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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 –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
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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 Super Bowl Philosophy:
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