Cervercia India Puerto Rico Presentacion- WWTP Upgrade L1

8/19/2019 Cervercia India Puerto Rico Presentacion- WWTP Upgrade L1

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Wastewater Treatment Plant UpgradeProject (WWTP)

Marlon CabreraEngineering Department

Cervecera de Puerto RicoMayaguez, PR


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Introduction

A common challenge for breweries is meeting currentwastewater discharge standards while accommodatinggrowth and anticipating more stringent discharge

regulations in the future. Cervecera de Puerto Ricowastewater treatment system had been in operation for along time, but years of service and increased hydraulic andorganic loadings had made it difficult to meet treatmentobjectives.

For years Cervecera de Puerto Rico wastewater treatmentplant was affecting the image of the company and hadbecome a priority for the future of the company.


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Potential Issues

• Regulatory Compliance of Waste Water Discharge

• Possible surcharges

• Controls were mostly manual, there were no instrumentation automated monitoringparameters of waste water treatment process

• Operation of Return Activated Sludge Systems (RAS) was inconsistent due a to pastretrofits and obsolete equipment

• Operation and maintenance of the treatment systems rotating biological contactors hadbecome a very high total operational costs

• Increased hydraulic and organic loadings

• Bad odor generation at the treatment plant

• Bad ima e of the com an


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Before Process Diagram of WWTP

Pista-Grit

Equalization TankDigester/

Thickener

Clarifier

Pump #1

Pump #2

Blockeddischargeconnectionsto/from reactor

Pressed if

needed

Reactor


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Previous Rotating Biological

Contactors


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Previous Rotating Biological

Contactors


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Previous Clarifier


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Legal Limits and Requirement of

Samples Applied Load

PARAMETERS DOWNLOAD LIMIT

BOD (mg/L) 250

TSS (mg/L) 250


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Before - Graph of BOD

0

200

400

600

800

1000

1200

1400

1600

B O D ( g / m l )

Month/Year

Biochemical Oxygen Demand


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Before - Graph of TSS

0

500

1000

1500

2000

2500

T S S ( g / m l )

Month/Year

Total Suspended Solids


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Challenges

• Regulatory compliance with the permit.

• Reduce the environmental footprint of the plant

• Cost effective technologies

• Limited budget of 1.3M

• Space construction limited

• Withstand large changes in demand while maintaining efficient

• Reduce odors

• Make changes without stopping operation

• Reduce total operating costs


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CERVECERA DE PUERTO RICO PILOT

study MOVING BED BIOREACTOR

(MBBR) TECHNOLOGY


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CERVECERA DE PUERTO RICOWWTP MBBR PROJECT


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Paramecium Vorticella

EpistilysVorticella

CERVECERA DE PUERTO RICO WWTP MBBR PROJECT


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0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00

4000.00

3578.00

1193.00

186.00 29.30 250.00

S O L U B L E B O D ( P P M )

SOLUBLE BOD 10/23/2009

INFLUENTE SOLUBLE BOD WWTP REACTOR SOLUBLE BOD MBBR #1

SOLUBLE BOD MBBR #2 PRASA BOD PERMIT LIMIT

CERVECERA DE PUERTO RICOWWTP MBBR PROJECT


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0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

61.08%

93.93%99.04%

SOLUBLE BOD REMOVAL 10/23/2009

BOD REMOVAL % WWTP REACTOR BOD REMOVAL % MBBR #1

BOD REMOVAL % MBBR #2

CERVECERA DE PUERTO RICO WWTPMBBR PROJECT


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Solution: Upgrading the WWTP

The Engineering Department along with EH&S evaluateddifferent treatment alternatives to determine the viability ofupgrading the existing facilities to achieve permitparameters.

• Moving Bed Biofilm Reactor (MBBR)

• Tank Dissolved Air Flotation (DAF), system without airsaturation


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MBBR Design Basis

PARAMETER UNITS INFLUENT EFFLUENT

Flow MGD 0.15 0.15

BOD5 (Soluble) MG/L 1,800


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Project Scope

Tasks Original Scope Currently AchievedReactor Tank Retrofit X X

Blowers Replacement X X

DAF Installation X X

Acid Dosing Station Automation X X

Caustic Soda Station Automation X X

Caustic Soda Receiving Station Automation X

pH/Temp Monitoring EQ Tank X X

pH/Temp/DO Monitoring Reactor Tank X X

Influent Flow Metering X X

Influent Temperature Monitoring X

Central process overview X X

Tank Levels X X

Belt Press automation X

Electrical Utilities X

Air Utilities X

Water Utilities X

Pads/Dikes/Civil Work X

Instrumentation and Integration X X

Aesthetical Improvement X

Waste Water Lift Station Upgrade XNew Laboratory Furniture X X


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Project Budget

• Project Budget $1,394,036

• Discharge Overcharges $98,069

• Negotiated PRASA Limits

• BOD - 5,633 mg/L

• TSS - 2,628 mg/L

• Currently consumed $1,358,641


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Actual Process Diagram of WWTP

Belt Filter

Press &

Container

Moving Bed

Biofilm

Bioreactor

(315,000 gals)

Digester

89,000 gals

Screens

DAF

UtilitiesBrew HouseCold BlockPacking Lines

PRASA

Equalization

Tank

292,000 gals

Lift Station

X X X

X XBlowers

Blowers


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Moving Bed Biofilm Reactor

(MBBR)

• A stand-alone biological treatment system with no needfor media backwashing

• Wastewater treatment plants of this type operate asfixed-film processes without activated sludge recyclebetween the bioreactor and clarification units

• Aeration supplied provides oxygen, essential formicrobial growth, and the energy required to dispersethe carriers completely throughout the system


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Moving Bed Biofilm Reactor(MBBR)


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MBBR System


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(MBBR)

Process uses 25 mm-diameter cylindrical plastic carriersthat provides environments in which bacteria andprotozoa can grow effectively.

M i B d Bi fil R t


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(MBBR)


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Dissolved Air Flotation

Operation (DAF)

Separates and optimizes solids prior to dewatering


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Operation (DAF)


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Operation (DAF)


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WWTP Retrofit


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WWTP Retrofit


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WWTP Retrofit


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WWTP Retrofit


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WWTP Retrofit


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Belt Press


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Now - Graph of TSS

2 0

1 6 0 0

1 0 2

0

2 6 0

2 3 0

2 4 0

2 2 0

2 0 0

1 5 0

1 4 0

1 1 0 1 5 0

2 7 0

2 8 0

1 4 3

1 3 5

1 2 1

1 1 0 9 0 3 0 3 0 2 0

1 5 2 0 1 5 1 20

250

500

750

1000

1250

1500

1750

2000

2250

2500

J a n - 0 8

M a r - 0 8

M a y - 0 8

J u l - 0 8

S e p - 0 8

N o v - 0 8

J a n - 0 9

M a r - 0 9

M a y - 0 9

J u l - 0 9

S e p - 0 9

N o v - 0 9

J a n - 1 0

M a r - 1 0

M a y - 1 0

J u l - 1 0

S e p - 1 0

N o v - 1 0

J a n - 1 1

M a r - 1 1

M a y - 1 1

J u l - 1 1

S e p - 1 1

N o v - 1 1

J a n - 1 2

M a r - 1 2

M a y - 1 2

J u l - 1 2

T S S ( g / m l )

Month/Year

Total Suspended Solids Efficiency

Actual TSS

Before TSS

Limit


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Now - Graph of BOD

1 0 . 0

0

7 0

0 . 0

0

1 3 3 . 0

0

1 1 1 . 0

0

1 9 3 . 0

0

1 2 8 . 0

0

1 0 1 . 0

0

1 2 1 . 0

0

1 9 3 . 0

0

1 3 3 . 0

0

4 2 . 0

0

2 4 . 0

0

2 4 . 0

0

4 0 . 0

0

3 0 . 0

0

1 8 . 0

0

2 1 . 0

0

1 4 . 0

0

1 1 . 0

0

6 . 0

0

8 . 0

0

7 . 0

0

1 0 . 0

0

7 . 0

0

8 . 0

0

8 . 0

0

-200

0

200

400

600

800

1000

1200

1400

1600

J a n - 0 8

M a r - 0 8

M a y - 0 8

J u l - 0 8

S e p - 0 8

N o v - 0 8

J a n - 0 9

M a r - 0 9

M a y - 0 9

J u l - 0 9

S e p - 0 9

N o v - 0 9

J a n - 1 0

M a r - 1 0

M a y - 1 0

J u l - 1 0

S e p - 1 0

N o v - 1 0

J a n - 1 1

M a r - 1 1

M a y - 1 1

J u l - 1 1

S e p - 1 1

N o v - 1 1

J a n - 1 2

M a r - 1 2

M a y - 1 2

J u l - 1 2

B O D ( g / m l )

Month/Year

Actual BOD

Before BOD

Limit

Biochemical Oxygen Demand Removal Efficiency


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Summary Savings

• Maintenance Costs 70%

• Chemicals 50%

• Generation of H2O

• Power Cost 35%

• Odor reduction

• Regulatory compliance without overcharges 100%

Documents

Cervercia India Puerto Rico Presentacion- WWTP Upgrade L1