#5 waveInsights from Veolia Water Technologies
Creating more value for the Food & Beverage market
WATER TECHNOLOGIES ACTIFLO® Pack Standardized high-performance clarification units Library Photo Veolia ©
WATER TECHNOLOGIES
Built upon the proven success of Veolia Water Technologies’ patented Actiflo® high-rate clarification process, a new fully standardized packaged option is now available. Veolia’s Actiflo® Pack is ideal for the treatment of all types of water including industrial process water, wastewater and reuse applications. • Cost effective, pre-engineered & pre-assembled high-rate clarification technology • Extremely compact design with unit footprint ranging from 3 m2 to 60 m2 • Wide capacity range: 2 to 2,500 m3/h • Easy retrofit into existing civil structures, with potential for significant civil costs savings • Operational flexibility and stability: no impact on treatment efficiency during sudden flow or raw water quality fluctuations www.veoliawatertechnologies.com/actiflo 3
waveInsights from Veolia Water Technologies
Creating more value for our customers
Water is the main component in the food & beverage market. All the industries in the market (dairies, breweries, etc.) have to deal with this resource and considering the many constraints imposed by the authorities and by the industry itself, this is a real challenge.
The quality of the water has to be impeccable, as health and safety issues are primordial. Manufacturers must avoid contamination that could come from air AVOID supply, water supply, raw materials or process equipment. At the same time, CONTAMINATION food & beverage companies have to be able to adapt to changes in the market, enter a new market, launch a new product or adapt existing products for a new country as quickly as possible.
To deal with all these challenges, we need to think on a global level: global solutions bring safety, leverage and economic savings. The food & beverage companies, together with their water & wastewater treatment partners, have to analyse the value chain from start to finish – not only manufacturing needs but also upstream (e.g., agriculture needs) and downstream (e.g., end customers’ expectations) needs. This market approach brings more value and has a better impact on the environment.
Veolia Water Technologies (VWT) provides solutions to the problems faced by the food & beverage industry in terms of water by providing ingredient (production) water and utility water (steam and cooling water) and by treating wastewater. On top of this, VWT provides solutions for optimizing resources and equipment for energy, water and commodity savings. Energy is saved by converting waste and wastewater to energy, providing electricity or heat for the plants. Water is saved by providing solutions to treat water which can then be reused in the plants. Finally, waste is transformed into valuable by-products, such as fertilizer, which can be reused or sold.
These solutions can be easily implemented, thanks to our standard products range and mobile solutions (dedicated to reverse osmosis, clarification, softening, etc., applications).
Throughout this magazine you can discover the solutions and services we have WATER & WASTEWATER already provided to clients, helping them to optimize their business, equipment EXPERTISE and resources. We hope you will find ideas and solutions to address your own challenges. VWT will always be by your side if you need advice and expertise regarding water or wastewater treatment. 4 WAVE #05
CONTENTS
Food & beverage overview Target: 06 18 Zero water discharge
Danone Dongsuh 10 Goal: zero net carbon in 2050 20 Improve the performance and the safety of your facilities
Mars Hydrex 11 Creation of a sustainable 21 The answer to your water wastewater treatment plant treatment chemical needs
Bacchus Namyslow Brewery Veolia Water Technologies Veolia to design and build a 12 secures key partnership in China 22 new, energy-neutral wastewater treatment plant in Poland
Jack Link's Hydrotech Discfilter Creating environmentaly The ideal filtration system for 13 sustainable waste/wastewater 23 fine solids removal treatment system
ElPozo Alimentación Minimising microbial risk in a remarkable example of the beverage industry through 14 environmental sustainability 24 hygienic design
Nestlé Associated British Foods 16 Zero H₂O = added value for 26 Veolia supplies in-house dairy plant wastewater technologies CONTENTS 5
Not just milk-and-water: Technomap 38 new technologies create a stir 28 in dairies
Woodlands Dairy Standardization 30 40 Anaerobic Resource Recovery Facility
MadTree Brewing Robert Wiseman Dairies Craft brewer to incorporate Reducing water consumption 32 Veolia’s Sirion™ Mega technology 41 for a higher economic value and to produce high purity water a lower carbon footprint
Premier Foods IDRAFLOT™ A mobile solution for the UK's New generation flotation unit 33 best-loved sweet pickle 42
Creating Value 34 through Anaerobic Technology
Paulaner brewery Environmentally friendly 36 wastewater treatment
BiosepTM An aerobic biological process 37 for treating municipal and industrial effluents 6 WAVE #05
Food & Beverage overview Brand reputation, water scarcity and stricter regulation are among the pressures driving food and beverage companies to be better water stewards.
Building pressures technology by food and beverage companies, Last year, 15 major food and beverage with investment estimated to grow to $6 companies received letters from a group billion by 2020. of global investors urging them to better manage water resources. The letters targeted The most important drivers fueling the companies identified in a report by the growth: NGO Ceres, “Feeding Ourselves Thirsty,” as having poor risk disclosure and management • Water scarcity and environmental practices with regard to water risks. Signing protection: rising global demand for water the letter were North American and European is increasing water stress in many regions. institutional investors responsible for Growing public concern about water managing $2.6 trillion in assets. consumption and pollution has resulted in increasingly stringent regulatory controls; The campaign reflects one of the growing • Reputational risk: valuable company pressures on the food and beverage industry. brands are vulnerable to damage as Water crises were ranked as a top global risk stakeholders challenge their water policies at the 2015 World Economic Forum. According and practices and actions like Ceres letter to the United Nations, the food sector uses multiply; 70% of the world’s freshwater supplies and • Operational risk: water scarcity and is particularly vulnerable to the problem of stricter regulations can directly hamper dwindling water supplies due to its reliance the operations of food and beverage on the resource as a producers due to their high level of water direct ingredient and usage; an input to agricultural • Demand growth in emerging markets: commodity production. the expanding middle and upper classes 87% in emerging markets is increasing of milk These and other forces demand for branded processed food and is water are fueling growing drink. Companies are investing in water expenditures in water technology to ensure the safety and RESOURCING THE WORLD 7
reliability of their products and to avoid consumption, new opportunities are opening conflict with host communities over water in process water technologies. Companies resources; worldwide are seeking solutions to improve • Improving technology: opportunities to the water efficiency of their processes and to recover energy and materials and to reuse ensure reliable sources of clean water needed water for processing are making water in their operations. Increasingly, wastewater technology investment increasingly cost streams are being treated to enable water to effective and even profitable. be reused within plants.
Energy recovery is also a significant driver Market characteristics within the industry. Companies are adopting The size of the global food and beverage energy efficient technologies such as TAKE UP market is estimated at $15 trillion and anaerobic digestion that bring additional SEVERAL CHALLENGES projected to increase to $20-25 trillion by value by generating renewable energy in the 2030. Opportunities for water technologies form of biogas. to serve the industry are myriad but complex. Additional opportunities for value added Water and wastewater technology needs are materials recovery include bio-plastics production, microbial fuel cells and nutrients recovery for bio-products, such as fertilizer. A simple cheese sandwich takes Increasingly stringent regulations are another about major force in wastewater technology 216 investment. This includes a number of litres of water developing countries that are significantly strengthening their regulations, imposing stricter limits on wastewater discharges highly specific due to the vast diversity of and increasing the costs. This is creating food and beverage products, processes and additional opportunities for pretreatment plants throughout the world. This presents technologies. a challenge to gaining widespread adoption of water technologies at even the subsector Sustainability, water efficiency and value level, such as dairies, breweries, meat recovery are real challenges for the food and processing. beverage market. Water companies like Veolia Water Technologies provide the solutions. � Adoption of new technologies is a slow process within the industry as a result of the high risks associated with food safety and hygiene. Food and beverage companies, conscious of the risks to their product and corporate brands, require ample proof of the benefits and lack of negative impacts provided by innovative technologies or solutions, particularly when there is direct interaction with the products.
As pressures mount on food and beverage companies with regard to their water 8 WAVE #05
$20-25 trillion projected 2030 global F&B market
9,263 trillion kcal projected 2030 annual global food consumption (+23% increase since 2012)
$6.0 billion projected 2020 F&B capital expenditure on water technology (+6.7% CAGR* since 2011)
70% portion of world’s freshwater supplies used by the food sector
5 billion projected 2020 global middle class population (+150% increase since 2009)
+40% projected 2050 increase in demand for water
+70% projected 2050 increase in demand for food
70% projected 2050 portion of the world population living in cities
65% projected 2030 portion of the world’s middle class living in the Asia Pacific region
51.6% portion of EU** food and drink industry revenues from SMEs*** (2011 data: €524 billion)
*Compound Annual Growth Rate 99.1% portion of EU food and drink industry **European Union ***Small and Medium-sized Enterprises companies that are SMEs CREATING VALUE FOR INDUSTRY 9 10 WAVE #05
Danone Goal: zero net carbon in 2050
anone and Veolia recently at Veolia, “our goal is to unite many solutions worldwide helping Dformed an innovative alliance all the Veolia expertise in order industrial clients to better manage in view of optimizing natural to help the Danone teams to the water resource, such as “Zero resources management. The achieve the ambitious goals they liquid discharge” systems, reclaim partnership covers all aspects of the have fixed. VWT’s technological solutions, cow water recovery water cycle, waste management, expertise combined with the systems, production of biogas from sustainable agriculture and energy global offer from Veolia will foster wastewater effluent, etc. efficiency. innovative solutions to contribute to a successful performance at On top of this, VWT will support ”At Danone we have three strategic the Danone sites (lower energy Danone in the industrialization resources: milk, water and plastic. & water consumption, better of its water treatment so that We want to be able to manage these valorization of all waste types) and they may be applied to different resources in a circular way, through to also benefit all those associated countries. In working on these recycling and leaving the smallest with the site ecosystem upstream joint projects with Danone, VWT possible environmental footprint”, and downstream (raw materials fully exploits its ability to offer summarizes Pascal de Petrini, suppliers, farmers, consumers, standardized solutions thanks to its Executive Vice President of Strategic communities nearby residents, etc.).” unrivalled technological portfolio Resource Cycles at Danone. and geographical coverage, with Danone’s goal is to halve its carbon For Bruno Valla, VP Alliance local subsidiaries able to offer emissions by 2030 and become Deployment at Veolia “it’s more their expertise to the Danone sites carbon neutral by 2050. than just a business partnership; located close to them. with Danone we share the same This partnership concerns values in wanting to create and “It’s very motivating working Danone’s 170+ factories and their develop circular economies around with the Danone teams on global environment located all over the industries and municipalities. These solutions. There is a real drive world, within its five divisions: common and strong values act as from the client to care about the Fresh Products, Early Life Nutrition an incentive to further optimize water resource, and go beyond the (ELN), Waters, Medical Nutrition the resources sustainability. traditional market expectations. We and Africa. Ultimately, Danone should reach started with some audits at Danone its environmental goals faster with Early Life Nutrition sites in order to The project will be deployed the benefit of our technologies and optimize the consumption in their gradually: 10-15 sites will be studied expertise. At the same time, we current or future plants and our yearly, concrete solutions for will enhance the circular economy recommendations are suitable for improvement will be identified, and ecosystems by supporting social rehabilitating existing equipment pilots will be initiated. The aim is & economic initiatives with our or setting up a reuse solution”, to find solutions that are adapted organization and network.” says Audrey Bachelay, Business to the sites’ need and that can be Development Manager at VWT, replicated to the rest of Danone’s VWT supports the success of the Markets & Offers Development facilities. alliance thanks to its technological department. � expertise in the food & beverage According to Laurent Panzani, industry and its global coverage. Global Director of Food & Beverage VWT has already implemented RESOURCING THE WORLD 11
Mars Creation of a sustainable wastewater treatment plant
The challenge Mars strives to have a complete sustainable units. The biomass is returned to the reactor production in the year 2040 (Sustainable and the final effluent is discharged to the In one Generation program). Through the sewer system. Complete operation and installation of the anaerobic Memthane® maintenance of the wastewater treatment treatment plant in Veghel (The Netherlands), plant is also planned. Mars makes significant progress in the achievement of its sustainability targets at Benefits for Mars: their largest chocolate processing facility in • Most compact solution and lowest the world. operational costs in comparison to other treatment routes Veolia’s solution • Net carbon footprint reduction of more VWT will supply the most appropriate than 150 Ton CO₂/year anaerobic wastewater treatment technology. • Maximization of renewable energy The solution differentiates by achieving production, up to 10% of gas consumption more than 99% removal in a one stage • More than 99% reduction of pollution anaerobic process. In the Memthane reactor equivalents the wastewater from Mars is biologically • Complete outsourcing of operations treated and converted into high calorific biogas. The treated effluent and biomass are separated by means of ultra-filtration
150 tons of Up to more Reduction
CO2 avoided than 10% on sewer annually energy savings cost 97%
Today, the Mars family of Associates is 80,000 strong in 78 countries around the world. Mars makes a lot more than just chocolate. Mars has six distinct and different businesses - Petcare, Chocolate, Wrigley, Food, Drinks and Symbioscience - which have helped the company reach billions of consumers and achieve more than $33 billion in global sales. From selling PEDIGREE® dog food in New Zealand to planting SEEDS OF CHANGE® in South Africa, Mars reaches out to nearly every corner of the globe. 12 WAVE #05 Bacchus Veolia Water Technologies secures key partnership in China
Leading Alcopop manufacturer becomes Veolia’s anaerobic technology reference in Chinese food and beverage market
Veolia Water Technologies China operations contains high James Peng, Solutions Director, is proud to announce its latest concentrations of biological oxygen Veolia Water Technologies in contract with Shanghai Bacchus demand (BOD), chemical oxygen China, concluded, “As a leading Limited Company (Bacchus), demand (COD), and suspended global provider of innovative water which will see Veolia design and solids. To mitigate Bacchus’s and wastewater solutions, Veolia’s build full turnkey knowledge of local wastewater discharge limits treatment has benefitted our plants for two of clients, who have Bacchus’s new had to mitigate greenfield factories wastewater in Tianjin and challenges in Chengdu, China. an increasingly The plants will environmentally integrate several of conscious market. Veolia’s innovative This is our first technologies partnership with – including Bacchus in China. the Biothane® Our suite of water Advanced Upflow and wastewater Anaerobic Sludge Blanket (UASB), wastewater challenges, both solutions offers maximum technical AnoxKaldnes™ Biological Activated projects feature Veolia’s high- advantages for our clients, and we Sludge™ (BAS), as well as tertiary performing anaerobic reactor, the look forward to recommending our and sludge treatments. Biothane Advanced® UASB. anaerobic technologies to more Food & Beverage manufacturers Established in 2003, Bacchus Renowned for its high organic operating in this region.” � manufactures the popular RIO® loading capacity and superior Alcopop series, and is wholly sludge retention characteristics, committed to developing, the Biothane Advanced® UASB producing, and expanding its reactor is particularly leading product to meet market suitable for the treatment demand. Upon project completion, of food and beverage-type both the Tianjin and Chengdu effluents, ensuring that factories will join Bacchus’s existing local regulatory standards production facility in Shanghai to for wastewater discharge boost the company’s production are met. In addition, the capacity to meet growing domestic compact solution supports demand. biogas production, which serves as an alternate Due to the nature of the Food & energy source, maximizing Beverage industry, wastewater renewable energy utilization generated from processing for Bacchus. CREATING VALUE FOR INDUSTRY 13
Jack Link's Creating environmentaly sustainable waste/ wastewater treatment system
methane-rich biogas, while UF membranes create a high-quality effluent that is discharged into the municipal sewer system.
Biogas from the Memthane system is then treated by Veolia’s Sulfothane system. This treatment step removes sulfur compounds from the biogas, which are highly corrosive and can damage downstream equipment. The scrubbed biogas is then sent to a Combined Heat and Power (CHP) Generator, creating onsite electricity and offsetting energy costs. THE CHALLENGE Jack Link's, a leading protein snack producer, THE RESULT was in need of a water treatment solution The Memthane and Sulfothane systems at its facility in Alpena, South Dakota. Jack have exceeded performance and client Link’s previous wastewater treatment system expectations. Final permeate discharge from consisted of a Dissolved Air Flotation (DAF) the Memthane system averaged less than 100 system for FOG (Fats, Oils, & Grease) and ppm BOD for greater than 98% BOD removal TSS reduction. Effluent from the system was rates. Membrane operation during the first discharged directly to the sewer system, 24 months of operation was stable, with flux and the city municipal treatment plant rates ranging from 9 to 18 lmh. was becoming overloaded as a result of the facility’s production increases and high BOD The Sulfothane system was able to reduce loads. the biogas’s H2S levels from 6,000-8,500 ppm to less than 10 ppm, which is well below the THE SOLUTION generator’s manufacturer specifications. Veolia Water Technologies partnered with Jack Link’s to develop a process that would Due to sustained process stability and solve the facility’s high BOD discharge issue, consistent high quality effluent, the city while simultaneously creating biogas as a treatment plant operation has improved byproduct to reduce the plant’s energy costs. greatly.
Veolia’s treatment process utilizes ENERGY POSITIVE WASTE/ Memthane® Anaerobic Membrane Bioreactor WASTEWATER TREATMENT PLANT (AnMBR) technology combined with a The system is not just energy efficient, it Sulfothane™ Biogas Desulfurization System. is also energy positive when operating at Memthane pairs anaerobic biological full flow. The biogas byproduct currently treatment with ultrafiltration (UF) produced in the anaerobic reactor generates membranes to create an industry-leading more electricity than the system consumes. anaerobic membrane bioreactor system. The The result is a fast return on investment for bioreactor converts the plant’s waste into a the capital purchase. � 14 WAVE #05
ElPozo Alimentación a remarkable example of environmental sustainibility
ased in the province of Murcia in the whilst embodying the company’s Bsoutheast of Spain, ElPozo Alimentación commitment to the environment. is a Spanish company with a 60-year track record in the market. Today, ElPozo meat Water partners since 2003. products reach a market of over one billion From process water, wastewater and potential clients in more than 80 countries, sludge treatment to energy efficiency making it one of the leading companies in the and water reuse. sector, both in Spain and internationally. Year after year, ElPozo has increased its market In wastewater… share and in 2014 it was the brand with the In 2003, VWT was awarded a turnkey project highest consumption figures in Spain, with a for the Industrial Wastewater Treatment Plant turnover of around €950 million. (WWTP) at ElPozo Alimentación’s production facility in Alhama de Murcia. The industrial WWTP was designed for a treatment capacity of 6,000 m/day and 23,880 kg COD/day, a pollution load corresponding to a population equivalent of 200,000 inhabitants. The treatment process consists of an activated sludge facility including the BIO-DENIPHO™ technology for the removal of organic matter, phosphorus and nitrogen.
…in process water… In 2005, VWT supplied two reverse osmosis units with a total capacity of 4,000 m/day ElPozo Alimentación is firmly committed for the production of water to feed the steam to the environment and sustainable boiler and the evaporative condensers, as well development. Proof of this commitment is the as for other uses at the factory. Since these company’s investment of over €11.5 million in units went into operation, VWT has also been a number of wastewater treatment initiatives entrusted with the provision of technical and projects aimed at reducing emissions assistance and Hydrex® chemical products through energy recovery. (antiscalants, products for plant cleaning Veolia Water Technologies (VWT) has provided and maintenance). At the end of 2015, VWT a response to these water treatment needs by was awarded a further contract to supply a offering sustainable, efficient technological 2,000 m/day reverse osmosis unit to cover solutions that increase process performance additional production requirements. RESOURCING THE WORLD 15
…for sludge treatment… new boiler to generate 5,000 kg/h of steam. In 2011, ElPozo Alimentación once again The scope of the contract also encompassed placed its trust in VWT for the remodeling of extending the piping network, and installing the wastewater pretreatment to deal with a new gas flare as well as a new biogas higher organic loading resulting from the desulphurization unit including VWT’s increase in the activity production, which Sulfothane™ technology, as a preventive went from 8,000 to 12,000 pigs processed measure to protect the facilities against per day. The work also included enlarging corrosion. the sludge line through the construction of two 3,050 m anaerobic digesters and the Towards a circular economy installation of a cogeneration system for In addition to energy valorization – and the production of 800 kW of electricity for consequently, a reduction of the carbon self-consumption at the WWTP and 400 kW footprint of the factory - ElPozo Alimentación of thermal energy to heat the sludge during and VWT have also undertaken a number of the digestion process, without the need for water reuse initiatives. These actions have any other fuel. The digesters also enable a enabled the reduction of water consumption reduction of 45% in sludge volumes, with per pig processed, achieving one of the lowest consequent cost savings in sludge treatment ratio sector in Europe. and final disposal. Veolia Water Technologies has become … and for energy valorisation the leading partner for companies which, At the end of 2014, with the aim of like ElPozo Alimentación, are committed maximizing the use of the biogas produced to sustainable development. VWT offers in the anaerobic digesters, VWT undertook such companies solutions ranging from the the task of modifying the gas line at the treatment of process water, wastewater and industrial WWTP to enable the excess biogas sludge to solutions aimed at reducing water produced at the plant to be exploited. Some consumption and increasing energy efficiency, of the biogas is used to heat the sludge in in order to promote and work towards a the digesters and the remainder is sent to a circular economy. � 16 WAVE #05
Nestlé
Zero H2O = added value for dairy plant
s part of its global commitment to Apreserve water resources, Nestlé turned to Veolia Water Technologies to develop a solution to reduce water consumption at its Lagos de Moreno plant in Mexico. The country’s population growth in recent decades has put increasing stress on groundwater resources. The state of Jalisco, where the plant is located, is one of the areas where the water scarcity problem is particularly acute.
The Lagos de Moreno plant is comprised of three units that produce ice cream, cereals and powdered milk for infant formula and requires 1.6 million liters of water per day, equivalent to the daily water consumption of 6,400 people. WATER USAGE REDUCED BY 78% “Nestlé is focused on creating a positive environmental impact,” says Nestlé engineer Nuria Navarrete. “We have set a target to reduce water usage per ton of finished product by 25% as part of our commitment to conserve water resources. We asked Veolia to provide a solution that would enable us to recover water from our process in order to avoid using deep well water in a high hydrological stress region of Mexico.”
The zero solutions solution In response, Veolia added new technologies to treat the effluent from Nestlé’s wastewater treatment plant so that it could be reused for non-food production applications such as cooling, cleaning and industrial uses. The effluent is composed of condensate recovered from the evaporation of dairy products, or “cow water,” as well as discharges from “clean in place” sanitization of processing equipment. CREATING VALUE FOR INDUSTRY 17
A polishing system featuring Veolia’s Aquantis industrial water conservation strategies membrane bioreactor treats the effluent according to Nuria Navarrete. “Including a to produce a filtrate virtually free of solids. recycling tertiary treatment in wastewater A further reverse osmosis treatment step treatment plants today has become a viable retains dissolved solids and salts to drinking- solution for many industries to increase their water quality levels. A final step involves profit and diminish their ecological footprint. capturing and reusing residual wastewater Technology costs are now more competitive in cooling towers and other services within and chemicals for treatment and spare parts the factory, reducing the factory’s water are also available in more sites with shorter withdrawal to zero. The project, called "Cero delivery times.” Agua" (zero water) by Nestlé, enables the treated water to be reused for non-food For Nestlé, the Jalisco Cero production applications, eliminating the Agua project is one of more plant’s need for external water resources. than 370 initiatives the company is undertaking “The Veolia-supplied water recycling in its factories around technology purifies water in a tertiary the world that are treatment of our wastewater treatment helping to conserve plant,” says Nuria Navarrete. “The water water. A world-first quality allows us to use it in services that do for the dairy products not have direct contact with the product, such industry, the zero-water as cooling towers, patio washing stations, technology is now being fountains and lavatories. By developing this rolled out at other Nestlé Cero Agua project as well as other initiatives, plants worldwide, starting we have reduced our 2015 water usage in with dairy factories in water-stressed Mexico by 78% compared to 2010.” areas of South Africa, Pakistan, India and China. Going global Nestlé’s success in implementing zero- In 2015, Nestlé's Cero Agua project won the water dairy production in Mexico offers Corporate Water Stewardship award at the hope for improved stewardship of a fragile 2015 Global Water Awards, held during the natural resource. The project has contributed Global Water Summit in Athens. “Twelve years to Nestlé’s success in reducing water ago, we were told that this couldn’t be done, consumption globally by one third during the due to cost implications, water quality issues past 10 years, even while global production and the technical complexity involved,” said has increased. Jim Knill, Nestlé’s head of dairy operations. “But we’ve shown that the technology works – Nestlé’s experience with the Cero Agua now we want to apply it elsewhere.” � project provides valuable insights for 18 WAVE #05
TARGET: Zero liquid Zero water discharge discharge in four steps Zero Liquid Discharge technology aims to reuse wastewater in a system. This technology has a bright future especially in regions around the globe where water reuse is mandatory.
A closed loop water cycle: So why utilize this this is the principle of sophisticated technology Zero Liquid Discharge when it would be simpler – or ZLD – technology. to treat and discharge A simple principle, but a water using traditional complex technology. Water wastewater treatment remains in a closed loop technology? “ZLD in the factory, where it is technology is critical gradually rid of all of its when the surrounding contaminants and is of high environment is fragile and enough quality to be reused cannot withstand even in the industrial facility’s the discharge of treated RECYCLED process. There are four wastewater effluent,” WATER decontamination processes points out Visintin. required to achieve “ZLD also offers another this: physicochemical major advantage: since pretreatment, biological no effluent is discharged, treatment, filtration and, water legislation need not finally, evapoconcentration be taken into account. Last SECONDARY (see opposite). Certain but not least, it sometimes RAW pollutants are purified allows you to avoid post- MATERIAL and reused in the process. treatment.” Another •Salts “ZLD technology has scenario in which ZLD is applications across multiple a must: in regions where industries including oil and water is scarce, its reuse gas, automotive, food and may be required by law. This beverage, pharmaceutical, is the case, for example, and others,” states Dionisio in California, which has Visintin, Marketing been struck by drought for EVAPOCONCENTRATION Manager of Veolia Water over a year and where all In the final stage, further water Technologies Italia’s businesses are required reclamation is achieved via evapoconcentration. The goal is to Solutions division. “At the to “close the loop.” Ever concentrate any remaining contaminants outset, this technology mindful of sustainability, through evaporation, and recover virtually all the water with minimum energy was geared toward large most industries are now consumption. manufacturing and looking to reduce their industrial complexes, but environmental impact, this is now no longer the especially their water case.” consumption. � RESOURCING THE WORLD 19
PHYSICOCHEMICAL PRETREATMENT BIOLOGICAL TREATMENT In the first step, materials such as sand and oils – along with Next, microorganisms are put other contaminants including heavy metals, fluorides and to work to remove organic gypsum – are removed. Veolia offers a comprehensive range contaminants, which results in of processes specific to particular contaminants including the byproduct of “solids” and coagulation, precipitation, decanting and filtration. CO2. Fluidized bed bioreactors, membrane bioreactors, and sequencing batch bioreactors can be used to optimize the biological processes.
WASTE WATER
FOUR-STEP WASTEWATER TREATMENT Zero Liquid Discharge technology consists in ridding wastewater of all of its contaminants, which requires four steps. Multiple technologies are available for each step, depending on the size and type of industrial application.
MEMBRANE FILTRATION Dissolved contaminants have been eliminated by biological treatment, but suspended contaminants remain. They are removed using various filtration technologies, including granular media filters (sand, activated carbon, etc.), microfiltration (membrane technology) and ultrafiltration membrane technology capable of removing bacteria and viruses as well as large organic molecules. 20 WAVE #05
Dongsuh Food Improvement of the performance and the safety of the Dongsuh food facilities thanks to the HYDREX™ range of water treatment chemicals and associated services
Dongsuh Food was founded in May 1968 and The Solution has been producing Maxwell House instant • Based on jar-test results on the produced coffee since 1970. Their main business is the wastewater, the chemical Hydrex was manufacture and sale of food & beverages chosen and agricultural products. The company is • Chemical consumption was reduced headquartered in Seoul, Mapo-gu Dongsuh through precision control and accurate building, with plants located in Bupyeong, dosing Changwon and Jincheon. Veolia Water Technologies proposed the The wastewater treatment within the most suitable chemical program based on manufacturing process is organized as the test results, and now provides Dongsuh follows: coffee process – 2 lines (500 m/day Foods with the Hydrex-6135, 6310, 6752 & 1,800 m/day); prima process: 500 m/day. chemicals for their wastewater treatment process. The challenges The Dongsuh Food team needed to use Benefits chemicals in wastewater treatment which • Cost reduction optimize both operational and economic • Reduced chemical consumption aspects. At the same time they had to • Improved flocculation efficiency reduce air pollutant emissions during sludge • Reduced energy consumption incineration • Regulatory compliance
Process Description
Coffee process 1 (High COD load) Primary Tertiary Coffee process 2 Aerobic chemical chemical Effluent (Low COD load) treatment treatment treatment Prima process (Low COD load) CREATING VALUE FOR INDUSTRY 21
Did you know that HYDREX™ covers all your water treatment chemical needs?
Veolia Water Technologies provides a full range of water treatment additives but also Boiler Water HYDREX 1000 SERIES associated services (expertise, audit, quick Treatment Products laboratory analysis, technical assistance, Cooling Water HYDREX 2000 SERIES emergency responses, etc.). You can also take Treatment Products advantage of our AquaVistaTM monitoring tools Drinking Water and on-line scanners; as well as equipment HYDREX 3000 SERIES Treatment Products such as tanks, dosing systems, etc. If you Membrane need water treatment chemical assistance, HYDREX 4000 SERIES Hydrex™ has the solution. Treatment Products Maintenance and HYDREX 5000 SERIES Cleaning Products Wastewater HYDREX 6000 SERIES Treatment Products
Biocides Products HYDREX 7000 SERIES
Industrial Application HYDREX 8000 SERIES Products Thermal Desalination, HYDREX 9000 SERIES bulk chemicals & Others
⊳AquaVista - Level 3: manage your automated control and monitoring system via your smartphone 22 WAVE #05
Namyslow Brewery Veolia to design and build a new, energy- neutral wastewater treatment plant in Poland
eolia Water Technologies will supply a our most innovative proprietary technologies Vnew state-of-the-art anaerobic-aerobic to help Namyslow Brewery achieve their goal wastewater treatment plant to Namyslow of having a highly-effective treatment system Brewery Ltd. The signed turnkey contract coupled with energy efficiency. We are confident includes the design, construction and that this new plant will allow Namyslow commissioning of the plant. Brewery to reduce their operating costs and improve their environmental footprint.” � The new wastewater treatment plant will provide Namyslow Brewery with a highly- effective treatment system coupled with energy efficiency. Proven anaerobic processes were selected to maximize the biogas production and convert it into energy. The energy will be used to power the wastewater treatment plant, covering operating costs and bringing additional profits to the brewery.
Veolia’s technological approach made it View of the EGSB WASTEWATER possible to reuse the wastewater as a resource anaerobic reactor - TO ENERGY Wastewater treatment for energy production and thereby lower plant for Tymbark in the plant's operating costs. The sustainable Olsztynek solution is based on Veolia’s Biobed® Advanced EGSB, a highly effective second generation anaerobic reactor using granular sludge technology, and on aerobic reactor AnoxKaldnes™ MBBR (Moving Bed Biofilm Reactor). A dissolved air flotation system ensuring the required discharge parameters was also included at the wastewater polishing stage. These processes were selected after conducting an analysis of the sewage produced by the brewery. AnoxKaldnes™MBBR reactor on the wastewater treatment plant for Tymbark in Dariusz Jasak, CEO of Veolia Water Olsztynek Technologies in Poland, said: “We put forth RESOURCING THE WORLD 23
NEW! The improved discfilter model HSF2200-1C The unit has been developed based on feedback from our clients and reflects the actual market needs. New advantages: • Capacity up to 200 l/s • 10-15% higher capacity per m2 of filter area • 14-21% smaller footprint compared to the HSF2200-1F • Minimized maintenance needs • Lower CAPEX and OPEX cost • Flexibility in material of construction Hydrotech Discfilter The ideal filtration system for fine solids removal
The HYDROTECH DISCFILTER is a mechanical and self-cleaning filter that offers a large filter area in a small footprint.
APPLICATIONS BENEFITS
� Ideal for “retro-fit” projects in � Small Physical and Carbon existing basins Footprint � Straight-forward Controls PERFORMANCES � Simple Operation and Maintenance � Reduces effluent phosphorus to � Ease of Installation (Package < 0.1 mg/L Design) � Up to 75% smaller than sand � Low Backwash Water Usage & filters Energy Efficient � Up to 20% smaller than other � Title 22 Approved cloth filters. � Continuous Operation � Energy reduced by 15% and footprint by 25% � The only system to be delivered as an assembled unit � O&M is simple and reduces operating costs 24 WAVE #05
Minimizing microbial risk in the beverage industry through hygienic design
hen producing any food or drink it water treatment process is the removal of Wis important to make every effort to chlorine residues, which is achieved using minimize microbial risk, and make products a carbon filter. It is vital that chlorine be for human consumption as safe as possible. removed during water treatment as it can Any microbial contamination is taken cause flavor defects. However, once it is extremely seriously, and can result in costly removed, there should be extra considerations product recalls in response to fears for human with regard to microbial contamination, as health. In addition to the serious health risks chlorine is often used as a disinfectant. Water from certain bacterial species, contamination involved in the production of beverages also with less harmful bacteria can result in the undergoes various filtration steps to remove spoilage of beverages, altering their quality any particulates and residual impurities. and flavor. Manufacturers must therefore address the possibility of contamination, which may originate from the air supply, water supply, raw materials and process equipment.
Water in the beverage industry The source of the drinking water used in production can influence the taste, appearance and overall quality of the final product. Hard water contains an increased presence of calcium and magnesium salts, which are particularly detrimental to soft drink production as they can cause alterations to pH, and affect microbiological stability and taste. Soft water is therefore recommended for use in soft drinks, and techniques exist that can remove water hardness and therefore the effects of these ions. The most widely used of these is reverse osmosis (RO), which is often the first step of a detailed water treatment programme for soft drink production. Another important stage of the CREATING VALUE FOR INDUSTRY 25
Importantly, the equipment used to carry out the highest product quality and safety. With Minimizing microbial this water treatment must also play a role the adoption of such hygienically designed in minimizing microbial risk. Manufacturers water treatment systems, manufacturers should consider adopting hygienically can future-proof their plants for upcoming risk in the beverage designed water treatment systems. These legislation. systems can be easily cleaned, maintained and monitored to ensure that high water Disinfectants are used across the beverage industry through quality is sustained throughout the industry to help minimize contamination manufacturing process. With hygienic design, by microorganisms. Making use of the different filters (e.g. media and carbon hygienically designed water systems helps hygienic design filters, RO and ultrafiltration systems) are to minimize the use of disinfectants, as optimized to prevent external impurities well as provide extra protection against from entering the system, and to offer reliable microbial contamination. Another important cleaning and disinfection while allowing issue with the use of disinfectants is the continuous monitoring. Hygienic design presence of disinfection by-products. Some of principles range from cleaning in place and these are classified as endocrine disrupting sterilisation in place (CIP/SIP) technologies to chemicals (EDC’s), which can interfere with optimized water flow that avoids stagnant the endocrine system and cause cancerous water and dead-legs, which are those areas tumors and abnormal development. within piping that have poor flow and are difficult to clean. In addition, these systems PurBev® provide maximum system availability To combat some of the problems associated due to longer cleaning intervals as well as with disinfection, while still minimizing economical operation, while still ensuring microbial risk. �
BENEFITS
• Optimum product quality and product safety by minimizing microbiological risks
• Maximum system availability thanks to longer cleaning intervals and maintenance cycles
• Economical operation based on high system efficiency and decreased need of cleaning supplies
• Low maintenance and service costs due to fewer components which are easily accessible
• Lower OPEX due to chemical, water and energy savings PurBev® reverse osmosis system • Sustainability: Longer lifetime and lower lifecycle costs (low TCO) 26 WAVE #05
Associated British Foods Veolia supplies in-house wastewater technologies
urnkey project maximizes treatment The challenge Tflow within limited land space. Faced with the challenge of designing a wastewater treatment plant located Veolia Water Solutions & Technologies within the client’s space constrained (Thailand) Ltd has built a partnership with manufacturing grounds, Veolia recommended Associated British Foods (Thailand) Ltd, key technologies that could effectively treat where Veolia provides the multinational their wastewater volumes and COD loads. food manufacturer with a full turnkey Poonpipat shared, “We had to be creative in wastewater treatment plant. This project designing a compact yet robust wastewater integrates several of Veolia’s innovative treatment plant that could handle a high technologies – including its Dissolved Air flow rate within a limited space. One of the Flotation (DAF), Biothane® Upflow Anaerobic most attractive features of Veolia’s water and Sludge Blanket (UASB), AnoxKaldnes™ wastewater solutions is its compact design, Biological Activated Sludge™ (BAS), which takes into account space constraints and Hydrotech™ Drumfilter – within that clients face without compromising on A FULL ABF’s Ovaltine manufacturing plant in performance.” RANGE OF Samutprakarn, Bangkok. With this end to WASTEWATER SOLUTIONS end wastewater package, ABF will be able The technologies to handle its wastewater treatment needs Apart from its efficient design, Veolia’s onsite, catering to both existing and future Dissolved Air Flotation (DAF) unit pretreats flow requirements projected for the next the raw wastewater, removing fat, oil, and decade. grease (FOG) before the Biothane® UASB anaerobic treatment process. The UASB Michael Poonpipat, Project Business anaerobic system then converts COD present Development Director, VWT Thailand, in the conditioned wastewater into biogas. said, “Working with ABF shows how we Veolia’s AnoxKaldnes™ BAS™, a combination can effectively provide a full range of of Moving Bed Biofilm Reactor (MBBR) wastewater solutions from start to end. technology with conventional activated Our experience in the food and beverage sludge (AS), is next applied to promote a industry has equipped us with the know- stable and more efficient activated sludge how to mitigate the client’s concerns, and process with improved sludge settling we are confident of meeting their project characteristics. The effluent then enters a expectations.” second DAF clarifier unit for biological sludge RESOURCING THE WORLD 27
ANOXKALDNES™ MBBR Leading edge biological treatment
APPLICATIONS � For new plants, especially those requiring a small footprint and easy operation
� For BOD/COD and nitrogen removal
� As a high loading system in front of existing biological separation, before the Hydrotech™ Drumfilter treatment - roughing reactor system separates the remaining particles from the wastewater. PERFORMANCES Turn wastewater to energy � Durable and stable process with high removal efficiency As companies become more aware of their at higher loading rates environmental footprint, manufacturers are � A high level of flexibility allows for optimized solutions now actively seeking to employ sustainable � High tolerance to load variations & toxics business practices. Through Veolia’s � Worldwide experience with > 800 reference plants recommended suite of wastewater solutions, the client can obtain biogas in the process of treating its wastewater, which becomes an BENEFITS alternative energy source for heating boiler � Increases the treatment capacity of existing installations systems that are used in manufacturing ABF’s � Small footprint products. � Fast start-up and recovery
Michel Otten, Technical Director, Asia The MBBR Pack provides all the advantages of a Industrial, Veolia Water Technologies, conventional MBBR system, in a standard prefabricated concluded, “This project with ABF carries package with a Plug & Play function that is easy to install. great significance for Veolia as it showcases our ability across disciplines, from conducting Veolia’s MBBR Pack is an effective and reliable solution, preliminary market studies, to recommending even contending with wide swings in the volumes of targeted engineered solutions, and finally wastewater to be treated and the carbon and nitrogen- to constructing the wastewater treatment based pollutants to be eliminated. Its small footprint, quick plant. It reaffirms Veolia’s leading position as a delivery and plug-and-play installation and commissioning professional water and wastewater solutions translate to a reduction in civil engineering and supplier, and also as a trusted design-and-build infrastructure costs while ensuring continuity of sanitation partner for manufacturers across different services during works. Its modular design makes for easy markets. Veolia looks forward to working transportation and expansion. Bundling with various Veolia closely with ABF to ensure flawless project pre or post-treatment processes allows for the MBBR PACK execution for a successful handover in June to perfectly address the needs and quality objectives of 2016.” � each client. 28 WAVE #05
We design and implement standard and customized solutions for the food & beverage market
6 BIO-ENERGY PLANT
3 WATER RECYCLING & REUSE
Cooling systems
Boiler Manufacture
5 SLUDGE TREATMENT
4 WASTEWATER TREATMENT
Mobile Water Solutions
Hydrex™ chemicals
2 UTILITY FEED WATER
7 SERVICES
1 PROCESS WATER PRODUCTION CREATING VALUE FOR INDUSTRY 29
We design and implement standard and customized solutions for the food & beverage market
INGREDIENT (PRODUCTION) WATER RECYCLING & REUSE WATER Food production is a water-intensive Water used in food production industry. Veolia understands this processes needs a safe and and is able to help clients meet 6 BIO-ENERGY PLANT continuous supply. Veolia’s water reduction goals and minimize technologies ensure that your their environmental impact by ingredient water is produced reliably, implementing technologies that 3 WATER RECYCLING & REUSE cost effectively, and meets the convert wastewater effluent into highest quality standards that your water that can be reused elsewhere operation demands. in the plant.
Cooling systems UTILITY WATER NUTRIENT RECOVERY Food and Beverage manufacturers Veolia’s sustainable approach to rely upon their utility operations to water can transform waste into Boiler provide reliable steam and cooling valuable by-products, such as Manufacture water to support their production fertilizer, that can be reused or sold. needs. Veolia’s equipment and chemical technologies cost 5 SLUDGE TREATMENT effectively produce the type of water SERVICES your utilities need to ensure steam • Digital offer: collection and quality, heat exchange efficiency and management of your data's 4 WASTEWATER TREATMENT environmental compliance. equipment • Laboratory Service / Testing • Bench-Scale Tests WASTEWATER • Pilot Tests Mobile Water Solutions Veolia is experienced in helping • Studies & Evaluations clients reduce their financial • Design Engineering exposure and comply with discharge • System Integration Hydrex™ chemicals requirements and stringent • Construction & Project environmental regulations. Management • Start-Up / Commissioning 2 UTILITY FEED WATER • Aftermarket Parts / Service 7 SERVICES ANAEROBIC DIGESTION • Full-Time On-Site System Convert Waste & Wastewater to Operations Energy • Remote Monitoring / Automation Anaerobic treatment technologies • Deionization Products offer a dual benefit for food • Water treatment chemical and beverage facilities. They simultaneously treat a wide range 1 PROCESS WATER PRODUCTION of waste and wastewater streams while creating energy-rich biogas as a byproduct that can be used to produce “green” electricity or heat. 30 WAVE #05
Flexibility and adaptability to the customer’s needs: a configurable standard product range
eolia Water Technologies offers unique quality of our service is optimal and the Vand the best designs for each water interventions are faster. In addition each treatment technology dedicated to the food Veolia standardized product comes with a & beverage industry, including clarifiers, list of spare parts and consumables available flotators, settlers, multimedia filters, reverse in stock on the Veolia logistics sites with osmosis units, softeners, ion exchange quick delivery times. deionizers, MBR, MBBR, .. The offer includes standard models with a Veolia standard systems are manufactured list of options, easily customizable by our in Veolia's manufacturing sites to strict modularity Veolia engineering team with FASTER quality standards, and using the best little need for design adjustment: ACCESS materials. Products are tested before • Comprehensive range of stand-alone shipment. Our skid-mounted units can be products or products that can be containerized and are easily transportable combined to meet all water treatment by road, sea and air-freight. They have applications from utility water production, short-lead-times as critical components are water as an ingredient, drinking water and always in stock. Veolia standard systems treated water re-use. are delivered with installation instructions • A total water solution including allowing a quick and secured start-up. equipment, chemicals, related Standardization can reduce the time for consumables and spares list, with service pre-commissioning a plant by up to 70%! contracts. Standard Systems come with performance • Standard systems based upon equipment EASY guarantees. that are repeatable everywhere. INSTALLATION & OPERATIONS • Robust in design The after-sales services for Veolia • Fast delivery & commissioning, delivered standardized systems is easy thanks to the ready-to-operate. repeatability of the work carried out by our Veolia service technicians. Therefore the RESOURCING THE WORLD 31
RAPIDE STRATA™ – Short Cycle Regeneration Ion Exchange Deionizer
The high performance range of Rapide Strata two-bed or three-bed units produce high purity water for beverage industry, boiler make-up , cooling water and ingredient water. The unique design offers savings of up to 40% on operational and wastewater costs ACTIFLO™ PACK ACP2 – High compared to conventional deionization Performance Clarifier systems. • Flow rates from 2.5 to 60 m/hr Veolia Water Technologies has • 7 standard models available in different developed and patented Actiflo™ versions according to American and which is today recognized as the most European standards and depending universal and the highest performing on water quality requirements: Rapide clarification process in the market. The Strata and Rapide Strata+ Actiflo process offers a great Process • Standard regeneration in 35-45 minutes stability thanks to the use of microsand that buffers the effect of raw water flow LOW or load variations. TECHNICAL RISKS In order to stay on the cutting edge, Veolia Water Technologies has extensively standardized the Actiflo in a range of package plants to comply with various customer expectations: • Systems that can be delivered, installed and commissioned very quickly • High level of local services based on reliable, efficient and modular solutions • Cost-effective products • The Actiflo Pack ACP2 range now includes eight models suitable for flow SIRION™ MEGA – High Flux rates from 300 m/d to 43 000 m/d, and Low Energy Reverse Osmosis depending on the application. � system
The Sirion Mega systems are fully standardized solutions developed for pure water production and water re- use applications. Completely flexible, they offer modular skid and membrane configurations with low operating costs. • Capacity from 5 to 139 m/hr (22 gpm to 612 gpm) • 10 standard models available according to American and European standards 32 WAVE #05
MadTree Brewing Craft brewer to incorporate Veolia’s Sirion™ Mega technology to produce high purity water
ast growing and critically acclaimed consistent quality and taste of the beers. As FCincinnati craft brewer MadTree such, we didn't want a standard RO unit.” Brewing has chosen Veolia Water Technologies’ Sirion Mega technology Hunt continued: “What we found most solution to ensure water quality control as appealing about Veolia's RO technology was the brewer undergoes a planned expansion. its ability to provide feedback, which will allow us to fine-tune the incoming water as The 100 GPM (gallons per minute) RO unit needed to be able to produce the high quality produces high purity water, removing up to of beers our customers expect. Moving ahead MAINTAIN 97% of dissolved inorganic and more than we are fortunate to be able to call upon PRODUCT QUALITY 99% of large dissolved organic material, Veolia's industry experience and technological colloids and particles—providing consistent expertise to help make sure we maintain the water quality for MadTree’s beer production high quality standards that have fueled our process. Any excess output from the RO will growth.” be directed to the boiler as water make-up thereby further delivering increased water & As part of the largest water company in the energy efficiency in operations. world, Veolia Water Technologies enjoys a commanding presence in the beer brewing Currently producing approximately 25,000 industry with more than 150 – and growing barrels of beer a year, the brewery expansion – brewery customers globally. Veolia’s more will increase production to 35,000 barrels than 350 proprietary technologies support annually. Furthermore there is enough its solutions and service value across the room to support future growth by adding entire spectrum of the brewing process potential capacity to boost output to – from product & process water, to water 180,000 barrels. recycling and wastewater solutions.
According to co-founder Jeff Hunt, “We’ve seen the explosive growth in the craft maintaining product quality was the brewing sector of the market, particularly in brewer’s over-riding objective when it the U.S.,” said Ted Lawson, Marketing Director contemplated expanding production to for Veolia Water Technologies, “and we meet increased customer demand. "Since recognize the growing needs these brewers water makes up 95% of beer, water quality have for improving both process water and plays an important part influencing our beer’s wastewater treatment. We are committed flavor profile. As we planned for our new, to leveraging our technical knowledge and expanded production facility it was critical to experience to add value by helping emerging us to be able to control the incoming water of brewers grow and succeed.” � our brewing process to insure we maintained CREATING VALUE FOR INDUSTRY 33
factory producing Branston pickle. It was an emergency of national proportions; creating Premier panic that England was about to lose what the Daily Mail called “a national treasure”. The fire devastated the factory and forced production to be shut down, threatening Foods shortages before Christmas. A mobile solution for The requirement the UK's best-loved To get production moving again and to sweet pickle meet the seasonal demand, Premier Foods hired in a temporary boiler to provide the steam for production needs such as cooking n the early hours of the morning, a and pasteurization. However, boilers need Imajor fire hit Premier Foods' the UK’s softened water, and the softeners had been largest food producer plant of Branston lost in the fire along with the boilers. A new pickle in Bury St Edmunds (28 million jars water softening plant to supply 30m/h was sold annually). For twelve hours 150 fire- urgently required. fighters from Suffolk and neighboring counties tackled the blaze at the only The solution Premier Foods turned to Veolia Water Technologies who provided one of its Mobile Water Services units to be on site ready to supply the temporary boiler with softened water. The Mobile Water Services softening unit is a complete water softening plant – tanks, pumps, controls and triplex ion exchange softener – installed in a standard 40’ shipping container. Once exhausted, the complete trailer is returned to Veolia Water Technologies’ central regeneration facility, which means zero discharge on site and no problems of handling or disposal of regenerant chemicals. On-site chemical systems can be completely isolated whilst maintenance or repair work is carried out.
The result The system was so successful that Premier Foods ordered a second unit which was on site within ten days. The two Mobile Water Services units supplied the site for nine months until Premier Foods’ new boiler-house was commissioned. And one trailer was retained for a further three months until the new plant had passed inspection. � 34 WAVE #05
Creating Value through Leading Anaerobic Technology
rocess effluents from the that can be sold, at least for and specific requirements, PFood and Beverage sector the granular sludge based such as future expansion or are characterized by highly technologies like Biobed® energy and/or water recovery biodegradable components with Advanced EGSB and Biothane makes the selection of the a high calorific value. Anaerobic Advanced UASB. This is not optimal treatment technology technology plays a key role in the case for aerobic treatment important. the effluent treatment and processes, which rely on resource recovery from these energy-intensive aeration to Anaerobic technology industrial effluent streams. oxidize organic material, while applied for brewery generating a large quantity of In order to increase its current Biothane is Veolia’s technology waste biomass which has to be beer production capacity, the centre for anaerobic disposed off. Paulaner brewery (Munich, technologies and is one of the Germany) decided to expand world's leading companies in and relocate their brewery. The the field of biological treatment ''Anaerobic proven to nature of brewery effluent is of industrial wastewater. be most appropriate most suitable for anaerobic treatment. The principle of anaerobic in view of Total Cost solutions is the utilization of of Ownership and This project had a key constraint anaerobic bacteria (biomass) Sustainability in terms of available space and to convert organic pollutants the effluent treatment plant or COD (Chemical Oxygen '' had to be installed in a building. Demand) into biogas without Biogas can be used for steam the presence of oxygen. and / or electricity generation. Compact, robust, high efficiency, Oil or gas fuel can be (partly) Biobed Advanced. The system Particularly adapted to treat replaced by biogas, resulting in is a granular biomass type of medium to high strength operational cost saving. treatment process. The granular wastewater, most of the biomass consists of different degraded organic material will There are many different bacteria which convert the be converted into methane, types of anaerobic processes. available organic fraction in while only a small fraction is Combining this with the the wastewater into valuable used for biomass production. uniqueness of each effluent, biogas. In top of the reactors, Produced biomass is a resource specific site conditions patented 3-phase Biobed
) E s ne a rgy (biog
Process Treatment effluent effluent Nutrient BIOTHANE Discharge recovery
Client
Water reuse RESOURCING THE WORLD 35
Memthane plant, Arla
Advanced settlers are installed, equivalent to 1 MW of electricity. back up service - 365 days per year. which separate the biomass from The Memthane effluent is post- This innovation is expected to the final effluent and the biogas. treated by Veolia’s Anitamox change the regular operation of The system is designed for process. The application of this biological wastewater treatment 2,800 m/day of wastewater technology saved more than 10% plants into automated self- and produces more than 9,000 in additional energy production. regulating plants, which are Nmbiogas per day (approx 2.8 The final stage of the plant is the monitored remotely. � MW). polishing of a small aerobic post- treatment, by means of the Biosep Complete resourcing of process. It combines the aerobic waste and effluent streams treatment with Ultra Filtration One of the world’s’ leading membranes. Approximately 67% of Summary confectionary and pet food the effluent is discharged into the Biothane has more than 600 producers asked Veolia to provide river and 33% is re-used after an references in the field of industrial a solution for the treatment of upgrade through Veolia’s Reverse effluent treatment. The Biothane production water effluents and Osmosis technology. anaerobic technologies prove to waste streams. The solution had have added value through: to meet sustainable targets to SMART plant operation • Compact & Small foot print maximize green energy recovery To increase the ease, reliability solutions and water re-use, have no impact and effectiveness of the operation • Production of a green energy on the environment and achieve of an anaerobic treatment source river discharge conditions. The plant, Biogas Manager Control® • Low operational cost available footprint was limited. SMART technology for anaerobic • Nutrient recovery wastewater treatment has • High removal efficiency The process concept selected is been developed. The technology • Minimizing Carbon -and Water based on Memthane technology. provides a new dimension in footprint at site Memthane combines anaerobic operating anaerobic granular digestion technology with wastewater treatment process To select the most appropriate ultra-filtration membranes. The through 24/7 real-time control. process, Veolia develops design membrane acts as a filter and This allows for minimal physical studies to roadmap treatment is a 100% physical separation of operational attendance. routes for the sustainable anaerobic biomass. Memthane This technology consists treatment of present process treats process effluent and food of a carefully designed effluents, aiming to optimize waste fractions in one anaerobic instrumentation and control energy production and close treatment process, is compact and package. It measures online water cycles. These studies are achieves high removal efficiencies quality parameters: water flow, based on full scale expertise (> 99%). The biogas is applied in COD reduction, biogas production and support by tests executed a Combined Heat Power (CHP) and biomass quality. The system at Biothane laboratories or Pilot unit, producing 2 MW of heat is provided with automated 24/7 Plants on site. 36 WAVE #05
Paulaner brewery Environmentally friendly wastewater treatment
he Paulaner brewery is one of the best- achieved by using aerobic organisms. These, Tknown German breweries, with a long however, need to be fed with oxygen, resulting tradition of the finest Munich art of brewing. in high operating costs and CO2 emissions. The annual production exceeds 2 million hectoliters. The popularity of Paulaner beer Paulaner selected an environmentally friendly has always extended beyond the city limits of anaerobic treatment. The degradation Munich, both nationally and internationally. process does not need oxygen, so the energy Paulaner beer is enjoyed in more than 70 consumption is considerably reduced. Another countries worldwide. advantage is the production of energy-rich biogas, which can be used on site in the boiler The challenge house. Due to the increasing popularity of Paulaner beer the existing To ensure a high level of operational production site Nockherberg reliability for their future in the center of Munich wastewater treatment, Paulaner reached its limits. In order chose the proven Biobed® system to secure ample capacities supplied by Aquantis, a German for future growth, Paulaner subsidiary of the leading Veolia decided to move the production Water Technologies group. � to Munich-Langwied. The new site has sufficient space as well as excellent connections to the highway. The new brewery had to be built with an Key Figures emphasis on modern and environmentally • Wastewater volume: friendly brewery technology as well as an energy and emission-optimized infrastructure. 2,800 m³/d • Load: The solution 23,500 kg COD/d The beer production process generates organically loaded wastewater streams which • Biogas production: are easily biodegradable. With conventional 385 Nm³/h biological treatment, biological degradation is CREATING VALUEVALUE FOR INDUSTRY 37
BiosepTM An aerobic biological treatment for wastewater treatment and water reclaim
n innovative solution developed by Biosep™ Pack - new standard AVeolia Water Technologies, Biosep™ membrane filtration units combines two proven technologies: > Flow rates from 4 to 110 m/hr • Biological treatment using activated > Flexible and modular solutions, sludge manufacturing in-house in the • Membrane filtration Veolia workshops Biosep™ produces very high quality water, > Guaranteed performances fully compliant with the highest standards identical to those of the for water reuse for irrigation, industrial and conventional Biosep™ process municipal applications. Biosep™ Pack is added to a biological With more than 120 references worldwide, aeration tank. The membrane Biosep™ is recommended for: bioreactor replaces the traditional • Significant reduction of carbon, nitrogen settling system and separates and phosphorus pollution perfectly the purifying biomass • High and simultaneous removal of from the treated effluent through bacteria depending on the treated water, microfiltration. The microfiltered completed by downstream disinfection. water is of excellent bacteriological quality and removal of TSS is Biosep™ is sold under the Neosep™ guaranteed at any time. Flow rates trademark in Japan, the United States, from 4 to 110 m/hr. Australia and New Zealand. � Applications > Small or medium sized industrial effluent treatment plants (800 to 10,000 PE) > Temporary solutions during refurbishment or upgrade work 38 WAVE #05
Not just milk-and-water New technologies create a stir in dairies
As global demand for milk, cheese, yogurt and other dairy products continues to grow, cost and energy management concerns are driving the introduction of new technologies in dairies to optimize and control costs of water usage.
In dairy plants, water usage is one of the quantities of milk, cheese and yogurt. major costs in the processing of milk which Demand is rising for greenfield projects is both a direct product and a primary raw to provide local dairy production in these material used to manufacture numerous regions, with 60% of the world’s new capacity products for consumption. On the ingredient development occurring in Asia alone between side, water is used in applications close to the 2005 and 2011. final product, as wash water for Cleaning in Place (CIP) to sanitize processing equipment, At the same time, price volatility, higher for heating milk and milk products and as production costs, competitive pressures cooling water. On average, producing one kilo and environmental concerns are causing of dairy product requires 2-4 liters of water. producers to seek further cost and efficiency savings, while ensuring that quality and Even greater volumes of wastewater -- up hygiene standards are maintained. to 14 liters per kg of dairy product -- are produced from processing steps, cooling Water saving technologies towers, boiler purges and cleaning operations, Of the forces shaping the modernization of which are often loaded with organics, fats, oil, the dairy industry, water usage, energy costs grease and suspended solids. and recovery of lost products are the key drivers of change. Less prominent but still Growing demand, but price pressure important is the need for standardization, remains operational and service improvement and Dairy producers are intensifying their focus on sustainability commitments. improving production and energy efficiencies, even while there is strong growth in global In seeking improvements across all of these markets. Annual growth of 1 to 3% in the areas, producers are increasingly turning to mature markets of North America and experts in the optimization of water use and Europe is being driven largely by demand for wastewater treatment like Veolia Water value added products from health conscious Technologies. consumers. To help plants meet their water requirements, Growth rates are even higher in emerging Veolia ensures continuous water supply market countries where increasing numbers that complies with state-of-the-art hygienic of people are consuming ever-greater standards and regulatory requirements RESOURCING THE WORLD 39
for wastewater treatment. Applications of Advanced reactor can be integrated on-site. water saving technologies that optimize Other standardized technologies, such as usage and treat water at the source through Biobed® Modular Plants, MBBR and Biosep™ refreshment of internal process water -- and MBR, can be quickly deployed onsite with a recovery of valuable products -- are enabling minimal footprint. producers to significantly reduce their external water consumption needs. For example, to treat the high strength effluents generated by cheese and whey Keeping the “Cow Water” production, Veolia’s innovative Memthane® Recovery of condensate from evaporation Anaerobic MBR is a perfect fit, using of dairy products, or “Cow Water,” for reuse cross-flow ultrafiltration membranes is a growing market with the potential for to achieve high COD/SS/FOG removal rapid return on investment. The benefits efficiencies for the treatment of streams. of condensate recovery, using hygienic RO systems, can be two-fold with savings in Inside job water consumption as well as in the recovery As the player offering the largest amount of of heat energy. Vapor condensate can be used differentiating technologies, Veolia plays a in numerous areas of the plant including leading role in emerging markets where its boiler and cooling tower feed water, CIP water, innovative technologies, proven through years reconstitution of powdered products and of operating experience around the world, cheese curd wash water. provide a ready response to greenfield project needs. Condensate is a good source of heat energy, offering significant savings in heating costs However, it is in mature markets that the by recovering the energy for purposes such as company’s offer is evolving most rapidly. pre-heating product or boiler feed water. In The successful results achieved through recovering the steam condensate for boilers technologies like Memthane® are opening and steam distribution systems, operating new opportunities to go deeper inside costs, chemical use and boiler makeup water customers’ upstream production processes. requirements can be significantly reduced. A condensate return system also reduces Another example is yogurt production. Use of energy costs as the already hot condensate membrane technologies has been shown to requires less energy to reheat. enable recovery of 1-2% of the production lost when rinse milk was flushed to wastewater Producers seeking to upgrade secondary during batch process production. In helping effluent for reuse as utility water for cooling customers extract this additional value, or boilers, as well as CIP water, soil and vehicle Veolia is contributing to the dairy’s improved cleaning, toilet flushing and irrigation are production process efficiency -- and increased turning to Veolia for turnkey or standardized profitability. solutions, depending on the complexity of the reuse scheme. With its full scope of in- 1 kg of house capabilities and its dairy product Technology array locally-deployed teams For wastewater, Veolia offers a wide array throughout the world, Veolia of technologies to treat wastewater is well-placed to help its dairy aerobically (such as MBBR, MBR, SBR or customers respond to rising more conventional activated sludge), as global demand with products well as to produce energy and biogas out of that are healthy, plentiful… Generates Requires anaerobic treatment of high organic load and more profitable. � 0.5 to 20.5 to effluent. Conventional and advanced granular 2.0 4.0 liters of technologies such as Veolia’s Biobed® liters of water for production 40 WAVE #05
The Solution Veolia Water Technologies proposed a resource recovery plant (RRP) capable of processing 1.5 MLD, which will later be upgraded to 2 MLD. The RRP will make use of Biothane’s state of the art Memthane® technology, capable of removing >95% of effluent COD. A piloting study was performed to provide an effluent specific treatment facility, ensuring Woodlands product performance and client satisfaction. � Effluent specifications Dairy Feed rate 1500 m/d Anaerobic Resource pH 12 Recovery Facility TCOD 10 g/l COD load 15 t/day
oodlands Dairy, 1000+ people, is Wone of the largest manufacturers of UHT milk in South Africa, marketed under Key Figures the brand FIRST CHOICE®. Woodlands Dairy is a local, Eastern Cape processor of farm • High COD loading: fresh milk, who produces and packages high quality dairy products. Dairy farming methods ~15 ton COD/day should not only have a minimal impact on • Growing effluent the environment but should also be animal friendly and boost public support for dairy demand farming. • Long-chain organics The challenge present in effluent Veolia Water Technologies South Africa (Pty) • Achieving plant effluent Ltd was awarded the contract by Woodlands concentrations below Dairy (Pty) Ltd to provide a viable processing solution for their growing process effluent municipal standards stream. The facility contains a milk sterilisation • > 95% conversion and packaging plant as well as a cheese factory. All process effluent is sent to a combined effluent sump. CREATING VALUE FOR INDUSTRY 41
Robert Wiseman Dairies Reducing water consumption for a higher economic value and a lower carbon footprint
ne of the major costs in milk processing the UK to install a RO recycle system, enabling Ois water: 1.3 liters of water is needed for them to recover 200m/day of process every one liter of milk processed. On top of wastewater. DAIRY RECYCLING this, 4.2g of chemical oxygen demand (COD) 50% OF ITS is produced from every liter of milk processed, The reverse osmosis process is driven by WASTEWATER which is then discharged into wastewater. pressure, but the MegaRO’s low-pressure membranes and high-efficiency pumps make Robert Wiseman decided to optimize its it one of the most energy efficient systems water and wastewater use by aiming to on the market. Low energy use means not reduce water consumption across its dairy only reduced carbon emissions but also low network by 25% over a five year period. operating costs. Moreover, the quality of the waste concentrate stream from the MegaRO The project was started in their main dairy is still good enough for the effluent to be plant located in Bridgwater, which processes discharged directly into the drainage ditch. 125 million liters of milk per day. "Because the operating cost of the MegaRO Veolia Water Technologies (VWT) is is low, the recovered water actually costs less supporting Robert Wiseman’s project by than mains water even after including capital providing a Dissolved Air Flotation (DAF) amortization. We expect to get a payback on system and a membrane bioreactor (MBR) the £130,000 (approx. €153,000) investment to reduce COD. The quality of the discharged in about two and half years." said Eleanor effluent more than meets the environmental Walton, Robert Wiseman Dairies' project requirements. In fact, the quality of the manager. treated effluent was so good that Robert Wiseman wanted to reuse it. Although the plant has only been in operation for six months, Walton had VWT therefore proposed its reverse osmosis enough confidence to be talking to (RO) system: MegaROTM to recycle the effluent Veolia Water Technologies about in order to use it for the CIP (Cleaning in a second plant to recycle another Place) system. The MegaRO technology uses 80m/day of wastewater. “We also a membrane to remove 99% of residual COD, want to roll out this kind of technology dissolved salts and bacteria from the treated to some of our other sites where they have an process wastewater, producing water of equal expensive sewer discharge” she says. � or better quality than the mains supply. VWT was one of the early pioneers of MBRs, thanks to its Biosep process, and using this expertise VWT were able to feed Robert Wiseman Dairies operates six the MBR effluent directly to the MegaRO dairies, 14 distribution depots and employs more than 4,700 employees. system with no set-backs. Robert Wiseman Robert Wiseman Dairies supplies a third became the first dairy industry business in of the UK’s milk. 42 WAVE #05
IDRAFLOT™ New generation flotation unit
Very compact, these units reach a high thickening and clarification grade allowing IDRAFLOT™ is suitable: ultra-flotation with the highest removal • As pretreatment upstream of efficiency on COD, suspended solids and fat. a biological plant to remove IDRAFLOT™ is a rectangular compact unit, biodegradable fats, suspended solids, easily transportable, manufactured entirely fibres, etc. The efficiency is up to in stainless steel. It is provided with lamellar 98% with consequent COD drop of packs, to achieve high treatment capacity between 70% - 80%. compared to its compact size, telescopic level • As a clarification plant downstream adjustment to optimize the sludge extraction of a biological plant to remove light with dry matter up to 8%. sludge particles not captured by secondary decanters. IDRAFLOT™ flotation units are protected by • For tertiary treatment three patents. They are intended to assure a • For sludge thickener perfect mixing of the waste with saturated • For liquid/solid separation in water and an uniform distribution of the industrial process plants (pulp water flow along the entire surface of the & paper, wine, etc.), Idraflot™ is unit. the best solution to potentiate surcharged or undersized plants. The saturation system warrants a complete and even saturation free from the formation Markets & Applications of big bubbles. • Dairy The reactor allows to sample and optimize • Slaughterhouses, meat, salami and the desired parameters through a very fat processing simple adjustment of chemicals (coagulant/ • Fishing industry flocculant). � • Canneries • Wine industry • Soft drinks production IDRAFLOT™ New generation flotation unit
Publication Director: Elise Le Vaillant Chief editor: Clément Leveaux Coordination: Séverine Le Bideau Contributors to this issue: Audrey Bachelay, Maria Jesus Fernandez, Vincent Fouquet, Mette Friis-Andersen, Nora Ikene, Stefan Jakubik, Aneta Jamróz, Dennis Korthout, Ivy Latour, Morgane Laurent, Séverine Le Bideau, Cécile Martin, Nathalie Martin-Ionesco, William Mengebier, Nuria Navarrete, Laetitia Paczka, Manon Painchaud, Laurent Panzani, Brandy Nussbaum, Heung Kap Park, Nicolas Rosen, Peter Stokes, Maria Sand Tandrup, Anna Troedsson, Evelyne Vermeulen, Bruno Valla, Dionisio Visintin, Steven Wilcox, Thomas Willetts Design: Veolia Water Technologies Graphic Design Team Photo credits: Veolia photo library / Christophe Besson / Christophe Majani d’Inguimbert / Stephane Lavoue / Jean-Francois Pellegry / Imag’in / R. Secco / Fotolia / iStock / Image Club Cover: Veolia photo library / Stephane Lavoue Printing: AlphaGraphics
10-31-1291 11/2016 @VeoliaWaterTech • Veolia Water Technologies www.veoliawatertechnologies.com