homework

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Intake and Wastewater Treatment Systems Design

For Ellison Brewery & Spirits

Presented to the

Faculty of the Civil and Environmental Engineering Department

Michigan State University

In Partial Fulfillment

Of the Requirements for the degree

Bachelor of Science

By

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Table of Contents

List of Tables 3

List of Figures 3

Executive Summary 4

I. Introduction 5

Problem Statement 5

Overview 5

Environmental Impacts 8

Reliability Requirements 8

Permits 8

II. Brewery Intake Water 11

Water Demand 11

Water Quality 12

Brewing Water Profiles 16

Intake Water Treatment Options 18

Activated Carbon Filter Design 20

III. Brewery Wastewater 22

Side Streaming 22

Lagoon Treatment 24

Aerobic Treatment 24

Oxidation Ditches 26

Direct Sewer Discharge 26

IV. Wastewater Treatment Design 28

Assumptions 28

Mechanisms of Anaerobic Digestion 30

Buffering Tank 32

Anaerobic Digester 33

Biogas Generation 37

Effluent Water Quality 39

Pump Design 41

V. Sewer Collection System 42

VI. Conclusion 45

VIII. Appendix 46

Pump Design Hand Calculations 46

Summary Flow Chart 47

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List of Tables

Table 1: Typical analysis of conditioned water from LBWL 15

Table 2: Common “Brewing Salts” 16

Table 3: Summary of target brewing water profiles 17

Table 4: Surcharge examples 27

Table 5: Comparison of typical brewery wastewater streams 29

Table 6: Important design parameters for UASB Reactors 35

Table 7: Comparison of treated effluent 40

Table 8: EPANET 2.0 output tables for links and nodes 42

Table 9: Sewer System Capacities 44

Table 10: Treatment process cost comparison 45

List of Figures

Figure 1: Location of Ellison Brewery & Spirits in East Lansing, MI 6

Figure 2: Map of proposed expansion site 7

Figure 3: Specific pollutant limitations under Meridian Township Sewer Discharge Permit 10

Figure 4: Typical brewery water use per department 11

Figure 5: 2016 Drinking Water Quality Report be ELMWSA 13

Figure 6: Relative dechloramination performance of carbon filters 22

Figure 7: Spent Grain generation process 23

Figure 8: Activated Sludge System 25

Figure 9: Summary flow chart for anaerobic digestion mechanisms 31

Figure 10: Process water buffering tanks 33

Figure 11: Upflow Anaerobic Sludge Blanket (UASB) Reactor 34

Figure 12: Example COD removal efficiency from comparative brewery 38

Figure 13: Bell & Gossett NRF Series pump performance curves 41

Figure 14: Meridian Sewer Collection Network 43

Figure 15: Construction Schedule 46

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Executive Summary

Ellison Brewery & Spirits have proposed an expansion of their current brewing facility to occupy

a 90,000 ft2 piece of cleared land east of their current location on Dawn Avenue. The new facility will

produce 50,000 barrels of beer (bbl) annually. This will require approximately 29,726 gallons of water

per day, and generate approximately 21,233 gallons of wastewater every day. Ellison Brewery is

currently discharging their wastewater into the municipal sewer collection system. They are seeking

alternative intake and wastewater treatment options to handle the large flows of high strength waste

expected from the new facility, and remove chloramine and chloride content from their municipal

intake water supply.

Several wastewater treatment options were analyzed for their feasibility at Ellison Brewery:

• Facultative Lagoon Treatment

• Aerobic “Activated Sludge” Treatment

• Oxidation Ditch Treatment

• Direct Sewer Discharge

• Anaerobic Digestion

Several water intake treatment options were analyzed for their feasibility at Ellison Brewery:

• Boiling

• Filtration

o Reverse Osmosis; Activated Carbon; Deionization

• Dilution

Granular activated carbon filtration was selected as the best option for intake water treatment. The

filter was designed to use a catalytically modified coconut shell activated media with high porosity that

will be capable of adsorbing chloride and removing chloramine through the chemisorption process. A

U.S Water Systems’ Fusion Superfilter Commercial Catalytic Carbon Filter 094-CSF was selected, and will

cost $995 - $1795.

Two wastewater handling and treatment methods are proposed. The practical and cheaper solution

is to continue discharging untreated waste directly into the sewer collection system. However, the scope

of the project required the design of an anaerobic digester treatment system. An Upflow Anaerobic

Sludge Blanket (UASB) Reactor will treat water to within the limits of the Meridian Township Sewer

Discharge Permit. The effluent BOD concentration narrowly exceeds the permit limit. However, the

municipality may be willing to extend the permit limits, or impose a reduce surcharge. The total cost of

anaerobic treatment will be between $738,330 - $1,249,365.

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Introduction

Pelfrey Pathway consultants have been tasked with designing a 1.1-mile long pathway from

Hagadorn Road at Shaw Lane to its termination at the intersection of Grand River Avenue and Park Lake

Road. The project includes the design of a single span bridge that crosses the Red Cedar River, and

approximately 1500 feet of wooden boardwalk. The project also requires rehabilitation strategies for

sections of Grand River Avenue, Hagadorn Road, Dawn Avenue, and Northwind Drive, and the vertical

and horizontal alignment of all path sections. A storm water drainage and detention system will also be

designed for the area at the end of Dawn Avenue. Additionally, the possible expansion of Ellison

Brewery & Spirits will require the design of an intake and wastewater treatment system. This project

represents the first phase of a trail system that will connect to the Lansing River Trail through Michigan

State University, and will eventually continue northeast to Lake Lansing Road.

Problem Statement

The scope of work for the environmental engineer on this project includes designing a water

treatment system that will condition the potable water purchased from the East Lansing – Meridian

Water & Sewer Authority for use in the brewing process. The design of a wastewater treatment system

is required to handle the large volume of high strength brewery wastewater produced by the potential

expansion. As part of the MSU Senior Design class requirements, the detailed design of an anaerobic

digester for treating brewery wastewater must be provided alongside a practical plan for the handling of

Ellison’s wastewater.

Overview

Ellison Brewery and Spirits opened its doors on October 2nd, 2015, and have been making

approximately 3000 - 5500 barrels of beer a year. The craft beer industry made up 12.3% of the $107.6

billion U.S. beer market in 2016, and Ellison is taking advantage of the craft beer craze by expanding

their production facility to 50,000 sq. ft., with an anticipated capacity of 50,000 barrels of beer/year.

(Mercer,2017) The expansion will require the consideration of impacts on the local ecosystem,

infrastructure and community, and re-licensing and permitting of the company’s facility operations and

discharge plan. A considerable scale up of water consumption and wastewater production will demand

creative and efficient treatment practices. As the brewery expansion is not yet operational, this report

will put to work engineering judgement in the determination of basic assumptions needed to design the

required systems. This report will compare alternative intake and wastewater treatment systems with

the goal of satisfying the scope of the class, permit requirements, and the possibility of the real life

implementation of a brewery expansion in this area. Figure 1 shows the current location of Ellison

Brewery & Spirits at the south end of Dawn Avenue. The pathway will travel along the river and turn

northeast near the brewery to follow the train tracks to its phase one termination point at Park Lake

Road.

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Figure 1: Location of Ellison Brewery and Spirits in East Lansing, MI.

The proposed expansion area for the brewery is east of the current facility, and composes

90,000 square feet of parking and green space. Figure 2 highlights the available space for the brewery

expansion, and identifies its orientation with respect to the pathway. The development of the new

brewery facility will influence the drainage profile of the area, and will affect the design of a new storm

water management system.

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Figure 2: Map of proposed expansion site. 90,000 sq. ft. is available, but only 50,000 sq. ft. will be used

for the production facility.

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Environmental Impacts

The proposed location for the expansion of the brewery will not disturb any protected wetland

locations. Since the location already contains a parking area and shopping center, it is unlikely that any

protected species will be threatened. The U.S. Fish and Wildlife Service monitors threatened and

endangered species across the country, and lists the protected species in region of Ingham County

where the brewery will be located. Three species are listed as either threatened or endangered in

Ingham County. The Indiana Bat, Northern Long-Eared Bat, and Eastern Massasauga Snake. The

endangered Indiana Bat’s “summer habitat includes small to medium river and stream corridors with

well-developed riparian woods and woodlots within 1 to 3 miles of small to medium rivers and streams”.

(U.S. Fish and Wildlife, 2017) The brewery is in relatively close proximity to the Red Cedar River, but the

proposed expansion is not anticipated to have a negative impact on this species. The immediate river

area will remain undisturbed, and no tree removal will be required for the brewery expansion.

Reliability Requirements

Ellison Brewery & Spirits has very limited reliability requirements. The temporary shutdown of

the brewery itself would have an immediate economic effect on the company’s employees, owners,

suppliers, and product vendors, but would not create any emergencies in the markets it serves. As will

be seen later in the report, the production of spent grain from the brewing process will be provided to

local farmers for animal feed. An interruption in production could have a negative impact on this

relationship, but is unlikely to cause any long-term damage.

On the other hand, the brewery will rely heavily on the consistent and predictable quality and

supply of potable water and grains. The system for intake water treatment will be limited to dealing

with a quality of water that meets the standards of the Safe Drinking Water Act. The brewery will be

unable to operate in the case of water shortages or interruptions to the distribution network that

services the brewery. In the same way, the brewery will be reliant on the access and availability of

municipal wastewater treatment. The brewery will be able to treat wastewater on site, but only to limits

of the Meridian Township Sewer Discharge Permit. The brewery will not treat wastewater to the

standards of the National Pollutant Discharge Elimination System (NPDES) permit that regulates the

discharge of effluent into waters of the United States.

Permits

Brewing beer and discharging wastewater requires licenses and regulating permits. Meridian

Township, the Michigan Liquor Control Commission (MLCC), Michigan Department of Environmental

Quality (MDEQ), and Environmental Protection Agency (EPA) are the regulatory bodies overseeing the

production of beer, and the treatment and discharge of wastewater. Ellison Brewery & Spirits is

currently licensed as a Microbrewery by the MLCC. This is enough for their current production level, but

the license restricts their annual production to 30,000 barrels. Ellison will need to apply for a Brewer

License that permits the unlimited manufacture of beer in Michigan.

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The EPA enforces some common legal drivers under the Clean Water Act that impact the treatment

of wastewater produced by the brewing process.

• Effluent Limitations Guidelines: national standards for industrial wastewater discharges to

surface waters and publicly owned treatment works.

• Pre-Treatment Streamlining rule: pre-treatment programs for the control of industrial

discharges into sewage collection systems

• NPDES Permit Program: regulating point sources (single, identifiable sources such as pipes or

man-made ditches) that discharge pollutants into U.S. waters.

• Sewage Sludge (Biosolids) Rule: requirements for the final use or disposal of sewage sludge.

• Total Maximum Daily Load (TMDL) and Impaired Waters Rule: states, territories, and authorized

tribes are required to develop lists of impaired waters that are too polluted or degraded to meet

set water standards.

The MDEQ has the authority from the U.S. EPA to administer the National Pollutant Discharge

Elimination System (NPDES) permit program. This program is designed to control the discharge of

pollutants into surface waters. The MDEQ also plays an important role in the licensing of treatment

plant operators and septage haulers, and the control of industrial pollutants into publicly owned

treatment works. In addition to wastewater regulations, the FDA regulates food and food ingredients

(including breweries) under The Federal Food, Drug, and Cosmetic Act (FDCA). This act allows the agency

to “enter and inspect, at reasonable times, within reasonable limits, and in a reasonable manner, any

facility, vehicle, equipment, material, container, and labeling used to manufacture, process, pack, hold,

or transport food. The FDA also regulates container labeling, and the use of spent grains from the

brewing process for use in animal feed.

Meridian Township will be the agency most closely regulating the discharge of wastewater from

Ellison Brewery. It will be necessary for the brewery to apply for, and acquire, a Sewer Discharge Permit

from Meridian Township. Figure 3 lists the pollutants regulated under the permit.

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Figure 3: The specific pollutant limitations set under Meridian Township’s Sewer Discharge Permit

In addition to the pollutant limitations, the permit places restrictions on temperature and pH.

The temperature in the effluent cannot exceed 40° C (104° F), and the pH cannot be lower than 5.5 or

higher than 10. (Ingham County Code Index)

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Brewery Intake Water

Water Demand

The abundance of clean water in the United States has contributed to the rise of microbreweries

over the past 20 years, and the cost of water and wastewater disposal have heavily contributed to

innovation in efficiency in every step of the brewing process. Beer is about 95% water in composition,

but the water used to produce a bottle of beer is much greater than the volume of water in the beer

alone. Water usage varies widely across brewers, but according to the Brewers Association, the U.S.

average is approximately 7 barrels of water for every barrel of beer produced. (Brewers Association)

Figure 4 shows the typical distribution of brewery water use as reported to Brewers Association.

Figure 4: Typical brewery water use per department.

Ellison Brewery and Spirits currently uses several optimization and recycling best practice

methods to increase efficiency and reduce water usage. However, for the sake of this project it will be

assumed that the national average of 7 barrels of water to 1 barrel of beer will be reflective of the water

demand once the expanded facility becomes operational.

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It is easier to grasp the volume of water necessary to produce the anticipated 50,000 barrels of

beer if familiar units are used.

1 Barrel = 31 Gallons

50,000 Barrels of Beer = (50,000 * 31) = 1,550,000 Gallons of Beer per Year

Multiplying this annual beer production figure by the industry average water use of 7 to 1

results in an annual water demand:

1,550,000 Gallons of Beer = (1,550,000 * 7) = 10,850,000 Gallons of Water Annually

As shown in Figure 4, the actual brewing of beer is not the only use of water in the brewing

process. Therefore, it is assumed for this project that water will be used consistently every day of the

year. Dividing the annual water demand by 365 days in a year will give the average daily water use.

Average Daily Water Use:

10,850,000 Gallons / 365 days = 29,726 Gallons of Water per Day

This figure includes some ancillary water usage for any drinking faucets or restrooms in the

production facility, but does not consider the water demand from any potential kitchen or bar service

areas. Including a kitchen or bar would increase the average daily water demand. However, the

proposed Ellison expansion will be for production only, and no onsite food or beverage services will be

considered.

Water Quality

Ellison Brewery and Spirits purchases its water from the East Lansing – Meridian Water & Sewer

Authority (ELMWSA), and will likely continue to get their water from this provider. The East Lansing –

Meridian Water & Sewer Authority gets their water from 29 wells that are approximately 400 feet deep.

Lime is added to treat for hardness, and Ferric Chloride chemically removes fine particulates from

suspension. The water then passes through a sand filter to polish the turbidity and hardness of the

water. The water goes through a disinfection process before distribution where Chloramine and Fluoride

are added. Figure 5 shows the results of a 2016 water quality report issued by The East Lansing –

Meridian Water & Sewer Authority, and Table 1 offers a basis for mineral and chloramine levels from a

report issued by Lansing Board of Water and Light. (2016 Water Quality)

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Figure 5: 2016 Drinking Water Quality Report by The East Lansing – Meridian Water & Sewer Authority

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Table 1: Typical analysis of conditioned water from the Lansing Board of Water and Light

While the ELMWSA does a fine job of producing consistently potable water for use by the

community, Ellison must further treat the incoming water before it is used for brewing beer.

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Brewing Water Profiles

Different types of beer call for different types of water. From IPAs to Stouts, the chemical profile

of the incoming water must be customized for the best possible product. The above water quality and

test report shows the amount of fluoride and chloramines present in the water. These must be removed

in order to achieve the ideal water profile for brewing. Ellison Brewery & Spirits filters their incoming

water and adds “brewing salts” like Calcium Carbonate (Chalk), Calcium Sulfate (Gypsum), Calcium

Chloride, Magnesium Sulfate (Epsom Salt), and Sodium Bicarbonate (Baking Soda). Table 2 shows some

of the common salts used for water adjustment in brewing. (Palmer, John, 2017)

Table 2: Common “Brewing Salts” used by brewers to adjust incoming water before use in process

A range of hardness, alkalinity, and pH is necessary in the composition of the water used in the

brewing process. Breweries commonly treat their intake water to remove minerals and chloramines,

and adjust mineral levels to create an ideal water profile for the objective beer type. Table 3

summarizes some of the various target water profiles used by brewers. These are not strict guidelines,

as brewers must make adjustments for brewing processes, ingredient chemistry, and flavor goals.

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Table 3: Summary of target brewing water profiles (all values measured in mg/L = ppm)

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Intake Water Treatment Options

Understanding the intake water quality, and setting goals for the profile of usable brewing water is

only half the battle. Brewers need to be able to adjust the mineral content in order to create the right

brewing environment. Therefore, it is often necessary to perform some amount of pre-treatment on the

intake water. Three common options are boiling, filtration (by means of reverse osmosis and deionizing

techniques), and dilution. (MoreBeer!, 2013)

• Boiling

Boiling the intake water is an easy treatment step, and has advantages that can make it

useful for small batch micro brewing or home brewing. Boiling reduces carbonate levels by

precipitating out calcium and magnesium. This process can reduce hardness. Boiling also

removes dissolved oxygen, and can reduce chlorine levels. Chlorine is a common disinfectant

added by treatment facilities, and if used in brewing can react in the mash to produce

chlorophenols that can give the beer an “off” flavor.

On the downside, boiling also removes calcium from the brewing water. This process

raises the pH, and can negatively affect the gelatinization of starch granules. Boiling also comes

with a high energy demand, a long time to complete the pre-treatment process, and a

significant space requirement.

• Filtration

o Reverse Osmosis

Reverse osmosis is the process of forcing water through membrane filters to remove

organics, inorganics, microbes, and some minerals. Reverse osmosis can be a very effective way

of softening water. RO comes with a higher initial capital investment, but can be an affordable

way of pre-treating large volumes of water over a long period. However, the RO process does

little to remove chlorine, and should be combined with carbon filtration.

o Carbon Filtration

Commonly used filters contain activated carbon, and a tightly spun lattice with permeability

of <0.5 um. The activated carbon is highly porous, and relies on van Der Wahl attraction

principles to remove ions from suspension. Treatment with carbon filtration can remove

chlorine and chloramine, and prevents microbes from passing through. In larger commercial

operations, ensuring that an appropriate contact time is available during filtration can mean

that large, or multiple, filters are used.

o Deionization

Deionization is the process of removing minerals using ion-exchange resins. Cations like

calcium, magnesium, sodium, and iron are exchanged for hydrogen ions, and anions are

exchanged for hydroxide ions. Deionization is capable of removing the entire mineral

concentration, but does not remove chlorine to an acceptable level.

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• Dilution

Dilution with distilled water can be an easy way of pre-treating intake water. The

decrease in measured minerals is in direct proportion to the amount of distilled water added.

The overall hardness of a water could be diluted to an acceptable range, and, with enough

distilled water, the chlorine levels could become imperceptible. Dilution comes with some

serious drawbacks when treating water on a large scale. The cost of purchasing or producing

enough distilled water renders this method impractical. Additionally, dilution reduces

concentrations, but it does not reduce the total load of minerals and chlorine in the water. As

will be discussed in the wastewater treatment section, there is an important distinction

between concentration and load, and simply diluting the intake water may not be enough to

ensure an optimal brewing environment.

The combination of reverse osmosis and carbon filtration can give the brewer a “blank slate”

process water profile, and allow for highly controlled mineral addition, pH balance, and alkalinity

control. While this process is ideal, it is also costly. The intake water is pre-softened at the treatment

plant, and contains levels of chloramine. It is recommended that the intake water pre-treatment process

involve a carbon filtration system for the removal of minerals and chloramine.

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Activated Carbon Filter Design

The design of an activated carbon filter first requires an understanding of what needs to be

removed from the water. There are different types of filter media that excel at removing different types

of minerals and chemical compounds. The water to be treated for Ellison Brewery & Spirits contains

chloramines. Therefore, a filter designed for chloramine removal is necessary.

Chloramines are a combination of chlorine and ammonia, and are used in water treatment as a

disinfectant stabilizer. They are often introduced into the water at the point of distribution to help keep

the water free of bacteria as it travels through the distribution network. Standard activated carbon

filters can effectively remove chlorine from intake water, but do a poor job of removing chloramines.

Long contact times and early breakthrough rates limit the use of standard granular activated carbon

(GAC) filters in the removal of chloramine. Catalytic or “surface modified” activated carbon can provide

a solution. In these types of GAC filters, a chemical process modifies the surface, and the carbon’s

catalytic properties are enhanced. Chemisorption overtakes adsorption as the mechanism of removal.

Catalytically active sites on the carbon decompose chloramine molecules into a carbon oxide that

further decomposes the molecules into chloride. Using a carbon that retains a high pore volume allows

the adsorption of the remaining compounds, and a highly polished product. (Guar, 2013) The two step

reaction mechanism can be seen below:

C* is the catalytically active site

Where: and

CO* is the carbon oxide intermediate

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Research was done to gather information for a U.S Water Systems’ Fusion Superfilter

Commercial Catalytic Carbon Filter 094-CSF, using AquaSorb CX-MCA Activated Carbon. In testing, a 25-

cm3 bed of GAC was set up in a 2.5 cm diameter column. The flow rate was maintained at 3.3 bed

volumes per minute. Test water containing 3 mg/L chloramine was treated, and the results are shown in

Figure 6. After ten thousand bed volumes, the AquaSorb CX-

MCA continued to achieve nearly 70% removal. (U.S. Water

Systems, 2017)

The breweries daily water demand of 29,726 gallons

is equivalent to approximately 20 gallons per minute.

However, as shown in Figure 4, an average of 25% of the

intake water is used specifically for brewing. Cleaning water

and bottle washing water may need to be treated, but this

means that a range of 5 – 20 gallons per minute will need to

be treated at Ellison Brewery & Spirits.

The filter pictured to the right is the 094-CSF-400-

CX, and is capable of running a maximum of 20 gal/min with

4.0 ft3 of bed volume.

The empty bed contact time (EBCT) of the filter can

be calculated by dividing the volume by the flow rate.

V = Carbon Bed Volume (ft3)

Q = Flow Rate (gpm)

C = Conversion Factor (7.48 gallons/ft3)

EBCT = (V x C)/Q

(4 ft3 x 7.48 gal/ft3) / (20 gal/min) = 1.5 minutes EBCT

(4 ft3 x 7.48 gal/ft3) / (5 gal/min) = 6 minutes EBCT

It has a tank size of 16” x 65”, and is designed to

have a catalytic GAC lifetime of 5+ years under normal operating

conditions. The pumps and electronic controller are operated by a 12-volt electrical system that costs

less than $2.00 a year in electricity charges.

There are several sizes and models of this tank designed to handle different max flow rates, and

they range in price from:

$995.00 - $1,795.00

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Figure 6: Relative dechloramination performance of a standard coal and coconut based activated

carbon, catalytic coal based carbon, and AquaSorb CX-MCA activated carbon. (Guar, 2013)

The AquaSorb CX-MCA Activated Carbon used in the U.S. Water Systems’ catalytic carbon filter

delivers high performance for low cost, and is proposed for use in the treatment of Ellison Brewery &

Spirits intake water treatment system.

Brewery Wastewater

There are numerous technologies available for the treatment of wastewater. The two

fundamental treatment techniques involve biological treatment by either aerobic or anaerobic

processes. Within these two branches, there are many different options. This proposal will analyze side

streaming pre-treatment, lagoon treatment, aerobic membrane bioreactor, oxidation ditching, and

direct sewer discharge before providing a detailed design of an anaerobic treatment system.

Side Streaming

The most common form of brewery wastewater pre-treatment is side streaming. Side streaming

is the process of separating high strength waste from lower strength waste at the source of waste

production. Spent grain, trub, and spent yeast are collected separately. Then they are either hauled off

site for agricultural use, or wasted down the drain. Depending on the limitations imposed by the

municipality, this could be enough treatment to reduce the nutrient load to an acceptable level for

discharge into the sewer without incurring a surcharge. Side streaming can be expanded to include the

collection of lauter tun plate rinsings, hop back rinsings, whirlpool rinsings, and waste beer. Many of

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these wastes are too wet to be hauled and used off site so they must be either hauled to landfills or

discharged to the sewer. However, some side stream products like spent grain can be used for cattle

feed or land applied fertilizer. (Brewers Association)

The side streaming process may only remove approximately 3% of the volume of wastewater,

but can account for up to 90% removal of BOD in some cases. For Ellison Brewery & Spirits, the side

streaming process will be focused on removing high strength spent grain waste and yeast. The spent

grain will be used as an animal feed supply for farmers, and the yeast will be discharged to the sewer.

Figure 7 highlights the process by which spent grain is produced in a brewery.

Figure 7: Spent grain is a high strength by-product of mashing during the brewing process.

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A separate drain and pump can be used to move the spent grain into temporary storage where

local farmers can truck it away. The storage tank is designed to be low maintenance, it will be necessary

to include a guided wave radar detector for monitoring spent grain depth in the tank. The tank will

qualify as a permit confined space under MIOSHA regulations, and an installed detector within the tank

is the safest way to monitor depth. Small brewery operations like Ellison will likely not be able to sell

their spent grain, but it is possible that farmers would be willing to absorb the cost of hauling in order to

acquire the product. However, it is important to recognize that volume, material, and cost are related.

The drier the spent grain, the more valuable it is. Water is not where the value lies in fertilizer. Spent

grain that has been reduced to between 70 – 80% moisture travels and stores well. If Ellison can work

out a deal that could net them some money for the spent grain, it may be worth the investment in a

simple belt press to reduce the water content of their spent grain before storage.

Lagoon Treatment

Treatment lagoons are a common and practical technique for the treatment of wastewater.

Lagoons can function aerobically, anaerobically, or as a facultative system (both aerobic and anaerobic).

In facultative lagoon, wastewater is first deposited in a deeper section of the pond. The flow velocity is

decreased, solids settle out, and an anaerobic process goes to work on the waste. As the water moves

from the deeper, anaerobic zone into the shallow zone, aerobic bacteria continue treatment. Facultative

lagoons offer high quality treatment under the right conditions, but require long detention times to

treat waste to acceptable discharge levels. These detention times increase as the strength of the waste

increases, and typical detention times can approach 200 days in northern climates. Facultative lagoons

are easy to operate, but it can be difficult to control harmful algae blooms that reduce the effectiveness

of treatment. They also require dredging as settled biomass can limit the function of the anaerobic zone.

The detention pond provided for storm water management near the brewery was considered as a

potential location. However, there simply is not enough space to design a lagoon that satisfies both

wastewater treatment and storm water detention. There is also the matter of permitting. A DEQ issued

NPDES permit would be necessary to regulate the discharge of water from the pond to the Red Cedar

River, and taking responsibility for meeting the permit limitations could become difficult if anything goes

wrong. For these reasons, lagoon treatment will not be considered a viable option for treating the

brewery wastewater.

Aerobic Treatment

Many different versions of aerobic wastewater treatment exist, and some form of this

treatment process is in place at nearly every municipal wastewater treatment facility. In traditional

activated sludge systems, flocs of oxygen-activated bacteria consume and remove organic waste from

pre-settled wastewater. Since the primary treatment tank is well mixed, there is usually a need for

settling in a secondary clarifier. Figure 8 is a diagram of how traditional activated sludge systems

operate. The cost in energy and disposal can become quite high with these systems since constant

oxygen and sludge removal is required. (Tilley, E., et al.)

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Figure 8: Activated Sludge systems require constant oxygen and sludge disposal

Systems like a membrane bioreactor (MBR) can achieve the same results with a smaller

footprint. In these systems, low-pressure microfiltration or ultrafiltration membranes are used to

perform solid – liquid separation. This means a smaller footprint and a higher solids retention time

(SRT). MBRs can achieve a high level of treatment, but still require high energy and operational costs

due to the continual demand for oxygen and removal of waste sludge. Membrane fouling can occur, and

high maintenance costs can be associated with MBRs.

Aerobic treatment is not commonly used in breweries except for where access to municipal

sewer systems is unavailable. Typically, brewers do not want to be in the business of treating

wastewater to such a high level. In the case of Ellison Brewery & Spirits, it is only required to meet the

limitations of the Sewer Discharge Permit. It is not economical to invest in the capital and operational

costs of an aerobic system to treat water that greatly exceeds regulation. For these reasons, aerobic

treatment will only be considered if other forms of treatment are not capable of reducing organic levels

to compliance with the Sewer Discharge Permit.

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Oxidation Ditches

Oxidation ditches include aerobic, anaerobic, and facultative zones. Oxygen is introduced into

the system by surface aerators like brush rotors, disc aerators, draft tube aerators, or fine bubble

diffusers. Dissolved oxygen concentrations is greatly increased in the zones following the aerators, but is

fully consumed in downstream sections. This results in

gradually facultative and anaerobic zones. Oxidation

ditches can treat water very effectively, but come with

many conditions that make it an unreasonable choice for

Ellison Brewery & Spirits. Capital and energy cost are

significant, and there is still the need for sludge wasting

from the system. In northern climates, there is a

problem of aeration rotors freezing. The cold

temperatures and fine mist produced by the rotors can

quickly cause problems that shut the system down, and

require time and money to fix. These systems also come

with a large outdoor footprint, and foul odors can be

released from the anaerobic zones. For these reasons,

oxidation ditches will not be considered as a viable treatment option for Ellison.

Direct Sewer Discharge

Many breweries with access to city sewer lines choose to discharge directly and not treat any of

their wastewater. This is only possible for breweries of a certain size since most publicly owned

treatment works (POTW) cannot handle the huge volumes of waste produced by large-scale breweries.

For smaller breweries, it is often cheaper to pay to deposit all their solid and liquid waste directly into

the sewer. Surcharges can be imposed and set by municipalities based on their capacity and ability to

treat high strength, high volume brewery wastewater. Table 4 identifies some of the surcharge costs in

different areas around the country. (Brewers Association)

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Table 4: Surcharge examples collected from medium sized breweries across the country

ELMWSA does not currently impose a surcharge. However, directly discharging without any side

streaming pre-treatment can be very costly. The populations of Syracuse, NY and Lansing, MI are similar,

and so the average value of $684 per month will be considered a reasonable surcharge for this proposal.

Under these assumptions, this is the most realistic and practical form of dealing with brewery

wastewater for Ellison Brewery & Spirits. It leaves all the difficulties associated with treating wastewater

to the professionals, and reduces risk and safety hazards for the brewery owners and operators.

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Wastewater Treatment Design

Beer is approximately 95% water in content, but an average of 70% (5 bbl wastewater : 1 bbl

beer) of the water used through the entire process ends up as wastewater. This is due to the need for

cleaning in place and waste from the packaging process. In the case of Ellison Brewery & Spirits, this

results in approximately 21,233 gal/day of wastewater. (Brewers Association)

1 Barrel = 31 Gallons

50,000 Barrels of Beer = (50,000 * 31) = 1,550,000 Gallons of Beer per Year

Multiplying this annual beer production figure by the industry average wastewater production

ratio of 5 to 1 results in an annual water demand:

1,550,000 Gallons of Beer = (1,550,000 * 5) = 7,750,000 Gallons of Wastewater Annually

Average daily wastewater production:

7,750,000 Gallons / 365 days = 21,233 Gallons of Wastewater per Day

Process water remaining after side streaming removal of 3% volume:

(21,233 Gallons / Day * .97) = 20,596 Gallons of Process Water per Day

In order to provide an accurate wastewater treatment design, it is necessary to establish some

baseline assumptions about the strength of brewery wastewater, and understand the mechanisms

behind anaerobic digestion.

Assumptions

The quality of brewery wastewater is uniquely different and stronger than domestic

wastewater. Brewery wastewater is high in sugar, alcohol, solids, and has a highly variable pH. Municipal

treatment plants are typically interested in load when it comes to the water they are treating, and

breweries produce very high loads of chemical oxygen demand (COD), biochemical oxygen demand

(BOD), and total suspended solids (TSS). Table 5 compares the typical strength of brewery wastewater -

with and without side streaming pre-treatment - with domestic strength waste and the Meridian

Township Sewer Discharge Permit, and illustrates the strength of some of the specific waste products of

the brewing process. (Mercer, 2017)

29

Table 5: Comparison of typical waste streams to discharge permit, and break out of high strength

brewing by-products by type

30

Mechanisms of Anaerobic Digestion

Anaerobic digestion is usually associated with very high capital costs (installed cost can be

between $700,000 and $1.2 million), and a certain level of experience to operate them successfully.

(Brewers Association) However, a healthy anaerobic digester can provide valuable methane in the form

of biogas, and provide some amount of return on investment. Anaerobic digesters are finding more and

more of a place in brewery wastewater treatment since the high strength waste, rich in sugars, provides

great food for bacteria. Anaerobic digesters for breweries are becoming more common in the United

States for breweries producing more than 100,000 bbl/year. The 50,000 bbl/year produced by Ellison

may not be an ideal scenario for anaerobic digestion, but the following sections will aim to provide a

detailed design for the practical implementation of an anaerobic treatment process for Ellison Brewery

& Spirits.

Designing an anaerobic digester first requires an understanding of the mechanisms and factors

that drive and limit the process. This section will explore the fundamental processes of anaerobic

digestion, and help identify the size requirements, hydraulic retention time, biogas production and

energy output, and effluent water quality. The anaerobic digestion process is typically carried out in four

stages: Hydrolysis; Acidogenesis; Acetogenesis; and Methanogenesis. Figure 9 summarizes the

anaerobic digestion process. (de Mes, 2017)

• Hydrolysis

Hydrolysis is the first step of anaerobic digestion. During hydrolysis, insoluble, complex

molecules like carbohydrates and fats are broken down to short sugars, fatty acids, and amino acids.

• Acidogenesis

In the second step, fermentative bacteria transform sugars and other monomeric organic

products of hydrolysis into organic acids, alcohols, carbon dioxide, hydrogen, and ammonia.

Acidogenesis also occurs during this step, and is the process where simple monomers are converted

into volatile fatty acids (VFAs).

• Acetogenesis

Anaerobic conditions are fully achieved during the third step, acetogenesis. During this step,

acetogenic bacteria use solved oxygen, carbon, and volatile fatty acids to produce acetic acid,

carbon dioxide, and hydrogen.

• Methanogenesis

During the fourth step, methanogenic bacteria (methanogens) transform acetic acid, carbon

dioxide, and hydrogen into a mixture called biogas. Biogas is made up of 50 – 75 % methane, 25 - 50

% carbon dioxide, and varying quantities of nitrogen and hydrogen sulfide.

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Figure 9: Summary flow chart of driving mechanisms within anaerobic digesters (de Mes, 2017)

Anaerobic digestion is a complex and delicate process that requires constant monitoring and

control. An environment in the digester that benefits one species may completely inhibit another, and

the digester can become quickly dysfunctional. With longer bacterial growth times than in aerobic

systems, anaerobic digesters can become hard to operate if they are poorly maintained. Temperature

and pH play very important roles in the successful biogas production and operation of anaerobic

digesters.

• Temperature

Temperature plays a very important role in anaerobic digestion. The temperature is inversely

proportional to metabolic rate, and plays a key role in biogas production. The higher the

temperature, the shorter the hydraulic retention time (HRT). Theoretically, anaerobic digestion can

occur anywhere in the range from 3 – 70 degrees Celsius, but three types of digestion are

distinguished depending on the temperature: psychrophilic digestion (10 – 20 ° C); mesophilic

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digestion (20 – 35 ° C); and thermophilic digestion (50 -60 ° C). Anaerobic digestion with biomass

temperatures below 15 ° C suffer from gas production so low that the operation is no longer

economically feasible. While thermophilic digestion produce more biogas in a shorter time, it also

produces higher volumes of free ammonia. Free ammonia can inhibit biogas production.

Additionally, operating a system in the thermophilic temperature range requires substantial energy,

and could cost more than it is worth to operate. The mesophilic range will be used as a target

temperature range for the design of Ellison’s anaerobic digester.

• pH

The pH of the biomass has a significant impact on the health and productivity of the two main

bacteria in anaerobic digesters, acidogens and methanogens. The best pH range for acidogens is 5.5

– 6.5, and for methanogens is 7.8 – 8.2. Methanogenesis is a rate-limiting step in anaerobic

digestion and biogas production. Therefore, a pH close to neutral is optimal. Part of the cost of

operating a healthy anaerobic digester is in providing alkalinity for the acid rich environment inside

the digester. In the case of brewery wastewater, pH can vary widely, with spikes from 2 to 12, but

generally maintains a pH of 4.5. It will be necessary to include buffering and conditioning tanks

before the anaerobic digester in the design of Ellison’s wastewater treatment system. Through the

process of anaerobic digestion, the pH will neutralize, and the pH of the effluent will be 7. This is an

acceptable pH for discharge into the sewer or any further treatment steps.

Buffering Tank

After side streaming, the remaining wastewater is called process water. It has lower COD, BOD, and

TSS, and should be moved to buffering and conditioning tanks for pH balance and equalization before

anaerobic digestion. Generally, brewery wastewater is acidic, around pH 4.5, but it can spike anywhere

from pH 2 to 12. It is important to monitor and record the pH of the wastewater generated from

different processes. After a short time, it will be possible to identify the times when pH spikes are

expected, and refine a treatment approach. pH adjustment can be achieved by dilution or chemical

addition. To raise the pH, 50% caustic sodium hydroxide (NaOH) is the cheapest way. However, NaOH

freezes at approximately 50 F. Using 30% caustic with potassium hydroxide (KOH) can lower the freezing

point, and make it easier to work with. This will increase the cost, but reduce the complications of

storing and applying the chemical. To lower the pH, a cheap acid can be used effectively. 96% sulfuric

acid (H2SO4) is considered the cheapest source. Another possibility could be harvesting CO2 from the

fermenter blow off and bubbling it through the wastewater storage tank. Safety is a drawback of

chemical pH control, and improper handling and storage of strong acids and bases can have lethal

consequences. Figure 10 shows the process of pH adjustment across mix tanks. Tanks like these can

function as holding tanks before discharge into the sewer system, and help equalize temperature and

flow. (Brewers Association)

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Figure 10: Process water after side stream solid removal receives chemical pH adjustment

Two tank are used for this process, and each tank should be designed to hold the full volume of a

day’s wastewater production (20,596 gal). The redundancy is to allow for extra space in the process in

the case that something goes wrong. There will be room if the digester needs to be down, or if there is a

mistake and an entire fermenter of beer is accidentally wasted. The additional tank could be bypassed

under regular operating conditions, or used as an additional equalization tank after digestion. A

retention time of 6 – 12 hours is recommended for buffering, but additional time may serve to balance

the pH of incoming wastewater, lowering chemical costs.

Anaerobic Digester

Continuous reactors like the Upflow Anaerobic Sludge Blanket (UASB) reactor are common in

the beverage industry. Process water from the conditioning tanks is pumped into the reactor, and

distributed evenly through the bottom of the reactor. This process helps to maintain a continually mixed

environment by providing a steady upward velocity within the tank, reducing settling and clumping. The

wastewater flows upwards through a “blanket” of anaerobic granular biomass. This is where the

anaerobic digestion process occurs, and bacteria convert organics to volatile fatty acids, methane, and

CO2. Since most of the organic waste in the water is in solution in a UASB reactor, there is significant

contact between granules and influent. Organics diffuse across granule surface layers, and contaminants

are removed as the water passes through the blanket layer. At the top of the reactor, a three-phase gas-

liquid-solid separator agitates gas bubbles free from formation sites at the surface of granular biomass.

The gas rises into a collection reservoir, and biomass settles back into the blanket layer. Treated effluent

passes over weir gates, and distributed to further process steps. The biogas can go straight to

conditioning and compression, and used for energy production. One unique use of biogas before

compression is to pass it through the headspace above the process water in the conditioning tanks. CO2

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can be removed from the biogas by diffusion at the gas/water interface. This helps purify the biogas for

use, and lowers the need for caustic chemical addition during pH balancing. Typically, CO2 and Hydrogen

Sulfide (H2S) are scrubbed from the biogas, and a purer methane fuel is produced. Figure 11 shows the

basic components of a UASB reactor system. UASB reactors are unique from classic anaerobic digestion

reactors because they typically do not require sludge recycling, and rarely need sludge removal. In

classic anaerobic digestion, influent with high solids content is fed into the digester. Bacteria need a long

time to breakdown the waste, and sludge recycling is required to provide the necessary solids retention

time (SRT). Additionally, sludge must be constantly removed and wasted from the digester. This

increases waste fees and O&M costs. The sludge in a UASB reactor consists almost entirely of granular

biomass and dead bacteria, and may only need to be removed once every two years. The wasted sludge

from UASB reactors is stable, and can be land applied or wasted in landfills. (Saleh, 2017)

Figure 11: An Upflow Anaerobic Sludge Blanket (UASB) reactor used for treating brewery wastewater.

Several important parameters govern the design of a UASB reactor. The majority of influent

organic concentrations should be in soluble form. UASB reactors achieve a high contact rate between

influent and biomass, and the lower the total suspended solid count the higher the efficiency. Table 6

highlights some ranges of important parameters for UASB reactors. (Saleh, 2017)

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Table 6: Important design parameters for UASB Reactors

The anaerobic digester will need to be designed to treat the full volume of brewery wastewater

produced in a day. Approximately 20,596 gallons of process water will need to be treated every day. This

translates to approximately 77,955 liters/day, or 3.25 m3/hr.

Calculations were performed across the range of acceptable values for a UASB reactor. The

following calculations summarize the assumed values and resulting size determination of the proposed

reactor:

Assumptions:

HRT = .5 days Upflow Velocity (V) = .5 m/hr Influent Flow Rate (Q) = 3.25 m3/hr

Calculations:

Tank Volume (Voltank) = (HRT) * (Q)

= ( .5 ) * ( 3.25 m3/hr )

= 39 m3

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Area of Reactor Bottom (A) = Q / V

= ( 3.25 m3/hr ) / ( .5 m/hr )

= 6.5 m2

Radius of Tank (R) = sqrt ( A / π )

= sqrt [( 6.5 m2 ) / π ]

= 1.44 m (approx. 5 ft)

Height of Tank (H) = Voltank / A

= ( 39 m3 ) / ( 6.5 m2 )

= 6 m (approx. 20 ft)

The calculated size of the tank seems to be reasonable in a practical and functional sense. A

diameter of almost 10 feet and a height of 20 feet is in line with expectations based on research of other

real systems. The OLR is the last limiting parameter, and is a function of organic concentration and tank

volume. The OLR was calculated using values from Table 5 by:

CODAVG = ( 9000 mg COD/L + 1800 mg COD/L ) / 2

= 5400 mg COD/L (converts to 5.4 kg COD/m3)

Daily Load = ( CODAVG ) * ( Daily Flow Rate )

= ( 5.4 kg COD/m3 ) * ( 78 m3/day )

= 421 kg COD/day

OLRCOD = ( Daily Load ) / ( Voltank )

= ( 421 kg COD/day ) / ( 39 m3 )

= 10.8 kg COD/m3 day

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The average BOD strength was taken from Table 5, and the OLR was calculated using the same

method. The OLR for the BOD in the system was found to be:

OLRBOD = 6.48 kg BOD/m3 day

The calculated OLRs for COD and BOD are within the acceptable ranges for the operation of a

UASB reactor.

Biogas Generation

Biogas is a methane rich, flammable gas that results from the decomposition of organic waste in

an anaerobic digester. While biogas is mostly methane, several other gases make up the remaining

components. (Biogas and Renewable Natural Gas, 2017)

Major Compounds:

• Methane ( CH4 ) [60 – 70%]

• Carbon Dioxide ( CO2 ) [40 – 30%]

Minor Compounds:

• Hydrogen Sulfide ( H2S )

• Ammonia ( NH3 )

• Hydrogen ( H2 )

Typically, anaerobic treatment of brewery wastewater generates about 0.4 – 0.5 Nm3 of biogas per

kg of COD removed, and the methane in biogas has a caloric value around 35 MJ/m3. Figure 12 shows

the annual removal efficiency of a Veolia Biobed UASB reactor used in the wastewater treatment

process of Unicer Brewery in Oporto, Portugal. This example treatment system is similar to the proposed

Ellison system. It uses a side streaming treatment process, and buffering and conditioning tanks before

anaerobic treatment. It can be assumed that the Ellison brewery will achieve similar removal

efficiencies. (“Biothane”, 2017)

38

Figure 12: Example COD removal efficiency from equivalent brewery anaerobic digestion process.

The average COD removal efficiency in the case of Unicer Brewery is approximately 87%. Using the

average value of COD removal (with side streaming) from Table 5 (pg. 8), the daily load of removed COD

can be calculated for Ellison Brewery & Spirits as follows:

Daily Average COD Load of Brewery Wastewater with Side Streaming:

( 1800 + 9000 mg/L ) / 2 = 5400 mg/L COD

77,955 L * ( 5400 mg/L ) * ( 1 kg / 106 mg ) = 421 kg total daily COD load

COD Removal at 87% efficiency: ( 421 kg ) * .87 = 366 kg/day

Biogas Generation: ( 366 kg/day ) * .45 Nm3/kg = 165 Nm3/day

Energy Potential: ( 165 Nm3/day ) * (70%) * ( 35 MJ/m3 ) = 4043 MJ/day

39

In 2016, the average monthly natural gas commodity price was $3.00 per million BTUs (MMBTU).

Conversion factor for methane to MMBTU is:

1 MMBTU = 28.32 m3 CH4

The annual value of the methane in the biogas produced by Ellison’s UASB reactor can be found by:

(115.5 m3 CH4/day) * (1 MMBTU/28.32 m3 CH4) * ($3/MMBTU) * (365 day/year) = $4466 /year

While this does provide some amount of return on investment, it may not be enough to offset

the high capital cost of a UASB reactor. However, these values are in line with research done on other

brewery’s anaerobic digester systems. The biogas produced from Ellison’s anaerobic digester can be

harvested and compressed. The biogas can be used to power a natural gas boiler for the heat exchanger

that produces influent biomass temperatures in the mesophilic digestion range of 20 – 35 ° C. The

addition of a waste gas burner will be added to the system after the digester for biogas overload

emergencies.

Effluent Water Quality

The ultimate goal of any wastewater treatment system is to efficiently and economically treat water

to the required standards. The anaerobic digester designed for Ellison Brewery & Spirits will be able to

achieve an 87% removal efficiency. Table 7 compares the treated effluent to the untreated influent and

domestic wastewater, and highlights the average outcomes. It can be seen that through side streaming

and anaerobic digestion, the wastewater ends up close to the strength of domestic wastewater, and

does not need further biological treatment. The effluent can be safely discharged to the sewer collection

system.

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Table 7: Comparison of Treated Effluent to Meridian Township Sewer Discharge Permit

The COD and TSS concentrations of the treated effluent comply with the Meridian Township

Sewer Discharge Permit, but the BOD concentration is slightly high. However, it is possible that the

ELMWSA would be willing to allow for such a minor exceedance. If the municipality is unwilling to

compromise in their enforcement of the permit limitations, it is advised that Ellison pay the small

surcharge. The cost of including an aerobic treatment process after anaerobic digestion does not make

economic sense.

41

Pump Design

A pump will be required to move water from the buffering tank to the anaerobic digester.

Effluent recycling in classic anaerobic digestion systems is commonly used to provide longer SRTs and

higher upflow velocities. However, the UASB reactor for Ellison will not require effluent recycling for any

reason. Hand calculations used to estimate the required pump head can be found on page______ of the

Appendix. The resulting pump head is equal to 9.93 feet. This value is estimated, and based on

assumptions. However, it helped focus the search for an appropriate pump. The product information for

Bell & Gossett’s NRF series single and 3-speed pumps is shown in Figure 13. (Bell & Gossett, 2017)

Figure 13: Bell & Gossett NRF Series pump performance curves

Based on the required pump head of 9.93 feet and the flow rate of 14.3 gal/min, the curves for

the NRF-9F/LW Single Speed Pump and the NRF-25 3-Speed

Pump were used in the EPA’s computerized simulation

software, EPANET 2.0. Table 8 shows the output tables of

the links and nodes connecting the EQ tank to the

anaerobic digester. A successful simulation was

conducted using the NRF-25 Pump through a 6 inch

diameter pipe network, and a tolerance of 8 feet

elevation between the tank and reactor. The iterative

method of EPANET 2.0 resulted in a flow rate of 15

gal/min. This is very close to the required flow rate of 14.3

gal/min, and it is expected that the pump will be capable

of operating at a high efficiency. SupplyHouse.com offers

the Bell & Gossett NRF-25 Red Fox Circulator 3-Speed

Pump for $84.95.

42

Table 8: Output tables of the links (top) and nodes (bottom) of the included in the pumping network

Sewer Collection System

The effluent from the anaerobic digester will be discharged directly to the sewer. Meridian

Township’s sewer system serves an approximate population of 39,668 (2010). Their collection system is

made up of approximately 195 miles of vitrified clay pipe (VCP) ranging in sizes from 6 to 48 inches. The

current infrastructure serving the brewery includes an 8-inch sanitary sewer line carrying water from the

brewery to a 36-inch trunk line, with an average slope of 0.048. The 36-inch trunk line expands to 48

inches before crossing the Red Cedar River near the proposed bridge location. At Hagadorn Road,

Meridian’s system connects to East Lansing’s 48-inch line through MSU. Meridian Township has included

in their Master Plan the additional development anticipation of what equates to between 8,000 to 9,357

people. With an average home consisting of approximately 2.4 people, this equates to the addition of

approximately 4000 homes. Figure 14 shows the locations and diameters of Meridian Township’s sewer

collection system in the area of the brewery and pathway. (“Collection System”, 2017)

43

Figure 14: 8-inch sanitary sewer lines connect to the 36-inch trunk line for Ellison Brewery & Spirits

The brewery will produce approximately 14.3 gal/min of wastewater. This will be a significant

source of flow for the current collection system, but should not overwhelm the system or require

upgrades. Depending on the capacity limitations of the current collection system, it would be possible

for the brewery to discharge into the sewer during off-peak hours at night. This would help limit any

capacity problems, and reduce demand on the municipal treatment plant. If Ellison is required to

discharge over a six-hour overnight time slot, a storage tank will need to be provided after digestion,

and the flow demand on the sewer system would increase from 14.3 gpm to 57 gpm. Table 9 shows the

carrying capacity, in gallons per minute, of different sized pipes at varying slopes.

44

Table 9: Sewer system capacities measure in gallons per minute. (CulverConstruction, 2017)

It can be seen that the flow rate of a low estimate slope pipe is sufficient for the volume of

wastewater being produced. It was advised that the current demand on the collection system be

assumed as zero for the purpose of this research. In this, case there is plenty of capacity to handle the

brewery’s effluent.

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Conclusion

The expansion of Ellison Brewery & Spirits’ production facility will generate some complicated

environmental engineering problems, and require creative solutions. Fortunately, there are many

treatment options available. The most practical design consists of discharging all waste streams into the

sewer, and paying the municipal surcharge. This option requires the least amount of capital investment,

and requires no technical skill. Using an anaerobic digester unlocks the energy potential in the brewery

wastewater, and provides an opportunity for sustainability and return on investment. The brewery can

expect to recover approximately $4466 per year in energy savings, and treat the water to acceptable

standards. However, discharge costs will not be zero. The municipality may choose to charge a fee due

to BOD concentration being out of compliance. There may also be a surcharge for any other brewing by-

products that go down the drain like spent yeast and trub. Table 10 identifies the expected costs of

various treatment options. Used tanks are available that can easily serve as buffering tanks. These tanks

can be made of stainless steel, plastic, or fiberglass. The price provided in the table lists a range of prices

for used tanks that include actuated mixers and controllers. UASB tanks can be made of coated stainless

steel. These types of reactors do not include any mechanical pieces, and could potentially be built at a

lower-than-market cost. Typically, anaerobic digesters cost a million dollars, but a vendor in China

advertises UASB reactors between five and fifty thousand dollars. It is unclear what the shipping cost

would be, but this may be a cheap way to obtain a UASB reactor tank.

Table 10: Treatment process cost comparison

Total Cost for Anaerobic Digester Treatment System:

$738,330 - $1,249,365

46

The construction schedule for the intake and wastewater treatment system will be heavily self-driven. It

will be necessary to delay construction of the new facility until the upgrade to the storm water

management system is complete. After the water resource work is complete, Ellison can begin

construction of their new facility and water treatment processes. Brewing can take place during the

procurement, construction, and start-up phases. Effluent from the brewing process can be run through

the system, but the initially low level of treatment will mean the surcharge will need to be paid for those

months. Sludge can typically be acquired from other breweries using anaerobic digestion. This may

come along with a small cost, but it will be crucial in jump-starting the digestion process. The

methanogens responsible for biogas production take a long time to reproduce, and the system will likely

take between 4 and 16 weeks to become operational.

Figure 15: Construction Schedule for intake and wastewater treatment at Ellison

47

Appendix

Pump Design Hand Calculations

48

49

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