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Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
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Opportunity For BOD Source Reduction The Beverage Industry 2009 Alan Sheppard Global Director Sales, Marketing and Distribution Recovery Systems ; Pat Anderson Director Innovation Responsible Resource
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This Case study was prepared with a third party auditor. The findings showed the amount of waste generated in beverage plants and the Recovery Potential of Recovery Systems are together accurate within +/-1%
Transcript of Opportunity For Bod Source Reduction 2009 Isbt Presentation With Guide P&A
OpportunityFor
BOD Source Reduction
The Beverage Industry
2009Alan SheppardGlobal Director Sales, Marketing and Distribution Recovery Systems ; Pat Anderson
Director Innovation Responsible Resource Solutions JohnsonDiversey
Risks
“If risk is a measure of sustainability, the world faces some massive challenges in the 21st century.”
Quoted from Alistair Johnston of KPMG, convener of the WBCSD Risk Champions Group
Historically the biggest risk to the beverage industry has been water
Current and future risks include Pollutants, including oxygen-demanding pollutants (BOD, etc.), released in discharge at a level which, either singly or by interaction with other pollutants, will cause interference with the POTW;
Water Footprinting
• Water footprint accounting ;• Blue water• Green water• Grey water
• the grey water footprint is the volume of polluted water, calculated as the volume of water that is required to dilute pollutants to such an extent that the quality of the water remains above agreed water quality standards.
• it is possible to reduce a company’s water footprint through pollution prevention and water reuse
And now comes…………….
Rising Costs of Treating B.O.D. Waste in Beverage Plants
• Municipal Plants face maximum Capacity
• EPA's Multi-Sector General Permit (MSGP)
• SECTOR U: FOOD AND KINDRED PRODUCTS
• Nations Infrastructure Gap• Full Cost Pricing • Costs of on-site treatment
Sources of B.O.D. Waste
• Start-Up of a Flavor (Sweeten the Filler) • Out of Spec Product during runs• End of Flavor Run (Matching Containers to
Beverage)• Pre-rinse in syrup tank CIP• Product returns to drain (can crusher)• Spills/ breakage at the filler or on the production
line
> 70% of beverage plant BOD comes from sugar based products
Options
Status quo (Reactive)• Continue to pay for on site treatment or POTW
surcharges – risky and not “Sustainable”
End of pipe (Proactive)• Treat at end of pipe (MBR,etc. ) –capital
intensive,• Haul it
Capture at source (Proactive)• Waste haul – expense and not “sustainable”• Concentrate (UF,etc.) – sell • Re-use internally
Four Barriers of Pollution Prevention Implementation
• Regulatory Structure Companies have become accustomed to complying with the mandates of the EPA after a regulation has been set, and generally have not acted to reduce effluents or other pollutants before regulations are in place
• Risks To alleviate this fear of risk, it is important to recognize that Pollution
Prevention measures are often small changes in manufacturing strategies, but small changes that can significantly improve efficiency and reduce waste
• Ruts If the process is working, why change it
• Resources Poor resources -- as a barrier to pollution prevention takes two forms -
lack of knowledge and lack of proper accounting
BOD Base & Overage Rate Changes
normal overage*rate, $/lb rate, $/lb
31-Dec-04 0.24930-Jun-05 0.27130-Jun-06 0.288 0.28930-Sep-06 0.317 0.755
* overage rate is added to base rate for overage pounds
BOD Variability
0
1,000
2,000
3,000
4,000
5,000
6,000
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
BO
D C
on
cen
trat
ion
, p
pm
2006 Flow-Wt. BOD (mg/L) - average 3807ppm
2005 Flow-Wt. BOD (mg/L) - average 3504 ppm
Historical BOD Data
0
800
1,600
2,400
3,200
4,000
Jan-05
Feb-05
Mar-05
Apr-05
May-05
Jun-05
Jul-05
Aug-05
Sep-05
Oct-05
Nov-05
Dec-05
Jan-06
Feb-06
Mar-06
Apr-06
May-06
Jun-06
Jul-06
Aug-06
Sep-06
Oct-06
month - year
ave
rag
e d
ail
y B
OD
, p
ou
nd
s
average dailyBOD limit: 1,037pounds per day
BOD as a Function of Brix
-
8,000
16,000
24,000
32,000
40,000
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5
Brix Units
BO
D,
pp
m
0
25
50
75
100
125
TS
S,
pp
m
Measured BOD, ppm
Calculated BOD, ppm
BOD = 8,458.5 • Brix
Brix vs. TimeDuring Flavor Changovers
0
1
2
3
4
9:54 10:03 10:12 10:21 10:30 10:39 10:48 10:57
time,
Bri
x
Line 1 changeover
Line 2 changeover
Line 3 changeover
Line 1: Orange to Diet CaramelLine 2: Diet Cola to Diet CaramelLine 3: CF Diet Cola to Cola
production
A B C D E F G
A: pale yellowB: orangeC: brownD: pale orangeE: brownF: brown-orangeG: pale yellow
samples taken every 3 minutes
DumpingCola
DumpingOrange
BOD vs. TimeDuring Flavor Changovers
0
6,000
12,000
18,000
24,000
30,000
9:54 10:03 10:12 10:21 10:30 10:39 10:48 10:57
time, 21
BO
D,
ppm
background: 3,020 ppm
productionproduction
samples taken every 3 minutes
A B C D E F G
DumpingColaDumping
Orange
Line 1 changeover
Line 2 changeover
Line 3 changeover
Line 1: Orange to Diet CaramelLine 2: Diet Cola to Diet CaramelLine 3: CF Diet Cola to Cola
A: pale yellowB: orangeC: brownD: pale orangeE: brownF: brown-orangeG: pale yellow
Brix vs. Time24-hour Sampling
0.0
0.5
1.0
1.5
2.0
17:05 20:05 23:05 2:05 5:05 8:05 11:05 14:05
time, 21-22 Feb 2007
Bri
x
Line 2 CIP
samples taken every hour
ThursdayWednesday
-
3,000
6,000
9,000
12,000
15,000
17:05 20:05 23:05 2:05 5:05 8:05 11:05 14:05
time,
BO
D,
pp
m
Line 2 CIP
samples taken every hour
ThursdayWednesday
background: 1,180 ppm
BOD vs. Time24-hour Sampling
BOD vs. TimeProduct Changeover – Root Beer to Diet Root Beer
0
2,000
4,000
6,000
8,000
10,000
9:43 9:52 10:01 10:10 10:19 10:28 10:37 10:46
time,
BO
D, p
pm
changeover
samples taken every 3 minutes
Production:Root beer
Production:Dt .Root beer
background: 1,980 ppm
Effluent Billing Rates
$ per k-gal Water Rate
0.70003 Rate: $/k-gal for all k-gals
1.344 Rate: $/k-gal for overage k-gals
$ per pound BOD Contaminant Rate
0.31677 Rate: $/lb for all pounds
0.75473 Rate: $/lb for overage pounds
BOD Opportunity
1. based on Brix-BOD relationship (BOD = 8,458.5 • Brix)2. based on overage rate of $ 1.0715 per pound BOD
Line 1 Line 3Line 2
Total annual non-Diet changeovers 682.1 590.1610.7Total annual Diet changeovers 271.4 226.1303.6
71.5 % 72.3 %Percent non-Diet changeovers 66.8 %
Grand total opportunity $ 799,833
Annual nonDiet recovery as syrup, gallons 16,310 21,40026,017Annual nonDiet recovery as syrup, pounds 147,791 192,600234,156
Recovered BOD, pounds 1 81,948 107,521130,720BOD surcharge avoided 2 $87,807 $115,209$140,067
Total annual recovered syrup “surcharge value” $343,083
Annual Diet & nonDiet recovery as syrup, gallons 22,800 29,60038,950Recovered annual syrup “floor value” $114,000 $148,000$194,750
Total annual recovered syrup “floor value” $456,750
Haselden Recovery Systems For xxxxxxx
Line One Analysis Week 1-29-07 52 Valve Filler Types of Waste to be Recovered: **FP-Finished Product
**RS-Raw Syrup
Number Flavor Changes Filler Bowl Size Start & Stop Dumps78 gallons X 2/3rds 52 gallons per dump
Number of Dumps per Changeover 2 DumpBlend Ratio 5 to 1 6 gallons FP=1 gallons RSEst. Loss Per Changeover 104 Gal FP / 17.33 Gal RS
Syrup Line Distance FeetSyrup Line Diameter InchEst. Loss Per Changeover Gallons Raw Syrup
Carbo-Cooler Dumps 355 gallons FP / 59 RS per dumpie; Hi/lo Brix, or C02 issues
Recovery PotentialNumber of
changeovers per week
Finished Product or Raw Syrup Opportunity Per
Flavor Changeover
Total Weekly Finished Product or Raw Syrup
Opportunity
PRS 23 Changeovers 104 Gal FP / 17.33 Gal RS 2,392 FP / 397 Raw Syrup
SRS 23 Changeovers Gallons Raw syrup Gallons Raw Syrup
Carbo-Cooler Dumps Average 1 per week 355 gallons FP / 59 RS 355 gallons FP / 59 RS
456 Gallons Raw SyrupPer Week
To determine savings potential, determine $ value for finished product or raw syrup.Example: 456 gallons RS per week, for 50 weeks per year equals total annual syrup loss: 22,800 gallons
Take 22,800 gallons per year x $ per gallon syrup costs for potential annual syrup savings.
Pollution Prevention (P2.ORG)• Promotes the development, implementation,
and evaluation of efforts to avoid, eliminate, or reduce pollution at the source
• Pollution Prevention is a win-win concept -- both for their business and for the environment
• Pollution Prevention is a means of reducing costs, increasing productivity and reducing waste
• For the environment, a lower effluent discharge equates to a "greener" planet
Accountability, Without it, Sustainability is just a good idea.Accountability, Without it, Sustainability is just a good idea.
