Pepsi Howell • Pepsi Production Facility in Howell, MI 1
Pepsi Howell Pepsi Howell • Pepsi Production Facility in Howell, MI – Production began in 1969 – Produce: • 12oz Cans • 16.9oz • 20oz • 1L • 2L • Fountain Syrup 2
Pepsi Howell • Pepsi Production Facility in Howell, MI – Produce 30 Million Cases/Year – 335,000 Square Feet Warehouse – Local Sales to Howell – Transport throughout Michigan Pepsi Howell 3
Pepsi Howell Can Line Filler – 1600 cans/minute 4
Can Line Packer – 12pk History • Why Pretreatment System – BOD Loading • Spikes in excess of 8,000 mg/L – Phosphorus • As high as 50 mg/L – Low pH • Acidic products, pH below 5 – Fluctuations Throughout the Day • High Sugar Days • Low Flow during Plant Downtime • High Flow during Production • Chemical Flow during Night 5
History • Constraints – Lack of Land Space – High Priority on “Clean” Effluent – Fluctuations in Flow from Production Facility • Initial Attempts – High BOD Capture for Slow-Release – Reduction of Waste Streams MBR Installation • Membrane System Installed – Maintain Healthy Biomass to Consume ‘sugar’ – Small Footprint – Very Clean Discharge • What is it? – Many Small Membranes to Filter Out Clean Water – Hollow Fiber Tubes with Nominal Pore Size of 0.04µm 6
MBR Installation • Overall System – Two Lift Stations – Equalization Basin – Aeration Basin (Digester) – Membrane Cassettes – Belt Press – Design flow rate 160,000 gallons per day, 220,000 gal. max MBR System EQ 7
Lift Stations Isabell McPherson MBR System EQ 8
Equalization Basin MBR System EQ 9
MMBR Tank & Aeration Basin MBR System EQ 10
Membrane Tank Zenon Membranes 11
Zenon Membranes Membrane Cleaning 12
MBR Cleaning MBR Cleaning 13
MBR Cleaning MBR Cleaning 14
MBR Cleaning MBR System EQ 15
Solids Pressing MBR System EQ 16
Permeate Flow to City of Howell Challenges • Fragile Sludge • Fluctuations in Sugar Loading and Plant Flow • Solids Removal • High Oxygen Requirement 17
Challenges: Fragile Sludge Started with Feed-Back Control – To ensure healthy biomass 100:5:1 ratio required (Carbon/Nitrogen/Phosphorus) – Phosphorus needs met with flow characteristics – Aqueous Ammonia added to Equalization Basin based on TOC Anaylzer results Challenges: Fragile Sludge TOC Analyzer – Real time analysis of Total Organic Carbon of Equalization Basin • Total Organic Carbon: Amount of carbon bound in an organic compound and is often used as an indicator of water quality • Rapid and accurate alternative to COD (chemical oxygen demand) – Programming • Dose Aqueous Ammonia as TOC increases • Challenges: • Analyzer requires large amount of maintenance • Expensive to maintain • Cannot react quickly to large and quick increases of TOC 18
Challenges: Fluctuations in Sugar Loading and Plant Flow Fluctuations – Plant runs 16-20 hours per day of various sugar and non sugar products – During off hours, cleaning is completed with large amounts of water and chemicals – Weekends with no plant production = no sugar for biology for 2+ days • Challenges: • Constant awareness of sugar loading • Addition of sugar during periods of plant downtime • Minimal sugar = death of biology Challenges: Solids Removal Filter press upgrade Spring 2008 – Double belt press – Press wash water uses system water (reducing loading, increasing efficiency) – Change in polymer (custom blended) and Custom feed equipment built May 2008 – Solids exiting press transitioned from 5-6% up to 10-13% and have reached 14-17% – Flow across press has moved from 8-10 gpm to 30-50 gpm and now runs at 90-110 gpm. – Mixed Liquor Suspended Solids (MLSS) dropping to desired levels of 7000-9000 ppm • Challenges: – Expensive to haul away solids – Currently solids are not being recycled – looking into an alternative use for the solids 19
Challenges: High Oxygen Requirement Aeration Upgrade – Two 150 HP blower motors running continuously (previously one 100HP blower) – Electrical upgrade to support blowers Increased Testing – TOC/COD, NH3, permeate testing – Automatic pH control – CST (Capillary Suction Time) monitoring CST and associated permeability 20
Biological Observation Biological Impact 21
Pepsi & City of Howell • Pepsi – Complete required daily testing per wastewater permit • Ammonia • Phosphorus • pH • Total Suspended Solids • BOD (outside laboratory) – Monthly Composite Permeate and Flow Reports – Semi-Annual Trending Reports Monthly Report – Composite Results Phosphorus BOD TDS TSS Ammonia pH August (mg/L-P) (mg/L) (mg/L) (mg/L) (mg/L-N) (SU) 1 0.734 3.5 950 1.5 0.61 7.6 2 0.626 2.3 840 3.5 0.18 7.6 3 0.731 9.8 1080 4.5 0.15 7.6 4 1.63 14.0 1030 3 0.22 7.4 5 1.05 52.0 1190 3.5 0.19 7.4 6 0.746 55.0 1340 5 0.03 7.5 7 0.644 34.0 1190 5.5 0.04 7.5 8 0.573 2.4 1040 1 0.03 7.6 9 0.539 2.1 1110 5 0.02 8.3 10 0.213 < 2.0 940 3 0.07 8.1 11 0.496 3.5 910 3.5 0.07 7.7 12 0.752 6.6 970 4 0.04 8.3 13 0.637 13.0 970 1.5 0.03 8.3 14 0.627 < 2.0 910 0.5 0.03 8.2 15 0.582 < 2.0 920 2 0.28 8.2 16 0.537 5.6 1240 1 6.90 8.2 17 0.489 < 2.0 1180 4 0.02 8.2 18 0.590 2.3 1140 0.5 0.03 7.9 19 0.694 6.3 1190 1 0.09 8.1 20 0.568 5.4 1070 3 0.78 8.1 21 0.556 < 2.0 1080 1.5 0.02 8.4 22 0.486 < 2.0 1100 2 0.15 8.3 23 0.444 < 6.0 860 0.5 0.03 7.9 24 0.424 19.0 710 2 8.64 7.8 25 0.463 5.8 630 4 7.30 7.4 26 0.489 6.1 560 3 1.75 7.5 27 0.501 13.0 540 2.5 12.80 7.8 28 0.330 17.0 570 3 4.63 7.8 29 0.312 11.0 600 3 1.71 7.7 30 0.289 33.0 630 3.5 8.86 7.8 31 0.324 57.0 640 3 15.65 7.4 Total 18.076 397.7 29130 84.5 71.31 243.6 AVE 0.583 12.83 940 2.7 2.30 7.9 22
Monthly Report - Flow MONTH August YEAR 2012 PRETREATMENT PLANT MCPHERSON PIT ISBELL PIT PERMEATE FLOW METER DAY GALLONS DAY GALLONS READING GALLONS 1 142,154 1 43,280 actual 239793 169,000 actual 2 150,761 2 46,221 actual 240000 207,000 actual 3 127,862 3 32,500 actual 240197 197,000 actual 4 97,100 4 46,371 actual 240324 127,000 actual 5 40,159 5 17,158 actual 240324 0 actual 6 49,816 6 20,107 actual 240389 65,000 actual 7 121,706 7 33,477 actual 240540 151,000 actual 8 149,071 8 46,883 actual 240705 165,000 actual 9 121,421 9 43,155 actual 240926 221,000 actual 10 116,505 10 38,793 actual 241098 172,000 actual 11 47,419 11 44,140 actual 241226 128,000 actual 12 18,704 12 17,038 actual 241254 28,000 actual 13 32,678 13 18,043 actual 241282 28,000 actual 14 148,143 14 44,739 actual 241464 182,000 actual 15 142,042 15 43,019 actual 241680 216,000 actual 16 154,164 16 39,405 actual 241899 219,000 actual 17 137,141 17 33,683 actual 242114 215,000 actual 18 126,657 18 36,101 actual 242310 196,000 actual 19 52,632 19 18,542 actual 242346 36,000 actual 20 52,980 20 27,538 actual 242376 30,000 actual 21 141,410 21 41,478 actual 242573 197,000 actual 22 163,714 22 49,636 actual 242765 192,000 actual 23 145,951 23 44,414 actual 242985 220,000 actual 24 150,243 24 50,247 actual 243214 229,000 actual 25 126,716 25 55,507 actual 243411 197,000 actual 26 125,370 26 31,523 actual 243541 130,000 actual 27 55,912 27 26,294 actual 243598 57,000 actual 28 150,862 28 48,106 actual 243813 215,000 actual 29 147,631 29 53,557 actual 244020 207,000 actual 30 157,468 30 50,323 actual 244239 219,000 actual 31 135,446 31 49,769 actual 244426 187,000 actual TOTAL 3,529,838 TOTAL 1,191,047 TOTAL 4,802,000 AVG 113,866 AVG 38,421 AVG 154,903 Pepsi & City of Howell Daily Bench Sheet 23
PERM Computer PH Lab PH Probe EQ COMP Low Hach High Hach Probe Ammonia PERM <VRS> T-PHOS Time of Sample: COMP <VRS> COD EQ <VRS> Low Hach High Hach Probe EQ Low Hach High Hach Probe Ammonia PERM <VRS T-PHOS EQ <VRS COD CST press%solids Perm TSS COMP TSS AR TSS TIN FILTER FILTER FILTER WET DRY DRY DRY DRY 1st 1st 1st Final Filter Filter Filter Standards Ran Weekly DRY DRY DRY Ammonia 1 mg/l LOT# A2054 RESULT = Dup Dup Dup Ammonia 10 mg/l LOT# A1272 RESULT = PH Probes Cleaned PH Probes Calibrated Phosphate 10 mg/l LOT# A2069 RESULT = EQ EQ COD 1,000 mg/l LOT# A1276 RESULT = AR AR Composite Fridge Chemical Treatment Volumes Checked: Hand Hand TEMP (F) Hydroxide Ammonia Probe Calibration (Daily) Ammonia Lot # STD mg/L MV QC Sample Slope TOC READINGS 1:00 AM 10:00 AM 8:00 PM 4:00 AM 1:00 PM 10:00 PM *If slope is not between -54 and -60, check for problems 8:00 AM 4:00 PM 1st Shift Intials: 2nd Shift Intials: Pepsi & City of Howell • Pepsi – Communicate with City of Howell on all challenges and discharge quality – Partner with City of Howell to complete an annual inspection of the entire facility • Continuous Improvement – Working with City of Howell on new QA-QC Sampling Program 24
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