industrial pretreatment · 2018-01-30 · •high protein, low sugar. drains ... •lead/lag...
TRANSCRIPT
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Industrial Pretreatment Tyler Glaze
Director of Quality
Short’s Brewing Co
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Short’s Brewing
• Founded in 2004 in Bellaire, MI
• Expanded in 2008 to Elk Rapids, MI
• Why did we choose those 2 locations?
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2002’s Decision
• Bellaire had “good water”.
• Water was not very expensive.
• Building was an old heap, but had tons of potential.
• Joe is from the area.
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2008’s Decision
• Move to Elk Rapids• More space for bottling• More space for brewing• 30x brewing capacity in square feet• 30x the BOD, TSS, Phos, etc.
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But where does that water go
• Beer• Steam
• Sidestream
• Spent Grains
• Drains
• Sewer (only sinks, toilets, breakroom)
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Sidestream
• Brewhouse -> Sugar, protein, spent hops
• Cellar -> Yeast, hops, tank rinses, little beer
• To the farmer, and the digester!
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Spent Grains
• 1000 lbs of grain in, 1150 lbs spent grain out
• Grains in -> Very wet grains out.
• Very happy cows!
• High protein, low sugar
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Drains
• All drains go to our WWTP
• Cleaning chemicals
• Caustic solutoins (High pH)
• Acids (Low pH)
• Sanitizers (Low pH, Bug Killer)
• Rinses (neutral pH)
• Beer (low pH, sugar)
• Solids (Mash, bottle caps, glass, sticks, gloves… you know the drill!)
• NO POOP
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The WWTP Philosophy
1.Control our own future
2.Keep it simple
3.Make it effective
4.Ignores the humps
5.Be a good neighbor
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Type of Treatment: Options!
• Aerobic MBR Treatment• Ultrafiltration
• Very thorough
• 8,000-10,000 mg/L BOD in
• ~<1 mg/L BOD out
• Anaerobic Treatment• Knockdown
• 8,000-10,000 mg/L BOD in
• 500-1000 mg/L BOD out
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Construction Photos
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IT ALL COMES TO A HALT
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OUR DESIGN BUILD FIRM CALLS
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THEY HAVE NO MONEY TO CONTINUE
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THEY ARE WALKING FROM THE JOB
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What happened?
• Design Build firm is shutting down
• Project is not complete
• Electrical is near complete
• Plumbing has barely started
• Software isn’t even on the radar
• Contractors haven't been paid by the DB firm
• We completed the project ourselves with a scrap of a budget remaining and help from our subcontractors.
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What happened when I started it up?
• Winter of 2014/2015 hits us.• DB firm was to provide training and on-site startup• No bugs• Software was garbage at this point• Nothing worked right• Foam• Some more foam• Remote access foam is really nice
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We finished it!Never enough thanks to those that helped us out back then.
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How we screwed it up
• Contracts and agreements• Background checks!
• Lien Waivers!
• We trusted someone• Never do that!
• Water Softener Discharge• AVOID IT ALL COSTS
• Heat Trace and Insulation• No full pipes without it!
• No Testing Capability
• Summer oil is not the same as winter oil• Blew up a blower
• Make sure the Blower’s safety systems are actually working• Blew up another blower
head• Something needs to
change ASAP
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Brewers do a lot for good reason
NO WATER = NO BEER
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Bad Days
• Foam Overs • Get a good antifoam
• Freezing in Winter Time
• Full EQ’s in conjunction with thirsty Michiganders
• Blower Explosion• Align your shafts!
• Get good bugs!• Hair from sludge, Thanks Kalkaska!
• Dead bugs – Truck was contaminated with Oil Field Junk
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Brewers use a lot of water
• Water use varies in our industry• 3 water : 1 beer
• up to 10:1
• Waste is easy to achieve
• Cleaning
• Rinsing bottles
• Vacuum pumps
• The brewer’s mop
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Pretreatment OperationsLiz Hart and Ryan Vedrode
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The best solution for Short’s because…
• 3 year agreement, beginning in March 2015
• Have a sweet membrane bioreactor - CH2M has 16 total staff with Membrane experience in Traverse City region
• 24/7 Operation
• Positive partnership with great synergy
• Wastewater operational expertise
• Affordable solution to reduce the burden on Short’s resources
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Good for CH2M because…
• Shared values• Environmental Stewardship
• Community Involvement
• Innovation
• Appreciation of great beer
• Broaden CH2M’s scope in a growing industry • Pretreatment of brewery waste presents unique challenges and
opportunities
• Gain experience with different equipment and treatment technology
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Operational Philosophy
• Remote Access Operation (Approximately 75%)• Make WWTP operational changes from nearly anywhere
• Monitor treatment plant status at any time
• Quick investigation and response to plant alarms
• Greatly reduces the financial impact of call-ins
• One downside is that security concerns can be mitigated, but not completely eliminated
• Onsite Operation (Approximately 25%)• Typically M,W,F
• Cleaning, Sampling, Equipment and Operational Adjustments, PMs, Discussion with Short’s team about Brewing schedule and activities
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IPP with Village of Elk Rapids
• CH2M handles the relationship with the Village of Elk Rapids• Spill Prevention / Action Plan• Monthly Data Sharing
• Sharing data and information with your Municipal WWTP is a good thing
• Pretreatment plant issues? Contact the Village• They happen!
• Making a beer with lactose? Hit the deck!
• IPP changes, run them by CH2M to make sure Tyler isn’t wrong!
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Facility Improvements, Process Optimization and Risk Mitigation
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Programming Optimization• Alarms that make sense• Flow control demystification – First iteration of controls
were not controlling anything• Blower speed based on DO concentration, NOT on/off
control• Lead/Lag controls on blowers, RAS Pumps, Membrane
permeate pumps• Back-up membrane flow controls!
• Paddlewheels AND a mag meter• “Low Flow” setpoints to prevent membranes from
running dry
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General Facility Improvements
• Equipment Modifications• Fixed level sensors in the EQ
and Aeration Tanks
• Ceiling insulation missed by contractors
• Standby Power
• Membrane bleed off valve for priming after cleanings or maintenance
• Equipment Redundancy• Aeration Blower
• Scouring Blower
• Membranes
• Network Switch
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Risk Mitigation
• Safety Improvements
• Replaced the chain fall hoist with an automatic crane
• Repaired the hook on the chain fall
• Repaired membrane cassette mounts
• Covered floor holes in original membrane covers
• Exhaust fans
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Process Optimization
Process Control
• Continual Wasting
• Target MCRT
• Equalization Tank
management plan
• Enhanced control of the
solids inventory to maintain
desired microbial population
DAF Operation
• Identified optimal air
pressure, effluent weir height,
replaced the DAF skimmer
rubber with a thicker, more
durable material to prevent
tears and increase solids
removal efficiency.
• Started adding polymer to the
DAF to increase %TSS
Removals
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Process Optimization
Membrane Optimization
• Created a cleaning schedule - In-line maintenance
cleanings quarterly, Recovery cleans annually
• Created a semi-annual membrane inspection procedure
• Monitor TMP daily to verify no issues are developing
(include graph)
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TMP (Transmembrane Pressure) Graph
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DAF in Operation
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Communication!!!
Get talkative with your teams.
Train your brewers to not spill shit.But if they do, call Ryan (Not Tyler or Liz) in the middle of the night
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Stuff that still needs to happen
• Remote Power Monitoring
• Backup Internet Connection• EWON?
• Another backup membrane• We beat up membrane 1 before
• Solids Concentration• Real loosey goosey right now