maverik inc.'s dairy etp's

Eco Sensitive Maverik Approach for the Dairy Industries

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About Us

• Maverik Inc. is multifaceted company involved in the businessof water treatment, waste water treatment and effluenttreatment projects. Its activities include Engineering,Designing, manufacturing, marketing and servicing. Weexecute the projects on turnkey basis.

About Dairy Effluent Generation

• The dairy industry is one of the most polluting of industries,not only in terms of the volume of effluent generated, butalso in terms of its characteristics as well.

• A chain of operations involving receiving and storing of rawmaterials, processing of raw materials into finished products,packaging and storing of finished products, and a group ofother ancillary operations (e.g., heat transfer and cleaning)will produce wastewater.

• In the dairy industry, some amount of wastewater getsproduced during starting, equilibrating, stopping, and rinsingof the processing units. However, a majority of wastewatergets produced during cleaning operations, especially betweenproduct changes when different types of products areproduced in a specific production unit and clean-upoperations. Dairy processing effluents are generated in anintermittent way and the flow rates of these effluents changesignificantly. The quality and quantity of the product contentin the dairy wastewater at a given time changes with theapplication of another technological cycle in the processingline.

About Dairy Effluent Generation

Sources of Waste Water

DAIRY PROCESS SOURCES OF WASTEPreparation Stages

1) Milk receiving/ storage

2) Pasteurization/Ultra heat treatment

• Poor drainage of tankers

• Spills and leaks from pipes

• Foaming

• Spills from storage tanks

• Cleaning operations

• Liquid losses

• Foaming

• Recovery of downgradedproduct


• Deposits on surface ofheating equipment.

3) Homogenisation

4) Separation/Clarification

Product Processing Stage

5) Market milk

• Liquid losses/leaks


• Foaming

• Pipe leaks

• Product washing

• Sludge removal from clarifier

• Damaged milk packages

• Overfilling

• Poor drainage

• Cleaning of filling machinery

• Leaks



6) Cheese Making

7) Butter Making

8) Milk powder manufacture

• Overfilling vats

• Incomplete separation of whey from curd

• Using salt in cheese making

• Product washing

• Vacreation( reduced pressure pasteurization using stream) and salt use.

Spills of powder handling

• Start up and shut down losses

• Plant malfunction

• Stack losses

• Cleaning of evaporators and driers

• Bagging losses


Sources Of Effluent Generation from Various Units of Milk Operation

CLARIFICATION/STANDARDIZATION

STORAGE TANK

RECEIVING

PASTEURIZATION

HOMOGENISATION

DEODORISATION

STORAGE TANK

PACKING

STORAGE

TRANSPORTATION

DS WW

DS WW

DS WW

DS WW,CW,ST

DS WW

ST, DS WW

DS WW

DS WW

DS WW

EF

EF

EF

EF

EF

EF

EF

EF

EF

EF

DS-Detergents and Sanitizing Agents, WW-Wash Water, ST-Steam, CW-Cooling Water.

Characteristics of Waste Water

• Dairy wastewater contains milk solids, detergents, sanitizers, milk wastes, and cleaning water.

• It is characterized by high concentrations of nutrients, and organic and inorganic contents.

• Salting activities during cheese production may result in high salinity levels.

• Wastewater may also contain acids, alkali with a number of active ingredients, and disinfectants, as well as a significant microbiological load, pathogenic viruses, and bacteria.

• Other wastewater streams include cooling water from utilities, storm water, and sanitary sewage.

Parameters UNITS GUIDELINE VALUE

pH - 4-12

Suspended solids mg/l 24-5700

BOD5 mg/l 450-4,790

COD mg/l 80 - 95000

Total nitrogen mg/l 15-180

Total phosphorus mg/l 11-160

Oil and grease mg/l 10

Total coliform bacteria Mpn/100ml 400

Magnesium mg/l 25-49

Potassium mg/l 11-160

Chloride mg/l 48-469

Calcium mg/l 57-112

BIS Guidelines of Parameters

Requirements for Anaerobic Digestion

Unlike aerobic wastewater treatment systems, the loading rate of anaerobicreactors is not limited by the supply of a reagent, but by the processingcapacity of the microorganisms. Therefore, it is important that a sufficientlylarge bacterial mass is retained in the reactor. For low rate systems the latteris achieved by applying a sufficiently long retention time. For high ratesystems the retention of biomass is increased in comparison with theretention of the liquid. The following conditions are essential for high rateanaerobic reactors

• A high concentration of anaerobic bacterial sludge must be retained underhigh organic (>10 kg/m3 /day) and high hydraulic (>10 m3 /m3 /day)loading conditions.

• Maximum contact must occur between the incoming feedstock and thebacterial mass.

• Also minimal transport problems should be experienced with respect tosubstrate compounds, intermediate and end products

Prevailing Anaerobic Technologies in India

• Conventional Anaerobic Digester

• Anaerobic Contact Digester

• Anaerobic Fixed Film Reactor

• Up-Flow Anaerobic Sludge Blanket(UASB) Process

• Two Phase / Hybrid Reactor

• Combined - Anaerobic & Aerobic Process

Modified Technology of UASB Provided

by Maverik

Treatment Methodology

• The manufacturing activities in a dairy are of the “batch” type, i.e. onebatch of milk is processed, the equipments is drained, thoroughlycleaned and the next batch is taken for processing. As a result, the flowof waste water form a dairy comes in slugs. This fact should be takeninto account in designing a waste water treatment plant to handledairy waste water.

• The amount of water used in a dairy (and hence the volume of wastewater produced) depends on its availability. However, an average valueof waste water generated ranges between 4 to 8 liters of milkprocessed. The bulk of water consumption goes toward cleaning of theequipment and floor washing. The average characteristics of dairywaste are: 5 day 200 C, BOD 1200 mg/l, COD 1800 mg/l, suspendedsolids 600-800 mg/l, oil and greases 200-900 mg/l. The ratio ofCOD:BOD is favorable for applying biological methods of treatmentpreceded by some form of pretreatment such as flow equalization andoil and grease removal

• Biological methods of treatment include: (i) non-mechanizedmethods such as a anaerobic treatment, aerobic ponds andcombination of these two and (ii) mechanical methods such astrickling filters, aerated lagoons and activated sludge processbased on extended aeration. In large dairies, it is possible to usethe anaerobic process such as anaerobic filter or Upflowanaerobic sludge blanket (UASB) process.

• The organic impurities in dairy waste are easily biodegradableand hence, can be conveniently subjected to biologicaltreatment. In view of high BOD value of the raw waste, it ispossible to digest the whole waste anaerobically after reducingits oil and grease contents. Anaerobic treatment reduces theoxygen demand of the waste water by 70%-80% and results in asizable reduction of power consumption for subsequent aerobictreatment. In addition, the gas produces by a anaerobicdigestion can be used as a source of energy.

Treatment Methodology

Comparison of Performance

0%10%20%30%40%50%60%70%80%90%

100%

Organic inWaste Water

AnaerobicTreatment

AerobicTreatment

Input

> Effluent

> Sludge

> Methane

> CO2

We Offer End 2 End Solutions

• Maverik is your ideal partner for delivering impact. We provide a one stop solutionby partnering with you across the entire spectrum of services required to executewaste management projects. We provide…

ConsultancyDesign the most efficient plant for

your requirement at your site

Engineering, Procurement &

Construction (EPC) Construct plant on

a turn key basis

Operations and Maintenance (O&M)

Operate the plant and provide designed

output

Customized Solution Provide your desired

output - fuel, fertilizer, & electricity - through

customized design

End Produce Sales Support

Monetize all produce from the

plant through marketing services

Modified UASB Technology - Our Forte’

• The digester is specially designed to process different types of substrates; be it liquid, semi solid or solid, it works on the basic principles of UASB technology

• The digester is compatible with numerous raw materials viz. animal dung, poultry manure, food, vegetable & fruit waste, slaughterhouse waste, starch, dairy & distillery waste water, sugar mill press mud, sisal unit effluent, De Oiled Cake, molasses, human waste, Sewage Waste Water, etc. To name a few

• The main difference between a regular UASB reactor and the MUASB digester is the acceptance of biodegradable solid contents along with liquids in the range of 0.1% to as high as 10%. The digester can be constructed in a variety of ways with a floating dome or with fixed dome with separate balloon storage. It is capable of taking multiple feed stocks with high SRT. Because of high SRT, the most of the influent solids are digested within the reactor and converted into biogas. And the yield of Biogas is higher than any other technologies

Benefits of Our Technology

Benefits of Anaerobic Treatment

• Low production of stabilized sludge

• Very low nutrient requirements

• Little if any energy requirement

• Production of biogas

• Reduction of green house gas emissions

• Very high loading rates (up to 35 kg COD.m-3.day -1)

• Relatively simple in operation and maintenance

Modified UASB Digester

Why Anaerobic Technology?

• High efficiency for the removal of organic matter as well as for the

nutrients.

• High treatment efficiency for biodegradable sludge

• Reduction of greenhouse gas emissions through methane recovery

• Minimal energy requirements

• Relatively short detention time (due to the relatively small volume

of the tanks)

• Biogas production (it is additional benefit)

Anaerobic digestion provides a variety of benefits. The environmental benefits include:

• Odors are significantly reduced or eliminated.

• Flies are substantially reduced.

• A relatively clean liquid for flushing and irrigation can be produced.

• Pathogens are substantially reduced in the liquid and solid

products.

• Greenhouse gas emissions are reduced.

• And finally, nonpoint source pollution is substantially reduced.

Benefits of Anaerobic Technology

On the economic side, additional benefits are provided.

• The time devoted to moving, handling, and processing manure is minimized.

• Biogas is produced for heat or electrical power.

• Waste heat can be used to meet the heating and cooling requirements of the dairy.

• Concentrating nutrients to a relatively small volume for export from the site can reduce the land required for liquid waste application.

• The rich fertilizer can be produced for sale to the public, nurseries, or other crop producers.

• Income can be obtained from the processing of imported wastes (tipping fees), the sale of organic nutrients, greenhouse gas credits, and the sale of power.

• Power tax credits may be available for each kWh of power produced.

• Greenhouse tax credits may become available for each ton of carbon recycled.

• Finally the power generated is “distributed power” which minimizes the need to modify the power grid. The impact of new power on the power grid is minimized.

Benefits of Anaerobic Technology

Bio Gas from Anaerobic Treatment Process of Waste Water

Never Ending Source of

Power, Fuel & Fertilizer

Real Time Applications of Biogas

CBG

POWER

THERMAL

BIO GAS STORAGE BALLOON

Vihar Pancholi,

(CEO)

Maverik Inc.

2, Giribaug Society,

Behind Centre Point,

R.C. Dutt Road,

Alkapuri, Vadodara – 390 007

Gujarat. INDIA.

Phone:+91-265-234 3010

Cell # +91 989 806 2970

email: [email protected]

Contact:

maverik inc.'s dairy etp's

Environment