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Commercial Application of an innovative membrane bioreactor for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site Presented by: Karen Kennedy. Product Portfolio 2001. Butter 32,833 Cheese 14,628 Rennet Casein 9,845 Acid Casein 6,097 Lactose 16,922

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Commercial Application of an innovative membrane bioreactor for waste water treatment at Glanbia Ingredients Ltd. Ballyragget SitePresented by: Karen Kennedy


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Product Portfolio 2001 for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • Butter 32,833

  • Cheese 14,628

  • Rennet Casein 9,845

  • Acid Casein 6,097

  • Lactose 16,922

  • Whey Powders 25,386

    105,711 Tonnes


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Development of the New Process Technology for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • Glanbia was faced with two major challenges following the issue of our IPC Licence in December 1998.

  •  i. Following the merger of the Avonmore Foods Plc. and Waterford Foods Plc. to form Glanbia Group, it was decided to close the Dungarvan site and process up to 60% additional milk and whey on the Ballyragget site. At the same time, the emission limit values in the new IPCL were being reduced.

  • The type of emission values outlined in this license could not be delivered by conventional technology. 

  • Glanbia carried out research on what technology was available in the latter half of 1998 with the objective of upgrading its waste water treatment plant for the 1999 peak season.


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OPTIONS CONSIDERED FOR PLANT EXPANSION for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • Remain with proven conventionaly technology

  • Extend existing biotower, increase clarification capacity

  • Or deviate from the norm and rewrite the rules of water treatment.


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Waste Water Treatment for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • Inputs

  • Milk per annum - 201M gallons

  • Whey per annum - 203M gallons

  • Outputs520 million Gallons Wastewater To Be Treated

  • 490 million Gallons Treated Permeate To River Nore

  • 3.5 million gallons of Sludge


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Loss Minimisation for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site


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Waste Minimisation: for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

Delactosed Permeate


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Acid Whey for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

Acid Whey Wash Water

Rennet Casein

UO

P

RO1 Gemini

800-850m3/day

Diverted from effluent to Cooling Line

<50mg/l COD

RO2

P

P

UF3

UF2

R

100m3/day

Off Site Treatment

P

R

Lactose

WPC

Waste Minimisation:

Whey Gemini Plant


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Recycled as Boiler Feed Make Up Water for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

RO Polisher

100m3/hr

Recover & use as pre-rinse for membrane CIP

5 Evaporators

Retentate

to Effluent

PreRinse in Whey CIP’s, evaps, tanks, silos etc.

General Cleaning

Waste Minimisation:

2nd Stage Condensate Polishing


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OPTION CHOSEN for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • To expand treatment capacity from 15,000Kgs COD to 30,000kgs/Day, 2 limiting factors:

  • Oxygen Transfer in aeration basin

  • And the inability of settlement in final clarifiers at MLSS above 2,000.

  • Solution – Suprafilt fine bubble air diffusers and Kubota membranes.

  • Operating now at 8,000 mg/l MLSS in the oxidation ditch


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BOD Reduction for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

BOD OUT

BOD IN

20,000kg/day

Conventional Technology 98.6%

Kubota Technology 99.5%

WWTP


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Out for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

Treated &

disinfected

effluent

Waste Sludge

(to further treatment)

Air in

Principle of Operation

In

Screened

Effluent ex oxidation Ditch


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Specific Innovative Elements for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

The Kubota membrane bioreactor is essentially a high MLSS activated sludge process where the Kubota membrane treatment units are submerged within the extended activated sludge tanks. Typically, the activated sludge is maintained in the range 15 – 20,000 mg/l MLSS.


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Specific Innovative Elements for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

In operation, the treated effluent through the membrane units is controlled by available gravity head (typically 1 – 1.5 metres).

The number of units installed is dependant on the maximum flow rate required. The plant at Ballyragget comprises 74 packs for a guarantee flow rate of 7,300 m3 per day. However, it is hoped that flow rates of 9,0003 per day will be achieved.


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The Filtration Spectrum for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

0.4 microns


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River Nore (Downstream) = Q4 Unpolluted for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site


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Improvements in Suspended Solids for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

1999

2000


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Improvements in Biological Oxygen Demand for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

1999

2000


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Improvements in Ortho P for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

1999

2000


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WWTP Flow for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

Preliminary treatment:

- Screen

- DAF

- Biofilters

Denitrification

tank

Feed 7-9000 m3/d

ExistingOxidation ditch (13000 m3)

16 t/d BOD

Recycle/return

sludge

Future capacity

Existing settlement tanks

Re-use

Outfall

to river

Kubota membrane units


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Energy Requirements for new plant for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • Upgrading and Expansion of the Treatment plant cost IR£3 Million, with the Kubota membranes costing IR£1.6 Million and the installation of a new aeration system, Suprafilt Fine bubble diffusers.

  • Aerzen fine bubble diffusers – 50-60% increase in Oxygen Transfer when compared with surface rotors.

  • Energy usage.

  • Conventional plant would not achieve the 10:15, BOD:SS standard


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Operational Difficulties Encountered for waste water treatment at Glanbia Ingredients Ltd. Ballyragget Site

  • 150% Of design airflow was required to maintain flux.

  • No Standby blower.

  • Membrane scaling incidents.

  • Membrane sliming.

  • Sludging between membrane plates, reduces flux.

  • Wear on plates.


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