WATER POLLUTION CONTROL RESEARCH SERIES
12060 FDS 11/71
ELIMINATION OF WATER POLLUTION
BY PACKINGHOUSE ANIMAL
PAUNCH AND BLOOD
U.S. ENVIRONMENTAL 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 arid 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. 20k6o.
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ELIMINATION OF WATER POLLUTION BY
PACKINGHOUSE ANIMAL PAUNCH
AND BLOOD
by
Beefland International, Inc.
2700 23rd Avenue
Council Bluffs, Iowa 51501
for the
Office of Research and Monitoring
ENVIRONMENTAL PROTECTION AGENCY
Project #12060 FDS
November 1971
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 - Price 50 cents
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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.
ii
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ABSTRACT
The operation of two dehydrating machines, for the drying of cattle
whole blood as well as paunch contents (rumen), at the Beefland
International, Inc., slaughtering plant at Council Bluffs, Iowa,
was studied*
The BOD and COD of the blood and rumen were established. The mean BOD
of the whole blood and rumen was determined as 156,500 ppm and 50,200
ppm, respectively. The mean COD of the blood and rumen was established
as 218,300 ppm and 177,300 ppm, respectively.
The economics of the drying process in costs per ton of dried product,
per 1000 Ibs live kill weight (LWK), and per animal were determined.
The dehydrating costs per ton of dehydrated product were found to be
$43.75/ton for blood and $38.46/ton for rumen. The average cost (blood)
and rumen) was $40.93/ton.
Laboratory studies were carried out on the dried whole blood and rumen
with a view toward their actual and potential use as legally accepted
feeds or feed additives. Percent moisture, protein, fat, carbohydrate,
and other analyses of the dried products are reported.
This report was submitted in fulfillment of Project Number 12060 FDS
under the (partial) sponsorship of the Water Quality Office, Environ-
mental Protection Agency.
iii
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CONTENTS
Section
I Conclusions
II Recommendations
III Introduction
IV Design, Construction, and Installation Phase
V Start Up and Modification Phase
VI Records and Study Phase
VII Economic Evaluation
VIII Acknowledgments
IX References
Page
1
3
5
7
21
27
35
39
41
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FIGURES
PAGE
1 BLOOD AND RUMEN FLOW 8
2 WASTE-WATER FLOW 9
3 DEHYDRATOR BUILDING WITH SUMP AND LIFT STATION
IN FOREGROUND; OVERHEAD RUMEN AND BLOOD LINES 11
4 DEHYDRATOR BUILDING; MAIN PLANT IN BACKGROUND 12
5 BLOOD DRYER FROM FIREBOX END 12
6 BLOOD DRYER FROM ADJUSTABLE SLEEVE END 13
7 RUMEN DRYER VIEW TOWARD FIREBOX END 13
8 SUMP AND LIFT STATION; PENS IN BACKGROUND 14
9 SEDIFLOTOR CLARIFIER WITH GREASE RETURN LINE 16
10 SEDIFLOTOR CLARIFIER WITH AIR SATURATION TANK 16
11 SEDIFLOTOR CLARIFIER SHOWING SKIMMER MECHANISM 17
12 SEDIFLOTOR CLARIFIER SHOWING EFFLUENT WEIR 17
13 LAGOON AND TWO AERATORS 19
14 LAGOON VIEW FROM ATOP CLARIFIER 19
15 BLOOD MANIFOLD AND HOLD TANKS 22
vi
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TABLES
No. Page
1 Dehydrator Building and Equipment Costs 10
2 Six-Month Production Data 28
3 Data on Fresh Whole Blood 29
4 Data on Undehydrated Rumen 30
5 GOD and BOD, of Rumen and Blood 31
6 Total COD and BOD of Rumen and Blood Combined 32
7 Plant Waste Water—BOD5 (ppm) 33
8 Analysis of Dehydrated Products 34
9 Annual Capital Costs 35
10 Dehydration Costs for Whole Blood and Rumen 37
vii
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SECTION I
CONCLUSIONS
1. Dehydration of cattle whole blood and rumen by gas-fired dryers
is an economically feasible method of handling these materials
in a beef-slaughtering operation.
2* The return on the sale of dried blood alone was greater than the
combined dehydration costs of the whole blood and rumen.
3. The average weight of 32.5 Ibs of wet blood generated per beef
animal (~1100 Ibs LWK) gives rise to 6.0 Ibs of dried blood
(5% moisture); while the average weight of 54 Ibs of wet rumen
gives rise to 8.5 Ibs of dried rumen (7% moisture) per beef
animal.
4. The dehydration of 92.4% of the blood and 75% of the rumen (the
additional 25% of the rumen either hauled away or rendered) repre-
sented a recovery of 82.4% of the total COD and 86.4% of the total
BOD5 generated by these materials.
5. The mean BOD of the whole blood and rumen was determined as
156,500 ppm and 50,200 ppm, respectively. The mean COD of the blood
and rumen was established as 218,300 ppm and 177,300 ppm, respectively.
6. The BODS of cattle whole blood is nearly twice the BOD of the rumen
per animal. The liquid and readily soluble phase of the rumen con-
stitutes 59% of the total BOD of the material.
7. The dehydrating costs per ton of dehydrated product were established
to be $43.75 for blood and $38.46 for rumen. The average cost (blood
and rumen) was $40.937 ton.
8. The dehydration cost for drying the rumen only was established as
160 per animal, as compared to the wet dumping cost of 150 per
animal when disposed of by means of a hauling contract from the
plant.
9. The cost of BOD,, removal or elimination by the dehydration process
of whole blood and rumen was determined as 2^0/lb for blood BOD5
and 80/Ib for rumen BOD,.. The mean cost was 407Ib of total BOD5
eliminated.
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10. The recovery of the blood and rumen by separate flow of these
materials in the slaughtering operation with subsequent dehy-
dration served to maintain the BOD,, of the plant waste water
at such levels that treatment of the waste water by a commercial
sedimentation-clarifier followed by an aerobic lagoon gave rise
to a plant effluent of an acceptable low BOD level.
11. Dried rumen is comprised of 12.7% protein on the basis of nitrogen
determination by the Kjeldahl method. The material should serve a
demand as a protein source in animal feeds. However, a strong mar-
ket does not exist for this product. A ready market exists for
dried whole blood.
12. The complete separation and dehydration of the whole blood and rumen
eliminates the potential of these materials as water pollutants.
There was no evidence to indicate that any appreciable air pollution
resulted in the drying of these materials.
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SECTION II
RECOMMENDATIONS
The dehydrating process for whole blood and rumen should be continued
at the Beefland International, Inc., plant as this phase of the slaugh-
tering operation has been demonstrated to be economically profitable.
In addition, it has provided a method of disposal of blood and rumen in
a manner which eliminates these slaughtehouse by-products as potential
pollutants to water quality.
As the dehydrated blood is the more valuable of the two products, greater
precautionary practices should be taken to minimize any loss of whole
blood in its flow from kill floor to the dehydrator. Additional holding-
tank capacity should be provided for wet blood to eliminate the need of
dumping of wet blood during emergency shutdowns or repairs of the dryer.
Practical reasons would likely limit the total holding capacity for wet
blood to one day's production.
All rumen generated should be dried. A greater storage capacity for
wet rumen should be provided and the drying time extended in order to
dehydrate each day's production completely.
At the same time, greater time and effort should be expended to estab-
lish a market for dried rumen. Such a market would include industries
involved in formulation of animal feeds of all kinds, as well as feeders
of fish, fowl, and mammals. Continued participation and support of
research on the use of dried rumen as an animal feed additive should be
carried out by the industry. The results of a feeding program of this
material to hogs in which Beefland is currently participating should be
carefully analyzed when completed. A continuation of this type of
research under the direction of competent animal feed nutritionists is
recommended.
The general recommendation is made to any existing or planned beef
slaughtering plant to consider installation of dehydrating equipment
for blood and rumen as a demonstrated profitable aspect of plant
operation. Such installations should provide sufficient storage
capacity for the wet materials corresponding to one day's full pro-
duction and one week's production of the dehydrated products.
Although there has not been any quantitative measurements made on the
extent of particulate emissions from the stacks of the dehydrators,
this has not appeared to have been of serious consequence. There have
been citizen complaints of odors, however, and provisions should be
made in new installations for scrubbers or other types of particulate
and fume controls to minimize or eliminate release of particulate
matter and odors into the atmosphere.
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SECTION III
INTRODUCTION
Beefland International, Inc., a public company organized for the pur-
pose of slaughter of beef cattle and production of high quality beef,
constructed its physical plant a few miles southwest of the city of
Council Bluffs, Iowa, in late 1968 and 1969 on a commercial tract of
the city. It went into production of beef carcasses in January 1970.
It has the highest rated kill capacity for a beef slaughtering opera-
tion ever approved by the U.S. Department of Agriculture.
The kill capacity for cattle at the Beefland plant is 250 animals per
hour. In a ten-hour day this represents a possible kill of 2500 ani-
mals and the production of a tremendous quantity of blood, paunch, and
manure, which must be disposed of in such a way so as not to further
tax the waste-carrying capacity of the nearby Missouri River or to
increase the ever growing problem of pollution of air, land, and water.
To handle this waste problem which was anticipated to run as high as
50 Ibs of blood, 50 Ibs of paunch, and 40 Ibs of manure per animal,
Beefland International, Inc., proposed to install facilities for the
drying of the whole blood and the paunch contents or rumen generated
in the slaughtering operation. The manure would be disposed of
directly for agricultural fertilizer.
A proposal by Beefland International, Inc., was submitted to the
Federal Water Pollution Control Administration, Department of
Interior, in the latter part of 1969, for partial support of the
dehydration project of blood and rumen. The proposal was approved
by FWPCA officials for an eighteen-month study period extending from
October 1, 1969 to April 1, 1971. The program was titled Project
Number 12060 FDS.
The project budget included construction of a dehydration facility
with installation of two dryers, one for whole blood and one for
rumen. A laboratory facility to carry out the necessary tests was
included in the project costs. It included also technical services,
operation and maintenance, administrative and contingency costs.
The total budget was $375,770.
The objectives of the project were to demonstrate the economic and
technical feasibility of completely separating the blood and rumen
generated in the slaughter operation, and drying of these materials
with a view toward the sale of the dehydrated products as animal
feeds or for feed additives. Three economics were to be shown,
that is, the costs of dehydrating the blood and rumen separately,
as well as the costs, in terms of 1000 Ibs live-kill weight (LWK) and
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per ton of dehydrated product, for the combined dehydrating process.
The COD and BOD- equivalents of the blood and rumen generated were to
be established by the laboratory work carried out to give an indication
of the pollution abatement aspects of this type of treatment of these
slaughterhouse products. Analytical work was also carried out on both
the dehydrated blood and rumen as to protein content, percent moisture,
and other analyses with a view toward their use or development as legal
animal feed additives.
The goals set in the proposal submitted by Beefland International, Inc.,
were to be achieved in an eighteen-month period and were to be developed
in three phases or stages.
Phase I included the period for the design, purchase, and installation
of the appropriate dryers to carry out the dehydration of the whole
blood and rumen. As these dryers were large pieces of equipment for
which space was not included in the original designs of the main slaugh-
tering plant, a separate building to house the dryers was required.
The design and construction of a separate laboratory, building and facil-
ities were also carried out during the initial phase of the project. All
equipment, chemicals, and apparatus required for the supporting labora-
tory work of the project were purchased specifically for the study.
Hiring of the necessary personnel to operate the dryers and to carry
out the chemical analyses was also part of this first phase.
Phase II of the project involved the training of the labor personnel
in the operation of the dehydrators and the development of the optimum
conditions for drying the whole blood and the rumen. Modifications of
the dryers and equipment were made during this period. A market for
the sale of the dehydrated products was to be established, particularly
that of the dehydrated rumen.
Phase III of the project was a period of operation and keeping of exact
records to establish costs of the dehydration process for both whole
blood and rumen. Records were kept on cattle kill, kill weight, con-
sumption of utilities, and weights of dehydrated materials produced.
Labor costs and drying times required daily and monthly were duly
recorded. Several carefully controlled weight studies were made to
establish the average weight of blood and rumen recovered per animal.
Laboratory results were established on the COD and BOD- characteristics
of fresh blood and rumen, as well as pertinent data on the chemical
makeup of the dehydrated products. Reports summarizing the data as
collected were submitted to the Project Officer of the FWPCA monthly,
beginning in March 1970, by the project director and technical advisor.
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SECTION IV
DESIGN, CONSTRUCTION, AND INSTALLATION PHASE
As the approval for Project 12060 FDS was received well after the design
and completion of the major portion of the physical plant at Beefland,
adaptations were necessarily made in the design and location of the dehy-
drator building and equipment for the proposed drying process for whole
blood and rumen. The laboratory, which initially was planned for loca-
tion within the main building of the plant just off the kill floor, was
finally housed in a separate building behind the main plant but within
reasonable distance of all sampling sites.
The following sections describe the blood and rumen flow design, as well
as that of the waste water flow. Although the latter had no effect on
the dehydration process, its capacity would have been affected seriously
had the dehydration of the major portion of the blood and rumen not been
carried out. The dehydration facilities are described in detail. Infor-
mation is also given in the following sections on the general sewage
system with its lift station, SEDIFLOTOR Clarifier, and lagoon or aeration
basin through which the plant effluent passes prior to discharge into the
city sewage system.
Blood and Rumen Flow
The blood of the cattle flow through several openings on the kill floor
directly to a holding tank below, from which it is periodically blown
over into holding tanks adjacent to the blood dryer in the dehydrator
building. Similarly, the rumen from each paunch is emptied into a hop-
per on the kill floor into a holding tank below. From the tank it is
likewise blown over periodically by means of air pressure through an
overhead line to a second holding tank adjacent to the rumen dryer in
the dehydrator building. The wet rumen is gravity fed into the dryer
from the holding tank. In the case of the blood, it is pumped from a
bottom line from the blood holding tanks into a manifold situated above
the firebox of the dryer, where it is coagulated with steam and then
augured into the dryer. Figure 1 is a schematic diagram which shows
this flow of blood and rumen from kill floor to the dryers.
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VAPOR
RELEASE
FIGURE 1. BLOOD AND RUMEN FLOW
Waste Water Flow
The waste water of the plant, which arises from many sources inside and
outside of the main kill-floor area, flows into a central sump. That
which arises from the slaughtering and processing operation on the kill
floor includes the water used in the periodic hosing down of all sections
during and at the completion of the day's operation, as well as that used
in the washing of carcasses and organs. The amount of blood in this
waste water varies during production hours with a peak at the final clean-
up period when the blood-drain area is scrubbed down. The waste water
from the cleaning of the outside holding pens for incoming cattle simi-
larly flows into the central sump. It is pumped continuously from the
sump to the SEDIFLOTOR Clarifier installation. The effluent of the
SEDIFLOTOR Clarifier flows by gravity into the plant lagoon. Details
of these components of the raw waste water treatment are given in sec-
tions of the report that follows. The general waste-water flow of the
plant is shown in Figure 2.
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( T
^^^^™
KILL FLOOR
AERATORS . AERATION BASIN
OS~\ , LAGOON
_ _. . . x_X /
o o /
Ol
I
/
J
\
J\
r PUUP3
RAW WASTE v <
— ?
SUMP J^~^~"--^ DEHYDRATOR BLDG.
^^
FIGURE 2. WASTE-WATER FLOW
Dehydrator Building and Equipment
The separate building housing the dehydrators is a 40lx80'x36l Kirey
building with corrugated metal sheets covering a metal framework. The
cost of the building erected was $21,500.00. The installation of the
foundations for the dryers and the concrete apron around the building
gave a total cost of $32,934.00 for the dehydration building.
Beefland International, Inc., entered into a sales agreement with the
American Pollution Prevention Company of Minneapolis, Minn., in Decem-
ber 1969, for the installation of two No. V9-820 McGehee Dryers with
Vacollectors delivered and installed to utilities. The separate cost
of these dehydrators was $52,000.00 for the blood dryer, which was a
"used" model, and $62,000.00 for the new rumen dryer. All of the
additional installations required, such as pumps, blowers, lines for
transport of blood and rumen from holding tanks below the kill floor,
installations of meters, etc., added an additional $34,272.05 to the
cost of the equipment and its installation. The total cost of dehy-
drator equipment and installation was $148,272.05. Table 1 is a sum-
mary of these costs.
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Table 1
DEHYDRATOR BUILDING AND EQUIPMENT COSTS
Building
Item
1.
2.
3.
Description
One 40'x80'x36' Kirey Bldg (in color)
Installation of Dryer Foundations
Building Apron (concrete)
Total
Cost
$21,500.00
8,234.00
3,200.00
$32,934.00
Equipment
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
One V9-820 McGehce Blood Dryer
One V9-820 McGehee Paunch Dryer
(Each of the above dryers equipped with
vacollector, storage tanks, stack and
connecting parts installed to utilities)
Charges by American Pollution Prevention
Company Relating to Blood or Rumen
Dehydrator or Both
One PEGIA-Z Marlow Pump (3-HP Motor)
Freight Charge
American Pollution Prevention Co.—Misc.
B. Grunwald--Blood Lines
F. J. MerwaId--Rumen Chute
B. Grunwald--Rumen Lines
Swift and Company--Blower
Peoples Natural Gas—Meters
Total
$52,000.00
62,000.00
9,500.54
1,147.29
41.76
99.46
4,632.78
1,428.54
13,695.05
1,590.00
2,136.63
$148,272.05
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Each of the McGehee dehydrator units has a drum diameter of 8 ft with
a length of 20 ft. The drum revolves on four sets of ordinary 700x15,
8-ply pneumatic tires (three tires per set) which are motor driven and
located at the four corners of the drum. A ten-foot long air-cooled
firebox is located at the front of each drum with a radial gas burner
of 15,000,000 BTU capacity at 50 psi. An adjustable sleeve located
between the other end of the drum and vacoHector allows for the con-
trol of the moisture content of the product. Each dehydrator is equip-
ped with a vacollector and gas release system. The stacks extend only
a few feet above the roof of the building.
The blood dehydrating system was equipped with a 12,000 Ib holding
tank for wet blood and a 30,000 Ib storage tank complete with unloading
facilities for the dried product. The rumen dehydrating system in-
cluded a wet surge feed bin of 250 cu ft capacity for the wet paunch
contents and a storage bin for the dried rumen of 1,250 cu ft capacity
with unloading facilities.
The first of the dehydrators (for whole blood) was put into operation
in mid-March 1970. The second unit (for the dehydration of rumen) became
operational May 1, 1970. Figure 3 through Figure 7 show views of the
dehydrator building and of the dehydrators.
HI
FIGURE 3. DEHYDRATOR BUILDING WITH SUMP AND LIFT STATION
IN FOREGROUND; OVERHEAD RUMEN AND BLOOD LINES
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FIGURE 4. DEHYDRATOR BUILDING; MAIN PLANT IN BACKGROUND
FIGURE 5. BLOOD DRYER FROM FIREBOX END
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FIGURE 6. BLOOD DRYER FROM ADJUSTABLE SLEEVE END
FIGURE 7. RUMEN DRYER VIEW TOWARD FIREBOX END
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Waste-Water System—Sump, Clarifier, Lagoon
Figure 2, page 9, shows the general flow of waste water in the plant.
It flows into a sump located between the main plant building and the
dehydrator installation. The sump is constructed of heavy concrete
walls with inside dimensions of the pit, IZ'xlZ'xlO1 deep. Four 4"
lines operated by Gorman-Rupp 15-HP motors in the lift station pump
the waste water to the SEDIFLOTOR Clarifier. Figure 8 is a view of
the sump and lift station.
FIGURE 8. SUMP AND LIFT STATION
The Fuller Company/General American Transportation Corporation, vendor
of INFILCO Products, contracted with Beefland for the installation of
a SEDIFLOTOR Clarifier for the treatment of the plant waste water. The
50'0" diameter by 9'9" deep SEDIFLOTOR Clarifier was installed on a
concrete slab with required underground piping. The rolled steel
plate siding of the SEDIFLOTOR is 3/16" thick.
The Clarifier mechanism includes a center column supporting the mech-
anism, platform and one end of the access walkway. Checkerplate and
handrailing are provided for the walkway and platform so that the drive
mechanism is accessible from all sides. The drive mechanism consists
of a VHP, totally enclosed, 230/460-volt, 60-cycle, 3-phase motor and
14
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enclosed reducer. A pinion keyed to the output shaft of the reducer
drives a ring gear mounted on antifriction bearings and is arranged to
rotate a drive cage surrounding the support column to which the bottom
sludge scrapers and the float skimming mechanism are attached.
The skimming mechanism consists of four skimmer arms terminating at
the inboard end with a common hub rigidly affixed to the drive cage.
The fabricated steel arms are fitted with flexible wiper edges and
are hinged in such a manner as to follow the contour of the scum
trough when passing over it.
The scraper mechanism consists of two scraper arms, each with a
series of scraper blades. The blades are straight with a steel
angle along the top edge to provide rigidity and each bottom edge
fitted with bronze squeegees adjustable for proper clearance. The
scraper blades are affixed to the structural steel members attached
to the inlet well which, in turn, is attached to and driven by the
vertical drive cage.
A rotatable inlet well is located centrally at the bottom of the tank
surrounding the raw waste inlet diffuser and pressurized recycle inlet
diffuser. The raw waste inlet consists of a slotted inlet diffuser
in the lower portion of the support column.
The scum draw-off trough extends inward from the effluent curtain
baffle and has a bottom sloping from the horizontal. It includes an
approach ramp and skimmer blade let-down strips. A peripheral curtain
baffle extending below the liquid level is fitted within the tank to
provide a submerged weir for the uniform take-off of the clarified
effluent*
A 7'0" diameter by 8'6" steel air saturation tank constructed in
accordance with ASME Code for 75 psi working pressure was set up
close by the Clarifier. This is furnished with inlet, outlet bot-
tom drain, access air outlet with air bleed-off. The air saturation
system includes air injection devices utilizing atmospheric air. Two
40-HP pressurizing pumps, having a maximum capacity of 1000 gpm each
and with a totally enclosed motor, are used in conjunction with the
air saturation of the waste water. There is no chemical treatment
carried out in the Clarifier. Figures 9 and 10 are two different
views of the SEDIFLOTOR Clarifier. Figures 11 and 12 are two views
of the top assemblies of the Clarifier.
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FIGURE 9. SEDIFLOTOR CLARIFIER WITH GREASE RETURN LINE
FIGURE 10. SEDIFLOTOR CLARIFIER WITH AIR SATURATION TANK
16
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FIGURE 11. SEDIFLOTOR CLARIFIER SHOWING SKIMMER MECHANISM
FIGURE 12. SEDIFLOTOR CLARIFIER SHOWING EFFLUENT WEIR
17
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The effluent from the Clarifier flows by gravity into the lagoon or
aeration basin. The lagoon was formed by excavating an area of about
200'x4QO' leaving a sand dike about its periphery. It was lined with
bentonite and limestone. The average depth of the water in the lagoon
is six feet with a surface area of 80,000 square feet. The operating
capacity of the lagoon is 3,600,000 gallons with a retention time of
four days. The 900,000 gallons/day discharge into the city sewage
line is through a stand-pipe located at the far end of the lagoon
from the inlet. Nine pounds of Digest II is added to the lagoon weekly.
Four 500V VORTAIR burgine surface aerators are mounted on concrete
columns in the lagoon. These entrain and disperse atmospheric oxygen
in large quantities of the waste water which the aerators pump from
the bottom of the basin and discharge radially. Each of these INFILCO
aerators consist of a 50-HP motor, speed reducer, base plate, couplings,
shaft, and a turbine-type rotor. The rotor consists of a horizontally
mounted circular flat plate from which a series of radial plates extend
rigidly downward. Each aerator has a constant-speed drive for operation
on 220-volt, 60-cycle, 3-phase alternating current 50-HP motor. Each
aerator is provided with an ice shield.
At the time of the construction of the lagoon provision was made by
construction of additional concrete piers for later installation of
four additional aerators if required. Figure 13 is a view of the
lagoon with two of the operating aerators. Figure 14 gives a pan-
oramic view of the lagoon taken from atop the Clarifier.
The cost of the entire waste-water system as described--sump, clarifier,
and lagoon--including all foundations, equipment, piping, and instal-
lation totaled $176,608.00.
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FIGURE 13. LAGOON AND TWO AERATORS
FIGURE 14. LAGOON VIEW FROM ATOP CLARIFIER
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SECTION V
START UP AND MODIFICATION PHASE
This period, which for purpose of categorizing the development of the
project, extended from early 1970 to the close of the year. During
this period, modifications of the dehydration equipment were carried
out which would give the most economical, efficient, and trouble-
free drying procedures for blood and rumen. The dehydrator work force
learned these procedures by trial and error working initially with the
engineer, Mr. W. L. McGehee, who designed and directed the installation
of the dryers.
The chemist employed for the analytical work of the project followed
the analytical procedures selected for use in FWPCA Laboratories for
the chemical analysis of water and waste samples (1,2). As part of
the work of the project involved chemical analysis of the dehydrated
blood and rumen with a view toward their use as feed or feed additives,
official AOAC methods were applied for the analysis of these materials
by the chemist (3). Quality control procedures as outlined in "Labora-
tory Quality Control Manual" were generally followed (4).
Dehydrator Equipment and Procedures
A major difficulty encountered early in the dehydration process was
in the pumping system that had been installed to transfer the blood
and rumen respectively from the hold tanks below the kill floor to
the hold tanks for the wet materials in the dehydrator building. The
distance separating these hold tanks is approximately 300 feet. The
pump system for transfer of these materials was changed after several
months of operation by modification of the hold tanks below the kill
floor to allow for periodic "blow" of the wet materials to the open
hold tanks in the dehydrator building by means of air pressure. A
minimum of 40-50 pounds of air pressure is needed.
Initially the engineer attempted to dry the blood by pumping the
wet blood directly from the hold tank to the dryer at a particular
rate. This procedure was soon shown to be impractical because the
blood baked onto and adhered to the inside lining of the drum. Steam
was then introduced into the 2" blood line prior to its entry into
the dryer, but plugging of the line with coagulated blood required
a shut-down two or three times daily to clean the line.
A trouble-free and readily controlled procedure for feeding the
blood into the dryer evolved by installing a six-foot length of
3" pipe in the blood line above the firebox of the dryer. Into this
"manifold" are tapped six short %" pipes along its length from a six-
foot length of 2" pipe steam line above it. Steam is introduced into
21
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iiia.i^'v.u x.. t^ui.e uj. a Kooet gear-s> i_y ie pump or
completed the modification. Figure 15 shows the blood "manifold"
located above the firebox of the dryer with the blood hold tanks in
the background.
FIGURE 15. BLOOD MANIFOLD AND HOLD TANKS
The hold tank for the wet blood is shown in Figure 15 as two separate
tanks or sections. This was a modification made several months after
the initial installation of a single holding tank for the wet blood
having the dimensions of 4' diameter by 32' height with a 10' false
bottom. The false bottom was lowered to 2' from the floor and the
upper section of the high tank separated and installed with connecting
lines adjacent to the bottom section of the original tank. This gave
two 16" high tanks which allowed for a much simpler clean-up operation
of the wet blood hold tanks which is required at the end of each day's
operation.
A 3/4" air line was installed in each of the blood hold tanks to keep
the blood agitated. Also, the plant operator has found that the
addition of a few gallons of melted tallow to each tank daily serves
as an excellent anti-foaming agent for the blood.
22
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Modifications of the blood dryer involved the installation of twelve
Vxl8"x36" steel lifter plates within the drum at strategic positions
to obtain more agitation of the drying blood as the drum turns. Sev-
eral bars were also installed at a position within the dryer which
serve to break up the wet coagulated blood as it enters.
The dry blood storage bin is a circular tank 48" in diameter and 32'
in height. The internal bottom of the storage tank is located mid-
way up its height or 16" from the floor. A slide gate has been
installed in the original divider to allow for storage of dry blood
in the bottom section. A screw conveyer was installed to empty the
bottom section. The top section is emptied by a simple gravity
chute.
Because of the considerable number of complaints of odors purportedly
originating from the dehydrator plant by residents of the city in
nearby residential areas during the first excessively warm period in
August 1970, a deodorizing system was installed in the stack of both
dryers. The system, installed by Rocket Dispensers and Fluids, Inc.,
of Aurora, Illinois, injects an aerosol mist of a masking agent having
a propylene glycol base directly into each stack through four small
jets operated by air pressure. The cost of the chemical used is
approximately ten cents per hour of dryer operation. This provision
has reduced the odor problem but has not entirely eliminated it.
The major modifications made in the rumen dryer was the installation
of larger lifters than those in the original equipment. Eight
V'xl8"x24" steel plates were installed for this purpose. A number of
additional steel plates were installed to act as plows within the
dryer to keep the drying rumen toward the front end of the dryer for
a longer period of time. A recir^ulating screw was installed to
transfer a desired quantity of dried rumen back to the front of the
dryer. This mixing of dry rumen with the entering wet material as
it is gravity fed into the drum improves the drying action, particu-
larly when excessively wet rumen is being dried. Break-up plates
and bars were also installed in the drum where the material enters
the dryer from the wet rumen hold tank.
With the particular design of the vacollector (a cyclone separator)
used, a considerable amount of particulate matter escaped from the
stack of the rumen dryer during drying operations. This loss was
almost entirely eliminated with the installation of a 52" cylindrical
duct with a bottom opening of 36" as an extension into the vacollector
at its discharge outlet leading to the stack.
Laboratory Equipment and Procedures
No major changes in the laboratory from the original plans or design
23
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were required. However, it was soon realized when the initial analytical
work on dehydrated rumen was carried out that the material required
preliminary treatment for uniform samples and reproducibility of results.
Dried rumen has a coarse texture with hay and other fibrous materials
up to several centimeters in length being evident in the material as it
emerges from the cyclone separator. Grain fragments are abundant and
even whole kernels of corn are found in the dried product. Originally,
a regular meat grinder with a butter-nut attachment was used to prepare
the dried rumen for analysis. When such a prepared sample was sorted
with a set of standard sieves, 787. of the sample passed through the
20-mesh sieve size, but only 97. passed through the 100-mesh sieve
after shaking with a manual circular motion. None of the sample passed
through the 200-mesh sieve. Forty-two percent of the sample was retained
on the 40-mesh sieve. A Sargent-Welch hammer-type pulverizer with six
interchangeable screens (20 to 125 mesh) was acquired and subsequently
used in sample preparation for all dried rumen analyses. The pulverizer
was also used in the preparation of dried blood samples for analyses.
In both cases, the material that passed through the 125-mesh screen
was used. All analyses made on the dehydrated products were those
given in "Official Methods of Analysis of the Association of Official
Agricultural Chemists," 10th Edition, 1965 (3).
As a major objective of the project was to ascertain the chemical oxygen
demand and the biochemical oxygen demand of the blood and rumen generated,
a great part of the time spent in the early stages of the analytical work
was devoted to the development of procedures and techniques for the deter-
mination of COD and 20°C, 5-day BOD of these materials. The best sampling
sites had to be determined for the dried products, as well as for fresh
blood and rumen sampling. The appropriate "seeding" and necessary dilu-
tions had to be determined for the BOD,, measurements on both fresh whole
blood and rumen.
The COD determination posed no particular problems. The L969 FWPCA
method for high-level COD was followed (1). Mercuric sulfate was not
used to tie up chloride ion, as it was demonstrated that the concen-
tration of this ion in the rumen was too low to affect the measure-
ment within its limit of accuracy. The rumen samples for COD deter-
mination were separated into their solid and liquid components for the
establishment of the COD value of each phase. The weighed sample of
fresh rumen was filtered through a modified Buchner funnel containing
a 200-mesh screen and washed successively with several 50-ml portions
of distilled water to extract the readily soluble components. The
liquid portion and all washings were combined and diluted to a given
volume (2,000 ml) and the COD determination was made on aliquots of
this solution. The solid, washed portion of the sample was dried over-
night at 105°C. After pulverizing the dried solid (125-mesh screen),
portions were used for the COD determination of the solid. The COD of
24
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both phases, as well as total COD could then be reported.
The COD determination of the fresh blood was made directly with given
volumes of blood samples. The initial sampling site for the blood was
from the blood holding tank below the kill floor, but more consistent
results were obtained when the blood samples were collected directly
from the animal as it drained. The samples of fresh rumen were col-
lected at the point where the paunches were opened and emptied into
the holding tank below. A mixed sample from five or more paunches
would be collected from which the test sample was taken.
The matter of finding the appropriate "seed" for the BOD analysis was
of major importance. Attempts at determining BOD of blood and rumen
without initial seeding were unsuccessful.
The best seed for BOD determination of the blood was found to be the
effluent of the plant's aerobic-type lagoon collected at the discharge
point. When 25 ml of the lagoon water was diluted to 1000 ml with
dilution water (doubly distilled followed by aeration), the 40-fold
dilution resulted in a 60% to 807, depletion of dissolved oxygen (DO)
after five days of incubation at 20°C. This appeared to have the
desired characteristics as a "seed" for the blood BOD. The most
satisfactory results were obtained for the blood BOD by making an
original 60-fold dilution of the blood sample with dilution water.
A 5-ml portion of this first blood dilution combined with 10 ml of
aerated lagoon water was then diluted to 2000 ml with dilution water.
BOD bottles of 300 ml were then filled for incubation. The method of
determination of DO on all blanks and incubated samples was the Winkler
method using the modified Azide-Iodide procedure (1).
Lagoon water was also used as the seed in the BOD determination of the
sump waste water. The usual dilution made was 1 ml of sump waste water
and 2 ml of aerated lagoon water diluted to a total of 1000 ml with
dilution water. The BOD determination of the SEDIFLOTOR Clarifier
effluent (where it drained to pass directly to the lagoon) did not
require seeding. The dilution with which the BOD bottles for incu-
bation were filled was made by diluting a 5-ml sample of the effluent
directly to 1000 ml with dilution water.
The BOD determination of the fresh rumen posed several problems. First,
there was the matter of determining the appropriate seeding material;
the second difficulty was the technique to be used in the determination
of the BOD of the dried solid phase. The samples of rumen were handled
in the manner described earlier in the procedure for COD of fresh rumen.
The liquid plus soluble portion were separated from the solid portion.
The latter was dried overnight. The liquid plus washings were diluted
in each analysis to an exact volume of 2000 ml. Both COD and BOD
measurements were then carried out with portions of this solution.
25
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Some settleable solids were always observed in the 2000 ml dilution
and agitation of the solution was always done prior to taking aliquots
for analysis.
The best seed for the BOD of fresh rumen was finally developed by using
the liquid drainage material from the cattle holding pens. This material
was aerated continuously, and periodically there was added to it portions
of the liquid phase of the fresh rumen. It took several months of nur-
turing this seeding material before consistent results for BOD of the
liquid phase of the fresh rumen were obtained. The seeding solution
was always filtered prior to its use.
The BOD of the solid phase was the most difficult technique to master.
It was finally done by the single bottle technique with introduction of
a very small weighed amount of the pulverized solid (10-13 mg) directly
into each individual empty BOD bottle. The bottle was then carefully
filled with seeded dilution water prepared by mixing 5-10 ml of the
rumen seed described above to 2000 ml with dilution water. The initial
DO of the seeded dilution water was determined on a filled bottle with-
out solid rumen. The DO demand of the seeded dilution water alone with-
out solid sample added upon incubation was negligible.
Several attempts to run total BOD on fresh rumen on homogenized blended
samples of the material always gave lower, as well as erratic data, as
compared to the values obtained by determination of BOD on the separate
phases. It was of interest to establish the BOD of the liquid and solu-
ble portions of the fresh rumen which would likely pass directly into
the sewer lines in other methods of handling the rumen waste problem.
Confirmation of the BOD of fresh rumen using a blended sample by the
oxygen probe method was initiated but not completed. The probe was
made available to the chemist only two months before the completion
of the project, which was insufficient time to calibrate the instru-
ment and to master the technique required for the determination.
26
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SECTION VI
RECORDS AND STUDY PHASE
This phase of the project is considered as represented by the six-
month period from January 1, 1971 to June 30, 1971, at which latter
date the project was completed. During this period accurate records
were kept of cattle slaughtered, percent of the rumen and blood that
was dried, drying time required, utilities used, labor required; all
other factors that would enter into the determination of costs in the
dehydrating procedures were established.
COD and BOD^ analyses of the fresh rumen and whole blood continued
into and throughout this phase of the project. Weight studies were
carried out during this phase to establish an accurate statistical
average of the fresh rumen and whole blood generated per animal of
the type slaughtered at the Beefland plant. A total of 10,638 head
was used to determine the average rumen content of the paunch by
weight and 7,324 head were used to determine the amount of blood that
was readily recoverable per animal.
Chemical analysis on the dehydrated products was also continued into
this phase. In addition, BOD determinations were carried out repeatedly
on the lagoon effluent in connection with the use of this material as
seed for BOD determinations. BOD values for the SEDIFLOTOR Clarifier
effluent and the sump waste water were also established to follow BOD
reduction in the waste water flow.
Production Data
The six-month production data is given in Table 2 on the following
page. The weight of wet rumen generated and recoverable per animal
was ascertained by a combination of data covering several study periods
and by two different approaches. A total of 10,638 head of cattle was
involved. One approach to determine the average of the paunch content
was the direct measurement of the weight of the rumen content of the
paunch at the site where the contents are emptied into the hopper leading
to the hold tank below the kill floor. The contents of each paunch were
emptied into a container and weighed. These measurements were carried
out until twenty-five or fifty were made and a mean weight established.
The other approach was the determination of the exact weight of the
dehydrated product obtained for one week's production. Official scale
weights were obtained. From the known kill of that week and the exact
number of paunches condemned (contents not dried), the number of paunch
contents dried was known. This information, along with moisture content
of both the fresh and dried rumen, allowed the calculation of rumen
generated for the week and per animal. The average weight of the rumen
content of the paunch per animal of 54.0 Ibs falls well within the range
of 40 to 60 Ib per head as reported by A. J. Steffen (5).
27
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Table 2
SIX MONTH PRODUCTION DATA
Total number of animals .slaughtered
Total live weight
Production hours on kill-floor
Production days
Average daily slaughter
Average live weight/animal
Total weight of wet rumen generated
Total weight of wet blood generated
Weight of wet material
recoverable/animal
Weight of dried product
recoverable/animal
Weight of dried product produced
Percent of wet material dried
Drying time required
Man-hours of labor required
Gas consumption
Electricity consumption
Steam consumption
Water consumption
Total sales
Blood
Dehydration
32.5 Ibs
6.0 Ibs
512 ton
92.4%
1,242 hrs
1,897 hrs
8,427.0 MCF
57,231.4 KWH
600 Ibs/hr
891,000 gals
$49,404.00
184,702 head
201,277,291 Ibs
1,159 hrs
135 days
1,368 head
1,090 Ibs
9,973,908 Ibs
6,002,815 Ibs
Rumen
Dehydration
54.0 Ibs
8.5 Ibs
588 ton
75%
1,260 hrs
1,816 hrs
8,540.4 MCF
46,443.6 KWH
none
none
Unreported
28
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Only 75% of the rumen generated (138,500 paunches) was dried. The con-
tents of condemned paunches were sent directly to the rendering cookers,
and the balance of the undried rumen was hauled away from the plant by
contract at fifteen cents per paunch.
The weight of wet blood recoverable per animal was also determined
during a week's production of known kill and all blood generated
being dried and official weight of the dried product obtained. From
the moisture content of both the wet whole blood and dried product,
the weight of blood obtained per animal was ascertained. During the
six-month period only 92.4% of the blood generated was dried (based
on total sales). Periodic shutdowns of the blood dryer and inadvert-
ent losses readily account for this yield as compared to that obtain-
able on the basis of the study period.
Gas consumption for both dryers was metered. As there were no meters
installed to determine the electricity usage, these values were based
on the measured usage of each dryer during operation by the Plant
Engineer. The blood dryer averaged 46.08 kilowatts per hour of drying
time, while the rumen dryer required 36.86 kilowatts per hour. Steam
use was also established by gauge pressure and flow while the water
consumption for cleanup of the blood holding tanks, floor, etc., was
estimated as 1% of plant use.
Undehydrated Blood and Rumen
Table 3 and Table 4 which follow summarize the chemical investigation
on fresh whole blood and undehydrated rumen. The data used to establish
the mean was that obtained after analytical procedures were well estab-
lished, and consistent results were obtained with each procedure. The
pH, % moisture, COD, and BOD are reported. Standard deviation for each
mean value is given, as well as the number of separate determinations
for each type of analysis counting back from the last one made at the end
of the project.
Table 3
DATA ON FRESH WHOLE BLOOD
Mean Std. Dev. No. of Detm's
PH 7.34 0.14 37
% Moisture 82.4 3.4 39
COD (ppm) 218,300 35,700 70
BOD5 (ppm) 156,500 58,000 35
29
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Table 4
DATA ON UNDEHYDRATED RUMEN
pH
% Moisture
COD (ppm)
Liquid Portion
(% Liquid)
Solid Portion
(% Solid
Total COD
% COD from Liquid
% COD from Solid
BOD (ppm)
Liquid Portion
Solid Portion
Total BOD
% BOD from Liquid
% BOD from Solid
COD and BOD- of Rumen and
Mean
6.54
84.7
51,940
(88.4)
1,138,000
(11.6)
177,300
26.7
73.3
28,240
151,900
50,200
59.1
40.9
Blood
Std. Dev. No. of Detm's
0.56 57
3.4 58
114
12,800
(3.3)
82,000
(3.3)
38,500
11,410 88
40,800 40
13,400
From the six-month production data and the COD and BOD values obtained
experimentally for undehydrated rumen and blood, the COD and BOD values
in terms of daily production, per animal, or per 1000 Ibs live-kill
weight can be calculated. Table 5 summarizes this data and type of
calculation.
30
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Table 5
COD AND BOD. OF RUMEN AND BLOOD
Rumen
Total COD of Rumen 177,300 ppra
Total BOD5 of Rumen 50,200 ppm
BOD5/COD Ratio of Rumen 0.283
Weight of Rumen Generated (54 Ibs/animal) 9,973,908 Ibs
Total Rumen COD Generated 1,768,400 Ibs
Total Rumen BOD- Generated 500,690 Ibs
Per
Day
13,100 Ibs
3,708 Ibs
Per
Animal
9.57 Ibs
2.71
Per
1000 Ibs LWK
8.78 Ibs
2.49 Ibs
Rumen COD
Rumen BOD,.
(As only 757. of the rumen generated was dried, any of the above
values multiplied by 0.75 give the recovered figure.)
Blood
Total COD of Blood 218,300 ppm
Total BOD5 of Blood 156,500 ppm
BOD5/COD Ratio of Blood 0.717
Weight of Blood Generated (32.5 Ibs/animal) 6,002,815 Ibs
Total Blood COD Generated 1,310,400 Ibs
Total Blood BOD5 Generated 939,440 Ibs
Per
Day
9,707 Ibs
6,959 Ibs
Per
Animal
7.10 Ibs
5.09 Ibs
Per
1000 Ibs LWK
6.51 Ibs
4.67 Ibs
Blood COD
Blood BOD5
(As only 92.4% of the blood generated was dried, any of the
above values multiplied by 0.924 give the recovered figure.)
31
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Table 6 relates total COD and BODj. in the same units as above for rumen
and blood combined in terms of amount generated and recovered as deter-
mined during the six-month study period.
Table 6
TOTAL COD AND BOD- OF RUMEN AND BLOOD COMBINED
Per Per Per
Generated Day Animal 1000 Ibs LWK
Total COD 22,810 Ibs 16.67 Ibs 15.29 Ibs
Total BOD5 10,667 Ibs 7.80 Ibs 7.16 Ibs
Recovered
Total COD
Total BODr
It can be readily shown from the data of Table 6, using any of the
units in which it is expressed, that dehydration of 75% of the rumen
and 92.4% of the blood that was generated gave a recovery of 82.47o
of the COD generated and 86.47. of the BOD5 generated.
It should not be concluded, however, that the balance of the COD and
BOD,, entered the waste-water system. The 257. of the rumen that was
not dehydrated either went through the rendering plant or was hauled
from the plant as wet rumen. Presumably, the 7.6% of the undehydrated
blood entered the waste-water flow. The BOD_ of this lost blood would
represent a waste-water loading of 0.387 Ibs of BODj./animal or 0.355
Ibs of BOD5/1000 Ibs LWK.
18,800 Ibs
9,210 Ibs
13.74 Ibs
6.74 Ibs
12.60 Ibs
6.18 Ibs
32
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BOD- of Plant Waste Water
Although the determination of BOD of waste water along different parts
of the flow from kill floor to final discharge into the sewer was not
part of the stated objective of the project, it was carried out on sam-
ples taken at three different sampling sites along its flow.
It was determined early in the experimental phase that the lagoon efflu-
ent collected at the discharge point into the municipal sewer line con-
stituted an excellent seed for blood BOD. In order to determine the BOD
reduction in the aerobic lagoon by aeration, BOD determinations were
made on samples of the Clarifier effluent taken at the point where it
flowed over the weir prior to discharge to the lagoon.
Samples of the waste water taken directly from the sump were also col-
lected for BOD determinations. This was under constant turbulence due
to flow from different sources. Foam and large pieces of fat were
usually evident on parts of the surface. Inclusion of these were
avoided in the collection of samples from the sump. Table 7 summarizes
the data on BOD of samples of the plant waste water taken from these
sampling sites.
Table 7
PLANT WASTE WATER—BOD5 (ppm)
Mean Std. Dev. No. of Detm's
Sump Water 1,220 300 36
SEDIFLOTOR-Clarifier Effluent 850 150 40
Lagoon Effluent 214 119 75
33
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Analysis of Dehydrated Products
The chemical analysis of the dehydrated products was the first type
of analytical work carried out in the project and continued through-
out the project period. Initially, the samples of the dried products
taken for analysis were composite samples collected periodically during
a particular day. Later, after consistent drying procedures were estab-
lished and products of quite uniform moisture content were obtained, the
composite sampling was extended to two days' production and even to an
entire week toward the end of the project. Table 8 summarizes the data
on the dehydrated blood and rumen.
Table 8
ANALYSIS OF DEHYDRATED PRODUCTS
Dehydrated Blood
7o Moisture
7. Protein
Dehydrated Rumen
7. Moisture
7. Protein
7. Fat
7. Crude Fiber
7. Calcium
% Ash
7. Carbohydrate
Mean
5.3
89.2
Std. Dev. No. of Detm's
1.7
4.1
110
100
6.8
12.7
3.1
26.2
0.59
7.2
1.47
40.8
1.9
1.5
0.6
3.2
0.09
0.7
0.25
5.3
96
88
86
88
60
88
60
44
(The 7. carbohydrate was calculated by subtracting total
percentage of moisture, protein, fat, crude fiber, and ash
from 100 for each sample as advised by Mr. Whitson of the
Iowa Agricultural Laboratory in Des Moines, Iowa. 7» Protein
based on Kjeldahl nitrogen.)
34
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SECTION VII
ECONOMIC EVALUATION
Annual Capital Costs
The capital investment in the dehydrator building and equipment was
itemized in detail in Table 1, page 10 of this report. The deprecia-
tion schedule followed by Beefland International, Inc., is a straight-
line method without residual book value based on a twelve-year schedule
for the building and a ten-year schedule for the equipment. The amor-
tization schedule (interest and reduction of principal) is based on a
97. annual interest rate.
Annual tax charged as a capital cost is based on the 1971 assessment
of $220,000.00 on a net property and equipment valuation for the Beef-
land plant of $5,854,450.00. The 1971 book value of the dehydrator
building and equipment was 2.795% of the total. Annual insurance cost
is calculated as 2.7957. of the total plant insurance premium for 1971
of $31,000.00. Despite an annually reduced book value for the building
and equipment, it is assumed that the annual tax and insurance costs for
the next ten-year period will remain essentially constant. Table 9 sum-
marizes the above data.
Table 9
ANNUAL CAPITAL COSTS
Capital Investment
Depreciation Period
Capital Costs (annual)
Amortization (97. annual interest)
Taxes
Insurance
Totals
Annual Capital Cost
Building Equipment
$32,934.00 $148,272.05
12 years 10 years
$ 4,599.00 $ 23,103.00
1,134.49 5,014.51
159.86 706.59
$ 5,893.35 $ 28,824.10
$ 34,717.45
35
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Dehydration Costs
The operating costs of dehydrating whole blood and rumen is based on
the production data for the six-month study period as given in Table 2,
page 28 of this report. Labor and administrative costs, as well as
cost of utilities and maintenance of equipment are included. Combina-
tion of operating costs as experienced during the project along with
estimated maintenance costs and the semi-annual capital costs allows
a determination of dehydration costs and costs for the BOD^ removal.
These data and cost figures are shown in Table 10 on opposing page.
Discussion of Dehydration Costs
For the sake of clarity certain of the data of Table 10 is explained
in detail in the statements that follow.
Labor cost, as expected, was the single largest item under operating
costs and was determined from payroll records for the six-month period
for all operators in the dehydrating process. The administrative,
supervisory, and secretarial cost was the best estimate of the admin-
istrator who acted as the Project Director.
The unit cost or rates of utilities werp as shown in the tabulation.
The rate for gas increased from $0.37/MCF to $0.4082/MCF midway through
the study period (April 1, 1971). The gas and electricity costs included
a demand charge (DC) made monthly. In the case of gas, this was deter-
mined by the fraction of gas used in the dehydration process times the
total demand charge for the plant for the month. The amount of the
demand charge for gas varied between $300 to $725 monthly during the
study period. The demand charge was prorated for each dehydrator on
the basis of the gas usage of each. The monthly demand charge for
electricity was constant. The demand charge for electricity for the
blood dryer was $86.40 monthly and $115.20 monthly for the rumen dryer.
The maintenance allowance for the dryers of $2,000 annually for each
is five times the amount estimated by the manufacturer to keep the
machines in good repair for a life expectancy of 25 to 30 years. This
generous allowance, however, would allow for relining of the dryers,
particularly the blood dryer, with corrosion resistant stainless steel*
every three or four years as required. Although the allowance is
indicated as the same for each dryer, the blood dryer would likely
have a greater maintenance cost than that of the rumen dryer because
of the greater corrosive action of wet blood. In addition to the
eventual expense of relining the dryers, maintenance costs that have
been incurred are those of replaced bearings, rubber tires, corroded
blood lines and break-up bars.
The semi-annual capital cost of $17,358.72 was not equally divided
36
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Table 10
DEHYDRATION COSTS FOR WHOLE BLOOD AND RUMEN
Blood Rumen Total
Operating Costs Dehydration Dehydration Costs
Labor ($3.05/hr) $ 5,785.85 $ 5,538.80 $11,324.65
Administration and
Supervision 900.00 900.00 1,800.00
(107. of the salary of one
secretary, administrator,
and supervisor)
Utilities
Gas ($0.4082/MCF plus DC)
Electricity ($0.0055/KWH
plus DC)
Steam ($0.42/hr drying
time
Water ($0.000273/gal)
Masking Chemicals
($0.lO/hr drying time)
Maintenance of Dryers (Est.)
($2,000/yr— each dryer)
4,799.65 4,939.94
833.17 946.64
521.64
243.24
124.20 126.00
1,000.00 1,000.00
9,739.59
1,799.81
521.64
243.24
250.20
2,000.00
Total Operating Costs $14,207.75 $13,451.38 $27,659.13
Capital Costs (semi-annual) 8,193.32 9,165.40 17,358.72
Total Dehydration Costs $22,401.07 $22,616.78 $45,017.85
Dehydration cost/ton $43.75 $38.46 $40.93
Dehydration cost/animal $ 0.12 $ 0.16 $ 0.28
Dehydration cost/1000 Ibs LWK $ 0.11 $ 0.15 $ 0.26
Cost/lb of BOD5 eliminated $ 0.025 $ 0.08 $ 0.04
37
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between the blood and rumen dryer, as the blood dryer cost $10,000.00
less (a used model) than the rumen dryer in the Beefland project.
(See Table 1, page 10). Forty-seven and two-tenths percent of the
semi-annual capital cost was assigned to the blood dehydration and
the remainder as the capital cost share of the rumen dehydration.
The dehydration cost per ton of dried blood was based on the total
six-month production of 512 ton. On the basis of 184,702 head of
cattle slaughtered, the cost per animal is I2c and the cost per
1000 Ibs LWK is lie. The dehydration cost per ton of dried rumen
was based on the total production of 588 ton. On the basis of only
757. of the paunch contents dried (138,500 paunches), the cost per
animal is 16$ and the cost per 1000 Ibs LWK is 15$. The cost per
ton of dehydrated material (blood and rumen) was based on the total
tonnage of 1100 ton and total costs.
The total receipts of $49,404.00 for the sale of dried blood during
the six-month study period represented a return of $4,386.15 over the
total dehydration cost of both blood and rumen during the same period.
Information on the exact amount of dried rumen sold was not available.
A portion of the dried rumen was sold for $20.00/ton. A considerable
amount was used for feed trials by both cattle and hog feeders in the
area. Some of the dried rumen was used as a soil conditioner.
It should be noted that a return of $20.00/ton for the dehydrated rumen
would represent a return of 8.5$ per animal or approximately 537. of the
dehydration cost of 16$ per animal. The 16$ dehydration cost per paunch
content should be compared to the 15$ hauling cost per animal paid by
Beefland for the wet rumen that was not dried. Sales of 127. of the
dehydrated rumen at the minimal price of $20.00/ton would represent a
break-even point between the cost of dehydrating the rumen and the cost
of wet dumping as a separate operation from the drying of blood.
Consideration of the data as given in Tables 5, 6, and 10 allows for a
determination of the costs of BOD removal or elimination by the dehy-
drating process. These values are given in Table 10 as 2%$ per pound
for blood BOD and 8$ per pound for rumen BOD. The mean cost is 4$ per
pound of BOD eliminated. The FWPCA publication, "The Cost of Clean
Water" (6), is an excellent reference to compare the reduction of BOD
loading of plant waste water in the industry by various processes of
handling blood, rumen, grease, etc. Costs of the processes described
are not readily comparable with the dehydrating costs as established in
this study.
38
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SECTION VIII
ACKNOWLEDGMENTS
This report was written by Dr. Donald J. Baumann, who acted as Tech-
nical Director of Project 12060 FDS during the eighteen-month study.
The author wishes to acknowledge the assistance given him by the
initial Project Director, Mr. Ray C. Burke, who held the position of
Vice President of Transportation and Marketing with Beefland Inter-
national, Inc., and under whose guidance the project was initiated.
Upon the resignation of Mr. Burke, Mr. James S. Gardner, Director of
Personnel at Beefland, was named to replace him as Project Director.
Mr. Gardner's assistance and cooperation in the progress of the study
since August 1970 is gratefully acknowledged.
Other Beefland officials and staff whose assistance and work on the
project in one capacity or another have been invaluable are:
Mr. Harry J. Nelson -- President of Beefland
Mr. Jack Brashear — Plant Engineer
Mr. Joe Gardella -- Accountant
Miss Connie R. Osborne -- Secretary
Mr. Merlin Hicks -- Operator, Dehydration Plant
Mr. James L. Cheney performed the chemical analyses required in the
project study. The reliability of his work and the accuracy of his
calculations made the monthly report duties of the Technical Director
an easier one.
Acknowledgment is also given to the officials at Creighton University
who provided space for the laboratory work of the chemist for well over
one-half of the study period which ended June 30, 1971.
The support of the project by the Water Quality Office, Environmental
Protection Agency, is gratefully acknowledged. The author particularly
wishes to express his appreciation for the interest and assistance
given him by Mr. George Keeler, of the Washington, D.C., EPA Office,
Mr. Jack L. Witherow, Chief, Agricultural-Mining Wastes Section of the
Ada, Oklahoma Regional Laboratory, Mr. Gene Ramsey of the Kansas City
Regional Office of the EPA, and the recently appointed Research and
Monitoring Representative, Dr. William Garner of the Kansas City EPA
region.
Mr. Otraar 0. Olson of the Kansas City EPA Office and Regional Director
of Water Quality Research and Development Office was the Project Officer.
His guidance and assistance during and following the project period have
been gratefully received.
39
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SECTION IX
REFERENCES
1. FWPCA Methods for Chemical Analysis of Water and Wastes, U. S.
Department of Interior, (November, 1969).
2. Standard Methods for the Examination of Water and Wastewater,
12th Edition (1965).
3. Official Methods of Analysis of the Association of Official
Agricultural Chemists, 10th Edition (1965).
A. Laboratory Quality Control Manual, Federal Water Pollution Control
Administration, South Central Region, Robert S. Kerr Water Research
Center (1969).
5. Steffen, A. J., "Waste Disposal in the Meat Industry, A Compre-
hensive Review," Proceedings of the Meat Industry Research
Conference (1969). American Meat Institute Foundation, Chicago
Illinois.
6. "The Cost of Clean Water," Vol. Ill, Industrial Waste Profile No. 8-
Meat Products (Part I), U. S. Department of Interior, FWPCA, 1967,
U. S. Government Printing Office.
ft U. S. GOVERNMENT PRINTING OFFICE :1972—484-484/180
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SELECTED WATER
RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
1. Report Kfo.
3. Accession No.
4. Title
ELIMINATION OF WATER POLLUTION BY PACKINGHOUSE
ANIMAL PAUNCH AND BLOOD
7. Author(s)
w
5. Report Date November, 19'
6.
8. Performing Organization
Report No.
Baumann, Donald J.
9. Organization
Beefland International, Inc.
Council Bluffs, Iowa
12. Sponsoring Organization
15. Supplementary Notes
10. Project No.
12060 FDS
11. Contract/Grant No.
13. Type of Report and
Period Covered
10-1-1969 to 6-30-1971
16. Abstract Tne operation of two dehydrating machines, for the drying of cattle
whole blood as well as paunch contents (rumen), at the Beefland
International, Inc., slaughtering plant at Council Bluffs, Iowa,
was studied.
The BOD,, and COD of the blood and rumen were established.
The mean BOD,
of the whole blood and rumen was determined as 156,500 ppm and 50,200
ppm, respectively. The mean COD of the blood and rumen was established
as 218,300 ppm and 177,300 ppm, respectively.
The economics of the drying process in costs per ton of dried product,
per 1000 Ibs live kill weight (LWK), and per animal were determined.
The dehydrating costs per ton of dehydrated product were found to be
$43.75/ton for blood and $38.46/ton for rumen. The average cost (blood)
and rumen) was $40.93/ton.
Laboratory studies were carried out on the dried whole blood and rumen
with a view toward their actual and potential use as legally accepted
feeds or feed additives. Percent moisture, protein, fat, carbohydrate,
and other analyses of the dried products are reported. (Baumann—
Creighton)
17a. Descriptors
* * * it
Dehydration, Cattle, Chemical Oxygen Demand, Biochemical Oxygen
Demand, Economics, Chemical Analysis, Water Pollution, Moisture
Content, Oxidation Lagoons, Proteins, Waste Disposal
17b. Identifiers
1c 1e * * *
Dehydrators, Blood, Paunch, Rumen, Slaughtering Plants, Dryers,
Dehydration Costs, Feed Additives
17c. COWRR Field & Group
18. Availability
19. Security Class.
(Report)
20. Security Class.
(Page)
Abstractor Donald J. Baumann
21. No. of
Pages
22. Price
Send To:
WATER RESOURCES SCIENTIFIC INFORMATION CENTER
U.S. DEPARTMENT OF THE INTERIOR
WASHINGTON, D. C. 20240
Institution Creighton University
WRSIC 102 (REV. JUNE 1971)
GP 0 9 J3.26T
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