PROGRESSIVE BREWERY WASTEWATER MANAGEMENT STRATEGIES© A Thesis Presented to The Faculty of Graduate Studies of The University of Guelph by SCOTT JAMES MASSEN In partial fulfilment of requirements For the degree of Master of Science June 2011 Scott James Massen© Library and Archives Bibliotheque et Canada Archives Canada Published Heritage Direction du Branch Patrimoine de I'edition 395 Wellington Street 395, rue Wellington Ottawa ON K1A0N4 Ottawa ON K1A 0N4 Canada Canada Your file Votre reference ISBN: 978-0-494-88931-2 Our file Notre reference ISBN: 978-0-494-88931-2 NOTICE: AVIS: The author has granted a non­ L'auteur a accorde une licence non exclusive exclusive license allowing Library and permettant a la Bibliotheque et Archives Archives Canada to reproduce, Canada de reproduire, publier, archiver, publish, archive, preserve, conserve, sauvegarder, conserver, transmettre au public communicate to the public by par telecommunication ou par I'lnternet, preter, telecommunication or on the Internet, distribuer et vendre des theses partout dans le loan, distrbute and sell theses monde, a des fins commerciales ou autres, sur worldwide, for commercial or non­ support microforme, papier, electronique et/ou commercial purposes, in microform, autres formats. paper, electronic and/or any other formats. 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Canada ABSTRACT PROGRESSIVE BREWERY WASTEWATER MANAGEMENT STRATEGIES Scott James Massen Advisors: University of Guelph, 2011 Professor Hamidreza Salsali Professor Ed McBean Brewery wastewater effluents exhibit high concentrations of nutrients and suspended solids. Treatment is further complicated by the batch-discharge nature of brewery wastes, and a widely variable pH. Effluents discharged directly to municipal sanitary systems are often subject to a high strength sewage surcharge (HSS) and can be a major expense to the brewer. The proper identification of contributory waste streams, by-product diversion and disposal techniques, and end of pipe treatment are essential to the development of an effective wastewater management strategy. This thesis contains a compliment of initiatives directed at reducing HSS fees at a local brewery, including a wastewater characterization study, value-added through anaerobic digestion of brewery by-product study, and investigation into a biological packed tower for end-of-pipe wastewater treatment. The major conclusions of this study will contribute to the formation of a stronger brewery wastewater management program. ACKNOWLEDGEMENTS The author of this report wishes to extend a special thanks to the following contributors: University of Gueloh Dr. Edward McBean: Academic Advisor Dr. Hamid Salsali: Academic Advisor Joanne Ryks: Laboratory Coordinator Laura Wright Head Technican Elora Dairy Cattle Research Station Joel Citulski: PhD Candidate Victoria Hillbom: MASc. Graduate Allison Chan: MASc. Graduate Victoria Sharpe: Co-op Student Labatt Breweries London. ON Charlotte Armstrong: Brewery Support Manager - Environment Health, Safety Debbie Cassel: Environment and Safety Specialist Emily Hahn-Trnka: Environment and Safety Specialist Jordan Meunier: Environment and Safety Specialist Dan Swystun: Co-op Student Alex Demianiuk: Co-op Student Steve Isaacson: Brewery Operations Specialist John McAllister: Brewery Operations Specialist Scott Durnin: Capital & Utilities Specialist Jay Cooke: Brewhouse Floor Manager Terry Mine: Brewmaster Patrick Hoofnaggles: Maintenance - Plumber Jim Fragily: Maintenance - Electrician Steve Eastendon: Maintenance - Electrician Ashley Farrington: Quality Control Laboratory Technician TABLE OF CONTENTS Chapter 1: Proposal arid Objectives 1 Chapter 2: A Literature Review on Brewery Water and Wastewater Management 4 2.1 Introduction to Brewing and Brewery Wastewater 4 2.2 A Background on the Brewery Industry 5 2.2.1 Labatt London, ON 5 2.2.2 Product Ownership 6 2.2.3 ABInBev Environmental Policy 6 2.3 The Brewing Process 7 2.3.1 Malt Preparation 9 2.3.2 Milling and Mashing 10 2.3.3 Wort Cooling and Fermentation 13 2.3.4 Maturation and Clarification 17 2.3.5 Bottling and Pasteurization 18 2.3.6 Powerhouse 23 2.3.7 Clean In Place 24 2.4 Wastewater Legislation for Breweries 25 2.5 Brewery Wastewater Constituents 31 2.5.1 Oxygen Demand 31 2.5.2 Total Suspended Solids 34 2.5.3 pH 34 2.5.4 Inorganic Pollutants 35 Chapter 3: Labatt London Wastewater Characterization 37 3.1 Wastewater Characterization Project Introduction 37 3.2 Wastewater Characterization Methodology 39 3.3 Wastewater Characterization Results 39 i 3.3 Wastewater Characterization Discussion and Recommendations 43 3.3.1 Brewhouse 43 3.3.2 Fermentation and Aging 43 3.3.3 Filtration 46 3.3.4 Bright Beer 49 3.3.5 Packaging 49 3.3.6 Powerhouse 52 3.3.7 Clean In Place 53 3.3.8 Main Effluent 53 Chapter 4: Added Value from Rebate Beer in Anaerobic Digestion 58 4.1 Introduction to Anaerobic Digestion 60 4.1.1 Background on Anaerobic Digestion 60 4.1.2 Biogas Facilities 63 4.1.3 Rebate Beer as a Co-Substrate 64 4.1.4 Digester Objectives 65 4.2 Bench Scale Digester Project Methodology 66 4.2.1 Source of Waste 66 4.2.2 Preliminary Biochemical Methane Potential Test 67 4.2.3 Digester Design 69 4.2.4 Start up Procedure and Operation 71 4.2.5 Digester Sampling Plan 75 4.2.6 Physical and Chemical Analyses of Digestate 76 4.3 Digester Results and Discussion 81 4.3.1 Feed Characteristics 81 4.3.2 Steady-State Digester Performance 84 4.4 Recommendations for Anaerobic Digestion of Brewery Wastes 91 ii 4.5 Anaerobic Digestion Project Conclusions 94 Chapter 5: Biological Packed Tower Retrofit Pilot 96 5.1 Introduction to BioTower Pilot 96 5.1.1 Problem Definition 96 5.1.2 Retrofit Opportunity 97 5.1.3 Background on Attached Growth Processes 98 5.2 BioTower Pilot Methodology 102 5.2.1 Experimental Apparatus 102 5.2.2 Daily Maintenance 106 5.2.3 Sampling Analysis 106 5.3 Results and Discussion 107 5.3.1 Operational Issues 108 5.4 Recommendations for End-of Pipe Treatment 113 5.5 Conclusions 114 Works Cited 116 Glossary of Terms 120 iii LIST OF FIGURES Figure 1: Basic Overview of Labatt Brewing Process (Labatt, 2007) 8 Figure 2: Clean-ln-Place Flow Diagram 24 Figure 3: Comparative Sewer System Charge Overview - Industrial (City of London 2008) 26 Figure 4: 2000-2009 High Strength Sewage Surcharge for London, ON 30 Figure 5: Average Wastewater Profile of Manual Clean Process for Krausen Tank 45 Figure 6: Diatomaceous Earth Slurry Particle Size Distribution 48 Figure 7: COD and BOD5 Loading of Brewery Effluent May 2009 to February 2010 54 Figure 8: TSS and VSS Loading of Brewery Effluent from May 2009 to February 2010 55 Figure 9: Labatt Brewery Main Effluent Particle Size Distribution 55 Figure 10: TP Loading and pH of Brewery Effluent May 2009 to February 2010 56 Figure 11: The carbon flow in the methane production process 61 Figure 12: BMP of dairy manure and rebate beer 68 Figure 13: Schematic drawing of lab digester 70 Figure 14: Methane production normalized by volatile solids destruction 87 Figure 15: Comparison of the oxygen demand reduction from digested feed stocks with varying dairy manure to beer ratios during steady state operation of bench scale anaerobic digester 89 Figure 16: A comparison of the solids destruction from digested feed stocks with varying dairy manure to beer ratios during steady state operation of bench scale anaerobic digester 91 Figure 17: Biological Packed Tower Schematic 103 Figure 18: Equalization Tank Arrangement 105 Figure 19: Results of COD reduction 24 hr. time series in brewery wastewater with ammonia nitrate supplements for investigation into the possibility if a nitrogen deficiency affecting biological wastewater treatment Ill iv Figure 20: Digester operation on trial 1of the 50% DM/50% RB feedstock 178 Figure 21: Digester operation for trial 2 of the 50%RB/50%DM feedstock 179 Figure 22: Solids analysis for the 50% DM/50% RB 180 Figure 23: Solids destruction for the 50% DM/50% RB 180 Figure 24: Solids analysis for the 75% DM/25% RB 180 Figure 25: Solids destruction for the 75% DM/25% RB 180 Figure 26: Solids analysis for the 100% DM 180 Figure 27: Solids destruction for the 100% DM 180 Figure 28: Digester Performance on the 75% DM/25% RB blend 181 Figure 29: Digester Performance on the 100% DM blend 182 Figure 30: Effluent VFA and Bicarbonate Concentrations of the 2nd 50% DM/50% RB trial 183 Figure 31: Effluent VFA and Bicarbonate Concentrations of 75% DM/25% RB trial 183 Figure 32: Effluent VFA and Bicarbonate Concentrations of 100% DM trial 184 LIST OF TABLES Table 1: The composition of barleys grown in Sweden and Montana (% (w/w) d.b.) (Briggs 1997) 10 Table 2: City of London 2007 Limitations on Discharges to Sanitary Section 4.8 29