Lessons Learned: How a Small Village Handled a Brewery Expansion

Transcription

1 Lessons Learned: How a Small Village Handled a Brewery Expansion Presenters: Blair Selover (FVOP), Dan Schlaff (Village of Dexter) & Tony Grant (NUBCo)

2 Proposed Agenda Introduction Initial Situation Original Smaller Brewery Expansion & re-location to larger facility Initial Steps to Handle Increased Load Expanded Brewery Start-up Action Plan & Current Operations

3 Introduction Village of Dexter Small to midsize community located near Ann Arbor Jolly Pumpkin/Northern United Brewery located in the Village Activated sludge wastewater treatment plant discharges to Mill Creek (Huron Watershed)

4 Village of Dexter (cont.) Average WWTP flow is ~0.3 MGD MAHL not updated since 1980s Surcharge rates not updated since 1980s WWTP operating fine with Jolly Pumpkin (only) as a small operation

5 Jolly Pumpkin JP Artisan Ales started in 2004 The JP brewery on Broad St maxed out at just shy of 2500 bbls of production before we moved to Bishop Circle Jolly Pumpkin - Belgian style ales Combined with North Peak and Grizzly Peak brewing to start Northern United Brewing Co. in 2009 NUBC now based in Dexter at a new, larger facility, making many types of beer

6 Initial Situation Original Smaller Brewery Original brewery location Broad Street in Dexter, MI Jolly Pumpkin brand only Approximately 3000 barrels per year Broad Street facility wasn t originally designated as an SIU Wastewater from smaller brewery was not real noticeable at the WWTP

7 Then Craft Beer becomes REALLY Popular

8 North Peak Jolly Pumpkin & Grizzly Peak Gourmet brews have taken off in Michigan Jolly Pumpkin/NUBC expanding operations

9 Jolly Pumpkin Brewery 2010 Broad Street Location in Dexter, MI

10 Expansion Move to Bishop Circle Big Increase in volume Plan to brew more NUBCo brands

11 Expansion (cont.) NUBCo approached Dexter Community Development Village meetings & correspondence re NUBCo wastewater service Existing brewery and proposed brewery to be designated as SIUs

12 New Facility, Expanded Operations More kinds of beer Higher production volume: Plan to brew 10,000 barrels in 2014 Increase to 20,000 barrels per year in near future

13 Action Plan for Handling Brewery Expansion The Question How much beer (byproducts) can the plant drink?! Outline the Needs/Challenges City/NUBCO Meetings jobs! (and beer) Challenges identified

14 Action Plan for Handling Brewery Expansion Challenges: Need MAHL, SUO updates NUBCO plant is SIU (by loading) Slug loading = batch process Start-up funds were very limited Brewery expansion leading WWT plan Options Pretreatment, Discharge to POTW, Liquid Haul

15 Initial Action Plan for Expanded Facility Sampling & Monitoring Maximum Allowable Headworks Loading (MAHL) Evaluation Industrial Discharge Permit Application Industrial Discharge Permit issued with Interim Limits

16 Initial Action Plan for Expanded Facility Sampling manhole and flow monitoring

17 SIU Discharge Permit Application Jan NUBC submitted completed permit application Slug loading and spill prevention plan Meeting with Village, engineer, and NUBCo to discuss anticipated flows, concentrations, loadings No data (production or ww characterization) was available

18 Maximum Allowable Headworks Loading Non-compatible pollutants based on: Chronic & acute toxicity water quality impacts Treatment & digestion inhibition Biosolids contamination (for land application) L Chronic Q POTW WQBELC *8.34* (1 R /1000 ) Avg L INHIB, Dig Q Sludge * INHIB, Dig R C Avg *8.34 L INHIB, Sec Q POTW * 8.34* CINHIB, Sec 1 R PRIM L Sludge Q Sludge TSS * 100 Sludge C *8.34* R avg Sludge * F Sorp

19 Maximum Allowable Headworks Loading Compatible pollutants (BOD, TSS, etc) most important for breweries, based on: NPDES discharge permit limits Treatment design/capacity Process modeling in GPSx L NPDES 8.34 * C (1 R NPDES Avg * Q ) POTW

20 BOD MAHL Review MORs Design Basis Process Modeling Estimate NUBC s higher flow & loading

21 BOD MAHL WWTP Capacity The 1998 Engineering Report was problematic Dexter Upgraded from RBCs to Activated Sludge BUT Engineer - Reduced the proposed design flows and loadings BOD rating was reduced from 1329 to 975 lb/d No ammonia or phosphorus capacity calculated No Max day limits were calculated F&V has documented the capacity of Dexter s WWTP as BOD 1495 lb/d based on current 10-states standards criteria And BOD 2,100 lb/d based on GPSx modeling & calibration Pursue Max Day Criteria? YES 1,600-1,800 lb/d (modeling, EPA eqn 5.5, big day loadings)

22 BOD Most important for brewery wastewater MAHL was needed to demonstrate real capacity of the Village s WWTP WWTP rated capacity 975 lb/d WWTP current loading 978 lb/d

23 Time for some Collaboration!!

24 BOD Most important for brewery wastewater Meeting NUBCo, Village Jan 2013 Workshop Village, NUBCo Feb 2013 Meeting F&V, DEQ, Village Feb 2013 MAHL Report March/April 2013 MAHL Submittal May 2013 Approval August 2013

25 BOD Most important for brewery wastewater WWTP monthly average BOD capacity is ~1,500 lb/d [CATEGORY NAME], [VALUE]*, [PERCENTAGE] Safety Factor, 150, 10% Allocate mass for Village domestic users, reserve, & SIUs (brewery, metal finisher) lb/d = 280 lb/d Remainder for SIU(s) including NUBCo *Mass units in lbs/day Metal Finisher, 5, 0% Reserve, 115, 8% Commercial, other Domestic, 350, 23% Residential, 600, 40%

26 Interim Permit for NUBCo An interim permit was issued Jan Covering NUBCo start up period 90 days = initial permit cycle 150 lbs BOD/day limit

27 Start Up Operations & Interim Permit Brewery wastewater had higher loading than anticipated when MAHL & interim permit developed Brewery was not able to reach these limits Avg. BOD lbs/day (in 2 to 3 hours!) Slug loading was causing issues at WWTP Equalization was necessary

28 Start-up funds were very limited Interim Action Plan for Expanded Facility Equalization Tank to Reduce Slug Loading Events

29 Higher Loading than Anticipated Average BOD frequently higher than permit limit of 150 lbs/day AVERAGE BOD (LB/DAY) NUBC Discharge

30 Action Plan for Handling Brewery Expansion Education, Development & Consensus Surcharges are required How to calculate surcharges Surcharges totaling $25,000/month were assessed Start-up Surprises Higher BOD than expected

31 Issues at the WWTP Slugs overloaded primaries Aeration system slug loaded; D.O. challenges Extra blower required, power consumption, mlss, sludge Babysitting Digester was under construction Increased operational requirements throughout

32 Equalization: Mitigate Issues at the WWTP 20,000 gal Frac Tank was rented (City paid a portion) Provided Flow EQ + Load EQ Septic tank & grinder pumps Throttled discharge from EQ tank Smoothed out the WWTP operations over the day Targeting avg gpm discharge from NUBCo

33 Continued Collaboration Letter from NUBCO to Dexter: NUBCO is looking at options to reduce BOD by separating yeast and spent grain. Permit: 150 lb/day BOD limit City: Need to make progress; issue progress report every 90 days

34 Current Operations & Next Steps Additional Steps to reduce BOD Install permanent, underground equalization tank Separate spent yeast from wastewater discharge stream Separate spent grain from wastewater discharge stream

35 Current Operations & Next Steps Proposed Site Plan for Brewery Wastewater Improvements

36 Current Operations & Next Steps Proposed Site Plan for Brewery Wastewater Improvements

37 Questions? For More Information: Blair Selover - FVOP Rich Grant F&V