Wastewater Management at an Animal Protein Rendering Facility J.B. Hess, W.A. Dozier, J. Spann and...
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![Page 1: Wastewater Management at an Animal Protein Rendering Facility J.B. Hess, W.A. Dozier, J. Spann and B. Thomas Poultry Science Department, Auburn University.](https://reader036.fdocuments.in/reader036/viewer/2022062404/551995a55503464d068b47b3/html5/thumbnails/1.jpg)
Wastewater Management at an Animal Protein Rendering Facility
J.B. Hess, W.A. Dozier, J. Spann and B. ThomasPoultry Science Department, Auburn
University and American Proteins, Hanceville, AL
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Rendering Industry
• Recycling• Inedible Human Food – Useful Products• Removed from Poultry Meat Production
Waste Stream• Protein Meals for Pet Food and Agriculture• Oil (Fat) Recovery for Biodiesel and Animal
Feed Usage
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Rendering Industry
• Input Intensive• Transportation of Raw Product• Cooking
– Energy Usage– Water Usage and Recovery
• Waste Management– Air– Water
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American Proteins
• Hanceville Alabama• Rendering
– Regional Poultry Plants – Offal– Frozen Farm Mortalities
• Poultry Products– Pet Food Animal Proteins– Feed Grade Animal Proteins– Oils
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American Proteins
Largest Poultry Rendering Plant in the US• Offal from 20 Poultry Processing Plants• 2 Billions Pounds per Year• 1000 Truck Loads of Offal per Day• Odor Control and Waste Management
Compliance are First Order Issues
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American Proteins Odor Control
• Scrubbers• Anaerobic Lagoon Cover• Biofilter Bed
– Cooker Gas Exhaust– After Scrubbers
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American Proteins Wastewater Facility
• Pretreatment• Anaerobic Lagoon• Two Aerobic Lagoons• Four-Stage Activated Sludge System• Tertiary Filtration• Ultraviolet Disinfection
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American Proteins Wastewater Treatment System
Pretreatment235,000 gpd
Condensate600,000 gpd
Anaerobic Lagoon
AeratedLagoon
AeratedLagoon
Anoxic Reactor #1Activated Sludge
Oxic Reactor #2Activated Sludge
Clarifier DiskFilter
UV Disinfection
Waste Sludge Lagoon
Mulberry Fork Warrior River
CoolingLagoon
ReuseLagoon
Feed Grade & Pet Food
6,000,000 gpd30,000,000 gpd
Make up WaterUp to 800,000 gpd
Averages450,000 gpd
Reclamation of Fats & Solids
Bio Gas
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Pretreatment Process - Mechanical
• Surge Wet Well• Fine-Mesh Drum Screen• First DAF Treatment• Second DAF Treatment
– Polyamine– Cationic– Anionic
• Pumped into the Anaerobic Lagoon
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DAF Units
• After Hycor Fine Mesh Drum• DAF #1
– Floating Solids– Mainly Fats – Back to Rendering
• Flow Equilizational Basin• DAF #2
– Flocculation Tube - Polymers• To Anaerobic Lagoon
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Anaerobic Lagoon
• Solids and flocculated Fats Returned to Protein and Fat Recovery
• Lagoon - Covered• Biogas Harvest
– Used to Heat Boilers
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Biogas
• Harvested from Anaerobic Lagoon• 2 Million Cubic Feet per Week• 70% Methane (carbon Dioxide, Hydrogen
Sulfide)• Biogas mixed with natural gas at a 10% rate to
fuel boilers• Could use more
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Aerobic Lagoons
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Activated Sludge Process
• Four Reactors• Two Anoxic – Denitrification• Two Aerobic – BOD Reduction, Nitritfication• Clarifier
– Removes Final Solids• Tertiary Filtration Disk
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Bioreactors 3 (anoxic) and 4 (oxic)
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Clarifier/Tertiary Filtration/ Ultraviolet Disinfection
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Water Use/Recovery/Reuse
• Potable Water Intake – 90,000 Gal/Day• 50,000 Gal. is for Boiler Makeup• Inflow of 900,000 Gal/Day
– 2/3 Condensate from Cooking Process– 300,000 Gal/Day Rendering Process
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Water Use/Recovery/Reuse
• Production Reuse Rate of 6 Million Gal/Day• Cooling Water System Recycles 30 Million
Gallons/Day – Condensing Vapors from Cooking
• Discharge Rate of 400,000 Gal/Day• Discharge – Mulberry Fork of Warrior River
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Water Reuse
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Supervisory Control and Data Acquisition
• Monitoring System• Inline• Ammonia• Nitrates• MLSS• pH• ORP
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Nutrient Reductions Through System
• Biological Oxygen Demand – 99.96%• Chemical Oxygen Demand – 99.65%• Total Suspended Solids – 99.81%• Total Kjeldahl Nitrogen – 99.52%• Ammonia – 99.95%
– From 2,500 mg/L to <0.5 mg/L• Oil and Grease – 99.90%
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Some Comparisons
• Organic Loading – City of 900,000 People• Hydraulic Loading – City of 10,000 People• Cullman County – 80,000 People
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Value of Reclamation
• Reclaimed Materials• Proteins and Fats• 400,000 Pounds/Week• $500,000 per Year• Waste Disposal Cost Avoidance
– $350,000 Per Year
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Awards
• 2001 Excellence in Industrial Wastewater Treatment (Physical/Biological Treatment) - Alabama’s Water Environment Association
• 2003 Clean Water Award Honorable Mention, Full Treatment Category – U.S. Poultry and Egg Association
• 2004 Clean Water Award, Full Treatment Category– U.S. Poultry and Egg Association
• 2007 Honorable Mention for Facility of the Year Award– Environment Protection
• 2008 Excellence in Industrial Wastewater Treatment (Biological Advanced Treatment) - Alabama’s Water Environment Association
• 2010 Clean Water Award, Full Treatment Category– U.S. Poultry & Egg Association, March 2010
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Conclusions
• American Proteins Rendering Plant Starts with Large Loads in Waste Water Handling
• Proven Systems in Mechanical and Biological Control Handle that Load
• Waste Solids are Recycled• Odor Control Systems are Important as Well• Consistent Quality has led to Industry Awards
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Wastewater Management at an Animal Protein Rendering Facility
J.B. Hess, W.A. Dozier, J. Spann and B. ThomasPoultry Science Department, Auburn
University and American Proteins, Hanceville, AL