Industrial Wastewater Treatment Beef Industry Case Studies
Beef Processing Wastewater Treatment - $80k Saved a Month!
First Beef Processing Facility
This facility slaughters 1,200 head of cattle/day and generates a wastewater flow of 80,000 gallons/day. The POTW that receives the wastewater was having difficulty handling the strength of the wastewater (BOD at 3,000 ppm and TSS at 1,800 ppm) and was charging the facility an average of $162,000 every 2 months ($7.75 per 1,000 gallons).
With some help from Integrated Engineers, the facility staff renovated the existing DAF unit and installed a 1.5- meter belt press to dewater the solids. The DAF loading was very high (exceeding the manufacturer's recommendation by 200%) at 1.5 gpm/sq-ft.
Based on preliminary jar testing, the system would require a dosage of Floccin™ KP+ at 216 ppm. Previous lab analytical showed this reduction to have a BOD of 400 ppm and a TSS of 250 ppm. This decreases the surcharges paid to the POTW down to $32,000/month. Subtracting the cost of the Floccin KP+, the overall savings is $80,000 per month. Treatment costs (chemical and surcharges are $3.25 per 1,000 gallons).
Second Beef Processing Facility
Another slaughterhouse had expended its production and could no longer meet its discharge permit for land application. Integrated Engineers was retained to retrofit their pretreatment system to reduce the BOD and overall nitrogen loading to the existing ponds.
Floccin™ E was the product of choice. The results are shown below and will allow the facility to actually bypass their ponds, if so desired. This will allow them to retrofit the pond(s), remain in 100% operation, and meet their discharge permit. During the design and operation of the new ponds, the reduction in aeration horsepower is estimated at 150 hp, saving $600/day in electricity.
Based on a flow of 350,000 gpd, this represents a reduction in BOD of 6,685 lbs per day, ammonia at 41 lbs per day, and nitrogen at 613 lbs per day. Assuming that all of the ammonia will convert to nitrogen, the total removed is 654 lbs per day.