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Wastewater Treatment Plant UpgradeProject (WWTP)
Marlon CabreraEngineering Department
Cervecera de Puerto RicoMayaguez, PR
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Introduction
A common challenge for breweries is meeting currentwastewater discharge standards while accommodatinggrowth and anticipating more stringent discharge
regulations in the future. Cervecera de Puerto Ricowastewater treatment system had been in operation for along time, but years of service and increased hydraulic andorganic loadings had made it difficult to meet treatmentobjectives.
For years Cervecera de Puerto Rico wastewater treatmentplant was affecting the image of the company and hadbecome a priority for the future of the company.
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Potential Issues
• Regulatory Compliance of Waste Water Discharge
• Possible surcharges
• Controls were mostly manual, there were no instrumentation automated monitoringparameters of waste water treatment process
• Operation of Return Activated Sludge Systems (RAS) was inconsistent due a to pastretrofits and obsolete equipment
• Operation and maintenance of the treatment systems rotating biological contactors hadbecome a very high total operational costs
• Increased hydraulic and organic loadings
• Bad odor generation at the treatment plant
• Bad ima e of the com an
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Before Process Diagram of WWTP
Pista-Grit
Equalization TankDigester/
Thickener
Clarifier
Pump #1
Pump #2
Blockeddischargeconnectionsto/from reactor
Pressed if
needed
Reactor
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Previous Rotating Biological
Contactors
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Previous Rotating Biological
Contactors
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Previous Clarifier
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Legal Limits and Requirement of
Samples Applied Load
PARAMETERS DOWNLOAD LIMIT
BOD (mg/L) 250
TSS (mg/L) 250
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Before - Graph of BOD
0
200
400
600
800
1000
1200
1400
1600
B O D ( g / m l )
Month/Year
Biochemical Oxygen Demand
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Before - Graph of TSS
0
500
1000
1500
2000
2500
T S S ( g / m l )
Month/Year
Total Suspended Solids
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Challenges
• Regulatory compliance with the permit.
• Reduce the environmental footprint of the plant
• Cost effective technologies
• Limited budget of 1.3M
• Space construction limited
• Withstand large changes in demand while maintaining efficient
• Reduce odors
• Make changes without stopping operation
• Reduce total operating costs
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CERVECERA DE PUERTO RICO PILOT
study MOVING BED BIOREACTOR
(MBBR) TECHNOLOGY
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CERVECERA DE PUERTO RICOWWTP MBBR PROJECT
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Paramecium Vorticella
EpistilysVorticella
CERVECERA DE PUERTO RICO WWTP MBBR PROJECT
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0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
4000.00
3578.00
1193.00
186.00 29.30 250.00
S O L U B L E B O D ( P P M )
SOLUBLE BOD 10/23/2009
INFLUENTE SOLUBLE BOD WWTP REACTOR SOLUBLE BOD MBBR #1
SOLUBLE BOD MBBR #2 PRASA BOD PERMIT LIMIT
CERVECERA DE PUERTO RICOWWTP MBBR PROJECT
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0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
61.08%
93.93%99.04%
SOLUBLE BOD REMOVAL 10/23/2009
BOD REMOVAL % WWTP REACTOR BOD REMOVAL % MBBR #1
BOD REMOVAL % MBBR #2
CERVECERA DE PUERTO RICO WWTPMBBR PROJECT
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Solution: Upgrading the WWTP
The Engineering Department along with EH&S evaluateddifferent treatment alternatives to determine the viability ofupgrading the existing facilities to achieve permitparameters.
• Moving Bed Biofilm Reactor (MBBR)
• Tank Dissolved Air Flotation (DAF), system without airsaturation
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MBBR Design Basis
PARAMETER UNITS INFLUENT EFFLUENT
Flow MGD 0.15 0.15
BOD5 (Soluble) MG/L 1,800
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Project Scope
Tasks Original Scope Currently AchievedReactor Tank Retrofit X X
Blowers Replacement X X
DAF Installation X X
Acid Dosing Station Automation X X
Caustic Soda Station Automation X X
Caustic Soda Receiving Station Automation X
pH/Temp Monitoring EQ Tank X X
pH/Temp/DO Monitoring Reactor Tank X X
Influent Flow Metering X X
Influent Temperature Monitoring X
Central process overview X X
Tank Levels X X
Belt Press automation X
Electrical Utilities X
Air Utilities X
Water Utilities X
Pads/Dikes/Civil Work X
Instrumentation and Integration X X
Aesthetical Improvement X
Waste Water Lift Station Upgrade XNew Laboratory Furniture X X
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Project Budget
• Project Budget $1,394,036
• Discharge Overcharges $98,069
• Negotiated PRASA Limits
• BOD - 5,633 mg/L
• TSS - 2,628 mg/L
• Currently consumed $1,358,641
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Actual Process Diagram of WWTP
Belt Filter
Press &
Container
Moving Bed
Biofilm
Bioreactor
(315,000 gals)
Digester
89,000 gals
Screens
DAF
UtilitiesBrew HouseCold BlockPacking Lines
PRASA
Equalization
Tank
292,000 gals
Lift Station
X X X
X XBlowers
Blowers
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Moving Bed Biofilm Reactor
(MBBR)
• A stand-alone biological treatment system with no needfor media backwashing
• Wastewater treatment plants of this type operate asfixed-film processes without activated sludge recyclebetween the bioreactor and clarification units
• Aeration supplied provides oxygen, essential formicrobial growth, and the energy required to dispersethe carriers completely throughout the system
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Moving Bed Biofilm Reactor(MBBR)
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MBBR System
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Moving Bed Biofilm Reactor
(MBBR)
Process uses 25 mm-diameter cylindrical plastic carriersthat provides environments in which bacteria andprotozoa can grow effectively.
M i B d Bi fil R t
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Moving Bed Biofilm Reactor
(MBBR)
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Dissolved Air Flotation
Operation (DAF)
Separates and optimizes solids prior to dewatering
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Dissolved Air Flotation
Operation (DAF)
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Dissolved Air Flotation
Operation (DAF)
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WWTP Retrofit
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WWTP Retrofit
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WWTP Retrofit
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WWTP Retrofit
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WWTP Retrofit
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Belt Press
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Now - Graph of TSS
2 0
1 6 0 0
1 0 2
0
2 6 0
2 3 0
2 4 0
2 2 0
2 0 0
1 5 0
1 4 0
1 1 0 1 5 0
2 7 0
2 8 0
1 4 3
1 3 5
1 2 1
1 1 0 9 0 3 0 3 0 2 0
1 5 2 0 1 5 1 20
250
500
750
1000
1250
1500
1750
2000
2250
2500
J a n - 0 8
M a r - 0 8
M a y - 0 8
J u l - 0 8
S e p - 0 8
N o v - 0 8
J a n - 0 9
M a r - 0 9
M a y - 0 9
J u l - 0 9
S e p - 0 9
N o v - 0 9
J a n - 1 0
M a r - 1 0
M a y - 1 0
J u l - 1 0
S e p - 1 0
N o v - 1 0
J a n - 1 1
M a r - 1 1
M a y - 1 1
J u l - 1 1
S e p - 1 1
N o v - 1 1
J a n - 1 2
M a r - 1 2
M a y - 1 2
J u l - 1 2
T S S ( g / m l )
Month/Year
Total Suspended Solids Efficiency
Actual TSS
Before TSS
Limit
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Now - Graph of BOD
1 0 . 0
0
7 0
0 . 0
0
1 3 3 . 0
0
1 1 1 . 0
0
1 9 3 . 0
0
1 2 8 . 0
0
1 0 1 . 0
0
1 2 1 . 0
0
1 9 3 . 0
0
1 3 3 . 0
0
4 2 . 0
0
2 4 . 0
0
2 4 . 0
0
4 0 . 0
0
3 0 . 0
0
1 8 . 0
0
2 1 . 0
0
1 4 . 0
0
1 1 . 0
0
6 . 0
0
8 . 0
0
7 . 0
0
1 0 . 0
0
7 . 0
0
8 . 0
0
8 . 0
0
-200
0
200
400
600
800
1000
1200
1400
1600
J a n - 0 8
M a r - 0 8
M a y - 0 8
J u l - 0 8
S e p - 0 8
N o v - 0 8
J a n - 0 9
M a r - 0 9
M a y - 0 9
J u l - 0 9
S e p - 0 9
N o v - 0 9
J a n - 1 0
M a r - 1 0
M a y - 1 0
J u l - 1 0
S e p - 1 0
N o v - 1 0
J a n - 1 1
M a r - 1 1
M a y - 1 1
J u l - 1 1
S e p - 1 1
N o v - 1 1
J a n - 1 2
M a r - 1 2
M a y - 1 2
J u l - 1 2
B O D ( g / m l )
Month/Year
Actual BOD
Before BOD
Limit
Biochemical Oxygen Demand Removal Efficiency
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Summary Savings
• Maintenance Costs 70%
• Chemicals 50%
• Generation of H2O
• Power Cost 35%
• Odor reduction
• Regulatory compliance without overcharges 100%
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