Ulaanbaatar, October 2015
Water and waste water treatment for Mining and Food industry
-practical examples and show-
Dipl.-Chem.-Ing. Thomas H. Weißer
Envirochemie
German-Mongolian Corporate Days
“Made in Germany”
Ulaanbaatar, October 2015
1. General Basics
2. Food industry: Biological waste water treatment
Examples in operation Maltery aerobic example Brewery anaerobic-aerobic example Dairy/Whey anaerobic example
3. Mining industry: Physical-chemical waste water treatment (Copper, Uranium, coal)
4. Practical example of flocculation and precipitation
Content
Ulaanbaatar, October 2015
EnviroChemie – Technology for Water
Steps of Treatment Results
Ulaanbaatar, October 2015
Ulaanbaatar, October 2015
General basics
EnviroChemie – Technology for Water
Ulaanbaatar, October 2015
Biological
industrial
waste water treatment
EnviroChemie – Technology for Water
Ulaanbaatar, October 2015
Nature and Technology / Waste Water Treatment
Ulaanbaatar, October 2015
Selected References
Ehrmann BIOMAR® AFB/OKB 1500 m³/d River
Hochland BIOMAR® OSB 240 m³/d River
Onken (Dr. Oetker) BIOMAR® OKB 200 m³/d River
Danone BIOMAR® OSB 3000 m³/d River
Baltika 3 x BIOMAR® ASB/OSB 7500 m³/d River
Oriflame ENVOCHEM® 300 m³/d Sewer
Stora Enso 2x SPLIT-O-MAT ® 2х24 m³/d Sewer
Otschakovo 2x BIOMAR® OSB 1900 m³/d River
SABMiller BIOMAR® ASB/OSB 7200 m³/d Sewer
Wrigley BIOMAR® 600 m³/d River
Pepsi Cola BIOMAR® 2000 m³/d River
Talwis BIOMAR® 720 m³/d River
Aquavisison/Coca Cola BIOMAR® 800 m³/d River
Glaverbel ENVOCHEM® 2х24 m³/d Sewer
Agranaobst BIOMAR® ASB/OKB 600 m³/d Sewer
INBEV Angarsk BIOMAR® ASB/OSB 7600 m³/d River
Hipp BIOMAR® OSB 200 m³/d River
Inventa Fischer BIOMAR® OSB 170 m³/d River
Kraft Foods study
Ulaanbaatar, October 2015
Messparameter und Analytik / Measurement and Analysis
Messparameter / measured parameters Abwassermenge amount of wast water pH-Wert pH-value Temperatur temperature Analytik / Analysis CSB (Chemische Sauerstoffbedarf) / COD (chemical oxygen demand) BSB5 (Biologische Sauerstoffbedarf in 5 Tagen) / BOD (biological oxygen demand within 5 days) NO3-N, NH4-N, NO2-N (Stickstoff / Nitrogen) PO4-P (Phosphor / Phosphorous) SO4-S (Schwefel / sulphur) Spurenelemente (K, Na, Mg, Cl, Ca, Fe, Mn, Co, Cu, Al, Se, …), trace elements
Ulaanbaatar, October 2015
Entscheidungskriterien zur Verfahrensauswahl / criteria for design of process Schmutzfracht / COD-Load
organisch anorganisch
Biologische Abwasserreinigung
Biological waste water treatment Chemisch/physikalische Abwasserreinigung
chemical-Physical WWT
Hohe CSB-/ high COD Konzentration CSB / COD > 2.000 mg/L
niedrige CSB-/ low COD Konzentration CSB/COD < 2.000 mg/L
Anaerob Aerob / anoxisch
Grenzwerte / Einleitbedingungen / Limits (Direkt- / Indirekteinleitung -discharge) Aerobic
Ulaanbaatar, October 2015
Comparison of Anaerobic and aerobic process Aerobic Anaerobic
COD Load - + / ++
efficiency + / ++ o / +
P- and N-Elimination ++ -
Excess sludge ++ -
Nutrients demand o / + - / o
Invest cost: - small plants - big plants
o +
+ ++
Area consumption - o / +
Energy demand (aeration) -- ++
Energy win (Biogas) - ++
Ulaanbaatar, October 2015
Anaerobic
Biological
industrial
wastewater treatment
EnviroChemie – Technology for Water
Ulaanbaatar, October 2015
COD balance – anaerobic degradation
COD in Input 100 %
CH4 (80 – 90 %)
COD in Output(10 %) Biomass (3 – 5 %)
● Only 3 - 5% of the COD in the feed is converted to biomass ● 80 - 90% of the COD in the feed is converted to methane
Ulaanbaatar, October 2015
Biogasproduction
OH2COO2CH2224
CODg
L
L
g
g
g
CH
CH
CH
O
CH
n
4
4
4
2
4
347,0
72,0
25,0
1. Stoichiometric production of biogas
Molmass: CH4: 16 g mol-1; O2: 2 x 32 g mol-1
rCH4 (1013 mbar; 0°C) = 0,72 g L-1
→ Oxydation of 0,25 g CH4 needs 1g O2
→ each g COD degraded 0.347 L methane is produced
Ulaanbaatar, October 2015
Energy yield of Anaerobic Biology
0
300
600
900
1.200
1.500
1.800
2.100
2.400
0
1.000
2.000
3.000
4.000
5.000
6.000
7.000
8.000
0 2.000 4.000 6.000 8.000 10.000 12.000
Leis
tung
[kW
ther
m.]
Dam
pf-E
rzeu
gung
[kg
/h]
CH 4
-Pro
dukt
ion
[m3 /d
]He
izöl
-Äqu
ival
ent
[kg/
d]C
O2-
Eins
paru
ng [
kg/d
]
Δ CSB [kg/d]
CH4-Produktion
Heizöl-Äquivalent
CO2-Einsparung
Leistung
Dampf-Erzeugung
Ulaanbaatar, October 2015
Possibilities of exploitation
Biogas utilisation
Gas motor Natural gas net
steam Hot water
Ulaanbaatar, October 2015
Advantages of the use of biogas Utilisation of biogas has the following advantages for a
company:
Cost savings due to substitution of fossil fuels
reduce CO2 footprints.
Improved image of the company by using green energy sources.
Biogas as an independent source of energy from the energy supplier
Generating energy on site
Ulaanbaatar, October 2015
Biomar ASB
Ulaanbaatar, October 2015
Biomar AHP
Ulaanbaatar, October 2015
Gas recirculation good mixing of the substrate (no elaborate intake system required) Adjustable good mass transfer (H2S, oil, grease) relatively insensitive to increased Solids in the wastewater
(classification effect) Gas Possibility of external gas conditioning (H2S) separator downstream on pent-up separator simpler reactor head and drain system Biomass fine-grained active biomass Operational safety No complex installations Because virtually the circulation flow no deposits Interior maintenance free
Biomar AHP
Ulaanbaatar, October 2015
Aerobic
Biological
industrial
Waste water treatment
EnviroChemie – Technology for Water
Ulaanbaatar, October 2015
Aerobic Microorganisms bacteria Yeast (fungus) rotifers paramecia……..
Tokophyra
Vorticella
Epistylis
Ulaanbaatar, October 2015
Aerobic degradation OnHnCOnOn)OCH( 2222
Molmass: (CH2O)n: 30 g mol-1; O2: 32 g mol-1
→ Oxydation of 1 g (CH2O) needs 1,07g O2
→ each kg O2 blown into ww needs 1,6 kWh electrical power (blower)
Ulaanbaatar, October 2015
COD in Input 100 %
CO2, Heat (50 %)
Biomass (50 %)
O2
COD Balance Aerobic degradation
Ulaanbaatar, October 2015
Nitrogen elimination: nitrogen cycle
organic bounded
NH4+
NO3-
NO2-
N2
CO2 Light
Ammonification
Nitratation
Denitrification
Nitritation
Biological N2-Bound
Ulaanbaatar, October 2015
Phosphatelimination: P-Precipitation PO4-PFäll = PO4-PZu – PO4-PBM – PO4-PBio-P – PO4-PAb
example: 10 mg/L = 40 mg/L – 8 mg/L – 20 mg/L – 2 mg/L
- excess phosphate must be removed from the wastewater by precipitation
- Precipitation: Transfer of dissolved ions (phosphate) within wastewater into unresolved particulate form Precipitation agent - Poly-Aluminium-Chloride (PAC) - Iron (III) Chloride
Fe3+ + PO43- → FePO4
- Separation by sedimentation, flotation or filtration
Ulaanbaatar, October 2015
Biomar OSB
Ulaanbaatar, October 2015
Aerobic Waste Water Treatment
BIOMAR ® OSB
Malthouse, Terbuni, Belgorod
Malthouse: Terbuni, Belgorod
• Plant Parameter:
• Project capacity: 1900 m3/d.
• Quality influent:
• COD 1900 mg/l
• BOD5 1520 mg/l
• Automation level: complete
• Area dimensions: approx. 1000 m2
• Start up: 2005
• Quality of treated waste water: Discharge into fishery waters of 1 st category
Ulaanbaatar, October 2015
Other projects in Russia
Concentrate production
Steirerobst, Moscow
Dairy Onken
Belgorod
Dairy Danone,
Moscow
Cheese Factory
Hochland, Moscow
Ulaanbaatar, October 2015
Anaerobic-aerobic Process
BIOMAR ®ASB-OSB
SAB-Miller, Kaluga
Ulaanbaatar, October 2015
Application example SAB Miller Kaluga
Ulaanbaatar, October 2015
Application example SAB Miller Kaluga
Ulaanbaatar, October 2015
Biological Anaerobic Whey treatment plant
Biomar® AWR Norrmejerier, SE-Umeå
Application example Norrmejerier Schweden
Ulaanbaatar, October 2015
Operation Biomar AWR at Norrmejerier
Parameter value unit
Input whey 200 - 300 [m3 d-1]
CODin 50.000 – 75.000 [mg L-1]
CODLoad 12.500 – 17.500 [kg d-1 ]
CODout 2.500 – 3.000 [mg L-1]
CODreduction 85 – 95 [%]
Biogasproduction 10.500 [m3 d-1]
Energie 80.000 [kWh d-1]
Ulaanbaatar, October 2015
Biomar AWR (Anaerobic Whey Reactor)
Particularly suitable for the treatment of whey / whey permeate Anaerobic process with loop reactor Gentle sludge flow control efficient biomass retention for high gas yield (filed for patent) finely structured biomass of particularly high activity
Norrmejerier, Umeå, Schweden
Ulaanbaatar, October 2015
Biomar AWR (Anaerobic Whey Reactor)
Ulaanbaatar, October 2015
Some of our Biomar clients