page 1 siemens water technologies water technologies strategies for water reuse in the food &...

Siemens Water Technologies

Water Technologies

Strategies for Water Reusein the Food & Beverage Industry

Process ExpoChicago, ILNovember 4, 2011


Topics for Today’s Presentation

I. Overview

II. In-Plant Cascading Water Reuse

III. Reject Recovery RO’s

IV. Treatment of Plant Effluent Water

V. Summary

VI. Questions


Water is a Global Crisis in the Making By 2025, Demand for Water Will Exceed Supply

Source: Valmont Water Management Group

Some other analysts put this point 10 years

earlier


Water Reuse - Overview

Nearly all major Food & Beverage companies have Sustainability goals related to water and energy usage Water Ratio – Water usage per unit of product Energy Ratio – Energy usage per unit of product

Water conservation and awareness should be the initial focus, and then water reuse.

Water Reuse is a key tool for reducing your plant’s water ratio


Water Reuse - Overview (Continued)

Identifying water reuse opportunities starts with a “Water Balance” of your facility Metering is needed to identify where water is going

and to measure your success

First find your water reuse opportunities that require minimal treatment. These are your “Low Hanging Fruit”: Maximize Condensate Return Empty Container Rinse Water

Any water stream can be reused with enough treatment. The key is to find the right streams and the right solution that will provide an economically justifiable project.



I. Overview




V. Summary

VI. Questions


In-Plant Cascading Water Reuse

The easiest and least expensive method of water reuse is capturing water used in the plant before it gets contaminated with other waste streams: Carbon Tower Backwash Multi-Media Backwash Cooling Water for Compressors Empty Container Rinse Water Steam Condensate Discharge from Container Cooler/Warmer Pump Seal Water CIP System Final Rinse Rainwater


In-Plant Cascading Water Reuse

These water streams are easy to capture and require minimal treatment for reuse

Match the water quality needed with the water streams that

are available. Some possible uses of reuse water include: Irrigation Cooling Towers Crate Washing Warmers/Coolers Toilet Flushing Truck Washing


Typical Water Treatment System PFD –With Carbon Tower and Multimedia Backwash Reclaim

MultimediaFilters

TreatedWater

Storage

To Distribution

Header

Polishers

City Water

Pumps

CarbonTowers

NanofiltrationOr

Reverse Osmosis

UV

Recirculation

B/W Reclaim

Tank To

Drain

TurbidityMonitor

From Distribution

Header

Cartridge Filter

Backwash Reclaim System

Reject toDrain


Case Study No. 1: Carbon Tower Backwash Reclaim

Carbonated Soft Drink Plant

Carbon towers are used to treat ingredient water at a soft drink facility

After initial flush to drain, carbon tower backwash water is captured in a 10,000 gallon storage tank.

Collected water is re-chlorinated and filtered by a bag filter and a cartridge filter to capture any carbon fines.

Reuse water is blended back into the incoming city water tank at no more that 10% of total flow.

Saves 10,000 gallons of water for each backwash.


Rainwater Harvesting – General Guidelines

Use rain water to reduce city water usage in non-critical applications: Irrigation Toilet Flushing Cooling Applications Feed water to in-plant water treatment system

Works best in areas with high annual rainfall

Recommendation: Capture rainwater from the roof rather than parking lots due to oils and other contaminants.

Numerous successful projects in Portland and Seattle areas on commercial buildings. This trend can be applied to industrial facilities as well.


Rainwater Harvesting – Main System Components

CollectionTank

DayTank

Rain Water

CartridgeFilter

PumpSkid

Water Users

DisinfectionSystem

CityWater

Backup

CoarseFilter System

Controls


Rainwater Harvesting – Underground Collection Tank


Rainwater Treatment System – Portland State University – Science and Eng. Bldg.


Case Study No. 2 - Rain Water Harvesting and Reuse

Carbonated Soft Drink Facility in Asia Rain water is collected, treated, and used to supplement city water.

Rain Water Harvesting & Treatment System

Includes: In-Ground Rain Water Collection Tanks with

Submersible Pumps – (2)

Central Collection Tank – 5,000 Gallons

Transfer Pumps (2)

Multimedia Filter & Bag Filter

Treated rain water goes into their incoming city water tank for treatment by the plant ingredient water

system.



I. Overview




V. Summary

VI. Questions


Membrane System Evolution

Timeline for Membrane Filtration:Recovery Rate

1980’s Initial Use of Membranes in Beverage70-75%

1990’s Acceptance of Membrane Filtration75-80%

2000’s Optimization of Membrane Systems80-90%

New Generation of Recovery Technology 90-95%

Future 95+%


Advantage of using a Reject Recovery RO

90% Recovery

0.1 x

0.9xX GPM

RO plus reject recovery RO

0.8x

0.2x 0.1 x

80% Recovery

0.2 x

X GPM

Standard RO

0.8x


Typical Water Treatment System PFD –With Reject Recovery RO

MultimediaFilters

TreatedWater

Storage

To Distribution

Header

Polishers

City Water

PumpsCarbonTowers

NanofiltrationOr

Reverse Osmosis

UV

Recirculation

RecoveryRO50%

BreakTank

From Distribution

Header

Reject Recovery RO

Optional Flow Path


Non-Carbonated Beverage Facility

Case Study Example No. 3 - Reject Recovery RO

Reject water collected from RO and Nanofiltration Units

Recovery RO sized for 90 gpm permeate

Recovery RO cost approximately $100,000

Annual water savings of 20,000,000 gallons

Annual water savings of $120,000 based on $6 per 1000 gallons for incoming water and wastewater treatment

Payback in about one year!

Reject Recovery RO


Reject Recovery RO’s

Reject Recovery RO’s have become very common in F&B Facilities with membrane water treatment Bottled Water Facilities Carbonated Soft Drink Facilities Non-Carbonated Beverage Facilities Food Production Facilities

Suitability can be limited based on water chemistry. Areas with high silica have limited application.

Don’t run at over 50-60% recovery rate due to high scaling potential. Water chemistry is critical.



I. Overview




V. Summary

VI. Questions


Treatment of Plant Effluent Water

The technology exists to treat any Food & Beverage plant wastewater back to potable water quality. If the plant already has a wastewater treatment system, then the economics of water reuse could be much more favorable.

Advancements in membrane technology are making water reuse more viable.

Membrane Bioreactors (MBR) is the leading technology for wastewater reuse.


Defining Requirements for Water Reuse

Objectives of treatment: To remove contaminates (organics, inorganics, suspended, dissolved) to a quality for beneficial reuse.

Typical Processes:

Removing Organics – Biological Degradation (anaerobic/aerobic), increased use of MBR or UF polishing

Remove Suspended Particles – Clarification and Filtration, increased use of MF and UF membranes

Remove Inorganic Dissolved Constituents - Reverse Osmosis, Microfiltration Softening, Demineralization (increasingly, Integrated Membrane Systems (UF+RO+CDI))

Disinfection (pathogen inactivation) – Chlorine, UV, Ozone


What is a Membrane Bioreactor?

The substitution of a membrane separation process for activated sludge secondary clarification and tertiary filtration.

Membrane Bioreactor


MBR

MBR (Membrane Bio Reactor) process uses membranes as an absolute barrier with very small pore size which gives a very clear treated water.


Water Reuse Solutions

Case Study Example No. 4 – Effluent Water Reuse System

Prescreen

PotableReuse Water

65 GPM

Reject to Drain

Chlorination

F&B PlantWastewaterTreatment(SBR)

IncomingPlant Water

ChlorinatedStorage

To Non-IngredientWater Uses

To Sewer

Reverse Osmosis UltraFiltration

Carbonated Beverage Facility



I. Overview




V. Summary

VI. Questions


Water Reuse - Summary

The economics of water reuse can vary widely depending on your circumstances: Cost of water and sewage in your location Availability of water (limitations on production) Volume of water used in your facility Impact of droughts on your region

Public acceptance of water reuse in the Food & Beverage industry is limited. Currently projects are only for non-ingredient applications.

Consider all of your water streams when looking for water minimization and water reuse opportunities (see next slide).


Water Reuse Solutions (Industrial – F&B) - Summary

Water Sources to be Reused Treatment Reclaimed

Water Users

Carbon Tower B/W Multi-media B/W Cooling Water Container Rinse Water Warmers / Coolers Line Lube CIP Water Pump Seal Water Rain Water Treated Wastewater

Multi-Media Microfiltration Ultrafiltration Reverse Osmosis Membrane Bioreactor Biological Treatment Clarification UV Disinfection Ozonation

Cooling Water Toilet Flushing Irrigation Process Water System Cooling Towers Wash Down Truck Washing Warmers / Coolers Boiler Feed Water


Water Reuse - Summary

Interest in water reuse is expected to grow dramatically in the near future.

Water reuse opportunities can be simple or quite complicated depending on the application.

Siemens Industry, Inc. can help you identify your potential water savings and reuse opportunities and apply the appropriate solutions.


Questions?


Thank You

David BridgersF&B National Account ManagerSiemens Industry, Inc.Water Technologies Business Unit

Atlanta, GAPhone: 770-921-1837Mobile: 404-414-8765E-mail: [email protected]

page 1 siemens water technologies water technologies strategies for water reuse in the food &...

Documents

water streams

water storage

ingredient water

water balance

water quality

water reuse opportunities

plant cascading water

possible uses of reuse