2/7/2014

Jessica Wooten Graceland Fruit Inc. John Barszewski FTC&H (final)

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Facility Information  The owner: Graceland Fruit, Inc. (GFI)  The location: Benzie County, Gilmore Township, Frankfort  Primarily manufactures sweetened dried fruit including cherries, cranberries, and blueberries.  GFI also produces fruit juice concentrates  GFI is the largest single employer in Benzie County

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Dantonio 34 Vs. Meyer 24

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Wastewater History  1973: GFI acquires a G.W. discharge permit to discharge fruit processing wastewater 75,000 gallons/day to rapid infiltration  1991: MDNR requires additional discharge and site data – wastewater characterization and hydrogeological information  1993: GFI installs 16 acres of year round spray irrigation  1998: GFI adds an additional 19 acres of spray irrigation

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History Continued  February 2003 FTC&H hired by GFI for environmental services  September 2004 GFI enters into an Administrative Consent Order with MDEQ  ACO requires construction of a wastewater treatment system  September 2005 FTC&H hired for wastewater services

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History Continued  ACO states WWTP to be in operation by August 2006 (less than a year!)  Construction delayed till spring of 2006  Start up began in February 2007

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Reminder: Michigan St. 34 Ohio St. 24

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Wastewater Process

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Michigan St. 24 Stanford 20 Stanford 4th and one!

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Graceland Design Parameters

Parameter Units Production Day Production Daily Ave. Flow gpd 55,000 Cleaning Daily Ave. Flow gpd 104,000 BOD5 lbs/d 4596 mg/l 10, 036 TCOD lbs/d 5,975 mg/l 13,047 TSS lbs/d 229 mg/l 500 Total Inorganic Nitrogen lbs/d 1.2 Total P lbs/d 1.2 Min. Temperature ºF 72

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Lions Coaching analytics  Since 1973 – 250 wins, 386 losses = winning 39%  Most outstanding coach – @ 50%  Playoffs: Monte Clark 0‐2 Wayne Fontes 1‐4 0‐2 0‐1

Now on to our next coach ‐ Jessica Wooten

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Industrial Operators Two Key Roles

 Keep Production from killing your bacteria

 Stay in compliance while production is trying to kill your bacteria

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GFI Waste Treatment

There are two classic ways GFI utilizes to biologically treat production wastewater;

AEROBIC & ANAEROBIC

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GFI Anaerobic  High rate upflow anaerobic digestion  Single stage mesophilic digester (95‐98)  Small area required ––hihigher F:M, dense biomasbiomas..  High loading capacity  Reduced solids production  Less energy required.  Methane produced as a future energy source.

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GFI Aerobic

 Alternating Sequencing Batch Reactors  Aerobic and anaerobic activated sludge treatment  Polishing of anaerobic effluent for GW discharge  Small footprint  SCADA controlled treatment  TtTemperature bfitbenefit (>10 c )

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Biogas Composition  GFI gas production

60% ‐ 80% = METHANE (CH4)

20% ‐ 30% = CARBON DIXODE (CO2)

1% ‐ 4% = WATER VAPOR (H20)

0% ‐ 2% = HYDROGEN SULFIDE (H2S)

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Challenges in the GF Industry

 High sugar concentration releases  Variable Flows  CIP’s (clean‐in‐place equipment)  MltilMultiple StSystem Cleans  Communication

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Production Discharge Characteristics

 High‐strength, simple sugars wastewater with low nitrogen and phosphorus concentrations

 Highly variable flows and concentrations, even for an idindus tiltrial process. PPidieriodic clileaning days nearly double the daily flow

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Using Brix to determine organic loading  Brix is the concentration of a sucrose solution in water as a percentage  For example: 10 Brix is 10% sucrose in water solution  BiBrix is a routiilnely moniidtored QC parameter in the production of sugary products; juice, soda, candy, fruit  The theoretical oxygen demand (ThOD) of sucrose is 1.1 g O2/g sucrose  Assuming all sucrose is oxidized under the conditions of the COD test, measuring Brix in the wastewater can approximate COD

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High Strength Spills THE BACTERIA CAN ONLY EAT SO MUCH FOOD IN A DAY.DAY.

 Production Plant releases on the order of 10 to 60 Brix  Capable of 60 Brix = 600000 COD = 300000 BOD (estimate)  Volume of Release dependent on system or equipment

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Worst Release  4‐weeks on job  3000‐gallons of 50‐Brix released  No communication  COD in Anaerobic Reactor 72,000 mg/l  Hook Fire Hose Up, flush system and Reseed  Process down 6 weeks  Cost to company in lost revenue, fines, start‐up close to quarter million dollars.

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CIP’s:  CIP (clean‐in‐place) is a term used to describe the chemical clileaning of process equipment.

 SANITIZERS, BACTERIACIDES, CHLORINE, OIL, PEROXIDE, LUBRICANTS, POLYMERS, ANTIFOAM, NITRITES, NITRATES, SULFITE, SOLVENTS, AMMONIA, CAUSTIC, ACIDS

 Knowledge of systems  Knowledge of industry jargon  Knowledge of chemicals used  Knowledge of concentration of chemicals used

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Communication  Policy implementation  Face time with Production Team  Coordination of Production Scheduling with WWTP  Management buy‐in  Supervisor knowledge of wwtp operations  Production Workers knowledge of wwtp operations and their impact  Tours  Each role is essential to operations

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Wooten’s Philosophy:

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