Brewery Water/Wastewater Conservation November 25, 2019 Presented - - PowerPoint PPT Presentation

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Brewery Water/Wastewater Conservation November 25, 2019 Presented - - PowerPoint PPT Presentation

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Brewery Water/Wastewater Conservation November 25, 2019 Presented By: Scott R. Shirley, Michael A. Smith, PE and Shane M. Mullen, PE CPESC to the Vermont Green Brewery Cohort Vermont Green Brewery Cohort Presenters Scott Shirley Head

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Brewery Water/Wastewater Conservation

Scott R. Shirley, Michael A. Smith, PE and Shane M. Mullen, PE CPESC

to the

Vermont Green Brewery Cohort

Presented By:

November 25, 2019

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Presenters

  • Scott Shirley – Head Brewer
  • Michael Smith, PE – Team Leader
  • Shane Mullen, PE CPESC – Senior Project Engineer

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Why is Brewery Water Conservation Important?

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Why is Brewery Water Conservation Important?

  • Impacts Environment
  • Impacts Community

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Why is Brewery Water Conservation Important?

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Water Supply Wastewater Disposal Brewery Water Resources

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Brewery Water Issues

  • Cost of water capacity
  • Brewery water needs conditioning ($)
  • More water use is more wastewater generated
  • Environmental impacts

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Brewery Wastewater Issues

  • Management of wastewater and residuals
  • Trouble finding capacity
  • Cost of capacity
  • Taking focus away from brewing

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Community Wastewater Issues

  • Environmental Management
  • Organic Load from brewing
  • Nutrient Load from brewing
  • Capacity limitations
  • Regulatory restrictions
  • Conflicts with growth goals
  • Inconsistent Approach

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What’s In the Wastewater

  • Organics/Solids:

 Spent Grains  Yeast  Biochemical Oxygen Demand (BOD5):

Best Management Practices – 2,500 to 3,000 mg/L Poor – 10,000 to 15,000 mg/L

 Total Suspended Solids (TSS):

Best Management Practices – 500 to 1,000 mg/L Poor – 8,000 to 15,000 mg/L

 pH

Typically in the range of 5 – 6 S.U.

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What’s in the Wastewater

  • Municipal Wastewater Treatment Facilities

 BOD5 - 250 to 350 mg/L  TSS - 250 to 350 mg/L  pH - 7 to 8.5 S.U.

A little brewery wastewater = A LOT OF CAPACITY

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Best Management Approach

  • Side Streaming:

Spent Grains Yeast Trub

  • First Rinse Management:

Collect additional solids and yeast

  • Pre-treatment:

Conditioning Aerobic Treatment Anaerobic Treatment

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Lawson’s Finest Liquids

  • Water Conservation:

Canning - Can Rinse Cooling Water CIP System: Lauter Tun Bright Beer Tanks

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Lawson’s Finest Liquids

  • Minimize Wastewater Generation:

Side Streaming

Trub Tank Bottoms First Rinse

Keg Returns Waste Beer from Taproom

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Wastewater Pre-Treatment

  • Conditioning
  • Aerobic
  • Anaerobic

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Conditioning

  • Typically for Municipal Connections
  • Settling and Buffering
  • pH Adjustment
  • Disolved Oxygen (D.O.)
  • Effluent Monitoring:

 Flow  DO  pH

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Aerobic Pre-Treatment

  • For Municipal Connections and In-ground
  • Settling and Buffering
  • pH Adjustment
  • Aerobic Treatment
  • Solids Separation
  • Effluent Monitoring:

 Flow  DO  pH  BOD  TSS

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Anaerobic Pre-Treatment*

  • For Municipal Connections
  • Settling and Buffering
  • pH Adjustment
  • Anaerobic Treatment
  • Solids Separation
  • Effluent Monitoring:

 Flow  DO  pH  BOD  TSS

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*for larger breweries

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When is Pre-treatment Required

  • Any Subsurface Disposal
  • Municipal Connections:

 Organic Loading is > 5% of Municipal Capacity  Hydraulic Loading is > 5% of Municipal

Capacity

 If community requires it in their ordinance

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What Brewers May Need to Do

  • Request Treatment Capacity from Community
  • Negotiate High-strength WW Agreement
  • Permitting
  • Design Review by Municipality and State
  • Residuals (spent materials) Management
  • Effluent Sample/Monitor/Report

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Planning Considerations

  • Work with a qualified engineering consultant
  • Detailed Wastewater Quality Analysis
  • Evaluate Packaged and Component Systems
  • Pilot Packaged Equipment
  • Hire a Licensed Wastewater Operator
  • Consider Long-term O&M
  • Consider Long-term Goals for Growth

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Trapp Brewery – Stowe, VT

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Background:

  • 50,000 bbl/year – New Brewery
  • Industrial capacity at Stowe WWTF
  • pH adjustment
  • Flow, pH and DO monitoring

Project:

  • Conditioning (pH)
  • No BOD removal
  • Cost: $300,000
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Trapp Brewery – Stowe, VT

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Trapp Brewery – Stowe, VT

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First Rinse Management

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Alchemist Brewery – Stowe, VT

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Background:

  • 9,000 bbl/year – New Brewery
  • Need capacity at Stowe WWTF
  • pH adjustment
  • BOD Removal
  • Flow, pH and DO monitoring

Project:

  • Settling
  • Conditioning (pH)
  • BOD removal (MBBR)
  • Cost: $750,000
  • $4,000 per lb. BOD rem./day
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Alchemist Brewery – Stowe, VT

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Yeast Not Good

Pilot Testing

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Alchemist Brewery – Stowe, VT

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Alchemist Brewery – Stowe, VT

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Woodstock Inn Station & Brewery Woodstock, NH

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Background:

  • 10,000 bbl/year – Existing Brewery
  • Heavy BOD load to Municipal WWTF
  • pH adjustment
  • BOD Removal – Failed System
  • Flow, pH and DO monitoring

Project:

  • Settling
  • Conditioning (pH)
  • BOD removal (Trickling Filter)
  • Cost: $500,000
  • $2,300 per lb. BOD rem./day
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Woodstock Inn Station & Brewery

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Pilot Project

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Woodstock Inn Station & Brewery

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Woodstock Inn Station & Brewery

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Woodstock Inn Station & Brewery

Trickling Filter

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Woodstock Inn Station & Brewery

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Biomass Growth

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Woodstock Inn Station & Brewery

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Biomass Growth

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Woodstock Inn Station & Brewery

Key Design Considerations:

  • Re-used much of the existing process equipment to save cost
  • “calamity” storage to protect Pre-treatment System
  • Primary Settling
  • Equalization for biological process
  • Flow metering (recording)
  • Composite sampling capabilities
  • PLC controls

Results:

  • Domestic Strength Wastewater Discharged
  • Solids accumulation at the Municipal WWTF back to normal

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Lawson’s Finest Liquids – Waitsfield, VT

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Background:

  • 14,000 bbl/year – New Brewery
  • Subsurface Disposal
  • pH adjustment
  • BOD Removal
  • Flow, pH and DO monitoring

Project:

  • Settling
  • Conditioning
  • BOD removal
  • Cost: $700,000
  • $4,500 per lb. BOD rem./day
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Lawson’s Finest Liquids – Waitsfield, VT

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MBBR & Trickling Filters

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Lawson’s Finest Liquids – Waitsfield, VT

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Lawson’s Finest Liquids – Waitsfield, VT

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Finished Construction

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Others In Progress

  • Brewster River Brewing – Jeffersonville, VT - Planning
  • Tree House Brewing – Charlton, MA – Piloting
  • Nobletown Brewing – Hillsdale, NY – Construction

Past Projects

  • Alchemist Brewing – Waterbury, VT – Metering & Sampling
  • Fiddlehead Brewing – Shelburne, VT – Capacity Allocation
  • Lawson’s Finest Liquids – Warren, VT – Permitting
  • Collaborative Brewing – Waitsfield, VT - Design & Permitting
  • Fat Orange Cat Brewing – East Hampton, CT – Design
  • Great Marsh Brewery – Essex, MA - Design

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Key Wastewater Planning Considerations

  • Every application is different
  • Brewery wastewater is nutrient deficient
  • Characterize your wastewater before doing anything else
  • Use “Wastewater Process Engineer” with brewery experience
  • There are no “black box” solutions
  • Evaluate Costs (20-year life cycle)
  • Evaluate Expandability of the WW System
  • Pilot new equipment before design
  • Involve community (WWTF) and State (Permitting) early
  • Best management practices reduce treatment costs
  • Design/Build approach can reduce construction cost

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Lawson’s Finest Liquids State of Vermont Vermont DEC Our Brewery Clients and Team Members

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Questions & Discussion

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Thank You for Your Time

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