United tate Indutrial Environmental Reearch Environmental Protection Laboratory Agency Cincinnati OH 45268 Reearch and Development EPA-600/2-83-005 Apr. 1983 Project ummary Multiple Water Reue in Poultry Proceing: Cae tudy in Egypt Ahmed Hamza, Huda. Lillard and Jack L. Witherow An indutrial-cale multiple water reue ytem wa invetigated for three year at a modern poultry proceing plant in Alexandria, Egypt. The ytem involved chlorination of cooling water from compreorand it ucceive reue a feed water for the chiller, prechiller, waher and finally for makeup in the calder. In all four unit poultry carcae are immered in water. Proce water in the prechiller and waher were purified alternatively by a preure leaf filter. Repone-urface analyi demontrated variable interacting effect of water rate, chlorine doage and proce time on the chemical and bacterial qualitie of the proceed carcae, and water ued in the immerion procee. Model were developed for prediction of the effect of operating condition on poultry quality. Long-term tudie at the plant indicated that ucceive utilization of prechlorinated water in a multiple ytem did not reult in ignificant buildup of contaminant (total and coliform count) and organic pollutant (greae, nitrogen compound, BOD and COD) in the immerion tank. The bacterial quality of the carcae proceed by the multiple reue water wa uperior to the quality of the typical ytem which utilize prodigiou quantitie of potable water in a once-through feed ytem without filtration and chlorination. Filtration, when incorporated with the multiple ytem, enhanced the water and carca quality with progreive elimination of the organic contaminant which would interfere with chlorination. The tudy demontrated a potential for ubtantial aving in water-an expenive commodity in arid area of Egypt-through application of thi multiple reue ytem. The concluion and recommendation of thi report are not directly applicable to poultry proceing plant in the United tate, ince water ue in thoe plant i regulated by the U.. Department of Agriculture. Thi Project ummary wa developed by EPA' Indutrial Environmental Reearch Laboratory, Cincinnati, OH, to announce key finding of the reearch project that i fully documented in a eparate report of the ame title (ee Project Report ordering information at back). Introduction In Egypt, water upplie are limited for new poultry proceing plant. The need for large quantitie of proceing water ha forced the indutry to develop water reue ytem. In April 1976, a four-year joint project between Alexandria Univerity and the United tate Environmental Protection Agency (EPA) wa initiated to develop, intall, and evaluate a multiple reue ytem at the Alexandria Poultry Proceing Plant (APPP). Concluion The following concluion were drawn from thi field invetigation: 1. Multiple water reue i a practical and viable option to conerve water
in poultry proceing in Alexandria, Egypt. 2. Chlorination and filtration of the reued water were effective in reducing accumulation of pollutant and contaminant of the immerion water. The total aerobic and coliform count of the carcae were appreciably lower than thoe count aociated with carcae treated in the normal once-through ytem, without chlorination. 3. In the Alexandria plant, optimum operation condition for the multiple reue ytem were achieved by uing a water makeup rate of 20 m 3 /d, while applying chlorine doage of 20 mg/l, with filtration of the waher water in a cloed loop. 4. Multiple water reue reduced ue of immerion water by 54% of the normal conumption in thi plant. Recommendation Baed on the reult of the tudy, the following recommendation are propoed. The poultry proceing indutry in Egypt hould invetigate multiple reue of the exiting once-through water ytem in the carca-cooling operation. Water flow to proce unit hould be monitored. Ue of potable water for feather fluming, fluhing of blood tunnel and cleanup operation hould be replaced by reued water from other procee. Coordination of activitie between indutry, regulatory agencie and reearch team i neceary for development of efficient water conervation cheme. Area needing further invetigation and evaluation are: long-term evaluation of cot, accumulation of contaminant, and operational problem of the continuou multiple water reue ytem; development of further ue of byproduct; and ue of pecific ening device for monitoring of pollutant in the immerion water. Decription of the Multiple Reue ytem The normal operation of the APPP involve initial filling of the immerion tank (chiller, waher and calder) and introducing makeup with once-through freh water in all tank. Detail of the operation, characteritic and flow of proce effluent are decribed elewhere. 1 Figure 1 i a flowheet of the multiple reue ytem (MR). The compreor cooling water wa ued for initial filling and makeup in the immerion tank. Makeup water wa continuouly pumped at a controlled rate to the chiller, and repumped at the ame rate to the prechiller and waher, in a counter-current flow arrangement. The overflow from the waher wa diverted to the calder a a replacement for part of the freh water requirement during proceing. chematic of the flow for both normal operation (once-through makeup) and MR are hown in Figure 2. Mode of operation of the MR ytem were a follow: 1. Treatment. A ga chlorinator (Capital Control Co., UA) wa intalled on the ubfeeding line to the immerion tank. Metered chlorine doage were injected into the line during initial filling (about one hour prior to tartup). Chlorine doage were con- City Water Figure 1. trolled during the initial filling, and in makeup water. Chlorine doage ued were 10, 20 and 30 mg/l, and water makeup rate were 10, 20 and 30 m 3 /d. 2. Treatment II. A high-preure leaf filter wa ued for renovation of the wah water in a cloed loop. The filter (Model 36H-805-4, Amafilter, Holland) ha a net filtering area of 7.5 m 2, working preure 4.5 Atm and an average capacity of 1000 L/hr filtered water. A local bentonite clay (equivalent pore ize 0.8µ) wa ued for coating the leave prior to filtration. 3. Treatment III. In thi mode, the filter wa connected to the prechiller rather than to the waher. Makeup water rate and chlorine doage for treatment II and III were the ame a thoe ued in treatment I. The ratio of makeup water ued in the MR and the normal nonreue ytem are given in Table 1. Multiple water reue ytem at poultry proceing plant, Alexandria, Egypt. 2
Makeup water (7 m 3 /d) (14 m 3 /d) (22.7 m 3 /d) (55 m 3 /d) wah water reued a makeup for the calder. Filtration of the chlorinated water in the MR (TRT II and Ill) further improved the quality of the waher water and chiller water a hown in Table 2. A anticipated, filtration of the waher water (TRTII) and chiller water (TRTIII) produced noticeable reduction in the upended reidue (R). With minor exception, the accumulation of pollutant wa decreaed by increaing makeup rate and chlorine doage in the MR. The normal waterue cheme produced more accumulation of COD, Total Reidue (TR), and Oil and Greae (O&G) in the waher and chiller. The ue of 10 and 20 m 3 /d in the MR reult in net aving of the immerion water of 77% and 54%. repectively (Table 1). Depite thi appreciable reduction of water ue, the quality of the waher and prechiller water wa better in the MR a compared to the normal ytem, due to the influence of filtration and/or chlorination in reducing the accumulation of pollutant. The AOVA reported in Table 3 indicate ignificant effect of the independent variable (treatment, date, time, and operating condition[water rate and chlorine doage])on pollutant aociated with the proce water in the four immerion tank. Interaction between the independent variable were ignificant in mot cae. The dependent variable are COD, BOD, TR, volatile reidual (VR), diolved reidual (DR) and O&G. Figure 2. Table 1. chematic of normal operation and multiple reue ytem. Ratio of Makeup Water in the MR and ormal ytem Makeup (MR) Chiller m 3 /d (2.5 + 7.0 b ) 10 1.43 20 2.86 30 4.28 Initial filling water. m 3 /d. Makeup water in normal ytem, m 3 /d. Effect of Multiple Reue on Chemical Characteritic of Proce Water A hown in Table 2, chlorination of water in the MR (TRT I) reduced the Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD) of the waher and chiller water in comparion with the normal once-through ytem. However, the BOD and COD of the calder water were appreciably higher due to the near abence of reidual chlorine and the ignificant accumulation of pollutant in Prechiller (2.5 + 14.0 ) 0.71 1.43 2.14 Waher (5.0 a + 22.7 b ) 0.44 0.88 1.32 Effect of Multiple Reue on Bacterial Count of Water and Carcae Chlorination (TRT I) in conjunction with filtration (TRT II and Ill) produced marked decreae in total aerobic count and coliform count of water and carcae a compared with the normal ytem (Table 4). However, minor exception were oberved. Bacterial count for water in the normal ytem were lower than the MR (TRT I) when uing chlorine doage of 10 mg/l and water makeup rate of 10 m 3 /d. However, increaing the water rate to 20 m 3 /d and chlorine doage to 20 and 30 mg/l produced marked decreae in bacterial count of proce water in the waher and chiller (Figure 3). On the other hand, a Figure 4 how, bacterial count on carcae were conitently lower in the MR compared to the normal ytem, even at the low water rate of 10 m 3 /d and chlorine doage of 10 mg/l. The reult reported in Table 4 indicate that the normal water ytem wa le effective than MR in removing bacteria from both water and carcae. With minor exception, the MR mode produced mean count lower than the normal ytem. The AOVA of bacterial count i reported in Table 5. In thi cae, mot independent variable and their interaction produced ignificant effect on bacterial count. The reult generally agree with AOVA reported in Table 3. 3
Table 2. Effect of Treatment on Mean Concentration of Pollutant in Proce Water, mg/l Table 3. Effect of Treatment end Operating Condition on Chemical Characteritic of Proce Water Proce TRT COD BOD TR R O&G calder Waher I II Ill I II Ill 1574 2145 1616 1538 1434 787 427 485 1235 1700 1542 2627 1156 1933 1419 2214 1220 1744 547 1842 351 830 396 1137 1182 784 762 523 427 91 74 93 100 242 126 43 99 calder COD BOD TR VR DR O&G TRT OPCO T.O. Date Hour H. T. (T) (O) (H) H. O. H. T. O. Prechiller Chiller I II Ill I II Ill 1883 384 402 156 1357 326 325 179 1431 2119 226 956 311 826 128 500 1020 1562 218 671 247 756 154 505 427 386 128 229 295 256 244 523 102 48 245 75 116 85 Waher COD BOD TR VR DR O&G Prechiller = ormal (once-through) ytem. I = Chlorination of MR water. II = Chlorination of MR and filtration of wahing water. Ill = Chlorination of MR and filtration of prechiller water. Data for TRT I, II end III are pooled for makeup rate 10-20 m 3 /day and chlorine doage 10-30 mg/l. Mean of 8 experiment. COD BOD TR VR DR O&G Chiller COD BOD TR VR DR O&G OPCO (O) = 1 water makeup 10 m 3 /d and Cl 2 doe = 10 mg/l = 2 water makeup 20 m 3 /d and Cl 2 doe = 20 mg/l = 3 water makeup 20 m 3 /d and Cl 2 doe = 30 mg/l TRT (T) I, II and Ill Hour (H) 1, 2, 3, 4, 5 and 6 ignificant difference at the 5% level ot ignificant difference at the 5% level 4
Proceing time. hour - 10 Water m/d - - 20 ---- 20 U- ormal C 2 mg 10 20 30 Comparing the effect of TRT II and TRT Ill on the bacterial count of the chilled carcae hown in Table 4 and Figure 4 indicate that TRT II (filtering the waher water) produced a better quality of chilled carcae. ince helf-life i dependent on the bacterial quality of the carcae in the lat immerion proce (chilling), it i recommended that the filter be ued in conjunction with the waher in plant that ue immerion waher o a to reduce bacterial level mot effectively. Effect of Chlorination, Water Makeup Rate and Proceing Time on Bacterial Count of the Chiller Contour plot available in the full report clearly demontrate the favorable effect of chlorination on the bacterial quality of water and carcae. Contour of relatively low bacterial count were dominant when uing chlorinated water, wherea the ue of nonchlorinated water in the MR wa aociated with higher total aerobic and coliform count. A proceing time increaed, bacterial count alo increaed. However, toward the end of the operation, the chlorination controlled count at lower level than nonchlorinated water. The ue of nonchlorinated water reulted in rapid increae in bacterial count in the lat tage of the operation period. Although the effect of water makeup rate did not follow a uniform pattern, the contour for chlorinated water indicate an optimum water makeup rate of 20 m 3 /d. The ue of thi water makeup rate in the MR reulted-in a net water aving of 54% compared to normal uage (Table 1). Reference 1. Hamza, A., aad,. and Witherow, J., Potential for Water Reue in an Egyptian Poultry Proceing Plant, Journal of Food ci. 43, (1978). Figure 3. Effect of treatment on bacterial count of proce water. 5
Log TC = Log 10 total aerobic count/ca Water Cl 2 Log CC = Log,, coliform count/ca m 3 /d mg/l 10 10 20 20 --- 20 30 ++ ormal Figure 4. Effect of treatment on bacterial count of carcae. 6
Table 4. Effect of Treatment on Mean Logarithmic Count of Table 5. Effect of Treatment and Operating Condition on Carcae and Water Bacterial Count of Carcae and Proce Water Proce TRT Log TW Log TC Log CW Log 10 cc TRT OPCO T.0 Date Hour T.H H.0 H.T.0 (T) (O) (H) Waher 5.00 8.30 3.30 6.90 I 4.04 4.45 3.67 3.71 II 3.40 3.73 3.01 3.28 Ill 3.99 4.68 3.74 4.17 Prechiller 4.69 6.20 3.32 4.99 I 3.59 4.08 3.25 3.61 II 3.15 3.07 3.88 2.68 Ill 3.65 3.78 3.29 2.37 calder Log TW Log CW Log TC Log cc Waher Chiller 4.83 6.27 I 3.17 3.29 II 2.59 2.71 Ill 2.93 3.21 3.11 4.75 Log TW 2.76 2.77 Log CW 2.32 2.30 Log TC 2.57 2.88 Log cc iv Log TW = Log 10 total aerobic count in water/ml. Log CW = Log 10 coliform count in water/ml. Log TW = Log 10 total aerobic count of carcae. Log CC = Log 10 coliform count of carcae. Other condition are imilar to thoe of Table 2. Prechiller Log TW Log CW Log TC Log cc Chiller Log TW Log CW Log TC log cc Log TW = Log 10 total aerobic count in water/ml. Log CW = Log 10 coliform count in water/ml. Log TC = Log 10 total aerobic count of carcae. Log cc = Log 10 coliform count of carcae. Other condition are thoe of Table 3, Ahmed Hamza i with the High Intitute of Public Health, 165 El-Horria Avenue, Alexandria, Egypt; Huda. Lillard i with the UDA, AR, Richard B. Ruell Agricultural Reearch Center, Athen, GA; and the EPA author Jack L. Witherow (alo the EPA Project Officer. ee below for contact) i with the Robert. Kerr Environmental Reearch Laboratory, Ada, OK 74820. The complete report, entitled Multiple Water Reue in Poultry Proceing: Cae tudy in Egypt, (Order o. PB 83-156 760; Cot: $13.00, ubject to change) will be available only from: ational Technical Information ervice 5285 Port Royal Road pringfield, VA 22161 Telephone: 703-487-4650 For information contact Kenneth Dotal at: Indutrial Environmental Reearch Laboratory U.. Environmental Protection Agency Cincinnati, OH 45268 7
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