Jessica Wooten Graceland Fruit Inc. John Barszewski FTC&H (Final)
Total Page:16
File Type:pdf, Size:1020Kb
2/7/2014 Jessica Wooten Graceland Fruit Inc. John Barszewski FTC&H (final) 1 2/7/2014 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 2 2/7/2014 Dantonio 34 Vs. Meyer 24 3 2/7/2014 4 2/7/2014 5 2/7/2014 6 2/7/2014 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 7 2/7/2014 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 8 2/7/2014 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 9 2/7/2014 Reminder: Michigan St. 34 Ohio St. 24 10 2/7/2014 Wastewater Process 11 2/7/2014 12 2/7/2014 13 2/7/2014 Michigan St. 24 Stanford 20 Stanford 4th and one! 14 2/7/2014 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 15 2/7/2014 Lions Coaching analytics Since 1973 – 250 wins, 386 losses = winning 39% Most outstanding coach –Wayne Fontes @ 50% Playoffs: Monte Clark 0‐2 Wayne Fontes 1‐4 Bobby Ross 0‐2 Jim Schwartz 0‐1 Now on to our next coach ‐ Jessica Wooten 16 2/7/2014 Industrial Operators Two Key Roles Keep Production from killing your bacteria Stay in compliance while production is trying to kill your bacteria 17 2/7/2014 GFI Waste Treatment There are two classic ways GFI utilizes to biologically treat production wastewater; AEROBIC & ANAEROBIC 18 2/7/2014 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. 19 2/7/2014 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 ) 20 2/7/2014 Biogas Composition GFI gas production 60% ‐ 80% = METHANE (CH4) 20% ‐ 30% = CARBON DIXODE (CO2) 1% ‐ 4% = WATER VAPOR (H20) 0% ‐ 2% = HYDROGEN SULFIDE (H2S) 21 2/7/2014 Challenges in the GF Industry High sugar concentration releases Variable Flows CIP’s (clean‐in‐place equipment) MltilMultiple StSystem Cleans Communication 22 2/7/2014 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. PidiPeriodic clileaning days nearly double the daily flow 23 2/7/2014 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 routilinely moniditored 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 24 2/7/2014 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 25 2/7/2014 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. 26 2/7/2014 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 27 2/7/2014 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 28 2/7/2014 Wooten’s Super Bowl Philosophy: 29.