WATER AND SEWAGE MANAGEMENT IN THE FOOD INDUSTRY

WATER AND SEWAGE MANAGEMENT IN THE FOOD INDUSTRY Associate Professor Smoczyński Michał Chair of Milk Science and Quality Management Faculty of Food Sciences Warmia and Mazury University in Olsztyn michal. smoczynski@uwm. edu. pl www. uwm. edu. pl

Learning targets § Understanding the characteristic of pollution in selected food industry § Understanding of management and treatment method of pollution in food industry § Learn about the research trend for wastewater management in food industry Water and sewage management in the food industry 2

Content - Food industry in Poland - Water consumption of different food products - Pollution generated by the selected branches of the food industry - Sewage management in the food processing plants - Example of research trends for wastewater management in the food industry Water and sewage management in the food industry 3

Food industry: A. Processing of animal products Ø meat processing Ø poultry Ø dairy industry Ø fish processing B. Processing of agricultural products Ø processing of grain and pasta Ø processing of potatoes Ø vegetables and fruit processing Ø sugar industry Ø oil production Water and sewage management in the food industry 4

Food industry in Poland Ø Approx. 15% of the whole industrial production, Ø 7% contribution to the GDP (Gross Domestic Product) Ø It employs more than half of million people Ø About 27 thousand companies Ø Only 350 large companies, and only 1400 had the status of medium-sized companies Ø It provides 21% of the food products sold on the domestic market Ø Many processing plants are characterized by the seasonality of production (mainly fruit, vegetable, sugar and starch industry) Water and sewage management in the food industry 5

Consumption of water in the food industry in Poland year 2002 Food industry branch Water consumption [mln m 3] Meat production 13, 1 Fish processing industry 0, 6 Fruit and vegetables industry 18, 3 Production of oils and fats 1, 7 Production of dairy products 23, 3 Production of sugar 7, 8 Production of beverages 15, 3 Total: 82, 8 Water and sewage management in the food industry 6

Water consumption of different food products Production Water consumption [dm 3/kg] Jam 13 -25 Canned bean 13 Frozen bean Canned vegetables Frozen fruits Production Water consumption [dm 3/kg] 12 Vegetable juices Concentrated fruit juice Puree 16 6 -12 10 Pickles 9 40 7 Depends also on: - type of production - the applied technology - implementation of closed loop water systems Water and sewage management in the food industry 7

Pollution generated by the selected branches of the food industry Branch Meat industry Pollutants emitted into the atmosphere -flue gases from coal fired boilers (CO, SO 2, NO 2), dust hydrocarbons - smoke from the smokehouse (over 250 compounds) - odor (eg. ammonia, hydrogen sulfide) coming from livestock, slaughterhouses, fertilizers, wastewater treatment burdensome for local society - ammonia from special cooling systems, typically discharged into the atmosphere Type of wastewater Type of waste - waste water from production (technological), the storage of livestock, slaughtering and processing division, contains organic substances (fat and protein), suspension, bacteria, they get into the sewage in the form of blood, piece of meat, fat, hair, soil, fertilizer, detergents etc. - non-production waste generated during washing vehicles and equipment - sewage exceeds acceptable levels of p. H, BOD 5, COD, dissolved solids and slurries - slaughterhouse waste eg. skin, bristles, blood - used machine oils, scrap metal, etc. - manure from storage of livestock, slag, ash - sludge from sewage treatment plants, communal living waste - packaging waste Water and sewage management in the food industry 8

Pollutants emitted into Branch the atmosphere - carbon Fruit and monoxide vegetabl (CO), sulfur es dioxide (SO 2), industry dust from the boiler - ammonia of cooling systems Type of wastewater Type of waste - waste water resulting from washing the raw materials and blanching - waste water resulting from washing facilities and equipment - waste water from the boiler and cooling water systems - chemicals used in water treatment. - specific indicators of pollution are: variable p. H value, high value of BOD 5, high concentration of suspension - solid waste from of agricultural products - remnants of peeling vegetables and fruit - ash and slag from boilers - packaging waste - sludge from sewage treatment plants Water and sewage management in the food industry 9

Pollutants emitted Branch into the atmosphere - carbon monoxide Dairy (CO), sulfur industry dioxide (SO 2), solids from the coal fired boiler - dust coming from manufacturing lines of dry milk and whey - ammonia from cooling systems Type of wastewater Type of waste - waste water from washing of floors and equipment - whey coming from cheese production - waste water from washing machines, boilers and cooling systems - chemicals precipitated during water softening - types of pollution: variable p. H, high value BOD 5, fats, total suspension - Ash and slag from boilers fired with coal - sludge from sewage treatment plants - rejects and scrap - packaging waste - municipal waste Water and sewage management in the food industry 10

Branch Sugar industry Pollutants emitted into the atmosphere - carbon dioxide (CO 2), sulfur dioxide (SO 2), nitrogen dioxide (NO 2), dust and dirt hydrocarbon from coal fired boilers and pulp dryers - dust created in lime (calcium oxide), sugar dust created during the transport, storage, packaging and briquetting of sugar - carbon dioxide (CO 2)and carbon monoxide (CO) in bulk gases generated in the saturation process - sulfur dioxide (SO 2)from the sulfur furnace Water and sewage management in the food industry Type of wastewater Type of waste - waste in the form of plant residues, dirt, sand, oils and fats, chemicals, additives, products and detergents - cooling water - sewage usually exceeds acceptable levels of COD, BOD 5, total nitrogen, suspended solids and dissolved solids - sludge and solid waste (beet and Packaging waste) - liquid waste (waste oils) - slag, sand, stones and contamination from beet 11

Concentration of pollutants in raw sewage from selected food plants Branch Potato industry Sugar industry Meat and poultry industry Dairy industry Fruit and vegetable industry Fish industry Oil industry BOD 5 COD [g O 2/m 3] Ether extract [g/m 3] TSS [g/m 3] Total phosphorus [g/m 3] Total nitrogen [g/m 3] p. H 400 -2500 700 -4000 No data 200 -1800 10 -60 20 -250 5 -8 600 -1300 2500 No data 100 -6500 10 -70 10 -200 6 -9 200 -1800 1000 -3500 300 -1000 400 -1500 10 -20 50 -200 6 -9 100 -2500 1000 -5000 45 -110 800 -1000 5 -20 55 -160 6 -9 200 -1500 400 -2800 10 -1400 50 -800 <1 <5 6 -9 >7000 >10000 100 -700 <3500 5 -50 500 5 -9 >5300 >8700 >6300 >2400 <100 No data 9 -11 Water and sewage management in the food industry 12

Sewage management in the food processing plants Wastewater and sewage from production Factory sewage pre-treatment plant Other waste Sewage system Municipal wastewater treatment plant Environment Water and sewage management in the food industry 13

Food wastewater in the environment Main problems: Ø organic substances (fat, oil, protein, carbohydrates) Ø residues of detergents and disinfectants Ø hot sewage, unfavorable p. H Ø microflora (pathogens, viruses etc. ) How to reduce possible threats? Ø equalizing sewage Ø avoiding the wave discharges Ø work organization and cooperation Water and sewage management in the food industry 14

Basic of wastewater treatment in food industry Size of particle, µm Dissolved particles Colloidal particles Suspension Rapidly sedimenting suspension <0. 01 -1 1 -100 >100 Pre-treatment Biological treatment Specific - mechanical - grates or sieves, settling tanks, flotation units, grease interceptors - mechanochemical - coagulants and polymers - fermentation of raw sewer (biogas recovery) including removal of biocompounds nitrogen and phosphorus ultrafiltration, reverse osmosis Water and sewage management in the food industry 15

Chemical wastewater treatment process involves application of selected chemical reagents, which due to their characteristics can be divided into: Ø Ø coagulants and flocculants disinfectants oxidizing agents reagents for correction of p. H Chemicals 1992 Chemicals 2012 PIX Calcium PIX Polymers Iron blends PAX Aluminium blends Iron aluminium coagulants Water and sewage management in the food industry 16

Example of efficiency of sewage treatment for meat plant (slaughter and processing) with chemical treatment [Flotation type DAF, PIX 112 at a dose = 250 g/m 3, flocculation with the anionic polyelectrolyte] Raw sewage Sewage after treatment Terms from municipal treatment plant COD [ mg O 2/dm 3] 1954 480 1000 TSS [mg/dm 3] 458 75 330 Ether extract [mg/dm 3] 922 19 50 Total solutes [mg/dm 3] 1083 1166 1200 Sulfur [mg/dm 3] 194 292 420 Phosphates [mg/dm 3] 26 0, 3 Not applicable Parameter Water and sewage management in the food industry 17

Special consideration of chemical wastewater treatment in food industry Branch Strategies for wastewater treatment Potato industry - wastewater from washing - due to the low content of COD/BOD 5 application of coagulants Fe (III) and Al is not necessary; they must be used for removal of hydrogen sulphide particularly when p. H <8 iron coagulants, optionally oxidizing agents - technological sewage containing starch - the most common method is precipitation with the use of the coagulant and anionic or cationic polymer - in the biological purification iron coagulants are especially effective, which additionally eliminate hydrogen sulphide during dehydration and the storage of sludge Spirit and yeast industry use of Fe (III) is most commonly recommended for removing of hydrogen sulphide from the anaerobic processes Fruit and vegetables industry removal of suspended solids with its simultaneous compaction with the use of Fe (III) salts and appropriate polymer Brewery industry - due to low content of suspensions and colloids, coagulants are not used. - in the presence of hydrogen sulphide salts of Fe (III) may be used or oxidizing agents containing sulphate (VI) iron (III) and nitric acid (V) Water and sewage management in the food industry 18

Branch Strategies for wastewater treatment Sugar industry Similarly to potato industry, but at p. H<8 sewage comprising simple sugars, more easily undergoes anaerobic processes, combined with the emitting of hydrogen sulphide Meat industry - mechanochemical pretreatment of wastewater by means of DAF flotation system, involving salt of Fe (III) or Al and adjustment of the p. H with the Na. OH and the use of anionic polymer; main objective is fat removal before biological treatment or discharge to the sewage system - polyaluminum chlorides and iron (III) compounds are used to remove phosphorus, scum and swelling caused by bacteria Dairy industry - the pretreatment of wastewater by means of DAF flotation assisted with chemical coagulant and the polymer before discharge to sewer is used - coagulating compounds based on iron or aluminum are used during biological treatment processes Fish industry - mechanochemical pretreatment is frequently used; problems and methods similar to meat industry Water and sewage management in the food industry 19

Dairy wastewater treatment Ø 11, 183 million litres of milk were processed in Poland in 2011. Ø milk consumption amounted 194 litres (without milk used for butter production) per capita Ø water consumption was 0, 7 -2, 5 m 3/t of processed milk Ø 25. 4 hm 3 of sewage was formed, of which 13. 8 hm 3 waste water was treated (9. 0 hm 3 biologically and 4. 8 hm 3 with increased nutrient removal) and removed to the environment. The remaining 11. 4 hm 3 did not require treatment or after pretreatment were discharged into the sewer Ø BOD 5 value of milk is equal to 104 000 mg O 2/L Water and sewage management in the food industry 20

The sequence of processing used for cleaning pretreatment: Ø removal of the contaminants of large size – straining process Ø mineral removal – sedimentation on sand traps Ø removal of fat - flotation process, Ø averaging of wastewater Ø coagulation of colloidal particles treatment Ø removal of impurities easily degradable – biological processes (aerobic and anaerobic) Water and sewage management in the food industry 21

Flotation Ø spontaneous flotation- spontaneous flow of fat to the surface Ø assisted flotation- fat is taken up on the surface by means of gas bubbles (usually pressurized air) Coagulation In the initial treatment of dairy wastewater process of coagulation may be used: Ø during pressurized air flotation (coagulants are dosed before the flotation chamber) Ø during biological treatment, when the precipitation will greatly reduce the pollution load Water and sewage management in the food industry 22

Activated sludge method single-use bioreactor - working with the secondary settling tank and a device for recirculation of sludge three-stage biological reactor - the division into three chambers: anaerobic, aerobic and hypoxic which allows for implementation of biological phosphorus removal, denitrification and nitrification Sequential Batch Reactor (SRB) Water and sewage management in the food industry 23

Example of research trends for wastewater management in the food industry Short characteristic Reference Use of whey as an addition to cereals in the production of ethyl alcohol Parashar A. , Jin Y. , Mason B. , Chae M. , Bressler D. C. Incorporation of whey permeate, a dairy effluent, in ethanol fermentation to provide a zero waste solution for the dairy industry. Journal of Dairy Science, 2015, 99: 1859 -1867 The use of condensate from UHT process to provide high quality water for the boiler - purification by reverse osmosis The possibility of using of a fat layer from dairy wastewater for production of biodiesel Suarez A. , Fidalgo T. , Riera F. A. Recovery of dairy industry wastewaters by reverse osmosis. Production of boiler water. Separation and Purification Technology, 2014, 133: 204 -211 Sivakumar P. , Anbarasu K. , Renganathan S. Bio-diesel production by alkali catalysed transesterification of dairy waste scum. Fuel, 2011, 90: 147 -151 Das B. , Sarkar S. , Sarkar A. , Bhattacharjee S. , Bhattacharjee New methods for the recovery of C. Recovery of whey proteins and lactose from dairy waste: whey proteins and lactose from the A step toward green waste management. Process Safety and whey Environmental Protection, 2016, 101: 27 -33 Water and sewage management in the food industry 24

Short characteristic Reference Use of whey as an addition to cereals in the production of ethyl alcohol Parashar A. , Jin Y. , Mason B. , Chae M. , Bressler D. C. Incorporation of whey permeate, a dairy effluent, in ethanol fermentation to provide a zero waste solution for the dairy industry. Journal of Dairy Science, 2015, 99: 1859 -1867 The use of condensate from UHT process to provide high quality water for the boiler - purification by reverse osmosis The possibility of using of a fat layer from dairy wastewater for production of biodiesel New methods for the recovery of whey proteins and lactose from the whey Suarez A. , Fidalgo T. , Riera F. A. Recovery of dairy industry wastewaters by reverse osmosis. Production of boiler water. Separation and Purification Technology, 2014, 133: 204 -211 Sivakumar P. , Anbarasu K. , Renganathan S. Bio-diesel production by alkali catalysed transesterification of dairy waste scum. Fuel, 2011, 90: 147 -151 Das B. , Sarkar S. , Sarkar A. , Bhattacharjee S. , Bhattacharjee C. Recovery of whey proteins and lactose from dairy waste: A step toward green waste management. Process Safety and Environmental Protection, 2016, 101: 27 -33 Water and sewage management in the food industry 25

Questions § Does the wastewater from food industry need to be pretreated before discharge into municipal wastewater treatment plant? § What kind of method can be used to pretreat food industry wastewater? Water and sewage management in the food industry 26

References: Konieczny P. , Szymański M. Ścieki przemyslu spożywczego – charakterystyka, zagrożenia, korzyści. Eko-net. pl – Firma i środowisko, 2005, 3, 16 -22. Kasztelan A. , Kierepka M. Oddziaływanie przemysłu spożywczego na środowisko w Polsce. Stowarzyszenie Ekonomistów Rolnictwa i Agrobiznesu, Roczniki Naukowe, 2014, 16(2), 109 -116. Puchlik M. , Struk-Sokołowska J. , Wołejko E. , Wydro U. Problem oczyszczania ścieków z przemysłu spożywczego w małych i średnich przedsiębiorstwach. EKO-DOK 2016, VIII Konferencja Interdyscyplinarne Zagadnienia w Inżynierii i Ochronie Środowiska, 2016. Smoczyński M. Nowe trendy w gospodarce wodno-ściekowej w przemyśle mleczarskim. Przegląd mleczarski, 2016, 7, 3 -6. Water and sewage management in the food industry 27

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