Stone Brewing Co Brewing and Residual Treatment What

Stone Brewing, Co. Brewing and Residual Treatment What comes in (influent), Must go out (effluent)!

Leo Schempp - Former Operations Manager, Leucadia Wastewater District Wastewater Manager at Stone Brewing Company CA Certified Wastewater Treatment Operator Grade V BS - Chem Eng, AS - Geo Info Systems (GIS) Lschempp 13@gmail. com Previous life: - Wastewater Instructor, Palomar College - US Navy – surface ships operating “on the water” 12/3/2020 2

History and Background • Founded in 1996 by Greg Koch and Steve Wagner • Initial brewery in San Marcos • Relocated to Escondido in 2005 • Stone Brewing World Bistro and Gardens 2006 opened in 2006 12/3/2020 3

History and Background • Packaging Hall built in 2014 • 2017 annual revenue ~ $250 million • Substantial part of the $1 billion economic impact craft breweries provide to the region 12/3/2020 4

Stone Brewing Locations Breweries: Escondido, CA Richmond, VA Berlin, Germany Bistros: Escondido, CA Liberty Station, SD, CA Napa, CA Richmond, VA Tasting Rooms: Shanghai, China Oceanside, CA Pasadena, CA Other locations: Petco Park, San Diego, CA Terminal 2, San Diego Intl Airport 12/3/2020 5

Beer production/sales • 19966 12/3/2020 6

Brewery Water Operations • Provide brewery with adequate water supply and quality – No chlorine or chloramine residual – Hardness objective: 110 -120 mg/L Ca. CO 3 – Ca Hardness objective: 70 mg/L Ca. CO 3 • What is incoming water source and quality? 12/3/2020 7

Brewery Water Operations • Provide brewery with adequate water supply and quality – No chlorine or chloramine residual – Hardness objective: 110 -120 mg/L Ca. CO 3 – Ca Hardness objective: 70 mg/L Ca. CO 3 • What is incoming water source and quality? 12/3/2020 8

Sources of San Diego County’s Water Supply LAKE SHASTA State Water Project (Bay-Delta) LAKE OROVILLE Typically, San Diego County imports significant potions of its water supply Colorado River Desalinated Seawater

Brewery Water Treatment • Carbon adsorption – EBCT 7 to 10 minutes – 80 to 120 gpm – Two 2000 -lb carbon units – Chloramine/THM removal – 2. 5 mg/L Total Cl 2 – Sample everyday 12/3/2020 10

Brewery Water Treatment • Reverse Osmosis – removes ~ 99% hardness – Need to blend hardness back in to meet objectives – 100% SPW – Bypass RO treatment – As CRW % increases RO treatment increases – Desal/CRW- bypass RO 80 -100% Desal and add minerals; RO below this – Desal/SPW Bypass RO and add minerals – Two 60 gpm trains 12/3/2020 11

Stone Brewing Co Escondido 2017 Volumes Remember: 1 Barrel [Fluid] = 31. 5 Gallons [US, Fluid] Brewery produced 296 kbbl (9. 3 Mgals – 28. 5 ac-ft) Brewery used about 42 Mgals of water (129 ac-ft) (4. 5 gals of water for every gallon brewed) Brewery recycled about 17. 5 Mgals this year Brewery rejected 1. 5 Mgal (4. 6 ac-ft) as brine Recycle ~ 40% of potable water used 12/3/2020 12

Sustainability Drivers • Economics • Short-term – water is inexpensive • $1000/$0. 005/gal = 200, 000 gallons or ~ 100 gallons/day for 5 years for reasonable ROI • Long-term – more water savings => more regional development => more beer drinkers • Savings Incentives Programs – MWD • $65, 000 in water savings rebates, so far • Image/Brand awareness 12/3/2020 13

Brewing Process Overview Malted Barely Milling Mashing Lautering Kettle Boiling Whirlpooling Centrifuging Packaging/ transporting Carbonating Filtering Fermenting Dry Hopping

Sustainability Drivers • Stress on water supplies – Water demand tripled in US between 1950 and 2000 – California in extreme drought • Pollution – Clean Water Act • Pollution prevention facilities • Discharge Permits 12/3/2020 – – Apply, then Comply or be Denied NPDES: Nation Pollution Discharge Elimination System Certified Labs, Certified Operators, Certified Reports Self-Monitoring and Reporting 15

Water and Wastewater Technology • Processes and Equipment that separate Liquids from Solids • Can be Biological, Physical, Chemical, or some combination of these three.

Another way of looking at the Environment (the world we live in) Grain, Hops Ingredients Brine City Water Brewery RO Water Wastewater Drain System Spent Grain Yeast Drip Tank Wastewater Facility (Separates Solids from Water) Solids Safe Disposal Site Clean Water

Stone Brewing Co 2016 Residual Volumes Liquids: Almost 50, 000 gals/day Recycled Water (for cleaning, heating, and cooling) never used for beer 42, 000 gals/day Brine (WDR R 9 -2014 -0097) High Strength Solids: 2, 500 tons per year of aerobic sludge (for composting) 1. 5 Mgal per year Spent Yeast (130, 000 ppm COD) 1. 9 Mgal per year LT Drip (80, 000 ppm COD) 12/3/2020 19

Cooling Tower HARRF (overflow) Brewery (Urea) 1999 Citracado Pkwy Sump Tank MBR AT North 65000 gallons EQ Rotary Screen 72000 gallons (RO feed) blowers Reclaim Water Tank (RO feed) Tank R R MBR Packaging Hall 1977 Citracado Pkwy (Permeate) WWRO#2 UF T sanitary sewer AT South 65000 gallons WWRO#1 Rincon Potable Water (Brine) (Coagulant) Cooling Tower (Polymer) EQ = equalization tank AT = aeration tank MBR = membrane bio-reactor UF = Ultra-filtered water RO = Reverse Osmosis T = Turbo-blower R = Rotary-lobe Blower Brewery 1999 Citracado Pkwy Screw Press Sludge Brine Tank ocean outfall

Membrane Bio-Reactor (MBR) • • Panels of fibers (micro-straws) ultra-filter solids as water is drawn out Panels are submerged in each Aeration Tank 20 panels (4’ x 7’) provide 45, 000 sq feet of ultra-filtration (. 4/1, 000 inch) Semi-permeable membranes leave solids in Aeration Tank One set of 20 panel per aeration tank Pumps pull 25 gpm thru each set Must watch Trans-membrane Pressure “TMP” • Max TMP Pressure is 8 psig

Brine from RO Units Flows To San Elijo Ocean Outfall lagoon

WW Liquid Processes (from Brewery to Ocean) Escondido

Co-Digestion Opportunity Remember Stone’s High Strength Residuals 1. 5 Mgal per year Spent Yeast (130, 000 ppm COD) 1. 9 Mgal per year LT Drip (80, 000 ppm COD) Stone’s the Residuals can be buffered to any stated p. H without significant decrease to this digester feedstock’s methane production potential. These “food grade” homogenous residual solutions contain extreme amounts of energy, without the introduction of any non-biodegradable solids! (“no forks, no shells, no seeds, etc”) 12/3/2020 25

Digester Calculations • Methane (CH 4) yield per pound COD = 3. 85 ft 3 https: //www. bae. ncsu. edu/extension/ext-publications/waste/animal/ag-707 -biogas-westerman. pdf • 5000 gal x 45, 000 mg/L x 8. 34 lb/gal = 1876 lb of COD • Result: over 7, 200 cuft of methane per truck • 4. 3 million BTU per truck or about 1300 kwh* * actual energy harvested a function of eng/gen efficiency 12/3/2020 26

Partnership with Encina Wastewater Authority So far in 2018: Stone delivered 1. 2 Million gallons of Hi-strength Residuals to produce about 1. 7 Million cu ft of methane (equivalent to 300, 000 kwh, 33% conversion? ? ) 100, 000 kwh = $16, 000 at $0. 16/kwh 12/3/2020 27

Avoidance, the real benefits More importantly, that’s 1. 7 million cu ft that is not released to atmosphere as a greenhouse gas 20 times more harmful than CO 2 http: //www. smithsonianmag. com/smart-news/how-America-stacks-upgreenhouse-gas-emissions-180963560/ and 450, 000 pounds of Oxygen demand that would require at least 27, 000 cu ft of air to stabilize in an activated sludge process. 12/3/2020 28

Aerobic Stabilization of High Strength Residuals (avoided cost estimate) 1. 5 Mgal x 130, 000 parts x 8. 34 lbs = 1. 626 M lb year M parts gal year 1. 9 Mgal x 80, 000 parts x 8. 34 lbs = 1. 267 M lb year M parts gal year 2. 894 M lb COD = 1. 446 M lb BOD requires 89 M cubic ft of air Over 1 year that’s 170 scfm (24 by 7 by 365, 8, 760 hours per year) (Assuming a 4 Hp (3. 2 Kw) blower provides 170 scfm & electricity @ $ 0. 16 per Kw. H) 12/3/2020 3. 2 Kw x 8, 760 hours x $0. 16/Kw. H = $4, 500 (avoided) 29

CA AB 1826 - 2016 mandate for reducing organic waste - Provides superb opportunity for CA wastewater treatment plants “to recommit, and even expand, the primary mission of our aptly titled “pollution control facilities” and to wonder/ask WHY Air Quality Regulators would impose any restrictions (other than best available technology) on running as much biogas through their installed co-generation systems as possible as opposed to what is “permitted”. 12/3/2020 30

CWEA Award 2/13/18 12/3/2020 31

Questions And don’t sweat it, Stone’s bugs are working 24/7!!