Flavour Industry Wastewater Management Case Study

Summary This study is carried out to propose an appropriate treatment technology for wastewater discharged from a flavor production factory. Industrial wastewater discharged from this factory ranges between 50–70 m³/d with an average value of 60 m³/d. The major source of pollution in this factory is due to cleaning of the vessels therefore the treatment has been carried out on the end-of pipe wastewater. The wastewater is characterized by high values of COD, BOD, TSS and Oil and grease 4646, 2298, 1790 and 626 mg/l respectively. Primary sedimentation of the wastewater for four hours reduced the COD, BOD, TSS and Oil and grease by 43, 47, 80 and 74%, respectively. For the treatment of the produced wastewater, the biological treatment process such as activated sludge, rotating biological contactor (RBC), up-flow anaerobic sludge bed reactor (UASB) have been selected. The results from each treatment process proved to be efficient for the treatment of such wastewater. The treated wastewater characteristics are in compliance with the Egyptian law which regulates the discharge of industrial wastewater to the sewerage system. The RBC was selected and installed by the factory as it has the advantage of low operating and maintenance costs. The factory RBC performance was monitored; characteristics of the treated effluent in terms of oil and grease, COD, BOD and TSS were 27, 362, 139 and 95 mg/l, respectively.     

Three Egyptian industrial wastewater management programmes

A pre-treatment programme for wastewater from factories, representing three main industrial sectors in Egypt, has been developed. The first case study was a factory producing potato-chips. Wastewater discharged from this factory was characterized by high values of BOD, SS and oil and grease (6000 mgO₂ l^–1, 6577 mg l^–1 and 119 mg l^–1 respectively). Chemical treatment using lime and lime aided by polyelectrolyte achieved good results. Residual values of BOD and SS after treatment were 97 mg l^–1 and 49 mg l^–1, respectively. Oil and grease concentrations were reduced by 91 percent. Treatment via activated sludge at a detention time of 4 hrs produced good quality effluent. The second case study was an automobile company, representing the metal finishing industry. Analyses of wastewater samples from the degreasing, phosphating and painting departments, as well as the end-of-pipe effluent were conducted. The end-of-pipe effluent contained high concentrations of oil and grease (366 mg l^–1), phosphorous (111 mg l^–1) and zinc (81 mg l^–1). Chemical treatment of end-of-pipe wastewater using ferric chloride aided by lime, produced high quality effluent. The third sector was the chemical industry. For this purpose a paint factory was selected. Characteristics of raw wastewater varied widely according to the production rate. Average values of COD and BOD were 1950 mg l^–1 and 683 mg l^–1. Oil and grease ranged from 63 to 1624 mg l^–1. Chemical treatment using ferric chloride in combination with lime at the optimum operating conditions achieved good results. Residual values after treatment of COD, BOD and oil and grease reached 120, 36 and 8.6 mg l^–1, respectively. An engineering design for each case study has been prepared.     

A comparative study on cost analysis,efficiency, and process mechanism of effluent treatment plants in Bangladesh

Investigations were conducted into the treatment of effluents produced during manufacturing processes at both a chemicals production facility and a paint manufacturing facility. A comparison of costs of wastewater treatment at both facilities was also performed. The untreated effluents from both facilities were high in biological oxygen demand (BOD), chemical oxygen demand (COD), and total dissolved solids (TDS). In addition, the effluents from the two facilities deviated significantly in dissolved oxygen (DO) content and pH levels. However, both facilities ultimately released treated wastewater with allowable amounts or levels of BOD, COD, TDS, DO, and pH as permitted by the Department of the Environment, Ministry of Environment and Forests, Bangladesh (DOE). The effluent treatment plants (ETP) at both facilities contained combinations of chemical and biological treatment processes. The treatment processes used at the chemicals production facility and at the paint manufacturing facility were continuous and semi‐batch processes, respectively. The biological treatment section of the ETP at the chemicals production facility has both anaerobic and aerobic units, while the paint manufacturing facility has only an aerobic unit. Annual installation and operation costs of the ETP at the chemicals production facility was Bangladeshi Taka (Tk) 1,300,000 ($16,667 US dollars) and Tk 800,000 ($10,257), respectively. The annual installation and operation costs of the ETP at the paint manufacturing facility were Tk 3,050,000 ($39,103) and Tk 6,200,000 ($79,488), respectively.     

Preliminary evaluation of the electrochemical and chemical coagulation processes in the post-treatment of effluent from an upflow anaerobic sludge blanket (UASB) reactor

The main objective of this paper was to perform a preliminary comparative study between chemical and electrochemical coagulation processes, both followed by flocculation and sedimentation of an effluent from an upflow anaerobic sludge blanket (UASB) reactor treating simulated wastewater from an unbleached Kraft pulp mill. The electrochemical treatment removed up to 67% (with aluminum electrodes) and 82% (with stainless-steel electrodes) of the remaining chemical oxygen demand (COD) and 84% (stainless steel) and 98% (aluminum) of the color in the wastewater. These efficiencies were achieved with an energy consumption ranging from 14 to 20 Wh l(-1). The coagulation-flocculation treatment with ferric chloride and aluminum sulfate removed up to 87% and 90% of COD and 94% and 98% of color, respectively. The addition of a high molecular weight cationic polymer enhanced both COD and color removal efficiencies. The two post-treatment processes proved to be technically feasible; however the economical feasibility could not be assessed since the experiments were performed with small reactors that could distort scale factors.     

Methanogenic toxicity and continuous anaerobic treatment of wood processing effluents

Wood processing effluents contain different types of phenolic compounds, from simple monomers to high molecular weight (MW) polyphenolic polymers, that can inhibit wastewater treatment. This work presents a comparative study of the methanogenic toxicity produced by three wood processing effluents (hardboard, fiberboard and BKME (kraft mill effluent)) using Pinus radiata, Eucalyptus and Tepa as feedstock (the last one being a native Chilean tree species). This study evaluates the influence of non-adapted granular and adapted flocculent sludge on forest industrial wastewater treatment as well as continuous anaerobic biodegradation of hardboard processing effluent using the upflow anaerobic sludge blanket (UASB). The adapted biomass (flocculent sludge) did not show any lag-phase signs. The 50% IC (the concentration causing 50% inhibition of methanogenic activity) was 4.3 g COD-effluent (chemical oxygen demand (COD)-of the effluent)/l and 2.8 g COD-effluent/l for the flocculent sludge and the granular sludge, respectively. The UASB system worked at low organic load rates (0.1-0.4 g COD/l d) with the COD removal ranging between 10 and 30%, and color removal did not occur under anaerobic conditions due to high MW. Indeed, the MW analysis indicates the presence of phenolic compounds over 25,000 Da in the anaerobic effluent.     

Photocatalytic degradation of organic wastes by electrochemically assisted TiO2 photocatalytic system

Photocatalytic degradation of organic wastes with nanosized titanium dioxide particles has been studied for a long time in order to offer an appropriate method for wastewater treatment, but its practical application is greatly limited by the slow process. In this work, an electrochemically assisted TiO2 photocatalytic system was set-up by combining a TiO2 photocatalytic cell with a three-electrode potentiostatic unit. The composite system revealed high photocatalytic activity towards organic wastes mineralization. After continuous treatment for 0.5 h, the maximum absorption of rhodamine 6G (R-6G) was reduced by more than 90%; chemical oxygen demand (COD) and biochemical oxygen demand (BOD5) of textile dye wastewater (TDW) were decreased by 93.9 and 88.7%, respectively. The biodegradability of TDW was also improved because the COD/BOD5 ratio decreased from 2.1 to 1.2. All these results indicated that the composite system could be used for effective organic wastes mineralization or as a feasible detoxification and color removal pretreatment stage for biological post treatment.     

Wastewater management in small- and medium-size enterprises: case studies

Wastewater management in small and medium-sized enterprises representing the chemical and food industries was investigated. The results showed that wastewater discharged from an ink-production factory was highly contaminated with organic pollutants. Anaerobic biological treatment followed by chemical coagulation using ferric chloride aided with lime proved to be very effective and produced an effluent that complied with national regulatory standard for wastewater discharge into public sewage network. Also, management of wastewater from a confectionery factory representing the food sector was carried out. Aerobic biological treatment using plastic-packed trickling filter proved to be an effective treatment method. However, application of in-plant control measures alleviated the requirement for the construction of a wastewater treatment plant. The applied pollution prevention and cleaner production measures involved good housekeeping, recovery of spent chocolate, modification of floor cleaning and installation of suction devices for the removal of sugar and starch powders. All improvement measures were documented by cost/benefit analysis.     

Anaerobic/aerobic treatment of meat processing wastewater

The meat processing industry is believed to produce highly polluted wastewater. Analysis of such wastewater indicated that the waste was highly contaminated with organic compounds as indicated by COD (1544mgO2l–1), BOD (646mgO2l–1), and TSS (1155 mgl–1). Moreover, oil and grease concentrations reached 144mgl–1 treatment of raw wastewater using Upflow Anaerobic Sludge Blanket (UASB) followed by Rotating Biological Contactors (RBC) was studied. Efficiency of the UASB for the removal of CODtotal, BODtotal, TSS, and oil and grease was 56%, 56%, 85%, and 58%, respectively. The quality of the UASB effluent barely complies with the regulatory standards for discharging wastewater into the sewerage network. UASB effluent was subjected for further treatment using a RBC unit to improve the quality of the treated effluent for reuse in irrigation purposes. Residual COD, BOD, TSS, and oil and grease, following RBC, was 132mgO2l–1, 40mgO2l–1, 44mgl–1, and 10mgl–1 respectively. The overall efficiency of the treatment units provided good quality effluent. The overall percentage removal of COD, BOD, TSS, and oil and grease was 91.5%, 94%, 96%, and 91%, respectively. Based on the quality of the treated effluent and guidelines recommended for wastewater reuse, it may be concluded that a slight to moderate restricted irrigation is applicable to reuse the treated effluent in the green belt around the factory. Disinfection should be applied to ensure the safety of such a process.     

Investigating the quantitative and qualitative status of effluent in the wastewater treatment plant in Iran Central Iron Ore

The aim of present study was to investigate the quality of the produced effluent from different units of the Iran Central Iron Ore in Bafq city and comparison of effluent with the standards. This study presents the physicochemical and biological parameters data of effluent of three Sequencing batch reactors (SBR) with a capacity of 160 m³?d^?1. Most common parameters include pH, total suspended solids (TSS), total nitrogen (TN), total phosphorus (TP), biochemical oxygen demand (BOD₅), chemical oxygen demand (COD), heavy metals, and total coliforms and fecal coliforms as biological indicators. Then, for each SBR system, the average of each parameter was determined, and results were compared with the standard recommended by the Iranian Environmental Protection Agency. Based on the results, some of the parameters, including BOD₅, COD, and TSS in the wastewater treatment plant (WWTP) effluent, are higher than the permitted amount for discharge to the surface water. Considering the BOD₅, COD, and TSS concentration in WWTPs, the treated wastewater is only suitable for agricultural and irrigation use. Therefore, wastewater produced by Iran Central Iron Ore Co. will need additional treatment to achieve standard quality of water before discharge in surface water and adsorbent well.     

Regeneration of industrial district wastewater using a combination of Fenton process and ion exchange—A case study

Regeneration studies of wastewater effluent from an organized industrial district (OID) for possible reuse in textile industry as process water was investigated. Advanced treatment methods including Fenton process, polyaluminium chloride (PAC) coagulation and ion exchange were applied on OID effluent. In Fenton process removal efficiencies for suspended solids (SS), chemical oxygen demand (COD), SAC₄₃₆ (spectral absorption coefficient), SAC₅₂₅ and SAC₆₂₀ were determined 61%, 36%, 35%, 49% and 67%, respectively. After Fenton process, wastewater samples were coagulated with PAC. Optimum removal efficiencies for SS, COD, Fe ion, SAC₄₃₆, SAC₅₂₅ and SAC₆₂₀ were determined 83%, 18%, 93%, 32%, 36% and 58%, respectively. Ion exchange experiments were conducted on chemically coagulated wastewater samples to improve the quality of wastewater. Optimum dosage of resins was determined. The experiments revealed that 1:1 resin ratio (20 mL H-type resin:20 mL OH-type resin) gave the best removal rates for the parameters considered in this study. Study results indicated that quality of the wastewater was suitable for the process water characteristics of textile industry and unit wastewater treatment cost was determined as 2.54 €/m³.     

Performance of an overland flow system for advanced treatment of wastewater plant effluent

Overland flow (OF) systems were evaluated and compared for advanced treatment of municipal and industrial effluents, including nutrients and nondegradable chemical oxygen demand (COD) removal. Three pilot plants were constructed at the Shahin Shahr Wastewater Treatment Plant (WWTP), Isfahan, Iran. Each pilot was assigned a specific wastewater and all were simultaneously operated for 8 months. Treatment of primary effluent, activated sludge secondary effluent, and lagoon effluent of textile wastewater was investigated at application rates (ARs) of 0.15, 0.25, and 0.35m(3)m(-1)h(-1). During 5 months of stable operation after a 3-month acclimation period, mean removals of total 5-day biochemical oxygen demand (TBOD(5)), total COD (TCOD), total suspended solids (TSS), total nitrogen (TN), total phosphorus (TP) and turbidity were 74.5%, 54.8%, 66.2%, 39.4%, 35.8%, and 67.7% for primary effluent; 52.9%, 52.9%, 66.5%, 44.4%, 39.8%, and 50.1% for activated sludge effluent; 65.7%, 58.7%, 70.3%, 41.7%, 41.3%, and 54.9% for textile wastewater lagoon effluent, respectively. The model of Smith and Schroeder, 1985. Field studies of the overland flow process for the treatment of raw and primary treated municipal wastewater. Journal of Water Pollution Control Federation 57, 785-794] was satisfactory for TBOD(5). For all treatment parameters a standard first-order removal model was inadequate to represent the data but a modified first-order model provided a satisfactory fit to the data. Based on the results of this study, it can be concluded that an OF system as advanced treatment had the ability to meet effluent discharge permit limits and was an economical replacement for stabilization ponds and mechanical treatment options.     

Performance assessment of a wastewater treatment plant producing effluent for irrigation in Egypt

A conventional activated sludge treatment facility was the subject of this study. The assessment was directed at determining the characteristics of the raw wastewater, the quality of the treated effluent and the efficiency of the various treatment units. Furthermore, the water quality along the effluent irrigation canal was monitored. The assessment of the quality of the treated effluent for irrigation is based on the guidelines established by the World Health Organization and the Egyptian decree 9/89 for the use of wastewater in agriculture. The results of the study indicated that the concentration of the raw wastewater was considered moderate. The mean values of the COD (Chemical Oxygen Demand), BOD (Biological Oxygen Demand) and total suspended solids (TSS) were around 250, 102 and 142 mg l–1, respectively. This was attributed to the high quantities of wastewater from industrial sources. The overall efficiency of the treatment facility was good. The mean residual COD, BOD and TSS were 25, 8 and 21 mg l–1 and the corresponding percentage removal values were 90, 92 and 85%, respectively. The maximum percentage removal of oil and grease was 84% with a mean residual concentration of 24 mg l–1. The total viable count (22°C and 37°C), faecal coliform and aecal streptococci were reduced by 99.9% compared to only 99.5% for Salmonella. Bacteriological examination of the dried sludge indicated a reduction of nine logs of faecal coliform and faecal streptococci, as compared to thickened sludge. Analysis of the Ni, Cu, Pb and Cr in the dried sludge indicated that their concentrations are within the permissible limits. Zinc exceeded the consent standards by 50%. The results of the analyses of samples collected at the beginning of the irrigation canal indicated insignificant changes from the characteristics of the final effluent. Samples collected at a distance of 2km along the irrigation canal showed mean reductions in the COD and BOD of 28.6 and 47%, respectively, which could be attributed to sedimentation and/or a self-purification effect. An increase in the total nitrogen, total phosphorus and total viable count was also recorded, which could be due to seepage from the agricultural land. From the data available it is evident that the treated wastewater could be used for restricted irrigation. The design and implementation of a monitoring programme is recommended.     

Phytoremediation of dairy effluent by constructed wetland technology

Constructed wetlands are artificial wastewater treatment systems consisting of shallow ponds or channels which have been planted with aquatic plants and which rely upon natural microbial, biological, physical and chemical process to treat wastewater and are gaining acceptance in the recent years as a viable option for the treatment of industrial effluents and removal of toxic components. In this study, an attempt was made to compare the efficiency of aquatic macrophytes like Typha sp., Eichhornia sp., Salvinia sp., Pistia sp., Azolla sp. and Lemna sp. to treat the effluents from dairy factory, under laboratory conditions in constructed wetlands. The biological oxygen demand and chemical oxygen demand of dairy effluent were reduced up to 65.4–83.07% and 70.4–85.3%, respectively, after treatment with constructed wetland technology.     

Performance and modeling studies of rotating biological contactor for treatment of vegetable oil wastewater

This study focuses on a lab-scale rotating biological contactor (RBC) treating vegetable oil wastewater with high BOD and COD. The fabricated RBC was checked for efficiency in degrading polluted wastewater under different operating conditions. The maximum removal efficiencies for BOD and COD were 95.75% and 89%, respectively. This high removal percentage was obtained with 30% submergence of 10 discs rotating at 8 rpm. For the first time, bio-kinetic models were applied to the experimental results for vegetable oil wastewater. The best fit was obtained with the modified Stover-Kincannon and Grau model. The saturation constant (K_s) values were 1.872 and 3.024 g/L/d for BOD and COD, respectively, for the modified Stover-Kincannon and Grau model. For the Grau second-order model, the saturation constant was 1.416 and 3.744 g/L/d for BOD and COD, respectively. The predicted effluent BOD and COD values of the modified Stover–Kincannon model fitted almost exactly with the experimental values. This clearly predicts that this model can be best used to predict effluent BOD and COD concentration in a Rotating Biological contactor treating vegetable oil wastewater. The kinetic parameters determined in this study can be used to improve the design and operation of continuous mode RBC systems.     

Use of artificial neural network black-box modeling for the prediction of wastewater treatment plants performance

A reliable model for any wastewater treatment plant is essential in order to provide a tool for predicting its performance and to form a basis for controlling the operation of the process. This would minimize the operation costs and assess the stability of environmental balance. This process is complex and attains a high degree of nonlinearity due to the presence of bio-organic constituents that are difficult to model using mechanistic approaches. Predicting the plant operational parameters using conventional experimental techniques is also a time consuming step and is an obstacle in the way of efficient control of such processes. In this work, an artificial neural network (ANN) black-box modeling approach was used to acquire the knowledge base of a real wastewater plant and then used as a process model. The study signifies that the ANNs are capable of capturing the plant operation characteristics with a good degree of accuracy. A computer model is developed that incorporates the trained ANN plant model. The developed program is implemented and validated using plant-scale data obtained from a local wastewater treatment plant, namely the Doha West wastewater treatment plant (WWTP). It is used as a valuable performance assessment tool for plant operators and decision makers. The ANN model provided accurate predictions of the effluent stream, in terms of biological oxygen demand (BOD), chemical oxygen demand (COD) and total suspended solids (TSS) when using COD as an input in the crude supply stream. It can be said that the ANN predictions based on three crude supply inputs together, namely BOD, COD and TSS, resulted in better ANN predictions when using only one crude supply input. Graphical user interface representation of the ANN for the Doha West WWTP data is performed and presented.     

Combined chemical and biological oxidation of penicillin formulation effluent

Antibiotic formulation effluent is well known for its important contribution to environmental pollution due to its fluctuating and recalcitrant nature. In the present study, the chemical treatability of penicillin formulation effluent (average filtered COD(o)=830 mg/l; average soluble COD(o)=615 mg/l; pH(o)=6.9) bearing the active substances penicillin Amoxicillin Trihydrate (C(16)H(19)N(3)O(5)S.3H(2)O) and the beta-lactamase inhibitor Potassium Clavulanate (C(8)H(8)KNO(5)) has been investigated. For this purpose, the penicillin formulation effluent was subjected to ozonation (applied ozone dose=2500 mg/(lxh)) at varying pH (2.5-12.0) and O(3)+H(2)O(2) (perozonation) at different initial H(2)O(2) concentrations (=2-40 mM) and pH 10.5. According to the experimental results, the overall Chemical Oxygen Demand (COD) removal efficiency varied between 10 and 56% for ozonation and 30% (no H(2)O(2)) and 83% (20 mM H(2)O(2)) for the O(3)+H(2)O(2) process. The addition of H(2)O(2) improved the COD removal rates considerably even at the lowest studied H(2)O(2) concentration. An optimum H(2)O(2) concentration of 20 mM existed at which the highest COD removal efficiency and abatement kinetics were obtained. The ozone absorption rate ranged between 53% (ozonation) and 68% (perozonation). An ozone input of 800 mg/l in 20 min was sufficient to achieve the highest BOD(5)/COD (biodegradability) ratio (=0.45) and BOD(5) value (109 mg/l) for the pre-treated penicillin formulation effluent. After the establishment of optimum ozonation and perozonation conditions, mixtures of synthetic domestic wastewater+raw, ozonated and perozonated penicillin formulation effluent were subjected to biological activated sludge treatment at a food-to-microorganisms (F/M) ratio of 0.23 mg COD/(mg MLSSxd), using a consortium of acclimated microorganisms. COD removal efficiencies of the activated sludge process were 71, 81 and 72% for pharmaceutical wastewater containing synthetic domestic wastewater mixed with either raw, ozonated or perozonated formulation effluent, respectively. The ultimate COD value obtained after 24-h biotreatment of the synthetic domestic wastewater+pre-ozonated formulation effluent mixture was around 100 mg/l instead of 180 mg/l which was the final COD obtained for the wastewater mixture containing raw formulation effluent, indicating that pre-ozonation at least partially removed the non-biodegradable COD fraction of the formulation effluent.     

含油污水回用处理新工艺研究

研究了一种处理回用含油污水的新工艺,二期炼油污水深度处理中试研究表明,以炼油企业二级处理达标排放污水为处理对象,在使用该工艺处理水量为0.5m3/h、水力停留时间为1.49h 以及污水中COD、氨氮、石油类的浓度变化分别为44.07～102.13 mg/L、28.37～50.01 mg/L、4.10～6.77 mg/L时,平均去除率分别达到94%、96.1%、91.9%,其排出水质符合循环水补充水的水质要求。对该工艺进行了5.5h抗冲击实验,结果表明其抗冲击能力优良。     

Optimization of Fenton's oxidation of chemical laboratory wastewaters using the response surface methodology

Establishing a treatment process for practical and economic disposal of laboratory wastewaters has become an urgent environmental concern of the Department of Chemical Engineering of the Universidade Estadual de Maringá (State University of Maringá), Brazil. Fenton and related reactions are potentially useful oxidation processes for destroying toxic organic compounds in water. In these reactions, hydrogen peroxide is combined with ferrous or ferric iron in the presence or absence of light to generate hydroxyl radicals (.OH). The feasibility of Fenton's reagent to treat waste chemicals from an academic research laboratory was investigated in this study. A response surface methodology was applied to optimize the Fenton oxidation process conditions using chemical oxygen demand (COD) removal as the target parameter to optimize, and the reagent concentrations, as related to the initial concentration of organic matter in the effluent, and pH as the control factors to be optimized. Maximal COD removal (92.3%) was achieved when wastewater samples were treated at pH 4 in the presence of hydrogen peroxide and iron in the ratios [COD]:[H2O2]=1:9 and [H2O2]:[Fe2+]=4.5:1. Under these conditions, it was possible to obtain simultaneously maximal COD removal and minimal chemical sludge after treatment, which is a residue that needs further processing.     

浅论COD与BOD5相关关系模式的建立

从ＣＯＤ与ＢＯＤ５的构成及降解动力学出发是新兴的以ＣＯＤＮＢ／ＣＯＤ为一常数进行研究,得到了ＢＯＤ５与ＣＯＤ的相关模式。应用五粮液废水的实测数据和数理统计方法对模式进行检验,证明其具有实用性,从而可从ＣＯＤ值快速预报ＢＯＤ值,此模式适用于城市污水和有机废水。     

微生物菌剂在酿酒废水处理中的应用研究

采用厌氧－好氧工艺,结合微生物菌剂对酿酒废水进行了处理研究。进水CODCr浓度可达到8,456.3-22,442.0mg/L,BOD55,040.0-9.557.1mg/L,pH3-4,可不调pH,采用微生物菌剂接种可启动厌氧反应器,COD有机负荷最高达到10.2gCOD/Ld,COD去除率稳定在91－95％,BOD去除率90－94％,出水pH6.6-7.1,出水CODCr在2,000mg/L以下,BOD5800mg/L以下。厌氧污泥可全部颗粒化。好氧处理系统中接种微生物菌剂,曝气10－12小时,可保证出水中CODCr在230mg/L以下,甚至直接达到国家一级排放标准。微生物菌剂的应用是取得该处理效果的关键。