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 E-mail: verhuelsdonk@wzw.tum.de
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
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
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
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
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
Process Flowsheet Pretreatment waste water Anaerobic Reactor Flotation Membran Bioreactor Ultrafiltration Reverseosmosis Disinfection Process water abstraction
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
Modular concept Membrane filtration Denitrification Nitrification
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 - www.huber.de/products/flotation/dissolved-air-flotation.html
Dissolved Air Flotation
Dissolved Air Flotation Analysis by Stephanie West and Marcus Verhülsdonk, TUM
Vacuum Rotating Membrane Bioreactor (VRM) Huber SE - Brochure: HUBER Vacuum Rotation Membrane VRM Bioreactor
Vacuum Rotating Membrane Bioreactor (VRM) 60-80 mbar low pressure 36 modules, 4 membranes/module 108 m² active area 10-15 l/m²h transmembrane flux 1-2 revolutions per minute Huber SE - Brochure: HUBER Vacuum Rotation Membrane VRM Bioreactor http://www.huber.de/products/membrane-bioreactor-mbr.html
COD Removal Intake HDF Outlet HDF 95 % VRM Filtrate Analysis by Stephanie West and Marcus Verhülsdonk, TUM
Process Flowsheet Pretreatment waste water Anaerobic Reactor Flotation Membran Bioreactor Ultrafiltration Reverseosmosis Disinfection Process water abstraction
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
Membrane separation Separation Process Dissolved matter Range of pressure Microfiltration >0.1 µm Zooplankton Algae Turbidity Bacteria Suspended solids Ultrafiltration 0.1-0.01 µm Polymers Virus Colloids Nanofiltration 0.01-0.001 µm Organic compounds Divalent ions Reverse osmosis <0.001 µm Monovalent ions 0.1-2.0 bar 0.1-5.0 bar 3-20 bar 10-100 bar http://www.dvgw.de/angebote-leistungen/forschung/technologie-report/aufbereitung/ausgabe-308/
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: http://www.scielo.br/scielo.php?script=sci_arttext&pid=s1516-89132005000400015
Reverse Osmosis Two 4 modules with 7 m² active membrane area per module Comparison of different membrane types (NF, RO) 60-70% recovery
Water Quality Feed Permeate Concentrate Rejection ph [-] 6,56 5,46 6,84 Temperature [ C] 21,6 23,9 24,3 Conductivity [µs/cm] 2712 373 5430 Sodium [mg/l] 547 69 1470 87 % Chloride [mg/l] 362 38 681 89 % Calcium [mg/l] 55 0,4 124 99 % Potassium [mg/l] 30 3,6 75 88 % 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
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
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