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A Sustainable Alternative for Whiskey Stillage Management to Produce Animal Feed and Biogas: Case Study at Makers
Mark Bourbon DistilleryPresented at:
Anaerobic Treatment of High Strength Wastes WorkshopMarquette University
September 17, 2009
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Presentation Agenda
• About Maker’s Mark Distillery• What were the drivers for this project?• Potential solutions considered and vetted• What was selected – a total alternate solution for stillage
management and PWW treatment• Benefits• Some Performance Data• Questions
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About the Maker’s Mark Distillery
• Samuels family Scotch / Irish heritage making whisky since 1771
• Old distillery purchased by TW Samuels family in 1953, changes the family recipe and renames the distillery Maker’s Mark.
• First case sold in 1958 • Distillery recognized by the Guinness
Book of World Records as the world’s oldest operating bourbon distillery
• Named a National Historic Landmark in 1980
• One of the world’s best selling premium bourbons
• The site consists of 620 acres, most of which is treated like a nature preserve
• Longstanding tradition of environmental stewardship
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What were the drivers for this project?
• Current practice of giving away “thick slop” or whole stillage to local farmers was risky, burdensome and bottlenecked facility production
• Planned capacity expansion (50%) could not be supported by current practice
• Energy prices (natural gas) climbing and long-term outlook for energy costs not positive
• Desire to implement a more sustainable solution (compared to a conventional dry house) that would not increase distillery carbon footprint
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Potential Solutions Considered
• Traditional dry house approach → DDGs production• Truck to another facility with excess dry house capacity• Whole stillage digestion• High-rate anaerobic digestion after novel solids
separation to produce DWG equivalent product and low TSS, high COD liquid stream
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Whole Stillage (Thick Slop) Characteristics
Parameter Thick Slop UnitsCurrent flow 631,400 gallons per weekFuture flow 970,200 gallons per weekTotal COD 86,000 mg/L
Soluble COD 28,000 mg/LTSS 38,750 mg/L
Phosphorus – P 472 mg/LNitrogen – TKN 3,450 mg/L
Temperature >200 °FpH 3.0 – 4.0 s.u.
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Selection Process & Considerations
• Solicited technical and cost proposals for whole stillage digestion and high-rate anaerobic treatment
• On-site pilot test of whole stillage digestion for 1 year
• Conducted treatability studies of novel solids separation followed by high-rate anaerobic treatment
• Developed dry house cap-ex and op-ex for comparison
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Whole Stillage Digestion
• Difficult process to control – unstable
• Solids destruction efficiency was low
• Residual solids have no little to no value after digestion, whereas DWG has significant value as an animal feed
• More biogas generated compared to Treatment of the soluble fraction of the stillage but $ value vs. additional costs not good
• CONCLUSION: Determined that whole stillage digestion was not feasible
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What Was Selected• Integrated Solution delivered as design-build
– Heat from whole stillage used to preheat water for mashing
– Thick slop solids recovery using FKC screw press (with lamella clarifier to capture “extruded” solids in the pressate and return back to the SP head box)
– Produce Distiller’s Wet Grains (DWG) for animal feed and pressate to high-rate anaerobic treatment
– Anaerobic treatment of pressate followed by anoxic/aerobic polishing by modifying existing SBRs
– All other process wastewaters introduced after anaerobic step for treatment
– Biogas integrated into existing boiler to supplement natural gas purchase
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Maker’s Mark Site Layout
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Benefits of the Integrated Treatment System
• De-bottleneck production and allow distillery expansion
• Remove risk of relying on farmers for disposal of co-product
• Significant Capital and operational cost savings over conventional dry house approach
• Produce renewable fuel-offset purchase of natural gas by 15 to 20%
• Ability to incorporate existing assets (WWTP) into design
• Heat recovery from whole stillage for mash H2O preheating
• Reduce carbon footprint of distillery by renewable fuel substitution and avoidance of additional fossil fuel required for traditional dry house approach
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Screw Press For Solids Separation
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22
Benefits of Screw Press Solids Separation
• Stillage Solids retained as animal feed, where they have value (~98% TSS capture achieved)
• Higher total solids content of screw press cake solids (~40% vs.32% typical using decanting centrifuge)– Reduced trucking costs– Reduced drying costs if grains to be used in biomass boiler in
the future• Screw press filtrate suitable for high-rate anaerobic treatment for
conversion of soluble organics to energy in the form of biogas• Lower energy needed – ~25% the hp of a centrifuge• Lower maintenance requirements
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Stillage After Preconditioning
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Screw Press Solids (Distillers Wet Grain)
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Pressate from the Screw Press
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Screw Presses at Makers Mark
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Load out of DWG
• Distillers Wet Grains (>40% DS)
• DWG equivalent as animal feed; virtually the same composition as normal DWG:– Protein– Crude fat– Crude fiber– Amino acid profile– Metabolizable energy
• Polymer(s) used are GRAS [Generally Regarded As Safe] for use in animal feed
Distillers Wet Grains (~40% DS)
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Clarifier, MFT & DAF
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High Rate Anaerobic Treatment
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MFT Anaerobic Reactor
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Biogas Integration Skid
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Anoxic – Aerobic Polishing for Direct Discharge
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AIS - Anoxic/Aerobic Final Treatment
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TOTAL RECYCLE
AIR LIFT PUMP
AEROBICBASIN
ANOXICBASIN
JET MIXING ORSUBMERGED
MIXER
AISINTEGRALCLARIFIER
X
CONTROL VALVE
NITRATED RECYCLE
Denitrified Water (Gravity Flow)
TREATEDEFFLUENT
INFLUENTWASTEWATER
The AIS System: Aerobic Polishing & Nitrification/Denitrification
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Final Effluent Discharge Requirements
Discharge ParametersParameter Discharge
Criteria Units
Temperature 31.7 max °CDissolved Oxygen 7.0 min mg/L
pH 6.0 - 9.0 s.u.
TSS 30/60 mg/L
Nitrogen, Ammonia 4/8 mg/L
Total Phosphorus 5 mg/L
Oil and Grease 10/15 mg/L
BOD-5 15/30 mg/L Discharge from Ecovation System
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Summary of Compliance Testing Results –June/July 09
1.3NANAmg/LTP
0.7NANAmg/LOP
1.1258NAmg/LNH4-N
115801,230mg/LVSS
198001,430mg/LTSS
722,22018,990mg/LsCOD
1593,05021,230mg/LCOD
Final Effluent
Anaerobic Effluent
PressateUnitsParameter
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Compliance Testing – June/July 09
• Average Daily System Inputs– Thick Slop Production – 43,600 gpd– Process WW Produced – 29,670 gpd
• Average Daily System Outputs– 45,500 scfm biogas (65 – 70% CH4)– YYYY ton of DWG– 70,460 gpm Treated Effluent Discharged– 780 gpd of Excess Biological Solids
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Special Thanks
Makers Mark• Denny Potter• Kevin Smith
• Dale BurroughsEnviron-Advent
• Carl Adams• Gaines Barry• Scott Reese
Ecovation• Tim Nock
• Bob Franklin• Mark Motylewski
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Always Ready to Help with the Proper Project PPE
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New Aeration / Tank Inspection System
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Thank you for listening
Questions ?