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Pepsi Howell

• Pepsi Production Facility in Howell, MI

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Pepsi Howell

Pepsi Howell

• Pepsi Production Facility in Howell, MI

– Production began in 1969

– Produce:

• 12oz Cans

• 16.9oz

• 20oz

• 1L

• 2L

• Fountain Syrup

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Pepsi Howell

• Pepsi Production Facility in Howell, MI

– Produce 30 Million Cases/Year

– 335,000 Square Feet Warehouse

– Local Sales to Howell

– Transport throughout Michigan

Pepsi Howell

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Pepsi Howell

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Can Line Filler – 1600 cans/minute

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Can Line Packer – 12pk

History

• Why Pretreatment System

– BOD Loading

• Spikes in excess of 8,000 mg/L

– Phosphorus

• As high as 50 mg/L

– Low pH

• Acidic products, pH below 5

– Fluctuations Throughout the Day

• High Sugar Days

• Low Flow during Plant Downtime

• High Flow during Production

• Chemical Flow during Night

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History

• Constraints

– Lack of Land Space

– High Priority on “Clean” Effluent

– Fluctuations in Flow from Production Facility

• Initial Attempts

– High BOD Capture for Slow-Release

– Reduction of Waste Streams

MBR Installation

• Membrane System Installed

– Maintain Healthy Biomass to Consume ‘sugar’

– Small Footprint

– Very Clean Discharge

• What is it?

– Many Small Membranes to Filter Out Clean Water

– Hollow Fiber Tubes with Nominal Pore Size of 0.04µm

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MBR Installation

• Overall System

– Two Lift Stations

– Equalization Basin

– Aeration Basin (Digester)

– Membrane Cassettes

– Belt Press

– Design flow rate 160,000 gallons per day, 220,000 gal. max

MBR System

EQ

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Lift Stations

McPherson Isabell

MBR System

EQ

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Equalization Basin

MBR System

EQ

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MMBR Tank & Aeration Basin

MBR System

EQ

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Membrane Tank

Zenon Membranes

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Zenon Membranes

Membrane Cleaning

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MBR Cleaning

MBR Cleaning

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MBR Cleaning

MBR Cleaning

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MBR Cleaning

MBR System

EQ

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Solids Pressing

MBR System

EQ

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Permeate Flow to City of Howell

Challenges

• Fragile Sludge

• Fluctuations in Sugar Loading

and Plant Flow

• Solids Removal

• High Oxygen Requirement

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Challenges: Fragile Sludge

Started with Feed-Back Control

– To ensure healthy biomass 100:5:1 ratio required

(Carbon/Nitrogen/Phosphorus)

– Phosphorus needs met with flow characteristics

– Aqueous Ammonia added to Equalization Basin based on

TOC Anaylzer results

Challenges: Fragile Sludge

TOC Analyzer

– Real time analysis of Total Organic Carbon of

Equalization Basin

• Total Organic Carbon: Amount of carbon bound in an

organic compound and is often used as an indicator of

water quality

• Rapid and accurate alternative to COD (chemical

oxygen demand)

– Programming

• Dose Aqueous Ammonia as TOC increases

• Challenges: • Analyzer requires large amount of maintenance

• Expensive to maintain

• Cannot react quickly to large and quick increases of

TOC

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Challenges: Fluctuations in Sugar Loading and Plant Flow

Fluctuations

– Plant runs 16-20 hours per day of various sugar and

non sugar products

– During off hours, cleaning is completed with large

amounts of water and chemicals

– Weekends with no plant production = no sugar for

biology for 2+ days

• Challenges: • Constant awareness of sugar loading

• Addition of sugar during periods of plant downtime

• Minimal sugar = death of biology

Challenges: Solids Removal

Filter press upgrade Spring 2008 – Double belt press – Press wash water uses system water (reducing loading, increasing

efficiency)

– Change in polymer (custom blended) and Custom feed equipment built May 2008

– Solids exiting press transitioned from 5-6% up to 10-13% and have reached 14-17%

– Flow across press has moved from 8-10 gpm to 30-50 gpm and now runs at 90-110 gpm.

– Mixed Liquor Suspended Solids (MLSS) dropping to desired levels of 7000-9000 ppm

• Challenges: – Expensive to haul away solids

– Currently solids are not being recycled – looking into an alternative use for the solids

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Challenges: High Oxygen Requirement

Aeration Upgrade

– Two 150 HP blower motors running continuously (previously one

100HP blower)

– Electrical upgrade to support blowers

Increased Testing

– TOC/COD, NH3, permeate testing

– Automatic pH control

– CST (Capillary Suction Time) monitoring

CST and associated permeability

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Biological Observation

Biological Impact

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Pepsi & City of Howell

• Pepsi

– Complete required daily testing per wastewater permit

• Ammonia

• Phosphorus

• pH

• Total Suspended Solids

• BOD (outside laboratory)

– Monthly Composite Permeate and Flow Reports

– Semi-Annual Trending Reports

Monthly Report – Composite Results

August

Phosphorus

(mg/L-P)

BOD

(mg/L)

TDS

(mg/L)

TSS

(mg/L)

Ammonia

(mg/L-N)

pH

(SU)

1 0.734 3.5 950 1.5 0.61 7.6

2 0.626 2.3 840 3.5 0.18 7.6

3 0.731 9.8 1080 4.5 0.15 7.6

4 1.63 14.0 1030 3 0.22 7.4

5 1.05 52.0 1190 3.5 0.19 7.4

6 0.746 55.0 1340 5 0.03 7.5

7 0.644 34.0 1190 5.5 0.04 7.5

8 0.573 2.4 1040 1 0.03 7.6

9 0.539 2.1 1110 5 0.02 8.3

10 0.213 < 2.0 940 3 0.07 8.1

11 0.496 3.5 910 3.5 0.07 7.7

12 0.752 6.6 970 4 0.04 8.3

13 0.637 13.0 970 1.5 0.03 8.3

14 0.627 < 2.0 910 0.5 0.03 8.2

15 0.582 < 2.0 920 2 0.28 8.2

16 0.537 5.6 1240 1 6.90 8.2

17 0.489 < 2.0 1180 4 0.02 8.2

18 0.590 2.3 1140 0.5 0.03 7.9

19 0.694 6.3 1190 1 0.09 8.1

20 0.568 5.4 1070 3 0.78 8.1

21 0.556 < 2.0 1080 1.5 0.02 8.4

22 0.486 < 2.0 1100 2 0.15 8.3

23 0.444 < 6.0 860 0.5 0.03 7.9

24 0.424 19.0 710 2 8.64 7.8

25 0.463 5.8 630 4 7.30 7.4

26 0.489 6.1 560 3 1.75 7.5

27 0.501 13.0 540 2.5 12.80 7.8

28 0.330 17.0 570 3 4.63 7.8

29 0.312 11.0 600 3 1.71 7.7

30 0.289 33.0 630 3.5 8.86 7.8

31 0.324 57.0 640 3 15.65 7.4

Total 18.076 397.7 29130 84.5 71.31 243.6

AVE 0.583 12.83 940 2.7 2.30 7.9

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Monthly Report - Flow

MONTH August YEAR 2012

PRETREATMENT PLANT

PERMEATE FLOW MCPHERSON PIT ISBELL PIT

METER

DAY GALLONS DAY GALLONS READING GALLONS

1 142,154 1 43,280 actual 239793 169,000 actual

2 150,761 2 46,221 actual 240000 207,000 actual

3 127,862 3 32,500 actual 240197 197,000 actual

4 97,100 4 46,371 actual 240324 127,000 actual

5 40,159 5 17,158 actual 240324 0 actual

6 49,816 6 20,107 actual 240389 65,000 actual

7 121,706 7 33,477 actual 240540 151,000 actual

8 149,071 8 46,883 actual 240705 165,000 actual

9 121,421 9 43,155 actual 240926 221,000 actual

10 116,505 10 38,793 actual 241098 172,000 actual

11 47,419 11 44,140 actual 241226 128,000 actual

12 18,704 12 17,038 actual 241254 28,000 actual

13 32,678 13 18,043 actual 241282 28,000 actual

14 148,143 14 44,739 actual 241464 182,000 actual

15 142,042 15 43,019 actual 241680 216,000 actual

16 154,164 16 39,405 actual 241899 219,000 actual

17 137,141 17 33,683 actual 242114 215,000 actual

18 126,657 18 36,101 actual 242310 196,000 actual

19 52,632 19 18,542 actual 242346 36,000 actual

20 52,980 20 27,538 actual 242376 30,000 actual

21 141,410 21 41,478 actual 242573 197,000 actual

22 163,714 22 49,636 actual 242765 192,000 actual

23 145,951 23 44,414 actual 242985 220,000 actual

24 150,243 24 50,247 actual 243214 229,000 actual

25 126,716 25 55,507 actual 243411 197,000 actual

26 125,370 26 31,523 actual 243541 130,000 actual

27 55,912 27 26,294 actual 243598 57,000 actual

28 150,862 28 48,106 actual 243813 215,000 actual

29 147,631 29 53,557 actual 244020 207,000 actual

30 157,468 30 50,323 actual 244239 219,000 actual

31 135,446 31 49,769 actual 244426 187,000 actual

TOTAL 3,529,838 TOTAL 1,191,047 TOTAL 4,802,000

AVG 113,866 AVG 38,421 AVG 154,903

Pepsi & City of Howell

Daily Bench Sheet

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Low Hach High Hach Probe

Ammonia PERM <VRS>

T-PHOS COMP <VRS>

COD EQ <VRS>

Low Hach High Hach Probe EQ Low Hach High Hach Probe

Ammonia PERM <VRS

T-PHOS EQ <VRS

COD

CST

TIN FILTER FILTER FILTER

WET DRY DRY DRY

DRY 1st 1st 1st

Final Filter Filter Filter

DRY DRY DRY

Ammonia 1 mg/l LOT# A2054 RESULT = Dup Dup Dup

Ammonia 10 mg/l LOT# A1272 RESULT =

Phosphate 10 mg/l LOT# A2069 RESULT = EQ EQ

COD 1,000 mg/l LOT# A1276 RESULT = AR AR

Hand Hand

Hydroxide

Ammonia Lot # STD mg/L MV Slope

1:00 AM 10:00 AM 8:00 PM

4:00 AM 1:00 PM 10:00 PM

8:00 AM 4:00 PM

Time of Sample:

PERMEQ COMP

Computer PH Lab PH Probe

press%solids Perm TSS COMP TSS AR TSS

Standards Ran Weekly

PH Probes Cleaned PH Probes Calibrated

Composite Fridge Chemical Treatment Volumes Checked:

TEMP (F) Ammonia Probe Calibration (Daily)

QC Sample

TOC READINGS

*If slope is not between -54 and -60, check for problems

1st Shift Intials: 2nd Shift Intials:

Pepsi & City of Howell

• Pepsi

– Communicate with City of Howell on all challenges and

discharge quality

– Partner with City of Howell to complete an annual inspection

of the entire facility

• Continuous Improvement

– Working with City of Howell on new QA-QC Sampling

Program

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August 2012 Phosphorus Composite Sample & Duplicate

Phosphorus (mg/L-P) Sample

Phosphorus (mg/L-P) Duplicate

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Ammonia Standard Results 10mg/L

Standard Results

Average