Wastewater Treatment on Dairy Industries (Milk Powder)

Wastewater Treatment on Dairy Industries (Milk Powder)

1. King Fahd University of Petroleum and Minerals Department of Civil & Environmental Engineering CE-541 (Wastewater Engineering) Term 212 Instructor: Dr. Haitham Elnakar By: Ziaul Haq Doost, Faisal Altowairqi, Abdullah Alghamdi Date: May 9 th , 2022 1

2. Food Industries Wastewater Treatment on Dairy Industries (Milk Powder) 2

3. O utlines I ntroduction Milk Powder Flow Process Wastewater Sources Wastewater to be Treated (Quality) Wastewater Minimization Treatment Approaches Conclusion 3

4. I ntroduction Industrial growth leads to contributing a large amount of contaminated water. The food process industrial becoming more important and expanding exponentially in line with population growth around the world. The role of water in the dairy industry is hugely associated with production. One liter of milk will consume around eight liters of water. The Dairy industry is one of the largest industries for contributing to wastewater. Wastewater will develop at every step of the dairy industry including the manufacturing of milk products, packaging, and storage of products 4

5. Milk Powder Flow Process 5

6. Milk Powder Flow Process 6

7. Processing waters: These are conditional clear fluids created during milk chilling in particular coolers and condensers. Wastewater Sources Cleaning wastewaters: dairy industries use CIP ( Cleaning In Place ). Cleaning wastewater also includes spilled milk and products, whey, pressings and brines, effluents from CIP cleaning or production tool malfunctions, and even operational mistakes. Milk and manufacturing leftovers account for more than 90% of the total organic solids in wastewater. Sanitary wastewaters: Water for sanitary purposes. It may be found in restrooms, shower rooms. 7

8. Wastewater Sources In milk production processing the water plays the most prominent role, it is used in each step of the production process, such as washing, cleaning, heating, disinfection, and cooling, so, water demand is notable in the milk production. Contaminated water, involving sanitary activities reaches 50-80 % of the all-consumed water in food industries, here the remaining 20-50 % is pure. D.S = Detergents & Sanitizing Agents W.W = Wash Water ST = Steam C.W = Cooling Water 8 Cleaning wastewaters:

9. Wastewater to be Treated (Quality) High Temperature Huge Variations in BOD, COD, TOC, PH, Fat, Oil, Grease (FOG), Total Nitrogen (TN), and TSS. 9

10. Wastewater to be Treated (Quality) ‏C 12 H 22 O 11 10

11. Wastewater to be Treated (Quality) Whey is the liquid remaining after milk has been curdled and strained. It is a byproduct of the manufacturing of cheese or casein and has several commercial uses. Sweet whey is a byproduct resulting from the manufacture of rennet types of hard cheese, like cheddar or Swiss cheese Lactose is a  disaccharide   sugar  derived from  galactose  and  glucose  that is found in  milk . 11

12. Wastewater Minimization Key benefits of the waste minimization effect reduce the following: const and time for disposal of wastes, controlling system installations. Construction of treatment and time. Time-saving and expense of environment management by workers and managers. Energy and raw materials cost. Management issues, long-term and short-term responsibilities for discharge, disposal of waste to the environment, and controlling. Disease and pollution because of distribution. For the laborers and workers potential hazards. 12

13. Wastewater Minimization Methods of Minimization Method # 1: In this method, a set of common and typical options will give, that do not need any complex procedure or any expensive equipment for implementing Decreasing the amount of water for washing purposes. Producing useful by-products from the whey, such as cake powder, protein, buttermilk, animal feed, and lactose. Separate high and low strength wastewaters, and use the low strength wastewater for washing the yards, and lawns. Repair and fix all leakages of the process pipelines. Use valves with a pressurized system for the washing halls and yards which can be controlled by workers. Raising educational awareness for managers, workers, and laborers. 13

14. Wastewater Minimization Method # 1: Continued… Environmental management group in the company organized. Regulations, and rules of waste management establish both outside and inside of the plant. Reducing, controlling, and minimizing the water and wastewater obtained from the process lines and surrounding of the plant. Daily data analysis, watch out and control of waste problems that arise in the plant. Controlling and reducing the chemicals used in the plant. Reuse of recycled water used in the plant after decreasing the total solids by separation units. Daily checkup of the systems, leakages, pipelines, valves, tanks, overflows, etc. Daily checkup and control of the materials in the plant and storage. Reproducing of by-products from the wastewater, especially concentrated ones. Keep up, upgrading of the plant by time. Maintenance and good housekeeping as daily responsibilities in the plant. 14 Consequently, after execution of the above-mentioned method for the industries, the following results were achieved:

15. Wastewater Minimization Method # 2: using water pinch technology Water pinch technology application to dairy plants resulted in consumptions of freshwater and wastewater effluent flowrate reduction up to 60% and 65% respectively. Pinch technology is mainly used in major chemical manufacturing plants or oil refineries where heating or cooling of feed streams is required . Pinch analysis uses the hot streams to heat the cold streams and vice versa, thus saving the hot or the cold utility loads which obviously helps in energy and cost savings. water pinch tests all possible configurations and the optimum will be selected, which minimizes the cost of operations, cost of freshwater, wastewater discharges, and minimizing contaminant mass loading. Finally, the optimal network leads to the minimum consumption rate of water and fewer effluent contaminants. 15 This water network will show a 39% reduction in effluent discharge costs. This system notably decreased the number of contaminant loadings in the discharges.

16. Wastewater Minimization Method # 2: Continued… using water pinch technology ( to design a maximum water reuse system ) 5-a 5-b 5-c 5-d 16

17. Wastewater Minimization Method # 2: Continued… using water pinch technology ( to design a maximum water reuse system ) 17

18. Wastewater Minimization Minimization by membrane: 18

19. Treatment Approaches Wastewater Treatment Options (Flow Chart) for Milk Powder Industries Flow Chart For Treatment Mechanical Treatment = Physical Treatment 19

20. Treatment Approaches Physical treatment is the type of treatment that removes suspended solids from the wastewater. Organic loads reduce insufficiently by the conventional mechanical approaches, as long as the solid concentration in dairy wastewater is low settleable. Screening Equalization Tank Influent Effluent With basin dimensions from 25-50% of the whole effluent volume, a 24-hour flow with the highest load effectively can be handled. 20

21. Treatment Approaches Physicochemical Treatment: Milk protein and fat colloids are problematic in the dairy industries and require mixed treatment, and physicochemical treatment is used for this purpose. FOG (Fats, Oils, and Grease) is the most important to be removed from the wastewater before discharging. Skimmed milk production rarely produces FOG, but the main source of the FOG is unskimmed milk, which causes the problem. Coagulants: Removing FOG from the top of the tanks, is the main challenge because the wastewater has high temperatures and the fats are soluble in it 21 Aluminum sulfate: (Al2(SO4)3 ferrous sulfate : FeSO4 Ferric chloride : FeCl3

22. Treatment Approaches Chemical Treatment: 80% of the fat will be removed during the reaction of H 2 O 2 and FeSO 4 with wastewater. pH less than 6.5 and more than 10 will cause corrosion of the system pipes. Hence, it needs to be adjusted to decrease side effects First Tank Second Tank Influent Effluent Acid Tank Base Tank 22

23. Treatment Approaches Biological Treatment: In most dairy industries, biological treatment work efficiently, because the wastewater suspended solids are more organic matter, which requires biodegrading Biological treatment has two main branches relying on the oxygen needs : Aerobic biological treatment systems Anaerobic biological treatment systems 23

24. Treatment Approaches Aerobic biological treatment systems: Nowadays, most dairy wastewater plants are aerobic units, although they have low efficiency, mostly because of filamentous growth and fast acidification which is caused by lactose levels and a low buffer capacity of the wastewater Aerobic biological treatment systems achieve a very positive response, during synthetic wastewater treatment with 1 g/L of total Kjeldahl nitrogen (TKN), and 4 g/L of COD at a pH of 11.5, more than 96% of degradation will be achieved and constantly continues mode. Filamentous growth is a nutrient-regulated growth response that occurs in many fungal species . In pathogens, filamentous growth is critical for host-cell attachment, invasion into tissues, and virulence. 24

25. Treatment Approaches Anaerobic biological treatment systems: Anaerobic units are more suitable for direct utilization of high-strength wastewater of dairies. They are more cost-effective than aerobic units, in case they properly operate. In addition, these units do not produce unpleasant odors . A notable problem of these systems is their start-up , which is too long , because of the complex substrate degradation , fat utilization, preliminary biomass adaptation before protein, resultant inhibition of methane production, and fast drop-in 25

26. Conclusion Wastewater from the dairy industries typically contains biodegradable materials and organic in which can deteriorate the environment and affect the ecosystems. Wastewater that comes from the dairy industries is highly polluted, in case of discharging untreated or partially treated, its effects strictly affect the environment. minimum standards for discharge of effluents from the dairy industry 26

27. Thank You 27