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Wastewater Management at an Animal Protein Rendering Facility. J.B. Hess, W.A. Dozier, J. Spann and B. Thomas Poultry Science Department, Auburn University and American Proteins, Hanceville, AL. Rendering Industry. Recycling Inedible Human Food – Useful Products

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Wastewater Management at an Animal Protein Rendering Facility


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    1. Wastewater Management at an Animal Protein Rendering Facility J.B. Hess, W.A. Dozier, J. Spann and B. Thomas Poultry Science Department, Auburn University and American Proteins, Hanceville, AL

    2. Rendering Industry • Recycling • Inedible Human Food – Useful Products • Removed from Poultry Meat Production Waste Stream • Protein Meals for Pet Food and Agriculture • Oil (Fat) Recovery for Biodiesel and Animal Feed Usage

    3. Rendering Industry • Input Intensive • Transportation of Raw Product • Cooking • Energy Usage • Water Usage and Recovery • Waste Management • Air • Water

    4. American Proteins • Hanceville Alabama • Rendering • Regional Poultry Plants – Offal • Frozen Farm Mortalities • Poultry Products • Pet Food Animal Proteins • Feed Grade Animal Proteins • Oils

    5. American Proteins Largest Poultry Rendering Plant in the US • Offal from 20 Poultry Processing Plants • 2 Billions Pounds per Year • 1000 Truck Loads of Offal per Day • Odor Control and Waste Management Compliance are First Order Issues

    6. American Proteins Odor Control • Scrubbers • Anaerobic Lagoon Cover • Biofilter Bed • Cooker Gas Exhaust • After Scrubbers

    7. American Proteins Wastewater Facility • Pretreatment • Anaerobic Lagoon • Two Aerobic Lagoons • Four-Stage Activated Sludge System • Tertiary Filtration • Ultraviolet Disinfection

    8. Feed Grade & Pet Food Condensate 600,000 gpd Pretreatment 235,000 gpd Reclamationof Fats & Solids Bio Gas 30,000,000 gpd Anaerobic Lagoon 6,000,000 gpd Oxic Reactor #2 Activated Sludge Anoxic Reactor #1 Activated Sludge Aerated Lagoon Reuse Lagoon Cooling Lagoon Aerated Lagoon Make up Water Up to 800,000 gpd Averages 450,000 gpd Clarifier Waste Sludge Lagoon Disk Filter UV Disinfection Mulberry Fork Warrior River American Proteins Wastewater Treatment System

    9. Pretreatment Process - Mechanical • Surge Wet Well • Fine-Mesh Drum Screen • First DAF Treatment • Second DAF Treatment • Polyamine • Cationic • Anionic • Pumped into the Anaerobic Lagoon

    10. DAF Units • After Hycor Fine Mesh Drum • DAF #1 • Floating Solids • Mainly Fats – Back to Rendering • Flow Equilizational Basin • DAF #2 • Flocculation Tube - Polymers • To Anaerobic Lagoon

    11. Anaerobic Lagoon • Solids and flocculated Fats Returned to Protein and Fat Recovery • Lagoon - Covered • Biogas Harvest • Used to Heat Boilers

    12. Biogas • Harvested from Anaerobic Lagoon • 2 Million Cubic Feet per Week • 70% Methane (carbon Dioxide, Hydrogen Sulfide) • Biogas mixed with natural gas at a 10% rate to fuel boilers • Could use more

    13. Aerobic Lagoons

    14. Activated Sludge Process • Four Reactors • Two Anoxic – Denitrification • Two Aerobic – BOD Reduction, Nitritfication • Clarifier • Removes Final Solids • Tertiary Filtration Disk

    15. Bioreactors 3 (anoxic) and 4 (oxic)

    16. Clarifier/Tertiary Filtration/ Ultraviolet Disinfection

    17. Water Use/Recovery/Reuse • Potable Water Intake – 90,000 Gal/Day • 50,000 Gal. is for Boiler Makeup • Inflow of 900,000 Gal/Day • 2/3 Condensate from Cooking Process • 300,000 Gal/Day Rendering Process

    18. Water Use/Recovery/Reuse • Production Reuse Rate of 6 Million Gal/Day • Cooling Water System Recycles 30 Million Gallons/Day – Condensing Vapors from Cooking • Discharge Rate of 400,000 Gal/Day • Discharge – Mulberry Fork of Warrior River

    19. Water Reuse

    20. Supervisory Control and Data Acquisition • Monitoring System • Inline • Ammonia • Nitrates • MLSS • pH • ORP

    21. Nutrient Reductions Through System • Biological Oxygen Demand – 99.96% • Chemical Oxygen Demand – 99.65% • Total Suspended Solids – 99.81% • Total Kjeldahl Nitrogen – 99.52% • Ammonia – 99.95% • From 2,500 mg/L to <0.5 mg/L • Oil and Grease – 99.90%

    22. Some Comparisons • Organic Loading – City of 900,000 People • Hydraulic Loading – City of 10,000 People • Cullman County – 80,000 People

    23. Value of Reclamation • Reclaimed Materials • Proteins and Fats • 400,000 Pounds/Week • $500,000 per Year • Waste Disposal Cost Avoidance • $350,000 Per Year

    24. Awards • 2001 Excellence in Industrial Wastewater Treatment (Physical/Biological Treatment) - Alabama’s Water Environment Association • 2003 Clean Water Award Honorable Mention, Full Treatment Category – U.S. Poultry and Egg Association • 2004 Clean Water Award, Full Treatment Category • U.S. Poultry and Egg Association • 2007 Honorable Mention for Facility of the Year Award • Environment Protection • 2008 Excellence in Industrial Wastewater Treatment (Biological Advanced Treatment) - Alabama’s Water Environment Association • 2010 Clean Water Award, Full Treatment Category • U.S. Poultry & Egg Association, March 2010

    25. Conclusions • American Proteins Rendering Plant Starts with Large Loads in Waste Water Handling • Proven Systems in Mechanical and Biological Control Handle that Load • Waste Solids are Recycled • Odor Control Systems are Important as Well • Consistent Quality has led to Industry Awards

    26. Wastewater Management at an Animal Protein Rendering Facility J.B. Hess, W.A. Dozier, J. Spann and B. Thomas Poultry Science Department, Auburn University and American Proteins, Hanceville, AL