5TICIZTNG" AND
PACKAGING OF SHORTENING. TABLE OILS. AND MARGARINE
Subcategory A 11 is a combination of Subcategory A 7 (i.e., edible oil
caustic refining, acidulation, oil processing and deodorization) with
the addition of shortening, tao'e oils, and margarine processing v/aste
load data presented in Subcategories A 13 and A 14. It is assumed that
the refining unit processes operate at a 454 kkg per day level. Sub-
category A 11 also assumes that the two additional unit processes (i.e.,
shortening, table oils packaging, and margarine packaging) operate each
at 227 kkg (250 ton) per day.
Total Processing Effluent
The total process effluent from Subcategory A 11 refineries represents
the highest pollutant wasteloadiny calculated for all the edible oil
refining rm.de! plants developed for tr,;s report.
Model Plant
It is assumed that the Subcategory A 11 plant has the same w^ste load
characteristics of Subcategory rt 7, with the addition of: 1) a short-
ening, table oils plasticizing ano/or packaging room and 2) a margarir?
plasticizing and packaging room. Each packaging operation is assumed t-
operate at a production rate of 227 kkg (250 ton) per day. The waste-
water characteristics of Subcate?ory A 11 pljpts are as follows:
Production 454 kkg
Flow 1574 cu ri.-'ddv (0.416 MGO;
BCr- 5,900 :ryj/l
COD 13,500 -ig/1
SS ' 3,200 i'tn/1
O&G 2,800 mg/1
pH range 3 to 9
BOO ratio L'O b7 k:j/t '- !4i.|4 Ib/ton)
COO ratio 46.60 kn/'k- '''^.l' Ib/ton;
'^ ratio 10.98 ki/^k-i (21.96 Ib/ton)
OiG ratio 9.95 kg/kkg'(1?.90 Ib/ton)
326
-------
DRAFT
SLIBlATEGURY A 12 - PROCESSING OP EUIDLE OILS BY CAUSTIC REFINING.
OIL PROCESSING, uLODURIZATIQfivAi'JL) I HE PLoTICIZING AND PALKAGliiG
OF SHORTENING. TABLE OILS, AND I1ARGAK1NE
Subcategory A 12 is identical to Subcategory A 11 with the deletion of
the unit process of acidulation. As a result, the final discharge from
the Subcategory A 12 plant will have a significantly higher pH and lower
pollutant waste load than Subcategory A 11.
Model Plant
The hypothetical Subcategory A 12 model plant is assumed to hjvc> the .-ji•<.•
daily production rates, assumptions, and waste loadings per unit prcu--.'.
as the Subcategory A 11 model plant with the deletion of the unit procr'-v
for acidulation. The wastewater characteristics of Subcategory A 12 cT--
"C :..!!!/ trin.",' sources of was'je.-uiU-r .;-jm."'.»t2'J ' :'d:-. -..'ii--
fro1, ••'arjdr'. ne r-y.. ui;".a t icn roo".:'.; I-'; waMewati'f cJr :. ';jr';p:) rr':•:". )!"••(•.
flfji.ii' uiijhinrj ouprat'ions contj in n'1," ri «••''. err ;cint'^ ''"I'l c'llcr1 nr ; yi'ii .: : ''>
daily cleanup r;f C.'P vLie«tn-: i;-i''jce ; eouipr.ent >. t; i i.: ing ':MP Uiii.-i'.v'1
f. iedning cycles: not rin^e, cauif./. «a'.;);, chlorine rin^e, final mi'-.-
sanitation, and air drying. The amount j of waste-water qer.ora tec! tro1"
the.se operations is primaril> Ji^'oncent ,irH~n ti-t,- '.loanl inesf. .'ird '.;f':
cieicy of the above threp operation1;. I'.viarinc production r^'n.: i'1'".
conbiJerdbly i"iorent and f ioor washing proceiiur^;, rtr.juire relatively laryer vnl'j'i.
of -vatt-r, Ave'-a^e pollutant conccitrafoiis. flow, and production for
the fOu'i' plants inv-esti9ated v/en? j^ follov.s:
327
-------
DRAFT
Production 112 kkg
Flow 170 cu m/day (0.1)45 MGD)
BOD 1440 mg/1
COD 4470 mg/1
SS 900 rng/1
OiG 1760 mg/1
oH 6 to 8
BOO ratio 1.93 kg/kkg (3.35 Ib/ton)
COD ratio 4.22 kg/kkg (0.45 Ib/ton)
SS ratio 1.34 kg/kkg (2.69 Ib/ton)
OSG ratio 2.36 kc/kkg (b.72 Ib/ton)
COU/CCJ ratio u.i3
Table 29 presents a statistical description of the data base collected
indicating irean, standard deviations, and minimum and maximum values.
Table 30 presents the calculated averaged data for each of the three
plants investigated.
Total Processing Effluent
The total «a',te load resulting from a margarine processing operation in
tonbination with an edible oils refinery represents a significant waste-
loac to the total processing e^'luen;. Based uoon the data provided by
the (AMM, it •; evident tha: t^.e -.vastewater characteristics for margari'
processing i: -:ignly viriau'.- fr::;: ^la'H to olant wi tn higher waste lo^i
being corral jt-vd «/i ti. larger p-"-ojcti'/! -'•'.^s.
Tht; "ypotiif :• :•> i nari'^r-pe ;: roc. -.•?. ". i rv] :'l'Vit 'or Subcateoory A 13 was
a:-:...:-.c-- to ;..-:-Jte a: a prcJ^;. ::.;!•. rate 'jf 2C7 kkg/day (2JO ton/day/.
Thi- ..jitt. valet- jnarac'.erist'cs tor- ijlr.cstegory A 13 plant" are as
"
Production 217 kkg
i: : -J* 3«0 T.-J - MI ..- ••;. ;;'.' '-'G:, }
LiOJ 26CU .;.. '
L:':O D/co •-•.;. ;
S3 loOO rq •
;;&fj 3oc-o ••:,; i
pM '•jn-.-ja 0 tc; i;
'j:-i -ai-.-.> i1.}.'. . : • • ; .',..'- ';.-.". on].
C'?i. -.itin 3.:..' -. : • • i .'7 "^ ilj/icr)
•o ^.';;- ; : .. . • .,.1 ib/tor;
f'&Ci i. til K:;, •- ; •; ; 1 1 .('.'? lh,'t.on)
yiLr -:•!•• oui.v ~ ;« • P."l-_i_ICI^! N_f >V. L' i ••' C _?OMi I .'.'G 3F 5HORT TN I f
-------
TABLE: w
•-. STATISnCAl. DESCRIPTION OF THE WASTEWA.TER CHARACTERISTICS
FCR MARGARINE. PROCESSING
rj
vc
S-. (-;."
C'.D (• ]•
e rj iib.'
CiU (la
'.' (it/:
;('
a/:
i ... ':i'. j ratio
'.21.
).
VARIANCE
O.G01 J
wJT5.30C6
127J
•>ii:
, S e c' t S
. t 3 9 » r 8
S f S e> 1 •"> 3 . P f t ?
i: * i. 2 o a i e c
-. T • * •? i«
11
. 2 il ?: e
. c i G e: 4
. i 15.1C a
O.C5C6
je.iicc1;
MINIK'M
o.cceooc
30.CC-Cf OC
2-.JOOOCO
fljC.CCCOCC
zz.ejfcrc
5 .9 7 J 2 : C
*.?2t7tJ
C. JSS^fI
0.5=0^*5
0 . : •: a t 3 S
8.6273JO
C.C?h-lt
O.C1I2C8
0.36P*?5
C.367fti7
MAXIMUM
O.I 11400
25:.500000
4J76.DOOnOO
3255«.000000
11907.COC060
i 1033. C1 1077
2! .1302C7
"3,t7202U
c\ .S3tdl?
51 ,795566
25.697781
20.((3(1783
615.J6i.6l5
COEfriCIENT OF
COVARIENCE (X)
5a,3u«
151.2t2
iue.»<;»>. cos
«2.741
103.528
N • r.crter o? d*ti points
No'.e: C-arputtr cslculdtlcr.j f;r tMs Uble show no r«9*r
-------
TABLE 30
PCLL'JTANT WASTE LOADINGS FOR THE PROCESSING OF MARGARINE
Edible Oil
Refinery by
Fror.tss Code
?9Wj-j
7SMCT.
79V05
Volume of
Production. Wastewater
Discharged
fH"j/day) (cu m/d.i^]_
1J4.0 219.5
119.1 176.7
£3.9 59.4
800
("'9/1)
4.05
0.95
1.36
COD
("ig/D
7.01
0.74
2,38
ss
(mg/1)
2.65
0.33
0.51
Oil &
Grease
(tng/1)
6.58
0.19
0.42
-------
DRAFT
employs strictly mechanical treatment of oils for the conversion of bulk
quantities of hardened oil into consumer sized packaging. The waste-
waters generated from these operations are principally from general
sanitation of filling and packaging equipment and general floor washing
procedures. The volume of water generated from the process is signifi-
cantly less than that for margarine processing due to the fact that
the finished products do not support bacterial growth and therefore re-
quire less rigorous sanitation procedures The average pollutant con-
centrations furnished by the Institute of Shortening and Edible Oil:,
(ISEO) from five plants were:
Production
Flow
BOD
COD
SS
O&G
PH
BOD
CUD
O&G
BOu/CC'J ratio
195 kkg (215 ton/day)
74.9 cu m/day (G.G1SS MGD)
160C mg/1
4000 mg/1
750 mij/1
770 mg/1
6 to 8
0.43 -Mf-.ya '.J
0. 19 kg/kk'j
0 13 kg/k^
0.19 kq/*U
Ib/
Ib/'
on)
.on)
.36 Ib./r.onj
Table 31 present1; a statistical description sf '.lie nt-cirt,, standard
deviations, and mnirr.u'n and r.dxinu;» va Liv, :al::'jlatr"j '•ror1' trie fivB
plants inves-icareo anri' sarr,i.:l!id. Tab',*; j,; pri."., <.•!!•.- -i .-.cscr';)'.UH •:;
tne shorten! ivj osla idllect'.'d a'. Od-.M uiant..
Mod1?! _^'lant
The hy!'ot.'ne("ica1 r/ior:?ning 2nd tJLle oil sr"jrc;:in;j "'O'Jcl ^lar.t .vj'.
ar."/L,i;'(;d to C-feiM^L' dt a prcsucti ;n I^VL-! of ^'i1.' kku •, L'bC ten. ; or (),i_. .
Tr.c data tase collecttJ ^a'i co'ivei't-.-j to a daily urvc^ctiun '•ate OT
?T7 kkg L-/ rJ''- i U' lv. 'ig by a 'ac. t;:r or 1.16 'i.-:., ^'.'7 > kg ' '') '•»•)
l.!£\ ~''G .•.•2".tO,.'J''.'.T ;! ui'CJ'-•_-•'-'• - .'" lj.'-.. J '.L .i,:: - ". "- ...:,,:i:. .tr •
s'-j '': i I OA l^:
Product ;oil
F 1 ow
BOD
cor; <
r c(
06G
LKH) r'3f--i
COC i-3',-i>
>'i I'd ' ' "
OSG ra l ! o
ROD.T:: rjrii
O ' C J f •'!•-. . •
.)C';.'L " :
i .."_• • i :
O.iif , .. ' ' : ' r1
1.1;: •..•••• : ••••
0. •-..' .' . . • :. ' >. •;
O.L'l io.:.: •••ton)
j O.L.:
331
-------
TABLE J?
f- JT>Ti'5TICAL CiCRIPTION OF TilE Wf\STEHATER CHARACTERISTICS FOR
SHGRTErH.'i;, AND IABLE OIL PACKAGING OP-EPATIONS
J-s.:--',.i '• *E.iN
to- ;-r,a' J- c .ci*7-7
f-Ti (ton.Ja^J <- 2l-.«*7i<-0
S ' : ;M) Jj 7J'. 7*ft:»
i' i-.'l. i i-.-,' '75.:::
;- f .- ,.••'.
."' v' !'. ''Si. 1
' « i j .
'": It. •,;,'.''''
- | ;( ,:j. .
• '.- ;,.-_.
• . ! •
w 1 • r •
- - . .
i ' ' • ' -
3. r,r. i -X
)!.. ....I: Fit -3
7 * •; . • 1 L ' '• !
i : t e . ? : i -• : t
f*. ,". 5*T"t
• = • . '. t : : . :
^ c . - 1 ; " '. '
: . - 1 - ' ; '
• . . = t • *
" . ' f ^ ' - i
: . : • '. '. • '
' . . ; T - - i
:..!-•-!
: . ; 7 7 • • t
"..'.*"'-.'. \
t ..=•!-•' 3
11. fi'-j Sjt:j ;? : • - '•>;--
lt.. ?.jt;c '- : :; .i--c-3
DIVIAHON
e.c
ii".1:
2 2 1 5 . ^
913.-
tu?o, -
f " 7 . ;
^ t
5S. i
2e? . 7
1 .i
C .'
C '
C. !
C'. -
C."
f. .7
c .?
C .1
i . t
IbJ.;
HT1
4ei» :
!7 | T
e,
«.
j
--P|tf
I '. ^b
•£ V
!c ?
C ,C?«6
C.=7°7
3 . 1 - *7
c . r ! o '
**.^*i*
2t5«3. 7ltu
S
3«
«?•:
ICt
4k2
£3
r
. c
1
2
V
;
*
c
s
;
0
c
0
:
2
.co37:o
. 7 r r o j o
. c o c : e c
. r^ r oc o
. c o a •: c 3
. c o c c •: s
. 1 7f ! C3
.«7t~77
. ^ : J ; r «
. 1 -c I t i
. f ! ? 3 C 3
. C : * 1 52
• ~ c _ i 3
! • r > 7 I t
.n:-5.'f 3
. C .' 4 t 1- 1
. '- . ^ f rf
** " \ 1 * "
!n7-r3
.5CC672
. i<;53*:
o.oflcn
U55.50CO
CO
CO
COEFFICIENT OF
COVAJUCNCC (S)
ISO.
S3.
«3S
C7?
i I293.ooc3oa ll'.Jja
d2"6.C3CC
27*30. CCCO
33CO.OCC:
e-2.CCJ!
2 5 V S ^ \ C
3 1 : . t " » i
1 3 i 1 . f - 1 C
-,5Qf S
£ . c<5 ?
1 . 3 c" I f-
1.735:
0 . t 675
3.73CC
1 .f t 7 C
C .cfjc
27 ,f7bS
U'b .ll^C 0
:o
•?0
C 0
55
C C
- 'j
CO
«2
^6
-S
:5
-1
3
-------
TABLE 32
rjiLUrAiil ...~^IL I.QADiNG: FOk SHUi:T£Nl,% AND TABLE OIL PROCESSING
Vnlii-e of
Edib'e Oil Production
Hefinery by
73-,05 Uc'
79SC3 250
79:09 it-
*?' ('.:. ''• •
n jbtt-wd tec BOD
12.9 0.13
7.19 0.046
17.9 O.li
23b.4 1.51
COD
i!T:2/li
0.22
0.12
0.24
ss
(mg/l)
0.052
0.041
C.12
1.03
Oil &
Grease
(mg/l)
0.056
0.052
0.067
0.28
i fi i . 7
1.87
-------
DRAFT
SUBCATEGORY A 15 - OLIVE OIL REFIIUUG
The refining of olive oil is similar to the refining of other edible oils,
except that it is done on a much smaller scale. The only wastewater gen-
erated is from caustic refining wash water with the following character-
istics:
Flow 1.13 cu m/day (0.003 MGO)
BOD 5700 mg/1
SS 296 mg/1
FOG 19b mg/1
Model Plant
Plant 79JG2 is the only olive oil refiner in the country using caustic .
refining. Thus, the mode) plant is Plant 79102 and is illustrated in
Figure 111. The plant will have wastewater characteristics as listed
above.
BEVERAGE.:,
oUBCATEGORY A 16 ^_ NLVJ LARG1 .M_A_LT_ B|V E-.AGE WWM'.i,",
In order to determine the waste«ater characti ri sties of tne nalt br-/v---;i .••
industry, information was rollecLe'j fro:' several >ourcps. The Units J
States Brewers Association (LSEA', c-: reflated one- r.f two types of s;ir.- •
to aM known breweries. They then rrccjced 3 report entitled "197- ur-. •:••
Effluent Westev;atcr Characteristics" '^',. ill even 1-rev.eries '.-.ere -.••'.•••.-;
curing the study and four brf. of brewery waste ca^ be idenv, •"••
but *.rp netrcdr> of disposal vor^ for eacn indivJual L'-ui-.L-r/. Furtcef.
inciiviaual breweries may vary r.n "•>••- :-,.'V:i.,fJr. of cli'-rr.sal DIS^J upon •:• • •• -
or i."wi ronnenta! 'actfrs, r u- '.'o-^ ••^j'.-i.n': '. 'UM-'V .ar. 'c nc 'i.-.c- !'•:!•• •
of Lno strangles of wjstP streams ?or "Me ent.ri; uiaustry, noi.e.'cr sov.'J
generalization'; can be i-i
S£ent_G_ra_i_n__L_iq'jor1 - This is one ^: '.!'•• -a-,'.. •• ; .;n 1 1 icanl source-. (.••' .•.•> '•
in :IIR brewing :-roccss. It. i. ••: ••.''.'.}. C.TTT,:-.;, '.Irilc.1 ".iilfrial , '".•;•
IJOO jnd suspenJfMJ solids and I ov. -. n uii. Accorcr.nq to Le'joe'ile'jr •/-"'•
flvi.M'j'io CDr.jentr3t.ions of ,.>..!.• .11.^ j' : v-.d-yJ :,:••! id', in spunt yrain li.u..-
drc Tj ,000 UK;, 1 and ,"0,OUO v,, ] . r •••. ; L-C '. ively. At these concerura t : .TI .
spent '.jrair li;;jor, if di \c 'Mr :\>.- \ , . j--. ;•»> c\rpc*/.".i to ccmpn'se 30 tu '. .
peruont of tin; Lotal plant loao. •••. rrjoorted by Stein (58), sj)eiU CT-J;'
liquor fron; P'lant 8<:BOH'.P'.' rernr. '••:.»•; -o.5 ^err;cnt of the total pouW:
of BUU and 60.3 percent of the to'. .1' :. i-'urds cf suspenaed solids, "cst
th« bri.-wericr- m subcategcry A !•„ J., --.ot disc hd rye spent grain liquor.
~ocd_ f
-------
POOR QUALITY OLIVE OIL
i
DEGUM
CAUSTIC
WASH
ACIDULATICN
BLEACH ING
CLAY
LCr.T_ I NO
FGM3
:E!Xnr<::ATiDN
I
F
K.LT-
HOLD.'.'JG TA'X.
- CLAY SL'_CGE
TC SOL 10 W»DT
SUBCATH •"':•"- .-. 15
OLIVL OIL CAUSTIC :-.i;:;i:;!rJG PROCESS
MODEL PLA
-------
DRAFT
is the evaporator condensate. This is a high volume effluent with little
or no suspended solids and up to 300 mg/1 BOD. The concentration varies
from plant to plant depending on whether yeast, lost beer, or other wastes
are evaporated along with spent grain liquor. Wet scrubbers, if utilized,
comprise a minor part of total feed recovery wasteload. Some plants
utilize cyclones, thus eliminating wet scrubber discharge. More than half
of the breweries in Subcategory A 16 operate feed recovery systems.
Lost Beer - This may represent from four to eight percent of beer produced.
Lost beer is primarily derived from packaging, fermentation, and finisning.
Since beer has a BOD concentration of approximately 125,000 mg/1, this can
account for a considerable part of the total plant load. Plant 32A02.'PC',
for example, estimated beer loss at 40 percent of the total pounds of BuD
discharged per day. Assuming no recovery, a four percent beer loss would
amount to a BOD load of 5.02 kg/cu m (1.3 Ib/barrel). Four of the breweries
in Subcategory A 16 practice some form of beer recovery.
Spent HODS. Trub, and Yeast - These are grouped together simply because
their metnod of disposal may oe similar, "ihey are all suitable for
addition to spent grains since they contain only carbohydrates, protein
materials, yeast, end beer residues. None of the plants in Subcategory
A 16 discharge hops, trub, or yeast to sewers.
Filter Aid - This must either be hauled away to land disposal or sev/e-'ed.
Considerac-le suspended solias would result were this waste to be die-
charged, hence all but one of t^e plants in Subcategory A 16 recover
filter aid by decant tanks, vacuum, or pressure filters.
Alkaline Wastes - These are generated frcn vessel cleanup and bottle
wasners. Residue from vessel walls is combined with caustic during
vessel cleanup. Paper labels, sodiun aluminate from aluminum labels,
and glue are combined with caustic discharges from bottle washers.
Although alkaline wastes may oe readjusted and r?used, tney are ever,:u-
ally sewered. Several plants ir Subcategory A 16 meter caustic into
sewers from holding tanks.
Combined ?!'pce_ss Flow
Data fron; 77 breweries were cauloyuec! :n the 'JSBA .vastewater character-
istics report, These brewers r<..:. n-:,<-.• nt (:••.: £7 percent of total saler, 4r."
the industry in 1973. Each Brewery reported the ratio of flow (Larrr-i- ,
600 (lb), and suspended sol'os ilb), to protection (barrels) for a fill-
capacity day. A full-capacity 'lay ,vas defined as the maximum output .si •. ••
could be sustained for a nu,noer ct' cenb-^jtive days. Eacn brewery .-,;-
assigned a reliability number based on the amount of accumulated data
and on sampling technique. Reliability numbers ranged from 0 to 10, ..••':•.
the higher numbers correspondirvj to '.i;ose breweries with more accurate
data. Breweries with reliaoility ratings of 8 to 10 were characterize:
by continuous metering with snort i'lto-'val flow proportional sanplino tri
a daily oasis for six or more HUM MS. breweries with reliability ratify
"v-6
-------
DRAFT
of zero had no data or data which would have an extremely high probability
of yielding misleading results. The year of initial construction and last
major expansion was presented for as many brewers as possible.
Based on the survey data, the arithmetic mean for all brewers was as
folloivs:
Flow Ratio 7420 1/cu m (7.42 Ib/bbl)
BOD Ratio 9.43 kg/cu m (2.44 Ib/bbl}
SS Ratio 3.83 kg/cu m (0.99 Ib/bbl)
Data for breweries in Subcategory A 16 are itemized and summarised in
Table 32. Scatter diagrams of flow, BUD, and suspended solids ratios vorc
production for Subcategory A 16 are illustrated in Figures 112, 113 ana il
Locj normal probability plots of flow, BOD, and suspended solids ratios .
are illustrated in Figures 115, 116, and 117.
Other significant parameters for combined process *low are pH, nitrogen,
and phosphorus. Several studies have documented the fact that pH may
vary widely over a 24 hour period. In fact, fluctuations of pH from L'
to 12 can be expected due to the batch nature of the brewing process.
In general, the pH of oreweries in Subcategory A 1C can be expected to
remain between 5 and 11 due to the large number of compensating opera-
tions taking place simultaneously. Metering of caustic from holding
tanks can be exoected to furtner buffer variations. Brewery waste ; r.
known to be deficient in nitrogen. O'Rourke and Tomlinson (55) defi"f.'.'
an average BOD/'N ratio of 43. L. Tests at Plant 82ro2MP9 (GO) e;£ar;l ••;!;•••;
a BOD/'J ratio of 50.7. These appear to be representative of thn indu:,':\
as a whole. Eased on treatment systems in operation the waste appears
to contain adequate phosphorus.
In order to demonstrate the daily variability of brewery waste, the fio,-.,
SOD, and suspended solids ratios for Plant 32A43 have been plotted f?r ?. ••
"lonth period as ;hov,n in Figure 1~6, 11^. end 120. The :ne data from l-'lant 82A1G. Thi:. ;•'•::''
has demonstrated superior in-house WH-.U' reduction prorodurer,. If WH'.
felt, however, that the raw wubtf l-M.-i;^ tor r.hic plant were not neces;^- •• :
t'conornical 1 y acnievable for the ot.'iei tirpwers in tnis '.ubcateqory in '-•>••
present configurations. For treat:;"1;! 'i.vstoi'i de^njn purposes, an avoi • :••
production for tnis Subcategory v.a1. cal-jlateri to be 1600 cu m (11! .£:.:•;
33;
-------
DRAFT
TABLE 33
WASTEWATER CHARACTERISTICS
SUBCATEGORY A15
(NEW LARGE BREWERIES)
Plant
82 A3]
82A02
82AC5
S2B07
82308
32.A09
82AI5
82335
82A43
82B56
82A56
sz.w
?2---
82A63
Mean*
Flow Ratio
(I/cum)
4640
•5230
7020
6350
9860
4970
1620
3550
4520
4600
5870
4860
4653
3730
54 TO
;rj.41 bbl/bbl) (2
ai"** t.' 1 *• tin i i *" fi ^ *• a f r«/\r*i
BOD 1
(kg
9
7
10
12,
17.
7.
1 .
').
8.
11 .
"i 5 .
n;
1 1
7 .
n
•; i 11.
3a tio
cu m)
.62
.88
.40
,90
,40
,38
~* 1
; '*
00
;j-
10
00
r, p
":
-A
.• ... 1, ] '•
SS f
(kg,
"i
-j .
3.
?.
4.
8.
5.
1.
i
L. ,
?_
3.
4.
\
3.
^
' T no ' i
V ' . 1
?atic
/CU Tl )
48
40
40
41
35
05
OZ
24
93
94
6K
T».
55
94
H',
!>'; '''I'1 '
Rel iabi " i ty
Number
10
8
8
7
5
8
10
•j
10
;
?
V)
9
'•
-------
O
73
t nnn
10000
rrriiuction (cu ru''jd/
i I Our- . |~
-------
•0
,-.'•) IQCO
PrcJuction (cu ~.'dd/;
I 11-!!!?{ 113
10000
-------
10
1C
1 COO
10000
Production {cu ff./
-------
95
'•••;f(.-r : • \ :!,.•• :'.li> Kf-1
r!'..i-i'i us
:.l,r. -Mr ••-. .". i.
i f w :-:: !•;•••! ': i iV M^
-------
o
72
-------
-------
25,030
:o r
DAILY
-------
38.7 f
Ji.9 -
3C.9 .
2 -V
19
PAlLv
-------
30.*-
Z 'i.
11 ,
FI.',.-[-:L ;;\
DAILY SUSPLM'i:: SOLl.'^ VARIABILITY
317
-------
DRAFT
barrels) per day. Process waste and non-contact water are assumed to be
separated. Cased on these assumptions, the model plant is defined as
follows:
Flow (HGD) 2.2
BOO (mg/1) 1900
SS (mg/1) 700
Total KN 40
pH 2 to 12
SUBCATEGQRY A 17 - OLD LARGE MALT BEVERAGE BREWERIES
The methodology for determining wastewater characteristics for this vj:?-
category was the same as for Subcategcry 16.
Process Waste Streams
Management Muestionnaires .vere available for t^ree of the four brewer";
in this subcategory. Prom tne questionnaire responses and frop plan'.
visits the following generalizations can oe maue. Due to the original
design of breweries in this subcatesory there is a tendency for spenL
wet grains to be sold and for scent grain liquor to be sewered instead
of evaporated. Spent hops, trjb, and yeai-t are generally added to t.'.o
wet spent grains, wlr !e lest beer, filter did, and caustic are usual ".-
sewered.
Combined Procecs Flow
Data for breweries i'-, fiis sjLi;ati."..;ury are itemized and summarize-,.! i:,
jb. Scatter jiasrai.is of flo*, L-.J, aiiu ..js^enJuc jol'.as ratios viir--i
duct ion are ploLted in ^-'igureb 1 i 1 , Mi, and i23. Log normal prob^m:;
plots of flow, BOD, and suspe^ceu sol^s ratu^ are illustrated in r-, ^
124, 125, and 126, A--e of fac'lifes 3rd effi:iercy of operation
result in higher raw .vastelcaJs fsr th-. j subcate^ory. Smaller tanka-:^
is cofi;:,ion, tnus caus'no :-iore .•.'atpr *.:: w j':.^d ••"• cleaning operatior-.
Collection arc! d'^posi I ion jr .-.uilui, ij irade rr.ore difficult by ola .ji...
ujtii ^ i pi'; -J.
''odej__PI_an_t
The raw was'i- i'1,"1.:! '^r t1'.; .,.: .: • • :..» , .•!•>•• : .v->ed OM the ;m-'dr val'j<--
presented ui Tai^t? 3:. "M.- •].••: • :•-.-:..,; S • ,-.j'\ . .1 Icui j'.i.-d to I'-'.1
P600 ru rn C/'lVJ iMrr-.-'-^ :o.- • ^' .-•••. .w!-t" mil not-. onMr • -' .,
n'(> j'.i..j"iiid to !%o '^L'IM-M U'j . . i •. ; .Mi :••.••.•_• j.- MJIV; 1 1 oir- t;i;?
is Oet iiu-?a .)•• *ol luv.1.. :
Flow , '•:.;.. . : .5
:• • ..... i
SS (m«J. , .
Total \'i
pii
-------
DRAFT
TABLE 35
WASTE WATER CHARACTERISTICS
SUBCATEGORY A17
(OLD LARGE BREWERIES)
Plant
82F04
82H36
82-346
S2G64
Flow Ratio
14,700
9380
9870
10,200
BOD Ratio
(kg/c:/ n)
18.9
-
20.9
''•6.7
SS Ratio
(kq/cc m)
9.62
-
7.85
4.64
Reliabilit
5
0
2
2
Mean
(11.0
11,000
18.3 7.35
(4.37 ;bs/t;;;]) C .90 Ibs/bbl)
-------
1-nOC
7 i?3CO i
IT.
ir
!000
icooo
f ir.!jf-:r. KM
?lltl; All i- i/i'V /. i 7
i i. ( V.' V • I ••:'•-!. I1Y
-------
i wo
looao
-------
12
10
o
XI
1000
cdjCt^on (cu t./ddy)
f I'"-I IP! I.:'}
..ill-/ •'•ii.r.r^Y A 17
n: ;i[ i;.i ^s CAPACITY
10000
-------
t: v..
JO tU (1C 90 35
S')l; .AH r.'i- )• A r/
-------
o
73
c- 1
!Q ZO 40
frrctot <
60 80 90 OS
lLf Irdicited
F I'.UKL 1lf,-,' A 17
-------
.10 if; ^n no os
-s C « .-•!-•-' Ir..\'.'d!po
-------
DRAFT
SUGCATEGQRV A 13 - ALL OTHEi: f:flLT BEVERAGE BRE'/OIF.j
The methodology for determining wastewater characteristics for this
subcategory was the same as for Subcategory A 16 and A 17.
Process Waste Streams
Management questionnaires were not completed by ail breweries in this sub-
category hence no comprehensive analyst, of methods of disposal is oos^-
ble. The constituency of the process ;trearrs remains identical to ihdt
described in SuDcategor.v A 17.
Conbined Proce_ss FT ow
Eighty-five breweries are included in this subcategory. The 27 plants
not responding to the USBA survey form part of this yroup. Twenty-five •
plants responding, but reporting no data, arp also included in this
group. Data for these breweries responding r; itemized ar,d surma nze:!
in Taule 36. Only six of the:;e breweries nave a reliability rating of
four or higher. The standard deviation for the group is quite high,
indicating the lack of a definitive data base. Scatter diagram: of flo.-.
BOD, and suspended solids ratios verus production are plotted in figure-.
127, 128, and 129. Log nonra'i ^r-JiJdD. luy plot: of flow, BOD and oui-
pended solid; ratios are illustrated in Figures 13C, 131, and 132.
Tne ra." ^/aste loads for the moce'i olant are based on the 30 percent
values for this subcategory as oriented in Table 36. This assumption
took into account tie statistical variance of the group in acdition to
tno fact that those six plants wun reliable data tended to exceed f.e
mean in several cases. The avefaw orc^jct'on for t'ns iuocategory .'.'.it
calculated to be 470 cu m (i'.
thr rodd plant is defined a:. 'oliL.yr,:
Flow (MG: ).:
BOD •>,:}. : ].:v
SS (my.'l o4,,
Total .'-;'. JO
PH ;. to ir
In order to determine the wastewater ^nnracteristics of this industry
a survey ;vai ^oiiduCteJ of all K,rr,.n i i r^r c1'".-, . Throe ;>lants were '.'i;. ;'>-••;
two plants were sanpled, and a -,oi--.:t.. Vi.J? nUHC for any e.xi3ting histor-ca'
data.
Waste Streji'j
As far back as 1935 Kuf (61) ideri;f-cd rteeping 'and germinating as
primary and ieconJury tvaste sources, respectively, from a malt house.
-------
•JRAFT
TABLE 36
WASTEWATER CHARACTERISTICS
SUBCATEGORY A IS
PLANT
82J59
82K32
82K44
82K50
82K55
82L03
82L10
82LM
82L17
82L20
82L21
82L23
82124
82L25
82L26
82L27
82L28
82L29
32L33
82L4Q
82L4C
82U7
62L4R
P2L6Q
O-M f. .-
>-' '. i. U *
02L68
8?M.i3
aZMi1?
a?11?"
82M31
82.''30
i!730
215T)
7froU
2470
10850
3910
10750
£950
3C10
1130
74 ff-
lCS -J
510
BOD RATIO
(kg/cu m)
9.05
2.20
9.82
7.50
7.42
15.08
1.66
e.ee
19.34
1.66
23.. ?c.
10.71
fe.62
5.99
5.76
3.97
2.55
5.4i
1.7C
1.66
14.93
14.37
4.10
0.66
5.88
1 5 . - 7
5.45
3.40
10.32
O.fi-1
2.32
(kg/cu m)
1.62
0.27
6.26
1.93
2.55
03
04
Q4
9.40
0.19
89
95
2.93
1 .47
1.24
5.38
L55
1.01
O.G4
4.76
6.36
C..39
1C 0-'
0.f>'5
RELIA6ILITY
NUMBER
8
6
7
7
6
1
2
1
1
1
3
1
3
0
0
0
0
0
0
0
0
0
0
0
n
357
-------
ORAF1
TABLE 3t (CONT'D)
PLANT FLOW RATIO BOD RATIO SS RATIO RELIABILITY
(1/cu mj(kg/cu m) (kg/cu m) ' M'HBER
82M41 11750 0
82M49 C
82M51 . 0
82M52 6620 0
82M53 5280 0
82M54 0
82M65 4900 0
82M67 8310 0
82M69 0
82M70 915C 5.41 2.44 0
82M71 VJO 0.5C C.04 C
82M72 9220 6.61 J.JJ 0
82M73 0
82M75 12900 0
82M76 15240 0
82X77 3440 0
MEAN (7710 1/bbl) (8.471/tbl) (3.641/LL.1)
8C Percent 10000 13.53 6.19
Value
(IP.CbaVbbl) (3.EbtVbt>l) ;i.cObbi/LLl)
-------
1COCO
rrO''-.i:i'ic-~i [f j
18
-------
cn
o
*• 10
10
1000
tcrcc
Production (-vu n/day)
FKi'jKf 1?8
Silf-CATf OHHY A Ifl
-------
10
L
looc
10000
Production icy .-n
-------
tOG'.-'J
A
-S
.X
J(» 60 fiO
Fen rrl ' Value ii'JiKl
95 95
§
-n
tJJW 130
MIF-CAI1; i R-. ft is
:• inw j'f-ni:.M--ft in T-IAGRAM
-------
Hf![: Pf i if •.-•': 11 iTi [.l/'XiV-M
-------
C3
30
L ._
Id t.T '10 TO
1 Cl'l J'flf • ! dlljf I 1IJ 1 f.dU'f!
' I il 'i .', i I I .• IT;' i 1 P
:!.:jr-' Mil <''•' iM'd,M'l! I TY L1
-------
DRAFT
According to Isaac (62) the steep liquor is a strong, deeply colored,
putrescible liquid which may contain high levels of suspended solids.
The quantity and quality of steep liquor varies according to the number
of steep water changes and according to the contact time for each change.
In general, the strength of the waste (as measured by BOD) decreases ap-
proximately 75 percent from the first to the last steep. This is illus-
trated by data from Isaac (62) and Simpson (63) presented in Table 37.
Wastes from germination are known to be smaller in volume and concentra-
tion than those from steeping, although insufficient data is available
to establish a specific proportion between the two.
Combined Process Flow
The significant parameters for this industry are flow, BOD, and suspended
solids. The ratios of these parameters to the number of barley bushel:,
processed were calculated for each of the 18 plants which responced to
the industry survey. These responses are itemized and summarized in
Table 38. In addition, a reliability nunber was assigned to each pljr:: _
jased on the method and duration of sampling as follov.'s:
Reliability 1 - 24 hour flow proDorf.ona! Sampling for ? con-
secutive cays or more.
Reliability 2 - 24 hour flow proportional sampling for less
than 5 consecutive days.
Reliability 3 - F'ow rnetered, grab sample:,.
Reliability 4 - Flow estimated, graa samples,
A separate arithmetic mean was calculated f"or those plants with reli-
ability numbers 1 ard 2. A log r.ean .-/as calculated to check ;he Dis-
tribution of the data,
In order to demonstrate the varv.i:''' t. 3f ;;vi 11 waste, one -Ian:. ..as
selected WHICH ia:J conductec s^/L-rji ^cnocis of fiv«»-dav. ^-nour. •'•
proportional sampling. Tosle j9 ji^s th-e remits of thor.e tests w>:n
the standard deviation for eac;: "Cj"Lir<.-J pa-amete!*.
Malting effluents can be cnaracterii;ed ar, consisting of highly soli:;..!-
organic materials. Based on t!ie ^VPH di r,tribiit ion of hifjh rel idl/i 1 :'..
plants throughout the snectrur- cr" ijrocurtion in i.ne industry, it ; s fi'i*
that the following levels are lypical .
BOD Ratio 4.55 ka/kkg (0.210 Ib/bu)
SS Ratio 0.77'j k i/i.kq (0.0.369 Ib/bu)
Flow Ratio 741J l/k(g (42.6 ral bu)
The pH of the waste varies between 6.0 and 8.0 as reported by Isaac (6?',.
The waste is deficient in nitrogen, a fact which was confirmed by wet.
sampling at plant S3A13,
365
-------
DRAFT
TABLE 37
ANALYSES OF MALTING STEEP UATER WASTES
300 CONCENTRATION (mq/1)
Plant
Designation
1st Steep
2nd Steep
3rd Stees
4th Steep
A
?60
920
185
254
B
1100
900
700
140
C
750
390
400
50
D
2800
2250
1 900
490
E
1900
1630
1890
450
F
2750
1300
1800
870
-------
DRAFT
TABLE 38
RESULTS OF MALT INDUSTRY UASTEWATER SURVEY
PLANT
83A02IS9
83A07IP5
83A081P9
83A09IS9
63A12JP9
83A131S9
83A15IP9
83A19IS9
83A22IP9
83A25IP9
83A27IS9
a3A28IS9
33A29IP9
83A3GIP9
83A31IP9
83A32IF9
83A33IP9
83A34IP9
MEAN
(AH.)
;. 1,2)
(ALL)
FLOW
11.800
8,780
f82
7,080
6,240
6,960
6,240
4,430
6,180
9,700
10,800
31,100
11,300
5,690
4,580
4,190
5,570
5,210
BOOR
7.29
4.41
0.459
6.05
3.74
29
72
43
52
03
14.59
66
44
16
93
92
3.37
S5R
0.446
1.45
0.0914
0.892
0.543
0.586
0.713
0.625
0.506
0,928
5.52
1.80
1.14
0.171
0.458
0.477
0.885
0.836
RELIABILITY
2
4
4
3
4
2
3
2
4
1
4
2
2
2
2
4
4
2
8,140 1/kkg 4.60 kg/kkg l.rnkg/kkg
46.8 gal/bu 0.221 Ib/bu 0.04S Ib/bu
*7410 1/kkg 4." kg/kkq 0.77C kg/kkg
42.6 gal/bu 0.216 lb/Du 0.026 Ib/bu
646C 1/kkg 3.70 kg/kkg 0.682 kg/kkg
37J gal/bj 0.177 Ib/bu 0,033 Ib/bu
* Calculated without F^nt P1A2?
cool ing water.
corcMned process
367
-------
DRAFT
TABLE 39
DAILY VARIABILITY OF MALT WASTE
DAY
1
2
3
4
5
MEAN
STD.
DEVIATION
FLOW
TMGD)
0.365
0.373
0.365
0.378
0.444
0.385
0.0334
FLOKR
TTTkkg)
9,210
9,420
9,210
9,560
11,200
9,700
BOD
IMG/I )
485
475
300
370
451
416
79.1
BODR
TWkkg)
4.43
4.44
2.74
3.01
5.01
4.03
ss
TFfG/1)
92
59
125
90
113
95.8
25.3
SSR
Tkg/kl
0.043
0.552
1.14
0.850
1.26
0.928
-------
DRAFT
Model Malt Plant
For the purpose of developing control and treatment technology and for
conducting cost analyses a model plant has been designed. The model
plant for Subcategory A 19 operates 24 hours per day, 365 days per year.
It processes 350 kkg (16,000 bu) of barley per day based on the mean
production of those plants surveyed. Suspended solids in the waste,
consisting mostly of grain and sprouts, are assumed to be removed by
screening prior to discharge. Non-contact and process water are assuned
to be separated. Based on the above ratios the model plant has the fol-
lowing wastewater characteristics:
Flow (f'.GD) 0.685
BOD (mg/i) 615
SS (mg/1) 104
Total KN (mo/1) 17
Total P (ng/i) 7
pH 6 to 9
SUSCATLGORY A 20 - lr.!I,';ERIES '.'.:I>QUT STILL:
in order to determine the waitevidter characteristics for the wire
industry (Subcategones A 2C arc A 21) "1 wineries were visited, 5
wineries were sampled, and an extensive literature search was con-
ducted.
A short discussion cf the m»tr.odolocy to fce used 'in this section is •-£-
quired. Basically, a ouilJing ilock asproac.'i .vill be usea. First, •.•.-inc1-
witnout stills will oe dsscribec. Zincs ~an.v wineries in ?«ew Yor< cm-
cha^ge to navigable waters ana since '.vineries in California do net,
the raw waste and effluent monitoring in f«'ew York were understandably
more extensive. For this rea:on •.-.astev.ate'" cnaracteristies for wineries
vitfiout stills rel;. heavily on New r'ork data. Second, winerier with
stills will be aescribed, These wireriei are all located in ^jl i fom-i.i.
They proc'uce the jJrr.e .vastei/atsr 3.. ,vi<-e'-ies without st:ill"> ol1...', .:•.)'.'•>.-
water a::,eciateo .-. itn :;.t i 1 loi--. .•;-.;•.. fie cha^oct-j:'.iiica 01 ••..ilia-:"
are 'airly ,/fl1 (JeTinea, -•• ij-.ji e"i',w,\. for wine>-it;s w.tn r.MMs
during crushing will be ti.c ±u;:; of tfie .-.jstev.'dter oroduced by dir>ti 11 ir.i;
added to f.he wastewater producea jy .-/irtries witnot;t '.tills. Durmcj :.: u
processing season all wineries ,/ill [•>.• ,.u-.;/i:ed to operate- v;i th the '.,;>•••
wastewater characteristic:, >-.'.:, contributes to tiic
totjl •..•ir^ry ef^lue'it 'a 3 not z^\ ,.ci'. jjtuinfented. As idcntiried in
Section III tne sources of v/aste'.vjtor ''jring crocessing are as follows:
lees, or v/a^down of filter pro ••-:••••. or cc-ntri fuyes with lees and fiit;.-r
tiid residue; fenin/nter wasnuown; -i'-,i inii-g tonk washdown; aging tank
JO-
-------
DRAFT
washdown; transfer hose, pipeline, and pump washdown; boiler and cooling
tower blowdcwn, water conditioning and regeneration rinses; and genera)
winery sanitation. During crushing, wastewater ;nay be generated from all
of the above plus crusher/stenaner and pomace press washdown.
Combined Process Flow
It is recognized that wastewater characteristics differ during the crush-
ing and processing season. For that reason waste loading has seen sepa-
rately correlated to kkg (tons) of grapes crushed and -co cu m (gallon-)
of wine produced. The ratio of flow, BOD, and suspended solids to cir^'ib
crushed for four New York wineries is presented in Table 40. Three of
these four wineries have 24 hour flow oroportional sampling with daily •'!:'.
and weekly BOD analyses. Based on the weighted mean for these wine'-;•:••.,
it is felt that the following ratios are typical for a winery without
stills during crushing:
Flow Ratio BOD Ratio SS Ratio
(1/kkg) (kg/kkg) (kg/kkq)
1528 3.57 1.16
(365 gal/ton) (7.14 Ib/ton) '.2.22 Tb/con)
It is noted that although these values are derived frcn New York wir>•?-i•>•;
they apply equally well to California .vineries wnich are estimated to :rr-
duce wastewater during crusning at 2.1 kg/kKg- -;4.i Ib/ton) (64).
Wastewater generated during processing nas been correlated to r"ini;re'j
wine produced. The flow, BGO, and suscer.oed solids to -.vine Droa^ct-c ••;: .
are presented in Table 41. Based on the weighted mean for these wire.r-:fr-
it is felt that the following ratios are typical for a winery wit'iC'j":
stil's during processing.
Flow Ratio BOD Ratio SS P^tio
(Veil m) (kg/cu r,) (kg/cJ m)
5.62 2.22
(5510 gdl/1000 gal) (55. 3 :!.« :.;i;G =il': ."T3:J Ib/lOOO gdl}
Ht-re again the values correlate tJ e>ti:-alcr, t'ror! Cj^for^-'
C.9C kg/cu m ""300 and 0.6 N/cu '• •; ^'^.-fijiid r.o'idi, since the produc*.
the New Yorn wineries has been increased by umel icration ana blenc in
Other parameter which c^re significant for trcdt'icnt system Design jr;
ni troyfii , and ^nospiiorus. In general tnc PH varies annually from 4.C
10.0 ./itn j daily Average of 7.?. i'.ii-a on over 100 sample; from pici'
84*OiJ and 34*03 the waste can bf c''rir,v:tcjri:ed as deficient in bot'i •;•
gen and phosphorus. BOU/'< ratics -.'jry from 78:1 to tl30:l ulth those .;
crushing being somev/nat nigher tnan rnose during processing. BOD/P ra
remain fairly consistent betwei-1." 1 •."•;.-' j:u CJS:1.
-------
DRAFT
TARLL 40
RAU l/ASTE CHARACTERISTICS DURING CRUSHIMC
WINERIES WITHOUT STILLS
PJ_ant
84E01
34E02
84FQ3
84E04
Leg Mean
Weighted**
Mean
Flow Ratio
(Vkkg)
1,970
7,290
1 ,037
1,091
1,380*
2,0)0
1,528
BOD Ratio
3.42
4.96
2.88
3.03
3.57
3.64
3.57
SS Ratio
1.47
1.57
0.44
o.r
0.95
0.76
1.16
Humber
of
12
16
16
!>
(365 grtl/ton) '7.14 ib/ton) I?, 32 lt>,"
* Calculated v/ithout plant d^X' wr,-. crt has combined process
and coo I ir.r) water.
** Cxclud'.-r, FLOUR .in.-: •-.!:.» f-jr p] jn
t.o "ic.-thoii
-------
DRAFT
TABLE 41
RAM HASTE CHARACTERISTICS DURIHS PROCESSING
WINERIES UITHOUT STILLS
Plant
34AC1
84AQ2
84 A 03
84VD4
Mean
Log Mean
Weighted**
Mean
Flow Ratio
(1/cu m)
7,280
12,400
2,940
1 ,290
3,840*
4,300
5,510
,5,510 gai.
VTTOOO gal '
BOD Ratio
(kg/cu m)
14.1
6.35
6.91
30.4
14.4
11.7
6.63
, 55.3 Ib 4
•1 ,OOC •:?.' •
SS Ratio
[kg/cu m)
4.70
1.52
0.79
4. J5
2.76
2.19
2.33
,. 19.4 Ib .
' i ,OJ'J gal-
Number
of
Samples
36
47
65
5
* C'llcuUt.ed without plant 24EC2 which has combined process
and cool ing
** Calculated without plant --i-'O" Iw 'o sij^ s^d rctliod of
ssfnl^n^. Labor C3l^ii'":*•?- -v'i*1"- ,1. : l.Tnt °.l^ '•! ^u/> to ill-
plant
-------
DRAFT
Model Plant
For tne purposes of control and treatment technology and cost analysis a
model plant has been designed. The production for wineries without stills
during crushing is 180 kkg (200 tons) per day based on average operating
levels for New York and California wineries. The production during pro-
cessing is 41 cu m (10,800 cal) of finished wine based on the average for
New York wineries. It is recognized that this figure may be a little
higher than California wineries without stills due to the aractice of
New York wineries to blend in up to 25 percent of California wines, i.e.,
a typical California production during a 70 day season would be J5 cu m
(6,730 gal). Based on fiis production level the raw waste lo?ds for tr,r?
model plant are as follows:
Crushing Processing
Flow (MGD) 0. 0730 0. 060
BOD (mg/i; 23CO 1200
SS (Tin/1} 760 420
Total M fiiy/l) 7 4
TotJl P (nr.g/1) 13 7
pH 4 to 1C) 4 to 10
The following process operations a re jLSumed:
1} Stems are considerec a solid waste to be spread on vineyard
property.
2) Pressed somace '-ay be jsc-d for distilling material, nay be
spread on vineyard property, or recovered ar, a by-prodjct.
3) Diat'-r.aceous earth (filter aid) is considered a i-olid war. te '?
be spread on vineyjra ?roLes .
5j Final effluent is bcreenpd tn rerov"! rolids.
SUBCAT[nORY A 21 -'wi'iL^j .!,,-> .il"'-- "'.-I',
As> previously described, '.he .s.v '.••.. .::of r'n.-- rtii-fnui in ;.r,i s iubcaLu :.:!•••
will be the s.-::np as tMat for v.':r«r '^s .vithout •. t'lls, :'lur. !.hn V'.d' •••..•• •
associated with ^tillage.
i'rocos" rt.Tvie vtn_w":
As cxpljiried in Section ill the r- i.-. -arpnal for distillation ,n.ioy Li? "•
pOM'.ice, or wlr>
-------
DRAFT
source of distilling material, it can generally be classified as a high-
strength organic waste with low pH. Typical values for different types
of stillage are reported in Table 42 ( 6b).
In order to determine the wastewater effluent due to stillage an average
volume and concentration must be defined which will apply equitaoly to
the wineries with stills. In order to calculate the average flow, data
from 19 California wineries with stills was obtained to determine the
average amount of distilling material produced per ton of grapes crushed.
This data is itemized in Table 43 (66). Based on tnis average of 746
1/kkg (179 gal/ton) the total quantity of stillage produced would be
the amount of distilling material increased by 15 percent due to stean
introduced in the still. The average volume of stillage per unit of
grapes crushed, therefore, is 853 1/kkg (206 gal /ton). As acknowledged,"
the concentration of sti llage-varies depending on the type of distilling
material jsed, Table 44 presents data from Skofis (67) arid wet sampling"
at plan;: ££.123 which has beer, used to verify the ranges of values ex-
pected. In botn cases 24 hour flow proportional samples were taken ^or
five or more days. Based on t.iese data and that presented in the litera-
ture (68, 69) it is felt that typical values for stillage are as follows:
BOD (ng/1) 12,000
SS (mg/i; M.CCC
Sy combining tht.-se values with the flew vclune of 65£ 1/kkg (206 gal 'tor'
the ratios ipounas of pnllutart to tDns of grapes crjshed) contric^ts: :\
stillaye are:
BOO 10.3 kg/kks ;20.5 Ib/ton)
SS 12.0 kg/xkg'lLM.O Ib/ton)
Combined
The total effluent durinq cruson^ frr a .-fnery wit:i '.till', t'en, i •»
coi'.'biiiat ion of i till age ai",u .r^':',^i9 .v.r:,'.cs a. shc.-'n below:
Uue to Crushing Due *.c. ';'"ace
Flow 1528 1/Uq 859 l'-k>: 2?90 1/kkg
(365 gal/tor.! ^ju ^il.'ton) (571 gal/ton)
BOD 3.67 kg/kkg 10.; >..i/Uj 13.9 kg/Ur;
(7.14 Ib/tcn) C'J.., ',:. ton} (27.7 Ib/ton;
SS 1.16 kg/kka 12.f: • i'l.t-1 13.6 kg/kkg
(C.32 Ib/ton) C4..J: ii,. ton) (27.3 Ib/ton)
As ev; Jenced by these calculation';., . :;l}jgp confibutcs 36 percent o' "
flow and 74 percent of the BlT j.-ij ;., ;.<-nJea solids in winery \vaste dun:
37J
-------
DRAFT
TABLE 42
STILLAGE CHARACTERISTICS
Total Solids
Volatile Sol ids
Suspended Sol ids
BOD
Total Acidity (CaC03)
PH
Total N
Tots! P
Conventional
Still age
(mo/1)
20,100
87.4
3,120
n ,000
3,170
4.7
271
n , 1 50
Lees
Still age
(mg/1 )
68,000
86.5
59,000
20,000
9,870
3.S
1,532
4,284
Pomace
Stillaqe
Jmg/1)
13,130
77.0
18,700
2,400
' ,220
3.7-6.8
330
1 ..110
-------
DRAFT
TABLE 43
DISTILLING MATERIAL PRODUCED PER TON CF GRAPES CRUSHED
Gallons Distil 1 ing
Tons of Grapes Gallons Distilling Material Per
Plant
(A)
(B)
(C)
(D)
U)
(F)
(G)
(H)
{1!
(J>
(0
(L)
('•*•}
\ f
(N)
(0)
(?)
\ 1
(0}
(R)
(S)
TOTAL
Received
79,633
58,448
53,514
34,137
50,488
39,769
24,480
HOS.fcC:
45,909
17,346
131 ,381
27,822
113,050
34,520
23,56?
2G,3co
25,920
6,296
?fl,762
1,032,297
Material Produced
21 ,659,432
22,532,405
7,898,299
6,768,676
14,292,9-19
10,234,742
7, 46 j, 034
12,271 ,?27
10,275,021
i c 7 r. o £ Q
- , uc .. , -..-'. ..
•33,995,334
5,06^ ,QRQ
"• 'JTT 1'!'3
;) i f o "> 1 O
O , 1 to , b . J
4 :o:j6:.
'•* A'/ • > "' •
,!,'<".'. ,:;j.;
1 ,701 .137
3. lfi.1,523
i •• i - •> -i i • •
1 .':J , . ^ . , i :.,_
Ton of Grapes
270.968
385.500
147.592
197.99
283.00
259.868
304.74
58.828
223. m2
1A6.S6
258.754
181.93
64.776
236.343
145.732
77.6CO
11 3. OH;:
270.193
lL7_i_7_9J
—r'tv^'foJ ' l"''.v'" -1-'"" 'J.T lions Distilling Material
l»U.)£f<.7' ^ - ., ... . ,
per r.jn .;' ir.v.-.no Received
-------
DRAFT
TABLE 44
STILLASE CHARACTERISTICS
PLANT 34CSO
Day
1
2
3
4
c
5
7
8
Average
SOD 55
(mq/J ) (rcg/1)
6,650 23,100
14,400 11,^00
5,620 10,200
11,100 1C,700
10,300 4.060
12,000 13, -130
18,300 33,200
7.650 JO.::Q
11,300 14,500
DATA FRO'-1
BOD
n.i v (-no ••"! '
1 1Z.OC3
•2 14,211
3 9,925
1 1 "* "* i~ *
lj,-fc;
4vcr,->.ge 12 ,"32
N
ina/Il
369
380
184
1 OC
152
26S
203
HI
250
Sr'.OFIS
SS
'"'C .'1 ''
5.ZS9
3,784
6.?S4
;,J95
2,9:6
«!.033
P
(mg/1 ?
221
321
204
273
242
308
425
209
28S
3-98
3.92
3.39
3.32
3.95
3.91
&
3.8
3.3
3.8
•3 a
3.3
3.3
3.9
LI
3.8
-------
DRAFT
crushing. A winery with stills is assumed to have the same wastewater
loads during processing as a winery without stills.
Model Plant
For the purposes of control ana treatment technology and cost analysis a
model plant has been designed. The production for wineries with stills
during crushing is 700 kkg (775 tons) per day based on the average of
the 19 wineries itemized in Table 43 over 70 days in 1974. The pro-
duction per day during a 70 day processing season is estimated to be
91 cu m (23,900 gal).
Based on these production levels the raw waste loads for the model plant
are as follows:
Crushing Processing
0.132
1210
424
4
7
4 to 10
i-'low (MGD)
BOO (mj/D
SS (mg/i;
Total KN (ing/1
Total P (mg/1)
pH
SU6CATE3C?'/ A 22 -
0.42?
5830
5750
) 103
494
3.5 to 6
GRAIN DISTILL
In order to determine the wastewater characteristics for t.he distilled
spir-'ts industry \Subcategories A 22, A 23, A 24 and A 25} 39 plants -,vere
contacted to obtain existing historical data, 13 plants were visitea.
3 plants were sanded, and a ccrplete "ite-ature searcn was con,jcted.
Process '.-.'aste Streams
Extensive un^t process researcr, has been conducted in riistilled spirits
Dlants since the !?2Ts. As i rosu't jf this -ese^rch, procec: /Mt.to
stroa".s can be defined quite acci.rately. Table 15 illustrates
the percent of total plant was Reload attributable to each unit o^oce'r
as reported by plants 8f>iC-l ana R'F:,"i." (70 and "1 ;. These figures
are reported merely to cstabl :sh : ^ene>'al hierarchy of waste loadin.;
that is felt to be representative of :he "idustry. Additional waste
reduction measures employed by these plants since testing are reporter!
feed ^ec every - The rajor source ••;;' wast^'.vjter wi'nin
plant is evaoorator Cv'jndensate. Evaooi'ii^r-r- condensate flows '.ji'l vary
based on nash concentration in ft? for^e-iters, percint of "!• jcl-.set,"
and beer still dilution. By roducinc beer goMonaQe toward 110 1 (?2 c.-.'-
per bushel, the liquid load to the .?v = - orators is reduced. Dy increasmo
the percent of "backset," less wats«" -usr. be added to obt?in a given boer
37T
-------
TADLE 45
PROCESS HASTE STREAMS
GRAIN DISTILLERS WITH STILLAGE RECOVERY
Subcategory A 22
Feed Recovery
Cookirui-'losM'ng
Pect" fying-Bott" inr:
Disti"ling
Ferrer.r. r.g
Pd'ver Mouse
Dcrestic
TOTAL
Percent of Total '..'a;to Lead
Plant Plant
35AOI 85A13
70
1 7
i
TOO
75
11
-------
gallonage. By using a reboiler, either internal or external to the still,
the amount of liquid added to spent stillage is reduced in comparison
with liquid added by sparging live stean. The flow for evaporator
condensate might vary between 97 1 (15 gal) and 79 1 (21 gal) per
bushel. The concentration of the condensate (as measured by BOD in
mg/1) varies mainly according to the design and operotion of the
evaporator. Data presented by Rullman in Table 46 (72)illustrates the
range of values th.it night be expected. A3 reported by Hurst (.73)
Plant 35AQ1 has achieved BCD concentrations of 300 mg/1 usina a
mechanical recompression evaporator. Results of other tests (74 and 75)
indicate that BOD concentrations of from 6CO to 300 mo/1 are generally
representative of the industry. An analysis of evaporator conc.ensatc
fron Plant JJb,".Ql is shown in raDle47. The main constituents of
the condensate are free organic acids, volatile with stean at reduced
pressure and, hence, not included in total solids figures.
•
Both barometric and surface condensers are being used on evaporators in
the industry. Flows for those discharges might vary between 350 and
570 1 (ICO and 150 gal) per bushel. EDO concentrations for baroretric
discharges are generally quite low depending on the Duality of the
intake water. The temperature of these discharges as they leave the
plant might range from S30 to 99°C (ISO9 to ?10"F).
Baronetric discharges are currently separated from process wastes*--ears
and routed to surface waters. '-:et scri;Dher discharge containing parti-
culate from drum and/or grain dryers may constitute the secondary waste-
load from feed recovery operations. Before their elimination, Plant ?,5-~l~
estimated these discharges jt ?7 percent (70) of the population
equivalent for reecf recovery. Several ylants have installed cyclones
to recover participate for addition to feeds, thereby eliminating the
waste lead.
flashing - Cooking - Mash pressure cooking in batch cookers with
vacuum cooiing to malting temperature will produce approximately
7.5 " (2 gal': of condensate so- bushel of grain mashed. 'Analyses at
P^ar: 35A23 '72} indicate t.';is concensaie "ay average 900 PO/1
DOD. The flow from continuous Locxers '.vouii: oe joii'fi wnat Ingner.
Mere again, both barometric and surface condensers are employed
in the industry. As indicated in Section .'II, ccoling may be by shell
and tube heat exchanger, thus reducing ;:->c wasteload.
Cooking vessel cleanup must also ::e la'.en ;nto account. In most plan:.1:
the nv>.sh will sirply be washed to the fo~< lo'.'/ir:g coc!:, then cleaned
with caustic during the weekend. Lnpjrpnble mash which is low in
volume but high in BOD and su?r;endc-'j solids concentration will in-
evi tably be sewered.
Rccti/yi'r.n - Got tl ing - As describe 1 ~::i T-JCtion III, the potential
wastes generatec from rectifying jre fusel oil column tails and rec-
tify inu column tails. A balance snrr": *or Plant 'J5A2.7 operatinn at
200 i;l.n ("TCO bushels) per day with .; •"-1 "i noutrjl cpirits unit
-------
TADLE 46
VAKIARILITY IN BOD CONCENTRATION OF
GRAIN DISTILLERY EVAPORATOR COilOENSATE
S'JBCATEGORY A 2?
Type of Evaporator
A. Standard short tube vertical
type, triple effect and fin-
ishing pan, natrual cir-
culation, basket type
seoarators.
B. Sane as above.
C. Same as jbove.
0. Sane as above.
E. Standard vertical, Tjad^ud?
effect and finish-In- san.
Forced circulation in -1th
effect and finishing pan.
Centrifugal separators.
F. Standard vertical, short tube,
triple effect and finishing
pan, natural circulation.
Baffle type separators.
G. Vertical long tube, outside
colandria, trinle effect
jnd finisninq pjn. Datura 1
ci rculaticn.
<
H. Same as above, after larger-
vapor bodies and basket type
sep;jr,Kcr-, .in.: .iu'.or;atic lovoi
controls ins tailed.
Remarks
Operated at maximum
capacity. Automatic
level controls.
Operated at 2/4 capacity
Operated at 1/2 capacity
Operated at 1/2 capacity,
manual level controls.
1/2 capacity. Automatic
level controls.
Full capacity. Manual
controls .
',/•", capacity. Semi-
Auto level controls.
3/4 capacity. Automatic
level controls.
BOO
(^c/
675
510
55
1520
321 :J
-------
TABLE 47
ANALYSIS OF GRAIN DISTILLERY EVAPORATOR COMPENSATE
SUBC.ATEGORY A 22
Biochemical Oxygen Demand (BOD) 1,100
Total Solids (3.0 gms/100 1) - --- 80
Ethyl Alcoho: (O.C4 Proof) 135
Aldehydes - — Trace
Esters Trace
Organic Acids, calc. as acetic 550
Fusel Oil, AOAC - - Lesi than 10
Messier N'-jfogen 12
pH - - 3.6
332
-------
DRAFT
consisting of aldehyde, rectifying, fusel oil, and vacuum columns is
presented in Table 48 (72). As noted, discharges at the plant
from the fusel oil column amount to approximately 7.6 1 (2 gal) per
bushel at 35 to 40 mg/1 BOD, and discharges frcm the rectifying colurn
approximately 33 1 (10 gal) per. bushel at 300 rrg/1 BOD. It should be
noted that at these rates the waste load from rectifying would comprise
more than four percent of the total plant load. Sobolov (76)
indicates that gin process residues would be higher due to the
presence of spent botanicals.
Bottling wastes, consist ing of glue, paper, and akonol, -appear to be
neg ; irjible.
Distilling - As noted in Section III, possible sources of waste fron
dis'ti 1 1 ing are doubler discharge and beer still cleanup. If the dou!;ir"-.
discharge is sewerea then the approximate flow for a dcubler raising
procf from 115° to 130C woi;ld be calculated as follows (??}•
One Bushel Mashed = Five Proo' Gallon (Yield)
Five Proof Gallon = J . 35 '..!ine Gallons at 115 Proof
= 3.35 Wine Gallons at 130 Proof
One Bushel 'lashed = 0.5 Gallons to Sewer
At these rates 2(X; concentration may b? from 50CO to 6000 mg/1.
Beer still cleanup discharges will of course vary thrcuahcut
the industry. P>ant 35AG1 iias estimated "0,300 'l (8000 "gal) at
1500 no/1 30D for a weekly water ana1 caus-ic wash. Plan*- 35;"30
(77) reports 38,000 1 (10,000 gal) at 2500 mg/1 J.JD once oer
week.
Fe^pnt"! iO - Stesr and water <•(•-;?e the i^jur • "'•:, ;.hji"-s . P'jr: 3:A?" \~'-\ no^
es*. :-3ted *e center wash j,. 3CCO 1 ."000 na ' .' ?.n.-. :f)CO *• ""?? ..... ,'"
CJ_ea_nu_p_ - Wastes fron wee^en-l :.i?ir;;2'; or;1 ror-ia'Viy estir-ateo and ^v-
on a daily ba1, is to deterrinp tct-il ,"'l.i'it c'isc^arnes . In order to c-s-
tablish the 02neral natu>*p and :nac;ni tude of .ve€':pr.d' ,- l(Mr,;ms . data is
presented in Table '*9 (7-1). These loaos would vary fro1^ plant
to r>i;mt accorrlinn to oppratinn pr^:cdi.re , nu:"berr. on: tvr "i of equip-
ment, ?.nd pi tint design.
"
The significant pa^i'iete^'S for tins industry are flow, BOD, and
solids. The ratio', 'if these par^f ••••<; -.0 !;uf,;;els Cashed >;ere calcu-
lated for ID plnnts. In addition, .; ••<: > i jbi 1 i ty ni;mber was assignee
to each plan: based on plant visit: .!'%j the i::etnod and Murjticn of
row waste samp linn as follows:
383
-------
DRAFT
TABLE 48
BALANCE SHEET FOR GRAIN NEUTRAL SPIRITS UNIT
GRAIii DISTILLERY
SUBCATEGORv 4 22
Uine Gal Ions
In_ (Per/Hour)
High -,'ine Feed (115° Proof) 1285
Aldehyde Column Steam (5,000 -) 600
Rectifying Colunn Steam (13,000 =) 1560
Fuse' Oil Column Steam (3.0CC -• 360
-use: Oil Column Dilution IVaiei 125
3930
Out
Concentrating Column Heads 70
Rectv'yin<] Colir-.r Product ('GC" Proo'"' '00
Fusel Oil lolumn Tails to Sewer 527
(35 to '50 ppm BOD)
Rectifying Co"'j.r'n T^i'ii to Sewer ,?53_3
(300 pen 3GD)
?930
354
-------
CRAFT
TABLE <»9
POLLUTION LOAD FROf! WCEK-EIiD CLEANUPS
GRAIN DISTILLER)
SUGCATEGOF.Y A ?2
Source
r,ash
Venturi fernenter wash
Beer sti 11 caustic
Gin still drop
Mash line caustic
Evaporator water .-/ash
Conveyer water 'vash
Centr'f^qe water wash
flow
iSilL
SO
1,000
8, COO
9,000
:^ooo
100
3,000
BO
in
20
1
1
3
1
1
D
Q/1)
,000
,100
.500
,200
,600
,600
900
SS
P.CCO
450
: ,500
1,500
600
27,000
700
385
-------
DRAFT
Reliability 1 -
Pceliabi 1 i ty 2 -
Reliability 3 -
Reliability 4 -
Reliability 5 -
24 hour flow proportional
sampling for three or more months.
24 hour flow proportional sampling
for at least one week.
Flow metered, grab samples.
Flow estimates, grab samples.
Plant estimates.
This data is itemized and summarized in Table (50). A seoarate
arithmetic rrean was calculated for those plants with rel-iability
numbers 1 and 2. As reported in Table (50) the means are as
follows:
All Plants
Plants (1,2)
Flow 3atio
(1/kkg)
5572
SOD Ratio
(kg/kkg)
3.95
SS Ratio
(kg/kkg)
2.57
(37.5
-------
DRAFT
^AN
TABLE 50
WASTEWATER CHARACTERISTICS
GRAIN DISTILLERY
SU8CATEGCRY A 22
Plant
85A01
" 02
^F>4
" 05
" 07
11 OP
" :3
" 15
;1 17
" 13
ii -» «
" 23
11 26
" 27
M oq
' 30
MEAN
Flowr
(Vkkg)
8120
3680
6770
3480
3450
3550
3690
5730
7230
7360
4050
70,500
7560
6120
7420
77,100
5572*
BOGS
(kg/kkg)
7.CB
1.79
4.07
1.08
1.17
6.25
6.97
1.72
2.64
L . u i
3.97
2.16
6.14
2.9°
5.63
6.4Q
3.95
SSR
(kg/kkg)
3.52
.545
1.44
.463
.711
.592
6.18
3.56
3.53
1 . 43
5.77
.536
5J6
2.57
Reliabi 1 i ty
1
3
4
4
3
5
2
4
4
4
3
3
?
2
*_
2
?:i Ib'bu) (0.1'14 Ih/hu)
65S2* 6.01 4.23
(1,2) (44.3 gjl/bu)(U.336 lb,>u) (0.237 Ib/bu)
* Averaged without S5A23 and 85A30 wn'ch have combined process & cooling v..ir,
-------
DRAFT
TABLE 51
DAILY VARIATIONS IK RAVI WASTE
GRAIN DISTILLERY
SUBCATE50SY A 22
Flow
(MGD)
7.00
8.10
7.84
7 . 53
7.63
7.79
7.77
8.53
7.64
;.r-
7.9?.
SS
(mg/1)
120
100
84
31
21
138
54
35
41
45
67
SS
QjVbu)
0.504
0.480
C-.349
f+ T 7 Q
C.082
?.573
C.24G
C.I 59
C.1.M .
C'.l'JC
r TO'""
5 . r. • " • •• '1
SOD
(mg/1)
40
109
53
121
124
100
53
43
91
100
30
BOD
(Ib/bu)
0.168
C.521
0.221
0.539
f.502
0.415
C.267
C.21S
C.J69
0.373
C.359
6.4 kg,'^
DEMATION
0.136
38!:
-------
DRAFT
per day. Screening is assumed to remove grain solids prior to discharge.
Based on these assumptions the raw waste loads for the model plants are
as follows:
380 kkg 90 kkg
Flow (MGD) 0.650 0.150
BOD (ng/1) 930 950
SS (mg/1) 650 670
Total KN(mg/l) 33 33
Total P (mg/1) 3 3
pH 5 to 11 5 to 11
SL'BCATEGOHY A 23 - GRMH DISTI.l.E-'S NOT QPEf'ATTN'G ST1LLAG!:' RECOVERY
SYSTEMS
The mathodOiOgy for aet^r.rnning trie wcntewater1 chtiracten^t; c<, for trv.'.
iubcategory was the san.e aj for Suucatn-gcry A 22.
Process Waste Streams
Process streams are assumed to -iave the same characteristics as those
in Subcategory A 22 with the following e/.ceptions:
Feed Recovery - Jisti1leries in this succa :egory :nay onerate in one of
two mooes: 1) wet spent stillage nay be collected in holding tanks and
sold as cattle feed, J) wet ssent stillags may be screened, with sol:ji
recovered by drying, and thin callage collected in Holding tank:- for
sale as cattle feed. Since the load ^cm evaporator condensata i: non-
existent, the wastewater discharge •, greatly reducea compared to dis-
tilleries in Subcategory A ?4.
Recti fyinq-L'Ottl ing - ''any disfi'lers in thic subcategc1'^ ~ay produce
only straight wiTir^e.-. Wastes js;-jcia'.t'j ..-ivi "?ul ti -:u\ j:;i. c-ptration
would therefore be •?] iminet?c , :~-j* -JC1;:.''•••'• ji •;>.:''•.or :•: ..r.-i'-i "•..•• j-" -.:,o
sai::e. Also, ^insney :-dy Da jh: L ;.••_•'.: • n :^,'H. jfttr i.iaturaii or:, '::ii.i
e) iminating bottl ing1 discnarge:.
Combined Process Flow
Lsss data exists for these ai s: • i '(••• -, t-i uue to tnu tdct ih.u nany eii.he-
sell to Banners cr jisc;ian;e •;::-••• ...i-.-,.-•. '.o -..?-.-.rr:-.. i.':ita oocan.ou :"r >.
three plants is presented oolow:
3i..L -:.itio SS Ratio
U-il;J_ll_ _(}.g/U;jj
•j.'.:s C.736
0..-9J 0.5:3
_1_02_ QJ.01
Mean 1780 0.947 0.634
Plant
05U04
85C:8
85D29
Flow Katio
I/ kkc)
1G30
1330
1975
-------
DRAFT
The mean for the suspended solids ratio was calculated without data fron;
plant 85B29 due to sampling error.
As expected, these ratios are approximately 70 percent less than the
ratios for distilleries with complete feed recovery systems.
Model Plant
For the purpose of developing control and treatment technology and for
conducting cost analysis, a model plant has beer designed. The daily
production for the sujcategory was set at 50 kkg (2000 bushels). Based
on these assumptions the raw waste loads for the model plant are as
fol lows:
90.8 cu m/day (0.024 MG3)
Flow
BCD (mg/1
SS {rig/1}
Total N
Total P
pH
IBCAT:GCR/ A 24 - MOLASSES DI
90.8
) 210
IOC
7
1
5 to
STILLER. 5
In order to determine tne wastewoter cnaracten' sties for this subcalu-
gory all k.iown ruin di'jtillers were contacted. Two plants were vis: tec!
anci a corrr^ete searcn of the literature was conducted.
Process Streai.'S
Areas of wastewatsr generation in the rum distilling process are 1) spent
molasses ^tillage, 2) boiler and cooling waters ci -J fermenter :.c;-idcwr , .
3) oarrel washings and analytical laboratory wastewaterr. , and 4) oottMn^
wastes. Table 5t out 'lines tne waste-water generated oer proof gallon
proauce-J as well as the percent contribution oy r.vpe of waste stredi"
.'79).
Spent Sti 1 lage
This stream accounts for approximate.,, £o oerce'it o, tne waste flc.-.1, over-
98 percent of the BCD and CCJ, and over 9G percent of tne solids otnurj-f.-
The cnemical constituents can fluctuate decenoing o-i fie variabilit/ c:
ash and sugar contents of Me nolas^ei *t?ed and the degree of acic;-i-
cation prior to fermentation. TJO!.-! bj Jt?:-;onstrdt«i. tie variability
of spent stillaye baied on tne type of rolaasas usad. Sucn variations
appear to have only minor effects on v>asttr trcatati !i t.-. In additiuii,
both cane and citrus molasses are used !.". Jistillers in the Jnitea 'jtatc'..
According to plants 85C43 and 85C^4 i/o, 79} these raw materials also
produce no noticeaole difference in -,vac,tev.ater effluent. Typical cnennca'
analyses and ionic concentrations of rv.--, ild.i are presented in Tables !.••'
and 55 respectively ("9;. It shoj.j a^c ^e noted that the temperature
of this waste stream ranges from ,V. to ~-\'. C (lob to Cl'O ' F) with a dart.
brown color of approximately
-------
TABLE 52
MOLASSES DISTILLERY WASTE STREAMS
1
~n
—4
Waste
Para.. ;:ter
or
Constituent
Total
Facility Waste
Generation
per .
Proor Gallon
% Contribution by Type of Waste Stream
Slops Boiler/Cooling Barrel Water Treatment
Stream Water & Fer- Washings & Analytical Lab.
mentpr W.ishdiiwn Wastewaters
Volume
Tijt.sl Solids
Total Dissolved
Solids
Total Suspended
Solids
Total Kjehlddhl
f!i trogcn
Total Phosphate
55.6 1 (l-t.7 gal) 66%
3.0 kcj (6.6 lb) 98%
1.0 ky (2.'i lb) 99^
4.2 kg (9.? lb) 91?
3.9 kg (S.f, lb) 91%
0.25 kg (0.56 lb) 97*
0.06 kg {0.11 lb) I COX
0.003 kg (0.007 lb) 1001
26%
3%
-------
DRAFT
TABLE 53
VARIABILITY OF MOLASSES STILLAGE
Type of Melasses
pH
Total Sol:ds %
Insoluble solids %
Ash %
Total nitrogen %
Reducing substances (as
invert sugar} *
Ca %
Sulphate (as £04) "
5-day SOD p.p. 100,000
Cuban
HionTc-s:
3.5
2.81
0.25
0.42
G.C6
870
Cuban
Lev; Test
4.2
7.12
0.68
2.3
0.13
1.0
0.26
0.52
1.950
392
-------
DRAFT
TABLE 54
CHEMICAL CHARACTERISTICS OF MOLASSES STILLAGE
Parameter Mean Ranee
Soluble COD (mg/1) 72.0CO 67.100 - 75.700
92,000 81,100 - 106.300
Total COD (nc/1) 74,300 71,500 - 78,900
99,800 " 83.6CC - 115,500
Soluble BOD (ing/1) 26,500 17,600- 32,300
47,400 40,600 - 57.50C
Total BOC hg/1) 32.900 19,81X5 - 41.5CO
54.300 45,800 - 67.COG
Volatile Acids (ng/lJS HAc) 4,920 3,610- 5.9?^
pu 4.35 4.?8 - 4.J5
Solids (ir.g/1)
Total 83,500 70,200 - 95,800
. total fixeo 20,500 19.4CO - 22.200
. total volatile 63,000 50,700 - 73,600
Total dissolved 77,700 . 77,400 - 35,600
. fixed dissolved 19,800 17.900- 21.5CO
. volatile dissolved £7.2Cj a*.500 - 6ed suspended -SCO 40 - " k7i'1
. volatile suspended 5,400 Z.50C -
Nitrogen (rg," as N)
- ;otal r^ehlduhi 1 , l'"0
.organic * i,C6C 770 - 1,??0
Total Orthophosphnte ('iig/l
as P04 9? 59 - 95
393
-------
DRAFT
TABLE 55
IONIC COMPOSITION OF MOLASSES STILLAGE
(Units of mg/1)
Constituent Mean Range Observations
Zr,
Cd
Pb
Fe
^a
LU
Co
Mn
Ca
tfg
Cr
K
Al
Cl
SOA
9.89
0.18
l.ln
81.0
372
32.3
C.60
10.6
2088
824
0.30
4259
'C.38
2110
4120
2.33
C.C9
0.77
42.0 -
209 -
7.0 -
0.19
2.38
1850 -
391
0.25
4C11
C.10
^330 -
35CC -
13. '.-3
- 0.32
- 1.50
150.0
523
124
- 0.76
- 15.6
2476
1728
- 0.33
4845
- 0.58
4400
48CG
t.
4
4
5
5
5
4
d
4
5
4
5
4
4
3
-------
DRAFT
The amount of mixing water added to the raw molasses ,can affect the
strength of tne ^tillage. When the water to molasses ratio is decreased,
a smaller volume of stillage results. Therefore, in order to minimize
cost, most rum distillers maintain a low water to molasses ratio.
The addition of NH4 and PC:4 nutrients appears to have little effect
on the wastewater character-sties. It is assumed that nearly IOC
percent of the nutrients added are utilized oy the yeast cells during
fermentation.
The use of indirect heat rather than live steam in 'a still
suits in a lower volume of stillage. The total pel jtant load rer.iain:
tne same. The use of direct heat would result in a 15 to 30 percent
reduction in water usage. Only one rum distiller is cur-ently in
the process of converting from live steam to indirect ^e ting.
The unique solubility properties of calciun: solfate ;jy:su;i), on? of
the raj or coiruonents of rur 'jtill^ge, has an impact on the 'readability
of the slops stream. Lmlike most compound?, gypsum becoues less solu:,
witn increased temperatures. Therefore, tne formation of scale is an
important consideration, especially • jr evaporation.
Boiling/Cooling Water 4nd Miscellaneous Cashes - Boiling/cooling waters
can represent 20 to 25 ^ercen'. af t,"e "total fTow from 3 rj.7! distillery.
Most of tne wasteload is in the form of susoerded and dissolvea soli<:s
(less than 10 percent of the r'ai
distillation processes.
r.n of fermenters usually is sent to the still wit.i the 'wort. '
Some plants may follow with a caustic, wa^h cycle which is then either
discharged or regenerated for future washings. Other plants jse a
detergent wash cycle which is directly sewerec. The initial holding
tanks for molasses seldom require washing since they are ra-ely erpty.
A r"inse once a year would be an exceptional ^
Barreling Operations - These operations involve a vinin'um of water us
(approximately 1.3 gallons jf water/rja I Ion of rum). Since alconol l.i.
for rum production oerr,:it the use of used oak barrels for aging, the
barrels are washed after usage. Thp resultant wastelcads are small
amounts of dissolved materials wivcn have migrated to the inside
surface of the barrel during maturation. These wastes are washed off
the barrels at the barreling site anc disposed of directly. Further
reuse of such wastes has not yet bc^-i explored.
-------
DRAFT
Bottl inc} - Due to tfie similarities in bot'ling operations between grain
dTsti 1 lers and run Manufacturers, trie res. "tiny wa;tc.' loads are abSuined
identical.
Combined Process Flow
All known existing data was collected in order to determine combined
process flows. The ratios were calculated for flow, BOD, and suspended
solids to proof gallons produced and are presenced in Table (56). Other
parameters requiring consideration are pri and temperature. pH averages
4.3 and temperature 100° C (212° F) due to the high percentage of
stillage in tne waste.
The production of the model plant is 3Q,C'CC proof Gallons per day, based
on the mean of tnose plants in Table 56. It is assumed that stillage
is discharged without treatment and that process and cooling water are
separated. Based on these assumptions tne raw waste loads fcr the
.node! riant are as follows.
illBCATEGOTi' A 2:
Flow i'l'GIi}
BOD (rq/1 )
SS (r:.g/l;
Total K,N
Total P
Temperature
pH
Color
- BuT7LI'ei^ plants ''ay only bottle beverage ale;1 •
pr-d'JC£d in .vinur^es and a ; sti 1 "er :es . or t.-.ey nay uciJi ticna 1 ly rrdist-:"
ana rectify purchased liquors in j"der t: "-anjfacturr suc.i products as
cocktails and cordials. The Bastes v-volved are thos^ frcn; redisti11ic : .
rectifying, and bottling, in order to demonstrate the general nature o;'
these wastes, data will be prpsent'.'O fro'ii plant 85D1C, a large recti*'er
uotiler. «lthouyn ti'is is not ntoriuEd to represent the typical wastes
for the entire spectrum of the industry, it does ;dentify unit process
wastes that may be common to other ?ottle^/rectifiers.
kedisti 1 1 ing - Boti> vodka and gin .T-J products which may be redistilled.
The residue from i'0di sti 1 lation en . i •'r „:•..• s the r:ajor waste associated
with this segment of the process, neaos from continuous column distil-
lation and bottoms from batch dist • 1'ation are collected in a holding '*.*•
396
-------
DRAFT
TABLE 56
RAV! WASTE CHARACTERISTICS
RUM DISTILLERS
Plant
85C34
35C3S
85C39
85C45
••.EA:I
Flow Ratio
(1 /proof qal }
25.7
23.8
255.0
378.0
21 ,3
(7.?2 gal/pq;
BOO -'at io
f kg/proof gal )
0.997
0.922
1.40
n.5?7
"."69
:';.125 Tb/og;
SS Ratio
(ko/pi-oof nal )
0.1*9
0.206
0.265
0.1 10
O.UT3
;C.292 Ib/pr;}
'Excludes Plants 3SCJ9 .end Br"-5 ,
ccoV.ng vater comDined.
reported orocess ari
397
-------
uHAFT
On an average of once per month 3000 1 (oOO gal) of this liquid must be
discharged. The approximate [SOU is 245,000 mg/1, the suspended solids only
6.3 mg/1, and the pH 5.6. If discharged at once, this would represent a
shock load of 7400 kg (16,300 Ib) of BOD. The residue from redistillation
can amount to one percent of the input to the still, but this waste does
not necessarily relate to total plant production since some alcohol used
is not redistilled. A correlation may be possible if linked to the vodka
and gin production for each plant.
Rectifying - The types and volumes of wastes from rectifying for plant
bSL'lu are listed below.
Type Volume I/day
Frame Filter Rinse 5700 (1500 gal/day)
Product Cniller Rinse 600 (1GO gal/day;
Vodka Column Rinse 2500 (650 gal/day)
Product Tank, Filter, Line
and Pump Rinse 7200 (1900 gal/oay)
Bonded Warehouse Rinse 4000 (1000 gal/day}
Winery Rinse 950 (250 gal/Jay)
ueroineralizer Regeneration 1900 (SCO gal/da>)
These wastes generally contain only dilute portions of alcohol that nave
adhereJ to surfaces during processing, except for denn'neralizer reae-io--jr. •'.•••
Periodically, the demineralizing resins must be recnarged by washing witn
caustic and acid. These are presently collected and neutralized before
discharge.
Bottling - These wastes consist mainly of filler cleanup and r-.i^cellaneoui
floor washing. Filler discharge win obviously vary depending en the
number of fillers, number of product changes, and volume used. Glue and
paper labels may also contribute to the load.
Bad Product - A small quantity of bad product is destroyed sericdicai 1v
due to the product not meeting quality standards or being diiconrinuec.
These are crusnsd in bottles w> tn the liauid being sewered. This may
amount to as much as 10,000 wine gallons per year, however it may vary
greatly depending upon the amount of new product activity or package
changes that occur.
Combined Process Flow
The combined process flow consists of biodegradable liquids with little
or no suspended solids. The flew -nay vary from 19CO 1 (500 gal) per -jj-, ,
for those small plants only cotthng, jp to 40.CCO 1 (10,000 gal) per da/
for large rectifier/bottlers. For the most part these flows will be lew"
in BOD concentration due to dilution fjctors. Heads from redistillation
and bad product discharge: may, however, be quite concentrated dependino
on the method of disposal. There is no existing data available concern-
ing combined process flow.
398
-------
JRAFT
It should be n 'ted that considerable non-contact water may be used in
large rectifying/bottling plants. Compressor and redistillation column
cooling wa*?i comprises the vast majority of '.his flow. Plant 35D10 gave
the following breakdown of water usage:
Percent
Sanitary Waste 5.9
Industrial Waste 5.7
Non-Contact Discharge 67.5
Boiler U'ater 3.9
In Product Jj.j
Total 100.0
Model Plant
For purposes of rost analysis and treatment systen design a rrodel c-"-;'it
n'jst se designed. The following assjr^Dticr-s have bee-; made;
1. Residue from redistillation Tiay amount to one percent cf '..-.e
input to the still, "or slants with redistillation this
wasie is assumed to oe collected in holding tanks.
2. Bad product ray accrue and periodical"y require disposal. '"••:
product is assumed tc be collected and Held Drier tc disposal.
3. Demir,er2 i izers .ray re -ised. requiring periodic regeneration
This is assured to be :ollectsd in holding tanks and neutral-
ized.
4. All other process wastes are assumed to be separated frcn ron-
contsrt ..'ater. The process Bastes are assumed tc result -rcr.
washdo-vni previously iternizea and to be b'0'i'?^'*a:able '..itn lev.
concentrations of 2C3 ind s.iperced so lie.,.
Based on these assun.ptions two model plants have been designed. Dlant :
is assumed or.ly to bottle. Plan; B is assumed to rectify and b.ttle.
The raw waste loads are as follows:
A B
Flow (cu ra/day) 4 40
(MGD) 0.001 0.010
SUBCA'EGORY A ?o - SOFT DRINK CA.J;.FRS
In order to determine the wastewati;r cr.aracteristies '•-.? the5 soft
drink industry ^ubcategory A26 and -\27', 74 plants were contacted
by phone, eight plants were visited, jr-i five plants were sampled.
In addition, a complete literature ;eirc'i was conducted.
-------
DRAFT
Process Waste Streams
The major waste streams associated with soft drink earners are filler
spillage, mixing tank washing, and fill tank and line washings.
Filler Spillage - Due to the type of container and the speed of the
line there is considerable spillage involved in canning operations.
This product waste may be characterized as high in BCD, total solids,
and acidity, and low in suspended solids and pH. Expected ranges are
as follows:
BOD (mg/1 ) 60,000-80,000
Total Solids 'mg/1) 1CO,CCO-120,OCO
Suspended Solids (mg/1) 50-2CO
Acidity (mg/1) 1 ,200-3,200
pH 2-3.5
Mixing Tajik h'asmng • Nixing roo::i wastes originate from t.'ie snail
residue of syrup Cuf.-.sed during flavor charges and the water required
to wash the nixing tanks. Syrjp used for carbonated beverages may be
as high as 800,000 -g/1 BCD. Knen diluted with wash water this waste
has the sane character as filler spillage, but it is lower ir. ccncentrat
and nigher in pn.
Fill Tank ord Line 'Jas rings - "^ese wastes, again, correlate closely
to the nur.'.Der of flavor changes. A small amount of syruo, and water
to flusn the filling lines, is -.ne source of waste. The character
of trie waste is the iame as t:iat from :ne m-'xing ranks.
Other Wastes - Additional waste :nay be created by washing bulk con-
tainers, periodic washing of syruo storage tanks, water treatment and
filtration oackwash, and plant cleanup. These are considered to be
Minor process discharges. Bo^er and compressor cooling water corpr:;e
the majority cf toe non-contac: water.
Corr.bir.tiu srocess Flew
In order to demonstrate the ccririied ..-aste craracteristies from soft
drink canners, one plant Mas teen seiec:o!d ,-/mcn conducted twent./-*C'ur
hour samplinc; over a oeriod of ."ere ti'dn -;ve days. Tne resjlts are
presented in Table 57. As expectsc t"e T^D concentra'.'icns were hign,
but the ratio of pounds of DDL to .jjllc^s L>roducea was >juite low, Thii
is explained by loe lew flow discnjrgpj ir, conjunction witn a higr.
volune of croduct'o^. The prl of '.ne wajie .'-as below six, indicating
-.he prsse".;e cf low pH product in tne waste.
Saseci on the average of all cannerr- -.urveyed -,t is felt that the
foil owing rjr.cs arc typical.
400
-------
TABLE 57
DAILY WASTf. CHARACTERISTICS
SOFT DRINK CANNING PLANT
Plant 86A27
Day
1
2
3
4
5
6
Averaq
flow
(MGD)
0.033
0.031
0.036
0.035
0.037
0.031
e 0.034
Ratio
(gal/1,000 ga
28!
277
305
280
296
253
282
BOO
U l«'9l) J
1650
960
1140
llbO
790
1480
1197
Ratio
[lb/1,000 gal
3.86
2.22
2.89
2.70
1.94
3.13
2.79
SS
1) (mgl)
151
177
118
192
219
376
206
SS
(lb/1,000 gal)
0.36
0.42
0.30
0.45
0.54
0.79
0.48
_E"
5.9
4.3
3.5
?.9
4.6
3.5
(282 1/cu m)
(.335 kg/cu m)
(0.057 kg/cu m)
-------
URAFT
Flow = 741 1/cu r.i (741 gal/UOO gal)
BOD =1.02 kg/cu m (8.51 lb/1000 gal)
SS = 0.123 kg/cu m (1.03 lb/1000.gal)
The pH is expected to vary between 3 and 7 except during periods of
cleanup when alkaline wastes will be discharged. Based on sampling at
Plants 86A22 and 36A29 the effluent appears to be somewhat deficient in
nitrogen but adequate in phosphorus for purposes of treatment. 300. N
ratios averaged 60:1, while BUC:P ratios wera 110:1.
Model Plant
For the purposes of control and treatment technology and cost analysis
a model plant has been designed. The production was set at 309 cu r-
(81,500 gal) per day. Based on this production and the ratios listed
above, the raw waste loads for the model plant are as follows:
Flow (I-1GO) 0.0610
BOD (mg/1) 1380
SS (mg/1; 167
Total KN (mc/1) 23
pH 3 to 7
S'JECaiESDaY A 27 - SOFT URI.JK 30T~L.';;G'CA^iir.: PLAi.JS
Tne .^ethology for determining the wastewaier characteristics for this
Sue-category was tne same as for Subcategory A 2G.
Process Waste Streams
The major waste stream associated with bottli1^ plants is t--e bottl'r.r;
jsner. Mixing tank and filler line ••vaindown is expected to be siri'or
:o t/2t from canning plants as previously discussed.
Bottle dasher - As described in Section III, the sources of ;"ol'jt3rt:
fron tne beetle washer and sugar r-jsiaj^s fron left-over product, sui--
pended solids from labels and rrator^'a: left in bottles, and caustir.
carry-over fro™ sprays and oakinr; tarks. Tj-:'ical values for prennse
and final rinse sections of a bott'.e wasrer taken at Plant S6A32
as follows:
P ror Ti'.so r;r>a1 •'inse
500 (nig/1) II -;0 35
SS (mg/1) 76 Z8
!•) Alkalinity (r.ig/1) 263 206
pH 10.3 10.3
The flow associated with this washer was 220 1/nin (60 GPi-i).
402
-------
URAFT
Combined Process Flow
The final discharge of any plant with a bottle washer will thus be
higher in flow, pH, and alkalinity than a plant which only cans.
Table 58 itemizes and summarizes the characteristics of plants in this
subcategory. A separate mean has been calculated for three plants wh-.cn
had conducted extensive monitoring. Many of the other plants had data
collected only from grab samples and flow estimates, ^or this reason
it is relt that the ratios for these three plants more accurately reflects
actua'i operating conditions. Based on tnese means it is felt the f&llD.-rrq
ratios are typical for this subcategory.
Flow BOD SS
Ratio Ratio Ratio
(1/cu m) (kg/cu m) (kg/cu rn)
•
3540 2.38 0.380
It should be noted that the three plants with the lowest flow ratios
were primarily carmers with minor oottle washing or, in the case cf
F^ant 36A29, a bottler wncse bot.les were being wasned by an outside
agent.
The pK for this subcategory is expected to vary bev.veen 5.r; 3nd IT ./if!
relatively nigh alkalinity due to ti.e bottle wasner. BCD to nitrcger:
and phosphorjs ratios are expecrec to remain 60:1 and 110:1, respective;..
Model
For the purposes of control and treatment technology and cost ar.aly;-. :
a model p.lanr. has been designed. The sroducfion was set at 135 cu "i
(35,900 gal) per day. Based on this production and the ratios listed
above, the raw waste lc<__:> for trie mocel plant are as follows:
now f;:G'J' 0.126
BOD (ir,G/n 660
SS (mg/1 j ;08
Total KN (.siy/l ; 11
pH 5.5 to 1?
SUBCATEGORY A 28 - BEVERAGE BASE S-RUPS AND 'OF CONCENTRATES
As discussed in Section III, it has ^een determined that tne ;rra
individual waste st-eams venerated in the ceverage base -nanufactur; ng
process are as follows:
1. Washing of mixing tanks and flavor tanks at the end of
each day ard between flavor changes.
2. Washing of :.yrup tank car:, ;.."!8 1 (55 gal) drums, and 19 !
(5 gal) containers prior to refilling.
3. General pla'tv: cleanup.
403
-------
URAFT
TABLE 53
RAW WASTE CHARACTERISTICS
A27
Plant
86A04
86A06
86A07
86A13
86A16
86A20
86A24
86A25
86A26
86A29
86A32
86A34
65A37
86A33
86A39
86A40
Mean
Mean
(38, 39, W)
F]ow Ratio
0/cu m)
1260
1990
. 4120
4520
6780
4290
9370
5910
6380
16?
2260
254.0
3C9C
2760
3991
3050
3905
32G7
BOD Ratio
ika/cu mj_
0.826
0.257
0.371
2.02
4.68
0.806
1.31
6.74
3 01
-------
DRAFT
Washing of Mixing Tanks
Plant 85S06 generates approximately 76 cu m/day (0.02 MGD) of wastewiter
from the washing of six mixing tanks and eleven flavor tanks which f'^eo
the mix tanks. It should be noted that this figure is highly variable
with the daily quantity dependent on the number of flavor changes made
and the number of batches mixea on any given day. The equipment is
commonly washed using automatic or manually operated spray ball devices
mounted within the equipment and the quantity of water used is usually
regulated closely.
Washing of Tank Cars, Drun.s and Containers
The cleaning of tank cars generally consists cf a hot water wash fol-
lowed by a sanitizing rinse. Drums are commonly washed in sealed wash
tanks. Each drum is fitted with one resealabie opening at the drum's
equator. The drums are positioned on a rack wih the opening face dc'./n.
Met wain water followed by hot rinse water is injected into the drum.
After droning, the drums are removed. The 19 1 ('j gj.1) containers are
washed by vertical placement (opening down^ in a revolving washer wnit.h
tei in? water output into eacn container.
Plant 87506 reported tne following daily quantities uf was. leva ter fron
each of these cleaning operations during a normal day
1. Tank cars (average eleven) - 5; CLJ m/day (0.01G KCD)
r. Li rums - 303 cu in/ Jay (O.C8 MGD)
3. Containers - 7!>00 I/day (2.CUO gal/day)
It i r, noted that th'- ;e quantities will vary within the plant and between
plants depending on daily cleaning requirements.
LU i;,.
f' quantities typk'il, ii-mj^.i '.•.'•.: 'iur-m; Ueanuu nt I'Lint :^
LOiisi itinq of pipe line steri ! lidtion and floor washinu, average 30
(O.QOB iibl') and this iiuantity '.%niilil not !•(> oxiiect.L'd to vary narkcdl,
throughout tne induc.tr/.
Nori - •' in 1: d c t Wator
1 lie re ij d jinill dincunt of non-i tmt.ji:; in.irlnnprv cooling water and hdi'h-i
blowi!..i'..i: afner.; t.pd in 'he 'iianutdi tLii ''• : •'' '..'rvi'mric li,i:;os.. Thir, non-
wdLfC ij Ljcii'ji'dlly ui jUiurgtu in 1,0 tii^ pi\n-fss wdslu •• t'.'edm or i-Mo s-> .....
••.ewers,
The wjs'n>-,,\:ter characteristics of tl>.o tot.il plant effluent for f'>ve
bevcrdgo bjse plants are summarized in Ijble 59. The data indic.dti.j
wide rannc of flow and BUD concentrations but consistently shr,w low
405
-------
TABLE 59
SIIWARY OF WASTEKATER CliARACTERISTICS |>
:UL'.ATl'iPY '. "> ! •«
PL1"/!
coo:
87S06
67S07
87508
67009
fe7',14
FLOW
cu m/day
598
63
125
•9t
459
cu ir/cu m
1.05
0.40
1.16
BOD
mq/1
1866
5910
3750
1110
3050
kg/cu m
2.02
1.43
3.56
SS
mg/1
32
328
40
162
353
kg/cu
0 032
0.016
0.36
35.1 12.2
-------
DRAFT
suspense i^Jids concentrations as compared to BOD concentrations. The
pollutant raiios were determined based on additional data provided by
Plants P7.SG6. 87S08, 87S14. Plants 87SG6 and 87514 showed good agreement
in ternij of wastewater flow per unit of product produced. However, the
polluter": loadings per unit of product produced are dissimilar. Plant
87SOB whicn generated roughly 60 percent less flow per unit of product
produced than Plant 87506 had a BOD pollutant loading 30 percent less and
a suspended solids loading 50 percent less. This indicates a rough cor-
relation of 0.5 between the two plants. The nutrient to BOD ratio
(BOU:N:P) was determined to be 100:3.1:1.1 based on tht data obtained
from Flint 87S09. It ,-nu'st be noted that only a limited number of data
points was available in determining the data presented in Table 59.
However, the data do offer sufficient information to allow reasonable
assumptions as to the anticipated characteristics of a model beverage
base marwacturing plant.
Model Plant
Bar-ea on the above considerations, a hypothetical rr,odel plant was develo^
for Subcategory A 28 and is illustrated in Figure 133. The plant gercra !_••
an avercge wastcwattr flow of 379 cu m/day (0.10 .'-'5D) due to waging o*
mixing and flavor tanks, washing of tank cars, drums, and containers, (ind
general plant cleanup. The model plant has the following average charac-
teristics.
Production 379 cu m/dav (n.10 USD)
now 379 cu m/day ;C. 10 IIGJ)
BOD 240C ng/1
SS 50 mg/1
pH 8.0
The assumed characteristics would be expected to vary with seasonal «ro-
ductio.i demands and the amount of cleanup operations conducted in the
plant on any given day. Tr.ero ir, :,or:e reason to believe tna: tne wwjt.c
cianf'ier sludge and cleanup.
Periodic discharge of tea .•.n."il'Je i1. U't1 only prococ-j wostt.M.-,jicr rjor1.-
prati'il in Hi'1 |>ro(.:»?j jing '.K iiis'.d.'l '.cj . There; i i nu reliable •••;,j_, L.I
eitimate the guantities of pollutant luddings of the clarifier wdbte
stream since the discnar'.ie ij 'lirji-, 1 . variable.
Cleanup Hati-r
Cleaning of equipment may be done cr> several different schedules as
indicated in the following:
407
-------
DRAFT
SUGAR
-------
DRAFT
1. One plant (99TQ4) operating 365 days per year implements
cleanup of the entire plant every ten days.
2. Two plants (99T01 and 99TC2) generally operating on a five-day per
week basis implement plant cleanup at the end of each week.
All plants contacted did some periodic cleaning of equipment during the
week as needed. All plants contacted also did some hosing of floors in
the plant for cleaning of leaks from connections. Equipment cleanup is
generally done by spray ball devices contained within the equipment which
are operated manually a: needed. The cleanup consists of the following
sequential steps: (1; fresh water rinse, (2) caustic wash, (3) fresh
water rinse, (4) acid rinse and (5) fresn water rinse.
Non - Contact Wa ter
A considerable amount of cooling water is generated in the processing
cf instant tea. Only one plant contacted (99TCK; separated all cooler!
water from process water. Two plants, 99TO? and S9T03, provided no
separation of contact and coolinc; ,-/ater and 'o recyciiny of cooling
water. One plant (99TQ1) recycled a majo' ity of the coolinc; v;ater
used in the process and discharged t.-ie unrecyded into the wasie^troam.
Total Plant Effluent
The wastewater characteristics of tMe instant tea industry are sunnar : .v-j
in Taole 60. The two plants (99TOZ ana 9y":0s), for *nich the portion
of total effluent attributable to srccess water .-.as w\ an<.\ '.!•?? Mcv.atcicd '.i
Model _Pl,— t
Bar,cd on the d
-------
TO I
TABLE 60
A 3(J - SUMMARY OF WASTEWATER CHARACTERISTICS
Flow
*94,700
49, £00
*167,hU()
46.5UO
SOD
Kg/KKg
41.1
52.4
196.3
10.0
S5
Kg/KKg
34.7
38.2
-
5.8
Vd'ues are high due to indeterminant amount of cooling
.••if-er in the plant effluent.
o
73
-------
DRAFT
MOuCL P' .A'i"> '" '•• ••
INSTANT TEA MA', .'•,.;
••••'*[';c"v A 30
*.5!NG PROCLSS
411
-------
DRAFT
clarifier tea sludge into the wastestream. All cooling water is dis-
charged separately from the process waste stream. The characteristics
of the model plant are as follows:
Production 9.1 KKg/day (10 ton/day)
Flow 450 cu m (0.12 MGO)
BOD 1000 mg/1
S5 750 mg/1
pH 6.0
Spent tea leaves from the centrifuge are sold as cattle feed or disposed
as solid waste.
SUBCATEGORY C 8 - CQFFEE RQAS'IMG IT ILIZING ROASTEP ;•)£T SCRUBBERS
Roaster Viet Scrubbers
A study conducted at a coffee roastino irant utilizing a once-througr>
type of wet scrubber reported an e'*lue.riL -.viUi a BOD of 100 to 500 nn/',
suspended solids of 180 to 240 :•"]/! ^rd a flow rate of 2100 liters per
kkg;(iOS gallons per ton) of areen beans roasted. No data arp
currently available on the wastewater characteristics o' the rer-irculatir.'
type of wet scrubbers used on co*fee roasters.
Total Eroccssirn Effl 'ent
Roaster wet scrubbers are the only source of wastewatef frc^ o. coffee
roasting slant. Table 61 orer • ':: i rjw v/dste sui:na--y of this '.%.jstew3tO'\
Model -lant
The "odd nlant. *or this subcatecorv is i rpf*?? ••casti-.-.'; olint which
utilizes a once-tnrouoh type of roaster wet scrjbber. The model nlant
roasts 30 kkg (73 tons) per dfly of nreen coffee be-ins.
W^s**?'•••'3*•?" - 'he only source of •.•Mst^-»,i.it'?r f•"?•" 'hf T'lrl "^-int • ; *'"•.•
as follows:
1. Flow r,ite - dvornnf - C. '"•' •-.] , ''".ff ' •;;.•._'}
2. ROD - 350 mg/1
3. :s - <:no nq/i
4. pll - 4.0 - 7.;.
5. 0.76 - kc BOCJ per kv.: ;' Tr»cn beans
6. 0.43 - kg SS per kkq of -,reen beans
7. N - Q nig/1 (assumed, none suspected)
?... P - 0 mg/1 (assumed, none suspected)
-------
[>RAKT
TABLE 61
RAW WASTE SUMMARY SUDCATEGORY C 8
COFFEE ROASTING
Parameter LOT Mean Minimum Maximum
Siiift Tine Hr/L)ay 8 88
'•"low :
-------
DRAFT
SUBCATEGORY C 9 - OECAFFE!'!AT n:i OP CQITEF
Extract Centr if ugo and Stil 1 plowdown
The blcwdown liquor from the solvent recovery still and the extract
centrifuge are normally disposed of as cart of the waste stream from the
decaf feination process. These blowdown liquors are a significant source
of both wastewater strength and volume from the decaffeinalion orocess.
They contain high concentrations (quantitative duta io not avai l*i>le)
of suspended solids, and to a lesser extent, COO.
Dch'dle_ri_n3_ Screen
Aftci the extrdct. ano the L- jnr, h-ive he>-n 'jHOiirdted, the be •:•, drr_> wd',.'"'
and 'irreenecf before drying . The dewut-jrinq •-, . r*"?n is the r,p'iTe <>1 '.lic^
nreutest volume of wdstevater in decaf feinatinn pl.ints which enplov
thi', device. Although no -j,ita ir, .WOT lab IP to qu.inr i*,3tivi-l v define •'•,':
Chui -J...trjr P: ' icj of thio '.•'.-IL U'vMtrr , i- : ', »'. t ::•',) rifi *h,i'. t.h'.1 '/.rnn'; ; ':
Of thir, c,our';e gf wd'^'e1./ i*.(?r > •: ]r.'r.^ fi.in .ill other', oxriniir. "/-"pri 1
pla'it Oeanup.
Clcjriup
in p'jnt; whirh '.<) net -.itil:/*? •} )'jv/,i ' ,-•••'!•; • !-'.•"••, . leiiitur ' '"• tK': •'•"•.'
si'ini f H'cint snurcf- of v/ar. 'p'.v.ster vo IVK ,'M i id i ' • VM , •!?(. j' ' i> i no • • M
pro: r-s'iif.n plant rlrViO'/p '. •, il i "[ii;r' ,:f. •-,(•<•• • ..• v/H r. t !' 0 * r -~'":: ?.*'
in '."C procssi dred (irp ",;,.;.; loi/n r. !:.»>Ji»). /jj.i'!/ -ru r.' -n- rw'..>' i
dfi / . The deca c*f-'ind I ; no i":ij !p"'f 'i^ • '. ' >-.f'r"i';'i ; ' . .•!'•' • 'I'-iru-1 ••.r:e' ' / :r :
•••pn* r:!-_>cined jc neces'^jrv rjijr •.'•!) •!!(• ,•.'(•"-. • .it t c; me • '.nrj i" irr--!', m ••
C ! 0.1 .":;.• cl periodically .ir-c) ,-il'jo i,,jr,'.'' "...ji H t,D lip -/us I. el i-id n' fhr> pl'in1. .
The '.Vjjnti ty and qu.il ify charji. ".'.•' 'S'~' '•. '' VH •;
ct^TJffeinot my ul-jMl-, *.irv •.>'•<• ;crir'. r^o-.e
ti'ii'f>'l *•<) fh" .irou"'. :' :'(!-.)'••• j ••..,..:'•; •!" -\ ':••/"" •'T:. '". i-lv' •
' 82 '• r .'in-rt 1 1 •"''•:,'. ' wo • " ' I .••)••:' •• • • ; i : . •"•.•.. :•"••!' '.,.,; v i . • r.
in il.'i;.) -KKJ thftt: folj Vdl : dtimr. m =!•."»>•"•"-', -T!'|- *.il'.- (j^ MIL',,. '
>!.i'i descritint) !'ho to'ii ;)>••• >• •• , ••''.!••• • . •'•.]•. MJ|, t'.i.-'j'i'- .
Mi "!•..•] P'ant
Tin- "Hjdyl jl.inf Inr '• II 1 '. •.,'('- T ' • i '! |in''u.' • i» •• ' ,i|' ;!•• 'r-. ,•'.•• '1,1 < i >r ; •, ,. '.-(•. i i •. • .
J'.i'":i| '. ''(' 1 i'H/ I'l ' I inill'l "'f''l '• T ;> •".•. "> i .' >."|u I pn-fi! |'n| tl.-i-ii-
,ir" '/n( i^'li-n). ihc "IC-C'I ;;!..'.( • -. ;• "•.-.i:". rr) tO OI'OGOj'j r)" lki'1 i 'jO *:r
o^ ife?;! beans per day, njier-at'f'j . - ,•••,!••; :,>MI- •;.)•' ^i-- :-!.v'. P>M- .•;<•..
" l1^' ^'.Ml <"• - r.S Of Wtl'. r i"-,,i '.•." '' ' '-P ••K'.'JH'I l.'t-int ',"|ll)'1 111' In-.!"
,i 1 1 ot the inui'ces listed dbovf ••;•• • -i" -iri-.jf yr- 1 siuan'.i ties of ^t»st"-
-------
DRAFT
TAMIL' 52
RAl-l WASTL SUM'IARV SUiiCATCGORY C 9 - DEUFrEKiATION OP COFFCE
Parameter NP L cornea n Minimum Maximum
Production kkq/'iav
tonu/day
flow '1LD 2
MGD
How Patio 1/Mq 2
ROD inq/1 2
Ib/fon
Ib'lTin
* 'jo' f >,|i>. •! ' •, i '•.. • .,[ .,-
55
60
0.242 0.213 O.??1:
0.07C1 0.062 r).f)7'i
4406 3980 T7 '
1164 1025 T;;';:
'',.". 3.U ••'.'•
1 .', f). ! f| "
H) •') • i in;- ;'i ' '.
7 . ') r> . ," '* .
i ', ) i!1..! 1. .
,,,,.... ,] i . ..i,-it " !<••] will- l ' . '-• '•'((• "'
'.' ' ••• '• ' "i.li'i *"'!(' •:.(>!:,r -f j c.^,,
-------
UKAKT
water coining from thi? debaterinr thp '.r^r' ".\'" " >"' ' '. .> ' 'v: ' p»v i '. i jf! .
plunti the onl .' source ;;' ..-i - '.'.!'.,• -;t»r 1% :!''3'n3qe ','' f of thu
'i'o.i 5torJ-io. AT.Hf •., :'i :n->. i •, il:,o ,: ..ou'-.u 01 /jstr.- '
1 1. 13 a Ifjj T, i an ; f i L.in4- v/n 1 1 ^v. r c •• '. ir.;c ''i.iri ;--'>ijni)', :)••(.•"' i HT.
In 'hp <,,: ' ;i'i IP '••••''fpp :
-,,..-,„;.. . ., r..«ri:t *"'.' '.n'ui: IP <•• ' • '.jents , The \olut '.:'H rt'su !'.•'•
f '' r f,'i:', vM.f.T,'. .i'i'..' ••;:)nt.fl •'•;". . "••"•li'.l -.r vr\ 3 i •-, ivhii.M •'•u':, t !"'0
rer.Ovfiij ;>,• ten! r Ifa'f.jt iun. •' »M • ••• v.-jrr.e nt v/a-jte load in nearlv
SL-'T?ip -'•'•ro ?,'3''.f. •' --ont'--'... '•'iP1'i;j .-liul b 1 CK'dOv.n . Tne i. •!
.'tpi '.-I'ji'iC' j"'J .'eanu;.' •.,!•.'• . • •• !'•.(•• c""tr-: ' u,;o T r? ni>rr-,iii
M'-JVO J' r.ir* r* t"G ''O.,' i . • ' •• ,'t-pdf: fro;'', tne Kl
416
-------
ORAKT
Extract- Concentrator Condensate
Before the extracted soluble coffee materials are converted to a solid
by drylfiq, the liquid extract is usually concentrated. Concentration
is accomDl ished either by heatinq or coolinc the solution. Whichever
method is utilized, a large volume of condensate is generated. Trris
condensate is the largest single source of wastewater flow from a
soluble coffee olant.
Cleanup
General cleaning of equipment and floors in a solucle coffee slant i:
also a significant source of waste ;?t3r generation, "loci's arc .jet
cleaned oS necessary durina oroduclion and thorougnly cleaned week I/.
The extractors and related equipment are self-cleaned dufinq production.
Once a week during general cleanup tne extractors are cleaned with a
caustic solution.
Total ?-ocess-'no Effluent
The quantity and quality chararts'^'stics of soluble cc^fc-" rrocp:: •! ••••:
wastewater can vary as =1 result of -jleaninf procedures and the ••.£*!••.-.
of grounds handling and disposal. Plants utilizing rotary dryinn of
spent grounds and e^ficie-^t cleaning procedures are the plants .vi'.".
the lowest wasteload. Table 63 • ncjjde: djt: oescnbino tne totul
nrocessing effluent.
Model Plant
The nodel olant for th:s subcato'cry is a hycotheticjl p'ant orodj - r. .
aooroximn tely eaual amounts pf sr^'.y ans freeze dried soljb'ie \_v/f:'efe.
'.vaste ccf'ee gorjnds ire oresiod to reduce v.ne moisture content ?!!•:
used as f'.;el for tne riant'; oilers. Cl'?2i"''r^ -f ire e "j.> ; r'::-.-r.t .••:
general slant cleaner occurs ,-;et^/. and ootn prccsr-sei jtilize :'•••
To'dl ki'-oduc tion at. '".f no^el "lin* 's v-~.;~~l '"> Sr.1 7°. ••'.•; 'r7 ' •
in .. '• 'iout s ::ei -.;,', ^ '. .< .;
extract concentrjto11 condens.itc!. ..^sier -r, uiiTi JT //as'-e load a
oenerated by centr'fuce b iovj-^v.-!, :"-J zem1--:; •. " p;in: r'-. .
PdiMT.ctt'i''.. o11 f.ne ".MS tev.'.itor *r- • ttii.1 r-c"Jr' ;. hint ir^ -iv.,uned •»'.
t'ol lows :
1. flow rate - avpi-j.;;c - "..i2 ;"ld {T..18 nnd)
2. BOD - 2400 r.u/1
3. SS - 1560 -nq/1
417
-------
UKAFT
TABLE 63
RAW WASTE SUMMARY
SUBCATEGORY C 10 - SOLUBLh COFFEE
Parameter
NP
Loa Mean
Minimum
Maximum
Production kka 3
tons
Flow mid 2
mgd
Flow Ratio 1/kkq 2
gal/' ton
BOO mg/i 3
kq/kko
Ib/ton
SS m.-j/l 3
kg/kkg
Ib/ton
78
86
0.617
0.180
7912
209 C
2377
18.8
39.6
1EE5
12.3
24.7
40
44
0.355
0.102
4505
1190
2136
16.9
33.7
623
5.4
10.3
153
169
1.09
0.315
13930
3680
294C
23.26
46.52
3565
28. J
56. b
Color cpu1
Joball - r< i ?. t. i num jn;'to
-------
DRAFT
4. pH - 4 tc 5
5, l']•:••, no'i^ir,'!.':',, AMD s;.1!:*
Pan Washlnq
The source of i/i ]'Md in i cake or ;np bakery is i'h'>
pro-LC'j'j of washirr; pans, "in .\.i siting r; alr.ost ;:••>('. IUSIVP to the IJM-
baking industry whether fie .:jkc?s ire fjll :, i^e :jr thr sn.iL;. cake /:.•
iioriMdily. thp pans tnar aro jr.PI in b'jkinn cakrr, "M-.t. he v/ashe'1 -i'1'"--
layer of cake L'-jinbi usual lv '-IT.JIMS in the pan and is r
MI t')t:
y
f thr> c n-.c
) ufld tllr
p' rile' ;i.in
wash /Alter ;,MV II.JVP a P,0!.' >t •/[> : -i ^.'' ^i-'i.1) -'n ' '
11'
'..uip :w .1 mi •••'^.j>- >
;f.-y| :n :•;.••,! t>,'
onro ^vrv 'i"n, '.'•
fl iir. i mi tPil pan \Y.!r.li mi; i-i Ilirir •''.!•
',')•.I- '\onn
A ip.iturc 'il v ')•' 'j.i 1 1 v '.".'I""/ !•,'• •• . .• .1 .va-.h >'!)!'!" :n './hi'1, ,;iV ,::•.!.-
r",uipi:ient is clfMtu'd. 1 tP"ir. -,N. -\ r. ';••.:!! IMMT';. nii>in.-i vat1,, II'M.I-
i ll'ii'ii.| j put -. c.r, •' .1 i 'ici'1". . ii'ii 'Mr;,] /'••'• ' ' •. .irp nn|-—,i i 1 v •!( '. rlnrn-'i i1
thut ,)IH)I) i V ns j.'OSS 1 I? i (' liPtnro j1'-! 'r •,:!i>r !)i;l(li) 'akfT'O I. hi.1 IViljt! f-fT
In ':')'.' wash rOO:::^. th^-;.i itr''lS ; • r";;-;'!1 •/ '-.iiuirl .r'.illf; 1|'.| v..i:"i
(i.lkp l;,il.r?r u>s !!\U' h/iVP I'-oi'L' t1'.)*"1 "• .v.r.h roo'il. 'joii'f r-MV be
in the "ijnnrr 'lij1, cr itvvl -li-'v ,,!'•• •• ,.>.' . ]>'\I-.M\I\ .it ''(in i i"'!,'ii! . '':
types of wjii) roons ai-f i.'V.ient ui i ' . 'M-J^ disiuviishers. Racks of c.iko
419
-------
DRAFT
pans and other items are rolled into these units. They are conpletely
dosed and then the equipment inside is washed in a manner similar
to that accomplished by home dishwashing equipment.
Clean-In-Place Equipment
Large equipment handling liquid or semi-solid materials are usually
fitted with clean-in-place (CIP) equipment. This equipment includes th
plumbing, controls, and sewer connections necessary to wash the unit
without moving it to the wash room. During interruptions in processina
caused by changes in variety of product or due to end of shift, cleanup,
equipment with CIP is normally dry cleaned as thoroughly as possible
and then wet cleaned using hot water and detergent supplied through tnc
CIP equipment. Wastewater discharge from CIP equipment is normally
through a direct connection :o the plant's plumbing system.
Examples of equipment with CI" include the following:
i. Large mixers for cake batter
2. Diping used to deliver the bdtter fror. tli>? mixer to
the depositer.
3. The depcsiter which '"ills each cake pan with the proper-
amount of batter.
Cleanup
General cleanup of ether eauipnerit jssor. idced with '.he bak inu ,'iror»'. i.
and the plant itself is a relative"'/ .-ninor contributor to the vncto
load. Conveyors used for the baking and coolina of rdkes arid
are usually dry 'leaned; however , they may be wet cleaned as
as once a week. Cleanup procedures in
cleaning of equipment and the floor sr
some wpf. :: ' .minq is normally ace or' pi
areas nidv De hosed down: mwev*r. "'ir^
01 "lop -md !'uct.t;t '" the v.'.ic.'. './!.••.' /
most plant"; stress the dry
es around the equipment..
. tied. Soir.e exceptional!/ .)'
--Tin" riv~tKC'i inrlu:!0 *'
in' *'r.)t. r'j.
The quantity and o^uality chsracfwr i ••' <
pie bakeries can vary (.ansidcrubly. "
trat.pd (.0 opera lino and clpnnup ;i -r>C'-
jnd tvr:p of product heinq produc ccl -in-.-
In-j.ii,nit Su'j'iies (83 ) show five <-,;.:
the nc\t ;ind three .old variations i.-i
••ata describing the total procer.r,'nq
Model IM jnt
.r, of wr»sr.pv.'-iter from (,nt» •!"•.!
'n-se variations can usually in>
n\''".- iiv.sori.itrd with the -jn-.r,;-;
Mip .-IG',OC icit(.'' • ' ' hypot he t. ical bilker-/ urnriij. : •
, '''-eviction includes both full sized
and snack takes, full sized pies,jrd
n'et yeast -c)ocds . The cakes
-------
DRAFT
snack cakes ore baked in pans which ore washf-d after each use. The |ves
and sweet yeast goods are baked on conveyors or in one-way containers
thus the containers require little or no wet washing. Operating procedures
stress dry cleaning of all equipment prior to their cleaning with water.
Total production at. the model plant is assumed to be 135 kkg (150 tons)
per day proc'uced in 24 hours per day, seven days per week operation.
j:er - Sources of wastewater from the model plant would include -]1!
sources listed above with the greatest strength and quantities of waste
coming from the pan washing equipment and the wash rooms. Lesser
quantities of wastewater are generated by the cloan-in-place eqnioment
and general plant cleanup.
Parameters of the wastev;ater are assumed as follows:
1. Flow rate - average - 0.45 mid (120,000 gpd)
minimum - 0.20 mid (53,000 gpd)
maximum - 0.60 >"id I'lCj/JCO gpd)
2. BOD - 23,000 wi/l
3. SS - 5,000 mo/1
4. Oil and Grease - 500 uiu/1
5. pH - 6.0 to 7.0
6. N - 2 nig/1 (defi;:;en;!
7. P - ?? 'Tig/1 (deficient.)
8. Ratio - kg 30") to >'*a 01" -voduct - 9^ . 2
9. Ratio - kg SS to M v-i • '•••; :: v f. jir. ' ' . '
IhR'iO piiramoN?rr, n(?n?r3lly fo'"yw Lno^e listed in fable 6J 'or this
•,ij|jCiJte!j''r'y with the cj«.enl n. r« nt •, ,',:'t'nr)c'c! iolui'i. The suspended '. '
'l.-ito reported for f>ubcatt;'l')rv '. • >,:••. ••••n'-, 'jnr^-il • -,t ii..il 1 v low. Th;-
i'.. Ddrti' uliir1 y true wheti i !."•••• . ••; • •. -:.i ','• /i^nrvi •,i.,',;..'''i'iii'n j.-O
');ito from Si/hdi togor icr. C ! , ''. '', •', nul !> i1 ("' i:ns whifii '.iid-i the1-
Mil.'Cd tegor ies . Thus, the fiijurn ,: ' ,^r:r. i-,i'i/l WHS ur,ed -ri'l !•; l;.r;c".
inrtata from ,' hiikery i|)iinning ",..; .i:--;oi ic^ C 1 und f. 3.
i'W '
With the exception of nan v;flMi"v% •. '»_. sources of wa^towdt.cr in ti.il *
nut ut.li;inr, prfn '.vashing arp i •!•••• i! t" thn--,p in Suhcate-gorv C !
Tnp principal rojrces of w.jst1"1.. i' ••• :•••
421
-------
DRAFT
T/nir 64 . Raw NJ:.:£ L-UVIA-
PILL, oOU'ii'NU TG, ANj J.-JM.'
GOODS UTILIZING f AN fcA5HH;
rO PLANT i_0f, nE
Hri,i:1UM
T ON /PiY 1
TI'T. H-'/n.". Y
VOLUi-lt "I'.D
'fl;f L/3-IC
( u A L / '•' I M >
•' A T i j L '<'".•
( GAL/ T -)".)
•' a T I r *.",/« '
11Q
c -i • u
1 :' ] 0 C
•3 O .
12 /
* r T r
11 .T
-------
ORAFT
1 . '/ash roon
2. Clean-in-place equipment
3. Cleanup
See the pr-vious discussion of Subcatonory C 1 for a description of
sources and their effects on the tou ! plant elfluent.
Total Prxes sing Ef*1'jent
The f|u ..; n t. i t y and quality of wa^tewat.r-'r f-Mi cake and [Tie hjl'.fr ioi, T
utilizing the pan washing var>/ coniideraDly. These variations can i
be troceci to operating and cleanup prrvj'Jjrer, associated i-'ith the j-
and type of product being produced. !n-plcint :. '.udies ( 84) show ;)aKt"I MI '..he plant ..ire produred !i- "'(.'
which 'jo'"ol Pf el •.' e'iniinati' ;'nn wjsnim. 'Jpi" .1 f.ino prnredures str"1,'
drv ':!(••>. -inirq of all emji'iiucn* nn nr ( .-/ c1 9. -in i ru; with v-jter. Total •
duct-ion at the nodpl plan', ir, 13C kkg (ZOO ton^) per day
hour;. :>er day, five days per woe''-
'. 'a '• *rwi! t»r - "o'jrr?3 of v/iic, Jfv/.if or 'Y'-''- • iir.' '"y;i'.'l t'ont w: '' ', m, ' ,i>
0) .•/.!•"•). L1 r.'.'lirii; tYi;1" ttH.' \V.:''.'l '•?•.'•—. If"','."' "•;•;"•.•.'
,i ffi ,;pppr "i * ^r! !".• T f^r 1.1 c-in ! " - ':' . .• • '•.;':".'";' •".'.'
!"!r
r.) •••- - ,ivc>- i :•
nii n irrnjr
j. G.r» - !.n?3 my/1
•i. oi i r, 'M-I.M^... . r?:- -ij. ;
f>. pH - G.O
6. N • 30 ruj/1 (deflc.gr.ti
-------
DRAFT
TABLE 65
RAW WASTE SUI1IIARY SUBCATEGORY C2
CAKES. PIES, DOUGHNUTS, AND SWEET YEAST GOODS NOT UTILIZING PAN WASHING
Parameter Log Mean Minimum Maxjnnxi
Prod kkcj/day 180
(ton/day) 200
Shift time hr/day 24
Flaw volume VGD 0.043' 0.037 0.nrJ
MLO 0.162 0.140 0.1'T;
Flow ratio 1/kkg 397 722 1064
(gal/ton) 215 IBS 25r;
5 day BOD mg/1 2190 1830
Ratio kg/kl-3 2.0 I .7
(Ib/ton) 4.0 .3.4 4.c
SS -iq/l 1020 950 1100
Ratio V.•:./'. l-i 0.°? 1.^6 1 .0
(Ib/ton) 1 . ''" \.'/?. ".f
0 ft G irn/1 f.'-'-. 570 «;jn
I'jf o ki/kin ,?.(-2 O.!)l
(I!)/ton; i.J'i 1.H2
-------
DRAFT
7. P - 15 ing/1 (sufficient)
8. 2.0 kg BOD per kkg of product
9. 0.94 kg SS per kkg of product
10. 0.63 kg 0 & G per kkg of product
SUBCA TTGp 3Y f 3 - BREAD AMD SUMS
Mi x i nc Jqujpnen t Cleaning
The cleaning of mixing equipment is the largest '-ourco of war>tew.::pr :r
a bread and bun bakery. The cleaning "iny he done; manually or with clf^
in-place (CIP) equipment, which consist:; of the plumbing, controls, jnd
sewer connections necessary to wash t)-p c'iui p.'urnr /lutomnt ic.il 1 v . The
mixinq ecu i per? .it is normally cleaned 'Mily hv t'ir:;t scrai;i'Kj !."'_' w.i 1 1 •
of the "ixers to remove adhering dc.:;':i" <'-n<\ fn^n v.-rr.hini) . The i,o,i:!
((try) notarial i ', either sc^d an jni":,;l f"ed or h i:.i| 1 >.;c as r,tM !•! •.•.•!•.;• .
In plants using tne continuous "nix "icthod. the nn'.err. jnd dout:': ',1'jn .
tdMks are then :-in.sed daily with writc-r. "n ;i!n;t., uc.ioi! the- Lj.utn '.;•
method, the mixer*, are norr.ally wet >-'.iMned one- i.n- twice u weok.
Gerc.>r,il i^tMninq nf floors .-ind u* ""•. • "I •, i ', fhc- otucr impnrtiiru sour-T
wflStew-itL'r from broad .ind oun biii- i'"'if. .Ironr, i i '. .in: 'u.M-!n,i 1 "i , ,-;.i 'H1 :
.) -,'•">. ;n the pr jij'jc t ion jrpa in wni:" '!)'"/ .!••(' r,o.i. r lotu :. in rr;c
iniximi area art; -.lenprally wet rle^nprl d.'iily usinf, ropu .11;^ DI>>. ^Li. '".'i
or TC rubber1', •.vriich vac:;un : he w-it-.-r md r. p • ' I ._• :' ^!-:jurr f'->:: f he :"..;•!
as i i. is ';5f»ci. Floor; tf.ro jGhriu^ L.'.e resi uf •'".• L'iani 3rr r.:;ir int>: v
fl several tidies a dav usino bi-on"''. .md .irv vi'
nr t '.V I '." » 1 WPP^ ll1 "F *h(? *"! I,"
and !n;> M.-t or v.H'.u.jrr; ••,(.: ru!;hc!- .
'. ''•!' r'jl'.t .i
I!M' 'iiuntit.y iir.'') 'utility ^'- w.r. ' "v: i '
f Oi". I'lprahl v. riv>rj(' Viirv •: i -.!'•. :!••
i'1 ir.mup r.ui'io ;
l.'iitii ' roi'i Viiri-%ir; ;
HIP ji.IV "O ' *V ' ("v*
|.>1 ; i lout. f,ir' !•';•-, •
J(Tj_ !'' .in-.
ic 'iMdC'l :;l.i!i!
'f.irl ^iiil bun1. .
r; ,irp ,1
nixed, b(iKi_"J in IMIIS (sor.iel irnes \-r"
prior to wet C ltd rung (if reflnired*
i ! ' c'.v ' r\'\
i M.) 'hi' '
IMI! lir>' l i. ,1 1 b.lkpry pro !:/._•
i : tc :i. All i terns
-------
DRAFT
TA M- 65. RAH *U$TE
•jRrfiO AND Tut.'/.
P4PAML7E-? NO ^-L-NT LOG MFAIJ MlNTMuM MAXI^'J"!
^ ? ? •.! < * •'.. / ? A Y 1-4 i» „ . « 21
(IC'I/TAO i*Li.U JO
S-IIM T1"T H->/C'. f iu «?L'.7 :6
FLOW J"L-,'.'ir I'J'J 1'. v'.GZc- C
r^3^vtrrL/'""C 1 <4 i . .- f 3
. <+ i' o . :
.3 : « . .,
.01-4 . . . ;
. '3 t 1 : . .
( '; -Vl. / . I 'H
r. ••». -'.•.•! r., t/-:-.-r-
! ^ .i L / r 3' • I
^ i * v .'. ~ p M :'". / •
•: •. T r" -•./•>;.".
IL'-/ f;M
r • •
( L IX T ?'. )
J 1 . '.
> . 1 <•
-------
DRAFT
is assumed to be 41 kkq (45 tons) per dav produced in 24 hours per dv/
five days per week.
Hastewater - Sources of wastewater from the model plant would include
sources listed above with nearly all of the wastewater generated by
cleaning of mixing equipment and floors throughout the plant.
Parameters of the wastewater are assumed to be as follows:
1. Flow - averaqe - 0.10 mH (0.026 mg-1}
minimum - O.OS3 mid ;0.01d irvjd )
maxirnuiii - 0.19 mid '0.051 .'Mid)
2. BOD - 42: m
3. SS - 214 nrj/1
4. pi! - 6.0 to 9.0
6. N - •' "KJ,." (.iv.ur '?'j ;
7. 0. "••'•' Kj BOD per \ *.•} -jf :TO-:-..(. :.
8 0..'6 kl CS ppr H.'j of ;.,-;..-;;...*.
14:?'1 -I"1!:
A feafjrp '•* v ••fjs''. •• 0'/<;•".• ;:;; ;? •)"-•' ^r1,--^-' ';••.-HI ' r :i ...'.;,-;
in v/hi.:n i'-rt-i"1'! 6 frou' "''^rt is """"''"c*. 'he c.'GJP.inc; .'.j. Ijw u^i,=
manually :: • tne ./ar,n ''OOn na/ be -js icnt" iTi / :>. i;]'"::*3 ^Mt'1-1". •: .r
Mil' 'Siamr •..-v;|--r. -•! .; • • ' f.,..| '. .• ••• -i, ....... ,-/ ;•;• •, •, |, •{-.,.' :'.'.'•'.
wi ', !l uQf'k i •.' "jllo I '. ' - 'I ' . ' '•' : . ' : • ' ..:'•'.-'•. j'.'jr :•;!:":.:'•.•
tht1 './fl'-h !•:•••"; /0'"'|JL ;"'-:l'lt'. ;< ; ' ' ;•"• r • ••> ••'•" .••••• • i-- •
" ' >• i" - I :•. :''•••• :'./•' • ••'
f'. tti?i! . "• •• '. o-->n-i n-r! s..o '. 1 • • . •••••••.. ' ' , •'• ::> '•'' -f-i '••,<.. i.
t'i'j :'l .ii:1.!--r,.-, .-onli'-O • , HIKJ .;•..••- , •• • T-"r1 r.",.1 ry ••. .. r. •• '
urn v ',/'V' -jt rv,v'n; '* t^ lii-j . • ; -. ! .,• "i
-------
DRAFT
of shift cleanim, eouirr'°nt v.'ith TIP is normal!1/ dry cleaned as
thoroughly as oousible and thin wet cleaned using hot uater and
detergent supplied through the CIP equipment. Wastewater discharge is
normally through a direct connection to the plant waste plumbing system.
Cleanm
General cleanuo of other equipment associated with the baking process
and the olant itself is the least significant contributor to the ivaste
load. Conveyors used for the baking and cooling of cookies and CMCKO".
are usually dry cleaned; hoi.-ever, they nay be wet cleaned as vrecuent'y
as once a week. Cleanuo orocec'ures in post olants stress the dr/
: lean irf of enuir-~ent and the floor sojces around the equipment.
However, exceptionally dirty areas may be hosed down, or more coroonl/
be cleaned v/ith a vacuum tyoe wet scruboer or a mop and bucket.
Totn 1 Processing Effl uent
The Quantity end Duality of wastewater from cook:e and cr-jc'.er bat *r •'-•'.
can vary considerably. The:e variations are usually the resjit of
cleanup procedures associj *••• : w^.h the type of product bemc o'-odjce-j
and the train: r/: and m-i".^.^'?^. o* the oe^onnel . Data collected
during this btuoy snow six foic' /ariations in CCD fron one day to tic
next -ind t'.v; fold variat'ins in .V3C tev,.- ter flow within a ;inile ^u!1.'. .
Table 67 includes data oer. C''n'b : ;r: t^e tr.-ts' TTCCT, :- 1 n-j •?r^";u(?nt *•. >•
this ',
rne -ndc! o'^r.t 'or this ^jbcate^'i".1 ''s a iiyccthet'cal ^
a variety of COOKI'B ana crac*er -:re^s. Pt-oducticri -inci^css cra:ke'"
iced and plr''r, cookies, sratzels ind ^lioar w^)fers. Tip -7551 :lart
produces COOK', e 'tens anD cracker i ter.s in ancro/ :n-dtel . eaaal
ouiint: * • tes . All i teni are bri tc'i "M.,v(J, baced .in rr"1'.1?.-- ,'e!t' •'-
ii'I TV ens ;'f.'-:?~t f,«~T~ .j'e-'c .•.'•.•::'•! ire ba^e: :n -.'latfi " r. :i ;'
(it reouireu'i. T')tal r^o^'./r'^n '-•• •••.»> --.^-'i •
1WU K^Q (2CO tons) per Jo. ;.r' MM.-: •• !•'• 'i:,uri.
••< r._tc".v i_t«r - .1. •;;'". CS 0' .v :. 4 (••• •!'.•• ' ,' '
HI' ; --iff: •••"•. :-, "•?•! 3b'.'V(? .;'h (."" ••••:t
L '" ...iSLe .i/ ' 'i : '' •!•' *''(' .,':isn '•>,•..-. •
iiri1 -;p"f>f i ti;-; !;. t':*.1 •; l"-in- •• n-p ' : ..... :,'
rl nv r.iie - -j-.o-'aa-.-1 - ..••'• -'"d ;90,0P'"'
•,'innviyn - :...;• -,1(3 (53.000
un - C.-o nid (ITO.OCO
-------
URAFT
Ta: LL 67 . - "L/ •'• i '!>
r. j « ••• A T i o t /', K .
( '...i./ I ..M
•'. :)£ Y i •.;;.• " ,/,.
••.•» i ;; r-,/.-:..
(u / / i - •' >
11.1
u . 0 J'>
o.f /"
u^ . /
-------
URAF1
2. BOD - 1200 mg/1
3. SS - 900 mg/1
4. pH - 6.0 - 8.0
5. Ratio - kg BOD to kkg of product - 2.0
6. Ratio - kg SS to kkg of production - 1.5
SUBCATEGORY D 1 - CANDY AND CONFECTIONERY PRODUCTS EXCLUDING GLAZED
FRUITS
Of the total number of confectioners contacted 15 were considered to
have reliable historical wastewater data on which to characterize the
industry as a whole. A summary of this data is given in Table 68.
Direct, product contact water usage was not observed in any segment of
this subcategory. The primary source of wastewater with the highest
pollutant loading is derived from the periodic or daily clean-up of
the plant. Although washdown is practiced in most parts of the plant
at some time, the' largest and most consistent area of washdown water
generation is the candy kitchen. Washdown water in the remainder of
the plant is usually restricted to mopping and wiping. Some machinery
parts and molding pans may be removed to a separate area for cleansing.
In addition, certain molding machines were observed to use a clean-in-
place system. Other areas which may contribute to the total effluent
loading are boiler blowdown, air scrubbers and barometric condensers.
Non-contact cooling water was observed to be either discharged to store;
sewers, surface water, sanitary sewers or was recirculated.
As noted In Table 68, the average flow ratio was 3770 l/-kkg (904 gal/
ton). The average BOD was S.lOkg/kkg (10.2 Ib/ton) with a range of
1.69 to 15.4 kg/kkg (3.:8 to 30.7 Ib/ton); suspended solids was 0.646
with a range of 0.168 to 2.50 kg/kkg ^0.326 to 5.00 Ib/ton). No cor-
relation between suspended solids and BOD was noted due to the solu-
bllized carbohydrates characteristically discharged by this industry.
Oil and grease loadings ranged from 0.05 to 0.832 kg/kkg (0.10 to
1.664 Ib/ton) with an average of 0.21 kg/kkg (0.42 Ib/ton) for the si».
plants with this data available. Var'aDility of the wasteloading and
flow was significantly influenced tw variations in processing, raw
materials, production level, wasnnown anu general housekeeping prac-
tices. Waste^ater in all plants visited was discharged to municipal
treatment facilities. Many plants utilized <>ome minor form of pre-
treatment and/or in-plant controls to reduce waste loadings; particu-
larly where oil and grease were of concern. Pretreatment was usually
1n The form of a grease trap. One plant, however, was considering
dissolved air flotation as a method of reducing effluent concentra-
tions.
430
-------
DRAFT
TABLE 68 RAW WASTE SUMMARY
CAiJDY AND CONFECTIONERY
PARAMETER
NO. PLANT
LOG MEAN MINIMUM
MAXIMUM
PROD KKG/CA"
t TON/DA r )
IS
97.0
30.7
307
SHIFT TIME MR/DAY i 4
FLOW VOLUME MGD is
FLOW RATS L/Sec 14
( GAL/MI N )
FLOW RATIO L/KKG 15
(GA-L/TCN )
5 DAY BOD MG/'_ 14
RATIO KGx'KKG
( LS/TON )
TSS MG/L 15
RATIO KG/KK3
(L3/TON )
OIL i GREASE MG/L 6
RATIO KG/KKG
(LB/TCN )
1 6.
0.
f> .
10B
3770
9C4
1290
5.
10.
172
0 .
1 .
55.
0.
0.
8
099
ao
1 0
2
646
29
7
21.
' 2
8
0
j
27
207C
495
523
i
3
54
0
0
13
0
0
.00
. 024
.71
. 1
. 69
. 38
. 1
. 1 68
.336
. 3
.50
.'10
338
0. <. 5Z
•
2 7 . C
<>29
6S6C
1650
3200
1 5.«.
3C. 7
5'.s
2. SO
5.0:
222.3
C. d-
1 . 68
PROCESS CODE
-------
DRAFT
Model Plant
The following Information reflects those conditions judged to be appli-
cable to a representative candy and confectionery product plant:
Production • 97 kg/day (107 ton/day)
Effluent Volume » 375 cu m/day (0.099 MGD)
Effluent characteristics:
BOD = 1300 mg/1
SS =170 mg/1
Oil and Grease = 56 mg/1
pH =7.7
Primary source of wastewater: Washdowns.
Special consideration: Oil and grsase.
SUBCATEGORY D 2 - CHEWING GUM
Data from a total of five plants were used to develop the wsstewater
character!sties as summarized in Table 69. Three of the datd points
contributing tc this summary were from plants visited by the con-
tractor. Other data points represent data contributed by the National
Association of Chewing Gum Manufacturers (NACGM). Because the NACGi'1
included much supplemental processing and water usage information with
the Historical data, it was concluded that such data could be reliably
utili:ed as part of the data base making the necessary wastewuter
characterization. ^
Water used in the manufacture of chewing gum Is primarily for air
scrubber systems with lesser quantities being consumed during plant
washdown. No direct finished product contact water use was observed
or indicated. Uashdown of the plant is usually restricted to mopping
and wiping in -sost areas with a separate room used for cleaning variour.
pieces of equipment. Some niscollaiieous water use general!) occurs
in cleaning of mixing room floors. Air scrubber water is usually re-
circulated and periodically purged.
The ratio of water use to production averages 4500 1/kkg (1080 gal/ton)
with an expected range of 3300 to 6130 1/kkg (792 to 1470 gal/ton).
This range is due primarily to variations in plant size and different
conditions affecting the performance of the air scrubber systems.
Expected BOD ratios ranged from 1.2 to 13.6 kg/kkg (2.s to 27.2 Ib/ton)
with an averaoe of 4.04 kg/kkg (8.07 Ib/ton). Suspended solids ranged
from 0.175 to 0.358 kg/kkg (0.351 to 1.71 Ib/tori) with an average of
0.388 kg/kkg (0.774 Ib/ton). Variability of the BOD and SS loadings
could not be rationalized in all cases, but is likely to be influenced
by variable amounts of sugar dust that is subsequently removed by the
air scrubber system. Differences in general cleanup practices are
suspected to account for a significant variation 1n wastewater pollutant
load.
432
-------
URAFT
TAOLc 69 . RAH HASTt SUMMARY
CHEWING GUM
p
PARAMETER
^D
-------
DRAFT
Intake waters are generally obtained from municipal water supplies;
however, some plants do utilize well water for non-contact cooling and
air washer make-up water. All effluents, except from one plant, ob-
served during the study were discharged directly to municipal treatment
systems. Pre-treatment was generally not employed; however, one plant
treated and subsequently spray irrigated its effluent.
Model Chewing Gum Plant
Bas*>j on available information, a representative plant for this sub-
category has been selected as follows:
Production: 70.9 kkg/day (78.2 ton/Jay)
Wastewater flow volume: 322 cu m/day (O.CC3 MGD)
Mastewater characteristics: BOD = 900 mg/1
SS = 95 mg/1
Oil and Greese = 30 mg/1
pH = 7.5
Primary Sources of Wastewater - Air scrubbers, cleanup operations.
Special Considerations •• None.
SUBCATEGORY D 3 - CHEWING GUM BASE
As in the case of Subcategory D 2, data for two of the plant; ;upplied
by NACGM were considered valuable for the reasons mentioned in the pre-
vious subsection. Table 70 summarizes the data from three chewing gum
base manufacturers.
During the production of chewing gum base, water is used for washing of
the natural gums, for contact and non-contact cooling, and for periodic
cleanup. The greatest volume of water is used during the washing oper-
ation with considerably less being used for general cleanup. The ratio
of water used to production would be expected to range from 1030 to
11,200 1/kkg (247 to 2690 gal/ton) with an average of 3400 1/kkg (815
gal/ton). Although the range of water use is great, tne total waste-
loading does not reflect the same wide range, suggesting different
approaches to water use to achieve tne same degree of product and/or
plant cleaning.
Expected BOD ratios range from 1.11 to 1.90 kg/kkg (2.21 to 3.80 Ib/ton)
with an average of 427 kg/kkg (2.9 Ib/ton); suspended solids from O.BCO
to 1.82 kg/kkg (1.60 to 3.63 lb/con) and an average of 1.21 kg/kky (2.41
Ib/ton). The reason for the variability of the wastewater flow cannot
be attributed to specific processing differences between plants but is
most likely due to differences in raw material quality; i.e., the amount
of extraneous material which must be removed.
The pH range (two plants) was from 8.76 to 9.5 with a numerical average
of 9.13. Sodium hyaroxide (NaOM) used as a bleaching agent, is the cause
of the above neutral pH. Surges of higher hydroxide ion concentration
Mould be expected during the bleaching cycle pump and subsequent rinsing
of the product to remove residual NaOH.
434
-------
DRAFT
TABLE 70 RAW WASTE SUMMARY
CHEWING GUM BASE
PARAMETER NO. PLANT
PROD KKG/OAY 3
(TON/DAY)
SHIFT
FLOW
FLOW
FLOW
5 DAY
RATIO
TIME HR/DAY 2
VOLUME MOD 3
RATE L/SEC 2
(GAL/TON )
RATIO L/K.XG 3
(GAL/TON)
BOO MG/M. 3
KG/KKG
(L6/TON )
TSS MG/L 3
RATIC KG/KKG
(LB/TON )
PH
2
LOG M^AN
aos
a 16
20.0
0. 094
6.40
133
3400
SIS
i
&7B8SI
435
-------
DRAFT
During periodic cleanup of equipment and processing areas, various sol-
vents are utilized to remove built-up gum residues. According to a treat-
ment feasibility study (85) prepared for a gum base plant, a maximum of
2000 gallons per week of solvent was used with a yearly average of 24,000.
This consumption was based on a production average of 5000 Ib/day.
Of the three plants used for characterization, two discharged wastewater
to municipal treatment systems and one plant employed its own treatment
system prior to discharge to a local tributary.
Model Gum Base Plant
Production: 105 kkg/day (116 ton/day)
Wastewater flow volume: 356 cu m/day (0.094 MGD)
Wastewater characteristics: BOD « 430 mg/1
SS » 355 mg/1
Oil and Grease = 30 mg/1
pH "9.1
Primary Sources of Wastewater - Gum base wash water, contact cooling water,
cleanup.
Special Considerations - Bleaching agent (sodium hydroxide), solvents.
SUBCATEGORY D 5 - MILK CHOCOLATE PRODUCTION WITH CONOENSORY PROCESSING
SUECATEGOSY D 6 - MILK CHOCOLATE WITHOUT CONDENSORY PROCESSING
As noted in Section III, some producers of chocolate products may also
engage in the condensing of milk for milk chocolate and were, therefore,
segregated for separate consideration. Wastewater characteristics for
fubcategory 0 5, Chocolate Production svlth Milk Condensory, 1s based on
six data sets which reflect the majority of chocolate and cocoa products
manufactured in the United States. Three data sets were used in charac-
terization of Subcategory D 6, Chocolate Production without Milk Condensory.
These data are summarized on Tables 71 and 72 and are further discussed
herein.
The presence of water 1$ not compatible with the production of cocoa
products; therefore, the open use of water is controlled so as to avoid
entrainment in the product. The major portion of wastewater generation
occurs during the periodic cleaning of holding or mixing tanks, trans-
fer buggies, and molding pans. The production area floors are also cleaned
on a periodic hasis, usually preceded by dry collection and then moppina,
and/or using industrial floor sweepers. Cocoa butter may be used as a
cleaning solvent with the later recovery of the cocoa better and chocolate
material. Washdown water is also generated during the cleaning of the con-
densed milk line and milk receiving areas, Subcategory D 5.
For Subcategory D 5 BOD loadings averaged 7.48 kg/kkg (14.9 Ib/ton) with
an expected range of 8.69 to 25.7 (kg/kko (4.35 to 12.9 Ib/ton); suspended
solids averaged 1.68 kg/kka (3.35 Ib/ton), ranging from 1.83 to 3.08 kg/kk.:
(1.83 to 6.15 Ib/ton). Oil and grease averaged 0.69 kg/kkg (1.38 Ib/ton)
with an expected range of 0,32 to 1.06 kg/kkg (0.64 to 2.12 Ib/ton) and for
436
-------
DRAFT
TABLE 71 RAW WASTE SUMMARY
CH.'COLATE, WITH MlLK CONDENSORY
PARAMETER NO. PLANTS
PROD
(
SHIFT
FLOW
FLOW
FLOW
5 DAY
RATIO
KKG/DAY 5
TON/DAY )
TIME HP/DAY s
VOLUME MOD s
RATE L/SEC 5
(GAL/MIN)
RATIO L/KKG s
(GAL/TON )
BOD MG/L 5
KG/KKG
(UB/TON)
TSS MG/L 5
RATIO
OIL t.
RATIO
KG/KKG
(LB/TON)
GREASE MG/L «
KG/KKG
(LB/TON)
LOG MEAN
333
367
22.4
0.201
7.22
10.4
4070
975
I860
7.48
a4.9
613
a. 68
3.35
169.5
0.69
1 .36
MINIMUM
aa?
129
16.
0.
1 .
24.
231 0
553
1300
4.
B.
306
0.
I .
76.
0.
C.
8
077
51
0
35
69
915
83
6
32
64
MAXIMUM
944
1040
24.
0.
34 .
546
7170
1720
2600
12.
25.
553
3.
6.
260.
1 .
? .
0
5*4
4 "
9
7
08
1 5
4
06
1 2
PROCESS CODE i 66*eoi, 66*eow, 66*eowi, ae"83!5, 66*83ws
437
-------
DRAFT
TABLE 72 RAW WASTE SUMMARY
CHOCOLATE, WITHOUT MILK CONDEN5QRY
PARAMETER NO. PLANTS
PROD
<
SHIFT
FLOW
FLGW
FLOW
5 DAY
RAT io
KKG/DAY 3
TON/DAY >
TIME HR/DAY 3
VOLUME MOD 3
RATE L/SEC 3
(GAL/MIN)
RATIO L/KKG 3
(GAL/TON )
BOO MG/L 3
KG/KKG 3
(LB/TOH )
T£S MG/L 3
RAT j o
OIL t
RAT ID
KG/KKG
(LB/TON )
GREASE MG/L i
KG/KKG
(LB/TON )
LOG
253
278
H3
0
20
320
6560
1 570
P05
4
9
229
1
3
1
1
2
MEAN
.3
.243
^ 2
.63
.24
.50
.01
.59
.Of
. 12
MINIMUM
50
5i>
8
0
12
200
5COO
1200
145
1
2
81
0
1
.3
. 5
. 00
.103
. 6
. 18
.36
.a
. 669
.23
_
-
~
MAXIMUM
1 2 ? 0
1400
15 .
0.
32.
51i
8620
2070
3420
1 6.
3<2
3.
6.
_
-
•
0
•
579
<.
1
1
3 8
76
PROCESS CODE tsjt 66*e2M, f6"e?.i4,
-------
DRAFT
Subcategory 0 6, the BOO averaged 4.63 kg/kkg (9.24 Ib/ton) with an expected
range of 1.18 to 18.1 kg/kkg (2.36 to 36.1 Ib/ton); suspended solids averaged
J.50 kg/kkg (3.01 Ib/ton), ranging from 0.669 to 3.38 kg/kkg (1.34 to 6.76
Ib/ton). 011 and grease for the one plant which analyzed this parameter
was 1.06 kg/kkg (2.12 Ib/ton).
BOD and suspended solids loadings appear to be dependent on the relative
amounts of chocolate products produced, i.e., cocoa, syrup, sweetened, un-
sweetened, and milk chocolate. Of special note is the necessary cleaning
of tanks and product containers of the chocolate syrup line. Oil and
grease variability is due to the efficiency of general operating house-
keeping practices jsed to minimize entrainment of cocoa butter in the
wastewater. In addition, Subcatego.-y 0 5 is influenced by washdcwn from
the milk condensing process and milk receiving area; the total wasteloadvig
for any one plant being dependent upon the a-nount of dry milk and/or con-
densed milk which may come from other sources.
Plants in these subcategories characteristically discharge their wastewater
to municipal treatment systems, usually after some form of preliminary
oil and grease removal. This pretreatment may involve only a grease trap
or, as in the case of one plant, a flotation unit. Non-contact cooling
water may either go to municipal treatment or be discharged to surface
waters; the latter being the situation in the larger plants.
Model_Chocolate Plant with Condensory
Production: ;,.0 ton/day
Wastewater flow volume: 761 cu rn/day
0.201 MGD
Wastewater characteristics:
600 • 1840 rag/1
SS » 415 mg/1
Oil and Grease • 170 rmj/1
Wi thout Condensory
240 ton/day
920 cu m/day
0.243 MGD
705 mg/1
230 mg/1
160 mg/1
Primary source of wastewater:
Special considerations:
Wasndowns,
Oil and grease removal
PET POOD
SUBCATEGORy B 5 - LOU MEAT CANNED PET FOOL)
General Plant Cleanup
Clean up in a low meat canned pet food plant is a continuous, minute-
to-minute process which contributes by far the largest share of both
volume and pollutants to the wastet/ater stream. Clean up r*fi basically
be divided into two nmin types: in-plant housekeeping and end of shift
clean up.
439
-------
DRAFT
Housekeeping- Housekeeping 1s the most continuous of clean up steps.
Th¥ various operations throughout a typical low meat pet food plant
generate considerable amounts of scrap. Included in this would be various
spillages from gravy tanks, can filling, meat thawing, grinding, etc.
Grinders as well as mixing tanks, filler bowls, double seamers, etc.,
also require periodic washdown to comply with 1n-plant and regulatory
sanitation requirements. All of these Individual operations contribute
heavily to the organic waste load. These streams are characterized by
small pieces of grain, starches, blood, meat scraps, and other formulation
ingredients. These waste streams constitute a major portion of the total
plant effluent.
End.pf_Shift Cleanup- End of shift clean up is to some extent similar
to the daily minute-to-minute operations inasmuch as all the floor and
equipment surfaces are thoroughly washed and rinsed. Additionally, however,
the larger cooking kettles are typically "boiled-out" with the aid of
detergents. Pipes may be disassembled and scrubbed with brushes. Large "
pieces of equipment such as extruders, grinders, screw conveyors, etc.,
may also receive a final "sanitizing" step. These types of cleaning opera-
tions are usually responsible for peak loadings and probably contribute
an equivalent amount of pollutants as would be experienced by an entire
shift of housekeeping washdowns.
Retort, Cooling Water
The only other process contributing to the wastewater stream is retort
cooling water. The water which is used to Cool the cans is basically
low load water, typically continuously circulated, although some plants
were observed to discharge this segment directly under NPDE3 permit.
Some of the plants not only recirculate cooling water but reuse it for
clean up, but this was atypical of the plants visited. No quantitative
data are available to determine its relative proportion in the was'ce stream.
Hpdel Plant
The model plant 1s one that produces 159 kkg of finished product generating
0.147 mgd of wastewater. Tiie average BOD loading as shown in Table 73 ii
3.55 kg/kkg with a range of 1.62 to 7,82 ko/kkg. The average BOD concen-
tration 1s 1,130 mg/1 with a range of 497 to 2,560 ng/1. The reason for
the wide variation in concentration is principally due to the various
product styles ana types found within this subcategory. The other
flow related parameters follow this same pattern.
SUBCATEGORY B 6 - HIGH MEAT CANNED PET FOOD
General Plant Cleanup
Clean up in a high meat canned pet food plant 1s a continuous, minute-
to-minute process which contributes by far the largest share of both
and pollutants to the wastewater stream. Clean up can basically be di
Into two main types: 1n-plant housekeeping and end of shift clean up.
440
-------
DRAFT
TA-UE 73 . *AW WASTE S
LOW MtAT CANNED PET FOOD
PARAKSTE*
P700
1
SHIFT
FLOW
FLOW
P.?*
5 Dflt
RATIO
T:S *
i? A T I 0
KKG/DAY
TON/OAV)
TIME H*/DAY
VOLUME MOD
RATE L/SEC
(GAL/'IIN)
RATIO L/Ki
. ^ 3 1 r- . 'i
1 r> >j '
.21 •!•.-•
.H? 11. .
441
-------
DRAFT
Housekeeping - Housekeeping is the most continuous of clean up steps.
The various operations throughout a typical high meat pet food plant gener-
ate considerable amounts of scrap. Included in this would be various
spillages from gravy tanks, can filling, meat thawing, grinding, etc.
Grinders as well as mixing tanks, filler bowls, double seamers, etc.,
also require periodic washdown to comply with 1n-plant and regulatory
sanitation requirements. All of these individual operations contribute
heavily to the organic waste load. These streams are characterized by
small pieces of meat, fat, starches, blood, and other,formulation ingredi-
ents. These waste streams constitute a major portion of the total plant
effluent.
End of Shift Cleanup - End of shift clean up is to some extent similar
to the daily minute-to-minute operations inasmuch as all the floor and
equipment -urfaces are thoroughly washed and rinsed. Additionally, howev.er,
the larger cooking kettles are typically "boiled-out" with the aid of
detergents. Pipes may be disassembled and scrubbed with brushes. Large -
pieces of equipment such as extruders, grinders, screw conveyors, etc.,
may also receive a final "sanitizing" step. These types of cleaning opera-
tions are usually responsible for peak loadings and probably contribute
an equivalent amount of pollutants as would be experienced by an entire
shift of housekeeping washdowns.
Retort Coolirg Water
The only other process contributing to the wastewater stream is retort
cooling water. The water which is used to cool the cans is bcsically
low load water, typically continuously circulated, although some plants
were observed to discharge this segment directly under NPDES perm.
No quantitative data are available to determine its relative proportion
in the waste stream.
Model Plant
The canned high meat pet food subcategory is characterised by several
different product styles as described in Section III. The processing
and meat handling techniques are diverse, and as such the ddta presented
show extreme ranges for concentrations ana loadings for all of the flow-
related parameters.
The model plant is one that produces 167 kkg of finished product genera:mc
0.179 mgd of wastewater. The average BOD loading as shown in Table 74
was 48.6 kg/kkg with a range from 29.2 to 80.8 kg/kkg. The average BOO
concentration was 11,800 mg/1 with a rang,; of 6,910 to 20,200 mg/1. The
reason for the wide variation in concentrations 1s principally due to
the various product styles found within this subcategory. The other flow-
related parameters follow this same pattern.
44!
-------
DRAFT
TABLE 74. RAW WASTE SUMMARY
HIGH MEAT CANNED DOG AND CAT FOOD
PARAMETER NO"PLANTLOG"MEAN ~ MINUMUM ~ MAXIMUM ~
PROD KKG/DAY
(TON/DAY)
SHIKT TIME riR/DAY
FLOW VOLUME MGD
FLOW RATE L/SEC
(GAL/MIN)
FLOW RATIO L/KKG
(GAL/TON)
5 DAY BOD MG/L
RATIO KG/KKG
(IB/TON)
TSS MG/L
RATIO KG/KKG
(LB/TON)
3 167
184
2 24.
3 0.
? 7.
124
3 4120
987
3 11,800
43.
97.
3 9130
37.
75.
0
179
84
6
2
6
1
153
169
--
0.
7.
123
J820
917
6910
29.
58.
2520
11 .
22.
182
201
--
178 0.
78 7.
125
4430
1060
20,200
2 80.
4 162
33.1UO
1 127
2 254
18.0
90.
8
PROCESS COD£(S): 47N79W , 47N79I , 47No3H
443
-------
DRA,TT
SUBCATEGORY B 7 - DRY PET FOOD
Genera 1 Plant Clean Up
Clean up in a dry pet food plant is generally a combination of both dry
and wet methods with each coming at different times within a processing
period.
Wet Clean Up - Wet clean up generally consists of periodic floor washings
along with some "end-of-production" equipment dean up. At "start-up" of
a production run, some "off-test" material is usually generated. The
excess is generally scooped away, but the floor areas around the extruder/
expander equipment is typically washed. Similarly, in some plants, the
fat application areas were observed to be periodically wet-cleaned to
.maintain sanitary conditions. Some plants had pre-blending or tempering
chambers in which water or steam was added to the pre-oiixed grains before
the extruders. These chambers were periodicaly scrubbed and rinsed.
The principal components discharged are bits of grain, finished -product, "
and minute f?t coated particles. Volume, however, from these clean up
operations is generally minor relative to non-contact cooling water.
Dry Methods - Dry pet food is essentially a blend of dry ingredients to
which water or steam has been added to facilitate the extruding/expanding
process. As such, most of the periodic, housekeeping type clean up involves
handling dry or semidry matetials which have been lodged between pieces
of equipment or have fallen on the floor. Continuous dry clean up is
a necessity for good housekeeping.
Non-Contact Cooling Water
The largest source of water in the manufacture of dry pet food 1s non-
contact cooling water and steam condensate from the extruder/expander
operation. This water acts as a dllutor for the clean up water, the
results of which are very low waste loads in terms of the various flow-
related parameters.
Model Plant
Dry pet foods are typically manufactured with similar equipment and proces-
sing techniques. Ac- a result, the wasto loadings and concentrations (wit1'
the exception of plant 47D611) show limit ad and predictable ranges. The
model plant produces 211 kkg/day of finished product with a resulting
effluent 0.019 ngd. As can be seen from Table 75 the flow ratio is
only 155 1/kkg is an indication of the small amount of waste loads
from these plants.
Average BOD loading was .032 kg/kkg with a range from .011 to .096 kg/kka'.
The average BOD concentration was 202 mg/1 with a range of 51 to 796 mg/1.
The other flow-related parameters follow the same pattern as described
above.
444
-------
DRAFT
TA3LE 75. RAH WA'JTE SUHKARY
DRY DUG AND CAT FOOD
paRAMHTE:^ NO PL.INT LOG MEAN MINIMUM nixmui-
POD Osi/CAY
5
F
c
F
5
R
T
'?
(TCN/DAr)
•^IFT TIHC HR/OAY
LOW VOLUME HJG
LDi: KATF L/S£C
(GAL/MINI
1 *1W -^ A T T ^ 1 / ^ K **
tGAL/TO! )
TAY cOC MG/L
AT 10 KG/
:-i .
?qe
c.:"e
G . : - :
-,--)7
o . : " :
•j • i ^ •
CCOEtSM
,"«70b3I2
445
-------
DRAFT
SUBCATEGQRY B 8 - SOFT-MOIST PET FOOD
General Plant Clean Up
Clean up -in a soft-moist pet food plant is a function of the type of soft-
moist product style manufactured. The products which call for the direct
use of meat, fish, or poultry generally require more periodic cleaning
than do the grain-based formulations. As 1s true in all of pet foods,
clean up can be divided into housekeeping and end of shift clean up.
Housekeeping - Housekeeping is the most continuous of clean up steps.
The various grinding, mixing, extruding, and conveying operations generate
scraps of grain, meat, and finished product. Typically these are disposed
of by dry methods such as scoops, shoveli, or brooms. Occasionally the
floors will be washed to remove minute particles which can't be removed
by scraping. These few uses of water contribute a small percentage of
flow and pollutants to the waste stream.
End of Shift Clean Up - End of shift clean up with regards to soft-moist
production is generally end of production dry clean up. At this time,
grinders, augers, mixing tanks, extruders, conveyors, etc., are completely
and thoroughly washed with detergents. A final sanitizing rinse sometimes
follows. This type of cleaning generates a peak flow and loading condition
which is generally responsible for a majority of the flow and almost an
of the pollutants.
Non-Contact Cooling Water
The on1 other source of water used in the production of soft-moist pet
food ii extruder cooling water or condensate from an expander. Flows
vary widely according to the type of process. No quantifying data are
available to further delineate these effluent streams. In some plants,
these non-contact cooling waters were observed to be discharged directly
unaer NPDES permi t.
Model Plant
The model soft-moist pet food plant produces daily 51.4 kkg of finished
product while generating an effluent of 0.017 mgd. As shown in Table 76
average BOD loading is 6.73 kg/kkg with a range from 6.28 to 7.20 kg/kkg.
The average BOD concentration was 4600 mg/1 with a range of 3420 to 6200
mg/1. The reason for the wide range of concentrations is due principally
to the surges of water attributable to the various clean up cycles within
varied time spans. The other flow-related parameters follow the same
pattern as described above.
446
-------
DRAFT
76. RAW WASTE SU'IHARY
SOFT MOIST DOG AND CAT FOOD
r>
P?03
(
S'-IIFT
FLOW
FLOW
F.OW
5 DAY
•
TIMd H-/CAY
VOLUME MGD
PATE L/S5C
< G A L / H I N )
R-UIO L/KKT,
(GAL/ TON)
900 HG/L
KG/«G
IL3/TOM
TSS MG/L
•? 4 T I 0
< J / f> K 3
(L3/TON)
NO PLANT LOG MfcAN
2 51. ^
55.7
2 16.0
2 0.017
2 1.3J
21.1
2 1<«60
350
2 <» 6C IJ
6.73
13. <•
2 109C
1 . 6 u
3.19
MINIMUM
2.02
2.23
6.00
—
0.057
1*0^
1010
-------
DRAFT
MISCELLANEOUS AND SPECIALTY PRODUCTS
SUBCATEGORY A 29 - FLAVORING EXTRACTS
As discussed In Section III, It has been determined, that a typical flavor
manufacturing plant produces flavoring extracts which are subsequently
combined with other extracts and/or Ingredients to produce finished
specific flavors. Natural extracts are produced by vacuum distillation,
solvent extraction, or expression of whole plants, plant parts, or plant
essential oils, while synthetic extracts are produced by the combination
of ethyl alcohol and organic acids. A discussion of the waste streams
which would be expected from the manufacturing of f'nished specific
flavors is presented below.
Vacuum Distillation
Wastewater generated by the vacuum distillation of essential oils and
plant tissues consists of still bottoms. The still bottoms from dis-
tillation of essential oils would be expected to contain terpenes while
distillation of plant tissues would result in remnant tissue in the
still bottoms.
Solvent Extraction
There is no wastewater generated from the solvent extraction of plant
tissues. All installations participating in the study indicated that
solvents were recovered and that spent plant tissue was hauled to
landfill.
Expression
The expression of essential oils from fruits generally results In the
generation of fruit water and spent fruit tissues. Fruit water becomes
part of the plant waste stream and spent plant tissues are generally
sold for production of pectin (citrus fruit only) or sold as cattle
feed.
Synthetic Flavoring Extracts
The organic synthesis of solvents such as ethyl alcohol, methylene
chloride, benzene, and toluene, with organic acids results in the
production of synthetic flavoring extracts. Based on available in-
formation, there appears to be no wastewater generated in this pro-
cess other than equipment cleanup.
Dehydration
The dehydration of flavoring extracts to produce dry concentrates
generates no process water other than cleanup since all liquid is
released into the atmosphere as vapor.
448
-------
DRAFT
Evaporation
The evaporation of flavoring extracts to produce concentrated flavors
generates no process wastewater other than cleanup since all evapo-
rated liquid 1s released into the atmosphere as vapor.
Finished Specific Flavor Blending Tanks
The blending of flavoring ingredients to produce finished flavors
generates no wastewater other than cleanup water.
Plant Cleanup
Plant 87E05 reported that organic synthesis tanks were cleaned either
by hot water flushing or steam, while stills and extraction tanks were
steam cleaned. The waste streams from the cleaning of organic syn-
thesis and solvent extraction tanks contain a certain amount of sol-
vents. The cleanup waste stream from the stills would not be expected .
to contain toxic solvents unless the flavoring extract distilled had
been initially produced by organic synthesis or solvent extraction.
Plants 67E03 and 87E05 both segregate these three cleanup waste streams,
along with still bottoms, from the remainder of the plant effluent.
The cleanup of finished flavor mixing tanks is generally done between
flavor changes and consists of a detergent wash followed by a final
rinse. Floors in the blending tank areas are hosed as needed to remove
spills and leaks from equipment connections.
Non-Contact Water
Non-contact condenser cooling water is generated in the vacuum dis-
tillation process. Boiler blowdown is another source of non-contact
water.
Total Plant Effluent
Based on the a^ove considerations it may be concluded that the quantity
and quality of tiie wastewater generated from the manufacturing of
finished flavors could be dependent on the following factors:
1. If the flavoring extracts used in the manufacturing of
finished flavors are produced in-house or purchased.
Purchasers of extracts would generally require no dis-
tillation, solvent extraction, expression, or organic
synthesis equipment anc! consequently, the waste streams
from these processes would be eliminated.
2. The form 1n which the finished flavors are produced. A
plant producing dry flavor concentrates and/or concentrated
449
^.....
-------
DRAFT
flavors might conceivably have a smaller waste flow with a lower
pollutant loading, especially if dehydration equipment is cleaned
without use of water.
Wastewater characteristic data was obtained for two plants during the
course of this study. The average wastewater characteristics of plint
87E02 were determined to be as follows:
Flow 5.7 cu m/day (0.0015 MGD)
BOD 0.017 cu m/cu m
SS 0.0155 cu m/cu n
pH 7.4
The plant's production operations consisted of the following:
1. Production of natural vanilla flavoring from the alcohol
extraction of raw vanilla beans.
2. Production of finished specific flavors from purchased
flavoring extracts.
3. Production of spices by dry grinding and blending.
4. Production of certified colors.
The total wastewater flow was attributable to cleanup operations such
as washing blending tanks between f";avor changes. The average flow
from the plant was estimated to be 5.7 cu m/day (0.0015 MGD) with a
range of 0 to 11.4 cu m/aay (0 to .003 MGD).
The average wastewater characteristics of plant 87E03 were determined
to be as follows:
Flow 125 cu m/day (0.033 MGD)
BOD 0.56 cu m/cu m
SS 0.054 cu m/cu m
pH 7.1
The production operations at this plant consisted of the following:
1. Production of synthetic flavors by organic synthesis.
2. Purification of essential nils by vacuum distillation to
produce standard extracts.
3. Blending of flavoring materials to produce finished
specific flavors,
The wastewater from the organic synthesis and vacuum distillation pro-
cesses was segregated from the rest of the waste stream, neutralized,
450
-------
DRAFT
and contracted to a private service for ultimate disposal. According
to plant personnel the contracted waste is composed of "soluble organics"
and totals 23 cu m/week (0.006 mg/week). A similar waste generated at
plant 87E05 was reported to be composed of the following constituents:
still bottoms, methylene chloride, methyl ketone, methyl hydroxide,
toluene, benzene, and carbon aromatics.
Model Plant
Based on available information from industry, it appears that plant
87E03 is mrre typical of the Industry than plant 87EO?.. Therefore,
plant 87E03 was selected as the model plant for Subcategory A 29 and
1s nius ated in Figure 135. The major wastestreams gener?ted at the
plant consist of still bottoms, and cleanup of stills, organic synthesis
tanks, and blending tanks. However, the wastestreams from the cleanup
of stills and synthesis tanks as well as still bottoms are segregated
from the remainder of the wastestream. All non-contact water is also
separated from the waste stream.
The wastewater characteristics of the model plant are as follows:
flow 125 cu m/day (0.033 MGD)
BOD 1350 mg/1
SS 130 mg/1
pH 7.1
SUBCATEGORY A 31 - 3UUIJ.LOH
The process description of bouillon manufacturing was presented in Section
III and it wo.s determined that equipment cleanup water constituted the
total wastewate:* flow from a bouillon manufacturing plant.
Equipment Cl?anup
Plant 99Q01 conducts e daily plant cleanup of equipment ustd in bouillon
processing and this wastewater war, found to have the following charac-
teristics :
Flow 114 cu n/day (0.03 MGD)
800 420C mg/1
SS 192 mg/1
FOG 150 my/1
pH 10.4
Plant 99Q02 which conducts periodic daily plant cleanup .and weekly cleanuo
of all equipment generated wastewater with the following characteristics:
Flow 720 cu ir./day (0.19 MGD)
BOD 1610 mo/1
SS 239 mg/1
FOG 82 mg/1
pH 6.9
451
-------
DRAFT
ORGANIC SOLVENTS,
ORGANIC ACIDS
ESSENTIAL OILS
* CLEANUP WATER
BOILER
NON-CONTACT
BOILER SLOWDOWN
ORGANIC
SYNTHESIS
1ETIC
/ORS
T
OWN
\
BLENDING
CLEANUP
VACUUM |
DISTILLATION I '
•' STILL |
BOTTOMS i
WATEP
NATURAL
FLAVORS
TO PRIVATE
SANITATION SERVK.E
CLEANUP WATER
BLEI-OING
CLEAhJUP WATER
GENERAL
PLANT
FIGURE 13?
MODEL PLANT FOR SUBCATEGORY A 29
FLAVORING EXTRACTS
452
-------
DRAFT
Dry Cleanup
1:ated Uti1i2ed dry Cleanin9 and generated no wastewater in
Total Plant Effluent
IH!n5i?!hPlant.eff!Ucnt 1S attr1butab1e to equipment cleanup and conse-
'
Model Plant
ri5nt/°r ^ S • Sl'<»cateSory ^ a hypothetical plant producing
C *xcl'jsive'* and is illustrated in Figure 136. The
ouinnn r • n proucn
n?anl nnAt Cf« *xcl'jsive'* and is illustrated in Figure 136. The
men! c?pf " If h°UPS P6r day« five da*S per week ^h daily equip-
followsT wastewater cha-acteristics of the plant are as
Production: 7.3 kkg/day (fc.O ton/day)
F]ow: 151 cu m/day (0.03 MGD)
BOD: 3000 mg/1
SS: 200 mg/1
FOG'. 150 mg/1
All cleanup in packaging areas is done with air. A greese trip prior to
discharge from the plant 1s provided to decrease the fats and oil con-en:
of the wastewater.
SUBCA'iEGORY A 32 - NON-DP IRY CREAMER
Based on processing information obtained during the course of this
study, the major source of wastewater generated in the manufacturing
of both liquid and powdered non-dairy creamer i> determined to be equip-
ment cleanup water. Generally, clean-in-place systems are used for
equipment cleanup. Minor contributors to wastestream quantity are
hosing of floors and wet scrubber discharge.
Clean-in-Place Systems
The clean-in-place systems used for equipment cleanup in non-dairy
creamer plants generally employ six cleaning cycles consisting of the
following sequential steps: (1) hot water pre-rinse, (?) caustic wash,
(3) chlorine rinse, (4) final rinse, (5) sanitation, and (6) air drying.
The quantity of water used in each of the six cycles is usually fixed
and thus water requirements are minimized. For plants of equal size
there is no indication that the quantity of water necessary for the
cleaning cycles would vary markedly. However, the frequency of cleaning
does vary, causing significant differences in wastewater quantity.
Within the Industry three distinct patterns of C1P system cleanup exist:
453
-------
DRAFT
INGREDIENTS
MIXING
TANK
CVEN
DRYING
GRINDING
PACKAGING
CLuANUP
WATEH
CLEANUP
WATER
CLEANUP
WATER
GREASE
TRAP
PLANT EFFLUENT
FIGURE 136
SUBCATEGCPY A .11 MODEL PLANT
PLAIvfT - BOUILLON MANUFACTURING PROCESS
454
-------
DRAFT
(1) cleanup at the ^nd of each day, (2) cleanup at the end of each week
(plants operating 24 hours per day), and (3) cleanup at the end of each
processing cycle (plants which produce creamer on an Irregular basis
and for varying lengths of processing). Assuming recycling of caustic
and acid rinse water, a typical plant will use about 7.57 cu m/day
(0.002 MGD) of water for each CIP system cleanup.
General Plant Cleanup
Liquid non-dairy creamer plants generally hose packaging area floors
continuously to remove product spills, "owdered non-dairy creamer
plants periodically hose floors in areas where spills of dry product from
equipment connections occur. The quantity of water used in hosing of floors
is unregulated in both rases.
Net Scrubber
In the case of powdered non-dairy creamer manufacturing, wet scrubbers
are used over the spray dryers to prevent dispersion of fine particulates
into the atmosphere. The effluent from each scrubber at Plant 99NN01
is approximately 16,000 I/day (4000 gal/day). The pollutant characteristics
were determined to be:
BOD: 4.6 mg/1
SS : 7 mg/1
F&O: 0.1 mg/1
Non-Contact Water
A substantial arco;..it of cooling water is needed in the msnufacturino
of non-dairy creamer. Based on plant water intake minus the quantity
of wastewater generated, the quantity of non-contact cooling water and
boiler blowdown for a typical plant would be about 378 cu m/day (0.10 MG?)
One multi-product plant (99NN02) producing liquid creamer recycled cool inn
water and oniy makeup water was needed. A powdered creamer plant (99'.'.'.C1,
discharjed non-contact cooling and boiler blowcowr, water separately frn~.
the waste stream with the quantity estimated at 454 cu m/day (0.12 HGD/.
T_o_taT__Pj"Qcess Effluent
•V
Plant 99NN01 producing only powdered non-dairy creamer generated a total
process effluent with the following average characteristics:
Flow: 56.8 cu m/day (0.015 MGD)
BOD : 1250 mg/1 (range 1000-15000)
SS : 415 mg/1 (range .355-475)
F40 : 2=0 mg/1 (range 227-275)
pH : 7.0 (range 6.8-7.2)
Plant 99NN02, producing liquid creamer In a multi-product facility,
generated wastewater with the following average characteristics:
455
-------
DKAFT
Flow
BOD
SS
F40
N
P
1800 cu m/day (0.47 MED)
3000 mg/1
2200 mg/1
140 mg/1
15 mg/1
8.0 mg/1
Although 1t 1s not possible to determine which portion of these pollutants
is specifically attributable to the manufacturing of liquid creamer,
the data are presented to Indicate that the wastewater from the plant
is nutrient deficient. This particular plant produces a wide variety of
products, each of which is composed of the same basic ingredients as
liquid creamer but in varying proportions. Therefore, it can be concluded
that the wastewaier from a plant producing solely liquid creamer would
also be nutrient deficient.
Model Plant
The model plant developed for Subcategory A32 as illustrated in Figure
137 is a hypothetical plant which would produce either liqid or
powdered non-dairy creamer. The plant operates five days per week
with two eight hour shifts per day. Clean-in-place system cleaning is
conducted perioJically as needed and at the end of each day and generates
approximately 7.57 cu m/day (0.002 MGD) cf wastewater with recycling of ceus
and acid rinse water. If the plant produced liquid creamer, trie only other
wastestreams generated would be hcsing of floors in packaging areas and
other general plant cleanup amounting to about 56.8 cu m/day (O.OT5 MGC;.
If th" plant produced powdered creamer, two spray dryers would be needed
and therefore two wet scrubbers are necessary. Combined flow from wet
scrubbers would be 30 cu m/day (0.008 MGD). An additional wastewater gore'-a
tion of 26.4 cu m/day (0.007 MGD) would be generated by hosing of dry prese
spills and general plant cleanup. In either case the total plant wastt
effl'.ien". is approximately 64.3 cu m/day (0.017 MGD).
Non-contact water is discharged separately from the waste stream and af-i:;"r-
to about SCO cu "'/day (0.10 MGD). There is no recycling of trie non-cortj*.;.
cooling or boiler blowdown water. The proposed model plant would have
the following cnaract^ristics:
Production: 90 KKg (100 ton) dry product
or 180 KK:j (200 ton) wet product
FTow 64.3 cu m/day (0.017 MGD)
BOD 1100 mg/1
SS 440 mg/1
F&O 265 mg/1
N 5.5 mg/1
P 2.9 mg/1
ph 7.0
456
-------
URAFT
PLANT WATER
SUPPLY
POWDERED CREAMER OB LIQUID CREAMER
NOTEi EITHER POWDERED BB. LIQU1J CREAMER
IS PRODUCED, NOT BOTH "
WA STEW A TEH
EFFLUENT
FIGURE 137
9UOCA7IGORY A32 - MODEL PLANT
HOII-OAIRY CREAMER MANUFACTURING
457
-------
DRAFT
SUBCATEGORY A 33 - YEAST
The use of water in yeast factories includes: (1) feed wort preparation;
(2) fermenter start water; (3) sterilization of molasses and feed wort
tanks, fermenters, and piping; (4) separation wash water; (5) cleaning
of separation and dewatering equipment; (6) miscellaneous floor and
equipment cleanup; (7) cooling water; and (8) boiler feed. Considering
strength and volumes, the wastestrearns from yeast production can be
ranked in the following order: (1) first separation beer, (2) second
separation beer, (3) third separation beer, (4) filtration water from
yeast dewatering; (5) fermenter and storage tank cleanup water; and
(6) floor and equipment cleanup water.
Table 77 shows the pollutant loads of the above operations at a typical
plant (99Y03) producing 76.5 kkg/day (84.3 ton/day). First separation
beer accounts for 43 percent of the total flow, 78 percent of the BOD,
and 31 percent of suspended solids at this plant. The high strength waste
of combined first and second separation beer account for 92 percent of
the total f, _,w, 90 percent of the BOD and 58 percent of the suspended sblfd:
reported from in-plant sampling. Third separation beer is reused for cold
washing during second separation.
Rudolfs and Trubnick (86) reported that first separation beer at a similei-
plant (99Y01) producing 82.2 kkg/day (90.6 ton/day) was responsible for
approximately 70 percent of tne plant raw waste load. The 800 of spent
beer may vary from 2000 mg/1 *o 15,000 mg/1. Wide variations in flow also
occur as the result of different water usage by individual plants during
centrifugal separation of yeast from spent nutrients.
Third separation beer was reused in the second separation by 66 percent
of plants supplying data, since it contains only -a small portion of plant
waste. First and second separation beer typically account for 50 percent
of tne flow and 75 percent of the SOD and SS plants that do not reuse
process water.
Discharges from yeast dewateri.-q consist o* water removed from the yea:*.
cream by rotary vacuum filters ard rece^:id-plate filter presses. Tacle 7?
presents the wa.tewater characteristics for five composite samples (Plant
99Y03) dewatering operations. Filter discharges, containing varying ai-oui.t:
of yeast and spent filter aid, cause substantial daily fluctuations in
strength. Quantities of water discharged depend upon production levels
and the moisture content of tne final product, but are generally less thar:
10 percent of plant flow.
Cleanup of fermenters and feed wort storage tanks is normally performed
using hot water and steam between batch operations to prevent bacterial
contamination during fermentation. Molasses storage tanks are cleaned
weekly using clean-in-place systems with hot water and a 3 percent sodium
hydroxide solution. Tank cleanup varies according to cleaning technique:
and equipment, and the age and size of the plant storage facilities, but
456
-------
TABLE 77
YEAST PLANT 99Y03
UNIT OPERATIONS WASTEWATER CHARACTERISTICS
Operation
Flow (cu
% Total
pH Bod (kg/day) % Total SS (kg/day) X Total
First Separation
Second Separation
Third Separation
Tank Hashdown
feast Dewatering
1.008
1,132
529<1)
79
109
43
49
--
3
5
6.8
7.0
6.8
5.8-13.5
6.8
6,656
1,317
324
571
191
78
12
3
5
2
317
273
142
121
15
31
27
14
12
16
TOTAL
2,328
100
11,059
100
1,0-2
100
(1) Third separation wash reused tn second separation.
-------
TABLE 78
o
YEAST DEWATERING EFFLUENT CHARACTERISTICS $
-\
PLAN! 99Y03
Day Flow Production COD BOD Ratio SS SS Ratio COD COD Ratio COD/COD
(cu m/day) (kkg) (mg/1) (kg) (kg/kkg) (mg/1) (kg) (kg/kkg) (mg/1) (kg) (kg/kkg) Ratio
1
2
3
4
5
290.0
377.0
492.0
95.4
307.3
103
76.5
85.0
85.4
99.3
4«0
700
r/ao
13(30
960
140
263
876
130
295
1.4
3.5
10.3
1.5
3.0
360
680
1320
1540
1080
30
256
650
141
332
0.29
3.4
7.6
1.7
3.3
2880
1532
3210
3085
2410
835
578
1579
294
741
8.1
7.5
18.6
3.4
7.4
0.17
0.46
0.56
0.44
0.40
Average 312.3 89.9 431 2.9 287 3.2 805 9.0 0.41
-------
TABLE 79
WATER USAGE AND WASTEWATER CHARACTERISTICS
YEAST PLANTS RECYCLING SEPARATION WATER-PLANTS 99Y01, 99Y05
VARIABLE
Flow (MGD)
Prod, (ton/day)
BOO (mg/1)
SS (oig/1)
COD (nig/1)
BOD (Ib/day)
COO Ob/day)
SS (Ib/day)
lh/ ton-BCD
Kg/kkg-BOD
lb/ ton-COD
Kg/kkg-COO
Lb/ton-SS
Kg/kkg-SS
BOO/COO Ratio
Flo* Ratio
N
126
126
126
126
1
126
1
126
126
126
1
1
126
126
1
126
MEAN
0.6933«»9
90.408730
6252.944444
1822.230159
14602.000000
36214.451772
91999.535950
10570.723429
401.560349
200.780174
1091.33494C
545.667473
116.654232
58.427116
0.461649
7679.939779
STANDARD
DEVIATION
0.083141
3.742085
1023.914718
999.185341
0.0
7280.916476
0.0
6041.406934
84.916591
42.458296
0.0
0.0
66.615573
33.307787
0.0
958.015079
VARIANCE
0.0069
14.0032
1018401.3489
998371.3466
0.0
53011744.7306
0.0
36498597.7454
7210.8275
1802.7069
0.0
0.0
4437.6346
1109.4086
0.0
917792.8924
MINIMUM
0.440000
69.200000
3600.000000
420.000000
14602.000000
19527.300000
91999.535950
2593.626000
202.986486
101.493243
1091.334946
545.667473
28.532739
14.266370
0.461649
4695.837780
MAXIMUM
0.910000
96.200000
10800.000000
8900.000000
0.0
68495.760000
91999.535950
52732.055000
794.614385
397.307193
1091.334946
545.667473
584.612583
292.306296
0.461649
9790.97S098
COEFFICIENT OF
CONVARIANCE (1)
11.991
4.139
16.349
54.833
0.0
20.105
0.0
57.152
21.147
21.147
0.0
0.0
57.007
57.007
0.0
12.474
o
30
H = Number of data points. note: Computer calculations for this table show no regard for significant figures.
-------
DRAFT
it typically generates less then 5 prrcent of the total flow, 5 percent
of the total EOD, and 15 percent of the suspended solids.
Floor and equipment cleaning is performed as needed to maintain bacterio-
logical cleanliness. Hot water and occasional small amounts of detergent
or caustic are used to clean molasses clarifiers, centrifugal separators,
filters, and packaging equipment. Cleanup effluent is a small part of
combined plant waste.
Table 79 presents a statistical analysis of combined plant raw effluent
data for plants that reuse third separation beer during second separation.
Although flow was found to range as high as 6800 cu m/day (1.8 MGD) in
a plant not recycling separation water, the generation of pollutants per
unit of production varied less than 10 percent for similar production
levels. The two largest producers both reported an average of 170 kg/kkg
(340 Ig/ton) of SOD, while suspended solids varied from 50 kg/kkg (100 lb/
ton) to 76 kg/kkg (152 Ib/ton).
*
Yeast effluents (86), composed predominantly of highly putrescible dis-
solved organic waste substances, have a specific yeasty odor that rapidly"
becomes unpleasant (87), a coffee color, and fairly high turbidity. The
wastewater contains yeast cells, fatty residue, albumens, and their de-
composition products and carbohydrates. Inorganic compounds include,
phosphates, large amounts of potassium, and sulphates. These effluents
putrefy easily as sulphates are biologically reduced to sulphides, and
require oxygen for stabilization in much the same manner as domestic
sewage. They are usually acidic since a pH of 4.5 is maintained during
fermentation. The pH of a total plant effluent samples collected during
this study ranged from 4.2 to 7.7, but more typical values were in the
range of 6.0 to 6.8
Since molasses is deficient in nitrogen and phosphorus, ammonia, and
phosphoric acid are both required chemical nutrients added in fermentation.
After yeast growth, the effluents from production are again nutrient
deficient. Analyses (73) of similar spent molasses in the rum industry
found the distillery slope to have a 94 percent phosphorus deficiency and
a 56 percent nitrogen deficiency. Plant 99Y20, operating an oxygen
activated sludge treatment system, adds ammonia and 227 I/day (60 gal/
day) of 70 percent phosphoric acid before treatment.
Model Plant
Based on the above discussion, a model plant for Subcategory A33 is
defined as follows:
Production 82 kkg/day (90.4 ton/day)
Flow 2650 cu m/day (0.7 MGD)
nf\f\ ^ •*/**> t*
BOD 6300 mg/1
SS 1850 mg/1
It is assumed that the model plant practices reuse of third separation
spent beer, and that first and record separation beer constitute 50
percent of plant flow and contribute 75 percent of the BOD and suspended
sol ids of raw w?.ste.
462
-------
DRAFT
SUBCATE6QRY A 34 - PEANUT BUTTER WITH JAR WASHING
The uses of water in peanut butter processing plants include: 1) jar
washing, 2} floor and equipment cleanup, 3) cool ing.water, 4) boiler feed,
and 5) vacuum seal water. Peanut butter is immiscible in water, and does not
not require the addition of water to the product during processing. In
fact, bacteriological cleanliness demands special attention to insure that
water does not enter the interior of pumps, piping, and other process
equipment. Water use varies widely for individual plants due to produc-
tion requirements, and dissimilar water conservation and recycling tech-
niques. For example, grinder cooling water may be discharged directly
after use or recirculated through cooling towers. Table 80 presents a
breakdown of water usage per operating day by a plant (99P21) producing
59 to 77 kkg/day (65 to 85 tons/day) and demonstrates that over 98 percent
of all water used does not contact the product.
•
Sources of polluted wastewater from peanut butter reduction can be ranked
in the following manner: 1) jar washer discharges, and 2) floor and equip-
ment cleanup discharges. All of the plants surveyed dispose of jar wasner
effluent and cleanup related wastewater, mixed with substantial amounts
of non-contact water, to municipal sewer systems.
Jar Washing - In plants employing jar washing to reclaim glass for pack-
aging, the detergent rinse is normally discharged and constitutes the
major process waste stream. Plant 99Y20, producing 10 kkg/day (11 tons/
day) has a jar washer discharge of 680 1 (180 gal) per 500 jars washed,
and a maximum daily discharge of 2040 I/day (541 gal/day). Approximately
6000 jars/month are washed at this plant. Jar washer effluent is a low
volume, high strength waste that produces 10 gm (0.022 Ib) of BOD, 3.3 grc
(0.0081 Ib) of suspended solids, 125 gm (0.0275 Ib) of COD, and 4.5 gm
(0.01 Ib) of fats and oils per 510 gm (1.125 Ib) jar washed. Table 81
shows the calculated results of plant 99P20 jar washer effluent sampling
after correcting flow to account for non-contact water.
Bad product manually scraped from improperly filled or sealed jars is
sold as inedible ell stock. Variations in pollutant loading per unit of
production may be attributed to differences in the number and size of jorb
washed, and the method of product removal from reclnimable glass.
The largest plant (99Y01) in the industry, producing 140 to 230 kkg/day
(150 to 250 tons/day), reported BCD concentrations nearly doubled and
suspended solids concentrations tripled while practicing glass reclama-
tion. Waste load data from this plant was not used in selecting a model
plant because the wastewater contained large, undetermined amounts of
non-contact water and resulted from the production of several products.
Floor and Equipment Cleanup - Other than jar washer effluent, floor and
equipment cleanup are the only other sources of process wastewater from
peanut butter production. ProdL:tion facilities typically operate five
days per week, 24 hours per day. Floors in processing areas are normally
463
-------
DRAFT
TABLE 80
APPROXIMATE WATER USAGE PER OPERATING DAY
FOR PEANUT BUTTER PROCESSING PLANT 99P21
VOLUME
SOURCE LITERS GALLONS
Cooling Towers 37,000 9,700
Cooling of Refrigeration and
Air Compressors 16,000 4,300
Boiler Fejd Water 9,400 2,500
Sanitary 16,000 4,200
Cleanup and Miscellaneous 1,100 300
With evaporation loss, estimated
discharge 65,000 17,000
464
-------
DRAFT
TABLE 81
JAR WASHER WASTEWATER CHARACTERISTICS PLANT 99P20
Flow
BOD
BOD Ratio
COD
COD Ratio
SS
SS Ratio
FOG
FOG Ratio
2040 I/day (540 gal/day)
7320 mg/1
1.41 kg/kkg (2.82 Ib/ton)
9150 mg/1
1.77 kg/kkg (3.53 Ib/ton)
2810 mg/1
0.58 kg/kkg (1.15 Ib/ton)
3550 mg/1
0.69 kg/kkg (1.37 Ib/ton)
465
-------
DRAFT
scrubbed daily using a small quantity of water and detergent, and the
water is collected using mops or vacuum equipped floor scrubbers.
Water use for equipment cleanup is typically less than 757 I/day (200
gal/day) and is normally sewered. One plant (99P13) reported an esti-
mate based on hose flow rates of 2710 I/day (715 gal/day) used for
cleanup. Table 82 lists cleanup frequency and quantities of water
used for equipment cleanup by a typical plant (99P21)\ Periodic equip-
ment cleanup occurring at weekly or less frequent intervals is usually
done using steam hoses in a specially designated area equipped with
grease traps on all drains. Equipment cleanup is performed between
shifts or on weekends, and normally is not done while production pro-
cesses are in operation. Plant cleaning procedures are subject to
occasional revisions due to equipment changes and constantly improved
programs of housekeeping and sanitation. Although no data is available
to document the strength of combined cleanup wastewater, an estimated 6.8
to 14 kg/day (15 to. 30 Ib/day) of product is reported lost to sewers. Resid-
ual product clinging to equipment may contain up to three percent added
vegetaole oil.
Model, Plant
Based on the above discussion of wastewater characteristics, the follow-
ing model plant was defined:
Daily Jar Washer Effluent 2044 I/day (540 gal/day)
Avg. Daily Cleanup Effluent 757 I/day (200 gal/day)
Avg. Daily Flow2801 I/day (740 gal/day)
The model plant assumes separation of all domestic sewage and non-
contact water from the process wastewater. Since strength of cleanup
wastewater is unknown, no determination of combined waste strength can
be made.
SUBCATEGORY A 35 - PEANUT BUTTER WITHOUT JAR WASHING
The uses of water a"d wastewater characteristics for peanut butter plant;
in Suscategory A 35 are identical co those in Subcategory A 34, except
that jar washing is not practiced.
Model Plant
The model plant is defined as follows:
Flow = 757 I/day (200 gal/day)
466
-------
SOURCE
TABLE 82
OCCASIONAL CLEANUP WASTEHATER DISCHARGED-PLANT 99P21
FLOU
OETtRGERf FREQUENCY PER YEARLY BOD COO SS FOG
CLEANUP (cu n.) (mq/1) (mg/1) (mg/l) (ing/1)
HI
I. Uarehouse concrete floor scrubber
2. Production building wood floor
scrubber
J. Chunk eo/ilpnent cleanup
4. Equipment exterior wipe-down
5. Equipment exterior wlpe-doxn
6. Elevator conveyor bucket cleanup
7. Process line piping cleanup
8. Bucket and drip pan cleanup
9. Oil stock druo wash
10. Elevator conveyor bucket cleanup
11. K»a nut elevator conveyor cleanup
1.1 1 liquid
Concentrate
None
Concentrate
Concentrate
Mnna
Mfino
21 kn P/*«1*r
» 1 kn Pmrf*r
dally
2/ueek
I/weed
I/week.
I/week
| fw j«L
1/mnnth
?/v«-.r
U4
95
76
1136
379
IfiQ
oaf,
1(14
*SR
nil
pftl
29521
9680
1936
5901$
19708
9841
Him
loira
ftftll
1117
3117
37600 85760 69800 189 10.8
28413 42346 16600 57J 8.0
?267 6783 2880 1217 6.1
1050 8464 370 1?6 11.5
1)766 37352 6460 399 9.9
-
-------
DRAFT
SUBCATEGORY A 36 - PECTIN
As described in Section III, there are two methods of manufacturing
pectin; precipitation by alcohol and precipitation by use of aluminum
compounds. The characteristics of each waste stream generated in the
alcohol precipitation process at plant 99K01 are presented in Table 83.
The waste stream characteristics of plant 99X02, which uses aluminum
precipitation in the recovery of pectin, are summarized in Table 84.
Comparison of similar waste streams from the two plants yields the
following observations:
1) The quantity of alcohol still bottoms generated per day
by plant 99X01 is approximately 4.5 times greater than
at plant 99K02. This is attributable to the fact that
more alcohol is used in the process at plant 99X01 and
therefore more still bottoms from the recovery of the
alcohol would be expected.
2) The amount of peel washwater generated at plant S9K02 is
greater than at plant 99K01 which is expected due to the
higher production at the former.
3) The quantity of general plant cleanup water is larger at
plant 99K01 than at plant 99K02 which is probably attrib-
utable to an unknown amount of cooling water included in
the waste stream of the former.
It shnuld be noted that t^ere is no evaporation of pectin solution pr-ior tc-
precipitation at plant &JK02 and therefore no caustic wash waste stream :s
generated, in contrast the pectin mother liquor waste strearr at plant
99K02 is not generated at plant 99K01 because this waste stream is ulti-
mately distilled for alcohol recovery ,-t plant 99K01 and as a result be-
comes a oortion of the alconol still bottoms. This observation supports
the previous comparison of still bottom waste streams. Additionally,
press liouor wastewater at plant 99KC2 is generated when filter sluice is
pressed to separate water from diatomaceous earth.
The wastewater analysis for the total plant effluent from three plant:
(99X01, 99X02 and 99K03) 1: presented in Table 35. It should be noted
that the alcohol still bottoms and filter sluice waste streams at plants
99X01 and 99K02 were not considered in arriving at the figures presented.
Plants 99X02 and 99X03 showed goc- agreement between waste flow generateJ
per unit of product produced. The slightly higher flow figure at plant
99K01 can be partially attributed to an undeterminable amount of non-
contact cooling water in the waste stream.
Model Plant
Based on the information presented above a model plant was chosen for
this suhcategory. The plant operates 2<* hours per day, 365 days per
463
-------
TABLE 83
HASTEHATER CHARACTERISTICS OF INDIVIDUAL WASTE STREAMS AT PLANT 99K01
Has test ream
1.
2.
3.
4.
Alcohol still
bottoms
Filter sluice
Peel washing
f \t» r%Ar*a 4-rt«- f~ .3HC t" 1 f"
Flow COD TS Cl pH
cu in/day mg/1 mg/1 mg/1
170 17,000 19,200 9,930 0.8
223 4,050 4,500 146 6.5
424 18,800 20,800 37 4.5
wa?h 0.0008 1,190 29.700 12.3
5. General cleanup,
non-contact coolfng
water 681 500 *( 18) *(7.0)
Total (excluding
items 1 * 2) 1,105 7.521 7,981 25.3 6.04
* Estimate based on plant intake water.
-------
TABLE 84
WASTEHATER CHARACTERISTICS OF INDIVIDUAL WASTE STREAMS AT PLANT 99K02
Flow
cu m/day
37.9
757
662
492
189
189
r.on
my/1
2,800
3,200
14,600
2,150
11,425
2.000
Cl
mg/1
160
95
38
170
*(20)
N
mg/1
25
235
406
224
__. _
PH
7.0
4.0
4.1
5.5
*(7.0)
Hastestream
1. Alcohol still
bottoms
2. Filter sluice
3. Peel washing (leach)
4. Pectin mother liquor
S. Press liquor
wastewater
6. General Plant
cleanup
Total (Excluding
items 1 & 2) 1.532 8,65b 76.7 259.6 4.59
•Estimate based on plant intake water
o
5
-------
TABLE 05
SUMMARY OF HASTEHATER CHARACTERISTICS
Subcategory A 36 - Pectin
PIM* FLOW COO BOO SS CL pH
cu ro./kkg kg/kkg kg/kkg kg/kkg kg/kkg
99K01 955 10,160 21.6 6.04
99K02 844 7,304 M4.821) 64.7 4.59
99K03 821 3,476 1,753
* Estimate based on BOO:COD ratio of 2:3 at the plant.
-------
DRAFT
year and has the following characteristics:
Production 1.8 kkg/day (2.0 tons/day)
Flow 1530 cu in/day (0.404 MGD)
BOD 4950 mg/1
SS 2100 mg/1
N 260 mg/1
pH 5.0 (4.6 to 6.0) range
The above characteristics are averages only and would be expected to vary.
Production is dependent on whether rapid set or slow set pectin is pro-
duced and whether the raw material used is dry or wet peel, it is assumed
that still bottoms, pressure filter cake sluice, wet spent peel, and non4-
contact water are separated from the process waste stream.
SUBCATEGCRY A37 PROCESSING OF ALMOND PASTE
There are currently four known processors of almond paste in the
United States. All four discharge their process wastewater to
municipal facilities. Results of a telephone survey to three plants
and one plant visitation indicate that the production of almond paste
contributes a relatively insignificant wasteload to the total waste-
load of the four multi-product processing plants. The production of
almond paste exists in combination with the production of a large
variety of other products such as nut pastes (i.e., pecan, walnut,
hazel nut, cashew, and apricot kernels), granulated nuts, and nut
toppings. The wastewater characteristics of almond paste processing
are currently unavailable for the following reasons: 1) the multi-
product plants contacted were unable to furnish historical data on
almond paste production alone, with the only available information
being that of the final combined products wasteload, 2) the actual
sampling of the almond paste production line was impractical due to the
combination of wastestreams from other product lines, and 3) produc-
tion data was unobtainable.
The industry has made no future plants for the construction of any
new almond paste processing plants and, as previously mentioned, dis-
charges its wastewaters to municipal facilities. Therefore, the
possibility of a future point source discharge from an installation
primarily engaged in the production of almond paste is minimal. Due
to a lack of information on the industry's product line, production
variability,, and wastewater characteristics, the development of ef-
fluent guidelines for almond paste processing at this time is not
feasible.
472
-------
DRAFT
SUBCATEGOtn B.1. - FROZEN PREPARED DINNERS
General Plant Clean Up
The wastes generated from these types of processing plants are a direct
function of the various raw ingredients used and subsequent handling steps
involved in transforming these ingredients into finishe- products. By
far the predominant waste loadings (flow. BOD, SS, COD, and oil and grease)
are generated durir/g clean up. Sanitation requirements are such that
in-process clean up is virtually continuous with one large entire-plant
clean up performed at the end of each operating day.
In-Process Clean Up - The raw ingredients are usually pre-processed elsewhere
and are then further processed, cooked, assembled, packaged, and frozen
at the prepared dinner plants. Consequently, the majority of the wastes
from these types of operations originate from clean up of vats, kettles,
fryers, mixers, and other equipment used in the preparation. Included •
in this group would be various spillages from gravy tanks, tray filling,
meat thawing, grinding, etc. In addition, equipment coming into contact"
with food must be cleaned every four hours.
End of Shift Clean Up - Because of sanitary requirements, a complete plant
clean up is performed after ;ach shift, and a general plant clean up is
undertaken at the end of each processing day. The floors as well as immov-
able equipment are cleaned, and this operation may involve the disassembling
of the equipment for a thorough cleaning and inspection. Included in
this type of equipment would be pipes, cooking kettles, infra-red cookers,
extruders, and injectors. The wastes generated typically contain fine
particles and dissolved organics from each ot the unit operations; conse-
quently the pollutants generated may vary widely from day to day within
a particular plant, depending on the products produced. Contributing
to the waste stream's pollutants ;re the necessary chemicals and detergents
required to remove the various organic stains and residues from the various
units of processing equipment.
Defrost Water
The prepared dinners are assembled and then individually quick-frozen
and stored in lar ,e blast refrigerated warehouses, along with raw ingredients
awaiting movement to the preparation area. Because of the large capacity
of the storage facilities, a considerable volume of wastewater is generatec.
The water which is used is basically low load water, typically continuous!/
circulated, although some plants discharge this segment directly under
NPDES permit.
Model Plant
The subcategory for frozen prepared dinners includes T.V. dinners, meat
pies, and other frozen dinners and entrees. Ingredients usually include
meat, fowl, or fish; vegetables; gravies; and minor additives. In addition,
473
-------
DRAFT
there may be added starches (such as noodles), grains (such as rice),
and a variety of small dessert dishes. The bulk of the wastes generated
originates from clean up of processing equipment.
The model plant is one that produces an average BOO loading of 15.6 kg/kkg
with a range from 9.41 to 25.9 kg/kkg as shown in Table 86 . The average
BOD concentration was 1530 mg/1 with a range of 718 to 3260 mg/1. The
wide range in concentrations was due largely to the product type and style
variations as outlined abcve. The other flow-related parameters follow
this same pattern.
SUE.CATEGORY B 2 - FROZEN BREADED A!pe and style variations as autlined above.
The other flow-related parameter? follow this sane pattern.
474
-------
OKAFT
TMLE86 . RAH HASTE S
FROZc.N P°cPA?iO DINNERS
P£RAMtTT*
P
C.OW RATIO L/ 1 j*
.0
.253 Q.J73 3.^:7
.1 3.13 3?. j
<*y.7 -)Z-'
53^0 lcr^v
i z 3 o -i?;
713 3£t>3
.b 9.U1 21-. >
.2 Id.d 51 . .
5*. a :-jj
.7 6.17 L' : . u
.5 12.3 i.-..7
-------
DRAFT
rfl3LE87. RAW
FPOZEN 3Arr£RE(j ANy JREAUEO S^tCI ALT IFS
p«l
NO PLANT LOG MEAN MINIMUM
i *^ *\ "^ • t *~
\ J U \ K U >
(T'J-l/OAY)
FLOW VOLUME "IGO
PL 3rf RAT«! L/i£C
(Sat/.-sir,')
F.DW RSTIO L/r;:'.•*/
-------
DRAFT
SUBCATEGORY B 3 - FROZEN BAKE3Y ITD-1S
General Plant Clean Up
The subcategory frozen bakery Items includes an assortment of commodities
such as frozen pies, cakes, doughnuts, cheesecakes, sweet rolls, etc.,
utilizing ingredients and techniques as detailed in Section III which
are unique to this subcategory. The majority of pollutant loadings are
the result of clean up of the various mixing, extruding, and forming equip-
ment. The various cleaning techniques, additives, and detergsnts used
to remove hardened dough, eggs, milk solids, and the like contribute sig-
nificantly to the wastewater loadings.
In-Process Clean Up - The raw ingredients, e.g., butter, sugar, cream,
etc., are purchased in bulk, received, blended under controlled conditions,
further assembled in the final product form, sometimes baked, packaged, '
and frozen. In order to maintain sanitary conditions, the frozen bakery_
dessert plants must thoroughly clean with hot water all the many mixing
vats, cooking Kettles, measuring devices, putrps, piping, etc., which have
come in contact with the ingredients and product. This clean up is conii"-
uous during tne shift as different products are manufactured.
End of Shift Clean Up - Because of sanitary requirements a complete plant
clean up is performed after each shift, and a general plant clean up is
undertaken at the end of each processing day. The floors as well as im-
movable equipment are cleaned, and this operation may involve the disas-
semoling of the equipment for a thorough cleaning and inspection. Also
included in this type of equipment would be pipes that are cleaned in
place as well as small mobile pieces used in batch preparations. The
wastes generated typically contain fine particles and dissolved organics
from each of the unit operations; consequently the pollutants generated
may vary widely from day to day within a particular plant, depending on
the products produced.
Defrost U'ater
The dessert items are assembled and then individually quick-frozen and
stored in large blast refrigerated warehouses, along with raw ingredients
awaiting movement to the preparation area. Because of the large capacity
of the storage facilities, a considerable volume of wastewater is genera:ed.
The water which is used is basically low load water, typically contin-
uously circulated, although some plants discharge this segment directly
under NPDES permit.
Model Plant
The model plant for this subcategory would be one manufacturing frozen
dessert items including pies, cakes, pastries, and rolls. The bulk of
the wastes generated originates fron clean up of processing equipment.
The model plant has an average BOD loading of 22.4 kg/kkg and the average
BOD concentration was 2,090 mg/1 as shown in Table 88. Average TSS load-ing
was 13.6 kg/kkg at a concentration of 1,270 mg/1.
477
-------
DRAFT
Z 88. RfliJ WflCTE SIT1MARY
PROJUCTS
NO PLANT LOG HtfiN
'*33 K<,:/DAY 1 5C.S
r. -II KT TIME H^/l'iY 1
r.3»- VOLUME: MOD i
L/3CT 1 6.3l
./'.'in uo
T TO L/<>\& 1 1G7DG
( GAL/i 3t;) 257:
478
5 3 i Y j C 2 .'10 / L 1
? a T I 0 * 3 / N •< • j ' 2 2 . U
IL-J/TC'.'J HU.6
T5SkiC/L 1 127C
' '. 7 I C H G / < s ". 1 3 . c
( L 3 / T C'.' > 27 .2
-------
DRAFT
SUBCATEGORY B 4 - FROZEN TOHATO-CHEESE-STARCH COMBINATIONS
General Plant Clean Up
The processing of frozen tomato-cheese-starch items (frozen pizza, macaroni,
lasagna, ravioli, etc.) involves the combining of preprocessed ingredients
into the final product form! The principal waste generation step is plant
clean up. The cleaning procedures are similar to those described for
the frozen prepared dinner subcategory, and its clean up, with very little
modification, can be applied to the frozen tomato-cheese-starch subcategory.
Defrost Water
Refrigeration water is generally recycled, but, if not recycled, contributes
a significant volume of clean water to the waste stream.
Spillage and Clean Up
The types of pollutants generated by a plant are a direct function of
the various raw ingredients used and the subsequent handling steps involved
in transferring these ingredients into finished product. An efficient
plant can hold its waste ingredients to under one percent of the incoming
ingredient weight, e.g., loss of less than one pound of tomato paste used.
Model Plant
All major ingredients are preprocessed elsewhere and arrive at tne manu-
facturing plant in bulk containers. These ingredients include tonato
paste, cheese, flour, milk, oil, noodles, seasonings, and meat. The waste
generated from plant clean up contributes the most significant portion
of the waste stream. A process summary is presented in Table 89.
The model plant is one that produces an average BOD loading of 18.8 kg/kkg.
The average BOD concentration was 239 mg/1. The average SS loading was
14.3 kg/kkg with a concentration of 180 mg/1.
SUBCATEGORY B 9 - PAPRIKA AND CHILI PEPPER
The subcategory paprika and chili pepper consists of wet sampling data
from two plants -- 99C50U and 99C51W. As shown in Table 90, average
BOD loading was 8.44'kg/kkg with a range of 6.32 to 11.3 kg/kkg. The
average BOD concentration was 391 mg/1 with a range of concentrations
from 253 to 604 mg/1. SS and flow ratio parameters showed similar
consistencies.
Model Plant
The model plant for Subcategory B 9 was selected to have a flow of
2000 cu m/day (0.5 MGD) with the following characteristics:
BOD 400 mg/1
SS 250 mg/1
pH 6 to 9
N&P Sufficient
479
-------
DRAFT
M3Li 89. kAW WASTE 1UMM6SY
FROZEN lOHArC-CHciZSC-LTA'CH UISHCS
NO
ICC MEAN
( ! ? N / C ft f )
S^IFT TIi-E H?/IV Y
c.0t-, VOLU-E '-IJL
- . j « -: A ; L L / % £ c
( G -' L / •'• I 4 )
2.1.1
1.92
(GAL/ 7 J'.)
' I -j / T Z '.' i
r:?, M-J/L
'•; i f I ~ *j/^; ',
c.-;/ r c ; )
•237
IB. *
37.5
430
-------
DRAFT
TA-JL£ 90. Riw WASTE SI.'^I
CHILI rEHPERS ATiO PAPRIKA
NO PLANT LOG
i •; < G / 0 A r
(TON/
SHI^T TIUL r|S>/DA'
FLOW yGLUME M^O
p.:)* -'ire- L/:-:C
5 jiY i3C Mu/L
'33 ^G/L
,i ric
-------
DRAFT
SUBCATEGRP.Y C 4 - EGG PROCESSING-
Liquid Egg Processing Equipment Cleaning
According to Siderwicz (88 ), cleaning of liquid egq handling equipment
is the largest source of .;astewater from egg processing plants. Virtually
all egg processors have clean-in-place systems for the cleaning and
sanitizing of their pasteurizing equipment, liquid egg holding tanks
and associated piping. This equipment is normally drained of egg
product as coroletely as Dossib1e before cleaning. The cleaning
is accompl ishe'l in three steos; pre-rinse, washing, and rinsing. 5o^e
egg processors have reduced their water consumption by recovering th&
final rinse water and reusing it in the ore-rinse step of the next
cleaning cycle. The quantity of wastewater and the waste load fror this
cleaning process depends on whether the eng product remaining in the
pipes after the pumps are shut off is discharged to the sewer or noes
to inedibles. No data is availsole to cjantita tively define the was':?-*
water generated by thesa cleaning processes as opposed to on egg process:-':
total effluent.
Egg Breaker K'astev.'ater
Hhen a substandard ego is broken the cue and sometimes the entire
breaking machine must re i/asred dcun. Sider/icz (38) indicates that tne
washing of the e?g breaking eauiorent is the second largest source of
wastewater flow and th* tnird nost i^nor.ant source of wastewater
strength. SchuHz (89 ) report; that
-------
DKAFT
from plant to plant, and the waste load varies dramatically, depending
on the housekeeping practices.
Combined Plant Effluent
Total discharge volumes from egg processing plants range from 0.015 to
0.53 mid (0.094 to 0.1- mgd). Total discharge per units of production
varies from 0.9 to 17.3 1 per kg (0.5 to 10 gal per Ib), with reir.arl.sble
differences in wastewater discharge for apparently similar operations.
Total production ranges from 4 to 35 kkg per day (4.4 to 94 tons re'-
day). The data collected indicated no relationship between tne tctjl
production per day and the total discharge per unit of production. "~c-
300 values of the total plant effluent from the plants surveyed reined
from 1,800 to 8,600 mg/1 and the suspended solids concentrations rj^c-r,
from 540 to 1,600 mg/1. Table 91 is a summary of the plant effluent.
•
Model Plant
The model plant for this subcategory is a hypothetical egg processing
plant which produces frozen, liquid and dried egg products. The ecci
are trucked to the dant in 21 kg cases (30 dozen eggs). After a s'ncr-
period of refrigerates storage, the eggs are loaded, candled, washea
and broken as describee in Section III of this document. The eggs are
then pasteurized and frozen, dried, or sold as liquid egg. Total ?-;:
broken at the model plant in a 24 hr per day operation (including ar.
8 hr cleanup shift) is assumed tc be 30 kkg per day (33 tons per da/).
Wastewater - Sources cf wastewater from the model plant would
all sources listed above. Inesjble eggs are recovered and sold or
handled as solid waste to help reduce the waste strength. Total
wastewater flow f:>r the -.ode1 slant is assumed to be 0.2 rid (0.05 -
and flow per kkq of eugs Dror>en is 6.5 I. Effluent BOD is 3,700 me
and the effVjert susp?ndea scrds concentration is 850 mg/1 . Thus.
waste load from the r.odel plant will be 23 kg BOD and 5.4 kg SS pe-- «• :
of eggs broken. !: is alio cics.re-j that this model plant utilize: i
catch basin to renove ihel's T"r^~ "ts waste stream. Some of the *<••-
technology described in Section Vil is jtilized by the model plant.
SUBCATEGORY C 5 - SHELL EGGS
Egg Hashing
Egg washing is the mjjcr source of wastewater strength and volume frcr-
shell egg plants. Egg washing -lacnines use a recircinating disinfect':;-:
detergent solution for wssnin-:. -..ii.-h is followed by a potable wdtsr
rinse. The rinse water added to the washer tank provides a continuous
overflow. Every four hours the ;.esher tank is dumped and refilled \-r~-
fresh water. Schult: (89) reporto-j that continjous overflow from the
egg washer had a COD of 935 :ng'l and suspended solids of 150 mcj/1.
Sanioles taken from an egg washer tnnk during this study had BOD valj
-------
DRAFT
E 91 . -
CGG
HO PL'
9
LCG MEA',1 Mi.'I
S-iTrT TI-c ~3/:-Y
27.1
9 . :•
a . J i
•-0- ^-rr !./-;
( J-L/'T
•. D ••• -in? . / •
«j^./1.
:u
i .:i
i '-J . tr>
j u : :
T;: MS/.
3 A T : : N ./-.-:;
< L • / r: •
359
C.I j
3 . J 7
J-3<«
7
-------
DRAFT
T4K-I92. Rf.
EGGS
P^lMtTi? ;:0 PLANT
POj<',G/";Y 7
-/_~Y 7
FLO.. ^'uL'J'lL MJU 5
P _ 0 W R i T t' . / n i C 7
(0. ••'./• :•;)
• . 3 .v -; L T ! "• L / •; v '• 7
( j-../ T j',)
5 ^ J .' ; 0 D " I- / . 7
IL'1/TC")
LOG rE*N MINIML-:. :u,I-;:
21.7 7.
2«OJ U . •D i " 1J.'
b e . 7 b . £ - • I -
z «, 7 c i ? '. : ? : ^ :
c . '> 3 j : . j •: : f . ".
i.ii o . i z : 11."
'i'> -j/L
U 7 I J <»/-,<.,
( L 0 / T J . )
73u
485
-------
DRAFT
Plant Cleaning
General cleaning of shell egg plants is a significant source of ivastpwater
generation. Some eggs fall to the floor during handling and must be
scraped up, mopped up, or rinsed into a floor drain. All equipment ?r\d
floors must be cleared periodically. The frequency of general plant
cleaning varies from plant to plant, and the v/a:;tcload varies dra.^atica1 !••,
depending on housekeeping practices.
Total Processing Effluent
Trie quantities and character! sties of wastewater from shell egg plants.
vary considerably. These variations are usually the result of ooernti'-r
and cleanup procedures, which depend on the training and management
of the personnel. Wastewater flow per unit of production varies from
plant to plant, but is generally consistent within 3 given plant.
Table 92 includes data describing the total processing effluent for
this subcategory.
Tue node, olart for this subcategory is a hypothetical shell cgc; p'ijr-,.
The eons are trucked to the slant in 21 kg cases (30 dozen egcs).
J3l sian' is ass'jnied to be 12.5 kk-j •;!•* ten;]
per say produced in einhr. hours per day, five days per week opera:;:,••.
We:stgwater - Sources of wastO'.'ate
frcm the -no del plant include ill
Iied'ble ecjss are recovered and sold.
u;-c-j tc Lie 0.013 mid (3500 gad). It
of tne sources listed above.
Tctal waste..-atsr vclure is a:
is_assurried that this r.odel plant utilizes a catch basin of a large
0.6 cm (0.25 in.), mesh screen to remove shells from the waste strea~.
436
-------
DRAFT
SU3CATEGOP.Y C 6 - MANUFACTUP.ED ICE
The quantity of water that is wasted is the parameter of most concern.
In fragmentary ice manufacturing the quantity of wastewater discharged
approximates the quantity of water incorporated into the ice. The
range in discharge is relatively narrow and is not highly operator-
dependent. On the other hand, the quantity of water used and waste-
water discharged from block ice manufacturing has up to 20-fold variations
from plant to plant. These variations are primarily due to water con-
servation practices or lack thereof, and rnoit of the variations in
water use are attributed to discharge of once-through cooling water.
The thrust of this program, however, is directed to process water end
the waste load in terns of kg of pollutant per kkg of product. There-
fore, the following discussion is directed to waste load ratner than
discharge volume.
The concentration of pollutants from ice manufacturing is nominal.
Pollutants, if tnese constituents should be classified as pollutants,
consist predominately of dissolved solids (salts) with very low
suspended solids, BOD, and nitrogen concentrations. The concentration
of salts and suspended solids in the waste stream is dependent on the
characteristics of the water supply. The water used in ice manu-
facturing must be potable, but if the water had a relatively high salt
and solids concentration, the :oncentration cf these constituents in
the waste stream will be proportionately high.
The major sources of these pollutants are the following:
1. Water pretreatrent, if required to remove suspended
solids. Predominant tre&tner.t methods are lirr.e,
sand filters, and carbon filters.
2. Core pumping. A number of block ice plants putr.p out
the unfrozen core water prior to complete freezing
of an ice block. Thi? core water has a volume of 10
to 22 liters (3 to 6 gal) per bloc!;, anJ i: contains
much of the solids and other imourities found in the
water supply.
3. Can dipping in a block ice plant is a source of a
small amount of salts. Pollutants in the waste stream
from can dipping are primarily brine remaining on the
exterior of the cans when they are removed from the
brine tank. However, prior to can dipping but after
lifting the cans from the brine tank, the cans are
suspended for several nir.utes to allow most of Uie
brine to drip back into the brine tanks. Chloride
concentrations! in the dip tank are nor.nally below
-------
DKAFT
that which would produce a salty ta^te in the wainr and
the solids are usually dissolved and of relatively low
concentration.
J- Slowdown from fragmentary ice making machines has
approximately twice the concentrations of dissolved
and suspended solids as the water suppiy.
4. Snow and end pieces generated by crushing, scoring, and
sawing block ice into sized or cube ice contribute re-
latively pure water with virtually no pollutants. Some
plants recycle this water for ice-baking and others
discharge it as wastewater.
Total Processing Effluent
The quantity and quality characteristics of wastewater from ice manu-
facturing plants is relatively constant in any particular plant. The
same processes are used repeatedly ir. both block and fragmentary ice
production. Thus, the only variations in quantity or quality of the
wastewater come from variations ir. the product mix. Wasteuater frc~
ice manufacturing plants is clean in comparison with other industrial
waste streams. Characteristics of the wastewater is similar to those
the water suoply with slight to 100 percrnt increase in chloride and
dissolves solid concentrations. Table 93 includes data dscricing
the total processing effluent for this ^ubcategory.
Model Plant
The rr.cdel plant for this subcategory is a hypothetical ice manufactur-
ing plant producing both b'lock and fragmentary ice. The block ice is
produced as described in Section III and core water is pumped from
the blocks. Both once-through compressor cooling water and core pump-
ing v^ater are discharged to the waste stream. The fragmentary ice
machine is located in the same building as the block ice facility and
its waste is discharged to the \-,n = te stream. Average total prccuctior,
is 17.2 kkg per day (19 tons per aay). Production is 24 hours per
day, five days per week for six months a year.
W£s_to'£3_te_r - Sources of wastewater from the model plant include all
fs listed ebove.
Parameters of the wastewater are assumed as follows:
1. Flow volume - average - 0.04 mid (11,000 gpd)
minimum - 0.01 mid (3, COO Gpd)
maximum - 0.19 mlcj (5U,000"gpd)
2. BOD - 1.2 mg/1
488
-------
DRAFT
TA3LE 93 . RJW WiSTE SUMMARY
O ICE
^^03
5 H I F
FLO*
F.04
FL:W
5 'DA
•<;TI
T jS
3CT T
P':eA"i£TJR
".O/DiJY
< To.'j/oA >• )
r T i MC MR/:- f
VOLUME -iO
xATC L/'EC
« iAL/.iri)
'•-AT 1C L/«o
( GML/TODJ
V ?.00 KC/L
0 KG/
-------
3. SS - 5.2 nv;/l
4. 0.004 - kg BOD per kkg of product
5. 0.012 - kg SS per kkg of product
SUBCATEGORY C 12 - SA.'.TOICHES
C1 ea_n_up =nd Total Conbin?d Process Haste
General cleaning is the only source of wastevater generation in mgs
pre-rad.aceri sandv/i'ch plants. General cleaning consists of washing
utensils in a smk or dishv/asher, wining off countsr tops, and mop:
floors. These orocedure; are normally eTiolcyod on a daily basis.
chopping ,-,K nines used in plants fat blend salad-type sandv/ic.n til
are cleaned daily witn a hose. The total voljr.e of process wistewa
from the plants contacted ranged fron 400 to 11,000 Ipd (ICO to
300C gpd).
Mode' Plan*
t
! ings
The -,odel plant for this subcateqorv is a hyoothetical plant
asse^Lles a variety of pre-pac-'.aged sar' j-ui'cnes. All of the irstaris'is
fron which t'o sandwicnes .are assenoled are processed before deliver;.
at tne sancwich plant. Trtal or.'duct^on at the nodel plant is assirs:
to be 4.5 k'Kg [5 tons) per ddy prcdjced in 3 -icurs per day, five doys
per -./eek.
Hasrewuter - Sources cf wastewater fro": the ."odel plant include genets'
c'eamng :f hano utensils, ccurrer tc-s and floors. The wastewater
f'ow from the model plant is 7,500 1 120CC gel) per day.
Two days of sampling were conducrc-; at a major producer cf prs-Dacl:a.:eci
sanawicnes. However, the samoles were taken by an employee of the D-lir.t
and apparently care froii the surface of the •_ ease trap. As a res:.It.
the values oDtsined '..-ere not reofesentaiive o~ tne plant's westewa:?'.
SUBCATEGORY D 4 - VINEGAR
Wastewater characterization is based on data from four plants eng&ged in
the production of vinegar from apole products. Mltr-uqh vinegar is also
produced fron grape oroducts and ourc^ased °tnanol, no historical data
for processors utilizing these rav. materials was available. Vinegar fre
apple products represents the largest segment of the industry and is a
good representation of the industry as a whole. Table 94 summarizes
the data collected.
Water use in the vinegar plant is pri'rarily in the filtration operation
with lesser amounts consumed for daily plant cleanup. Wooden holding
tanks, when not in use for v.negar storage, are filled with water to
avoid shrinking of the wood; draining of these tanks occurs as necessary.
490
-------
DRAFT
i-jL-I 94. RAW WASTE LlMVflR
n,WiM£T.:?
(ioc: Oii./j:v>
hi: 1-LtNT LOT, M£CN
t» 7 fc. . 1
2 C.I
Mf.lMUH ".{.('•.•'..*•
J J . 3 1 -3 .'
7.93 s ; . =
SHIFT TI---F.
FLC'A VCLU-lE "^'3D
c'. 3 ^ "*-Tf L/3ET.
PL^W -'filTO L/Co '1
(GAL/1JO-"1 O.'.L)
5 jAY jJD MT'.'L
?aTIO KG, CJ '"
I _o/ 1 ^ ju ^i_ )
T 3 S Nl 1? / L
0,ir:o K:,/CU w
( L T / J 3 j 0 C- - L )
0. ^
lira
117C
195C
1.9,
It. C
.fc 5w
3 . J 3 11. -
0 . C 11 i. .. •
531 71b :
1 .20
i:. 3 .''
U . 3 1 7
2 .C>3
491
-------
DRAFT
Non-contact cooling water is also used in the vinegar Generators and may
or may not be recycled. The ratio of wastewater to production averaged
1170 1/kkg (1170 gal/1000 gal) with a range of 540 to 2550 1/kkg (130
to 610 gal/ton).
The expected range of BOO ratios is from 1.20 to 3.07 kg/cu m (10.0 to
25.6 lh/1000 gal) with an average of 1.92 kg/cu m (16.0 lb/1000 gal);
suspended solids is from 0.317 to 1.36 kg/cu m (2.63 to 11.3 lb/1000
gal) with an average of 0.654 kg/cu m (5.46 lb/1000 gal). The range of
waste loadings is not directly related to any observed differences be-
tween tlie processors. However, the handling of filter washwater and
storage tank sedimentation can greatly influence the waste loadings.
Of particular importance in the vinegar process 1s the presence of acetic
acid in the effluent. The arithmetic average pH for three plants with
raw effluent data was 5.17 with a range of 4.59 to 5.50. Surges of waste-
water with lower pH can be expected during the flushing of holding tanks_
and cleanup of spillages.
Model Vinegar Plant
Production:
Wastewater flow volume:
Wastewater characteristics:
Primary source of wastewater:
Special consideration:
78 cu m/day (20,000 gal/day)
90.8 cu m/day (.024 HGD)
BOD * 1950 mg/1
SS » 660 mg/1
pH = 5.2
filtration operation, waslidowns.
pH adjustment.
SUBCATEGORIES El (MOLASSES, HONEY. GLAZED FRUIT, AND SYRUPS). E 2
(PDPCCR,;;. E 3 (PREPARED GELATIN DESSERTS). E 4 (SPICES). E 5 (DE-
HYDRA TEJSOL'P) , AKD E 6 (MACARONI. SPAGHETTI. VERMICELLI. AND NODDLES)
The processes associated with Subcategories E 1 through E 6 have been
found to generate little wastewater. What little wastewater that is
generated results from equipment cleanup and floor washing. The volume
generally amounts to less than 4000 I/day (1000 gal/day). The pollu-
tant loading is comparable to that of domestic sewage. The develop-
ment of model plants is not necessary for these Subcategories.
SUBCATEGORJES F 2 BAKING POUDER). F 3 (CHICORY). AND F 4 (BREAD CRUMBS
NOT PRODUCED IN BAKERTTsT
As described in Section MI, the processes associated with these sub-
categories are dry processes that generate no contact process waste-
water. Therefore, development of model plants is not necessary for
these Subcategories.
492
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DRAFT
SECTION VI
SELECTION OF POLLUTANT PARAMETERS
HASTE'^ATER PARAMETERS OF POLLUTIONAL SIGNIFICANCE
Major wastewoter parameters of pollutional significance for the
miscellaneous foods and beverages industry include BOO ( 5-day
20°C), COO. suspended solids, and oil and grease. Minor parameters
of significance include pH, nickel, alkalinity, total dissolved
solids, nutrients (forms of nitrogen and phosphorus), color, chlorides
and temperature. On the basis of all evidence reviewed, there does
not otherwise exist any purely hazardous or toxic pollutants (e.g.,
heavy metals, pesticides) in waste discharged from the miscellaneous
foods and beverages industry.
When land disposal of wastewater is practiced, contribution to ground
water pollution must be prevented. Under land disposal procedures,
all practices should be in general accord with the Environmental
Protection Agency's "Policy on Subsurface Emplacement of Fluids by
Well Injection" with accompanying "Recommended Data Requirements
for Environmental Evaluation of Subsurface'Emplacement of Fluids
by Well Injection" ( 90 ).
Significant pollutional parameters for the protection of ground
water from land disposal include BOD, COD, pH, temperature, total
dissolved solids, and nutrients.
RATIONALE FOR SELECTION OF IDENTIFIED PARAMETERS
The rationale for selection of the significant parameters for the
miscellaneous foods and beverages industry is given below:
Organics
Biochemical oxygen demand (BOD) is a semi-quantitative measure
of the biologically degradable organic matter in a wastewater. For
this reason, in wastewater treatment, it is commonly used as a measure
of treatment efficiency. It is a particularly applicable parameter
for the misc2llaneous foods and beverages industry since the wastes
are highly biodegradable with very few'exceptions.
The primary disadvantage of the BOD test is the time period required
for analysis (five days is normal) and the considerable amount of care
that rots t be taken to obtain valid results.
Under proper conditions, the chemical oxygen demand (COD) test can
be used as an alternative to the BOD test. The COD test is widely
used as a means of measuring the total amount of oxygen required for
493
-------
DRAFT
oxidation of organic; to carbon dioxide and water by the action of a
strong oxidizing agent under acid conditions. I" differs from the BOO
test in that it Is Independent of biological assimilability. The major
disadvantage of the COO test Is that It does not distinguish between
biologically active and inert organics. The major advantage 1s that it
can be conducted in a short period of time, or continuously In automatic
analyzers. In many instances, COO data can be correlated to BOD data
and the COD test can then be used as a substitute for the BOD test
where a reliable relation:hip can be demonstrated to exist. Considerable
difficulties occur with the COD tej.1. in the presence of chlorides.
The measurement of total organic carbon (TOC) offers a third alter-
native for an Indication o organic concentrations. This test offers
the potentiality of a high degree of reliability and produces results
in a matter of minutes. However, at the present time the equipment
required for the test is relatively expensive, has not beer, used
extensively to date, and has had little exoerience in the -niscpllanpnus •
foods and beverages industry.
With a few exceptions, the wastevaters generated by the miscellaneous
foods and beverages industry contain relatively hvjh levels of readily
biodegradable organics.
Suspended Solids
Suspended solids serve as a parameter for measuring the efficiency
of wastewater treatment facilities and for the design of such facilities.
Suspended solids concentration in water affect light penetration,
teir.perature, solubility products, and aquatic life. Upon settling,
solids may blanket organisms or their habitats, either killing the
organism or rendering the habitat unsuitable for occupation. Suspended
solids concentrations greater than 80 mg/1 in fresh water streams have
been reported (91 ) to be detrimental to fisheries.
Suspended solids arc & major pollutant parameter for most of the
subcategories discusred in this document. It is relatively minor for
most of the confectionery operations as well as for a few other products
for which carbohydrates are of greater importance.
Oi 1 and Grease
Floating oils may interfere with reaeration and photosynthesis
and prevent respiration of aquatic insect:; which obtain their oxygen
at the water surface. Free and emulsified oils may interfere with
fish respiration and destroy algae and other plankton. Deposited
oily substances on the bottom of a stream bed may destroy benthic
organics.
494
-------
DRAFT
Oil and grease is a major parameter for the vegetable oil processing
and refining industry, the bakery and confectionery industry, the pet
food industry, and fnr several of the miscellaneous products.
These oils and greases of animal and vegetable origin should not be
confused with petroleum wastes. The oils and greases generated by
the industries which are subject to this study are readily biodegradable
in both municipal and private treatment systems.
£H
pH is an important criterion for in-process control, odor control,
and bacterial growth retardation. Highly acidic or caustic solutions
can be harmful to aquatic environments and can interfere with water
or was.tewater treatment processes. The acceptable range for successful
performance of biological treatment and a healthy fresh water habitat
is between 6.0 and 9.0.
Several of the subcategories discussed in this document require
minor pH adjustment before discharge or biological treatment. It is
perhaps most significant for vinegar which produces an effluent
with high concentrations of acetic acid.
Nickel
Nickel as a pure metal does not consitute a serious threat to
receiving waters; however, many of the salts of nickel are soluble
in water and may be hazardous to aquatic life. Since the acute and
chronic toxicity values of nickel vary widely, the EPA ( ?2 ) has
proposed a limiting appMcation factor of 0.02 of the 96 iour LC5Q
as required to provide adequate protection for aquatic life.
The only known source of nickel 1n process waste water from the
miscellaneous foods ard beverages industry would be attributable to
the edible oils refining irHustry where small amounts of nickel are
used in the process. The discharge of nickel from ed^'Mf oil refining
plants-has been found to be very insignificant under present operating
practices. Effluent limitation of nickel within technological capa-
bilities and pollution control requirements is justified in a p"f-
cautionary sense, due to the potential polluting effects attribuf.a:/ie
to this material.
Alkalinity
Alkalinity in'water is a measure of hydroxide, carbonate, and bi-
carbonate ion<->. Its primary significance in water chemistry is its
indication of a water's capacity to neutralize acidic solutions.
In high concentrations, alkalinity can cause problems in water treat-
ment facilities. However, by control of pH, alkalinity is also controlled.
495
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GRAFT
Total Dissolved Solids
The quantity of total dissolved solids in wastewater is of little
meaning unless the nature of the solids are defined. In fresh water
supplies, dissolved solids are usually inorganic salts with small
amounts of dissolved organics, and total concentrations may often
be several thousand milligrams per liter.
It is not considered necessary to recommend limits for total
dissolved solids since harmful salts and organics are limited by other
parameters.
Nutrients
Forms of nitrogen and phosphorus act as nutrients for the growth
of aquatic organisms and can lead to advanced eutrophication in surface
water bodies. In water supplies, nitrate nitrogen in excessive con-
centrations (.an cause methemog'lobinemia in human infants and for this
reason has been limited by the United States Public Health Service to
ten milligrams per liter as nitrogen in public water supplies ( S3 ).
Under aerobic conditions arnnonia nitrogen is oxidized to nitrite
and ultimately to nitrate nitrogen. Phosphorus compounds are commonly
used to prevent scaling in boilers and orthosphosphate may occur in
boiler blowdowns. The use of phosphate detergents for general cleaning
can contribute phosphates to total wastewater discharges. When applied
to soil, phosphorus normally is fixed by minerals in the soil, and
movement to ground water is precluded.
Co|or
True water color is a result of substances in solution after
suspended materials have been removed. It may be derived from mineral
or organic sources and may be the result of natural processes as well
as manufacturing processes.
The effect of extreme water color on aquatic life is to limit
light penetration, thereby restricting the photosynthetic zone and
inpacting benthos. Otherwise, color nay serve as an indirect indica-
tion of pollution and be aesthetically objectionable.
The production of soluble coffee, tea, rum, and yeast results in a
wastewater with considerable color, The effectiveness of biological
t-eatment for color removal is questionable. Carbon filters or other
devices may be necessary for color removal in some instances, but present
technology for color removal from these wastewaters is nonexistent.
The acceptable limits of color in navigable waters are highly
dependent on the natural levels of color in the waters and the degree
496
-------
DRAPT
of available dilution. The Environmental Protection Agency ( 92 )
has proposed that acceptable conditions regarding the combined effect
of color and turbidity in water will be met if the water's compen-
sation point Is not changed by more than 10 percent from Its seasonably
established norm, and if no more than 10 psrcent of the biomass
of photosynthetic organisms is placed below the compensation point
by such changes.
Chlorides
Chlorides can cause detectable taste in drinking water in salt (sodium,
calcium, magnesium) concentrations greater than about 150 mg/1;
however, the concentrations are not toxic; drinking water standards
are generally based on palatability rather than health requirements.
In the application of wastewater to land, no practical limits can be
recommendec by this document since chlorides are generally non-toxic
to crops, although some fruit trees are sensitive to chlorides. A
consideration of crop irrigation with wastewater should take into
account chloride concentrations.
The operations discussed in this document which discharge significant
chloride concentrations are block ice production, olive oil production,
and pectin production. In the case of block ice production, the
concentrations in the wastewater are within drinking water standards.
The concentrations for olive oil and pectin are considerably higher
and attention must be given to specific discharges.
Temperature
The discharge of heated waters, with inadequate dilution, may result
in serious consequences to aquatic environments. Generally, problems
of heated water are associated with various cooling waters that are
not subject to recommendations in this document. One process stream,
currently discharged in some cases from rum distilling, approaches
the boiling point of water; however, recommended control technology
developed in Section VII would eliminate this problem.
METHODS OF ANALYSIS '
During the course of this study a number of wastewater samples were
collected and analyzed at the laboratories of Environmental Science
and Engineering, Inc., dainesvilie. Florida. The following outlines
the analytical methods used.
Solids
Total solids was determined by drying an aliquot of sample at
1048C according to LPA methods (EPA, Methods for Chem^.al Analysis
of ...Water and Wastes. 1974, p. 270; Standard HethodsTpp. 535-536).
497
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DRAFT
Dissolved and suspended solids were determined by glass fiber
filtration and drying at IfVTC, (Standard Methods, pp. 535-536).
Volatile solids was determined by combustion at 550°C, (EPA Methods.
1974,_p. 272; Standard Methods, p. 536).
pH and Temperature
pH and temperature were determined at the time of sample collection.
Nitrogen and Phosphorus
Total nitrogen was determined by the Kjeldahl digestion procedure
(Standard Methods, p. 469) and total phosphorus by the ascorbic acid
method (Stenoard "Methods, p. 526, 532).
Oil and Grease
Oil aid grease was determined gravimetn'cal ly by the liquid-
liquid extraction technique with hex?ne. The procedure is a modif-
ication of the technique described in EPA Methods . pp. 22G-228.
BOD
BOD was determined by oxygen depletion i: 20°C using a membrane
electrode to measure DO (Standard Methods., pp. 439-495; EPA Methods,
1974, pp. 11-12).
cog
COD was determined by dichronate oxidation followed by titration
with ferrous ammonium sulfate (Standard Methods , pp. 495-490; EPA
Methods. 1974, p. 20).
Color
Co^or was deternined cclorimetrica" ly on a Klett-Si'mmerson colorimeter
and is reported in chloroplatinate units, a variation of the method given
in EPA Methods. 197-4, pp. 36-38 and Standard Methods, pp. 160-162. While
this method is designed for natural waters, the najcr need for color
analyses has been in the tea and coffee industries where the nature
of the color of the wastewaters approximates that of natural waters.
Amronia was determined by a selective ion electrode (EPA Methods . 197",
pp. 165-167).
496
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DRAF1
Ch jo ride
Chloride was determined by titration with mercuric nitrate (EPA Methods,
1974, pp. 29-30; Standard Methods, pp. 97-99).
TOC
TOC was determined by catalytic combustion to C02 followed by infrared
analysis of the COz nith a Dow-Beckman Model No. 915 Carbonaceous
Analyzer (EPA Methods. 1974, pp. 236-238; Standard f'ethods. pp. 257-259).
499
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DRAFT
SECTION VII
CONTROL AND TREATMENT TECHIJOLOGY
This section identifies, documents, and verifies as completely as possible
the full range of control and treatment technology which exists or has
the potential to exist within each industrial subcategory identified
in Section IV. In addition it develops the control and treatment al-
ternatives applicable to the node! plants developed in Section V.
The development of model treatment alternatives for each r-ubcategory
is based on the treatment nodules listed in Table 95.
The modular approach to treatment is used in order to allow the eval-
uation of alternative treatment chains, both in terms of probable
treatment efficiency and cost effectiveness.
In those cases where plants within a subcategory are expected to be
distributed tnroughcut the United States, the prime choice of treat-
ment for t.^at subcategory has beer, developed as the least land'de-
pendent alternative, nevertheless, since it would normally be expected
that at least se^c members of the subcategory would have available
land (where "available land" is defined as land that is ov;ned by the
processing plant or can be leased or purchased for a reasonable price,
and that can be suitably used for waste disposal), more land dependent
alternatives have also been developed.
Other factors which could affect the choice of a particular treatment
train for a particular plant include the following:
1. Seasonally of plant operation,
2. Expected skill of operating personnel,
3. Non-water quality aspects (as describad in Section VIII) such
as noise, odor, solids residue disposal, etc.,
4. Degree of pollution reduction within the process.
Since the purpose of this document is to develop recoraiended effluent
limitation guidelines for point source discharges into navigable waters,
municipal treatment is net directly considered as a treatment alternative,
but it would obviously be economically attractive in many cases if
available, f-'or overall completeness, costs associated with municipal
treatment v.ill be discussed in Section VIII even though not directly
applicable to the study.
In addition to the treatment modules discussed herein, a considerable
number of other modules could be considered. For example, anaerobic
digestion could be used in most instances 'nstead of aerobic digestion
(and the possible recovery of mothone gas as an energy source should
r,ot be discounted); however, for the purposes of this document, it.
501
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DRAFT
TABLE 95
WASTEWATER TREATMENT UNITS USED IN TREATMENT TRAIN ALTERNATIVES
A. No Treatment
B. Pumping station
C. Equalization
0. Chemical Flocculant Addition
E. Clarifier (includes sludge pumping)
F. Acid Neutralization
G. Caustic Neutralisation
H. Nitrogen Addition
I. Phosphoru; Addition
J. Air Flotation (includes punping stalion)
K. Activated Sludge (includes sludge pumping and clarifier)
'_. Aerated Lagoon (includes settling pond)
M. Stabilization Pond (aerobic, anaerobic, flocculation)
N. Dual Media Pressure Filtration (includes pumping station)
0. Cc-ntrifugation
Q. Sludge Thickening
i. Aerobic Digestion
S. Vacuum Filtration
T. Sand Drying Beds
U. Spray Irrigation
V. Truck Haul ing
W. Pipe Line
X. Roughing Filter
Y. Storage Tank
Z. Activated Carbon
502
-------
DRAFT
was determined that aerobic digestion would be quite effective
and would adequately represent the associated costs. In addition,
anaerobic digestion systems may be more land dependent as compared
to aerobic processes.
Biological filters or discs could be used in some cases in lieu of
activated sludge systems, and, in fact, activated sludge systems are
currently employed by several plants. Also, various modifications
of activated sludge other than the complete nix system could be
successfully used by many plants. However, complete mix activated sludge
was selected in this document because of its demonstrated ability to
effectively treat high concentration waste loaJs on a reliable and
sustained basis. Other treatment unit processes were not considered
with similar justifications applicable for biological filters.
It must be noted that the treatment systems considered herein are for
subcategories containing, in most cases, numerous plants located through-
out the United States. If a treatment plant is to be designed for a
particular industrial operation, the design should be preceded by a
characterization of the process wasteweter of the specific plant and
by pilot plant studies in order to provide an optimum treatment sysiem
for the given process. To the extent possible, the performances of
the treatment systems discussed herein has been reflected by the demon-
strated perfornance of treatment facilities presently designed for the
waste, or as reflected by pilot plant studies for the same or similar
wastes.
The operational theory and design procedures for the treatment processes
discussed herein may be found in any of a number of sources, including
Metcalf and Eddy (94); Fair, Geyer, and Qkun (95); Clark, Viessman, anJ
Harrier (96); Kemerow (97); and Eckenfelder (98).
Unless indicated by performance of existing or pilot plant results for
the specific wastes, determination of pollutant reductions through
conventional secondary treatment measures has been strongly guided by
experience in treating general food processing wastes. Ample evidence
exists as to the ready biodegradabil ity and treatability of food nro^s-
sing wastes, and studies have continued to support the ability of
properly designed, operated, and maintained activated sludge systems
to achieve high efficiencies of removal of BOO (95 percent or greater).
The following discussion of each module includes assumptions that,
unless otherwise stated for a subcoteoorv, are applicable to all sub-
categories. Unit A is defined as i"j ndd aional treatment above that
already employed by the model plant; it does not necessarily mean that
no treatment whatsoever is being used. For example, ail plants represented
by the model plant may enploy pnr.ary sedimentation. In such instances,
raw wastewater from the model plant would be the effluent from the
sedimentation process.
503
-------
Unit P, tf.c pumping stulion,illustrated in Figure 138, is assumed
tc ronsiit of two pui.ips, each capobli; of pumping 100 percent capacity
at £5 ppi-ccnt efficiency. The pumping station operates at a head of
70 it U3G ft).
Unit L, the equalization basin, provides twenty-fcur hour detention
time. Mixing is provided by 0.05 cu m (0.5 cu ft) .of diffused air per
liter (gallon) capacity. The basin is a circular, 0.794 cm (5/15 in)
steel tank on a concrete base.
Unit D provides for the addition of chemicals for flocculation.
The system consists of chemical storage and dry chemical feed through
a vibratory hooper.
Unit E consists of a circular steel clarifier as shown in Figures
139 and 140. The system includes sludge and skurn collectors, sludge
pumping with two pumps at 100 percent capacity, and all necessary
electrical and mechanical facilities. The clarifier is designed for
a surface over-flaw rate of 20,400 1/day/sq m (500 gpd/sq ft).
Unit F, acid neutralization, is provided by a 50 percent solution of
sodium hydroxide (NaOH). The system includes two chemical purcps, a fiber-
glass lined tank, with 30-day storage capacity, and a pH control system.
Unit G, caustic neutralization, is provided by a 93 percent solution
of sulfuric acid (H^S04/ usiny the same system as used for sodium
hydroxide addition. The feed system is illustrated in Figure 141.
Unit !i, provides for addition of nitrogen if the wastewater to be
biologically treated is considered to be deficient in nitrogen. A
deficiency is assumed if the BOD:IJ ratio is less than 20. As illus-
trated in Figure 142, the system for nitrogen addition consists of
a steel pressure tank which provides 30 days storage for anhydrous
ammonia, and an ammoniator for feed control.
Phosohorus addition, if necessary for biological treatment, is provided
by Unit I. Phosphorus addition is considen.-d necessary if the BOO:F
ratio'is less than 100. This system, illustrated in Figure 143,
consists of a 30-day capacity fiberglass lined storage tank for phos-
phoric acid and a chemical pump.
Unit J is a dissolved air flotation module for the removal of oil
and grease from waste-water, it. is designed for an overflow rate of
24,000 l/day/r,q m (600 gpd/sq ft).
Unit K is a complete mix activated sludge unit, as shown in
Figure 144, which includes a clarifier such as that described for
Unit E. The MLSS is assumed to be 3COO -ng/1 and the BOD Icadinn rate
to be 0.50 kg/cu m (35 Ib BOO/1000 cu ft). Return sludge capacity is
150 percent of influent. Aeration Is provided by fixed surface aerators
504
-------
DRAFT
LADDER
^
0*
'
i.sn
©
^^\
\^rj
MTN.
0
1.5D
DSSUCTION ^ELL CIA
I I PUMPS
*
t
t
0
a
r
a
A
fr A ft - > . » • * ¥
1 0.6 M
I
0.6 « WIN. ^
» r^
« i.fc. !» 6 t ' ^, •
\ 20 CM
— *1 T
• » •« * »• »
A
1
v
( 7
*. • ? • ' » .' *.'«
.\ '
e
• i
. 4
*
4
^^^#/ i
30 CM !
3. *,•} M MAX.
CM
-------
CIA FT
DIRECTION OF ROTATION
OF ARMS
FIGURE nr
CLAP IFir» MODULE
PLAN VIEW
30ft
-------
o
;o
•-tUDOF
PlPf
— LA /'•: I. .'' _J f^*^HJe^JT
— f^--J- .• 1
_3
SECTION x-
CLARIFIER MODULE
ELEVATIfTJ VIEW
-------
DRAFT
NAOH
OR
H2SO4
— '
h
ppyfi
(KXP
CM
FEED
PUMP
9^—^
WATER
R.OW
NEUTRALIZATION SYSTFM
-------
-J
O
t ?
f*l3 STORAGE
STEEL TAf*
18 ATM
JL "
)
|V1 ,jvrt tv^ 1
1*^ P<* PQ I - •— j
l*wl . . . J 1
WATER
AMdNlATDR
FIGURE -.«?
NITROGEN ADDITION SYSTEM
-------
STORAGE
TO
OR POO
1/1
PfflSPHHRUS ADDITION SYS1TM
-------
ESI
AEFATIOI
BASINS
RETLRN
SLLDGE
EFFLUENT
CLARIFIER
WASTE SLUOCe
FIGURE I**
ACTIVATED SLUDGE SYSTIM
-------
DRAFT
(as Illustrated in Fvjure 145). It is assumed that 1.5 kg of oxygen
(1.5 lb oxygen) arc required per kg (pound) of influent BOD.
Unit L Is an aerated lagoon system as Illustrated in Figure 14G. It
is assumed that the lagoon achieves the same level of pollutant reduc
tion as Unit K; the lagoon has a length to width ratio of 2:1, and
1s lined with 10 mil PVC. It has a depth of 3.7 a\ (12 ft) and is
completely mixed. It 1s designed based on the relation
B/A
where B B effluent BOD, mg/1
A • Influent BOD, mg/1
K s BOD removal rate constant, I/days
V • volume, cu m
Q • flow rate, cu m/day
The value of K is assumed to be 1.0 for soluble wastes.
Aeration is provided by surface aerators and the same basic assumptions
are used as were used for Unit K, except that a mixing requirement of
26.3 kw/cu m (0.5 hp/lOuw cu ft) may be an overriding factor.
A separate settling lagoon (Unit M) is provided for sedimentation of
solids. The lagoon is 2.4 m (8 ft) in depth and a minimum of two
settling lagoons are used. The lagoon Is lined with 10 mil. PVC lininq.
It Is assumed that the sludge accumulates for five years, is 60 percent
oxidized, and consolidates to a solids content of 15 percent. Oncp
each five years one pond 1s decanted and the sludge 1s removed by
dragline and hauled away.
Unit N 1s dual med'a pressure filtration using anthracite and sand.
Pumping is provided to nroduce an influent head at 30 in (100 ft).
Backwash is five percent of flow. The feed is applied at a loading
rate of 2.7 1/sec/sq rr, (4 gpm/sq ft).
Unit 0, centMfugatlon, 1s a unit, process applicable to only a few
subcategories within the miscel Km?ous food and beverages industry,
The assuuptions used for each arr>l:catio' will be diseased for each
subcategory using ccntrlfugation.
The sludge thickener, Unit Q, is a co^Tcte basin using mechanical
agitation. It is conservatively aisur..eo that the sludge ij thickened
to a solids content of 2.0 percent.
512
-------
a
/ \
CABLJES
PRflflLE
F IttD rW<» Af.l AtRATUH
-------
AREA
FIGURE l<.
-------
DRAFT
Unit R, aerobic cludgs digestion, shov.'n in Figure 147, consists of a
circular tank constructed of 0.64 cm (0.25 in.) steel. It has a depth
of 3.7 m (12 ft) and a detention time of 20 days. Aeration is provided
by floating surface aerators at the rate of 75 mg/l/hr. It is assumed
that a sludge thickener prcceeds this unit and the solids content of
the influent sludge is 2.0 percent. It is further assumed that 30 percent
of the influent solids are volatilized during digestion.
Figure 148 illustrates Unit S, vacuum filtration. The loading rate of
sludge onto the filter is assumed to be 20 kg/sq m/hr (4.0 Ib/sq ft/hr).
Each filter operates for 12 hr/aay. It is assumed that the effluent
solids concentration is 15 percent. Chemical addition, in the form of
ferric chloride, is at the rate of 7.0 percent by v.'eight of dry solids,
and this weignt "is included in the design loading rate.
The sand drying beds, Unit T, include a tile urderdrain system with
one collection sump common to all beds. Each bed is 6.1 m
(20 ft) by 30 m (100 ft) and has 15 cm (6.0 in) of sand over 30 cm
(12 in) of gravel. The beds are constructed with a slope of 0.5
percent. It is assumed that five dryings of a 20 cm (8 in) layer of
sludge is possible per year. It is further assumed that the volume
of the dried sludge is 50 percent of the applied volume and that the
dried sludge is trucked to land disposal.
The spray irrigation system, Unit U, consists of 10.16 cm (4 in.)
PVC laterals pieced at intervals of 30 n (100 ft) on a 25.4 cm (10 in.)
PVC main. "Rainbird" type sprinklers are placed at intervals of 24 m
(80 ft) on each lateral. A shut-off valve 'is located at each connection
of a lateral with a main. The wastewater application rate is assumed
to be ^6,800 1/ha/day (5000 gal/acre/cay) and, if sludge is to be applied
for irrigation, the application rate is assumed to be 56 kkg/ha/yr
(25 ton/ac/yr).
Unit V consists of disposal of process wastewater and/or sludge by
truck hauling to an approved sewage treatment plant or land disposal
site. It is assumed for cost purposes that an outside contractor is
employed to perform this service.
Unit W includes a cast iron pipeline requiring 1.2 m (4 ft) excavation.
The line has a gate valve at every 300 m (1000 ft) interval and an air
relief valve every 600 m (2CCO ft").
Unit X is a trickling filter for biological waste treatment not followed
by a solids settling unit. Such filters are commonly termed a "roughing"
biological filter.
Unit Visa storage tank which may be used f?r storing either wastewater
or sludge.
515
-------
DRAFT
"C" DIA.
FIGURE 1*7
AEROBIC DIGESTION SA5IN
516
-------
HYDRAULIC
SYST&!
SCRAPER
SLCOGE RESERVOIR
SLUDGE CAKE
FIGURE I/-P
VACHJM SLUDGE FILTRATION
-------
DRAFT
Unit 2 is an activated caroon module. The activated carbon unit is
employed commonly for removal of color and organics from wastewatcr.
All treatment trains to be developed include flow measurement devices
(Figure 149) a flow proportional sampling station, and if the size
and complexity of the treatment plant justifies, an office-laboratory
building.
SUBCATEGORY A i - OILSEED CRUSHING. EXCEPT OLIVE OIL. FOR DIRECT SOLVENT
EXTRACTION AliD PREPRLSS SOLVElit EXTRACT Ml* OPERATIONS
The process wastewatcrs generated from the solvent extraction of oilseed
and by-product cake or meal represent a relatively minor waste load in
comparison to the raw waste load generated by edible oi] refineries (i.e.,
Subcategories A 5 through A 12) as average BOD and oil and grease concen-
trations for the fon.ier facilities average 311 and 252 mg/1, respectively.
The average flow rate is 140 cu m/day (0.037 I1GD).
Wastewater discharged from the solvent extraction process results fron the
following processes. 1) soybean oil degumming, 2) wastewater generated
by wet scrubber systems, 3) steam condensates contaminated by oil, fatty
acids or hexane solvent, and 4) in-plant cleanup of oil or rciscella spillage,
Existing In-Plant Technology
Wastewaters generated from the drying of wet lecithin in the degunwir.g
of soybean oil represents a major contribution to the total waste load of
a soybean solvent extraction operation. At the present time the industry
has not developed an economical in-plant method of reducing degumming
waste loads.
Only one plant (75S-13) was observed to utilize a wet scrubber system
for the in-plant reduction of air particulates in milling, handling, and
unloading areas. Rockwell (21) reports that the use of dry cyclcne
systems is still the most coir.;;icn dust collection system used in the coin
Industry. /U present, the industry has not developed
-------
<
LO
^
Erf
'FIX*
v /
f ?
Jr^
/
HI
DIFFERStNTIAL
OR
TRANSMITTER
I-ORIZQNTAL
rn
r-
i
i
i
i
c^.
oi
txj
. « ^
ir
HI
DIFFERENTIAL
CR
TRANSHITTER
VERTICAL FLOW
FIGURE 1<,9
FLOW MEASUREMENT SYSTTfMS
-------
WATER TO
t\j
o
OIL TO RECOVERY
FROM PROCESS
HATER STRIPPER
fi
u
rn
\
\
\\
1
-.-'•i-r-C
J
\ \ \ \ J
1
s
s
^
r
m
\\ \\ \\
r
\
y
\
V
1.
V
""•
i \
.' " ' * '
\ \ \ \ \
p
v
s
N
\
FIGURE ISO
SUTff* DECAWTtR SYSTEM
-------
DRAFT
Floatable oils and sludges removed from grease traps and gravity separa-
tion basin; arc commonly trucked to landfill operations by either
plant personnel or a contractor. A number of plants recover the floatable
and pump then to a reprocessing system.
The raw process wastes generated from solvent extraction and prepress
solvc-nt extraction operations after the pretreatment step of gravity
separation consist primarily of errulsified hydrocarbons and other
associated compounds that are not readily separated by pretreatment
practices. Results of plant visitations and verification sampling
condj'-ted during this study demonstrated that these process wastes,
after pretreatment for the removal of floatable oils, are readily bio-
degradable in normal biological waste treatment systems. Plant visita-
tions and historical data received from one South Central and three
Midwest secondary treatment systems clearly indicate reasonable removal
rates for BOD, suspended solids, and oil and grease. Tcble 96 presents
a summary of these treatment systems and indicates treatment chains, the
percent of BOD removal across the system, and final discharge data for "
each system. A more detailed discussion concerning the treatability
of edible oil wastes is presented in this section for Sub^ategory A 5.
Selection of Control and Treatnent Technology
In Section V, a hypothetical model plant was developed for Subcategory A 1.
It was assumed that the model plant provided the following treatment units
before final discharge to a treatment facility:
1. Separate discharge of procer.r .'aters and non-contact water,
2. Gravity separation and skimming of the final process water
effluent,
3. Floatable oils and sludges removed by the pretreatment step
of gravity separation and skimming either hauled to land-
fill facilities by in-plant personnel or pumped to an oil
• reprocessing system.
The raw wastewater charcteristics after gravity separation and skimming
were assumed to be «s follows:
BOD 340 mg/1
SS< 210 mg/1
O&G 380 mg/1
Flow 146 cu m/riay (0.030 MGP)
Table 97 lists the pollutant affluent loading from the Subcategory A 1
plant and the estimated operating efficiencies of each of the eight
treatment trains selected for this subcatcgory.
521
-------
ro
PJ
Plant
TABLE 96
FINAL DISCHARGE DATA FOP TREATMENT SYSTEMS HANDLING
SOLVENT EXTRACTION PROCESS WASTES
Percent BOD Final Discharge
Production Flow Treatment3 Efficiency BOD SS Oil &
Across Grease
kkg/day cu in/day Chain System (mg/1) {mg/1) (mg/1)
Reference
75S01b
75SOlb
75S02C
75SC2C
75513d
7551 3d
75S13d
7SSI3d
75Sile
635
635
454
454
1189
1500
1646
1443
816
1087
420
871
939
1226
1154
1097
1200
897
C,L,E,H.C12
C,L.E,M,C12
GT,(2)L
GT.(2)L
GT,(2)L
CM2)L
GT.(2)L
GT,(2)L
F.G.S.G.J, ft
L,N.C12
82.7
96.5
76.4
86.2
ND
ND
ND
ND
96-99
17
9
33
11
10
13
13.5
23
40
31
24
52
23
38
94
87
70
50
9
35
50
26
ND
37
13.5
ND
1.0
1972-73 Survey
1973-74 Survey
1972-73 Survey
1973-74 Survey
1S72-73 Survey
1973-74 Survey
October 1974 Survey
KoveTiber 1974 Survey
November 1974 Survey
a) C = Equalization basin; L « Aerated lagoon; G * Caustic addition; J .« Air flotation; N = Dual Media filtration
E = Clarifier; H = Stabilization pond; Clg = Chlor^nation; GT = <5rease trap; GS = Gravity, separation &
skinning; fiD = No data.
b) Treatment system handles boiler (slowdown, storm water runoff, soybean oil deguirming, and solvent
extraction plant wastes.
c) Treatment system handles soybean oil degunming, solvent extraction process wastes, and cooling tower
blowdown.
d) Treatment system handles cooling tower blowdown, caustic refining, feed mill elevator, storm water runoff,
boiler blowdown, and solvent extraction plant wastes.
e) Treatment system handles raw edible oil refinery wastes and solvent extraction process wastes.
-------
TABLE 97
StWWRT OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY A 1
Treatment Train
Alternative
A 1-1
A l-II
A l-III
A l-IV
A 1-V
A 1-VI
A 1-VII
A 1-VIII
A
fljBCKQY
BjBCKQYBN
BCL
riCLBH
BjBCJ
B,BCJKQY
BCJL
Effluent
BOO
0.061
0.0072
0.0036
0.0072
0 0036
0.018
0.0036
O.OC36
Effluent
SS
fcg/kkg
0.038
0.0090
0.0045
0.0090
0.0045
0.011
0.0045
0.0045
Effluent
O&G
kg/kkg
0.069
0
r
0
0
0
0
0
.0054
.0027
.0054
.0027
.021
.0027
.0027
Percent
BOD
Reduction
0
88.
94.
88.
94.
69.
94.
y
1
2
1
8
1
94.1
Percent
SS
Reduction
0
76.
88.
76.
88.
70.
88.
83.
3
2
3
2
2
2
2
Percent
O&G
Reduction
0
92.
96.
92.
96.
70.
96.
96.
2
0
2
0
3
0
0
-------
DRAFT
Alternative- A 1-1 - This alternative provides no additional treatment
than gravity separation and skimming.
Alternative A 1-11 - Alternative A 1-1 with the addition of a flow
equalization basin, an activated sludge unit, secondary clarification,
a sludge recirculating pump, a sludge thickening tank, and a sludge
holding tank. Sludge is hauled to a landfill facility every twelve
days. The activated sludge unit also includes a control house and one
full time operator.
Alternative A 1-II1 - Alternative A l-II with the addition of dual
media pressure filtration with a pump station to generate sufficient head
for the filter operation. A schematic diagram of Alternative A l-III is
presented in Figure 151.
Alternative_A J-IV - Alternative A 1-1 with the additives of a flow
equalfzation basin, an aerated lagoon with a settling pond, and one full
time operator.
Alternative A 1-V - Alternative A 1-IV with the addition of dual media
pressure filtration >and a pump station to generate sufficient head for
filter operation. A schematic diagram of Alternative A 1-V is presented
in Figure 152.
Alternative A 1-VI - Alternative A 1-1 with the addition of i flow
equalization has 1,1 and pressurized air flotation utilizing chemical
flocculating agents to enhance floe formation and floatability of wastes.
Oil, water, and solid waste skir.-jnings are pumped to an in-p'iant oil re-
processing system.
Alternative A 1-VI I - Alternative A 1-VI with the addition of a complete
mix activated sludge unit, secondary clarification, sludge recirculating
pump, sludge thickening tank, and sludge holding tank. Sludge is hauled
to a landfill every 30 days. The unit also includes a control house and
one full time operator. Figure 153 presents a schematic diagram of treat-
ment Alternative A 1-VlI.
Alternative A 1-VI 1 1 - Alternative A 1-VI with the addition of an aerated
lagoon v,:tth a settlTng pond and one full time operator. Figure 154 prn-
sents a schematic diagram of treatment Alternative A 1-VIII.
SUBCATEGpJJY_A_ ? - OILSEED CS'JS'iT.'G. EXCEPT OLIVE OIL. BY MECHANICAL
PKESS OFIKA'TIU':.':)
Existing and Potential In-Plant Technology
The extraction of vegetable oils from oilseeds by the mechanical scrc-.y
press method results in a relatively small volume of wastcwater genera M.-J,
i.e., loss than 4,OuO liters (1000 gallons) per day. Because of the sr.-j 11
volume of wastewater produced, tue industry has not made an effort to
524
-------
DRAFT
IN-PV.ANT
RECOVERY OF
FLOATABLE OILS
PROCESS
WASTEWATER
GRAVITY
SEPARATION
PRETREATMENT
INFLUENT
BOD » 360 MG/L
SS * 210 MG/L
ObG •* 300 MG/L
FLOW » 0.146 CU M/DAY (0.039 MGC)
*
i3ze GAL/DAY
,^
SLUDGE I I
EQUALI?ATIOJ
THICKENING
h
ACTIVATED
SLUDGE
370 GAL/DAY
•OLD INC
TANK
PONDS
HAUL EVERY
12 DAYS
DUAL -MED 1*
ALTEBNATIVE
A l-II
EFFLUENT
BOD « *o MG/L
ss « so MG/L
066 • 30 MG/L
ALTERNATIVE
A i-n:
EFFLUENT
BOD • 20 MG/L
SS « 25 MG/L
OIG * 15 MG/L
FIGURE isi
SUBCATEGORV AI
ALTERNATIVES II
- III
52S
-------
DRAFT
IN-fVANT RECOVERY
OF FLOATABLE OILS
PROCESS
WASTEWATER
SEPARATION
PRETREATMENT
3QD » 340 MG/L
SS « 210 MG/L
OtG a 380 MG/L
FLOW » O.U8 CU M/DAY (0.039 MOD)
EQUALIZATION
AERATED
SETTLING
°ONOS
CX/AL-MEDIA
FILTRATION
ALTKRNATIVC
A 1-IV
'BFFLUENT
BOO • <>o MG/L
ss « so MG/L
OCG a 30 MG/L
ALTERNATIVE
Al-V
EFFLUENT
BOD • 20 MG/L
SS - 25 MQ/L
OtG = IS MG/L
152
SUBCATEGORY AI
TREATMENT ALTERMftTlVES IV - V
526
-------
DRAFT
TO IN-PLANT RECOVERY
OF FLOATABLE OILS
PRETREATNENT
GRAVITY
SEPARATION
INFLUENT
SCO • 340 MG/L
SS " 210 MG/L
OtG - 360 MG/L
FLOW - 0.146 CU M/DAY (0.039 MOD)
EQUALIZATION
DISSOLVED AIR
FLC'ATJON
SLUDGE
THICKENING
ACTIVATED
SLUDGE
ALTERNATIVE
•-» A i-vi
EFFLUENT
BCD • 102
SS • 63
C4G a U4 MG/L
OLOING
SLUDGE TO
TRUCK
ALTERNATIVE
A 1-VII
EFFLUENT
BCO - 20 MG/L
SS • 29 MG/L
OfrG • »5 MG/U
FIGURE 183
SUBCATEGORY At
TREATMENT ALTERNATIVES VI -
VII
527
-------
DRAFT
PROCESS
WASTEWATE*
GRAVITY
SEPARATION
INFLUENT
aoo = SAO MG/L
SS a 210
oto >• 3ao
FLOW = ft. 1.46 OJ M/DAY (0.039 MGO)
TO
OF FLOATABLE OILS
PLOW
EOJALirATIOl
DISSOLVED AIR
FLOTATION
LAGOGN
SETTLING
1
i
ALTERNATIVE
A 1-VIII
EFFLUENT
BOO a 20
SS s 25 MG/L
QCG = 15 MG/L
ALTERNATIVE
A 1-VI
BOO s 102 MG/L
SS = 63 MCJ/U
060 « 114 MG/L
PIGURE is*
SUBCATEGORY AI
TREATMENTT ALTERNATIVE VI - VIII
528
-------
DRAFT
reduce the resulting waste load. The majority of process wastewaters
generated from mechanical screw press operations results from two sources:
contamination of steam condensates from steam cooking operations, and
general floor washing and equipment cleanup of oil and miscella spillage.
Existing treatment and control technology applicable to mechanical screw
press facilities consists of observance of in-plant water use conservation
through dry cleanup of floors and equipment. In practice, solid materials
are removed by dry cleanup procedures such as floor sweeping and/or
vacuuming. Containment devices are commonly utilized in oil storage areas
for the entrapment of spillages. Dry cleanup of oil spills is presently
practiced vnthin the industry but does not presently receive widespread
application. The majority of plants visited during the study utilized
both wet and dry cleanup procedures. Plants which practiced wet cleanup
generally employed high pressure, low volume hoses in their cleanup pro-
cedures to reduce water usage. Hoses are generally equipped with automatic
shut-off valves.
End-of-Line Technology
The majority of plants visited discharged their small waste volume to
municipal sewers or landfill facilities. A number of plants trucked
their wastes to a nearby edible oil refinery where the oils were re-
covered in the acidulation process. These plants were observed to
recycle their process wastewater into boiler feed makeup water.
Selection of Control and Treatment Technology
In Section V it was determined that it was unnecessary to develop a
model plant for mechanical screw press operations due to the small
volume of wastewater discharged per day. The most practical disposal
of these wastes would be to municipal waste treatment systems, or by
hauling to suitable land disposal sites for land application and disposal.
Alternative A 2-1 - This alternative provides no additional treatment.
Alternative A 2-II - This alternative consists of a storage tank and
truck hauling of the wastewater to a municipal sewage treatment facility
or suitable lard disposal site.
SUBCATEGORY A 3 - OLIVE OIL EXTRACTION BY HYDRAULIC PRESSING AND
SOLVENT EXTRACTION
As discussed in Section III, there are only two olive oil processing
plants 1n the United States and both are located in California.
Furthermore, plant 79102 is the only plant which utilizes either the
hydraulic press or solvent extraction processes for the recovery of
olive oil. The contiol and treatment practices at the plant are pre-
sented below.
529
-------
DRAFT
Existing In-Plant Technology
Plant effluent consists of centrifuge fruit water and a small amount of
water which drains from cannery pits and culls during storage. Any
equipment cleanup is clone by dry processes resulting in no additional
discharge of wastewater.
Potential In-Plant Technology
Examination of in-plant processes suggests no additional method or pro-
cedure to further reduce pollutant loads and wastewater volume for this
industry.
End-of-Line Technology
Plant 79102 is presently achieving zero discharge of wastewater by col-.
lecting and truck hauling its effluent to a municipal treatment fa-
cility without adverse effects on the system. Biological treatment of -
similar olive oil wastewater at plant 79101 has been attempted and.
although a 97 percent treatment efficiency was achieved, tns initial
high strength of the waste resulted in an average effluent BOD of 1300
mg/1. Since the ability of advanced waste treatment for the same or
similar wastes has not been proven, biological treatment is not recom-
mended as an alternative for olive oil process wastewater. However,
due to the disposal practices of plant 79102 and the proven biodegrad-
ability of the waste at plant 79101, there is no reason to suspect that
olive oil processing wastewater is inherently incompatible if discharged
to a properly designed well-operated municipal treatment facility.
Selection of Control and Treatment Technology
In Section V the raw waste load of the model plant was presented as
follows:
Flow 10.9 cu m/day (0.0029 MGO)
BOD 63,000 mg/1
SS 14,000 mg/1
FOG 3,220 mg/1
pH 5.1
Taking account of the basic olive oil production process and the
fact that all olives are grov/n in California, it may be logically
assumed that new olive oil plants using hydraulic press or solvent
extraction '/ill be located in areas with the same or similar con-
ditions to those of California, i.e., locations near olive orchards
and in rural arrai where ^nd is available and suitable for waste-
water application. These conclusions lead to the following possi-
ble disposal alternatives.
530
-------
DRAFT
Alternative A 3-L - This alternative consists of spray irrigating the
process effluent. An area of 0.23 ha (O.G acres) of land would be re-
quired. It is assumed that the effluent would not need to be pumped
more than one-half mile. The overall benefit resulting from this
alternative is a 100 percent reduction of process wastcwater pollu-
tants to navigable waters.
Alternative A 3-11 - This alternative consists of four 0.10 ha (0.25
acre) ponds with a depth of two feet to retain the yearly effluent
expected from the plant. The yearly net evaporation in the climates
where olives are grown has been conservatively estimated at 0.86 meters
(3.4 inches). The operation of the ponds would consist of completely
filling the ponds, one at a time, so that v/astewater in the first
pond would be allowed to evaporate as the second was filled, the
second pond allowed to evaporate as the third pond was filled and so
on. In this way, the first pond would be dry at the time the fourth
became full, and the filling cycle could continue. Who, dry, the
ponds would be dredged periodically to remove accumulated sludge. The
ponds would be lined to prevent percolation of wastewater into the
fresh water aquifer.
Alternative A 3-III - This alternative consists of land application of
the waste effluent and would require 0.4 ha (1.0 acres) of land. The
land would he terraced with each terrace graded to level. Waste ef-
fluent would be piped onto the terraces (one terrace at a time) and
the depth of coverage regulated to about 7.6 cm (3.0 in.). As a ter-
race dried, it would be plowed in preparation for the next applica-
tion of waste material. This system is used extensively and effec-
tively by wineries in the same area of California as a means of ulti-
mate waste disposal.
SUBCATEGORY A 4 - OLIVE OIL EXTRACTION BY MECHANICAL SCREW PRESSING
As discussed In Section III, there are only two olive oil processing
plants In the United States and both are located in California.
Furthermore, plant 79101 is the only plant which utilizes the screw
press.process for the recovery of olive oil. The control and treatment
practices of the plant are presented below.
Existing Ir-Plant Technology
Wastewater generation is minimized to some extent by the retention of
fruit wash water until it becomes objectionable in quality.
Potential In-Plant Technology
There appears to be no technology which could be applied to decrease
th« quantity of wastewater generated from fruit washing or the centri-
fuge discharge since the water in wash tanks is commonly retained as
long as possible already and since centrifuge discharge is a function
531
-------
DRAFT
of tin amount of water contained in the fruit initially. The pollutant
loadings in these two discharges are also a function of the raw material
and cannot be significantly reduced through in-process controls.
Centrifuge sludge is the one area where improvement can be made. Since
the sludge has such a high fats and oils concentration, a considerable
portion of potential product is being wasted. Therefore, techniques
such as solvent extraction might conceivably be utilized to remove a
portion of the oil from the sludge.
General plant cleanup generated little v/ater and need not be seriously
considered as a means to substantially reduce the waste load.
End-of-Line Technology
At present plant 79101 is achieving zero discharge of all process waste-
water by means of land application. Plant 79102, which generates a
similar strength waste strean as plant 79101, is also achieving zero
discharge of wasteivater by collecting and truck hauling of its effluent
to a municipal treatment facility. Biological treatment of olive oil
wastewater at plant 79101 has been attempted and, although a 97 oercent
treatment efficiency was achieved, the initial high strength of the
waste resulted in an average effluent BOD of 1300 mg/1. Since the
ability of advanced waste treatment for the same or similar wastes has
not been proven, biological treatment is not recommended as an alterna-
tive for olive oil process wastewater. However, due to the disposal
practices of plant 79102 and the proven biodegradability of the waste
at plant 79101, there is no reason to suspect that olive oil process-ing
wastewater is inherently incompatible if discharged to a properly de-
signed well-operated municipal treatment facility.
Selection of Control and Treatment Technology
The model plant for Subcategory A 4 was presented in Section V with the
raw wast- water characteristics assumed to be as follows;
Flow 114 cu m/day (0.030 HGD)
BOD 30,000 mg/1
SS 57,000 mg/1
O&G 20,000 r.ig/1
pH 5.5
Since olives are grown solely in California, both olive oil manufac-
turing plants are located in close proximity to olive orchards in
that state. It is therefore concluded that any new source olive oil
manufacturer would locate In California in rural areas where land is
readily available. These conclusions result in selection of the
following recommended treatment alternatives as presented below.
532
-------
DRAFT
Alternative A 4-T - This alternative consists of spray Irrigation of the
process effluent which would require 2.4 ha (6.0 acres) of land. It is
assumed that the waste effluent would not have to be piped more than one
half mile. The overall effect of this alternative Is a 100 percent reduc-
tion of all pollutants from navigable waters.
Alternative A 4-II - This alternative consists of four, one acre, lined
evaporation ponds with a depth of two feet. The evaporation to be ex-
pected from the ponds, based on conservative estimates from meteorologi-
cal data for olive growing areas of California, 1s 0.86 m (34 in.) per
year. This evaporation rate led to the selection of the two foot depth
requirement. The system would operate by completely filling the ponds,
one at a time, so that the first pond filled would be allowed to evap-
orate as the second was filled, the second allowed to evaporate as the
third was filled, and so on. Ir, this way the first pond would be dry
at the time the fourth became full and the cycle continues. When dry,
the ponds would be dredged to remove accumulated sludge. No discharge •
of process wastewaters to navigable waters would result.
Alternative A 4-1II - This alternative consists of land application of
the waste effluent and would require 1.6 ha (4.0 acres) of land. The
land would be terraced with each terrace graded to level. Waste ef-
fluent would be piped onto the terraces (one terrace at a time) and
the depth of coverage regulated to about 7.6 cm (3.0 in.). As a terrace
dried it would be plowed in preparation for the next application of waste-
water. This system is used extensively and effectively by wineries in
the same area of California as a means of ultimate waste disposal.
SUBCATEGORY A 5. PROCESSING OF EDIBLE OIL BY CAUSTIC REFINING METHODS
ONLY
The following discussion of existing and potential 1n-plant treatment
and control technology may be generally applied to subcategories A 5
through A 12. Table 98 presents & summary of the present 1n-plant
treatment and control technology for theedibleoll refining industry.
The principle source of process wastewater generation for Subcateoory
A 5, edible oil refineries, is the caustic refining operation Itself,
tank car cleaning, material storage and handling, and general depart-
ment cleanup. Non-contact cooling water 1s not Included within the
definition of process wastewater.
In-PI ant Technology
<
The centrifuged wash v;aters containing sodium soaps, free fatty acids,
phospholipids, and residual oils from the unit process of caustic re-
fining represent a major contribution to the total waste load of an
edible oil refinery. Data compiled from six caustic refining operations
found OOD and oil and grease concentrations to average 6,900 and 5,000
mg/1, respectively. Currently, the edible oils industry has not developed
an econonical in-olant method of reducing these caustic refining waste
loads.
533
-------
TA3LE 98
OF PPESENT IMPLANT CONTROL Ar.'D TREATftEriT CONTROL TECHNOLOGY FOR THE
EDIBLE OIL REFINING INDUSTRY
nha><> on reduction of
water to lane.
?a. General: Improved nalntenance and house-
keeping pratlces; Inproved operator awareness
and (raining.
2b. Wet cleanup: Departmental 1re<) containment
basins; tnplant spill plans; reduction of
water usage to absolute mlniaum by use of low
volmre high pressure noizle hoses and standard-
lied cleanup procedures. Establishment of oil
recovery sjsteas for resale as Inedible oil pro-
duels.
?c. Dry cleanup: HaximM Iflpleaentatton of drr
clearup procedures; vacuum cleaning, sweeping.
dry cheatca) adsorption of spill naterlal.
Rerarks
la. Covering spill preventatlon, contalnnent and
recovery.
1c. Steaa cleaning nay be used as • viable
alternative.
2a. Reduction of BOD suspended solids, and
oil and grease levels; plants should m-er-
take a program to identify sources of in-
plant generation of wastewater and encourage
employee participation in reduction effort.
2b. Departmental localization of spills Is highly
desirable to reduce the Impact of er-jlsificatlo
as wastes are ccoilned prior lo treatment,
therefore reducing the cost of final treatment.
2c. Presently practiced but not cocnonly applied
throughout the Industry. Implementation of
dry cleanup substantially reduces end-of-line
treatment costs.
3. Caustic Rcftnln?
3. No controls presently recomended.
-------
Iratte Miter Source
4. $3«pstock A^ldulatlon
I. tlracftlng
6. HydmgeMtlon
7.
8.
9. Plastlciilng ft Padci-.g'ng
Opera It u~.s
10. Ron-Contact Cool tog Hater
11. Process Waste FlMl effluent
In-Mant Control
4. Me controls presently recomnended.
Sa. Cry cleanvp of spent bleaching adsorbent.
5b. Reclrcul»tlon of contact cool In) Mter
fro* ojrooetrlc cond«>;iser.
Recovery of otl fro* filter cake to i*
js in Inedible oil product.
nded.
6. Dry cleanup of filter press.
7. Mr- rontr>3j presently rtc
8 |nstaH«lljn rf distillate recovery syite
if tne bnanetric condenser system.
9. Ciew-tr»-PJ«te eo.ulpa>ent with containment
*rd rectrculition.
10. Rf cycle iKd regie. Sep«r«tlon of non-
contact cool 1*9 niter fro* process wastes.
11*. jri' >«nttoHr>9 md •djustnent where necesury
lib. Flew equ«lltatlm where necessity
Cr«*Uy septrvtlon tnd sktaring for IN
of flMUblt oils.
5». elimination of this discharge point will
significantly reduce concentration of
BOO. suspended sot Ids, greases and oils
In the final Haste loads.
Sc. Technology to date ttas not established
economic feasibility for all plants.
6. Reduce or eliminate discharges of catalyst.
I.e.. nickel.
Reduction In entraiment of fatty materials
on cooling tower grlllate and tower basin
resulting In fewer Banual cleaning operations
of cooling tower.
10. Essential In
-------
DRAFT
Wash v/atcrs discharged from the cleaning of tank cars Is a major
source of wastewater generation for all edible oil refineries. Tank
cars are cleaned to remove and recover crude oils and fats that adhere
to the walls of the tank car. Tank car washing Is commonly accomplished
by the use of a mechanical rotating-head spray assembly that applies
a detergent solution followed by rinse water to the tank car interior.
Wastewater from this operation may represent once through water use
or the wash water may be recycled with makeuo water. BOD and nil snH
grease concentrations for tank car cleaning operations at five edible
oil refineries averaged 2950 mg/1 and 930 mg/1, respactively. Currently,
the Industry commonly practices recirculation of caustic tank car clean-
Ing solutions to reduce waste loading. In addition, several plants have
established systematic tank car washing procedures with the emphasis on
reducing the volume of water used to v/ash each car. An alternative method
utilizing steam cleaning has been found effective for a limited number of
facilities. Wastewater from tank car cleaning is commonly collected in .
sloped drains that empty into baffled gravity separation basins. Floatable
oils generally are recovered for resale as an inedible oil'product, and -
the resulting wastewater 1s discharged to final gravity separation
facilities, skimming devices, and pH control facilities.
Another major source of wastewater generation occurs ~,n conjunction
with receiving, storage, and transfer areas within the plant. Waste
waters from these areas result from general cleanup procedures, acci-
dental spills, valve or tank leakages, and/or pump failures. BOD and
oil and grease concentrations from transfer and storage areas
average 8,000 mg/i and £ 200 mg/1, respectively. Existing treat-
ment and control technology applicable to receiving, storage, and
transfer' areas consists of observance of in-plant water use conser-
vation through dry cleanup of floors and equipment. In practice,
solid materials are removed by dry cleanup procedures such as floor
sweeping and/or vacuuming. Containment devices are commonly utilized
In oil storage areas for the entrjpment of spillages. Plants which
utilize strictly wet cleanup procedures find that the final waste
treatment of oil spills is most diffic-lt when these wastes are
combined with emulsified contaminants from other areas of the plant.
Dry cleanup of oil spills is presently practiced within the Industry
but does not presently receive widespread application. The majority
of plants visited during the study utilised both wet and dry cleanup
procedures. Plants which practiced wet cleanup generally employed
high pressure, low volume hoses in their cleanup procedures to reduce
water usage. Hoses are generally equipp-.'d with automatic shut-off
valves.
Potential In-Plant Technology
Potential in-plant control and treatment technology would Include
Improvements ir, general plant maintenance and housekeeping practices
with maximization of dry cleanup procedures (i.e.* vacuum cleaning,
and the utilization of dry chemical absorption) where feasible.
536
-------
DRAFT
The effect of these measures would iubstantiully reduce and minimize
potential pollutant loading resulting from the process. The industry may
also very advantageously adoptan industry-wide approach toward im-
provement of operator awareness regarding general dry cleanup pro-
cedures, and pollution control methods. In addition, individual
plants may well develop a program to identify sources of in-plant
wastewater generation and encourage employee participation in reducing
water usage and related wastewater generation. Each plant should
establish method: and procedures for the localization and convenient
cleanup of oil spills ™
-------
DRAFT
TABLE 99
EXISTING TREATMENT CHAIN AND MAJOR DESIGN FACTORS OF PLANT 75F-10
FOR THE BIOLOGICAL TREATMENT OF EDIBLE OIL REFINERY WASTES
2
3
Treatment Unit
First pH mix tank
Significant Design Features
8.2 I/sec (130 gpm) capacity, adjust the raw
waste pH of 1.5 to 3 to insure adequate separa-
tion of oil and water for gravity separa-
tion.
Flow equalization tank 851.6 cu. m (225,000 gallon) capacity.
Skimning tank
Second pH mix tank
Dissolved air flota-
tion (2 units) wit!,
chemical addition.
Aerated lagoon (2
units)
Stabilization lagoon
Dual media filter
with chlurinatlon
before and after
Final Effluent
1135.5 cu m (300,000 gallon) capacity operating
at a fixed level for continuous mechanical
skimming. Recovered oil will be pumped to a
oil holding tank, 37.8 cu m (10,000 gallon)
capacity. Here steam and gravity will be jred
to separate oil and water with the water beirg
sent back to the flow equalization tank.
Anhydrous ammonia addition with automatic
pH control and alarm equipment to raise the
pH to 7.
Retention time, along with the ratios of
lime, alum, and polyelectrolytes are
varied to produce the maximum amount of
pollutant reduction. 68.1 cu m (18,000 gallon)
capacity each.
4542 cu m (1,2 million gallon) capacity, with
five 14.9 kw (20 hp) floating surface ae-a'.ors
and a five to six day retention time per l^accn.
Same design as above but without surface
aerators (overall retention time In the
three basins is 15 to 18 days)
Suspended solids and bacteria removal.
No data on retention time dosages or
design.
BOD, 40 mg/1; SS, 50 mg/1; Oil end Grea-.e
l.Cmg/li Total Phosphorus, 9 mfl/1; Nickel,
0.02 mg/1; pH, 7 - 8.
53B
-------
DRAFT
75F-10. The treatment efficiency data for oil and grease compiled
from plant 75F-10 art? considerably higher than those reported by Loehr
( ICC ) for several Midv/est municipalities. The following total grease
removal efficiencies vere reported by Loehr for municipal activated
sludge units: 34 percent, Topeka, Kansas; 85.7 percent, Cleveland,
Ohio; and 94 percent, Madison, Wisconsin. Progressive grease removals
Indicated by the Topeka, Kansas, study were45 percent by primary treat-
ment; 75 percent by secondary treatment; and C4 percent by complete
treatment. Average removals of BOD and suspended solids were 85 and 82
percent respectively. Results of this study also Indicated a reasonably
reliable correlation betv/een oil and grease end suspended solids con-
centrations in the biologically treated final effluent.
Presently over 95 percent of the edible oil refineries within the
United States discharge their process rastewaters into municipal sewage
systems. As concluded by this study, pretreatment technology for the
edible oils industry involves gravity separation of floatable fats,
oils, and greases, and pH control of the remaining wastewaters. Tre^t-
ment of the resulting wastewaters in municipal systems after such
pretreatment is reported to be acccmplished without difficulty. In
fact, it is the industry's contention that joint treatment of edible
oil refinery wastes with domestic sewage is the most efficient and
economical method of wastewater tre ment.
The treatability studies by McCarty (101 ) give further support to the
biodegradability of edible oil refining wastes. Edible oil processing
and soap mariufacturing wastes were combined on a one to one ratio
on a COD basis with domestic waste in a laboratory scale activated
sludge unit. Results of the study indicated that mixed wastes
occurred at nornal operating efficiencies of 60 to 80 percent for
oil and grease removal, with normal sludge digestion and with no
significant adverse effect on oxygen transfer. Adams and Eckenfelder
(162) report that biological treatment of oil and greases of vegetable
and animal origin 1s the best means for reducing the oil content of
these wastes to acceptable levels before final discharge to receiving
waters. They also note that pretreatnent precautions be observed to
remove floating and non-emulsified oils and greases before subsequent
discharge tc a treatment facility. Occasionally, pH neutralization
1s necessary before discharge to the biological system. Adams and
Eckenfelder also report the reduction of e pretreated influent of
hexane extractive content ranging from E-m to 1500 mg/1 to an effluent
level of less than 15 mg/1 using ei'tnpr ^crated laaoons or activated
sludge facilities (97 to 99 percent cf 'ficiei.cies). In addition, no
abnormal behavior was observed in s'udge handling processes such as
gravity and flotation thickening, stabilization by aerobic Digestion,
or by dewatering using vacuum or pressure filtration. Watson et al
(103) reports on the performance of a pretreatment facility in
'Champaign, Illinois, treating the combined' wastes from an edible oils
refinery and a margarine, salad dressing, and cheese processing
539
-------
DRAFT
TABLE 100
EXISTING TREATMENT CHAIN AMD MAJOR DESIGN FACTORS FOR THE EDIBLE
OILS-MARGARINE, SALAD DRESSING AND CHEESE PRETREAMENT
FACILITIES AT CHAMPAIGN, ILLINOIS
Number Treatment Unit
1 (2) lift stations
2 Surge tank
3 Flotation clarifier
4 Grease storage tank
5 Aeration basin
Final clarifier
Aerobic digestor
(2) sludge lagoons
Significant Design Features
Cheese Plant, two 7.5 kw, 850 1/min
(10 hp, 225 gpm) pumps. Oil Plant,
two 5.6 kw, 945 1/min (7.5 hp, 250 gin)
pumps
Capacity 302 cu m (80,000 gallons)
minimum detention time at average
flow--1.5 hours maximum detention time
at average flow—4.5 hr
Capacity 288 cu m (76,000 callons)
air pressurization on recycle, surface
settling rate, 58 square M (625 square
feet), 50 percent recycle, average flow.
Heated, capacity 68 cu m (18,000 gallon)
Capacity 8,600 cu m (2.27 million
gallons); detention, 4.5 days at
average flow; aeration, 3.5 kw, 224
cu rr. 'Tin (4.75 hp, 8,000 scfr) anci six
floating aerators totaling 157 kw (2iG
hp)
Capacity, 379 cu m (ICO,000 gallons);
surface settling rate, 11 cu m/day/
sq m (270 gpd/sq ft)
Capacity 1,400 cu m (3G5.000 gallons);
three 20 cu m/min (50 hp, 700 scfm) blowers
Located at Champaign-Urbana sanitary
district site. Each lagoon is 0.4or ha
(1 one) x 2.4 M (8 ft) deep
540
-------
DRAFT
operation. The Champaign pretreatmcnt facility was reported to
typically operate within the following ranges of removal efficiencies:
COD, 96.4 to 99.4 percent; suspended solids 90 to 9i percent; and oil
and grease 93 to 99.5 percent with about 72 percent being removed in
primary treatment and about 25 percent removed by the secondary unit.
In order that the plant could meet the municipal ordinances
of 200 mg/1 BOD, 200 mg/1 SS, and 100 mg/1 of fats, oil and greases,
the design features listed in Table 100 were adopted for the Champaign
plant based upon a 1980 waste loading capacity.
Selections of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 5. The model plant was developed to include the following treatment
units before final discharge to a treatment facility;
1. Surge control and/or flow equalization,
2. Gravity separation and skimming,
3. In-plant oil recovery system,
4, pH control.
The raw v/astewater characteristics after gravity separation, skimming,
and pH control were taken as follows:
BOD 6,600 mg/1
SS 3,600 mg/1
Oil and Grease 3,500 mg/1
Flow 314 cu m/day (0.083 MGD) '
Table 101 lists the pollutant effluent loading from the Subcategory
A 5 plant and the estimated operating efficiencies of each of the
eight treatment trains selected for this Subcategory.
AU?rnat1ve A 5-1 - This alternative provides no additional treatment
other tnan gravity separrtion, skimming, and pH control.
Alternative A F-II - Alternative A 5-1 with the addition of pressurized
air flotation utilizing chemical flocculating agents to enhance floe
formation and floatability of wastes. Oil, water, and solid waste
skimmings are pumped to an in-plant oil reclamation system for dewaten
and recovery of inedible oils.
'Alternative A 5-111 - Alternative A 5-II with the addition of activated
sludge-, secondary clarification, sludge recirculating pump, sludge
thickening tank, vacuum filtration, and a sludge holding tank. Sludge
is hauled to a landfill facility every seven days. The activated
sludge unit also Includes a rnntrol liause and 'MO full time operators.
Alternative A 5-IV - Alternative A 5-111 with the addition of dual
media pressure filtration with pump stations to generate sufficient
head for the filter operation.
541
-------
A 5-1 A
A 5-11 8J
A 5-III BJKQSY
A 5-IV EJKQSYBN
A 5-V BJKQSYBIIZ
A 5-V1 BJL
A 5-VII BJLBN
A 5-VIII BJIBNZ
SUMMARY
Effluent
BOD
kg/kkg
4.59
1.37
0.069
0.035
0.021
0.069
0.035
0.021
TABLE
OF TREATMENT
Effluent
SS
kg/kkg
2.49
0.75
0.069
0.035
0.017
0.069
0.035
0.017
101
TRAIN ALTERNATIVES
Effluent
O&G
kg/kkg
2.39
0.73
0.069
0.014
O.C07
0.069
0.014
0.007
Percent
BOD
Reduction
0
70.1
98.5
99.2
99.5
98.5
99.2
99.5
Percent
SS
Reduction
0
70.0
97.2
99.2
99.6
97.2
99.2
99.6
Percent
O&G
Reduction
0
69.5
97.1
99.4
99.7
97.1
99.4
99.7
o
-n
— \
-------
DRAFT
Alternative A 5-V - Alternative A 5-IV with the addition of activated
carbon before final discharge. A schematic diagram of Alternative
A 5-V is presented in Figure 155.
Alternative A 5-VI - Alternative A 5-II with the addition of an aerated
lagoon including a settling pond.
Alternative A 5-VII - Alternative A 5-VI with the addition of dual
media pressure filtration and a pump station to generate sufficient
head for filter operation.
Alternative A 5-VI 11 - Alternative A 5-VII with the addition of
activated carbon before final discharge. A schematic diagram of
Alternative A 5-VIII is presented in Figure 156.
SUBCATEGORY A 6 -PROCESSING OF EDIBLE OILS BY CAUSTIC REFINING AND
AClDULATIOiJ METHODS "
The existing and potential in-plant treatment and control technology
and existing end-of-line technology for Subcategory A 6, Edible Oil
Refineries, are essentially as those discussed in Subcategory A 5 and
outlined in Table 98.
Selection of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 6. It was assumed that the model plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control and/or flow equalization.
2. Gravity separation and skimming.
3. In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation,
and pH control were assumed to be as follows:
skimming,
BOD
ss
O&G
now
7,600 mg/1
3,400 mg/1
3,000 nig/1
534 cu m/day (0.141 MGD)
Table 102 lists the pollutant effluent loading from the Subcategory A 6
model plant and the estimated operating efficiencies of each of the eight
treatment trains selected for this subcategory.
Alternative A 6 -I - This alternative provides no additional treatment
other than gravity separation, skinning, and pH control.
543
-------
DRAFT
TO IN-PLANT OIL
RECOVERY SYSTEM
INFLUENT
BOO = 6.600 MG/L
SS = 3.500 MG/L
OfrG s 3.SOO MG/L
FLOW = 0.314 CU M/DAY (0.083 MGO>
DISSOLVED A IB
FLOTATION
r
ACTIVATED
SLUDGE BASIN
•ALTERNATIVE
A5-II
EFFLUENT
BOD = 19BO MG.'L
SS = 1080 MG/L
OtG = 1050 MG/L
SLUDGE
THICKENING
SECONDARY
CLAHIFICATION
VAQAJM
FILTRATION
SLUDGF
STORAGL
CXJAL-MEDIA
FILTRATION
SLUDGE TO
TRUCK HAUL
ADSORPTION
FIGURE
--^ALTERNATIVE
A 5-1II
EFFLUENT
BOD = 100 MG/L
SS • 100 MG/L
OtG » 100 MG/L
-•ALTERNATIVE
A 5-IV
EFFLUENT
BOD » so MG/L
SS - AO MG/L
OtG = 20 MG/L
--^ALTERNATIVE
A 5-V
EFFLUENT
BOD B 30 MG/L
SS » 20 MG/L
OtG « 10 MG/L
SUBCATEGORY AS
TREATMENT ALTERNATIVES II THROUGH V
544
-------
TO IN-PLANT OIL
RECOVERY SYSTEM
INFLUENT
BOD = 6.600 MG/L
SS * 3,600 MG/L
OCG = 3.500 MG/L
FLOW = 0.314 CU M/OAY (0.083 MGO)
1
DISSOLVED AIR
FLOTATION
AERATED
LAGOON
ALTERNATIVE A II EFFLUENT
BOO = I960 MG/L
SS = 1080 MG/L
OtG = 1050 MG/L
SETTLING
PONDS
DUAL MEDIA
FILTRATION
ACTIVATED CARBON
ALTERNATIVE A VI EFFLUENT
BOD = 100 MG/L
SS =100 MG/L
OEG = 100 MG/L
ALTERNATIVE A -VII
EFFLUENT BOD = 50 MG/L
SS » 40 MG/L
DtG = 20 MG/L
ALTERNATIVE A -vm
EFFLUENT BOD = 30 MG/L
ss = ?n MT,/L
OtG - 10 MG/L
FIGURE 106
5UBCATEGDRY AS
TREATMENT ALTERNATIVES VI THROUGH VIII
-------
TABLE 102
SUfWARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY A6
o
33
Treatment Train
Alternatives
A6-I A
AS- 1 1 B,J
A6-III BJKQSY
A6-IV BJKQSY8N
A6-V flJKqSYBNZ
A6-V1 BJL
A6-VII BJLBN
A6-VI11 BJLBNZ
Effluent
BOO
kg/kkg
8.95
2.68
0.134
0.067
0.035
0.134
0.067
0.035
Effluent
SS
kg/kkg
4.03
1.21
0.121
0.061
0.030
0.121
0.061
0.030
Effluent
F, 06G
kg/kkg
3.51
1.05
0.105
0.023
0.012
0.053
0.023
0.012
Percent
BOD
Reduction
0
70
98.5
99.2
99.6
98.5
99.2
99.6
Percent
SS
Reduction
0
70
97.0
98.5
99.3
97.0
98.5
99.3
Percent
F, O&G
Reduction
0
70
97.0
99.3
99.6
97.0
99.3
99.6
-------
UKAI I
Alternative A 6 - II - Alternative A 5 -I with the addition of pressurizc-d
air flotation utilizing chomical flocculating agents to enhance floe
formation and floatability of wastes. Oil, water, and solid waste skimmings
are pumped to an in-plant oil reclamation system for dewatering, and re-
covery of inedible oils.
Alternative A 6 - MI - Alternative A 6-II with the addition of activated
sludge, secondary clarification, sludge recirculating pump, a sludge thick-
ening tank, vacuum filtration, and a sludge holding tank. Sludge is hauled
to a landfill facility every four days. The activated sludge unit also
includes a control house and two full-time operators.
Alternative A 6 - IV - Alternative A 6-III with the addition of dual
media pressure filtration with pump stations to generate sufficient
head for the filter operation.
Alternative A 6-V - Alternative A 6-IV with the addition of activated
carbon before final discharge. A schematic diagram of Alternative A 6-V
is presented in Figure 157.
Alternative A 6-VI - Alternative A 6-II with the addition of an aerated
lagoon including a settling pond.
Alternative A 6-VI! - Alternative A 6-VI with the addition of dual media
pressure filtration ?.nd a pump station to generate sufficient head for
filter operation.
Alternative A 6-VIII, - Alternative A 6-VI] with the addition of activated
carbon before final discnargc. A schematic diagram of Alternative A 6-
VIII is presented in Figure 158.
SUBCATEGORV A 7 PROCESSING OF EDIBLE OILS BY CAUSTIC REFINING. ACIDU-
LATIO:;, OIL •' OCESSI.'i'G. AND CEODORI2A7ION McThODS
The existing and potential in-plant treatment and control and end-of-line
treatment technologies for Suucategory A 7 are essentially as those dis-
cussed in Subcategory A 5 and outlined in Table 98 with the addition of
the following discussion of in-plant technology for the u,iit processes of
oil processing and deodorlzation.
In-Plant Technology
011 processing includes the wastevater-s 5em?rated from the unit processes
of blenching, hydrogenation, and winteriration.
In general, the majority of bleaching operations visited practiced dry
cleanup of the spent bleaching absorbent. However, mc-it plants discharge
a significant portion of the absorbent to the scwe" during floor washing
operations. In the hydrogenation process, the industry commonly utilizes
dry cleanup of the spent nickel catalyst from the filter prsss area. How-
ever, a few plants discharge small amounts of catalyst to the sewer during
517
-------
DRAR
TO IN-PLANT OIL
RECOVERY SYSTEM
INFLU6MT
BOD = 7.600 MG/L
SS » 3,400 MG/L
OCG = 7..000 MG/L
FLOW -» 0.534 CU M/DAY tO.)41 MGD)
5LLDGE
THICKENING
VACUUM
FILTRATION
SLUDGE
STORAGE
SLUDGE TC
.TRUCK MAU.
DISSOLVED
FLOTATION
ACTIVATED
SLUDGE BASIN
XAWIF [CATION
A^-MEDIA
PILTPATION
'•'. ARSON
'! DM
•• ALTERNATIVE
BOO = 22PC
ss = 1020
OtG = 90C
•-— Al TERNAT1VE At- 11 ;
3CX5 •» 115 MG/L
GS = 102 MGA
OtG " 90
E A6-IV
Ef FI ' JF;MT
POD « sr MG,I
SS = 5>"l MT«1.
OtG -• ^0 ""Y'L
157
£^. 0.6
ALTERNATIVES II THRU V
"•'ALTERNATIVE A6-V
EFFLLF'NT
,3DD - 30 MG/L
SS = 55 MG/U
= 10 M.VL
-------
DRAFT
TO IN-^XANT OIL
PECOVERY S-.-STEM
INFLUENT
BOO = 7,600 MG/L
SS * 3,400 MG/L
CfcG * 3,000 MG/L
PLOW • 0.534 CUM/DAY (C.U1 MGO;
DISSOLVED AIR
CLOTAT ION
AERATED
I.ASOOM
J_
.SETTLING
ise
•»• ALTEF-iNATIVE A6- I I
SOD = 2280 MG/L
S3 = J020
OtG = VOO
A6-V1
UfNT
DUD - 115 Vtt/-
SS a 102 MGA.
OtG = ^
A6- /I I
EFFV/JENT
HfjO - *? M6/1.
as = so IC/L
20 MG/U
A'.
A6-vi n
flO.) = 30
SS » 2S H&/L
ntG sr 10 MG/L
ALTERNATIVES vl THRU vi.n
549
-------
DRAFT
floor washing operations. A small number of plants have developed the
technology for rccoverin? nickel from the spont catalyst, but this pro-
cedure is not widely applied throughout the industry. In the unit orocoss
of dcodorization, fatty materials are concentrated within the deodorizer
stripping steam and are removed by barometric condenser water where they
are eventually deposited in the cooling tower basin and subsequent blow-
down. Distillate recovery systems are commonly employed by the industry
to reduce the concentrations of these materials in the v/astewater dis-
charge fron the contact cooling tower. The distillate recovery system
Utilizes a liquid oil spray which condenses the fatty materials before
they reach tne barometric condenser, thus removing approximately 90 to
95 percent of the waste distillates.. The recovered distillate is sold
as a by-product.
Potential In-Plant Technology
Potential in-plant technology would include improvement in general house-
keeping practices, in the bleaching and hydrogenation processing areas, •
maximizing dry cleanup procedures were possible. The industry .-nay ad-
vantageously deve'op a program toward improvement of operator awareness
regarding general dry cleanup procedures and pollution control methods
in the aforementioned processing areas.
Selection of Ccntrol and Treatment Technology
In Section \!, a hypothetical model plant was developed for Subcategory
A 7. It waii assumed that the mode) plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control and/or flow equalization.
2. Gravity separation and skimming.
3, In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation, skimming,
and pH control were assumed to be as follows:
BOO 6,400 mg/1
SS 3,100 mg/1
OAG ' 1,500 mg/1
Flow 1J4VCU m/day (0.303 MGO)
Table 103 lists the pollutant effluent loading from the Subcategory A /
model plant and the estimated operating efficiencies of each of the
treatment trains selected for this Subcategory.
Alternative A 7-1 - This alternative provides no additional treatment
Other than gravity paration, skimming, and pH control.
5GO
-------
TABLE 103
SUfflttY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY A7
en
Treatment Train
Alternative
A7-I A
A7-1I B.J
A7-III BJKQSf
A7-IV BJKQSY8N
A7-V BJKQSYBMZ
A7-VI BJL
A7-VII BJLBN
A7-VIH BJLBWZ
Effluent
BOD
kg/kkq
16.09
4.85
0.252
0.126
0.076
0.252
0.126
0.076
Effluent
SS
kg/kkg
7.04
2.35
0.^5?
0.126
0.063
0-252
0.126
0.063
Effluent
F, O&G
Xa/kkjL
3.93
1.13
0.252
0.051
0.025
0.252
0.051
0.025
Perrent
GOD
Reduction
0
69.8
98.4
99.2
99.5
98.4
99.2
99,5
Percent
SS
Reduction
0
70.0
96.8
98.4
99.2
96,8
98.4
99,2
Percent
F, OSG
Reduction
0
7K3
93.6
98,7
99.4
93,6
98,7
99.4
-------
DRAFT
AT term two A 7-11 - Alternative A 7-1 with the addition of pressurized
<;ir flotation utilizing chemical flocculating agents to enhance floe
formation and floatability of wastes. Oil, water, and solid v/aste skimmings
are pumped to an in-plant oil reclamation system for dewaterlng, and re-
covery of inedible oil*.
Alternative A 7-1II - Alternative A 7-II with the addition of activated
sludge, secondary clarification, sludge recirculating pump, a sludge thick-
ening tank, vacuun filtrat'icr,, and a sljdge holding tank. Sludge is hauled
to a landfill facility every ten days. The activated sludcie unit also
Includes a control house and two full-time operators.
Alternative A 7-IV - Alternative A 7-111 with the addition of dual
media pressure filtration with pump stations to generate sufficient
head for the filter operation.
Alternative A 7-V - Alternative A 7-IV with the addition of activated
carbon before final discharge. A schematic diagram of Alternative A 7-V
is presented in Figure 159.
Alternative A 7-V1 - Alternative A 7-11 with the addition of an aerated
lagoon including a settling pond. The aerated lagoon unit also includes
a control house with two full-time operators.
'Alternative A 7-VIj - Alternative A 7-VI with the addition of dual media
pressure filtration and a pump station to generate sufficient heed for
filter operation.
Alternative A 7-V1II - Alternative A 7-VII with the addition of activated
carbon before finTTdisr.harge. A schematic diagram of Alternative A 7-
VIII 1s presented in Figure 160.
. . _b*
SLIBCATEGORY 6 -_PRCCE;SII.'G QC EDIBLE OILS UTILIZING CAUSTIC REFINING.
OIL PROCESSING." A.'.'D OEOiX)R!ZATIC,;J
The existing and potential 1n-plant treatment and control technology
and end-of-line treatment technology for Subcateqory A 8 are essentially
as those previously outlined in Table 98 and discussed in edibie oil
refinery Subcategorics A 5 and A 7,
Selection of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 8. It was assumed that the model nlant provided the following treat-
ment units before tinal discharge to a treatment facility:
1 Surge control and/or flow equalization.
2. Gravity separation and skimming.
3. In-plant oil recovery system.
4. pH control.
552
-------
DRAFT
TO IN-PLANT OIL
RECOVERY SYSTEM
4
BOO = 6.400 MG/L
SS = 3,100 MG/U
OtG a 1.500 MG/L
FLOW = 1.147 CU M/DAY (.303 MOD)
DISSOLVED AIR
FLOTATION
I
ALTERNATIVE A?- 11
EFFLUENT
BOO - 1S»?0 MG/L
SS = 930 MG/L
OtG = 450
ACTIVATED
SLUDGE BASIN
SLUDGE
THICKENING
i
VACUUM
FILTRATION
'
1
SLUDGE
STORAGE
SECONDARY
CLAHIF1CATION
•
r " ' ~ '
i
UUAL-MEDIA
PJLTOATION
_ .
-» ALTERNATIVE AT-III
100 MG/L
SS = 100 MG/L
OtG e 90 MGA.
*. AL'E&NATIVE A7- ;v
SLUDGE TO
TRUCK MAUL
A2SOHPTI3N
SOO - 50 MG/L
SS = 50 MG/L
OGG - 20 MG/L
A7-v
159
SUBCATEGQRY A?
TREATMENT AL'L^^TJvES II THRU V
a«^' - 3C MG ".
55 = 25 MG/L
OI.G = 10 MG/L
553
-------
DRAFT
TO IN-PL>NT OIL
RECOVERY SYSTEM
BOD = 6,400 MG/L
SS B 3,100 MG/L
OtG a 1.500 MG/L
FLOW = 1.1*7 cu M/DAY (0.303 MGOJ
DISSOLVED AIR
FLOTATION
u ^ ALTERNATIVE A?-II
30D - 1930 MG/L
SS = ')30 MG/L
= 450 MG/L
AERATED
LAGOON
SETTLING
DONCS
DUAL-MEDI*
FILTRATION
ALTERNATIVE A--VI
ePF! :iTNT
8U) = 100 MG/L
SS » 100 MG/L
OtG a 90 MG/V
i -— ALTERNATIVE A7-VI I
CARBON
160
BOD = 50 MG/L
S5 - 50 MG/L
OtG = 20 MG/L
-*• ALTERNATIVE A7-VIM
EFR-LTNT
90D = in MG/L
SS • 2*> MG/L
OtG •- 10 MG/L
rREATMENT
A7
Vl THRU
554
-------
DRAFT
The raw wastewatcr characteristics after gravity separation, skimming,
and pii control were assumed to be as follows:
BOD 5,700 mg/1
SS 3,100 mg/1
O&G 1,400 mg/1
Flow
-------
TABLE 104
SUWWRY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY A8
Treatment Train
Alternatives
A8-I A
AB-II B,J
A8-III BJKQSY
A8-1V BJKQSYBN
A8-V BJKQSYBNZ
A8-VI BJL
A8-VH BJLBN
"*-VIII BJLBNZ
Effluent
BOD
kg/kkg
11.73
3.53
0.204
0.102
0.051
0.204
0.10.
0.051
Effluent
kg_/kkg_
6.3Q
1.90
0.204
0.102
0.051
0.204
0.102
0.051
Effluent
O&ti
kg/kkg
2.81
0.859
0.102
0.041
0.020
0.102
U.U4I
0.020
Percent
BOO
Reduction
0
69.9
98.3
99.1
99.6
98.3
99.1
99.6
Percent
SS
Reduction
0
69.8
96. B
98.4
99.2
96.8
98.4
99.2
Percent
O&G
Reduction
0
69.4
5.4
.2
99.3
96.4
98.5
99.3
-------
ORAh i
TO IN-PLANT OIL
3ECCVERY SYSTEM
INFLUENT
BOO = 5 . 700 fJtG/L
SS = 3 . 1 00
PLOW = 0.927 CU M/DAV (0.2*5 M3D )
FLOTATION
TI VE A3- ! :
VACUUM
FILTRATION
STORAGE
ACTIVATED-
SLUDGE 5ASI'
- MED I A
1
SLUDGE
THICKENING
SECONDARY
CLAWI^ICATJC-N
IP'''
. ; • "* ^*~..
iS - 1 '•- '*•«",_
SLUDGE TC
TRUCK -WUL
AL reqji
EFPL-JEUT
9CD = .'-•• '*S.-
ss - 2'j MG/L
etc -- 10 MG/
557
-------
DRAFT
TO IN-PLANT OIL
RECOVERY SYSTEM
*
INFLUENT
BOD = 5,700 MG/L
SS = 3.100 MG/L
06G = 1.400 MG/L
R-OW = 0.927 CU M/DAY (0.245
DISSOLVED AIR'
FLC~AT; 3N
T
AERATED
-AGCKN
T
^air
T
'^A^^
ALTE
ALTE
EFFL
VE AS-II
900 = 1^25
SS = 930
OtG = ^t"
EFFLUENT SOD = ]00 VG,
ss = 100 MG/
OCG = 50 MG/
Ef-'R-UENT BOO = ?'- •*-,
'-JS - Si'. Mr./1.
ALTERNATIVE A8-VII!
30D = ,'S MG.-
ALT°r.A-;VES .'I -HRL1 VIII
558
-------
DRAFT
SUBCATEGORY A 9 PROCESSING OF EDIBLE 01 IS UTILIZING CAUSTIC REFINING,
AcmuL/vrio;.'. OIL PROCESSING. DLGLiOHiz/MUjiniLri.uus. AI;D THE PKUUUCTIIM
UF MIOKTLUli.Li A. ID T/AULL J_1_L_S
The existing and potential in-plant treatment and control and end-of-line
treatment technologies for Subcategory A 9 are essentially those pre-
viously outlined in Table 98 and discussed in edible oil refinery
Subcategories A 5 and A 7. A detailed discussion of the existing and
potential in-plant treatment and control technology for the processing of
shortening and table oils is presented in Subcategory A 14.
Selection of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 9. It was assumed that the model plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control and/or flow equalization.
2. Gravity separation and skimming.
3. In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation, skimming,
and pH control were assumed to be gravity separation, skimming, and pH control.
Alternative A 9-11 - Alternative A 9-1 with the addition of pressurized
air flotation utilizing chemical floccjlating agents to enhance floe
tormation and f loatabil ity of wastes. Oil, water, and solid waste sH:rinn r,<:i
are pumped to an in-plant oil reclamation system for dewatering, and re-
covery of inedible oils.
Alternative A 9-1II - Alternative A 9-U with the addition of activated
sludge, secondary clarification, sludge recirculating pump, a sludge thick-
ening tank, vacuum filtration, and a sludge holding tank. Sludge is hauled
tu a landfill facility every nine days. The activated sludge unit also
includes a control house and two full-time operators.
Alternative A 9-IV - Alternative A 3-III with the addition of dual
media pressure filtration with pur.p stations to generate sufficient
head for the filter operation.
559
-------
TABLE 105
SUMMARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY A9
o
TO
Treatment Train
Alternative
A9-1 A
A9-II B,J
A9-III BJKQSY
A9-IV BJKQSYBN
A9-V 6JKqSYBNZ
A9-VI BJL
A9-VII BJLBN
A9-VIII BJLBNZ
Effluent
BOD
kg/kkg
17.12
5.15
0.252
0.131
0.073
0.362
0.131
0.073
Effluent
SS
kg/kkg
8.68
2.62
0.262
0.131
0.073
0.262
0.131
0.073
Effluent
F. OSG
kg/kkg
4.35
1.31
0.131
0.058
0.029
0.131
0-058
0.029
Percent
BOD
Reduction
0
70.0
98.5
99.2
99.6
98.5
99.2
99.6
Percent
SS
Reduction
0
70.0
97.0
98.5
99.2
97.0
SB. 5
99.2
Percent
F, O&G
Reduction
0
70.0
97.0
98.6
99.3
97!0
93.6
99.3
-------
DRAFT
Alternative A 9-V - Alternative A 9-IV with the addition of activated
carbon before final discharge. A schematic diagram of Alternative A 9-V
is presented in Figure 153.
Alternative A 9-VI - Alternative A 9-II with the addition of an aerated
Tagoon including a settling pond. The aerated lagoon also includes a
control house and two full-timer operators.
Alternative A 9-VII - Alternative A 9-VI with the addition of dual media
pressure filtration and a pump station tc generate sufficient head for
filter operation.
Alternative A 9-VIII - Alternative A 9-VII with the addition of activated
carbon before final discharge. A schematic diagram of Alternative A 9-
VIII is presented in Figure 164.
SUBCATEGQRV A 1G ' PROCESSING OF EDIBLE OILS BY CAUSTIC REFINING. OIL
PROCESSING. DEQDCRIZATIQN ,-iLTHi.JS; A;.b "!iE PLASTIC.lZIi.Ci *M PAC^GIi.G
OF SHUkUiJlllG A.'.J TABLE UlLS
The existing and potential in-plant treatment and control technology and
existing end-of-line tecnnology for SuDcategory A 10 refineries are es-
sentially as those previously outlined in Table 98 and discussed in detail
In edible oil refinery Subcategories A 5, A 7, and A 14.
Selection of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 10. It was assumed that the model plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control and/or flow equalization.
2. Gravity separation and skimming.
3. In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation, skimming,
and pH control were assumed to be as follows:
BOD 5,250 mg/1
SS 3,000 mg/1
Ofcti 1 ,300 mg/1
Flow 1,101 cu IT,/day (0.291 MGD)
Table 106 lists the pollutant effluent loading from the Subcategory A 10
model plant and the estimated ooerating efficiencies of each of the eirjht
treatment trains selected for this Subcategory.
Alternative A 10-1 - This alternative provides no additional treatment
other than gravity separation, skimiiui, and pH control.
561
-------
DRAFT
TO IN-PLAN7 OIL
RECOVERY 3YSTEM
i
VACUUM
FILTPATIQN
j
SLUDGE
t
TPVJCK.
INFLUENT
BOO = 5.900 MG/L
SS = 3,000 MG/L
OtG = 1.500 MG/L
FLOW = 1,32! CU M/DAY f0.3^9 MGD)
DISSOLVED AIR
FLOTATION
ALTERNATIVE AO-
FFFLUEMT
BOD = 17">0 MG-'!
ss - ^01 MG/_
OtG = ^50 MG/L
SLUDGE
THICKENING
'
ACTIVATED
SLUDGE BASIN
»
SECONDARY
CLARIFICATION
DUAL-MEDiA
FILTRATION
ALTERNATIVE A
CCCl i.ffMT
BOO = 90 MG/L
55 = 90 MG/L
cue = 45
ttOD --. .-5 MG/l.
•")£,G .- ,;•? MT,."
Aw-
BCD = £5 MG/L
c.^ •= 25
06G - 10
TREATMENT
II THRU V
-------
DRAFT
TO IN-PLANT GIL
RECOVERY SYSTEM
i
tf^T-UENT
BOD = 5,900 MG/L
SS = 3,000 MG/L
CI.G = 1 ,500 MG/L
PLOW = 1,3- .
_». r 5 - ^i, ^,. _
OtG = 10 MC,/._
juRCATEGGRY AJ
rPEfl.-".'ET A,."o-;.}-IV£S VI THRU VIII
563
-------
TABLE 106
SUMMARY CF TREATMENT TRAIN ALTERNATIVE": FOR SUBCATEGORY AID
Treatment Train
Alternative
A10-I A
A10-II B,J
A10-III BJKQSY
5 A10-IV BJKQSYBN
e»
A10-V BJK'QSYBHZ
A 10- VI BJL
A1U-VII BJLBN
A10-VIII DJLBNZ
Effluent
BOO
kg/kkg
12.76
3.82
0.194
0.097
0.048
O.IS4
0.097
0.048
Effluent
SS
Icq/kkq
7.14
2.13
0.219
0.129
0.055
0.219
0.109
0.056
Effluent
F, O&G
kg/kkg
3.23
0.947
0.097
0.048
0.024
0.097
0.048
0.024
Percent
EOD
Reduction
0
70.0
98.5
99.2
99.6
98.5
99.2
99.5
Percent
SS
Reduction
0
69.5
96.9
98.5
99.2
96.9
98.5
99.2
Percent
f, O&G
Reduction
0
70.0
97.0
98.5
99.2
97.0
98.5
99.2
-------
DRAFT
Alternative A ID-11 - Alternative A 10-1 with the addition of pressurized
air flotation utilizing chemical flocculating agents to enhance floe
formation and floatability of wastes. Oil, water, and solid waste skimmings
are pumped to an in-plant oil reclamation system for dewatering, and re-
covery of inedible oils.
Alternative A 10-111. - Alternative A 10-11 with the addition of activated
sludge, secondary clarification, sludge recirculating pump, a sludije thick-
ening tank, vacuum filtration, and a sludge holding tank. Sludge is haulec'
to a landfill facility every six days. The activated sludge jnii also
includes a control house and two full-time operators.
Alternative A ID-IV- Alternative A 10-111 with the addition of dual
media pressure filtration with pump stations to generate sufficient
head for the filter operation.
Alternative A 10-V - Alternative A 10-IV with the addition of acf.vat-v:
carbon before final discharge. A schematic diagram of Alternative A lii-Y
is presented in Figure 165.
Alternative A 10-VI - Alternative A 10-H with the addition of an aerated
lagoon incluaing a settling pond. 1 he aerated lagoon also induces a co:itr;. 1
house with two full-time operators.
Alternative A 10-VH - Alternative A 10-71 with the addition of dual media
pressure filtration and a pump station to generate sufficient head for
filter operation.
Alternative A 10-VIII - Alternative A 1C-VII with the addition of activate.-:;
carbon oet'ore final discharge. A schematic diagram of Alternative A 13-
V1I1 is presented in Figure 166.
SUBCATEGORY A 11 - PPQC.ESS I !IG OF ED! MTJ?! i: BY CAUSTIC REFI j! IJJG, AC I D!J -
LAT ID..', OIL P'f.i'-c. g 5 i i -G. Ob"OCORJ rAT"V"T""f" ~" "•',„.. \',D ^^'i'-li'^'^lllLlTiG •'•',,':'
pATisAvTi .,ii ^'"""crf;;;7TT7rr~7 Hl)T7~7j7~ J -ef inprit.-i i:ro pssertio".',.•
as those previously out-lined in Table ';S and discussed in detail in adii/ir
oil refinery Gubcategories A 5, A 7, A 13 and A 14.
Selection of Centre! and Tre at men t Jc 7 'v- H Moy
In Section V, a hypothetical model plant .-/us developed for Subcategory
All. It was assumed that the r.'odel plant provided the following treat-
ment units before final discharge to d treatment facility:
565
-------
DRAFT
TO IN-PLANT OIL
RECOVERY 5YSTEM
4
SLuDGE
THICKENING
1
VACUUM
FILTRATICN
J_
SLUDGE
STORAGE
KLUDGE TC-
TRUCK -IAUL
INFLUENT
BOO = 5,250 MG/L
SS = 3.000 MG/L
OtG = 1.300 MG/L
FLOW = I. 101 CU M/DAY (0.291
SISSCLVED AIR
-— ALTERNATIVE
BOD - 1575 MG/L
55 = -if.10 MG/L
- 39C MG/L
ACTI
Z.LJDGE 3ASIN
CL AW I f
NkA
I '.A
pv
TION
BOD = 90 MG/L
SS - ?0 MG/L
?CG = ^0 MG/L
. ; /
DOC =
.'JtG
V3 MG/L
5 MG/L
CO f-IG/!
«_ ALTFRNATI VE AID-
7CD - J" MC '!..
ss = 23 MG/L
•Jf.O - I'l MG/L
566
-------
DRAFT
TO IN-PL>NT OIL
RECOVERY SYSTEM
I
INFLUENT
BOO = 5,250 MG/l
55 = 3,000 M-V
EFFLUEMT
' ?••> MG/L
. = 3f. MG/L
•3 = «.') MG/L
/E ATI /:
90D - -.0 M(-,.-'.
Jf,G - ?0 MG,T_
.».ALTERNATIVE AI ••-;:
3co = 20 MG/L
OtO = 10 MG/L
/'HI
-------
DRAFT
1. Surge control and/or flow equalization.
2. Gravity separation and skimning.
3. In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation, skimming,
and pH control were assumed to ba as follows:
BOD 6,900 mg/1
55 3,200 mg/1
OiG 2,800 mg/1
Flow 1,574 cu m/day (0.416 MGD)
Table 107 lists the pollutant effluent loading from the Subcategory A 11
model plant and the estimated operating efficiencies of each of the eight
treatnent trains selected for this subcategory.
Alternative A 11 -I - This alternative provides no additional treatnent
other than gravity" separation, ski.Tming , and pH control.
Alternative A .11- II - Alternative A 11-1 with the addition of pressurise
air flotation uiilizing chemical flocculating agents to enhance floe
formation and floatability of wastes. Oil, water, and solid waste skir^i
are pumped to an in-plant oil reclamation system for dewatering, and re-
covery of inedible oils.
Alternative A 11-111 - Alternative A 11-11 with the addition of activated
sludge, seconaa>y clarification, sludge recirculatlng pump, a sludge thick
ening tank, vacuum filtration, and a sludge holding tank. Sludge is najl
to a landfill facility every eight days. The activated $iud?<.-? unit also
includes a control house and two full -time operators.
Aljternatri/e A 11 -IV - Alternative A ll-III with the addition of dual
media pressure filtration with purr.p stations to generate sufficient
head for the filter operation.
Alternative A_lJ-\/ - Alternative A 'II -IV with *he addition of
carbon before final discharge. A schematic diagram of Alternative A 11-V
is presented in Figure 167.
Alternative A 11 -VI - Alternative A 11-11 with the addition o^ an .K'ro'.'yJ
Tagoon including a settling pond. The derated lagoon also includes a ..r.-r.t:
house and two operators'".
A1 terna t we A 1 V-VJJ - Alternative A 11 -VI with the addition of du.il ir-cJi.i
pros sure f i 1 tr'a L i or, dnd a punp station to gprn.rjty sufficient head {"or-
f i Her operation.
Alternative A 11 -VI 1 1 - Alternative A 11-VII with the addition of act; vote J
carbon before final discharge. A :choirutic diagram of Alternative A 11-
VIII is presented in Figure 168.
560
-------
TABLE 107
o
§
SUMMARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY All
Treatment Train
Alternative
All-I A
All-II B,J
All-I 1 1 BJKQSY
All -IV BJKQSYBN
All-V BJKQSYBNZ
All -VI BJL
All-VII BJLBN
All-VIII BJLBNZ
Effluent
BOD
kg/kkg
20. b7
6.14
0.312
0.156
0-076
0.312
0.156
0.076
Effluent
SS
kq/kkg
10-98
3.33
0.347
0.174
0.087
0.347
0.174
0.087
Eff.uent
0*G
kg/kkg
9.95
2.92
0.295
0.069
0.035
0.295
0.069
0.035
Percent
BOD
Reduction
0
70.1
98.5
99.2
99.6
98.5
99.2
99.6
Percent
SS
Reduction
0
69.7
97.2
98.4
99.2
97,2
98.4
99.2
Percent
O&G
Reduction
0
70,6
97.0
99,3
99.6
97.0
99.3
99.6
-------
DRAR
INFLUENT
BOD = 5.900 MG/L
SS = 3. ZOO MG/L
OtG = 2.800 MG/L
FLOW = 1,574 CU M/3AY
i 0.4 16 MGD)
TO IN-PLANT GIL
RECOVERY SYSTEM
DISSOLVED A IP
FLOTATION
E)QD - 1770
SS - -J60 MG/L
ACTIVATED
5LUDGE BASI^
SLUCXX
THJCKEN1MG
1
SECONDAR1"
CLAH!PICATION
T
VACUUM
FILTRATION
SLUDGE
t
SLUDGE -0
TRUCK HAUu
ALTERNATJVE AI i-: r
ADSORPTION
BOD = 90 MG/L
SS = 100 MG/L
OtG = 85 MG.'L
EF-LuCNT
BOD = «.5
iS = 50 MG/-L
^£G = 20 MG/L
BOD - 22
ss = as MG/L
~)fcf, = jo MG/L
An
-L~^«
-------
ORAFT
TO IMPLANT OIL
RECOVERY SYSTEM
4
INFLUENT
BOO = 5,900 MG/L
SS = 3,200 MGXL
OtG = <>.800 MG/L
FLOW = 1,574 CU M/OAY (C.4I« riGO)
DISSOLVED AIR
FLOTATION
AERATED
LAGOON
ALTERNATIVE M1-1
EFR..UENT
BCD = 1770 MG/L
SS = 360 MG/L
3tG = B'O MG/L
UUAi_-MEDIA
FILTRATION
1 ALTERNATIVE AH-
EFFLUENT
BOO = 9y MG/L
SS = 100 MG/L
= 85 MG/L
ALTERNATIVE »
«nr|r< uerj-
300 = 45 MG/L
3S = 50 MG/L
ntc =20 MG/L
FIGURE \&s
SUBCATEGOPY An
TREATMEf/7 ALTEPr.AT lYtS VI THRU VII!
EFFLLENT
300 - 22 MG/L
ss - 35 MG/L
3E.G = 1"! MG/L
571
-------
DRAFT
SUDCA7ESORY A 12 - PROCESSING OF CDIOLE OILS BY CAUSTIC REFINERY. OIL
PKUCESj'j'i.ri iil'JHOD. Ai'JL) THE Pi.AS'flClZATlQN AHU PACKAGING OF SHORTENING.
TABLE OILS. AM HAKGAlllNb"
The existing and potential in-plant treatment and control and existing
end-of-linc technologies for Subcategory A 12 refineries are essentially
as those previously outlined in Table 98 and discussed ^n detail in edible
oil refining Subcategories A 5, A 7, A 13, and A 14.
Selection of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 12. It was assumed that the model plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control and/or flow equalization.
2. Gravity separation and skimming.
3. In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation, skimming,
and pH control were assumed to be as follows:
BOD 5,400 mg/1
SS 3,200 mg/1
04G 3,000 mg/1
Flow 1,355 cu m/day (0.358 MGD)
Table 103 lists the pollutant effluent loading from the Subcategory A 12
model plant and the estimated operating efficiencies of each of the eight
treatment trains selected for this Subcategory.
Alternative A 12-1 - This alternative provides no additional treatment
other than gravity separation, skimming, ar.d pH control.
Alternative A 12-11 - Alternative A 12-1 with the addition of pressurized
air flotation utilizing chemical flocculating agents to enhance floe
formation and floatability of wastes. Oil, water, and solid waste skin:nir,.;:<
are pumped to an in-plant oil reclamation system for dev;atering, and re-
covery of inedible oils.
Alternative A 12-111 - Alternative A 12-11 with the addition of activated
sludge, secondary clarification, sludge re-circulating pump, a sludge thick-
ening tank, vacuum filtration, and a sludge holding tank. Sludge is hauled
to a landfill facility every five days. The activated cludge unit also
includes a control house ard two full-time operators.
Alternative A 12-IV- A1tentative A 12-111 with the addition of dual
media pressure filtration with pump stations to generate sufficient
head for the filter operation.
572
-------
TABLE 108
SUMMARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY AT 2
o
n
Treatment Train
Alternative
A12-I A
A12-II B,J
A12-III BJKQSY
A12-IV BJKQSYEN
A12-V BJKQSYENZ
A12-VI BJL
A12-VIII BJLBN
A12-VIII BJLBNZ
Effluent
BOO
kg/kkg
16.?G
d.84
0.239
0.119
0.060
0.239
0.119
0.060
Effluent
SS
kg/kkg
9.14
2.87
0.287
0.143
0.072
0.287
0.143
0.072
Effluent
O&G
kg/kkg
8.83
2.69
0.269
O.OfiO
0.030
0.269
O.G60
0,030
Percent
BOO
Reduction
0
70.1
98.5
99.3
99,5
98,5
99,3
99,6
Percent
SS
Reduction
0
69.6
97.0
98.5
99,2
97,0
98,5
99,2
Percent
0&5
Reduction
0
69,5
97,0
99,3 .
99,6
97.Q
99,3
99,6
-------
DRAFT
Alternative A 12-V - Alternative A 12-IV with the addition of activated
carbon before final discharge. A schematic diagram of Alternative A 12-V
is presented in Figure 169.
Alternative A 12-VI - Alternative A 12-11 with the addition of an aerated
lagoon including a settling pond. The aerated lagoon unit also includes a
control house and two full-time operators.
Alternative A 12-VII - Alternative A 12-VI with the addition of dual media
pressure filtration and a pump station to generate sufficient head for
filter operation.
Alternative A 12-VIII - Alternative A 12-VII with the addition of activated
carbon before final discharge. A schematic diagram of Alternative A 12-
VI I I is presented in Figure 170.
SUBCATEGORY A 13 -PLASTICIZING AND PACKAGING OF MARGARINE
Existing In-Plant Technology
The wastewaters generated from equipment cleanup, sanitation, and floor
washing, represents the major wasteload contribution to margarine pro-
cessing operations as reported average pollutant concentrations for BOD
were 1437 mg/1; oil and grease, 1760 mg/1; and flow volume of 170 cu m/
day (0.045 MGD). Information received from the National Association of
Margarine Manufacturers indicates that all plants utilize clean-in-place
(CIP) systems for equipment cleanup. Most plants commonly practice the
recycling of caustic or acid rinse waters, and sanitation solutions, there-
by limiting the CIP system wastewater discharge. During floor cleanup, the
industry commonly utilizes high pressure, low volume hoses with automatic
shut-off valves for the reduction of water usage.
Potential In-Plant Technology
The quantity of wastewater produced by clean-in-place systems could be
reduced by the further recycling of the final chlorine rinse to be used
as the initial rinse water. Improved equipment connections in packaging
practices could result in decreased pollutant loading of wastewaters by
decreasing the amount of spills in the packaging area. The establishment
of dry cleanup procedures such as the wiping down of equipment before
cleaning would reduce pollutant waste loads.
Existing In-Plant Technology
There presently exists no complete treatment system handling margarine
processing wastes alone. Watson, oL aj_. (103) reports upon the pe. formancc-
of a pretreatment facility in Champaign, Illinois treating the combined
wastes from an edible oils refinery and a margarine, salad dressing, and
cheese processing operation. The Champaign pretreatment facility was re-
574
-------
DRAF'
TO IN-PLANT OIL
SYSTEM
i
INFLUENT
BOO = 5.AOC MG/L
SS = 3.200 MtVL
OtG = 3,000 MG/L
FLOW = 1,355 CU M/DAY (0.358 MGO)
DISSOLVED A is
-L3TATI3N
ALTERNATIVE A12-II
EFFLUENT BOO -- 1620 MG/L
-- *. SS = 960 MG/L
3tG = 900 MG/L
AcKATED
_AGOON
ALTERNATIVE A12-VI
EFR.UENT 3OD = 80 MG/L
* 5S = 96 MG/L
otG = 90 MG/L
FILIATION
ALTERNATIVE
EFFLUENT BOD = <*0 MG/L
-^ ss = -e MG/L
CCG =2? MG/L
ALTERNATIVE Ai2-vi::
EF'L'JENT 5OO - 20 VC/..
"• S5 = 2^ MG/L
O&G = i 0 MG/
170
: THRU VI II
575
-------
DRAFT
TO IN-PLANT ci
RECOVER*
A
THICKENING
VACUUM
*ILTRATION
3LUDGE
i TORAGE
I
t
SL -OGE
--IAUL.
INFLUENT
BOD = 5,400 MG/L
SS = 3,200 MG/L
OfcG = 3,000 MG/L
FLOW = 1.355 CU M/DAY (0.358 MOD)
J_
DISSOLVED
EFFLUtNT
BOD = 1620
SS = 960 MG/1
OtG - 900
ACTIVATED
oLUDGE = AS I is
SECONDARY
. -MEDIA .
^ALTERNATIVE A
"EFFLUHNT
BOD = so MG/L
SS = 96 MG/L
01.G - 90 MG/L
"'IGl^E !.6^
A 1,2-:
NT
SCO = «»0 MG/L
::.5 = 4ft MC/i.
OLG =20 MG/L
i VE
..'CO - .'JO MG/L
ss = ?4 MG/T.
= 10 MG/L
"3EATMEKrr ALT"'.A"IVE3 II "
-------
DRAFT
ported to typically operate within the following ranges of removal efficiencies:
BOD 96.4 to 99.4 percent; suspended solids 90 to 93 percent; and oil and
grease 93 to 99.5 percent with about 72 percent being removed in primary
treatment and about 25 percent removed by the secondary unit. In order
that the plant could meet the Municipal ordinaces of 200 mg/1 BOD, 200
ITKJ/I SS, and 100 ng/1 of fats, oil and greases, the design features listec
in Table IOC .;ere adopted for the Champaign plant based upon a 1980 wastp
loading capacity.
Selection of Control ano Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 13. It was assumed that the model plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control and/or flow equalization.
2. Gravity separation and skimming.
3. In-plant oil recovery system.
4. pH control.
The raw v/a^tewater characteristics after gravity separation, skimming,
and pH control were assumed to be as follows:
BOD 2,600 mg/1
SS 1,800 mg/1
O&G 3,900 mg/1
Flow 340 cu m/day (0.09 MGD)
Table 109 lists the pollutant effluen- loading from the Subcategory A 13
model plant and the estimated operating efficiencies of each of the six
treatment trains selected for this subcategory.
Alternative A 13-1 - This alternative provides no additional treatment
otherc'than gravity separation, skinming, and oH control.
Alternative A 13-11 - Alternative A 13-1 with the addition of pressurized
air flotation utilizing chemical flocculating agents to ennance floe
formation and floatability of wastes. Oil, water, and solid waste F.kir.-n :,-•;:.•,
are pumped to an in-plant oil reclamation system for dewatering, and re-
covery of inedible oils.
Alternative A 13-711 - Alternative A 13-11 with the addition of activated
sludge, ieconoary Clarification, sludge recirculating pump, a sludge thick-
ening tank, vacuuti filtration, and a sludge holding tank. Sludge is hauled
to a landfill facility every tv/enty days. The activated sludge unit also
includes a control house and two full-time operators.
Alternative A 13-IV- Alternative A 13-111 with the addition of dual
medu pressure filtration with pump stations to generate sufficient
head for the filter operation. A schematic diagram of Alternative A 13-IV
is presented in Fiyure 171.
577
-------
TABLE 109
SUMMARY QP TREATMENT TRAIN ALTERNATIVES FOR SUJCATFCCRY A13
Treatment Train
Alternative
A13-I A
A13-II 8,J
A13-III BJKQSY
A1, 3- IV 6JKQSYBN
A13-V BJL
A13-VI BJLBN
Effluent
BOD
3.92
1.17
0.060
0.030
0.060
0-030
Effluent
SS
kg/kkg
2.72
0.811
0.075
0.037
0.075
0.037
Effluent
O&G
kg/kko
5.81
1.75
0.075
0.037
0.075
0.037
Percent
BOD
Reduction
0
70.1
98.5
99.2
99.2
99,2
Percent
SS
Reduction
0
70.1
97.2
98.6
97.2
98.6
Percent
O&G
Reduction
0
70.0
98.7
99,4
98,7
99,4
-------
DRAFT
TO JN-PLANT CIL
RECOVERY SYSTEM
4
SLUDGE "0
TRUCK HAUL
INFLUENT
BOO = 2.600 MG/L
SS = 1,800 MG/L
3CG = 3,900 MG/L
FLOW = 340 CU M/DAY C.09.MGD)
DISSOLVED AI»
FLOTATION
ACTIVATED
SLUDGE SASIN
ALTERNATIVE A13-H
EFF .JENT
BOP- = 780 MG/L
55 = 540 MG/L
U£,G = 1170 MG/L
SLUDGE
THICKENING
1
1
VACUUM
FILTRATION
1
t
SLUDGE
STORAGE
SECON3ARV
CLARIFICATION
1
OCAL-MEDIA
PIL~RATION
-» ALTERNATIVE A13-I I
SS = 50 MG/L
T£.^ = 50
413-
3QD = 20 ^.'L
SS - 25 MG/L
OtG = 25 MC/L
-IGURE
5UBCATEGGRY Ai3
TREATViEt'Tr AL^ESr.ATT/ES II THRU IV
5/9
-------
DRAFT
Alternative A 13-V - Alternative A T3-1I with the addition of an aerated
lagoon including a settling pond. The aerated lagoon also includes ore
full-time operator.
Alternative A 13-VI - Alternative A 13-V with the addition of dual media
pressure filtration and a pump station to generate sufficient head for
filter operation. A schematic diagram of Alternative A 13-VI is presented
in Figure 172.
SUBCATEGORY A 14 - PLASTICI2ING AMD PACKAGING OF SHORTENING AND TAGLE
OILS
Existing In-Plant Technology
The wastewater generated from equipment cleanup and periodic floor washing
procedures represents a relatively insignificant waste load contribution to
the total waste load of an edible 01 i refinery. In general, filling equip-
ment is wiped clean before being subjected to cleaning solutions. Acc.ioen.tal
spills result in infrequent floor washing operations. The industry co;;;;;:cr.ly
separates their ncn-contuct water discharge from its process waters with the
non-contact water being recycled.
Potential In-Plant Technology
Because of the small volumes of water used and the relatively insignficant
waste load resuUing from shortening and table oil packaging, no recom-
mendations are made for the further reduction of waste strengths or volumes.
End-of-Line Technology
No known end-of-line treatment system presently exists for the packaging
of shortening and table oils alone. All present plasticizing an'd packaging
wastes are handled by municipal treatment.
Selection of Control and Treatment Technology
In Section V, a hypothetical model plant was developed for Subcategory
A 14. It was assumed that the model plant provided the following treat-
ment units before final discharge to a treatment facility:
1. Surge control*and/or flow equalization.
2. Gravity separation and ski<-.-nng.
3. In-plant oil recovery system.
4. pH control.
The raw wastewater characteristics after gravity separation, ikimr.in.j,
and pH control were assumed to be as follows:
500
-------
DRAFT
TO IN-PUANT OIL
RECOVERY SYSTEM
i
INFLUENT
BOD = 2.600 MG/L
S3 = 1,800 MGVL
OfcG = 3.900 MG/U
FLOW = 340 CU M/DAV (.09 MGO)
I
DISSOLVED AI
FLOTATION
A13-U
4ERATED
LAGOON
*
OUAL-MECIA
-V^C - 780 '«G/U
S3 - 5*0 MG/L
OtG = ! 170 MG/'
•-» ALTERNATIVE
BOD = 40 MG/L
"55 - 50 MG/^
OtG = 50 MG/L
9OC = 2
SS - 25 MG/L
O.-.G --25 MG/L
TREATMENT ALTF^J/-
v THRU vi
-------
DRAFT
BOD 1,500 mg/1
SS 1,100 ing/1
04G 550 ,'.3/1
Flow 87 cu m/day (0.023 I1GD)
Table 110 lists the pollutant effluent loading from the Subcategory A 14
model plant and the estimated operating efficiencies of each of the six
treatment trains selected for this Subcategory.
Alternative A 14-1 - This alternative provides no additional treatment
Other than gravity separation, skimming, and pH control.
Alternative A 14-11 - Alternative A 14-1 with the addition of pressurized
air flotation utilizina chemical flocculating agents to enhance
-------
TABLE 110
CUWARY OF TREATMENT TRAIN ALTERNATIVES
o
73
Treatment
Train
Alternative
A 14-IA
A 14-IIBKQSV
A 14-IIIBXQSVN
A 14-IVBKQSVNZ
A 14-VBL
A • 4- VI BIN
A 14-VIIBLNZ
Effluent
BOO
kg/fckg
0.56
0.029
n.015
'J.C08
0.029
0.015
0.008
Effluent
SS
kg/kkg
0.42
0.038
0.015
0.008
0.038
0.015
0.008
Effluent
O&G
kg/kkg
0.21
0.021
0.008
0.004
0.021
0.008
0.004
Percent
800
Reduction
0
94.8
97.3
98.6
94.8
97.3
98.6
Percent
SS
Reduction
0
90.9
96.4
98.1
90.9
96.4
98.1
Percent
O&G
Reduction
0
90.0
96.2
98.1
90.0
96.2
98.1
-------
DRAFT
INFLUENT
BOO - \.soo MG/L
ss = 1,000 MG/L
3E.G = 55C MG/L
= 87 CD
CO.323 MGD)
ACTIVATED
5L-CGE 9ASZN
SLUDGE
THICKEN ING
SECOf^CApv
CLARIFICATION
VACUUM
5L.UOGE
TOR ACE
, ALTERNATIVE
-' EFTUJENT BOC = T5
«. SS = 1 OC
G6G = 55
ALTERNATIVE
,0 MCi/L
i'C MG/
SLUDGE T"
TRUCK -'
AI«-IV
BOO = 2?
^ ss = 20
OfcG - 10
ALTERATIVES n THP>J iv
-------
API
3OO = 1 .SCO MT,/L
SS = 1. 000 "O'l.
OtG = 550 "G/L
FLOW =.- »7 cu M/D
MOD)
AERATEC
LAGOON
SETTLING
=CNCS
i — ALTERNATIVE
6OD = 73 M6/L.
5S = 100 MG/L
= 55 HG/L
9CO - "1 ^G--;
oi . «.0 MG/L
OtG = 20 MG/L
ALTERNATIVE A;
E=FLUFNT
BOO = 2C MG/L
SS = 20 MGA.
Ct,tj = 10 MG/L
TREATSNT ALTERNATIVES V THRU VII
585
-------
In~Plant Technology
Examination of in-plant process suggests no additional method or proc-
edure to further reduce pollutant loads and wastewater volume for this
subcategory.
Fml-nf-Line Technology
At present, the v/astewater is hauled weekly to a municipal treatment
facility with no apparent adverse effects on the treatment system.
However the wastev/ater flow is considered too small to warrant recom-
mendation of biological treatment as a viable treatment alternative for
this subcategory.
Selection of Control and Treatment Technology
The model plant for this subcategcry was presented in Section V and had •
the following wa^tewater characteristics:'
Flow 1100 I/day (300 gal/day)
BOD 5700 mg/1
SS 296 mg/1
FOG 195 mg/1
Three treatment alternatives were selected for this subcategory and are
' discussed below.
Alternative A 15-j - This alternative consist:, of spray irrigation cf th.;
wastewaier which v.ould require 240 sq m (2600 sq ft) of land. The overall
benefit of this alternative is a 100 percent reduction of pollutants to
navigable waters.
Alternative A 15-11 - This alternative consists of land spreading of the
effluent. The daily wastev/ater would be allowed to flow onto a 0.05 ha
(0.12 acre) plot of land at a depth of 7.6 cm (3 in). The land would
be disced monthly. Tne overall benefit of chis alternative is a poiluri.-t:
reduction to navigable waters of 100 percent.
Alternative A 15-1 II - This alternative c.cns-:-.ts cf hauling the wastewa :•:•;•
to a municipal treatment system or to en app-ovec1 land disposal site.
SUBCATEGORY A 16 - NEW LARGE MALT BEVERAGE BREV.CRIES
The discussion in this section appli.es also to breweries in subcategories
A 17 and A 10, unless otherwise noted.
Technology
In-plant technology for waste reduction relates directly to those waste
streams a^scusscd in Section V.
566
-------
DRAFT
Existing In-Plant Technology - Spent grain liquor consists of liquid from
dcwatering screens and wet grain presses. In order to eliminate this waste
some plants feed wet spent grain into gas fired rotary dryers; however,
because of the high moisture content of the wet spent grain (80 to 90 percent)
fuel costs associated with this method of recovery can be quite high.
Plant 02A16 centrifuges spent grain liquor and returns it to the brewing
process. Although this alternative eliminates spent grain liquor as a
source of waste, the decision to return it to the process stream affects
the taste of the final product. This method, therefore, can not be recom-
mended for all brewers. If spent grain liquor is to be discharged, several
methods, all of which are primarily directed toward reducing concentrations
of suspended solids, exist for reducing the levels of waste. Any solids
produced would then be returned to ^iiiins drying. Many plants use vibrating
screens. Centrifuges have been shown to decrease suspended solids from 8
to 0.4 percent while producing a 25 percent cake. Plant 82A53 has taken •
spent grain liquor and passed it through a hydra-sieve. Reverse osmosis
and vacuum filtration were tested by Plant 82K04 but were found unfeasible:
As explained in Section V, lost beer is generated from filler-closers, a ,
and bottle crushers, and keg dumps. This beer n.ay be wholly or partially
collected and sent to multiple effect evaporators as it is at plant 8?A16.
Waste beer at plant 82A61 is collected and fed to a submerged combustion
concentrator. The more volatile alcohol is evaporated and the residue
added to spent grains. This procedure leads to a 50 to 60 percent redac-
tion in BOD loading from waste b^er. In general, waste reduction through
beer recovery involves first the collection then the disposal of lost beer.
In terms of economy, rejected cans and bottles are most easily recovered,
followed by lost beer from keg dumping which might be collected prior to
reaching floor drains, ana finally Deer on the floor around fillers and
seamers which is most effectively recovered by originally designing separate
drainage and collection systems.
Alkaline wastes are generated in the brew house and in packaging, the
latter resulting rrom caustic solutions used in bottle washers. In some
bottle washers caustic may be u?ed until exhausted, and sewered as often as
once per *ee<, but in many plants caustic is reclaimed. In this pro-
cedure caustic and label pulp are pumped to holding tan^s, screenec, re-
adjusted in make-up tanks, and returned tc the soaker. At periods
ranging from four to six months the contents of the soaker is sewered.
Some plants may add a final holding tank from which caustic is metered
to the sewer system.
Brewhouse caustic is not contaminated with label pulp. This caustic
may be durv.ped every two to four weeks or readjusted and reused for
longer periods. Here again, holding tanks may be utilized to prevent
shock loadings to treatment systems. Sulfuric acid may be added to
lower the pH, or carbon dioxide gas n,ay be mixed with the caustic in
recarbonation pits to produce the same effect.
587
-------
DRAFT
As described In Section V, spent hops, trub, and yeast may be hauled
away by truck or addtd to spent grains as an alternative to discharge to
sewers.
Suspended solids resulting from the discharge of diatomaceous earth may
amount to as much as 4400 kg (9200 Ib) per day in d large brewery such
as plant 82F04. Alternatives to discharge are decant tanks or vacuum
and pressure filters, with the resulting cake beirn hauled by truck.
Potential Io-^ant Technology - Foree (104) reports that the stabiliza-
tion of brewery press liquor by the submerged anaerobic filter process
results in COO removals of 90 percent at loading rates up to 6400 kg/
cu m (400 Ibs/cu ft) per day, however, no cost deta was presented. Stein
(58) tested the use of the submerged combustion e aporator for concen-
trating brewery spent grain liquor. DUP to the high fuel cost associated
with the evaporator it was considered not to be an economically viable
alternative to conventional multiple effect evaporation.
Other waste reduction possibi]- ties are total effluent pH control,
hydraulic equalization, and screening prior discharge. These are coiraon
methods of operation for those breweries maintaining treatment systems.
End-of-Line Technology
Knowledge of present waste treatment practices is limited to those two
breweries treating their own '.-.-astes, and to those municipal systems that
receive a substantial part of" their ^low from breweries. Schwartz and
Jones (105) reported the effects of brewery waste on nine municipal
treatnent systems receiving more than ten percent of their total wastes
from breweries and the method of treatment of each of the brev/eries is
itemized in Table 111. The performance of plants utilizing trickling
filters for complete secondary treatment has been below standard; low
BOD removal efficiencies and ndcr problems caused two of the facilities
to convert to variations of the activated sludge process. The use of
tricklinc filters after primary clarification can achieve 45 to 6n
percent "£00 removal althougn odor rray still be a problem. Eignt of
the nine plants use some form of the activated sludge process.
Sludge bulking lias been a major problem with plug-flow and conventional
activated slucJge systems, although the kraus process has controlled this
problem to some degree. The complete mix activated sludge system, opera too
at about 0.25 to 0.30 kg BOO/kg/MSS, should help maintain adequate dis-
solved oxygen levels throughout tne aeration basins. In a pilot plant
study, Schwartz and Jones (105) found that the sludge could be treated
aerobically without odor problems.
During the course of this study each of the two breweries that treat their
own wastes were visited and sampled. A flow diagram fo>- the waste treai~o;
-------
3RAF'
INFLUENT
SLUDGE
HOLOIMG
PAS IN
-------
DRAFT
TABLE 111
WASTE TREATMENT PLANTS HANDLING BREWERY WASTES
Treatment Haste
Plant Treatment
(Brewery) Sccuene_e_
A Clarificr
roughing fil-
ter, activa-
ted sludge
(contact stab-
ilization),
clarifier,
chlorination
B GMt chamber,
clarili?r
S'ludor (Krsus
process),
clarif-.pr,
chlorination
Settling basin
activated
sludge (Krav/s
process),
settling basin
D Grit cfiarcber,
settling
basin, acti-
vated sludge
(Kraus process),
settling basin,
Chlorination
E Pretreatrcr.t
(brewery
wastes)
equal uation
basin, clari-
fler, roughing
filter, c!-r.-if-
1er, tricklinq
filters.
ier. lagoons
Sludge
Disposal
Sequence
Asrobic dioostion
sludgp lagoon
Storage,
flotstioi, vacuum
filtration, land
disposal
Anaerobic digestion,
drying beds,
lard disposal
Flotation,
anaerobic digestion
sludge lagoon
Thickener
anaerobic cJi:sstijf;
dry:ng tcdo,
lanC disposal
Total
Flow,.
rr.qd
?.6S
4.6
6.6f<
J.5
Brewery
Flow,
mtjd
2.65
Approximate Treatment
Efficiencies, percent
Suspended
BOO Solid-;
60-85
30-70
90
85-90
1.2
0.7C 0.35
94
90
o.es
60-70
35-6C
-------
DRAFT
TABLE 111 (COflT'D)
Equalization
basins, clar-
Ificr.
roughing
filter, acti-
vated sludge,
(conventional),
clarificrs,
chlorination
Clsrificrs.
trickling
filters,
activated
sludge, settl-
ing basins
Flotation,
thickenecs.
vacuum filters,
land disposal
3.2
3.2
Anaerobic digestion
drying beds,
kiln drying,
sale as fertil1zer
20
1.5
Grit chambe1".
clarifiers,
roughing
filters, acti-
vated sludge
(contact stabil-
ization;, clarif-
iers, layoon
Aerobic digestion
sludge- lagonns,
spray irrigation
i.O
1.0
95
Clarifiers,
activated
sludge (com-
plete nix.),
clarificrs,
chlorinaticn
Thickeners,
spray irrigation
*9.6
•5.6
90+
Design Values
591
-------
DRAFT
BOO
Suspended Solids
Influent
Loading
(kg/day)
11.100
(24,600 Ib)
3.940
(8.690 Ib)
Percent
Removal
97.3
89.3
Effluent
Concentration
(mg/1)
56
78
Due to excellent in-plant control no equalization was required. Both
caustic and decant are rcetered into the treatment system. Wastes from
spent grain liquor were eliminated by direct drying in gas fired rotary
dryers, thus contributing to lower than mean waste loading compared to
other new large breweries. Primary clarification removed settleable
solids before roughing filters. No phosphorus adjustment was required
The trickling filters were operating at about 45 percent BOD removal at
hydraulic leading of 44 1/sq m (1 gprn/sc ft) with no objectionable odor.
At the tiire of the visit, the reaeration basin was operated as a. contact
basin. BOD removal through final clarification was approximately 90
percent. Approximately 5.4 kkg (6 ton) of sludge per day was being
spray irrigated over a 32 ha (BO acre) acre. Design loadings presentea
by McWhcrter (1C6) are given in Table 112. A flow diagram for the wasta
treatment system at plant 82A16 is shown in Figure 176. Mean operating
values for significant parameters over a one year period are as follows:
BOD
Suspended So: ,d?
Influent
Loading
(kg/day)
10,800
(23,800 Ib)
3/./0
(7.000 Ib;
Percent
Removal
94.6
87.7
Effluent
Concentration
(mg/1)
48
32
Due to excellent in-plant control, the '•aw waste BOD ratio delivered
to the treatment; system is approximately 17 percent of the mean for
other new large breweries. The treat"ent system is a high rate acti-
vated sludge plant using a modification of the Hatfield process. Equali-
sation is provided by a surge sasin wth four hours detention tire.
During plant visitation, the effluent from the surge tank by-passed the
primary clarifier ana entered the stabi 1 i zation section of the aerafior
basin. Loading rate for aeration is 21.3 kg/cu n/day (1.23 Ib/cu ft/day).
Thircy percent of the sludge from secondary clarifiers is returned to
the aeration oasins. Waste activate-;: sluoge is concentrated to 5.5 perccn*
solids in dissolved air flotation cells and J.jwatered on vacuum filters
used alternatively at 38 kg/sq m/hr (7.5 Ib/sq ft/hr). Ferric chloride
and lime are added to produce t filtered sludge containing 18 percent
solids. Durinn the visitation, filtra*e was being returned to the primary
clarifier after decanting. Approximately 12 kkg (13 ton) of sludge per
day is hauled by truck and spread on ccupany property.
592
-------
DRAFT
TABLE 112
TREATMENT PLANT DESIGN UNIT LOADINGS
Primary Clarifier
Trickling Filters
Activated Slud'.e
Final Clarifier
Polishing Lagoon
Aerobic Digestion
Sludge Spray Disposal
Surface Loading
Heir Loading
Detention
BOD Loading
Hydraulic Loading Including
Minimum
Maxima
BOO Loading
Aeration Capacit;
Return Sludge Rate
BOO/HLSS Patio
MLSS Concentration
Contact Bas'n
Reaeration Basin
Detention
Contact Casin
Reaeration Sasin
Surface Leading
Weir Load'ng
Detention
BOD Loading
Detention
Solids Retcnf.cn
MLSS Concentration
Liquid Loading
Solids Loading
Application interval
665 gpd/sq ft
5820 qpc'/ft
1.9 hr
300 lb/IOOO cu ft
Recircul;j:icn
1 gpm/sq ft
2 gpm/sq ft
100 lb/1000 cu ft
1.5 lb 0?/l5 BOD
50 percent
0.38
2000 irg/1
6000 mg/1
4.9 hr
10.5 hr
509 gpd/so ft
5950 gpd/sq ft
3.7 hr
50 Ib/day/acrc
15 days
10 days
15,000 7.Q/1
1 inch depth/Gppl icarien
0.1 Ib/sq ft/ecol icat::r.
1 to 7
593
-------
:.TAFT
INFLUENT
BAR
CHAMBER
EQUALIZATION
TANK
o
PRIMARY
Q-ARIFIER
^v SLUDGE
SLUtXiE HOLDING
TANK.
AERATION
STABILIZATION
SECTION
tCONTACT
SECTION
SECDNpARY
ARTFTTATTON
5LODGE
FILTERS
CAKE HAULEO
BY T-RUCK
1 76
-------
DRAR
Winilell (107) reports that dried sludcjc is a suitable ingredient when
substituted into animal feeds. In 1975 plant 82A16 will install a sludge
drying evaporator using vegetable oil as a carrier liquid. The oil will
then be removed by centrifuging so that the sludge can be used as animal
feed.
Potential technology for brewery waste is centered around the control
of sludge bulking caused by filamentous organisms. Eckenfelder (108
109) has reported the advantages of oxygen aeration in the activated
sludge system in order to maintain F:M ratios conducive to brewery waste.
Lewis (110) has reported on tests at plant 82A16 to apply pure oxygen
treatment through ceramic diffusers. At present, a biogrowth problen has
halted their consideration for use until further research is completed.
SELECTION Of CONTROL AND TREATMENT TECHNOLOGY
In Section V a model plant was developed for n
-------
TABLE 113;
SUMMARY OF TREATMENT TRAIN ALTERATIVES
Subcategory A 16
Treatment Train
Alternative
A 16-1 A
A 16-11 E1BCFHL
A 16-111 E13CFHLBN
A 16-IV E1BCFHLBNZ
A 16-V B1E1BCFHKQRSY
A 16-VI B1E1SCFHKQRSYBN
A 16-VII BiElBCFHKQRSYBNZ
A 16-VIII 31E1BCFHKQRYU
A 15-iX 31E1BCFHKQRYUBM
A 16-X E1E1BCFHKQRYURBNZ
A 16->I B1E1ECFHKQRT
A 1C-.X-I BlrllBCFHKQRTBN
A 16-XiII 31E1PCFHKQRTBNZ
Effluent BOO
(kg/cu w.}
10.55
0.?8
0.14
0.07
o.zs
0.14
0.07
0.28
0.14
O.CP
0.28
0.14
0.07
Effluent SS
(kg/cu m)
3.89
0.39
0.19
0.09
0.39
' 0.19
0.09
U.39
0.19
0.09
0.39
0.19
0.09
Percent BOD
Reduction
0
97.4
98.7
99.4
97.4
98.7
99.4
97.4
98.7
99.4
97,4
98.7
99.4
Percent SS
Reduction
0
90-0
95.0
97.6
90-0
95.0
97.6
90.0
95.0
97.6
90.0
95.0
97.6
-------
DRAF1
INFLUENT
BOD = 1900 MG/L
SS = 700 MG/U
PLOW = 8300 CU M/OAY (2.2 MSD >
A
SCREENING AND
GRIT REMOVAL
ADJUSTMENT
NUTRIENT
ADDITION
AERATED
SEALING
"ONCS
EOjAuIZAT
ION
JIJAL-
FILT?
MEDIA
--^ALTERNATIVE A16 II
BOD =50 MG/L
35 =70
Ai.TEtJT.iATI'/E A16 III
BOD =25 MG/L
SS = J5 MGx'L
CARBON
ALTERNATIVE
BOD - 1^ MG'
SS =1? ^-
iv EFFLUENT
TREA7MFM ALTERNAT J -JS ,1 '-(ROUGH I'
-------
DRAFT
INiFLUENT
BOO = '900 MG/L
ss = 700 MG/L
FLOW = 8300 CD M/DAY (2.2 MGO)
SCREENING AND
GRIT SEMOVAL
"LOW
EQUALIZATION
PH
ADJUSTMENT
NUTRIENT
ADf/lTION
ACTIVATED
SLUDGE
I!
SLUDGE
THICKENING
AEROBIC
DIGESTION
VACUUM
SANO
BEDS
3PR.AY
IRRIGATION
SECDNDARv
CLARIFICATION
' I'lfct I *
ALTERNATIVE
"• A 16-Vl I. X, X2 ; I
EFFLUENT
BOD = 50 MG/L
SS = 70 MG/L
TIVT
EFFLUENT
BOD - 25 MG/
SS = 35 MG/L
A
12 MG/L
S = 17 MG/L
CIGURE 178
ALTERNATIVES AI*-V THRCUGH
598
-------
DKAFT
effect of Alternative A 16-IV is a BOC reduction of 99.4 percent and a
suspended solids reduction of 97.6 percent.
Alternative A 16-V - This alternative consists of a screen and grit
chamber, pumping station, diffused air flow equalization with twenty-four
hour detention time, pH adjustment, nutrient addition, complete mix
activated sludge system with fixed surface aerators, secondary clarifiers,
control house, sludge thickening producing two percent solids, aerobic
digestion producing a 3.5 percent solids, vacuum filtration producing lb
percent solids, sludge storage, and truck hauling. The predicted effluent
concentrations are 50 rng/1 BOD and 70 mg/1 suspended solids. The overall
effect of Alternative A IG-V is a BOD reduction of 97.4 percent and a
suspended solids reduction of 90.0 percent.
Alternative A 16-VI - This alternative1 adds dual media filtration to the
treatment modules in Alternative A IG-V. The predicted effluent concen-
trations are 25 mg/1 BOO and 35 mg/1 suspended solids The overall effect
of Alternative A 16-VI is a BOD reduction of 98.7 percent and a suspended
solids reduction of 95.0 percent.
Ly? A 16_-V_I_[ - This alternative adds activated carbon to the
treatment modules in Alternative A 16-VI. The predicted effluent con-
centrations are 12 mg/1 BOD and 17 mg/1 suspended solids. The overall
effect of Alternative A 16-VI I is a BOO reduction of 99.4 percent and
a suspended olids reduction of 97.6 percent.
Alternatu 'iJ-VIII - This alternative replaces vacuum filtration in
AHerna'.v.-- ib-V with sludge storage and spray irrigation it the rate
of 50CO (ja1,. .jtric acre/day with land at $l660/acre. The predicted
effluent concentrations are 50 mg/1 HOD and 70 mg/1 suspended solids.
The overall effect, of Alternative A 16-VIU is a BOD reduction of 97, '1
percent and a suspended solids reduction of 90.0 percent.
A 1 tern alive A 16 - 1 X - This alternative adds dual media filtration to
the t red t men t moaules in Alternative A 16-VI 11. The predicted effluent
concentrations are 25 i..q/l B(. '. and 35 mo/1 suspended v.lids. The overal
effect of Alternative A 16-iX is .1 BOU reduction of 'J2.7 percent and a
suspended iolids reduction of 95.0 percent .
-_ Lv_°_ A j(irA - This alternative1 add1.. activated carbon tu the
treatment modules in Alternative i\ It'-lX. The predicted effluent con-
centrations are U1 mg/1 UOU and 17 nuj/l suspended solids. The overall
effect ot Alternative A 1G-X is a BOD reduction of 99.4 percent and a
sui.pt.nded r.olids reduction of 97.6 percent,
A1 tern.it K'f A Iti-xi - This altoniative replaces vacuum filtration in
Alternative A Ib-V with sand dryin.j l.pd'.; at a land cost of S.IS'JO/iicrp.
Dried sludge is trucked. The pn-duted efrluent concentrations are
599
-------
HKAFT
50 ing/1 BOU and 70 mg/1 suspended solids. The overall effect of Altor-
nativi* .. l';-XI is a BOD reduction of 97.4 percent and a suspended solids
reduction p." 97.4 percent.
Altei native A 16-XII - This alternative adds dual media filtration to
the t'-patment modules in alternative A 16-XI. The predicted effluent
concentrations are 25 mg/1 BOU and 35 mg/1 suspended- solids. The overall
effect of Alternative I is a QOD reduction of 98.7 percent and a suspended
solids reduction of 95.0 percent.
Alternative A 16-XIII - This alternative adds activated carbon to the
treatment nodules in Alternative A 16-XII. The predicted effluent concen-
trations are 12 mg/1 BOD and 17 mg/1 suspended solids. The overall effect
of Alternative A 16-XJII is a BOD reduction of 99.4 percent and a suspended
solids reduction of 97.6 percent.
SUBCATEi-ORY A 17 - OLD LARGE MALT BEVERAGE BREWERIES
In-plant technology for this subcategory is the same as that for Sub-
category A 16. No breweries in this subcategory operate end-of-line
treatment systems.
.Selection of Control and Treatment
In Section V a model plant was developed for old large breweries.
The raw waste was assumed to be as follows:
Flow (MGD)
BOD (mg/1)
SS (mg/1)
Total KN
PH
7.5
1700
670
34
2 to 12
Table 114 lists the effluent loading and the estimated operating efficiency
of each of the ten treatment trains for this subcategory as illustrated
In Figures 179 and 'i60.
Altornjtive A 17-1 - This alternative involves no added control or treat::-«?!i-
The efficiency of BOD and suspended solids removal is zero.
Alternative A 17-11 - This alternativp consi ts of a screen and grit
chamber, pumuing station, diffused air flow eqjalization with twenty-four
hour detention time, pH adjustment, nutrient addition, aerated lagoons,
settling ponas, arid sludge removal once every five years. The predicted
effluent concentrations are 50 mg/1 BOD and 70 mg/1 suspended solids. Tlu.-
overall effect of Alternative A 17-11 i-j a BOD reduction of 97.0 percent
and a si/spendt'd solids reduction of 89.5 percent.
600
-------
TABLE 114
SUWWRY OF TREATMENT TRAII! ALTERNATIVES
Subcategory A 17
en
o
Treatment Train
Alternative
A 17-1 A
A 17-11 E1BCFHL
A 17-111 E1SCFHIBN
A 17-IV E1BCFHLBNZ
A 17-V 51F1BCFHKQRSY
A 17-VI B1E1BCFHKQRSYBM
A 17-VtI BinBCFHKQRSYBNZ
A 17-VIII BIElBCFilKQRYU
A 17-IX BlElBCFMKQRYUBri
A 17-X B1E13CFHKQRYURBNZ
Effluent BOD
(kg/r m)
18.56
0.55
0.27
0.13
0.55
0.27
0.13
0.55
0.27
0.13
Effluent SS
(kg/cu m)
7.32
0.76
0.38
0.19
0.76
0.38
0.19
0.76
0.28
0.19
Percent BOO
Reduction
0
97.0
93. 5
99.3
97.0
98.5
99.3
97.0
98.5
99.3
Percent SS
Reduction
0
39.5
94.7
97.5
39.5
94.7
97.5
89.5
94.7
97.5
-------
ORAFT
INFLUENT
BOD = 1700 MG/L
SS = 670 f1G/L
FLOW = 28.000 CU MXDAr (7.5 MGD)
i
SCREENING AND
GRIT REMOVAL
FLOW EQUALIZATION
ADJUSTMENT
ADClTiCN
AERA'ED
-A60UN
SETTLING
"ONDS
-MEDIA
APDOf.
ALTERNATIVE'
toA 17-11
EFFLUENT
BGD = 50
ss - 7o MG/L
—•A 17-11'
HF'LUlvTJT
BOD - ,:rj
:s - 3'?
A 17-tV
r"r -= i? WJ/
". - 17 MG/L
SuBCA'l" L--- .--.7
ALTERNATIVES n THROUGH
-------
INFLUENT
BOO = 1700 MG/L
SS = 670 MG/L
PLOW = 28,000 CU M/DAY (7.5 MGD)
SCREENING AND
GRIT REMOVAL
(.1
*
I
AEROBIC
DIGESTION
SLUDGE
THICKENING
SAND DR
BEDS
VACUUM*
FlLTRATfCN
IRRIGATION
FLO*
CGUALlZATION
Ph
ADJUSTMENT
NUTRIENT
ADDITION
ACTIVATED
SLUDGE BASIS
SECONDARY
CLARIFICATION
DUAL-MEDIA
FILTRATION
ALTERNATIVE
«.A J7-V, VIII,
EFFLUENT
BOO = 50 MG/L
SS * 70 MG/L
ADSORPTION
•^A 17- VI . IX, X
PF^L'JENT
BOD = JS MG/l.
^ = 35 MG.-L
A 1 ^ - V I I I . X, XIII
BOD = 12 MG/L
'^S = I*
TREATMENT ALTE-".aTr/fc£, v THROUGH XIII
603
-------
DRAFT
A1tornatvyo A T/-111 - This alternative adds dual media filtration to
the treatment modules in Alternative A 17-11, The predicted effluent con-
centrations are 25 mg/1 BOD and 35 mg/1 suspended solids. The overall
effect of Alternative A 17-111 is a DOO reduction of 98.5 percent an9.3 percent and a suspended soli^i
reduction of 97.5 percent.
Alternative A 17-Vljj - This alternative replace; vacuum filtration in
Alternative A i'-V w:th sludge storage and ripray irrigation at the rate
of 5000 gal/ac'-e/dciy. The predicted effluent concentrations are 50 nig • !
BOD and 70 mg/1 'luspen^ed solids. The overall effect of Alternative A
17-VIII is a BOD reduction of 97.3 percent jnd n suspended solids reduc-
tion of 89.5 percent.
Alternative A V^'-IX - This alternative adds dual media filtration to tnr>
treatment nobles in Alternative A 17-VI]]. The predicted effluent con-
centrations oro ;_'!, i;!cj/l BOD and '5C> i-.-j/l :uspc;iucd solids. The overall
effect of A1 lernative A 17 is a BUD reduction of 98.5 percent and a susr-eM-^
solids reduction of 91.7 percent.
liO-1
-------
ons
DRAFT
Alternative A 17-X - This alternative adds activated carbon ti* the treat-
ment modules in Alternative A 17-1X. The predicted effluent conccntratio,,^
are 12 mg/1 HOD and 17 ng/1 suspended solids. The overall effect of
Alternative A 17-X is a liOD reduction of 99.3 percent and a suspended solids
reduction of 97.5 percent.
Sandbed drying was not deemed to be an economically feasible alternative
due to the large volume of sludge produced.
SUBCATEGORY t\ 18 - ALL OTHER MALT BEVERAGE BRFV.'EP.IES
In-plant technology for this subcategory is the same as that for
Subcategory A 16. No breweries in this subcategory operate end-
of-line treatment systems.
Selection of Control and Treatment Technology
In Section V a model plant was developed for all other breweries not
included in Subcatcgories A 16 or A 17. The raw waste was assumed
to be as follows:
Flow (MGD) 1.2
BOD (mg/1) 1400
SS (mg/1) 640
Total K'i 28
pH 2 to 12
Table 115 lists the effluent ''oading and the estimated operating
efficiency of each of the th..:.een treatment trains for this sub-
category as illustrated in Figures 181 and 182.
Alternative A "IS-1 - This alternative involves no added control or
Treatment. Tre"efficiency of BOD and suspended sol Ids removal is zero.
AT ternative A 19-11 - This alternative consists of a screen and grit
Chamber, pu;v.ping station, diffused air flow equalization with twenty-
four hour detention time, pH adjuct.rent, nutrient addition, aerated
lagoons, settling ponds, land at ''C'O per acre, and sludge removal
once every five years. The predicted effluent concentrations are
50 mg/1 BOD and 70 mg/1 suspended -.olids. The overall effect cf
Alternative A 18-11 is a BOD redur.fion of 96.
-------
o
TABLE 115
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
Subcategory A 18
Treatment Train
Alternative
A 18-t
A 18-11
A is-ni
A 13- IV
A 13-V
A 13-VI
A 13- VI I
A 18-VIII
A 18-1X
A 18-X
A 18-XI
A !8-X!!
A 18-XI!i
A
EiBCFHl
E13CFHLEN
ElBCFhLifiZ
31E^-:?i.KORSY
BiEIE-WSYSfl
BinBCFIKQRSYJHZ
BitlBCFHKORyiJ
BlEISCFMCaYUBN
B1E13CFHKQRYUF6MZ
BIEIBCFMKORT
Biei£CFHKQKTCN
BIEIECTHI' '"TPN7
Effluent BOD
(i-.g/cu m)
13.53
0.48
0.24
0.12
0.4S
0.24
C.12
0.43
0.24
0.12
0.48
0.?4
0.12
Effluent SS
(kg/cu m)
6.19
0.68
0.34
0.17
0.68
0.34
C.17
0.6R
0.3--
0.17
0.68
0.34
0 ]~
Percent BOD
Reduction
0
96.4
98.2
99.0
96.4
98.2
99.0
96.4
93.2
99.0
96.4
93.2
99.0
Percent SS
Reduction
0
S9.1
54.5
97.3
G9/I
96- S
97.3
89.1
94'. 5
97.3
89.1
94.5
S7.3
-------
DRAFT
6CO - UOO MG/L
SS = 6«0 MG/L
FLOW = 4500 CU M/DAY (1.2 MOD >
SCREENING
GRIT REMOVAL
PH
ADJUSTMENT
NUTFvItNl
ADDITION
. IHP'I
*•* 19- III
BOC s ?•! Mr,
;s = 13 Mr,, (.
BOD ' 12
5& i 17
TREATMENT ALTERNATIVES 11 THROUGH IV
-------
DRAFT
BOO = 1400 MG/L
SS = 640 MG/L
FLOW = *SOO CU M/DAY (1.2 MOD)
AEROBIC
DIGESTION
SLUDGE
THICKENING
J
SCREENING AND
Gfi IT REMOVAL
EQUAL IZATJON
PM
ADJUSTMENT
NOTR1ENT
ADC IT ICN
SAND DPVlNG
BEDS
VACUUM
IRRIGATION
MAt*.
SOD * 12
SS = 17
"LLCRPT;
T
I<9-V> 1
*-V, V]II, /
JFVT
BOD =•• 5C
*" A i«- vi, ix, *:
ROD T ZS *'&.-:.
r^- - n1) Mr,. ,
. 1C
Aia
ALTERNATIVES V 'MRQUGH Xlll
-------
DRAFT
Alternative A IS-IV - This alternative adds activated carbon to the
treatment modules In Alternative A 18-111. The predicted effluent
concentrations are 12 mg/1 000 and 17 mg/1 suspended solids. The
overall effect of Alternative A 18-IV 1s a BOD reduction of 99.0
percent and a suspended solids reduction of 97.3 percent.
Alternative A 18-V - This alternative consists of a screen and grit
chamber, pumping station, diffused air flow equalization with twenty-
four hour detention time, pH adjustment, nutrient addition, complete
mix activated sludge system with fixed surface aerators, secondary
clarlfiers, control house, sludge thickening producing two percent
solids, aerobic digestion producing 3.5 percent solids, vacuum fil-
tration producing 15 percent solids, sludge storage, truck hauling,
and land at 516,000 per acre. The predicted effluent concentrations
are 50 mg/1 BOD and 70 mg/1 suspended solids. The overall effect
of Alternative A 18-V 1s a BOD reduction of 96.4 percent and a
Su tended solids reduction of 89.1 percent.
Alternative A 18-VI - This alternative adds dual media filtration to
the treatment modules in Alternative A 18-V. The predicted effluent
concentrations are 25 mg/1 BOD and 35 mg/1 suspended solids. The
overall effect of Alternative A 18-VI 1s a EOD reduction of 98.2
percent and a suspended solids reduction of 94.S percent.
Alternative A 18-VII - This alternative adds activated carbon to the
treatment rr-.odules to Alternative A 18-VI. The predicted effluent
concentrations are 12 mg/1 BOD and 17 ing/1 suspended solids. The
overall effect of Alternative A 18-VI' is <) BOD reduction of 99.0
percent and a suspended solids reduction of 97,3 percent.
AlternativeA 18-VIII • This alternative replaces vacuum filtration
TrTATter native A^TtfTv/ith ;ludge ttorage and spray irrigation. The
predicted effluent concentrations are 5C mg/1 BOD and 70 mg/1 suspended
solids. The c-erall effect of Alternative A IS-VIII is a BOD reduction
of 96.4 percent and a sjspendeJ solids reduction of 89.1 percent.
Alternative A 18-TX - This alternative adds dual media filtration
to the treatment ir.adulcs in Alternative A 18-VIII. The predicted
effluent concentrations are 25 mg/1 BOP and 35 mq/1 suspended solid'..
The overall effect of Alternative A H:-'X is a BOD reduction of 98.2
percent and a suspended solids reduction of ?4.5 percent.
Alternative & IP-x - This alternativp aids activated carbon to the
treatment rocuios vi Alternative A IB-IX. The predicted effluent
concentrations are 1,? mg/1 OOD and 17 nig/I suspended sol'ids. The
overall effect of Alternative A 18-X is a GOD reduction of 99.0
percent and a suspended solids reduction of 97.3 percent.
609
-------
DRAFT
Alternative A 18-XI - This alternative replaces vacuum filtration in
After-native. A 10-V with sand drying beds. Dried sludge is hauled by
truck. The predicted effluent concentrations are 50 mg/1 BOD and 70
mg/1 suspended solids. The overall effoct of Alternative A 18-XI is a
BOD reduction of 96.4 percent and a suspended solids reduction of 96.-;
percent.
Alternative_A 18-XIL - This alternative adds dual media filtration to
the treatment modules in Alternative A 18-XI. The predicted effluent
concentrations are 25 mg/1 GOD and 35 mg/1 suspended solids. The
overall e ^ct of Alternative A 18-XII is a BOD reduction of S8.2
percent ana a suspended solids reduction of 94.5 percent.
Alternative A 18-XIII - This alternative adds activated carbon to
the treatment modules in Alternative A 18-XII. The predicted effluent
concentrations are 12 mg/1 BCD and 17 mg/1 suspended solids. The
overall effect of Alternative A 18-XI1I is a BCD reduction of 99.0
percent and a suspended solids reduction of 97.3 percent.
SLBCATEGORY A 19 - MALT
Existing In-Plant Technology
As discussed in Section V, steeping and germinating create soluble
organic wastes which may contain high levels of suspended solids if
not prooerly screened. Plant d3A13 has installed a 30 mesh vibrating
chain link screen prior to final discharge. This effectively removes
all the sprouts in the ivaste stream in addition to creating a marketable
by-product. The elimination of these solids enhances biological treatment.
Potential In-Plant Technology
Potential waste Deduction centers around good in-plant supervision.
For example, the number of steep changes and the amount of water required
is, of course, a quality dec'icion. Djnrvj i^teapip^, nc'-ever, cloie
operator- supervision can minimize t,he amount of overflow in the steep
tanks without affecting quality standards. Water reduction can also be
exercised in germination by maintaining a closed spray-anc-refrigeratiur
cycle so that only makeup is required. While both of these measures
are undoubtedly practiced by some nu listers it is felt that these are
areas of possible pollution abatement for other members of the industry.
End-gf-Line Technology
There is currently one one separate "alt house treating its own waste.
Figure 133 illustrates this treatment system as it now operates. Current
removal rates are 97.7 percent BOD 3rd 91.6 percent suspended solids.
Originally t!ie final clorifier en'luont was being discharged to navigable
waters with only a 77 percent reducf.cn of BOD. In 1971 the aerated laqc^
w«?re added on to the original systu;".. Approximate unit effluents as of
August 1974 are as follows:
610
-------
CMAfT
DIGESTED
SLUDGE
SPRAYED
scfigai
TRICKLING
FILTER
AERATED
LAGOON
'^'ICKLIKIG
FILTER
AEPATTiD
LAGOON
CLARIFIgR
AERATED
LAGOON
IS SUBMERGED
AERATORS
DEPTHS 4 . 6 M
DETENTION
SUBMERGED
HELICAL
AERATORS
4.6 M
DENT ION
73
AERATORS
<* .6 M
DENT ION =
5 DAYS
1
1
AIR = 96 CU
LACOOsI
DETENTION
h
I—
= 1 DAY
Y
POLISHtMC.
LASflgS
163
CCNTROL AND TREATVpfT
83AJ3
-------
DRAFT
SS
Influent 800 84.2
Primary Filter 450 67.4
Secondary Filter 210 251.4
Clarifier 200 51.0 '.
Lagoons 18 7
No sludge disposal has been required during the last two years although
spray irrigation facilities are available.
According to Isaac (62) the two principal biological processes used
for the treatment of malting wastes outside the United States are
bacteria beds (trickling filters) and activated sludge. The bacteria
bed systrm
-------
01
u*
TABLE 116
SUMMARY OF TREATMENT TRAIN ALTERNATIVES - SUBCATEGORY A 19
MALT
ALTERNATIVE
A19
A19
A19
A19
A19
AI9
A19
- I
- II
- Ill
- IV
- V
- VI
- Vll
EFFLUENT
BOO
KG/KKG
4.55
0.22
0.11
o!?2
0.11
0.2?
0.11
EFFLUENT
SS
KG/KKG
0.77
0.13
06
13
06
0.13
0.06
PERCENT
BOD
REMOVAL
0
95,
97.
95.
97,
95,
PERCENT
SS
REMOVAL
0
83.
92,
83
92,
83.
96.6
92.2
-------
DRAFT
FLOW a 2.590 CU M/DAY f0.665 MOD)
BOO = 6,15 MG/L
SS = 10ft MG/L
N = 17 MG/L
P = 7 MG/L
PLOW
EQUALIZATION
ADDITION
AERATED
LAGOON
SETTLING
ALTEPN»TIVE
A 19-11
_ EFFLUENT
COD = 30 MG/L
SS = 17 MG/L
SliDCATEGOPY *19
-u~Pr^TiVE5 II THRU III
614
-------
DRAFT
FLOW = 2,590 CU M/DAV
BOO » 615 MG/L
SS = 104 MG/L
N = 17 MG/L
P = 7 MG/L I
-------
DRAFT
settling ponds mth dredging every five years. The predicted treated
effluent concentrations ore 30 nig/I COD and 17 mg/1 suspended solids.
The overall effect of Alternative A 19-IJ is a BOD reduction of 95.2
percent and a suspended solids reduction of 83.1 percent.
Alternative A 19 - _IIj_ - This alternative consists of adding dual media
TTItration to the treatment chain in Alternative A 19-11. The predicted
treated effluent concentrations are 15 mg/1 BOD and 8 mg/1 suspended solidi.
The overall effect of Alternative A 19-111 is a reduction of 97.6 percent
Alternative A 19 - IV - This alternative consists of a control house,
pumping station, flow equalization, nutrient addition in the form of
43.24 kg/day (95.32 Ib/day) anhydrous ammonia, a complete mix activated
sludge system, sludge thickening, aerobic digestion, and spray irrigation.
The predicted treated effluent concentrations ore 30 mg/1 BOD and 17 n.g/1
suspended solids, The overall effect of Alternative A 19-IV is a reduc-
tion of 95.2 percent of the BOD and 83.1 percent of the suspended solids'.
Alternative A. 19 - V - This alternative consists of adding dual media
filtration to the treatment chain in Alternative A 19-IV. The predicted
treated effluent concentrations are 15 mg/1 COD and 8 mg/1 suspended
solids. The overall effect of Alternative A 19-V is 96.6 percent GOD
reduction and 92.2 suspended solids reduction.
Alternative A 19 - VI - This alternative replaces spray irrigation of
sludge in Alternative A 19-IV with sanclbed drying and truck hauling.
The predicted treated effluent concentrations are 30 mg/1 BOD and 17 mg/1
suspended solids. The overall effect of Alternative A 19-V] is a reduction
of 95.2 percent of the BOD and 83.1 percent of the suspended solids.
Alternative A 19 - VII - This alternative adds dual media filtration to
the treatment chain in Alternative A 19-VI. The predicted treated effluent
concentrations are 5 mg/1 BOD and 8 mg/1 suspended solids. The overall
effect of Alternative A 19-VII is a reduction of 95.2 percent for BOD
and a reduction of 92.2 percent for suspended solids.
SUBCATI'TEV A 20 - mfOIES WITHOUT STILLS
In-Plant Technology
As described in Section V. stems, pressed pomace, and filter aid arp
assumed to be separated from waste'-ntor to be sent to treatment
facilities. If these an? properly disposed, the lees from racking
represent the greatest potential source of high strength waste. If
tanks are fully drained and lees p,.r,r,<-il through filter presses or
centrifuges, little waste results. If Ices are sewered, the strength
o* the waste will change appreciably. Separate water metnrs should be
instailuj MI ai1 major departments of the winery such as crushing,
fermentation, pressing and bottlir.q. P-y accurately identifying water
usage, both reduction procedures and future planning will be benefited.
616
-------
DRAFT
Water pressure regulators and pressure nozzles mny also be used to
reduce the quantity of water used for clc.'inup. Sweeping rather than,
or prior to, hosing down floors m?y be applicable in some areas of
the winery. Reused water from tank cleaning may be used as makeup
wash water for other nearby tanks. Slowdown from water-cooled re-
frigeration units may also be reuied. Wastewater which Is not suitable
for in-plant reuse may be suitable for such areas as, lawn and land-
s caping, vineyard frost protection, vineyard irrigation, end vineyard
heat protection.
End-ot--Line Technology
As described in Section V the effluent from wineries in this sub-
category is a medium to high strength organic waste deficient in
nitrogen and phosphorus. It is amenable to treatment by a number of
alternatives including aerattd lagoons, biological discs, activated
sludge, und land irrigation. During the course of this study six
wineries with treatment systems v/ere visited. Figures 186 through 191
show a block diagram of each of these systems.
Plant 84*10 utilizes four ponds, each of 5700 cu m (1.5 MG) volume
with a total aeration capacity of 27 kw (36 hp), According to Ryder
(111) average effluent concentrations were 22 ng/1 30D and 29 mg/1
suspended solids in March 1972. The treated effluent is utilized to
irrigate approximately 6 ha (15 ac) of landscaped areas adjacent to
the winery. A similar system operated by the sane company has achieved
BOD removal rates of 97.2 percent. P-- ' 34*09 has recently completed
construction of a two lagoon system as shuwn in Figure (187). The
effluent from this system will also be used for winery irrigation.
Toffle.Tiire, et_ a_1_ (112) reports that the dual lagoon system as it was
originally constructed at Plant 8J*03 achieved a BOD removal of 96
percent. According to Rice (113) SOD removal re'nain^d between 94.7
and 95.6 percent from 1971 through 19/M. Suspended solids levels in
the aerated lagoon remained high due to bacterial and algal growths.
In general, lagoon systems per for") well with winery waste when suf-
ficient land is available. Little suDervisio.i is required and large
volumes of water1 iCt as m buffei- for fluctuations in pri and waste concer
trations.
Two activated sludge systems are brinq used to treat, winery waste ex-
clusively. Figures (IfiS) and (189) show Mock diagrams of each system.
Annual opera Ing efficiencies are a:, follows:
Plant Plant
B4AQ1 84A03
BOD Removal 97.3 97.6
Suspended Solids
Removal 89.5 C6.5
617
-------
IffLU&fT.
PH
*D JUS WENT
SURFACE AERATWS
VOLUME = 5 TOO CU M
DEPTH = 3M
L>GQCM
SURFACE AERATORS
VOLUME = 5700 CU M
DEPTH = SH
LAGOON I?
•JLRFACE AERATORS
VOLUME - 5700 CU M
DEPTH - 3M
SURFACE AERATCKS I
VOLUME = 5700 CU M!
DEPTH = 3M I
LAGQCM
FiGURE l«fi
COr,7T--;jL AJD TREATMENT
-------
INFLUENT
VTXCMF = I3.orr, ,-u M
DEPTH = } M
n AERATORS
= 13.000 CO
D6PTH = 3 M
LAGDTfl
-------
DRAFT
*lVI>.
i ^w*.
-------
NUTRJENt AND
PM
I r* I 'Jl M F
SOLIDS HAULED
IU VINcYARD
-» EFFLUENT
FIGURE | &,
AND TTfcATMEMT
ft ANT s<... 01
-------
CONTROL Arc rREflT?>Erir
-------
DRAFT
"T91ENT
AND PH
ADJUSTMHNT
EQUALIZATION
TANK
12 CU M/WIN
VOLUME =
472 CU M >
B^ACTOff
AERATION =
30 CU M/MJN
VCX.UME =
400 CU M
REACTOR
AERATION =
30 CU M/MIN
VOLUME *
400 CU M
CLARIF1EP
SLUDGE
191
AETJ4TICN =
40 CU M/M1N
VOLUME =
cu M
^LJDGF
DISPOSAL
TO LANCF1LL
CDNTPCL
r PLANT e
-------
DRAFT
On a short term basis, considerably higher suspended solids removals
have been achieved by Plant C4A03. Tertiary treatment by sand filtra-
tion at Plant 84A01 has not achieved the predicted 50 percent reduc-
tion, hence suspended solids removal is also somewhat lower than ex-
pected. Both plants provide aerobic digestion for sludge, although
Infrequent wasting of activated sludge has been required. Close
operational control of pH is required, especially at Plant 84A01 where
the aeration volume of 2360 cu m (624,000 gal) is relatively small.
A rotating biological disc has been used at Plant 84*02. A flow diagram
of the complete system is shown in Figure 190. The original pilot plant
study (114) indicated a BOD removal of 95 percent at a loading rate of
2.8 1 (0.75 gal) per day. Data collected during this study indicated
BOD and suspended solids removals at 93.0 and 56.1 percent, respectively.
Once again, the low level of suspended solids removal is due to the poor •
operation of the sand filter; in many cases solids were increased by
filtration.
Several wineries in this s-ubcategory discharge treated waste to irri-
gation systems. Due to climate and soil permeability, this method of
disposal is almost exlcusively practiced in California. A further dis-
cussion is included in Subcategory 21 fcr those wineries disposing stil-
lage by intermittent irrigation.
Selection of Control and Treatment Technology
In Section V a model plant v:as developed for the manufacturing of wine
in wineries not utilizing stills. It was assumed that th*1 mode: plant
provided screening of its wastev;ater prior to discharge, "he raw
wastewater characteristics after screening were assumed to be as follows:
Crushing Season Processing Season
Flow 0.073 MGD 0.060 MGD
BOD 2300 ir.g/1 1200 mg/1
SS 760 mg/1 420 rcg/1
P 13 mg/1 7 mg/1
Total N 7 mg/1 4 mg/1
Due to the fact that, larger flow and pollutant loadings are generated
during the crushing season, the treatment system designs are based on
the crushing season values presented above. Tables 117 (Crushing Seasmj
and 113 (Processing Season) list the pollutant effluent loading and
the estimated operating efficiency of each of the ten treatment alter-
natives selected for this subcategory. It should be noted that the
pollutant, concentrations in the treated effluent remain the same during
the crushing and processing season. The treatment alternatives presented
below are illustrated in Figures 102 and 393.
624
-------
TABLE 117
SUMMARY OF TREATMENT TRAIN ALTERNATIVES - SUBCATEGCRY A 20
WINERIES (CRUSHING SEASON)
ro
tn
Alternative
A 20-1
A 20-11
A 20-111
A 20- IV
A 20-V
A 20-VI
A 20-V I I
A 20-VIII
A 20-IX
A 20-X
Effluent
BOD
kg/kkg
3.57
0.77
0.38
0.23
0.77
0.38
0.?3
0.77
0.33
0.23
Effluent
SS
kg/kkq
1.16
0.115
0.054
0.031
0.115
0.054
0.031
0.115
0.054
0.031
Percent
BOD
removed
0
97.8
98.9
99.4
97.8
93.9
99.4
97.8
98.9
99.4
Percent
SS
removed
0
90.1
95.3
97.3
90.1
95.3
97.3
90.1
95.3
97.3
-------
TABLE 118
SUMMARV OF TREATMENT TRAIN ALTERNATIVES - SUBCATEGORY A 20
UINERIES (NON-CRUSHING SEASON)
en
rsj
O
Alternative
A 20-1
A 20-11
A 20- III
A 20-IV
A 20-V
A 20- VI
A 20-VII
A 20-VIK
A 2U-IX
A 20-X
Effluent
BOO
kg/ cu m
6.63
0.277
0.133
0.033
0.277
0.133
O.G33
0.277
O.U8
0.083
Effluent
SS
kg/cu m
2.33
0.415
0.194
0.111
0.415
0.194
0.111
0.415
0.194
0.111
Percent
BOD
removed
0
95.8
97.9
93.7
95.8
97.9
98.7
95.8
97.9
98.7
Percent
SS
removed
0
82.2
91.7
95.2
82.2
91 . 7
95.2
82.2
91.7
95.2
-------
DRAFT
FLOW = 276 CU M/DAY (0.073 MOO>
BOD = 2,300 MG/L
SS = 760 MG/L
N = 7 MG/L
P = 13 MG/L
EQUALIZATION
PH
SAND DRYING
BEDS
ADJUSTMENT
NUTRIENT
ADDITION
AEROBIC
DIGESTION
ACTIVATED
SLUDGE BASIN
SLUDGE
THICKENING
1.
I
SECONDARY
CLARIFICATION
SLUDGE
STORAGE
-MED I A
DUAL-MEDIA ALTERNATIVES
FILTRATION A 20-11, V
:-_-_» EFFLUENT
BOD = SO MG/L
SS = 75 MG/L
ALTERNATIVES
A 20-1II. VI
* EFFLUENT
BOD =25 MG/L
SS = 35 MG/L
ALTERNATIVES
A 20-IV, VII
«• EFFLUENT
BOD = 15 MG/L
ss = 20 MG/L
i.
CAPECt.'
ADSORPTION
FIGURE
TREATMENT ALTERNATIVES II THRU VII
527
-------
DRAFT
FLOW = 276 CU M/OAY
BOD = 2,300 MG/L
SS a 760 MG/L
N = 7 MG/L
P = 13 MG/L
(0.073 MGO)
EQUAL IZAT:ON
Ph
J
ADJUSTMENT
NUTS! £
ADC1
LAJAL. MEDIA I
FI"TR!Z1-.L
ALTERNATIVE
A 20-VIII
EFFLUENT
SOD - s:- MG/L
'S3 = 7J MG/L
^ALTERNATIVE
* A 20-IX
EFFLUENT
BOD = 25 MG/L
iS = 35 MG/L
BOO = 15
SS = 20 MG/L
E 103
SU'BCATEGORY
ALTERATIVES VIII THRU X
628
-------
DRAFT
Alternative A 20-1 - This aHernative provides no additional treatment
to the screened wastewa ter.
Alternative A 20-II - This alternative consists of a control house, a
pumping station, flow equalization, nutrient addition, acid and caustic
neutralization, a complete-mix activated sludge system, sludge thickening,
aerobic digestion, dual media filtration, a sludge holding tank and spray
irrigation of digcstor sludge. Flow equalization is provided to dampen
the effect of shock loadings to t.he activated sludge system. Nitrogen
and phosphorus addition is provided to increase the deficient raw
wastewater BOD.-N.-P ratio of 100:0.3:0.57 to the required 100:5:1. Both
acid and caustic neutralization are provided to accommodate the model
plants pH range of 4.0 to 10.0. The combined efficiency of the activated
sludge system and dual media filtration module is estimated at 97.8
percent during the crushing season and 95.8 percent during the processing"
season. Sludge thickening and aerobic digestion are orovided to decrease^
the volume of sludge which is subsequently spray irr-jgated.
The overall benefit of this alternative is a BOD reduction of 97.8 per-
cent and a suspended solids reduction of 90.1 percent during the crush-
ing season and 95.8 and 82.2 percent respectively during the processing
season.
Alternative A 20-1II - This alternative is identical to Alternative
A 20-11 except an additional dual media filtration module is provided
to further reduce the effluent BOD and suspended solids loadings.
Tlie overall effect of this alternative is a BCD reduction of 98.9 per-
cent a suspended solids reduction of 95.3 percent during the crushing
season and 97.9 and 91.7 percent, respectively, during the processing
searon.
Alternative A'gfMV - Thfs alternative is identical to Alternative A 20-1II
with the addition of activated carbon adsorption to further reduce the
effluent BOD and suspended solids loadings,
The overall benefit or this alternative is a BOO reduction of 99.4
percent and a suspended solids reduction of 97.3 percent during crush-
ing season and 98.7 and 95.2 percent, respectively, during the proces-
sing season.
Al ternativo A 20-V - This alternative replaces the spray irrigation of
digestor sludge in Alternative A 20-11 will) sand drying beds. The
overall benefit of tint alternative is a BOD reduction of 97.8 per-
cent and a suspended solids reduction of 90.1 percent during the
crushing season and 95.8 and &2.2 percent, respectively, during the
processing season.
629
-------
DRAFT
Alternative A 20-VI - This alternative is identical to Alternative
A20-V with the addition of dual media filtration. The overall benefit
Of this alternative is a BOD reduction of 98.9 percent and a suspended
solids reduction of 95.3 percent during crushing season and 97.9 and
91.7 percent, respectively, during processing season.
Alternative A 2Q-VII - This alternative is identical to Alternative
A 20- VI with the addition of activated carbon adsorption.
The overall benefit of this alternative is a BOD reduction of 99.4 per-
cent and a suspended solids reduction of 97.3 percent during crushing
season and 98.7 and 95.2 percent, respectively, during processing sea:cn.
Alternative A 20- VI 1 1 - This alternative consists of a pumping station,
Tlow equal i zation, nutrient addition, acid and caustic neutralization,
aerated lagoons, stabi 1 izjtion ponds, and dual media filtration. Flow
equalization, nutrient addition arid neutralization provide the same
benefits as previously discussed in Alternative A 20-11. The aeroted
lagoon and dual media filter would be expected to provide the same
treatment efficiency as the activated sludye system and dual media
filtration module of Alternatives A 20-11 und A 2C-V.
The overall benefit of this alternative is a BOD recjction of 97.8
percent and a suspended solids reduction of 90.1 percent during crush-
ing season and 95.8 and 82.2 percent, respectively, during processing
season.
Al ternative A 20- IX - Thi-j alternative is identical to Alternative
A 20- VI II with the addition of a second dual media filtration module.
The overall benefit of this alternative is a BOD reductic" of 98.9
percent and a suspended solids reduction of 95.3 percent a.irinq crushing
season and 97.9 and 91.7 percent, respeLli vely, during processing season.
Alternative A>(KX - This alternativp is identical to Alternative
A";2cPlX wi'th the addition of activated carbon adsorption
The overall benefit of this alternative is a BOD reduction of 99.4
percent and a suspended solids reduction of 97.3 percent durincj crushinn
season and 98.7 and 95.2 percent, respectively, durincj processing son-.;;n.
SUOCATLC.ORY A 21 - HII.'ERIES i.'ITt! :T : Lj. o
In-Plant Technology
During the processing season the same methods of In-plant reduction
are applicable for thi; subcaiegory ar, for wineries without stills.
630
-------
DRAFT
During crushing, however, stillago disposal requires additional method:;
of conservation.
Physical Methods - The volume of the still age may be reduced 15 percent
by using indirect heat rather than live stsam in the still. In addition,
the amount of water used in the preparation of distilling material will
have a direct effect on the total volume of stillage. The Coast Labora-
tories (115) recommended maintaining distilling material at eight percent
alcohol by volume in order to reduce distilling and handling costs. In
a separate report (116) the following methods of separating solids from
stillage were investigated:
1 . Settling by gravity
2. Filtration
3. Screening
4. Centrifuging
5. Flocculation L>y chemicals
Centrifuginq and screening were proven to be the most effective and all
wineries we:-e advised to use one of these two types of mechanical
Chemical Methods - Solids removal by chemical means has been investigated
by Vaughn and Marsh (117) dnd Schroeder (118). Liming causes the suspe^.
solids £nd colloidal material to settle as a sludge. This treatment pre-
cipitates the tartrates and reduces the BOD by 50 percent, althougn de-
wfitenng the sludge may be difficult. "lot flenrire (119) indicates, how?1. «r
that this problem can be overcome. Detart-at'on, coagulation, and floe-
culation with polyelectrolyte addition were all considered to be less
effective tnan centrifugation.
End-of-Line Technology
In consideration of the seasonal nature of stillage wastes, the location.
climate, and soil of wineries di scharqi'ig stillage, ana the lack of any
demonstrated cost effective alternative, it is considered that waste di---
posal by intermittent irrigation is a satisfactory method of trea^irer.t
provided no
-------
DRAFT
Studies by York (124, 125, 126) indicate that intermittent irrigation
has no deleterious effect on the :,oi I as measured by salt content, nitrate
concentration, and soil clogging, imporviousness , and impacting. A study
by the City of Fresno, California (127) indicates that some degradation
of well water exists, but that this may be controlled by proper measures,
i.e., control of nitrate leaching by elimination of ammonia, removing
leathers, and nitrogen-harvesting of winter crops.
Anaerobic treatment of wine stillage appears to be feasible, although
further treatment would be required. Stander (128) experimented with
a clarigester with 7.2 days detention time. The system resulted in a
COD removal of 96 percent. Tofflemire (119) noted, however, that ammonia
in the digester would cause an additional oxygen demand in the receiving
water. Chadwick and Schroeder (129) studied both aerobic and anaerobic
treatment of settled stillage on a pilot plant scale. Effluent of 1,100
to 2,500 mg/1 of COD, which appeared to be nonbiodegradable, existed after
treatment. Schroeder (118) suggested that centrifugation followed by tv.'o.
aerated lagoons and a stabilization pond in series will produce effluent;
of 75 mg/1 BOD, but ncted that biological treatment will not substantial",'
alter the salt content of tne wastev:ater. Since the resultant '.•/astcv.'a'.crr
will probably be used for irrigation, direct land disposal by interim tte-it
irrigation is a more cost-effective method of disposal.
Selection of Control and Treatment Technology
In Section V a model plant was developed for wineries with stills. The
raw waste volume due to crushing and distilling was assumed to be 16GO GJ
(0.443 MfiD). The operati.,o efficiency of th3 treatment chain selected 'cr
this subcateqory is 100 percent BCD and suspended solids renoval .
Alternative A 21-1 - This alternative provides no additional treatment
to the raw waste.
Alternative A 21-11 - This alternative consists of a holding tank purr,;:'.:
station, 2..', km of pipeline, and land at 4,100/ha {'1 .f-CO/ji'T > . !>..• • -.:'
flow is applied at a r.ite of T?5 ci; r;Avee>-/'wi ""COiCOO if:l A ".••:••:/ acre ' •
Leveling and discing are assumed to cost J-'tlLYyear. !ia (il^t/yc-ar/acrc) .
SUBCATEGURY A 22 - GRAIN Dir/nLLFP.S Wf.P.ATT;;G STIL LACE" KL'COVnY ^YSTF." ' .
The discussion in this section applies to both S-jbcategory A 22 and "ui/-
category A 23 (except for evaporation).
In-Plont Technology
As described in Section V, many plants operate barometric condenser svs'.-i'-'s
for mash cookers, mash coolers, and evaporators and, as reported by plan:..
8SA01 and S5A29, this can amount to as riucn as 20 percent of the total i\ :';
load. By replacing the barometric condensers with surface condensers tin-.
load can be eliminated from the systcw. This water may then be recycled
for other in-plant uses.
632
-------
DRAFT
Since the evaporator condensate contributes a majority of the total plant
waste, any possible reductions in this area should not be overlooked. Added
instrumentation for automatic operation of evopo»ators will tend to reduce
the load. Replacing worn out evaporator sections wtih newer designs will
also reduce the waste. The load to the evaporator can be reduced by using
spent stillage as a sterilizing medium and by using indirect heating rather
than live steam in the still.
Water usage can be considerably reduced by recycling non-contact waters.
Many plants have, of course, already made such changes. Mash cooling wator,
still condenser wuter, and refrigeration condenser water are all suitable
quality for other in-plant uses.
End-of-line Technology
Grain distillery wastewater treatment encompasses a wide range of bio-
logical proce.ves. These include aeration lagoon, trickling filter, and-
activated sludge -.ystens. During the course of ths study eleven of thevj
systems were visited. Table- 119 summarizes the type and efficiency of c^-_'-.
of these systems. Figures 194 through 201 present flow diagrams for eacK
of these systems.
Many plants operate variations of the aerated lagoon. Plants 82A02 .ind
82A22 both have ore aerated lagoon and ore stabilization pond. Althouj"
both systems had comprehensive effluer.t data, the influent was not reg^lo--'..
monitored. Both maintained ^proximately 30 days detention followed bv
chlorination (since sanitary sewage was present). Plants 8&A04 and 85/T"
employ as many as five laoootv: in series to achieve as much as nine ronr.' •
detention. Plant 85AZ7 has -,ni tailed sjomerged helical aerators. This
treatment system was only receiving one-third the expected load during ti~?
period of 92.7 percent BCJ removal. In general, BOD removals of 96 pore.-.'.
can be expected from these- types of systems. Suspended solids removals
are somewhat lov;er than expected c!ue to the growth of algae m the staiM--'-
zation ponds. Sand filtration has been demonstrated to improve susper, ;c-:
solidi removalj Lonsiderajly :n buch coses.
Several activated sludge systems exir,t throucjho'Jt the production rpecl--.-
in the industry. Plants C/SA1/' and or.A].;' installed -ock filters in !?«.•.
These systems operated we'. 1 into the.- "H,!-1 i-oO'i when the filter nocli-:-
began to break do\.n. Ai that tine U \:a?, decided to upgrade the systry
by adding contoct stabilization. Plant 3uA07, Figure 197, operates a io-di-;c systcn cprrift-d by plant 85A01. Tohmaas arc'
Koehrsen (78) have compared tr.e eff'cicnciev of the two types of system,
during different stages of operation. In general, the activated s'ludy;
process demonstrated advantages over the bio-disc based on economics,
treatment performance, and ability to .'\indle shock loado. Expected re-
movals for activated sludge systems are 96 percent for BOD and 92 percent
633
-------
DRAFT
TAKLE 119
TREATMENT SYSTEM SUMMARY
SU8CATECORY A22
TREATMENT SYSTEM PERCENT REMOVAL
PLANT DESCRIPTION BOD SS
85A01 Activated Sludge, 97.5* 90.7*
Bio Disc.
8?A02 Aerated Lagoon 87.0 75.7
Stabilization Pond
85A04 Aerated Lagoon, 93.3 84.4
Stabilization Ponds
85A05 Aerated Lagoon, 93.3 73.8
Stabilization Ponds
85A07 Activated Sludge 91.9 02.H
85A1L Oio Disc.
85A17 Activated Sludae 35.6** 93.2
Contact Stabilization
85A18 Activated Slu-J(je, 96.6 94.3
Contact Stabi1i nation
85A22 Aerated Lagoon, 96.2 72.2
Stabilization Pond
85A27 AeratcJ Lagoon-, 98.7 34.3
85A29 Aeraied Lagoons, 97.3
Trickling Filters,
Stabilization Pond:,
* Activated Siud'Ju l-'jrtinn
** B.i •:-, ;.jJc-J
C34
-------
CMCFIU.
FIGURE 194
CONTROL AND TREATMENT
PLANT 85Afi1
-------
o
73
I'J-'L'JFNT
;_rk_i f 1^4," i iiiri- — -,
(?) 11 f «• iFRA r;f-'
vHLUMF - fl.sir. .;ij v
OFr-TK = 1 V
UtTENTjr-N TI»t - IS .' iir
P-RIMAPT
•T' AERATION
vc.CUME = 8 Snn o i M
D6PTH - 3 M
•:^TF;N' IHN TIW - is o
SECOND ART
1
1 1
1 !
4VS
STEP
AERATION
•
-------
o
If^UJtiNT
(6) t, KM
vrxi>e -
CUM
>n AERATIDM
VOLUME = en.000 cu M
LAGOON »2
NO AERATION
VOLUMi = 50.000 CU M
LAGOON
':C'.JMF = 10.000 CU M,
NO
VOLUMF
. 000 CU M
LAGOON
FIGURE ii,0
A'f) TR
-------
AERATION
(2126KW AERATORS
VOLU»C=I200CUM
DETENTION
6 DAYS
(2)
-------
PIT
f*JTRIENT AND PH
ADJUSTMENT
I^LUTNT
EFFLUENT
K.REEM
TANK
FIGURE loe
COMROL AM) TREATMENT
PLArfT
-------
(<•) 1SKM AERATORS
VOLUME = 17.000 CU M
DEPTH = 3M
TION TIME =
CAYS
NO AERATION
VOLUME = 3.200 CU M
OEPD1 - 15M
OtTERNTltJM
7 DAYS
JFFLUENT
i-AGCOi
C1-1.CRINATION
199
ATO TREATMEMT
PLA1IT 85A2?
-------
DRAFT
COMPRESSORS
A[P 5.0 CJ M/MIN
INFLUENT
74 SI
HELICAL
VOLUME - 15.
Tr- = .3 M
15 SURHERGED
HELICAL AERATC3PE
= 26.000 cu
= 3 M
EFFLUENT
PCUISHING
CCN'~r
-------
DRAFT
for suspended solids. Nutrient addition will be required. With twenty-
four hour flow equalization, pli variations are expected to be adequately
buffered.. —
^election of Control and Treatment Technology
Two model plants were developed in Section V for grain distillers operating
stillage recovery systems. It is assumed that neither model plant provides
treatment of its wastewater prior to discharge, but both provide screening
of the effluent. The nine applicable alternatives discussed below are
identical for model plants A22-A and A22-B which have the following
wastewater characteristics:
Model Plant A22-A Model Plant A22-B
Production 330 kkg/day (1G.OOO bu/day) Production 90 kkg/day (3,500 bu/day)
Flow 2500 cu m/day (0.650 MGD) Flow 570 cu m/day (0.150 r.GJ)
BOD 930 mg/1 BOD 950 ng/1
SS 650 mg/1 SS 670 mg/1
Total KN 33 mg/1 Total KN 33 mg/1
Total P 3 mg/1 Total P 3 mg/1
Figures 202 and 203 present simplified flow diagrams for model plant A22-A
treatment alternatives, and Figures 204 and 205 illustrate the identical
treatment chains applicable to model plant A22-B. Tables 120 and 121
present calculated removal efficiencies for A22-A and A22-B treatment al-
ternatives, respectively.
Alternative A 22-1 - This alternative provides no additional treatment
to either moael plant. The removal efficiency is :ero.
Alternative A 22-11 - This alternative consists of a pumping station,
diffused air flow equalization, nutrient addition, and aerated lagoons
with settling ponds. The predicted effluent concentrations are 40 ng/'i
BOD and 50 mg/1 suspended solios. The removal efficiency of alternative
A 22-Ali is 95-7 percent of the DCL'. .inJ 92.3 percent of tha iusuenc'-.j
solids.. Alternative A 22-BIi removes 9b.8 percent Of the BOD ana 92.5
percent of suspended solids.
Alternative A 22-111 - This alternative adds dual media filtration to
the treatment cnain in Alternative A 22-11. The predicted effluent
concentrations are-COng/1 LCD ,m;i ::r •:•'}/} suspended solid:.. The ovt.-rVi 1
affect of Alternative A 22-AIIi is .1 roouulion of 97.8 percent of the Li-J-j
and 96.9 percent of the suspercrd solids. Alternative A 22-BII I remover.
97.9 percent of the BOD anH 96.3 percent of suspended solids.
Alternative A 22-IV - This alternative consists of a control house,
pumping station, diffused air flow «ri;a 11 ration, nutrient addition, a
complete mix activated sludge r.ystc-:, sludge thickening, aerobic digestion.
and sand drying beds. The prr.-dictcj effluent concentrations are 10 mg/1
b43
-------
DRAFT
INFLUENT
BOO = 930 MG/L
S3 = 650 MG/L
FLOW = 2500 CU M/DAr (0.650 MGD)
FLO*
EQUALIZATION
ADDITION
AERATED
LAGOON
SETTLING
°DND5
ALTERATIVE A22A-I
EFFLUENT
BOO » 40 MGXL
SS • 90 MGxT.
UUAL-MEDIA
ALTERNATIVE A22A-IJI EFFLUENT
BOD ;• 20 MG/--
OS = 25 MG/L
202
SU8CATEGORY tzzA
TREATMEW ALTERATIVES II THROUGH III
-------
DRAFT
INFLUENT
BOD = 930 MG/L
SS - 650 MG/L
= 2Soo cu M/DAY to,65
AERO6IC
DIGESTION
SLUDGE
THICKENING
SAND DRYING
BEDS
VACUUM
FILTRATION
SPRAY
IRRIGATION
IFLOW
EQUAL I 2ATIQN
NUTRiENT
ADO IT ION
ACT IVATEC
SLUDGE BASIN
SECONDARY
CLARIF
ICATION I
-MEDIA
^NAT/F A.TTA /, VT f.
,v MG/L
IV. VI , V
UE:>I7
SOD = ^.o MG^-L
SLUCGP
TREATMENT «LTE=?NATIVE.S IV THROUGH IX
•ppi VIS1aSriiw-
-------
DRAFT
INFLUENT
BOO - 350 MG/L
SS =• 67C MG/U
R_0» = S70 CU M/DAY (0.150)
EQUALliATION
ADDITION
LAGOON
SETTLING
-MEDIA
P 1L T»?AT 1 ON
ALTERNATIVE
EFFLUENT
BOD = «0 MG/L
56 = SO MS/L
BOO =
1 1
III
646
-------
ORAfT
-950 M&/L
5S = 670 M5/L
- 570 CU M/DAY (0.150
FLOW
j
1
1
1
1
i
i
p
1
wS?'u<
t
SI.COGE
THK:KENI^
VACUUM
1
^LUC-'GE HAS! .
J ;
SECJ.I^OAPV
CL.AP; !: ICATK-N
*. ALTE^7N>
A22-B IV,
- 7 ! EFFLUENT
1 t 1PP ~ 'rt
1
i I
I
•• — 1 "IT"
_ i*tf — C rt
*•" 1 \ ' ^* ATI Of *j
t • ^ ' ;
T t
; M.kJDGE 'C .v.rrwNA-:'A: */:'. -j . .MI. i* CFTLL^NT
'PUC1< ^11L
i rOD
1 '
*?lOC - .' '"• '*'. '""'.
1
'i IV THROU&-I
647
-------
a
>
TABLE 120 3
S'JM-IARY OF TREATMENT TRAIN ALTERNATIVES
SUBCATEGORY A22A
Trecunent Train
Alternative
A 22A-I
A 22A-II
A 22,-VlII
A 22A-IV
or, A 22A-V
^^
A 22A-VI
A 22A-VII
A 22A-VIII
A 22A-IX
Effluent BOO
fkg/kkg)
6.02
0.26
0.13
0.26
0.13
0.26
0.13
0.26
0.13
Effluent SS
(kq/kkg)
4.21
0.32
0.16
0.32
0.16
0.32
0.16
0.32
0.16
Percent BOD
Reduction
0
95.7
97.8
95.7
97.8
95.7
97.8
35.7
97.8
Percent SS
Reduction
0
92.4
96.2
92.4
96. R
92.4
96.2
92.4
96.2
-------
TABLE 121
OF TREATMENT TRAIN ALTERNATIVES
S'iBCATKORY A22B
Treatment Train
A] ternative
A 223-1
A 22B-II
A 223-III
A 228- I'/
A 223- V
A 22E-VI
A 22E-V1I
A 22B-VIH
A 228- 1 X
Effluent BOD
:>-i/Hc^)
5.99
0.25
C. 13
C.26
C.I 3
0.2f
0.13
T.26
0.13
Effluent GS
(fcq/kkq)
4.23
0.32
0.16
0.32
0.16
0.32
0.16
0.32
0.16
Percent BOO
Reduction
0
95.7
97.9
95.7
97.9
95.7
97.9
95.7
97.9
Percent SS
Removal
0
92.4
96.2
92.4
96.2
92.4
96.2
92.4
96.2
-------
DRAFT
COD and 50 mg/1 suspended solids. Alternative A 22-AIV is expected to
remove 95.7 percent of COD and 92.3 percent of suspended solids. The
eve-all effect of Alternative A 22-3IV is a reduction of 95.8 percent of
the iJOD and 92.5 percent of the suspended solids.
Alternative A 22-V - This alternative provides in addition to Alternative
A 22-1 V a pumping station and dual media filtration.. The predicted ef-
fluent concentrations are 20 mg/1 COD and 25 mg/1 suspended solids.
Alternative A 22-AV removes 97.8 percent of the BOD and 96.9 percent of
the suspended solids. Alternative A 22-BV removes 97.9 percent of the
BOD and 96.3 percent of tiie suspended solids.
Alternative A 22-VI - This alternative replaces sand drying beds in
Alternative A 22- IV with vacuum filtration and truck hauling or sludge.
The predicted effluent concentrations are 40 mg/1 BCD and 50 ir,g/1 suspen-' •.
solids. The overall effect of Alternative A 22-AV1 is a reduction of 95*7
percent of BOD and 92.3 percent of suspended solids. The overall effect.
of Alternative A 22-13VI is a reduction of 95.8 percent of the BOD and 92.":',
percent of the suspended solids.
Alternative A 22-V 1 1 - Tfris alternative odds a pumping station and dual
media filtration to Alternative A 22-VI. The predicted effluent concen-
trations are 20 mg/1 BOD and 25 mg/1 suspended solids. The overall effoci
of Alternative A 22-AVII is a reduction of 97. R percent of BOD and 96.9
percent of suspended solids. Alternative A 22-BVli rer.oves 97.9 per- en i
Of the BOD and 96.3 percent of the suspended solids.
Alternative A 22-VI 1 1 - Thi^ alternative replaces sand drying beds in
Alternative A 22-iV with spray irri^aticii of the sludge. The predicted
effluent concentrations are 40 mg/1 BOD and 50 mg/1 suspended solids.
Th* overall effect of Alternative A 22-AVIII is a reauction of 95.7
percent of the BOD and 92.3 porrent of fr; -u:-rer.dcd solids. The over;iV;
effect cf Alternative A 22-EVIii i:. a redjction of y5.3 percent of the
BOD and 92.5 percent of the suspended solids.
Al tcr-afive A 2?- IX - This altcrr.ativa uJb;. dual media filtration to
Alternative A 22-Vi ' I . The predi.tC'J cf : ] up-.t conc^itrations arc 20 inn
BOD and' 25 mg/1 su' ended r-f'iido. Al io'''V: ti vo A J2-AIX ros'j1t;s in 'J7. .
percent reduction i.f BOD nnj 9G.9 r.i'rc.i.-n*. ••(-•duct.ion of suspended solio.,
Alternative A 22-IUX removes i>7.:J perc-rnt of the bOD ana 96.3 percent o'
the suspended sol ids.
SUBCATEGPRY A 23 - GRAIN D1ST !LLF '-/;
In-Pi ant Technology
No plants in this subcatc^ory operate evaporator systems. Atmospheric
cool inn is more conmon than pressure cooking, therefore, cooker baroii'ct
condensers are not 4 source of pollutants. Since fow plants In this
subcategory operate multi-column di st i 1 'dfion units, doubler discharge
nay generate the only waste from dim lotion. Waste reduction measures
650
-------
DRAFT
Include recycling of water from mash coolers, still condensers, and refrig-
eration systems. Caustic cleanup may be collected, adjusted, reused,
or meteredTo treatment systems. Slops holding and transfer must be
supervised to avoid spillage.
End-of-Line Technology
Historically, due to the low level of raw waste for this subcategory,
the primary method of treatment has been small aerated lagoons followed
by stabilization ponds. Efficiencies of these systems are expected to
be somewhat lower than those in bubcategory A 22 due to the fact that
effluent concentrations are approaching the lower limit achievable frcm
stabilization ponds, unless further treatment such as sand filtration
is added. It is also felt that spray in-igafion of the final effluent
may be a viable alternative due to the rural locale of these distilleries.
Selection of Control and Treatment Technology
In Section V, a model plant was developed for grain distillers not
operating stillage recovery systeris. The wastewater characteristic:.
of the node! plant were determined to be as follows:
Flow 91 cu m/day (0.024 HGD)
BOD 210mg/l
SS 160 mg/1
TKN 7 mg/1
P 1 mg/1
Table 122 lists the effluent pollutant loadings and the estimated treat-
ment efficiency of each of the four treatment alternjtives selected fcr
this subcategory. All treatment alternatives are illustrated in figure
206.
Alternative A 23-1 - This alternative provide: no additional treatment
"of the raw waste effluent.
Alter rut j ye A 2 3 • 11 - This alternative ccr-'it-ts of r.cret>riin'j, d pu::;:>i: .
station, nutrient addition, anJ an aerated Ijjcon :;yst*jn. Screonin-j
Is assumed to have ronovod th? lanjo car felt", of debris which ore
subsequently disposed as solid waste. Nutrient addition i:; provided
to increase the BOD:N:P deficit of the wastewuter from 100:3.33:0.48
to the required 100:5:1. The aerated laooon and sottlinn pond wouiJ
provide an estimated BOL< and susnervled solids removal of'fjS.7 and 75.0
percent, respectively.
The overall benefit of this alternative is a TOD reduction of 35.7
percent and a suspended solids reduction of 75.0 percent.
Alternative A 2 3-111 •• This alternative is identical to Alternative A
23-11 with the addition of dial-media filtration which would provide
an additional SOD and suspended solids removal of 7.2 and 12.5 percent,
651
-------
TABLE 1:2
OF TREATMENT TRAIN ALTERNATIVES
SUBCATEGORY A23
tn
ro
Treatment Train
Al ternati ve
A 23-1
A 23-11
A 22-111
A' 2 3- IV
Effluent BOD
(kg/kkg)
0.3^1
O.G54
C.027
0
Effluent SS
(kg/kkg)
0.29
0.072
O.C36
0
Percent BOD
Reduction
0
85.7
92.9
100
Percent SS
Reduction
0
75.0
87.5
(GO
-------
DRAFT
INFLUENT
BOO =210 MG/L
SS - 160 MG/L
FLOW 91 CU M/DAY (0.02'
NUTRIENT
ADDITION
AERATEC
LAG3CN
SETTLING
ALTERNATIVE A23
ROD = 30 MG/L
SS = 40 MG/L
I I EFFLUENT
3PRAY
IRRIGATION
Al_ ."ERNATIVE A23 TV
BCD - 0 MG/L
SS - 0 MG/L
i-LTERN. ~T .'C 1
BOD = IE MG/L
'5 = 20 MG/L
I I I EFFLUENT
I ~> ;cEi 306
ALTE^NATI.I?. ;j THFCUGH iv
-------
respectively, over thai of Alternative A 23-11. The overall benefit
of this alternative is a DOD reduction of 92.9 percent and a suspended
solids reduction of 87.5 percent.
Alternative A 23-IV - This alternative consists of the same treatment
modules as Alternative A 23-11 with the addition of spray irrigation of
the treated effluent at a land cost of $4,100/hectare ($1,160/acre).
The overall benefit of this alternative is a BOU and suspended solids
reduction of 100 percent to navigable waters.
SUBCATEGORV A ?4 - MOLASSES DISTILLERS
Existing In-Plant Technology
As described in Section V, spent stillage is the primary waste in molasses Ji
tilling. Three methods of stillage waste reduction exist: 1) the character
of the stillage may be changed by centrifuging after fermentation to remoVe
yeast residues. According to Jackson (130) a reduction of up to nine percent
total solids can result from centrifugation. The spent yeast may either t
-------
DRAFT
Incineration., which has been used in some- cases for disposal of the con-
centrated syrup, offers the possibility of potash recovery for fertilizer.
Two United States manufacturers, however, have found a market for the
concentrate as an animal feed supplement. One plant ships Its concentrate
from Florida to Mississippi. Another plant finds it economical to barge
the by-product from New York to Louisiana.
Other methods for overall plant effluent reduction are the reuse of boiler/
cooling v.aters for fermc-nter rinse, barrel wash, general cleanup, or for
make-up in the raw molasses mixture. In addition, any caustic cleanup
may be reclaimed and adjusted for reuse instead of being sewered. These
methods are, of course, being currently practiced by some distillers.
Potential In-Plant Technology
Ahlgren (131) has tested ultra-filtration of rum distillery slops in con-
junction with evaporation in order to separate the insoluble material!, inf;
i separate stream which would not require evaporation. This would be ace :.-.••
plished by a membrone separation technique which would remove the yeasts
and other particulates so that they could be recoinbined with the evaporator
concentrate for sale as arxinal food material.
Plant 85C34 has experimented with the use of stillage as make-up for the
raw molasses mixt- e. Since this practice may affect the tast? of the
final product, it :annot be recommended for all molasses distillers; how-
ever, this practice as it is used in the grain distilling industry can
reduct eh amount of sti"Hage up to 25 percent.
End-of-Line Technology
A wide range of methods have been explored for the treatment of molasses
distillery effluents. Extensive studies (132) have shown that se'li^ent.;' •••
and coagulation are not satisfactory treatment alternatives since most or
the pollutants are m,ii solution. Sen, et_ *J_, (133) reported that trick!:-,:
filters treating undiluted classes distillery waste were not practical
due to the high organic concentration and low filtering rates rc-qjirc-a. Y^
activated sludge process nas Lten 5r.cv.ri ';o operate efficiently only w::.-•-
treating a one percent solution of rum slops combined with domestic ::e...; • •
(134). Wnen ten percent run sloss '.••ere nixed with domestic sewage, Gurr-. v.
'135) found th=t the neutralized, diluted waste treated by activated s !-.:;•
25 percent average COD removal) could enhance further treatment.
Of all the treatment processes available for raw stillage, only anaorc! :•:
digestion appears i.o be feasible. Uhaskaran (136) found that it was po> ..
to carry out anaerobic digestion of the raw waste at 37°C and a BOD load;-.;
of 3.0 kg/a'ay/cu :n (0.133 lb/duy/cj ft) wi :n a detention time of 10 day:..
BOD removals greater than 90 percent were obtained while a ratio of 25:1
methane gas to waste volume was maintained. This treatment was followed
by activated sludge to produce an effluent with 63 nigl DOD. Seven plant'.
655
-------
DRAFT
in India and ton plants in Japan (137) are presently utilizing methane fer-
mentation combined with activated sludge to achieve 40 to 120 nigl LOD in
the final effluent. Bhaskaran also operated a pilot plant showing that a
quadruple effect forced circulation evaporator with forward feed achieving
a 60 percent concentrate is quite suitable for the subsequent incineration
and recovery of potassium salts for fertilizers.
Shea, e_t aj_ (138) investigated the anaerobic contact process at the pilot
scale, and developed design criteria for full scale application. Capital,
operation, and maintenance costs were also estimated.
As previously described, the raw stillage may be evaporated rather than
treated. Plant 85C44 has recently built an extended aeration treatment
system designed only to handle the evaporator condensate. Other plant
wastes will be sent to landfill. Design parameters were 320 cu m/day
(0.085 MGD) at 200 mg/1 BOD. Figure 207 illustrates a flow diagram for
the system. Plant 85C43 has also just finished construction of an activarc-
sludge unit designed to handle both evaporator condensate and other pi jr.-;
wastes. Existing plant loads are expected to average 104 cu n/day (L^.GJO
GPD) at 1GOO iv.cj/1 BOD. Evaporator load i:- expected to be 2/6 cu m/day
(73,000 GFL1) at GOO mg/1 bOD. No effluent data is presently available.
Figure 203 presents a flow diagram for the treatment system.
The two method: of treatment which were considered for the purpose of this
stud;/ were.. 1) evaporation of raw stillage fo"lo,-/ed by activated sl'Jdy-
treav •.'it <•, ccndensate, or 2) use of anaerobic contact process for p.ii-'.iji
treatment of rew stillage, followed by activated sludge. The former wai
determined to be more cost effective when the additional treatment re'.:----. •"•••
for the anaerobic process was-considered. For this reason evaporaticr, -..-' .
alternative treatment systems will be presented.
Selection of Control and Treatment Technology
The model plant developed in Section V for the rur.i distilli.ic industiy r.-c?ss wasi:ei.'ater is assumed to be •;oq>-cf!atod from a1! non-contact v,,-> :•••-.
High strength wastes (molasses ilops) nre? assumed to be 89 percent of '..'.•.:
total non-contact flow and to contain :?? ;>erc.:r.t of the BOD ond 97 pt-ri .-••'
of the susfcr.ic-d soliJs. When treatcJ separntc-ly, high strength wa•;.):••':. .:•-..•
all other wastes have the followiruj v/a-;tewuter characteristics:
High Strength Wastes All Other V.'astes
BOD 39,100 niq/1 BOD 2.04S mg/1
SS 7,230 r.ig/1 SS 1,964 mg/1
Flow 733 cu i:i/day (0.195 MGD) Flow 79.5 cu m/day (0.021 ;:GD)
656
-------
AEROBIC
DIOTSTOR
Prl ADJUSTMENT
NUTRIEN1 ADDITION
TO LAND
DISPOSAL
COOLING WATER
AERATED
LAGOON
FIGURE 207
CONTROL AND TREATMENT
HM1 65C43
-------
AEROBIC
DIGESTQR
LAND SPREADING
FIGURE ?08
CONTROL AND TREATMENT
Pi.AfiT
-------
DRAFT
Table 123 shew the removal efficiencies of each of the treatment alternatives,
Figures 209 and 210 present simplified flow diagrams illustrating each of
the choson treatment chains.
Alternative A ?fl-i - This alternative adds no treatment to the model
plant. I he efficiency of BOD and suspended solids removal is zero.
Alternative A 24-11 - This alternative consists of concentrating high
strength molasses slops (still^ge) by multi-effect evaporation, and then
treating evaporator condensate and all other wastes with a treatment chain
consisting of a control house, a pumping station, flow equalization, nutrient
addition, a complete mix activated sludge system, sludge thickening, acrcv.ic
digestion, vacuum filtration, sludge storage, and truck hauling. Evaporation
is predicted to remove 97 percent of the SOD and 99 percent of the suip'ji'.dod
solids from high strength wastes. Tv/o day storage of distillery slops a"£
seven day storage of mola.sses by-product is provided, and all necessary
pumping equipment is included.
Yhe predicted effluent concentration is 50 r.ig/1 GOD and 30 mg/1 suspe-vj.a
solids. The overall affect of Alternative A 24-11 is a 99.9 percent re-
duction of BOD and a 99.6 percent reduction of suspended solids.
Alternative A ?4-!I I -• This alternative consists of adding dual media
filtration to the treatment, chain in Alternative A 24-11. The predicted
effluent concentrations are 25 mg/1 of BOD and 15 mg/1 of suspended sores.
The overall effect of Alternative A 24-IJI is a 99.9 percent reduction
of BOD, and a 99.8 percent reduction of suspended solids.
Alternative A 24-IV - Thij alternative consists of replacing vacuum
filtration in Alternative A 24-11 with spray irrigation. The predicted
effluent concentrations are 50 mg/1 COD and 30 mg/1 suspended solids. The
overall effect of Alternative A 24-IV is a 99,9 percent reduction of :,i;:,-
sol ids.
Alternative A ?&-V_ • Th ilternatU'C ado's dual tr.edia filtration to tnc
trcat.ven: cn
-------
TABLE 123
SU8CATEGORY A 24
SUMMARY OF TREATMENT ALTERNATIVES
Effluent BOD
Effluent SS
Treatment Train
Alternative
A 24-1
A 24-11
A 24-111
A 24-IV
o
0 A 24-V
A 24-VI
A 24-VII
A 24-YII1
A 24-IX
(kg/ 1000 proof
gallons)
969
1.16
C.58
1.16
0.58
1.16
0.58
1.16
0.63
(kg/ 1000 proof
gal Ions)
163
0.69
0.35
0.69
0.35
0.69
0.35
0.69
0.35
Percent BOD
Reduction
0
99.9
99.9
99.9
99.9
99.9
99.9
99.9
99.9
Percent SS
Reduction
0
99.6
99. B
99.6
99.8
99.6
99.8
99.6
99.8
-------
DRAFT
IKKLUENT
RAW
GOD « 39.100 MG/L
55 = 7,230 MG/L
FLOW - 738 CU-M/DAY (0.195 MGD)
TOTAL KN = 1.110 MG/L
TOTAL P • 55 MG/L
i
SLOPS
STORAGE
I
I
I EV
EVAPORATION
1
i
PY-^ROOUCT
STOP AGE
AEROBIC
DIGESTION
iANU
BFU
VACHJM
e'ILTRATICNi
SPRAY
IRRIGATION
PLANT WASTED
BOD = 3.849 MG/L
SS = 1 ,964 MG/L
FLOW = ao cu M/DAY to.021 Mtir»
F;_OW
EQUALIZATION
NUTR 1 Er.T
"ADDITION
ACTIVATED
SLUDGE •••.*3!N
SLUDGE
TMK.KENINS
1
1
SECONPARY
CLARIFICATION
«. ,x TERfgAT I VE
DUc.L-MEC.IA
^ILTRAT!':*^
CPR.UENV
BOD = SO MC..-I
"1
.' . v , v T i
80D .- J5 '<•/'
SS -• IS MG/L
SLUDGE TO
TRUCK HAUL
FIGURE ?
ALTER? JATIVE?. 1J THRU IV
-------
DMFT
INFLUENT
RAW STILLATE
BOO = 39. 100 :iG/L
SS = 7, J20 MC/L
FLOW = 736 CU M/RAY (C.I95 MGD)
TOTAL KN = 1.110
TOTAL •» = 55 MG/L
SLOPS
STORAGE
INFLUENT
OTHER PLANT WASTES
BOO = 2.8*9 MG/L
SS = 1,964 MG/"_
FLOW = eo cu
(0.031 MGO)
EVAPORATION
PLOW
BY-PRODUCT
STORAGE
NUTRIENT
ADDITION
AERATED
LAGOON
SETTLING
°ONDS
| ~
ALTERNATIVE A2<.-vi!i
EFR.UENT BOD = so '»
S3 = 30 HC
AL.
SS = 1
lc
TREATMENT Ai.TL'R:i; r;vES VIJ I THRU IX
662
-------
DRAFT
BOD and Ib mg/1 suspended solids. The overall effect of Alternative A 24-
VII is n 99»-9 percent reduction of DOD, and a 99.8 percent reduction of
suspended solids.'
Alternative A 24-VIIL - This alternative consists of replacing the
complete mix activated sludge system and sludge handling modules in
Alternative A 24-11 with aerated lagoons and settling ponds. The settling
ponds are dredged every five years. The predicted affluent concentrations
are 50 mg/1 BOD and 30 mg/1 suspended solids. The overall effect of
Alternative A 24-VIII is a 99.9 percent reduction of BOD, and a 99.6 percern
reduction of suspended solids.
Alternative A 24- IX - This alternative adds dual media filtration to
Alternative A 24-VIII. The predicted effluent concentrations are 25 no/1
BOD and 15 mg/1 suspended solids. The overall effect of Alternative A L'4-i:
is a 99.9 percent reduction cf BOD, and a 99.8 percent reduction of SUG- .
pended solids.
SUBCATCGQRY A 25 - BCITLING M'.'J BLENDING OF BEVERAGE ALCOHOL
Technology
Non-contact cooling water may be separated and discharged to storm
sewers as in Plant 85011 or to navigable waters as in Plant 85013
•if allowable. While this does not reduce pollutant, loadings, it does
improve treatment economics. Residue fro:", redistillation may be col-
lected in a holding tank for subsequent disposal. Bad product may te
collected and held rather than crushed ar.d sewered. Deminerdl i :er
water regeneration cischarges may be collected ana neutralized for
subsequent disposal. All other process wastes are ascumnd to be
minor in strength.
End-of-Hne Technology
There are no known plants in this si/l)caU"jr»r^ which discharge P.ni from nun-co.nLjct watpr. M.nv
waste cnaractcri sties for the two TO del pionts were:
A B
Flow 4 cu m/clay (0.001 liGD) 40 cu in/day (0.010 MGD)
663
-------
DRAFT
The alternatives listed below all achieve 100 percent removal of raw
v/aste loading. Therefore, no discharge of pollutants to navigable
waters is recommended.
Alternative A 25-1 - This alternative provides no additional treatment
to the raw wastewater.
Alternative A 25-11 - This alternative provides daily truck hauling of
all plant process v/astes to municipal treatment facilities or approved
land disposal sites. A holding tank is provided.
Alternative A 25-111 - This alternative provides truck hauling on a monthly
basis for rectifier bottlers. At this time redistillation residue, bad
production, and demineralizer regeneration are hauled. No truck hauling
is provided for small bottlers, however, since it was assumed in Section v
tliat their effluent contained no redistillation residue or bad product.
AH other process wastes for both model plants are spray irrigated.
A holding tank, pump, and pipeline are provided.
SUBCATtlGORY A 26 - SOFT DSI.'IK CANNERS
In-Plant Technology
As identified in Section V, the major sources of waste for this sub-
category are filler spillage, mixing tank washing, and fill tank and
line washing. At present the reduction of waste from filler spillage
ha: not been fully addressed by scft drink manufacturers. Procedures
for col'txting lost product have been established, however, by the malt
beverage industry. Applying this technology to the soft drink Industry
would entail the collection ana Molding of lost product for separate
disposal. Mixing tank v/astes could also be collected in order to reduce
the load on v/aste trestwent systems. A portion of the water used to
flush full lines and fill tanks (tne first two or three minutes or until
the flow is clear) could be similarly collected. These combined col-
lected wastes nay then be disposed by landfill ing, land spreading, or spray
irrigating, In long term planning some form of sugar recovery froin
these collected wastes may be profitable.
t-n^L9.1~line Technology
As identified in Section V, the waste from soft drink canners contains
orijaric materials which are amenable to treatment by biological process!,.
During the course of this study,data was collected from three plants
with was tec/a tcr treatmtnt systems, bince these plants were all bottlers
the case histories will be presented in bubcategory 27. There is no
reason to suspect that similar systems, tailored to the effluent charac-
terisitcs of :.oft drink canners, would not function properly.
6G1
-------
DRAFT
Selection of Control and Treatment Technology
In Section V" a model plant was developed for soft drink canners. The
raw wastewater characteristics were assumed to be as follows:
Flow 229 cu in/day (0.0605 MGD)
BOD 1300 mg/1
SS 167 mg/1
N 23 mg/1
P 12.5 mg/1
Table 124 lists the pollutant effluent loading and the estimated operat-rg
efficiency of each of the seven treatment alternatives selected for thir
subcategory. The schematics of the treatment alternatives are illustrated
in Figures 211 and 212.
Alternative A 25-1 - This alternative provides no additional treatment
to the raw waste effluent.
Alternative A 25-11 - This alternative consists of a control house,
flow equalization, nutrient addition, a complete-mix activated sludge
system, sludge thickening and spray irrigation of the thickened sludge.
Flow equalization is provided for two reasons: (1) the pH uf the inter-
mittent flow from the plant can vary from 3.0 to 7.0 and, therefore,
equalization will provide neutralization without chemical addition, ard
(2) to dampen shock loadings to the activated sludge system. Anhydrous
ammonia addition is provided to increase the wastewater BOD:N ratio
from 100:1.67 to the required 100:5. The activated sludge system would
provide an estimated 94,9 percent treatment efficiency. 'The sludge from
sludge thickening is spray irrigated at a land cost of SI,660/acre.
The overall benefit of this alternative is a BOD reduction of 94.9 percent
and a suspended solids reduction of 76.0 percent.
Alternative A 26-1II - This alternative consists of the ra-e treatment
module'., ub Alternative A 26-11 with the addition of dual -'iiedia filtration
which would provide an additional estimated £C9 and suspended solid:> re-
duction of 2.6 and 12.1 percent, respectively. The overall benefit of
this alternative is a BCD reflection of 'J7.5 percent and a suspended s.)li-.:v
reduction of 88.1 percent.
Alternative A 26-IV - This alternative consists of the z;me treatment
modules as'A)ternative A 26-1! except spray irrigation of thickened
sludge is replaced by sludge haulm/}. The overall benefit of this
alternative is a 1301) reduction of 54.9 percent and a suspended solids
reduction of 76.0 percent.
Alternative A 26-V - This alternative is identical to Alternative A 26-IV
with the addition of dual-media filtration. The overall benefit of this
-------
TABLE 124
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
SUBCATEGORY A 26
SOFT DRINK CANNERS
o
Z3
3
Treatment
Train
Alternative
A 25-1
A 26-11
A 26-1 II
rt 26-IV
er>
cr<
A 26-V
A 26-VI
A 26-VII
Effluent
BOO
kg/cu m
1.02
0.052
0.026
0.052
0.026
0.052
0.026
Effluent
SS
kg/cu m
0.1?3
0.030
0.015
0.030
0.015
0.030
0.015
Percent.
BOD
Removed
0
94.9
97.5
94.9
97.5
94.9
97.5
Per.-ent
SS
Removed
0
76
88.1
76
88.1
76
88.1
-------
ORAF1
INFLUENT
FLOW = 229 CU I*/DAY (0.0605 MGO >
BOD = 1.380 MG/L
SS = 167 MG/L
N = 23 MG/L
P = 12.5 MG/L
I
FLCw
rl
SLUDGE
STORAGE
smear
TRU<
SPRAY
IRRIGATION
SLJOGE
BASIN
ISLLCGE
THICKENING
SECONDARY
CLARIFICATION
r
DC!Ai_-MeDi A
A 26-: I I C. V
rr-L'jE'-iT
BCT - 35 MG/L
S5 = 20 MG/L
ALTERNATIVE;.
A 26-11. t :
BOD = 70 KG,'L
SS = *0 MG/L
FIGURE 211
A26
TREAW.7 ALTEr^WTIVEf II THRU V
667
-------
DRAFT
INFLUENT
FLOW = 229 CU M/DAY 10.0605 MGO)
BOO = 1,380 MG/L
SS = 167 MG/L
N = 23 MG/L
P = 12.5 MG/L
EQUALIZATION
NUTRIENT
ADDITION
AERATED
LAGOON
SETTLING
"QNDS
UUAL-ME3IA
FILTRATION
ALTERNATIVE
A 26-VI
EFFLUENT
BOD =70
SS = 40 MG/L
ALTERNATIVE
A 26-VlI
EFFLUENT
BOD =35 MG/L
SC = 20 MG/L
FIGURE 212
SUBCATEGORY A26
TREATMENT ALTERNATIVES VI AfC VII
668
-------
DRAFT
alternative is a BOD reduction of 97.5 percent and a suspended solids re-
duction of 80.1 percent.
Alternative A 26-VI - This alternative consists of a pumping station,
flow equalizaLion, nutrient addition, and an aerated lagoon. Flow
equalization and anhydrous ammonia addition are provided for the same
reasons given in Alternative A 26-11. It is assumed that the aerated
lagoon provides the same treatment efficiency as the activated sludge
system of the previous alterndtives.
The overall benefit of this alternative is a BOD reduction of 94.9 percent
and a suspended solids reduction of 76.0 percent.
Alternative A 26-VII - This alternative is identical to Alternative A
26-VI with tht addition of dual media filtration. The overall effect
of this alternative is a BOD reduction of 97.5 percent and a suspended
solids reduction of 83.1 percent.
S'JBCATEGGRY A 27 - SOFT DRINK BOTTLING OR CCflBIf.rD BOTTLir.'G/CAMKING
PLANT'S
In-Plant Technology
Plants in this subcategory can incorporate waste reduction measures dis-
cussed for soft drink canners, i.e., trie collection and holding of fill*1:-
spillage (canners only), mixing tank washing, and fill tank and line wasrir.o.
In addition, wastes from the bottle washer must be addressed. The character
of final rinse water was documented in Section V. This may be recireflates
to the prennse section. Water pressure at the spray heads of bottle >vas;;er
may exceed manufacturers specifications. Pressure reducing stations iray ce
required to maintain specifications. Pressure reducing stations nay be
required to maintain recommended levels. Solenoid valves may be installed
on city v/ater inlets to cut off the rinse water completely when the washr-r
is not operating. Caustic can be metered into treatment system insteuJ of
being dumped from soakers. Unused product left in returnable bottles "!<:y
be collected and disposed of separately along v.ith other proc'jct -.-.accei,.
A similar method of disposal may be required for unused product left in
returnable cannisters.
End-of-Line Technology
Aerated laqoons or variations of activated sludge are both employed in t''v.->
treatment of soft drink wastes. Figures 213, 214, and 215 illustrate :nr:.-L'
such systems. Plant 86A16 is a small bottler producing only 18 cj m
(•i,900 gal) per day. The aerated lagoon and polishing lagoon system utilise
by this plant is achieving 92 percent COD and 73 percent suspended solids
removal. Increased efficiencies could be expected, however, because at ti.••-.".
the aerator is not operated.
The treatment system'at plant 86A32 w.is undersigned and consequently is r.r.;
ercly overlcadivri liydraul ical ly. A cf-n-^idurable amount of study of in-ni.;:-.'.
water reduction has taken olace. Nevertheless, it appears that the present
669
-------
FIGURE 213
COTTROL AND TRFATMFIM'
o
i.
= 930QM
DEPTH = 3.<,M
(i) <.KW AFRATCR
AERATFD
LAGOON
AREA = 1760SQM
DEPTH = 2.W
NO AERATION
POLISHING
LAGOON
EFFLUENT
-------
DRAFT
EQUALIZATION
TANK
AERATION
CLARIr
AEPAT1CN
CHAMBER
(1 ) A
-------
PH AND
NUTRIENT
ADJUSTMENT
FFFLUENT
FIGURf 215
CONTROL AND TRFAT»€Nrr
-------
DRAFT
will have to be expanded. Current BOD removal is approximately G9 percent.
Effluent suspended solids levels were higher than those in the raw ,/aste
due to overloaded sand filters which passed solids to the clear well.
Plant 86A29 is not yet operational, hence no effluent data is available.
Predicted values are 15 mg/1 for both BOD and suspended solids. Sludge
will be trucked to a larger treatment facility.
Selection of Control and Treatment Technology
In Section V $ model plant v/as developed for soft drink earners. The raw
wastewater characteristics were assumed to be as follows:
Flow 477 cu m/day (0.125 MGD)
BOD 660 mg/1
SS 108 mg/1
N 11 mg/1
P 6 mg/1
Table 125 lists the pollutant effluent loading and the estimated operating
efficiency of each of the seven treatment alternatives selected for this
subcategory. The schematics of the treatment alternatives are illustrated
in Figures 216 and 217.
Alternative A 27-1 - This alternative provides no additional treatment
to the raw waste effluent.
Alternative A 27-11 - This alternative consists of a control house, flow
equalization, njtrieru addition, a complete-mix activated sludge system,
sludge thickening and spray irrigation of the thickened sludge. Flou
equalization is provided for two reasons: (1) the pH of the intermittent
flow from the plant can vary from 3.0 to 7.0 and, therefore, equalization
will provide neutralization without chemical addition, and (2) to dampen
shock loadings to the activated sludge system. Anhydrous ammonia addiiior,
is provided to increase th» wastewater's BOD:N ratio from 100:1.67 to the
required 1CO:5. Acid neutra.li'zatior. is provided to ecccr:odate the fre-
quently high alkalinity of ;he wastewater. The activated sludge system
would provide an estimated 89.4 percent treatr.ent efficiency. The sludge
from sludge thickening is spray irrigated at a land cot of 51,660/acre.
The overall benefit of this alternative is a BOD reduction of 89.4 percent
and a suspended solids reduction of 6J.O percent,
Alternative _A 27-111 - This alternative consists of the same treatment
modules as Alternative A 26-11 with the addition of dual-media filtration
which would provide an additional'estimated BOO and suspended solids re-
duction of 2.6 and 12.1 percent, respectively. The overall benefit of
this alternative is a BOD reduction of 94.7 percent and a suspended solids
reduction of 81.5 percent.
Alternative A L'7-IV - This alternative consists of the same treatment
modules of Alternative A 26-11 except spray irrigation cf thickened sludge
673
-------
TABLE 1?5
SUMMARY OF TREATMENT TRAIN ALTERNATIVES - SUBCATEGORY A27
ALL OTHER SOFT DRINK PLANTS
ALTERNATIVE
EFFLUENT
600
KG/CU ff
EFFLUENT
SS
KG/CU II
PERCENT
BOD
REMOVAL
PERCENT
SS
REMOVAL
A27 - I
A2? - II
A27 - III
A27 - JV
A27 - V
A?/ - VI
A27 - VII
2.30
0.24
0.123
u. 24
0.123
C 24
0.38
0.14
0.07
0.14
0.07
0.14
0.07
0
89.
94.
89.
94.
89.
94.7
0
63.0
81.5
63.0
81.5
63.0
81.5
-------
DRAFT
INFLUTNT
FLCW = 477 CU M/DAY (0.126 MGO)
BOD = 6oC IG/L
SS - 108 MG/L
N s 11 MG/L
P = * MG/L
PLOW
EQUALIZATION
ACTIVATEC
SLUOGS BASIN
SLUDGE
•THICKENING
SECONDARY
CLARIFICATION
SLUDGE
STORAGf
DUAL-MEDIA
FILTRATION
SPRAY
IRRIGATION
I
ALTERNATIVES
A 27-111 t V
EFFLUENT
BCD = 35 MG/L
SS = 20 MG/L
ALTERNATIVES
A 27-11 t lv
••^EFFLUENT
BOO = 70 MG/L
SS = 60 MG/L
FIGURE 216
SURCATEGCRY A27
ALTESWTIVES II THRU V
675
-------
DRAFT
INFLUENT
FLOW * *77 CD M/DAY (0.126 MGO)
BOD s 660 MG/l.
SS * 108 MG/L
N = 11 MG/t.
p a 6
PLOW
EQUALIZATION
ADJUSTMENT
NUTRIENT
ADDITION
AERATEC
L'GODN
SETTLING.
PONOS
DUAL-MEDiA
FILTRATION
ALTERNATIVE
_^ A 27-VI
EFPLUENT
BCD « 70
SS & 40 HG/L
ALTERNATIVE
A 27-VII
EFFLUEIVT
BOD = 35 MG/L
SS = 20 M
-------
DRAFT
is replaced by sludge hauling. The overall benefit of this alternative is
a DOD reduction of 39.4 percent and a suspended solids reduction of 63.0
percent. _
Alternative A 27-V - This alternative is identical to Alternative A 26-1V
with the addition of dual-media filtration. The overall benefit of this
alternative is a BOD reduction of 94.7 percent and a suspended solids
reduction of 01.5 percent.
Alternative A 27-VI - This alternative consists of a pumping station,
TTbw equalization, nutrient addition, and an aerated lagoon. Flow
equalization and anhydrous ammonia addition are provided for the same
reasons given in Alternative A 26-iI. It is assumed that the aerated
lagoon provides the same treatment efficiency as the activated sludge
system of the previous alternative.
The overall benefit of this alternative is a BOD reduction of 89.4
percent and a suspended solids reduction of 63.0 percent.
Alternative A 27-VII - This alternative is identical to Alternative A
26-VI with trie addition of dual-media filtration. The overall effect
of this alternative is a EOD reduction of 94.7 percent and a suspended
solids reduction of 81.5 percent.
SUBCATEGORY A 28 - BEVERAGE BASE SYRl'PS AND/OR CONCENTRATES
Existing In-Plant Technology
Wastewater generated from the manufacturing of beverage bases consists
solely of cleanup water as described in Section V. Most plants regulate
the amount of water used in all cleanup operations. Some plants discharge
non-contact water into the wastestream and others to storm sewers.
Potential In-Plant Technology
Assuming that 50 percent of the cleanup water is wash water and 50
percent is rinse water, recycling all or a major portion of rinse water
could conceivably reduce the quantity of wasteflow and water use by 50
percent. Additionally, recycling of caustic wash water and separation
of all non-contact water from tne waste-stream would substantially reduce
the volume of the process wastewater stream.
Reduction of pollutant loadings in the waste stream could be accomplished
by recycling of caustic wash water and by avoiding any spills during re-
ceiving ingredients and filling tank cars, drums, ar.d container's.
End-of-Line Technology
Presently all known beverage manufacturers discharge wastewater to
municipal systpr.is with no apparent adverse effects on the treatment
systems. The waste stream could be slightly deficient in nitrogen
based on the DOD:N:P ratio of iOO:3.1:K1 at PU,,t 87S09. However,
677
-------
DRAFT
the data is not sufficient to warrant a valid conclusion that nutrient
addition prior to biological treatment is necessary or desirable.
Based on these facts, along with consideration of the origins of the
wastewater-and its characteristics, the wastewater is judged to be
amenable to biological treatment with or without nutrient addition.
Selection of Control and Treatment Technology
A model plant for Subcategory A 28 with the following wastewater charac-
teristics was presented in Section V.
Flow 379 cu in/day (0.10 MGD)
BOO 2400 mq/1
SS 50 n.;/l
pH 8.0
Table 126 lists the treatment alternatives and their expected efficiencies.
The treatment alternatives are illustrated in Figures 218 and 219.
Alternative A 28-I - This alternative consists of a pumping station, a
flow equalization basin and an aerated lagoon. The flow equalization
tank is recommended to provide a steady flow to the lagoon, preventing
shock loadings and thereby increasing the efficiency of the aerated
lagoon. Due the biodegradabi lity of the waste'.vater, the aerated lagoon
would provide a BOO reduction of 95.8 percent and a suspended solids
reduction of 40 percent.'
The overall benefit of this alternative is a BOD reduction of 9b.8
percent and a suspended solids reduction of 40 percent.
Alternative A 28-11 - This alternative consists of a pumping station,
a flow equalization" tank, a complete mix activated sludge basin, a
sludge thickener, an aerobic digester, a sludge holding tank and land
application of sludge following digestion. The flow equalization tank
is provided to dampen shock loadings to the activated sludge basin
which would be expected due to the variations in cleanup activity during
the da.y in a beverage base manufacturing plant. The activated sludge
basin would reduce the 300 and suspended solids loadings of the waste-
water' to 100 ng/1 and 30 mg/1, respectively. A two day sludoe holding tanl;
U provided to reduce the cost of haulinq sludoe of land aooTica-
tion. The amount of land required vo accommodate the yearly siudge
production Is 85 ha (210 acres).
The overall benefit of this alternative is a BOD reduction of 95.8
percent and a suspended solids reduction of 40 percent.
Alternative A 20-111 - This alternative consists of the same treatment
modules as Alternative A 2B-II except land spreading of sludge is re-
placed by vacuum filtration provides a significant sludge reduction as
678
-------
Ol
•xl
TABLE 126
SUMMARY OF TREATMENT ALTERNATIVES
BEVERAGE BASE SYRUPS AND/OR CONCENTRATES
Subcategory A28
Treatment
Alternative
A 28 -
A 28 -
A 28 -
A 28 -
A 28 -
A 28 -
A 28 -
A 28 -
A 28 -
A ?8 -
A 28 -
A 28 -
A ?8 -
I
II
III
IV
V
VI
VII
VIII
IX
X
XI
XII
XFII
Effluent
BOO
kg/cu m
0.01
0.01
0.01
0.01
0.005
0.005
0.005
0.005
0.0025
0.0025
0.0025
0.00?5
I1
Effluent
SS
kg/cu m
0.003
0.003
0.003
0.003
0.001
0.001
0.001
0.001
0.0005
0.0005
0.0005
0.0005
0
Percent
Reduction
BOD
95.8
95.9
S5.8
95.8
97.9
97.9
97.9
97.9
93.9
98.9
98.9
98.9
, •
100
Percent
Reduction
SS
40
40
40
40
80
80
80.
80
90
90
90
90
100
-------
DRAFT
FLOW * 3'ro cu M/DAY -.--LUENT
BOD - 100 MG/L
SS = 30 MG/L
ALTERNATIVE
•—•A 2S-V
EFFLUENT
BO = 50 MG/l.
SS = 10 MG/L
CARBON
ADSORPTION
ALTERNATIVE ASB-
BOO = 2t MG>*L
SS - 5 MGA.
FIGURE 216
SUBCA-EGORY A29
TREATMENT ALTERNATIVES I. V, AND IX
680
-------
DRAR
Il^UUENT
= 379 CO M/DAY (0.10 MOD)
BCD = 3,400 MG/t
SS * SO
FL3W
EQUALIZATION
AEROBIC
DIGESTION
ACTIVATED
SLUDGE BASIN
SLUDGS
THICKENING
VACUUM
FILTRATION
SECONDARY
CUAWIFI CATION
SAND
3EDS
SLUDGE TO
TRUCK. HAUL
ALTERNATIVES
-•*• A ?e-n - rv
EFFLUENT
BOO = ioo
SS s 30
UJAL-MEDJA
FILTWATICN
». A 29-VI - VJII
EFFLUENT
BCD = 50 MG/L
SS - 10 MG/L
ADSORPTION
ALTERNATIVES A 26-X - XlJ
EFFLUENT
BOD = 35 MG/L
SS = 5 MG/L
FIGURE £19
SUBCATEGORY A28
TREATMEKT Ai.ft»J.»TTwc«; f'-tv, VI-VIII. AND X-XIl
-------
DRAFT
compared to Altcrnutivc A 23-11. thereby reducing hauling costs. A
sovon-day *1ud
-------
DRAFT
Alternative A_?8-J(_?r - This alternative consists of the same .nodules as
Alt(.jrnativc_A 22-V1I v/ilh the addition of activated carbon. The overall
effect of this alternative1 is a BOD reduction of 90.9 percent and a sus-
pended solids reduction of 90 percent.
Alternative A 28-X1I - This alternative consists of .the same treatment
modules as Alternative A 28-VIII with *he addition of activated carbon.
The overall benefit of this alternative is a COD reduction of 98.9 percent.
and a suspended solids reduction of 90 percent.
Alternative A 28-XIII - This alternative consists of a pumping station,
a holding tank and spray irrigation which would required 8.1 ha (20 acres)
of land. The overall benefit of this alternative is a 100 percent reduc-
tion of pollutants.
SUBCA7EGORY A 30 - INSTAUT TEA
Existing In-Plant Technology - Existing methods of reducing wastewater
quantity and pollutant loadings include separation of non-contact cooling
water from process water, recirculation of non-contact water, and elimina-
tion of clarifier tea sludge from the process wastestream. Plant 9ST04,
which separates non-contact cooling water from process water and does not
discharge clarifier tea sludge into its wastestream, exhibited 3 waste-
water quantity approximately 67 percent less than the rest of the
industry and BOD and surpended solids loadings approximately 78 and
83 percent less, respectively, than the --est of the industry. Plant
99701 decreased waste flow by construct.cn of a cooling tower and sub-
sequent recycling of cooling water as cooling tower makeup.
Potential In-Plant Technology - Separation of all non-contact cooling
water anu boiler blowdoi;n could be implemented to reduce wastewater
quantity. Recycling of non-contact water coulc also reduce overall
water use in the plants. Pollutant reductions in the process wastestrean
could be realized by disposal of clarifier tea sludge separately from
the wastestream. This could be accomplished by centrifugation of the
sludge with the solids portion subsequently utilized as cattlefeed or
disposed as solid waste.
Additionally, the reuse of fresh rinse wcter as makeup for the caustic
and acid rinses could conceivably reduce wastewater from equipment cleanup
by as much as 60 percent. This is based or. the assumption that each
of the five cleanup cycles comprises 20 pe-cent of the total equipment
cleanup flow. Therefore if tiiree cycles were reused,60 percent less
wastewater would be generated. Caustic and acid rinses could conceivably
be recycled, to further reduce waste volume. The use of low output, nigh
pressure nozzles for external equipment cleanup and floor washing
could also reduce wastewater volume.
End-of-Line Technology - Instant tea process wastewater has been shown
to be biodegradable and well suited for biological treatment. Presently,
G83
-------
DRAPT
two instant U-a manufacturing plants operate secondary treatment systems
to reduce pollutant loadings prior to municipal discharge. Tlie treatment
system flou diagram for plant 39T01 is illustrated in Figure 220.
The treatment system consists of the following major components.
1. A 53 cu m (0.014 KG) primary clarifier for removal of settleable
solids.
2. A C80 cu m (0.180 MG) activated sludge tank which is aerated by
the addition of diffused air,
3. A 409 cu rn (0.1C8 MG) aerobic digester aerated by use of diffused
air.
4. A 20-foot diameter secondary clarifier with a volume of
121 cu m (0.032 I1G).
5. Adjustment of v/astestream pH by the addition of litr.ewater
prior to aeration.
The detention time of the activated sludge system is 24 hours minimum,
48 hours maximum. Sludge generation from the aerobic digester totals
approximately £00 Kg/day (900 Ib/day) of dry solids at 2 to 4 percent
solids concentration. The overall efficiency of the treatment s-ystem
is a BOD reduction of 87 percent and a suspended solids reduction of
52 percent.
The wastewater treatment system at plant 9ST04 has the following major
components:
1- Screening of wastewater with solids going to landfill.
2. A 40 cu m (0.01 MG) equalization tank.
3. A 285 cu m (0.075 MG) activated sludge basin with a detention
time ranging from 36 to 48 hours and with aeration provided by
two mechanical aerators.
4. Two rectangular clarifiers in parallel.
5. An aerobic digester, mechanically aerated, with sludge disposal
to a cesspool.
6. Gaseous ammonia addition for neutralization of raw wastewater
prior to activated sludge basin.
The system has been in operation for less than 12 months and some diffic'jitv
1n optimizing efficiency is being experienced. The overall efficiency
of the treatment system at this plant is a BOD reduction of 88 percent
and a suspended solids reduction of 52 percent. Higher efficiencies
would be expected after operation optimization.
Selection of Control and Treatment Technology
A model plant was developed for instant tea processing in Section V. The
raw wastewater characteristics were assumed to be as follows:
Flow
BOO
ss
PH
454 cu m/day (0.12 MGD)
1000 ing/I
750 ipg/1
5.0 to 6.8
684
-------
DRAFT
TEA PROCESS INFLUENT
PH ADJUSTMENT
PRIMARY
CLARIFFP
14.000
CAP.- c I TY
160,ooo GAL.
CAPACITY
ACTIVATES
AERATION BASIN
109,000 GAL
CAPACITY
CONOAR
Q.ARIFER
22.000 GAL
CAPACITY
FIGURE 220
SECONDARY TREATMENT OP INSTANT TEA PROCESS WASTEWATER
PLANT 99Toi
685
-------
DRAFT
Table 127 lists the pollutant efflu >nt loading and the estimated operating
efficiency-«f each of the treatment trains selected for this subcatcgory.
Figures 221 and 222 illustrate the treatment alternatives.
Alternative A 30-1 - This alternative provides no additional treatment to
the raw waste effluent.
Alternative A 30-11 - This alternative consists of a pumping station,
TTow equalization, primary clarification, a complete mix activated sludge
system, a sludge thickener, an aerobic digester, and a vacuum filter. Flow
equalization is provided to dampen the effects of shock loading to the
system which would be expected due to variations in cleanup activities
during the day. The primary clarifier is assumed to remove 20 percent
of th» BOD and 33 percent of the suspended solids. The activated sludge
system is designed for a BOD loading of QOO Ibs per day, a detention time
of 34 hours, and a BOD reduction of 96 percent. The reduction of BOD
is assumed based on the high biodegradability of the waste and the data
from existing systems. The quantity of sludge from the vacuum filter is*
estimated at 1500 I/day (400 gal/day) for a yearly tstal of 219 x TCP cu m
(773 cu yd) of sludge to be hauled.
The overall benefit of this alternative is a BOD reduction of 96 percent
and a suspended iolids reduction of 85.3 percent.
Alternative A 30-III - This alternative consists of the same modules
as Alternative A 30-11 except vacuum filtration is replaced by sand
drying beds resulting in twice the anount of sludge to be hauled per
year than that of Alternative A 30-11.
Alternative A 30-1V - This alternative consists of a pumping station,
TTow equalization, and an aerated lagoon. The lagoon volume is 10,900 cu n
(2.88 I-IG). The overall efficiency of this alternative is a BOD reduction
of 96 percent and a suspended solids reduction of 85.3 percent.
Alternative A 30_-V - This alternative consists of the same modules as
Alternative A 30-11 with the addition of dual-media filtration. The
overall benefit of this alternative is a BOD reduction of 98 percent and
a suspended solids reduction of 97.3 percent.
Alternative A 3CM/1 - This alternative is identical to that of Alternative
A 30-1II with "the addition of dual-media filtration. The overall benefit
of this alternative is a BOD reduction of 98 percent and a suspended solids
reduction of 97.3 percent.
Alternative A 30-VII - This alternative consists of the same module:; as
Alternative A 30-IV except for the addition of dual media filtration, me
Overall benefit of this system is a BOD reduction of 98 percent and a suspended
solids reduction of 97.3 percent.
Alternative A 30-VI11 - This alternative consists of a pumping station
and flow equalization followed by spray irrigation. The land require-
ment for this alternative is 9.7 ha (Z4 acres) and it is assumed that
68G
-------
TABLE 127
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
Subcategory A 30
(INSTANT TEA)
Treatment Train
Alternative
A30 I
A30-II
A30-III
A30-IV
A30-V
A30-VI
A30-VII
A30-V11I
Effluent
BOD
kg/kkg
50
2.00
2.00
2.0
1.0
i.O
1.0
0
Effluent
SS
kg/kkg
37.5
5.50
•3.50
5.50
1.0
1.0
1.0
0
Percent
Removal
BOO
0
96
96
96
98
98
98
100
Percent
Removal
SS
0
85.3
85.3
85.3
97.3
97.3
97.3
100
-------
INFLUENT
FLOW = 45* CU M/OAY (0.12 MGC'i
BOO = 1,000 MG/t
5S = 750 MG/L
IFLOW
EQUALIZATION
1
1
1
DIGESTION I
f
SLurxiE j-
THICKENING
^_J VACUUM
~"1 FILTRATION ~*
SAND DRYING
BEDS ""*
1
SLUDGE TO
TRUCK HAUL
I PR iMAPY
j CLARIFICATION
I
A>T"IV
SLUDt-3
J
I
^ ^EO
BASIN
r
[SECONDARY
C^A^I^ICATIQN
(
CAJAL- MEDIA
FILTRATION
L
ALTERNATIVES
"A 30-11. i;j
EFFLUENT
BOD = 40 MC-/L
ss = no MG/L
ALTEPNATIVES
" A 30-v. vi
EFFLUENT
6QD = 20 MG/L
SS = 20 MG/L
FIGURE ^i
SUBCATE30RY A3O
ALTERNATIVES II. III. V. AND VI
688
-------
DRAF1
INFLUENT
FLOW = 45
B-C< = 1 . OOO MG/L
SS = 750 MG/V.
FLOW
EQUALIZATION
AERATED
LAGOCN
SETTLING
DONDS
L.
ALTERNATIVE
•-» A 30-iv
EFFLUENT
90D =40
SS = 110 MG/L
CXJAL-MEDIA
FILTRATION
ALTERNATIVE A 30-vn
EFFLUENT
BOS = 2C :-G/L
SS - 20 MG/L
FIGURE
SUBCATEGCWY A30
TREATMENT ALTERT4ATIVE5 IV AND VII
C89
-------
DRAfT
the spray fielci will be a maximum of one-half ;iii1e from the plant.
The overall benefit of this alternative is a BOD and SS reduction of
100 percent in terms cf discharge to navigable waters.
SUDCATCGOKY C 8 - COFFEE ROASTING UTILIZING ROASTER WET SCRUBBERS
In-Plant Technology
At the present time, no measures are employed to reduce the strength
of the v/astewater from coffee roaster wet. scrubbers. The volume of flow
from the wet scrubbers is determined by the degree of odor control desired
and the type of scrubber used. The flow can be minimized by selecting a
type of wet scrubber which effects the desired degree of odor removal
with the least amount of water consumption.
One plant contacted during this study and a pilot plant study indicate
that a ^circulating type of roaster wet scrubber can be utilized. The
use of a recirculating type of scrubber could reduce the volume cf waste-«
water generated per kkg (ton) of product by more than 90 percent. The
solids wiich accumulate in the recirculation tank could be disposed of in-
a landfill. In this way, wastewater discharge froTi roaster wet scrubbers
could be nominal .
End-of-Line Technology
Coffee roasting plants which utilize roaster wet scrubbers normally dis-
charge their wastev/ater to municipal systems. Since roaster wet scrubter
wastewate- is not particularly strong (GOD of 100 to 500 mg/1 and
suspended sol'id5 of about 200 mg/1), municipal treatment systems have
able to treat the wastes with no difficulty. As a result, no informatio
has been develo-ed on possible methods for treating the wastewater from
roaster wet scr
Selection of Control ard Treatment Te thnol igy
In Section V of this document, a model plant was developed for coffee
roasting utilizing onre-throjgh roaster wet scvbbers. The raw waste-
weter characteristics without screening were as follows:
BOD 350 ing /I
SS 200 mg/1
Flow 0.063 mid (0.017 mgd)
Since the strength of coffee roaster wet scrubber wastewater is approximately
that of normal domestic sewage, no prct'^atment before discharge to
municipal systems should be necessary. Jt is assumed that conventional
biologicai treatment methods are applicable to these wastes because cf
their similarity to municipal sewage.
12!', lists tho pollutant effluent, 'noil inn, and the estimated operatirp
officirncy of n.ir.h of tlic% five t'-cat.iont trains selected for this sub-
category.
690
-------
Treatment Train
Alternative
C 8 - I A
C 8 - II BEGKOSV
C « - ITT REGKOSVN
r « - IV BL
C 8 - V BLN
TABLE 128
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
Effli-ent
BOO
kg/kkq
0.76
0.043
0.021
0.076
o.tijt;
Effluent
SS
kg/kkq
0.43
0.043
0.013
0.086
0.025
Percent
BOD
Reduction
0
95
97
90
95
Percent
SS
Reduction
0
90
97
UU
94
-------
DRAFT
Alternative C 2 __- _ j_ •• This alternative provides no additional treatmen
to tde sciTcricd w
Alternative C 8 ^ j_l - This alternative consists of a pumping slJtion,
caustic neutralization, a primary clarifier, an activated sludge aeration
basin, secondary clarifier, sludge thickening vacuum filtration, and
sludge pumping and storage.
Alternative C 8 - III - This alternative consists of all of the treatment.
modules of Alternative C 3 - II with the addition of dual medio pressure
filtration and the associated pumping station. A schematic diagram of
Alternative C 8 - III is shown in Figure 223.
Alternative C 8 - IV - This alternative consists of a pumping station,
aerated lagoons, and associated settling ponds.
•
Alternative^ C 8 - V - This alternative consists of the treatment modules.
of Alternative C 8 - IV with the addition of a dual media pressure
filtration and the associated purr-ping station. A schematic diagram of
Alternative C 3 - V is shown in Figure 224.
SUBCATEGC';y C 9 - .DECAFFcI.'.'ATIQN OF COFFEE
In-Plant Technology
Currently efforts to reduce the waste load from plants producing decaf-
feinat.J coffee center on instruction of the personnel in water con-
servation. Since the equipment and floors are wet cleaned, the
volurre of wastewater generated can be minimized by use of efficient
cleanup procedures. Sone plants, especially those which are subject
to municipal surcharge programs, also stress the handling of screened
solids for disposal as solid waste.
Reductions in wastewater volume could be achieved through elimination of
the dewatering screen or redesigning it to reduce the Quantity of water
required to prevent clogging of the screen. In addition, voter meters
could be installed at the cleanup stations to make cleanup personnel
accountable fo- their water usage.
Reductions in wastewater strength could be accomplished by segregation
of the wastewater sources within the decaffeination process; e.g., the
hiqh strength/low volume waste itrean from centrifuge blcwrfown could
be handled as a sludge and hauled away for land disposal (burial).
In addition, by installing a storage tank, the equipment cleaning
solutions could be used several times before becoming so dirty that
they must be disposed to the waste stream; currently these clearing
solutions are used only once.
692
-------
DRAFT
INfLUENT
TRUCK HAUL
BOD = 350 MG/L
SS = 200 MG/L
FLOW = o.oes MLD to.oi? MGOI
PUMP 1 NO STAT I ON
PR IMARY CLAr? J r : ER
AUSTIC NEUTRALIZATION'
NUTRIENT ADDITION
ACTIVATED SLUDGE
AERATION' BASIN
SECONDARY CLARTFIER
j VE c s - I !
EFFLUENT
BOD
SS
FLOW
=20 MG/L
= '20 MG/L
= 0.065 MLD
(0.017 MOT' )
DUAL MEDIA P J L T£R
ALTERNATIVE c. R •:!!
BOO - 10
Sb r 6 MG-'L
PLOW = c . - * 5 ML r> i n . o i 7 vo D
CONTROL /»ND T~CATM£r,jT AL Tf R'JA r : Vf S C 8 - !I AMO III
-------
DRAFT
Cnd-of-Linr Technology
All of the «k?caf fcinated coffee producers in this country discharge
their wastes to municipal treatment systems; therefore, no complete
treatment systems are currently usr-d to treat this type of wastewater.
Three plants are known to utilize primary clarification followed by a
multi-stage? evaporative concentrator to pre-treat their soluble and/or
decaffeination coffee process wastewaters prior to discharge to municipal
sewers.
Some producers of decaffeinated coffee, in this country and abroad,
have conducted studies on the characteristics and treatabilit> of
coffee prc'-tssing wastes. The National Coffee Association has reportpd (1!
that the wastewaler is biologically treatable. Municipalities currently
receiving coffee decaffe'nation v/astewoter report no particular problems
in treating the waste. Unlike soluble coffee process wastewater, the
color characteristics of this wastewater are such that they apparently
do not create ? problem during treatment.
Selection of Control and Treatment Alternatives
In Section V, a model plant was developed for decaffeinated coffee
production. It was assumed that the model plant provided screening
of its wastewater pncr to discharce. ihe raw wastewater characteristics
were assumed as follows:
1. Flew rate - average - 0.24 mid (70,000 gpd)
2. BOD - 864 mg/1
3. SS - 1590 mg/1
4. pH - 4.3 to 7.2
5. 3.8 kg BOD per kkg of green coffee processed
6. 7.0 kg 53 kkg of green ccff'ee processed
7. H - 0 mg/1 (deficient)
8. P - 0 mg/1 (deficient)
TablelcJlists the pollutant effluent lead-inn and the estimated operating
efficiency of each of the three tre-itivo-it trains selected for this
subcategory. A schematic diagram of al! of the following alternatives
is shown in Figure 225.
Alternative C 9 - I - This alternative provides no additional treatment
to the screened wasteuoter.
G95
-------
TABLE 129
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
Treatment Train
Alternative
9-1 - A
C 0 - II - BCEGVY
C 9 - III - BCEGHIKQVNY
Effluent
BOO
kg/kkg
3.8
2.5
0.09
Effluent
SS
kq/kkg
7.0
1.8
0.09
Percent
BOO
Reduction
0
35
97
Percent
SS
Reduction
0
75
99
o
C7>
-------
DRAFT
INFLUENT
SLUDGE
THI r.KEN ING
VACUUM
F ILTRATION
BOO = 864 MG/L
SS = 1590 MG/L
FLOW = 0.2
-------
DRAFT
_._ve_C_^j;_n_- This alternative consists of a pumping station.
flow equol ,tLt:r"ri basin, primary clarificr, caustic neutralization,
vacuum filler, a;.d sludge storage tank.
Alternative C 9 - III - This alternative consists of the treatment
modules of AHernative C 9 - II plus nitrogen addition, phosphorus
addition, activated sludge aeration basin, secondary clarifier,
sludge thickening, a dual media filter, and associated pumping
station.
SUSCA7EGORY C 10 - SOLUBLE COFFEE
In-Plant Technology
Currently the efforts of soluble coffee manufacturers to reduce the
waste load from their plants center around reduction of water consumption.
Cleanup personnel in some plants are educated in water conservation
practices. Contact and non-contact waste streams have been separated
in many plants to permit the reuse or direct discharge to navigable waters
of non-contact wastewaters.
Several oiher procedures could be utilized to control wostscoter fron
soluble coffee plants. Use of rotary drying in lieu of grounds pressing
as a means of reducing the moisture content of spent grounds sub-
stantially reduces the plant waste load. However, rotary drying uses
more energy than grounds pressing. One plant contacted indicated that
it was planning on installing water metsrs at each cleaning station.
The cleanun forenan would then be responsible for insuring that water
consumption VMS within the prescribed limits. One plant contacted
indicated that they planned to install a storage tank to permit recovery
and reuse of caustic cleaning solutions.
End-of-line Technology
All soluble coffee plants discharge to municipal sewers. In most cases
the municipal treatment systems are ones servinn large cities, with the
result-that the wastewater froni the coffee olant is only a small per-
centage of the average daily flow through the treatment facility. Where
this situation exists, the municipal treatment systems reportedly are
capable of adenuately treating the soluble coffee plant wastewater.
However, soluble coffee plants winch are located in small municipaliti?s
have found that the municipal treatment systc-ns , e incapable of treating
their entire wasleloac). Chalmers (1*0) has studied this prohl?1', and in
at least three instances soluble coffee plants (two are in the United
States) have installed pre-tre,itr.ient systems which utilize clarifiers
and multi-stage evaporative concentrators to remove a majority of
the waste; load (ospocuilly suspeni-lfvl solids and color) from the waste
stream. The result inn condensa', ? is then discharged to the municipal
tre.iti"cnt systesi, for further r.reiiti:i?nt, and the concentrated sludge is
dispose.! hy burial O'i land or ocean dumping. The capital cost and the
opor.i'cion onrl maintenance cost, for cvapor.Uivp condensers as a trentnie-it
mcl.'ioJ art? hu;ii. .A sinnific.utt n"rc<.MUiiflc of the operating cost is for
enrrciy, both elccLric.il consKii'jt'ion and fuel oil.
698
-------
DRAFT
One plant of these tliroo plants plans to replace it:- evaporative
condenser pre-trc.nmpnt system with a physical-chemical pro-treatment
system utiTTzing .n'r flotation or ccntrifucjdtion, chemical addition, and
carbon absorption for suspended solids and color removal. Pilot tests
of this system are just beginning and final selection of the treatment
modules to be utilized has not been made. As a result this method of
treatment could not be included within the scope of this report at the
present time.
In addition, it has been reported that at least one complete
treatment facility for soluble coffee wastewater is operating outside
this country. Information concerning this treatment system is not
published and unavailable at the present time.
Selection of Control and Treatment Technology
In Section V a model plant was developed for soluble coffee processing.
It was assumed that tne model plant provided screening of its wastewater
prior to discharge. The raw wastewater characteristics after screening
were assumed as follows:
1. Flow - 0.62 mid (0.18 mgd)
2. BOO - 2400 mg/1
3. SS - 1560 mg/1
4. pH - 4 to 5
5. N - 0 mg/1 (deficient)
6. P - 0 mg/1 (deficient)
7. Color - 2775 Cobalt - platinum units
TableUOlists the pollutant effluent loading and the estimated operating
efficiency of each of the four treatment trains selected for this sub-
category.
Alternative C 10 - I - This alternative provides no additional treatment
to the screened wastewater.
Alternative C 10-11 - This alternative consists of a punning station,
flow equalization basin, primary clarifiet , multi-stage evaporative
concentrator, caustic neutralization and sludge storage tank. The
removal efficiencies ;hov/n in Table uOfor Alternative C 10-11 are based
on data collected during this study from a plant employing this treatment
train. A schematic diagram of Alternative C 10-11 Is shown In Figure 2wC.
The primary purpose of this treatment train 1s the removal of color.
699
-------
TABLE 130
SUWARY OF TREATMENT TRAIN ALTERNATIVES
Effluent
BOD
Treatment Train
Alternative
C 10 - I - A 18.8
C 10 - II - BCED1GVY 1.9
C 10 - III - CCEGH1KQSVNY 0.47
C 13 - IV - BCED1GHJKQSVY 0.19
Effluent
SS
12.3
0.25
0.35
0.04
Percent
COD
Reduction
0
90
96
99
Percent
SS
Reouction
0
99
94
99*
o
o
-------
TRUCK HAUL ._ SL IJO
r
SLUDGE
THICKENING
F I I. T R A T I ON
SLUDGE
THUCK
nAUL
INFLUENT
BOD = 2600 MG/L
55 = 1560 MG/L
FLOW = 0.62 MLD (O.i 8 MOD)
PUMP 1 NO STAT ION
r
FLOW EQUALIZATION
EVAPORATIVE
c A L' s T i c N <:
NUTRIENT A
— — . AL
ACTIVATED SLUDGE
AERATION BASIN
BCD
iS
LOW
SECONDARv CLARIFIfTR
ALTERNATIVE C ;o IV
BCD
55
L ow
r $ M i., / L
5 MG/L
n . i H MG
CONTROL AND TREATMENT A '_ ' ;. - \ AT ] v> S C 10- ! I AND IV
7:11
-------
DRAFT
AVtcrn.niye C_HMJ_L ' Thi'J alternative consists of a pumpimj station,
flow cqu'aTi*ot ion "basin, prim.iry cliirifier, caustic neutral izotinn,
nitrogen addition, phosphorus addition, activated sludge aeration basin,
secondary clarifier, sludge pumping, sludge thickening, vacuum filter,
sludge storage, and dual medi* filter. A schematic diagram of Alternative
C 10-111 is shov/n in Figure 2a?.This alternative is presented for use at
plants which do not have a significant color problem associated with
their wastewater.
Alternative C 10-I_V - This alternative consists of the treatment modules
of Alternative C 10-11 plus nitrogen addition, phosphorus addition,
activated sludge aeration basin, secondary clarifier, sludye Dumping,
sludge thickener, vacuum filter, and sluoge storage. A schematic
diagram of Alternative C 10-IV is shown in Figure 220.
SUBCATEGORY F 1 •• TEA DLENDIIiG
As described in Sections III and V of this document, the blending of tea
is a dry process generating no wastev/ater. Therefore, no wastewater
control and treatment technology is necessary,
SUBCATEGORY C 1 - BAKERY AKD CC.'.'FECTIQJ.'ERY PRODUCTS
In-Plant Technology
In-plant technology and procedures aimed at /educing waste load are
primarily divided into two subcategoriys: production procedures, and
cleanup operations. Since essentially all wasteuater originates fron
cleaning equipment, both existing and potential methods of reducing
either the strength or volume cf the waste stream are aimed at less
frequent wet cleaning of equipment.
Existing In-Plflnt Technology - U1th pan washing as the greatest single
source of high strength waste, considerable efforts have been made to
reduce or eliminate this operation. Cake bakeries attempt to \vash
their pans as infrequently as possible; however, the majority itill
wash the pans after .each use. So"n? types of cakes, particularly the
snack ca^.os, are amenable to production methods which eliminate pan
washing 5nt1rely; however, full si:e cakes are almost universally baked
in pans that do require wet cleaning. Three approaches to decreasing
the pan washing v.'dste load hjve been noted:
1.
2.
Dry cleaning the cake pans to the greatest extent possible
Baking cakes in one-way containers; e.g., aluminum foil pans
or paper cupcake liners witir.h nlso serve as partial containers
for the finished product
3. The complete elimination of c.ike pans
702
-------
f;'1 \\ I
INFI UENT
BOD = 2«>00 MG/L
SS = 1560 MG/L
FLOW = 0.62 MLD 'O.I& MOD)
PIJMP ING 3T AT I QN
FLOW EQUAL ! ZAT i c'
SLUDGE
THICKENING
VAC UUM
F IL TRA7 icy
l RUCK
HAUL
PR 1 MA=T" CLAR I F 1£R
APR AT I ON SA c j M
S;LC.7NC.- Aftv Ci. AR J f I£
3
DUAL • ^ i A ~ 1 LTE3
PLOW
4S MG/L
o . 6,7 *L
c AU?T i c NEUTPA;. ) r
NITROGEN ADD IT;..-,
S AQDITI'
( •"' . I 8 '"M3 )
CONTROL AfJD TRiA-'V.1 /..•--', AT J vf C 10 - III
-------
DRAPT
Modifications and approoche? to cleaning oquiimcnt in the pl.mt Usclf
have and will continue to decrease wnstc iooils. In general, niananemmt
of bakeries-stresses the dry cleaning of as much equipment as possible
before it is cleaned with water, particularly !>akcries which have their
own wastewater treatment facilities. In such plants, mixers, vats, hand
utensils, and conveyors are cleaned as thoroughly as possible by hand
using rubber scrapers, rags, and air hoses. Then they are either moved
to the wash room or for larger equipment, they are washed uiing their
clean-in-place System. The success of this approach ir. reducing the
waste load appears to hinge on the motivation of the individual workers
within the bakery. The extra effort required in thoroughly scraping a
vat or mixer may appear to be busy work to many employee:., ana they mur,t
be continually reminded of the importance of thorough dry cleaning before
the use of water in cleaning any equipment.
PptentiaJ In-Plant Technology - Potential methods of reducing a cake
ba'kery's wast'e load hinge on decreasing the amount of wet cleaning
required. The reduction or elimination of pan washing using one of t'u
approaches listed above .vi 11 have the greatest, impact on reduciivi
strength of a bakery's waste stream, increased stress or dry c
particul&i ly of equipment taken to the wash room for final wet c 1 ea m n.:,
will minimize the amounts of pollutants entering the waste stre.nr..
Another potential approjch is a decrease in the number of varieties
of cakes and pies produced in a single bakery. Some bakeries make
hundred:- of varieties of cakes. After the mixing and depositing of
the batter and filling for each variety of cake, the equipment is usual1. .
cleaned before the next variety of cake is mixed. These variety-induce.:
cleanings occur as frequently as every two hours. By reducing the nur.'.i r1
of product variations, a bakery can reduce its waste load.
End-of-Une "^chnolocy
Only one t-jkery in this subcatpgory is known to have a wastewater t-e?t-
ment system tnat dDDroaches the de.iree of trpat-ent required prior to
disch-i^^r to nav^Cdflt! \iAte*S. "'i? ',ic: 1''.;, is ntypicjl N> this '.i;b-
category 1:1 t.'at the Sa!;ory is 1 cciiti1.^ v/np'-;- trea trout pluiit sffluent
can be dicposed of ^ iii infiltration Tioppn*;. Another unjsujl feature
1s the fact that the system employs pnysical-chemical i".et.'io •:•:•.-•• \'...n- sensitive as witnessed In- t'i-.
fact that tl'p desifjnrr of th? r-\".-'.f' h,i-. h"'.-n retained Ji its chief
operator. AcUitiondlly, with the outlawing of infiltration as a
704
-------
DRAFT
CHEMICAL TANK:
INFLUENT
STATJSN
SCREENS
ATE
AM 'JM C
TANK
_ 9ACX Ai S
" T AN«c
I
L
:L.AB;F;E«
CENTR;PUOEI
C-NTACT
P .'
C2
705
lf ffi
-------
DRAFT
method in the location of the bakery, additional refi1 ''nont of this
system and/or additional treatment modules will have be incorporated
to accoinnotfnte surface discharge. Thus, this physic, chemical approuch
nay serve as a pro-treatment to a conventional biological system, but
will not provide the degree of treatment needed for surface discharge,
at least in its present configuration.
Sludge disposal is receiving some attention by bakeries 1n this and
other subcategories. One bakery spr.w irrigates its sludge. Two plants
are experimenting with feeding the sludge to c«tt1e.-
Selection of Control and Treatment Technology
In Section V, a model plant was developed for the production of cakes,
pies, doughnuts, and twee' y i5t goods utilizing pan washing. The
wastewater was screened prior tc discharge, and ir.s characteristics
after screening were assumed to be as follows:
BOD 28,000 mg/1 or 94.2 kg/kkg
SS 5,000 mg/1 or 16.8 kg/kkg
Oil 8 500 mg/1 or 1.7 kg/kkg
Grease
pi 6.0 to 7.0
N 2 mg/1
P 20 mg/1
Flow 0.45 mid (120,000 gpd)
Production 135 kkg/day (150 tons/day)
Table 131 listi th-:
efficiency of each of the treatment trams selected for th's subcate ;c'-y.
Alternative C 1 - 1 -1 This alternative provides no odditional tr^tt-u-•
to »he wasteivater.
A11 er na tj vi^ C _ J -__I_f - This altcrniUivp consist: • ' the treatment nuH-il-;-
used in the pnysicai-chp'incal tn/afrnt rvr.t(V 'ipscribt'^ .'^ove. txcL1;',.- •"•',
are the el i-nnotion of thp chlonn- »ontact tank, infiltration lrt(joc-r.
and associ.itrd cquiwnent. Solids omi sludge arc aiiumed to be trucl haul-."J
to a sanitary landfill.
70G
-------
TABLE 131
SlffKARY OF TREATMENT TRAIN ALTERNATIVES -
SUBCATEGORY C 1
Treatment Train
Alternative
C 1 - I A
C 1 - II BCDEFOV
C I - III BCOtEHlKQSVO
C 1 - IV BCOEehlKQSVT;
Effluent
BOO.
tg/(ckg
94.2
4.7
G.47
0.24
Effluent
SS
k3Afro
16. t'
0.50
0.34
0.17
Effluent
0 i G
kg/fckg
1.7
0.02
0.01
0.005
Percent
BOO
Reductions
0
95
99
99
Percent
SS
Reductions
0
97
98
99
Percent
0 8 G
Reductions
0
99
99
99
1
-------
DRAFT
INFLUENT
BOD = 29.000
SS = 5.000 MG/L
Dtw = 500 MG/L
CHEMICAL TANKS
A L U M ! N U v [
L
^ ANJOfJIC
^^M^L < cL bL . POL V i E
TH I CKEN I NG
*
VACUUM
FIuTRA-TON
l
SOLIDS TO
TRUCK HAUL
PUMPING STATION
\
SCREENS
*
CLOW EQUALIZATION
TANK
i
p 1 R5T' CL AR I^ i EP
SECOND CLABIFIEP
•
BACK V/ ASH
TANK
..
• SLUDGE TANK
1
AERATION BASIN
*
CL AP ! F 1 £9
«. ALT£
EFF.
Br
<
m
1 "UL T 1 -f'ED I A
|
SLUDGE TO
TRUCK HAUL
DONATIVE Cl - I I I
-UENT
DO = 1^0 MG/L
55 = 100 MG/L
,G = 2 MG/L
ALTERNATIVE Cl - IV
EFFLUENT
3CD •-• 70
SS = 50
OcG = l MG/L
F :--.--'£ 229
'••EN' ALTERNATIVES C: -in AND Ci - iv
709
-------
DRAFT
Another potential approach is a decrease in the number of varieties of
items produced in a single bakery or on a single production line. Usuolly
when variety changes are made, several pieces of equipment must be wet
cleaned. The items involved include mixers, depositors, and intercon-
necting pipes and pumps. These variety-induced cleanings occur as
frequently as every two hours. By reducing the number of product
variations, a bakery can reduce its waste load.
End-of-Line Technology
Only one bakery in this subcatego-y is known to have a wastewater
treatment system discharging to navigable waters. This treatment plant
is shown schematically in Figure230. It has been developed and nodiffed
over several years. It has provided adequate treatment for the
bakery's waste. The most recent oerformance data indicate BOD and
suspended solids reductions averaging 99 percent and 98 percent,
respectively. The plant was designed to handle 0.195 mid (50,000 cpd)
with a BOD concentration of 2,500 rtg/1 (a BOD loading of 473 kq per day
or 1,040 1b oer day). Currently, the average daily flow is approx-
imately 90 percent of design and BOD concentrations average 2,210.
The BOD concentrations in the effluent currently average 8 mg/1 and
range from 7 to 9 mg/1. No design parameters were established for
suspended solids; however, current influent concentrations average
approximately 1,020 mg/1, and the effluent averages!2 mq/1 with ranges
from 6 to 15 mg/1. Similarly, no design criteria was established for
oil and grease. The current influent oil and grease concentration
averages about 695 mg/1 wh'le the effluent contains an average of 8
mg/1 and ranges from 2 to 18 mg/1.
The design of this treatment facility appears to be particularly
appropriate to bakery wastes for the following reasons:
1. The air flotation unit 1s effective in removal of oil and
grease and suspended solids.
2. The plastic media trickling filter 1s credited by plant
personnel with removal of significant amounts of oil and
grease, arid an adjustment of the pH such that no chemical
neutralization 1s requi.-ed. Measurements of filter in-
fluent and effluent (141)indicate near neutralization of
the raw waste's pH of 5 by the unit. The filter is also
effective in*handling the shock loading applied by the bakery.
Selection r>f Control and Treatment Technology
In Section V, a model plant was developed for the production of cakes
and other bakery products using methods that did not involve pan
washing. It was assumed that screening was provided all wastewater
befora discharge. The raw wastewater characteristics after screening
were as follows:
710
-------
DRAFT
EFFLUENT FROH
MANUAL PH CONTROL
EQUALIZATION TANK
1
DISSOLVED AIR FLOTATION
I
NUTRIENT ADDITION
\
ROUGHING FILTER
,
ACTIVATED SLUDGE
1
AERATION BASIN
1
CLARIF IER
*
CLARI F IER
SLUDGE RETURN \
AEROBIC STADIL1ZATION
POND
AHROB 1C STABILIZATION
POND
/ SKIMV : \-c-s
AND Excir:-.s
SLUDGE: TL-
TANK T3UCK
FOR SP^AV
IRRI GAT J wr;
EFFLUENT TO
FIGURF 230
EXISTING TREATMENT TECHNrLDGY - SUBCATEGORY C 2
711
-------
TABLE 132
SUMMARY OF TREATMENT TRAIN ALTERNATIVES SUBCATEGORY C 2
Treatment Train
Alternative
I
II
III
IV
V
VI
VII
VIII
A
BCJV
BCJVHX
BCJSVHXK
BCJSVHXKN
BCJSVHKM
BHL
8HLU
Effluent
BOD
kn/kko
2.0
1.0
0.50
50
0.025
0.025
0.20
N/A
Effluent
SS
kq/kkq
0.94
0.23
0.14
0.042
0.011
0.022
0.28
N/A
Effluent
OfiG
ko/kka
0.63
0.19
0.085
0.026
0.013
0.013
0.19
N/A
Percent
BOD
Reduction
0
50
75
97
99
99
90
100
Percent
SS
Reduction
0
70
85
95
99
98
70
100
Percent
O&G
Reduction
0
70
85
95
98
98
70
100
-------
DRAFT
INFLUENT
BOD = 2190 MG/L
SS = 1020 MG/L
OtG = 685 MG/L
FLOW = 0.16 MLO (43.000 GPD >
SLUDGE ^
PUMP V
VACUUM
F ;LTER
1 "~ i
1 1
r- — ,
j SLUDGE ».
JTHI CKSiNER
, I »L.'JD(jc
""[ STOWAGE
SLUDGE TO
TRUCK MAUL
FLOW EQUALIZATION
""" TANK
1
DISSOLVED AIR
FLOTATION
AlTEPNATIVE C 2- " 3
_^_ EFFLUENT
BOD = noo MG/C
SS = 310 MG/L
k ,.-r,,,-kiT ut^ = 206 MG/L
Nlj'RIENT vi-
ADDITJON
\
ROUGH !NG FJLTEP. ALTERNATIVE C 2-117
-_^. _ -M^ — ** FKF1 UFNT
^C;^:;^NS;^?N ODD » 550 MG,L
1 . "" " ,.".' , ... fiS - 1 5 S r/^ -i
^ OtG = 103 MG/I.
J [SECCN'DAr-VY CLARIFIED
ALTERNATIVE •" "•-!''
, "*" EFFLUENT
DUAL-MEDIA I eor, m ^ „,.,._
r.lL'EP7 J SS = o M-J/U
1 0 (. o :- j 1 M G / U
ALTERNATIVE C ?-V EFFLUENT
BOD - 28 MG/L
SS = 1 i. MG/L
Of. G - 10 MG/L.
TREATMENT ALTERNATIVES C ?-II THROUGH C 2-V
71-1
-------
DRAFT
3. Sludge thickener
4. Additional capacity for vacuum filtration
Alternative C 2-V - This alternative includes the treatment moduler in
Alternative C 2-IV with the addition of a dual media pressure filtration
system.
Alternative C 2-VI - This alternative includes the treatment modules
in Alternative C 2-V with two aerobic stabilization ponds replacing
the dual media pressure filtration system.
Alternative C 2-VII - This alternative consists of the following:
1. Caustic neutralization
2. Nutrient addition (nitrogen)
3. An aerated laqoon system
Figure 232 Illustrates this alternative schematically.
AUernative C 2- VI11 - This alternative includes the treatment modules
Trf Alternative C 2-VII with the addition of spray irrigation (see
Figure 233).
SUBCATEGORY C 3 - BREAD AND BUNS
In-Vlant Technology
At the present tine, many bread and bun bakeries are aware rf their
wastewater problem. Sanitary, contact,and non-contact wastewaters have
b.een separated in nany plants. Some plants emphasize dry cleaning of
equipment and floors prior to wet cleaning.
In addition, wastewater flow and strength could be reduced if all floors
were vacuumed, scraped, or swept before wet cleaning. Where CIP systc-.s
are used, if the final rinse water fro*" one cleaning operation were
utilized as the pre-rinse water for the subsequent cleaning operation, the
volume of wastewater would be reduced.
End-of-Line Technology
No bakery 1n this subcategory is knov;n tc have ? wastewator treatment
system that approaches the degree cf treatment required for discharge
to navigable waters. All of the bakeries surveyed in this subcategory
discharge to municipal sewage systems, and none of them provided treat-
ment other than screening.
715
-------
DP. APT
INFLUENT
BOD = 2190 MG/L
SS = 1020 MG/L
OtG = 685 MG/L
FLOW = 0.16 MLD (43,000 GPD)
CAUSTJC NEUTRAL I?ATTON
NUTRIENT ADDITION
(NITROGEN)
I AERATED
LAGOCN
5TABILI2ATI ON
POND
STABILIZATION
PONU
SPRAY
•»./
.ALTERNATIVE C 2~V]
EFFLUENT
BDD = 219 MG/L
SS = 306 KG/i.
OtG = 206 MG/L
\\f IRK I GAT I
ALTERNATIVE C 2-VIII EFFLUENT =: 0
FIGURE £32
TRCATMCNT ALTf HNAT J VCS C r-Vll AND C 3-VI1I
71C
-------
DRAFT
Solection-of Control aid Treatment Technology
In Section V of this document, a model plant was developed for bread
and bun bakeries. The raw waste characteristics after screening were
assumed to be as follows:
1. Flow - 0.10 mid (0.026 mgd)
2. DOD - 422 mg/1
3. SS - 214 mg/1
4. pH - 6.0 to 9.0
5. P - 0 mg/1 (deficient)
6. M - 0 mg/1 (deficient)
Since all known bread and bun bakeries currently discharge to municipal
sewers, a transfer of treatment technology i=> required. Plants in
Subcategory C 2, manufacturing cakes and pies without utilizing pan
.-.jshing, have a waste strength greater than, and a waste source similar
to, plants producing bread and buns. In addition, the waste strength
of bread and bun bakeries is less than twice that of municipal sewage.
Since there is no indication of any particular complicating characteristic;
of bread bakery wastewater, the treatment alternatives discussed belov;
were selected based on their satisfactory ;.. ;>-fomance in treating
municipal sewage and wastes from Subcategory C 2 .
Table 133 lists the pollutant effluent loading and the estimated ooerating
efficiency of each of the four treatment trains selected for this ;ub-
category.
Alternative C 3 • I - This alternative provides no additional treatment
to the screened wastewater.
Alternative C 3 - II - This alternative consists of a pumping station,
TTow equal1zation basin, primar;/ clarifier, nitrogen addition,
phosphorus addition, activated sludge aeration basin, secondary clarifier,
sludge pump, sludge thickener, vacuum filter, and sludge sturaae. A
schematic diagram of Alternative C 3 - II is shown in Figure 233.
Alternative C 3 - III - This alternative consists of the treatment
modules of Alternative C 3 - II with the addition of a dual media
filter and associated pumping station. A schematic diagram of Alternative
C 3 - 111 1s shown in Figure 233.
Alternative C 3 - IV - This alternative consists of a pumping station,
nitrogen adoinon, phosphorus addition, aerated lagoon, two settling
ponds, pumping station, and dual media pressure filter. A schematic
diagram of Alternative C 3 - IV is shown in Figure 234.
717
-------
Treatment Train
Alternative
C 1 - I
C 3 - II BCEHIKQSVY
C 3 - III BCEHlKfiQSVY
C 3 - IV BHILM
TABLE 133
Sunrrary of Treatment Train Alternatives
Effluent
BOD
0.88
0.045
0.012
0.044
Effluent
SS
kg/kkg
0.46
0.045
0.0)1
0.044
Percent
BOD
Reduction
0
95
98
95
Percent
SS
Reduction
0
«5
ytf
88
o
-------
DRAFT
INFLUENT
BOO = *22 MG/L
SS = 214 MG/L
FLOW = 0.10 MLO (0.026 MGD>
PUMPING STATION
RETURN
SLUDGE
THICKENER
VACUUM
FILTER
SLUDGE
STORAGE
«• FLOW EQUALIZATION
PRIMARY CLARIFIER
ACTIVATED SLUDGE
AERATION BASIN
SECONDARY CLAPIFIER
DUAL MEDIA FILTER
NITROGEN 'ADD IT I ~
PHOSPHORUS
ADD I 7 ION
•» ALTERS/AT i vs C 3
II
BCD =21
SS = 21 MG/L
FLOW = o.io VI_D
< o. crt••••-•_•' >
ALTERNATIVE C H- I I I EFFLUENT
SLUDGE TO
TRUCK HAUL.
BCD = 10 MG/L
SS -- ; 5 MG/L
FLOW = o.jo MLD (0.026 MGO>
FIGURE 233
CONTROL AND TREATMENT ALTE f>NATI VF.S C 3-1 I AND III
719
-------
DRAFT
INI'LUGNT
BOO = *22 MG/L
SS = 214 MG/L
FLOW = o.io MLD (o.ose MGDJ
PUMPING STATION
AERATED LAGOON
SETTLING PONDS
DUAL MEDIA FILTER
NI TROCEN ADC I 7 : T •;
PHOSPHORUS ADDITION
EPFLUCNT
BOD = 21 MT,/L
55 = 21 MG/L
FLOW = o.,:o MLD to.oce MGD>
FIGURE 234
CONTROL AND TRF.AT'-'CNT ALTERNATIVC C 3 - IV
7?0
-------
DP-APT
SUBCATEWKY C 7 - COOKIE Af.'D CRACKER MANUFACTURING
In-Plant Technology
Additional measures could be taken to reduce wastewater flow and
strength. If all floors were vacuum cleaned before being wet cleaned,
the strength of the wastcwater from the p'lant would be reduced. Utiliz-
ation of CIP systems in v/hich the final rinse water from one cleaning
operation was utilized as the pre-rlnso water for the subsequent
cleaning operation would reduce the volume of wastewater generated by
the clcanina of the icina handling equipment. Since cleaning of the
1dnrj equipment is usually necessary before changing to the production
- ' a'different variety of cookie, changes of product should be made
as infrequently as oossible in order to reduce both volume and strennth
of wastev/ater.
End-of-L1ne Technology
No bakery in this subcategory is known to have a wastewater treatment
system that approaches the degree of treatment required for discharge
to navigable waters. All of the bakeries surveyed in this suocategory
discharge to municipal se'.vage systems. Most plants have grease trans
as a fcrm of pre-treatment to reduce sewer blockages resulting from
the high (average 500 ng/1) concentrations of animcl and vegetable fats
1n the waste stream. However, grease traps appear to he high-maintenance
items if they are to operate properly. One cookie and cracker bakery
removed their traps when air floatation was installed.
Some plants successfully utilise flow eaualizatlon and air floatation
as pre-treatrent nodules. They have been shown to reduce the concentra-
tion of oil and grease being discharged to the municipality to less tnan
100 mg/1. The sludge generated from the air floatation treatment
process 1s normally hauled by a disposal contractor to a rendering
service.
Selection of Control and Treatment Technology
In Section V a model plant was develcoed for cookies and cracker orortuc-
tion. The raw wastewater characteristics aftnr screening were assineJ
to be as follows:
ROD
SS
O&G
PH
Flow
At present no cookie and cracker manufacture has a complete treatment
system, because all such plants currently discharge to municipal
sewage treatment systems. As a resjlt, a transfer of treatment
technology from a simllflr Industry is required. Plants in subcateqory
1200
900
500
6.3 -
0.34
mg/1
mp/1
mg/1
8.7
mid
or 2.0
or 1.5
or 0.85
(0.09 mgd)
kg/kkg
ko/kkg
kg/kkg
-------
DRAFT
C 2, manufacturing cakes and Dies without utilizing pan washing, hove
both ci waste strength and war.te sources (raw materials involved as
well as operations generating the wastes) similar to plants manufacturing
cookies and crackers. The .reatmont modules of the treatment alternatives
discussed below were selected based on their satisfactory performance
1n treating wastes from subcategory C '(.. Alternative C 7-II 1s considered
to be an effective method of pre-treatment due to its current widespread
usage as a method of pretreatment 1n the cookie and cracker industry.
Tab1el34iists the pollutant effluent loading and the estimated o&eratinq
efficiency of each of the six treatment trains selected for this sub-
category.
Alternative C 7 - I - This alternative provides no additional treatment
to the screened wastewater.
Alternative C 7 - II- This alternative consists of flow equalization,
air floatiori, a pumoing station, and storage for separated solids and
grease. It is assu:red"that the separated solids are truck haul'ed to
a rendering company at no cost to the bakery.
Alternative C 7 - III - This alternative consists of the treatment
modules of Alternative C 7 - II with the addition of an aerated lagoon
and the associated settling ponds. The schematic diagram of Alternative
C 7 - III is shown in Figure 235.
Alternative C 7 - IV - This alternative consists of the treatment
modules of Alternative C 7 - II with the addition of activated sludge,
secondary clarifier, sludge pumping, sludge thickening, and vacuum
filtration.
Alternative C 7 - Vi - This alternative consists of the treatment module:
of Alternative C 7 - V with the addition of dual nieJia pressure filtration
and the associated pumping station. The schematic diagram of Alternative
C 7 - VI is Shown in Figure 236.
SUBCATEGORY C 12 - SANDWICHES
Jn-Plant Technology
Sandwich manufacturers generate relatively small volumes of wastewater
(a few thousand liters per day at most), and consequently have not
made any particular effort tc reduce their waste load.
Virtually all wastewater from sandwich plants 1s a result of cleanup
operations. Therefore, efficient cleanup or-ocedures (water conservation
practices) and training of the cleonup personnel would be the p> imary
means of reducing sandwich producer's process wastewater.
-------
TABLE 174
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
;
Treat-rent Train
Alternative
C
C
C
c
>
3 c
c
7 -
7 -
7 -
7 -
7 -
7 -
I
II
HI
IV
V
vr
A
CJ
CJL
CJLN
CJKQSV
CJKQSUN
Effluent
BOO
kg/kkg
2.0
0.8
0.1
0.05
Effluent
SS
kg/xkg
1.
0.
0.
0.
5
45
15
06
C-^ 0.10
0.05
n
03
Effluent
OiG
kg/kkg
0.
0.
0.
C.
0.
0.
85
3
09
05
09
05
Percent
BOO
Reduction
0
60
95
98
95
98
Percent
SS
Reduction
0
70
90
96
93
96
Percent
OSG
Reduction
0
65
90
94
90
94
-------
DRAFT
TRUCK
HAUL
INFLUENT
BOD = 1200 MG/L
SS = 900 MG/L
OCG = 500 MG/L
FLOW = 0.34 MLD (0.09 MGD>
PUMPING STATION
FLOW EQUALIZATION
AIR FLOATATION
AERATED LAGOON
SETTLING
PONDS
ALTERNATIVE C 7 - HI EFFLUENT
BOD = 60 MG/L
SS = 90 MG/L
DtG = 50 MG/L
FLOW = 0.34 MLD '0.09 KGD }
FIGURE 235
CONTROL AND TREATMENT ALTERNATIVES C 7 - 111
724
-------
Div.rr
INFLUENT
BOD = 1200 MG/L
SS = 900 MG/L
FLOW = 0.34 MLD (0.09 MGO )
OtG = 500 MG/L
RENDER
FIR
ING
MS
SLUC
THICK
VACL
RET
SLUDGE,
)GE
>HNER
•
JUM
FILTER
• v.
URN
1.
l
FLOW EQUALIZATION
TANK
1
DISSOLVED AIR
FLOATAT ION
ACTIVATED SLUDGE
AERATION BASIN
1
SE: CNDARY
^
CLARIFIER
DUAL MEDIA FILTER
1
ALTERNAT I VE C 7- I I
BOD = 480 M3/L
- SS = 270 "G/L
ALTERNATIVE C ?-v
«. EFFLUENT
BOD a 60 WG/L
SS = 60 MG/L
SLUDGE
STORAGE
1
ALTERNATIVE C 7 - VI EFFLUENT
BOD =30 MG/L
SS = 20 MG/L
FLOW = 0.34 MLD (O.C9 MGD )
OtG = 20 MG/L
SLUDGE TO
TRUCK HAUL
FIGURE 236
CONTROL AND TREATMENT ALTERNATIVES C7-II. V. AND VI
72b
-------
DRAFT
End-of-Line Technolooy
All of the~plants contacted during this study discharqo their wastcwatcr
to municipal sev/ers. No particular problems v/ere reported by these
municipalities in treating the wastcwater. Some plants utilize grease
traps to prevent clogging of sewer lines, but this''is the only method
of pre-treatment currently in use. No studies of the treatability or
characteristics of the wastewater have been performed.
Selection of Control and Treatment Technology
In Section V, a model plant was developed for sandwich manufacturing.
The flow from the model plant is 7,600 1 (2,000 gal) per day. This
volume of wastewater is small enough and the strength great enough
that direct treatment is impractical. As a result, the wastewater should
be treated by a municipal system.
•
Alternative C 12 - I - This alternative provides no additional treatment
to the screened wastewater.
Alternative C 12 - II - This alternative consists of a storage tank
and truck hauling of the wastewater to a municipal treatment facility.
SUSCATEGORY D 1 - CANDY AND CONFECTIONARY
Existing In-Plant Technology
Two plants have screening, filtration, centrifugation and reverse osmosis
units which result in no discharge of wastewaters from processing areas,
specifically from candy forming machines which require constant cleansing.
The plants utilizing reverse osmosis also incorporated screening, dia-
tomaceous earth filtration, centrifugation and in-process reuse of re-
covered materials. Wire mesh screening and centrlfuging were primarily
used for removal of particulate materials and oil substances, respectively
Filtration with diatomaceous earth was employed prior to reverse osn^sis
for removal of suspended solias; thereby preventing clogging of reverse
osmos'is menil *anes.
Sugars recovered from the reverse osmosis equipment are condensed in
evaporators and recycled to the processing line. Defective candy fron
certain other plants are frist dissolved and then filtered through dia-
tomaceous earth to remove coloration, etc. The reclaimed syrup is then
reused in preliminary steps of processing.
Cooling and condenser water were recycled in 85 percent of the plants
visited. Compressor and steam condensate water were reused in over 50
percent of the plants.
Waslidown water is the primary source of waste effluent from this industry.
Most plants employ various methods of in-plant controls to reduce its
Impact. All plants use dry collection of solids by sweeping or vacuuming
726
-------
DRAFT
prior to washdowns. Actual washdov/n with hoses is limited generally to
tho kitcheji area. Alternatively, wet mopping or wiping is done in the
remainder of the plant areas. Furthermore, many plants have blocked
sewer outlets and eliminated hoses to reduce water usage in specific
areas.
Edible solids such as starches and contaminated candies are generally
disposed of by contract haulers for animal feed supplement. Non-edible
solids and paper are generally hauled av/ay to landfill areas or, in
certain instances when liquid wastes (sludges) are involved, are taken
to farm lands to be used as fertilizer.
Potential In-Plant Technology
Plants can usually realize substantial savings in treatment or in sewer
costs through either reducing usage or recycling certain processing
waters. Recycling of cooling or condenser waters should be considered
by all plants as an economical method of reducing wastewater. Much of
the waste currently being discarded or lost in plant effluent can be
reused when processed or reclaimed in an acceptable manner. For exanple,
preliminary wash waters from the "kitchen" cooking kettles and holding
tanki can be recovered and, with a minimum amount of reprocessing, most
sugar can be removed and reused. This is currently being done in a few
plants with substantial savings being realized, not only from a treatment
standpoint, but also in product recovery.
Clean-in-place (CIP) units and flow control valves which are jseu on
certain types of equipment are water and cost saving devices that can
be employed by all plants.
Reducing the use of water in generaly by 'increasing workers' awareness
1s another bas^c step in good water management. Water use could be mini-
mized by common sense techniques like turning off faucets and hoses when
not In'use, by using high-pressure, low-volume water supply systems, and
by dry clean-up in-plant valves are a valves are a valuable contribution
to water conservation measures.
End-of-Line Technology
Of the total of 20 plants visited during this study, 15 had no form of
pre-treatment measures. Every plant visited discharged the majority of
its wastes directly to municipal sewage systems. Pre-treatment systems
that were observed consisted of three'plants which utilized grease and
oil removal systems. These systems varied in degree of sophistication
from an ordinary grease trap to a small aerobic system.
Grease and oils, as mentioned in Section V, are the primary concern of
certain manufacturers in this subcategory. Test results from one plant
utilizing a name brand filter show reductions in grease and oil loadings
of 89 percent. Ordinary grease traps have been found to be effective
1n removal of oils and greases to acceptable levels for subsequent.
727
-------
DRAFT
biological treatment. Suspended solids and BOD were reduced by 87
and 92 percent, respectively, at the one plant utilizing an aerobic
treatment system.
Two plants currently have treatment systems either proposed or under
construction. One plant has under design a dissolved air flotation
unit with recycle; and the other plant is constructing an aerobic
digestion system with an 825,000 gallon capacity.
Dissolved air flotation treatability results show an average concen-
tration reduction in hexane solubles of 100 mg/1 to 40 mg/1 with a
corresponding 10 percent reduction. Maximum hexane soluble loadings
wererreduced from 750 mg/1 to 100 mg/1, during these tests, corresponding
to 86 percent reduction.
Selection of Control and Treatment Technology
In Section V a model plant was developed for candy and confectionery
processing. The raw wastewater characteristics after screening and
grease trap were taken as follows:
BOD 1300 mg/1
SS 170 mg/1
O&G 555 mg/1
Flow 375 cu m/day (0.099 MGO)
Table 135 lists the pollutant effluent loading and estimated operating
efficiency of each of the seven treatment trains selected for this sub-
category.
Alternative D 1-1 - This alternative provides no additional treatment
to the screened wastewater.
Alternative D l-II - This alternative consists of a pumping station,
flow equalization, and an aerated lagoon system with nitrogen addition.
Alternative * 1-1II - This alternative replaces the aerated lagoon
.system of Alt' ^native D-II with an activated sludge unit. In addition,
the treatment train incorporates sludge thickening, aerobic digestion
and truck hauling or'dewatered sludge.
Alternative D 1-IV - Alternative D 1-1V is identical to Alternative D 1-I1I
except for the addition of sand drying beds for sludge disposal.
Alternative D 1-V - This alternative provides the addition to Alternative
D 1-IV a dual media pressure filtration system as a final treatment step.
Alternative D 1-VI - This alternative adds, to Alternative D l-II, a dual
media pressure filtration system.
720
-------
DRAFT
TABLE 135
SUMMARY OF TREATIOT TRAIN ALTERNATIVES
SUBCATEGORY D 1
Treatmtnt Train
Alternative
Dl-I
01-11
Dl-III
Dl-IV
Dl-V
Dl-VI
Effluent
BOD
mg/1
1300
65
39
39
20
26
Effluent
SS
mg/1
170
30
20
20
10
10
Percent
BOD
Reduction
0
95
97
97
98.5
98
Percent
SS
Reduction
0
82
88
88
94
94
729
-------
DRAFT
SUPCATCGORY D 2 CHEUING GUM
Existing In-PIfmt Technology
Of the total of 14 plants contacted or for which data were supplied by
the National Association of Chewing Gum Manufacturers, 50 percent recycled
all or most of their cooling and chill waters. Three of these plants
discharged wastev/ater from cooling directly to municipal sewage systems
along with their waste streams. Two plants discharged cooling waters
into storm sewers, and the remaining two plants either spray irrigated
or eliminated this waste through well disposal. Cooling waters comprise
the largest flow volumes associated with this Industry (i.e. 70 percent
of the plants contacted discharged over half'their water as non-contact
cooling water, either in the form of overflows or once through discharges).
Non-contact cooling water does not fall within the definition of process
wastewater used in this study.
In terms of waste loadings, the two most significant sources of wastewatrers1
1n this industry are air scrubbers and clean-up waters. Air scrubbers
were used by 75 percent of the plants contacted. One of the primary
uses of air scrubbers is to clean ambient air of foreign substances,
primarily sugar particles. Many techniques wsre observed to be used
by various plants to minimize the effect of this source of effluent
on wasts loadings. One method enployec! by several plants was to re-
circulate the air scrubber water until saturated, then to purge the
holding tanks completely anH refill. Other plants continually sup-
plied fresh make-up waters to the scrubbers; thereby keeping concentra-
tions at certain levels by regulating make-up water volumes. One plant
contacted used a completely dry technique to capture sugar dust in the
air, eliminating the use of water altogether. This system even segre-
gated sugars by flavor and color.
Clean-up operations varied significantly from plant to plant. Because gu:n
In contact with water forms a sticky mass, most plants employ dry clean-
Ing by scraping or sweeping. Minimal wet cleaning 1s employed at the
plants, and generally wet cleaning was done by mopping or scrubbing
with solvents (SAV-A-SAL), disinfectants, and water subsequent to dry
removal by sc.-jping or sweeping. Cleaning rooms were utilized by almost
all plants to clean machinery and equipment.. This equipment was period-
ically dismantled and subjected to extensive steam or hot water cleanings
with the optional use of solvents or cleaners.
Damoged or defective chewing gum was usually recycled to the processing
line. At one plant the "bowl'cake" (by-product ^ft after gum bases
have been rmjlted and screened), was retained and returned to the gum
base refinery to be reprocessed. Other waste solids, with the exception
of paper 1n certain instances, were dupos°d at sanitary landfill sita;.
Two plants visited separated and recycled paper products. This procedure
nay be employed at other plants to reduce solid wastes.
730
-------
DRAFT
Damaged or_defective chewing gum was usually recycled to the processing
line. At one plant the "bowl cake" (by-product left after gum bases
have been melted and screened), was retained and returned to the gum
base refinery to be reprocessed. Other waste solids, with the exception
Of paper in certain instances, were disposed at sanitary landfill sites.
Two plants visited separated and recycled paper products. This procedure
may be employed at other plants to reduce solid wastes.
Potential In-Plant Technology
Plants not currently recycling cooling, condenser or chill water should
consider this as a major step in water management. Recycling of ste^rr,
condens^te, which was done at one plant visited by the contractor, should
also be a step towards water conservation. Air scrubber water can pcssi-
bly be eliminated and substituted by dry collection by suoar particles
except in cases where humidity control is desired.
Minimizing the use of water in clean-up operations has been pursued
ty most plants contacted; however, educating plant personnel
of the necessity for water conservation would be helpful toward accom-
plishment cf desirable water management policies.
End-of-Line Technology
Of the total number of plants contacted, only five employed some type
of treatment for their wast?waters. Two plants simply treat their
wsstewaters by employing settling basins before discharging to municipal
systems. Settled natter is generally hailed away under contract. One
plant discharges only dcr.estic waste to a municipal systen and stores
all processing and clean-up wastes in a holding tank, v/fiich is taken
to a sanitary landfill for disposal. Two plants utilize activated
sludge with aeration lagoons and final spray irrigation to treat and
dispose of wastes. These practices have resulted in no discharge
of process wastewater pollutants to surface waters from these two
plants. Reductions from the activated sludge system averaged 96 per-
cent BOO '-eroval, 90 percent rcroval of suspended solids and 88 per-
cent volatile solids removals. Influent pH averaged 8.6 and decreased
to 7.6 after treatment and prior to irrigation.
Selection of Control and Treatment Technology
In Section V a model plant was developed for chewing gum processing.
The raw wastewater characteristics after screening were assumed to be
as follows:
BOO 900 fflg/1
SS 95 mg/1
O&G 50 mg/1
Flow 322 cu m/day (0.085 MGO)
731
-------
DRAFT
Table (36 lists the pollutant effluent loading and estimated operating
efficiency of each of the eight treatment trains selected for this sub-
category. _
Alternative D 2-1 - This alternative provides no additional treatment
of the screened wastewater.
Alternative P_2-_Ij_ - This alternative consists of a pumping station, a
flow equalization basin, and an aerated lagoon system witli nitrogen
addition.
Alternative D 2-III - This alternative replaces the aerated lagoon system
of Alternative 0 2-11 with an activated sludge unit. In addition, the
treatment train incorporates sludge thickening, aerobic digestion, and
truck hauling.
Alternative D 2-IV' - Alternative D 2-V 1s identical to Alternative D 2-MI
except for the addition of sand drying beds for sludge disposal.
Alternative D 2-V - This alternative adds, to Alternative D 2-IV, a dual
media pressure filtration system as a final treatment step.
Alternative 0 2-VI - This alternative adds a pumping station, pipe line
and spray irrigationttc the treatment train of Alternative D 2-11.
Alternative D 2-VI? - This rlternative adds a pumping station, pipe line,
and spray in igation to the treatment train of Alternative D 2-III.
5UBCATEGORY D 3 GUM BASE
Existing In-Plant Technology
As explained in Section V of this report, only three plants in this
subcategory were considered of significant benefit for establishing
1n-plant technology. Process cooling water 1s redrculated at two
o^ these plants. The other plant identified from the national Associ-
ation .of Chewing Gun Manufacturers survey rf^d ret Indicate any re-
cycling of cooling water.
The primary waste sources 1n this industry are derived from washdowns
and processing. Dry cleaning methods are a ,'reliminary step used by
all plants before the major washdown process. Dry cleaning methods
include dry-scraping and vacuuming. Cleansing agents such as tr1 -scd'iun-
phosphate are spread on the floor to remove the softened gum deposits.
These washdown flows avenged 15 percent of the plant flows and are
high in wastu pollutant loading Reductions ;n the use of solvt-tr. har.
been initiated at one plant with a 45 percent decrease over a three-
year period.
732
-------
DRAFT
TABLE 136
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
SU3CATEGORV D 2
Treatment Train
AT ternative
D2-I
02-11
D2-III
D2-IV
D2-V
D2-VI
'D2-VII
Effluent
BOD
mg/1
900
45
3D
30
20
0
0
Effluent
SS
mg/1
95
30
20
20
10
0
0
Percent
BOD
Reduction
0
95
97
97
98
100
100
Percent
SS
Reduction
0
68
79
79
89
100
100
733
-------
DRAFT
Potential In-Plant Technology
Air scrubbers were found to be used at only one gum base plant. Con-
trolling the effluent discharged from this source by recycling would
help minimize the discharge.
Another source of contaminated water comes from the repeated hot
water washing of natural gum materials. By limiting the number of
washings or by recycling of this water (i.e. by reusing the final
wash water for the preliminary wash of a new batch of gum), significant
reductions could be realized in flow. As mentioned previously,
Increasing workers' awareness of pollutional problems will help sig-
nificantly in water management.
End-of-Mne Technology
Significant advances in treatment have been accomplished in this
industry, particularly at one plant which handles about 80 cu m/day
(20,000 gpd) of the wastewater with a BOD of 1500 to 2500 rr.g/1. The
system used at this plant employs screening, settling, mixing, digestion,
clarification and final chlorinat'cn to achieve 90.1 percent removal
of BOD. According to Oxford (142 ), this percentage of BOD removal
can be increased to S5 percent by proper management. This plant
discharges to a municipal sewage system. One plant that does not
currently have a treatment system discharges directly into surface
waters. This plant has a preliminary treatment system designed and
will discharge their treated waste to a municipal plant when the
municipal facility is constructed. This system is designed primarily
to collect all processing wastes and separate by settling all pre-
cipitated CaCOj and settled gum base, which is then stored and trans-
ported by trucKS for land disposal. In addition, the solvent phase
1n the settling tank may be drained for further amelioration of the
effluent.
Selection of Control and.Treatment Technology
In Section V a model plant was developed for chewing gun base processing.
The raw wastewater characteristics After screening were assumed to be
as follows:
BOO 430 mg/1
SS « 355 mg/1
0&6 30 mg/1
Flow 356 cu m/day (0.094 MGD)
Table 137 lists the pollutant effluent loading and estimated operating
efficiency of each of the elgnt treatment trains selected for this sub-
category.
Alternative D 3-1 - This alternative provides no additional treatment
to the screened wastewater.
734
-------
DRAFT
TABLE 137
SUMMARY OF 7REATMTNT TRAIN ALTERNATIVES
5UUCATEGOW 0 3
Treatment Train
Alternative
D3-I
D3-II
D3-III
D3-IV
D3-V
- 03-VI
D3-VII
Effluent
BOD
mg/1
430
30
25
25
10
0
0
Effluent
ss
mg/1
355
30
25
25
10
0
0
Percent
BOD
Reduction
0
93
94
94
98
100
100
Percent
SS
Reduction
0
92
93 .
93
97
100
100
73S
-------
DRAFT
-e D 3-11 - This alternative consists of a pumping station,
a "flov/ equaHzation basin, and an aerated lagoon system with nitrogen
addition.
Alternative D 3-1 I.I - This alternative replaces the aerated lagoon
system of Alternative 0 3-III with an activated sludge unit. In
addition, the treatment train incorporates sludge thickening, aerobic
digestion and truck hauling.
Alternative D 3-IV - Alternative D 3-V is identical to Alternative D 3-III
except for the addition ot" sand drying beds for sludge disposal.
Alternative D 3-V - This alternative adds, to Alternative D 3-IV, a dual
media pressure filtration sytem .is a final treatment step.
Alternative D 3-VI - This alternative adds a pumping station, pipe line •
ancfspray irriganon to the treatment train of Alternative D 3-II.
Alternative D 3-V1I - This alternative adds a pumping station, pipe line
and" spray irrigation to the treatment trair of Alternative D 3-iII.
SUBCATEGDP.IES D 5 AND D 5 CMOCOLATF
Existing In-Plant Technology
The open use of *ater as mentioned in Section III is not compatiole
with the production of chocolate products; therefore, the use of water
1n-plant is extensively regulated to prevent entrainment in the product.
Since washdowns are the primary source of wasteloading, stringent dry
cleaning and mopping are employed at all plants. A variable amount of
clean-up water is used during the cleaning of mixing tanks, transfer
buggies, milk condensing pansi and certain production areas. Steps
taken by plants to limit water use in these clecning operations in-
clude: installing v/ater saver hose nczzles, sealing off drains, and
In one case utilizing a high-pressure steam neated washdcwn system.
Three 'plants which process condensed milk use clean-1n-p1ace units in
thej,r condcnsory system. One plant has
-------
DRAFT
as to the necessity for good housekeeping, reduced v/ater usage, proper
maintenance, and correct disposal or salvaging of products that can
be reused in the process.
End-of-Une Technology
AT! plants visited discharged to municipal treatment systems; two provided
pretreatment of their v.-sste streams. One of these plants utilized a
grease trap which was cleaned monthly by a sanitary service. The other
plant employed a dissolved eir flotati?n system for oil and grease re-
moval. One large plant is planning to purchase a municipal treatment
plant for use as an industrial pretreetrnent plant.
5 e lection of Control and Treatment Technology for Subcategory D F.
In Section V a model plant was developed for chocolate manufacture
with condensory processing. The raw wastev/ater characteristics af*f-
screening were assumed to be as follows:
BOD 1840 mg/1
SS 415 mg/1.
OfcG 170 mg/1
Flow 761 ru m/day (0.201 MGD)
Table 138 lists the pollutant ef'luent loading and estimated operating
efficiency of each of the treatment trains selectee for this subcategcry.
Alt.jr native D 5_-I_ - This alternative provides no additional treatment
to the screened wastewater.
Alternative D 5-11 - Thir alternative consists of a pumping station,
a flow equalization basin, and air flotation with chemical addition.
Alternative D 5-1 II - This alternative replaces the air flotation mcdu'c
in Alternative D 5~II with an aerated lagoon syster.i with nitrogen adjucn.
Alternative J S-IV - This alternative replaces the aerated lagoon systcr
of Alternative 0 5-III with an activates sludge unit. In addition, tie
t»?atment train incorporates sludge tuickening, aerooic digestion and
truck haul ing.
Alternative D 5-V - Alternative D 5-V is identical to Alternative D 5-IV
with the addition of sand drying beds for- sludge disposal.
Alternative. LJ 5- VI - Air flotation with chemical addition is utilized
between the equalization basin and the activated sludge unit of Alternative
Alternative D 5-VII - This alternative adds, to Alternative D 5-VI. a dual
media pressure filtration system as a final treatment su?.
737
-------
ORAPT
TABLE 138
-SUMMARY OF TREATMENT TRAIN ALTERNATIVES
SUDCATEGORY D 5
Treatment Train
Alternative
05- 1
05-11
D5-III
D5-IV
D5-V
DS-VI
05-VII
D5-VIII
Effluent
BOD
mg/1
1840
1288
92
60
fO
40
20
64
Effluent
SS
nig/1
415
287
60
40
40
29
10
43
Effluent
ODG
mg/1
170
68
17
17
17
7
2
7
Percent
BOO
Reduction
0
:o
9i5
97
37
98
99
97
Percent
SS
Reduction
0
30
85
90
90
93
98
90
Percent
OBcG
Reduction
0
60
90
90 _
9C
96
99
96
738
-------
DRAFT
Alternative D 5-VII1, - In this treatment train air flotation with
chemical addition precedes the aerated lagoon system of Alternative
U b-III. "Trucking of flotation solids is required with this alter-
native.
Selection of Control and Treatment Technology for Subcategory D 6
In Section V a model plant was developed for chocolate without
condensory processing. The raw wastewater characteristics after
screening were assumed to be as follows:
BOD '705 mg/1
SS 230 mg/1
O&G 160 mg/1
Flow 920 cu n/day (0.243 MGD)
•
Table 139 lists the pollutant effluent loading and estimated operating
efficiency of each of the treatment trains selected for this subcategory':
Alternative 0 6-1 - This alternative provides no additional treatment
to the screened wastewater.
Alternative D 6-II - This alternative consists of a pumping station and
a flow equal nation basin.
Alternative D 6-III - This alternative consists of Alternative D 6-II
followed by air flotation with chemical addition.
Alternative D 6-IV - This alternative adds to Alternative D 6-II ar
aerated a.goon system with nitrogen addition.
Alternative D 6-V - This alternative replaces the aerated lagoon syster of
Alternative D~6-IV with an activated sludge unit. In addition, the treat-
ment train incorporates sludge thickening, aerobic digestion and truck
hauling.
Alternative P 6-VI - Alternative D 6-VI is identical to Alternative D 6-V
with the addition of sand drying beds fcr sludge disposal.
Alternative D 6-VII - Air flotation with chemical addition is utilized
between the equalization basin and the activated sludge unit of Alter-
native D 6-VI.
Alternative D 6-VIII - This alternative adds, to Alternative D 6-VI I, a
dual media pressure filtration system as a final treatment step.
Alternative D 6-IX - In this treatment train.alr flotation with chemical
addition precedes the aerated lagoon system of Alternative D 6-IV.
739
-------
DRAFT
TABLE 139
SUMMARY OF TREATMENT TRAIN ALTERNATIVES.
SUBCATEGORY D 6
Treatment train
A1 ternati ve
D6-I
D6-II
D6-III
D6-IV
D6-V
D6-VI
D6-VII
06-VIII
Effluent
BOD
mg/1
705
494
35
30
30
25
10
25
Effluent
SS
mg/1
230
161
35
30
30
20
10
24
Effluent
OBG
mg/1
160
64
16
16
16
5
2
5
Percent
BOD
Reduction
0
30
95
96
96
96
99
96
Percent
SS
Reduction
0
30
95
87
87
91
96
90
Percent
BOcG
Reduction
0 .
60
90
90
90
97
99
97
740
-------
DRAFT
PET FOODS
SUDCATEGOKY B 5 LOW-MEAT CAMMED PET FOOD
In-Plant Control Technology
The main sources of pollutants in the pet food industry are general
plant cleanup, Including housekeeping and end-of-shift cleanup. There-
fore, in-plant procedures to reduce waste loads in this subcategory must
of necessity center around these areas. It is essential that .proper
employee training an
-------
5. In addition to implementation of water conservation
_and reuse, the processor should look at his handling
of solid waste. A well-operated plant will, insofar
as possible, avoid solid waste contact with the liquid
waste stream. Where this is not feasible, the solid
waste 1s removed prior to reaching the waste treatment
system. Screens of 20 mesh or smaller are usually
adequate to remove a large portion of settleable
solids. Continuous removal of the screenings is
desirable to avoid excessive leaching of solubles
by the liquid waste stream from separated solids.
End-of-Line Technology
Only one existing secondary treatment plant 47N64 discharging to surface
waters was identified. As far as known, all other manufacturing
plants in this subcategory discharge to municipal-owned sewage works.
The one existing secondary treatment plant is located in the northeast
and utilizes extended aeration activated sludge treatment preceded by
screening and primary gravity clarification. Table 140 provides data
pertinent to design of individual treatment units. Note the approxi-
mate 2:1 dilution of the wastewater by cooling water after primary
treatment and prior to the aeration basin. An analysis of weekly and
bi-weekly reported treatment performance over the period January to
August, 1974, shows vhe following effluent quality characteristics:
BOD, average 30 mg/1, range 5 to 75 mg/1
SS, average 48 mg/1 , range 12 to 104 mg/1
The above results reflect approximately the following average percent
removals: BOD 92 percent and suspended solids 84 percent basej upo-
average reported raw waste BOD of 370 mg/1 and suspended solids of
300 mg/1.
The relatively poor suspended solids removal in comparison to the BOD
removal performance is an inherent problem in the extended aeration procs:
where.little or no sludge removal from the secondary system is practiced.
The extended detention time in the aeration basins tends to develop fine,
Inert suspended solids which are difficult to settle and pass easily
over the secondary clarlfier weirs.
Selection of Control and Treatment Technology
A model plant for low-meat canned pet food was developed in Section V.
The raw wastewater characteristics were as follows:
Flow
BOD
SS
U&G
pH
(0.3 MGD)
1,100 mg/f
700 mg/1
400
6 to 9
742
-------
TABLE 140
SUMMARY OF TREATMENT ALTERNATIVES FOR SUBCATEGORY B5
LOW MEAT CANNED PET FOOD
li Treatment
I Alt. unit
1 B5-I None
1
I ^ 85- I I Flow Equal.
I £ Dis. Air Flot.
if
E BS-ni Act. Sludge
Plf
fcr
I B5-IV Filtration
Unit influent
Characteristics, mg/1
BOO TSS O&G
1.100
1,100
1.100
330
33
700
700
700
140
28
400
400
400
200
40
Cumulative
percent removal
BOD TSS 0;
0
0
70
97
98
0
0
80
96
93
0
0
50
90
95
Effl.
17
14
20
98
98
95
-------
DRAFT
The following treatment alternatives have been selected for this
subcategor^:
Alternative B 5-1 - This alternative Assumes no additional treatment.
Alternative B 5-II - This alternative provides flow equalization,
dissolved air flotation, and vacuum filtration of sludge. The
expected DOD removal benefit 1s 70 percent.
Alternative B 5-111 - This alternative provides complete mix activated
sludge and sludge thickening addition to Alternative 8 5-11. The
expected BOU removal benefit is 97 percent.
Alternative B 5-IV- This alternative adds dual media filtration to
Alternative B 5-iII. The expected BOO removal benefit is 98 percent.
A summary of the pollutant removals expected is presented in Table 140.
A schematic diagram of Alternatives B 5-1 through B 5-IV is presented
1n Figure 237.
SUBCATEGORY B 6- HIGH-MEAT CANNED PET FOOD
In-Pi ant Technology
The existing and potential in-plant technology for Subcategory B 6
1s the same as for Scbcategory B 5.
End-of-Line Technology
This subcategory is characterized by extremely strong wastes in terms of
BOD, SS, and Oils and Greases. Nevertheless, two existing secondary
treatment plants (47N-78 and 47N-79) are achieving excellent removals
with activated sludge treatment preceded by well designed primary
treatment units. The key to the success of these plants aopears to
be the high percentage "emovals of SS and Oils and Greases in their
primary treatment units and the extendeo detention tine provioed in
the activated sludge aeration basins. The two existing plants referred
to are uwned by the same company and are virtually exact copies of each
Other -- one 1s located In the northeast and the other in the middle
west. Table 141 provides data pertinent to design of individual treat-
ment units. An analysis of weekly reported treatment performance over
the period April, 1971 to December, 1972 for plant 47N-79 shows
the following effluent quality characteristics:
BOD, average 8 mg/1, range 1-50 mg/1
SS, average 80 mg/1, range 1-2000 mg/1
04C, average 800 mg/1, range 80-8000 mg/1
COD, average 90 mg/1, range 30-2000 mg/1
pH, 6 to 8
744
-------
DRAFT
RAW WASTEWATER
FLOW =0.3 MGO
BOD s 13,000 MG/L
SS = 5.100 MG/L
0 t G •- 7.600
PUMPING
STATION
SLUDGE
SLUDGE
CENTRIFUGATION
DISSOLVED AIR
FLOTATION
WASTE
ACTIVATES
SLUDGE
[ACTIVATED SLUDGE I
DISCHARGE
ALTERNATIVE 56-3
BOD = 6,500 *£/L
SS sr 1 ,530 MG/L
0 G G = 3. a<. r. "G
DISCHARGE
AL.TERNAT3VE P6- ' IT
BOO = 1 .55: ••'J/_
SS = 310 MG/L
VACUUM
FILTER
SLUDGE
DISPOSAL
DUAL ME
FILTRAT
OIA
I ON
ALTERNATIVE P«-1V
tKX> = 195 Mo/_
SS = 16C VG^i.
DISCHARGE
ALTERNATIVE 86-v
BOO = ICO MG/L
SS « to MG/L
0 I G => 160
FIGURE:
CONTROL AND TREATVEVT ALTERNATIVES
• B6-I TMRT'oGH B6-V
-------
TABLE 141
OF TREATMENT ALTERNATIVES FOR SUBCATEGORY B6
HIGH HEAT CANNED PET FOOD
Alt.
Treatment
unit
Unit influent
Characteristics, mg/1
BOO SS OSG
Cumulative
percent removal
BOD SS OAG
B6-I
B6-II
B6-III
C6-I7
BS-V
None
Flew Fqual.
Centrifuges
Dis. Air F>ot.
Act. S'tudge
Filtration
13.00C
13.0CO
6,500
1,950
195
5,100
5.100
1,500
310
160
7,600
7,600
3,000
1,060
320
50
85
99
99
70
94
97
99
60
86
96
98
Fin.
Effl.
100
40
T60
99
99
98
-------
DRAFT
Th2 above results are prior to installation of chlorination and sand
filter tertiary treatment units.
Percent removals reflected by the above resi'lts ere approximately as
follows: BOD, 99 percent plus; SS, 98 percent, OiG, 96 percent,
and COD, 98 percent.
Obviously, oil and grease removal 1s the major problem still facing
this plant, and it is expected that the use of chlorine and sand
filters as teritary treatment will reduce the oil and grease loads.
Selection of Control and Treatment Technology
A model plant for high-meat canned pet food was developed in Section V.
The plant was assumed to produce 270 kkg/dry (300 ton/day) of product
and have a wastewater with the following characteristics:
BOD 13,000 mg/1
SS 5,100mg/1
O&G 7,600 mg/1
pH 6.8 to 8.4
N 640 mg/1
P 210 mg/1
The following treatment alternatives have been selecteJ for this
subcategory:
Alternative B 6-1 - This alternative assumes no treatment in addition
to screening already incorporated into the processing plant.
Alternative B 6-II - This alternative consists of a pimping station,
A flow equalization basin, centrifugation, and sludge storage. As
shown in Table 141, the expected SOD reduction benefit for this
alternative is 50 percent.
Alternative B_6-HI - This alternative provides the addition of
dissolved air flotation and vacuum filtration to Alternative B 5-!II.
The BOD reduction oenefit expecr.ed for this alternative is 85 percent.
Alternative B 6-IV - This alternative provides the addition of complete
mix activated sludge tn Alternative B 6-111. The expected BOD reducficr.
benefit is 99 percent.
Alternative D 6-V - This alternative provides the addition of dual
media filtration to Alternative 0 6-IV. The expected BOD reduction
benefit is 99 percent.
A schematic diagram of Alternatives B 6-1 tnrough B 6-V is presented
in Figure 238.
747
-------
DRAFT
SUQCATEGGRY B 7 - DRY PET FOODS
In-Plant Technology
In-plant technology for Subcategory B 7 Is the same as for Subcategory
B 5.
End-of-Line Technology
This Subcategory is characterized by low volume flows of weak to moderate
strength a; was described in Section V of this document. All existing
dry pet food manufacturing plants which were identified during this
Investigation discharge to municipal systems. One plant (47M-65)
which manufactures, both dry and soft-moist pet food, provides
extensive pretreatnent prior to municipal discharge; however,
rpproxinately 90 percent of its flow volume is generated by manufacture
of soft-moist pet food. It was not possible, therefore, to draw any
conclusion'; regarding dry pet food wastewater treatability from this
plant. The model treatment plant design is based upon utilization of
the activated sludge process for treatment of wastewater from a dry
pet food manufacturing plant.
Selection of Control and Treatment Technology
In Section V a model plant was developed for dry pet food. It has a
production of 270 kkg/day (300 ton/day), a wastewater flow of 114 cu rn/day
(0.03 MGD), and the following wastewater characteristics:
BOD 200 mg/1
SS TOO mg/1
OAG 250 mg/1
pH 6 to 9
N 4 P Sufficient for biological treatment
Table 142 lists the pollutant effluent loading and the estimated operat'nc
efficiency for the four alternatives selected. The alternatives are
schcvjtically presented in Figure 239.
Alternative B 7-1 - This alternative provides no additional control and
treatment technology above current practices.
Alternative B 7-11 - This alternative provides a pumping station, a
114 cu m~( 30,DOC> gal) capacity equal ization basin, and a dissolved air
flotation unit. The expected BOD reduction benefit is 50 percent.
Alternatvve_B^7-III - This alternative provides, 1n addition to Alternative
B~7-iT. a coi.ipfete mix activated sludge system. The aeration basin has
a detention time of 30 hours and an aeration of 1.4 kw (2 hp). The
expected HOD removal benefit.is 90 percent.
749
-------
TABLE 142
SUMMARY Of TREATMENT ALTERNATIVES FOR SUBCATCGORY B7
DRY DOG AND CAT FOOD
Unit influent Cumulative
Alt.
B7-I
67- 1 1
B7-III
87- IV
Fin.
F_ffl.
Treatment
unit
None
Flow
Ois.
Act.
equal.
Air Plot.
Sludne
Filtration
Characteristics, mg/1
BOD TSS 0&6
200
200
200
100
20
!0
100
100
100
20
14
4
250
250
250
125
38
19
percent removal
BOD TSS 0)
0
0
50
90
95
95
n
0
80
86
96
96
0
0
50
85
92
9>
-------
DRAFT
RAW WASTEWATER
FLOW =
BOO = 200 MG/L
SS = 100 MG/L
0 t G = 250 MG/L
(0.03 MOD)
PUMPING
STATION
FLOW EQUALIZATION
SLUDGE
MAULING
DISSOLVED AIR
FLOTATION^
ACTIVATED SLUDGE
DUAL MEDIA
FILTRATION
DISCHARGE
ALTERNATIVE B?-II
BOD = 100 MG/L
ss = 20 MG/L
0 t G = 12S MG/L
DISCHARGE
ALTERNATIVE 67-111
800 a 20 MG/L
SS - 1* MG/L
0 t G * 38 MG/L
DISCHARGE
ALTERNATIVE e?-iv
BOO * 10 MG/L
SS n 6 MG/L
0 C G = 19 MG/L
FIGURE ?3S
CONTROL AND TREATMENT ALTERNATIVES
BT-I THOUGH B7-IV
-------
DRAFT
Alternative 13 7-fV - This alternative adds dual media filtration to
Alternative lj 7-III. The expected BOD reduction benefit is 95 percent.
SUBCATEGORY B 8 - SOFT-MOIST PET FOOD
In-Plant Technology
In-plant technology for Subcategory B 8 is the same as for Suocategory
B 5.
End-of-Line Technology
All existing soft-moist pet food manufacturing plants which were
identified during this investigation discharge to municipal sev/age
systems. One plant (47M-65) provides extensive pretreatmsnt prior
to municipal discharge, and data from this p^ant are helpful in assessing
primary treatment pollutant removal capabilities. The same plant also
provides secondary aeration and clarification of the primary effluent; "
however, tht secondary treatment is relatively ineffective because
the activated sludge from the secondary clarifier is not recirculated
into the aeration basin. Design indorsation for this plant is given
in Table 14?. The plant should not, however, be considered a represent-
ative overall facility as it is presently designed and operated. Thougn
certain individual unit processes perform adequately, major difficulties
are experienced because: (1) there is no aerated equalization basin
at the beginning of the treatment cnain to control surges, lower
temperatures, and prevent anaerobic degradation; (2) there is no
return of secondary clarifier sludge into the aeration basins; and
(3) solids (sludge) removal and treatment equipment is inadequate.
The treatment plant described is required by city ordinance to meet
the following criteria: BOD - 400 mg/1, SS - 450 mg/1, and O&G - 100 mc/1.
This requirement must be met after the treatment facility waste is diluted
by 1.5:1 or 2:1 by cooling water and sanitary waste.
An analysis of six effluent samples, three in July, 1972 and three in
July 1974, snows the following effluent quality characteristics:
BOD, average 703 ng/1 , range 216-1, 479 mg/1
SS. average 88C mg/1, range 372-1, 916 mg/1
O&G, average 300 -ng/1, range 83-816 mg/1
pH, 6 to 7
Temperature, 86-90°F
The above results reflect approximately the following average percent
removals: BOD, 82 percent; SS, 59 percent; O&G, 61 percent; based
upon average reported raw waste BOD of 3,060 mg/1, SS of 2,120 mg/3 ,
and oil and grease of 770 mg/1.
•« SLth1s Dretreatment facility 1s reported by the owner as
$750,000 in 1964. Equivalent 1974 cost would be close to $2 million.
7b2
-------
TABLE 143
SUMMARY OF TREATMENT ALTERNATIVES FOR SUBCATEGORY 88
SEMI-MOIST PET FOOD
Unit influent Cumulative
Alt.
88-1
88-11
B8-III
B8-IV
F1n.
Effl.
Treatment
unit
None
Flow Equal.
Dis. Air riot.
Act. Sludge
Filtration
Characteristics, mg/1
BOD" TSS O&G
3,900
3,900
3,900
1,560
160
80
2,100
2.100
2,100
420
210
53
800
800
800
160
50
25
percent removal
BOD TSS 01
0
0
PO
96
98
0
0
CO
90
97
0
0
80
94
97
-------
DRAFT
if construction Indexes are applied to compensate for inflation in
costs. Present annual operating costs are reported as $407,000/year
including-a 5150,000 cost for solids trucking and disposal, with the
remaining $275,000 tagged for labor, maintenance, and energy.
Selection of Control and Treatment Technology
A model plant for soft-moist pet food was developed in Section V. It
was assumed to have a production of 500 kkg/day (550 ton/day) of
finished product and to generate 114 cu m/day (0.03 MGO) of wastewater
with the following characteristics:
60D .3.900 mg/1
SS 2.100 mg/1
OSG 800 mg/1
pH 6 to 7
N & P Sufficient for biological treatment
Table 143 lists the pollutant effluent loading and the estimated operating
efficiency of each of the alternatives. Figure 240 i llustrates .the t'-ij.-
ment alternatives.
Alternative B 8-1 - This alternative provides no additional control
and treatment technology.
Alternative B 8-FI - TMs alte-native provides flow equalization,
dissolved air flotation, and vacuum filtration of sludge. The
expected BOD reduction benefit is 60 percent.
Alternative 3 3-III - This alternative provides, in addition to
Alternative B 8-II, a complete mix activated sludge system. The
expected BOD reduction benefit is 96 percent.
Alternative B 8-IV - This alternative provides, in addition to
Alternative B 8-III, dual media filtration. The expected BOD reduction
benefit is 98 percent.
MISCELLANEOUS AND SPECIALITY PRODUCTS
SUBCATEGORY A 29 - THE PRODUCTION OF FINISHED FLAVORS BY THE BLENDING
OF FLAVORING EXTRACTS, ACIDS. AND COLORS
Existing In-Plant Technology
The known in-plant technology practiced at flavoring extract plants
consists of the following: solvent recovery, separation of non-contact
water from the process wastestream, and separation of cleanup water
used in solvent process areas from the process wastestream. It is
assumed that solvent recovery is practiced throughout the entire
industry. However, it is not known to what extent separation of
7b4
-------
DRAFT _
RAW WASTEWATER
FLOW = lift CU M/DAY (0.3
QOD = 3,900 MG/T,
S5 = 2,100 UGA.
O £. C = 600 MG/L
i
PLMPING
STATION
FLOW EQUALIZATION
1
DISSOLVED AIR
FLCTATTON
SLUDGE
TWICKENER
•
r
• T^CT
FILTER
DUAL MEDIA
FILTRATION
SLUDGE
DISPOSAL
ALTERNATIVE 56-
SOD = 1.560 fG.
SS = «20 A'^'L
O t G = 160 MG.
DISCHARGE
ALTERNATIVE es
SOD = 16C MGXL.
SS - Z10 MG/L
0 I 6 = SO MG/
DISCHARGE
Al..TEPNAT;ve 00-IV
600 - 80 MG/L
SS = 53 MG/L
0 t G s 25 MG/U
FIGURE 2
AM) •mEATl/ENn' ALTERNATIVES
Be-I THROUGH Ba-iv
-------
DMFT
non-contact water and cleanup water used in solvent process areas
is practised in the flavoring extract industry.
Potential I.vPlant Technology
^cycling of non-contact cooling water or at least, separation of
this water from the process wastestream could reduce the quantity
of wastewater generated at a given plant. Additionally, the pos-
sibility of reusing rinse w,?ter as makeup for wash water should
not be overlooked. The use of high pressure, low volume nozzles for
hosing of floors end external equipment cleanup would also reduce
the quantity of waste fiaw.
End-of-Line Technology
Two plants 87EC3 and 87E04 operate treatment systems prior to discharge
to navigable waters. From available in forma tic? the remainder
of the industry discharges to municipal treatment systems. The
treatment system at Plant B'Jr.03 is a physical system consisting
of the following sequential
1. A holding tank.
2. A centrifuge with centnfuged solirfs be-ir.g ciiscaroed as
solid waste.
3. A sand-gravel filter for dewatsring.
4. Two identical activates carbon systems in series each
containing 0.9 kkg (1.0 ten) of carbon.
Flow in the sand-gravel filter and tne activated carbon systems is
from bottom to top. The treated effluent from the fina1 activated
carbon unit is mixed in a 1:10 ratio witr non -contact water prior
to discharge into a river. The average BOD of the mixed effluent
is 24 mg/1. Assuming tnat the non-contact wjter nas a BOD cf 10 mg/'i
(a very logical approach), the BOD of the treated effluent will
be approximately 160 rrig/1. The average COD of tr.e raw waste
effluent was determined to be 1360 rcg/1 , an< thus the treatment
efficiency of this system 's estimated to be abouc 83 percent.
Plant S7E04, with a treatment system consisting pf partial sedimen-
tation followed by an aerated lagoon, rtported average treated
effluent concentrations of 35 mg/1 BOD and 52 mg/1 suspended
solids. However, no raw waste load aata were available for tn
-------
DRAFT
Selection of Control and Treatment Technology
A model plant was developed for flavoring extracts manufacturing
in Section V. The raw wastewater characteristic? were assumed
as follow::
BOD 1350 mg/1
SS 130 mg/1
pH 7.1
Table 144 lists the pollutant effluent loading and the estimated
operating efficiency of each of the eleven treatment alternatives
selected for this subcategory. The alternatives are illustrated
in Figures 241 and 242.
Alternative A 29-1 - This alternative provide? no treatment.
Alternative A 29-11 - This alternative consists of spray irrigation
of the v/asie effluent requiring 2.7 ha (6.6 acres) of land.
The overall benefit of this alternative is a pollutant reduction of
100 percent to navigable waters.
Alternative A 29-111 - This alternative consists of a pumping station,
a flow equalization tank, a complete mix activated sludge system,
a sludge thickener, vacuum filtration, and a sludge storage tank.
The flow equalization tank is provided to dampen shock loadings to the
system due to intermittent cleanup operations within the plant.
The activated sludge system would be expected to provide a BOO
removal of 92.6 percent and a suspended solids removal of 76.9 percent.
Vacuum filtration is provided to decrease sludge volume, thereby de-
creasing sludge hauling costs. A seven-day sludge storage tank to
decrease frequency of hauls is provided, further decreasing haulin9
costs.
The overall benefit of this system is a BOD reduction of 92.6 percent
and a suspended solids reduction of 76.9 percent.
Alternative A 29-IV - This alternative consists of the same modules
as Alternative A 29^111 except vacuum filtration is replaced by an
aerobic digester followed by sand drying beds. This results in twice
the sludge volume produced per day than in Alternative A 29-111. A
three day sludge storage tank is provided.
The overall benefit of this alternative is a BOD reduction of 92.6
percent and a suspended solids reduction of 76.9 percent.
Alternative A 29-V - This alternative consists of a pumping station,
a "Flow equalization tank, and an aerated lagoon. The efficiency of the
aerated lagoon is assumed to be the same as that for the activated sludge
system included within Alternatives A 29-111 and A 29-IV. The overall
benefit of this alternative is a BOO reduction of 92.6 percent and a
757
-------
TABLE 144
SUMMARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY A29
FLAVORING EXTRACTS
Alternative
A29-I
A29-II
A29-III
A29-IV
A29-V
A29-VI
A29-VII
A29-VIII
A29-IX
A29-X
A29-XI
Effluent
EOD
kg/cu m
0
0.041
0.041
0.041
0.020
0.020
0.020
0.0123
0.0123
0.0123
Effluent
SS
kg/cu m
0
0.0123
0.012:
0.0123
0.0062
0.0062
0.0062
0.004
0.004
0.004
Percent
BOO
removal
0
100
92.6
92.6
92.6
96.3
96.3
96.3
97.8
97.8
97.8
Percent
SS
removal
0
100
76.9
76.9
76.9
88.5
88.5
88.5
92.3
92.3
92.3
-------
DRAFT
INFLUENT
PLOW = 125 CU M/DAY
BOO = 1,250 MG/L
55 B 130 MG/L
(0.033 MGD)
i
FLOW
EQUALIZATION
AERATED
LAGOCN
SETTLING
FILTRATION
CARSON
ADSORPTION
L.
ALTERNATIVE
A 29-V
EFFLUENT
BOO = 100 MG/L
SS » 30 MG/L
ALTERNATIVE
A 2V-VIII
EFFLUENT
BOD a 50 MG/L
SS = 15 '•'G/L
ALTE« NATIVE
A 29-XI
EFFLUENT
BOO - 30 MG/L
SS = 10 MG/L
FIGURE 262
A29
TREATMENT ALTERNATIVES V. VIII, XI
760
-------
DM FT
suspended solids reduction of 76.9 percent.. This alternative is Alter-
native A 23-111 »vitli Lhe addition of duol-media fiH.rotion which would
provide an additional COD and suspended solids reduction of 3.7 and 11.6
percent,'respectively.
Alternative A 29-Vj - Tin's alternative consists of the same treatment
modules as Alternative A29-IIIwith the addition of-dual-media filtration.
The overall benefit of this alternative is a BOD reduction of 96.3 percent
and a suspended solids reduction of 83.5 percent.
Alternative A 29-V1J - This alternative consists of the same treatment
modules as Alternative A29-IVwith the addition of dual-media filtration.
The overall benefit of this alternative is a PCD reduction of 96.3 percent
and a suspended solids reduction of 88.5 percent.
Alternative A ?9-VlI_l - This alternative is identical to Alternative A ?9-V
with the addition of activated carbon which would provide an additional
BOD and suspended solids reduction of 1.5 and 3.8 percent, respectively.
The overall benefit of this alternative is a BOD reduction of 97.8
percent and a suspended solids 'reduction of 92.3 percent.
Alternative. A 29-IX - This alternative consists of the same modules
as Alternative A Z9-VI with the addition of activated carbon as il-
lustrated in Figure 242.
The overall benefit of this alternative is a BCD reduction of 97.8
percent and a suspended solids reduction of 92.3 percent.
Alternative A 29-X - This alternative is identical to Alternative
A" 29-V11with the addition of activated carbon.
The overall benefit of this alternative is a BOD reduction of 97.8
percent and a suspended solids reduction of 92.3 percent.
SUDCATEGORV A 31 - BOUILLON PPOC'JCTS
In-Plant Technology
Since wastewater generated by the production of bouillon products is a
result of equipment cleaning, there exists little potential in-plant
technology for wastewater control. General housekeeping should be
optimized; dry cleaning before wet cleaning or instead of wet cleaning
Should be employed as much as possible.
End-of-Line Technology
All existing bouillon manufacturers discharge to municipal treatment
systems with no apparent adverse effects. The wastewater constituents
761
-------
DRAFT
are mostly—highly biodegradable proteins which are well suited for
biologica.1 treatment.
Selection of Control and Treatment Technology
A model plant was developed for bouillon product manufacturing in Section
V. It was assumed that the model plant provided a grease trap prior to
wastewater discharge. The raw wastewater characteristics after the grease
trap were assumed to be as follows:
BOD 3000 mg/1
SS POO mg/1
FOG 150 mg/1
Table 145 lists the effluent pollutant loading and the estimated operati^'j
.efficiency of each of the seven treatment alternatives selected for this
subcategory. Figures 243 ?nd 244 illustrate the treatment alternatives -
Alternative A 31-1 - This alternative consists of a pumping stcticn,
holding tank, ana spray irrigation. The land requirement for this
alternative is 2.4 ha (6.0 acres).
The overall benefit of this alternative is a 100 percent reduction of
poli Jtants to navigable waters.
Alternative A 31-11 •• This alternative consists of a pumping rtaticn, a
flow equalization tank, a complete mix ectivated sludge basin, a sludge
thickener, and a vacuum filter. Flow equalization is provided to
dampen the effect of i,hock loadings duf to large cleanup flew at the .
end of each day. The complete rrix activated sludge system would provide
a BOD reduction of 95 percent, a suspended solids reduction of 80 percent
and a fats and oils reduction of 72 3 percent. Sludge thickening and
vacuum filtration are provided to reJuce the quantity of daily sludge
generated thereby rec-cing hauling costs. A sludge storage tank is pro-
vided to reduce 'tne frequency of hauls and further reduce hauling costs.
The overall benefit-of this alternative Is a HOD reduction of 95 percent,
a suspended solids n-duct ion of 80 percent, and a fats and oils reduction
of 7J.3 percent.
Alternative A 31-111 - This alternative consists of the same treatment
modules as Alternative A 31-11 with the exception that the vacuum filter
is reolaced by sand drying beds. This, results in tv.-ice the amount of
sludge to be hauled per day than that of Alternative A 31-111.
The overall benefit of this alternative is a BOD reduction of 95 pe-cent.
a suspended solids reduction of 80 percent, and a fats and oils reduction
of 73.3 percent.
Alternative A 31-IV - This alternative consists of a pumping station, a
flow equalization 'ank, and ar. acraud lagoon. The efficiency of this
alternative would be expected to be tne san:e as that of an activated
sludge system.
-------
TABLE 145
SUW1ARY OF TREATMENT TRAIN ALTERNATIVES
SUBCATEGORY A31
BOUILLON PRODUCTS
Treatment Train
Alternatives
A31-I
A31-H
AM- 1 11
A31-IV
A31-V
A31-VI
A31-VII
BOO
kg/kkg
0.0
2-34
2.34
2.34
1.09
1.09
1.09
SS
0.0
0.626
0.6Z6
0.626
0.313
0.313
0.313
FOG
kg/kkq
0.0
0.626
0.626
0.626
0.313
0.313
0.313
Percent
BOD
Removed
100
95
95
95
97.6
97.6
97.6
Percent
SS
Removed
100
80
80
80
90
90
90
Percent
FOG
Removed
100
73.3
73.3
73.3
86.7
86.7
86.7
-------
DRAFT
INFLUENT
PLOW • 11« CU M/DAY (0.03 MCO)
BOO = 3.000
SS = 200 MG/L
FOG = ISC MG/L
SLUDGE TO
TRUCK MAUL
1
1 VACUUM
FILTRATION
•_M_
SLUDGE
THICKENING
i
AEROBIC
SANO DRY If*
BEDS
L
r
ACTIVATED 1
SLJOGE 9ASU- 1
t
CLARIFICATION
UUAL- MEDIA
c 1 1_ n; i T I OJ
,
«
1
ALTERNATIVES
A 3I-IT. Ill
eFtriuE>."r
*" BOD = 150 MG/
ss a 60 MG/L
POG =4Q MG/L
~ ~* A 31-V, VI
EFFLUENT
SLUDGE TO
TRUCK f'AUL
BOD = ?0 Mu/L
ss •••• 20 MG/L
FOG =20 MG/L
242
9UBCA7F50RY A31
ALTERATIVES II, III, V, AND VI
764
-------
DRAFT
PLOW s 114 CU M/DAY'<0.03 MOD)
BCD = 3,000 MG/L
SS = 200 MG/L
FOG = ISO MG/L
LAGOCN
SET
f»Q
TUNG
: ON
A 31-JV
EFFLUENT
BOO • 150
S3 * 40 MG/L
FOG a
-------
DRAFT
The overall benefit of this alternative is a COO reduction of 95 percent,
a suspended solids reduction of CO percent, and a fats and oils reduction
of 72.3 percent.
Alternative A 31-V - This alternative is identical to Alternative A 31-11
with the addition of dual media filtration. The overall benefit of this
alternative is a BOD reduction of 97.6 percent, a suspended solids re-
duction of 50 percent, and a fats and oils reduction of 86.7 percent.
Alternative A 31-VI - This alternative consists of the same modules as
Alternative A 31-"III with the addition of dual media filtration.
The overall benefit of this alternative is a BOD reduction of 97.6 percent,
a suspsnded solids reduction of 90 percent, and a fats and oils' reduction
of 86.7 percent.
Alternative A 31-VII - This alternative consists of the same modules as >
Alternative A 31-iV with the addition of dual media filtration.
The overall benefit of this alternative is a BOD reduction of 97.6 perc;r,t,
a suspended solids reduction of 90 percent and a fa'vS and oils reduction
of 86.7 percent.
SL'BCATFGCRY A 32 - NON-DAIRY CREAMER
Existing In-Plant Technology
Information was obtained fror, two plants during the study. Both plants
used clean-in-place (CIP) systems for eouiprent cleanun. Plant 99iiN'Cl
recycled caustic ind acid rinse water and thereby limited ihe CIP syste-:
wastewater discharge to 7.6 cu m/day (O.OG2 MGD). In contrast, plant
99NC2, a multi-product facility generated 227 cu n/day (0.06 f-'GO) of
wastewater fr. :; CIP systems, i.on-contact water and boiler blowdown at
one plant was separated from the process wsstestream and was recycled
at the other—both of these procedures being desirable practices.
Potential IP-'°Ian.t Techno logy
The quantity of wastewater generated hy clean-in-place (CIP) systems can
be further reduced if final or chlorine rinse is recycled and used as
initial rinse. This could conceivably reduce uastewater quantity by as
much as 30 percent. Non-contact water could also be recycled, as is dor.o
at plant 99N02, so that only makeup water would be added as needed.
Improved equipment connections and packaging practices in liquid non-dairy
creamer plants could result in a decreased pollutant loading by reducing
product spills in packaging areas. In powdered non-dairy creamer plant:,
cleanup of equipment in dry product areas, as well as dry product spills
should be done with air in order to reduce quantity and pollutant, loading
of wastewater.
766
-------
DRAFT
End-of-Lino Technology
The only known end-of-line technology currently employed in the non-dairy
creamer industry is spray irrigation of waste effluent by plant 99NN03,
hov/ever, this plant is a multi-product facility (cereals are also pro-
duced) an no information is available to determine the quantity or pol-
lutants contributed to the waste stream by the liquid creamer production
alone.
The remainder of the plants contacted discharge without pretreatment to
municipal systems v;ith no apparent adverse affects to the municipal treat-
ment facilities. Consequently, the application of transfer technology in
the form of biological treatment is considered to be feasible for the ncn-
dairy creamer waste effluent.
Selection of Control and Treatment Technology
A model plant for liquid and powdered non-dairy creamer processing was
developed in Section V. The quantity of wastewater generated was'deter-
mined based on the assumptions of recycling of caustic and acid rinse
water from clean-in-place (CIP) systems and separation of non-contact
water from the process wastestrean. The raw wastewater characteristics
of the model plant were presented as follows:
Flow: 64.3 cu m (0.017 MGD)
BOD: 1100 mg/1
SS: 440 mg/1
O&G: 260 mg/1
N: 5.5 mg/1
P: 29 mg/1
pH: 7.0
Table 146 lists the pollutant effluent loading and the estimated operative
efficiency of each of the five treatment trains selected for this suDcate-
gory. The treatment alternatives are illustrated in Figures 245 and L-5.
Alternative A 32-1 - This alternative consists of spray irrigation whic~
would require a 129 cu m (0.034 MGD) holding tank and a 1.4 ha (3.4 ^cre;
spray field. The overall benefit of this system is complete reduction
of pollutants to navigable waters.
Alternative A j2-II - This alternative consists of a pumping station,
nutrient addition, a flow equalization basin, air flotation, a complete n.-.
activated sludge system, a sludge thickener, and a storage tank to retail
one week's sludge production. Nutrient addition is provided to increase
the BOD reduction in the activated sludgo system as the BOD:N:P ratio of
the wastswater entering that activated sludge system was determined to ~e
100:0.8:0.44, requiring the addition rf 2.1 kg (4.7 Ibs) of anhydrous
ammonia and 0.51 kg (1.1 Ibs) of phospnoric acid per day. Flow equalization
1s provided to dampen shock loadings which would be expected due to the
Intermittent cleanup practices of the non-dairy creamer plant. Removal cf
fats and oils is accomplished by the air flotation module. The accu;;:ulit:d
scum would be skinned and passed into the sludge thickener. Air flotation
767
11 n
-------
TABLE 146
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
(NON-DAIRY COFFEE CREAMER)
Subcategory A 32
•sj
o»
C3
Treatment Train
Alternative
A32-I
A32-II
A32-I1I
A32-1V
A32-V
Effluent
900
kg/kkg
0
0.0218
0.0243
0.0106
0.0106
Effluent
SS
kg/kkg
0
0.071
0.071
0.0142
0.0142
Effluent
F&O
kg/kkg
0
0.0425
0.0125
0.0142
0.0142
Percent
BOD
Reduction
100
96.8
96.8
98.6
98.6
Percent
SS
Reduction
100
77.2
77.2
95.5
95.5
Percent
F&O
Reduction
100
77.4
77.4
S2.5
92.5
-------
DRAFT
FLOW = 64.3 CU M/DAY CO.017 MOD)
BOD = J.I 00 MG/L
SS = 440 MG/L
FOG = 265 MG/L
FLO*
EQUALIZATION
NUTRIENT
ADDITION
AERATED
LAGOON
SETTLING
ALTERNATIVE
A 32-1::
.^.EFFLUENT
BOO = 35 MG/L
SS = 100 MG/L
FOG = 60 MG/L
FILTRATION
ALTERNATIVE
A 32-VI
EFFLUENT
BOD = 15 MG/L
SS = 20 MG/L
FOG a 20 MG/L
FIGURE 246
SUBCATEGORY O2
TREATMENT ALTERNATIVES III AND VI
-------
DRAFT
would provide a DO'J removal of 60 percent, a suspended solids Deduction
of 50 percent, and a fats and oils reduction of 42 percent, with the reduc-
tion of fats and oils decreasing foaming in the activated sludge process.
Due to the high biodegradability of the waste effluent, the complete mix
activated sludge module v/ould be expected to provide a BOD reduction of
94.6 percent, a suspended solids removal of 45 percent and a fats and
oils reduction o: 55 percent. The quantity of sludge generated by the
activated sludge system v/ould be 7070 I/day (1G70 gal/day). Sludge
thickening is provided to concentrate the sludge to two percent solids
and decrease the sludge quantity to 1730 I/day (467 gal/day) thereby
decreasing sludge hauling costs. A holding tank for seven days sludge
volume was recor-T.ended to further decrease frequency and thus cost of
sludge hauling.
The overall benefit of Alternative A 32-11 is a BOD reduction of 96.8
percent, a suspended solids reduction of 77.2 percent and a fats and
oils reduction of 77.4 percent.
Alternative A 32-111 - This alternative consists of a pumping station,
nutrienc addition, a flow equalization tank, an aerated lagoon,- and t»:o
settling ponds. The nutrient addition r.odule and flow equal ization tank
perform the saxs functions as indicated for Alternative A 32-11. Due to
longer retention and settling time, removal of fats and oil? prior to
aerating is unnecessary. The quantity of sludge which would need to be
removed by draining and dredging settling ponds every five years is
estimated to be 25.8 cu m (33.7 cu yds).
The overall effect of Alternative A 32-111 would be expected to be the sd~9
as that for Alternative A 32-11.
Alternative A 32-IV - This alternative consists of the treatment modules
of Alternative A 32-111 with the addition of sand filtration. Sand
filtration provides an additional BOD removal of 1.8 percent, susDer.cted
solids removal of 18.3 percent and a fats and oils' removal of 15.1 percent.
The overall benefit of this alternative is a BOD reduction of 93.5 pe^co-r,
a suspended solids reduction of 95.5 percent, and a fats and oils reducf.cn
of 92.5 percent.
Alternative A 32-V - This alternative consists of the treatment modules
of Alternative A 32-11 with the addition of sand filtration.
The overall benefit of this alternative is the same as that of AHernative
A 32-IV.
SUBCATEGORY A 33 - YEAST
This discussion relates directly to the process for yeast product des-
cribed in Section III and d-tails existing and potential in-plant
771
-------
DRAFT
modification: for reducing volume and sr.renyth of wastewater dis-
charges. Treatment methods used by the industry arc reviewed, and
treatmenfr-aHernatives ore presented for the model plant defined in
Section V.
In-Pi ant Technology
In-plant process controls for the reduction of wastewater generation
primarily consist of segregation process wastev/ater from other sources
reuse of cooling water and boiler condensate, and recovery or dry hauling
of spent filter aids. Dry hauling of molasses clarifier sludge and
reuse of third separation spent beer in the second separation process
are other important methods of reducing wastewater generation. Third
separation beer, resulting from final cold water washing and centrifjgal
separation of yeast cream from spent nutrients, can either be discharged
.or used as dilution water during the second separation since it is of .
relatively low pollutant strength. While no significant reduction of
pollution load results, overall water use may be lowered up to 50 percent
with recycling. One major producer (?9Y20) is currently conducting a
bacteriological survey to determine the feasibility of reusing spent
beer at their plants. This is especially important for plants that
practice by-product recovery and biological treatment of resulting low
strength wastes, since lower overall water use would significantly
reduce hydraulic loading of the treatment system. The wastewater charac-
teristics of two plants (99Y02 and 99YC5) that currently reuse final
spent beer are compared with the waste load of a plant (99Y20) that dis-
charges all separation water in Table 147.
Filter aids used in rotary vacuum filters and filter presses for yeast
dewstering include such materials as potato starch and dietomaceous
earth. Spent filter precoat nay te handled dry and trucked directly
to land disposal, mixed with water and the slurry discharged, or the
slurry supernatent may be discharged after settling. One plant (99Y23)
recovers potato starch vacuum filter precoat as a by-product after settling
The sludge produced by mechanical clarification of moUsses in the pre-
paration of feed wort may bo discharged directlv or collected for lard
disposal. At the three plants (99Y20, 99Y08, and 99Y11) that practice
evaporation of spent beer, the sludge nay be added directly to the
molasses by-product.
A small portion of pollutant loads can be attributed to housekeeping
practices that result in accidental spills or molasses losses to drains,
and improperly maintained equipment and ir,c.chinery. These housekeeping
contributions are generally shock leads that occur during daily or
weekly maintenance and washdown periods. Costs of effective in-plant
control of these sources are negligible when compared to the costs of
treatment of polluted effluents and lost raw materials. Measures for
the control and minimization of these sources can be effected by good
772
-------
DRAFT
TABLE 147
COMPARISON OF WASTEWATER CHARACTERISTICS
AND SPENT DEER REUSE
Yeast Plant 99Y02
Production (kkg/day) 82.2
Flow (cu m/day) 2650
BOD (rng/1) 6276
BOD (kg/day) 16330
SS (mg/1) 1735
SS (kg/day) 4513
Final Spent
Beer Reused
99Y05
76.5
2854
6766
19310
353
1008
Final Spent
Beer Discharged
99Y20
87.5
5299
2813
14190
1250
6624
773
-------
DRAFT
housekeeping-practices. The partial reuse of boiler condensate for hot
water washdowns is one demonstrated method cf water conservation.
Acid and caustic wastes are streams resulting from the cleaning of evap-
orators, molasses storage tanks, and other equipment'. Acid and caustic
waters are presently discharged or recycled as part of clean-in-place
systems. All evaporator cleanup at one plant (99Y23) is returned to
the system. The quantities of acid and caustic wastes are not sufficient
to significantly affect the pH of the combined waste flow. In general,
it can be stated that there is existing technology that will allow
zero discharge of acid and caustic v/aste.
Table 148 presents a summary of in-plant control and treatment technology
for the yeest indjstry. It is probable that no yeast factory in the United
States practices optimum in-p'ant control, but it is also probable that all
plants practice scne degree of in-plant control. Also, it is not -
always possible or cost effective to achieve the best in-plant controls,
especially in older plants. In such cases, ncney for in-plant mod-
ifications might be better spent for wastewater treatment. The model
treatment technology developed later in this section and the cost
analyses of Section ViII are based upon reasonable steps taker, in-plant
to reduce pollution loedings.
End-of-Line Technology
Wastewater treatment at 11 of 13 operating yeast factories consists of
discharge to municipal treatment systems. Three plants (99YOS, 9SY11,
and 99Y20) feat high strength wastes, consisting of first and second
separation, by means of evaporation to obtain molassfts by-products.
All cf these plants directly discharge third separation beer, evaporator
condensate, and other low strength wastes to the municipal system. Plant
99Y08 provides only evaporation before discharging to a municipal system.
The remaining two plants (99Y11 and 9SY20) utilize trickling filters ana
activated sludge, respectively, before discharging to navigable waterways.
Table 149 shows the existing treatment practices in the yeas'; industry.
Several methods of treating soluble carbohydrate yeast wastes have been
used in the United States and in Europe. Eldridge (143) reports tliat,
in general, ye^st effluents are best stabilized by primary fermentation
treatment in anaerobic tanks followed by secondary treatment using per-
colating filters. A European exar'ple of this method is the Slagelse,
Denmark, yeast plant where the concentrated wastes, i.e., the yeast wort,
are isolated from the dilute wastes (now called the Danish process) and
treatment of each wastestream is carried out separately. The concentrated
774
-------
DRAFT
TABLE 148
SUMMARY OF IH-PLANT CONTROL ANU TREATMENT TECHNOLOGY
SUBCATEGOriY A 33
Wastewater Source
Inolant Control
Remarks
Storm and
Cool ing Water
Third Separation Beer
Spent rilter Cake
Molasses Clarifies
Sludge
Floor '...'ash and
Miscellaneous U'aste-
Acid and Caustic
Wastes
1. Separation from
Proces: Water
1. Reuse in second
Separation
Dry Haul
Byproduct Recovery
1. Dry Haul 1,
2. Byproduct Addition
1. Improve housekeeping 1
and maintenance prac-
tices; use water orly
when necessary and re-
use when possible
1. Collection and Reus? 1,
Significant
tion of hydra-j 1 •;:
load to trsatre".:
Difficult for o".
plants
Siynificant redu
tion of overai1
water usage
No discharge is
technically feac
No discharge is
technical ly fsr::
Significant 201-
SL-spended sol i;
duct ion achievc
No dischat ce is
technicallv fea
775
-------
DRAFT
TABLE 149
SUBCATEGORY A 33
SUMMARY OF END OF LINE TREATMENT
AND CONTROL
Separation
*•*
c
'O
r~
O.
* -o
r— 3
*^ ^"
C U. l/!
O
— en -o
<-> c o<
fl3 *f— *J
fc. r— rT
o .* :»
i-> (^ ,,*•
TO '^ A*'
> I- 0
UJ t— CC
X X
X
X X *
Ol
F>~
U
y
D
GC
X
X
X
UK
UK
UK
UK
UK
UK
UK
UK
QJ
en
i-
ry
-C
t/1
.PB
o
X
X
X
X
X
X
X
X
X
X
X
X
X
Filter
Water
«/>
t- (U
01 en
•*-< TJ
•— 3
LU (/^
CD T3 OJ
C -Ol Ol
•r- *J I.
r^ C
J< > -C
• ^ J-> (^
U U -r-
K- « Q
X
X
X
X
X
X
X
X
X
X
X
X
>>
s.
HI
>
o
u
Ol
Of
4~)
1C
o
o
u
0.
UK
UK
UK
UK
X
UK
X
X
X
UK
UK
UK
Washdown
Water
in
I- OJ
01 en
*-> "c
-- 3
U. 1/1
co -a 01
c m en
•— ITS J=
•i- 1-" to
S_ U •—
^ « Q
X
X
X
X
X
X
X
X
X
X
X
X
X
Cool i
Water
Ol
u
^
0}
UK
X
X
UK
UK
UK
X
ng Misc.
Water
c/)
U 01
4-> t?
r— 3
i-L LO
01 en ^3
en c o>
u — Z>
~ ^ >
t/i .»— «j
O h- <
X
X
UK
XXX
X
X
X
X
X X
X
X
X
—
»o
l_
^
LT
5
X
X
X
X
X
X
X
X
X
X
X
Note: UK * Unknown
776
-------
DRAfT
wastes arc digested anscrobic.illy; the remaining dilute effluents are
treated with-high rate trickling filters. Figure 247 shows a
diagram of this treatment system. A COO reduction of 70 to GO percent
is obtained for a retention time of four days in the digesters. The
concentration of sludge in digestion must be maintained because it is
the main carrier of methane bacteria. The fermentation gas obtained
has a value of 6000 to 6500 Kcal/cu.m (26 BTU), or about 0.5 cu m
(Ifl cu ft) collected for each kg of BOD removed, and is used nainly
for heating to maintain the 30 to 40°C necessary in the digester's.
The amount of digested sludge discharged is about 0.5 percent of the
wort, and is used in making vitamin B^- The object of aerating the
wort is to remove hydrogen sulphide so that the gas may be burned in
boiler furnaces. About one hour of aeration, consuming 3 to 5 cu m
Of air per cu m of waste is required to oxidize 98 perc2nt of the
hydroor-n sulphide to elemental sulphur. The recirculation ratio for
*he trickling filters is at least 1.3. A BOO reduction of 94 percent
1s attained using both digestion and high-rate trickling filters.
ilant (99Y24) operating in Illinois during the 19
-------
RECIRCU.ATION
DILI/TED
WASTES *
SETTLING
»-D
EQUALIZATION
»
1
1
1
1
fl-f.,T !.T.«GC
IIK4I RAFE
Til KM. ING
FlLlt«
INtC" MTPIATC
T.l.t 11. U*
T/>^»<
DIOt . no 5LUX* Ll.l'/r/.'
•;ECOM> STAGE
M i ( j i • r; a rr
mil n l'*i
I li if i'
FINAL
OX£MTRATEO
-n
FIGURE 247
SL^GHLSE. DENHARK YEAST PLANT TREATMfNT SYSTEM,
-------
•vj
•o
<«t
CXTHAMCCV
tier.T ',*"£
°'.r"™«. rovto,
u r-"L i J«o cu n
66 .« c< •• N:II»«
stci>c G'»Q;
940 V»J M
>n «i 11 .rx::r,i
OvtB, c.
.Mb*-^'^
tniCKLl'^G ri(.ru>
- 5 n rron.
:n cu « '«N c«^»Cir>
•INM. (XMI'ICO
r "
itJXVi
FATI fvlAlAV tW-*> nAl«.l*«
FIGURE 218
PLANT 99Y24
TRCATML>rr SYr>I
ID St»»» SCKR-
r
-------
DRAFT
Another plnnt (?9Y25 ) oner-nino in Illinois (?9Y?5) in the 19-10's
treated yeaSt wastes with a liOD of 4200 to 7600 nig/l usin^j a system
consisting, of six fixed-cover digrsters operated in three digestion
stages of two tanks ecch. The system produced an overall BOO reduction
of 80 to 85 percent and destruction of an average of 50 percent of the
volatile solids.
Rudolfs and Trubnick ( 86 ) describe in detail a systen once usec! for
five years by plant 99Y05. the systen (Figure 249} consisted of two
equalization tanks, one for concentrated wastes (sp^nt \:ort) and one fcr
dilute wastes (wash water and cooling water), two steam heated digesters
in series, a circular hosper-bottcned settling tank for retention
and recycling of digester sludge, two 1.2 m (4.0 ft) deep trickling
fillers, and a final settling tank' for filter sludra. Careful control
of loading, acclimatization of the seed sludge, maintenance of proper
proportions of seed and substrate, and provisions for adequate contact
between the seed and the substrate resulted in peak digester efficiency .
of 95 percent ECD reduction (with a leading of 1.5 kg/cu m) in the digesters
Maintenance of prooer concentration and neutral pH in the trickling
filter achieved a BOD reduction as high as 75 percent, and the corbmec
syste- obtained SO to 93 percent removal of over $000 kg/dcy (9000 Ib/cay)
of BOD. The optinurn pH of the influent to the trickling filters was
7.0, and efficiency fell rapidly at lower pH values. Below a pri of 5.C
the trickling filter- were clogged by a growth of wild yeasts. Sodium
hydroxide was used to maintain suitable pH values.
Buswell ( 145 ) has pointed out t!-at while anaerobic treatment provides
flexibility in loading, tne 300 of tne effluent ra-ely has a BOD of
less than several nunored mg/'i , and that it is usually necessary to
finish treatment of the anaer-obic trcct-.ent effluent by the aerobic filter
bed method before discharging the final effluent. Anaerobic digestion
was used in Puerto Rico by one plant (99Y14) for a short time, but the
treatment system and plant never performed adequately and are not curre-.tly
operating.
The annual wastage of salts ( Uli } jy y?ast factories is considerable.
As early as 1530 rention was nade of t;-,e possibility of concentrating
the ln>h strength wastes (spent beer) and using the concentrate as
fertilizer or for cattle feed. Recovery of molasses by evaporating to
dryness is currently practiced by three plaits in the United States. One
plant (99Y11) is currently startir? by-product recovery operations, and
little information is available on recovery methods at one other facil^t.-
(99Y01), although the process was reported to be performing aaequately.
At the third plant (99Y20) .3 113,000 t.g/hr (250,000 Ib/hr) evaporation
plant has been installed to handle the highly concentrated molasses
wastes (first and second separator beers) discharged from the centrifugal
separators, and an oxygen activated sludge syster,; is used to heat the
remaining combined plant wastes. FujureSiSO, 251, and 252 present the flow
paths of plant wastestreams and treatment system operations. This
7CO
-------
73
DILUTE
WASTE *"
EQUAL I
1 ANK
ViASTE
ZATION
SECOND
i.'iGEsr
i
EQUAL 1 2ATION
TANK
PR1
STAGE SET
"JN TAN
\
\
\
\
MARV
TLING
K
r
/-.;:
/
/
F I NAL
F.RST STAGE SETTLING
DIGEST ION
i
o
•t
.1
i.j
a
in
a
TRICKLING
FILTER
1
1 •
WET WFLt
I
TRICKLING
FILTER
\
.,,...-*. in SFWFR
TREATMErfT AND CONrROL
PLANT 99Y25
-------
t 3
FIRST AMD SECOND
OtPAHATQH SEEK
A.MO (HHtR
MOLASSES WASTES
CITY
PIVLH v*ATER
NO ONLY)
EVAPORAT JON
U
SU.IDGE
J L
PRODUCTION FACH
AFKATtD
EQUAL(ZATJON
VATEO
St UDGE
r.OOLlNG WATER
SANITAWV
FIGURE ?.-*/
YEAST n WT Q
iri) W/VSU WAtCH
-------
on A i
| ^
1""
I
I aci*wita
> T
STai-s "T—•
si^°s I
TO 9IO.Cf.lfM.
FIGURE 251
YEAST PLANT oovro
BY-F.tCDUCl RLCOVERY USING EV/TQi
-------
DRAFT
FIGURE 252
YEAST PLVfT 99Y20
BIOLOGICAL TnlAT-Tr/T A\0 CCNTTRDL
784
-------
DRAFT
systc:: has treated an cvoraqe of C3.7 r:!:n..'v.-rct: (01.5 ton/wrek) of COD
and 33.1 kkn/>/eek (42.0 ton/week) of total suspended soMUs with a
demonstrated removal of 91.4 percent of the BOD and 77.8 percent of the
total suspended solids.
Concentration of the high strength wastes takes place in a multi-effect
evaporation plant. First and second separator beers end other moljsrcs
wastes are pu:-ped to £.iy one of four surg_ tanks and then preheated ar.d
degosified in packed column type atmospheric flash strippers. The
degassed waste?., containing 2 percent total solids are concentrator1 •>
three falling fi In mec:h:nical reco;"prcssion evaporators ir. series to
20 percent total solics. The evaporator condensite is sewered to t.ne
biological treatnent system. A triple effect vacju~ evaporator -is then
used to further concentrate the v/asto to ''0 percent total solids, anc
the ccndensate is again sent to the oxygen-activated sludge system.
Sludge from biological treatment is mixed with the 40 percent TS material
and concentrated to 65 percent in a forced ci rculatiori ( \FC ) eva^ra-Di"
and the condensete frcn this final stage sent to biological trsatre-.t.
Finally, th3 65 percent tctcl solids material is pumped to storace f:r
future resale as anina! ^eed. The evaporators are reported ;o re-rove
90 percent of the 50L nnri 93 p-3~:ert o* the suspended colics fron nign
strength wastes. Reve-se osnosis, ultrafiltration, and other nethods
(see rum distilling) of concentration were considered tjt were founc
to be unfeasible for this plant.
All low strength wastes, including third separator beer, evaporator
condensate, and plant washings, are sent to the biological treatment
syst2rr. The first stage of the $yst2:n consists of neutralization,
nutrient addition using phosphoric acid, and aerated equaliiatior
in three
parallel to remove suspended solids. Clarifier overflow (treated er''1_;-n'
is then discharged to a navigable waterway. Clarifier sludge i~> purpecf
to a surge tank, then concentrated, certrifuged, and pasteurize!, and
finally pumped fron a second surge tank back to tne last stage of evap-
oration. Sorce sludge is returned :o the reactor. This sophisticated
system worked well after some •••icdif:cation to el'nindte fouling in the
evaporators, although the final jffluent still exhibits a brown color.
Selection of Control and Treatnpnt Technology
In Section V a node! plant was developed for the yeast industry. It
is assumed that the model plant provides no treatment of its wastewater
prior to discharge, and that coo'ur.u water ond domestic sewage arc
separated from process wastewatcr. The chosen flow assumes that third
separation beer is reused as di'utnn v/asn v/ater during second separa-
tion. The raw wastewatcr characteristics of the model plant are:
785
-------
Production
Flow
BOO
ss
52 M.o (vO.4 ton/Jr.-)
2,600 cu v. (0.7 ri3D)
6,300 mg/1
1 ,850 mg/1
The treatment alternatives which include equ;il ization v/sre net judged
to require neutralization. Biological treatment requires the adcition
of both r.itrcoen anu phosphorus. In alternatives ir.cl u-.hr.; r.'j'cs:.j^ Dy-
p-oduct recovery, evaporation is assured to receive 5C percent of "ctsl
plant flo.. (sce.-.t beos), 75 percent of the HDD and susperd-i-d :>ol-;-r, ct.d
removes 93 percent of the BC'J ana 99 percent of the suscinaea so1!^.
Table 153 lists the -oll-jtant leading and calculated re~;..cl c •'•"•;:~ n: -es
cf each of t-e treatment alternativ/-~s selected -or this suscnteccv-
Figures 253 aid 254 preview sir.Dl if ied flew diagrams for tne trcstv.er.t-
alternatives in tnis subcategory.
AUer^.-f've A 32-1 - Th-'r- alternative includes ,-o additicr.sT cc^tr?! cr
treai~i-riu. Tr.e e-fficiency of CC.J and Si-sperccd solids i-ev.cva'f is :c-rj.
AHernativg " 33-11 - This alternative consist: of a control HCJ^O, D'jrc-
109 s'tuvic,-., r,uiri3,i: acditicr,, flc\/ ec-alizaticn wiir. I- "cur cete-ti'.",
tire, ae-:t2d leccprs, anc sett^^g pc-vds. 'n-tr-ient adci.:ori cc-;-;ts of
1012 kc/cay (2^31 Ib/cay) -•' ;r,h,:r;..js -,..:7.cma and 47- i,g.'ddy (1C-4 :z/
day) of phospncric acid. The predicted efflusr: ccncentraf: en? are 1^3
mg/1 BCD cr.c 5C r.c/1 sus:.ei52d solids. The over-all effect of Al~r'T.=-
tive A 33-11 is a 5CU reduction of 9S.4 percent and & suspc-'ided relics
red'JCt:cn of 97.3 percent.
A1 te.-r:t-'vg " 33-!! I - This a'ter^=tive adds cuel red-'a fiitraticr: to tr.c
trea:ir:-nc c/-2:n in Alternative A 32-11. The predicted effluent concen-
trations are 5^ .ng/l BOD ana 25 -g/1 sjspenoed solids. The cverail e"f-?:
of Alternative A 33-111 is a BOD reduction of 99.2 percent and a susper.LC
solids reduction of 98.7 percent.
Alto-net-vq A 33-IV - This a ]J:erra :i vc arlds activated carbcri to the treat
ment ciiaui ir. Alternative A 23-Iii. The predicted efflue'it cc-jicont-^iic:'.
are 25 ir.g/1 BOD and 13 i^g/1 suspended solids. The overall effect of
Alternative A 33-IV is a COD redi.'Cfion of 99.5 percent and a suspended
solids reduction of 99.3 percent.
AHeri-jtive A 33-V - This alternative consists of a control house ,. pu v'r
station, flew equalization with 24 hour detention tir.'e. prirary cla"i;"i-
cation, nutrient addition, cc"iplote mix activated sludge- system v;ith
fixed surfticc aerators, sludge thicl'.eninn producing 2 percent solids,
aerobic digestion producing 3.5 percent solids, vacuum filtration pro-
ducing 15 percent solids, sludge storage, r.nd truck hauling. Nutrient
addition consists of 759 kcj/day (157-1, Ib/doy) of anhydrous un^oni-i r,;-.d
355 kg/day (783 Ib/cJay) of phosphoric aci^. The predicted effluent con-
centrations ore 100 mg/1 iiOU und jQ ng/1 suspended solids. The overall
786
-------
TABLE 150
SUMMARY OF TREATMENT ALTERNATIVES
SUBCATEGORY A33
Treatment Train Alternative
A33-I A
A33-II BCHIL
A33-III BCHILN
A33-IV BCHILNZ"
A33-V P.CEHIKQP.SYV
A33-VI BCEHIKQRSYVW
A33-VII BCEHIKQRSYUNZ
A33-VIII BCEH1KQRUV
A33-IX BCEHIKQRUYN
A33-X BCEHIKQRUYNZ
A33-X1 BCFIHIL
A33-XII BCFIHILN
A33-X1II BCFIHILNZ
A33-XIV BCEFIHIKQRYSV
£?3-XV rririHIKQRvsV")
Effluent BOD
(kq/kkg)
203.57
3.?3
1.62
0.81
3.23
1.62
0.81
3.23
1.62
0.81
3.23
1.62
0.81
3.23
1.62
Effluent SS
(kg/kkg)
59. 78
1.62
0.81
0.10
1.62
0.81
0.40
1.62
0.81
0.40
1.62
0.81
0.40
1.62
O.J^
Percent BOO
Reduction
0
9:1.4
99.2
99.6
93.4
99.2
99.6
99.4
99.2
99.6
98.4
99.2
99.6
98.4
9*!2 '
Percent SS
Reduction
0
97.3
98.7
99.3
97.3
98.7
99.3
97.3
98.7
99.5
97.3
98.7
9?. 3
97.3
93.7
-------
TABLE ISO(CONT'D)
Treatment Train Altemative
J33-XVI BCEFfHIKqRYSVNZ
A33-XVII BCEFIHIKQRYU
A33-XVIN BCEFIHIK.QRYUN
A33-XIX BCEFIHIKQRYUNZ
A33-XX YBU
Effluent BOD
kn)
ss
0.81
3.23
1.6?
0.81
0
0.40
l.f?
O.P1
0.40
0
Percent BOO
Rodnc t "ion
98.4
99.2
99.6
100
Percent SS
Ruction
99.3
97.3
98.7
99.3
100
-j
a
o
-------
i!
t;co « st;5 I-;,L
if. = 277J w;^.
!3i' CU
SS
co ::. !••::
•'..-" L
A 33 -> ;v
TK-'.vX-H /I
-*•<
CL AS :
A^TC—.^I JVE A 23-V. Vlll, XIV, J".
. EFFLUENT
BCD 103
SS SO '
Tlv-E V 3J-V1, IX. XV,
£S • 25
">iAT 3 v~
moo ?s ••<; i
ss u I-O-L
GUn-Z 2C-3
SUBCATEGC.Tf A 33
TRCATMCNT ALTL:~.kJATlVCG V THi-XGH X. XIV THROUGH XIX
-------
DPAi'T
'L0» • IMS Cu »^)t» co.Ji
4 •Ll'»J'l>TI
FIGURE 254
SUBCATEGC3Y A 33
TREATMENT ALTERNATIVES II TK2CUC-H IV. XI THROUGH XIII
70U
-------
DK/'rr
effect of AUcr-:.:ti'.o A 33-V i. a LiCj ;-; .:i;.t •, .1 of OG.-1 percent ;.ru! j
Su:.pci---'-«j i-M'il: redact ic.n of C-7.2 ;• :r^...i t .
Alternative- A 32-VI - This alternative adds dunl media filtration lo
troaliiierH cncnn in Alternative A 32-V. The predicted effluent concen-
trations arc iiO i;ig/l TJD and 25 mrj/1 suspended solids. The overall
effect of Alternative A 33-Y! is a COD reduction of 99.2 percent and
a suspended solids reduction of 9C.7 percent.
A1ternr.ti 70 •'. r?-VTI - This al torn''.-1'1-"1 adds activated carbon to the
trcil. .-~ ; c:nr. i.n •"•! tornctiv: .-. 2- .".-VI. The "-redictj'J effluent co: -
centra ti or.: are 25 .n-c/1 C3J and ".2 ,-r.rj/l susF?".dcd solids. The ove-v'n
effect of Al ternat: ve A 33-VIi is a KOD reduction of 99.5 percent cr.d
a susp-3r,c.'e-- sori-3 red-cticn of 99.3 percent.
Alterr.?.t-: .••:• a ?j.-',']II - This alterative repls::-:; vac---. :• f,ltraf:cn er.j
truck hau'i ing in Alternative A 33-v .vith spray irrication. The pre-
dicti-d eff'ij^-it ccncrintrotions 2 re 103 r:a/l LCD and :D -.-.-I sucr^r.;:.-.:
solids. Tr.e overall •. "'c-zt of Altc-rnativc- A 23-V1II is a 2C3 rc-dJC'.ic'1.
of S3. 4 ire:'C2r,; and a suspcr-.cec sends reJjctio:. of S7.3 percent.
Alte>-5t:ve •'• 32-IX - This altcrr.jti ve adds dual -ei-.'-'a fi'trit-c" tc t'
n Alternative A 33-VII!. The predicts effluent c:-.::
.^ii: c'a-.n
tratior.s are 50 -g/" BCD and 2: r;/l suspended solids. The overall e*f
of Alterrativs A 33-i.X is a BCD reduction of 93.2 perce:i: arc a Su":-ci;
sclids redaction of 92. 7 perrent.
Alterrati v» A 33-X - This alternative adcs activated careen to the tr--;:-
ment craT"; in ;«] ternati ,-e A 33-IX. The predicted eff'::3-t ccnc-srt-:. :i; • s
are 25 HT/! ECO and 13 r,c/l suspended -o"i;ds. T'r:e cve»"2ll effect of
Al terra tiv-2 A 22-X i: a £jD recjcti on of rS.6 perceni an3 a susper.ui-a
solids recucticn of 99.3 percent.
Alternative A 33-X I - This alternative consists of pu.-m'rg first and
seconj S£u_rjc;c:~i 3e3r to en evacoration sy^te- for r-icli^ses by-^'-td-rt
roccver1.1, SPU then irc;ting ev=:"r; 1C" c^^dc^ratc; and •'•''•-.^r 1c".; f •••:"••_ :'
wastes Jsir.a the treat: £-1:. trail ^c-i^r-oeu in »'-~ar,'.>.z;v8 A 33- •! e-.c-:?::: :
nutrient acdit'on ccnjiits of ?2? i.n/cay (725 iD/day} cf anhyd'ous z-'z:,::
and 154 kg/day (.'40 Ib/day) of phrsc.'ioric acid. The predicted effluGr.t
conce.-trations are 100 ;r.g/l COD and 50 ;-.:g/1 suspended solids. The ov:;!':.:;
effect of Alternative A 33-XI is a COP reduction of S3. 4 percent and a
suspended solids recuction of 97.3 percent.
Alternative A 33-X 1 1 - This alternative adds dual irodia filtration to
Alternatro A 33-XI. The predict?.! effluent ccncentrj .. ions are 50 ;-ij/l
BOD and 25 tvo/1 suspended solidi. The overall effect of Al tcrr.a t i v:
A 33-X 1 1 is R 300 reduction of 99.2 percent and a suspended solids re-
duction of Qfi.7 percent.
791
-------
Al LfiTiOt^v? A 7 j_" •'•' '' " "•''''is a!tornj I i vc adds Activated carbon to lh?
tirerrinic'rrr'ohvrrrTn /iY'jcrn;five A 33-.XII. Tho prcdictc'd effluent con-
centrations orr 25 rr.n/1 I;C,D and 13 ;iiy/l su:pei n i ' « i- 3 o ^ i' -- — / C ' • ~ £. •- s~ *z r C^'T^C
fl I ™ t> _/ ' ' ' ^ < . — -f t» • • W I w" ^>, I ~l M . ~ ^ «_.. J W t ">--.« >._ V * W ' M ' ' *- I
Alternctive A 33-.XV: is c 2G3 rcc:.ct:cr; of 99.6 percent and a
solids reduction of 99.3 percent.
Alterr^tiv? a "?-XVn - Th.-.i sit2r?:.ti :e replac:c vacu-r, filtritioi f.'_
true!: iT = ulir.g in .Alternative A 33-XIV with sorciy irrigation. The pre-
dicted effluent concentrations are 100 ;~g/l i?CD and £0 r:g/l suspended
solids. The overall effect of Aiterr.ctive A 33-.-.VI! is a 2CD redjcti:.-,
of 98.4 percent and a suspended solids reduction of 97.3 percent.
A He -na t i vo A 53 - XV111 - This altorr.ctive adds dual r^.edia f-iltratic".
to tn? ti~e:. v:"t c:i=in in .1' t^rr.cti .'0 A 3j-''.VII. The predicted cc ••:.•"'-
trations are i-G rr;^/! C?C and 2'i r.c/1 suspc-.".ded solids. The overall
effect of Alternative A 33-XViII is a BOD re-Jucticn of 95..'' percent cr'.i
a suspended solids reduction of v3.7 percent.
Alternative- A 33-XIX - Tins al term five- ;dds activated carbon to the
trcotv.eni cn^in in. Mlternative A 33-X1.'; i I. The predicted eft'luci*
concentrations ere 25 i:;-./! GOD ei\i 13 i-c/1 susi'enaed soli'is. The
overall effect of Altcn-.nive A 33-XIX is a COD rcdiici-iop of 99.6 per-
cent and a suspended solids reduction of 99.3 percent.
Alternative A 33-XX^ - This alterative consists of a holding tank, purg-
ing station, ar,a spray irrigotion o- the raw affluent. Tho'efficiency
of DOD and suspu-nded solids remove' i; ICO percent.
792
-------
Df;/.rr
suLc;.v:o:':r A 3' -
In-Plant
In-plant process controls for the reduction of wastewater generation in
peanut butter plants primarily consist of non-contact cooling wate"
reuse, reuse of detergent cycle wash water in jar washers, use ot stc;i.i
and specially designator areas for major equipment cleanup, and dry
collection cf peai'ui :l::ns, hearts, crd fire particles ^or by-pro-: ct
-a/-r,./Q,.v, ni-,-0,- techniques for the reduction i.aste'./uter strengtn incliciij
i of process area floor cleanup watsr anti the use of
cleanup area floor dra'.ns.
recovery. Otr.e
vacuum collection
grer.se traps on all
Several methods of non-cont
reduce water usage are >)rac
exchangers at se.eral locat
pipe heating (to condition
as a closed loop system req
Condensate _is ccllectec: ar.d
small emeu n't is di sciiar^ed.
units is acco-."-l i :hec by -.w
water storage tar^s. This
ton/Jey) snd discmrcc-s 65
smaller plant (5SP2-) prtdu
culating only ?. portion of
197 cu in/aay' (o.G52 M3D;.
act -..-itsr conservation that rigni'ica
ticed by one large plant (5yr21). He
ions on hot v/ater lines used for proc
oils and product for punpir.g) are des
uiring only & srrall amount of make up
reused for boiler feed water, and a
Cooling of refrigeration ana cc~ipre
o cooling towers recircuiaiing water
plant produces 59 to 77 kkg/cay (£3 t
cu m/day (0.017 !'3D). in comparison,
cing 10.5 kkg/cay ("••"> .7 ton/day; ar.c
its cooling water, was found to disc
ntly
re:~--
Non-contact water is cor.rcnly conbined v/ith other plant wastes at r^s
9SF01, 95-14, a;:d S9P21 .v^c-i --..oresen: the tnr?? largest pearut tu-.-:-
pr&ducers. While all of the ranjfacturers surveyed practice v=i\."'.-.;
degrees of wate.- reuse, none ..'ere found to completely ieg^ega-cs r:-:-
conta:t water from relatively Ic1-/ volume, high streigth wastes (sf?
Section V) such as .jar washor effluent or cleanup •..'cst2»ater. Se?a"--'-n
of the aoove waste streams is 3 potential in-plant modification tna; .o-lc
reduce process wastawater volume by at least 90 percent, and wojlc ™*'ne
effluents to only .vater in ccnt.'rt with ccrtiTinants. It r.ust be r^n,
hov.ever, that generation of ssi lutants per unit of prcducficn •.-.cj'i ^c
decr.^.ise, and pollutan-; concentrations would necessarily increase, -£>••-
cially during cleanup penocls (see Table 150). For example, sarp'.t
analyses of combined jar washer and non-contact water discharge Ou ;••"!;.:•
99P20 shew a BOD of 60 nig/1, but jar washer efflueit alone ,ias a CG
BOD of 7320 mg/1 (see TaL-le 149). Also it is to be expected tnat ar-;
regation of non-contact and process wastewatsrs would be mere difficll
at older plants.
Jar washer effluent, which is nornally discharged, is the only pcllut
source during processing. It \s tecnnically feasible to eliminate t';.
waste stream by diverting it to a holding tank. Such action would
significantly reduc-2 pollutant generation per unit of production.
793
-------
Alco, in'.c£Dver.'jr.'. on t!:c rr.cUiod of r.-apiialV-' scraping DeO'iut butler '??
jars to Le ivcksiK-J i.mlc roc'-jrc tlie amount of produ-.t left in ji>ro, :iCi,
reducing waste g.-neration pvr unit of production i:i the jar washer
effluent.
Wastewater from floor cleanup is normally batch dumped from buckets
or drained froi.i a holding te.nk inside a vacuum floor scrubber. Mo
st23r,i hoses or v.a:er hosts are used in processing areas. Eciu'pn-ynt
wipedown is perfor,-7?d weekly ana scrub tucketr aurip^c' et a sterTi pit
where all major aquipneoi cleanup takes placF.-. The stean pit i; typi:
a crncrote slar- equi'jp=d .vilh st?ar.i ho'.cs, hot water hcCi~2, n; .1 •ji'~2.!>
traps or all drcins. It rray albc •inch.d? stainless steel tinl-.b to
provide a deterrent s^ak fc,- equipment forii difficult to cledn. Ch.r-
equipment, elevoto- buckets, drip sans, m'psline :ectionr,, an^ otnc-r
equipr.^nt ren;ov;.d fro^i processing ar=as 'is inarually cleanc-d wi.ii
hot v/ater and ste£in or detergent after residual product is scraped
into crutrs for oil stctk recovery. Rerouting of drain lin£i after
the areas? traps to a holding tank would complete!./ an'ninate cleanup
w£;tu..'iter discharges and is technically feasible.
End-cf-Linc Techno!057
Peanut butter plants do not utilize co^histicated end-of-lins t-ear.T.en
systems. All of the pleiits surveyed have installed grease trc^s en si
floor drains. One mjl'.i -product plant (99P13) provides oil ski.-.rir,-
o* peanut Butter v/as tester only because these discharges are corrjire
with the effluent fr-jm margarine prod'jcticn. All of the plants surv:;-
dn'scharne jar washer and clsr^L'p effluents, ccnbired '.-.'ith large *r-.z'.r~
of non-contact water, to municipal sewer systems.
Selection of Control and Treatment Techncl^gy
Based on the model plant developed in Section V, two treati^£nt alterr.:
that provide no discharge cf process wastewatei" wer? cnosen. It is
assured that the !i:odel plant proxies gr'.-use traps on all floor drain;
that ncn-con:act v.acer anj cort-stic se-.'oce are scD?.-"ted fro.-i '.u.e p-r
wastivater. The ,.oStev:ater flo.v from tiie rrode" plant is 2800 I/day
(7CO gal/day).
Al^o^nati ve A 34-1 - This altsrriative provides no adJitinnal treatrer
to the model p1?n;. The rsroval efficiency of ECD, s-jspended soli-s.
and oil and grease is zaro.
A 34-^1 - This alternative consists of <* holding tar.k , p'^'
ing station, and spray imcjfion of the effluent. This alternative
provides 100 percent removal of BOD, suspended soliJs, and oil and
794
-------
DRAFT
AT t e r_na_t i v? _A 34 -111 - This altcnv-li ve replaces spray irrifjnlio!! in
AHer I'mti ve /'A j-i-il with truck hauling of the? effluent, ar.d til so
providers 1QJ) percent removal of COD, suspended solids, and oil and
grrase.
SUDCATEGCRY A 35 - PEANUT BUTTER PLANTS WITHOUT JAR '.-.'ASHING
The existing and potential in-plant and end-of-line technology for
peanut butter plants without jar washing is identical to Subcategory
A 34 except that jar washing is not included.
Selector) of Control and Treatment Technoloav
Based on the node! plant developed in Section V, two treatment alter-
natives that provide nc discharge of process wastewater were chosen
for Subcategory A 35. It is assumed that the model plant provides
grease traps on all floor drains ar^d that non-contact water and do-
mestic sewage are separated from the process v;astewater. The waste-
water flow fro;* the model plant is 757 I/day (200 gal/cay).
Alternative A 35-1 - This alternative provides no additional treat-
ment ic tre rr.ocel plant. The renoval efficiency of SOD, suspended
solid;, and oil and grease is ze-o.
Alternative A 35-11 - This alternative consists of a holding tank,
pulping station, and spray irrigation of the effluent. This alter-
native provides 100 percent removal of BOD, suspended solids, and
oi1 and grease,
Alternative A 35-1II - This alternative replaces spray irrigation in
Alternative n 55-iI with truck hauling of the effluent and also pro-
vides 100 percent removal of BOD, suspended solids, and oil and grease.
SUSCATEGORV A 36 - PECTIN '
As previously discussed in Section III, there are three knw.vn producers
of pectin in the United States. Curing the course of this study ail
three plantb were visited. The information which was obtained regard-
ing the control and treatment practices of the industry is presenter
below.
In-Plant Technology
Plant 99K01 practices water reuse in the following ways :
1. Barometric condenser cooling water for the pectin evaporator i!
recycled through a cooling tower. Makeup water is added j',
needed. Tliis practice decreases the cooling vater dischar-'o
by approximately 5700 cu m/day (1.5 MGD).
795
-------
2. The tubular heat exchanger on the alcohol distillation ccl
is cooied by 2COO 1/min (750 gpm) of rater from a cooling
tower. There is a sr.iall blowdown of approximately 11 cu
(0.0029 MGD) from the system. This practice decreases cooling
water discharge by about 4090 cu m/day (1.08 MGD).
3. Cooliny v;ater used in a plate exchanger to cool condensed
alcohol is subsequently used in a vacuum cooler prior to
being stored for further use elsewhere in the plant.
Plant 99K02 reported several areas of water reuse including the fcl'c.-..
1. Peel v;ash. water is reused in the conveycrc? of peels to grind-
Ing and pasteurization, and aiso as cooling tov.er makeup
water.
2. Nash pump seal water is used to sluice diatomite cake frorr the
pressure filters.
3. A cooling tower is used to min-imize cooling water discharge
from the plant.
Plant 99KC3 also recycles all cooling water through d cooling tov/c-- t*:-
decreasing fresh water requirements by 200 prrcent. Whereve-" possib".;- .
three plants reclaim acid and alcohol used in the pectin process tc --'••
raize the discharge of these substances into the waste stream. Vacuu"
filter cake, composed mainly of soent peels, is segregated from tre ..ir.:
stream, dried, and utilized as cattle feea at plants 99K01 and 9SK02.
End-of-Line Technology
Plant 99K03 is currently discharging its entire process v-aitewater (in-
cluding still bottoms ana spsnt peel) to a municipal treatnent syste-
with no aoparent adverse effect on tne system. Plant 99\C2 utilizes
three methods of ultiirate wastewater discosal for specific process
waste streams. Alcohol still bottoms and water softener regenerate
are segregated and truck hauled to a municipal treatment system. S^nt
peel is dewatered in i press, dn'ed, and utilized as cattle feed. T: ...
press liquor waste stream along witn peel wash end reuse water, sper:
diatomacenus filter cake end sluice water, pectin mother l:qucr, bo i'.-..:•
blowdown, and cleanup water (all of low inorganic content) are distr-_-
uted into 120 ha (290 acres) jf land by check and furrow irrigation.
Plant 99K01 also recovers spent peel for subsequent use as cattle feed.
Waste streams low in inorganics (peel wash water, diatomaceous filter
cake and sluice water, plant cleanup and miscellaneous waste streams)
arc used to irrigate corn, barley, ard Sudan grass crops. The alcoriol
still bottoms, caustic evaporator \vash water, water softening regen-
erate, and boiler blowdown are neutralized and subsequently discharges
to a municipal industrial outfall I vie.
796
-------
Ion exchange has been a'.'tempted at plant 99K02 for treatment of some
process waste streams with poor results. At present, the plant is
considering construction of an oxygen activated sludge system for treat-
ment of its process waste (excluding alcohol still bottoms and water
softening regenerate) along with other citrus process wastes generated
at the plant.
Selection of Control and Treatment Technology
In Section V a model plant was developed for pectin processing. The raw
wastewater characteristics of the plant were assumed to be as follov/s:
Flow 1530 cu m/day (0.404 MGD)
BOD 4950 mg/1
SS 2100 mg/1
N 260 mg/1
pH 4.6 to 6.0
Table 151 lists the pollutant effluent loading and the estimated oper-
ating efficiency of each of the ten treatment alternatives selected for
this subcategory as illustrated in Figures 255 and 256. It is assumed
that truck hauling of alcohol still bottoms, diato^aceous filter cake
and sluice water, and water softening regenerate to landfill is pro-
vided for each alternative. It should be noted that biological treat-
irent will not provide reduction of inorganics in the wastewater. Citrus
wastes have been shown (146) to be biodegradable ir an efficiently o-era:t
complete-mix activated sludge system. The organic constituents of the
pectin wastewater are similar to these of citrus processors and would
therefore also be expectf-d to be biodegradable under similar conditions.
Alternativa A 35-1 - Thic alternative provides no additional treatment
for the raw v/asr.c c "fluent. The overall reduction of pollutants is zero.
Alternative A 36-11 - This .Jternative consists of a pumping station and
a holding tank followed by spray irrigation of tha raw waste effluent.
This alternative would require 32.4 ha (80.0 acres) of land and prov.ro
a 100 percent reduction of pollutants to navigable waters.
Alternative A 36-111 - This alternative consists of a puir.ping station,
a flow equalization tank, caustic neutralization, complete-mix activated
sludge basins, sludge thickening, aerobic digestion, and vacuum filtra-
tion. A flow equalization tank is provided to dampen shock loadings to
the activated sludge basins. Neutralization of the waste is accompli'.. ••-
by the daily addition of an estimated 9£ kg (220 Ib) of sodium hydroxide
to the raw wastewater The complete-nix activated sludge systcrr. would l>a
expected to provide a BOD and suspended solids reduction of 94.9 and
90.0 percent, respectively. The ano-jnt of sludge wasted from the vacuum
filters is estimated et 25 cu nt/day (0.0066 MGD>.
The overall bene''t of this alternative is a BOD reduction of 94.9 percen-
and a suspended sdids reduction of 90.0 percent.
797
-------
Ion exchange has been attempted at plant 99K02 for treatment of some
process waste streams with poor results. At rrosent, the plant is
consideriTrg construction of an oxygen activated sludge system for treat-
ment of its process waste (excluding alcohol still bottoms and water
softening regenerate) along with other citrus process wastes generated
at the plant.
Selection of Control and Treatment_Technology
In Section V a model plant was developed for pectin processing. The raw
wastewater characteristics of the plant were assumed to be as fellows:
Flow 1530 cu m/day (0.404 MGD)
BOD 4950 mg/1
SS 2100 mg/1
N 260 mg/1
pH 4.6 to 6.0
Table 151 lists the pollutant effluent loading and the estimated oper-
ating efficiency of each of the ten treatment alternatives selected for
this subcategory as illustrated in Figures 255 and 256. It is assured
that truck hauling of alcohol still bottoms, diatomaceous filter cai:e
and sluice water, and water softening regenerate to landfill is pro-
vided for each alternative. It should be noted that biological treat-
ment will not provide redjction of inorganics in the wastewater, Citrus
wastes have been shown (146) to be biodegradable in an efficiently o;:e'-2tec
complete-mix activated sludge system. The organic constituents of th-
pectin wastewater are similar to those of citrus processors and would
therefore also be expected to be biodegradable under similar conditions.
Alternative A 36-1 - This alternative provides no additional treatn'2:u
for the raw waste effluent. The overall reduction of pollutants is :crc.
Alternative A 36-11 - This alternative consists of a.pumping station and
a holding tank followed by spray irrigation of the raw waste effluent.
This alternative would reouire 32.4 ha (80.0 acres) of land and pro.-icie
a 100.percent reduction of pollutants to navigable waters.
Alternative A 36-III - This alternative consists of a pumping statior,
a flow equalization tank, caustic neutralization, complete-mix active.::-d
sludge basins, sludge thickening, aerobic digestion, and vacuum filt'vi-
tion. A flow equalization tank is provided to dampen shock loadings ta
the activated sludge basins. Neutralisation of the waste is accc-ipliji :c
by the daily addition of an estimated 98 kg (220 Ib) of sodium hydror.v.!e
to the raw wastewater The complete-mix activated sludge system wou'd i:«r
expected to provide a BOD and suspended solids reduction of 94.9 and
90.0 percent, respectively. The amount of sludge wasted from the vacuum
filters is estimated at 25 cu m/day (0.0066 MGD).
The overall benefit of this alternative is a BOD reduction of 94.9 percent
and a suspended solids reduction of 90.0 percent.
797
-------
TABLE 151
OF TREATMENT TRAIN ALTERNATIVES
SUBCATEGORY A 36 - PECTIN
to
co
Alternative
A 35-1
A 36-11
A 36- 1 II
A 36- IV
A 36-V
A 36-VI
A 36-VI I
A 36-V11I
A 36- IX
A 36-X
Effluent
•50D
4128
0.0
208.5
203.5
208.5
208.5
104.3
104.3
104.3
104.3
Effluent
SS
kg/kkg
1751
0.0
175.1
175.1
175.1
175.1
83.4
83.4
83.4
83.4
Percent
BOO
Removal
0.0
100
94.9
94.9
94.9
94.9
97.5
97.5
97.5
97.5
Percent
SS
Removal
0-0
TOO
90
90
90
90
95.2
95,2
95.2
95.2
-------
DRAFT
INFLUENT
PLOW * l.fSO CU M/DAY (0.40 MOD)
BOO = 4.950 «G/L
SS = 2.100 MG/L
PLOW
EQUALIZATION
PH
AD JUSTMENT
-
AEROBIC
DIGESTION
»
SLUDGE
THICKENING
1 SPRAY
IRRIGATION
VACUUM
FILTRATJCK
!
SLUDGE TO
TRUCK MAUL.
t
S^ND DRY; UG
ecus
r
ACTIVATED
SLUDGE BASIN
T
SeCCNOARv
CLAWirlCATION |
i . 1
S£™?W
f
- 36- vl I. wj;;. ix
BOD = 125 MG/L
os = icr MG/L
*• A 36-111, IV, V
EFFLUENT
BOO =230 MG/L
SS " 210 f-'G/L
FIGURE ;:-.
SUBCATEGORY
TREATMENT ALTERNATIVES III, IV. V, VII. VIII. IX
799
-------
DRAFT
I^LUENT
R.G* t l.b^O CU M/DAY (0.40 MOD)
BOD s 4,950 MG/U
SS a a.100
EO^T:
CtJ
ADJUSTMENT
AERATED
LAGOCN
PlLTRATJDN
ALTERNATIVE
.*. A 36-vI
BOO =
A 36-K
eco = i2i
SS = 100 MG/U
FIGURE 2
5UBCATECORY A3ft
ALTERNATIVES vi AND x
BOO
-------
DRAFT
Alternative A 30- IV - This alternative consists of the same modules as
ATtcrni/five A 36-111 except vacuum filtration is replaced by sand drying
beds, resulting in twice the daily sludge production over that of Alter-
native A 36-111.
The overall benefit of this alternative is a BOD and suspended solids
reduction of 94.9 and 90.0 respectively.
Alternative A 36-V - This alternative consists of the same treatment modules
as Alternative A 36-1 Ji except vacuum filtration is replaced by spray irri-
gation of daily sludge produced. This would require a spray field of ap-
proximately 2.3 ha (5.7 acres).
The overall benefit of this alternative is a BOD reduction of 94.9 percent
and a suspended solids reduction of 90.0 percent.
Alternative A 36-VI •• This alternative consists of a pumping station, a
flow equalization tank, caustic neutralization and an aerated lagoon.
The overall effect of this alternative is a BOD reduction of 94.9 percent
and a suspended solids reduction of 90,0 percent.
Alternative A 36-VI I - This alternative is identical to Alternative A 36-111
with tne add; tion of dual-media filtration which would provide an esti-
mated additional COD and suspended solids reduction of 2.6 and 5.2 per-
cent, respectively.
The overall benefit of this alternative 1s a BOD reduction of 97.5 per-
cent and a suspended solids reduction of 95.2 percent.
Alternative A 36-VIII - This alternative is identical to Alternative
A 36- IV with the addition of dual-media filtration. The overall bene-
fit of this alternative is a BOD reduction of 97.5 percent and a sus-
pended solids reduction of 95.2 percent.
ive A 36- IX - This alternative consists of the same modules as
Alternative A 36-V with the addition ov dual-media filtration. The
overall benefit of this alternative- is a POD reduction of 97.5 percent
and a suspended solids reduction of 95.2 percent.
•c
Alternative A 36^X_ - This alternative consists of the same treatment
modules as Alterna'tive A 36-VI with the additicn of djjl-media filtra-
tion. The overall benefit of this alternative is a BOD reduction of
97.5 percent and a suspended solids reduction of 95.2 percent.
SUBCATCGDRY A 37 - PROCESSING OF ALMOND PASTE
There are currently four known processors of almond paste in the
United States. All four discharge their process waste-vater to
municipal facilities. Results of a telephone survey to three plants
and one plant visitation indicate that the production of almond par-te
001
-------
DRAFT
contributes a relatively insigificant waste load to the total waste
load of the four multi-product processing plants. The production of
almond paiie exists in combination with the production of a large
variety of other products such as nut pastes (i.e., pecan, walnut,
hazel nut, cashew, and apricot kernals), granulated nuts, and nut
toppings. The wastewater characteristics of almond paste processing
are currently unavailable for the following reasons: 1) the multi-
product plants contacted were unable to furnish historical data on almond
paste production alone, with the only available information being that
of the final combined products waste load, 2) the actual sampling of the
almond paste production line was impractical due to the combination of
waste streams from other product lines, and 3) production data was
unobtainable.
The industry has made no future plants for the construction of any
new almond paste processing plants and, as previously mentioned, dis-
charges its wastewaters to municipal facilities. Therefore, the pos-
sibility of a future point source discharge fror an installation
primarily engaged in the production of almond p<*ste is minimal. Due
to a lack of information on the industry's prrduct line, production
variability, and wastewater characteristics, the development of
effluent guidelines for almond paste processing is not feasible at
this time.
SUBCATEGQRY.B 1 - FROZEN PREPARED DINNERS
Existing and Potential In-Plant Technology
The majority of wastes from the frozen specialties plant originates
from clean up of the vats, kettles, friers, mixers, piping, etc.,
which are used during preparation of the various components of
the final product. General plant cleanup, usually a continuous
process, is also a najor wastewater source. Substantial reduction,
therefore, in raw waste load and w?..,tewater treatment cost can be
realized by careful in-pi ant water management:
1. Installation of automatic shut-off valves on water
hoses may save up to 60 gallons per minute per hose.
Without: automatic shut-off valves, employees do not
turn off hoses. Cost for a long life valve is approxi-
mately $40.
2. Central clean up systems (valvcd or triggered hosas)
should be installed. These commercial systems
generate a controlled high pressure supply ot hot
or warm water containing a detergent. They are reported
to clean better with less volume of water used.
002
-------
DRAFT
3. • That portion of very dilute wastcualer (such as defrost
. water) which is not reused or recircu'ated, should
be discharged separately from the process wastewater.
4. Good housekeeping Is an Important factor 1n normal
pollution control. Spills, spoilage, trash, etc.
resulting from sloppy operation may be heavy con-
tributors to liquid waste loads. Improvements will
result from educating operating personnel in proper
attitudes tov/ard pollution control and providing
strategically located waste containers, the basic aim
being to avoid loss of product and normal solid waste
Into the liquid waste stream.
5. The processor should look at his handling of solid
waste. A well-operated plant will, insofar as pos-
sible, avoid solid waste contact with the liquid
waste stream. Where this is not feasible, the
solid waste is removed prior tc reaching the waste
treatment system. Screens of 20 mesh or smaller are
usually adequate to remove a large portion of
settleable solids. Continuous removal of the screenings
1s desirable to avoid excessive leaching of solubles
• by the liquid waste stream from separated solids.
End-of-Line Technology
This subcategory is characterized . strong wastes in terms of BOD,
SS, and 0 4 G. Nevertheless an existing secondary tre?tment plant
(38*50) is achieving excellent pollutant removals with activated
sludge treatment preceded by a series of primary treatment and
biological treatment units. Table 152 provides data pertinent to
desing of Individual treatment units. An analysis of dally reported
treatment performance during the months of October and November, 1974,
for plant 38*50 shows the effluent quality characteristics shown
below. The company reports these results are typical of plant per-
formance since 1972.
BOD, average 9 mg/1, range 1-27 mg/1
SS, average 37 mg/1, range 4-137 mg/1
O&G, average ICnig/l, range l-30my/l
pH, 7 to 8
Ninety-nine percent plus removals are reflected by the above
results based upon average influent characteristics of BOD -
3,500 mg/1, OSG - 3,000 iiig/1, and SS - 4.SOO mg/1. Th«se results
were confirmed by sampling.
This plant was expanded over a ten year period beginning 1n 1962,
and treatment unir.s were add"d as effluent discharge requirements
003
-------
TADLE 152
TREATMENT UNIT CHAIN AND MAJOR DESIGN
FACTOKS FOR EXISTING TREATMENT PLANT
TREATING WASTEWATER FROM FROZEN PREPARED DINNERS
AND OTHER SPECIALTY FOODS
No. Treatment unit
1 Sweco vibrating screens (2),
20 mesh, 48 inch.
Gravity sedimentation
tanks (2), 10 ft x 125 ft
x 10 ft deep, 187,000 gal
capacity total.
Dissolved air flotation
tanks {2} 200 sq ft surface
area each.
Anaerobic lagoons (3), in
series, 1.93 I1G capacity
each with 100 percunt
recirculation from final
lagoon to first lagoon.
Roughing filters (2),
first, filter is 5,500 cu ft
of plastic media, second
filter is 11,000 cu yd
of rock media.
Activated sludge aeration
tanks (4) rectangular with
mechanical surface aera-
tors, 141,000 gal capacity
each.
Final claritiers (2), first
clarifier has 962 oq ft
surface are.), second Clari-
fier lias 1,590 sq ft
surface area.
Significant design
factors
300 gpm rated capacity,
remove approximately
1,000 Ibs/day of
screenings.
•
200 gpc3/sq ft overflow
rate and 9 hr detention
at design flow of
0.5 mgd.
1,250 gpd/sq ft over-
flow.
11 day retrtntion at
design flow. Thick
scum nat on lagoons
surface aids odor
prevention.
Hydraulic loading is
30 gpd/cu ft per day,
BOD loading is approx-
imately 0.36 Ib BOD/cu
ft per day.
27 hour retention tine,
DOD loading is approxi-
mately 50 Ib BOD/1,000
cu ft, 100 percent
sludge rc> circulation
capacity.
500 gpd/sq ft overflow
rate at design flow vf.
0.5 mgd.
804
-------
TABLE 152_ (Continued)
Significant design
bio. Treatment unit factors
8 Chlorine contact tank. 30 minute detention at
design flow.
9 Sludge handling - Primary sludge and waste activated
sludge is centrifuged, thickened and disposed to
landfill. Grease skimmings are recovered and approxi-
mately 4,500 Ibs/day are sold.
SOS
-------
DRAFT
grew more stringent. An engineer designing a new plant would not
design the new plant in exactly the same manner. Nevertheless,
much can .be learned from the long term effectiveness of the des-
cribed treatment plant when it is necessary to treet very strong
wastes and produce effluents of extraordinary quality, as 1s the
case here. The key to the success of the treatment system des-
cribed appears to be to remove SS and O&G, and the combination
of biological secondary treatment units 1n series, i.e., anaerobic
lagoon roughing filter, and activated sludge. Each treatment
unit acts to remove a percentage of the wastewater pollutants
and prepare the wi.st« properly for the following treatment unit.
Table 153 presents reported pollutant removal efficiencies through
each successive treatment unit described previously>in Table 151.
The performance of the gravity clarlfler and air flotatinr primary
treatment units should be noted. Ths relatively low percent removals
through the anaerobic lagoons is deceptive according to the plant
op"-ating staff who report that the anaerobic lagoon biological
activity converts the dissolved organic pollutants into forms more
. readily treated by the subsequent aerobic biological processes. In
addition, the anaerobic lagoons act as a flow equalization and
buffering unit for the succeeding treatment processes. Company
personnel report that prior to construction of the anaerobic
lagoons, performance of the trickling filters and activated sludge
units was less efficient and more erratic.
Selection of Control and Treatment Technology
A model plart for Subcategory B 1 was developed 1n Section V. The
raw wastewater characteristics were as follows:
Flow (0.3 MGD)
BOD 2000 mg/1
55 1500 mg/1
O&G 2000 mg/1
N 45 mg/1 (deficient)
P 21 mg/1 (sufficient)
The following treatment alternatives have been selected for this
tubcategory:
Alternative<_B 1-1 - This alternative assumes no additional treatment.
Alternative B 1-11 - This al'or-vHve provides flow equal izatlon,
d issol ved air flotation, an-i vacuum filtration of sludge. The
expected ODD removal benefit is 60 percent.
AItcrna MVP. P 1 - III - This alt^r^ntive provides the addition of
compTete mix activated sludge with two aeration basins and sludge
thickening to Alteinative 01-11. The expected BOO removal
benefit Is 96 percent.
806
-------
UMCT
TAbLf. 153
REPORTLO PD1FOKMANCE FOK TREATMENT
TI; DLSCJUCKD in TAJJLE
Percent reduction*
BOD Gf.O Cf,
39 79 73
15 14 16
6
Treatment unit
Gravity sedimentation
Air flotation
Anaerobic lagoon
Trickling filter
Activated sludge
Totals
4
15
99
99
7
(3)
99
'Typical screened raw waste characteristics
are: BOD - 3,500 ing/1, 0:.G - 3,000 ing/1,
and SS - 4,500 nn/1.
807
-------
DRAFT
Alternative C 1-IV - This alternative adds dual media filtration
to Alternative U l-III. The expected BOD removal benefit is 98
percent.
A summary of the pollutant removals expected is presented in
Table 154. A schematic diagram of Alternatives B .1-1 through
B 1-IV is presented in Figure 257.
SUBCATEGORY B 2 - BREADED AND BATTERED FROZEN PRODUCTS
In-Plant Tech' \cgy
The existing and potential in-plant technology for Subcategory B 2
is the same as for Subcategory B 1.
End-of-Line Technology
This Subcategory is characterized by strong wastes in terms of BOD and "
SS per unit of production as tabulated in Section V of this document.
Design of theoretical treatment chains is difficult in this sub-
category because of extremely wide fluctuations in the flow
volume generated per unit of production. All plants identified
which manufacture breaded and battered frozen products discharge
into municipal systems. No secondary treatment or exemplary pre-
treatment facilities were found to exist in this subcfctegory.
Characteristics of the waste are amenable to secondary treatment and
technology transfer of activated sludge is appropriated and well-founded.
Selection of Control and Treatment Alternatives
In Section V, a model plant was developed for breaded and battered
frozen products. The plant has a flow of 190 cu m/day (0.05 MGD).
The wastewater characteristics are as follows:
BOD 4,000
SS 4,000
O&G 400
N & P (sufficient)
pH 6 to 9
The following treatment alternatives have been selected 'or this subcate^or;-:
Alternative B 2-1 - No additional treatment.
Alternative B 2-II - This alternative consists of flow equalization, dissolved
air flotation, and vacuum sludge filtration. The expected BOD reduction
benefit is 60 percent.
Alternative B 2-111 - This alternative consists of the addition of
activated sludge to Alternative 3 2-11. Additional vacuum filtration
808
-------
o
10
TABLE 154
SUWARf Of TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY Bl
FROZEN PREPARED DINNERS
Unit Influent
Cumulative
Alt.
Bl-I
B1-II
Bl-III
Bl-IV
F1n.
Effl.
Treatment
unit
None
Flow Equal.
DIs. Air Plot.
Act. Sludge
Filtration
Characteristics, mg/1
BOD TSS O&G
2,000
2,000
2,000
800
60
40
1,500
1,500
1,500
300
90
23
2,000
2,000
2,000
400
120
60
percent removal
BOD TSS 01
0
0
60
96
98
98
0
0
80
94
98
98
0
0
80
94
97
97
-------
DRAFT
RAM WASTEWATER
FLOW =
BOD = 2000 MG/L
SS - JSOO MG/L
D t & - 2000 MC-/L
(0.3 MOD)
PUMPING
STATION
FLOW EQUALIZATION
TRUCK
HHULING
—L
SLUDGE
THICKENER
*
VACUUM
FILTER
DISSOLVED AIR
FLOTATION
ACTIVATED SLUDGE
DUAL MEDIA
FILTRATION
DISCHARGE
ALTERNATIVE El-I I
BOD = 800 MG/L
SS » 800 MG/L
O t G = 400 MG/L
DISCHARGE
ALTERNATIVE Bl-III
BOD * BO MG/L
SS • 90 MG/L
0 C G « 120
DISCHARGE
ALTERNATIVE Bl-iv
BCD « 40 MG/L
SS = 23 MG/L
0 t G = 60 MG/L
FIGURE
CONTROL AND TREATMENT ALTERNATIVES
Bl-I THROUGH Bl-lV
810
-------
' DRAFT
capacity is required for thickened waste activated sludge. The aeration
basin required 19 kw (25 hp) aeration. The expected BOD reduction
benefit is"96 percent.
Alternative B 2-IV - This alternative provides the addition of dual media
filtration to Alternative B 2-III. The expected BOD reduction benefit is
98 percent.
A summary of the pollutant removals expected is presented in Table 155. A
schematic diagram of Alternatives 8 2-1 through B 2-1V is shown in Figure 258.
SUBCATEGORY B 3 - FROZEN BAKERY DESSERTS
In-Plant Technology
The existing and potential inplant technology for Subcategory B 3 is
the same as for Subcategory B 1.
End-of-Line Technology
This Subcategory is characterized by strong wastes in terms of BOD,
SS, and 0&G as described in Section V of this document. The rich ingredients
(butter, sugar, cream fillings, etc.) are washed from processing equipment
and dissolved in the wastewater. No plant was identified which manufactures
exclusively frozen bakery desserts and provides secondary treatment
prior to direct discharge. However, plant 38*bO, described under the prepared
dinners subsection of this Section VII, provides excellent "technology
transfer" data for this Subcategory for two reasons: First, the previously
described treatment plant under Prepared Dinners also treats wastewater
from preparation of frozen pies; and second, the reported characteristics
of the wastes from preparation of frozen bakery desserts are very similar
to the characteristics of wastes reported from preparation of prepared
dinners.
An extensive pretreatment plant was Installed at one of the nations
largest manufacturers of frozen bakery desserts, and provides activated
sludge treatment prior to discharge into the municipal system of a
small community. This pretreatment plant usually achieves better than
90 percent removal of COD, SS md OSG. Table 156 provides data pertinent
to design of individual treat! it units. An analysis of monthly reported
treatment perfor-ance from May, 1973 through September, 1974 shows the ef-
fluent quality characteristics shown below.
COD, average 63? mg/1, range 325-1, ?50 mg/1
SS, average 132 mg/1, range S5-227 mg/1
O&G, average 57 mg/1, range 10-106 mg/1
Average raw waste characteristics through the same period are as follows:
Flow, average 0.125 mgd, range .09-0.18 mgd
COD, average 5,700 mg/1, range 4,500-7,700 mg/1
SS, average 1,550 mg/1, range 800-2,500 mg/1
O&G, average 650 mg/1, range 250-950 mg/1
-------
TABLE 155
SUfWARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY B2
BREADED AND BATTERED FROZEN PRODUCTS
Unit Influent
Cumulative
Alt.
B2-1
B2-II
2 B2-III
IM
B2-IV
Fin.
Effl.
Treatment
unit
None
Flow Equal.
Dis. Air Plot.
Act. Sludge
Filtration
Characteristics, mg/1
BOD TSS O&G
4,000
4,000
4,000
1.600
160
80
4.000
4,000
4,000
COO
160
80
400
400
400
80
30
15
percent removal
BOD TSS 01
0
0
60
96
98
98
0
0
80
96
98
98
0
0
80
92
96
96
-------
DRAFT
RAW WASTEWATER
FLOW = 190 CU H/DAY (O.C5 MGO)
BOO = &000 MG/L
SS * *000 MG/L
0 (, G = *00 MO/L
PUMPINti
STATION
FLOW EQUALIZATION
. i
SLUDGE
"VACUUM
FTLTFP
DISSOLVED AIR
FLOTATION
ACTIVATED SLUDGE
DISCHARGE
ALTERNATIVE 63-11
bOO - UOO MG.L
SS = 800 MG/L
0 C 0 » 80 MG/L
DUAL MEDIA
FILTRATION
DISCHARGE
'» ALTERNATIVE 82-III
BOP = 160 MG/L
SS e 160 MG/L
0 I G - 33 MG/L
TRUCK
HAULiNG
DISCHARGE
ALTERNATIVE B2-1V
BOD = 80 MG/L
SS = 60 MG/L
C. t G * IS MG/L
FICUCF. 2!ii:
CONTRC3L A^€l TPcATMENT ALTERNATIVES
82-I THROUGH 82-IV
313
-------
DRAFT
TADLE 156
TREATfCNT U11IT CHAIN AJJD MAJOR
DESIGN FACTORS FOR EXISTING PRE-TREATMTNT
PLANT TREATING WASTEWATER FROM
FROZEN DAKERY PRODUCTS
No. Treatment unit
i Comminuter
2 Chemical flocculaticn tank(l)
with 4,300 gal capacity.
Have capability tea add lime,
ferric chloride, and
nutrients.
3 Dissolved air flotation
tank(l) with 16 ft diameter
and 12 ft depth. The air
requirement, is 2-3 cfm @
50 pci. Water is pumped
from top portion of tank,
mixed with air from com-
pressor, and fed to
pressurized tank for injec-
tion to bottom of flotation
unit.
4 Aeration tankj(2), each
with 213,000 gal capacity.
Three 60 HP blowers can
supply a maximum of 6,000
cfm. Normal air require-
ment is 4,000 cfm. One
20 HP mechanical aerator
aids the process.
5 Aerated storage tanks (2)
of 183,000 gal capacity
each, to be used for
storage of surge loads or
execs, aeration capacity
for the activated sludge
process. After storage,
water can be returned to
the flotation or acti-
vated sludge units.
Significant design
factors
48 min retention at
average flow of 130,000
gpd.
3.8 hr retention at
average flow. 650
gpd/ft2 overflow rate.
3.3 day retention at
average flow. MLVSS
concentration ranges
from 3,000-6,000 mg/1,
3 day total retention
time at average flow.
814
-------
DRAFT
TABLE 156 (Continued)
" Significant design
No. Treatment unit factors
6 Final clarification tanks(2), 27 hrs total retention
each 14' x 50* x 14 deep. with a 93 gpd/ft2 over-
A high percentage of the flow rate.
solids arc returned to the
activated sludge process.
7 Sludge storage pit that
accepts waste activated
sludge and the solids from
the air flotation unit.
815
-------
. DRAFT
Average percentage reductions therefore are: COD-89 percent,
SS-91 percent, ond 0&G-91 percent. These are excellent removals
for a pre-treatment facility.
Performance of the air flotation unit notes particular attention.
The company takes separate samples of the air flotation unit effluent
(See Table 156 for description of design characteri'stics). Average air
flotation unit effluent characteristics are as follows:
COD, average 3,500 mg/1, range 1,700-5,000 rrri/1
SS, average 600 mg/1, range 400-1,000 mg/1
O&G, average 230 mg/1, range 70-600 mg/1
Referring to the noted raw waste characteristics, it can be seen
that the air flotation units achieve the following average percentage
reductions cf this waste: COD-18 percent, SS-6'1 percent, and 0&G-64
percent.
Selection of Control and Treatment Technology
A model plant for frozen bakery desserts was developed in Section V.
The raw wastewater characteristics were as follows:
Flow 114 cu m/day (0.3 MGD)
BOD 4000 mg/1
SS 3000 mg/1
O&G 1COO mg/1
N 40 mg/1 (deficient)
P 7 mg/i (deficient)
pH 6 to 9
The following treatment alternatives have been selected for this
subcategory:
Alternative B 3-1 - This alternative assumes no additional treatment.
Alternative B _3^Ij_ - This alternative provides flow equalization, dissolve^
air flotation, and vacuum filtration of s)udge. The expected BOO removal
benefit is 70 percent.
Alternative B 3-111 - This alternative provides complete mix activated
sludge with two aeration basins and si urine thickening addition to
Alternative B 3-11. Nutrient addition in the amounts of 220 kg/day
(490 Ib/day) UH3 and 120 kg/day (260 Ib/dayjHjPOfl 1s necessary. The
expected BOD removal benefit is 97 percent.
Alternative B 3-TV - This alternative adds dual media filtration to
AlTernative ti fTi'l. Tho expected BOD removal benefit 1s 98 percent.
A Stimmary of the pollutant removals expected is presented In Table 157.
A schematic diagram of Alternatives B 3-1 through B 3-IV is presented
1n Figure 259.
816
-------
TABLE 157
SUWARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY B3
FROZEN BAKERY PRODUCTS
Unit Influent
Cumulative
Alt.
83- 1
B3-II
B3-III
83- IV
Fin.
Effl.
Treatment
unit
Kone
Flow Equal.
Dis. Air Flot.
Act. Sludge
Filtration
Characteristics, mg/1
BOO TSS O&G
4.000
4,000
4,000
1,600
160
80
3,000
3,000
3,000
600
180
45
1.000
1,000
1,000
200
60
30
percent removal
BOD TSS 01
0
0
60
96
98
98
0
0
80
94
98
98
0
0
80
94
97
97
-------
DRAFT
RAM WASTEWATER
FLOW = 114 CU M/DAY (-0.3 MGD)
BOD a 4000 MG/L
SS * 3000 MG/L
O 6 G = JOOO MG/L
SLUDGE
THICKENER
PUMPING
STATION
FLOW EQUALIZATION
FILTER
DISSOLVED AIR
FLOTATION
ACT.WATED SLUDGE
DUAL MEDIA
FILTRATION
DISCHARGE
ALTERNATIVE E3-II
" EOD » 1600 MG/L
ss s 600 MG/L
0 I G = 200 MG/L
—- DISCHARGE
ALTERNATIVE B3-)v
BOD » 80 MG/L
SS = 45 MG/L
C t G » 30
TRUCK
HAULING
DISCHARGE
ALTERNATIVE 33-1li
eco = 160 MG/L
SS - 180 MG/L
0 £ G = CO MG/L
P1GURE 25
AfO TȣA7VEf^ ALTERf'-'ATIVES
B3-I THOUGH B3-IV
818
-------
DRAFT
SUDCATEGQKY D 4 - TOMATO-CUE SE-STARCH COi'.PI HAT IONS
In-Plant Technology
The existing and potential in-plant technology for Subcategory B 4
1s the same as for Subcategory B 1.
End-of-Llne Technology
This Subcategory 1s characterized by weak wastes in terms of BOD,
SS, and O&G. The principal product is frozen pizza and the manu-
fc. Curing facilities are careful to waste as little of their
expensive ingredients as possible. In addition, the process waste
stream is normally substantially diluted by the cooler (freezer)
wa'-.er from the freezing process. No plant was identified which
m?.iufactures exclusively frozen tomeco-starch-cheese specialties
and provides secondary treatment prior to direct discharge or
discharge to a municipal sev;age syste. Characteristics of the
waste in terms of BOD and SS are similar to typical municipal waste
(see Section V of this document). Examination of the characteristics
of this waste indicate an expected high degree of pollutant removal
through conventional biological treatment methods.
Selection of Control and Treatment Technology
A model plant for tcmato-starch-cheese products was developed in
Section V. T.he raw wastewater characteristics were as follows:
Flow 378 cu m/day (0.1 MGD)
BOD 700 mg/1
SS 400 mg/1
O&G 200 mg/1
N & P (sufficient for biological treatment)
The following treatment alternatives have been selected for this
Subcategory:
Alternative 6 4-1 - This alternative assumes no additional treatment.
Alternative B 4-11!- This alternative provides f'ow equalization,
dissolved air flotation, and vacuum filtration of sludge. The
expected BOD removal benefit is 40 percent.
AVternatiye B 4-1*I - This alternative provides two complete mix
activated" sludge" s>otems in parallel and sludge thickening addition
to Alternative P 4 II. The expected BOD removal benefit 1s 90
percent.
A summary of the pollutant removals expected is presented 1n Table
158. A schematic diagram of Alternatives 0 4-1 through B 4-III is
presented in Figure ?60.
819
-------
1
INJ
TABLE 158
SUWARY OF TREATMENT TRAIN ALTERNATIVES FOR SUBCATEGORY B4
TOMATO-STARCH-CHEESE COMBINATIONS
I
I M"'
Hi - ..
I
Hn
• DM I»T
Treatment
unit
Unr»0
rWJi.tr
Flow equal.
Dis. Air Flot.
urn i innuent
Characteristics, mg/1
BOO TSS O&G
700
700
700
400
400
400
200
200
200
Cumulative
percent removal
BOO TSS 0
0
0
40
o
V
0
70
0
70
Act. Sludge
Fin.
Effl.
420
40
120
40
60
20
94
94
90
90
90
90
-------
DRAFT
SLUDGE
THICKENER
TRUCK
HAULING
FILTER
RAW WASTEWATER
FLOW a 378 CU M/DAY (0.1 MGO)
800 * 700 MG/L
SS - 400 MG/L
0 t G * 200 MG/L
PIPING
STATION
FLOW EQUALIZATION
DISSOLVED AIR
FLOTATION
ACTIVATED SLUDGE
DISCHARGE
ALTERNATIVE B*-III
BCD • *o MG/L
ss • to MG/L
0 C G * 20 MG/L
DISCHARGE
ALTERNATIVE 04-JI
BOD = 420 MG/L
SS = 120 MG/L
0 t G = 60 MG/L
FIGURE "£,(3
co^^rRDL AND TKEAiwrT ALTERNATIVES
B*-I THROUGH B<,-III
821
-------
DRAFT
SUDCATCGORY B 9 PAPRIKA AND CHILI PEPPEP.
In-Ptant Technology
Various on-going studies are being done in an effort to Increase crop
yields, facilitate in-plant processing and maintain existing high quality
standards. At tne same time, the individual processors are conducting
these studies with the intention of minimizing their effluent wasteloads.
These efforts encompass field research as well as in-plant controls.
Efforts have been directed towards mechanical harvesting in an' effort.
to reduce field costs. Mechanical harvesting, however, causes more pod
splitting, bruising, and breaking, and in some cases is responsible
for increased dirt and debris loadings. The various field work being
done is being directed toward the el inrinat-ion of excess dirt and
debris and is at the same time achieving a reduction in field damage.
These efforts should reduce the organic loads *::?*rienc3d within the
processing plants.
The predominant flow volume and waste loads are generated in the
washing stages. Dry reels, however, were observed in most installations
to reduce the dirt, debris, and "bits" from the field prior to the
soak tanks. In most cases, consideraole amounts of organics were kept
from the waste stream; the debris from the dry reels was collected and
removed as dry waste.
The other main source of wastewater originates from normal end-of-ohift
cleanup, at which time all tanks, conveyors, dicers, etc. are emptied,
opened, and thoroughly washed and sanitized. Here again, employee
training and good management are of great importance to reduce
pollutant generation.
Substantial reduction in both processing raw waste load (flow and
pollutant content) and wastewater treatment cost can be realized
by careful in-plant water management and reuse.
1. Installation of automatic shut-off valves on water
hoses may save up to 60 gallons per minute per hose.
Without automatic shut-off valves, employees do not
turn off hoses. Cost for a long life valve is
approximately $40.
2. Installation of central clean up systems (valved or
triggered hoses). These commercial systems generate
a controlled high pressure supply of hot or warm
water containing a detergent. They are reported to
clean better with less volume of water used.
3. Installation of low-volume, high-pressure systems on all
water sprays which cannot be eliminated.
822
-------
DRAFT
4. -Elimination of all unnecessary water overflows.
Many plants operate water valves wide open regardless of
actual need. Examples are make-up water supplies to
spray lines and washers. One way to help solve this
problem 1s Installation cf quick opening ball valves
In water lines after globe valves. The globe valve
Is used by the operator for on-off operation.
5. Maximization of in-plant water recirculation by multiple
use of water in the same unit process or reuse in other
unit processes.
6. Good housekeeping is an important factor in normal pol-
lution control. Spills, spoilage, trash, etc. resulting
from sloppy operation may be a heavy contribution of liquid
waste loads. Improvements will result from educating
operating personnel in proper attitudes toward pollution
control and providing strategically located waste containers,
the basic aim being to avoid loss of product and normal
solid waste into the liquid waste stream.
7. In addition to implementation of water conservation and
reuse, the processor should look at his handling of solid
waste. A well-operated plant will insofar as possible avoid
solid waste contact with the liquid waste stream. Where this
1s not feasible, the solid waste is removed prior to reaching
the waste treatment system. Screens of 20 mesh or
smaller are usually adequate to remove a large por-
tion of settleable solids. Continuous removal of
the screenings is desirable to avoid excessive
leaching of solubles by the liquid waste stream from
separate solids.
8. It 1s, of course, impossible to predict with exactness
.the effect of in-plant pollution control such as
water use reduction and water reuse.
End-of-L1ne Technology
As described 1n Section V of this document this subcategory is
characterized by moderately weak wastes slightly stronger than the average
domestic municipal waste. All plants identified in this subcategory
discharge to municipal systems. No secondary treatment or pre-
treatment other than screening was identified. To formulate
effluent guidelines for the subcategory activated sludge technology
transfer must be appropriately adopted. Removal efficiencies
compatible with a well operated municipal secondary sewage treatment
plant are to be expected.
823
-------
DRAFT
Selection of Control and Treatment Technology
A model plant for Subcategory B 9 was presented in Section V. It
had a flow of 1900 cu m/day (0.5 MGD) with the following characteristics:
BOD 400 mg/1
SS 250 mg/1
pH 6 to 9
N & P Sufficient
Table 159 lists the treatment alternatives and their expected efficiencies,
Alternative B 9-1 - This alternative assumes no control and treat-
ment of the present waste load contribution.
Alternative B 9-11 - This alternative includes a pumping station,
fTow equalization, complete mix activated sludge (two basins and
two clarifiers) with a detention time of 17 hr and aeration of
(60 hp), sludge thickening, and vacuum filtration. The dewatered
sludge is truck hauled to land fill or suitable land disposal site.
Alternative B 9-111 - This alternative assumes the addition of
dual meaia filtration to Alternative B 9-11.
SUDCATCGORY C4 - EGG PROCESSING
In-Plant Technology
In-plant procedures designed to reduce the waste load from egg pro-
cessing plants center on proper training of the employees and efficient
management. The principle methods for reducing the waste load, as
described by Siderwicz (88), are the following:
1. The condition of the incoming eggs should be checked and poor
handling practices reported to the shell egg distributor.
2, . Personnel who lead eggs into the washer, candle the eggs,
and operate the breaking machines must be provided with an
easy and efficient method for removing and discarding
Inedible eggs.
3. Egg washer brushes should be properly adjusted so as to effect
good cleaning and eliminate excessive breakage during washing.
4. Breaking machines should be periodically inspected to insure
that trays are aligned correctly to oitch eggs released from
the breaker cups and that water consumption per breaking
machine is not in excess of 4 to 6 1pm (1-1.5 gpm).
5. Inclined augers should be used to transfer the egg shells to
the hauling vehicle in order to aid in the recovery of adhering
egg solids from the broken shells.
824
-------
TABLE 159
o
53
MODEL TREATMENT MODULE CHAIN AND ESTIMATED POLLUTANT REMOVALS
SUBCATEGORY B 9
Unit Influent
O>
ro
u-i
Cumulative
Alt.
B 9-1*
B 9-II
B 9-III
B 9-IV
Fin. Effl.
Treatment
Unit
None
Flow Equal.
Act. Sludge
Filtration
Characteristics,
BOD TSS
400
420
400
30
15
250
250
250
30
15
mg/1
04G
0
0
0
0
0
Percent Removal
BOO TSS OSG
0
0
93
96
96
0
0
-
94
94
0
0
100
100
100
-------
DRAFT
6. Soilage of product frorr vats should be el iminntcd through
careful monitoring during filling, preferably with the use of
electronic probes.
7. Piping should be kept to a minimum and should be sloped to
allow the product to drain by gravity after the pumps are
turned off.
8. Equipment should be "chased" with water before cleaning to
recover as much product as possible, especially if the product
is to be dehydrated.
9. Land disposal of eqg \asher wastewater should br considered
as a method of reducing the plants waste loao which must be
treated.
Many of these proce'Juros have had wide acceptance in the eyg processing
industry. Siderwicz (S3 } has reported a 40 percent reduction in BOD
loading, after implementation of the in-plant technology discussed
above, document the effectiveness of these types of procedures.
End-of-Line 1 PO lino logy
Hee, at. al.. (l4v> have considered the waste treatment alternatives
for egg procesing plants and concluded that aerobic ponds and aerated
lagoons are the most acceptable treatment alternatives. Moats and Harris
(148) reported a laboratory scale approach which yielded an 80 to 90
percent removal of BOO fret! egg wastes, initially ranging from 1000 to
2200 mg/1. The method used was acidification to pH 4.7 and heating to 75°C
(170 F). However, due to the high energy requirements, this method
of treatment has not been ^stalled at any plants. Bui ley, et^. aj_. (lag)
have reported 90 to 95 percent removal of 800 in a laboratory study of
a continuous treatment model for egg wastes ranging in concentration
from 2780 to 03C ng/l. The treatment model utilized in this study
was a two-stage a' -ned lagoon. Bailey (150) performed pilot plant to:.:?.
of trickling filter treattient of egg processing wastes. Up to 60 percsn:
BOD removal was reported for wastes ranging in concentration from 1600
to 6000 mg/1.
Cornell University (151) has conducted laboratory studies on several
methods of treating egg processing wastewater. The most efficient
method of treatment was an anaerobic lagoon followed by an aerated la
-------
DRAFT
At the prwent time, virtually all egg processing plants discharge row
effluent to municipal systems, navigable waters or land application.
One plant included in this study has a 0.5 ha (1.2 acre) four-cell
diffused aeration lagoon. However, flow from tho plant Is about 6,000
mid (1,500 gp-J), and the lagoon system is providing total retention of
the plants wastes. The wastewater from this plant has a DOD concentra-
tion of 2100 mg/1 and a suspended solids concentration of 750 mg/1.
Samples taken during the summer of 1974 (152) from the fourth cell of
the lagoon had BOD concentrations averaging 9 mg/1 and suspended solids
of 7 mg/1.
Anotiier plant included in this study has screening, a settling basin, a
holding lagoon aid spray irrigation facilities, for disposal of their
wastes. Two other processing plants have treatment facilities; however
neither is being operated currently due to the inability to obtain
significant waste reductions. One treatment plant incorporates a
trickling filter followed by an activated sludge system. The other
employes an aeration tank.
Selection of Control and Treatment Technology
In section V of this document a model plant was developed for the egg
processing industry. The raw waste characteristics were assumed to be
as follows:
BOD 3700 mg/1 or 2'J kg/kkg
SS 8SO mg/1 or 5.4 kg/kkg
N 300 mg/1
P 40 ng/1
pH 6.7 -9.0
Flow 0.2 mid (0.05 mgd)
Table 160 lists the pollutant effluent loadino and the estimated oocratinn
efficiency of each of the five treatment trailr selected for this suu-
category.
Since" most egg processing plants are located in rural areas, treatment
modules were not delected to minimize land requirements. In addition.
Cornell University (151) and one of the plants contacted indicated orcbl-.-;
in applying activated sludge treatment to egg processing wastes becau^f.1
of fxressive foaming of the wastewatcr during tre-V.iient.
AUeiviaMve C 4 - I - This alternative provides no treatment except
a catch basin to collect the shells from the waste stream.
Alternative C 4 - II - This alternative consists of a two-cell aerated
Iflgoon and associated settling ponds. The ?5 percent removal indicated
1n Table 160 is based on the study by Culley, ej^. aj_., (149) and the
45 day detention time of this treatment train.
827
-------
TA3LC 160
Treatment Train
Alternative
C 4
C 4
I 4
C 4
p C 4
C3
- I
- 11
- Ill
- IV
- V
A
L
Lfl
ML
WLM
••T^MBKW 1 J W 1 • I *_U *•*«•'
Effluent
BOO
kg/fcfcg
?3
1.2
0.69
0.45
0.30
iv 1 i \. it u » n rii t ^- i iitl^ll
Effluent
SS
5.4
1.1
0.33
0.54
0.16
' t j
Percent
BOO
Reduction
0
95
97
93
99
2
5
— i
— 4
Percent
SS
Reduction
1
0
80
94
90
97
-------
DRAFT
Alternative C 4 - III - This alternative consists of the treatment
module oT/ftlter native" C 4 - II with the addition of a dual media filter
and associated pumping station. The schematic diagram of Alternative
C 4 - III is shown in Figure 261.
Alternative C 4 - IV - This treatment alternative consists of an anaerohic
lagoon, a aerated lagoon and associated settling ponds. The laboratory
studies (151) of this treatment method indicated anaerobic and aerobic
detention times of 10 and 5 days, respectively.
Alternative C 4 - V - This alternative consists of Alternative C 4 - IV
with the addition of a dual medic filter and associated pumpinn station.
A schematic diagram of Altei native C 4 - V is shown in Figure 262.
SUBCATF.GORY C S - SHELL EGGS
In-Plant Technology
In-plant procedures designed to reduce the wasteload from egg processing
plants center on employee training and rr.anaoement. The principal factors
which can contribute to reducing the wasteload are described by Siderwicz
f!53 for egg processing. The factors which are applicable to shell
egg handling plants are as follows:
1. The condition of incoming eggs should be checked and poor
hand-ling practices reported to tr>e supplier of the eggs;
e.g., the farmer or trucker.
2. Personnel who load eogs onto the washer, candle the eggs,
and operate the grading machines must be provided with'an
easy and efficient method of removing and discarding
Inedible eggs. Most shell egg plants currently use buckets
on the floor to collect inedible eggs. A more efficient method
with less chance of spillage should be used.
3, Egg washer brushes should be properly adjusted so as to effect
good cleaning and eliminate excessive breaking during washing.
4. Land disposal (burial) of egg washer wastewater should be
considered as a method of reducing the plarts wasteload v/hich
must be treated or discharged to a municipal sewer.
End-of-Line Technology
At the present time most shell egg plants discharge unscreened wast*-
water to municipal svit^ms or navigable waters. Some plants utilize
evaporation/percolation retention ponds. Spray irrigation has been
utilized by some plants, but it (;s< been found unacceptable as a result
of associated odor problems.
829
-------
DRAFT
INFLUENT
BOD = 3700 MG/L
S3 = 850 MG/L
FLOW * 0.2 MLC (0.05 MGP)
SETTLING
j POND
AERATED
LAGOON
AERATED
I.AGCON
PUMPING
i ATION
DUAL MEDIA
FILTER
EFFLUENT
BOO = 100 MG/L
55 = 60 MG/L
FLOW = 0.2 MLP CO.05 MGD)
FIGURE 251
CONTROL AND TREATMENT ALTERNATIVE C4 - III
330
-------
DRAFT _
INFLUENT
BOD = 3700 VG/L
SS = 850 «G/L.
PLOW = 0.2 MUD
-------
DRAFT
The chemical composition of wastewater from shell egg handling plants
is very similar to eqq processing wostewater, except that the con-
centration of pollutants in the egg processing wastewater is higher.
A few egg processing plants have treatment facilities, and several
studies have been conducted on egg processing wastewater. The
information available on egg processinq wastewater treatment is
discussed in detail in Section V of this document under Subcategory
C 4, Egg Processing.
Selection of Control and Treatment Technology
In Section V of this document a model plant was developed for the shell
egg industry. The unscreened raw waste characteristics were assumed
as follows:
1. Flow - 0.013 mid (3500 gpd)
2. pH - 6.7 to 9.0
3. BOD - 1500 mg/1
4. SS - 500 rmj/1
5. Ratio - kg BOD to kkg of product - 1.56
6. Ratio - kg SS to kkq of product - 0.52
The treatment modules in the treatment trains described below were
selected on the basis of the 1iterature and treatment plants for
Subcategory C 4, Egg Processing.
Tablel61 lists the pollutant e'fluent loading and the estinated oceratinc;
efficiency of each of tne six treatment trains selected for this sub-
category.
Alternative C 5 - I - This alternative provides no treatment except
a eaten DdSui fj collect the shells fr;in the wacte :,'..rean.
Alternative C 5 - II - This alternative consists of a two-cell aeratr'i
Tagcon and associated settling jor»ti;.. The 95 oercent removal indicate-;
in Table 161 is b.ised on the laboratory and full scale studies by Bui'.'-/
et. al., (u - HI 15 shown in Figure 263.
832
-------
TABLE 161
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
Treat-rent Train
Alternative
C 5 - I
C 5 - II
C 5 - III
C 5 - IV
C 5 - V
A
L
IN
ML
MLN
Eff'ijent
BOD
kg/Uq
1.56
0.073
0.047
o.o;i
0.315
Effluent
SS
kq/kkq
0.52
0.075
0.021
O.OJ1
0.010
Percent
BOD
Reduction
0
9i:
97
98
90
Percent
55
Reduction
0
85
95
90
98
-------
r
Fir T i'L I f'C
POND
L
I NTLUC MI
000
SS
FLC •/
= ll>00 MG/L
= 500 MG/L
= 0.0)3 MLO (0.0035 MGD )
LAGGUM
I
PUMP I NO
•JiT AT ; ON
DUAL MFD J A
r I L "! L '/
iri_.
litTTI. IMC- 1
ZT'
--•ALTERNATIVt
C 5-11
EFFLUENT
BCO = 75 MG
n.ow - o.sj.:? MI.
r t r:. '.•(. • 11
HDD • '••:• '••.-,/l..
f !. OW i . •'; ; J ML O ( O . I'O '. :• Mi'.,D '
I i.-i::-' T03
\NP Ti~r-v, ••'! ••" M.Ti f;ry\T.'VE5 C 5 - II AND III
rr.-i
-------
DRAFT
Alternotive C 5 - JV - This treatment alternative consists of an
anaerobic "*agoon, a aerated loooon and associated settling ponds.
The laboratory studies (ly.) of this treatment method indicated
anaerobic and aerobic detention times of 10 and 6 days, (\>spectively.
Alternative C 5 - V - This alternative consists of Alternative C 4-
IV with the addition of a dual media filter and associated pumping
station. A schematic diagram of Alternative C 5 - V is shown in Figure ?';•*.
SUBCATEGORY. C 6 - MANUFACTURED ICE
In-Pl'int Technology
In-plar.t technology and procedures are ai^ed at reducing the quantity
of wastewater discharged from ice manufacturing plants. Sorre plants
reduce their v;aste stream by incorporating a closed cooling system,
with the water used to cool the compressors recirculated through cool-
Ing towers. The cooling towers must bo blown down periodically. Some
plants u'ith once--through v/ater cooling of their compressors route this
water to their dip tanks prior to discharge.
In fragmentary ice manufacturing, the water to be frozen may be passed
through a cooling tower or other type of heat exchanger to. reduce its
temperature before it is passed through the ice machine. Excess water
flowing through the fragmentary ice making machine and water used dur-
ing blowdown operations is re-cycled to this precooler, thus, almost
eliminating.discharge from fragmentary ice plants.
End-cvf-Line Toenrplogy
No ice manufacturing pUnt in the country is known to have any form of
wastewater treatrent facility. Wd^teveter is normally discharged
directly to municipal sewers or to novlaahle waters. One manufacturer
of fragmentary ice dumps excess water into an abandoned water v/ell and
distributes it through an infiltration fi»ld similar to those used in
septic tanks.
The only conceivable treatment to redi/cp the dissolved solids concen-
tration cf the wastcwater to the levo' :,f l!;e water supply is a dennn-
er^lizatlan process iuch as el^ctn••••',-.:•.]yi~,rj, revert; osiricsis, or ion
exchanne. Dnr; ice nianut'ac'.i.Tcr i:. kr-.r;-..n io have initftlled a reverse
osmosis unit to treat its incc.r.inn v/.urr t.upply, but no pldntr. have
installed der.nnpral i ration equirrant :n trcit waste-water, nor have ,;(>>•
pilot r:r bench rests been run to lit torn; me their efficiencies. From
a tcchnic.il sMfcipo int, it is iii.-bious •..•isct'icr the benefits of dis-
rh^r^ir.g a partially de.nint'ral wed wnstewater would justify the proble:.::.
created by Qencration and disposal or the concentrated brine generates
in the treatment facility.
P35
-------
DIM FT
INFLUENT
BOD = 1500 MG/L
SS = 500 MG/L
FLOW . = o.oi3 MLD (0.0035 MGD>
ANAEROBI
LAGOON
AEROBIC
LAGOON
PUV.P I NG
STATION
DUAL MED.A
f I L 7 E P
•ALTERNATIVE
C 5-IV
EFFLUFW
BOO = 30 MG/L
SS = 30 MG/L
FLOW = 0.013 MLD
EFFLUENT
BOD = 15 MG/L
SS =10 MG/L
FLOW - 0.013 i0.0035 MGD )
FIGURC 264
CONTROL ANO T1CATNTN7
C 5-IV ANH v
nac
-------
DRAFT
Selection of Control and Treatment Technology
In Section V, a model plant was developed for ice manufacturing. The
characteristics of its wastewater were assumed to be as follows:
1. Flow volume - average • 0.04 mid (11,000- gpd)
minimum - 0.01 mid (3,000 gpd)
maximum - 0.19 mid (50,000 gpd)
2. BOD - 1.2 mg/1
3. SS - 5.2 mg/1
4. 0.004 - kg BOD per kkg of product
5. 0.012 - kg SS per kkg of product
Alternative C 6 - I - This alternative provides no additional treatment
to the wastewater. Since wastewater from ice manufacturing plants has
been shown to be virtually free of pollutants, no treatment of the ice
manufacturing waste stream is deemed necessary. The direct discharge
of these waste;.aters to navigable streams may, in some instances,
actually improve the quality of the receiving water. This was found
to be the case at one plant.
Subcategory 0 4, Vinegar
Existing In-P13nt Technology - Two plants of the four summarized
on Taole 94\ Section V recycled non-contact cooling water from
the vinegar generators. Cooling water heat exchange may be either
evaporative (cooling tower) or conductive (refrigeration); refri-
geration allowing for a completely closed system. Filter washwater
from two plants was held for 24 hours to allow for settling out
of the filter aid material prior to discharge, thereby realizing
a significant reduction in suspended sol'ids. Also, drainage of
the last few inches of the vinegar storage tanks into a settling
tank "and subsequent dry handling of the resulting sediment reduces
suspended solid loadings.
Potential In-Plant Technology - One of the first water-saving tech-
niques should be" to recycle a'll non-contact cooling waters. Contact
cooling waters, used to cool and clean product containers after
pastuerization should be considered for recycling.
Advantageous waste management is demonstrated in such things as
adequate training of employees, close planv supervision, good
housekeeping, proper maintenance, ond sa'iva^ing products that
be reused in the process, e.g., filter aids. These improvements
w"11 not require large sums of money to implement and may result
if economic returns as a result.
837
-------
DRAFT
End-of-Une-Technploov - Out of a total of seven plants visited
or contacted by the contractor, two had treatment systems resulting
In zero discharge. Four of these discharged to municipal systems
and one to a local tributary.
Treatment systems employed at the two zero discharge plants were
screening, extended aeration and holding ponds, with final discharge
to spray irrigation. Plants discharging to municipalities screened
the effluent and adjusted pH prior to final discharge. The one
plant discharging to a local tributary utilized screening, aerated
lagoon and final holding ponds with a retention time of 250 days
before discharging. This plant realized a 94 percent reduction
in BOD and COD loadings, and 54 percent in suspended solids.
Selection of Control and Treatment Technology
In Section V a model plant was developed for vinegar processing.
The raw wastewater characteristics after screening were assumed to
be as follows:
BOD 1950 mg/1
SS 660 mg/1
pH 5.2
Flow 91 cu m/day (0.024 MGD)
Table 162 lists the pollutant effluent loading and estimated operating
efficiency of each of the treatment trains selected for this subcategorv.
Alternative D 4-1 - This alternative provides no additional treatment
to the screened wastewater.
Alternative D 4-IT - This alternative consists of a pumping station,
flow equal ization basin and acid neutralization.
AUer_natwe_ 0_4_^|_n - This alternative ^lids to Alternative D 4-H an
aeraTed" Id 130011 system with nitrogen addition.
A_He_rnat_ive O^tlX. " This alternative replaces the aerated lauoon
system of Alternative D 4-1II witn an activated sludge unit, in addi-
tion, the treatment train incorporates sludge thickening, aerobic
digestion and truck hauling.
Al^e_rn^tj_ve__D_4_-y - Alternative D 4-V is identical to Alternative D 4-IV
except~Yor the" addition of sand drying beds for sludge disposal.
Alternative D 4-VI - This alternative adds, to Alternative D 4-V, a dual
media pressure filtration system as a final treatment step.
Alternative D 4-VII - This alternative adds a pumping station, pipe line
and spray "irrigation to the treatment tr.iin of Alternative D 4-III.
Altcrnati vc_ D 4-VIII - This alternative adds a pumping station, pipe
1 ine and spray irrigation to the treatment truin of Alternative D 4-IV.
-------
TABLE 1€2
SUMMARY OF TREATMENT TRAIN ALTERNATIVES
SUBCATEGORY 04
Treatment
Train
Alternative
I
11
III
oo IV
CJ
to
V
VI
VII
VIII
Effluent
BOD
mg/1
1950
1950
98
60
60
30
0
0
Effluent
SS
mg/l
660
660
50
30
30
20
0
0
Percent
BOO
Reduction
0
0
95
97
97
98
100
100
Percent
SS
Reduction
0
0
92
95
95
97
100
100
-------
DRAFT
SUCCATEGOKIfS E 1 (MOLASSES. HONEY. AND SYRUPS). E 2 (POPCORN) ,
E 3 (VKEPMKU GELATIN ULSSOUS), E 4 (SPJCLS). E LTTULHYUKATLLT SOUP) ,
fceTUTACAkCMI. SPAGHETTI. VEKHICELLl . AND NUUUi.ES) "
Existing and Potential In-Plant Technology
In general, wastewater volumes and loadings can be 'reduced by the dry
cleaning of equipment as much as possible before cleaning with water.
Mixers, vats, hand utensils, etc., should be cleaned as thoroughly as
possible by rubber scrappers, cloths, and air hoses. Wastewater volume
can be effectively reduced by the use of high pressure spray nozzles
Instead of open-ended hoses or garden type nozzles. The overall effec-
tiveness of in-plant water conservation and pollutant load reduction de-
pends on a combination of management awareness and employee training.
End-of-Line Technology
Virtually all of the plants in Subcategories E 1 through E 6 presently
discharge process wastewater to municipal sewage systems. Those plants
which do not have an access to municipal treatment have a choice
of a number of low cost disposal alternatives. The low volumes of waste-
waters generated make truck hauling practical and feasible—whether to
a municipal sewage plant or to land disposal. Those plants that have
available land can install retention ponds, land spreading systems, spray
or ridge and furrow irrigation, or even small land-related treatment and
disposal systems should loccl conditions permit.
Due to the low volume of these wastes, hauling to nearby treatment facil i lie:
or disposal at suitable landfill sites is the preferred handling metnod.
All of these production processes result in either no production of process
wastewater or very small quantities of wastewater resulting from cleanup
operations.
SUBCATEGORIES F 2 (BAKING POWDER). F 3 (CHICORY). AND F 4 (EREAD
CRUMBS NOT PRODUCED IN BAKERIES/
MS discussed In Sections III and V, the plants associated with these
Subcategories all employ dry processes which do not generate process
wastewater. No control and treatment technology for process wastewater
is necessary or appropriate for these industry subcategories.
840
-------
DRAFT
SECTION VIII
~ COST, ENERGY AND NOU-WATER QUALITY ASPECTS
This section presents an evaluation of the costs, energy requirements, and
non-water quality aspects associated with the treatment and control alter-
natives developed in Section VII in terms of the model processes and plants
developed in Section V.
COST AMD REDUCTION BENEFITS OF ALTERNATIVE TREATMENT AND CONTROL
TECHNOLOGIES
In absence of complete cost information for individual processes, the cost
figures developed herein are based on reliable actual cost figures reported
for various installations coupled with engineering estimates. An estimate
completely applicable to all members of an entire industry is obviously im-
possible. For instance, it must be realized that land costs vary widely.
Construction cost, in terms of both labor and material costs, is another
element that is highly variable. The costs presented herein have been de-
veloped for the different industry subcategories, rather than the entire
industry, thus reducing some of the variability expected in costs. These
costs are, nevertheless, intended to serve as a guide only,.principal iy for
subsequent economic impact analysis to he conducted by the U.S. Environmental
Protection Agency.
Assumptions for Cost Analysis
The following assumptions are common for all of the cost estimates in thi:
section:
1. All costs are reported in August 1972 dollars. All engineering
cost estimates were cade in December 1974 costs and converted to
August 1972 dollars by the Construction Cost Index of the
Engineering Mews Record.
2. Annual interest rate for capital stock is taken to be eight per-
cent.
3. All investment cost is deprcciovcd ov«r a period of 20 years
except rolling stock which is depreciated over ten years.
1. Salvage value is taken as zero at the end of the depreciation
period.
5. Depreciation is attributed by the straight line method.
841
-------
'DRAFT
6. Total yearly cost = (investment cost/2) (0.08) + yearly de-
pjeeciation cost + operating cost.
7. Power costs = $0.04/kw-hr.
8. Excavation and fill is estimated at $!i.92,/cu m ($3.00/cu yd)
for December 1974.
9. Personnel costs for operation is $5.00/hr plus 50 percent fringe
benefits, administration, and other overhead.
10. All capital construction work is performed by an outside con-
tractor using normal profit margins.
11. When between 10 and 20 aeration units are purchased, a discount
of 5.0 percent is obtained. When more than 20 units are pur- •
chased, the discount is 7.5 percent.
12. The December 1974 cost of steel is $0.20/kg ($0.45/15).
13. The December 1974 cost of concrete is $134/cu m ($175/cu yd).
14. The December 1974 cost of contracted truck hauling of dewatered
sludge or solid waste is $0.77/cu m ($1.00/cu yd).
15. The December 1974 cost of contracted truck hauling of liquid
sludge or wastewater is $5.28/1000 1 ($20.00/1000 gal).
The Feasibility and Costs of Municipal Treatment
Although the purpose of the document is to recommend effluent limitations
guidelines for point source discharges into navigable waters, discharge to
municipal treatment systems is a viable alternative for some installations
and is now the case for many existing plants. To avoid redundancy, costs
for this alternative are not provided for every subcategory, but are ad-
dressed in the following discussion.
The combined treatment of municipal and industrial wastes often offers an
attractive alternative for industry, if municipal treatment is available.
Many plants within the miscellaneous foods and beverages industry dis-
charge to municipal sev/ers and, in fact, all plants within some of the
subcategories discussed in this document use municipal treatment. Pre-
treatment for these Industrial wastes varies from non-existent to the
equivalent of secondary treatment.
Many of those plants which do not presently utilize municipal facilities
may not have the feasible option to do so because of location restraints.
Others do not use municipal treatment by choice because of municipal
treatment cost or because they had already invested heavily in separate
treatment facilities before municipal treatment became available.
642
-------
• DRAFT
It is conceivable that some plonts currently discharging to municipal
treatment will in the future decide to provide separate treatment as
municipal charges will inevitably increase. It is even more conceiv-
able that more stringent requirements for pretreatincnt will be made by
municipalities In the future.
Municipal wastewater charges vary widely, as was Illustrated 1n a sur-
vey by Maystre and Geyer (155) in 1970. The results of the survey
indicated that about 10 percent of small cities, 15 percent of middle
size cities, and 20 percent of larger cities had industrial waste
charges. All of the 28 cities responding to the inquiry based sur-
charges on BOO and suspended solids, or their equivalents per unit
volume, and on the excess loads of the individual plant relative to
some average value stipulated by ordinance. Some cities also consid-
ered excess loads of grease and chlorine demand.
Based on the unit costs of treatment applied by the 28 cities, the in-
vestigators calculated the surcharge cost per month for two hypothetical.
Industries, both having BOD and suspended solids concentrations of 800 ::-.;/]
but one industry having a flow of 2230 cu m/month (100,000 cu ft/month) '
and the other a flow of 28,320 cu m/month (one million cu ft/month). The;
surcharge for the smaller industry ranged from SB/month to $269/nionth wink-
the surcharge for the larger industry ranged from $78/month to $2690/~cnIh.
VEGETABLE OIL PROCESSING AND REFINING
Cost and Reduction Benefits of Alternative Treatment Technologies
for Subcate'gory A 1 - Oilseed Crushing. Except Olive Oil .Joy Direct
Solvent Extraction and Prenr?r,r.
A model plant representative of subcatecgry A 1 was developed in
Section 'J for the purpose of applying control and treatment alter-
natives. In Section VII, eight alternatives were selected as being
applicable engineering alternatives. These alternatives provide for
various levels of waste reductions for the model plant which processes
816 kkg (900 ton) of raw oilseed per day.
Alternative.A 1-] - This alternative assumes no treatment and no re-
duction in the waste load. It 1$ estimated that the effluent from a
816 kkg (900 ton) per day plant i:; 140 cu m/day (0.039 MC) per day. Tr.
BOD waste load is 0.061 kq/kk? <(\12? Ib/ton), the suspended solid'..
load is 0.033 kg/kkij (0.076 Ib/ttin), and the oil and grease load is
0.069 kg/kkg (0.123 Ib/ton). The n;odel plant developed is assumed to
discharge its process wastewater and noncontoct waters separately, and
to provide gravity separation and skimming of process waters. Floato.t?1v
oils and sludges from the gravity separation are pumped to an -in-plant
oil recovery system.
Costs: 0
Reduction Benefits: None
043
-------
DRAFT
Alternative A l-II - This alternative provides a flow equalization
basin, complete-mix activated sludge, secondary clarification, a
sludge recicculating pump, a sludge thickening tank, and a sludge
holding tank.
The resulting BOO waste load 1s 0.0072 kg/kkg (0.014 Ib/ton), the
suspended solids load 1s 0.0090 kg/kkg (0.018 Ib/ton) and the oil
and grease load is 0.0054 kg/kkg (0.011 Ib/ton).
Costs: Total investment cost: $172,650
Total yearly cost: $ 32,580
An Itemized .^reakdov/n of costs 1s presented in Table 163. It 1s assumed
that land costs $82,040 per hectare ($33,200 per acre). It is further
assumed that one operator is required.
Reduction Benefits: ROD: 88.2 percent
SS: 76.3 percent
O&G: 92.2 percent
Alternative A 1-IH - This alternative provides in addition to
Alternative A 1-1! dual media filtration with a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.0036 kg/kkg (0.0072 Ib/ton), the
suspended solids load is 0.0045 kg/kkg (0.0090 Ib/ton) and the oil
and grease load is 0.0027 kg/kkg (0.0054 Ib/ton).
Costs: Total investment cost: $189,960
Total yearly cost: $ 37,680
An itemized breakdown of costs is presented 1n Table 164. It 1s
assumed that land costs $82,040 pe-- hectare ($33,200 per acre). It
Is further assumed that one operator is required.
Reduction Benefits: SOD: 34.1 percent
SS: 88.
-------
DRAFT
TABLE 163
ITEMIZED COST SUMMARY FOR ALTERNATIVE A l-II
(OILSEED SOLVENT EXTRACTION)
ITt"IZFD CCST SU'fASY FC-& WARTPfcATER
DESIGN- KFFICIENCt-... 88.2 PERCENT KOD RtCuCTIO
TREATMENT
61..CCM&C-L t-CLSE
i*. , .PU^PI-G STATIC*
C...EQIAUZ4TJC.N BASIN
K.,.ACTIVATED SL'JDGE
G. . .Sl.l.cr-c Tt-ITKES'ER
Y... HOLD I NT, TANK
INVESTMENT ccsTst
i.
I , LAN!)
3.
a.
TCUL
YEARLY
CC£TSl
LABCW
r C * fc »
1.
2 .
3. C
u. K
TC1AL
TCTAl. YEARLY CCST?i
I . Y fc" * t L Y C n f - A T I k G
3 . Y e' A f L v r. v r 5 T •• F s
CCST o r c r , (. u v
3. C
TC7AL
97510.00
55600.00
9750.00
9750.00
172650.00
^630.00
0.0
2 5 C 0 . G 0
i^eao.oo
CC5T 19520,00
6910.00
5650,00
32580.00
R.I 5
-------
DRAFT
P 164
ITHIZITD CO*T SUMI1ASY FOR ALTERNATIVE A 1-JII
(OILSEED SOLVENT EXTRACTION)
ITEMIZES CCST 3l»-"A'«Y FG? HSTFM7EP T»F.i7"EN7 CHtJN
DESIGN EFFICIENCY,., g-J.l C •- ~- •
TREM^F'-T «(
RL.rrMUCl "CLSE
9,. .(--ut-'PTN':- £74 TIC1.
C . . . f r, it L I 2 t ~ I C K F * 3 I K-
" . . . * C T I v A T F i; C L t C G F.
C...FLLCC-E THCKc>E*
V,, .^ni.CTNG T^--
^!!!ru4L ^Ft-ja r-p££.r:L«t FILTR^IK-
INVESTMENT CC£T£t
1. CCNSTfiLCTIO 111«>UO.OO
2. LiN" SStUO.OO
3. f fCilNEEPI^R 111<50,00
ti, CCMlNGc-.CY 111^0.00
7CT4L 1^9960.00
vG CCSTSt
1. L4DC1* 1209C.OT
2. POr<< 69QO.OO
J. Ct-EK-lCALf 0,0
U . »• A I f. T £ -^ 4 ••• C E f. c i - p . 11 S 3 e F 0 . : 0
23360.00
TCTAL VEA,LY CCST.cj
1. YfA-'LY ret'-1*!:'.' CC£7 2336C.CC
CC'1 C r r r ^ E-v 7hCO.OO
3 . C e r n f u 4 T I'/' 6 7 ?. 0 . 0 0
T n 4 '„
846
-------
_
a
c
!»•.* I
I
I
I
I
I
1«J.» I
til.I
o
III.: :
n.
5
31.C )
i*.;t
3tT t.ff; TEAPLY COSTS F-HP 9 .'P.rATEI&lRr /> i . ALTtPNATIVE II £. Ill
-------
DRAFT
TAJM.E 165
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 1-IV
(OILSEED SOLVENT EXTRACTION)
T&EMfc^T CHAIN
. . . es.2 P
YEifiLY C P E R A T I \ G CCSVS
C. . .E-^Ui J ZiTICK »->S!N
L . . . A L R i t f. C L i * r C v
CCST5J
3. rC.'.STRLCTICN 12311P.OO
? . 1. * *• 0 3 3 3 C . 0 C
3. CKGIi.Ff- -;\G 123 1C. 00
a. rrr TiNGf-:k cv 12210.00
5. r-VC Lir-c'" 3t.80.00
KT4L lb«7«0.00
2. PC'^-Trf 10600.00
J. c*t"-«:c*L s o.o
«. ^^I.S'Tr..A:,r:i:R£tPWLIES lf/50.00
5. PVC L. TNrP 100.00
TCTAL 25110.00
TCTAL VPASLY ccr-'i!
J. Vffl''1.'- C-i'-i 7 I\G CC:sT ,?51«0,05
C . Yffl"w»r >vL'PT"Fv^
CCST «[••-•-•. ft: v 61*;O.GC
3, Cu°(^C. IiT ii\ 7^70. CO
, TCT*L. 39870.00
-------
DRAFT
further assumed that one operator is required.
Reduction Benefits: COD: 8P.2 oercent
— SS: 76.3 percent
OiG: 92.2 percent
Alternative A 1-V - This alternative provides in addition to Alter-
native A 1-IV dual media filtration with a pump station to generate
sufficient tiead for filter operation.
The resulting BOD waste load ii 0.036 kg/kkg (.0.007? Ib/ton), the
suspended solids load is 0.0045 kg/kkg (O.OCSO Ib/ton) and the oil
and grease load is 0.0027 kg/kkg (0.0054 Ib/ton).
Costs: Total investment cost: $172,050
Total yearly cost: $ 43,970
An itemized breakdown of costs is presented in Table 166. It is assumed
that land costs $4100 per hectare ;ST6SO per ^cre). It is further
assumed that one operator is required.
Reduction Benefits: EOD: 94.1 percent
SS; 08.2 percent
O&G: 96.0 percent
A cost efficiency curve is presented in Figure 266.
AJJ.ernat jvg A ' 1 - VI - This alternative provides a flow equalization
basin, and pressurized air flotation utilizing chemical flocculating
agents ;.o enhance floe formation and floatability 01' wastes. Oil
and grease waste skimmings are purrped to an in-plant oil reclamation.
system.
The resulting BOD waste load is 0.018 kg/kkg (0.036 Ib/ton), the
suspended solid:, load is 0.011 kg/kkg '0.022 Ib/ton), and the oil
and grease load is 0.021 kg/kkg (0.042 Ib/ton).
Costs: Total investment cost: $149,370
Total yearly cc-st: $ 31,200
An item/ed breakdown cf costs i;, presented in Tab!'? 167, It is
assumed that land costs $32,040 per hectare ($33,29' per acre). It
is further ass uned that one operator is required.
Reduction Benefits: BOD: 69.8 percent
SS: 70.2 percent
O&G: 70.3 percent
A1ternjtiVP A 1-VII - This alternative provides in addition to Alter-
native A 1-VI a.conplete :;iix activated sludge unit, secondary clarif-
ication, a sludge rocirculating pump, a sludge thickening tank, and
sludge haul ing.
849
-------
DRAFT
TABLE
ITEMIZED COST SUMMARY FUK ALTERNATIVE A 1-V
(OILSEED SOLVENT EXTRACTION)
ITEMIZED C^ST SL^HARV FOR x _...._,. , w .. ,
OKSIGN EFFICIENCY... 9U.i PE^CCNT 3CD HEDUCTJCk
TREATf-FNT f'CTlLESi
YEARLY
P.. .PULPING
C.. .ES
L. . . AE
B. . .PUwF
N...OUAL
Tio BASIN
LA^CC'W
STATICN
IA PRESSl-KE
CCSTS!
1.
3!
5. FVC
TC'TAL
^ C- C C S T S :
2. FC'^ER
3. CHEMICALS
PVC
TCTAL YEARLY CCSTS:
l. YEARLY CP£PATIKG CCST
2. YfAPLY IKVEST^EM
3. CK
TTTAL
1375^0.00
3330.00
13750.00
13750.00
3660.00
172050.00
12760.00
0.0
3300.00
100.00
28t50.00
6880.00
8Oit0. 00
43970,00
850
-------
00
LTI
tfl
8
ft
8
>
>
LI
i'1.0
Z »»'•«
101. i
10.»
•1.0
11.0
o«.c( f.i:
EFFICIENCY
FIGURE,
«c.sc
INVESTMENT A^ YEARLY COSTS FOR SUKATEGORY At. ALTERNATIVES iv t v
-------
DRAFT
TABLE 167
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 1-VI
(OILSEED SOLVENT EXTRACTION)
COST SlP"A5Y rO«? ^ASTEXATER T&EAT^EM CH4IK'
EFFICIENT... 70.0 PERCENT «CO K
"CCULESf
B...
C...POI
J...4IR KLCTATICN
CCSTSt
1. CC^STRUCTIC'- 78110.00
2. LANO 556^0.00
3i t-^Ci!'NEEcI'JG 7610.CO
«. CTNTP-it-'NCY 7610,00
(CTAL
ATI\G CC5TS!
it LAFH^ 12UQO.OO
2. PC'-E» 2120,00
3. CHEMICiLS 0.0
U. f-A]MTE''-AKCE|l£L?DLl£S 5930,00
TCTAL £05«0,00
TCTAL- YFABLY CCSTS:
1. YEAPLY CPE«ATI\G CCST 205^0.00
2. VEASLY IUvrESf-ffN.T
CCST occCVE^v 5970.00
TCTAL 3120o',00
852
-------
DRAFT
The resulting ROD waste load is 0.003G ko/kkg (.0072 Ib/ton), the
suspended solids load is 0.0015 kg/kkg (0.0090 Ib/ton) and the oil
and grease load is 0.0027 kg/kkg (0.0054 Ib/ton).
~~ Costs: Total investment cost: $209,400
Total yearly cost: $ 40,690
An itemized breakdown of costs is presented in Table 168. It is
assumed that land costs 582,040 per hectare ($33,200 per acre). It
is further assumed that one operator is required.
Reduction Benefits.
BOD: 94.1 percent
SS: 88.2 percent
O&G: 96.0 percent
A cost efficiency curve is presented in Figure 267.
Alternative A ]-VHI - This alternative provides in addition to
Alternative A 1-VI (dissolved air flotation) an aerated lagoon system
including a settling pond.
The resulting BOO waste load is 0.0036 kg/kkg (0.0072 Ib/ton), the
suspended solids load is 0.0045 kg/kkg (0.0090 Ib/ton) and the oil
and grease load is 0.0027 kg/kko (0.0054 Ib/ton).
Costs: Total investment cost: $188,4CO
Total yearly cost: $ 43,300
An itemized breakdown of costs is presented in Tat^e 169. It is
assumed that lane costs $4100 per hectare ($1660 per acre). It
is further assumed that one operator is required.
Reduction Benefits:
BOO: 94.1 percent
SS: 88.2 percent
O&G: 96.0 percent
A cost efficiency curve is presented in Figure 268.
Cost and Reduction Benefits of
for St/b c <\tg^of y A 2 - Oilseed
Mechanical Screw Press— D
Alternative Treatment Technologies
nsiiing. Except nijve nn~ hy
No model plant was developod for this subcategory in Section V as
the industry presently discharges less than 4000 liters (1000 gallon)
of process wastewater per day to municipal facilities. In Section VII
two alternatives were considered as being applicable engineering alter-
natives for handling these small volumps of waste.
Alternative A 2-1 - This alternative provides no additional treatment.
853
-------
DRAFT
TABLE 16C
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 1-VII
(OILSEED SOLVENT EXTRACTION)
ITEMIZED COST SL^APV FDR *ASTE*&TER TRtATfEK'T CHAIN
DESIG^ EFFICIENCY... Qu.l PtHCENT BCD
M'JCULES:
Pl..fOMRCL HCLSE
B. ..PL'^IM- STATIC
C...KGIALIZATICK B
K. . .ACTIVATED SLL-C3E
C...SLLCGE TUC
INVESTMEST CCST3:
. 1.
2.
2.
TCTAL
2, HOI-:*
3.
YEARLY :
TCTAL
TCTAL YEARLY CCSTSt
1. YEARLY CPE*ATI\G CCST
2. YEAMLY INVESTC^T
CCST
3.
TCTAL
127360.00
56640.00
12740.00
12740.00
209460.00
12«90.CO
ueso.oo
0.0
733-0.00
24670.00
2^670.00
6360,00
7640.00
«0690.00
854
-------
Mi.I
1C-
a
u
o
*
U.T
kl.l
«».»
ll.O
»».te
so.co tj.so
EFFICIENCY
FIGURE 267
AND YEARLY COSTS FC« SUGCATEGORY Al, ALTERNATIVES VI & VII
-------
DRAFT
TABLE 169
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 1-VIII
(OILSEED SOLVENT EXTRACTION)
COST SL^AKY FOR '*ASTF>ATEM TSEATU£HT
DESIGN EFFICIENCY.,. Qu.J PERCENT, BCD fcECUC
TREATMENT *Cr:uLESt
B. . .Pu^Pirr, STST TO
C. . ,Er:iALIZJTIC'x P4SIN
L. . .4ER47FD IACCCN
CCS
T£i
i. cosis tcrio
2 . L A N' n
3. E»-GI-Ec^I\(i
<*, CC^TJ\Gc"CY
s. ^vc ur-t^
TCT AL
151210. CO
3330.00
15120. CO
15120.00
3680.00
isaufco.co
YEARLY CP?RA7IN3 CCSTi:
1. LA6CQ 12^
-------
II*.9
CD
in
M.O) «»,'( «O.C« «!.»( «).««
EFFICIENCY
i •
FIGURE ;69
INVESTMENT AID YEARLY COSTS TOR SUBCATEGORY Al, ALTERNA.TIVE VIII
o
;o
-------
DRAFT
Costs: 0
Reduction Benefits: None
Alternative A. 2-11 - This alternative consists of a storage tank and
truck hauling of the wastewater to a municipal sewage treatment facility
or suitable land disposal site. The resulting waste volume to be trucked
averages less than 4000 liter (1000 gallon) per day.
Costs: Total investment cost: $19,450
Total yearly costs: $ 1,510
Reduction Benefits: 100
.Cost and Reduction Benefits of Alternative Treatment Technologies
.for Subcategory A 3 - Hydraulic Pressina and Solvent r*f-rflrHnn nf
Ol.ive Oil
A model plant representative of Subcategory A 3 was developed in Section
V for the purpose of applying control and treatment alternatives. In
Section VII, three alternatives were selected as being applicable engineer-
ing alternatives. These alternatives provide for various levels of waste-
reductions for the model plant which utilizes 21.7 kkg (24 ton) of whole
olives and 65.3 kkg (74 ton) of cannery pits and culls per day to pro-
duce olive oil. It is estimated that the effluent from the model plant
is 10.9 cu in (0.0029 MG) per day. The BOD concentration is 63,000 mg/1,
the suspended solids concentration is 14,000 mg/1, and the oil and grease
concentration is 3220 mg/1.
Alternative A -3-1 - This alternative consists of a pumping station, a
holding tank and spray irrigation of the raw waste effluent.
The resulting 800 waste load is 0.0 kg/kkg (0.0 Ib/ton), the suspended
solids load is 0.0 kg/kkg (0.0 Ib/ton), and the oil and grease load is
0.0 kg/kkg (0.0 Ib/ton).
Costs: Total investment cost: $40,850
Total yearly cost: $ 5,460
An itemized breakdown of costs is presented in Table 170. It is assumed
that land costs $4^00 per hectare (S1G60 per acre). It is further
assumed that no operators are reciuircd.
Reduction Benefits: BOO: 100 percent
SS: 100 percent
Of.G: 100 percent
Alternative A 3-11 - This alternative consists of four 0.10 ha (0.25
acre) evaporation ponds, lined with PVC fabric to prevent contamination
of the fresh water aquifer.
The resulting BOD waste load is 0.0 kg/kkg (O.C Ib/ton), the suspended
solids lead is 0.0 kg/kkg (0.0 Ib/ton), and the oil and grease load 1s
0.0 kg/kkg (0.0 Ib/ton).
858
-------
DRAFT
TABLE 170
ITEMIZED COST SUMMARY FOR .»rr.NATIVE A3-i
(OLIVE OIL, HYDRAULIC PRESS AND SOLVENT EXTRACTION)
[TEHirrO CGST SU>iPY FCC *AST?*ATFR TREATMENT
3ESJCf. EFFICIENCY.. . 100.0 PERCENT POO «tuUCTIC\
nCDL'LES;
Y. . .
CCSTSt
1. CCNSTSLCITC^ 31020. CO
3. EK'GINEESI^G J 100. CO
ti. CCM^GE'-rv 3100.0''
TCTAL
YEAPt Y CPERAllKG CCSTSi
1 . I Af-P- C.O
2. PCXFP S50.CO
3, OEujruS 0,0
«. K»IK'TE^»NCE?SLFDL1ES 1120.00
TCTAL 1970. PO
TCTAL YEARLV CCSTSi
1. Y^APl.Y CPfATIKG CCST 1970.00
2. YEARLY I^VTCTMCKT
CCST RECL'v^ry - 1630.00
3. r?;nrp::i": :•<. iB60.oc
TCTAL
859
-------
DRAFT
Costs: Total investment cost: $60,330
Total yearly cost; $ 6,920
An itemized breakdovm of costs is presented in Table 171. It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed that~no operators are required.
Reduction Benefits: BOD: TOO percent
SS: 100 percent
O&G: 100 percent
Alternative A 3-III - This alternative consists of land spreading the
raw waste effluent.
The resulting BOD waste load is 0.0 kg/kkg (0.0 Ib/ton), the suspended
solids load is 0.0 kg/!ckg (0.0 Ib/ton), and the oil and grease load is
0.0 kg/kkg (0.0 Ib/ton).
Costs: Total investment cost: $21,720
Total yearly cost; $ 8,330
An itemiz 'j.-eakdown of costr, is presented in Table 172. It ib assumed
that land .->sts $4100 per hectare (S1660 per acre). It is further
assumed tf-UL ons half-time operator is required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
O&G: 100 percent
Cost and Reduction Benefits of Alternative Treatment Technologies for
Subcateonrv A & - mechanical Screw Pressino for the Recovery/ of niiv» r'i "•
A model plant representative of Subcategory A 4 was developed in Section v
for the purpose of applying control and treatment alternatives. In Section
VII, three alternatives ' -:re selectea as being applicable engineering
alternatives. These alternatives provide for various levels of waste
reductions for the r.odel plant which utili:es 13.5 kkg (43 ton) of whole
olives per day to produce olive oil. It is estimated that the efflt;r?rt
from a 4"3.5 kkr (4fi ten) per day plant ic. 114 cu m (0.030 MG) per day.
The BOD waste load is 78.2 kg/kkq (156 lb/t.on), the suspended solids
load is 149 kq/kkg (297 Ib/ton), and the oil and grease load is 52
kg/kkg (104 Ib/ton).
Alternative A 4-1 - This alternative consists of a pumping station a
holding tank and spray'irrigation of the raw waste effluent.
The resulting COD waste load is 0.0 r:q/k'-:g (0.0 lb/to'0, the suspended
solid-; load is C.O kq/kkg (0.0 Ib/ton), and the oil and grease loa^l is
0.0 kg/kkg (0.0 Ib/ton).
Costs: Total investment cost: $92,030
Total yearly cost: $10,840
860
-------
DRAFT
TABLE 171
ITEMIZED COST SUMMARY FOR ALTERNATIVE A3-II
ITEMIZED COST SUMMARY FOR MASTEWATLK TREATMENT CHAIN A 3-1 I
DESIGN EFFICIENCY. .. 100 PERCENT BOD REDUCTION
TREATMENT MODULES:
EVAPORATION POND
INVESTMENT COSTS:
1. CONSTRUCTION 48,170.00
2. LAND 2.920.00"
3. ENGINEERING 4,8?0.00
4. CONTINGENCY 4.8L'O.Ofi
TOTAL 60,330.00
YEARLY OPERATING COSTS:
1. LABOR 300.00
2. POWLR 0.00
3. CHEMICALS 0.00
4. MAINTENANCE & SUPPLIES 340.00
TOTAL 1,6*0.00
TOTAL YEARLY COSTr>:
1. YEARLY OPERATING COST 1,640.00
2. YEARLY INVESTMENT
COST RECOVERY 2,410.00
3. DEPRECIATION ' 2,870.00
TOTAL 6,920.fM)
-------
DRAFT
TABLE 172
ITEMIZED COST SUMMARY FOR ALTERNATIVE A3-1II
ITEMIZED COST SUMMARY FOR WASTEWATCR TREATMENT CHAIN A3-III
DESIGN EFFICIENCY...100 PERCENT BCD REDUCTION
TREATMENT MODULES:
PUMPING STATION
LAND APPLICATION
INVESTMENT COSTS:
1. CONSTRUCTION 16,720.00
2. LAND 1,660.00
3. ENGINEERING 1,670.00
4. CONTINGENCY 1,670.00
TOTAL 21,720.00
YEARLY OPERATING COSTS:
1. LABOR 6,230.00
2. POWER 100.00
3. CHEMICALS • 0.0
4. MAINTENANCE & SUPPLIES 130-00
TOTAL 6,460.00
TOTAL YEARLY COSTS:
1. YEARLY OPERATING COST 6,460.00
2. YEARLY INVESTMENT
COST RECOVEivi' 870.00
3. DEPRECIATION 1,000.00
TOTAL 8,330.00
862
-------
DRAFT
An itemized breakdov/n of costs is presented in Table 173. It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed that_no operators are required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
O&G: 100 percent
Alternative A 4-11 - This alternative consists of four 0.4 ha (1.0 acre)
evaporation ponds lined with PVC fabric to prevent contamination of the
fresh water aquifer.
The resulting BOD waste load is 0.0 kg/kkg (0.0 Ib/ton), the suspended
solids load is 0.0 kg/kkg (0.0 Ib/ton), and the oil and grease load is
0.0 kg/kkg (0.0 Ib/ton).
Costs: Total investment cost: $254,970
Total yearly cost: $ 49,530
An itemized breakdown of costs is presented in Table 174. It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed that operators are required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
O&G: 100 percent
A1ternative A 4-III - This alternative consists of land spreading the
raw waste effluent.
The resulting BOD waste load is 0.0 kg/kkg (0.0 Ib/ton), the suspended
solids load is 0.0 kg/kkg (0.0 Ib/ton), and oil and grease load is O.C
kg/kkg (o.O Ib/ton).
Costs: Total investment cost: $46,140
Total yearly cost: $11,390
An itemized breakdown of costs is presented in Table 175. It is assun.ed
that land costs $4100 per hectare (-15EC per acre). It is further
assumed that one half-time operator ir required.
Reduction Benefits: BOD: 100 percent
SS: 'iDO percent
O&G: 100 percent
Cost and "eduction "onefits of AT fr-Mt^vc Treatment Technologies
for SuhCdtenorv-A-5. - Processing of E'glb'le Oil by Caustic HefinTfifl_._
A model plant representative of Subcategory A 5 was developed in Section
V for the purpose of applying control and treatment alternatives. In
Section VII, eight alternatives wore selected as being applicable cn
neering alternatives. These -il tcrn.iti vet. provide for various levels
863
-------
DRAFT
TABLE 173
ITEMIZED COST SUMMARY FOR ALTERNATIVE A4-I
(OLIVE OIL, MECHANICAL SCREW PRESS EXTRACTION)
Zr.S CCST SUGARY PCS t-i
•SI 5-. fc'FFICIiMTv. .. iCO.n ^
T MC.-DLLE;:
PCD »ECL'CTICK
CHAT\
Y. . .
U...SP-B4Y TpKIGATIfN
JVF.STMEM CCSTS:
1.
£. LAND
3. CNGINPFRJVJ
«. CCfTI>.i;FkC'
fcO. 30
ft610.00
66!C.00
92C?0.00
1. LABTK 0.0
2, FCr-F* 960.00
3. OEMCALo 0.0
u, fAIMTrVAVCFi£lF?LlES 2210.00
TCTAL 3190.CO
LCSTSr
1. VEAKLY ccE = iTisr, COST 3i9o.oo
2. VEAKLY p.VFST"?NT
CCST-?CCVr=Y 36PO.OO
3. CED;- CIATir,-, 3970.00
TCTAL 10B«0.00
864
-------
DRAFT
TABLE 174
ITEMIZED Cn'ST SUMMARY FOP. ALTERNATIVE A4-II
ITEMIZED COST SUMMARY FOR WASTCWATER
DESIGN EFFICIENCY. .. 100 PERCENT
TREATMENT CHAIN A4-II
TREATMENT MODULES:
INVESTMENT COS'
EVAPORATION POND
CONSTRUCTION
LAND
ENGINEERING
CONTINGENCY
TOTAL
YEARLY OPERATING
1 ,
2,
3.
4,
COSTS:
LABOR
POWER
CHEMICALS
MAINTENANCE
SUPPLIES
TOTAL
TOTAL YEARLY
COSTS
1 ,
2.
YEARLY OPERATING COST
YEARLY INVESTMENT
COST RECOVERY
3. DEPRECIATION
TOTAL
205,010.00
8,960.00
20,500.00
20,500.00
254,970.00
1 ,660.00
0.00
0.00
25,370.00
27,030.00
27,030.00
10,200.00
12,300.00
49.530.00
B65
-------
DRAFT
TABLE 175
ITEMIZED COST SUIWARY FOR ALTERNATIVE A4--III
ITEMIZED COST SUMMARY FOR WASTEWATER TREATMENT
DESIGN EFFICIENCY. ..100 PERCENT
CHAIN A4-I II
TREATMENT MODULES.
INVESTMENT COSTS
1,
2,
3,
4
PUMPING STATION
LAND APPLICATION
CONSTRUCTION
LAND
ENGINEERING
CONTINGENCY
TOTAL
YEARLY
OPERATING
1.
2.
3.
4.
COSTS:
LABOR
POW:R
CHEMICALS
MAINTENANCE
& SUPPLIES
TOTAL
TOTAL YEARLY
COSTS
1 .
2.
YEARLY OPERATING COST
YEARLY INVESTMENT
COST RECOVERY
3. DEPRECIATION
TOTAL
32,920.00
6,640.00
3,290.00
3,290.00
46,140.00
6,230.00
830.00
0.00
500.00
7,560.00
7,560.00
1,850.00
1,980.00
11.390.00
866
-------
DRAFT
of waste reductions for the edible oil model plant, which refines
454 kkg (500 ton) of crude edible oil per day.
Alternative^ 5-1 - This alternative assumes no treatment and no
reduction in the waste load. It is estimated that the effluent from
a 454 kkg per.day plant is 314 cu m per day. The BOD waste load is
4.59 kg/kkg (9.18 Ib/ton), the suspended solids load is 2.49 kg/kkg
(4.98 Ib/ton), and the oil and grease load is 2.39 kg/kkg (4.78 Ib/ton).
The model plant developed for Subcategory A 5 is assumed to have separate
discharge of non-contact and process wastewaters, in-plant gravity sep-
aration, skimming, pH control, and an oil recovery systen for the
skimmed oil and water wastes.
Costs: 0
Reduction Benefits: None
A1ternativp A 5-11 - This alternative provides pressurized air floatation
utilizing chemical flocculating agents to enhance the formation and float-
ability of wastes. Oil and grease skimmings are pumped to an in-plant oil
recovery system
The resulting BOD waste load is 1.37 kg/kkg (2.74 Ib/ton), the suspended
solids load is 0.75 kg/kkg (1.50 Ib/ton), and the oil and grease load
1s 0.73 kg/kkg (1.46 Ib/tor).
Costs: Total investnent cost: $145,530
Total yearly cost: $ 42,500
An itemized breakdown of costs is presented in Table 176. It is assumed
that land costs S32,G40 per hectare ($33,200 per acre). It is further
assumed that two operators are required.
Reduction Benefits: 9QD: 70.1 percent
SS: 70.0 percent
O&G; 69.5 percent
Alternative A 5-III - This alternative provides in addition to Alter-
native A 5-11 a complete mix activated sludge unit including a secondary
clarifier, sluuge recirculation, sludge thickening, vacuum filtration,
and a sludge hcldinn tank.
The resulting BOD waste load is 0.059 kq/kkg (0.14 ib/ton), the suspended
solids load is 0.060 kg/kkg (0.14 Ib/ton), and tne oil and grease load
is 0.069 kg/kkg (0.14 Ib/ton).
Costs: Total investment cost: $354,770
Total yearly cost: $ 32,560
An itemized breakdown of costs is presented in Table 177. It is assumed
that land costs $82,040 per hectare ($33,200 per acre). It is further
assumed that t-vc operators are required.
867
-------
DRAFT
TABLE 176
ITEMIZED COST SUMMARY FOR ALTERNATIVE A5-II
(EDIBLE OIL REFINING)
ITEMIZED COST SL^fAftY FOR NA PIpi-. A T£R TREATf'EM
DESIGN EFFICACY. .. 70,0 P£PCEf>T BOD R£DLCT1O
31..CCNTRCL
TREATMENT
INVESTMENT CCSTSI
1.
2.
3.
TCTAL
YEARLY CFERATIKG CCSTS;
i.
2. PC'*ER
3.
STATIC*
TCTAL
TCTAL YEARLY CCSTSt
i. YE^PLY C?S^/IT:».C CCST
2. YEAXLY INVEST ^FK-T
CCST RECCVE»v
3, CEPKECIATICN
TCTAL
71300.00
59970.00
7130.00
7130.00
1^5530.00
.00
U "?0.00
0.3
5QPO.OO
32«00.00
32"00.00
5820.00
«250.00
^2500.00
868
-------
DRAFT
TABLE 177
ITEMIZED COST SUMMARY FOR ALTERNATIVE A5-III
(EDIBLE OIL REFINING)
CPST «
SI ? * A TEP
3EDUCTICN
•<.. .ACfJVATEC 1-l.UDGE
C...SLL:GE Ti-icKrf,?;
S... VAC Li:* P7L1 P ATli.:
Y...HLLCl^r. TANK
I. CC',5
2. LAND
. CCNTI \GENCY
YEARLY CPESATING CCST5:
i. LftBOS
2. Pt>E*
3. CKE-'ICALS
« . ^ilKTESAN
TC7AL
TCTAL YEARLY CCSTS:
1.
2.
.CO
.00
.on
.00
,00
15350.00
2MO.OC
iOhPO.OO
CPP34TIKG CCS7 53630,00
1 *- V F £ T * fc" s T
7CTAL
869
-------
DRAFT
Reduction Benefits: BOD: 90.5 percent
SS: 97.2 percent
- O&G: 97.1 percent
Alternative A 5-TV - This alternative provides in addition to Alter-
native A 5-III dual media pressure filtration equipped with a pump
to generate sufficient head for filter operation.
The resulting BOD waste load is 0.035 kg/kkg (0.070 Ib/ton}, the
suspended solids load is 0.035 kg/kkg (0.070 Ib/ton), and the oil
and grease load is 0.014 kg/kkg (0.028 Ib/ton).
Costs: Total investment cost: $336,850
Total yearly cost: $ 91,380
An itemized breakdown of costs is presented in Table 178. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 99.5 percent
SS: 99.6 percent
O&G: 99.7 percent
Alternative A 5-V - This alternative provides in addition to Alter-
native A 5-IV an activated carbon adsorbtion unit before final discharge.
The resulting 60D waste load is 0.021 kg/kkg (0.042 Ib/ton), the
suspended solids load is 0.017 kg/kkg (0.034 Ib/ton), and the oil and
grease load is 0.007 kg/kkg (0.014 Ib/ton).
Costs: Total investment cost: $459,900
Tota1 yearly cost: $117,120
An itemized breakdown of costs is presented in Table 179. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that tv.o operators are required.
Reduction Benefits: BOD: 99.5 percent
SS: 99.6 percent
O&G: 99.7 percent
A cost efficiency curve is presented in Figure 259.
Alternative A 5-VI - This alternative provides in addition to Alf.er-
native A 5-11 (i.e., dissolved air flotation) an aerated lagoon *it*.
a settling pond.
The resulting BOD waste load is 0.069 kg/kkg (0.14 Ib/tnn), the
suspended solids load is O.OG9 kg/kkg (0.14 Ib/ton), and the oil
and grease load is 0.069 kg/kl:g (0.14 Ib/ton).
870
-------
DRAFT
TABLE 178
ITEMIZED COST SUMMARY FOR ALTERNATIVE A5-IV
(EDIBLE OIL REFINIilG)
CTST SlNHAHr FCP WASTE **T£P TREATMENT CHAIN,
DESIGN EFFICIENCY... "P.2 FEKCF^ 9CD MtCLTTJCK
TREATMENT VCCl'LES;
B1..CLMCCL HCLSE
J.t.tl* PL^TATICS
K. ..ACTIVATFC CLL,D
C, . .SLl. CGL T H i C'•< c i-
INVESTMENT CCSTS:
i.
3!
TOTAL
YEARLY CREATING CCST3:
2.
3,
TCTAL
TCTAL YEARLY CCSTS:
1 . Y£ARLY : ° T 9 A T ! f. G C C i
2 • Y E 4 w L v I N v F c T " P \ T
crsr "Fccvrsv
3. D
TCTAL
59Q70.00
?72«0.00
27?i)0,00
.UhfiSO.OO
20050.00
i' b 1 0 . C 0
11550.00
S S S 7 0 . G 0
5^570.00
15070.00
871
-------
DRAFT
TABLE 179
ITEMIZED COST SUMMARY FOR ALTERNATIVE A5-V
(EDIBLE OIL REFINING)
DESIGN
CTST SiH»ASY PGP
CIE^Y,.. 90.5
TREATMENT CHAIN
& KS.DUCTICK
STATIC^
J . . . A i R * i. n A T i c *
K... ACTIVATED SLI.
S...VACL':"
V...HCLC!KG
N . . . r, o /. !. " - C I A PGESSLHE FIITRA'\
2. . . AC T I Vi TK L" CAi-cC\ iT j'.n>-" i'. :*
CCSTSJ
1. C"N5TKICTIC»»
2.
3. E'
4. C<
TCTAL
YEARLY OPERATING CCSTFi
2,
3.
TCTAL
TCTAL YEARLY CCST£|
J . YE,«.«»i y
2. YEARLY
CLS7 -
3. Cf
TC7AL
333270,00
5^^70.00
33230.00
33330.CO
23520.00
2610.CC
2 71C 0 . C C-
78720.CC
CCST 78720.00
r
i e«o o. o o
20000.00
117120.00
872
-------
00
a.
8
u.
o
9
8
o
\J
• J.f
«;,3 IT-
1C
«i,ce
EFFICIENCY
tee.eo
FIGURE 26'>
iri\i5'r?-iEfn AND YEARLY co:jis FOR SUBCATHGORY AS. ALTERNATIVES 11 THRU v
-------
DRAFT
Costs: Total investment cost: $249,080
Total yearly cost: $ 92,170
An itemized tTreakdov/n of costs is presented in Table 180, It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that one operator is required.
Reduction Benefits: BOD: 98.5 percent
SS: 97.2 percent
O&G: 97.1 percent
Al ternative A 5-VI I - This alternative provides in addition to Alter-
native A 5-VI duaPmedia pressure filtration and a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.035 kg/kkg (0.070 Ib/ton), the
suspended solids load is 0.035 kg/kkg (0.070 Ib/ton), and the oil
and grease load is 0.014 kg/kkg (0.028 Ib/ton).
Costs: Total investment cost: $281,160
Total yearly cost: 5101,010
An itemized breakdown of costs is presented in Table 181. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further ass uned that one operator is required.
. Reduction Benefits: BOD: 99.2 percent
SS: 99.2 percent
O&G: 99.4 percent
Alternative A 5-VIII - This alternative provides *n addition to Alter-
native A 5-VI I an activated carbon adsorbticr unit oefore final discnar-.:
The resulting BOD waste load is 0.021 kg/kkg fO.042 Ib/ton), the
suspended solids load is 0.017 kg/kkq (0.034 Ib/ton), and the oil
and grease load is 0-007 kg/'kkg (0.014 Ib/ton).
Costs: 'iotal investment cost: $354,210
Total yearly cost: $126,730
An itemized breakdown of costs is presented in Table IS?. It is as?.jrr-"1
that land costs $4.100 per hectare v$l(i5C per acre). !t is further
assumed that one operator is
Reduction Benefits: BOO: 99.5 percent
SS: 99.6 percent
GSG: 99.7 percent
A cost efficiency curve is presented in Figure 270.
874
-------
DRAFT
TABLE ICO
ITEMIZED COST SUMMARY FOR ALTERNATIVE A5-VI
• (EDIBLE GIL REFINING)
CTST Sl^A'iY fPc «A37E*
DESIGN EFFICIENCY... Qfi.5 FEBC^.T
MCCLLESi
TC7AL
,
CC?TS>
•
A *
3, E'GI--
a. CC'k--7!
5. FvC L
7C7AL
2.
3.
s. PVC L;
TC7AL
CC=7£j
1, YEARLY
2 , Y E * K i. v
CCS7 -•'
3,
7 C 7 A L
£ " C r
20077O.P3
" 0 0 0 . C n
.CO
l.OP
"150.00
CCS7
0.0
10370.00
210.00
69960.00
12250.CC
<» 2 1 7 0 , C 0
875
-------
DRAFT
TABLE 181
ITEMIZED COST SUMMARY FOR ALTERNATIVE A5-VI3
(EDIBLE OIL REFINING)
C?ST SL^MAPV FCP ^A:
DFSIGN EFFICIENCY... 93.5 PE«C£LP?Ll££ 11210.CO
5. FVCLT'-£^ • 210. C10
TCTAL 75900.00
TCTAL YEARLY CCSTS;
1. Y£4DLY CPfc-A-rivG CCST 75900.CO
CCST RrrrvERv 11250.00
3. CF.aRECIATICN 13860.00
TCTAL 101010.00
87 G
-------
DRAFT
7 . . . 4 C T ! V 6 T :. i'i C - ? f C .N A L i <~ f *• T T L
TABLE 182
ITEMIZED COST SUN-MARY FOR ALTERNATIVE A5-VII!
(EDIBLE OIL REFINING)
ITEMIZED CCST S L *," A i Y FCC fcASTt* *TE« '
DESIGN EFFICIE' CY... 99,5 B£»CEM rCD
TREATMENT MGOULESi
e...PULPING STATIC*:
J...' I^ Pu''1 ti:rv.
L ... A »•:; A T t n L * r. c r;!-.-
P Pi'^PTfn <-Tiit^M
l' t • • « r- * v^'-li-
i.
2.
5. FVC LT.E^ ftl50.CC
TCTAL 35^210.00
VEABLY CPERAT^G CCSTS:
1. LABTF I2uqo,00
2. POEa 550MD.CO
3, C ^ K " I : : L 3 0.0
a. r^ IMF S4'.r£c. SLP = ..':LS ?72< L
-------
CD
~J
it)
«*.
1
o
2
§
<
u
J
V-
J5I.O
si*.i
JJ«.J
m.«
£ in.?
M.I
5«.»
»».:
t'
70.CC TJ.fJ
TI.OC »!.:: M.CC et.tt ti.tt it.es ij.ee jto.oo
EFFICIENCY
FIGURE 270
INVESTMENT AT-JD YEARLY COSTS FOR 'JIFiCAll:GORY As, ALTERNATIVES V? THRU VIII
-------
DRAFT
Cor. t .Irif1 Pfil'jc * '
Subr.a tenory A 6
Acidul.ition
i (jp •"!("• r;n f \ f",
- L"dil>;
> Oil
of Al torn ••>'•!
i-'roct'SsirKj
i vi? Tr^ifn^nt Tr
I)V CuUSLlC
He: f i n
•tolcniL'S for
.M and
A model plant representative of Subcatcgory A G was developed in Section
V for the purpose o* applying control and treatment alternatives. In
Section VII, eig^c. alternatives were selected as being applicable engi-
neering alternat • - :s. These alternatives provide for various levels of
waste reduction: for the mode1 plant which refines 454 kkg (500 ton) of
crude edible oil per day.
Alternative A 6-1 - This alternative assuir.es no treatment and no reduction
in the waste" load. It is estimated that the effluent from a <*54 kkg
per day plant is 534 cu m f 0.141 MG ) per day. The BOD waste load is
8.95 kg/kkg (17.90 It)/ ton), the suspended solids load is 4.03 kg/kkg
(8.06 Ib/ton), and the oil and grease load is 3.51 kg/kkg (7.02 lb/ton).
The model plant developed for Subcategory A 6 is assumed to have separate-
discharge of non-contact and process wastewaters , in-plant gravity sep-
aration, skimming, pH control, and an oil recovery system for the skin-
men oi' and water wastes.
Costs:
Reduction
Benefits:
0
None
.Mternat-j i-e A 5- II - This alternative provides for the addition of
pressurized air flotation utilizing chemical flocculating agents tr
enhance flee formation and float;,bi 1 i ty of wastes. Oil, water, ana
sol'-d waste sicimmings are pumped to cin in-plant oil reclamation
system for dewatsring, and recovery of inedible oils.
The resulting BOD waste load is 2. 58 kg/kkg (5.36 lb/ton), the suspended
solids lo£d is 1.21 kg/kkg (2.42 lb/ton), and the oil and grease load
is 1.05 kg/kkg (2.10 lb/ton).
Costs: Total investment cost: $154,540
Total yearly cost: S 44,140
An itemized breakdown of costs is presented in Table 183. It is
assumed that lar.d costs 532,040 per hectare (S33.2CO per acre).
is further assured that two operators are ream red.
It
P.?ductiori Denef-its:
BOD:
SS:
O&G:
70 percent
70 percent
70 percent
Alternative A 6-1 IT - This alternative provides for the addition of
activator iluoce. secondary clan fic.i tion , clud'je recirculation psjinn,
3 sludge thickening tank, vacuum filtration, and a sludge holding tank.
Sludge is hauled to a landfill facility every four days. The activate.1
sludge unit also includes a control house and two full-time operators.
879
-------
DRAFT
TABLE 183
ITEMIZED COST SUMMARY FOR ALTERNATIVE A6-II
(EDIBLE OIL REFINING)
ITE* Z£C CCST S
DESIGN £PF!C!£k-CY,. . 70.0 F E « C F. ;> T 2CC
TREATMEM
P. . .
PI , .
f?L '•CLSE
TCTAL
1.
2.
3.
LAfO
TCTAL
G CCST5-
1.
2.
3.
It, M
TCT^L
CCSTS?
1. YE.AWI.Y CP?PATIKC
2. YEARLY I-^E£T!-E?.
CCST
3.
TCTAL
7679C.CO
623<50.CO
7*.ec.oc
0,0
6220.00
33J50.00
33350.00
(-180. C"1!
4610-CO
»• aiuOt 00
G80
-------
DRAKT
The rosultino 1300 wa-.to load is 0.13 kg/kk? (0.27 Ib/ton), the
suspendc-J solids loud is 0.12 ky/r.lg (0.t-"« Ib/ton), and the oi' and
grease load is 0.10 kg/kkg (0.2\ lo/ton).
Costs: Total investment cost: $460,940
Total yearly cost: $105,880
An itemized breakdown of costs is presented in Tdule 184. It is
assured that land costs ?82,040 per hectare ($33,200 per acre). It
is fu-ther assumed that two operators are required.
Reduction Beneftis: BOD: 98.5 percent
SS: 97.0 percent
O&G: 97.0 percent
Alternative A 6-IV - This alternative provides for the addition of
dual media pressure filtration with purrp 'taticns to generate sufficient
head fcr the filt.-?r operation.
The resulting SOD was to load is 0.067 kg/kkg (0.13 lb/tc"0, the i-jspe^^.-d
solids loan is y.Ofi kg/l'.kc (0.12 ib/ton), and the oil and grease load
is 0.023 k.v'kkvj (0.0'5 Ib/'ton).
Cost^: Total in,-es:^nr. CO^T: T"-'!?,190
Total yearl> cost: $116,050
An itemized breakdown of costs is presented in Table 135. It is
assumed that land costs $82,040 ner hectare ($33,2riQ per acre). Tt
is further assumed that two operators are required.
Reduction Benefits: COD: 99.3 percent
SS: 93.5 percent
Ca^: 99.3 percent
Al tern.j t i vg A 6-V - ThTs fll ternafi ve provities for the addition of activate-.
carbon absorption before final cii:,cnaroe.
The resulting BCD waste load is 0.025 !:g/!:kg (0.070 Ib/ton). the
suspended solids load is 0.030 kq'ki-.g (O.C53 Ib/ton). and the oil
and grsase load is 0.012 kg/kkg (0.021 Ib/ton).
Costs: Total investment cost: $52C-,340
Total ye.ir'iy cost: $14S,7SO
An itemized breakdov/n of costs is prc-r.onte'l in Table ISfi. It is e;sur,fj
that 1-ind costs SS2,CJO per he? to re C3.:,200 per acre). It is fui ther
assumed that two operators aro required.
Reduction Benefits: BOrJ: 99.6 percent
SS. 99.3 percent
OiG: 99.6 percent
A cost efficiency curve is presented in Figure 271.
681
-------
DRAFT
TABLE 104
ITEMIZED COST SUMMARY TOR ALTERNATIVE A6-III
(EDIBLE OIL REFINING)
crsi SI^AF.Y FOR
DESIGN EFFICIENCY... 9?. 5
MC5L'L££i
8. . .
K.. .
INVESTMENT CCSTSJ
1 . C C f •: S
2. L»KD
3. EKGI
TCTAL
YEARLY C»EPATI\G CCSTS:
1.
?.
3. C
(I. "
TCTAL
ER TRFATVFST
BCD KeCueTIC*
C - A
STATION
«-cuse
inc1-.-
C 5.LLC5E
Cf
TCTAL YEARLY CC5TS1
1 . YEARLY C
d, YEARLY I
CCST S E c C V t" - v
3. DE
TCTAJ.
JVG
33219C.CO
62310.00
33220.00
33220.00
46G9UG.00
2 6 o o r.. o o
130"0.CO
6 7 5 J 0 ., (1 0
19930.C'O
losseo.oo
882
-------
DMPT
TABLE 185
ITEMIZED COST SUMI'ARY FOR ALTERNATIVE AG-IV
(EDIBLE OIL REFINIf-'G)
d'^IZFD CTST Sl^Mis-r PC'S *4STP'*ATEI5
TRfiTVEK/T "
r>n' (i c C .
8. . .PL^Br- r, 'T4TTCN
r i . . c c N T «• c t -CLSF
•3 ... A I s F L •" T 4 1 T C "^
S...V4CIL" ?
r. . ,-''i:;'-r.
1.
2.
3.
TCTAL
•-G CCSTSi
1 . L
s! 1\
TCT^L
TCTAL YEARLY CCS'S:
1 , YE.A
CC5
3. r.E
TCTAL
623?0,00
36cUO.00
362JO.OO
<"57i.50.00
32330. CO
r = i;-^:> G CCST
j i v r S T " t *- T
13620,00
70^0.00
. 00
116050.00
-------
DRAFT
^PCIA PPESSI.PE FKTR
Z,.,4CTIViTt.C C J ^ [' C \ /-CSC^^TT
TABLE 186
ITEMIZED COST SUMMARY FOR ALTERNATIVE A6-V
(EDIBLE OIL REFINING)
ITE-IZFD CCST Sl^Af-Y
DESIGN EeFICI£'-CV. . . 9°.fe Pt'JCE'^7 BCD
"CCLLESt
B. ..PL"- °'.\r. 5T4TICN'
BltfCC^T^lt- ^ C L $ r"
K.!!ACTTV;TFC SLLDGE
S.i.VACLLN FTLTRATI!
INVEST'-EM CC3TS:
2. LAKD 6231C.05
3. ENGINE-3:^ U650C.OO
«. CCNTI'.3E:^C> atSOO.OO
TC7AL 6203uO.OC
1, LA6C= ' 2-•' E v T
CCS7 P E C " •• >- ^ v 2«810.CO
3. CEPr,EC!iT if\ 27900.00
TCTiL la87eo.CO
824
-------
CO
CO
U1
10
c
u.
CJ
I/)
Q
in
O
tli
O
i
u
J
a
5
EFFICIENCY
FIGURE 2'I
AND YEARLY n.rvis rna 5-iocftrrooRY A&.
-------
DRAFT
Altcrnojivc A 6-VI - This alternative provides in addition to Alter-
native !\ G-II (i.e., dissolved air flotation) an aerated lagoon system
including A settling pond.
The resulting DOD waste load is 0.13 kn/kkg (0.27 Ib/ton), the suspended
solids load is 0.12 kg/kkg (0.24 Ib/ton), and the oil and grease load
Is 0.10 kg/kkg (0.21 Ib/ton).
Costs: Total investment cost: $374,050
Total yearly cost- $152,640
An itemized breakdown of costs is presented in Table 187. It is assured
that land costs S-IIOO per hectare ($1660 per acre). It is further
assumed that two operators are required.
Reduction Benefits: BOD: 93.5 percent
SS: 97.0 percent
OiG: 97.0 percent
Alternative A 6-'/n - This alternative provides in addition to Alter-
native A 5-VI dual media pressure filtration vnth a pur.p station to
generate sufficient head for filter operation.
The resulting BOD v.-aste load is 0.067 kg/kkg (0.13 Ib/ton), the suspended
solids load is 0.051 kg/kkg (0.12 Ib/ton), and the oil and grease load
is 0.023 kg/kkg (0.046 Ib/ton).
• Costs: Total investment cost: $410,3CO
Total yearly cost: $!6C,DGO
An itemized breakdown of costs is presented in Table 183. It is
assumed that land costs $4100 per hectare ($1560 per acre). It is
further assumed thst two operators are required.
Reduction Benefits: VJCD: 99.2 percent
bS: 98.5 percent
O&G: 99.2 percen:
AT tcrnati ve A 5-VIII - Tfm alternative provides I'M addition to Alter-
native A 6-VII an activ?ted carbon adsorption unit prior to final dis-
charge.
The resulting BOD waste load is 0.035 kg/kkg (0.070 ib/ton), the
suspended solids load is C.03C kq/l.kg (O.CCO Ib/ton). a^d tf.e oil
and grease loao is 0.012 kg/kLg i'0.024 Ib/tcn).
Costs: Total investment, cost: 5533,400
Total yeariy coot: $195,540
An itemized breakdown cf costs is presented in Table 139. It is
assumed that land costs 5-ViOO per hoc Mr? ($1560 per acre). It is
further assumed that two operator*, ore >-•;•:•>!.;ired.
8%
aii»MB!;;£Zi*l_
-------
DRAPT
TABLE 187
COST £U"KAP.Y FO?. ALTERNATIVE A6-V!
(EDIBLE CIL RFTirjIMG)
ITEMIZE? CfST SLVAHY FCR USTF^TES T"£iT"e>T
DESIGN EP?IC!£* CY, .. 42.7 PEKCF.NT BCD ^ECtC
J...AIK FLf '.'TrC1-
L...4EO ;T£T. LiGCC^
CCSTii
i.
2,
3.
5. P'vC i.j>E*
30MJO.CQ
C-ooC.fiC
30010,00
30010. CO
6950.00
G CCS^S:
1. L4=C«
2. FO^-
5. PVC
12 " 90.00
9159C.OO
0.0
l^^CO.fP
350. CO
TCT&L Y
CCSTSf
1. YEi
2 . v i: *
ccs
3. CEc
TCT*L
E N T
152 6 JO, CO
837
-------
or/Mr
TEMIZED COST SUyVA:-'* f'V ALT£"' /.TV/t A6-VIJ
(EDIBLE GIL "EFMH'^;
ZES C CST Si. ^'I'APv rrs VAj7=*i-;~» T^E^T''^*
DESIGN EFFJC!c*C Y. , , so, 3 rt'TE'-T ?C^ ^TC '.'C T ILK
p p ; • ^ 3 •; > •; 2'v'rrrk'
J.,fM- -L'-Ti* ::\
L . . . i fc •• 4 T : -. li.CC"--
B.,,PJ"'3I^« SV- *:.;•.
^ . . , fj •.; * L •"• r : i - - f s 2 u - E P : L T = A i
I N V E S 7 K E M C C S T 5 :
1, crK?TS:.cT!:-. 2703CO.OO
2 . L 4 '•- " 5 C 0 C . 0 <*
3. £••?:• -.--.<< :i'C 33C3C.CC
«. C'-.'t.::' r-F--:-' 33C3o.cc
s. PVC LJs(rfi espc.cc
TCT4L «103CC.CC
1. LAFC= i2iSO.CC
2. Fr-E1* ^VflSo.j.r!
3. C*-f°:Ci'. 3 0,0
a . H i I :j - •-. ^ \ C £ * £ . = ~ L I E. S i 5 3 7 0 . C C
5. ?vc . ii- r^ :}Sc.:o
1 C 1 4 L 1 2 fc i 3 0 . C 0
FCTAL YEARLY CCST£t
C?^-iT:>.r. CCST 12M3C.OO
2. YEARLY !"'. ti7^^T
3. CEPBEJIiTIfTs 2C«2fcO.OO
L 1^2600.00
863
-------
DRAFT
TABLE 189
ITEMIZED COST SUMMARY FOR ALTERNATIVE A6-VIII
(EDIBLE OIL REFINING)
ITEMIZED CCST rl^KAfrv FC* >• « •<• 1 c '•< i TF^ TP-iATVENT Ck * I
)E3ICN tf-'f IClf^CV... qp.t- Pfc.sCf'T 3.CD PcClCTICK
-f.Ci.LESj
L , . , i E c i T t r. L i ;. c r ^
f .. .P'jvt- :i-r. :-;i-Tr^
^...^l.'AL "'-"./li PWfSSLKE PJLT-A'
Z . . . A C T ! v t ' •• " -flP-C^ v- .-; r > - : T r -
i. CC^!^.TCl T
CCfT ^ECTv-fc-v 21Jiio.OO
3. C£F«;CI*T::^
889
-------
DRAFT
Reduction Benefits: DOD: 99.6 percent
SS: 99.3 percent
0&G: 99.6 percent
A cost efficiency curve is presented in Figure 272.
Cost and Reduction Benefits of Alternative Treatment Technologies for
Subcateqory A 7 - Edible Oil Processing by Caustic Refining,
Acidulation. Oil Processing, and Deodorization
A model plant representative of Subcategory A 7 was developed in
Section V for the purpose of applying control and treatment alter-
natives. In Section VII, eight alternatives were selected as being
applicable engineering alternatives. These alternatives provide for
various levels of waste reductions for the model plant which refines
454 kkg (500 ton) of crude edible oil per day.
Alternative A 7-1 - This alternative assumes no treatment and no
reduction in the v/aste load. It is estimated that the effluent from
a 454 kkg per day plant is 1147 cu n (0.3C3 MG ) per day. The COD
waste load 15 16.09 kg/kkg (32.18 Ib/ton), the suspended solids load
is 7.84 kg/l:kg (15.68 Ib/ton), and the oil and grease load is 3.93
kg/kkg (7.86 Ib/ton). Tne model plant developed for Subcategory A 7
is assumed to have separate discharge of process and non-contact
wastewater, in-plant gravity, separation, skimming, pH control, and
an oil recovery syscem for skimmed oil and water wastes.
• Costs: 0
Reduction Benefits: None
Alternative A 7-II - This alternative provides for the addition of pres-
surized air flotation utilising chemical flocculating agents to en-
hance floe formation and flcatability of wastes. Oil, water, and
solid waste skimmings are pumped to an in-plant oil reclamation system
for dewatering, and recovery of inedible oils.
The resulting BOD ^aste load i: 4.35 kg/kkg (9.70 Tb/ton), the suspends
solids load is 2.35 kg/kkg (4.70 Ib/ton), and ths oil and grease load 13
1.13 kg/kkg (2.26 Ib/ton).
Costs: Total investment cost: $133,640
Total yearly cost: $ 49,530
An itemized breakdown of costs is presented in Table 190. It is
assumed that land costs 582,040 per hectare ($33,200 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 69.8 percent
SS: 70.0 percent
Q&G: 71.3 percent
890
-------
JJi.O
in
a
3
u
t^.;0
u.e:
: t j. e«
t'FFICIKNCY
YEARLY GOTIS F:r.-. r;ijBr:Ar:nrjRY As. ALTERMAT1VES VI THRU VIU
-------
DRAFT
TABLE 190
ITEMIZED COST SIT'IARY FOR ALTCBr.'ATIVE A7-II
(EDIBLE OIL REFINING)
ITEMIZED CC2T S I M K A * Y Ff>'
DESi;i-- EFFICIENCY... 70.0
YE43LV
1.
2.
3.
TCTAL
2.
3.
TCT*L
TCTAL YEARLY CCST£|
:. Y!-/
2. YE
? T F. '•• ,4 T F 9
«CO KECUCTICN
CCS! SF.CC
3.
TCT&L
100?<»O.CO
73300.00
10:30.00
10C30.0C
3 P a 0 . C 0
o.o
6S30.CO
35760.00
CCST 35760.OC
7750.00
6020.00
U9530.00
C92
-------
Alternative A__7-IJI - This allerriativu provided in addition to A1tcr-
nuYiYcr/O- "iT'cbi";)"!'.' to mix aclivotcd si mho, secondary Glorification,
slud'jo rocircul.Uing PUIPD, a r. ludgo thici-.cninq "ank, vacuum filtration,
and a sludge holding tank. Sludge is htiulcd to a landfill facility
every ten d*ys. The activated sludge unit also includes a control
house and two full-time operators.
The resulting BOD waste load is 0.25 kg/kkg (0.50 Ib'/ton), the suspended
solids load is 0.25 kg/kkg (0.50 Ib/ton), and the.oil and grease load
is 0.25 rg/kkg (0.50 Ib/ton).
Costs: Total investnent cost: $672,560
Total yearly cost: $151,370
An itemized breakdown of costs is presented in Table 191. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that two operators arc required.
Reduction Benefits: BOO: 98.4 percent
SS: 96.8 percent
O&G: 93.6 percent
Alternative A 7-TV - This alternative provides in addition to Alter-
native TTT^TTTlfudl media pressure filtration with a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.13 kg/kkg (0.25 Ib/ton), the suspended
solids load is 0.13 kg/kkg (0.25 Ib/ton), and the oil and grease load is
0.051 kg/kkg ('0.10 Ib/ton).
Costs: Total investnent cost: $718,630
Total yearly .cost: $164,520
An itemized breakdown of costs is presented in Table 192. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is furthe- assumed that two operators are required.
Reduction Benefit:.: 300: 39.2 percent
SS: 98.4 percent
O&G: 98.7 percent
A1tern3tiveJ\ 7-V - Thir, alternative provides in addition to Altcr-
native A 7- IV actuated c.irbon .idwptio:; before final discharge.
The resulting BOO waste load 1C 0.070 In/Ug (0.15 Ifo/ton), the DLSPL-M-!"
solids load is 0.063 kq/kkq (0.13 Ib/ton), and the oil nnd grease load
is 0.025 kg/kkg (O.C50 Ib/ton).
Costs: Total investment cost: $1,004,970
Total yearly cost: $ 210,450
893
-------
DRAFT
TABLE 191
ITEMIZED COST SUMMARY FOR ALTERNATIVE A7-III
(EDIBLE OIL REFINING)
ITE«!Zrn CPST fLfH^Pv FCC XASTF* ATER T>-E*T''EKT
OESIGi. EFFICIENCY... 9G.U PERCENT PGD
TREATMENT
YEARLY
fll..CCMRCi. HCI Sfc
e . . . P t y f i K- ? s f * T i r N
J.. .AIB FLriAllCN
SLLOGE
S . . . V * C 1 1 f
Y,..hOLC!NG
VE'BLY
CCSTEl
1 .
2. L 4s 0
3. EMU'.F^I^
U. CCNTINGF'.CY
TCTAL
fl V9 3 CO. CO
73 j CO. CO
a 99 '/o. oo
672560.00
ccsrsr
i.
2,
3.
TCTAL
1.
2.
3 . r F. P B F r I
1CTAL
51:30.00
17?70.00
-------
DKAFT
TABLE 192
ITEMIZED COST SUWARY FOR ALTERNATIVE A7-IV
. (EDIBLE OIL REFIMHIG)
!TE.''-iZt'D COST Sl^Afcv FQP k A?TF c I TF«
DESIG* fcFKICIf^CY... v9,2 PERCF^T pen RkC';CTJCK
b...HJ"*-I^G SU7ICN
J... AI^ 'LCT4TTC"
<...ACTIVATtC 51.LOGE
C...SLL'GF T^-IC*ER
S...VACLL'' FIL". 4T!Cf«
P, ,.DUi'f)!'-r- ^•7ifI
MF:IA ^P
•CCSTjjj
1. CC>'STRICT I CN 537770.00
2. LAf-0 73300.00
3. E^I^E0!* G S370C.CO
u. CC'-.TINGE^CY 5378C.OO
TCTAL 71S630.00
1. LAPO1? 2'I9«JO.CO
2. PCVF-» 5?000,00
3, r^f^iciL!- 5530.rc
«. ^ A I '•: T r '•• * ^ C E». S ' » « L I E 2 : 70on.CO
TCTAL 103500,00
TCTAL YEA9LV CC?TS:
1 , YM«LV CPt°4T!kr. rCST !?JS
2 . Y K & P L. Y
CCST
3. CFP^fC!iTirs ie270.00
TCTAL 1 6 a b 2 0 . C !>
095
-------
DRAFT
An itemized iroakdov/n of costs is presented in Table 193. It 1s
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further'assumed that two operators are required.
Reduction Benefits: BOD: 99.5 percent
SS: 99.2 percent
0&G: 99.4 percent
A cost efficiency curve is presented ii Figure 273.
Alternative A 7-VI - This alternative provides in addition to Alter-
native A 7-11 an aerated lagoon and settling pond.
The resulting GOD waste load is 0.25 kg/kkg (0.50 Ib/tnn), the suspended
solids load is 0.25 kij/kkg (0.50 Ib/ton), and the oil and grease Icuid
is 0.25 kg/kkg (0.50 Ib/ton).
Costs: Total investment cost: $607,720
Total yearly cost: $266, 550
An itemized breakdown of costs is presented in Table lrJ4. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 98.4 percent
SS: 96.8 perctnt
O&G: 93.6 percent
Alternative A 7-VII - This alternative provides in adaition to Alter-
native A 7-VJ dual meciia pressure filtration and a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.13 kg/kkg (0.25 Ib/ton), the suspended
solids load is 0.13 U/kkg (0.25 Ib/ton), and trie oil and grease load
is 0.051 kg/kkg (0.10"Ib/ton).
Costs: Total inver.tir.cnt cost: $65.i,790
Total yearly cost: $279,680
An itemized breakdown of costs is presented in Table 195. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: HOD: 99.? percent
SS: 98.4 percent
O&G: 98.7 percent
Alternative A 7-VIII - This alternative provides in addition to Alter-
native A /-VJl activated carbon adsorption hefore final discharge.
The resulting OOD wiste load is O.C7i'> l.n/U.g (0.15 Ib/ton), the suspended
solids load is 0,063 kg/kkg (0.13 Ib/ton), and the oil and grease load
Is O.C25 kg/kkg (0.050 Ib/ton).
896
-------
DRAFT
TABLE 193
ITEMIZED COST SUf'.MARY FOR ALTERNATIVE A7-V
(EDIBLE OIL REFINING)
ITEMIZED ePST S l^i* AMY FI_B xASTfi'iTFR
DESIGN. EFFICIENCY... 9-
v...K"i:r«r- Tiw
p.. .PUUPI.KG jTJTir^
^... 0 0 A L rfn* F K E S S i. ' E F T (. T c A
2 , . . A C T I V A T P i* r « K - 1 N /• f- S C- L T T i.
1. CCVST^LCTirs 776390.00
2. LAND 73300,00
3 . E K CI:. F V = I ^. r, 7 7 f> a o . 0 5
ti . C C N 7 !k. i; H «. C v 776^0,00
TCTAL
1. LAC-C1';
?. FC-:^ 635^0.00
3. (HEMJCALS %539.CO
a , "«IMKV. A'CE'Sl. PPUIES 3SblO.C^
TCTAL 129670.00
CPM'i::vr; CCST
I. YfAKLV I'. v(-M"frKT
C f sT D E ; r v«:;,- v «o 2 o o. r c
3. CEP*F.c.lA':r»> 065^0.00
TCT*L 2J6U50.CO
ft'.r;
-------
10*.•
It
8
o
•Jl
Q
TU.l
III.*
O3
•JD
C3
0
u
<
a
3
• 3;."
J.M.*
J«:.J
|C«,*
II.:• tj.te (>,co
EFFICIENCY
AND
FIGURF
OUSTS FDR SllBCATEGORY AT. ALTERNATIVES II THRU V
-------
DRAFT
TABLE 194
ITEMIZED COST SUMMARY FOR ALTERNATIVE A7-VI
(EDIBLE OIL REFinillG)
ITFCI7EP Cr£7 S
OE?IPf' tFMClE^CV,.. 9P.u
TRFAT/E'.T "
PI .,Cr.rv7urL i-CLPr
b,..P'juf I-T, STOIC'.
J . . . i ! c H. r U 7 ; r >.
CCSTS:
1 . f. f K S 7 s t .• 1 IC *• I '. V f r T ' • ' T
ccci -ec.r-.r-v 2«3io.rc
i . t *• !-• -. c c : i * : • ». 3 o c ^ c . : '•
1C7*L ? fr 6 5 *: C. . ^ S
099
-------
DRAFT
TABLE 195
ITEMIZED COST SUW'ARY FOR ALTERATIVE A7-VII
(EDIBLE OIL REFIfllKG}
C^ST SI^^KY FCK ^A
EFUCIE^CY.., Qn,2 Pf.
TREATMENT
HC'D
7 «F AT "TNT WCCLUE Si
P1..CL'*TPCL HCLSF
f ...f"J"t:!'T; Vmir-
J . , . * 1 B f-"LCT47!CK
L . . . » F -' * 1 e 15 L t. C, C C K
YEARLY
TCT»L
CCSTSl
1.
r. 7 T c K
3. F.K (•''.!; I. Kl'-G
fa . C O T?«. ti ?• k r v
5. "VC LI'F*
7 C1 41
'•0 CC2TS:
525620.00
t7PO.CC
5?5eC.CC
5 2 5 6 C . T. 0
1 f- ? 7 0 , 0 0
6^3790,00
2. FOF" 1725^0. 20
3. r^F."ILiLS o,C
«. UAI^'":--•:!;»* 1. Pt»LlF 3 22",?; . : P
b. PVCLIN^> 7aOiC-o
TCUL 2211I10,CO
rc'. p» T p> r
2pn?o, co
27Vf-PO.cc
900
-------
WAFT
Costs: Total invo'.linent cost: t'j/10,130
Total yearly cost: $331,020
An i tcmized-breakdovm of costs is presented in Table 196, It is
assumed that land costs $4101) per hectare (SIGGO per acre). It
is further assumed that two operators are required.
Reduction Dene-fits: BOD. 99.5 percent
S3: 99.2 percent
O&G: 99.4 percent
A cost efficiency ci.'rve is presented in Figure 274.
Cost and Reduction Bene__MjEs_of_AJ t££nati_ve Trc>,-itr"ojnt Techno1 no ips ____
for Subcau?riory A fj _-_ J c! T_bJ ^^^r'^r^'^TTi^bv^^iJ^ji^^'j'!^''
Oil Processing, and beodorizatiu'ri ""
A model plant representative of Subcutc^iory A 8 was drvdoped in Sec Li on
V for the purpose of applying control and treatment alternatives. In
Section VII, eight alternatives we-e selected os bfinq applicable (:t wastewators . in-pl.jiit 'irjvi*,' •-'f;i-
aration, skinming, pH control, and on Oil recovery system for the :.ki>-
mcd oil and vjotor waste:'..
Costs: 0
Reduction Benefits: None
Al tfrn,-it ' ve A 8- 1 1 - This «il tern.it : .'^ (.rovirifi prn-.Tiirlrf-l ..ui Pn*. !!;.•!
uti 1 ; ;• r.Q ~chc-.H o 1 f 1 or • •.!.!'. ; :•." .'r;--r.!'. . to eniuince Hoc fn-ia I i'jn jnd M.:.
ebility of was lei. Oil, wfltrr, nnrl ^"l-ifj war,*!. •, ki:r,:-:inq:, .)(-•• C:;ITII»--J '-•
an in-plant '•• il roc lamo tinn f.v';U'"i tor dewaJ.i.T inri, -irul i"-ic:ov"i'"v nl
i nr»rtib le oi i .. . *
The resullifi'i i;n'' wa?.fr In.i'.l i r- > . ' /.• ••j/l. l.cj ( 7 .'',(> Ib/ton), tdp -,ul-|:»r>.«.-i
sol His Iwtd i" 1 . '.'0 ko/l.t.(| (?,. ,7 lu/ton'/, and tfie oil and rjrro'.r lojj ' -.
O.rtf> ky/kk(j (1.72 lb/fon).
Costs: lot.i) invc: ".merit coil: S'9
Total yeiirlv ror-t: $ 49,000
An itcmircil breakdown of co^ts is !••'"• r-n»pd in T.iMp 197. It is
asitii-.-.od th.it. l,v.! c:or. r:, ;;'-2,0'iC ; : •,,._:.. ire ('JT.roo per acre). It
Is f-jrllicr .T.'.^-'L-!! :hat tv.o oiic1' i'. <"• .1
90 1
-------
DKAn
TABLE 196
ITEMIZED COL'T SUMMARY FOR ALTERATIVE A7-V1II
(EDIBLE OIL REFI.'JI.'IC)
C''ST SLPMAPY FTP :•. 45TF. > A TFi ^ 7HFAT"[*T C *• A I'
RESIGN EFFIC'ESCV... 99.5 P'UCPKT PC D «fL'wCT!Ck
Bl . .CC'.TPCL t-CLSE
B. . .^L'^HI'.r, ETaTIC''
J...AJS F'.rTtTrc*>
L . . . A 1.1- A T f 'J !. 4 0 C r '-'
e.. .pi'y-i^. r-TiTio'
YEARLY
i. cr
2 . L / '•- 0
3. '. K c r F r" r. r,
«. c c v T : i. ^ f *•r Y
*. HVC L:KEy
TC7AL
.G Cl'MS:
1. l.Arn?
2. r c v. f K
3. C-f."lrALS
U . K A I N 1 ? • /• 'CM
5. PVC L:trc
TCTAL
C.CST
2 . Y !•: f n L T
CCST "v
3.
• ; T "
16270.00
2 tee 0.00
J81070.CO
0.0
uOb«0, CO
7
-------
U1
sr
(.1
G
i;
a
111.! I
• M.I I
'».•-
ii. t?
it.::
«r.e«
EFFICIEf-iCY
i v r'.cr; rns c.1 ;ar;Tcrj~5RV A7 AI Tro-jrTH.TC UT -rucn i/rrt
-------
DKAFT
TABLE 197
ITEMIZED COST SUI"1ARY FOR ALTERNATIVE A8-II
(EDIBLE OIL REFINING)
ITEMIZED CO^T £L'--vi(.y PCR >-A r, T F-• < T E *' TKE
CES.TGK EFFICIEKCY.., 70.0 PtRCf-.t-T &LO Ffc
uLCt'LES:
BI..COM-CL KISF.
B . . . P L u t I M r, STATIC1
Y. . . HCi. DINK 7A>> K
CCST£>
1. CCNSTBLCTILK 10?C70.00
?- LiNO 6Cȣ)7C.OO
3. EK'GIf.F.E«»!^{: 10510.00
t. cr>r:NiE-:>cv 10210.oc
1c. 61PO.OO
904
-------
DRAFT
Reduction benefits: I presented in Table 193. It is
assumed that Innd cost: $82,040 per hectare ($33,200 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 98.3 percent
SS: 96.8 percent
O&G: 96.4 percent
Alternative A 3-IV - This alternative provides in addition to Alter-
native "AnrTTT~d\jTi nedia pressure filtration with a punp station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.10 kg/kkg (0.20 Ib/ton), the suspcnrf.-.i
solids load is 0.10 ko/kkg (0.20 Ib/ton), and the oil and grease loaJ
is 0.041 kg/kkg (0.082 Ib/ton).
Costs: Tota> iiwstirpnt cost: $628.5°0
Total ycjjrly cost: 5140,210
An itemized breakdown of costs ir, presented in Table 199. It is
assumed that land cor.ts $82.0-0 ppr hectare ($33,?CO per jcrr-i. It
is further assumed that two opi'i\itorr, an.- required.
Reduction Uer.efi to: BOD: 99.1 percent
SS: 9G.4 percent
O&G: 98.2 percent
ATjLon!.')f.J_vp_ •> "-'«' - This alternative provider, in addition to Altnr-
natV-'o A S-IV activated carbun .iJsorption before fit\al discharge.
The rrs: itinq 30D waste load is 0.001 l.q/kkt] (0.10 Ib/ton), the sucper.:.
solids '-ofld is 0.051 kq/kkq (0.10 Ih/ton), and the oil and grease load
is O.OCO kQ/U.g (0.0-50 Ib/lon).
905
•k- ~^'
-------
DRAFT
TABLE 193
ITEMIZED COST SUMMARY FOR ALTERNATIVE A8-III
(EDIBLE OIL DEFINING}
ITT-1I7ED COST SLl'i'AfiY FCR I-A S T r K A 7 F P T^iTV'ENT OAIK
B... pu-'^r.r, s7«
J...aic r L r* i 4 7 I
V. . .^C'LCTKG Tt^
S...VACLU'- FILTKATJCN
Y...I
i. c r i>. s T fi L c 11 f. N
H . . LAKD b<5.E«
3. C H t MIc/L S UJOO.OO
a. ;'AIMTE!.'-Kr'-RELP^l IES 15??".CO
TCTAL 70960.00
TCTAL YEARLY CC£7Si
1. YCiPL^ C"f='.I-7j'G CCST 7«<560,^0
2. YEARLY I^vt ,'.7"fNT
CCST e.'r:T /f"Y 23ii30,00
3, DEP»ECUTir\ 25790.00
TCTAL iseico.oo
90G
-------
DRAFT
TABLE 199
ITEMIZED COST SUMMARY FOR ALTERNATIVE AS-IV
(EDIBLE OIL P.EFINIilG)
ITEI'.IZED COST Sl"*APY FTP '••* STF • * T£» TRfcAT^EKT CHAIN
C-ESION tFr ICIEf C Y. .. -y^.l PERCENT GCO «cuUCT!CN
"CCLLE5!
CI. KLSF
J.. .
f», . .
C C S T 5.1
1.
2 . L A r,
3. E'-G
K... ACTIVATED 5LIDGE
0. ..SLir.GE Tt-irKEN^
S, . . VACLl'"' ML TS4TICN
Y.. .KT.LC'IJ-.R :i'>K
R...CUMPUG STATIC*1
fECIA
TCTiL YEARLY
TCTAL
:C CCSTSs
2,
3.
U. I"
1CT«L
2. YtAKLY I" VF«T-.-FNT
Cr«T SECC'.Fiv
J. CfPSFCI*TlC^
CCST
065520.CP
6V970.CO
12110.00
^100.00
159^0.00
B71ZIO.OO
27530.00
U0210.00
907
-------
DRAFT
Costs: Total investment cost: $056,530
Total yearly cost: $183,240
An itemized breakdown of costs is presented in Tablo 200. It 1s
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
08.G: 99.3 percent
A cost efficiency curve is presented in Figure 275.
Alternative A 8-VI - This alternative provides in addition to Alter-
native A 8-II (i.e., dissolved air flotation) an aerated lagoon in-
cluding a settling pond.
The resulting BOD waste load is 0.20 kg/kkg (0.41 Ib/ton), the suspended
solids load is 0.20 kg/kkg (0.41 Ib/ton), and the oil and grease load
is 0.10 kg/kkg (0.20 Ib/ton).
Costs: Total investment cost: $488,440
Total yearly cost: $206,100
An itemized breakdown of costs is presented in Table 201. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOO: 98.3 percent
$5: 96.8 percent
O&G: 96.4 percent
Alternative A 8-VII - This alternative provides in addition to Alter-
native A 8-VI dual media pressure filtration with a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.10 kg/kkg (0.20 Ib/ton), the suspended
solids load is U.10 kg/kkg (0.20 Ib/tcvi), and the oil and grease load
is 0.041 kg/kkg (0.082 'b/ton).
Costs: Total investment coot: $531,310
Total yearly cost: $218,140
An itemized breakdown of costs is presented in Table 202. It is assumed
that land costs 54100 per hectare ($1660 per acre). It is further
assumed that two operators are reouired.
Reduction Benefits: BOD: 99.1 percent
$S: 98.4 percent
OSG: 98.5 percent
900
-------
DRAFT
TABLE 200
ITEMIZED COST SUflMARY FOR ALTERNATIVE A8-V
(EDIBLE OIL REFINING)
t) COST SIK.-ACY FCR '.-
DESIGN r.FFICJtMY.. . Qo.t =E"CF^T F(.:t) REUuC T 1C »
S!
1.
2.
3.
D 1 . . I. ;. -^ i -". L f-L L j: C
8. . .Pl-'T- T.G cTiTIf:N(
JATC r , f^TiTT.-i
o « i ' J. N fL 'l-ili_f-
Y. . .ML'ir,] .G T«V<
K. . .iTTlv/.TfcT. HLCGE
Cci i rt r° L* TI_T^L^C» C~
t.«;'LL be. TrlC^E'-E"
S. . . VATk.1 :< FJLTKiATlLN'
Y. . .MDL-TV; TAM<
4 P i : M b T >> *" CTA7*'"K.
»•••'• r . ' *.* ^ 1 * 1 . w ^
* . . . I" 1' « L '' : ' I A v = r 5 S 1 •
- • . . ACTIVE Tt '. r ;,;•:-•. .
CC'.ST HECTICS
LAN.D
EVG:f.'t£c-.I'.'C
^F F H TPA ;
K .- i." r" *• 7 *, I •'
6554-tO.OC
6«»P70,00
. 65550.00
656530,00
1. L * t (J •
?• ^C^^e u«;i uo. ^r
3. !>tuICiU 4 100. 00
TCTiL YtiPLY CCS'S:
1. Y F * P- 1. Y C » t " * T I *• G CCST
2, V[ .'. l«|. Y \: M :M."!;K T
CCM -fCCv^-v 3"2tO.OO
3, nEPKfi; IATir> 39330.00
909
-------
(T
_J
Cl
o
u.
o
I
2
•<
LJ
>
Q
5
J'l.l
4M.«
tlt.t
2IC.»
i«.:
n.ss «l.co
ue.co
EFFICIENCY
FIGURE z'f'j
YEARLY cnsrs FO^ SUBCATEGORY AS, .ALTERNATIVES n THRU v
I:.
-------
DRAFT
TABLE 201
HEMIZED COST SUMMARY FOR ALTERNATIVE AB-VI
(EDIBLE OIL REFINING)
TCTiL
IT F ' : 1 2 F D C P 3 T £ L " K A H Y ?CV '.• * S H ' * T E P Tfit^T^EM O 4 I
CEIblGf. F.FP JCIF'-CY.. . «J«,2 f-E^Ct'-T °c: ?. c. 0 1 C 7 I'J K
TPEAT>'FM nr OLLFS:
PI . .fL^ T' LI. cC'.SE
P.. ,»li" P! M. SliTJC'v
J . . . A I - F L r ' A ' I f "V
L . . . A fc K * T ? !?
I r, v • S T " E M C C S "! S :
i. crr. = TKLCTj:
2 . L * f- C fcCCO.CC
3. n '>orv rFuik'G 35 iso. oo
«. crvTl^r.E' f S^l^C, 00
s . P v c i. : «• f - i ? : «; c . ( .1
TC7*L u p. 6 a t1 o . 0 0
VE1RLY CPERATI^G CCSTSr
2. PCi"£w 119500.00
3, OflCaLS 0.0
(I. ^ilMTtK4frtRcLcoLifs 1 7 ? 5 o . ft C
5. HVC L!1-' . 6 00. CO
, 00
Y- AW|. >, T k _ i ,. T ,.(... T
c t: 5 T ,< ' r •.-••• Y 1 9 ^ u a . r ,1
2 « 1 2 c . s r.
?001 00. CO
911
-------
DRAFT
TABLE 202
ITEMIZED COST SUMMARY FCR ALTERNATIVE A8-VI1
(EDIBLE OIL REFINING)
ITEMIZED C C 5 T £ l f s- e H Y F f fi y. A .« T F. N * T E fr TREATMENT O A I K
DESIGN EFFICIENCY, ,. 99.1 Pf-PCENT PCC
TRF
Cl..rC>.T>-TL
b. . .
L A P C C
YEARLY
TCTAL YEARLY
CC5TS:
J. CC"S'.pnLCT!CK
2 , L A >>.r;
3, FKGT'.Pr'np.T,
a. C f> T j s r, r.; \ r Y
5. FVC LlNFi*
TCTAL
.3 CCSTSt
1, lAGCR
2. PC;-!-:'.
3. CHE"ic:i
L : - E -
CT5T B F C f •« F 5 v
6000.00
60.00
ai?60.00
12100.00
531310,01
2«<5<5C. 00
0,0
i e u i c , c o
600 , 00
170620.00
. 00
P1250.CO
?6?70.00
912
-------
DRAFT
Al ternnti_v_c_ A_O^V_IIX - This aHcrnotivr provides in addition to
ATterna'tive A 8-V1I activated carbon adsorption before final discharge.
The resulting^ 000 waste load is 0.051 kg/kkg (0.10 Ib/ton), the suspended
solids load is 0.051 kg/kkg (0.10 Ib/ton), and the oil and grease load
is 0.020 kg/kkg (0.040 Ib/ton).
Costs: Total investment cost: $759,220
TotaV yearly cost: $263,200
An itemized breakdown of costs is presented in Table 203. It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed th.it two operators are required.
Reduction Benefits: BOD: 99.5 percent
SS: 99.2 percent
04G: 99.3 percent
A cost efficiency curve is presented in Figure 276.
Cost and. Poduction Benefits of Alternative, Treatment Techno! _cgiii-plant. qruvity ',<-p-
aration iind skimming, pll control, ;ni'J iir. oil rt-covery system for re-
clalmation of waste oil and greaso skimniings.
Cost: 0
Reduction Benefits: None
Al tcrn.it i vo A 9-1 1 - This alternative provides the addition of pres-
surized a n""f lota t ion utilizing c'viical 1'locculating nqcnts to enhance
floe forn.it ion and floatability of wastes. Oil, water, ond solid woste
skimmings are puinpod to an in-pl.nt oil 1'vi.l.iiiiiit.ion system for do-
watering, and recovery of inedible oils.
913
-------
Irt
5
_i
d
Q
t/i
Q
I/I
s
rs
>J
v.c:
EFFICIENCY
FI'.-ijRE
;•;.•-:.-••:-n' -vo YLARLY rn'is FCR S:BCATE:-C-V AS. ALTER-;-TIV'S n -"^D vi THRU vn
-------
DRAFT
TABLE 203
ITEMIZED COST SUWARY FOR ALTERATIVE A8-VIII
(EDIBLE OIL REFINING)
I T ?! * : Z ? C CCS! S L * w A i< Y K~ t:
OF.. > EFFICIENCY... 99.
f-'* T •"•< E 4 T "
"CD 'JL:uC
O A I
P1..CLMOCL -CLEF
i?.. , PO^ISG .^T'.TK
L . . , i fc '" .' 1 i r> L •"•• C f v
H...fL^r.G STMICN
K , . . f i. ' L »' F ,: I A ? •: L c S . •? E c I L T H A '
r... 4 L f * v A T F r c * "• fr. *• A ? t' r - r> T T L '«
TCTAL
1 . C r t. s T ; i. - T '
2. L A f. r
3 . E * (, T • <•' "'!'
u. c:'.T :'."'••.:
5. f-VC LI'-1;"?
TCT4L
•G CCSTS:
1, LAaC?
2. POP"
3. C^-K ••!:*_;
« . " A I ' " J '. i '. •'
5. PVC LT'-ER
TCTAL
i . Y t i N L * :
j. vt. am.* :
c r F T ••»••
3. rf
TCTAL
6 i 7 5 3 : . C 0
b 0 C 0 . 'i 3
7 £rt . : r
i o o . •• c
C, CO
1 3 J15 0 . C 0
o.c
::.?°^:t£ 3b9K.rG
b 0 C . ft 3
195]7C. f0
3 C 3 7 0 , C .3
37h^O.CO
2h3
-------
DRAFT
The rrer,cntcd in Table 20T . It is
assured that land cost: £22, CO scr hectare ($33,220 per acre). It 1:
furtlHM- assumed that tv/o oper-itors are '-oTjired.
Reduction Ben..-f ; •;:. ; HOD: 98. S
55: 97.0 po
Oft'i: '.)"/ ,(i pm-< n r.
Al tprinti Vf. A Q-IV - This fjl t-.-rnnt i1. '• p •••'•.•••' .jot, wi Lh Vie addition of
Alternative A y-ill dual :r,cr.!io pr1.". Mji'11 filtration '.-,•-. :.h a pui-;; :. t,o '. -, en
to generate sufficient head for filtci- -ipc-'-jtion.
The resulting BCD waste lo.nl i'. 0.1.'> i.-.'n.-i (0.26 ll>/ton). V\f rur-pen-ii"
solids load is 0.13 kg/l'k'i (O.TG ib, '.(.ni , ind Uie oil and i.jrt.Mse lo.id
is 0.0'JP kg/kkg (0. 12' Ib/ton) .
Costs: Total in-,?:.-. ••;;. t -,----,t: S7'13,MO
Total yearly cujt: Sl/1,020
An itcn'ized breai-.dov/n of cor.tr. is rr^'.^i-rM in Table 206. It is assunv.-"
that land costs :r.r,0-iO per ht-ctaf. '• • • . "CO por acre). It is further
assumed that two operators are
916
:. a
-------
TABLE 204
ITTMIZED COST SUKMW FOP. ALTCRflATIVE A9-II
(EDICLL OIL REFIi!ir.'G)
FT r .-AS7E*MF.' T;~EiT"t*T
DESIG-- fMCmCY.., 70.C F^lE'-f r':n Rtfl-ClICN
81 ..Ct^^l'L l-CLSE
3.. .P1.•••-• f.: ?TIT:C-.
J. , .AI1- FL^TITIT1
j. r r N s T r L c 11 o- 1 o u cc o. c o
2. Lif.t 76c30.o?
3. F '> G1; '• (•" J' G 1C-u c o. r:
c . C C •- T Il f- M- C Y 1 f it C n . 0 .1
TCTAL 2 G m 0 G.C 0
; o. c o
e . P C '. F" u 2 5 f.. 0 C
3 . O c •'•' i f i I. S 0 . C
«. KAi1-7c'..'.'.Ci:|(SLf-cLlES 7C^C.CO
TCT4L 36etC,00
1, U'A'-'L- r^'V'-A" I" ^ r7£T 3h?f.0,0n
a. Yt .-.PLY r \ -cT'T( T
cc:^i cc-r-v-t.Y "OftO.co
3. Ct^cr.;.-.*:;'*. t>t-^o.c^
TTT»L scst.o.oo
917
-------
limn
TABLE 205
ITEMIZED COST SUMMARY FOR ALTERNATIVE A9-1J:
(EDIBLE OIL RCFIMiiG)
ITE"IZK" Cr3' 3l"l'A1-'Y FLP i» i « T K * i 7 -' " Ts z. * T '•'•'. T C^ftlf.
DESIGN EFFICIENCY... 9 f . ^ PERCENT "rD SEC^ruc*.
TREAT^TNT '•'CCtLcci
R 1 . .r.L'NTPCI ^-CL^F
E. .,P';"rING £7iTIf^
J . . . * J P ' ! r T -'• T T C •••
Y. . ,HLLC Jk-r- V1 •:
INVESTMENT CCSTS:
1. CCN'STC.,CTICN SjiJOtO.OO
2 . LAND 71fc j 0.f C
3 . L K C-1 ^ E • 1v G 5 \ 5 C 0 . 0 t?
I K r: E " C V 5 1 ~> (l (1 . ^ A
69^590.C 0
YE4PLY
?, HC'E'? 5 f 3 " 0 . " C
3. Ct-B.'^IC.iL^ 5ni:.c,-l
». !^I^Tf'Ni^CrK5LPpl. I E S J ^ 7 i •*. ? 0
7CTAL 9 » 9 2 0 , C C
TCTAU YEARLY CC£T£:
1. YEARLY CC-fSiT^G CCST 98<5cO.CC
2. YLA9LY I f« V r £ T »• P M
CCST w^r.rvrcv ?77?O.CO
3. CE°PEC TaTir> 30=500. OC
TC7AL 157bCO.Cn
-------
Di'Ai T
TABLE 206
ITEMIZED COST Cl':"'A3Y r(P. /'.LTEWI'TIVE A9-IV
(EDIBLE OIL REFINING)
' f.'"! J r P C " -1-. 7 F L v '•' l i- v F C 5 •• /< " T c i-
YEARLY C"f'A
p 7 » r /. * ^ (. \ T ;
Cr l<£:^LCTIC^
,"s . .PCK-T! r- SU7ICN
J...'!»• •-' ^'.'.!'.'.
K...*CTiViTf. ELL^Ct
S.. . ViCL I.'" FTL7? it:/-.'-
Y. , .^HLr T' - 7^<
C . . .^."•FI'*:.. c7i'TC'-
'.. . .r- - * L l t r> I i P 5 i > S L :-• c F ! L 7 r, 4 i s
i. (•['< '.TCU.-.'IC1
2 . L '. i ^
3. Ef.MMF'J/- 3
**. C C fv T I Mi E .--' Y
7CTAL
i . Iir^---y
3 . C -r. " IC i •_ *
«. ^AI'^F.W.'.r.r &SLK?L
TCT A|.
VE4KLV CCST5I
t! . Y t 4 r I. V I • \ r c T v r .. T
H 1 AL
( i' •.'
.on
.CO
, c*
.0"
SfiiO.OO
. 11' 9 i e 5 j o, r- c
JO^btO.OO
33J30.CO
17 u-; o. c c
-------
ORAKT
Reduction uuncfiU: COS: 11.?.
_ SS: fi3.5 perc'.v.t
O&C: 98.6 percent
Alternative A 9-V - This alternative provides with the addition of
Alternative A 9-IV activated carbon adsorption before final discharge.
The resulting BOD VMS to load is 0.073 kg/kkg (0.15 Ib/ton), the suspended
solids load i5 O.C73 l-g/i;kg (0.15 Ib/ton), end the? oil and grease load
is 0.029 kg/kkg (O.OoS Ib/Lon).
Costs: Total investment cost: $1,075,820
Total yearly cost: S 229,000
An itemized breakdown of costs is presented in Table 207, It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that tv/o operators are required.
Reduction Benefits: ROD: 99.6 percent
SS: 99.2 percent
O&G: 99.3 percent
A cost efficiency curve is presented in Figure 277.
Alternative A 9-VI - This alternative provides in addition to Alter-
native^ 9- II (i.e., dissolved air flotation) an aerated lagoon system
including a settling pond.
The resulting BOD v/aste load is 0.26 kg/l:kg (0.52 Ib/ton), the suspended
solids load is 0.26 kg/kkg (0.52 Ib/ton), and the oil and grease load
is 0.13 kg/kkg (0.26 Ib/ton).
Costs: Total investment cost: $684,150
Total yearly cost: $305,590
An iteiiized breakdown cf cor>t^ is prc-i>en;.c'! in Table '108. It is assuned
that land costs $4100 per hectare (S1GGG per acre). It is further
assumed that two operators are required.
Reduction Benefits: BOD: 98.5 percent
SS: 97.0 percent
O&G: 97.0 percent
Alternative A 9-VII - This alternative provides wi Hi the addition of
Alternalive A 9-VI dual media pressure filtration with a pump station
to generate a sufficient head for filter operation.
The rc&ultinq BOD waste load is 0.13 ka/kko (0.26 Ib/tnn), the :,ur.pcnd<'d
solids lond is 0.13 kn/kkg (0.25 Ib/ton), and the oil and grease load
is 0.058 kg/kkg (0.13~lb/lon).
920
-------
DHACT
TABLE 207
ITEMIZED CCU SUGARY FOR ALTERNATIVE A9-V
(F.DI3LE OIL RE
i:f F IClt'-C V, . . ? - . ft
El , ,C( M5CL
e...^/'-i'-G
J...M- -LC"
K...4C7! V4T:
S...V4CU" '•
v.. .Hn.C'rG
f-...Pl U^I'^
£TMT'_'-
ATir.'-.
? 5 L L " 2 E
^ici-^1-1>
ILTt IT K
' • 5- £ I'- Z F IL 7'
1.
3!
7CTAL
1.
P C * F «
C*-£"ICALS
TCT4L
TCTAL YE*BLY CCGT5:
2 . Y t A c L Y I •• v F 5 V' r '. T
CC5T S'-r.fVf cv
TCT4L
6 3 ? '.- ft 0 . C 0
76bJC. PO
63?70.00
1075^30. CO
5E30.CO
1 3 6 0 1 0 . C 0
136010.00
u30?0 . 00
22900o!ofl
OZ1
-------
W
DC
<
d
Q
i/l
B
Ill
O
U
<
1)
a
':. i
m.l
I.6
n. a
c
EFFICIENCY
FIGURE 277
r:.vrcr> :EI.T .-v;:; YEARLY f.rsis FOR suErA
Edr.Y A?, ALTTKU/VI ivts n THHUUGM v
-------
Di'AFT
TABLE 208
ITEMIZED COST SUMMARY FOR ALTERNATIVE A9-VI
OIL REFINING)
O COST SLVHA--Y FCB uSTF
DESIliN cPFIClE'.CV... S85? PEhCFNT HL'D HtCUTlCV
MCCLLESi
YE4PL''
TCTAL
81.
?...pi"pr^
J...AI1 FLt
1.
2.
3.
5. PVC LP.EK
TCTAL
•C CCSTS!
1. LABOR
2. POEfl
3. CHEHICiLS
5. P'
TCTAL
CCSTs:
1. Y
2. YE««
CCST
3. DP
TCTAL
Lli-EP
?. T I >: N'
T I C ^
5*17730.00
7830.00
SU77&.CO
54770. CO
1«»050.00
IJ50.00
1<>3620.CO
0.0
P7370.CO
33P?0,nO
305590.00
923
-------
DRACT
Costs: Total invcstii'vit c.os,t: ?732,710
Tot.il ye.irly cost; $310,590
An itemized breakdown of costs is presented in Table 209. It is
assumed that land costs $4100 per hectare (S1GGO per acre). It 1s
further assumed that two operators are required.
Reduction Benefits: BOD: 99.2 percent
SS: 98.5 percent
O&G: 98.6 percent
Alternative A 9-VI II - This alternative provides in addition to Alter-
ative A'9-Vli activated carbon adsorption before final discharge.
The resulting EOD waste load is 0.073 kg/kkg (C.15 Ib/ton), the suspend."
solids load is 0.073 kg/kkg (0.15 Ib/ton), and the oil and grease load
is 0.029 kg/kkg (0.058 Ib/ton).
Costs: Total investment cost: $1,065,380
Total yearly cost: $ 376,990
An itemized breakdown of costs is presented in Table 210. It is assuired
that land costs $4100 per hectare (SlcGO per acre). It is further
assumed that two operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
O&G: 99.3 percent
A cost efficiency curve is presented in Figure 278.
Cost and R eduction Benefits of Alternative Treatment Technologies fn r
SubLJteri~r~/ A TO, Edible Oil ProcucT'i'n "_.• C.iuStiC Refvnnq, '_6_\1 j-V"'~a : .
and Shorvemiui and Tjiiir >'n\ Prr'i'iction
A model plant representative ot "uLicato'Sory A 10 was developed in
Section- V for the purpose of applyinn control and treatment altcrnntivr'.
In Section VII, eight alternative:, vuM-e srU'cte-J ar, i>eing iipplicabln
entjineering alternatives. These nl tj;rnativcs provide for various
levels of waste reductions for the model plant which refine:, 454 kko
(500 ton) of crude edible oil per clay.
Altprnative .*\ 10-1 - Tn^r' al trniiiti'/c -isMimes no treatment ,ind no
reiiuction in the waste load. !t ii. P:.titrated that the efiluent f>-om
3
-------
DRAFT
TABLE 209
ITEMIZED CCST SUMMARY FOR ALTrRI-'ATIVE A9-VII
(EDIBLE OIL REFIUIKG)
!TEV!ZFC CCST <-\.">'tr-<< PCH miSfn-iTP.* 7»«K 4TVFM O Al
DFSlf.N tFFICU'-LV... oo.;3 PE = TF''T
TREAT"E'.T KCTLLESf
n ..rc.1-
P. . .P-..'"PP 5 FT MIC'.
J...AIK Ki.r,74T!C'''
P.!!^l ^PIM- ST-s-tlfT'-.
F1L'
C C b T S I
i.PO
i.OC
3. F!. r T^'frppI'.•G bey 20. co
«. crr> T! -PF'-ry 56P20.('«
5. PVC LI^-F.K i«5050,0!;
TCT'U 73Z7VO.OO
>. L4ETC 2*""0.00
?. PC^F» 202720,GO
3, oe-rcAL? o.o
4. f'AlNTu'.At-CERi'. -r-LlFS i5i.7C.CC
5. FVC L T^t-> HfaO.r.o
^0.on
2. YE
CCS1
3. CtPHtCUTJOs 36PUO.CO
-------
DRAfT
TABLE 210
ITEMIZED COST SUMMARY FOR ALTCtttATIVE A9-VIII
(CDIBLE OIL RCFINIf.'G)
ITFi'IZEO CT.ST Stt^iPy PCS >/. S T E v. t T r « Ti'.EiT^":\7
Dt'SIGf. EFf- TCIE'-CY. . . 90.6 f-tFCF.M rCC ^L'L'uC T JQ
B...PDuP!"r, 5T4TK1-'
^-...n'jiL "£ci* kctssuf.fr
2...ACTIVfrTM" CA- r,; i:
INVESTMENT CCS"Si
i.
2. LAI 0
3. ff.GI* FESISG
U. rcNTlNGE'.Ci'
5. PVC LINF*
TCTAL
7830.00
8 6 E £ C . C 0
665wO.no
50.00
VEAHLY
PC-.-.ER
2.
2 1 2 U « C . M
0. 0
« 3 I« 0 . 0 0
'.CO
5 . P V C
TCTAL
i. YfARLY CPF?ATI\c: cCST PP.JflCO.CO
2. YEARLY 3 KvfST'-'P\T
c c s i u e::r«/ r»v o ? ^ ? o, c T
J. rrFKEClAlio S?P«n.oo
TCTAL 376900.CO
9ZC
-------
i: i •. e
u
a
1/1
'4
1/1
a
a:
•M:.J
a
t'-.s
11!.»
f .0 i'
ii'.tt 7«.c: ti,:: M.eo *e.ec ti.cc u.cfl »».t» ici
EFFICIENCY
FIGURE 27F,
A^ YEARLY COST'S FOR SL'BCATtGORY A9, ALT. II > NO VI THRUUbH VIIJ
-------
DUAI I
separation and :.'<• ininiing, ;•!! control, rind an oil recovery system for
rccloiiM tion of v.tistu oil o.id Qrcosc :.i. ii;i;i)in«js.
Costs: 0
Reduction Benefits: None
Altcrnative A 10-11 - This alternative provides for the addition of
pressurized a'ir flotation utilizing cho.'nical flocculating agents to
enhance floe formation arid floaUbi li ty of wastes. Oil, water, and
solid waste skimings are pumped to an in-plant oil reclamation
system for dewatering, arid recovery of inedible oils.
The resulting BOD waste loud is 3.82 !jg/kkg (7.04 Ib/ton), the suspend")
solids load is 2.13 kg/kkg (4.36 Ib/ton), and the oil and grease load
is 0.95 kg/kkg (1.£9 ib/ton).
Costs: Total investment cost: $191,780
Total yearly cost: $ 49,200
An itemized breakdown of costs is presented in Table ?11. I' is
assumed that land costs CE2,C40 per hectare (533,200 per acrp). It
is further assumed that two operators are required.
Reduction 2enefits: BOD: 70.0 percent
SS: 69.5 percent
O&G: 70.0 percent
Alternative A"10-III - This alternative provides in addition to Alter-
native A 10-11, complete nix activated r,ludge, secondary clarification,
sludge recirculating purcp, .1 sludge in it ken ing tank, vacuum filtration,
i»nd a sludge holding tank. Sludoe is n.iuled to a landfill facility
evory six day,, The activated uludqc -jnit also includes a control
house and two t'uil-time operators.
The resulting PuD waste load <-, 0.1° in.'kkn (0.30 Ib/ton), the suspend' :
r,nlids load is 0.22 kg/l.'.J .'C.-ln Ib/inn'i, and thp oil and grr.ijp load
is 0.097 kg/l.ky ;C.19 Mj/ton;.
Costs: Total investc-crit cos!.: J.600,850
Total yearly tost: $133.730
An itemized br< akdown of cortr. is ;jn.-Dented in Table 2U'. It is
assumed that lond COStr, '"".0-10 pi?r hectare (i33./00 per arrc). It
is further assumed that two operators nrc required.
Reduction Benefits: BCC: 98.5 percent
5S: 96.9 percent
Of.G: 97.0 percent
Al l-i'rngfivc A_ 1£-J_V - This al ternat i VL- provides in addition to Alter-
native A fl>~i l~! dual irc;ln prossur-,.:,.: ::l!ration with a pump station to
fjc:'.oiMtc sufficient head for filler MI.'.
-------
DRAFT
TABLE 211
ITEMIZED COST SUMMARY FOR ALTERNATIVE MO-11
(EDIBLE OIL FEFIKIKG)
JTF"!ZFD rrST !-l/
t r?
Rl . .
If«VEST''EM
1 .
3. FM, TV'•-„;.•;• .-.
U . C C M I'. G f ' f v
rf>F.?tTIisG fC'Tf,
1. L4-r
r."M RCD SEDLCTJCN
9 ^ 7 u 0 . 0 !>
73300.00
q C 7 C . C r.
•?870. CO
1917PC.OO
VE*PLY
. Af-w 3
-------
RRACT
TABLE 212
ITEMIZED COST SUMMARY FCP, ALTERNATIVE A10-III
(EDIBLE OIL REFINING)
I T F. " I Z E r; CrST S u n-- 4 r? y FTP
DESIGN EpFICIt^CY... Vfi.S
S T F •• « T r » T S F /. T " f M f> 4 J •
61 . .Cof. TMTL k-CLEf
fi... ^ L u P IK r- «i .M i r: \
J. ..4 IP FLrTAT!CV
K . , . * C T T V A T f n c L ,, * r r
C.,.5LLCCir TI-ICKF.''!:-
S , ,. ^ A C L L»- F I L T t 4 T IC
YEAMLY
TCTiL
1.
2.
3.
TCT4L
>C CCSTS!
2. PC^fH
3. OtuTC
«. ^AI'-'TE
1CT4L
CCSTSl
1. Vt4PLV
2. V
l. CEP*FCI«T
s^t^o. oo
73300. CO
6PCS50.CO
'.CO
ISM 0. CO
e 3 3 a c. c o
P33?0i CO
cJ030.0P
^63PO.CC
133730.00
030
-------
DRAFT
The resulting ['CD «/uSt.i? load is 0.007 i''j/kkij {0.19 1l>/ton), the suspended
solids load is 0.11 kq/kl:«j (H.22 Ib/ton), and the oil and grcose loud
is 0.048 kg/Hg (0.096 Ib/ton).
Costs: Total investment cost: $G46,270
Total yearly cost: $146,640
An itemized breakdown of costs is presented in Table 213. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
1s further assured that two operators are required.
Reduction Benefits: GOD: 99.2 percent
SS: 98.5 percent
O&G: 98.5 percent
Alternative _A 1Q-V - This alternative provides in addition to Alternative
A 10-JV activated carbon adsorption before final discharge.
The resulting BOD waste load is D.048 kg/kkg (0.095 Ib/ton), t^e sussrri^o.}
solids load is 0.056 kg/kkg (0.11 Ib/ton), and the oil and arcase load
Is 0.024 kg/kkg (0.048 Ib/ton).
Costs: Total investment cost: $919,530
Total yearly cost: $199,530
An itemized breakdown of costs is oresented in Table Z14. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that two operators ara required.
Reduction Benefit:.: BOO: 99.6 percent
SS: 99.2 percent
O&G: 99.2 percent
A cost efficiency curve is presented in Figure 279.
Alternativg A 10- VI - This alternarive ::—ivider, in addition to Al'er-
native A 10-11 {i.e., dissolved oir flotation) an aerated 1 age-on and
a settling pond
The resulting BOD waste load is 0.19 kg/(:kg (0.3? HVton), the suspendrJ
solids load 1r, 0.22 kg/kkg (0.44 'h/'toiO, and the oil and q reuse
is 0.097 kg/kkg (0.19 Ib/'ion).
Costs: Total inv"r,t.n-,.-: :t -ost: $600,4^0
Total yearly cost: $26?, 740
An i tend ;.i?d breakdown of costs ;•'. ; r« ••..•;'. t.od in !.:!>1r 215. It is
dr.r,tiin?rl thjt lond costs $4100 per hectare ('l^GO -^r acre). It ii
further assumed that two operotors ,ir- required.
931
-------
DRAFT
TABLE 213
ITEMIZED COST SUMMARY TO" ALTERf.ATIVE A10-IV
(EDIBLE OIL REFI.','I.';G>
CFS1G.'. EFFIGIES1: ., ,
TREATMENT
P J . .CC^
P. . .p^
J ... A 1
C . , . S L L D P ? Tt-I
S...VACLL1' r:i_
Y.. .HCLCJs.r, TA
a,..PbvFisr- =T
N...DU4L " E n 1 1
PE<=CEM PCD r'
Ci. 1-CL5!-:
K P 5TATIC'"1
F I L T " A '
YE4RLY
1.
LAND
477476. CO
7 3 3 G 0 . C *
a7753.00
6Ufc27C.CC-
3.
TCTAL
'G CC;TS$
2 '. FOE
3. C H E H
i . K 4 I ^ T E •'- A .'-. C £ ii £ L ? - L I f & 1 fc 3 1 0 . 0 0
TCTAL 931^0.00
^O?. 00
TCTAL YEARLY CCST=:
2. YEARLY r v - = T-<
CCST KEfC\--Y
3. C^F«
TCT*I.
CCST
2Pfc5C.CO
932
-------
DRAFT
TABLE 214
ITEMIZED COST SUM'MY FOR ALTERNATIVE A10-V
(EDIBLE OIL REFINING)
ZrD COST Sl"KA*v
DESIGN EFFICIENCY.., «
TBE4TV£.VT CHAIN
6. ..
K,..»CTIVA1£C SLLDGE
C...SLLCG5 T»IP.K
>-...rL'»L vPCI-i P'-ESSLBE FILTCA'
Z , . . A C T I v A T t n C A - r C v. A '; £ r ;< w T ! c '.
YEAPLY
CTAL
i.
2 . l A N 0
3. EKGI'
CCSTSi
?.
3. C
CCST5J
S. V
2. Y
CTST
7CUI.
705190,00
73300.00
?05?0.00
70520.00
919530,00
TES
5«700,CO
«3
-------
v>
a
o
Q
LO
I-
l/l
o
IJI.T
>-
_J
£
<
u
a
<
u
tit.i
»*.-
/
EFFICIENCY
FIGURE 279
YEARLY COSTS FOR SUBCATEGQRY Aio. ALT. II THROUGH
-------
TABLE 215
ITEMIZED CPST SUMMARY FOR ALTERNATIVE A10-VI
(EDIBLE OIL REFINING)
I T F_ > I z r. (
OE.SIG'.
nsi s i »"• * - Y FC^
TCIFfCY. .. 99.=
^rcvT'Cl t-Cl.cF
..PliOJ!I'«G £1 »1 I
c * a I s
1.
2, L«M1
3. ENGIr.rieI'u
a. cCMi.».;r•• cY
CP£»*TII.5 r.C£T<
1, L
?. P
i-.
R .
TCT6
CC5TSJ
1. Yt
2. YE
CC
3. Cs
TCT/.L
LI
7 0 0 0 . C 0
1601P.PP
6COOPO.OO
161^70.00
0.0
213PO.OO
710.00
C^E»*TIV(i C'.ST 205050.00
) ^^ v t; £ 7 K P K T
?«!h70.0n
935
-------
DRAFT
_ Reduction Benefits: NOD: 90.5 percent
SS: 'J6.9 percent
O&G: 97.0 percent
Alternative A 10-VII - This alternative provides in addition to Alter-
native A 10-VI dual media pressurized filtration with a pump station
to generate a sufficient head for filter operation.
The resulting BOO waste load is 0.097 kg/kkg (0.19 Ib/ton), the suspended
solids load is 0.11 kg/kkg (0.22 Ib/ton), and the oil and grease load
is 0.04B kg/kkg (0.056 Ib/ton).
Costs: Total investment cost: $645,910
Total yearly cost: $275,650
An itemized breakdown of costs is presented in Table 216. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed th-it two operators are required.
Reduction Benefits: BOO: 99.2 percent
SS: 98.5 percent
O&G: 98.5 percent
Alternative A 10-VI11 - Th^s alternative provides in addition to Alter-
native A 10-VII activated caroon adsorption before final discharge.
The resulting BOD waste load is 0.042 kg/kkg (0.096 Ib/ton), the suspended
solids load i"s 0.056 kg/kkg (0.11 Ib/ton), and the oil and grease load
1s 0.024 kg/kkg (0.048 Ib/ton).
Costs: Total investment cost: $919,160
Total yearly cost: $326,050
An itemized breakdown of costs is presented in Table 217. It is
assumed that land costs S4100 per hectare (S1660 per acre). It is
further assumed that tv/o operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
C&G: 99.2 percent
A cost efficiency curve is presented in Figure 280.
Cost and Reductioni_Benefits of .Vj^.prn/it v-n Treatment Technologies for
Subcat cnory A_l_l_.__L_dji_bl_c Oil I roijyi T; i n ::.' ir,-i 11 s 11 c I: c/i i nng, Ac'i HTTToTi :.n:,
Ui 1 Processing. and Oeooor123 Lion, aril tnc :)rrjQuc tion of ShprtcnYnn,
Table Oils, .ir.'ri *'..Trnarine
A model plant representative of Subcatr-norv A 11 was developed in
Section V for the purpose of applying control and treatment alternatives.
In Section VII, eioht al ternnti ves •.-.•" rp '.plpcted as being applicable
engineering alternatives. Tnese a', tcnijtives provide for various
-------
DRAFT
TABLE 216
ITEMIZED COST Sb.".K'4E«A7J"-, CCST ?17860.00
2. ^YEAPLY I.WEST'-'H ST
CCST RFCrVFOY 256UO.OO
3. f/£PP»:CI»TlL3K 31950,Of,
TCTAL 275650.00
937
-------
DRAFT
TABLE 217
ITEMIZED C03T GUrMARY FOR ALTfRi.'ATIVE A10-VIII
(EDIBLE OIL REFINING)
I T K f ! Z ? C r T 3 T £ L " M A s Y FCC HSTE*
DESIGN EFFICIENCY. .. <»
7 0 0 0 . C 0
YEARLY
CCSTS?
2.
3.
5, PVC
TCTAL
iS1. "PLIES
16010.PO
«l9l*O.CO
2U990.CO
i7P«?«»o.no
0.0
3°^SC.CO
710,00
2i(3670,CO
TCTAL YEARLY CCSTSl
1. YEARLY
2. YEARLY INVESTMENT
CCST "ECCvt' = v
S. CE
TCTAL
I'>r. CC£T 2u2t70,00
3 *» 7 7 0. C 0
« 5 M 0 , 0 0
930
-------
(31.
Ul
5
d
o
»•!.*
CJ
o
V)
s
in
3
u
J51.J
ilS. •
111.*
M.DO ti.ct
EFFICIENCY
-------
AP r
levels of wasto reductions for the? r,;odcl plont which refines 4'jl kkcj
(500 ton) of-crude edible oil per day.
Aj tern ati ve A 11 -1 - This alternative assumes no treatment and no
reduction in the v;aste load. It is estimated that the effluent from
a 454 kkg per day plant is 1574 cu m (0.41G MG) per day. The BOD
waste? load is 20.57 kg/kkg (41.14 Ib/ton), the suspended solids load
is 10.98 kg/kkg (21.96 Ib/tcn), and the oil and grease load is 9.95 kg/kkn.
(19.90 l!i/ton).
The model plant developed for Subcategory A 11 is assumed to have sep-
arate di1-charge of process and non-contact v/astewaters, in-plant'qravi'y
separation and skimming, pH control, and an oil recovery system for re-
clamation of waste oil and grease skirniings.
Cost: 0
Reduction Benefits: None
Alternative A 11-IJ - This alternative provides for the addition of
pressurized air flotation utilizing chemical flocculating agents to
enhance floe formation and floatability of wastes. Oil, water, and
solid waste skirrmings are pumped to an :n-plant oil reclamation system ,
for dewacering, and recovery of inedible oils.
The resulting BOD waste load is 6.14 kg/kkg (12.28 Ib/ton), the suspended
solids load is 3.33 kg/kkg ( 6.66 Ib/tcn), and the oil and grease load
is 2.92 kg/kkg (5.84 Ib/ton).
Costs: Total investment, cost: $215,730
Total yearly cost: $ 52,410
An itemized breakdown of costs is presented in Table 218. It 1s
assumed that land costs S82.C40 pe.- hectare ($33.200 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 70.' percent
SS: 69.7 percent
O&G: 70.6 percent
Al ternatiye A 11-1II - This alternative provider, in addition to Alter-
native 1TTT-11 complete mix activated sludne. secondary clarification,
sludge recirculating pump, a 'ludac thickening tank, vacuum filtration,
and a sludge holding tank. Sludge is hdulea to a landfill facility
every eight days. The activated ^I-.i.-Jfjc unit also include?, a control
house and two full-time operators.
The resulting SOD i\-aste load is 1.21 k.v'kkg (0.6Z Ib/ton), the suspend .1
solids load is 0.35 kg/kkg (0.70 'L./Lon), ind the oil and grease load
is 0.30 kg/kkg (0.60 Ib/ton).
940
-------
DRAFT
TABLE 210
ITEMIZED COST SUMMARY F0!> ALTERNATIVE All-I I
(EDIBLE OIL REFINING/
I TE''-I 7F. p f"' iL"w4«Y Ff.» .*i -;TP - M f -' T^rfT'-r"^.
DESIG'- ^K^ K ir '^"V . . . 7?.^ FrPCE'^T f^LC " t C L C 7 I
3. E K G I k- -. r "• : ' G 11350.0^
t1. r.r.:v7I»> ,,• f k r Y 1 I i J 0.0"
H'UL 215730. Of
C c !T 5 ft T l 'x c- C 1 S T T t
2. >* r r r ^
3. C*-*-;C4LS 0.0
(i . f 4 I M P ' i '. r t R £ i. P c L I £ S 7160. CO
TCT4L 36S9C.OO
1. Yt4pL^ C2!;"'.* 1 '• '• IC.ST 3
e . N •_ 4"«l • ; '.•.-; T1- - *. f
CC5T -L'..v^v et30.C?
3, rrf = Kc i * T:L-\ s7t;f'.op
TC14L 52tl 1C. CO
9-5)
-------
DRAM '
Costs: Totdl irivestricnt cost: $761 ,7r)0
Total yearly cost: $l/b,f!30
An itemized brcokdov/n of cost: is presented in Table 219. It is
assumed that land costs $22,040 per hectare ($33,200 per acre). It
Is further assumed that two operators are required.
Reduction Benefits: GOD: 9815 percent
SS: 97.2 percent
O&G: 97.0 percent
Alternative A 11-IV - This alternative provides in addition to Alter-
native "A 11-lD dual "iedia pressure filtration with a purcp station
to generate a sufficient head for filter operation.
The resulting BOD waste load is 0.16 kg/kkg (0.31 Ib/ton), the suspended
solids load is 0.17 kg/kkg (0.35 Ib/ton), and the oil and grease load
1s 0.069 kg/kkg (0.14 Ib/ton).
Costs: Total investment cost: $813,(580
Total yearly cost: $191 ,110
An itemized breakdown of costs is presented in Table 220. It is
assumed that land costs 582,040 per hectare (533,200 per acre). It
is further assumed that iwo operators are required.
Reduction Benefits: BOD: 99.2 percent
SS: 98.4 percent
O&G: 99.3 percent
Alternative A 11-V - This alternative provides In addition to Alter-
native A 11-IY activated carbon adsorption before final discharge.
The resulting BOD waste load is 0.0^6 kg/kkg (0.15 'b/'.on), the suspsndc;
solids load is 0.087 kg/kkg (0.17 Ib/ton), and the oil and grease load
is 0.025 kg/kkg (0.070 Ib/ton).
Costs: Total invest-'-nt cos*.: $1,214,^40
Total yearly cost: $ 256,440
An itemized breakdown of costs is presented in Table 221. It is
assumed that land costs $02,040 per hectare (533,200 per acre). It
1s further assumed that two operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
ORG: 99.6 percent
A cost efficiency curve 1s presented in Figure 281.
942
-------
DRACT
TABLE 219
ITEMIZED COST SUMMARY FOR ALTERilATIVE All-Ill
(EDIBLE OIL PIFIKI.'.'G}
ITETZEP
DESIGN t
. Of.?
HCD
PI
e.
J.
K.
r.
s.
CCSTSl
1.
2.
3.
TCTAL
1. LM'CR
^. PC'-f"
3.
YEARLY
TCTAL
TCTH YEARLY CCSTSI
1. YcAPUY
CCSl
3.
1CTAU
-LCTi i 1CN
: SLLCCE
5o8ieo.oo
79970,00
1,00
i.OO
761790.CO
6900,0')
19360.OC
111270.00
CCST 111270,00
r
30070,00
175fl3o|oO
-------
DPAFT
TABLE 220
ITEMIZED COST SiriVWY FOR ALTERNATIVE All-IV
(EDIBLE Oil. REFINING)
I T £ i' I 2 f D C "• :i T SI '"• i .. Y F C S t J.? T F •• * T K a 7 « £ 4 T "•!: N T C >• t I'
'f^-TCltKCY... «c.j Pf»c-M HCr, "ECuCT IC-k
e. ..rve:-.- ET4JK'.
J ... A I " F L f T 4 U C'.
c...SLI"ot T^ICM^:
S...V4CLU'- = 1 L T C 4 7 I
>....Dl.»l
1. CCSSTFLCTICs t|lfc70.00
3. E.^GT'.fi^^'C 61170.OC
6M7C.rO
TCT4L M39PO.OO
3. CHt^ICALS 69CO.OO
U, K A I f- T F. NAN-CE^SlPfLluS 20150,CO
TCt*t 121550,00
TCT4L YEARLY CCSTJt
1. vt««t.Y CPF'-1*''!1 ? CC«T 121850.OC
i. >EA6LY iNvfiT-fT
CT5T CKrrvF=v 325*0.00
TCTAi. 191UO.UO
944
-------
DRAFT
TABLE 221
ITEMIZED COST SlOMY FOR ALTCP.NATIVE All-V
(EDIBLE OIL REFIfilUG)
D CrST £l»'v«rV P"* .-. 4?1 F»i ' ?c
r'?IC::'.CV. . . 99.f. Ff'C.P.M jLD
R...Pl^^f, ST.-. TT
J...*!1' FLCTATJC1-
K,..*C7iv/.rrr tLM
P . . . ° b " u 1 '• C F i « f ! '_'
N. . .nuu -rr i» ^i-'h'
CCST5:
1.
2. LAND
3.
3. CKE'-'If:1. S
<(. K»J?.
TTTtL
TCT»L VEABLV crsit t
1. Y
s.
F I L T R 4 I '
; -' -•- } i( i.
7«><;70.00
9
-------
iii'.o
VI
5
d
O
u.
O
V)
I
u>
VI
n
j
11.« IT-
'».ec
it.at
EFFICIENCY
FIGURE 281
AND YEARLY COSTS FDR SUBCATEGORY An. ALTtRNATIVtS li TrtKUUGH V
-------
DM IT
AT tcrn-i ti VP A J1 - V! - This alternative provides in addition to Alter-
native- A fl-TI fi.c., dissolved air flotation) an ai.'nncd lagoon
system including a settling pond.
The resulting .BOD waste load is 0.31 kg/kkg (0.52 Ib/ton), the suspended
solids load is 0.35 kg/kkg (0.70 Ib/ton), and the oil and grease load
is 0.30 kg/kkg (0.60 Ib/ton).
Costs: Total Inbestment cost: $76B,500
Total yearly cost: $353,770
An itemized breakdown of costs is presented in Table 222. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits:
BOD:
SS:
O&G:
98.5 percent
97.2 percent
97.0 percent
Alternative A ll-VH - This alternative provides in addition to Alter-
native A 11-VI dual media pressure filtration with a pump station to
generate a sufficient head for filter operation.
The resulting BOD waste load is 0.16 kg/kkg (0.31 Ib/ton), the suspended
solids load is 0.17 kg/kkg (0.35 Ib/ton), and the oil and grease load
is 0.069 kg/kkg (0.14 Ib/ton).
Costs: Total investment cost: $820,670
Total yearly cost: $369,050
An itemized breakdown of costs is presented in Table 223. It is
assuned that land costs $4100 per hectare ($1660 per acre). It 1s
further assumed that tv/o operators are required.
Reduction Benefits:
BOD:
SS:
O&G:
99.2 percent
98.4 percent
99.3 percent
Alternative A 11-VIII - This alternative provides in addition to Alter-
native A Ti-VII activated carbon adsorption prior to final discharge to
navigable waters.
The resulting BOD waste load is 0.075 kg/kkg (0.15 Ib/ton), the suspended
solids load is 0.087 kg/kkg (0.17 Ib/ton), and the oil and grease load
is 0.035 kg/kkg (0.070 Ib/ton).
Costs: Total investment cost: $1,?20,850
Total yearly co;t: $ 434,380
947
-------
DRAI'T
TABLE 222
ITEMIZED COST SUMMRY FOR ALTERNATIVE All-VI
(EDIBLE OIL REFINING)
Kn C°ST £(."f'ASY FTP -
Elicit' CY... 9E.? f
»CO Rfc.ClCTIO
MCDLLLS.-
B1 ..CHK IRCL *-CL£f!
L. ,.
YE4HLY
i.
c. .
3.
5. PVC
TCTAL
CCSTSl
1.
2.
3.
M070.00
?e2"0.00
7665CO.CO
24V90.00
230770.00
0.0
5. FVC LUE' 1020.00
TCTAL 2850^0.CO
TCTAL YEARLY CCSTSl
1. YFAPLY C°E=ATISG CCST 2P5euo.oo
2. YEARLY r
3. r
370CQ.OO
3S3770.00
948
-------
TABLE 223
ITEMIZED COST SUMMARY FOR ALTERNATIVE All-VII
(EDIBLE OIL REFINING)
FO CPST Sl."f*f«Y
DESIGi. EFTIC!E*CY. .. 99.?
•CNT MCCl.'LF.Sj
L * T
T i«00 H
t-CLSF.
IKVEST^'EM CCSTSt
1.
2. LiN
3. FKG
«. CC^
5.
TCTAL
YEASLY CP£"4T^.£ CCSTSt
1. UPC"
2.
3.
4. !•»!
5. PVC
TCTAL
TCTAL YEARLY CCSTfl
1. YEARLY
2. YEAHLV
3.
TCTAL
r^tSSUKE
65C10.00
65610.00
SflOSSO.Ofi
0.0
lOcO.OO
JKG CCST 295620.00
/F£'*-F. f. T
vr^-Y 32e?o.no
iC' uo600.cn
269C50.00
949
-------
DRAFT
An itemized breakdown of costs is presented in Table 224. It is
asrumed that Jand costs $4100 per hectare ($1660 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
O&G: 99.6 percent
A cost efficiency curve is presented in Figure 282.
Cost and Reduction Benefits of Alternative Treatment Technologies
for Subcateqory A 12, Edible OH Processing by Caustic Refining.,
Oil Processing, and Deodorization, and the
Table Oils. i andlaroarlng ___
A model plant representative of Subcategory A 12 was developed in Section
V for the purpose of applying control and treatment alternatives. In
Section VII, eight alternatives were selected as being applicable engi-
neering alternatives. These alternatives provide for various levels
of waste reductions for the model plant which refines 454 kkg [500 ton)
of edible oil per day.
Alternative A 12-1 - This alternative assumes no treatment and no re-
duction in the waste load. It is estimated that the effluent from
a 454 kkg per day plant is 1355 cu m (0.353 MG) per day. The BOO
waste load is 16.20 kg/kkg (32.40 Ib/ton), the suspended solids
load is 9.44 kg/kkg (18.88 Ib/ton). and the oil and grease load is
8.83 kg/kkg (17.66 Ib/ton).
The model plant developed for Subcategory A 12 is assumed to have
separate discharge of process and non-contact wastewaters, in-pTant
gravity separation and skimming, pH control, and an oil recovery
system for reclamation of waste oil and grease skimmings.
Costs: 0
Reduction Benefits: None
Alternative A 12-11 - This alternative provides for the addition of
pressurized air flotation utilizing chemical flocculating agents to
enhance floe formation and floatability of wastes. Oil, water, and
solid waste skimmings are pumped to an in-plant oil reclamation
system for dewatering, and recovery of inedible oils.
The resulting BCD waste load is 4.84 kg/kkg (9.68 Ib/ton), the suspended
solids load Is 2.87 kg/kkg (5.74 Ib/ton), and the oil and grease load
is 2.69 kg/kkg (5.38 Ib/ton).
Costs: Total investment cost: $202,970
Total yearly cost: $ 50,800
950
-------
DRAFT
TABLE 224
ITEMIZED COST SUMMARY FOR ALTERNATIVE All-VI11
(EDIBLE OIL REFINING)
DESIGN EFFICIENCY... 99.6
NT MODOLESt
ei.
B..,*'.'-PI
S74TK.N
STATIC^
"fc'CIi
IKVES7MEK7 CCS7SI
I.
3. l>GI>'f
U. CCKTIf
5. PVC
rcm
YEAHLY CPE"4TING CCS7S»
I. LABOR
2. PCKF*
3. C*Ek'ICALS
H.
6660,
99160.
99160.
05
00
OC
1220650,00
5. PVC
TCTAL
TC7AL YE4PLY CCS7«|
1.
2. Yfc-i^
CCST
3. CCFKcCI»7inN
1CTJL
2U9
-------
so
in
IL
O
V)
§
O
u
X
u
»^
s
T».(t
i«.tt it.t) ff.ce ii.c
EFFICIENCY
. ct
ieo.ee
FIGURE 282
INVESTMENT AM) YEARLY COSYs FOR SUBCATEGORY All, ALTERNATIVES II AND VI THROUGH VIII
-------
DRAFT
An itemized breakdown of costs is presented 1n Table 225. It is
assumed that land costs Jfl2,040 per hectare ($33,200 per acre). It
1s further assumed that two operators are required.
Reduction Benefits: BOD: 70.1 percent
SS: 69.6 percent
O&G: 69.5 percent
Alternative A 12-111 - This alternative provides in addition to Alter-
native A 12-11 complete mix activated sludge, secondary clarification,
sludge recirculating pump, a sludge thickening tank, vacuum filtration,
and a sludge holding tank. Sludge is hauled to a landfill facility
every five days. The activated sludge unit also includes a control
house and two full-time operators.
The resulting BOD waste load is 0.24 kg/kkg (0.48 Ib/ton), the suspended
solids load is 0.29 kg/kkg (0.57 Ib/ton), and the oil and grease load
Is 0.27 kg/kkg (0.54 Ib/ton)
Costs: Total investment cost: $672,950
Total yearly cost: $152,640
An itemized breakdown of costs is presented in Table 226. It is
assumed that land costs $82,040 per hectare ($33,200 per acre).
Reduction Benefits: BOD: 98.5 percent
SS: 97.0 percent
04G: 97.0 percent
A1 ternative A 12-7V - This alternative provides in addition to Alter-
native A 12-1II dual media pressure filtration with a pump station to
generate a sufficient head for filter operation.
The resulting BOD waste load 1s 0.12 kg/kkg (0.24 Ib/ton), the suspended
solids load is 0.14 kg/kkg (0.29 Ib/ton), and the oil and grease load
1s 0.060 kg/kkg (0.12 Ib/ton).
Costs: Total investment cost: $722,000
Total yearly cost: $166,810
An itemized breakdown of costs is presented 1n Table 227. It Is
assumed that, land costs $82,040 per nectare ($33,200 per acre). It
1s further assumed that two operators are required.
Reduction Benefits: BOD: 99.3 percent
SS: 98.5 percent
O&G: 99.3 percent
Alternative A 12-V - This alternative provides in addition to Alter-
native A 12-lV activated carbon adsorption before final discharge to
navigable waters.
953
-------
DKAFT
TABLE 225
ITEMIZED COST SUMMARY FOR ALTERNATIVE AT2-11
(EDIBLE OIL REFINING)
CCST S
fc'FFlCIENCY,..
?,"» te
70.0 «-tPCEK7 "DO RtClCTIO
C C S T 3
2. L
3.
TC7*L
YEAPLY
CPESAT1NG
j.
2,
3.
CCSTSl
TCT>L YEARLY
CHEMICALS
4, h
TCTAL
CC£Tct
1. YtABLY
2. YFA»LY
CCST K
3. l)
TCTAL
CPE»*T^K CCST
ISVESTNFNT
S052PO.OO
7*630.00
1C530.00
10530,00
202970.CO
21990.00
0.0
70^0.00
56360.00
36360.00
filcO.OO
6320.00
50000.00
954
-------
DRAFT
TABLE 226
ITEMIZED COST SUKKARY FOR ALTERNATIVE A12-III
(EDIBLE OIL REFINING)
JTF,MIZFD CC£T JL^A^y F:* »iSTE'**TFR Tfi£ATt'£KT CHAIN
:i£NCY. .. 9P.I: »c"C!:M PCD
"CCLLiSi
».!!?--PI'G STATICN
fC SLL05E
INVESTMENT CCSTS:
i. CCKSTPLCTICK U969UO.OO
£. L/'.: 76630.00
0. CC»iTIi»(if>CY a969o]oO
TCT*L o72950,00
u CCST5!
1, I.AP.TB 2
-------
DRAFT
TABLE 227
ITEMIZED COST SUMMARY FOR ALTERNATIVE A12-IV
(EDIBLE OIL REFINING)
ITE^IZFP CHST SI^^SY FCP k * S Tfv. i T E » TREATMEM O*IN
DESIGN EFFICIENCY... V9.3 f?»C£r.T BCD RECLCTIC*
YEARLY
MCDUL££|
ej
E.
J.
",
c.
s.
v,
E.
CT^f- TANK
FP.f- S7«T
l. "F. 01* t'WESSLftE
CCSTSl
1.
c.
3.
CCf.STSLCTJC*'
TCTAL
CC£.'3i
2.
3.
TCT*L
TCT4L YEARLY CCSTSl
>. YE*SLY
2. YMP-LV
CCST
J. OFFRECUTICs
537P10.CC
76620.00
537PO.OO
51780.00
722000.00
2«9<90.00
57ltO.OO
5490,00
1802C.CO
105660.00
CCST J0566C.OO
32270.00
166610.CO
956
-------
DRAFT
The resulting COD waste load is 0.060 kg/kkg (0.12 lu/ton), the suspended
solids load is 0.0/2 kg/kkg (0.14 Ib/ton), end the oil and grease load
1s 0.03 kg/kkg (0.06 Ib/ton).
Costs: Total investment cost: $1,063,760
Total yearly cost: $ 225,270
An Itemized breakdown of costs is presented in Table 228. It is
assumed that land josts 582,040 per hectare ($33,200 per acre). It
is further assumed that two operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
O&G: 99.6 percent
A cost efficiency curve 1s presented in Figure 283.
Alternative A 12-Vj - This alternative provides in addition to Alter-
native A 12-11 (i.e., dissolved air flotation) an aerated lagoon
system including a settling pond.
The resulting BOD waste load is 0.24 kg/kkg (0.46 Ib/ton), the suspended
solids load is 0.29 kg/kkg (0.57 Ib/ton), and the oil and grease load
Is 0.27 kg/kkg (0.54 Ib/ton).
Costs: Total investment cost: $706,850
Total yearly cost: $319,260
An Itemized breakdown of costs is presented in Table 229. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 9B.5 percent
S3: 97.0 percent
OiG: 97.0 percent
Alternative A 12-VII - This alternative provides in addition to A1t?r-
native A 12-VI dual media pressure filtration and a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.12 kg/kkg (0.24 Ib/ton), the suspended
solids load is 0.14 kg/kkg (0.29 Ib/ton), and the oil and grease load
1s 0.060 kg/kkg (0.12 Ib/ton).
Costs: Total Investment cost: $755,880
Total yearly co'-.t: $333,s50
An Itemized breakdown of costs Is presented In Table 230. It Is
aisunwd that land costs $4100 per hectare ($1660 per acre). It 1s
further assumed that two operators are required.
957
-------
DRAFT
TABLE 228
ITEMIZED COST SUTCIARY FOR ALTERNATIVE A12-V
(EDIBLE OIL REFINING)
ITEMIZED CCST SLVi-4-v FGP fcASfE^ATE* TwcAT^tM
DESIGN EFFICIENCY... 99.t PE*CEM BCD REdjCTICN
TREATMENT MCDULtSi
Bl
B,
J.
K.
c.
s.
Y.
AIR FLOTATICN
vATfr. SLUDGE
OU*L
TASK
STATIQf-
TA PSESSl.RE
INVEST*tST CCSTSJ
I. CCKSTfilCTICK
2. UNO
3.
TOTAL
622610.00
76630.00
62260.00
A22tO.GO
1063760.00
YEARLY CP£«ATJKO
1. LA6CR 2«990,00
2. PC^EP 67130.00
3. CHfcHJCALS 5«90.0C
0. HA1NTENANCEBSLPPLIE2 35750. CO
TCTAL 133360.00
TOTAL YEARLY CCSTSI
1. YEARLY
2. YE^LY
CCST PECOVF^v
3. DEBSECI*T!CK
TCTAL
cCST 1333eO.OO
S2550.00
UC360.00
225270.00
95S
-------
in
o
ft
»-
z
o
u
8
««*.«
Itt.f
TSl.t
• »f.»
M1.»
»^«.s
J««.»
ill.*
IX.
t:.t IT-
c'
ii.to
EFPJCJENCY
,/
••-»,
ICI.tt
FIGURE 283
INVESTMENT AM) YEARLV COSTS FOR SUBCATEGORY Alz, ALTER^WT[VES II THROUGH V
-------
DRAFT
TABLE 229
ITEMIZED COST SUMMARY FOR ALTERNATIVE A12-VI
(EDIBLE OIL REFINING)
I T E " IZ E 0 C'.'ST *i?rl*i Ft.. R *i.«Tf^. iiES TFEM"EKT O 4 J K
PESIGN EFFICIENCY... 9S.S Pc«CENT SCO &ECUCfIO
t-CLSf
YEAPLY
TCT4L
i.
2.
3.
t,
5.
CCST5J
l.*6CR
PC/EH
3.
5. FVC
TCT*L
565750.00
8000.00
stseo.co
56560.CO
19910.00
706650.00
24990.00
0.0
25390.00
68C.OO
256050.00
CCSTSJ
1. YEARLY CPCKATHC CCST 256050.00
2. YtARLY JKVFSTMfM
CCST '(ECCVESY 29270.00
3. .OfPWECIATIC.' 3
-------
OARi'T
TAB'E 230
ITEMIZED COST SUMMARY FOR ALTERNATIVE A12-VII
(EDIBLE OIL REFINING)
CCST £
F(.B
=9.3
c...i»l V
CHAIN
PCO KECLC TIL'S
STiTJC-'J
6... ?..'"?• I
?T»TILA
FILTRA'N
i.
2.
3.
5. PVC
TCTAL
YEARLY OPERATING CCSTSi
i.
3.
si
TCTAl
TCTAL YEARLY CCSTS!
i. YEARLY
2. YtASLY
CCSl
3.
606650.CO
eooo.co
60660.00
M660.00
19910.00
755flfiO.OO
213600.00
0.0
26150,00
6*0.00
265620,00
CCST e65e>5o.oo
302HO.OO
37390.00
333*»50.00
961
-------
DRAFT
*
Reduction Benefits: BOD: 99.3 percent
55: 98.5 percent
0&G: 99.3 percent
Alternative A 12-VIII - This alternative provides in addition to Alter-
native A 12-VII activated carbon adsorption before final discharge to
navigable waters.
The resulting COD waste load is 0.060 kg/kkg (0.12 Ib/ton). the suspended
solids load is 0.072 kg/kkg (0.14 Ib/ton), and the oil and grease load
is 0.030 kg/kkg (0.060 Ib/ton).
Costs: Total investment cost: $1.097,630
Total yearly cost: $ 391,900
An itemized breakdown of costs is presented in Table 231. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 99.6 percent
SS: 99.2 percent
O&G: 99.6 percent
A cost efficiency curve is presented in Figure 284.
Cost and^Reduction Bg^efi^s of AUernative Treatment Technologies
Tor" SubcTtecory A~l3, Hial i'i^'izinq~and Pack'acpru]~b~f (ternartne
A model plant representative of SuDcategory A 13 was developed in Section
V for the purpose of applying control and treatment alternatives. In
Section VII, six alternatives were selected as being applicable engi-
neering alternatives. These alternatives provide for various levels
of waste reductions for the model plant which processes 227 kkg (250 ton)
of margarine per day.
Alternative A 13-1 - This alternative ?ssumes no treatment and no
reduction in the waste load. It is estimated that the effluent from
a 227 kkg per day plant is 340 cu m (0.09 MG ) per day. The BOD waste
load is 3.92 kg/kkg (7.84 Ib/ton), the suspended solids load is 2.72 kg/kkg
(5.44 Ib/ton), and the oil and grease load is 5.81 kg/kkg (11.62 Ib/ton).
The model plant developed for Sub:ategory A 13 is assumed to have sep-
arate discharge of process and non-contact wastewaters, in-plant gravity
separation and skimming, pH control, and an oil recovery systen for re-
clamation of waste oil and grease skimmings.
Cost: 0
Reduction Benefits: None
Alternative A 13-11 - This alternative provides for the addition of
pressurized air flotation utilizing chemical flocculating agents to
enhance floe formation and floatability of wastes. Oil, water, and solid
962
-------
OARFT
TABLE 231
ITEMIZED COST SUMMARY FOR ALTERNATIVE A12-VIII
(EDIBLE OIL REFINING)
ITEMZFD CCST Si^fiPY FCC **ST£utTEP
DESIGN EFFICIENCY... 90.6 PERCENT = C
TREATMENT
9. .."'lyf-
J...AIP
STATTC.N
1. CC'vSTRLCTICK
3l
INVES7"EST
5. PVC I
TCT4L
YEARLY CPERATJNS CCSTSi
2.
3.
FVC LIN£.=<
TCTAL YEARLY CCSTJi
1. Y
2, Y
CCST
3. D
8000.00
691UO.OP
8
-------
\t>
cr
8
§
f.o
115.1
Jli.O
• t.t »
u.ce
EFFICIENCY
FIGURE 284
-------
DRAFT
TABLE 232
ITEMIZED COST SUMMARY FOR ALTERNATIVE A13-II
(MARGARINE PROCESSING)
CCST SL^AfcY FUR *ASTF**TE& TPEATKEKT CHAIN
FFFTClf-CY... 70.C PERCENT POO REDUCTION
e...nU"FlKG STATION
J...AIH
1. CPKSTBLCTIO
7CTAI.
YEARLY OPERATING CCST£j
TCTAL YEARLY
2.
3. CHEMICALS
A. ^
1CTAL
73150,00
5*>970.00
7aio,oo
157C.CO
0.0
5970.00
32530.00
1. YFArLY CPEPATIKP CCST 32530.00
2. YEASLY IPVFST^FKT
CCST PECCV£fiY 5660,00
3. DEPPFCIATICN
-------
DRAFT
TABLE 233
ITEMIZED COST SUMMARY FOR ALTERNATIVE A13-II1
(MARGARINE PROCESSING)
IT£»-T7FO CfST SU'"*»Y fCP *•• * STF.1.' ME*
DESIG* fcFr JCI^CY... 9P.5 Pf-'CFf-T 9CO FEClCTICN
STi'ICK
TCK
SLL'OGf
IKVES7MEKT
1, CCNSTfclCl JO
2. L-iNO
3.
«. Cl
CCS75i
1. L*PO=
c.
3.
YEARLY
TC7«L
TCTAL YEAflLV CC51S!
1. VF4P.I. Y
?. Y
Cf.SI
3. r-
19fc030.CO
59970.00
19600.00
19600.00
2QS200.00
2«990.00
9690.00
2060.OP
9670.00
46630.00
COST Ufr630.00
r
neio.oo
11760.00
7C2PO.OO
967
-------
DRAFT
An itemized breakdown of costs is presented in Table 234. It is assumed
that land costs $32,010 per hectare ($33,200 per acre). It is further
assumed that two operators are required.
Reduction Benefits: BOD: 99.2 percent
SS: 98.6 percent
O&G: 99.4 percent
A cost efficiency curve is presented in Figure 285.
Alternative A 13-V - This alternative provides in addition to Alter-
native A 13-11 (pressurized air flotation) an aerated lagoon system
with a settling pond.
The resulting BOD waste load is 0.060 kg/kkg (0.12 Ib/ton), the
suspended solids load is 0.075 kg/kkg (0.15 Ib/ton), and the oil and
grease load is 0.075 kg/kkg (0.15 Ib/ton).
Costs: Total investment cost: $277,070
Total yearly cost: $110,220
An itemized breakdown of costs is presented ir. Table 235. It is
assured that land costs $4100 per hectare ($1650 per acre). It is
further assumed that one operator is required.
Reduction Benefits: BOD: 98.5 percent
SS: 97.? percent
O&G: 98.7 percent
Alternative A 13-VI - This alternative orovides in addition to Alter-
native A 13-V dual media pressure filtration and a pump station to
generate sufficient head for filter operation.
The resulting BOD waste load is 0.030 kg/kkg ^0.060 Ib/ton), the suspended
solids load is 0.037 kg/kkg (0.074 Ib/ton), and the oil and grease load
is 0.037 kg/kkg (0.074 Ib/ton).
Costs: Total investment cost: $'.'09,790
Total yearly cost: $119,300
An itemized breakdown of costs is presented in Table 236. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that one operator is required.
Reduction Benefits: BOD: 99.2 percent
SS: 98.6 percent
O&G: 99.4 percent
A cost efficiency curve is presented in Figure 286.
968
-------
DRAFT
TABLE 234
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 13-IV
(MARGARINE PROCESSING)
V' rr.M ?•<_»>• fit ?_-= u A STC f * TE"
KFF irir'-CY . . , <}"f-^ p, £1M IlN
J...4JS Fl-CTiTirV
f.. . .iCTlVJ-rrr SLLS-E
G. ..Fi.Lr.5!: T^ICkcV!:".-;
5...V.rLL' c'LTF4TT:
V...KLL)^^.
CR
YEARLY
CCS1S :
1 .
i. CCMTNC-ENCY
1C7AL
?. ^C^.E»
3. CK»-If*LS
1C1U
CC5T£t
1. YF/CLY CFfS
2. Y^/OI. Y JKVE
3. DEPRECIATION
223300.CO
5<»970.CO
22330.00
2?330.0f>
327930.00
15110. CO
2060.00
CCST 5?7feO.OO
13UOO.CO
969
-------
\o
•~j
o
8
o
III.l
• 1.1
ti.et «c.«« M.«t tA.ti n.t« tt.tt M.CI »5.e> »i.c« ieo
EFFICIENCY
FIGURE 205
INVESTMENT WD YEARLY COSTS FOR SUBCATEOORY A13. ALTERNATIVES 11 THRU IV.
-------
DARPT
TABLE 235
ITEMIZED COST SUIV-IARY FOR ALTERNATIVE A13- V
(MARGARINE PROCESSING)
DES1C-K
YEARLY
TCTAL
CCSTb:
1.
2 . L t •'- D
3. f "Gl'-Srsi'-t
5. PVC IT^e*
TC'TAU
cC5Ts:
I. LAI'T
2.
3.
tt.
5.
TC7AL
CC£TJ»
1. YC
2, Yt
CCET
3. r^
TCT*L
0.
10170.
230.
65U90.
CFFPifl^G CCST 85u?0.
PP35lo.ro
aoro.co
2?3«>0.00
?23^0.00
*3PO.PO
277070.00
0
00
00
00
00
ro
CO
i3tso.
110220.
971
-------
DRAFT
TADLE 236
ITEMIZED COST SUMMARY FOR ALTERNATIVE A13-VI
(MARGARINE PROCESSING)
ITE.v'i'ZFD
DESIGf. EFFICIENCY.., «>«?.? DERCEU
TREATMENT HCDlLESl
PI. .
R?DUC1JCK
IKVEST^EM CCS1S:
1.
2.
3.
u.
YEARLY
1C-UL
1.
2.
5. PVC LINER
TCTAL
TCTAL YEARuY f-CSTSt
i. YEARLY CPE°ATING CCST
2. YEARLY ISV
3.
TCTAL
251170.00
flOOO.OO
25l<0.00
25120.00
55520.Ob
0.0
loeeo.oo
230.00
9U20.00
91620.00
12390.00
J5290.00
119300.00
972
-------
3 »»*.
b
in
Ill.l
J«}.f
Z !>».
vo a
•3 u
Itt.*
tl.l
M.I
•••
ri.o ti.ti it,it «f,ci 11.to «i.«e u«,i«
EFFICIENCY
FIGURE 286
INVESTMENT AND YEARLY COSTS FOR SURCATEGORY A 13. ALTERNATIVES II, V, AND VI
-------
DRAFT
Cost and Reduction Benefits of Alternative Treatment Technologies
_for"T»bc_ategory A 14, Plasticizinjj_ii n
-------
DRAFT
TABLE 237
ITEMIZED COST SUMMARY FOR ALTERNATIVE A14-II
(SHORTENING AND TACLE OIL PROCESSING)
"C'JtLES:
c.
5.
V.
ei .COMect
P.
5I.LDGE
.ELLCPE TH'
. VACll" F ILTCiTIUN
B1PKCSY
YEARLY
TCTfiL
1 .
2.
3.
TC741.
G CCSTS:
1.
Z,
3. CHEMICALS
U, f
TCT4L
CCSTSt
1. r
2. *
CCST
3.
TCT*L
122710.00
5
-------
DRAFT
Costs: Total investrent cost: $217,340
Total yearly cost: $ 44,070
An itemized breakdown of costs is presented in Table 238. It is
assumed that land costs $02,040 per hectare ($33,200 per acre). It
is further assure-' that one operator is required.
P.eJuction Benefits: BOD: 97.3 percent
SS: 96.4 percent
O&G: 96.2 percent
Alternative A Id-IV - This alternative provides in addition to Alter-
native A 14-111 activated carbon adsorption prior to discharge to
navigable waters.
The resulting BOD waste load is 0.008 kg/kkg (0.016 Ib/ton), the Suspended
solids load is 0.008 kg/kkg (0.016 Ib/ton), and the oil and grease load
is 0.004 kg/kkg (O.OOG Ib/ton).
Costs: Total investment cost: *?59,260
Total yearly cost: $ 62,190
An itemized breakdown of costs is presented in Table 239. It is
assumed that land costs $82,040 per hectare ($33,200 per acre). It
is further assumed that one operator is required.
Reduction Benefits: BOD: 98.6 percent
SS: 98.1 percent
O&G: 98.1 percent
A cost efficiency curve is presented in Figure 287.
Alternative A 14-V - This alternative provides in addition to Alter-
native A 14-1 an aerated lagoon system with a settling pond.
The resulting BOD waste load is 0.02S kg/kkg (0.058 Ib/ton), the suspended
solids load is 0.038 kg/kkg (0.076 Ib/ton), and the oil and grease load
is 0.021 kg/kkq (0.042 Ib/ton).
Costs: Total Investment cost: $147,390
Total yearly cost: $ 34,810
An itemized breakdown of costs is presented in Table 240. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that one-half time operator is required.
Reduction Benefits: BOD: 94.8 percent
SS: 90.9 percent
O&G: 90.0 percent
976
-------
DRAFT
TABLE 238
ITEMIZED COST SUMMARY FOR ALTERNATIVE A14-III
(SHORTENING AMD TABLE OIL PROCESSING)
TRE'T^E-VT CHAIN
TP'-rv... 97.3 PERCENT BCD RECUCTTO
STATION
F IL T R » • K
^ ...» '. • A • "
C.. .SLLTGr
S... V i
Y...H;;Lr>:
K.. .DUAL
INVFSTMEM CCSTS:
1.
2.
CC^STCLlf.TIC^
136000.00
S«]ao.OO
13600,00
13600.00
2)7340.00
124140.00
7670.00
1870.00
5190.00
t.
TCTAL
ccsiSi
1. LAbOR
?. FOt*
3. CHEMICALS
0. f
1CTAL
TCTAL YEARLY CCSTE:
1. YfAfiL> TFEPATIKG CCST 27220.00
2. YEARLY IKl'ESTfFKT
CCST RF.CrvE^Y fi6«)0.00
3. LrPfiErTfTJ3K 8160.00
TCTAL ««070.00
977
-------
DRAFT
TABLE 239
ITEMIZED CO:T Slir-'APY FOR ALTERNATIVE A14-JV
(SHORTEHIKG AND TABLE OIL PROCESSING)
ITFMIZF[, CP5T SUV
f'CfMLEE:
PECICTICK
TCTAL
LAND
1.
2.
3.
«. CONTINGENCY
TCTAL
CCSTSi
2. PCKF"
3. CHFMICHS
fl. K
TCTAL
170900.00
SUJflO.OO
17090.00
170*0.00
12'I90.00
1C02C.OO
1670.00
17160.00
11560.00
CCSTSt
1. YEARLY CPE»»TIKG COST 111560.00
2, Yfc'ifiLY I»:VF£TKENT
CCST WECCVF.RY 10370.00
3. ntPHECl-TION 102AO.OO
TCTAL 6
97D
-------
1*1.1
VD
•»J
VO
O
O
5
z
(£.
a
i
6
111.I
I'l.f
M1.J
• 1.*
*i.ci
i.J5 ««.» •*.(* M.ec . *».e) «'.o «i.ti «'.o
EFFICIENCY
FIGURE 287
IWES1MEMT ArO YE/\RLY COSTS FOR SUBCATEGORY A14. ALTIRNftTIVES II IHHUUviK IV
iii.lt
-------
DHAFT
TABLE 240
ITEMIZED COST SIU'IAP.Y FOR ALTERNATIVE A14-V
(SHORTENING AND TABLE OIL PROCESSING)
POT
BCD FEDLCTICN
BL
V£ARLY
TCT*L
L... AERATED I
CCSTSf
1
PVC
TL'Til.
3.
5. PVC L
TCTAL
\
CCSTSl
1, YEARLY-
?, YE
CCSV
3. CF^
TCTAL
llfrlrlO.OO
333C.OO
11690.00
1 16*0.00
3770.00
625C.OO
13660.00
0.0
1640.00
140.00
Z1710.00
ccsi amo.oo
r
5900,00
7ZOO.CO
34610,00
980
-------
DRAFT
Alternative A U-VI - This alternative provides in addition to Alter-
native A l"4TV dual media pressure filtration and a puff.p station to
generate sufficient head for filter operation.
The resulting COD waste load is 0.015 kg/kkg (O.C30 Ib/ton), the suspended
solids load is 0.015 kg/r.kg (0.030 Ib/ton), and the oil and grease load
U 0.008 kg/kkg (0.016 Ib/tan).
Costs: Total investment cost: $163,350
Total yearly cost: $ 39,520
An itemized breakdown of costs is presented in Table 241. It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed that one-half time operator is required.
Reduction Benefits: BOD: 97.3 percent
SS: 96.4 percent
O&G: 96.2 percent
Alternative A U-VI I - This alternative provides in addition to Alter-
native A 14-Vi activated carbon adsorption before final discharge to
navigable waters.
The resulting BDD waste load is 0.008 kg/kkg (0.016 Ib/ton), the suspended
solids load is 0.008 kg/kkg (0.016 Ib/ton), and the oil and grease load
is 0.004 kg/kkg (0.008 Ib/ton).
Costs: Total investment cost: $205,260
Total yearly cost: $ 57,640
An itemized breakdown of costs is presented in Table 242. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that a one-half tirre operator is required.
Reduction Benefits: BOD: 98.6 percent
SS: 98.1 percent
OiG: 98.1 percent
A cost efficiency curve is presented in Figure 288.
,Cpst and Reduction Benefits of Alternative Treat^nt
Technologies for 5luhcateonry_A,1t; - rn_wo on
A model plant representative of subcategory A 15 was developed in
Section V for thj purpose of applying control and treatment alter-
natives. In Section VII, three alternatives were selected as being
applicable engineering alternatives. These alternatives provide for
various levels of *aste reductions for the model plant which produces
7.6 cu m (0.002 MG) of refined olive oil per day.
981
-------
DRAFT
TABLE 241
ITEMIZED COST SUWARY FOR JLTCRfJATIVE A14-VI
(SHORTCMNG Af.'D TABLE OIL PROCESSING)
TKEiTf'M- "C
YEARLY
'T- PT/. TI'J"
f. ..Pi'v''i' r. s
^...r'ttL .-EC:*
1 . CC
I. lAKr
i. E>-c i' ff>-:•:
t>. CC' .TJ'.f-f.f>
cCETSi
I.
2,
3.
tt.
PVC
TCT4U YEAPLY CC£T£i
I. Y
2. Y
3. ri
TCTAL
130^0.00
333C.&0
13020.00
13C5C.OO
37^0.CO
163350.CO
62^0.00
152«!C.OO
0.0
3310.00
100.00
34990.00
6530.00
flcoo.oo
39520.00
(SL)BK
98?
-------
TABLE 242
ITEMIZED COST SUI'.MRY FOR ALTERNATIVE A 14-VII
(SHORTENING AND TABLE OIL PROCESSING)
7ED CTS? «I^A~Y
s EFFICIENCY... «JB.f P£PCE
P. . , PUV^IKT. S
L. . . AfCMF* L
E. . ,PU?r-lK5 STATIC^1
K...DUAL ''fri* p^rs
2... ACTIVtirr Cit-rC
k- 0
CCSTS:
1.
c .
3.
u.
5. CVC L!
TCTAL
CCSTS:
1.
5. PVC LINER
TCTAL
TCTAL YEAPLY cC5Ts$
i, YE.ARLY
2. *EJRLY
CCST K
3.
TCT
" f- Cf^' " T C '-
165100.00
3330.00
USiO.Ofi
1S5JO.OC
3770,00
205260.00
6250.00
17650.00
0.0
15290.00
1 (10 * 0 0
39330.00
30330.00
8210.00
10100.00
983
-------
o
a
fe
a
8
•—•
te
C)
l_>
>-
>
O'.l
llt.t
ICI.t
tl.l
o
•e.t*
«j'.cs
«i!ei »».»«
'••»» " c« ii.il M.tt tie. it
EFFICIfNCY
FIGURE 288
AW YEARLY COSTS FOR SUBCATEPORY AK . ALTERNATIVE V THROUGH VII
-------
It is estimoted thot the effluont from
-------
URAFT
TABLE 243
ITEMIZED COST SUMMARY FOR ALTERNATIVE A15-I
(OLIVE Oil REFINING)
:n CPST SI^A-Y F?S v «STF» ATF.R TRE^T^EKT
ETFTCIL^C v... j cc.r FFKCFM "DC Fc'fu.e
1.
3. f *
t. ct
TCTiL
7,\-rpj
fCSTSi
2.
3, CHEMICALS
u. H
7CTAL
CCST£:
l. VEA3LV CPCRATI^C. CCS*
2. v F. A K L Y I^v-?^^•E^T
CC5T
3, C
2«>?O.OC
2920.00
3773C.OO
0.0
630.CO
0.0
1060.00
1910.00
1010.00
1510.00
1750.00
5170.00
986
-------
DRAFT
TABLE 244
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 15-11
(OLIVE OIL REFINING)
ITEMIZED COST SUMMARY FOR WASTEWATER TREATMENT CHAIN
DESIGIi EFFICIENCY... TOO PERCENT BOD REDUCTION
TREATMENT MODULES:
INVESTMENT COSTS:
1.
2.
3,
4.
LAND SPREADING
CONSTRUCTION
LAND
ENGINEERING
CONTINGENCY
TOTAL
YEARLY OPERATING COSTS:
1. LABOR
2. POWER
3. CHEMICALS
4. MAINTENANCE & SUPPLIES
TOTAL
TOTAL YEARLY COSTS:
1. YEARLY OPERATING COST
2. YEARLY INVESTMENT
COST RECOVERY
3. DEPRECIATION
TOTAL
3000.00
1660.00
300.00
300.00
5260.00
0.00
0.00
0.00
150.00
150.00
150.00
210.00
180.00
540.00
987
-------
UNAFT
Alternative A 15-111 - This alternative consists of hauling the waste-
waTeF lo a municipal" treatment facility.
The resulting BOD waste load is 0.0 kg/cu m (0.0 lb/1000 gal), the
suspended solids load is 0.0 kg/cu m (0.0 lb/1000 gal) and the oil .and
grease load is 0.0 kg/cu m (0.0 lb/1000 gal).
Costs: Total investment cost: $0.
Total yearly cost: $1,200
Reduction Benefits: BOD: 100 percent
SS: 100 percent
O&G: 100 percen".
BCVCRAGES
Cost and Reduction Benefits of Alternative Treatment
Tecr-nolocPss for Subcateaory A 16 - new Large Breweries
A model plant representative of subcategory A 16 was developed in
Section V for the purpose of applying control and treatment alter-
natives. In Section VII, thirteen alternatives were selected as being
applicable engineering alternatives. These alternatives provide for
various levels of waste reductions for the model plant which produces
1500 ru m (12,800 bbl) per day.
Alternative A 16-1 - This alternative assumes no treatment and no re-
duction in the waste load. It is estimated that the effluent from a
1500 cu m (12,800 bbl) per day plant is 8300 cu m (2.2 m) per day.
The BOD waste load is 10.55 kg/cu m (2.722 Ib/bbl), and the suspended
sclids load is 3.89 kg/cu m (1.004 Ib/bbl).
Costs: 0
Reduction Benefits: None
Alternative A 16-11 - This alternative provides screening and a grit
chamber, flow equalization, neutralization, nutrient addition, and an
aerated lagoon system.
The resulting BOD waste load 150.28 kg/cu m (0.072 Ib/bbl) and the sus-
pended solids load is 0.39 kg/cu m (0.100 Ib/bbl).
Costs: Total investment cost: $2,355,740
Total yearly cost: $1,055.530
An itemized breakdown of costs is presented in Tablt 245. It is
assumed that land costs $4100 per hectare ($1660 per acre). It 1s
further assumed that two operators are required.
Reduction Benefits: BOD: 97.4 percent
SS: 90.0 percent
98B
-------
DRAFT
TABLE 245
ITEMIZED COST SUMMARY FOR ALTERNATIVE A16-II
(NEW LARGE BREWERIES)
YEARLY
TCTAL
nr^'lZFi1- COST SLS'PifiY
CES!P>. 'FFKl
c..
F..
I-..
L..
L..
ACIL
CCST£l
1.
e •
3.
f.
5.
CCSTSt
QD
I AGCCN
3. CHfc»TC*LS
5. PVC L
TCT
-------
DRAFT
Alternative A 16-IH - This alternative provides in addition to
Alternative A 16-11 dual media filtration.
The resulting COD waste load is 0.14 kg/cu m (0.036 Ib/bbl), and the
suspended solids load is 0,19 kg/cu m (0.019 Ib/bbl).
Costs: Total investment cost: $2,495,160
Total yearly cost: $1,088,090
An Itemized breakdown of costs is presented in Table 246. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOO: 98.7 percent
SS: 95.0 percent
Alternative A 16-IV - This alternative adds activated carton to
Alternative A 16-111.
The resulting BOD waste load is 0.07 kg/cu m (0.018 Ib/bbl), and the
suspended solids load is O.OS kg/cu m (0.023 Ib/bbl).
Costs: Total investment tuit; $3,798,200
Total yearly cost: $1,324,820
An itemized breakdown of costs is presented in Table 247. it Is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 99.4 percent
SS: 97.6 percent
A cost efficiency curve 1s presented 1n Figure 209.
Alternative A 16-V - This alternative provides a control house, screen-
1ng and a grit chamber, flow equalization, neutralization, nutrient
addition, a complete-mix activated sludge system, sludge thickening,
aerobic digestion, and vacuum filtration.
The resulting BOD waste load Is 0.2B kg/cu m (0.072 Ib/bbl), and the
suspended solids load 1s 0.39 kg/cu m (0.100 Ib/bbl).
Costs: Total Investment cost: $3,730,960
Total yearly cost: $1,029,500
An Itemized breakdown of costs Is presented in Table 2<>8. It Is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
1s further assumed that six operators are required.
Reduction Benefits: BOD: 97.4 percent
SS: 90.0 percent
990
-------
DARFT
TADLE 246
ITCMPFD cc/sr SU:W\P.V FOR ALTERNATIVE Aie-m
(NEW LARCC BP.EWERIES)
Cr5T
.. 'Vo.7 PtRCEM PfH
fc'l. .S
h. ..'
L...
U...
^.K t^.L3TID^
r LtG
D L AG
2.
3. f '-
P1"G
3. PVC Li:.EH
TCT*L
fj resist
u
2.
3.
0.
5. PVC
TC7»L
YE*«»LV CCSTJI
26U10.00
cr«r
3. CEP'-'
1CTAL
19SSPO.OO
73770,00
2495160.00
7*190.00
635*0.00
5200,00
CCST
991
-------
DARPT
TADLE 247
ITEMIZED COST SUMMARY FOR ALTERNATIVE A16-IV
(NEW LARGE BREWERIES)
I T F. f I 2 F P
DESIGN
S L *• f * -• V F C B k flSTf*«TER TRE4THEM
.. «*«5.n i'fc*CFM SCO KEtUCTICK
TREATKfr-T ''CCtLESi
YEAFLY
F...ACIO MPLTP4LIZ4TIC'-
K, , .»• ITTT.Fi.
L. ..*E"ATEP LAPCCN
L...
2 . . t C1: V A 1 £ P
1. CC
2 . L i' D
3.
fl.
5. PVC LINER
1CTAL
CCSTSi
1*
2.
3.
A.
5.
PVC LINEN
TCT*L YEARLY CC.ST£|
1. YEARLY
?.» YEARLY
CCST
3. C
3061680. CO
306170, 00
308170.00
73770,00
379PZOO.OO
3*990,00
728220. CO
7«19C.OO
151700.00
5200.00
96«300.00
CuST «5f-U300.00
P
151930.00
!Pfi590.00
132^620.00
992
-------
&
in
in
°
»M
o .,,,,
»»co
EFFICIENCY
FIGURE 289
INVESTMENT wo YEARLY COSTS FUR SUBC/VTEGORY A u, ALTERMATIVE iv
-------
DRAFT
TABLE 248
ITEMIZED COST SUKMARY FOR ALTERNATIVE A16-V
(NEW LARGE BREWERIES)
Sf-'APY fC-0
DESK,.', hFFICIM.tr... 97.0
*CC
CHAIN
E\ . .
^...Pu-
C. . .E.'vL
F...ACI
^..^iT
*.. .ACT
CMKBER
S. ..ViCtu1-1 FJLTP4T1CV
Y. .. iCTIVMtl CiK^C.. ASS
1 . CC'
3! eisIi'KEEP:
TCT4L
OFFP4TISC CCSTSJ
2.
3.
ti,
7CTAL VE&HLV CCSTSi
CCST ePr.CVFt.-y
CH
TCTAL
3.
30^8630.00
P66?0.00
30?6-tO.CO
30?fttO.OO
3730960.00
113770.00
b!390.00
CCST
1P17PO.OO
994
-------
DRAFT
Alternative A 16-VI - This alternative provides dual media filtration
in addftion to. Alternative A 16-V.
The resulting BOD waste load is 0.14 kg/cu rn (0.036 Ib/bbl), and the
suspended solids load is 0,19 kg/cu m (0.049 Ib/bbl).
Costs: Total investment cost: $3,870,380
Total yearly cost: $1,062,060
An itemized breakdown of costs is presented in Tab'le 249. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
1s further assumed that six operators are required.
Reduction Benefits: BOD: 98.7 percent
SS: 95.0 percent
Alternative A 1C-VII - This alternative adds activated carbon to
Alternative A 16-V1.
The resulting BOD waste load is 0.07 kg/cu m (0.018 Ib/bbl), and the
suspended solids load is 0.09 kg/cu m (0.023 Ib/bbl).
Costs: Total investment cost: $5.173,420
Total yearly cost: $1,298,800
An itemized breakdown of costs is presented in Tat e 250. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
1s further assumed that six operators are required.
Reduction Benefits: BOD1 95.4 percent
SS: 97.6 percent
A cost efficiency curve is presented 1n Figure 290.
Alternative A 16-VIH-This alternative replaces vacuum filtration in
A 16-V with sludge storage and spray irrigation.
The resulting BOD waste load is 0.2B kg/cu m (0.072 Ib/bbl), and the
suspended solids load 1s 0.39 kg/cu m (0.100 Ib/bbl).
Costs: Total Investment cost: $3,652,280
Total yearly cost: $ 933,750
An itemized breakdown of costs is presented In Table 251. It is
assumed that land costs $6150 per hectare ($2490 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 97.4 percent
SS: 90.0 percent
Alternative A 16-JX - This alternative adds dual media filtration to
Alternative A iTPVTlI.
99S
-------
DRAFT
TABLE 249
ITEMIZED COST SUI1MARY FOR ALTERNATIVE A16-VI
(NEW LARGE BREWERIES)
CT5.T SLPK4KY FTR
EFFICIENCY... ofl.7
TCT*L
"CDULESt
PI
F.J
e.
c.
F.
RECTION
R GPIT CH4KPFR
.SLLTPF
.P04L
CCSTEr
1. CCNSmCTTO
2.
3.
PKESSLfiE
TVT4L
CCSTS:
l.
3- CHEMICALS
(I.
1,
2. »£*»!. Y
rt'ST K
96620.00
3i<>«eo,oo
Siaaeo.oc
3670360.00
1.00
«765iO.OO
M377C.OO
53300.00
718550.00
7J«S<0.00
15^20.00
166fc«?0.00
1062060.00
996
-------
UiiAFT
TABLE 250
ITEMIZED COST SUMMARY FOR ALTERNATIVE A16-VII
(NEW LAFT.E BREWERIES)
C"?ST Sl"MtFY F.;.G h&STE*ATEC T«£*m».T CHAIN
EFFICIENCY... 90. a PtnCF.M fiCC
P1..COKTTL i-CISc
E J . .SCSEE^UG H G'»IT
C . . . r (> L' A L : Z / T I C r. p i s I N
F . . . * C I r I-. F L T H A L I Z * T I C N
S , . , w i C IC ^ F I L "I >.
K... Di.il ''FT
Zi«-ACTIVATF.c C * " f C N * S fr' C ^ * T f'; ••
INVESTMENT CCSTSl
2. L*^D 96620.00
3. £KGINtEBl»>G U23C70.CC
TCTAL 5173^20.00
»G CCSTSl
7«970.00
2. FC*m 507650,00
S. Cl-EfIC*L3 113770,00
lES UU30.0C
TC.T4L Y
OPE^MJ'.r CCST
J^»P5•tK•F^7
fcv 206«»
-------
t
ui
me. i
*-
Hit.I
""••
u
(••1.1
««.(!
..X
«f.M «I.M ••.!! •>.«! «t.«t Crn WO YEflRLY CCSTS FOR SU8CA1TGORY A 16. ALTHR14AT1VE VII
-------
DRAFT
TABLE 251
ITEMIZED COST SUW.ARY FOR ALTERNATIVE A1G-VI1I
(NEW LARGE UREWERIES)
• IC I E * C v , ,. e 7 , u
iTIH'LEfi
. STi'E '• T
1CT41.
F J, .SC*tf
P.. ,pL'»""
C...£r.i-,..'; I
per
JKC f. CfIT
r, 57MIC''-
*t:niTir.N
«LLDCt
O4lN
>. . .HI. I [ I' T-
L. .
1. CP fTPlfTir*
I.
1CT4L
CCSTSt
i. L«»ri
2. PCi-EI
300660.00
3C06«0.00
3652290.00
U30350.CO
7«190,00
277«0,00
i. * ? t« L v r '• K &«n * P CT?T
E. Yl4"»Lr I'•\rjTcFM .
CCSl^FfCv^-f
3. rcpf-tc'A'jr^ iht'tic.on
999
-------
DRACT
The resulting BOD waste load Is 0.1* kg/cu m (0.036 Ib/bbl), and the
suspended solids load is 0.19 l-.g/cu in (0.049 Ib/bbl),
-Costs: Total investment cost: $3,791,680
Total yearly cost: $ 966,310
An itemized breakdown of costs 1s presented In Toble 252, It is
assumed that land costs $6150 per hectare ($2490 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 98.7 percent
SS: 95.0 percent
Alternative A 16-X - This alternative adds activated carbon to
Alternative A 16-IX.
The resulting BOD waste load is 0.07 kg/cu m (0.018 Ib/bbl), and the
suspended solids load is 0.09 kg/cu m (0.023 Ib/bbl).
Costs: Total investment cost: $5,0(J<',720
Total yearly cost: $1,203,040
An itemized breakdown of costs is presented in Table 253. It 1s assumed
that land costs 56150 per hectare ('2490 per acre). It is further
assumed that six operators are required.
Reduction Benefits: BOD: 99.4 percent
SS: 97.6 percent
A cost efficiency curve is presented in Figure 291.
Alternative A 16-XI - This alternative replaces vacuum filtration in
Alternative A 16V with sand drying.
The resulting BOO waste load 1s 0.28 kg/cu m (0.072 Ib/bbl), and the
suspended solids load Is 0.39 kg/cum (0.100 Ib/bbl).
Costs: Total Investment cost: $6,764,510
Total y«arly cost: $1,527,890
An Itemized breakdown of costs 1s presented 1n Table 254. It 1s
assumed that land costs $20,510 per hectare ($8300 per acre). It 1s
further assumed that six operators are required.
•t
Reduction Benefits: BOD: 97.4 percent
SS: 90.0 percent
Alternative A 16-XII •• This alternative add* dual media filtration
to Alternative A 16-XI.
The resulting BOD waste load 1s 0.014 kn/cu m (0.036 Ib/bbl), and the
suspended solids load is 0.019 kg/cu m (0.049 Ib/bbl).
1000
-------
DRAFT
TABLE 252
ITEMIZED COST SUMMARY FOR ALTERNATIVE A1P-IX
(NEW LARGE BREWER]tiS)
SIC', ff FKIt-LY... 9-,.7
T' P? T >'Cr.l LESS
PI ..CC-
Fl . .SC-rF"J(.C R G
P . . . P i * = I k: r, s T i T I r
C.. .ft ,.'•!.! Z«lirK F>
L.,.Sr«!.'V IK
[ K V f 11 * f * T C C S T 5 i
1. CC^STPLCTJCV 3122950.00
2. L4M*
-------
DI'.AFT
TABLE 253
ITEMIZED COST SUMMARY FOR ALTERNATIVE A16-X
(NEW LARGE BREWERIES)
EeFTCItNCy... 99.
-------
01
Q«
_J
_j
X
If)
O
l/l
O
tt
111
•)•*.•
, . .
3 -• i ^ . :
••»"•*
OJ.S •
»i.te
«r.c:
EFFICIENCY
FIGURE 291
iNVESTTtNT AM) YEARLY COSTS FOR SUBCATEGORY A 16, ALTERNATIVE X
ic:
-------
DliAPT
TABLE 254
ITEMIZED COST SUMMARY FOR ALTERNATIVE A16-XI
(NEW LARGE BREWERIES)
rrr crsr «L"*A»Y FOP msr*
. t'M IC!t.\LY. .. C
CCsTir
1.
2.
3.
YE&HLY
TCUL
IK-REI.CY
CCSTJj
1. LA"3CK
3.
-------
UK/il I
Costs: Total Investment cost: $6,903,930
Total yearly cost: $1,560,460
An itemized breakdown of costs is presented in Table 255, It is
assumed that land costs $20,510 per hectare ($0300 per acre). It
1s further assumed that six operators are required.
Reduction Benefits: BOD: 98.7 percent
SS: 95.0 percent
Alternative A 16-XIII - This alternative adds activated carbon to
Alternative A~16-XII.
The resulting BOD waste load is 0.07 kg/cu m (0.018 Ib/bbl), and the
suspended solids load is 0.09 kg/cu m (0.023 Ib/bbl).
Costs: Total investment cost: $8,206,970
Total yearly cost: $1,797,190
An itemized breakdown of costs is presented in Table256. It is
assumed that land costr $20,510 per hectare ($8300 per acre). It
is further assumed that six operators are required,
Reduction Benefits: BOD: 99.4 percent
SS: 97.6 percent
A cost efficiency curve is presented in Figure292.
Cost and Reduction Benefits of Alternative Treatment Technologies
for Subcateqory A 17 - Old Large Breweries"
A model plant representative of subcategory A 17 was developed in
Section V for the purpose of applying control and treatment alternatives.
In Section VII, thirteen alternatives were selected as being applicable
engineering alternatives. These alternatives provide for various levels
of waste reductions for the model plant which produces 2600 cu m (22,000
bbl) per day.
Alternative A.17-1 - This alternative assumes no treptr.ient and no re-
duction in the waste Inad. It is estimated that the effluent from a
2600 cu m (22.000 bbl) per day plant is 23,000 cu m (7.5 MG) per day. Tne
BOD waste load is 18.56 kg/cu IP (4.78 Ib/bbl), and the suspended solids
load is 7.32 kg/cu m (1.89 Ib/bbl).
Costs: 0
Reduction Benefits: None
Alternative A 17-11 - This alternative provides screening and a grit
chamber, flow equalization, neutralization, nutrient addition, and an
aerated lagoon system.
The resulting BOO waste load 1s 0.55 kg/cu m (O.lfl Ib/bbl), and the sus-
pended solids load 1s 0.76 kg/cu m (0.20 Ib/bbl).
1005
-------
DRAFT
TABLE 255
ITEMIZCD COST SUMMARY FOR ALTERNATIVE A16-XII
(NEW LARGE BREWERIES)
n?'*TZpfc
rr-SIG" EFF7C
BCD
TP-*T"t^T CHAIN
CCSTfi
1.
c •
3.
PI .
El.
P...
C..
F..
C..
»..
T..
KISF
.G R G^IT
F. 0 L i L I 7 i T I C i. "r * S 1
c ri vftTR r
L '. t R E T-
fc. CCM1K-1EMCY
TCTAL
CCSTSj
i. IAPOR
E. F C fc E «
3. C^fl
TC7*L
TCT4L YEARLY CCStJj
1. YEARtr
2 . T E t K L Y I K' V f S T f r K T
CCST ^
5572100.00
217010,00
557210.00
557210.on
6^03930.00
117270.00
7 « 1 9 0 . 0 0
9^9970.CO
1ST OC99VO.OO
276160.OC
334330.00
1560060.00
1000
-------
UNAPT
TABLE 256
ITEMIZED COST SUMMARY FOR ALTERATIVE A16-XI11
(NEW LARGE BREWERIES)
fTZer CCST Sl"*Af-. vF. ?7"FKT
CC5T MECC'vesy 3PB2PO.OO
3. rFPUL'ClAl jns
L 17V7190.00
1007
-------
o
CD
u.
r>
in
8
»('!.•
;*r.f
1
V
i
1111.1
11,1.0
FIGURE 292
INVESTTCHT AND YEWLY COST FOR SUBCATEGORY A 16. SU8CATEGO!:.V »
-------
DRAFT
-Costs: Total investment cost: $7,125,250
Total yearly cost: 53,328,060
An itemized breakdown of costs is presented in Table 257. It is assumed
that land costs $4100 per hectare ($1660 per. acre). It is further
assumed that two operators are required.
Reduction Benefits: BOD: 97.0 percent
SS: 89.5 percent
Alternative A 17-1II - This alternative provides in addition to .Alter-
native A 17-1] dual media filtration.
The resulting BOD waste load is 0.27 kg/cu m (0.07 Ib/bbl), and the sus-
pended solids load is 0.38 kg/cu m (0.10 Ib/bbl).
Costs: Total investment cost: $7,526,890
Total yearly cost: 13,422,120
An itemized breakdown of costs is presented in Table 258 . It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed that two operators are required.
Reduction Benefits: BOD: 98.5 percent
SS: 94.7 percent
Alternative, A 17-IV - Tnis alternative adds activated carbon to AUer-
native A 17-111.
The resulting BOD waste load is 0 13 kg/cu m (0.03 Ib/bbl), and the sus-
pended solids load is 0.19 kg/cu m (0.05 Ib/bbl).
Costs: Total investment cost: $11,677,060
Total yearly cost: $ 4,195,440
An itemized breakdown of costs is presented 1n Table 259, It 1s assumed
that land costs $4100 per hectare ($1660 per acre). It 1s further
assumed that two operators are required.
Reduction Benefits: BOD: 59.3 percent
SS: 97.5 percent
A cost efficiency curve Is presented 1n Figure 293.
Alternative A 17-V • This alternative provides a control house, screen-
Ing and a grit chamber, flow equalization, neutralization, nutrient
addition, a complete mix activated sludge system, sludge thickening,
aerobic digestion, and vacuum filtration.
1009
-------
DRAFT
TABLE 257
ITEMIZED COST SUMMARY FOR ALTERNATIVE A17-I1
(OLD LARGE BREWERIES)
PES1GK H.«^ ICJENCY... 97.ft
N'T "CCt'LtSj
Ei
P.
C.
L.
L.
T CCSTFt
1 .
2.
3.
5. FVC
1C7AL
fiEDuCTICN
YEARLY
.ACTC \FLTS4lI7iTJCN1
..v/iTscr,Ff /r::::c^
LU-CCN
.SETTLING ^
i. LAtCR
2, POER
3.
5.
TCTAU
7CTAL YE»RLY ccsTst
1. Y
CCST
3.
5697^60.PO
55310.00
5697SC.OO
569750.00
7U5250.00
2*900.00
EIPP1.1ES U566C.OC
J760C.OO
3689550.00
r, rCST2£B9550,00
KT
?85010.00
353500.00
33?flOfeC.OO
1010
-------
DRAFT
TABLE 258
ITEMIZED COST SUMMARY FOR ALTERNATIVE A17-II1
(OLD LARGE BREWERIES)
"CD
El ..SfFFM^ 8
e...?r^r.T, Mi-
C . , .E-'.-t^L 1 Z*7 I r»' P
^...SF Til JV
I K V ?. £ T * E ^ 1 C C S T £ :
1 .
2.
3.
TCTAL
5. PVC
1CTAL
1.
•»
t.
3.
«.
S.
3.
PVC
CC5T
FKgSSl.'PE FlLTRAi>.
6022160.00
S5J10.CO
603Z2C.OO
603e?0.00
232960.00
.00
23J1710.00
2H760.00
1511^0.CO
j?«eo,oo
3ClnPO.CC
3735fiO.OO
3^:2120.00
ion
-------
DRAFT
TABLE 259
ITEMIZED COST SUKMAF.:' FOR ALTERNATIVE A17-IV
(OLD LARGE DREWERICS)
DESI&' f.
Sl^ARY FLP WiSTF.KATFP TREATMENT
^CV. . , 90.3 PLHCFM BCD
"CDLLES:
El . .SCPfcE'-'lKC- R PR
,PL' f:^G STiTICK'
L. .
TCT4L VEAPLV
z..,4Ciiv«Tfcc
1.
2.
3.
*.
5.
TCTAL
E.^ CY
CCST£»
c,
3,
5. FVC
TCTAl.
5531C.OO
11677060.00
2, YEARLY
CCSt •'
3.
H TAL
2*12030.00
LS 201761).00
AKCEtSLPPLlES "50f70.00
17POO.OO
31*7270.00
CST3U7270.00
. PO
1012
-------
o
Ul
»»»«.«
5 '•*•••'
3
9 •«•*.:
v>
IMi.C
u ft"'.:
FIGURE J73
ATC YEARLY COSTSVo1? SU8CATEGORY A l', AlTCRMftTlVE IV
-------
IJKfll
The resulting DOD waste load is 0.55 kg/cu m (0.14 Ib/bbl), and the sus-
pended solids load is 0.76 kg/cu m (0.20 Ib/bbl).
Costs: Total investment cost: $11,377,110
Total yearly cost: $ 3,107,230
An itemized breakdown of costs 1s presented in Table 260. it is
assumed that land ccsts $41,000 per hectare (516,600 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 97.0 percent
SS: 89.5 percent
Alternative A 17_-VI - This alternative provides dual media filtration
in addition to Alternative A 17-V.
The resulting GOO waste load is 0.27 kg/cu m (0.07 Ib/bbl), and the
suspended solids load is 0.38 kg/cu m (0.10 Ib/bbl).
Costs: Total investment cost: $1'1,778,750
Total yearly cost: $ 3,201,290
An itemized breakdown of costs is presented in Table 261. it is assumed
that land costs '41,000 per hectare (16,600 per acre). It is farther
assumed that six operators are required.
Reduction Benefits: BOO: 98.5 percent
SS: 94.7 percent
Alternative^ 17-VII - This alternative adds activated carbon to
Alternative A 17-VI.
The resulting BOD waste load 1s 0.13 kg/cu m (0.03 Ib/bbl), and the
suspended solids load is 0.19 kg/cu m (0.05 Ib/bbl}.
Costs: Total Investment cost: $15,928,940
Total yearly cost: $ 3,974,630
An Itemized breakdown of costs is presented 1n Table 262. It 1s
assumed that land costs $41,000 per hectare ($16,600 per acre). It
1s further assumed that six operators are required.
Reduction Benefits: BOD: 99.3 percent
SS: 97.5 percent
A cost efficiency curve Is presented in Figure 294.
AU.crnativc A 17-VI.II - This alternative replaces vacuum filtration 1n
A~1/-V w\th siudgtT storage and spray irrigation.
1014
-------
DRAFT
TABLE 260
ITEMIZED COST SUW1ARY FOR ALTERNATIVE A17-V
(OLD LARGE BREWERIES)
CESIG'.
SLwr/.t97P.PO
15J83«JO.OO
^81670.00
21070.00
209h5PO.OO
CCGT20«5t500.00
ossoeo.oo
555650.00
3107220. OH
-------
UNA FT
TADLE 261
ITEMIZED COST SUMMARY FOR ALTERNATIVE A17-VI
(OLD LARGE BREWERIES)
C05T Elt'KARY
EFKICIE^Y... <
M?TE»m» TPMT^EM CHAl*
PCD REDUCTJO
MCCLLE5!
F.../CIC -.'FLTCHlZi
IN'R ETiTICN
K...4CTIV/TFC ELUOGt
C.. ,«Ll PCf Ti-irKf.^E^
CCSTS:
1, CCKSTRLCTIO
2.
3,
TCTAL
OPERATING CCSTSt
3i
TCTH
YFAPLY
?.
3. r£
TC'TAL
9595560.00
26^050.00
959560.00
«59560.CO
11776750.00
70970.00
1570610.00
461670.00
«71150.00
575730.0n
32C1200.00
1016
-------
DRAFT
TABLE 252
ITEMIZED COST SUMMARY FOR ALTERNATIVE A17-VII
(OLD LARGE BREWERIES)
47 r.
SF
«EDICTIO
AT 10
^...ACTIVATE: 51. L^3E
K...5LI. r^E T"ICir£»;EP
" . . . 1 1: *• t r i r r ] r. E 5 : r *
v. ,.'
CCSTff
1.
3.
«.
1CTU
YEARLY CPERaTJNG CCSTSi
1. L
TCT4L
3.
2 . Y f. t k i V
n .e7 M
3. t
P»ESSLhE
4 i. a r » Ar
1305«070.CO
26
-------
o
09
3
&
2
IT
O
U
5
o
u
«»:».:
.;j itc.tt
vramx
EFFICIENCY
FIGURE 29'i
tnR cmnraTFcnBY o. t-r
\i\\
-------
DHAFT
The resulting DOD waste load is 0.05 kg/cu m (0.14 Ib/bbl), and the sus-
pended olids load is 0.76 kg/cu m (0.20 Ib/bbl).
~~ Costs: Total investment cost: $11,233,200
Total yearly cost: $ 2,833,190
An itemized breakdov/n of costs is presented in Table 263- It is
assumed that land costs $6150 per hectare ($2490 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 97.0 percent
SS: 89.5 percent
Alternative A 17-IX - This alternative adds dual media filtration to
Alternative A 17-VIII.
The resulting BOD waste load is 0.27 kg/cu m (0.07 Ib/bbl), and the
suspended solids load is 0.38 kg/cu m (0.10 Ib/bbl).
Costs: Total investment cost: $11,634,8AO
Total yearly cost. $ 2,927,240
An itemized breakdown of costs is presented in Table 264. It is
assumed that land costs 56150 per hectare ($2490 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 98.5 percent
SS: 94.7 ptrrenl
Alternative A 17-X - This alternative adds activated carbon to Alter-
native A 17-IX.
The resulting BOD vnste load is 0.13 kg/cu m (0.03 Ib/bbl), and the
suspended solids loai is 0.19 kg/cu m (0.05 Ib/bbl).
Costs: Total investment cost: $15,765,030
Total yearly cost: $ 3,700,570
An itemized breakdown of cost? is presented in Table 265. It is
assumed that land costs tssumed that six operators are required.
Reduction Bent-fits: BOD: 99.3 percent
SS: 97.5 percent
A cost efficiency curve 1s presented 1n Figure 295.
Alternative A 17-XI - This alternative replaces vacuum filtration in
Alternative A 17-V with sand drying beds. This alternative was not
deemed economically viable and therefore was not costed.
1019
-------
DRAFT
TABLE 263
ITEMIZED COST SUMMARY FOR ALTERNATIVE A17-VIII
(OLD LARGC BREWtRlES)
17FMZF" T
DtSTf '• 't
CHAIN
Ii.vi £T-'C' T CT
TV,. . t:7.0
B i . . C r '• T P r; i. > • c I K F
M..«C':F'-lKr- 8
H. . .PI.UFT^G ST
C.. .ft'1 II.. HiTIfK rASH
P , . . •* C * " k-F L " - i L I J 4 H L K
»-..,' IT ^ r ' f N i r, r IT IC N
^...'•'.-••T1'.'.TFP r-Lir-ct
c... 51 •. r r. F T c i r x F *. t ff
", .. tcuri-it; rjr-i-STLr
V, . .Mr LI: I \K TCKK
1 .
2.
3.
CHAISE
1.
?.
3.
«. H
TCT6L
TCT4L VfcABLV CCSIC!
1. Vf
2. Vh
J. ri>"5fr
13CD70.00
925260.00
1133320C.OO
7^970,00
1^30160.00
241760. OP
£o 81770.00
162&7CO.OO
CC5T1626700.00
55? 1 60. ^ C
26331QO.PO
1020
-------
DRAFT
TABLE 264
ITEMIZED COST SUMMARY TOR ALTERNATIVE A17-IX
(OLD LARGE BREWERIES)
O Cr£T
'.:?LLE Sr
."< vj.STFn.4TEB
"CLEF
G •• G"JT
STATIC*
CCiTS:
1.
2.
3.
YE4.RLY
CC?TSt
1.
2.
3.
r SLITGE
130070.00
71970,00
1886f:t.
TCTAL YEARLY CCSTji
1. vfc«KLY Cch&4T I'.r- CCST1686610.00
2. Y f A h L Y J VV F « T"* N T
Crsi qec'.'vfCY
-------
DRAFT
TABLE 265
ITEMIZED COST SUMMARY FOR ALTERNATIVE A17-X
(OLD LARGE BREWERIES)
ITFHT2EC CT.ST S
OL?JGf. FFFJCI^CY... 99.3
PI,
El.
e..
c..
*..
c..
s..
v..
I ..
•s.
Z,.
CCSTSl
1. COSTSICTICK
2. LAND
3. f'«C I '• f E K : N G
u. cci
TCTH
t TE5
T LCD fcct'UCT
HCLSE
C &
w ^ ^ ! ' • R 5T*
''l.£LI7iTjr'. ciSJN
r. I L N ' LI <• * L ! 7 * T I L N
* ! L C I > P 74
CCSTSi
^,
3.
CCSTSI
1. YftKLr
i.'. Vfct^lY
CLST P
3. rr
130CS600.00
J3C070.CO
157&5C30.00
7*970.CO
1562910.00
Z«|?80.CO
3et7tO.PO
CCST22Ht^?C.OC
7ft?75C.OO
3700570,00
102
-------
_
rl
6
u.
a
in
8
S
vj
>
>
EFFICIENCY
FIGWE 295
«• rnn ci«raTPnnRY A 1?. ALTERNATIVE X
-------
own
The resulting COD waste load is 0.55 kg/cu m (0.14 Ib/bbl), and the
suspended wlids load 1s 0.76 kg/cu m (0.20 Ib/bbl).
Reduction Benefits: BOD: 97.0 percent
SS: 89.5 percent
Alternctive A 17-XII - This alternative adds dual media filtration
to Alternative A 17-Xl. This alternative was not deemed economically
viable and therefore was not costed.
The resulting BOD waste load is 0.27 kg/cu m (0.07 Ib/bbl}, and the
suspended solids load is 0138 kg/cu m (0.10 Ib/bbl).
Reduction Benefits: BOD: 98.5 percent
SS: 94.7 percent
Alternative A 17-XI1I - This alternative adds activated carbon to
Alternative A 17-Xl!. This alternative was not deemed economically
viable and therefore was not costed..
The resulting BOD waste load is 0.13 kg/cu m (0.03 Ib/bbl), and the
suspended solids load is 0.19 kg/cu tr. (0.05 Ib/bbl).
Reduction Benefits: BOD: 99.3 percent
SS: 97.5 percent
Cost and Reduction Benefits of Alternative Treatment Tec^nolog1es
for Subcategory A 13 - All Other Breweries " "
A model plant representative of subcategory A 18 was developed 1n
Section V for the purpose of applying control and treatment alter-
natives. In Section VII, thirteen alternatives were selected as belr.j
applicable engineering alternatives. These alternatives provide for
various levels of waste reductions for the model plant which produces
470 cu m (4000 bbl) per day.
Alternative A 16-1 - This alternative assumes no treatment and no
reduction 1n the waste load. It is estimated that the effluent from
a 470 cu m (4000 bbl) per day plant is 4500 cu m (1.2 HG) per day.
The BOD waste load is 13.53 kg/cu m (3.491 Ib/bbl), and the suspended
solids load Is 6.19 kg/cu m (1.60 Ib/bbl).
Costs: 0
Reduction Benefits: None
Alternative A 18-11 - This alternative provides screening and a grit
chamber, flow equalization, neutralization, nutrient addition, and «n
aerated lagoon system.
The resulting HOD waste load is 0.08 kg/cu m (0.12 Ib/bbl), and the
suspended solids load 1s 0.68 kg/cu in (0.18 Ib/bbl).
1024
-------
DRAFT
Costs: Total investment cost: $1,314,140
_ Total yearly cost: $ 530,240
An itemized breakdown of costs is presented in Table 266. It is
assumed that land costs $4100 per hectare (51G60 .per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 96.4 percent
SS: 89.1 percent
A1 ternativg A 18-_IIj^ - This alternative provides in addition to
Alternative A 16-11 dual madia filtration.
The resulting BOD waste load is 0.24 kg/cu m (0.06 Ib/bbl), and the
suspended solids load is 0.34 kg/cu m (0.09 Ib/bbl).
Costs: Total investment cost: $1,432,200
Total yearly cost: $ 551,760
An i ten'zee1 breaMown of costs is presented in Table 267. It is
assumes that land costs $4100 per hectare (S1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 98.2 percent
SS: 94.5 percent
AUernative A 18-IV - This alternative adds activated carbon to
Alternative A 18-111.
The resulting BOD waste load 1s 0.12 kg/cu m (0.03 Ib/bbl), and the
suspended solids load 1s 0.17 kg/cu m (0.04 Ib/bbl).
Costs: Total investment cost: $2,337,000
Total yearly cost: $ 706,630
An itemized breakdown of costs is presented in Table 268. It 1s
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Reduction Benefits: BOD: 99.0 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 296.
Alternative /.. 1P-V - This alternative provides a control house, screen-
ing and a grit chamber, flow equali:otion, neutralization, nutrient
addition, a complete mix activated sludge system, sludge thickening,
aerobic digestion, and vacuum fi
1025
-------
DRAFT
TAOLE 266
ITEMIZED COST SUMMARY FOR ALTERNATIVE A10-II
(OTHER BREWERIES)
SlI^'At^ FHR k.AMf
DtSK-" F'FlCJf NCV... 0.00
«10J60.00
UJOJ60.00
53770.00
6631P.OO
5302iJO.OO
1026
-------
DI'AI'T
TABLE 267
ITEMIZED COST SUMMARY FOR ALTERNATIVE A1C-III
(OTHER BREWERIES)
PI
7 (•" E * " *• £ !• 7 " f.' T i / L £ £ !
F1,.?C5«P*!\C K &-IT
C , . . f b 11, L 1 ? i T i r N t /• £ J'»
P . . . *• C I C ^ELl^iLl^A'.lC^
u. . .'"iTiCGE:. "^LIlKi-
L , . . ^'.' - / "i c n L » C [ C N
••'Tilt PkLSS'-'-E
T f
" t'. 7 C C 5 < 5-1
j. cr- ?-i=uc7i:f.
?. U • M;.
3. lM:;--.FFHl»r.
J. C O 7 J '.: c -* C Y
b.
YEARLY
TC7AL
CC?T£:
3.
«. t'
*>. F<
TCT4L
Y CCSTfil
17950.On
J 11660.00
ijflteo.oo
3*1 00.CO
34000,00
?«010.00
2890.00
"Z376C.OO
r.CS7
3. •;; P-FCU7IP-'.
70710.00
bb!7tO.OO
1027
-------
DKAFT
TABLE 268
ITEMIZED COST SUMMARY FOP. ALTERNATIVE A18-IV
(OTHER BREWERIES)
ITFM1ZFO
DCSIG' E
Sl"HPv
YEARLY
PCD
CHAIN
El. .Sr&EF'-JKG § G»I7
C...F(JLtLl?i7ICs BA£lf.
F « . . /• C ID '. F I 7 R 4 i T 2 & ~i J C • N
L . . ./.- Ct7t R L
L . . . t f R t T F f; L t R C C K'
f^...ni*L rFDJi P«E
Z. .. ACTIVATF? CARPCN
1.
C.
3.
«.
5.
TCTAL
CCSTS;
3.
5. PVC LIMIH
TCTaj.
CCSTSr
1. YF.4PI.V
?, YE4PLY
CCS7
3, rE
TCTAl-
1900790. C/0
J7050.DO
190060.00
19COPO.OO
2337000.00
357ti30.00
3^^00.00
77090.00
«97200.00
CCST «97?00.00
93i)t?0.00
115950.00
70tt.30.CO
1020
-------
int.
o
IV
ID
tn
a.
s
fe
co
p
s
tn
o
V
«
0,
a
TIC.a
«>c.t
«T.CC
»«.co
eFTICIENCY
PIGUKE 296
INVESTMENT AND YEARLY COSTS POP SU3CATEGORY A Jo, ALTERATIVE W
-------
DRAf F
The resulting BOD waste load is 0.40 kg/cu m (0.12 Ib/bbl), and the
suspended_sol ids load is 0.60 kg/cu m (0.18 Ib/bbl).
Costs: Total investment cost: $1,506,780
Total yearly cost: $ 440,710
An itemized breakdown of costs is presented in Table 269. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOO: 96.4 percent
SS: 89.1 percent
Alternative A 18-VI - This alternative provides dual media fil-
tration in addition to Alternative A 1B-V.
The resulting BOD waste load is 0.24 kg/cu m (0.06 Ib/bbl), and
the suspended solids load is 0.34 kg/cu m (0.09 Ib/bbl).
Costs: Total investment cost: Si,594,850
Total yearly cost: $ 461,230
An itemized breakdown of costs is presented in Table 270. It is
assumed that land costs 5^1,000 per hectare ($16,600 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 98.2 percent
SS: 94.5 percent
Alternative A 18-VII - This alternative adds activated carbon to
Alternative A 18-VI.
The resulting BOD waste load is 0.12 kg/cu m (0.03 Ib/bbl), and the
suspended solids load is 0.17 kg/cu m (0.04 Ib/bbl).
Costs: TotPl investment cost: $2,499,660
Total yearly cost: $ 616,110
An itemized breakdown of cost: is presented in Table 271. it is
assumed that land costs $41,000 per hectare (516,600 per acre).
It is further assumed that six operators are required.
Reduction Benefits: BOD: ''9 0 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 297.
AU?rnn'.iv(! A 18-VTII - This alternative replaces vacuum filtration
in A 1G-V with sluo'yo storage on;l spray irrigation.
1030
-------
DRAFT
TABLE 269
ITEMIZED COST SUMMARY FOR ALTERNATIVE A13-V
(OTHER BREWERIES)
ITEMIZED fDET St'TAKY
DESIG'.
? -.4 $TFf *TEH TRE'TVEKT CHAIN
, t Pfcr'CEIT 5CP KEDL'CTICN
IKVEST-cKT
B1..CTKTRCI.
61..SCSEFNH H E GRIT ChAK'9£R
P...UJ^-I^G STATION
C...rCu/LIZiTirs p A £ I K
^.. ..ACTT: NE.IhtLlZ*1 id-
K. . . ACTI VATK
C . . . S L L C G T
S.. . VACLU" FRTR4TICN
V. . . Kf.Ll ING TANK
SLUDGE
LAND
3.
«.
TCTAL
YEARLY OPERATING CCSTSi
1. LA9CR
2. PC*r.H
3.
TCTAL
TCTAL YEARLY CCSTSt
1. VE/PLY
2. YEiKLY
CCST K
3. D
TCTAL
1201760.00
646UO.OC
15067eo.CC
7^970.00
165670.00
50320.00
17170,00
308330.00
COST 308330.00
60270.00
72110.00
440710.00
1031
-------
DKAF7
TABLE 270
II£MIZCD COST SUMMARY FOR ALTERNATIVE A18-VI
(OTHER BREWERIES)
ITF.''J?~"' rr.ST «LM^4hY rj=
CPSIG.-. EFFICIENCY... of. 2
6Pi'. «ECuC
K. . .*:iiv4Tfr SLLC&E
C, . . FLU'CE T*-ir«r'-?o
S. . ,V&CU" FTLTt;4TlC^
V.. .Hftr. I\E Ti'-K
1.
2.
3.
H.
7C7AL
YEARLY CPERAT1KC CCSTSl
1.
V275170.00
3, OE-'ICUS
TCTM YEARLY CC£T«|
1. YfAO|
2. YtA.Vt
Cl'57
3. rtPci
I N v
1275PC.OO
127??0,00
15^4650.00
7U97P.CO
177250.00
5C320.00
320930.00
3?C'
-------
DRAH
TABLE 271
ITEMIZED COST SUMMARY FOR ALTERNATIVE A18-VII
(OTHER BREWERIES)
OCSJC-.S tFFKSu'-CY...
CS ' ASTFL.ATFR
) . 0 F^PCFM HID
CHAIN
R1..CC' i
EJ ..l-C^f
GRIT d-Ai-et*
r., . •' •:.'., i u ! 71 * 1C K 51 £ I K
' .. -; f k c
R...AI srf-'ir rir-F?TCw
S...VACLI." FIL^MIL'I
INVF5V-M
2...*cTiv»TtC : A 6 r- r N
2.
u.
TCTAL
CCSTS:
1. UArt-
3.
1.
2,
3.
CC£T <--r.
AL
202920.00
202950,00
7"
-------
a
CJ
en
tr
<
A
a.
a
Q
o
VJ
V
£
UJ
U'l.f
,.-»?.r
«J.:c
FIGURE
INVESTHENT pt*> YEARLY COSTS FOR SUBCATEGQRY A 18, ALTERfWTIVE VII
-------
D11 f '• *
• I'M l
The resulting COD uaste load is 0.1C kn/cu m (0.12 Ib/bbl), and
the suspended solids load is 0.68 kg/cu m (0.18 Ib/bbl).
Costs: Total investment cost: $1,473,950
Total yearly cost: $ 405,140
An itemized breakdoi/n of costs is presented in Table 272, It is assumed
that land costs $6150 per hectare ($2490 per acre). It is further
assumed that six operators are required.
Reduction Benefits: BOD: 96.4 percent
SS: 89.1 percent
Alternative A 18-IX - This alternative adds dual media filtration
to Alternative A 18-VII1.
The resulting BOD v/aste load is 0.24 kg/cu «n (0.06 Ib/bbl), and the
suspended solids load is 0.34 kg/cu m (0.09 Ib/bbl).
Costs: Total investment cost: $1,562,010
Total yearly cost: $ 425,670
An item'zed breakdown of costs is presented in Table 273. It 1s
assumed that land costs $6150 per hsctare ($2^90 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 98.2 percent
SS: 94.5 percent
Alternative A 18-X - This alternative adds activated carbon to Alter-
native A 18-IX.
The resulting BOD waste load is 0.12 kg/cu m (0.03 Ib/bbl), and the
suspended solids 'load is 0.17 kg/cu.m (0.04 Ib/bbl).
Costs: Total investment cost: $2,466,820
Total yearly cost: $ 580,540
An itemized breakdown'"of costs is presented in Table 27/1. It is
assumed that land costs $6150 per i-,ec .are ($2190 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 99.0 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 29Q
AUcrnotivo A 1P-jT[ - This alternntn-c replaces vacuum filtration In
Alternative A )U-V with sand drying i-cds.
1035
-------
DRAFT
TABLE 272
ITEMIZED COST SUMARY FOR ALTERNATIVE A18-VII1
(OTHER BREWERIES)
FFMCIEVCV... 96.
«UD
YEARLV
TCTAL
. ,.»CTI ViTET, S
., .*-PI:JT-
CCSTSi
1.
3.
1. CCNTJK&EN'CY
TC74L
>G CCST5I
1.
2.
3. CHEVITAlS
TCUL
CCST«i
CCM
3. r-
TTT*
1210250.00
21660.00
12JCPO.OO
1P1020.00
M73950.00
7«<570,00
155730.00
^73570.00
CCST 273b70.00
72bjo!of"
1036
-------
DKAFT
TABLE 273
ITEMIZED COST SUMMARY FOR ALTEHNA'WE A1B-IX
(OTHER 3REI/ER1ES)
r>r_cjr..'. fFP-ICJE'-C*... «?.2
7«•?.'•• 7 "LTUl.tE:
h'J ..ri.TT.-7CL t-Cl SF
c I . .:crrf 'jjh.f: ». RHJ
P., .Pl"r!\a S^MICN
C.. ,f :.•!.-:. IZ ATI rv KA£
»-'...4CT!- (Tl 7-/l.T2iT
v.. .-i.'.. "I^-r.
L...St-5/LY J
.F7"E(-T CC?T?S
1. CC
2. L*M' PlbfrO.OO
3. EKGI'.ff-^l's'G 126360.00
iKGtKTY 12f360.CO
2. PCv-EC 167120.00
3t Cu
4). ^A
TCTAL
TCT6L YtAKLY PCSTEl
I. Vl'aftlY CBiDif I'f- CCTT SBM70.00
?. NhAK'.Y jsvtJT^M. T
CC ^1 *7CCvCi: Y fc?i-PO.O^
3. in-B«;tlI*UC». 770? 0.00
1037
-------
DUAfi
TADLE 274
KEKIZED COST SUMMARY FOR ALTERNATIVE A18-X
(OTHER BREWERIES)
TlffJZP' CTi>T £t»
ft SI •'•'•• ErHCTE^LY... *,*.? KcfcTFM ^tT * E ? '.• C T 1 1
t C r x T i r f t :• L f t L K £ !
K! ..rrklPCL HCL5F
F. J . . !-' C s F * k. T •• G « P R 1 T C H A v P £ R
f . ..f""^!^' £T6T!u'-
K. ..
CCSTSl
1. CCNFTSLfTjCK 8037fr^O.CO
2. L«^D 2 1660, CO
3. F^GIKfRlvr. 2037^0.00
a. CC^^^GE^CY 203760.00
TC7AL
2. «•(•»?* 191v «»*C7C.(T
5. r.i r-t-cr r'f:r\
1038
-------
5
u.
o
o
CJ
O
s
c
u<
o
-I
* i:. t
. . . . . . . . .
EFFICIENCY
FIGURE 2?.T
IMVESTWENT /VJD YEARLY COSTS .FOR SUBCATEGORY A in, ALTERNATIVE X
«.i: jc:
-------
DRAFT
The resulting GOD waste load is 0.48 kg/cu m (0.12 Ib/bbl), and the
suspended solids load is 0.60 kg/cu m (0.18 Ib/bbl}.
Costs: Total investment cost: $2,694,560
Total yearly cost: $ 638,610
An itemized breakdov/n of costs is presented in Table 27S It is
assumed that land costs $20,5)0 per hectare ($8300 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 96.4 percent
SS: 89.1 percent
Alternative A 18- XI I - This alternative adds dual media filtration
to Alternative A 1G-XI.
The resulting BOD waste load is 0.24 kg/cu m (0.06 Ib/bbl), and the
suspended solids Toad is 0.34 kg/cu m (0-OS Ib/bbl).
Costs: Total investment cost: $2.782,630
Total yearly cost: $ 659,140
An itemized breakdown of costs is presented in Table 276. It is
assumed that land costs $20, CIO per hectare ($8300 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 98.2 percent
SS: 94.5 percent
Alternative A 18-XIII - This alternative adds activated carbon to
Alternative A 18-XII.
The resulting BOD waste load is 0.12 kg/cu m (0.03 Ib/bbl), and
the suspended solids load is 0.17 kg/cu m (0.04 Ib/bbl).
Costs: Total investment cost: $3,687,440
Total yearly cost: S 814,010
An itemized breakdown of cr-its is presented in Table 277. It is
assumed that land costs $2o,510 per hectare ($8300 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 99.0 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 299 .
Cost and Reduction Benefits of ALternaMve-Treatment Technologies
A 19 - fialt
A model plant representative of subcotegory A 18 was developed 1n
Section V for the purpose of applying control and treatment alter-
1040
-------
DRAFT
TABLE 275
ITEMIZED COST SUMMARY FOR ALTERNATIVE A18-XI
(OTHER BREWERIES)
ITF'-JZF.C CTST SL'-TAPV Ffjft WASTEMTE* TREATKEM CHAIN
ct'Fic-s Ecn:iE>c Y. .. st.u PI«CEM ecs REDUCTICN
TRTAT^CKT ^-CCULfc i }
P-i . .CC^'T^CL HCLSE
El. .SCKEr'vlKG t G^IT CMMPPR
P. . . PUf'PTf^G STATIC''
P. . ,
BEDS
1. CCNSTKLCTICN 21hfilCO,PO
2. LAND ICOOiC.CO
3, EN'GI^PESI'.G ? 162 JC, 00
,00
3. C^E^'ICAl S 3"<*00.00
CC57E:
1. YfAPLV CPcfATIi>G C'.'ST flCUOO.Oft
2. YC/HLV IKVFST^ENT
CCST RPcr\'F^'Y 1077EO.OO
5. CfPkFClATK'K 1?9730.00
TCT*L 63(610.00
1041
-------
DRAFT
TABLE 276
ITEMIZED COST SUMMARY FOR ALTERNATIVE A1C-XII
(GTHIIR BREWERIES)
DESK-'- EFFICIENCY... <)/>.?
"CDLA.F. E:
'-CLSE
. , , 4 C T C * ? I 'i s t L 1 2 * 1 I C N
. . .MT^r.f F\ tr.tTTlC'N
, . .ACT] VATec 5|.i<3GE
r,
1. CCNS751CTICK
2.
3.
YEARLY OpERATIK'G
PCI--FW
3.
«. ^
TCT*L
CCST5:
1. Yf*RLY
3. P£
TCTAi.
i.OO
lOCOfcO ,00
233550.00
233550.00
7^970.00
U6J7C.OO
3^*00.00
IStltC.OO
^13700. 00
LOST
-------
P^M'T
TABLE 277
ITEMIZED COST SIMM P. Y F03 ALTERNATIVE A18-XIII
(OTHER ERCl/CRICS)
C-ST S
FD' kASTF* ATF. c TREAT^'F^T CHAlK
-------
2
o
c
u.
o
IT!
JTM.f
tiot.t
cr
i
<
u
—
*1>.D
. . .
FFTICIENCY
FIGURE 299
INVESTMENT AND YEARLY COSTS FOR SUBCATF.GOFTy A 16, ALTERNATIVE XIII
-------
DliAfT
natives. In Section VII, seven alternatives were selected as being
applic3ble""eng-ineerinf) alternatives. These alternatives provide
for various levels of waste reductions for the model plant which
produces 350 kkg (16,000 bu) per day.
Alternative A 19-1 - This alternative assumss no treatment and no re-
duction in tne waste load. It is estimated that the effluent from
a 350 kkg (16,000 bu) per day plant is 2590 cu m (0.685 HG) per day.
The BOD waste load is 4.55 kg/kkg (C.21C Ib/bu), and the suspended
solids load is 0.77 kg/kkg (0.037 Ib/bu).
Suspended solids in the waste, consisting mostly of grain and sprouts.
are assumed to be removed by screening prior to discharge.
Costs: 0
Reduction Benefits: None
AT ternative A 19-11 - This alternative provides a control house, flow
equalization, nutrient addition, and an aerated lagoon systesr..
The resulting BOD waste load is 0.22 kg/kkg (0.011 Ib/bu), and the
suspended solids load is 0.13 kg/kkg (0.0062 Ib/bu).
Costs: Total investment cost: $1,200,150
Total yearly cost: $ 572,660
An itemized breakdown of costs is presented in Table 278. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that two operators are required.
Suspended solids in the waste, consisting mostly of grain and sprouts,
1s assumed to be removed by screening prior to discharge.
Reduction Benefits: BOD: 95.2 percent'
SS: 83.1 percent
Alternative A 19-111 - This alternative provides in addition to
Alternative^A 19-11 dual media filtration.
The resulting BOD waste load is 0.11 kg/kkg (0.0053 Ib/bu), and
the suspended solids load is 0.06 kg/l;l;g (0.0029 Ib/bu).
Costs: Total investment cost: $1,245,740
Total yearly cost: $ 583,300
An itemized breakdown of costs is presented in Table 279. It is
assumed that land costs $4100 per hectare ($1660 per acre). It Is
further assumed that two operators are required.
Suspended solids in the waste, consisting mostly of grain and sprouts.
Is assumed to be removed by screening prior to discharge.
1045
-------
ORAfT
TABLE 278
ITEMIZED COST SUMMARY FOR ALTERNATIVE AT9-11
(MALT)
ITEMIZED CCST SL^'VAPY FOR *A£T!>»1£P TFfcAT^ENT CHAIN
DESIf-K EFFICIENCY... ec§i pfcfrCEM fiOR REDUCTICK
*CDL'LtSi
F...PUKPJVG ST4TICA
C. . .
YEARLY
CC5TS
1
c
7CTAL
LINER
CCSTS!
LABOS
FOEF
i.
2.
3.
5. FVC L
TCT*L
TCTAL YEARLY CCSTSl
1. YEiPLY
2. YEARLY
rest
3.
TCT»L
959690.00
12710.00
95970.00
95V70.0C
1200150.00
4015^0.00
3030.00
34080.00
1640.00
465260.00
CCST Oi5280.00
48010.00
&9370.00
572660.00
1046
-------
DRAFT
TABLE 279
ITEMIZED COST SUMMARY FOR ALTERNATIVE A'.9-I1I
(MALT)
ITEMIZED CTET Sl^A&Y FCP MSTItATE* 1"EATKEKT CHAIN
DF.?:GN EFFICIENCY... 07.5 PERCENT eoo REDUCTION
YEi"LY
t-CLSE
ST*T
C...ECI 'LI7ATICK
K...N-iTRr:G!:i. tcr
LiC-CCM
L. ..
B, ..P'JKP
N,.,CL/4L
CCSTSt
1 . CC
2. LAKD
3. El.fr!
5. PVC
TCTAL
CCSTSl
i. LARCR
J,
5. PVC LINER
TCTAL
TCTAL YEARLY CCSTSi
1.
' 2.
CCST RECCVFSY
3.
TCTAL
<>976fcO.OO
12740.00
1.00
).on
35760.00
1245740.00
200QC.OO
3030.00
3«710.00
1640.00
CPEPATU6 CCS' '71820,00
61650.00
583300.00
1047
-------
DM FT
Reduction Benefits: 30D: 97.6 percent
SS: 92.2 percent
A cost efficiency curve is presented in Figure 300.
Alternative A T9-IV - This alternative provides a control house, flow
equalization, nutrient addition, a complete mix activated sludge
system, sludge thickening, aerobic digestion, and spray irrigation.
The resulting BOD waste load is 0.22 kg/kkg (0.011 Ib/bu), and the
suspended solids load is 0.13 kg/kkg (0.0062 Ib/bu).
Costs: Total investment cost: $709,240
Total yearly cost: $176,410
An itemized breakdown of costs is presented in Table280. It is
assumed that land costs 541,000 per hectare ($16,600 per acre). It
is further assumed that three operators are required.
Suspended solids in the waste, consisting mostly of grain and sprouts,
is assumed to be removed by screening prior to discharge.
Reduction Benefits: BOD: 95.2 percent
SS: 83.1 percent
Alternative A 19-V - This alternative adds dual media filtration to
Alternative A 19-IV.
The resulting BOD waste load is 0.11 kg/kkg (0.0053 Ib/bu), and the
suspended solids load is 0.06 kg/kkg (0.0029 Ib/bu).
Costs: Total investment cost: $761,830
Total yearly cost: $187,330
An itemized breakdown of costs 1s presented 1n Table 281. It Is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further assumed that three operators are required.
Suspended solids in the waste, consisting mostly of grain and sprouts,
1s assumed to be removed by screening prior to discharge.
Reduction Benefits: BOD: 97.6 percent
SS: 92.2 percent
A cost efficiency curve is presented in Figure 301 .
Alternative A 19-VI - This alternative replaces spray irrigation of
sTudge in Alternative A 19-IV with send bed drying.
The resulting BOD waste load is 0.22 kg/kkg (0.011 Ib/bu), and the
suspended solids load is 0.13 kg/kkg (0.0062 Ib/bu).
1010
-------
O
.o
•A
-I
h
8
5
Q
\j
j
. .
EFFICIENCY
FIGURE 300
AND YEARLY COSTS F.OR SieCATFT-QRY A 10. ALTERNATIVE III
tce.ef
-------
DRAFT
TADLE 280
ITEMIZED COST SUMMARY POR ALTERNATIVE A19-IV
(KALT)
*, A7ER
EFFICIEKCV... 95.1 PEPC*M ecc KECUCTICN
BJ..CCKT6CL
K...4CTJV47L-C SLUDGE
CCSTs:
1. CC^T^UCTIO 562570.00
c. LAK-0 3*150.00
3. E^GIf'EEKlKR bft?60.00
4, CCKTJKGENCY 56?60,00
TT1AL
YEARLY OPERATING CTSTSt
J, L4BCR J7«BO.OO
1. FOE* 6e'90.00
3. C*E*!CALS 3030.00
0. MIK'TE'Af-'CEfi SLPPLIES 10V90.00
7C7A1. 1
YEARLY CCSTSI
J. YfcARLY TPFP47JKG CCST 11^290.00
2. YEARLY p- v F S f ^ F ^ 7
CC£T kFCCvC^Y 28370.CO
3. CtFKfClATjpt' 33750.00
7C7AL 176ii!0.00
'050
-------
DRAFT
TABLE 281
ITEMIZED COST SUMMARY FOR ALTERNATIVE A19-V
(MALT)
* AS TF-A Tp F. 7&EATMFKT C*
DESIC-. fc'fr TCIE'.CY, .. 97.5 PE^CF.M ?CD ^f'JC TIC*-.
PI . .CfMCCl I-CI 5'1
E. . .PI^PIM-- 57 MICA'
c . . . E i i i i. ; 7 1 7 : r.s = 4
^ . . . * 1 T =: r t F k- A : c i T I
K. , .iC^IViTtR SLLDG
-
L , . . S P fi 4 v I e c : p A T 1 C K
kl,..DL-*L >Ti:iA FR[S5unE FltTRAM
CCSTSi
1. CO 5TS(.CTICK 600560.CO
2. LAfO Ml EC. 00
3. FKGI^E£B1^G 60060.00
>C CCST 120P30.00
2. YEASLY T^vF£T"F>.T
r.L'ST ^FCrvKPY 30470,00
3. CtFPPClATJTA J6030.CO
TC1AL 187330.00
1051
-------
11
5
I/)
o
i
in
to
c
111
V
§
_i
tfS.»
»«*.!
t.i.t
• It..
J'l.t
. . . . .. .
EFFICIENCY
FIGURE 301
INVESDCNT AT40 YEARLY COSTS TOR SUBCATtGORY A IQ. ALTCRNATIVE V
-------
DRAFT
Costs: Total investincnt cost: $971,480
Total yearly cost: $229,030
An itemized breakdown of costs is presented in Table 282. It is
assumed that land costs $41.000 per hectare ($16,GOO per acre). It
is further assumed that three operators are required.
Suspended solids 1n the waste, consisting mostly of grain and sprouts,
is assjned to be removed by screening prior to discharge.
Reduction Benefits: BCD: 95.2 percent
$$: 83.1 percent
Alternative A 19-VII - This alternative adds, dual media filtration to
Alternative A 19-V1.
The resulting BOD waste load is 0.11 kg/kkg (0.0053 Ib/bu), and the
suspended solids load
-------
DRAFT
TADLE 282
ITEMIZED COST Sl«WWY FOR ALTERNATIVE A19-VI
(MALT)
YEARLV
ei ..CD-TOCL
e...Pi;Kf-r.G
C, . ,F'"LM. IZ/. TICK '^^SI
H. ..MT^
K. ..ACTIV
P. .,AtRC»:C CIGE
V.. .HCLSI'.G TAKK
T...S/.ND
LAND
1.
2.
3.
TCTAL
• G CCSISi
e.
3.
U. H
TCTAL
TCT.4L YEARLY CCfeTft
J. YF4RLY
2. YE&KI.Y
CCFT KI
3. DF.P^C
TCTAL
!TFMi2F.r c"ST SLM-^FV PCS V.^?TEI-ATE» TREATMENT
c:-s:r^ EFFICIENCY... 95,1 PE^CEKT PCD
TREtTfFN'T MCCL-LL'Si
775270,00
*5 150.00
77b3P.OO
77530.08
37U60.00
61920.00
3030.00
CCST Iuuu50.00
3«P60,00
«6520.00
229830.00
1054
-------
DRAFT
TACLC 2C3
ITEMIZED COST SUWARY FOR ALTERNATIVE A19-VII
(MALT)
CTST ;• t_ •" C A = Y r C S VASTErATFR T»EAT>£K7 C >• A ! N
PI ..C0> Tf.CL *-CLSE
F.. . .c'-'"?! f.r, ?74T!0
C...Fc:>L''..I7i7]!^ =4 Sir.
C,,.SLLDGE T'-Jr»'P'.F.»»
p...4t;<:o!: r::• Esic«
Y, . ,1-lClCr r, 7iK<
e,..
CCSTS:
1. CCKSIRLCTIC^ 813260,00
2. HO 41150,00
3. EK-GIK-EE^IMG emc.oo
fl. CrMlK&EN'Cv 81330.00
TCTAL . 1017070,00
YEARLY CPERATIKG CCST5-
1* I'. BC? 37^80,00
2. PC^EP 67630.00
3. CMEMiruS 3030.00
It. fAlK'TEt 4SCE8SLPPLIES ^2650.00
TCTAL 1509<50.00
TCTAL YEARLY CCSTSi
i. YFAKI.Y cct = ATiKG rcsr 150^90.00
2, YEtt'LY J». v T i T >- c K T
CCS7 efCCvE°Y «066C.OO
3. CECREC!«TICS ^8800.00
TCTAC
105S
-------
o
T»
e»
u.
U
Q
n
v
IT
^. 3«*.»
U
Q
I
«;.ce
y
4?!:e
EFFICIENCY
P! CURE 302
YEARLY COSTS FOR SURCATEGORY A 10. ALTCRI'AT IVE VII
ice.f.
-------
DRAH
may be spread on vineyard property, or may be recovered as a by-product
(3) diatomaccouc earth (spent filter aid) is considered to be a solid
waste to bcTprtud on vineyard property, (4) no distillation is done
on the premises, and (5) wastewater is screened prior to discharge.
Alternative A 20-I - This alternative assumes no treatment and no re-
duction in tne waste load. It is estimated that the effluent from a
l&O B-g (20C.G tor) per day plant is 276 cu n (0.073 MG) per day.
The EDO waste load is 3.57 kg/kkg (7.14 Ib/ton), and the suspended
solids load is 1.16 kg/kkg (2.32 Ib/ton).
Costs: 0
Reduction Benefits: None
Alternstive A 20-11 - This alternative provides a control house, flow
equalization, nutrient addition, neutralir^tion, a complete mix
activated sludge system, sludge thickening, aerobic digestion, dual
media filtration, and spray irrigation of sludge.
The resulting BOD waste load is 0.77 kg/kkg (1.54 Ib/ton), and the
suspended solids load is 0.115 kg/kkg (0.230 Ib/ton).
Costs: Total investment cost: $414,130
Total yearly cost: $116,400
An itemized breakdown of costs is presented in Table 284 . It is
assured that land costs $41,000 per hectare ($16,600 per acre).
is further assumed that three operators are required.
It
Reduction Benefits:
BOO: 97.8 percent
SS: 90.1 percent
Alternative A 2Q-III - This alternative adds dual media filtration to
Al tentative A 20-11.
The resulting BOD waste locd is 0.33 kg/kkg (0.76 Ib/ton), and the
suspended solids load is 0.0540 kg/kkg (0.108 It/ton).
Costs: Total investment cost: $434,350
Total yearly cost: $122.300
An itemized breakdown of costs is presented in Table 285. It is
assumed that land costs 541,000 per hectare ($16,600 per acre).
is further assumed that three operators are required.
It
Reduction Benefits
BOD: 98.y percent
SS: 95-3 percent
1057
-------
DRAFT
TABLE 284
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 20-11
(WINERIES WITHOUT STILLS)
CHM SL^KA"* PIF- IP./^TOiTCK TRfcAT^EM C»-*lK
DESIO t'f ICJc'.vY... «,7.f *£PCEM fcL'L) FJELUC 1
S3. .CCKTBCl.
fc. . ."1."=!" f.
" , . . '-v 1 T c c C r •> t r, « I T I C
I. ,.cnC eP-r^L!: iD^M
^...'C.':. '•.VLf-UTtt
G . . . : ^ L ; T 3 r KEiTs-tLi
K. ..'•( v; v«7er fLLiGE
IK-VEST-tM CCSTS!
1. CCKST^TTCK 331230.00
e. LAND 16b60.00
3. f.K5:vP«;^IV'G 33120.00
«. CC';TINRFNCY 33lcO.OO
TCTAL «1(7F>.t;vCFR£l.PPulFS
1CT4L
>• C(!ST«:
1. v K A r H CBf»4TlKG CCCT V « a 6 0.0 0
2. Y E A <•• i. \ ! i^ v -7 £ T ^ F »• T
l°fl70.CO
1058
-------
DMFT
TABLE 285
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 20-111
(WINERIES WITHOUT STILLS)
J T ;; * ]
O A I K
'1CIt-'' ry... SP.<, ?--s(
'<~r.i LES:
''CC; ^ Cue TICK
-I ..r-> 1*CL
5 . .. PI ' -• I' C- S1: T J C N
^ . . . i- r '• • 11 7 i- -, ! T s f- i i I r.
f ,, , if.~.:- '> fi i, 1 r A 1.1 2 * T T L' f1
r-,. . C i'. *• T j r > ? i T = .'LJ^i''K1
*... * r:: n T F : 5 L L L- G =
1. . . 5LL'-i?F T-1'.crf.F*
T* M
YEAB'.Y C
1.
ti . C C N T I ,\ :• F »• C '
1CTAL
1.
2, rT^F^
: . r >- E '* c i L
t. >* i'-TfM'
1C 1 * L
i. vrif-LY
e. VI,:«CLY
JO.CO
7530.00
1C?10.CO
^050.00
17370,Cfl
lPc'300.00
1059
-------
DRAFT
A1tcmativo-A 20-IV - This alternative provides in addition to Alter-
native A 20-111 activated carbon.
The resulting DOD waste load is 0.23 kg/kkg (0.46 Ib/ton), and the
suspended solids load is 0.031 kg/kk»j (O.OC2 Ib/ton).
Costs: Total investment cost: $502,200
Total yearly cost: $1''5,770
An itemized breakdown of costs is presented in Table 286. It is
assured thct land costs $41,000 per hectare ($16,600 per acre). It
is further assumed that three operators are required.
Reduction Benefits BOD: 99.4 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 303.
Alternative A 20-V - This alternative replaces spray irrigation of sludge
in Alternative A 20-11 with sand drying beds.
The resulting 30D waste load is 0.77 kg/kkg (1.54 Ib/ton), and the
suspended solids load is 0.115 kg/kkg (0.230 Ib/ton).
Costs: Total investment cost: $492,450
Total yearly cost: $134,160
An itemized breakdown of costs is presented in Table 287. It is
assumed that land costs $41.OOCperhectare ($16,600 per acre). It is
further assumed that three operators are required.
Reduction Benefits BOD: 97.8 percent
SS: 90.1 percent
Alternative A 20-VI - This alternative provides in addition to Alter-
native A 20-V dual media filtration.
The resulting BOD waste load is 0.38 kg/kkg (0.76 Ib/ton), and the
suspended solids load is 0.054 kg/kkg (0.108 Ib/ton).
Costs: Total investment cost: $512,680
Total yearly cost: $140,070
An itemized breakdown of costs is presented in Table 288- It is
assumed that land costs $41,000 per hectare (516,600 per acre). It
is further assumed that three operators are required.
Reduction Benefits BOD: 98.9 percent
SS: 95.3 percent
1060
•B
-------
DRAFT
TABLE 286
ITEMIZED COST SUMARY FOR ALTERNATIVE A 20-IV
(WINERIES WITHOUT STILLS)
DFSK'' tFF!CIi>w>... '/V.I ^i^CF'.T fLC R
TRi- A7f-'«-vT "[ f LLES:
f " . ..'f. '• i •-:•'_ l-CLSr
b...l-|""'"T-r. 51 Miff'
r. . . r ,'',il. ;7iTir;> t. aST
* . . ,f ' '. Kli-t'- AT.* !T JCN
I., , •:"-CS»-
•c . . . - r. r r '.
i . ...-^i v '•t-ic-i ir--
'• . . , r - r I - ~ I 1 1 PSESS'.Pf r I L T C 4
2...*CTlVMtr
CtiSTS:
?. L4I.C J6A60.0P
3, t^'GJ.'^ tt-'lNG flOttC.OO
«. CCNTIKlf^rv <* 0^60. 00
TCT4L 5
CPERATJN5 CCST.Si
1. UBC«* 37^60.00
c. Fr..-P-> 31770.00
. 3, Ct-L-J^ALi 753C.OO
i. "ii1 'r^.i' 'F?SL P^
1. Y K A it L w C ': Z "< i T I '. C ;C5T Jf-S^PO.OO
i.'. VtO;»LT r:..-;?feM
CCST i • i- '„ •.;•.':-> ?rc<)o.oo
3. OtPSFr. IMK^.
1061
-------
o
r\j
5
Q *J*
u.
o
in
8
9
Ili.C
*
iet'te
FIGURE 303
INVESTWNT AND YEARLY COSTS FOR SUBCATCGORY A 20. ALTERNATIVE IV
-------
DRAFT
TABLE 287
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 20-V
(WINERIES WITHOUT STILLS)
C ~ S T SL^t-v Ff= ,.\ « ' f • A T *•" P TiK*TwEM C H 41 ••
CESIC^ FFFTCH'-rv.. . 97." ?" ^
T fc L 11 " f. *• T *'C C 1; L i £ :
ei..rcrTPCL
B, .,pi.'-'^jvr; ?T^TIC^
c... c r 1.1 L : 7 i 11: N s«s T i
I. . .fHrs^Hr&i 5
F. . .AC H' '.FLTP/l. IZ*TICN
r <• A L s T r ^fclfo4ziT
. . ,IF*' PIC C JP": STCR
. . . s : M; " a v i K ? ?FCS
>...ni. SL '-'eCIA ?=c5S
i.
J. LAKL1 19<;90.PO
3. fc*Gir-fEPlwG 3^370.00
«. CC\TJKGE^C* 3«»370.00
1.
2.
3. CHEMK*L S 7530.CO
0. njNTFisM.CFREI FPLIES E1170.00
TCTAL
-------
DRAFT
TABLE 288
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 20-VI
(WINERIES WITHOUT STILLS)
J T F ^ I 2 R D e r S 7 S'.^" «" y P ,• c KiSTPkMEV TP£J*7UFKT C M I N
G'v FFFICTfNrY... ip.e PFKCtrT ?Cr, *£ t l.T. T
BJ ..r.f
R. . .PL^t- J'vP STATIC'-
^ . . . ' T : s '. :- r ••> i r •: T T T r •.
I...p^r5"i-^ci. ? A:C'T:
F...i£.T^ I.CLTCJLT?« TT
G . . , c 1 1 « T : r t? L : - * L i z « T i c f
"... . tcTr.'tT?: SVLCJE
C,..FL«.rPP T(-K-'-''-C
°. , . «F«! "1C rirvSTC'
T . . . ? » ^ r, r " v i s r- c f •: s
INVESTMENT CTSTEI
1. CCKSTRL-CTICK i'10570.00
'I. CCNTI^CE^-CY 11C60.PO
TCTAL 512MO.OO
1. HbC» i^SC.OO
2. PC^FW 27950.00
3. CHE^ICHS 7530.00
tt, l-AJNTf-'SAM:E!ELPcLIES 219flO.Cn
TCTAL 9^930.00
CCST£f
1. YFiHIY CPFSaTJKG r T S T 9t'9?0.0n
2. >EiM.Y iN^'EV'Ff.T
CCS1 -ECfv^hV >C51C.OC
UCQ7c!cO
106/J
-------
DRAFT
Alternative A 20-VII - This alternative adds activated carbon to
AHernative-A 20-VI.
The resulting BOD waste load is 0.23 kg/kkg (0.46 Ib/ton), and the
suspended solids load is 0.031 kg/kkg (0.062 Ib/ton).
Costs: Total investment cost: $580.520
Total yearly cost: $164,530
An itemized breakdown of costs is presented in Teble 289. It is
assumed that land costs $41,000 per hectare (i16,600 pe- acre). It
is further assumed that three operators are required.
Reduction Benefits BOD: 99.4 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 304.
Alternative A 20-VI11 - This alternative provides flow equalization,
nutrient addition, neutralization, an aerated lagoon system, and dual
media filtration.
The resulting BOD waste load is 0.77 kg/kkg (1.54 Ib/ton), and the
suspended solids load is 0.115 kg/kkg (0.230 Ib/ton).
Costs: Total investment cost: $413,090
Total yearly cost: $172,300
An itemized breakdown of costs is presented in Table290. It is
assumed that land costs $4100 per hectare (51660 per acre). It is
further assumed that one operator is required.
Reduction Benefits BOD: 97.8 percent
$$: 90.1 percent
Alternative A 20-IX - This alternative provides in addition to Alter-
native A 20-TlII dual media filtration.
The resulting BOD waste load is 0-38 kg/kkg (0.76 Ib/ton), and the
suspended solids load is 0.054 kg/kkg (0.108 Ib/ton).
Costs: Total investment cost: $433,290
Total yearly cost: $178,210
An itemized breakdown of costs is presented in Table 291. It is
assumed that land costs $4100 per hectare ($1660 per acre). It 1s
further assumed that one operator is required.
Reduction Benefits BOD: 98.9 percent
SS: 95.3 percent
-------
DRAFT
TABLE 2B9
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 20-VII
(WINERIES WITHOUT STILLS)
ITfriZrD CTST Sl^i-'APY F(JC kfSTF*ATFK TRfM'fKT
DE5IGJ-' EFFTrin-CY... Q0.3 CEPCFKT PCf;
'T^T "CDULES:
Bl..fr»^''r'CI- ^-rLSF
9...»*i;v-™.r. ^TAiTC"
r.. .FRI ti :7Mjrs pi
F . . . * C T •: 1-PIT=HT2'-
G . . . r ft L ? T j r sELT^iL
" . . . ' C T 1 V i T r r- c L (. r f.
C...CL'.:C:C Tt-ir^ffe
1 . . . S A *• ^
^...CUiL MPri
f^...r»U'.. "•P^J
2.ti ACTlVATrC
1. CCN'STSLCTTCK tfcllJO.OO
c. LAKn 1«?9g*icns 7530,00
Rt.C''*T !DK PE030.CO
TTTiL
inr-G
-------
(fl
5
I/)
Q
in
u> »*».•>
o
u
li
>- i 1 1 . 1
-i
CJ
«.-..-? «i.se
«J.:.- »i.
ict.te
FIGURE 304
INVESTftNT ATC YEARLY COSTS FOR SlJBCATEGORY A 20, ALTtWJATIVE VII
-------
DRAFT
TABLE 290
COST SIT-MRY FOR ALTERNATIVE A 20-V1I1
{WINERIES WITHOUT STILLS)
FFFIC7ENCY. .. 97.
C p &
R.'. ,PL.-"f-Ih G M.'. TTCV
C . . . »•' r. L «L I ? '. f T f »• ° i f I ^
*-'...' T ' =r:" ^ ^ ir r i T T r f.
I . . .Pt-rj'Pp-PhLS- ArrD!T!C''
F...iC*r '.-Fl.TRiLlZATjL^
G . . . C i L 5 T t r »' c ! T " 11.1 Z M I C N
L . . . i t 'i * T F Is I. 4 T C C N
K . . .r u a L M r r I A "WcSSunE FlLT**'K
TCTAL VEARLY
1 .
3.
fi.
5, P\T LINER
1CTAL
1.
£.
3.
5. P
TCTAL
1 . v£
2. Vf
c f
3. r«
TTT4L
» 3 3 0 , 0 r
33350.00
33350.00
7530.CO
?c30.00
190.00
CCST 1353^0.00
!l
IfrSZO.OO
? 0 U ti 0 , 00
172300.00
1068
-------
DRAFT
TABLE 291
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 20-IX
(W1NLRIES WITHOUT STILLS)
T C * * I >
CtSIC-c trf :r !£K: y. , .
c . . . r - ; ^ ;. : r r. T ; c i c t ? i K
F . . . *'.: r - «• i T- i L r ? A T i c t-
G. P.C/.LF'!r ?• 'I ^iLiZAT
1. COSI^ICIKN 35C32P.cr;
c. L*1^" i 33 0,00
3. EHGT'-EfcHi-.G 35030. CO
H. CC^1TI^6E^rv 35C3P,00
5. PVC LTK'tP 65PO.OO
YEARLY CPEPATJK3 cCSTS:
i. ittr* ijico.oo
2. PC'.''F* 106220.00
3. OE''ICiLS 7530.00
-------
OK AFT
A1 to rna tiypJLgO^X. " This alternative provides in addition to Alter-
nalfive~/\ 20-IX activated carbon.
The resulting WD waste load is 0.23 kg/kkg (0.46 Ib/ton), and the
suspended solids load is 0.031 kg/kl:g (0.062 Ib/ton).
Costs: Total investment cost: $501,160
Total yearly cost: $202,670
An itemized breakdown of costs is presented in Table 292. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that one operator is required.
Reduction Benefits: BOD: 99.4 percent
SS: 97.3 percent
A cost efficiency curve is presented in Figure 305.
Cost and Peduct'S:1 Benefits of Alternative Treatrent Techro' ocies for
Subcategory A 21 - r.'iner'ies with Stills
A model plant representative of Subcategory A 21 was developed in Section
V for the purpose of applying control and treatment alternatives. In
Section VII, two alternatives were selected as being applicable engi-
neering alternatives. These alternatives provide for various levels
of waste reductions for the model plant which processes 700 kkg (760 ton)
of grapes per day.
Al ternsti ve A 21-1 - This alternative assumes no treatmen*. and no reduction
in the waste loaa. It is estimated that the effluent from a 700 kkg
(760 ton) per day plant is 1700 cu m (0.442 MG) per cay. The BOD waste
load is 13.9 ko/kkg (27.7 Ib/ton), and the suspended solids load is
13.6 kg/kkg (27.3 Ib/ton).
Costs: 0
Reduction Benefits: None
Alternative A 21-11 - This alternative consists of & holding tank, pumping
station, pipeline, and land spreading.
A
The resulting BOD waste load is zero, and the suspended solids load is
zero.
Costs: Total investment cost: $381,640
Total yearly cost: $ 52,310
1070
-------
DRAFT
TADLE 292
ITEMIZED C03T SUMMARY FOP, ALTERNATIVE .A 20-X
(WIIO1ES WITHOUT STILLS)
T •* E
P. . .°LIMf- !•' ."- ?!•* TTC'.
r... F I'.'.->'-::;• j •••> - i s: f
>-.. ."I'»r:-K *rnn:c-^
I. . .-'nTSP-1--! ? iTCTTT-K.
p...tc!r • KL*(- '. i. IZITI;I>
G ... o. L r *:r •• ^!. T c t L: •' t r T c s.
T • ~ i 4 r c r K
M - " • i e •;££'- = K r IL 7 s t ' o.
'••' : I i r=£SSu«c FlLTRi'K
. . . A C T i V t- I r.'" r i 5 - L N 4 !'. S > r' r- ' : 1 ^
1. C^STC^T'CK 406*70.00
c. L*M5 n30. On
3. E * GI K E E - ; K C- 40*90.00
«. C C K1 T; »• G F' C V fi 0 fc P C . 0 0
i. ?vc I.TKFB B5PO.OP
TCTAL 501160.00
1.
2. Krr.E9 10^170.00
3. C*E**CA' S 7530.00
« . i-'i I^-TENiNCF* SLPPL IFS 2f^00.00
5. PVC l.!^E? 1PO.OO
TCT/L 157780.00
1. Yt'AC
2. vri
CT51
3. r
-------
o
•>j
INJ
tf>
K
O
o
u.
o
tf)
Q
<
(ft
O
o:
_i
Vi.f
IM.O
•it.e
JJ>-8
«
»i.ee
e? ico.c:
FIGURE 305
INVESTMENT AND YEARLY COSTS FOR SURCATEGORY A 20, ALTERNATIVE X
-------
DRAFT
An itemized breakdown of costs is presented in Table 293. It is assumed
that lond cost*. '-"103 per hectare (11660 per acre). It is further
assumc-d that two operators are required.
Reduction Benefits: 30D: 100 percent
, SS: TOO percent
Cost and Reduction Benefits of Alternative Treatment Technologies
for Subcotogory k ~22
Recovery Systems
- Grain Distillers Operating Stillage
Two model plants representative of Subcateqory A 22 were developed in
Section V for the purpose of applying control and treatment alter-
natives. In Section VII, nine alternatives were selected as being
applicaMe engineering alternatives. These alternatives provide for
various levels of waste reductions for model plant A 22-A which pro-
duces 380 kkg (15,000 bu) per day.
Alternative f- 22- A- 1 - This alternetive assumes no treatment and.no
reducticn in the ivaste load. It is estimated that the effluent from
a 380 kkg (15,030 bu) per day plant is 2500 cu m (0.650 MG) per day.
The BOD waste load is 6.0t kg/kkg (0.336 Ib/bu), and the suspended
solids load is A. 21 kg/kkg (0.236 Ib/bu).
The model plant assumes screening of the effluent prior to discharge.
Costs: 0
Reduction Benefits: None
Alternative A 22-A- I I - This alternative provides flow equalization,
nutrient addition, and an aerated lagoon system.
The resulting BOD waste load is 0.26 kg/kkg (0.015 Ib/bu), and the
suspended solids load is 0.32 kg/kkg (0.018 Ib/bu).
Costs: Total investment cost: $1,231,320.
Total yearly cost: $ 602,940
An itemized breakdown of costs 1s presented in Table 294. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that one operator is required.
•c
The model plant assumes screening of the effluent prior to discharge.
Reduction Benefits. BOD: 95.7 percent
SS: 92.3 percent
Alternative A 22-A- II j - This alternative provides 1n addition to
Alternative A 22-A-II dual media filtration.
1073
-------
DRAFT
TABLE 293
ITEMIZED COST SUWAHY FOR ALTERNATIVE A 21-1]
(WINERIES WITH STILLS)
>. A <• T I •" *
i. cp.fTsirT ;(.••• ?75roo.oo
2 . L •'••>• ;' fe 1 ^ *' 0 . 0 0
i. fc '• o T • « f » I * P
YE;Ar'. V JPf> •!'•':' S CCST5r
1. L'='.1C fi.C
2. PT ••»•••* ^pec.o
3. C(-f.(MCiL5 0.0
<-. f'A]vTFf-fi' CF
i'-'TAL
TCT4L Yti'-'LV CCSTS:
1. Y?iM.> Ce6-i?*TlNC CIST 2050C.CO
CCST hPCCvF'V 15P70.00
3. DkP^KIMTCN 16500. PO
1CTAL 52310.00
-------
LIRA FT
TABLE 294
ITEMIZED COST SUGARY FOR ALTERNATIVE A 22-A-II
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY SYSTEMS)
C C"ET SLV."ASY Fne 1-. A ?
EFFICIENCY... 55.7 F
i 7 E « 7
» CC
ccsT.?:
i.
7. K'^GIvEE-J'-.G
J. COT'^-L^CY
5. FVC L!^'^
TCTil
•«G CCSTS?
c.
3.
«.
5. PVC
TCTAi
TCTAL VEARLY CCSTS«
1. YtARLY
2. YEAHLY
CCST P
3. OEP^F.C
TCTAL
12Q90.00
377SC.OO
i2313?0,00
6150.PO
fli?0.on
J5SO.OO
CCST
C' 02 94-' 0.00
1075.
-------
The rosuUiny UCu v/oslc load is 0.13 kq/kkg (0.0073 Ib/bu). and the
suspended solids lo-ec.
The model plant assumes screening of the effluent prior to discharge.
107o
-------
DRAI
TABLE 295
ITEMIZED COST SUM'WRY FOR ALTERNATIVE A 22-A-III
(GRAIN DISTILLER3 OPERATING STiLLASE RECOVERY SYSTEMS)
r.CET Su'i-ATY Ff~.s HSTE*4TE& T"£iTi'EKT
DESIG?- KF'ICI^C* , .. 97. P PP.'
"L'CL.LES:
E...
C...F'
K...[-i'iL "FCIA FRiSELRE
:CSTS:
2• L AN^
3. tSGI^ trlcl"G 10252C.CO
4. Cf^TIKC-F.'-CY 102i2C.OO
?. FVC LINE* 377CO.OO
TCTAL l?7fcc50.CO
YFAPLY OPERATING COSTS!
1. LABOP
2. PC^FB «3*>1"0.00
3. C^EIJ:CALS 6950.00
5. PVC LIKEH 15
TCTAL
TCT4L YEARLY CCST£t
j, YEARLY cpEpnit'f- CCST «:<
CCST HFCCvEWY 5105C.CO
3. [>Ep REC! fiT ICK feSlfcC.OO
TCTAL 613U20.00
1U7/
-------
o
-«j
CC>
$
I
Q
U.
O
1
z
t—t
*-
iccr.o
•'••*
I
r;
tfl.J
««.ee
FIGURE 306
AND YEARLY COSTS FOR SUOCATEGURY A ?.?.~A-111
-------
DRAFT
TABLE 297
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 22-A-V
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY SYSTEMS)
EFFICIENCY...
»J TFP
^ eco
ei ..C
6. . ,PJ"?IN(; 5
H. ..:.:!>• !",-;•:>. m'
1...PHC5 P^r^LS iD
K. . . ^:TT v/ TFT sit
TCTAL
CCSTSs
3.
4. CCN7IVGFNCY
TCT*L
Cf.STSi
1.
I.
3. CKE"irAI.S
4.
2. Y'tt-.LY IKVFS
CCST hrcrvrc
3. CtPKECJ.'. TIO
47730.00
1022PC.OO
1^75110.00
37«»C.OO
6^270. CO
6950.00
167190.00
lP7jQO.no
51000. CO
61370.00
1080
-------
DRAFT
Reduction Benefits: BOD: 97;B percent
SS: 96.9 percent
A cost efficiency curve is presented in Figure 307.
Alternative A ??-A-VI - This alternative replaces sand drying beds in
Alternative A 22-A-1V with vacuum filtration.
The resulting BOD waste load is 0.26 kg/kkg (0.015 Ib/bu), and the
suspended solids load is 0.32 kg/kkg (0.018 Ib/bu).
Costs: Total investment cost: $839,260
Total yearly cost: $221,570
An itemized breakdown of costs is presented in Table 298. It is
assumed that land costs 541,000 per hectare ($16,600 per acre). It
is further assured that three operators are required.
The node! plart assures screening of the effluent prior to discharge.
Reduction Benefits: BOD: 95.7 percent
SS: 92.3 percent
Alternative A 22--A-•VII - This alternative provides in addition to Alter-
native A cZ-A-v'l aual media filtration.
The resulting BOD waste load is 0.13 kg/kkg (0.0073 Ib/bu), and the
suspended solids load is 0.16 kg/kkg (0.0390 Ib/bu).
Costs: Total investment cost: $884,220
Total yearly cost: $232,060
An itemized breakdown of costs is presented in Table 299. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further assumed that three operators are required.
The model plant assumes screening of the effluent prior to discharge.
Reduction Benefits: BOD: 97.8 percent
SS: 96.9 percent
A cost efficiency curve is presentsd in Figure 308.
Alternative A 22-A-VIII - This alternative replaces the sard drying
beds in Al ternative A 22-A-IV with spray irrigation.
The resulting BOD waste load fs 0.26 kg/kkg (0.015 Ib/bu), and the
suspended solids load is 0.32 kg/kkg (0.018 Ib/bu).
Costs: Total investment cost: $838.600
Total yearly cost: $212,850
10B1
-------
c
rs;
f.M.5
in
5
8 KT*''
fe
a "'-1
u
«? 7
If'.t
«l.cc
FIGURE 307
INVEST>£Mr AND YEARLY COSTS TOR 5'JBCATFRORY A 22-A-V
-------
DRAFT
TAOLE 298
ITEMIZED COST SUMMARY FOR ALTERATIVEA 22-A-VI
(GRAIN DISTILLERS OPERATING STKLAGC RECOVERY SYSTEMS)
.. vs. 7 FE-CFNT ~c:
VE4RLY
tCTAL
p i.. u *• T - r L •• L '. i -:
{' . . . ' L "• - I v r- • 5 T .' 7 ! r N
P. . .F'.L :'..:?.'.71'•> ^51^
",.. •••1 • - -' r •> *p-:: T i r •>
!,..>»»-TiShf--Li A ^o MICA
K . . , t C T J v i T r r 5 L L C '• :
r...ML:c.r 7t-:r -^r EC
f,..Arf-:a;r ri^e:?Tr-
S...viCUl tTL'-iTITN
v.. .*LL:!>- P TAM<
J . rn STUfTILK
2. LAI.D
CCSTS;
1. L
2. PC^F*
5. CHEMICALS
a. f'.
TCT4L
!. VE*?LY CCF^i
£. Yt/H-V !» VrJ
66T5J P.CC
«6t?O.CO
66050,00
66050.00
37«"O.CO
i 37 Of. 00
15130,00
*1":; C ? 5 T ?4lf3?C,00
Trf NT
1083
-------
uimrr
TABLE 299
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 22-A-VII
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY SYSTEMS)
C ' 5 T P L -v K p * F C13 »/.FT?Uitrk TJ-t'ATFM r « /. 1 K
FIClEi-n... C7.? f--c
TREATHEM >'(
P1..CC.MHCL
C . . . f r t 4 L : ? « 1 i r N a * s I ,\
5 L L ^ r-
t. , , V»CU •• F K 1 = O I*
V. . .-rLDTrvf< T*N*
P. ..PLC-.PJ:• - 5i MT:^
K . . . C L• / L •• F C 1 4 P 5 c e i
T^E^T CCSTii
1. Cr*.ST«?LCTILK 6Q7970.00
3.'
TCT/.L
Yt APLV CPEp/ i I^r. CCilTS:
J . L At?PK J70PO.OO
3. CHFMiCMS l?700.r,0
/i. k/TK'TFNA^Ct&SLPPLlE£ 157EO.CO
TCTAL
TCTAL Vt'PLY CCfiS;
] . VFiPt. v CP^ t"4TI>>. C
?. V
3. L'S-
TTTiL
10,' .
-------
o
c->
en
Li
-------
:,, Ui-ni7frl lirookdov/n of costs is presented in Table 300. It is
.,,.,,,1 t,iot I'-nd costs S.
Model plant D produces 90 kl;g (3500 bu) per day.
Alternative A 22-B-I - This alternative assumes no treatment and no re-
duction in the waste load. It is estimated that the effluent from a
90 fckg (3500 bu) per day p:ant is 570 cu ir (0.15 MG) per dav. The
ODD waste load is 5.99 kg/kkg (0.335 Ib/bu), and the suspended solids
load is 4.23 kg/kl;g (0.237 Ib/bu).
The nodel plant assumes screening of the effluent prior to discharge.
Costs: 0
Reduction Benefits: None
-------
DRAFT
TABLE 300
ITEMIZED COST SITMAPY FOR ALTTRMATIVC A 22-A-VIII
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY SYSTEMS)
f'ST Sl'-KAPY PC.R »-tSTr u A TE«
PESIS'. EPFICJE<^CY... 95.7 PERCEM OLD REDljCTIO
KlSE
p. ..
1... Pi-:?*- '-r-LS iCDlT
K. . .ACT 3\ iT? " fLl ?C£
c.f ,j>LLcr.= :'-::-':••.::»
R . . . 4 1 f' L P 3 c r ; r c i T : ?.
CCSTSi
i .
3. ENPJ'
«. COT
TC1AL
YEARLY OPERATING CCSTSi
1. L»tTi
3, C
0.
TCTAL
TCTAL YEAR1 Y CCET5t
1. VfiCLY
2. Y£tH v i
CC5-T ctt
3. rfl'RI.CJi
667C-OP. 00
57ueo.cc
6t>7frO. Cft
6fr7tO.CC
635690.00
37«JPO.OO
7
-------
UK AFT
TABLE 301
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 22-A-JX
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY SYSTEMS)
HCL5F
STATIC*-
£ 'J L A t ! 2 ; T ; r K H i S I
FC SL'-'OCF
ITEMIZE"!) CCiT Sl^KARY PC1" I--AS1 F> ATE? TR£iT.vErT CHAIN
TESir.S. tFFICIE'-CY... C7.e PE&CPM FCD PECUCTICN
Rl
e.
c.
H.
I.
K.
C.
U.
B.
iNVESTKfcKT CC5T£j
i.
2. LAND
3.
it.
TCTAL
STATIC'-'
iA FKESSLfiE
CPEPA7JKC
U
2.
3. CHEMICALS
(I. H
TCT1L
TCTAL VEARLY ccsTji
t, YEARLY
2. YEARLY
CCST »
3.
1CTAL
66P610.00
37460.00
66660.00
60660.00
663910,00
37480,00
63590.00
69SO.OO
15620.00
CCST 1U36«0.00
A1320.00
219710.00
10UU
-------
in
-------
CRAFT
AU_c_rna t i vc A ?2-D-11 - This alternative provides flow equalization,
nutrient udditu/n, and an aerated lagoon system.
The resulting HOD waste load is 0.25 kg/kkg (0.014 Ib/bu), and the
suspended solids load is 0.32 kg/kkg (0.015 Ib/bu).
Costs: Total investment cost: $348,170
Total yearly cost: $132.190
An itemized breakdown of costs is presented in Table 302. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that one operator is required.
The model plant assumes screening of the effluent prior to discharge.
Reduction Benefits: BOD: 95.8 percent
SS: 92.5 percent
A1tern?.t-ivg A 22-B-III - This alternative provides in addition to Alter-
native A 22-li- II dual media filtration.
The resulting BOD waste load is 0.13 kg/kkc (0.0^73 Ib/bu), and the
suspended solids load is 0.16 kg/kkg (0.0090 l!,/bu).
Costs: Total investment cost: $373,300
Total yearly cost: $139,050
An itemized breakdown of costs is presented in Table 303. It Is
assumed that land costs $4100 per hectare ($1660 per acre). It is
.further assumed that one operator is required.
The model plant assumes screening of the effluent prior to discharge.
Reduction Benefits: BOD: 97.9 percent
SS: 96.3 percent
A cost.efficiency curve 1s presented in Figure 310.
Alternative A 22-B-IV - This alternative provides a control house, flow
equalization, a complete mix activated sludge system, sludge thickening,
aerobic digestion, and sand drying beds.
The resulting BOD waste load is 0.25 kq'kkq (0.014 Ib/bu), and the
suspended solids load is 0.32 kg/kkg (O.Olb Ib/bu).
Costs: Totdl investment cost: $332,290
Total yearly cost: $ 97,130
An itemized breakdov/n of costs is presented in Table 304. It is
assunied that land costs $41,000 per hectare ($16,600 per acre). It
is.further assumed that three operators are required.
109C
-------
URAFT
TABLE 302
ITEMIZED COST SUMMARY FOR ALTERNATIVE A ?2-C-II
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY)
I'lE^ITF^ Cr'T Sl^/!rY Ft"
DESICU tFFJCIKKCY.., 95. P
T CLO
B.. .l-
C.. .r
1 . . .P^CF.
L , . . L • ~ '-
r. S7ATK*'
ZiTKN f:4ElN
L i r, c r •<
e .
3.
4.
5.
E * C T •• F E K I» 0
cr^ TIVC.P.-CY
,cc
.on
.CO
7 5 J C . C n
TCTAL
1.
?.
3.
S. PvC
TCTAl
)fifcO.OO
380,00
101090.00
i. Y£A«LY CPfP*TI>.G COST 101090. '0
2. YE*RLY IKVCSTHFM
CCS1 sifCCvri-Y 13«J30.00
3. r.uPurciiTirN i7\7o.co
TC7AL 13tl90.CC
1UDI
-------
DUAPT
TABLE 303
ITEMIZED COST SUGARY FOR ALTERNATIVE A 22-B- III
(GRAIN DISTILLERS OPERATING ST1LLAGE RECOVERY)
TKpi Tf'Pf. T
rr.=
"CM-
]_t < ,
?...BL1"CT'-G S'/TTCK
c... r.'. i A i. j 7 MI r s H : s I
I K V": E T
TCTAL
i . C r •- 5 T * L C 7 T t.:
e , L A1 f
3. f*'C-?'"':fe!'>"
^v: LI*'?'"
TC7U
i.
3. r>t:nit:*LS
S.
TC74L
CC5TJ:
1. YFAFL.Y
2. Vf APl.Y
CCS1 *
3. P
7C7AL
31' c 51 c. r o
" P 3 0 . 0 0
sonec.on
3 0 n ! 0 . C C1
79
-------
u.
o
(.1
o
••J
>
>
k.'
>-
•J
*
)?'.» I
n;,:
FIGUPE 310
AJJO YEARLY COSTS rQR 5Uer.aiErrnRY A ?2-B-Hl
-------
TADLE 204
ITEMIZED COST SUIWiP.Y TOR ALTERNATIVE A 22-B-IV
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY)
CCST Elf'UBY FOB > ASTFu 47? P T»r*TH£NT CK«JN
P-CSICK EFFICItf-CY... 95.*» *»fc*»Cff.T fCD
8I..CCMRCL
e...puu?p.'G
C,..F'JL*l I2/.TIC
I N. V F S
YEAPLV
TCT&L
T...S/.KC rt-vii
CC ST F:
J. C057K>.CT!t>
2. L**C
3. n r,i».FE»:j...6
Tcm
PCWF.J*
3.
1.
TCT4C
1. YEiPLY C»F«»ATIKp CCST
2. YE*PLY IN^FST^FM
CCST
j.
P6372C.OO
15P?O.CO
26370.00
26370.00
332H90.00
37U80.00
14760.00
leeo.oo
6920,00
66020.00
66020.00
13250.00
1 S fr ? 0 . 0 0
97130.00
1094
-------
uliAR
The model plant assumes screening of the effluent prior to discharge.
-Reduction Benefits: COD: 95.0 percent
SS: 92.5 percent
Alternative A 22-P-V - This alternative provides dual media filtration
in uddfffun tc "the treatment chain in Alternative A 22-B-IV.
The resulting BOD wfcste load is 0.13 kg/kkg (0.0073 Ib/bu), and the
Suspended solids load is 0.1C kg/kkg (0.0090 lb/bu).
Costs: Total investment cost: £357,500
Total yearly cost: $103,990
An itemized breakdov/n of costs is presented in Table 305. It is assumed
that land costs $41 ,000 per hectare ($16,600 per acre). It is further
assumed that three operators are required.
The model plant assirrss screening of the effluent prior to discharge.
Rfldu:tion Benefits: BOD: 97.9 percent
SS: 96.3 percent
A cc^t efficiency curve is presented in Figure 311.
Alternaf'vf A ??-S-VI - This alternative replaces sand drying beds in
ATternat'ive A c2-B-~rv v.'ith vacuum filtration.
The resulting BOD waste load is 0.25 kg/kkg (0.014 lb/bu), and the
suspended solids load is 0.32 kg/kkg (C.018 lb/bu).
Costs: Total investment cost: $387,710
Total yearly cost: $106,650
An Itemized breakdown of costs Is presented in Table 006. It Is
Assumed that land costs $41,000 per hectare ($16,600 per acre). It
1s further assumed that three operators are required.
The model plant assumes screening of the effluent prior to discharge.
Reduction Benefits: DOD: 95.8 percent
SS: 92.5 percent
Al to ma t i vc A Z1N 5_-V II - This alternative adds dual media filtration tu
AHcYna 1 i ve A" Z 2-tp
The resulting fO caste load is 0.1? Ig/kkn (0.0073 lb/bu), and the
suspn.dc.-d solids load is 0.16 kij/kkg (0.0030 lb/bu).
Costs: Total invpstmrnt cost: $412,920
Total yearly cor.t: $113,510
1095
-------
UMFT
TABLE 305
ITEMIZED COST S'Jir.Ai».Y fOR ALTERATIVE A 2i!-B-V
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY)
DESI^ EKFKI5.UV... 57.«.
T fi F * ' "{•''• T " L r LI E 5 f
•
H . . , D I " *- T '• ' S T .-. 7 I T K
c . . . r :. • i L : •/ A T i r i p 4 s i N
C . . . c- _'. r C. r T u : - - c >.. r q
P ..,'l =: r;: :: - p M c«
^...^'•'r ? = v*>'' ^t^s
K ...-.'»• i \ r- 51«11 c K
^...!>>1A<. T. c j;. rcpssiflf
«t cr'.T:f.o«'.:v 26u7o.oo
TC7AL 357500,00
YEARLY CPF.9iTjs& CCSTSr
1. Lter.H 37(J?C.OO
2. FC^fK 2«0?0.00
3. et-f-ICALS 1660,00
4, ^ iJ^'Tr.^A^:Lll$LPBLIES S250.C-0
7*610,00
TCT»| VEAflLV CCSTJJ
i, vt«rLv rcf-'tTi-.s crsr
2. ^et-L Y jv vr c-r, , ST
CCM wECrvc-v
3. rFFTEci/Tj-s 170PO.OO
K1AL 103990.00
1090
-------
o
C1
O
I
CJ
Q
*.
111.I
<
CL
l_"
•'.f '
»?.tf «j.:: «*.::
-------
UKAFT
TABLE 306
ITEMIZED C02T SUGARY FOR ALTERNATIVE A 22-D--VI
(GRAIN DISTILLERS OPERATING ST1LLAGE RECOVERY)
I T F •" I Z £ £ C r. - T - '
DESK1- EFUCILN
•y r.y.e >.• t £7 r ,- 4 7 f C i
05. f Ff.PCFM PLO
?J . .CiVTcC! hCL
B... PI^PIM:- S'4
C , . . E CI A 1.1 7 i T J f
SLl.TGF
1. CCi.STPiCnO
3.
t. C
TCT*L
CDE;'ATIsr, CCSTSf
I.
2.
3. CHt^'K»LS
TCTAL
TCTAL YEA«LV CCS7SI
1. YF«kLV Cpf:?/.TI'.G
2. Yf A^L V IKVf S7-FN
3.
?
-------
UKAFT
An itemizc-d breakdown of costs is presented 'in Table 307. It is
assumed thul land costs £11,000 per hectare ($16,600 per acre). It
is further assjjmod thot three operators art? required.
The model plant assumes screening of the effluent prior to .discharge.
Reduction Benefits: BOD: 97,9 percent
SS: 56.3 percent
A cost efficiency curve is presented in Figure 312.
Alternative A 22-R-Vni - This alternative replaces the sand drying
beds in Alternative A 22-8-IV with spray irrigation.
The resulting BOO waste load is 0.25 kg/kkg (0.014 Ib/bu), and the
suspended solids load is 0.32 kg/kkg (0.01B Ib/bu).
Costs: Total investment cost: $388,320
Total yearly cost: $102,870
An itemized breakdown of costs is presented in Table 303. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further essurred tlut three operators are required.
The model plant assur.es screening of the effluent prior to discharge.
Reduction Benefits: BOD: 95.8 percent
SS: 92.5 percent
Alternative A 22-B-IX - This alternative adds dual media filtration, to
Alternative A 22-B-VIII.
The resulting BOD waste load is 0.13 kg/kkg (0.0073 Ib/bu), and the
suspended solids load is 0.16 kg/kkg (0.0090 Ib/bu).
Costs: Total Investment cost: $404,3^0
Total yearly cost: $107,620
An Itemized breakdown of costs is presented in Table 309. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further assumed that three operators are required.
The model plant assumes screening of the effluent prior to discharge.
Reduction Benefits: BOD; 97.9 percent
SS: 96.3 percent
A cost efficiency curve is presented in Figure 313.
1099
-------
UHAFT
TABLE 307
ITEMIZED COST SUGARY FOR ALTERNATIVE A P2-D-V1
CGRA'N DISTILLERS OPERATING STILLAGE RECOVERY)
Crt'T ElM'ACY f[,:> k-iSTF1' .'.Tc» TF-EiVEM C H 61
FICIENCY. .. 45
S...V-
>>... r u 4 L f ? c i A i-c F. £ s L s E P i L T & A > >
CCSTS:
1. CCf-STRlCTTCN 317730.03
2. LAKC 3U50.CO
3. EKGI»Er:»I"G 31770.OJ
41. CCMl\GE^rY 31770.00
TCTAL
CCSTSi
1. L*BP*
2. PC»*n
3. CHEMICAL? «350.00
-------
a
_)
d
0
fe
n
g
-t
CT
O
a
u5
>
2
U
«:.t: «».te «j.«e ••'.c: <*.rt ?».;{ «».tc <(.cc »».ec
FIGURE 312
INVESTMENT /»JD YEARLY COSTS FOR SUBCATEGORY A 22-B-VI-VlI
-------
IWAFT
TABLE 300
ITEMIZED COST Sl'M'tARY FOR ALTERNATIVE A ZV-B-V
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY)
DESK-'- F.FF!C!C>CY. . , <55.P PfPC^.t ROD
I.. .MJCSC'-LKLE *rciT
K. ..6CTIViTiir St LDPt
Y. . .k-C'LCIf-r. 7AI.K
3. PNGl^fFCIMG 3C7tO.OO
(I, CC^7 If GENT Y 30760.00
L 3P6320.00
1. L»30» 37«JeO.OO
8. POER Z06CO.OO
3. Ct-E^lCALS 1860.00
TC1U 66680,00
TC7tL Y
1. YE*SL> fPFBA7IM: CCiiT
?. vfARL^ 1 »• V i- f: T f r t, T
CCST Hrcrvty i5«»3c.co
I *" 10ef.7o!c'!
no?
-------
DRAFT
TADLE 309
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 22-D-IX
(GRAIN DISTILLERS OPERATING STILLAGE RECOVERY)
DESIGN' EFFICIE^CV,.. w?.0 Pk"C!M fcCD RtCUCTICK
fT.DULESs
Bl.
O...I
KLSF
»• . . . w I f F r: c E •>. 4 r c r T I c
I. . .
C. . .
". ..
Y. . .
r TAKK
IPciGiTjC
KR STiTTCN
CCSTSJ
i.
2.
3.
TCTAL
YEARLY OPERATING CCSTSl
CCNSTRUCTICN-
2.
5. CHEMJC4LS
(I. H
TCTAL
TCTAL YEARLY
2. YE*RLV
CCST R|
3. P
TC1AL
32J 000.00
32100.00
32100. 00
37^80.00
22250.00
1660.00
10690.00
72190.00
iti7o.no
l*?i?60.00
107620.00
1103
-------
in. i
s ,».,
U
j.st «i.'.t «i..tt ««.:t ««.:: »».ec <».«
FIGURE 313
AND YEARLY TOSTS PQR SlBCATEGORY A 2Z-B-V1I-IX
us.c«
-------
DRAFT
Cost "gi)r'y"A"23 - "riro"in Distillers No't~'OjK.'futi'ng StiTl's
A model plantTepresentativo of Sulicatcgory A 22 was. developed in
Section V for the purpo'e of applying control and treatment alter-
natives. In Section VII, five alternatives were selected as being ,
applicable engineering alternatives. These alternatives provide
for various levels of waste reductions for the model plant which
produces 50 kkg (2000 bu) per day.
Alternative .A 23-1 - This alternative assumes no treatment and no re-
duction -n the waste load. It is estimated that the effluent fron
a 50 U:g (2000 bu) per day plant is 91 cu m (0.024 HG) per day. The
BOD waste load is 0.3S kg/l:kg (0.021 Ib/bu), and the suspended solids
load is 0.29 kg/kl:g (0.016 Ib/bu).
•
Costs: 0
Reduction Benefits: None
A1 ternativ.' A r.3-11 - This alternative provides a pumpinq station
and aerated l.igoon system.
The resulting BOD waste load is 0.06 kg/kkg (0.0034 Ib/bu), and the
suspended sc,ids load is 0.07 kg/kkg (6.0039 Ib/bu).
Costs: Total investment cost: $133,720
Total yearly cost: $ 28,200
An itemized breakdown of costs is preserve in Table 310. It is
assumed that land costs $4100 per hectart (ilC>60 per acrp). It is
further assumed that one half-time operator is required.
Reduction Benefits: BOD: 85.7 perce/rc
SS: 75.0 percant
AH?rnat_ive A_?.-hJU ' Tnis alternative provides 1n addition to Alter-
native A 23-11 dua"l media filtration.
The resulting BOD waste load is 0.03 kg/kkg (0.0017 Ib/bu), and xhe
suspended solids load 1s 0.04 kg/kkg (0.0022 Ib/bu).
Costs: Total investment cot':: $149,750
Total yearly cost: $ 32,940
An 1t.em1?i:d breakdown of costs is presented in Table 311. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further ar-MjnM?d that one half-time r-i'rr.itor is required.
Reduction Benefits: BOD: 92.9 percent
?jS: 87.5 percent
A cost efficiency curve 1s presented
-------
DRAfT
TABLE 310
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 23-11
(GRAIN DISTILLERS NOT OPERATING STILLS)
rnST Sl"-A?f
DESIGN EFFTCI-*CV... 65.7 PtRCEM
TREATMENT
5-TOTf'K'
L*GCCN
CLSTi
1
s. ^v: LIKES
1CTAL.
YEARLY OPERATIC CCJTSI
1. L*«0«
2. ^CvEft
3. r.l-'EMIC*LS
5.
TCT*L
LINER
105670.00
^3?C.OO
10570.00
10570.00
35PO.CC
133720.00
6250.00
5170.00
60.CO
«790.00
60.00
16330.00
TCTAL VEARLY CCcTEl
i. YEARLY CPE^TIKG CCST 16330.00
2. Yf.ARLY IN'VpfT^fKT
CLST ^F.CTvF.hY 5350.00
3. PEr'KKCUMO 6teO.OO
TCTAL P62CO.CO
no->
-------
DRAFT
TADLE 311
ITEMIZED COST SUM'-lARY FOR ALTERNATIVE A 23-IJJ
(GRAIN 01STILLCKS NOT OPERATING STILLS)
FC=. v.i 5TE - A 1 P«<
DE.SIGK EFF KI£NCY. .. <52,V ^c*CEM !>CD REDUCTION
e. ..PUFFING S
L...ACKAUD
YE4PLY
5. P«
1CT*1
a,
s. PVC i:
KUL
CCSTSi
1, YF.4KLV
CCST
3. PEPFFCIOJC.S
TC14L
3330. PO
1JQOO.OO
3560.00
1^9750.00
6250.CO
6620,00
60.00
6440.00
60.00
19630,00
19630.00
5990.00
73ZO.OO
32900,00
1107
-------
O
CO
lit.I
:-. II».t
o ui.t
L.
o
(fl
§ lll.l
1*1.1
irt
o i..e
>-
>-
I ••••
— M.t
i
••-•
Iff.*
•t.C* 11.11
|. •• If.tl f».ff
•*.!• ««.<* «|.1t
FIGURE 314
AM) YEARLY COSTS FOR SLBCATEGORY A ?3-in
-------
DRAFT
Alternative A 23-IV - This alternative provides in addition to Alterna-
tive A 23-11 spray irrigation.
The resulting~OOD waste load is zero, and the suspended solids load
is zero.
Costs: Total investment cost: $224,040
Total yearly cost: $ 70,590
An Itemized breakdown of costs 1s presented in Table 312. It is assumed
that land costs $4100 per hectare (S16GJ per acre). It is further
assumed that one half-time operator is required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
A cost efficiency curve is presented in Figure 315.
Cost and Reduction Benefits of Alternative Treatment Technologies for
Suijcategory A ?4 - Molasses Distillers
A model plant representative of Subcategory A 24 was developed in
Section V for the purpose of applying control and treatment alternatives.
In Section VII, nine alternatives were selected as being applicable
engineering alternatives. These alternatives provide for various
levels of waste reductions for the model plant which produces 30,000
pg per day.
Alternative A ?4-I - This alternative assumes no t-eatment and no re-
duction in the waste load. It 1s estimated that the effluent from a
30,000 pg per day plant is 818 cu m (0.216 MG) per day. The BOD
waste load is 969 kg/1000 pg (2140 lb/1000 pg), and the suspended
solids load is 183 kg/1000 pg (403 lb/1000 pg).
Costs: 0
Reduction Benefits: None
Alternative A 24-11 - This alternative consists of concentrating high
strength molasses slops (stillage) by multi-effect evaporation, and then
treating evaporator condensate and all other wastes with a treatment
chain consisting of a control house, a pumping station, flow equalization,
nutrient addition, a complete mix activated sludge system, sludge thick-
ening, aerobic digestion, vacuum filtration, sludge storage and truck
hauling. Evaporation is predicted to have an investment, cost of $2,193,310
and a yearly cost of $609,620. Evaporation is assumed to remove 97 per-
cent of the BOD and 99 percent of the suspended solids from high strength
wastes. Two day storage of distil line; slops ancl seven day storage of
molasses by-product 1s provided, and all necessary pumping equipment is
Included.
1109
-------
DRAFT
TABLE 312
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 23-IV
(GRAIN DISTILLERS NOT OPERATING STILLS)
, ., 1 ro.n Pi>C'?M rCT R£CUC1!O
L . ...TH -Tt '; L i:-LZ>
V , , ,t'C'.Lr I'-'1 T*' x
j. n^FT-if-Tir*
i. LAI-:- i! 3*0. CO
3. f^G?:s?"JvG J7ii*O.CO
a. t TM !>> &<"'.!• T l7i.JO.C-0
S. f'.CLT^^- 35«0,Cf»
6130.00
3. C>-E"ICALS *0^0
U, f-AlMF* ASTEf JLFPUIE5 7260.00
*.. FVC LINft- feO.OO
1C1*L 50990.00
TCTAL VE*RLY
1. VM^LV C^rc/T^c COST 50990,00
2. Vf*F»l > p Vf fT'EKT
rcsr »*f t r^ >•;
3 . f. f f «•: K J •' 1 ; ''
-------
r>
5
ri
o
u.
o
I/)
•8
V
>-
5
§
»T.'
• r.C '
«».tc
3J5
INVESTttNT *N> YEARLY COSTS FOR SUBCATCGORY A ?3-IV
-------
DRAFT
The resulting COD waste load is 1.16 kg/1000 pg (2.56 lb/1000 po.), and
the suspended solids load is 0.69 kg/1000 pg (1.52 lb/1000 pg),.
Costs: Total investment cos';: $2,644,060
Total yearly cost: $ 690,640
An itemized breakdown of costs is presented in Table 313. It 1s
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further assumed that six operators are required.
It is recognized that, although not included in the above costs, add-
itional boiler and cooling capacity may be required for evaporation.
Cost recovery fron saleable by-products is not reflected in the costs.
Reduction Benefits: BOD: 99.9 percent
SS: 99.6 percent
Alternative A 24-111 - This alternative consists of adding dual media
filtration to the treatment chain in Alternative A 24-11.
The resulting BOD waste load is 0.58 kg/1000 pg (1.28 lb/1000 pg), and
the suspended solids load is 0.35 kg/1000 pg (0.77 lb/1000 pg).
Costs: Total investment cost: $2,671,130
Total yearly cost: $ 705,710
An itemized breakdown of costs is presented in Table 314. It is
assumed that land costs $41,000 per hectare ($16,600 per acre). It
is further assuned that six operators are required.
Reduction Benefits: BOD: 99.9 percent
SS: 99.6 percent
A cost efficiency curve is presented in Figure 316.
Alternative A 24-IV - This alternative replaces vacuum filtration in
Alternative A 24-fl with spray irrigation of sludge.
The resulting BOD waste load --'s 1.16 kg/1000 pg (2.56 lb/1000 pg), and
the suspended solids load is 0.69 kg/1000 pg (1.52 lb/1000 pg).
Costs: Total investment cost: $2,638,610
Total yearly cost: $ 692,540
An itemized breakdown of costs is presented in Table 315. It is
assumed that land costs $4100 per hect3>-= (11660 per acre). It is
further assumed that six operators are j.'juired.
Reduction Benefits: BOD: 99.9 percent
S$: 99.6 percent
1112
-------
IMAFT
TABLE 313
ITEMIZED COST SUMMARY FOR ALTERNATIVE.A23-II
(MOLASSES DISTILLERS)
ITE''I7ED CPST SL^KAKY ^QC KASTE*ATE» T"E
DESIGK EFFICIENCY.,. 9«).e PERCENT PCD REDUCTION
TREATMENT MODULES:
91..TDKTPOL
B, . . PL'Kf- JN5 STATION
P!..''ULTJPL£ FFFECT
Y. . . HDL" IN'G TAK-K
P...Pb^FIKG STATION'
Y... HOLD ING TANK
P...PUFFING £T
E. ..PL^PINT- ST
C. , .EliLAl IZATITN BASIN
I...
K...ACTIVATED
C...SULDPE THICKENER
TIGESTCR
FILTRATION
Y,,.MOLT.ING TAM<
CCSTSI
1.
2.
3.
«. CONTINGENCY
TOTAL
CCKSTPL'CTICN
LAND
YEARLY OPERATING CCfilSs
2.
3,
O£"ICALS
0.
TCTAL
Z161160.00
26660.00
219120,00
216120.00
'Z6U4060.00
7
-------
DRAFT
TABLE 314
ITEMIZED COST Sl'WARY FOR ALTERNATIVE A24-II1
(MOLASSES DISTILLERS)
CCST Sl^'AkY FC5 fc/STFUATE;- TPE 4 T ^."N 7 CHAIN
DESIGN EFFICIENCY... 99.9 PERCENT PCD &ECLCTICN
C1..CCMPCL
e. ..PUFFING STMICN
Fl . .".uLTIrl £ ECF'CT
V...iOLCTNG T«^K
fc. ..Pt^^y-C S14TIC*
f. . .-OLCINC tiN*'
R. . .^•'•PUG 57
-------
_J
VI
8
>
»t«.c
v.c:
o
73
««.Jc
««.co »».ec
l'»!CH^»
FIGURE 316
*NO YE/WLY COSTS FOR SUBCATEGORY A 2<.-III
-------
UMFT
TABLE 315
ITEMIZED COST SUI1MARY FOR ALTERNATIVE A24-IV
(MOLASSES DISTILLERS)
CGFT Sl'-ViPy P'.fi »AS7Fv.M?R TRctT"£r-T CHAIN
K EFFICIF>CY... 99.: rES»CE>7 SOD R
7RL'ATI'.£KT
93
9.
Fl
Y.
e.
v.
p.
e.
c,
K
I.
*.
C.
R.
V.
I.
5Tt7IO^
TANK
STATIC^
STATIC1^
M.
.ACT/47EC SLUDGE
,SLi i:PE 7t-IC
CIGESTCR
,SPP*Y IRRIGATION'
CCS76?
1.
Zi
3.
CO7IKCEKCY
YEARLY OPERATING CCSTSl
1.
2.
3.
TC7AL
7CTAL
i» YEARLY r
2. YFAfclY 1*
CC£7
3.
7T74L
3163560.00
16330.00
216360.00
263C610.00
7"970.00
337450.00
«5599o!oO
COST «55990.00
r
131010.00
1116
-------
DRAFT
Alternative A_24-V - This alternative provides in addition to Alternative
A 24-IV dual media filtration.
The resulting COD waste load is 0.58 kb/1000 pg (1.28 lb/1000 pg), and the
suspended solids load is 0.35 kg/1000 pg (0.77 lb/1000 pg).
Costs: Total investment cost: $2,665,690
Total yearly cost: $ 699,620
An itemized breakdown of costs is presented in Table 316. It is
assumed that land costs $4100 per hectare (S1660 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 99.9 percent
SS: 99.8 percent
A cost efficiency curve is presented in Figure 317.
Alterr.ntive A 24-VI - This alternative replaces vacuum filtration in
Alternative A 24-11 with sand drying beds.
The resulting BOD waste load is 1.16 kg/1000 pg (2.56 lb/1000 pg), and
the suspended solids load is 0.69 kg/1000 pg (1.52 lb/1000 pg).
Costs: Total investment cost: $2,759,100
Total yearly cost: $ 718,490
An itemized breakdown of costs is presented in Table 317. It is
assumed that land costs 520,510 per hectare (S8300 per acre). It
is further assumed that six operators are required.
Reduction Benefits: BOD: 99.9 percent
SS: 99.6 percent
Alternative A 24-VII - This alternative adds dual media filtration to
Alternative A 24-VI.
The resulting BOD waste load 1s 0.58 kg/1000 pg (1.28 lb/1000 pg), and
the suspended solids load is 0.35 kg/1000 pg (0.77 lb/1000 pg).
Costs: Total investment cost: $2,786,170
Total yearly cost: $ 725.560
An itemized breakdown of costs is presented in Table 318. It is
assumed that land costs $20,510 per hectare ($8300 per acre). It
is further assumed that six operator: are required.
Reduction Benefits: BOD: 99.9 percent
SS: 99.8 percent
A cost efficiency curve 1s presented in Figure 318.
1117
-------
UKAF
TABLE 316
ITEMIZED COST SUMMARY FOR ALTERNATIVE A24-V
(MOLASSES DISTILLERS)
^. t>'FKlr. NCt. ..
B...P •:»•? I k.G
PI . ."ill I cLp_
B, .
F.. .
»-. ..f ^k> )•• r. s? AT:
Yf*RLY
C...SI LCCF
SLLDGE
Y... H
D... SI-PAV IPCIC*T!Cs
N...OUAI CECIA FBESSIRE
CCSTSl
3.
THTii.
NT, CCSTSl
1.
2.
3.
TCTAL YE4RLY CCSTSl
1.
2.
CCST
22061^0.00
JB330.00
??0610.00
220610.00
2665690.00
7
-------
tr
_i
o
i ICM-'
VJ
C !••!.*
Z
KJl.I
tr
ai
O
a.
<
u
««.C« KC.Ci
FIGURE 317
AMJ YE/WLY COSTS FOH SUBQATEGORY A
-------
DRAFT
TABLE 317
ITEMIZED COST SUMMARY FOR ALTERNATIVE A24-VI
(MOLASSES DISTILLERS)
CTST
DESIGI.
PPfi
9Q.6
TSE4VEKT CHAjK
POD *ECuC7ICN
El
B.
PI
Y.
e.
T.
t-r.LSE
,»".»LT;PLE
£T*tJC^
It'-K
STiTIC'.'
.FOliLI7ATIC> S^S
4C^.:^IC
S A^n
5LI.OGE
,SAKD ORYIKP BEDS
CCSTSI
i.
2.
3.
TCUL
CP£P*TIKC- CCSTJ;
1.
Z.
3,
It. K
KT*l
TCTAL YEARLY CCS7.S»
1. YEARLY
2. YEARLY
3.
TCTAL
22B0360.C)C>
22660.00
see 00 o.oo
2759100.00
7«970.00
336600.00
55350.00
^71310.00
CCST fl713lO,00
136BJO.OO
716490.00
1120
-------
DRAFT
TABLE 318
ITEMIZED COST SUMMARY FOR ALTERNATIVE A24-VII
(MOLASSES DISTILLERS)
fctSir.iv tFrJCltHY.
TRh'AT"F»'T '1C t: (AtS:
.."uLTI»Lf
J). ..«".'*'? ^.5 STiTI' *
B. ..°'jvr r;.r, fTiTiL'N'
K. ..i^TUuTbC
C . . . S L I C C c Tt-
«, ..tETC-If CIGESTCP
CCSTSl
1. CCNST^lCTIC* 2302930.00
2. LAKt 22*60.00
3. E*C-!"rferpjK,G 230290.00
u. CCKTIf.crKfY 230290.00
TCTAL 2766170.00
YEARLY CPERATlivC CLST?!
1, H&Cfr 7*970.00
2. K'^r^ 3«08«0.00
3. f •-t"."' Al i
-------
o:
<
g 15*1. »
O
11
in
5
nit. i
*:*.!> •
v.r*
«l.te
riGUPE 31 B
INVEST>ENT MC YEARLY COSTS FOR SUBCATEGIRY A 2A-VII
-------
DRAFT
Alternative A 24-VI11 - This alternative replaces the activated sludge
and sludge handling nodules in Alternative A 24-11 with an aerated
lagoon system.
The resulting BOD waste load is 1.16 kg/1000 pg (2.56 lb/1000 pg), and
the suspended solids load is 0.69 kg/1000 pg (1.52 lb/1000 pg).
Costs: Totu* investment cost: $2,665,000
Total yearly cost: 800,510
An itemized breakdown of costs 1s presented in Table 319. It is
assumed that land costs $4100 per hectare ($1660 per acre). It is
further assumed that six operators are required.
Reduction Benefits: BOD: 99.9 percent
SS: 99.6 percent
Alternative A 2-3-IX - This alternative provides in addition to
Alternative A 24-VIII dual media filtration.
The resulting 300 waste "toacl is C.58 kg/1000 pg (1.28 lb/1000 pg), and
the suspended solirfs load is 0.35 kg/1030 pg (0.77 lb/1000 pg).
Costs: Total investment cost: $2,692,880
Total yearly cost: $ 807,580
An itemized breakdown of coats is presented in Table 320. It is
assumed that land costs $4100 per hectare ($1660 per acre). It
1s further assumed that six operators are required.
Reduction Benefits: BOD: 99.9 percent
SS: 99.8 percent
A cost efficiency curve 1s presented in Figure 319.
Cost..and Reduction Benefits of Alternative Treatment Technologies for
Sjjbcategory A 25 - Bottling and 81 end ire, of Bcverajje Alcohol
Two model plants representative of Subcategory A 25 were developed
in Section V for the purpose of applying control and treatment alternatives.
In Section VII, three alternatives were selected as being applicable
engineering alternatives for each model plant. These alternatives
provide for various levels of waste reductions for the model plants.
Model plant A produces a flow of 4 cu m/day (0.001 MGD).
Altonyative A 25-A-I - This alternative assumes no treatment and no
reduction in the waste load.
Costs: 0
Reduction Benefits: None
-------
DRAFT
TABLE 319
ITEMIZED COST SUMMARY FOR ALTERNATIVE A24-VIII
(MOLASSES DISTILLERS)
c? CC£T ?L»'r;Pv Ff.s k/?TrwMPP 7PEM'-'E'>7 CHAIN
EFFICIENCY... 99.S rftTEN? PCC PECLCT1O
r i.. i
p...i
pl , .^••.•LT7t'Lf EF-'eFCT Evfif;:ci7CR
r. . . «n ::*: 7iM-
e. ..pL:"^!»-r 57*710'
v... W.;L: ]*o 7AKf
^...Pl^^'I^T, 57i7IC^
e. ..PL^PIM-. £7iTic^
C...Fr.i.tLI?*7;!:K P*SIN
H. . .M 7«CC-P'' «rcJTIC'»
I...Durir--C-i:LS ACDI7ICN
L...iEBi7E^ LAP^CN
CCS7Sf
J. CCNS7BI.CTICK 22C6570.00
2, LA^t^ 5630.00
3.
5. BVC LP'F"» 12080.00
TC.T4L ^ 266?eOO.OO
1. L*PCfi 7«»70.00
p. Pf^^w <(J7i30.00
3. CHFHC^LS «3«>0.00
U. ^41^'Tf ' .'.'>n HSLPPLHS ^36^0.00
LINCH ^?0,00
i. YE/.PLv c'-c^n'r. ccgr 5t>08«ft,oo
2, YF*RLV r^vsifFNt
ClfT F,ecrvrsy J0b630.00
J. C-tP^ECUtlCK 133000,00
TCT*L 600510.00
-------
DRAFT
TABLE 320
ITEMIZED COST SUMMARY FOR ALTERNATIVE A24-IX
(MOLASSES DISTILLERS)
2F? CTGT '(.^Ktfcv rr=> w*PTF*MFP TRfiTKr>. T CHAIN
D£:iG> tFUCIr'-CY... 9«.<> ff.PCEKT fiCT *
-------
8
2
3
s
10
o
u
— :•.»/.»
ce
• t'.c
FIGURE
INVESTftNT AND YEARLY COSTS FOR SUBCATEGORY A 2&-IX
-------
URAFT
Alternative A 25-A-I1 - This alternative provides daily truck hauling
of afl pi oni process wastes to municipal treatment facilities or
approved land disposal sites. A holding tank is provided.
The resulting-BOD waste Toed is zero, and the suspended solids load is
zero.
Costs: Total investment cost: $12,860
Total yearly cost: $16,470
An itemized breakdown of costs is presented in Table 321. It is assumed
that land costs $4100 per hectare ($1660 per acre). It is further
assumed that no operators are required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
Alternative A 25-A-III - This alternative provides for spray irrigation
of the final effluent. A holding tank, pump, and pipelines are provided.
The resulting BOD waste load is zero, and the suspended solids load it
zero.
Costs: Total investment cost: $38,270
Total yearly cost: $ 5,210
An itemized breakdown of costs is presented in Table 322. It is
assumed that land cost.i $4100 per hectare ($1660 per acre). It
is further assumed that no operators are required.
Reduction Benefits: 300: IOC percent
SS: 100 percent
Model p -*t B h*s a flow of 40 cu m (0.01 MG) per day.
Alternative A 25-B-I - This alternative assumes no treatment and no
reduction in the waste load.
Costs: 0
Reduction Benefits: None
Alternatiye A 25-B-II - This nlternative provides daily truck hauling
for all plant process wastes to municipal treatment facilities or
approved land disposal, sites. A holding tank is provided.
The resulting BOD waste load is zero, and the suspended solids load is
zero.
Costs: Total investment cost: $ 14,670
Total yearly cost: $153,470
1117
-------
LMFT
TABLE 321
ITEMIZED COST SUMMARY FOR ALTERNATIVE A ?5-A-II
(BOTTLING AtlD BLENDING OF BCVERAGE ALCOHOL)
1 1 F K 1 ? F 0 f f M < u •". t .. 1 = f S V A e T F n i T t W
DF.SK,i> EFFi:itr C Y, . . K-C'.C FEPCEKT POD
v. . .^L'Ltl-vr. T/.^K
V... TPLO t-4(.Ll
i;
1. CCKSTGLCTICN
?. L'KO
3. F» GH ffCI'.G
65C.CO
1. L*^r^ 0.0
*. >-r^Fc o.o
3. CHM'iraf o.o
fcS lSU50.0f>
I5o50,00
2. ^ttfcLY IK'VFST^EKT
CCS1 -ECTVFfev 510.00
3. CLPRECT'TI'-K 510.00
TC7AL
1128
-------
DRAFT
TABLE 322
ITEMIZED COST SUWAP.Y FOR ALTERNATIVE A 25-A-II1
(BOTTLING AND BLENDING OF BEVERAGE ALCOHOL)
Cr£T El^-ihV pnc t
CIftrv. ,.1<'0.0 ^
CD
TRf ATf £KT »• C^L'Lfc'F :
CCST-!
].
? •
3.
TCTAL
[%IM; T4NK
TCK
i.
2 .
3.
* F s
"«U'Uisi'-CE«£LPPLlES
CCSTfs
i. YfARLY
2. vpjBLY
CCSTStTCvfiPY
3. CFPf-fTIMTUK
3 (i 0 0 . C f
2
-------
DRAFT
An itemized breakdown of costs is presented in Table 323. It Is
assumed that land costs $1100 per hectare ($1660 per acre). It is
further assumed that no operators are required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
Alternative A 25-B-1II - This alternative provid?s truck hauling on
a monthly basis for redistillation residue, bad product, and deminer-
alizer regeneration. It is assumed these wastes are collected in
holding tanks. All other process wastes are spray irrigated. A
holding tank, pump, and pipeline are provided.
The resulting BOD waste load is zero, and the suspended solids load
is zero.
Costs: Total investment cost: $48,860
Total yearly cost: $ 6,360
An itemized breakdown of costs is presented in Table 324. It is
assumed that land costs $4100 per hectare ($1660 per acre). It
is further assumed that no operators are required.
Reduction Benefits: BOD: 100 percent
SS: 100 percent
Cost and Reduction Benefits of Alternative Treatment Technologies for
Subcategory A 25 - Soft Drink Canners
A model plant representative of Subcategory A 26 was developed in
Section V for the purpose of applyinp control and treatment alter-
natives. In Section VII, seven alternatives v/ere selected as Keing
applicable engineering alternatives. These alternatives provide
for various levels of waste reductions for the model plant which
produces 309 cu m (81,500 gal) per day.
Alternative A 26-1 - This alternative assumes no treatment and no re-
duction in the waste load. It 1s estimated that the effluent from a
309 cu m (81,500 gal) per day plant is 229 cu m (0.0605 MG) per day.
The BOD waste load is 1.02 kq/cu m (0.505 lb/1000 gal), and the
suspended solids load is 0.123 kg/cu m (1.03 lb/1000 gal).
Costs: 0
Reduction Benefits: None
Alternative A 26-11 - This alternative provides a control house, flow
equalization, nutrient addition, a conolete mix activated sludge
system, iludge thickening, and spray irrigation of sludge.
The resulting BOD waste load is 0.052 l.g/cu m (0.43 lb/1000 gal), and
the suspended solids load is 0.030 kg/cu m (0.25 lb/1000 gal).
1130
-------
DRAFT
TABLE 323
ITEMIZED COST SUMMARY FOR ALTERNATIVE A 25-B-1I
(BOTTLIIJG AND BLENDING OF BEVERAGE ALCOHOL)
CTST SL^-'ACY PCR ^iSTE»MEH TrF
CESIG* EFUCIENCY...100.0 PEPCFM SCO Kfc
MC.DULES:
KVESTf.FNT
YE4PIY
TCTAL
1
c
3
4
TCTAL
V. .. TF-LCK H*Ll ING
TPLC TICS
CCSTSt
1.
<*.
3.
«. f-
TCTtL
CCSTSt
i. YE»»IY
e. YEARLY
CCST
3.
7CT4L
CC3T
?750.00
990. CO
1«670.00
0.0
0.0
0.0
;S 152280.00
152360.00
590.00
60C.OO
153«70.0C
1131
-------
DKAFT
TABLE 324
ITEMIZED COST SUMMARY FOR ALTERNATIVE-A 25-B-III
(BOTTLING AND BLENDING OF BEVERAGE ALCOHOL)
ECO
COS1 SL^A^V fC-
DESIGK EFFTC:L^CV, .. ico.o
TfiF.ATMF.VT »:
CCSTS:
1. CCN
2. Ltr.r;
3. FM.lv? PH J i r,
YEARLY CPE
G C-C5TS!
2.
3.
U. !'
TC1*L
TOTAL YE4PLY CCSTf}
it Yf.»«LY
Z.
! CCST
3.
TCTAL
CCST
37MO.CC
"310.00
37 10,Or
37tO.CO
|