wastewater treatment plant upgrade project (wwtp) (wwtp) marlon cabrera engineering department...
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Wastewater Treatment Plant Upgrade Project (WWTP)
Marlon Cabrera Engineering Department
Cervecera de Puerto Rico Mayaguez, PR
Introduction A common challenge for breweries is meeting current wastewater discharge standards while accommodating growth and anticipating more stringent discharge regulations in the future. Cervecera de Puerto Rico wastewater treatment system had been in operation for a long time, but years of service and increased hydraulic and organic loadings had made it difficult to meet treatment objectives. For years Cervecera de Puerto Rico wastewater treatment plant was affecting the image of the company and had become a priority for the future of the company.
Potential Issues • Regulatory Compliance of Waste Water Discharge
• Possible surcharges • Controls were mostly manual, there were no instrumentation automated monitoring
parameters of waste water treatment process
• Operation of Return Activated Sludge Systems (RAS) was inconsistent due a to past retrofits and obsolete equipment
• Operation and maintenance of the treatment systems rotating biological contactors had
become a very high total operational costs • Increased hydraulic and organic loadings • Bad odor generation at the treatment plant • Bad image of the company
Before Process Diagram of WWTP
Pista-Grit
Equalization Tank Digester/
Thickener
Clarifier
Pump #1
Pump #2
Blocked discharge connections to/from reactor
Pressed if needed
Reactor
Previous Rotating Biological Contactors
Previous Rotating Biological Contactors
Previous Clarifier
Legal Limits and Requirement of Samples Applied Load
PARAMETERS DOWNLOAD LIMIT
BOD (mg/L) 250
TSS (mg/L) 250
Before - Graph of BOD
0
200
400
600
800
1000
1200
1400
1600
BOD
(g/m
l)
Month/Year
Biochemical Oxygen Demand
Before - Graph of TSS
0
500
1000
1500
2000
2500
TSS
(g/m
l)
Month/Year
Total Suspended Solids
Challenges • Regulatory compliance with the permit. • Reduce the environmental footprint of the plant • Cost effective technologies
• Limited budget of 1.3M • Space construction limited
• Withstand large changes in demand while maintaining efficient • Reduce odors • Make changes without stopping operation
• Reduce total operating costs
CERVECERA DE PUERTO RICO PILOT study
MOVING BED BIOREACTOR (MBBR) TECHNOLOGY
MBBR #1
MBBR #2
ACID PUMP
ACID TANK
INFLUENT PUMP
EFFLUENT
AIR CONTROL VALVES AIR PRESSURE
REGULATOR
INFLUENT LINE ACID PUMP
CERVECERA DE PUERTO RICO WWTP MBBR PROJECT
CERVECERA DE PUERTO RICO WWTP MBBR PROJECT
Paramecium Vorticella
Epistilys Vorticella
CERVECERA DE PUERTO RICO WWTP MBBR PROJECT
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
3578.00
1193.00
186.00 29.30 250.00
SOLU
BLE
BOD
(PPM
)
SOLUBLE BOD 10/23/2009
INFLUENTE SOLUBLE BOD WWTP REACTOR SOLUBLE BOD MBBR #1
SOLUBLE BOD MBBR #2 PRASA BOD PERMIT LIMIT
CERVECERA DE PUERTO RICO WWTP MBBR PROJECT
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
61.08%
93.93% 99.04%
SOLUBLE BOD REMOVAL 10/23/2009
BOD REMOVAL % WWTP REACTOR BOD REMOVAL % MBBR #1
BOD REMOVAL % MBBR #2
CERVECERA DE PUERTO RICO WWTPMBBR PROJECT
Solution: Upgrading the WWTP
The Engineering Department along with EH&S evaluated different treatment alternatives to determine the viability of upgrading the existing facilities to achieve permit parameters. • Moving Bed Biofilm Reactor (MBBR) • Tank Dissolved Air Flotation (DAF), system without air
saturation
MBBR Design Basis
PARAMETER UNITS INFLUENT EFFLUENT
Flow MGD 0.15 0.15
BOD5 (Soluble) MG/L 1,800 <250
TSS MG/L 2,000 <250
COD (Soluble) MG/L 2,350 <425
Ammonia MG/L No data available -
P MG/L No data available -
Temperature ° C 20-38 -
Project Scope Tasks Original Scope Currently Achieved Reactor Tank Retrofit X X Blowers Replacement X X DAF Installation X X Acid Dosing Station Automation X X Caustic Soda Station Automation X X Caustic Soda Receiving Station Automation X pH/Temp Monitoring EQ Tank X X pH/Temp/DO Monitoring Reactor Tank X X Influent Flow Metering X X Influent Temperature Monitoring X Central process overview X X Tank Levels X X Belt Press automation X Electrical Utilities X Air Utilities X Water Utilities X Pads/Dikes/Civil Work X Instrumentation and Integration X X Aesthetical Improvement X Waste Water Lift Station Upgrade X New Laboratory Furniture X X
Project Budget
• Project Budget $1,394,036
• Discharge Overcharges $98,069 • Negotiated PRASA Limits
• BOD - 5,633 mg/L • TSS - 2,628 mg/L
• Currently consumed $1,358,641
Actual Process Diagram of WWTP
Belt Filter Press &
Container
Moving Bed Biofilm
Bioreactor (315,000 gals)
Digester 89,000 gals
Screens
DAF
Utilities Brew House Cold Block Packing Lines PRASA
Equalization Tank
292,000 gals
Lift Station
X X X
X X Blowers
Blowers
Moving Bed Biofilm Reactor (MBBR)
• A stand-alone biological treatment system with no need
for media backwashing • Wastewater treatment plants of this type operate as
fixed-film processes without activated sludge recycle between the bioreactor and clarification units
• Aeration supplied provides oxygen, essential for
microbial growth, and the energy required to disperse the carriers completely throughout the system
Moving Bed Biofilm Reactor (MBBR)
MBBR System
Moving Bed Biofilm Reactor (MBBR)
Process uses 25 mm-diameter cylindrical plastic carriers that provides environments in which bacteria and protozoa can grow effectively.
Moving Bed Biofilm Reactor (MBBR)
Dissolved Air Flotation Operation (DAF)
Separates and optimizes solids prior to dewatering
Dissolved Air Flotation Operation (DAF)
Dissolved Air Flotation Operation (DAF)
WWTP Retrofit
WWTP Retrofit
WWTP Retrofit
WWTP Retrofit
WWTP Retrofit
WWTP Retrofit
Belt Press
Now - Graph of TSS
20
1600
10
20
260
230
240
220
200
150
140
110
150 270
280
143
135
121
110
90
30
30
20
15
20
15
12
0
250
500
750
1000
1250
1500
1750
2000
2250
2500
Jan-
08
Mar
-08
May
-08
Jul-0
8
Sep
-08
Nov
-08
Jan-
09
Mar
-09
May
-09
Jul-0
9
Sep
-09
Nov
-09
Jan-
10
Mar
-10
May
-10
Jul-1
0
Sep
-10
Nov
-10
Jan-
11
Mar
-11
May
-11
Jul-1
1
Sep
-11
Nov
-11
Jan-
12
Mar
-12
May
-12
Jul-1
2
TSS
(g/m
l)
Month/Year
Total Suspended Solids Efficiency
Actual TSS Before TSS Limit
Now - Graph of BOD
10.0
0
700.
00
133.
00
111.
00
193.
00
128.
00
101.
00
121.
00
193.
00
133.
00
42.0
0 24
.00
24.0
0 40
.00
30.0
0 18
.00
21.0
0 14
.00
11.0
0 6.
00
8.00
7.
00
10.0
0 7.
00
8.00
8.
00
-200
0
200
400
600
800
1000
1200
1400
1600
Jan-
08
Mar
-08
May
-08
Jul-0
8
Sep
-08
Nov
-08
Jan-
09
Mar
-09
May
-09
Jul-0
9
Sep
-09
Nov
-09
Jan-
10
Mar
-10
May
-10
Jul-1
0
Sep
-10
Nov
-10
Jan-
11
Mar
-11
May
-11
Jul-1
1
Sep
-11
Nov
-11
Jan-
12
Mar
-12
May
-12
Jul-1
2
BOD
(g/m
l)
Month/Year
Actual BOD Before BOD Limit
Biochemical Oxygen Demand Removal Efficiency
Summary Savings
• Maintenance Costs 70% • Chemicals 50% • Generation of H2O • Power Cost 35% • Odor reduction • Regulatory compliance without overcharges 100%