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share your experiences today #BevExpo2016
Presented by Chris Woods
Sustainable Brewery Concept
share your experiences today #BevExpo2016
Core Services
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Contents
• Reduce, Reuse & Recycle• Nijhuis Sustainable Brewery Concept• Water, Waste & Energy Audits• Process Water Reuse• Waste Water to Value• Our Experiences
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The Global requirement for change
• Food and beverage manufacturing uses high volumes of water, heat and energy
– 10 to 70 tonnes of water used per 1tonne of product
• 10% of a countries energy use goes into the growing, processing, packaging and
shipping of food
• 50% of all food is wasted, approximately 1.2-2 Billion tonnes
• Typically 70% - 80% of incoming water is discharged as waste water
• Water and energy supplies are rapidly diminishing
Reducing our water, heat and energy use and reducing waste...........
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Reduce Reuse & Recover Water Resources
The challenges in the beverage market typically concerns:
• reduce the fresh water intake and reduce wastewater discharge costs• reuse wastewater for process cleaning purposes, reuse process water from pasteurisation lines and
cooling water towers• recover resources to use them as an energy source, heat source or sell them as fertilizer
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Sustainable Brewery Concept
Water
Brewery Plant
Energy
Heat
Was
tew
ater
Process WaterProcess Water DisinfectionReuse
Water
Sludge Management
Solid Fertilizer
Reduced Disposal
Cost
Modular Solutions
Fit for Future
Recovered Water
Wastewater to Value Plant
Recovered Heat
Recovered Energy
Water discharge to river or sewer
Recovered spent grains
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Goals
• Improve efficiency
• Reduce cost
• Create value
A Four Stage Process• Discovery : what we are doing right• Dream : what we can achieve• Design : the ideal we can co-create• Destiny : where do we want to go
Water, Energy & Heat Audits
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Process Water Disinfection
Industry description:Pasteurisation and filling lines will suffer from Biomass contamination that exists of filamentous bacteria in a layer of EPS (exo polymer sugar) resistant to chlorineConventional / Challenge: • Production stops for cleaning• Require disinfection in situ online without
chemicals• Keep the system continuously clean
The Smart Solution• Nijhuis Ozone Solutions water re-use• Redox control for ozone dose rate results
in optimal OPEX• Expected ROI 1.5 – 2.5 years Additional advantage• Ozone cannot contaminate • Bacteria cannot become resistant to
Ozone • In situ CIP without production stop
Beverage pasteurisation line
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Aerobic vs Anaerobic Treatment
Requires typical 0.5 kWh/kg COD •Good effluent quality•Biological nitrogen removal•Watercourse discharge possible•High sludge production
Produces typical 3.5 kWh/kg COD • Low sludge production• No biological nitrogen removal• No phosphorus removal• Often post-treatment required
CO2
Aerobic treatment Anaerobic treatment
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BIOCTOR – Aerobic Solution
Flow COD COD TSS TSSSource m3/year mg/L kg/d mg/L kg/d
Influent 64,150 3291 211 605 39Effluent 64,150 78 5 19 1
Sequencing Batch Reactor• Aerobic degradation of organics• Discharge to watercourse
Sludge Thickening• Reduction of sludge volume
Modular Construction• Rapid site installation• Off site fabrication
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BIOCTOR – Aerobic Solution
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AECOMIXTM – Anaerobic Solution
Payback Calculation
Additional Benefits• >95% COD removal• Return of water to watercourse• Reduced carbon emissions• Low operator input• Low odour risk• Tertiary treatment possible for
reuse
Aerobic
brewery example
Operational Costs 175m3/day
Sewer Cost Without Treatment £ 442,469
Watercourse Discharge Cost £ 20,000
Electrical Cost £ 13,248
Sludge Disposal Cost £ 98,000
Chemical Supply Cost £ 10,915
Labour Cost £ 10,800
CAPEX Investment £ 695,000
Gain From Investment £ 289,506
Payback Period (years) 2.40
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AECOMIXTM – Anaerobic Solution
Flocculator/Dissolved Air Flotation (DAF)• Removal of suspended solids • Prevents solids build up
Performance
Aecomix - UASB• Up-flow Anaerobic Sludge Blanket Reactor• Biogas with a high concentration of methane is
produced as a by-product
Flash Aeration• Removes excess H2S
Flow COD COD TSS TSSSource m3/year mg/L kg/d mg/L kg/d
Influent 109,500 4811 527 573 63Effluent 109,500 342 37 516 57
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AECOMIXTM – Anaerobic Solution
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AECOMIXTM – Anaerobic Solution
Payback Calculation Anaerobic
brewery example
Operational Costs 300m3/day
Sewer Cost Without Treatment £ 993,869
Sewer Cost With Treatment £ 270,456
Electrical Cost £ 16,425
Sludge Disposal Cost £ 15,330
Chemical Supply Cost £ 104,504
Labour Cost £ 10,800
CAPEX Investment £ 980,000
Gain From Investment £ 576,354
Payback Period (years) 1.70
Additional Benefits• 1,350m³ biogas per day• Trade Effluent Compliance• Reduced Carbon Emissions• >90% COD Removal• Low power consumption
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Achieve your goals with Nijhuis solutions
Chemical free
Meeting sustainable requirements
Lower the environmental footprint
Combine productivity & energy efficiency
Ensure minimum life-cycle cost
4 important goals to achieve at the same time!
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Questions ?