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Water Technologies

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  1. Water Technologies Strategies for Water Reusein the Food & Beverage Industry Process Expo Chicago, IL November 4, 2011

  2. Topics for Today’s Presentation • Overview • In-Plant Cascading Water Reuse • Reject Recovery RO’s • Treatment of Plant Effluent Water • Summary • Questions

  3. Water is a Global Crisis in the Making By 2025, Demand for Water Will Exceed Supply Some other analysts put this point 10 years earlier Source: Valmont Water Management Group

  4. Water Reuse - Overview Nearly all major Food & Beverage companies have Sustainability goals related to water and energy usage Water Ratio – Water usage per unit of product Energy Ratio – Energy usage per unit of product Water conservation and awareness should be the initial focus, and then water reuse. Water Reuse is a key tool for reducing your plant’s water ratio

  5. Water Reuse - Overview (Continued) Identifying water reuse opportunities starts with a “Water Balance” of your facility Metering is needed to identify where water is going and to measure your success First find your water reuse opportunities that require minimal treatment. These are your “Low Hanging Fruit”: Maximize Condensate Return Empty Container Rinse Water Any water stream can be reused with enough treatment. The key is to find the right streams and the right solution that will provide an economically justifiable project.

  6. Topics for Today’s Presentation • Overview • In-Plant Cascading Water Reuse • Reject Recovery RO’s • Treatment of Plant Effluent Water • Summary • Questions

  7. In-Plant Cascading Water Reuse • The easiest and least expensive method of water reuse is capturing water used in the plant before it gets contaminated with other waste streams: • Carbon Tower Backwash • Multi-Media Backwash • Cooling Water for Compressors • Empty Container Rinse Water • Steam Condensate • Discharge from Container Cooler/Warmer • Pump Seal Water • CIP System Final Rinse • Rainwater

  8. In-Plant Cascading Water Reuse • These water streams are easy to capture and require minimal treatment for reuse • Match the water quality needed with the water streams that are available. Some possible uses of reuse water include: • Irrigation • Cooling Towers • Crate Washing • Warmers/Coolers • Toilet Flushing • Truck Washing

  9. Typical Water Treatment System PFD – With Carbon Tower and Multimedia Backwash Reclaim From Distribution Header Recirculation Nanofiltration Or Reverse Osmosis To Distribution Header City Water Pumps UV Multimedia Filters Carbon Towers Treated Water Storage Polishers Reject to Drain Turbidity Monitor B/W Reclaim Tank Cartridge Filter To Drain Backwash Reclaim System

  10. Case Study No. 1: Carbon Tower Backwash Reclaim Carbonated Soft Drink Plant Carbon towers are used to treat ingredient water at a soft drink facility After initial flush to drain, carbon tower backwash water is captured in a 10,000 gallon storage tank. Collected water is re-chlorinated and filtered by a bag filter and a cartridge filter to capture any carbon fines. Reuse water is blended back into the incoming city water tank at no more that 10% of total flow. Saves 10,000 gallons of water for each backwash.

  11. Rainwater Harvesting – General Guidelines • Use rain water to reduce city water usage in non-critical applications: • Irrigation • Toilet Flushing • Cooling Applications • Feed water to in-plant water treatment system • Works best in areas with high annual rainfall • Recommendation: Capture rainwater from the roof rather than parking lots due to oils and other contaminants. • Numerous successful projects in Portland and Seattle areas on commercial buildings. This trend can be applied to industrial facilities as well.

  12. Rainwater Harvesting – Main System Components Coarse Filter System Controls Rain Water Pump Skid Disinfection System Water Users Collection Tank Day Tank Cartridge Filter City Water Backup

  13. Rainwater Harvesting – Underground Collection Tank

  14. Rainwater Treatment System – Portland State University – Science and Eng. Bldg.

  15. Case Study No. 2 - Rain Water Harvesting and Reuse • Carbonated Soft Drink Facilityin Asia • Rain water is collected, treated, and used to supplement city water. • Rain Water Harvesting & Treatment System Includes: • In-Ground Rain Water Collection Tanks with Submersible Pumps – (2) • Central Collection Tank – 5,000 Gallons • Transfer Pumps (2) • Multimedia Filter & Bag Filter • Treated rain water goes into their incoming city water tank for treatment by the plant ingredient water system.

  16. Topics for Today’s Presentation • Overview • In-Plant Cascading Water Reuse • Reject Recovery RO’s • Treatment of Plant Effluent Water • Summary • Questions

  17. Membrane System Evolution Timeline for Membrane Filtration: Recovery Rate 1980’sInitial Use of Membranes in Beverage 70-75% 1990’sAcceptance of Membrane Filtration 75-80% 2000’sOptimization of Membrane Systems 80-90% New Generation of Recovery Technology 90-95% Future 95+%

  18. Advantage of using a Reject Recovery RO 80% Recovery 90% Recovery 0.8x 0.8x 0.9x X GPM X GPM 0.1 x 0.2x 0.2 x 0.1 x Standard RO RO plus reject recovery RO

  19. Typical Water Treatment System PFD – With Reject Recovery RO From Distribution Header Recirculation Nanofiltration Or Reverse Osmosis To Distribution Header City Water UV Carbon Towers Multimedia Filters Pumps Treated Water Storage Polishers Break Tank Recovery RO 50% Optional Flow Path Reject Recovery RO

  20. Case Study Example No. 3 - Reject Recovery RO • Non-Carbonated Beverage Facility • Reject water collected from RO and Nanofiltration Units • Recovery RO sized for 90 gpm permeate • Recovery RO cost approximately $100,000 • Annual water savings of 20,000,000 gallons • Annual water savings of $120,000 based on $6 per 1000 gallons for incoming water and wastewater treatment Payback in about one year! Reject Recovery RO

  21. Reject Recovery RO’s • Reject Recovery RO’s have become very common in F&B Facilities with membrane water treatment • Bottled Water Facilities • Carbonated Soft Drink Facilities • Non-Carbonated Beverage Facilities • Food Production Facilities • Suitability can be limited based on water chemistry. Areas with high silica have limited application. • Don’t run at over 50-60% recovery rate due to high scaling potential. Water chemistry is critical.

  22. Topics for Today’s Presentation • Overview • In-Plant Cascading Water Reuse • Reject Recovery RO’s • Treatment of Plant Effluent Water • Summary • Questions

  23. Treatment of Plant Effluent Water • The technology exists to treat any Food & Beverage plant wastewater back to potable water quality. If the plant already has a wastewater treatment system, then the economics of water reuse could be much more favorable. • Advancements in membrane technology are making water reuse more viable. • Membrane Bioreactors (MBR) is the leading technology for wastewater reuse.

  24. Defining Requirements for Water Reuse • Objectives of treatment: • To remove contaminates (organics, inorganics, suspended, dissolved) to a quality for beneficial reuse. • Typical Processes: • Removing Organics – Biological Degradation (anaerobic/aerobic), increased use of MBR or UF polishing • Remove Suspended Particles – Clarification and Filtration, increased use of MF and UF membranes • Remove Inorganic Dissolved Constituents - Reverse Osmosis, Microfiltration Softening, Demineralization (increasingly, Integrated Membrane Systems (UF+RO+CDI)) • Disinfection (pathogen inactivation) – Chlorine, UV, Ozone

  25. What is a Membrane Bioreactor? The substitution of a membrane separation process for activated sludge secondary clarification and tertiary filtration. Membrane Bioreactor

  26. MBR MBR (Membrane Bio Reactor) process uses membranes as an absolute barrier with very small pore size which gives a very clear treated water.

  27. Water Reuse Solutions

  28. Case Study Example No. 4 – Effluent Water Reuse System Carbonated Beverage Facility Incoming Plant Water To Sewer Wastewater Treatment (SBR) F&B Plant To Non-Ingredient Water Uses Potable Reuse Water 65 GPM Chlorinated Storage Reverse Osmosis UltraFiltration Prescreen Reject to Drain Chlorination

  29. Topics for Today’s Presentation • Overview • In-Plant Cascading Water Reuse • Reject Recovery RO’s • Treatment of Plant Effluent Water • Summary • Questions

  30. Water Reuse - Summary • The economics of water reuse can vary widely depending on your circumstances: • Cost of water and sewage in your location • Availability of water (limitations on production) • Volume of water used in your facility • Impact of droughts on your region • Public acceptance of water reuse in the Food & Beverage industry is limited. Currently projects are only for non-ingredient applications. • Consider all of your water streams when looking for water minimization and water reuse opportunities (see next slide).

  31. Water Reuse Solutions (Industrial – F&B) - Summary Water Sources to be Reused Reclaimed Water Users Treatment • Carbon Tower B/W • Multi-media B/W • Cooling Water • Container Rinse Water • Warmers / Coolers • Line Lube • CIP Water • Pump Seal Water • Rain Water • Treated Wastewater • Multi-Media • Microfiltration • Ultrafiltration • Reverse Osmosis • Membrane Bioreactor • Biological Treatment • Clarification • UV Disinfection • Ozonation • Cooling Water • Toilet Flushing • Irrigation • Process Water System • Cooling Towers • Wash Down • Truck Washing • Warmers / Coolers • Boiler Feed Water

  32. Water Reuse - Summary • Interest in water reuse is expected to grow dramatically in the near future. • Water reuse opportunities can be simple or quite complicated depending on the application. • Siemens Industry, Inc. can help you identify your potential water savings and reuse opportunities and apply the appropriate solutions.

  33. Questions?

  34. Thank You • David Bridgers • F&B National Account Manager • Siemens Industry, Inc. • Water Technologies Business Unit • Atlanta, GA • Phone: 770-921-1837 • Mobile: 404-414-8765 • E-mail: david.bridgers@siemens.com