Dipl.-Ing. Marcus Verhülsdonk. Chair of Food Chemistry and Molecular Sensory Science, Technische Universität München

Transcription

1 Possibilities of a holistic concept for the reuse of water and recovery of recyclable material from the wastewater generated by beverage industries an example concept for breweries Dipl.-Ing. Marcus Verhülsdonk Chair of Food Chemistry and Molecular Sensory Science, Technische Universität München verhuelsdonk@wzw.tum.de

2 Intelligent Water Management Fresh water (Process water) Quality? Quantity? Fresh water (Drinking water) Total water consumption Recycling How? Required resources? Economic efficiency? Waste water Waste water

3 Water in breweries Fresh water (Input) Drinking water (TwVO 2001) NO drinking water Water for production Brewingliqour Washrooms Process water Cooling Steam Brewery Wastewater (Output) Category A Category B Category C Category D Category Category Z

4 Water in breweries Process water, that is not in contact with the product (beer), can be replaced by recycled wastewater. Creating a sustainable water cycle

5 Possible savings in a brewery Worldwide beer production in 2008: 1.8 billion hl Total consumption of fresh water: 0.4 m³/hl 30% fresh water replacement possible by high quality process water Possible savings worldwide: 240 Mio m³ fresh water

6 Objectives Complete separation of turbidity Biological removal and recycling of organic substances Recovery of process water Efficient and sustainable integration of the recycling process Modular configuration International alignment

7 Process Flowsheet Pretreatment waste water Anaerobic Reactor Flotation Membran Bioreactor Ultrafiltration Reverseosmosis Disinfection Process water abstraction

8 Pretreatment Process scheme Acid/ Base Flocculation agents Pipe flocculator Intake 1,0-1,5 m³/h Dissolved Air Flotation Denitrification V =4,5m³ Nitrification V = 5,5 m³ Membrane basin V = 11,0 m³ Hopper Sludge Sediment Filtrate Recirculation Recirculation Excess-Sludge

9 Modular concept Membrane filtration Denitrification Nitrification

10 Dissolved Air Flotation Wastewater intake Effluent weir Flotate outlet Tube feeder Effluent box Pressure release valve Centrifugal pump Lamella separator Pressurized water line Sediment removal To sludge thickener Effluent channel Air compressor Huber SE -

11 Dissolved Air Flotation

12 Dissolved Air Flotation Analysis by Stephanie West and Marcus Verhülsdonk, TUM

13 Vacuum Rotating Membrane Bioreactor (VRM) Huber SE - Brochure: HUBER Vacuum Rotation Membrane VRM Bioreactor

14 Vacuum Rotating Membrane Bioreactor (VRM) mbar low pressure 36 modules, 4 membranes/module 108 m² active area l/m²h transmembrane flux 1-2 revolutions per minute Huber SE - Brochure: HUBER Vacuum Rotation Membrane VRM Bioreactor

15 COD Removal Intake HDF Outlet HDF 95 % VRM Filtrate Analysis by Stephanie West and Marcus Verhülsdonk, TUM

16 Process Flowsheet Pretreatment waste water Anaerobic Reactor Flotation Membran Bioreactor Ultrafiltration Reverseosmosis Disinfection Process water abstraction

17 Process water abstraction Filtrate from MBR UF HPP RO 1 Permeate Hopper Filtrate Hopper UF Filtrate Concentrate Recirculation Concentrate Feed-pump HPP RO 2 Permeate Air Backwashpump Concentrate Recirculation Concentrate

18 Membrane separation Separation Process Dissolved matter Range of pressure Microfiltration >0.1 µm Zooplankton Algae Turbidity Bacteria Suspended solids Ultrafiltration µm Polymers Virus Colloids Nanofiltration µm Organic compounds Divalent ions Reverse osmosis <0.001 µm Monovalent ions bar bar 3-20 bar bar

19 Ultrafiltration Membrane material Hollow fiber dimensions Outer/Inner Diameter MWCO Polyetheryulfon (PES) 1,35/0,70 mm 120 kda Membrane area 23 m² Flux Outside-In Hollow fiber membrane Picture Hollow fiber membrane:

20 Reverse Osmosis Two 4 modules with 7 m² active membrane area per module Comparison of different membrane types (NF, RO) 60-70% recovery

21 Water Quality Feed Permeate Concentrate Rejection ph [-] 6,56 5,46 6,84 Temperature [ C] 21,6 23,9 24,3 Conductivity [µs/cm] Sodium [mg/l] % Chloride [mg/l] % Calcium [mg/l] 55 0, % Potassium [mg/l] 30 3, % Magnesium [mg/l] 22 <0,1 52 >99 % Phosphor [mg/l] 17 <0,1 38 >99 % Sulfate [mg/l] 14 <0,1 27 >99 % Feed RO Permeate Concentrate Concentrate

22 Holistic concept Spent grain Fermentation Dewatering Solubles Dry spent grain Combustion Excess sludge 2500 mg/l COD T=35 C Wastewater Anaerobic Reactor E th WT 17 kwh/m³ T=15 C Flotation/ Sedimentation ~400 mg/l COD ~30 mg/l COD Aerobic Reactor UF/RO Process water Wastewater Biogas E el = 1,75 kwh/m³ E th = 3,25 kwh/m³ Light load Concentrate Daten zum Energiegewinn aus Biogas: K.-H. Rosenwinkel, Effizientes Wassermanagement durch integrative Ansätze, BVE Fachtagung 2010

23 The research project Nachhaltige Wasserkreisläufe in der Getränkeindustrie zur Schonung (natürlicher) Wasserressourcen is promoted by the Bavarian Research Foundation. Project partner: Stephanie West, Brigitte Helmreich, Karl Glas Technische Universität München Franz Bischof Hochschule Amberg-Weiden, Amberg Ralph Teckenberg, Thomas Pohlers HUBER SE, Berching Georg Friedrichowitz, Armin Eisenhofer Grünbeck Wasseraufbereitung GmbH, Höchstädt a.d. Donau