WATER POLLUTION CONTROL RESEARCH SERIES • 12060 DSB 09/71
DEMONSTRATION OF A
FULL-SCALE WASTE TREATMENT SYSTEM
FOR A CANNERY
U.S. CNVIRONMENTAL PROTECTION AGENCY
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WATER POLLUTION CONTROL RESEARCH SERIES
The Water Pollution Control Research Series describes the
results and progress in the control and abatement of pollution
in our Nation's waters. They provide a central source of
information on the research, development and demonstration
activities in the Environmental Protection Agency, through
inhouse research and grants and contracts with Federal, State,
and local agencies, research institutions, and industrial
organizations.
Inquiries pertaining to Water Pollution Control Research
Reports should be directed to the Chief, Publications Branch
(Water), Research Information Division, R&M, Environmental
Protection Agency, Washington, B.C. 20460.
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DEMONSTRATION OF A FULL-SCALE WASTE TREATMENT SYSTEM FOR A CANNERY
By
Leale E. Sfreebin
Associate Professor
George W. Reid
Professor and Director
Alan C. H. Hu
Research Engineer
School of Civil Engineering and Environmental Science
University of Oklahoma
Norman, Oklahoma 73069
for the
Office of Research and Monitoring
ENVIRONMENTAL PROTECTION AGENCY
University of Oklahoma Research Institute
1808 Newton Drive
Norman, Oklahoma 73069
Project #1672 OURI
Con tract #12060 DSB
September, 1971
For sale by the Superintendent of Documents, U.S. Government Printing Office
Washington, D.C., 20402 - Price $1.50
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EPA Review Notice
This report has been reviewed by the Environmental Protection
Agency and approved for publication. Approval does not
signify that the contents necessarily reflect the views and
policies of the Environmental Protection Agency nor does
mention of trade names or commercial products constitute
endorsement or recommendation for use.
11
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ABSTRACT
In 1967, the Stilwell Canning Company was discharging a portion of their wastes to
Stilwell1 s Municipal waste treatment system and the rest to an irrigation system. Both
were inadequate; therefore, a new system had to be developed.
SHI well Canning Company, Stilwell, Oklahoma, cans and freezes a wide variety of
vegetables and fruits including spinach, strawberries, green beans, yellow squash,
okra, peas, beans, white potatoes, and sweet potatoes with potatoes being the domi-
nant product. It is situated in a small community with a population of only 2,600 and
during the potato processing season has a mean population equivalent of 150,000.
The company is located on a small receiving spring fed stream which has a summer flow
roughly equivalent to the waste flow. Consequently, a high treatment efficiency is
required in order to maintain acceptable stream standards.
To meet the imposed requirements a two-stage aeration system was designed which con-
sists of screens to remove the large suspended particles, a minimal solids aeration unit
to remove a portion of the soluble organic matter, an extended aeration unit for solids
destruction and effluent polishing, and a final clarifier. This system is the first one
of this design known to treat a cannery waste; therefore, an operational study of this
system was undertaken.
The system was studied over one operating season and data collected on the removal
efficiencies of each unit process in the system. The treatment system performed more
efficiently than expected in the design assumptions. Removal efficiencies of greater
than 95% were obtained for most of the processing season, even though because of
plant expansion the organic and hydraulic load was higher than expected.
It has been demonstrated conclusively that (1) the Stilwell canning wastes can be
treated successfully by a two-stage activated sludge process. (2) The two-stage aera-
tion process is very stable and capable of accepting shock loads without being ad-
versely affected. (3) The two-stage aeration process is a flexible system allowing
adequate capacity for varying waste loads; that is, the units can be operated indi-
vidually or in combination to match the flow and strength variations. This provides
high treatment efficiencies at the lowest operational cost. (4) Any one of the units,
such as the minimal solids unit, can be started up readily by recycling the mixed
liquor from one of the operating units.
This report was submitted in fulfillment of Project Number 1672 OURI and Demonstra-
tion Contract Number 12060 DSB between the Water Quality Office, Environmental
Protection Agency, and the University of Oklahoma Research Institute.
in
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CONTENTS
Section Page
I CONCLUSIONS 1
II RECOMMENDATIONS 3
III INTRODUCTION 5
IV LITERATURE REVIEW 7
V DESIGN OF TREATMENT FACILITIES 19
VI PLANT SCALE STUDY 27
VII DISCUSSION 57
VIII ACKNOWLEDGEMENTS 89
IX BIBLIOGRAPHY 91
X APPENDICES 95
APPENDIX A. CANNING PROCESSING FLOW SHEETS 97
APPENDIX B. ANALYSIS OF WASTE STREAMS 107
APPENDIX C. LABORATORY ANALYTICAL METHODS 111
APPENDIX D. PLANT PERFORMANCE DATA 115
APPENDIX E. PLANT INFLUENT, MODULAR UNITS 133
AND SYSTEM ANALYSES
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TABLES
Table No. Page
1. Potato Wastes Characteristics (From Literature Review) °
2. Summary of Aerobic Biological Treatment Results
(From Literature Review)
3. Volume and Characteristics of Cannery Wastes ''
4. Waste Characteristics After Screening and Treatment
"I Q
Efficiency of Filters
5. Design Criteria
6 . Production Record 28
9ft
7. Production Schedule
8. Flow Data 33
9. Estimates of Parameters 5°
10. Error Analysis 61
11 . Plant Influent Study 63
12. Modular Unit Study of Sweet Potatoes and
Vegetables 69
13. Modular Unit Study of Irish Potatoes and
Vegetables 70
14. Modular Unit Study of Vegetables 71
15. Plant Effluent Study 77
Id. Cost of Waste Treatment System 87
B-l Analysis of Waste Streams Sampled 109
VI
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Table No. Page
D-l Plant Performance Data of Sweet Potatoes and
Vegetables 117
D-2 Plant Performance Data of Irish Potatoes and
Vegetables 122
D-3 Plant Performance Data of Vegetables Only 127
VII
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FIGURES
Figure No.
1 . Flow Diagram ................................... 22
2. Schematic Flow Diagram ............................ 23
3. Aerial View of the Waste Treatment Plant ................. 26
4. Waste Flow Variation .............................. 34
5. Plant Influent and Settled Influent COD .................. 35
6. Treatment Plant Performance - COD .................... 37
7. Treatment Plant Performance - COD .................... 38
8. Treatment Plant Performance - SS ...................... 39
9. Treatment Plant Performance - VSS ..................... 40
10. Treatment Plant Performance - pH ...................... 41
1 1 . Temperature of Plant Influent and Effluent. ................ 42
12. MLSS and MLVSS of Minimal Solids Unit ................. 43
13. DO in Minimal Solids Unit .......................... 44
14. Total COD Loading Rate of Minimal Solids
Unit ......................................... 45
15. Soluble COD Removal Rate of Minimal
Solids Unit
16. SVI of Minimal Solids Unit .......................... 47
17. HRT of Minimal Solids Unit .......................... 48
VIII
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Figure No. Page
18. MLSS and MLVSS of Extended Aeration Unit 49
19. DO in Extended Aeration Unit * . . 50
20. Soluble COD Loading Rate of Extended
Aeration Unit 51
21. Soluble COD Removal Rate of Extended
Aeration Unit 52
22. SVI of Extended Aeration Unit 53
23. HRT of Extended Aeration Unit. 54
24. SS and VSS of Return Sludge 55
25. SVI vs Soluble COD Removal Rate - Minimal Solids 79
26. SVI vs Soluble COD Removal Rate -
Extended Aeration 80
27. TKN of Sludge vs COD Removal Rate - Minimal Solids 82
VSS
28. TKN of Sludge vs Soluble COD Removal Rate -
VSS
Extended Aeration 83
29. SVI vs TKN of Sludge. 84
VSS
A-l. Flow Sheet of Irish Potato Processing 98
A-2. Flow Sheet of Sweet Potato Processing 99
A-3. Flow Sheet of Green Vegetable Processing 100
A-4. Flow Sheet of Green Bean Processing 101
IX
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Figure No.
A-5. Flow Sheet of Peas and Beans Processing
i /
A-6. Flow Sheet of Squash Processing '
A-7. Flow Sheet of Okra Processing '
A-8. Flow Sheet of Blackberry Processing 105
A-9. Flow Sheet of Strawberry Processing '°°
E-l. Plant Influent VSS vs SS ] 35
E-2. Plant Influent YDS vs DS 136
E-3. Plant Influent TVS vs TS 137
E-4. Plant Influent Total COD vs TVS I38
E-5. Plant Influent Soluble COD vsVDS 139
E-6. Plant Influent VSS vs SS 14°
E-7. Plant Influent VDS vs DS HI
E-8. Plant Influent TVS vs TS H2
E-9. Plant Influent Total COD vs TVS 143
E-10. Plant Influent Total COD vs VDS 144
E-l 1. Plant Influent VSS vs SS 145
E-12. Plant Influent VSS vs SS 146
E-13. Plant Influent VDS vs DS 147
E-14. Plant Influent VDS vs DS 148
E-15. Plant Influent TVS vs TS 149
E-16. Plant Influent TVS vs TS 150
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Figure No. Page
--"- -v i i ir% •
E-17. Plant Influent Total COD vs TVS 151
E-18. Plant Influent Total COD vs TVS 152
E-19. Plant Influent Soluble COD vsVDS. 153
E-20. Plant Influent Soluble COD vs VDS. » . . 154
E-21. COD Removal Rate vs Soluble Effluent
COD 155
E-22. COD Removal Rate vs Soluble Effluent
COD 156
Er23. COD Removal Rate vs Soluble Effluent COD* 157
E-24. MLVSS vs MLSS * . 158
E-25. ML Solids COD vs MLVSS 15$
E-26. MLVSS vs MLSS 160
E-27. ML Solids COD vs MLVSS 161
E-28. MLVSS vs MLSS 162
E-29. ML Solids COD vs MLVSS 163
E-30. Soluble COD Removal Rate vs Soluble
Effluent COD , . . 164
E-31. Soluble COD Removal Rate vs Soluble Effluent
COD 165
E-32. Soluble COD Removal Rate vs Soluble Effluent
COD 166
E-33. MLVSS vs MLSS T67
E-34. ML Solids COD vs MLVSS 168
E-35. MLVSS vs MLSS 169
XI
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Figure No. Page
E-36. ML Solids COD vs MLSS 170
E-37. MLVSS vs MLSS 171
E-38. ML Solids COD vs MLVSS 172
E-39. Plant Effluent VSS vs SS 173
E-40. Plant Total Effluent COD vs VSS 174
E-41. Effluent Solids COD vs VSS 175
E-42. Plant Effluent VSS vs SS 176
E-43. Total Effluent COD vs VSS 177
E-44. Effluent Solids COD vs VSS 178
E-45. Plant Effluent VSS vs SS 179
E-46. Plant Total Effluent COD vs VSS 180
E-47. Effluent Solids COD vs VSS 181
XII
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SECTION I
CONCLUSIONS
On the basis of the findings from this plant scale investigation, the following conclu-
sions are drawn:
1. It has been demonstrated conclusively that the SHI well canning wastes
can be treated successfully by a two-stage activated sludge process,
without pH adjustment of the incoming wastes.
2. The two-stage aeration process is very stable and capable of accepting
shock loads without being adversely affected and provides high rate of
removal with high treatment efficiencies.
3. The two-stage aeration process is a flexible system allowing adequate
capacity for varying waste loads; that is, the units can be operated in-
dividually or in combination to match the flow and strength variations.
This provides high treatment efficiencies at the lowest operational cost
required to maintain a good receiving stream quality.
4. Any one of the units, such as the minimal solids unit, can be started up
readily by recycling the mixed liquor from one of the operating units.
5. The final clarifier is inadequate at the peak flows. During the peak pro-
cessing season the retention time is as low as 1 .15 hours.
6. Substrate removal rates in the minimal solids unit follow zero order ki-
netics. An average COD removal of 90% was obtained for potato wastes
and 84% for vegetable waste. About 50% of the COD removed can be
attributed to bio-precipitation and settling since approximately 50% of
the influent COD is present in the sertleable, suspended or colloidal form.
7. The extended aeration unit was very successful in effluent polishing.
The average plant soluble COD were 84, 44, and 33 mg/l for sweet
potato and vegetable wastes, Irish potato and vegetable wastes, and
vegetable wastes alone, respectively. The corresponding BOD in the
plant effluent was about 20% of the COD values, which indicated
biodegradable organic removal for the system of greater than 99%.
8. Foaming problems in aeration basins can be controlled by maintaining
a MLVSS level of at least 2000mg/l.
9. Loss of sludge from final clarifier during the processing of sweet potatoes
was a result of nitrogen deficiency.
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10. A TKN/VSS ratio of 5% in the sludge is required in order to control
sludge bulking.
11. Temperature effect was not significant during the course of study.
12. The rapid fluctuations in flow and waste strength resulting from the
frequent changes in products processed negated the reliability of a
laboratory model in simulating a full-scale system, and therefore,
they were not pursued.
13. Solids handling facilities in the system are not adequate.
14. The anaerobic digested sludge has a rubber-like consistency which
may make it unsuitable as a soil conditioner.
15. The rate of digestion is extremely slow; therefore, the use of anaero-
bic ponds for solids disposal from a cannery waste treatment plant is
probably not the optimum system.
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SECTION II
RECOMMENDATIONS
Based on the results from this study the Following changes and/or additions are recom-
mended:
1 . A solids disposal facility other than anaerobic ponds should be added
to this system. The recommended process is primary sedimentation fol-
lowed by vacuum filtration. The filter would be used to dewater the
return sludge as well as the sludge from the primary ctarifier. The fil-
ter cake, until a market can be developed, will be disposed of in the
existing sanitary land fill.
2. A study should be initiated to find economical uses of solid waste pro-
duct, which, while processing some products, amounts to more than 40
percent of the raw product purchased.
3. A second final clarifier should be added to the system. It should have
a capacity large enough to increase the combined retention time of both
final clarifiers to four hours.
4. The inplant piping should be improved to allow the operation of each
unit separately in parallel or in series.
5. A water savings and reuse study should be undertaken to decrease the
water demand. It is anticipated the water demand could be decreased
by at least 30 percent, and probably 50 percent or more.
6. A study of this magnitude should be spread over a longer time period,
allowing for two processing seasons. This cannery processes a variety
of vegetables and fruits, some over a very short period of time, which
makes it difficult to obtain enough data to reach sound conclusions.
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DEMONSTRATION OF A FULL-SCALE WASTE
TREATMENT SYSTEM FOR A CANNERY
SECTION III
INTRODUCTION
General
The canning industry and in particular the potato processing industry has grown very
rapidly in the past decade. The 1967 and 1969 USDA (1) production figures indi-
cated a total potato crop of 245,272,000 hundred weights in 1959 and 294,192,000
hundred weights in 1968. The total quantity of potato processed by all food indus-
tries increased from 47,824,000 hundred weights in 1959 to 69,429,000 in 1964
(there was no record on potqto processed in 1968). This corresponds to approximately
19% of the total crop in 1959 and 29% in 1964. Many of these processing plants are
located in rural areas or in small towns where sewage treatment facilities are not
available or at leqst were not designed to treat a waste of high organic content. In
the processing of potatoes, 20 to 50% of the processed raw potato is discharged as
waste. Such waste can be composted and sold as fertilizer, used as feed for live-
stock, or for by-products extraction if it is economically feasible. Waste flows range
from 840 gallons to 5,000 gallons per ton of raw potatoes processed, depending on the
desired product. The rapid growth of the potato industry has resulted in a correspond-
ing increased volume of waste with potentially the same increase in water pollution.
The characteristics of the potato waste are high organic strength, high starch content,
large volume, low nutrients, and pH values which vary with the method of peeling
used. Research on biological treatment of potato wastes reported at the initiation of
this study, with the exception of that reported for lagoons, has been done using bench
scale models. It is essential that these Studies be related to full scale plant operation,
so that high rate and modular processes can be designed and economically applied.
A study supported by the Federal Water Quality Administratibn'was undertaken for
this purpose at the SHlwell Canning Company.
Stilwell Canning Company, SHlwell> Oklahoma, cans and freezes a wide variety of
vegetables and fruits which include spinach, strawberries, greeri beans, yellow
squash, okra, peas, beans, white potatoes, and sweet potatoes with potatoes being
the dominant product. It is situated in a small community with a population of only
2,600 and during the potato processing season, has a mean pbpulaHon equivalent
of 150,000. It is located on a small receiving spring fed stream which has a summer
flow roughly equivalent to the waste flow. Consequently, a high treatment effi-
ciency is required in order to maintain acceptable stream standards.
Benefiting from the grant-in-aid program of the Federal Water Quality Administra-
tion of the U.S. Department of Interior and a grant from the Economic Development
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Administration Office, of the U.S. Department of Commerce, a wastewater treat-
ment plant was constructed and started operation in May, 1969.. The design was
based on studies by Reid and Streebin (2) and consists of screens to remove the large
suspended particles, a minimal solids aeration unit to remove a portion of the soluble
organic matter, an extended aeration unit for solids destruction and effluent polish-
ing, and a final clarifier. This system is the first one of this design known to treat
a cannery waste; therefore, an operational study of this system has been undertaken.
Objective
The objective of the research is to show that high organic, large volume, nutritionally
unbalanced cannery wastes can be successfully and economically treated to a high
degree by a two-stage biological process. The results will be used to establish de-
sign criteria for the treatment of potato and vegetable wastes.
The scope of this research includes:
1. Characterization of the various vegetable and potato wastes as they
reach the waste treatment plant.
2. Determination of waste flows.
3. Evaluation of the performance of each modular process and the en-
tire system.
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SECTION IV
LITERATURE REVIEW
A review of technical literature has been undertaken to assemble the pertinent results
of other investigators. The literature cited includes three subjects: potato waste,
nutrient supplementation, and other vegetables and fruit wastes. A brief summary is
given below.
Potato Waste
Waste Characteristics
Cooley et al (3) studied the characteristics of several potato processing wastes.
They found that the waste flow from the potato flake factory was 2643 gallons per
ton of raw potato processed with a suspended solids (SS) of 23.7 Ibs per ton or
1080 mg/l, and the pH of lye peeling stream was 12.6 and that a stream peeling
was 7.3.
The average volume of waste per ton of raw potato from the potato flake industries
as surveyed by Francis (5) was 5000 gallons with an average BOD of 59 Ibs or 1720
mg/l and a SS of 91 Ibs or 2580 mg/l.
Porges and Towne (6) reported a waste flow of 1990 gallons per 1000 Ibs of potatoes
processed into potato chips with an average BOD of 25 Ibs or 1380 mg/l and a SS
of 33 Ibs. or 1710 mg/l.
The Potato Chip Institute and the National Technical Task Committee (7) reported
an average BOD of 25 Ibs per 1000 Ibs. of raw potato processed, and the BOD/Solids
ratio of 0.453.
Vennes and Olmstead (8) quoted, in their investigation on the potato flake waste,
an average flow of 5000 gallons with a BOD of 1410 mg/l and a SS of 2180 mg/l
based on one ton of raw potato processed.
Atkins and Sproul (9) studied a lye peeling french fry processing plant in Maine and
found that in-plant improvements reduced the waste flow from 2520 gallons per ton
of raw potato to 2310 gallons per ton, the plant composite BOD of 2460 mg/l to
1150 mg/l, the SS from 1750 mg/l to 1310 mg/l; and the COD of this waste was
reduced from 3500 mg/l to 1790 mg/l. The BOD to COD ratios were, respectively,
0.7 and 0.4 before and after the in-plant improvement with lye peeling pH of 11.5
to 11.1.
Fergason et al (10) determined the BOD of the protein water from a potato starch
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plant to be about 3900 mg/l with a COD of 6000 to 7000 mg/l and on average BOD
to COD ratio of 0.64.
Kueneman's study (11) on a primary waste treatment plant, in Idaho, indicated a
waste flow of 3650 to 4200 gallons per ton of raw potatoes, COD of 2000 to 2500
mg/l, and pH of 11 to 12 using a lye peeler and 6 to 6.5 using a steam peeler.
Kueneman further stated that the waste flow could be reduced to 200 to 400 gallons
per ton with considerable water re-use.
Forma (12) analyzed the process wastes from several potato processing plants in Idaho
and reported an average flow of 2700 gallons per ton of potato processed and a COD
of 3300 mg/l.
Potato processing wastes contain some nitrogen and phosphorous. Atkins and Sproul
(9) presented information indicating a BOD/P ratio of 350 to 1.
Dostal (4) in a study of two potato processing and one starch plant over a two year
period reported the following data per ton of product: a waste volume of 4200 gal-
lons, BOD of 90 Ibs, COD of 210 Ibs, suspended solids of 110 Ibs, total phosphate
of 0.6 Ibs and total nitrogen of 3.5 Ibs, for a BOD/N/P ratio of 100/3.9/0.7.
Reid and Streebin (2) measured a COD strength of 3190 mg/l, a COD/N ratio of
570/1 and a N/P ratio of 2.5/1 for Irish potato wastes and a COD of 4500 mg/l,
a COD/N ratio of 2600/1 and N/P ratio of 0.55/1 for sweet potato wastes.
A summary of the potato waste characteristics as found in the literature is shown in
Table 1.
Screening, Primary Settling and Sludge Dewatering
Screening serves to remove the coarse material that might interfere with subsequent
operations in treatment, and therefore is generally used as the first step in food
waste treatment. Ballance (13) indicated that all types of vibrating screens have a
great advantage over the other moving screens for producing a solid fraction that is
relatively low in moisture content (80%). He further stated that for potato waste
a 20 mesh screen could remove approximately 35% of the total solids. Barnes
(15) reported that a SS removal of 35% could be be obtained by a 10 mesh screen
with a corresponding BOD reduction of 27%.
The Potato Chip Institute and the National Technical Task Committee (7) reported
approximately 50% of the suspended and 90% of the settleable matter of composite
potato waste stream could be removed with a 15 to 30 mesh screen.
According to investigations by Hindin and others (14) the screened solids had a
COD of 108 g/l, a total solids content of 10 to 15% and a volatile solids content
of 9 to 14%.
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TABLE 1
POTATO WASTE CHARACTERISTICS (FROM LITERATURE REVIEW)
•o
POTATO Waste
PROCESS Flow
FOR Gal/Ton
Potato Flake 2643
Potato Chip 2007
Potato Flour 880
Potato Starch 838
Potato Chip 3980
Potato Flake 5000
French Fry 2310
Potato Starch
Various
Products 2700
Various 3650-
Products 4200
Irish Potato Canning
Sweet Potato Canning
Potato Pro- 4200
cess ing And
Potato Starch
ROD pH
SS BOD COD ^g± Lye Steam
Ibs/Ton mg/l Ibs/Ton mg/l Ibs/Ton mg/l Peeling Pealing
23.7 1080 33 1540
36 2090 14.5 840
19 2590 23 3140
28.9 4140 25.8 3680
33 1710 25 1380
91 2580 59 1720
1310 1150
3900
110 90
51 2320 0.64 12.6 7.3
49.4 2860 0.293
37.3 5080 0.617
51 .4 7380 0.502
1790 0.4 11.3
6500 0.64
3300
2000- 11- 6.0-
2500 12 6.5
3194
4500
210 .41
Ref.
(3)
(6)
(8)
(9)
(10)
(12)
01)
(2)
(4)
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Sedimentation is the least expensive method of solid liquid separation used to remove
finer suspended matter from the waste water. The experiments by Reid and Streebin
(2) on settling of potato waste for one hour showed approximately 38% COD reduction
with 5.1% solids in settled sludge for Irish potato and a COD reduction of 44% with
5.7% solids in settled sludge for sweet potato.
Dostal (4) reported that primary treatment of potato waste by sedimentation at an
overflow rate of 800 gpd/ft2 could remove 41, 45, 73, 21, 21 percent of the BOD,
COD, SS, PO, and N respectively. He also reported a BOD/N/P ratio of 100/
5.2/0.9 for primary clarifier effluent.
The work of Sproul and others (14) showed a SS and BOD removal of 80 and 60%
respectively by primary settling at overflow rates of 600 to 1000 gal/day/sq. ft.
Activated Sludge
Buzzell and others (16) investigated the feasibility of treating the waste from a potato
starch plant using a continuous flow, complete mixing activated sludge pilot unit.
It was found that this system gave excellent BOD reductions even at rather high or-
ganic loadings. When units were loaded at less than 80 Ibs of BOD per 1000 Ibs of
mixed liquor suspended solids (MLSS) per hour of aeration, BOD removals were 95%
and above. At a MLSS concentration of 3500 mg/l, this loading is equivalent to
420 Ibs of BOD per 1000 cu. ft. of aeration capacity per day. As the BOD loading
was increased above 80 Ibs, the BOD removal efficiency dropped off rapidly. The
simulated waste studies had an average BOD of 3700 mg/l. It was further pointed
out that foaming was a problem, and it tended to increase with decreased aeration
time. No nutrients were added in this study.
Atkins and Sproul (9) studied the feasibility of treating a potato waste from a lye
peeling french fry plant using a complete mixing activated sludge laboratory unit.
The aeration time studies varied from 6 to 20 hours. At a 6 hour aeration time, the
BOD loading ranged from 191 to 358 Ibs per day per 1000 cu. ft. of aeration vol-
ume; and the MLSS concentration ranged from 3600 to 4500 mg/l. At these loading
rates BOD removals of higher than 90% were maintained. The sludge could be settled
satisfactorily at all aeration times studied; however, the sludge density increased
with an increase in aeration time. No nutrients were added in this study. The in-
fluent pH was 11.8 and that of the treated effluent varied from 8 to 9. The cor-
responding COD removal was 90% and the SS removal above 90% with a sludge
volume index (SVI) of 100 to 190. It was concluded that without pH adjustment, at
a MLSS level of 4000 mg/l, and an aeration period of 6 to 8 hours, a BOD reduction
of 95% or above could be obtained. Their study also showed that adjustment of pH
did not significantly improve the treatment efficiency. The authors briefly studied
the contact stabilization process. Their results showed that a 78% COD removal
was possible with a contact time of one hour and stabilization time to 6 to 8 hours.
10
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In this study the pH of the wastes was adjusted to 8.0 before feeding the treatment
Unit; the MLSS concentration in the stabilization unit was maintained at 4000 mg/l;
and sludge returned was 33% of total volume in the contact compartment. At a con-
tact time of 30 minutes with 2 hours of reaeration, COD removal was 49%. It was
concluded that further investigation into this type of treatment would be highly desir-
able. Sproul et al (14) found that the growth rate for a settled steam peeling waste
was about 0.0005 mg/l/nour. According to Sproul, this would indicate a BOD re-
moval of 92% with an aeration time of 6 hours and a mixed liquor volatile suspended
solids (MLVSS) of 3500 mg/l. Based on the laboratory work at the University of
Maine, Sproul (17) presented a tentative design criteria for complete mixing acti-
vated sludge treatment of lye peeling potato processing waste without pH adjustment.
The investigator recommended a BOD loading of 200 to 400 Ibs per 1000 cu. ft. of
aeration volume per day with a MLSS concentration of 3000 to 4000 mg/l and an
aeration time of 8 hours. Foaming problems in the aeration tanks will be minimized
if the biological solids are kept at the higher level. Reid and Streebin's study (2)
on treating potato processing waste using an activated sludge system at the University
of Oklahoma showed comparable results with other investigators. A minimal solids
aeration unit of 3 hours detention time yielded a 50% COD reduction. The extended
aeration studies showed a COD reduction of 96.5% in 17 hours of aeration time. The
biosorption process was also studied, but it only yielded a 25% COD reduction. These
studies further indicated that nutrients will be required to maintain a BOD/N ratio of
approximately 100 to 1 which is much less than the normal combining ratio. This ratio
is substantiated by Ekenfelder (33).
Trickling Filter
The use of biofilters to treat potato wastes has also been investigated. Buzzell and
others (16) found that a 90% or better BOD removal was obtained on high rate filters
with a loading of up to 3000 Ibs BOD per acre-foot per day. Pailthrop and Filbert
(18) presented data indicating that BOD could be reduced from 1680 to 280 mg/l or
84% by treating a primary settled lye peeling potato waste through to super rate Dow
Chemical Company's Surfpac Filter. The recirculation ratio was 6 to 1; however,
the loading rate was not given.
A summary of the organic and hydraulic loadings used for the design of aerobic bio-
logical treatment processes as obtained from the literature cited is shown in Table 2.
Anaerobic Digestion
Hindin and Dunstan (19) made studies on the treatment of the settled solids from the
potato chip waste by using anaerobic digestion. Their experiments showed that mix-
tures of potato waste solids and raw domestic sludge can be satisfactorily treated by
conventional anerobic digestion as long as the feed does not contain more than 50%
potato solids. The loading rate used in their laboratory investigation was 0.075 Ibs
volatile solids per day per cu. ft. of digestion capacity with a detention time of 33
11
-------
days. The volatile acids did not exceed 1400 mg/l in the study. It is generally ac-
knowledged that as long as the total volatile acids are less than 2000 mg/l as acidic
acid, no inhibitory effect on the activity of the methane bacteria will occur. 'J_owas
concluded that the digester was under a stress when treating a feed containing 70 /o
potato solids. This was probably due to a growth factor deficiency rather than the
presence of inhibitory substances.
Ling (20), in a study of starch-gluten waste, used a model of a conventional sedimen-
tation tank to separate the solids which were forwarded to a continuously recirculated
anaerobic digestion laboratory unit. The digester was maintained at a temperature of
about 95°F. This experiment showed an 80% removal of volatile solids at a loading
of 0.1 Ibs volatile solids per day per cu. ft. of digester volume. The author furthur
pointed out that the maximum allowable loading of the digestion process had not been
reached at this loading.
Both digester and anerobic lagoons give off very offensive odors (21, 22) and are un-
satisfactory in the area where odors cannot be tolerated.
Nutrient Supplementation
Efficient and successful biological oxidation of organic wastes require nitrogen (N)
and phosphorous (P) for the anabolic reactions, i.e. the synthesis of new cell tissue.
Many industrial wastes, such as potato processing waste, do not contain adequate
quantities of nitrogen and phosphorous for these reactions; hence, they require the
addition of nutrients.
Servizi and Bogan (23) demonstrated that synthesis is proportional to the change in
free energy of oxidation. Since the free energy for most organic compounds is the
same, -3160 to -3587 cal/g COD, it follows that synthesis will be proportional to
the COD reduction of the substrate or waste.
Since in bio-oxidation both the synthesis and respiration proceed simultaneously,
nitrbgen will be released and assimilated simultaneously. Some of the nitrogen will
be recovered and reused for synthesis. Therefore, the quantity of nitrogen required
depends on the aeration time. The general formula for biological cell mass has been
expressed as C5H7O2N (23), in which 12.4% is nitrogen. Sawyer and his associates
(25, 26, 27) studied the nutritional requirements of activated sludge with industrial
wastes and expressed the assimilation of nitrogen in terms of a BOD to nitrogen ratio,
BOD/N. They concluded maximum nutritional requirements need not be supplied in
order to achieve satisfactory treatment. Critical nutritional requirements on the basis
of BOD removal are estimated to be 3 to 4 Ibs of nitrogen, and 0.6 Ibs of phosphorous
per 100 Ibs of BOD* removed respectively. This is approximately equivalent to a BOD/
N/P ratio of 150/5/1 at 20 C. A critical nitrogen deficiency tends to decrease the rate
of BOD removal, impair the settling and dewatering characteristics of the sludge,
12
-------
and decreases the rate of sludge growth. The critical nutrient concentration was de^
fined as the minimum amount of a nutrient which must be present to maintain BOD
removals at a high rate. Any reduction of nutrient concentration below the critical
amount would cause the BOD removal to fall off rapidly. The percentage nitrogen
content of dried activated sludge based on volatile matter is a good index of nutrient
deficiency. A value of less than 7% for nitrogen and 1.2% for phosphorous is indi-
cative of a critical deficiency.
The maximum requirement is the maximum amount of nutrient which can be taken up
by'the sludge. Assuming the nutrient fully available, the sludge will tend to remove
up to the maximum nutrient requirement from solution and fix it in the sludge. Ac-
cording to Weinberger's work (28), only nitrogen present in the form of NH3~N is
considered to be 100% available for the bacteria.
Heukelekian and others (29, 30), in their tests on a number of industrial wastes,
established a BOD/N/P ratio of 100/5/1 as being generally desirable for a maximum
stabilization rate. The observed BOD values included only carbonaceous oxygen
demand. Jones (31), in his studies on sludge bulking, showed that the critical BOD/
N ratio was 40/1, and below this value the specific growth rate decreases. He fur-
ther indicated that the cell mass contained 6.5% of NH4 and 9.0% of NO3-N at
the equilibrium nitrogen concentration. This was based on the assumption that d| Ihe
nitrogen had been taken up by the cell. Oginsky and Umbreit (32) indicated that,a
n'ftrogen content of 1.7% in the cell mass was adequate and phosphorour, sulfur,
etc., were not usually limiting. This concentration is much lower than reported by
other investigators, and low concentrations generally result in sludge bulking. Saw-
yer (33) reported that the phosphorous requirement was about one fifth of the nitrogen
requirement. Eckenfelder and Burns (34) showed a critical requirement of 4.3 Ibs N/
100 Ibs BOD removed. This is based on their two year study of nutrient requirements
at the West Virginia Pulp and Paper Company activated sludge plant; below this level
organic removal efficiency was lowered.
Since most industrial wastes are deficient in nutrients, the addition of nitrogen and
phosphorous in the biological treatment system is usually required. The cost of main-
taining a BOD/N/P ratio of 100/5/1 in the activated sludge system, as used in gen-
eral practice, is tremendous. Furthermore, the nitrate content in the treated effluent
encourages heavy algae growth in the receiving water. Reid (35) pointed out that as
the degree of treatment for organic removal increased, the dilution requirements for
the maintenance of dissolved oxygen levels for receiving water decreased, while the
dilution required for the control of nutritional pollution as measured by algae concen-
trption tended to increase. Hence, for higher level treatment, discharged nutrients
rridy dictate the treatment process. Komolrit, Krishnan and others (36, 37) found
that with initial high biological solids concentration in the aeration vessel, carbpn
could be incorporated into non-nitrogen cell constituents in the absence of an.exo-
genous source of nitrogen by first storage and later synthesis; and for a short period
13
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TABLE 2
SUMMARY OF AEROBIC BIOLOGICAL TREATMENT RESULTS (FROM LITERATURE REVIEW)
TREATMENT
PROCESS
Complete Mixing
Activated Sludge
Complete Mixing
Activated Sludge
Contact Stabilization
Activated Sludge
Complete Mixing
Activated Sludge
Minimal Solids
Extended Aeration
Contact Stabilization
High Rate
Trickling Filters
Dow Chemical
Surfpac Filter
Process
Water
Potato
Starch
Lye Peel
French Fry
Lye Peel
French Fry
Steam Peel
Stilwell
Potato Waste
diluted
with water
Potato
Starch
Lye Peel
Organic
Loading
4200 Ibs BOD
1000 cf-day
191-3581- Ibs BOD
1000 cf-day
3600 mg/l COD
1400 mg/l COD
800 mg/l COD
3000 Ibs BOD
acre ft-day
Aeration
time
hr.
15
6
1.5
6
3
17
0.5
158 gal
sf-day
MLSS Percent Nutrient
Organic Supplemen-
mg/l Removal tation
3500 95% BOD None
3600 90% BOD None
4500
4000 78% COD None
?^??cc 92% BOD None
MLVSS
50% COD None
96% COD
25% COD None
90% BOD None
84% BOD None
Ref.
(16)
(9)
(9)
(15)
(2)
(2)
(16)
(18)
-------
of time the removal efficiency would not be impared. After substrate removal, the
protein was then synthesized from the carbohydrate stored in the cells by aeration in
the presence of nitrogen. Using this idea, Gaudy and his associates (38, 39) studied
the feasibility of reducing the nitrogen supply by controlled addition of nitrogen to
the returned sludge rather than continual addition to the incoming waste. In their
laboratory experiment, the nitrogen deficient waste was fed continously to a feeding
aerator without addition of nitrogen; the mixed liquid was then passed to a clarifier
for solids separation, from which a portion of the sludge was forwarded to an endo-
genous aerator where the exogenous nitrogen was added; then the sludge was recycled
to the feeding aerator. It was found that with a COD/N ratio of 70/1 a solids con-
centration of 700 mg/l and a hydraulic detention time of 4 hours in the feeding
aerator, the overall removal efficiency after settling was 96%. The substrate used
was acetate; therefore the corresponding BOD/N ratio was 47/1.
Other Vegetable and Fruit Wastes
In the United States, nearly half of all vegetables and fruit produced are canned or
frozen. About 90% of the peaches and pineapples, 80% of all tomatoes, 65% of the
peas produced and more than 50% of all sweet corn harvested in this country are
canned. Many other products such as beans, okra, spinach, collard greens, mustard
greens, oranges, apples, strawberries, pumpkin, squash and mushrooms are also
canned or frozen.
Since these agricultural products are highly seasonal, almost every cannery processes
a wide variety of foods in its operation. Because such a wide variety of products are
processed in individual canneries, various waste flows and concentrations can be
found.
The characteristics of various products as presented by Mercer (40) are reproduced in
Table 3. Burbank and Bumagai (41) studied the feasibility of treating pineapple waste
by activated sludge. The organic constituents as measured by COD ranged from 24.1
to 32.8 Ibs per ton of pineapples processed with a weighted average of 26.2 Ibs per
ton. The waste contained a high carbohydrate concentration which accounted for 80
to 90% of the soluble COD. As demonstrated from a completely mixed activated
sludge laboratory system, carbohydrate removal was feasible; with a maximum load-
ing rate of 17.5 Ibs sugar/lb MLSS/day, 98% carbohydrate removal was obtained;
however, sludge settling was poor. They further demonstrated that sludge growth was
partly due to celluloseutilization, and that 80% of the COD removal was attributed
to synthesis. The nutrients in the waste were sufficient for biological treatment.
The University of Oklahoma has studied the characteristics of tomato waste from an
Oklahoma cannery (42). It was found that one hour of settling would reduce the
COD of the lye peeling stream from 1830 to 1600 mg/l and 1550 to 1260 mg/l for the
steam peeling stream. The COD of the packing stream could be reduced from 1220
to 1020 mg/l for the same settling period. The BOD of the settled lye peeling stream
15
-------
was
,.„ 940 mg/l, and the BOD of the settled steam peeling stream was 860 mg/l. The
feasibility of treating this waste has been studied in a batch unit using unacclimated
sludge. After 24 hours of aeration, the COD was reduced from 1230 to 160 mg/l
with a MLVSS increase from 1235 to 2405 mg/l. It was anticipated that better organic
removal could be expected with we 11-acclimated sludge.
Glide (43) reported on Campbell Soup Company spray irrigation system at Paris, Texas.
Waste was applied at a rate of 0.25 in/day after 10 mesh screening and pretreatment
for grease recovery. Flow ranged from 1.8 to 2.8 MGD, and normal application was
limited to a maximum of 2 hours at a time. Extremely tight clay soils allowed very
little infiltration; runoff was collected in terraces to be conducted off the field; Sol-
uble BOD was adsorbed on the litter; wastes average 850 mg/l; and effluent as it ran
off the property averaged less than 10 mg/l, with a corresponding COD of 51 mg/l.
The vegetative cover of the disposal field produces a protected habitat for soil micro-
organisms and presents a vast area for the absorption of organic impurities; the system
functions as a horizontal grass trickling filter.
Also included in the report was a study of the Napoleon, Ohio, plant. Its soup pro-
cessing wastes are treated by a two-stage trickling filter with intermediate aeration
between the filter and settling stages. However, during the tomato season, tomato
wastes were handled separately on a spray irrigation system. During 1964 to 1965 the average
waste applied reached a peak of 1.4 in/day with some spray lines reaching peaks of
4 to 5 in/day. Tests results revealed that, on a mass basis, the percent reduction for
COD, BOD, nitrogen, and phosphate were respectively 81, 85, 73, 65%.
Skrinde and Dunstan (44) found that trickling filters loaded from 1400 to 4000 Ibs BOD
per 1000 cu. ft. per day became decreasingly efficient because of excessive slime
growths. Activated sludge provided satisfactory treatment under proper loading, al-
though Sphaerotilusgrowth caused bulking and loss of suspended solids. Joint treat-
ment with municipal sewage on a roughing filter provided reasonable BOD removal
without excessive slime growth. All biological processes for treating pea wastes re-
quire supplemental nutrients.
Zinkfoose (45) described the treatment for pea waste after mixing with settled domes-
tic sewage. Waste flows from three processing plants produced a combined flow of 5
MGD with a BOD of 850 mg/l. The waste contained very little settleable material;
therefore, no primary clarification was used. The settled sewage and industrial wastes
were mixed in a control structure and portions diverted to the different plants. The
portion of the mixed waste diverted to the industrial treatment plant was applied to
parallel trickling filters. Identical clarifiers followed each filter. Sludge was re-
turned to the domestic plant for digestion.
Dickson (46) presented a paper on a large cannery using lagoon treatment. The Sleepy
Eye, Minnesota, plant processed peas and corn with waste flows amounting to 60
16
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TABLE 3
VOLUME AND CHARACTERISTICS OF CANNERY WASTES
Product
Apples
Apricots
Asparagus
Beans, baked
Beans, green
Beans, kidney
Beans, lima, dried
Beans, lima, fresh
Beets
Carrots
Cherries
Corn, cream style
Corn, whole kernel
Cranberries
Mushrooms
Peaches
Peas
Potatoes, sweet
Potatoes, white
Pumpkin
Sauerkraut
Spinach
Squash
Tomatoes
Waste Volume
gal/case
25-40
57-80
70
35
26-44
18-20
17-29
50-257
27-70
23
12-40
24-29
25-70
10-20
6600
45-60
14-75
82
—
20-50
3-18
160
20
3-100
BOD
mg/l
1680-5530
200-1020
16-100
925-1440
160-600
1030-2500
1740-2880
190-450
1580-7600
520-3030
700-2100
620-2900
1120-6300
500-2250
76-850
1200-2800
380-4700
1500-5600
200-2900
1500-6880
1400-6300
280-730
4000-11000
180-4000
Suspended Solids
300-600
200-400
30-180
225
60-150
140
160-600
420
740-2220
1830
200-600
300-675
300-4000
100-250
50-240
450-750
270-400
400-2500
990-1180
785-1960
60-630
90-580
3000
140-2000
17
-------
million gallons in one season. The BOD of the pea waste averaged 1000 mg/l while
the corn waste was usually twice as much. Total pond area was 38 acres or about
6.3 acres per pond. An interesting point was that the wastes from the last few days
of the canning season were held during the winter in order to maintain a good algae
and bacteria population for operations the following spring.
Webster (47) of Seabrook Farms Company, Bridgeton, New Jersey, made pilot plant
studies on treatment of vegetable processing wastes using high rate and deep high
capacity biofilters. Raw wastes were screened before being discharged to primary
settling tanks. The primary effluent was split into two streams, one portion going to
the deep filter, the other to the high rate filter. Both deep and high rate filters
were followed by secondary settling tank. The New Jersey Department of Health
required a plant effluent BOD of no more than 60 mg/l at that time. The deep and
high rate biofilters were seeded with settled domestic sewage and acclimated for 16
days. More than 4000 experimental tests were made, the results of the waste analysis
and the treatment efficiencies are summarized in Table 4 below.
TABLE 4
WASTE CHARACTERISTICS AFTER SCREENING
AND TREATMENT EFFICIENCIES OF FILTERS
Product
Flow
After Primary
BOD, mg/l Overall Removal
Final Effluent % BOD Removed
Processed MGD Screening Effluent Deep High Rate Deep High Rate
Peas
Beets &
Corn
Lima
Beans
Potato
Spinach
5.82
8.18
7.56
2.76
7.43
68
223
142
227
137
49
195
125
23
59
32
19
32
31
22
66.3
73.4
77.7
72.3
85.8
78.5
90.3
The author concluded that the deep type filter would produce a satisfactory effluent
with loadings less than 12,000 Ibs BOD per acre-foot per day. The high rate bio-
filter would be the most economical and would produce a better effluent quality
with loads amounting to 5000 Ibs per acre foot per day or less. The retention times
and overflow rates for the settling tanks were 75 minutes and 1578 gallons per sq.
ft. respectively.
18
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SECTION V
DESIGN OF TREATMENT FACILITIES
Background
Before 1969, the Stilwell Canning Company wastes were divided into two streams.
The strong wastes from Irish and sweet potatoes were pumped about three-fourths of
a mile over a 500 foot hill to a holding lagoon and then spread on a fruit orchard.
This system was not operated properly and, as a result, several problems existed, not
the least of which were odors which at times were noticeable more than a mile down-
wind. To control odors, sodium nitrate was added to the lagoon; however, some of
the fruit trees were killed. At this point the orchard owner issued an order to stop
irrigation.
The weak wastes from vegetable products were discharged to the city sewage treat-
ment system, which was designed for 6,000 people and was treating the waste from
2,600 people plus the cannery waste with a population equivalent of from 7,200 to
15,000; this completely overwhelmed the treatment plant. The effluent was dis-
charged into Caney Creek, a spring fed stream. While the cannery was in operation,
a five mile reach of the stream had no trace of dissolved oxygen. After flowing six-
teen miles, Caney Creek discharges into Lake Tenkiller, a major water recreation
area. For many miles downstream there were numerous complaints of odors and in
general a bad rapport prevailed between the city residents and the canning company
even though the cannery employs 450 people in a town of 2,600.
The problem was to provide an integrated treatment system for the canning company
capable of treating the high strength, nutritionally unbalanced, large volume wastes
to a degree compatible with the receiving stream. This was no small task because
the organic load per shift varied by more than 60 fold, from a volume of 0.39 MGD
and COD of 150 mg/l for spinach wastes to greater than 1.91 MGD and a strength
of 5,500 mg/l while processing sweet potatoes.
Based on the information gathered and reported in the literature review, several
treatment processes were considered including trickling filters, minimal solids, mod-
erate solids, extended solids aeration and biosorption systems. The incoming waste
in question has a very high organic strength; therefore, trickling filters and biosorp-
tion systems were deleted from consideration because they are not capable of treat-
ing high strength waste to the degree required without polishing ponds or other terti-
ary treatment systems. Minimal solids aeration has a high loading rate, a short
solids retention time, and a high growth rate. With this process the removal rates
are extremely high, the removal efficiencies low, and the MLSS highly dispersed;
therefore, the process though efficient in terms of dollars per pound of COD removal,
must be followed with another process. For such a high strength waste moderate
19
-------
solids aeration could produce effluent of good quality provided a high MLVSS con-
centration and low loading intensity are maintained. However, this would result in
a size diseconomy. Extended aeration has a very low loading rate, about 1/lOOth
the rate of that in minimal solids system, and a solids retention time perhaps 100
times as great. This process is efficient in terms of percentage removals for wastes
of low strength; however, it would also suffer from size diseconomies for strong
wastes. Therefore, a dual or two-stage aeration process was chosen.
The first stage aeration is a-high rate process with high loading capacity, fo]lc-w*d
by a more efficient polished-effluent-producing process, that is, minimal solids Fol-
lowed by extended aeration. The two-stage system combines the desirable character-.
istics of both (48). The high rates of removal are provided by the minimal solids
unit and effluent polishing and aerobic sludge digestion by the extended aeration.
basin.
Recommended Process
The design capacity of a domestic sewage treatment system is generally based on an
estimation of the population to be served in the future. For example the design per-
iod may be twenty years. The design of waste treatment facilities for an industry,
however, is usually based on the future production of the industry and the strength
and quantity of the waste thus generated. Possible technical innovations in the In-
dustrial processes and its effect on the characteristics and volume of waste must dlso
be considered in the development of a plan for the ultimate facilities.
The implementation of such designed facilities usually is not carried out in one stage
due to economic reasons. In practice the pertinent structures will be built first to
meet the immediate demand, and the facilities which can be expanded easily will
be constructed later or added in stages.
The Stilwell industrial waste treatment plant was designed for a flow of 1.5 MOD
with an average BOD of 1,500 mg/l which was considered adequate for the immediate
future. For the ultimate plan, two alternatives were conceived. Alternative one
was to build a plant for full aeration and hydraulic capacity which could be expanded
to meet increased organic load with the additon of a primary settling tank and solid*
disposal facilities. Alternative two was to approach the designed plant capacity in
steps by increasing the volume of aeration tanks but with a primary clarifier and
vacuum filter sized for full hydraulic capacity and installed during the initial phase
of construction. Previous studies indicated that approximately 50% of the influent
COD can be removed by primary settling, but there was insufficient evidence to
suggest a method of degrading the sludge economically. Primary settled sludge will
normally contain 95 to 98%water. A thickener can reduce moisture content to 90%,
which is higher than 65% considered as the maximum for compositing; and the mois-
ture content is also too high for disposal directly to a sanitary landfill. Further
20
-------
dewatering by a process such as vacuum filtration, centrifugation, air drying, etc.,
will still be required leaving a solid waste disposal problem. Therefore, alternative
one was selected; that is, full capacity aeration tanks were constructed without a
primary clarifier and vaccum filter.
The system was designed so that it would accomplish a high degee of teatment at the
design capacity without a primary settling tank. With the addition of a primary
clarifier and a reactor for sludge disposal the capacity of the system will be increased
by a factor of nearly two.
The two-stage aeration system designed and constructed, as shown in Figures 1 and
2, consists of No. 10 screens to remove gross solids which are trucked to an existing
landfill. After screening, the waste flows to a minimal solids basin, which was de-
signed to remove 50% or more of the soluble COD, and then to two extended crea-
tion basins in parallel, designed as effluent polishing and aerobic sludge digestion
units. Aeration is followed by final clarification for solids separation. Provisions
are built into the system to return the sludge to either minimal solids and/or extended
aeration units with a sludge recirculotion ratio of approximately one to one. Occa-
sionally it is necessary to withdraw excess sludge from the system which is routed to
an existing sludge retention pond for anaerobic stabilization.
Operational flexibility of the treatment plant at present is such that the minimal
solids unit can be bypassed with waste flow going to either one or both extended
aeration units. For vegetable wastes only the extended aeration units are required.
Either one or both of the extended aeration units can be used, depending on the
strength of the vegetable wastes to be treated. During the potato processing season,
two-stage aeration is used. At present, flow from the minimal solids unit cannot be
diverted to the final clarifier without passing through the extended aeration unit be-
cause of the in-plant piping configuration. If necessary, a bypass can be provided
which Would allow any one of the treatment units to be operated individually or in
conjunction with other units so that the system can be operated as minimal solids,
moderate solids, or extended aeration process, or a combination of any of these pro-
cesses. Other parameters that can be controlled are the amount of sludge returned
to the aeration basins and the power input to the surface aerators.
The final design criteria is given in Table 5. All the aeration basins are earth struc-
tures with concrete aprons to prevent wave erosion from the operation of the surface
aerators. Final clarifer, pumping house, chemical and laboratory building, Parshall
flume and other structures are made of concrete. The total construction cost for the
treatment facilities was $287,435.00. Figure 3 is an aerial photograph of the treat-
ment plant.
21
-------
Raw Waste
To Truck Loading
» *
Slue
Reter
Por
V
1
GO
v>
V)
«:
Future Facilities
Figure 1 Flow Diagram
22
-------
CO
Screen Sump
1007.0
Parshall Flume
1006.8
1003.0
To Sludge
Retention Pond
Pri mary
Clarifier
1002.5
1000.6
M.H.
1000.3
Minimal
Solids
(High Loading)
AeraHon
Basin
1000.0
996.4
992.3
Extended
Aeration
Basins
996.0
991.3
T
991.3
Final
Clarifier
990.5
T
990.0
984.5
Sludge
Pumps
Figure 2 Schematic Flow Diagram
-------
TABLE 5
DESIGN CRITERIA
1. Design Flow = 1.5 MGD
BOD - 1500 mg/l = 18,600 #/day
2. Minimal Solids Unit
Loading rate = 500 #/1000 cu. ft.
_ 18, 600 * BOD/day
Volume 500 ff BOD/1000 cu. ft.
= 37,000cu. ft.
= .28MG
Use 0.30MG
Depth = 8 ft .
Top = 116 ft. x 66 ft.
Bottom = 84ft. x 34ft.
HRT = 0.3/1. 5 = 0.2 day = 4. 8 hrs.
O2 required = 0.8 x Ibs BOD removed
= 0.8 (18,600) (0.4) = 6000 Ibs/day
O2 transfer = 2 IbAr/Hp
Hp required = 125 hp.
Hp provided = 2 surface aerators @ 75 Hp
= 0.5 Hp/ 1000 gal.
3. Extended Aeration
Loading rate = 40 lbs/1000 cu. ft.
BOD = 0.6 (18,600) = 11,200 Ibs BOD/day
Volume = 280,000 cu. ft.
= 2.10MG
MinHRT =36 hrs. = 1.5 days
Volume = 1.5 (1.5 MGD) = 2.25 MG
Two basins in parallel each with volume =1.12 MG
Depth = 8 ft .
Top = 232 ft. x 102ft.
Bottom = 200ft. x 70ft.
©2 required = 1 .2 x Ibs BOD removed
= 11,200 (.95) (1.2)
= 10,600 Ibs/day
O2 transfer = 2 Ibs/hr/Hp
Hp required = !° = 220 Hp
Hp provided = 3 surface aerators @ 40 Hp per basin-total 240 Hp
= 0.11 Hp/lOOOgal.
24
-------
TABLE 5
(Continued)
4. Final Clarifier
Overflow rate = 800 gpd/ft2
Depth =8 ft.
Diameter = 50 ft.
DT= 1.89hrs.
Weir loading = 10,000 gpf/day
5. Return Sludge Pumps
2 sets of centrifugal pumps @ 500 gpm and TDH = 48 ft.
6. Chemical Feeder
1 set dry feeder @ 1000 Ibs/day
25
-------
r-0
o
Figure 3 Aerial View of the Waste Treatment Plant
-------
SECTION VI
PLANT SCALE STUDY
General
As has been indicated, the Stilwell Canning Company cans and freezes various kinds
of vegetables. A typical production record and schedule are given in Tables 6 and
7.
The Stilwell Canning Company generally operates on the basis of a 6-day week with
two shifts per day, namely 8:00 a.m. to 6:00 p.m. and 6:00 p.m. to 4:00 a.m.,
with a daily clean-up from 4:00 a.m. to 8:00 a.m., plus intermittent wash-down
during the operation time. Their operation is highly climate dependent, and what
they process depends on what is available from their contracted farms which, in
turn, depends on the previous days weather. The processing flow sheets for their
various products are shown in Figure A-l through A-9, Appendix A.
Canning operations began April 22, 1969, with spinach as the major product. At
this time the waste was being diverted through the domestic trickling filter waste
treatment plant. This plant, located 500 feet upstream from the industrial waste
plant, was overloaded and was producing an effluent with a high COD and a notice-
able green color.
The plant scale study of this two-stage activated sludge system originally scheduled
to cover a period from September 1, 1968 to January 1, 1969, but postponed be-
cause of a delay in construction work, actually began May 19 and ended December
5, 1969 when the cannery closed their operation for the year.
Study Approach
The primary purpose of this project was to study treatment performance and cannery
waste characteristics; hence, the sampling program had to be developed to monitor
the changes in waste flow and strength and to establish the effects of these changes
on treatment efficiencies accordingly.
In any sampling program, considerable thought must be given to the location of sam-
pling points. Sampling points should conform to hydraulic suitability; that is, points
of high turbulence that assure good mixing should be selected. The points must also
be located so that individual process unit efficiencies could be determined. Exam-
ination of the plant layout indicated that sampling from the Parshall flume, the mini-
mal solids unit, the extended aeration unit, after the final clarifier, and the return
sludge line would yield homogeneous samples that could be used to determine waste
characteristics and plant efficiencies.
27
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TABLE 6
PRODUCTION RECORD
Year*
Production
Cases
*April - December
Peak Month
TABLE 7
1969 PRODUCTION SCHEDULE
Peak Production
Cases
1966
1966
1967
1968
1969
1,494,266
1,650,000
1,750,000
1,800,000
1,979,000
October
September
September
234,311
268,000
295,541
Month
Products
Production
Cases
May Spinach, Mustard Greens, Col lard Greens, No record
Turnip Greens, Strawberries, Irish Potatoes available
June Irish Potatoes, Green Beans, Squash, Peas, 235,923
Blackberries
July Irish Potatoes, Green Beans, Okra, Peas, 253,565
Squash
August Irish Potatoes, Sweet Potatoes/ Okra> Peas 263,925
Sept. Sweet Potatoes, Irish Potatoes, Okra> Peas, 295,541
Butter Beans, Green Beans, Squash
Oct. Sweet Potatoes, Irish Potatoes, Okra, Peas, 271,198
Butter Beans, Lima Beans, Squash, Turnip
Greens, Mustard Greens
Nov. Sweet Potatoes, Collard Greens, Turnip Greens, 179,452
Spinach
Dec. Spinach 17,606
Case = 24 No. 303 cans
28
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Sampling and flow determinations were also considered within the cannery but were
not run after June 13. This was due to the fact that the cannery usually processes
more than three kinds of products in a shift, and the various waste streams within a
process were integrated with streams from other simultaneously-operating processes
before the total waste flow of one particular product can be sampled. Referring to
the processing flow sheets in Figure A-l through A-9, notice that there is a mini-
mum of four waste streams (excluding blackberry) per product processed. Therefore,
a complete analysis and flow determination of waste streams from each product pro-
cessed was not practical as it would have necessitated the complete analysis of a
minimum of twelve streams plus the analysis of the waste treatment system.
The approach used was to classify the waste into three categories, on which the data
presentation and evaluation wer4 based. The classifications are listed below:
1. Sweet potatoes and one or more kinds of vegetables.
2. Irish potatoes and one or more kinds of vegetables.
3. Vegetables only.
This classification can be justified if the following facts are considered:
1. The cannery operates two major production lines, that is, a potato
line and a vegetable line. The plant set-up is such that the sweet
potatoes and Irish potatoes cannot be processed simultaneously, al-
though it is possible for two or more vegetables.
2. The strength of the various kinds of vegetables ranged from 148 to
688 mg/l of COD, and that of Irish potatoes and vegetables and
sweet potatoes and vegetables ranged from 1080 to 4229 mg/l and
2400 to 5550 mg/l of COD respectively. The difference in strength
depended on the type, amount, and quality of the raw product be-
ing processed.
3. In comparison to that of potatoes, the strength of the vegetables can
be considered a weak waste. On an organic loading basis (Ibs COD/
day/1000 cu. ft.) the potato waste contributed approximately 90%
of the total load while Irish potatoes were being processed and 95%
while processing sweet potatoes.
In order to monitor the variation of waste strength due to the change in production,
several samples per shift were taken and analyzed immediately. A flow proportioned
composite was then calculated; the shift composite samples were used in the data
evaluation. The grab samples served the dual purpose of providing immediate infor-
mation on tfie waste characteristics and plant efficiency and also helped in evaluating
29
-------
the effects of shock loading on the treatment system. The effects on treatment pro-
cesses due to changes in waste strength could be readily observed in basins of short
retention times; therefore, the plant influent and minimal solids unit were sampled
three or more times during a shift while the extended aeration unit and plant efflu-
ent were sampled only once a day.
Plant Start-Up
The construction work on the treatment plant was completed on May 1, 1969; how-
ever, the plant did not start operation because of construction difficulties with the
influent sewer. A temporary sewer was laid on May 12 so that the cannery wastes
could be discharged to the waste treatment plant. One month later the contracted
sewer line was completed.
The treatment facilities, being variations of the activated sludge process, require
seeding and acclimation in order for the substrate removal process to begin. Since
no activated sludge plants were available in the nearby area, primary effluent from
the domestic plant was pumped to the industrial plant. Pin point floe was noticed
in the minimal solids basin within a few days. One week was required for all basins
to fill because of the low flow associated with green vegetable wastes and the leak-
age beneath the impounding dikes of the aeration basins which occurred during the
start-up period. This seepage which was very noticeable at the foot of the dike
slopes decreased considerably during the first two months of operation and by June
only a few wet spots remained.
During the start-up period several other difficulties were also encountered. In May
and early part of June, because of operational problems with the vibrating screen,
it was bypassed, thus resulting in shooting flow through the Parshall flume. An ac-
curate determination of flow was impossible due to high energy turbulence in the
flume. The screen difficulties were corrected on May 27, and energy dissipating
baffles were installed on June 9 in the incoming channel of the flume. Accurate
flow metering was then possible. In the minimal solids unit high energy transfer
from two 75 H.P. aerators and small surface area (7650 sq. ft.) of the basin com-
bined to produce uneven flow over the collecting weir. A splash board was installed
around the effluent collecting weir, and this successfully solved the problem. One
of the sludge pumps failed to work on May 27 and was not repaired until June 15.
Aerators in the extended aeration basins were out of order from time to time. The
sludge rake in the final clarifier would not rotate until being corrected on May 30.
No scum removal device or sludge flow meter were provided in the plant.
Also during this period green vegetables were the major products processed and con-
sequently no frothing problems occurred. All sludge was returned to the extended
aeration basins.
Further few grab samples of cannery processing streams were collected in the cannery
30
-------
and analyzed during the start-up of the treatment plant to aid in control of the system
during this period. The results of the data are shown in Table B-l, Appendix B.
The data after June 1 were used in the evaluation of the two-stage activated sludge
treatment plant.
Operation
The operation of the two-stage activated sludge system started in May7 1969, with
the processing of green vegetables, such as mustard greens, col lard greens and tur-
nip greens, as the major products. The plant scale study began in June while the
major products were green beans and squash with twelve shifts of Irish potatoes,
peas and squash among them. From July 1 to July 9, the products were okra, green
beans and squash; and for the rest of the month, the major products were Irish po-
tatoes, okra, green beans and squash with eleven night shifts of green beans inter-
mingled.
In this three month period, all sludge was returned to the extended aeration units
except during shifts when Irish potatoes were processed. As there was no sludge
flow meter, the flow was estimated from the pump characteristic curve. This flow
was 660 gpm or 0.95 MGD which was approximately equal to the inflow. For the
Irish potato processing shifts, sludge was partially returned to the minimal solids
unit with a sludge flow that ranged from 0.1 to 0.46 MGD. In June, when Irish
potato wastes were being treated, sludge was not returned to the minimal solids unit
and the MLVSS concentration was less than 1,000 mg/l there were foaming problems
in both stages of aeration. It was especially serious in the first unit. However,
the situation was corrected when all sludge was recycled to the minimal solids unit.
From August until November, during the time potatoes were being processed, the
sludge was recycled to the minimal solids unit so the unit loading applied (Ibs COD/
day/lbs MLVSS) could be lowered. The excess sludge was wasted regularly into a
sludge retention pond for further stabilization anaerobically.
In August, Irish potatoes, okra, and peas were the major products; and in September
and October, sweet potatoes, Irish potatoes, beans, peas, and squash were the major
products, with some night shifts of green vegetable processing interspersed. From
November 1 to 11, sweet potatoes, collard greens, turnip greens, spinach, and Irish
potatoes were processed. After November 11 through the end of the processing sea-
son, the only products processed were turnip greens and winter spinach.
Since the system was being operated experimentally it was important to determine
the minimum nutrients required while processing each product or combination of pro-
ducts. During vegetable processing only, no nutrients were added and the treatment
efficiency remained high indicating nutrients were not required. As the dominant
product shifted from vegetables to potatoes the total nitrogen concentration in the
system declined and on October 14 sludge bulking occurred. Ammonium nitrate
with a nitrogen content of 33.5 percent was then added at the rate of 1000 Ibs per
31
-------
day until the TKN/VSS ratio in the MLVSS increased to 5 percent and a trace of
nitrogen was recorded in the effluent. Sludge bulking declined and after approxi-
mately three weeks the treatment system1 resumed its normal high removal efficiency.
Nitrogen addition was stopped on November 21 after which only green vegetables
were processed. For the entire period phosphate and pH adjustment were not re-
quired.
Analytical Determinations
In general the analysis of the two-stage activated sludge treatment system included
the following.
1. Plant Influent after Screening - Total, Settled and Soluble COD;
Suspended and Volatile Suspended Solids (SS & VSS); Dissolved
and Volatile Dissolved Solids (DS & VDS); Total Kjeldahl Nitrogen
(TKN), Ammonia Nitrogen (NH3~N), Nitrate and Nitrite Nitrogen
(NO3-N & NO2-N); Total Phosphate; pH; Temperature
I
2. Minimal Solids Unit-Mixed Liquor COD (MLCOD), Settled and
Soluble COD; Mixed Liquor Suspended and Mixed Liquor Volatile
Suspended Solids (MLSS & MLySS); Dissolved Oxygen (DO); TKN,
NHg-N, and NO3~N; pH; Temperature
3. Extended Aeration Unit and Final Clarifier - Total and Soluble
Effluent COD; MLCOD; MLSS & MLVSS; DO; TKN, NHg-N,
and NO3-N; Total Phosphate, Effluent SS and VSS; pH; Tem-
perature i
4. Sludge - SS and VSS; TKN
A few biochemical oxygen demand (BOD) and MLSS settling determinations were
also performed. All laboratory analytical determinations were made in accordance
with Standard Methods (48) except for some procedure changes as discussed in Ap-
pendix C.
Results
The flow data were taken from a continuous flow recorder installed in the Parshall
flume at the entry to the waste treatment plant. The flow recorder charts were
analyzed and flow volume was determined in million gallons (MG) per unit of time
using IBM computer facilities at the University of Oklahoma.
The flow measured at the treatment plant was a combination not only of all waste
streams but of infiltration into approximately 1.5 miles of sewer line between the
cannery and the treatment plant, and domestic sewage from eighteen families.
32
-------
The results of the flow analyses are given in Table 8, and the daily flow variation
for a six day work week during the six months is shown in Figure 4.
TABLE 8
FLOW DATA
Min. Max. Mean Median
Daily Flow, MGD 0.35 1.91 1.12 1.19
Shift Flow, MG/lOhrs
Sweet Potatoes
& Vegetables 0.15 0.89 0.61 0.58
Irish Potatoes
& Vegetables 0.38 0.78 0.53 0.53
Vegetables
only 0.17 0.87 0.44 0.46
Daily Clean-Up,
MG/4hrs 0.01 0.23 0.13 0.13
The two-stage aeration system performed beyond expectations. The system was orig-
inally designed to treat a waste of 1,500 mg/l BOD or 2,250 mg/l of COD at a flow
of 1.5 MGD. This was expected to be an adequate capacity for the near future; how-
ever, due to unforeseen circumstances, by the time the treatment plant was completed,
it was operating above design capacity. During the study period, the flow reached
a daily peak of 1.91 MGD and a shift peak of 0.89 MG/10 hrs which corresponded
to 2.13 MGD, and an instantaneous peak of 2.4 MGD. The waste strength exceeded
the design COD of 2250 mg/l for a significant portion of the canning season as re-
lated in Figure 5 and while processing sweet potatoes and vegetables it exceeded
5500 mg/l. Approximately 50% of this COD can be removed by settling. Even at the
high strengths and flows while processing sweet potatoes plus vegetables, the average
efficiencies for the system exceeded 95% COD removal, 94% SS and 96% VSS re-
moval. The removal efficiencies for vegetable wastes were 82%, 80%, and 74%
with regard to total effluent COD, effluent SS and VSS respectively. Only during
approximately three weeks following the extremely high flows in October, as can
be seen in Figure 4, which is also a period of nitrogen deficiency and sludge bulk-
ing, as can be seen later in Figure 22, did the total COD removal efficiencies drop
33
-------
Q
O
o
O
June
Oct
31
Nov
30
Dec
Figure 4. Daily Waste Flow Variation
-------
CO
CJ1
§ 3
Q
O
U
0
17646
June
30
31
31
30
July "' Aug ~ Sept " Oct
Figure 5 Plant Influent and Settled Influent COD
31
Nov
30
Dec
-------
significantly. During this period as shown in Figure 6, the total COD removal drop-
ped to 66% and once even to 3%, but the soluble COD in the plant effluent remained
approximately the same as during normal operation as can be seen in Figure 7.
It is interesting to note that on August 14, the cannery dumped corn syrup into their
waste line; this suddenly increased the COD concentration to 12,000 mg/l resulting
in a total load on the system for approximately 10 hours of 53,000 Ibs. Even with
this extreme shock the system remained stable producing a high quality effluent as
can be seen from the curve labeled plant effluent in Figures 6 and 7. However,
changing from a strong waste to a relatively weak waste or the reverse affected the
calculated removal efficiencies. For example changing from a shift producing a
strong waste to a shift of weak waste lowered the plant removal efficiency tem-
porarily, because the residual COD in the treatment system due to strong waste
was higher than that due to weak waste. In general, changing from a weak waste
to strong waste showed an increase in plant efficiency for a short period due to a
dilution effect; however, the effluent concentration increased. The performance of
the treatment system with regard to COD, SS, VSS, and pH are shown in Figures 6
through 10. Temperature variations of both plant influent and effluent are shown in
Figure 11. During the six month operation period, as is shown in Figures 13 and 19,
the dissolved oxygen concentration in all aeration basins were maintained above
1 mg/l except for two short periods in August; hence, aerobic conditions were
maintained. The laboratory analyses data which include MLSS, MLVSS, DO, COD
loading and removal rate, SVI, and HRT of both minimal solids and extended aera-
tion units, are presented in Figures 12 through 23; and the sludge SS and VSS are
shown in Figure 24.
Tables D-l in Appendix D presents the influent, modular unit, and effluent analy-
ses and plant performance for sweet potatoes and vegetables; Table D-2 for Irish
potatoes and vegetables; and Table D-3 is for vegetables only.
36
-------
CO
XI
8
3
.£
Q
O
u
0
Minimal Solids
Soluble Effl
June 3° July 31 Aug 31 Sept 3° Oct 31 Nov
Figure 6 Treatment Plant Performance - COD
-------
CO
CD
o
o
o
Q
O
u
0
Minimal Solids
Settled Effl
June
July W1 Aug *" Sept " Oct
Figure 7. Treatment Plant Performance - COD
Nov
Dec
-------
CO
co
co
30 ,
June July
31
Aug
31
Sept
30
Oct
31
Nov
Figure 8 Treatment Plant Performance - SS
-------
oo
CO
0
30.
Dec
Figure 9 Treatment- Plant Performance - VSS
-------
June
30
July
31
Aug
31
Sept
30
Oct
31
Nov
30
Dec
Figure 10 Treatment- Plant Performance - pH
-------
40
<0
-------
CO
6
8
O
o
Sludge returned to M.S.& E.A.
without wastinq
Sludge returned to M.S. with intermittent wasting
Sludge returned to E.A. intermittentwasti
without wasting
30 , .
June July
31 . 31 _ t 30 _ t
Aug Sept Oct
31 M 30n
Nov Dec
Figure 12 MLSS and MLVSS of Minimal Solids (High Loading) Unit
-------
12
10
8
O
Q
4
June
30
31
31
July "' Aug "" Sept
Figure 13 DO in Minimal Solids (High Loading) Unit
30 31 30
Ocfr Nov Dec
-------
en
X
o
Q
O
U
to
«)
.Q
4)
D)
1
Q
O
U
25
20
15
0
June
30
July
31
Aug
31
Sept
30
Ocf
31
Nov
30
Dec
Figure 14 Total COD Loading Rate of Minimal Solids (High Loading) Unit
-------
25 -
20 .
X
o
Q
^x
O
u
_Q
OO
oo
>
_J
^
_Q
15
o
Qi
"5
o
O
U
10
0
June
30
July
31
Aug
31
Sept
30
Oct
31
Nov
30
Dec
Figure 15 Soluble COD Removal Rate of Minimal Solids (High LoadingXUnit'
-------
600
500
400
c 300
200
100
0
June
30
31
31
30
Ocf
July "' Aug W1 Sept
I Figure 16 SVI of Minimal Solids (High Loading) Unit
31 „, 30 ^
Nov Dec
-------
00
24
22
20
18
16
14
12
10
8
6
4
2
0
June
30
July
31
Aug
31
Sept
30
Oct
31
Nov
30
Dec
Figure 17 HRT of Minimal Solids (High Loading) Unit
Based on Influent FlowOnly
-------
o
o
2 3
c
0
June
30
31
31
30
July Aug Sept Oct
Figure 18 MLSS and MLVSS of Extended Aeration Unit
31
No\
30,
Dec
-------
Oi
o
12
10
8
c 6
O
4
June
30
July
31
Aug
31
Sept
30 Oct 31 Nov
30
Dec
Figure 19 DO in Extended Aeration Unif
-------
X
o
o
u
1/1
3
_8
SI
"o
O)
o
3
Q
O
-------
Oi
KJ
X
o
Q
0.6
0.5
00
O
u
_Q
0.4
£
"o
~0 0.3
1
(U
O O-2
u
_0)
_Q
O
1/5 0.1
0
June
30
31
31
30
31
July *" Aug "' Sepf "" Oct
Figure 21 .Soluble COD Removal Rate of Exfended Aerarton Unit
Nov
30
Dec
-------
600
500
Cn
GJ
E
c
400
300
200
100
0
June
30
July
31
Aug
31
Sept
30
Oct-
31
Nov
30
Dec
Figure 22 SVI of Extended Aeration Unit
-------
Ul
0
June
30
. .
July
31
.
Aug
31
Sepf
30
Oc^
Nov
30
Dec
Figure 23 HRT of Extended Aeration Unit
-------
Cn
01
12
10
8
c
coj'
f
June
30
July
31
31
30
Aug "" Sept Oct
Figure 24 SS and VSS of Sludge
31
Nov
30
Dec
-------
SECTION VII
DISCUSSION
General
The basic objective of research work in the field of waste treatment, regardless
of whether it is a laboratory model or a pilot plant study, is to collect and
analyze data that could be geared toward the establishment of response function
under controlled conditions.
For plant scale studies, it is obvious that many factors cannot be controlled. As
indicated in Section IV, the flow, waste strength, organic loading rate, etc.,
all fluctuated widely. Therefore, it is much more difficult and sometimes im-
possible to obtain such a response function. This does not negate the value of
plant scale studies. It is still possible to place constraints on the loading factors
and determine their reliability using statistical techniques, and it is possible to
check or correlate conventional design approaches with full-scale field studies.
In this section, numerous correlations between the important parameters for all
three waste categories have been developed. To develop these correlations the
least square curve fitting technique was applied using the IBM 360 computer.
The results were interpreted and are reported below.
Waste Flow
The waste flow for the 1969 processing season is shown in Figure 4 and flow data
were summarized in Table 8, Section VI. A cyclical variation of a weekly
nature is exhibited and indicates weekend shutdown. It is also evident that
flow showed a trend of gradual increase with a peak in October, and then de-
clined toward the end of the processing season. This generally reflects a rise
in production; however flow is also dependent upon the type and quality of
products being processed as well as seasonal variation.
In the Stilwell area the wet season generally extends from late fall to early
spring; consequently, the vegetables arrive at the cannery soiled more than
usual. This necessitates more wash-water in the canning operation. Potatoes,
supplied from Idaho, Louisiana and Arkansas, are bruised during transportation.
In the canning operation, it is the practice to recycle those potatoes through
the processing line for more washing and abrasive polishing so that a consistent
quality can be maintained. Thus, more water for less product results.
57
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Waste Flow Prediction Model
Estimates of flow volume in cannery operation are needed for planning and de-
sign purposes. Data taken in the study of the Stilwell Cannery were used to
develop and verify a prediction scheme which then mightbe used to predict^flows
at the Stilwell site or in predicting flows for design purposes at other locations.
Not enough periods of processing of single vegetable types could be obtained
during the six months of study to examine even the most commonly occurring
vegetable types separately. Therefore, the indicated approach was decomposi-
tion of the flow into portions associated with each of the vegetables. The ap-
proach chosen was the linear model listed below with multiple regression esti-
mates of the parameter.
+b.P.
F is flow volume in gallons during the period for which production is reported;
a is a constant flow associated with the cannery being in operation for the
period and represents internal waste water, cooling water, clean-up, etc.,
which cannot be associated with individual processes; b is a coefficient; I is
the infiltration and domestic sewage input below the cannery; P; is the produc-
tion in cases for the i th vegetable type, and bj is the flow per case (fpc) for
the i th vegetable type. I was estimated by base flow during nonproduction
periods .
Initial analysis was done on the basis of separate shifts. The shift values were
generally reasonable, although the estimated fpc for squash was negative for
both shifts and for okra in the night shift. The break between shifts was based
on payroll information provided by the cannery.
Observing the processes indicated that the time of division between shifts was
not always reliable, as the actual processing might precede or follow the nom-
inal shift by several hours and cause significant error in the flow breakdown
between shifts. To avoid this source of error, the two processing shifts were com-
bined and run as an individual data value. The estimates of fpc were all posi-
tive; the estimate of the constant, a, was smaller for the work day than for either
shift; and the multiple correlation coefficient was higher than that for either of
the individual shifts. The results of this run are shown in Table 9.
The coefficient b would normally be 1 .0 but was allowed to be fitted, because
it was desired to see if the estimates of infiltration by using periods of no produc-
tion were reliable. Values for the coefficient much less than or greater than 1 .0
would indicate unreliability. In the study, the coefficient ranged from 1.0 to
58
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TABLE 9
ESTIMATES OF PARAMETERS
Constants
Constant a
Infiltration coefficient b
Vegetable Type
Sweet Potato
Irish Potato
Okra
Peas
Beans
Squash
Green Beans
Mustard Green
Turnip Green
Col lard Green
Spinach
Values
ISl^OOgals
1.30
Flow Per Case (gals)
157
153
6
26
72
5
41
109
69
35
61
t Value*
4.71
t Value
13.15
12.17
51.00
2.81
3.06
0.39
8.17
5.97
7.54
1.71
7.98
*t = 1.29 @ 10%, t = 1.66 @ 5%, t = 2.36 @ 1%
levels of significance.
59
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1.6, Indicating a fair estimate; to obtain a better estimate more data must be
collected.
Referring again to Table 9 only squash has a t value less than the tabulated value
at the 5 percent level of significance and squash and col lard greens have values
less than the tabulated value of the 1 percent level of significance. This indi-
cates a high degree of statistical reliability, since the reliability of the estimate
increases with an increase in the t value.
The error analysis for this run is shown in Table 10. The sources of error in esti-
mating this relationship are:
1. Error in flow measurement
2. Error in reporting production
3. Variability in flow per case
4. Variability in non-process water
The first source of error is normally about 5% to 10% based on the listed perfor-
mance for the flow measurement device. However, several days during the study
period, the capacity of the flow meter was exceeded and the flow measured man-
ually. The error induced by measuring the flow manually is unknown.
The magnitude of the second source is uncertain. The production figures should
be exact; however, it was possible some processing was partly completed and
the vegetables stored and finished and reported the next day.
Errors from the third and fourth sources are due to estimating averages for values
which actually show a distribution. There is certain to be some variation in fpc
because of the differences in raw product quality for a vegetable type, such as
seasonal variation, variation due to operating personnel and that due to a change
in quantity of product processed per unit of time. The amount of water, flowing
during a shift, which is not process water will vary also.
As indicated in Table 10 the multiple correlation coefficient is above .9 which
indicates a relatively high correlation. The standard error of the estimate is
148,600 gallons per day which is less than 15 percent of the average flow per
work day which is 969,900 gallons.
60
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TABLE 10
ERROR ANALYSIS
Multiple Correlation Coefficient 0.906
Standard Error of Estimate 148,600 gals
Average Flow per Work Day 969,900 gals
The estimates of fpc for the eleven vegetable types are reasonable in magnitude
and are in general agreement with published figures. Since the flow per case
accounts for approximately 90 percent of the total average flow, it is tempting
to use the values of fpc as estimates of the average amount of water associated
with each case of a particular vegetable processed in this cannery. This should
be cautioned against especially for products with low flow such as okra and squash.
The model can be used to predict flows at this site or used at another site by esti-
mating the number of cases processed. The constant term can be estimated as a
percentage of the average predicted flow based on assumed production and esti-
mated fpc. In general there are Infiltration sources which must also be estimated.
Waste Load
The waste flow is screened twice, once at the cannery and again upon entering
the treatment plant, with solids being disposed of by burying near the cannery.
As most of the particulate matter is removed at the cannery the difference in
waste load before and after screening at the plant site is negligible. Therefore,
samples of incoming waste were taken after screening.
Throughout the study period, COD tests were used as a measure of waste strength.
BOD test were also performed at the time of COD analyses; and the BOD/COD
ratio of the influent potato waste was approximately 0.7, which is comparable
with that of the other investigators (15).
The characteristics of the wastes, as classified in three categories, are summarized
in Tables D-l, D-2, and D-3 of Appendix D. Notice that approximately 50% of
the total COD can be attributed to solids for both Irish potato and sweet potato
wastes, as it can be removed after 30 minutes of settling. However, for vegetable
61
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wastes, only 15% of the total COD is settleable. It Is worthy to point out that
the average TKN/COD ratio for vegetable wastes is 4.8% and that of Irish
potato and sweet potato is around 2%. Therefore, nitrogen supplementation is
only necessary for potato wastes.
The variability in non-volatile solids for vegetable wastes alone is largely due
to uncontrollable factors such as the quality of raw material, weather conditions,
and water quantity used in processing. The VSS/SS ratio, as indicated in Table
D-3, ranged from 9.7 to 93%, which is approximately a ten-fold difference.
Much of this variability is due to field moisture conditions. Winter spinach be-
cause of wet weather had much higher inorganic solids present in the SS. Ex-
cluding winter data, VSS versus SS correlation improved; and VSS/SS ratios
changed from a ten-fold to four-fold spread. The effect of non-volatile solids
on a mixture of potato and vegetable wastes is depressed because of the high
solids concentration in potato waste, and thus allows for a better correlation of
all parameters studied.
The results of the statistical analyses of the plant influent data are listed in Table
11 and are plotted in Figures E-l through E-20 of Appendix E. As shown in Figures
E-4, E-5, E-9, E-10 and E-17 through E-20, the lines of best fit for total COD
versus TVS and soluble COD versus VDS are quite consistent and appear to follow
a linear model although there is considerable variability with a coefficient of
variation ranging from 0.62 to 0.98. The relationships between VSS and SS,
VDS and DS, TVS, and TS for both sweet potato and vegetable wastes and Irish
potato and vegetable wastes show very good correlations as indicated in Figures
E-l, E-2, E-3, E-6, E-7 and E-8. The equations derived for the solids relation-
ships of vegetable wastes, as shown in Figures E-ll through E-16, do not correlate
as well, because the vegetables were processed in the late fall and early winter
during the rainy season and the non-volatile solids concentration varied widely
due to the weather changes. If it were possible to obtain more data on vegetable
wastes from the following processing seasons, the solids correlation for vegetable
wastes could certainly be improved.
Substrate Removal and Biosolids Growth
The stabilization of organic wastes in the aerobic biological wastes treatment pro-
cess is brought about through the metabolic activities of mixed culture heterotroph-
ic microorganisms. A portion of the organic waste is converted to end products
such as carbon dioxide and water to obtain energy for synthesis of the remaining
portion into new biosolids and simultaneously to sustain life. After most of the
organic waste is stabilized, or only a limited amount remains, the microorganisms
then obtain the energy needed to sustain themselves by consuming their own
62
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TABLE 11
PLANT INFLUENT STUDY
Correlation Number of
Line of Best Fit Coefficient Observations
r n
Sweet Potatoes and Vegetables
VSS=0.785 SS+ 117 0.922 22
YDS = 0.951 DS-158 0.982 22
TVS = 0.89 TS- 112 0.964 22
Total COD = 0.974 TVS + 815 0.873 22
Soluble COD = 1.12 VDS + 48 0.979 ' 22
Irish Potatoes and Vegetables
VSS= 0.964 SS- 32 0.994 45
VDS = 0.872 DS - 84 0.979 45
TVS = 0.948 TS - 183 0.992 45
Total COD = 0.839 TVS + 886 0.723 45
Soluble COD = 0.876 VDS + 367 0.824 45
Vegetables
VSS= 0.619 SS+ 73 0.514 17
VDS = 0.366 DS+ 106 0.572 16
TVS = 0.0946 TS +299 0.369 16
Total COD = 0.683 TVS + 119 0.738 16
Soluble COD = 0.935 VDS + 3.8 0.871 14
Vegetables Winter Data Excluded
VSS= 0.502 SS+ 11 0.879 13
VDS =0.258 DS+ 171 0.367 12
TVS = 0.455 TS + 92 0.63 12
Total COD = 0.517 TVS + 195 0.615 12
Soluble COD = 0.902 VDS + 19 0.819 11
63
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protoplasm; and such a process is commonly referred to as endogenous respiration.
Endogenous metabolism is a function of the active biosolids and becomes signifi-
cant under food-limiting conditions. Under such conditions, microorganisms are
forced to utilize their own protoplasm until all that remains is a relatively stable
humus-like organic residue which resists further degradation. This inert organic
residue, an insoluble and non-biodegradable fraction of the microorganisms, ac-
cumulates in the system at the rate of about 11 to 15% of the ultimate BOD re-
moved (51).
In the biological oxidation process, Eckenfelder (52) showed that at high substrate
levels the rate of substrate removal per unit of biosolids will remain constant to a
limiting substrate concentration below which the rate will become concentration
dependent and decrease. It is generally accepted that the substrate removal kine-
tics can be described by a modification of the Michaelis-Mention equation which
is mathematically expressed as:
in which,
=• -j— = rate of change of substrate (BOD or COD) per unit of biosolids
with respect to time
F = substrate (BOD or COD) concentration present in the reactor
S = biosolids under aeration
K = maximum substrate removal rate
f = Michael is Constant, equal in magnitude to the substrate concentration
at which (1/S) (dF/dt) = K/2
At high substrate concentrations, F is much greater than f, then Equation (1)
becomes:
s dT = K
1 dt
t
64
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J- (F. - F ) = Kt
o i e
F.-F
® *— IX /O\
1 ' XV — IN (Z)
in which,
F. - influent substrate concentration
F = effluent substrate concentration
t - hydraulic retention time in aeration vessel
or COD; - CODe
MLVSS(t) = K (3)
in which,
COD. - COD
e
1 v
... \,<-c(.\ is the COD removal rate designated as ACOD expressed
. . - Ibs COD removed/Day
in terms of n-—.• .•: 5 >>-,;—• '- or
Ibs MLVSS
mg COD removed/Day
mg MLVSS
COD. = influent waste COD in mg/l
COD = soluble effluent COD in mg/l
e
t = hydraulic retention time in aeration tank in days.
From equation (3) it is obvious that for high substrate concentrations the COD re-
moval rate follows a zero order reaction.
At low substrate concentration f is much greater than F, then Equation (1) can be
expressed as:
65
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In a completely mixed activated sludge system, the effluent substrate concentra-
tion is assumed to be equal to the concentration of substrate remaining in the aera-
tion vessel. Hence, Equation (4) can be written as:
= K FS
TT~ — i\. r J »
dt 1 e
And a material balance can be developed as below:
Q(F. - Fe) -
F -F -.
M e dt
f.-f ...
i e _ dr
"~T~""dT
F.-F
F.-F
i _ e K p
"SltT 1 e (5)
Equation (5), a general mathematical expression for first order kinetics, represents
a response function for a completely soluble waste and does not include the rapid
initial removal due to biosorption. If a significant portion of the COD in the
waste is present in the colloidal, suspended or settleable form, then equation (5)
must be modified since it only takes into consideration the soluble COD that can
be removed through bio-oxidation. The particulate COD will be removed by
direct settling or by adsorption (biosorption) on to the MLSS and subsequent set-
tling. Therefore, if biosorption and settling are included then equation (5) be-
comes:
66
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or COD. -COD
MLVSS(t) 6 ^COD^I (7)
where I is an intercept due to settling and biosorption.
Based on the relationships expressed in Equations (3) and (7), if /COD is plotted
against CODe, the organic removal function can be readily visualized and studied.
Due consideration of these basic concepts of bio-oxidation is important in the in-
terpretation of the results obtained from this study.
The increase of bio-solids in a biological system is expressed mathematically as:
AS = a BODu|t(or COD) - bS (8)
or AVSS ACOD , .
MLVSS a MLVSS "b w
in which,
AS = net growth of bio -so I ids
a = growth rate constant
b = endogenous respiration rate constant
... ..-- = is the net growth of bio-solids per unit of time
per MLVSS expressed in terms of Ibs VSS increased/Day
Ibs MLVSS
mg VSS increased/Day
°r mg MLVSS
Oxygen is required in aerobic biological treatment systems to provide a terminal
hydrogen acceptor for catabolic reactions. The amount of oxygen required can be
expressed mathematically as:
(10)
.ACOD/Day
a D
MLVSS MLVSS
in which,
O^Day
... y-_ 's the total oxygen required per day per unit of MLVSS expressed
67
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r Ibs Oo/Doy
m terms of *•' ' _
Ibs MLVSS
a1 = oxygen utilization rate constant for synthesis
b' = oxygen utilization rate constant for endogenous respiration
Modular Units and System Evaluation
Considerable data were collected on COD removal rates and remaining COD con-
centrations as well as MLSS and MLVSS concentrations during the course of this
study. The results of the modular units study are summarized in Tables 12, 13,
and 14 and plotted in Figures E-21 through E-40, Appendix E.
Minimal Solids Unit Evaluation
Figures E-21, E-22 and E-23, show the COD removal kinetics in the minimal solids
unit for the three waste categories. The COD removal rates versus the soluble
effluent COD in the minimal solids unit for sweet potato plus vegetable wastes,
are shown in Figure E-21. The upper line is based on the total influent COD and
the lower one is based on the soluble influent COD. The best-fit line for the
soluble COD removal rate versus the soluble effluent COD is essentially a horizontal
line, indicating that the COD removal rate is independent of the soluble effluent
COD or the soluble COD in the aeration basin; that is, the organic removal rate
follows zero order kinetics. Therefore, referring to Figure E-31, the average
soluble COD removal rate as developed in Equation (3) is 2.55 Ibs COD/day/lb
MLVSS. Referring to the COD removal rate based on total influent COD versus
the soluble effluent COD, the line of best fit shows a slight upward slope; however,
it is reasonable to interpret it as zero order rather than first order reaction. The
difference between the upper and lower lines of best fit is due to the removal of
COD present in settleable, suspended or colloidal form by bio-precipitation and
settling. Referring to Table D-l, Appendix D, it can be seen that from 41 to 63%,
with an average of 51%, of the total influent COD can be attributed to solids
and colloids. The upward slope of the line reflects the solids COD removed by
settling. The difference between the intercepts of the two lines of best fit is
2.53, or 50% of the total COD removed, which corresponds very closely with
the average solids COD of the influent. Since the hydraulic retention time in
the aeration basin is short, ranging from 3.4 to 6.4 hours with an average of
5.26 hours, the biochemical degradation of particulate matter through hydrolysis
and their subsequent removal is small and can be neglected.
For Irish potato plus vegetable wastes, as shown in Figure E-22, comparable results
with that of sweet potato plus vegetable wastes were obtained; hence, the above
reasoning can be applied to their interpretation. That is, soluble COD removal
68
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TABLE 12
MODULAR UNIT STUDY OF SWEET POTATOES AND VEGETABLES
Correlation Number of
Line of Best Fit Coefficient Observations
Minimal Solids (High Loading) Unit
Based on Total Influent COD:
A S? tDw«Pcgy = 5 . 08 + 0 . 001 52 COD 0.387 19
MLVSS e
Based on Soluble Influent COD:
2.55 - 0.000359 COD 0.209 19
ML Sol ids COD= 1.1 96 MLVSS + 470 0.961 19
MLVSS=0.917MLSS-247 0.992 19
Extended Aeration Unit
.c =0.00118 COD -0.023 0.694 16
MLVSS e
MLSolidsCOD=1.312MLVSS+58 0.963 17
MLVSS=0.894 MLSS-209 0.986 18
69
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TABLE 13
MODULAR UNIT STUDY OF IRISH POTATOES AND VEGETABLES
Correlation Number of
Line of Best Fit Coefficient Observations
Minimal Solids (High Loading) Unit
Based on Total Influent COD:
A M?vD/{^qy=5-2° + 0.00963 COD 0.325 40
MLVSS e
Based on Soluble Influent COD:
—. =2.56+0.00134 COD 0.106 39
MLVSS e
ML Solids COD = 1.369 MLVSS-59 0.989 71
MLVSS=0.839MLSS-28 0.996 71
Extended Aeration Unit
= 0.192-0.000802 COD 0.129 34
e
ML Solids COD= 1.339 MLVSS+ 110 0.994 33
MLVSS = 0.725 MLSS-222 0.916 34
70
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TABLE 14
MODULAR UNIT STUDY OF VEGETABLES
Correlation Number of
Line of Best Fit Coefficient Observations
Minimal Solids (High Loading) Unit-
Based on Total Influent COD:
= 7.98 -0.0387 COD 0.414 13
Based on Soluble Influent COD:
= 5.16 -0.0266 COD 0.446
i i I \/rC — *•* • I V/ — V/ • VZ-W X- V./ LX V/ e *f*TW 1 O
ML Solids COD = 1.075 MLVSS + 12 0.952 13
MLVSS = 0.847 MLSS - 62 0.877 13
Extended Aeration
*. =0.0391 -0.00038 COD 0.244 13
MLVSS e
ML Solids COD = 1.375 MLVSS-3.32 0.957 15
MLVSS =0.796 MLSS-425 0.917 15
71
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follows zero order reaction; and the solids portion is removed by adsorption, floc-
culation and settling. The average soluble COD removal rate is 2.56 Ibs/day/lbs
MLVSS , which is essentially the same as that of sweet potato plus vegetable wastes.
Figure E-23, shows the COD removal rate versus the soluble effluent COD based
on both total and soluble influent for vegetable wastes. The data are so erratic
that it is impossible to develop a COD removal rate versus COD effluent relation-
ship. This is not unusual in a system in which there is no sludge returned to the
aeration basin, in other words, in a system in which the MLVSS concentration is
very low (less than 500 mg/l).
The percentage of COD removals for various waste categories is summarized in
Tables D-l, D-2, D-3. It can be observed that the average soluble COD removal
for Irish potato and vegetable wastes in the minimal solids unit was 87%, with a
range from 64 to 99%. During periods when sweet potato plus vegetables were
processed, all sludge was returned to the minimal solids unit, resulting in an aver-
age COD removal of 92%, with a range from 76 to 99%. The average COD re-
moval for vegetable wastes in the minimal solids unit was 82%.
The COD removal efficiency for vegetable wastes was lower than that of potato
plus vegetable wastes; however, the average soluble COD remaining in the mini-
mal solids unit for vegetable wastes was 66 mg/l, as compared to 349 mg/l for
Irish potato plus vegetable wastes. This indicates that a much lower effluent
strength can be obtained while treating only vegetable wastes.
Figure E-24 through E-29, show the MLVSS versus MLSS and the ML solids COD
versus MLVSS relationships in the minimal solids unit. For all three waste categor-
ies excellent correlation coefficients were obtained. The regression coefficients
for MLVSS and MLSS are close to the average MLVSS/MLSS ratios as listed in
Tables D-1, D-2, and D-3. The lines of best fitfor ML solids COD and MLVSS
give positive intercepts which can be considered as the COD attributed to the
non-volatile solids in the mixed liquor.
As there is no primary settling tank in the treatment system, and it is impossible
to differentiate bio-solids from organic solids as determined by solids analysis,
the entire MLVSS was used to compute the COD removal rate. Therefore, both
the COD load applied and removed per day per unit of MLVSS are higher than
indicated.
Extended Aeration Unit Evaluation
\
As stated earlier in this paper, the extended aeration unit with final clarifier
serves the dual purpose of effluent polishing and solids digestion. The soluble
effluent COD of the minimal solids unit is taken as the input COD load to the
72
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extended aeration unit. The effluent flow and its MLVSS concentration from the
minimal solids unit, are considered as the solids load.
-i.
The correlation of soluble COD removal rates versus the plant soluble effluent
COD in the extended aeration unit for the three waste categories is shown in
Figures E-30, E-31 and E-32. The line of best-fit for sweet potato plus vegetable
wastes indicates that the soluble COD removal rate follows first order reaction
kinetics with a fair correlation coefficient, as shown in Figure E-30. The soluble
COD removal rate constant designated as KI in Equation (8) is 0.00118. As to
soluble COD removal rates for Irish potato plus vegetable wastes and that of veg-
etable wastes alone, no correlation could be found; however, the plant soluble
effluent COD, except for one or two instances, was always less than 140 mg/l
for the Irish potato plus vegetable wastes and 30 mg/l for vegetable wastes alone.
The reason for the poorer correlation for the Irish potato plus vegetable wastes and
vegetable wastes alone than for sweet potato plus vegetable wastes was because
of the more frequent changes in product processed and the long retention time in
the extended aeration basin, making it impossible to develop good correlations.
As indicated in Tables D-1, D-2 and D-3, the average detention time in the ex-
tended aeration basin for sweet potato and vegetable wastes, Irish potato and veg-
etable wastes, and vegetable wastes alone were 1.58, 1.96 and 3.32 days respec-
tively. Because of the long retention time and frequent changes in waste charact-
eristics, the mixed liquor was always a mixture of many wastes. The frequent
changes in waste characteristics were the result of irregularly intermingling the
processing shifts of Irish potato plus vegetables and that of vegetables alone, re-
sulting in wide COD fluctuations in the aeration basin. Sweet potato and veg-
etable processing was more continuous and of longer duration; and when raw sup-
plies were exhausted, Irish potatoes and vegetables were processed in their place.
Therefore, the COD fluctuations were less pronounced than in the previous case.
Figures E-33 through E-38, show the relationship between MLVSS and MLSS, and
between ML solids COD and MLVSS for all three wastes categories. Again, excel-
lent correlations were obtained.
Throughout this study all loading rates are expressed in terms of a unit organic load
(Ibs COD/Day/lb MLVSS); and no mention is made of volumetric loading, which
is also often used in the field of waste treatment. Referring to Tables D-1, D-2,
D-3, an average volumetric loading rate for the three waste categories in both
stages of aeration can be calculated. Applied loads to the minimal solids unit
based on total influent COD for sweet potato plus vegetable, Irish potato plus
vegetable, and vegetable wastes alone were 1160, 714, and 86 Ibs COD/Day/
1000 cu. ft., respectively. When compared to conventional loading rates of 100
Ibs BOD/Day/1000 cu. ft. for high rate activated sludge systems, the minimal
solids unit at Stilwell is extremely efficient, with extremely high loadings. Mini-
mal solids soluble COD loads to the extended aeration unit for sweet potatoes plus
vegetables, Irish potatoes plus vegetables and vegetable wastes alone were 12.3,
73
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12.5, and 1.74 COD/Day/1000 cu.ft. respectively. Reported loading values of
20 Ibs BOD/Day/1000 cu.ft. for extended aeration systems are common. In addi-
tion to the soluble effluent COD loading from the minimal solids unit, a high
solids loading was also applied to extended aeration units. An average solids load-
ing in terms of Ibs VSS/Day/cu.ft. was 0.171, 0.129, and 0.033 when processing
sweet potatoes plus vegetables, Irish potatoes plus vegetables and vegetable wastes
alone, respectively. Comparing the general loading rate of 0.1 Ibs VS/Day/cu.ft,
applied to high rate anaerobic digesters and the 0.1 to 0.2 Ibs VS/Day/cu.ft.
applied to laboratory aerobic digestors as reported by other investigators (50), the
Stilwell extended aeration unit was subjected to fairly high loadings.
The solids removal efficiencies were a function of the products processed and the
methods of operation of the system. During June, July and the first week in
August, vegetables were the dominant products processed and during this period
the sludge was returned to either the extended aeration unit or simultaneously to
the minimal solids and the extended aeration units without intentional sludge
wasting except on June 11. From August 7 to August 30, Irish potatoes plus veg-
etables were the dominant products and sludge was returned to either the minimal
solids or simultaneously to the minimal solids and the extended aeration units with
intermittent sludge wasting. Following August 30, the sludge was returnee to the
minimal solids unit and the excess wasted to the anaerobic sludge stabilization la-
goon. From August 30 to the first part of November, either sweet potatoes or
Irish potatoes were processed simultaneously with vegetables, with sweet potatoes
being the dominant potato product. The sludge return schedule is shown in Figure
12.
As stated previously, the extended aeration unit was designed to handle ail solids
with no credit being given to the minimal solids unit since the bio-solids produced
were not returned directly to this unit and therefore the sludge retention time (SRT)
was much less than the SRT in the extended aeration unit. The solids removal ef-
ficiencies in the extended aeration unit were computed using the following formulae:
1. All sludge returned to the minimal solids unit.
I I
1
J
MS
MLVSS.
E A
QRf, VSS
•^
kr / P (
\
\
R!
:) to. o v;<;
/ *•*•* V jj .
J
\
\
Volatile Solids Removal =
---- ----- ^ Q VSS_.
wi' Ri
gQ.+QR.)MLVSS.-ZQ.VSSe.-lQw.VSSR.-aR.VSSR|
74
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2. Sludge returned to both minimal solids unit and extended aeration unit.
3
1
•W-]
1
b
s
MS
MLVSS.
i
111' VSS*i
1
|
1
| (
1
X
QR2i'V
EA
A
'SSRi
I
/-
Mb I f~ t
•» ( F 1
V
1
~N
Ci
1 —
/
r
i
.
^ /^i V/CC
— •'•Q., V55 .
i ei
SQ.+Q_..)MLVSS.-2Q.VSS
Volatile Solids
3. All sludge returned to extended aeration unfts.
Q ., VSS_.
wr Ri
.-2Q .VSSD.-IQDI.VSSD.
» wi Ri Rli Ri
i
MS
MLVSS.
!
QR
E A
' VSSRi
•» ( F (
i
- A
1
^ Q VSS
i ei
Q.MLVSS.-QW.VSSR.-Q.VSS
Volatile Solids Removal = —
Q.MLVSS.
i i
r VSSRI
Q .VSSn. = 0 if there is no sludge wasting.
wi Ri
The weighted average VSS removal in extended aeration was 66%, 62% and 85%
respectively for sweet potato plus vegetables, Irish potato plus vegetable, and
vegetable wastes only. Median and range values for the three waste categories
are summarized in Tables D-1, D-2 and D-3 of Appendix D.
The computed volatile solids removal efficiences were erratic as a result of the
intermittent sludge wasting procedure. In other words, a controlled sludge wast-
ing on an even interval or continuous basis would level off the erratic removal
75
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efficiences. This is not easy, because of the large variability of the products to
be processed and consequently the variation of the waste strength.
System Evaluation
The correlation of plant effluent parameters have also been studied. The results
are listed in Table 15, and in Figure E-39 through E-47. Good correlations for
effluent VSS versus SS relationships for all three waste categories were obtained.
Effluent COD and VSS relationships are fairly good for both sweet potato plus
vegetable, and Irish potato plus vegetable wastes. However, the COD versus
VSS correlations for vegetable wastes alone are rather poor; this is probably due
to residual effects of strong wastes from previous shifts. Although the percentage
COD removal for strong waste was high, the residual effluent was of sufficient
magnitude that when mixed with the low vegetable COD effluent of the following
shifts it resulted in a higher plant effluent concentration than would exist if only
vegetables were processed, thus lowering the observed plant efficiency. Conse-
quently, the COD and VSS relationship of vegetable wastes was affected.
The average plant soluble effluent COD for sweet potato plus vegetable, Irish
potato plus vegetable, and vegetable wastes alone were 84, 44, 33 mg/l respec-
tively. For potato wastes this study showed a BOD/COD ratio of approximately
0.2, which is consistent with that of 0.16 to 0.30 as reported by Atkins and
Sproul (15). Based on the BOD/COD ratio of 0.2, the plant effluent would have
a corresponding soluble BOD of 17 mg/l for sweet potato and vegetable wastes,
and 9 mg/l for Irish potato and vegetable wastes.
The plant performance data as shown in Tables D-l, D-2, and D-3, indicated an
overall average COD removal of 97, 99, and 82% for sweet potato plus vegetable,
Irish potato plus vegetable, and vegetable wastes alone, respectively. On a BOD
basis, the removals are much higher than these figures. The plant VSS removals
were 97, 98, and 74% for sweet potato plus vegetable, Irish potato plus vegetable,
and vegetable wastes, respectively. The VSS in the effluent is mainly inert organ-
ics from polysaccharides resulting from bio-solids decay.
Correlations for oxygen uptake studies were poor; therefore, these studies were not
reported. However, dissolved oxygen concentrations in the aeration basins were
monitored frequently. Residual oxygen was detected at all times during the course
of the study period. The average dissolved oxygen content in the minimal solids
unit was 4.36 mg/l and ranged from 0.2 to 8.1 mg/l with a median of 4.6 mg/l.
In the extended aeration basins, the average dissolved oxygen content was 3.4
mg/l with a median of 3.15 mg/l and a range of 0.5 to 9.8 mg/l.
Solids Separation and Disposal
The overall performance of an activated sludge system depends on the ability of
the final clarifier to separate and retain the solids from the effluent. It is impossible
76
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TABLE 15
PLANT EFFLUENT STUDY
Correlation Number of
Line of Best Fit Coefficient Observations
Sweet Potatoes and Vegetables
VSS = 0.711 SS-0.741 0.899 20
Total Effluent COD = 1.356 VSS + 64.48 0.673 20
Effluent Solids COD = 0.811 VSS + 2 0.825 20
Irish Potatoes and Vegetables
VSS = 0.892 SS-16.45 0.93 35
Total Effluent COD = 1.431 VSS + 34.06 0.902 35
Effluent Solids COD = 1.097 VSS + 5.46 0.921 35
Vegetables
VSS =0.538 SS+ 6.48 0.926 17
Total Effluent COD = 0.692 VSS + 34.19 0.288 17
Effluent Solids COD = 0.449 VSS + 841 0.529 17
77
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to produce a good quality effluent unless most of the solids can be separated and
returned to the system or wasted. Since the settleability of the MLSS is generally
measured by the Sludge Volume Index (SV1), and the total COD removal efficiency
is related to the settleability of the solids the SV1 is plotted against the COD re-
moval rates for minimal solids and extended aeration units. No apparent relation
between these two parameters can be observed (refer to Figures 25 and 26). Nor-
mally, one would expect better settling at lower loading rates (extended aeration)
than at high loading rate (minimal solids); however, the solids in the minimal
solids unit seem to settle better than in the extended aeration unit. The reason for
this apparent anomaly is not well understood. However, the better-then-expected
settling in the minimal solids unit can be attributed to stabilization of the solids
in the extended aeration system. Solids are recirculated from the final clarifier
to the minimal solids unit. If the system was so designed that the minimal solids
system could be operated separately, solids separation from this unit would be much
more difficult. As indicated in Tables D-l, D-2 and D-3, the average SVI for
sweet potato plus vegetable, Irish potato plus vegetable, and vegetable wastes
alone in minimal solids were 197, 132, and 124, respectively and in extended
aeration were 250, 147, and 126. Normal SVI varies from 55 to 150 in diffused
air plants and from 200 to 300 at mechanical aeration plants (53). As presented in
Tables D-l, D-2 and D-3, the highest SVI occurred in both aeration units when
treating sweet potato wastes which were nitrogen deficient and had the highest
waste flow. Therefore, it is postulated that inadequate nutrient feed to the system
deteriorates the settleability and separation characteristics of the solids. In general
the final settling tank of an extended aeration system with 24 hour aeration is de-
signed with 4 hour detention time based on incoming waste flow. The final clarifier
in this system has a detention time of only 1.89 hours based on 1.5 MGD. This
lower retention time accentuates the problem of inadequate solids separation; how-
ever, if the conditions, such as nutrient addition, are maintained at the optimum,
solids separation can be adequately accomplished. This has been verified by fol-
lowing the treatment efficiencies in the 1970 canning season. During this season,
nutrients have been maintained at the optimum level, the loading rate higher than
the 1969 season, and no separation problems existed until flows exceeded 2.5 MGD.
In the course of the study, excess solids were wasted to an anaerobic sludge pond.
The volume of solids wasted ranged from 0.006 to 0.343 MGD with an average of
0.13 MGD and a median of 0.112 MGD. This does not include the period of
sludge bulking when solids were wasted involuntarily for 16 hours per day for two
weeks. The corresponding weight of solids wasted ranged from 322 to 20,451 with
a mean of 7,750 Ibs SS/day-
The rate of sludge stabilization in the anaerobic ponds is extremely slow. Solids
were pumped to the pond for the first time in August 1969 and solids loading stop-
ped in December 1969. No sludge was added again until late September 1970.
It was anticipated that with two lagoons operating alternate years, allowing one
78
-------
300
200
I/O
100
0
0
I I \
Minimal Solids Unit
* *
• • •
12
16
20
24
Removal
28
Ibs MLVSS
• Figure 2£ SVI vs Soluble COD Removal Rate
32
36
-------
00
o
400
300
\
E
- 200
>
S)
100
A
1 1 1 1 1 1 1
Extended Aeration Unit
• •
• •
.*•
"~ • m
^. ^ V
•* •
% » • •
-» » ••
•i • »• • • • •
f
, * '
1 1 1 1 1 1 1
0
0.1
0.2 0.3 0.4 0.5
Soluble COD Removal Rate A'^ ^.^
Ibs MLVSS
0.6
0.7
Figure 26 SVI vs Soluble COD Removal Rate
-------
full year for digestion, the sludge would be well stabilized and would be removed
from the lagoon and spread on fields as a soil conditioner. However, after one full
year the sludge in the bottom of the lagoon had approximately the same consistency
and color as when it was first pumped to the lagoon. The digested sludge had a
rubber-like consistency making questionable its value as a soil conditioner. From
these observations anaerobic digestion of the sludge may not be the most desirable
or economical method of treatment.
Nutrient Requirements
Several nutrients and trace elements are essential for the metabolism of organic
matter by microorganisms. These nutrients are needed only for synthesis and are
released from the endogenous phase and are again available for reuse. All but
nitrogen and phosphorous are usually present in sufficient quantity in the carrier
water. As stated earlier in this chapter, the waste generated from sweet potato
and Irish potato were deficient only in nitrogen.
In this study total Kjeldahl nitrogen was used as a measure of nitrogen content in
the VSS; ammonia, nitrate nitrogen, and total phosphate in the plant effluent were
also monitored. When nutrients in low concentration were detected in the effluent
it was assumed that the treatment system was not deficient nutritionally; however,
when high concentrations were found in the effluent, nitrogen dosage was lowered
so that nutritional pollution could be prevented. A nitrate nitrogen concentration
of 1 rng/1 in the effluent was used as a criterion.
The TKN/VSS ratios of the returned sludge are plotted against the COD removal
rates for both aeration units in Figures 27 and 28. No relationship exists between
the two parameters; however, the average TKN/VSS ratios were found to be 6.38
and 6.93 in the minimal solids unit and extended aeration tank, respectively. Re-
ferring to plant effluent data as listed in Tables D-l, D-2, and D-3, the average
ammonia nitrogen concentration in the effluent was 0.3 mg/1, nitrate nitrogen
1.7, and phosphate 0.14, which would indicate that the microorganisms had suf-
ficient nutrients, except during the sludge bulking period, when the nitrogen con-
tent of the MLVSS dropped to a low of 3.1%. The situation was corrected after
two weeks of nitrogen supplementation from an exogenous source. When the nitro-
gen level reached 4.6, settling began to improve.
When SVI is plotted against sludge TKNASS ratlos as shown in R9ure 29' a trend
exists which appears to follow a hyperbolic curve the higher the TKN/VSS ratio
the lower the SVI. A minimum TKN/VSS ratio of 5% is required to avoid sludge
bulking and a ratio of between 5 and 10% could give a SVI below 200 provided
other conditions were favorable.
It should be noted that pH is another environmental factor of importance in an acti-
vated sludge system; pH should be maintained between 6.5 to 9.0 to support a
81
-------
OD
CO
z
^
12
<£ 8
c
-a
0
0
I I I
Minimal Solids Unit
Sweet Potatoes and Vegetables
Irish Potatoes and Vegetables
Vegetables
TKN A ™
VSST= 6-38
= 6.38
r = 0.09
n = 22
68 10 12
rr^n D i D t Albs COD/Day
COD Removal Rate ,, ... ' 7
Ibs MLVSS
14
Figure 27
TKN
VSS
of Sludge vs COD Removal Rate
ACOD/Day
-
16
18
-------
00
CO
12
10
# 8
c
(U
f
5 6
o
Z t/v
^
4
2
0
C
1 1 1 1 1 1-
Extended Aeration Unit
Sweet Potatoes and Vegetables •
Irish Potatoes and Vegetables A
"" Vegetables ^ ~
r A
-| A A 1
•
^ A
•
TKN_ COD/Day
. . VSS 6'yJ U-I8V MLVSS
* = 6.93
• r = 0.0114
n = 20
1 1 1 1 1 1
) 0.1 0.2 0.3 0.4 0.5 0.6
Snltibla COD Rnmnval R.fn Albs COD/Da/
Ibs MLVSS
Figure 28
TKN
of Sludge vs Soluble COD Removal Rate
-------
500
400
Sweet Potatoes and Vegetables
Irish Potatoes and Vegetables
Vegetables
Minimal Solids
A
T
Extended Aeration
t
T
E
c
300
200
100
SVI =72 +
r = 0.432
n = 40
549
TKN
VSS
8
TKN
VSS
10 12
of Sludge in %
14
16
18
Figure 29 SVI vs ~- of Sludge
-------
normal bacterial culture. Below pH 6.5 the fungi will compete with the bacteria
with predomination at a pH of 4.5 or below. Above pH 9.0 retardation of the
metabolic rate is observed. Thus, it is important that pH be maintained at the
proper level.
The variation in pH of incoming wastes, plant effluent, and each stage of the
treatment process is summarized in Tables D-l, D-2 and D-3. The average incom-
ing pH of the three wastes categories ranged from 5.9 to 7.7, although the pH
reached an extreme high of 10.3 when blanching water was discharged and an ex-
treme low of 4.6 during an Irish potato shift. During the course of the study, pH
never presented any operational problems. The natural buffering capacity of the
system was adequate to offset the pH variations encountered in this waste. The
average pH in the minimal solids unit while treating wastes from each category
ranged from 6.9 to 7.3, and that in extended aeration ranged from 6.9 to 7.2.
The plant effluent had an average pH of 7.2 to 8.0. The pH variation before and
after treatment is shown in Figure 9.
Cost Analysis
Cost of treatment consists of the annual fixed charge for costs of construction of
treatment facilities and the annual cost of operation and maintenance. The total
construction cost of the plant was $287,435. Based on an amortization over 20
years with an interest rate of 7%, the breakdown of the cost into an annual fixed
charge is $27,131. The annual operation and maintenance charge is $54,691,
which included $5,000 per year for major improvements. This makes a total annual
charge of $74,000 per year. The annual cost does not include the cost of sludge
handling. However this is not a significant cost because city equipment and per-
sonnel are used during slack periods.
From the past few year's records of the cannery operation and their future produc-
tion plans, it is postulated that the cannery would operate three hundred days per
year, two shifts per day and one hundred days for each of the three major product
categories, namely sweet potatoes plus vegetables, Irish potatoes plus vegetables,
and vegetables alone.
The waste load in terms of total pounds of COD, SS, and VSS applied and removed
for each waste category is the product of the average concentration, shift flow,
and total number shifts per year. The yearly waste load is the summation of the
three waste categories.
The yearly waste load consists of approximately 6,527,000 Ibs of COD, 3,149,000
Ibs of SS, and 2,633,000 Ibs of VSS; and that of plant effluent is 252,000 Ibs COD,
157,000 Ibs SS, and 106,000 Ibs VSS, also based on average effluent concentrations,
The cost of treatment is approximately 1.13 cents per pound of COD applied or 1.18
85
-------
cents per pound of COD removed; 2.35 cents per pound of SS applied or 2.48
cents per pound of SS removed; and 2.81 cents per pound of VSS applied or 2.93
cents per pound of VSS removed. Compared to the reported primary treatment
cost of 2 cents to 6.4 cents per pound of BOD removed for potato waste (54), the
cost of treatment at Stilwell is extremely economical.
The cost analysis is summarized in Table 16.
86
-------
TABLE 16
COST OF WASTE TREATMENT SYSTEM
Total Cost of Construction $287,435
Amortization Factor: 20 years @ 7% interest 0.09439
Annual Fixed Charge for Cost of Construction 27,131
Annual Cost of Operation and Maintenance
2 Operators @ 1,000/month $ 12,000
Power charge 10 months @ $2,300/month 23,000
Nutrients 6 months @ $750/month 4,500
Office supplies 500
Laboratory supplies 1,000
Equipment repair 869
In-plant improvement 5,000
Total Annual Charge $ 74,000
Annual Waste Load COD Applied = 6,527,000 Ibs
Annual Waste Load COD Removed = 6,275,000 Ibs (based on total effl.)
Annual Waste Load COD Removed = 6,378,000 Ibs (based on soluble effl.)
Annual Waste Load SS Applied = 3,149,000 Ibs
Annual Waste Load SS Removed = 2,993,000 Ibs
Annual Waste Load VSS Applied = 2,633,000 Ibs
Annual Waste Load VSS Removed = 2,527,000 Ibs
Annual Cost of Treatment per Unit of Waste Load:
Per Pound of COD Applied = 1.13$
Per Pound of COD Removed = 1.18$ (based on total effluent)
Per Pound of COD Removed = 1.16$ (based on soluble effluent)
Per Pound of SS Applied = 2.35$
Per Pound of SS Removed = 2.48$
Per Pound of VSS Applied = 2.81$
Per Pound of VSS Removed = 2.93$
87
-------
SECTION VIII
ACKNOWLEDGEMENTS
This investigation was supported by Demonstration Grant No. 12060 DSB from the
Water Quality Office, Environmental Protection Agency, for which, we express our
sincere appreciation.
The cooperation of the personnel at the Stilwell Department of Utilities and that of
Stilwell Canning Company is gratefully acknowledged.
Thanks are extended to Mr. John R. Palafox who helped in performing numerous lab-
oratory analyses and assistance throughout the study; to Mr. Edward Seely for his con-
tributions in the development of the waste flow model, and to Mr. Frank C.H. Hu
for his assistance in drawing all the figures and graphs in this paper.
The support of the project by the Water Quality Office, Environmental Protection
Agency, and the help provided by Mr. George Keeler, Mr. Ken Dostal, and Mr.
Robert L. Miller, the Project Officer, is acknowledged with sincere thanks.
89 AWBhKC LIBRARY U.S. EPA
-------
SECTION IX
BIBLIOGRAPHY
1 . U.S. Deparl-ment of Agriculture Statistical Report Service, Potatoes/ Sweet
Potatoes, Statistical Bulletin No. 409, Washington, D.C., (July, 1967, and
August, 1969).
2. Reid, G.W., Streebin, L.E., Klehr, E.H., and Love, O.T., Water Treatment
Facilities for a Large Canning Company, Center for Economic Development-State
of Oklahoma, Publication No. 1, (November, 1966).
3. Cooley, A.M., Wahl, E.D., and Possum, G.O., "Characteristics and Amounts
of Potato Wastes from Various Process Streams," Proceedings of the 19th Industrial
Waste Conference, Purdue University, Engineering Extension Series No. 117,
p. 379 (1964).
4. Postal, K., "Secondary Treatment Potato Wastes" Report No. 12060 Environ-
mental Protection Agency, (July, 1969).
5. Francis, R.L., "Characteristics of Potato Flake Processing Wastes," Journal of
Water Pollution Control Federation, XXXIV, p. 291 (January, 1962^
6. Porges, R., and Towne, W.W., "Wastes from the Potato Chip Industry," Sewage
and Industrial Waste, XXXI, p. 53 (January, 1959).
7. U.S. Department of Health, Education, and Welfare, Committee on Potato Chip
Wastes of the Potato Chip Institute International in Cooperation with the National
Technical Task Committee on Industrial Wastes, Potato Chip Industry, Public
Health Service Publication No. 756, Washington, D.C., (I960).
8. Vennes, J.W., and Olmstead, E.G., "Stabilization of Potato Wastes," North
Dakota Water and Sewage Works Conference, (1961).
9. Atkins, P.F., and Sproul, O. ., "Feasibility of Biological Treatment of Potato
Processing Wastes," Journal Water Pollution Control Federation, XXXVIII, p. 1287
(August, 1966).
10. Furgason, R.R., and Jackson, M.L., "Bacterial Utilization of Potato Starch
Wastes," Proceedings of the 15th Industrial Waste Conference, Purdue University,
Engineering Extention Series 196, p. 258 (I960).
11. Kueneman, R.W., "Performance of Primary Waste Treatment Plants in Northwest
U.S.A.," Proceedings of the International Symposium on the Utilization and
Disposal of Potato Wastes, New Brunswick Research and Productivity Council,
Fredericton, New Brunswick, Canada, p. 285 (May, 1965).
91
-------
12. Formo, H.G., "Problems and Approaches in the Treatment of Wastes from
Potato Processing Plants," Proceedings of the 10th Pacific Northwest In-
dustrial Waste Conference/ (1961).
13. Ballance, R.C., "A Review of Primary Treatment Process/' Proceedings of
the International Symposium on the Utilization and Disposal of Potato Wastes,
New Brunswick Research and Productivity Council, Fredericton, New Bruns-
wick, Canada, p. 200 (May, 1965).
14. Hindin, E., "Disposal of Potato Chip Waste by Anaerobic Digestion," Wash-
ington State Institute of Technology Bulletin No. 225, (1961).
15. Sproul, O.J., Keshavan, K., Hall, M.W., and Barnes, B.B., "Waste-
water Treatment from Potato Processing," Water and Sewage Works, CXV,
p. 93 (February, 1968).
16. Buzzell, J.C., Jr., Caron, A.L.J., Rykman, S.J., and Sproul, O.J.,
"Biological Treatment of Protein Water From Manufacture of Potato Starch -
Part I and II," Water and Sewage Works (July and August, 1964).
17. Sproul, O.J., "Potato Processing Waste Treatment Investigation at the Univer-
sity of Maine," and "Panel Discussion Session B," Proceedings of the Interna-
tional Symposium on the Utilization and Disposal of Potato Wastes, New Bruns-
wick Research and Productivity Council, Fredericton, New Brunswick, Canada,
p. 295, 412 (May, 1965).
18. Pailthorpe, R.E., and Filbert, J.W., "Potato Waste Treatment in Idaho Pi-
lot Unit Study," Proceedings of the International Symposium on the Utiliza-
tion and Disposal of Potato Wastes, New Brunswick Research and Productivity
Council, Fredericton, New Brunswick, Canada, p. 285 (May, 1965).
19. Hindin, E., and Dunstan, G.H., "Anaerobic Digestion of Potato Processing
Wastes," Journal of Water Pollution Control Federation, XXXV, p. 486
(April, 1963).
20. Ling, J.T., "Pilot Investigation of Starch - Gluten Waste Treatment," Pro-
ceedings of the 16th Industrial Waste Conference, Purdue University, Engineer-
ing Extention Series 109, p. 217 (1961).
21. Carlson, D.A., "Biological Treatment of Potato Wastes," Proceedings of the
13th Pacific Northwest Industrial Waste Conference, Washington State Uni-
versity, p. 79 (April, 1967).
22. Murray, H. R., "Problems in Treatment of Potato Wastes, " Proceedings of the
13th Pacific Northwest Industrial Waste Conference, Washington State Uni-
versity, p. 95 (April, 1967).
92
-------
23. Servizi, J.A., and Bogan, R.H., "Free Energy as a Parameter in Biological
Treatment," Proceedings of the American Society of Civil Engineers, 89, SA3,
17, (1963). ~
24. Hoover, S.R., and Porges, N., "Assimilation of Dairy Waste by Activated Sludge,
II. The Equation of Synthesis and Rate of Oxygen Utilization," Sewage and In-
dustrial Wastes, XXIV, p. 305 (March, 1952).
25. Helmers, E.N., and Sawyer, C.N., etal., "Nutritional Requirements in the
Biological Stabilization of Industrial Wastes I, Experimental Method," Sewage
and Industrial Wastes, XXII, (September, 1950).
26. Helmers, E.N., and Sawyer, C.N., etal., "Nutritional Requirements in the
Biological Stabilization of Industrial Wastes II, Treatment with Domestic Sewage,"
Sewage and Industrial Wastes, XXIII, p. 884 (July, 1951).
V-T* ^-^^™^—
27. Helmers, E.N., and Sawyer, C.N., etal., "Nutritional Requirements in the
Biological Stabilization of Industrial Wastes III, Treatment with Supplementary
Nutrients," Sewage and Industrial Wastes, XXIV, p. 496 (April, 1952).
28. Weinberger, C.W., Doctoral Thesis, Massachusetts Institute of Technology
(1950), Abstract reported by Sawyer, C.N., Biological Treatment of Sewage
and Industrial Waste, Vol. I. Edited by McCabe, J., and Eckenfelder, W.W.,
New York: Reinhold Publishing Corporation, (1956).
29. Heukelekina, J., and Gellman, I., "Studies of Biochemical Oxidation by Direct
Methods, II. Effect of Certain Environmental Factors on Biochemical Oxidation
of Wastes," Sewage and Industrial Wastes, XXXIII, p. 1546 (December, 1951).
30. Gaffney, P.E., and Heukelekian, H., "Oxygen Demand Measurement Errors in
Pure Organic Compounds, Nitrification Studies," Sewage and Industrial Wastes,
XXX, p. 503 (April, 1958).
31. Jones, P.H., "The Effect of Nitrogen and Phosphorous Compounds on One of the
Microorganisms Responsible for Sludge Bulking," Proceedings of the 20th Indus-
trial Wastes Conference, Purdue University, Engineering Extension Series No.
118, p. 297(1965).
32. Oginshy, and Umbreit, An Introduction to Bacterial Physiology, W.H. Freeman
and Company, San Francisco and London, 2nd Ed., p. 275 (1958).
33. Sawyer, C.N., "Bacterial Nutrition and Synthesis," Biological Treatment of
Sewage and Industrial Waste, Vol. I, Edited by McCabe, J. and Eckenfelder,
WW., New York: Reinhold Publishing Company, New York, (1956).
34. Eckenfelder, W.W., "Theory of Biological Treatment of Trade Wastes, " Journal
93
-------
of Wafer Pollution Control Federation, XXXIX, p. 240 (February, 1967).
35. Reid, G. W., "Water Requirements for Pollution Abatement, " Committee Print
No. 29, Water Resources Activities in the United States, United State Senate
Select Committee on National Water Resources, (January, 1960).
36. Komolrit, K., Goel, K.C., and Gaudy, A.F., "Regulation of Exogenous Nitro-
gen Supply and Its Possible Application to the Activated Sludge Process, " Journal
Water Pollution Control Federation, XXXIX, p. 251 (February, 1967).
37. Krishman, P. and Gaudy, A.F., "Substrate Utilizations," Journal of Water Pol-
lution Control Federation, XL, p. R54 (February, 1968).
38. Goel, K.C., and Gaudy, A.F., "Regeneration of Oxidative Assimilation Capacity
by Intracellular Conversion of Storage Products to Protein," Applied Microbiology,
XVI, p. 1352 (September, 1968).
39. Gaudy, A.F., Goel, K.C., and Gaudy, E.T., "Continuous Oxidative Assimila-
tion of Acetic Acid and Endogenous Protein Synthesis Applicable to Treatment of
Nitrogen-Deficient Waste Water," Applied Microbiology, XVI, p. 1358 (Septem-
ber, 1968).
40. Mercer, W.A., "Canned Foods," Industrial Waste Water Control, edited by Gurn-
ham, C.F., New York: Academic Press, (1965).
41. Burbank, N.C., and Kumagai, J.S., "A Study of a Pineapple Cannery Waste,"
Proceedings of the 20th Industrial Waste Conference, Purdue University, Engineer-
ing Extension Series No. 118, p. 365 (T965).
42. Reid, G.W., and Streebin, I.E., Industrial Waste Study for Aliens Canning
Company. A Report to Oklahoma Economic Development Foundation, Norman,
Oklahoma, December, (1968).
43. Gilds, L.C., "Experiences of Cannery and Poultry Waste Treatment Operations,"
Proceedings of the 22nd Industrial Waste Conference, Purdue University, Engineer-
ing Extension Series No. 129, p. 675 (1967).
94
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SECTION X
APPENDICES
Page No.
A. CANNING PROCESSING FLOW SHEETS 97
B. ANALYSIS OF WASTE STREAMS 107
C. LABORATORY ANALYTICAL METHODS 111
D. PLANT PERFORMANCE DATA 115
E. PLANT INFLUENT, MODULAR UNITS AND
SYSTEM ANALYSES 133
95
-------
APPENDIX A
CANNING PROCESSING FLOWSHEETS
97
-------
APPENDIX A
CANNING PROCESSING FLOW SHEETS
IRISH POTATOES
I
Dry Screen
Wet Screen ------------ *- Waste Flow *
Scalding Bath ----------- *• Waste Flow
Wet Screen ------------ »- Waste Flow*
Steam Peeling ---- • ------- **• Waste Flow*
Wet Screen & Spraying -------- +> Waste Flow*
Polisher (Abrasive Peeling) ------ *> Waste Flow
Spraying ------- - ------ ^ Waste Flow*
Sorting & Rinse ----------- ^ Waste Flow*
FREEZING PROCESS , , CANNING PROCESS
Packing -*•—, - -^-Canning
• Waste Flow
Freezing & Cooking
Storing Cooling
Dry Storage
* Major Stream
Figure A-l Flow Sheet of Irish Potato Processing
98
-------
SWEET POTATOES
Dry Screen
Wet Screen ^ Waste Flow*
Scalding Bath *• Waste Flow
Wet Screen *- Waste Flow*
Steam Peeling ^ Waste Flow*
Wet Screen & Spraying *• Waste Flow*
Polisher (Abrasive Peeling) >• Waste Flow
Spraying --»• Waste Flow*
Sorting & Rinse • ^ Waste Flow*
Sugar and/or Other Additives
FREEZING PROCESS . 1 CANNING PROCESS
Packing ---- *• -^Canning
-- -------- »> Waste Flow
r
Freezing & Cooking
Storing Cooling
Dry Storage
* Major Stream
Figure A-2 Flow Sheet of Sweet Potato
99
-------
GREEN VEGETABLES
t
Dry Screen
Pick Belt
Spraying —^-Waste Flow*
Water Bath ^ Waste Flow
Blanching •»- Waste Flow*
CANNING PROCESS FREEZING PROCESS
i'
* *
Cutting Cooling
Cutting & Chopping —»••Waste
J Flow
Canning *• —T- •* Packing
Cooking ^ »-Waste
^ Flow
Cooling
Dry Storage
* Major Stream
Figure A-3 Flow Sheet of Green Vegetable Processing
100
-------
GREEN BEANS
Dry Pick Belt
Dry Screen
Vine Remover
Water Bath & Spraying —»-Waste Flow*
Snipper
Grader
Cutter
Grader
Spraying & Pick Belt —»*Waste Flow
Hopper
Blanching »-Waste Flow*
Canning »• Waste Flow
Cooking
Cooling
Dry Storage
* Major Stream
Figure A-4 Flow Sheet of Green Bean Processing
101
-------
PEAS & BEANS
Husk Remover
*
Air Cleaner
Flotation & Spraying-—
Froth Flotation Cleaner —
Blanching —•
Holding Tank -——-
Blanching -—
Air Cleaner
I
Packing —
Freezing & Storing
-*>Waste Flow*
•»•• Waste Flow
-^ Waste Flow *
-»-Waste Flow*
-»• Waste Flow
•»• Waste Flow
* Major Stream
Figure A-5 Flow Sheet of Peas & Beans Processing
102
-------
SQUASH
Pick Belt
Lye Wash -
Rinse
Cutter
Spraying —
Blanching -
Cooling —
Dewatering
Pac
cmg
Freezing & Storing
-^ Waste Flow*
-*-Waste Flow*
-•*• Waste Flow*
—*• Waste Flow
•-*• Waste Flow
• Waste Flow
* Major Stream
Figure A-6 Flow Sheet of Squash Processing
103
-------
OKRA
Stem Remover ——-^ Waste Flow
Blanching - ------- »- Waste Flow*
Water Bath — — -*- Waste Flow*
Packing ------ — *• Waste Flow
Freezing & Storing
Major Stream
Figure A-7 Flow Sheet of Okra Processing
104
-------
BLACKBERRIES
Spraying — »• Waste Flow *
Pick Belt
Canning *• Waste Flow
Cooking
Cooling
Dry Storage
Major Stream
Figure A-8 Flow Sheet of Blackberry Processing
105
-------
STRAWBERRIES
Vibrator & Pressure Wash — *• Waste Flow*
Pick Bell-
Spraying ••*• Waste Flow*
Slicing & Sugar Addition -»» Waste Flow
Packing •*• Waste Flow
Freezing & Storing
Major Stream
Rgure A-9 Flow Sheet of Strawberry Processing
106
-------
APPENDIX B
ANALYSIS OF WASTE STREAMS
107
-------
APPENDIX B
TABLE B-l
ANALYSIS OF WASTE STREAMS SAMPLED
Date
May 19
May 22
May 26
May 27
May 27
May 28
May 29
June 5
June 6
June 9
Product Processed*
Irish Potato
Peeling Stream
after settling
Strawberry
Packing stream (sugar added)
Washing stream
Potato & Strawberry
Before screening
After screening (^ 10 screen)
Col lard Greens, Potato & Strawberry
(Strawberry packing stream excluded
Col lard Green Blanching stream
Col lard & Mustard Green
Strawberry Washing Stream
Strawberry Packing Stream
Strawberry & Turnip Green
Strawberry Washing Stream
Turnip Green Blanching Stream
Tumip Green Packing Stream
Strawberry Washing Stream
after settling
Tumip Green & Sliced Tumip
Packing Stream
Turnip Green & Sliced Tumip
Blanching Stream
Turnip Green & Sliced Turnip
Packing Stream
Turnip & Mustard Packing Stream
Green Beans with Wash- Down Water
Green Beans
Green Beans
Okra Frozen
Okra & Green Beans
Squash
Squash & Green Beans
COD
mg/l
7070
75000
10600
13200
5100
4550
3450
650
187
298
1050
9100
910
2350
610
298
2040
1690
533
567
274
410
32
100
152
39
112
440
204
nH TemP
PH OG
6.85
6.35
6.35
4.3
4.5
6.15
6.35
5.8
7.3
7.3
4.5
4.2
5.3
4.45
7.05
7
4.65
6.8
7.2
7
7.1
7.05
7.05
6.7
7.45
7.05
6.7
6.6
25
30
25
23
22
30
22
26
25
27
26
21
26
27
29
109
-------
TABLE B-l
(Continued)
Date
June 10
June 1 1
June 12
June 13
Product Processed*
Squash
Potato (all streams up to peeling
and including peeling)
Potato after settling
Potato soluble
Potato & Squash Waste Stream
Potato & Squash after settling
Potato & Squash soluble
Potato Waste Stream
Potato after settling
Squash Waste Stream
Squash after settling
Squash soluble
Blackberry Canning Waste
COD
mg/l
485
5340
1920
1890
1450
1390
1300
4250
1240
480
390
380
490
PH
5.9
5.2
6.6
7.0
7.3
6.8
Temp
°C
29
34
30.*
30
25
27
Only those products sampled are listed.
110
-------
APPENDIX C
LABORATORY ANALYTICAL METHODS
111
-------
LABORATORY ANALYTICAL METHODS
Chemical Oxygen Demand (COD)
The total COD sample was withdrawn from a well mixed 500 ml sample, and the settled
COD sample was taken from the supernatant of a 500 ml sample after settling for 30
minutes. Forty ml of a well-mixed sample was centrifuged for 10 minutes at 10,000 rpm
in a Sorval Superspeed Type SS-1 centrifuge; the centrate was used for the soluble COD
determination. The procedure as outlined in Standard Methods (49) was followed.
Solids Determination
The suspended solids concentration was determined by taking a 40 ml well-mixed sample
from each unit, and from the plant influent and effluent. The sample was centrifuged
for 10 minutes at 10,000 rpm, and the centrate was poured off for soluble COD and dis-
solved solids determinations. The pellet was then washed into a tared porcelain dish
with distilled water and placed in a drying oven and evaporated to dryness at 103°C
for 8 to 10 hours. The difference between the gross and tare weights times the appro-
priate dilution factor gave the concentration of suspended solids in mg/l. The porce-
lain dish containing the residue was placed in a muffle furnace at 600°C for 15 to 20
minutes, cooled in desiccator and weighed. The difference between the two gross
weights times the appropriate dilution factor gave the concentration of volatile suspend-
ed solids in mg/l. The same procedure was used for determining the total dissolved and
volatile dissolved soldids, except a 100 ml sample of the centrate was evaporated to dry-
ness.
Total Kjeldahl Nitrogen (TKN)
A Labconco Micro Kjeldahl digester Model-A was used for digestion, and a Labconco
Micro Still was used for distillation of the sample. The procedure as outlined in Quan-
titative Bacterial Physiology Laboratory Experiments (50) was followed in Total Kjeldahl
Nitrogen determination. A sample size of 2 ml was used. For ammonia nitrogen deter-
mination, a 20 ml sample size was used for distillation in the Labconco Micro Still.
The distillate was collected in a 2% boric acid solution, nesslerized; and then the per-
cent transmittance was measured in a Bausch and Lomb Spectronic 20 colorimeter at a
wave length of 425 mu. Except for the sample size and distillation equipment, the
method as outlined in Standard Methods (49) was followed.
Dissolved Oxygen (DO)
Yellow Springs Instrument YSI 54 Oxygen Meter was used for dissolved oxygen monitor-
ing which was standardized against Winkler method.
113
-------
pH_
An Orion Model 404 Specific Ion Meter was used for all pH measurements.
Nitrate and Nitrite Nitrogen and Total Phosphate
Nitrate and Nitrite Nitrogen and Total Phosphate were analyzed and the results were
used as spot checks for nutrient adequacy. Therefore, Hach methods were used in their
determinations and standardized against appropriate methods as outlined in Standard
Methods (49).
Settling Characteristics
The settling characteristics were determined visually by placing one liter sample of the
mixed liquor in a one liter graduated cylinder and observing the volume occupied by the
sludge after 30 minutes.
114
-------
APPENDIX D
PLANT PERFORMANCE DATA
115
-------
TABLE D-l
PLANT PERFORMANCE DATA OF SWEET POTATOES AND VEGETABLES
COD, mg/l
Total
Settled
Soluble
Solids, mg/l
SS
VSS
DS
YDS
TS
TVS
VSS/SS,%
TVS/TS
pH
Temp, °C
Nutrients, mg/l
TKN
Total
Settled
NHL-N
NOg-N
COD, mg/l
ML
I V* 1_
Settled
Soluble
Min
Plant
2400
1310
1220
970
836
1294
1095
2295
1931
65.
76.
5,
21
21
14
13
0
Performance
2770
41
31
Max
Influent Analyses
5550
3452
3240
2540
2378
3120
2851
5660
5229
,69 96.36
,03 92.39
.3 8.9
33
119
35
.7 17.5
.5 7.5
of Minimal Solids Unit
5240
910
488
Mean
3826
2076
1841
1740
1482
1849
1600
3589
3082
85.57
85.79
6.3
29
54.5
23.7
15.6
3.8
4259
362
303
Median
3880
2050
1810
1743
1478
1822
1586
3531
2938
87.45
86.24
6.3
30
47.5
23
3.6
4480
278
204
117
-------
TABLE D-l
(Continued)
Solids, mg/l
MLSS
MLVSS
MLVSS
MLSS, %
pH
Temp, o £
Nutrients, mg/l
ML TKN
NO3-N
Organic Loading Rate
#COD/Day
#MLVSS
Organic Load Removal Rate
Based on Settled Effluent
A#COD/Day
#MLVSS
Based on Soluble Effluent
A#COD/Day
#MLVSS
COD Removal, %
Settled
Soluble
HRT, hrs
SVI, ml/g
DO, mg/l
Min
2090
1724
77.7
5.9
19
18
0.01
4.09
COD
4.0
COD
4.0
74
76
3.4
113
0.7
Max
4420
3835
87.6
7.3
29
457
10.0
9.26
7.7
7.7
99
99
6.4
261
6.9
Mean
3445
2913
84.3
7.0
25
180
3.6
6.14
5.4
5.5
90
92
5.3
197
4.1
Median
3346
2884
85.1
7.0
26
175
2.2
5.93
5.2
5.4
93
95
5.3
200
4.2
118
-------
TABLE D-l
(Continued)
Min
Max
Performance of Extended Aeration
MLCOD, mg/l 2125
Solids, mg/l
MLSS 1800
MLVSS 1506
MLVSS
MLSS, % 71.6
pH 6.0
Temp, oc 16
NCyN, mg/l 1.4
Soluble Organic Loading Rate
#COD/Day
*MLVSS 0.007
Solids Loading Rate
#VSS/Day
Cu. Ft. 0.114
Soluble Organic Removal Rate
A#COD/Day
*MLVSS 0.001
Soluble COD Removal, % 9
Solids Removal, % 45
HRT, days 1.06
SVI, ml/g 159
DO, mg/l 1.0
Solids Flow, MGD 1.40
5130
4265
3673
86.1
7.5
28
3.2
0.271
0.260
0.222
99
72
1.96
320
7.1
2.77
Mean
Unit
3788
3354
2788
82.8
7.0
23
2.3
0.082
0.170
0.073
67
66
1.58
248
3.7
2.04
Median
3880
3417
2832
83.4
7.0
24
2.4
0.055
0.161
0.054
72
67
1.56
250
3.6
2.07
119
-------
TABLE D-l
(Continued)
Flow, MGD
SS, mg/l
VSS
TKN
TKN
VS17 %
Plant
COD, mg/l
Total
Soluble
Solids, mg/l
SS
VSS, mg/l
pH
Temp, °C
Nutrients, mg/l
Total TKN
NI-L-N
NCX-N
Total PO,
4
Plant COD Removal, %
Total
Soluble
Min
Returned
0.454
3295
2760
18
3.1
Effluent Analyses
19
T
10
7
6.1
15
3.5
0.4
0.01
0.15
93
3.3*
95
Max
Sludge
Mean
0.966 0.697
10830
9250
457
13.6
and Plant
344
3190*
268
176
2915*
164
2390*
7.6
28
28.0
1.1
17.00
1.00
99
99
7130
5927
180
5.8
Performance
120
84
61
41
7.2
23
15.8
0.7
1.72
0.35
97
97
Median
0.690
7255
6085
175
4.8
128
89
47
33
7.3
24
0.6
0.05
0.24
97
98
120
-------
TABLE D-l
(Continued)
Min Max Mean Median
Plant Solids Removal, %
SS
VSS
87 99
-45*
87 99
-47
95.71 98
96.86 98
"'Bulking sludge, solids unloaded
121
-------
TABLE D-2
PLANT PERFORMANCE DATA OF IRISH POTATOES AND VEGETABLES
M.in
Max
Mean
Median
Plant Influent Analyses
COD, mg/|
Total
Settled
Soluble
Solids, mg/l
SS
VSS
DS
VDS
TS
TVS
vss/ss, %
TVS/TS
PH
Temp, °C
Nutrients, mg/l
TKN
Total
Settled
NH3-N
COD, mg/l
ML
Settled
Soluble
Solids, mg/l
MLSS
1080
710
642
400
378
782
574
1185
982
84.4
77.8
4.6
22
32.0
3.9
0.21
Performance of
383
95
49
367
4229
1810
1660
2760
2690
1728
1495
3911
3663
99.9
95.8
7.0
37
77.0
53.0
1.10
Minimal Solids Unit
5460
1420
939
4570
2661
1290
1179
1285
1196
1153
921
2419
2113
93.6
87.2
5.9
32
49.9
37.0
3.5
0.72
2765
520
349
2152
2713
1320
1183
1292
1176
1160
919
2441
2127
94.2
86.8
5.9
33
45.5
45.5
0.85
2315
554
323
1690
122
-------
TABLE D-2
(Continued)
Min
MLVSS
MLVSS
MLSS, %
PH
Temp, °C
Nutrients, nng/l
MLTKN
NH -N
NO3-N
Organic Loading Rate
#COD/Day
*MLVSS
Organic Load Removal Rate
Based on Settled Effluent
#COD/Day
#MLVSS
Based on Soluble Effluent
A#COD/Day
#MLVSS
COD Removal, %
Settled
Soluble
HRT, hrs
SVI, ml/g
DO, mg/l
216
54.37
5.9
20
21
0.07
0.16
2.41
COD
2.22
COD
2.34
35
64
4.7
43
0.2
Max
3917
96.57
7.7
32
224
0.75
0.25
44.33
34.13
35.52
98
99
8.3
256
7.6
Mean
1779
82.20
6.8
28
83.1
0.38
0.20
10.55
7.90
8.78
80
87
5.9
119
4.0
Median
1460
83.50
6.9
28
52.5
0.32
7.79
5.59
6.42
82
86
5.7
123
3.5
123
-------
TABLE D-2
(Continued)
MLCOD, mg/l
Solids, mg/l
MLSS
MLVSS
MLVSS
MLSS, %
pH
Temp, C
Nutrients, mg/l
ML TKN
N03-N
Min
Performance of
725
685
344
37.6
6.5
20
37
0.1
Max
Extended Aeration
4875
5610
3580
63.5
8.0
31
210
8.1
Mean
Unit
3017
3184
2087
85.8
7.0
27
123
4.6
Median
3185
3228
2291
60.9
6.9
27
177
5.7
Total PO4
Soluble Organic Loading Rate
#COD/Day_
"MLVSS0.009
Solids Loading Rate
#VSS/Day
Cu. Ft.
0.047
Soluble Organic Load Removal Rate
A^COD/Day
ffMLVSS 0.006
Soluble COD Removal, %
35
0.780
0.237
0.770
98
9.5
0.146
0.129
0,138
81
0.084
0.135
0.090
89
124
-------
TABLE D-2
(Continued)
Solids Removal, %
HRT, days
SVI, ml/g
DO, mg/l
Solids Flow, MGD
Flow, MGD
SS, mg/l
VSS
TKN
TKN
vss;%
Min
10
1.48
58
0.5
1.37
Returned Sludge (to
0.168
1180
510
84
6.7
Max
99
3.38
380
7.0
2.28
Minimal Solids)
0.806
12630
10220
623
13.0
Mean
62
1.92
147
2.0
1.94
0.481
7025
4834
359
8.4
Median
80
1.82
132
1.5
2.01
0.462
7885
4835
407
8.0
Plant Effluent Analyses and Plant Performance
COD, mg/l
Total
Soluble
Solids, mg/l
SS
VSS
PH
Temp, °C
Nutrients, mg/l
Total TKN
NHL-N
N03-N
22
10
8
T
6.4
21
T
0.07
0.08
440
133
310
295
8
31
14
0.96
9.00
101
44
71
47
7.3
27
7
0.52
3.65
62
34
50
30
7.2
27
7
2.76
125
-------
TABLE D-2
(Continued)
Plant COD Removal, %
Total
Soluble
Plant Solids Removal, %
SS
VSS
Min
86
96
79
79
Max
99
99
99
99
Mean
97
98
95
96
Median
98
99
96
98
DO at Outfall, mg/l 1.8 7.3 5.2 5.4
126
-------
TABLE D-3
PLANT PERFORMANCE DATA OF VEGETABLES ONLY
COD, mg/l
Total
Settled
Soluble
Solids, mg/l
SS
VSS
DS
VDS
TS
TVS
VSS/SS %
TVS/TS
pH
Temp, °C
Nutrients, mg/l
Total TKN
NhL-N
3
Plant Influent
148
129
96
18
15
221
116
365
165
9.68
22.1
6.1
17
T
T
1.95
Plant Influent
Analyses
688
543
466
1643
212
678
415
2321
568
92.86
72.3
10.3
30
35
0.87
9.10
Ana lyses
388
323
274
331
93
484
283
830
377
50.11
51.8
7.7
26
15
0.38
5.93
375
323
292
175
82
491
275
676
372
48.
63.
7
28
14
0
6
57
4
.4
.45
.75
Winter Data Excluded
COD, mg/l
Total
Settled
Soluble
Solids, mg/l
SS
VSS
214
174
109
18
15
688
543
466
318
212
409
340
295
156
89
392
331
295
163
75
127
-------
TABLE D-3
(Continued)
D
YDS
TS
TVS
VSS/SS %
TVS/TS
COD, mg/l
ML
Settled
Soluble
Solids/ mg/l
MLSS
MLVSS
MLVSS
MLSS, %
PH
Temp, °C
Nutrients, mg/l
Total TKN
NH3-N
Organic Loading
^COD/Day
295
150
365
165
39.88
24.37
Performance of
132
49
5
123
63
40.82
6.8
10
3.5
0.01
664
415
894
568
92.86
7.23
Minimal Solids Unit
3772
468
148
3289
2657
86.03
7.9
30
14.0
1.82
495
299
656
390
61.61
60.31
660
159
58
711
447
58.67
7.3
24
9.9
0.92
491
290
664
400
65.75
64.56
235
138
55
254
136
56.80
7.4
26
11.0
*MLVSS
0.34
14.16
Organic Load Removal Rate
Based on Settled Effluent COD
A#COD/Day_
*MLVSS 0.16
5.21
4.15
12.24
4.29
3.64
128
-------
TABLE D-3
(Continued)
Min
Based on Soluble Effluent COD
A#COD/Day
#MLVSS 0.29
COD Removal, %
Settled 33
Soluble 66
HRT, hrs 5.1
SVI, ml/g 58
DO, mg/l 2.5
Performance of
MLCOD, mg/l 499
Solids, mg/l
MLSS 800
MLVSS 334
MLVSS
MLSS, % 34.17
pH 6-7
Temp, °C 7
TKN, mg/l 5.2
Soluble Organic Loading Rate
#COD/Day
mo . _•• ^. ' ' f\ rtrt
Max Mean
3.85 4.77
89 65
98 84
17.6 10.6
261 124
8.1 5.3
Extended Aeration Unit
3440 1285
1925 1479
940 732
79.44 52.93
7.7 7.2
29 23
7.7
,c n 01 n n W^
Median
3.25
68
83
10.4
96
5.5
1097
1490
775
52.04
7.3
25
55
n o?o
*MLVSS
129
-------
TABLE D-3
(Continued)
Solids Loading Rate
#vss
Cu. Ft.
Soluble Organic Removal
A#COD/Day
^MLVSS
Soluble COD Removal, %
Solids Removal, %
HRT, days
SVI, ml/g
DO, mg/l
Solids Flow, MGD
SS, mg/l
VSS
TKN
TKN
VSS, %
Min
0.027
Rate
T
9
68
1.59
50
2.6
1.211
Returned
1560
720
21
3.56
Plant Effluent Analyses
COD, mg/l
Total
Soluble
Solids, mg/l
SS
VSS
5
T
3
T
Max
0.121
0.210
99
99
5.51
279
9.8
2.678
Sludge
6700
5100
350
15.60
Mean
0.060
0.033
73
85
3.31
126
4.6
1.844
4176
2294
201
8.40
Median
0.057
0.015
82
89
3.16
110
3.6
1.886
4475
2450
224
8.16
and Plant Performance
230
146
202
102
55
33
43
30
23
15
25
20
130
-------
TABLE D-3
(Continued)
PH
Temp,
Nutrients, mg/l
Total TKN
NO0-N
o
NO ~N
Total PO,
4
Plant COD Removal, %
Total
Soluble
Plant Solids Removal, %
SS
VSS
Min
6.3
7
T
0.13
7.4
0.10
37
65
47
29
Max
8
29
28
0.54
18.8
0.18
98
99
99
99
Mean
7.4
23
9
0.34
13.8
0.14
82
91
80
74
Median
7.5
25
7
15.0
93
98
86
76
DO at Outfall, mg/l
3.5-
11.0
7.9
8.3
131
-------
APPENDIX E
PLANT INFLUENT, MODULAR UNITS AND SYSTEM ANALYSES
133
-------
CO
Oi
^ 1
to
IIII19
Product's Processed: Sweet Potatoes and Vegetables
VSS = 0.785SS+ 117
r =0.992
n =22
0
1 2
SS in 1000mg/l
Figure E-l Plant Influent VSS vs SS
-------
I I I I
Products Processed: Sweet Potatoes and Vegetables
CO
CN
o
o
o
oo
a
*/•
YDS = 0.951 DS - 158
r =0.982
n =22
0
0
DS in 1000 mg/l
Figure E-2 Plant Influent VDS vs DS
-------
Products Processed: Sweet Potatoes and Vegetables
CO
TVS = 0.89TS - 112
r =0.964
n =22
345
TS in 1000 mg/l
Figure E-3 Plant Influent TVS vs TS
-------
CJ
00
O)
£
o
O
o
Q
o
u
o
o
0
0
Producfs Processed: Sweef Potatoes and Vegetables
Tofal COD = 0.974 TVS + 815
r = 0.873
n = 22
345
TVS in 1000 mg/l
Figure E-4 Planf Influenf Tofal COD vs TVS
-------
CO
o
c
Q
O
-------
o
c
X 1
0
I I I I
Products Processed: Irish Potatoes and Vegetables
VSS = 0.964SS-32
r = 0.994
n = 45
SS in IOOOmg/1
Figure E-6 Plant Influent VSS vs SS
-------
o
c
• ^
^f)
O
Products Processed: Irish Potatoes and Vegetables
YDS = 0.872 DS - 84
r = 0.979
n = 45
8 10 12
DS in 100 mg/l
Figure E-7 Plant Influent YDS vs DS
14
16
18
-------
ho
3
o
o
o
I I I I I
Products Processed: Irish Potatoes and Vegetables
•^ •
TVS = 0.948TS - 183
r = 0.992
n = 45
I
I
I
2 3
TS in 1000 mg/l
Figure E-8 Plant Influent TVS vs TS
-------
CO
Q
O
if 2
£
"o
0
I I
Product-s Processed: Irish Potatoes and Vegetables
Total COD = 0.839 TVS + 886
r = 0,723
n = 45
| TVS in 1000 mg/l
Figure E-9 Plant Influent Total COD vs TVS
-------
IF
o
a
O
u
_a
I I I I I
Product's Processed: Irish Potatoes and Vegetables
Soluble COD = 0.876 YDS + 367
r = 0.824
n = 45
I
0
8 W ]2
YDS in 1000 mg/l
14
16
18
Figure E-10 Plant Influent Toral COD vs YDS
-------
en
o
o
c
CO
I I I I
Products Processed: Vegef-ables
VSS = 0.619 SS + 73
r = 0.514
n = 17
0
I
I
8 10
SS in 100 mg/l
12
Figure E-ll Plant Influent- VSS vs SS
14
16
18
-------
O)
O
o
00
Product's Processed: Vegetables
Winter Dara Excluded
VSS = 0.502 SS + 11
r = 0.879
n - 13
I
0
SS in 100mg/l
Figure E-l 2 Plan!" Influent- VSS vs SS
-------
Products Processed: Vegetables
ro
o
o
• •
Q
YDS = 0.366 DS + 106
r = 0.572
n = 16
0
0
345
DS in 100 mg/l
Figure E-13 Plant Influent YDS vs DS
6
-------
oo
o
o
CO
0
0
Products Processed: Vegetables
Winter Data Excluded
YDS = 0.258 DS + 171
r = 0.367
n = 12
DS in 100 mg/l
Figure E-14 Plant Influent VDS vs DS
-------
-N
•O
I
8
o
o
Products Processed: Vegetables
1
TS in 1000 mg/l
TVS = 0.0946TS + 299
r = 0.369
n = 16
Figure E-15 Plant Influent TVS vs TS
-------
Ol
o
O)
o
2 3
c
oo
0
Produces Processed: Vegetables
Winter Data Excluded
TVS = 0.455TS + 92
r = 0.63
n = 12
4 5
TS in 100 mg/l
8
Figure E-l 6 Plant Inlfuent TVS vs TS
-------
Ol
4
o
o
O
O
U
•2 2
Products Processed: Vegetables
Total COD = 0.683 TVS + 119
r = 0.738
n = 16
3 4
TVS in 100 mg/l
Figure E-l 7 Plant Influent Total COD vs TVS
-------
O)
o
o
Products Processed: Vegetables
Winter Data Excluded
Ul
NO
O
U
~D
"o
Total COD = 0.517 TVS + 195-
r = 0.615
n = 12
0
3 4
TVS in 100 mg/l
Figure E-18 Plant Influent Total COD vs TVS
-------
CO
8
Q
o
u
U
O
to
0
0
Product's Processed: Vegetables
Soluble COD = 0.935VDS + 3.8
r =0.871
n =14
YDS in 100 mg/l
Figure E-19 Plant Influent Soluble COD vs YDS
-------
Ol
TO
o
o
Q
O
U
—
_D
0
0
Products Processed: Vegetables
Winter Data Excluded
Soluble COD = 0.902 YDS + 19
r = 0.819
n = 11
4
YDS in 100 mg/l
Figure E-20 Plant Influent Soluble COD vs VDS
-------
Oi
(JI
rr,n D . D^ Albs COD/Day
IZ
2 10
4
2
0
1 1 1 1 1 1 1 ' 1
Minimal Solids Unit
Products Processed: Sweet Potatoes and Vegetables
• Based on Total Infl COD A Based on Soluble Infl COD
ACOD/Day % ACOD/Day 2 55 0 000359 COD
MLVSS " e MLVSS ' ' 6
r = 0.387 r = 0.209
n=19 n= 19
T= 19-29°C
T mean = 24.7°C * *
J." ' ' * *
'A ' '
f* ' 4 * * .
I
3456
Soluble Effluent COD in 100 mg/l
8
Figure E-21 COD Removal Rate vs Soluble Effluent COD
-------
Ol
o-
20
X
o
Q
O
U
to
15
0)
"o
0)
o;
Q
O
U
10
i i i I i
Minimal Solids Unit
Products Processed: Irish Potatoes and Vegetables
• Based on total Infl COD
5.26 + 0.00963 CODe
r = 0.325
n = 40
T = 20 - 32°C
Tmean = 28.15 C
A Based on Soluble Infl COD
= 2.56 + 0.00134 CODe
r = 0.106
n = 39
0
3456
Soluble Effluent COD in 100 mg/l
Figure E-22 COD Removal Rate vs Soluble Effluent COD
-------
12
Ol
•vl
o
a)
a:
Q
O
U
Minimal Solids Unit
Products Processed: Vegetables
10 '
8
j
4
A
*
Based on Total lnfl COD
ACOD/Day
MLVSS
r =0.414
'.98-
A Based on Soluble lnfl COD
ACOD/Dfly = 5.16-0.0266 COD.
Mtvss
r = 0.446,.
n= 13
T= 22-30°C
Tmean = 24.5 C
0
20
40
60 80 100 120
Soluble Effluent COD in mg/l
140
160
180
Figure E-23 COD Removal Rate vs Soluble Effluent COD
-------
o
o
o
Minimal Solids Unit
Products Processed: Sweet Potatoes and Vegetables
01
CO
to
2
MLVSS = 0.917 MLSS - 247
r = 0.992
n = 19
0
0
2 3
MLSS in 1000 mg/l
Figure E-24 MLVSS vs MLSS
-------
Oi
1
8 4
o
a
O
u
O
CO
0
• i
Minimal Solids Unit
Products Processed: Sweet Potatoes and Vegetables
ML Solids COD = 1.196 MLVSS + 470
r = 0.961
n = 19
2 3
MLVSS in 1000 mg/l
Figure E-25 ML Solids COD vs MLVSS
-------
O)
E
Minimal Solids Unit
Products Processed: Irish Potatoes and Vegetables
CN
o
c
l/->
MLVSS = 0.839 MLSS - 28
r = 0.996
n = 41
0
0
2 3
MLSS in 1000 mg/l
Figure E-26 MLVSS vs MLSS
-------
8
o
Minimal Solids Unit
Products Processed: Irish Potatoes and Vegetables
a
O
u
o
00
ML Solids COD = 1.369 MLVSS - 59
r = 0.989
n = 41
0
MLVSS in 1000 mg/l
Figure E-27 ML Solids COD vs MLVSS
-------
o
to
\ 3
I 2
0
0
MinimaJ Solids Unit
Produces Processed: Vegetables
MLVSS = 0.847MLSS-62
r = 0.877
n = 13
2 3
MLSS in TOO mg/l
Figure E-28 MLVSS vs MLSS
-------
o
o
Minimal Solids Unit
Products Processed: Vegetables
Os
CO
Q
O
U
v>
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~ 2
CO
__l
ML Solids COD = 1.075 MLVSS + 12
r = 0.952
n = 13
0
0
2 3
MLVSS in 100 mg/l
Figure E-29 ML Solids COD vs MLVSS
-------
0.3
t/l
OO
O
(J
0.2
o
>
o
Q)
8 OJ
~o
0
0
Extended Aeration Unit
Products Processed: Sweet Potatoes and Vegetables
-0.023
MLVbb
r = 0.694
n = 16
T = 16-27.5°C
T mean = 23.1 C
20
40
60 80 TOO 120
Soluble Effluent COD in mg/l
140
160
180
Figure E-30 Soluble COD Removal Rate vs Soluble Effluent COD
-------
X
o
Q
O
CO
0.6
0.5
Extended Aeration Unit
Products Processed: Irish Potatoes
and Vegetables
- 0.4
o
D
O
0)
a
O
-D
_2
o
CO
0.3
0.2
0.1
T= 20-310C
T mean = 27.17 C
I*
20
40
60 80 100 120
Soluble Effluent COD in mg/l
140
Figure E-3T Soluble COD Removal Rate vs Soluble Effluent COD
160
180
-------
Q
O
U
oo
_l
-Q
I I
Extended Aeration Unit
Producf-s Processed: Vegetables
40
ON
-------
CN
_ 3
c
CO
Extended Aeration Unit
Products Processed: Sweet Potatoes and Vegetables
MLVSS = 0.894MLSS-209
r = 0.986
n = 18
2 3
MLSS rn TOGO mg/f
FfgureE-33 MLVSS vs MtSS
4
-------
o>
4
Extended Aeration Unit
Products Processed: Sweet Potatoes and Vegetables
CO
O
U
0
ML Solids COD = 1.312 MLVSS + 58
r = 0.963
n = 17
MLVSS in 1000 mg/l
Figure E-34 ML Solids COD vs MLVSS
-------
C"
3
0
Extended Aeration Unit
Products Processed: Irish Potatoes and Vegetables
MLVSS = 0.725 MLSS - 222
r = 0.916
n = 34
MLSS in mg/l
Figure E-35 MLVSS vs MLSS
-------
Q
O
U
I I
Expended Aeration Units
Products Processed: Irish Potatoes and Vegetables
XI
o
o
oo
ML Solids COD = 1.339 MLVSS +110
r = 0.994
n = 33
0
MLVSS in 1000 mg/l
Figure E-36 ML Solids COD vs MLSS
-------
8
o
^c
to
0
I
Extended Aeration Unit-
Products Processed: Vegetables
MLVSS = 0.796 MLSS-425
r = 0.917
n = 15
0
MLSS in 1000 mg/l
Figure E-37 MLVSS vs MLSS
-------
8
o
Q
O
U
-8
o
co
0
I
Extended Aeration Unit
Products Processed: Vegetables
ML Solids COD = 1.376 MLVSS - 3.32
r = 0.957
n = 15
0
MLVSS in 1000mg/l
Figure E-38 ML Solids COD vs MLVSS
-------
CO
_c
to
>
4)
200
150
100
50
0
0
I I I I I
Product's Processed: Sweet Potatoes and Vegetables
VSS = 0.711 SS-0.741
r = 0.889
n = 20
20
40
60
80 100 120
Effluent SS in mg/l
140
160
180
Figure E-39 Plant Effluent VSS vs SS
-------
X)
400
300
Q
o
u
c
0)
£ 200
a
"o
100
0
I I I I
Products Processed: Sweet- Potatoes and Vegetables
0
I
Total Effluent COD = 1.356 VSS + 64.48
r = 0.673
n = 20
I
50 100
Effluent VSS in mg/l
150
Figure E-40 Plant Total Effluent COD vs VSS
-------
XI
(Jl
TOO
75
Q
O
3
.i*.
-------
XI
o-
300
250
_ 200
£?
c
> 150
c
o
D
100
50
I I I
Producf-s Processed: Irish Potatoes and Vegetables
I _
VSS = 0.892SS- 16.45
r = 0.93
n=35
0
I
0
50
100 150
Effluent SS in mg/l
200
250
300
Figure E-42 Plant Effluent VSS vs SS
-------
400
300
a
O
c
0)
D
D
'o
200
100
0
Products Processed: Irish Potatoes and Vegetables
/•
0
50
Total Effluent COD = 1.431 VSS + 34.06
r = 0.902
n = 35
100 150
Effluent VSS in mg/[
200
Figure E-43 Total Effluent COD vs VSS
-------
00
CO
Q
o
u
300
250
200
150
o
1/1
I 100
50
0
I I I I T
Products Processed: Irish Potatoes and Vegetables
I ~
I
Effluent Solids COD= 1.097 VSS + 5.459
r = 0.921
n =35 ':
0
50
100 150
Effluent VSS in mg/l
200
Figure E-44 Effluent SoJWs (SOD vs VSS
-------
120
100
\ 80
O)
co
co
•4-
C
O
60
40
Products Processed: Vegetables
20
0
_L
JL
_L
VSS = 0.538SS + 6.48
r = 0.926
n= 17
1 I
20
40
60 80 100
Effluent SS in mg/l
120
140
160
180
Figure E-45 Plant Effluent VSS vs SS
-------
400
Products Processed: Vegetables
oo
o
D)
.E 300
Q
O
U
c
a>
UJ
200
100
Total Effluent COD = 0.692 VSS +34.19-
r= 0.288
n= 17
_L
I
0
50
TOO
Effluent VSS in mg/l
150
Figure E-46 Plant Total Effluent COD vs VSS
-------
100
Product Processed: Vegetables
00
Q
O
U
t/>
•£
~6
to
t:
_D
14-
M-
LU
75
50
25
•
I
Effluent Solids COD = 0.449 VSS + 8.41
r = 0.529
n= 17
0
25
50
Effluent VSS in mg/l
75
100
Figure E-47 Effluent Solids COD vs VSS
-------
_nbject Field & Group
05 D
SELECTED WATER RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
Organization
University of Oklahoma Research Institute
Norman, Oklahoma 73069
Title
Demonstration of a Full-Scale Waste
Treatment System for a Cannery
1 Q Authors)
Srreebin, Leale E.
Reid, George W.
Hu, Alan C. H.
16
21
Project Designation '
EPA, WQO Contract No.
12060 DSB
Note
22
Citation
23
Descriptors (Starred First)
industrial Wastes, *Waste treatment, *Canneries
Aerobic treatment, Sanitary Engineering
25
Identifiers (Starred First)
*Food wastes, waste characteristics
27 Abstract The objectives in this study were to determine the removal efficiencies of a two-stage
—aerobic biological treatment system while processing high strength, large volume, nutritionally un- ^
balanced cannery wastes, and to determine the waste characteristics resulting from the processing of a wide
variety of fruits and vegetables.
The system was studied over one operating season and data collected on the removal efficiencies of each
unit process in the system. The treatment system performed more efficiently than expected in the design
assumptions. Removal efficiencies of greater than 95% were obtained for most of the processing season,
even though because of plant expansion the organic and hydraulic load was higher than expected. It has
been demonstrated conclusively that:
1. The Stilwell canning wastes can be treated successfully by a two-stage activated sludge process.
2. The two-stage aeration process is very stable and capable of accepting shock loads without being
adversely affected.
3. The two-stage aeration process is a flexible system allowing adequate capacity for varying waste
loads; that is, the units can be operated individually or in combination to match the flow and
strength variations. This provides high treatment efficiencies at the lowest operational cost.
4. Any one of the units, such as the minimal solids unit, can be started up readily by recycling the
mixed liquor from one of the operating units.
This report contains many figures and graphs and 43 references. (Streebin - University of Oklahoma)
Abstractor m
Dr. Leale E. Streebin
Institution
University of Oklahoma, Norman, Oklahoma 73069
WR:102
------- |