BHJ USA in St. Joseph, MO is a processor of meat and meat byproducts for the pet food industry. They operate 24/7 and generate wastewater the entire day. The wastewater contains levels of fats, oils, greases, and total suspended solids in excess of the levels permitted to be discharged to the municipal sewer in St. Joseph. Therefore, in order to operate the plant, they needed a waste water treatment system to reduce these levels.
BHJ had many years of experience with Kemco Systems in another of their plants and decided to enter into discussions with them about their new plant. Together they evaluated BHJ’s needs and the decision was made to utilize a DAF (Dissolved Air Flotation System) as the main treatment process. The DAF is supplemented by a rotary screen to remove large solids prior to the DAF. The action of the DAF is supplemented by coagulating and flocculating chemicals supplied by a local vendor. Kemco also supplied a 5.5 million btu/hr., On-Demand, 99.7% efficient water heater to meet the facility’s hot water needs. In conjunction with BHJ and BHJ’s mechanical contractor Kemco’s Engineering Department did all the piping, electrical, and mechanical design for the heater and waste water treatment equipment.
Recently a highly respected consultant in the water industry issued a wastewater treatment challenge:
Could we treat a high strength dairy waste that was not treatable using conventional Dissolved Air Flotation? A waste that was generated by the cleaning of dairy evaporators and dryers and other process equipment. The waste was very high in COD and TSS – so high it was being hauled to an off-site disposal facility. Everyday. At great expense.
The consultant was risking his reputation and a 20-year relationship with this prominent dairy cooperative to bring in Kemco. This dairy has a knack for “going green” and they wanted to further their sustainability efforts by eliminating or minimizing a persistent waste stream, converting it into a reusable and beneficial condition.
Here’s what happened:
After conducting bench and pilot tests, Kemco designed and built a system to remove the butter fats, milk proteins and other solids using a ceramic microfiltration system (CMF); to follow that, a reverse osmosis (RO) system was built to remove the dissolved contaminants – glucose, lactose, milk salts and detergents.
The full scale system was installed at the dairy in September 2015. The dairy operators were trained to operate and maintain the system, and the results followed.
- The treated water is good enough to reuse, supplying water to the plant’s belt spray system.
- The treated water no longer has to be hauled off-site for disposal.
- Lots of money is being saved!
Contact us if you want to learn what we can do for your waste water concerns.
Excel Linen Supply in Kansas City is the largest supplier of linens to the food and beverage industry in Kansas City and surrounding areas. After relocating their plant they were faced with very high waste water surcharges. They already had in place a Kemco DAF (Dissolved Air Flotation System) as their main treatment process. This system kept Excel in compliance with the local waste water treatment standards as far as prohibited contaminants were concerned but did not reduce enough of the dissolved contaminants to eliminate surcharges.*
After extensive pilot testing and evaluating various treatment technologies Excel made the decision to install a Kemco Ceramic Microfiltration System (CMF) followed by a Reverse Osmosis (RO) system. The CMF removes all the prohibited contaminants: fats, oils, greases and suspended solids by filtration and does not require any treatment chemicals. However there are still dissolved contaminants in the water such as BOD/COD and surfactants. These contaminants, while not prohibited in the sewer system are subject to surcharges. Water from laundries almost always exceeds these limits and incurs substantial surcharges.
The RO system removes these dissolved contaminants to a level at which, if the water were to be discharged, would incur no surcharges. Moreover the quality of the water is so good that it can be recycled back into the laundry for all stages of the washing process. In fact the water from the RO is better than the incoming city water since it contains no hardness and is still warm.
Kemco provided the system on a “Turn Key” basis and was responsible for mechanical, electrical, piping design, rigging and installation. Electrical power wiring was done by a local contractor.
Currently Excel is recycling about 80% of the water that would have normally gone to the sewer. In other words they have reduced their city water consumption and water charges by 80% and have eliminated the waste water surcharges.
* A DAF system will remove fats, oils, greases and suspended solids but not much in the way of TDS (total dissolved solids).
Sustainability, energy efficiency, “Green” concepts, LEED building design are often touched on in commercial laundry design meetings and reviews, but how often do decision makers grant the approval to move forward with these ideas realizing the environmental impact if these ideas are not incorporated?
Fuel Energy and Water – Water is still required to wash; water is heated. Commercial laundry machinery designs have limitations to the amount of water they can save. Heat energy required varies directly with the amount of water. In machines that heat water on board, one of the most fundamentally inefficient means of heating water, live steam injection, is employed. Filtering 100% of the wastewater not carried forward to drying machinery and recycling that filtered water optimizes the gallons per pound used for production and captures the heat available in the wastewater directly minimizing the amount of live steam injection that is required to achieve washing temperatures.
Our project of the month show cases a commercial laundry in the Pacific Northwest that has realized fuel and water use efficiency and sustainability objectives.
- 55,539,274 gallons recycled in 27 months
- Achieving a 79% recovery rate
- 210,438 therms of heat energy
With Kemco’s water recycling system operating watch the numbers grow!
This Kemco CMF/RO filtration system is designed to treat waste water from a Dairy’s evaporator and dryer CIP system. This waste stream contains a mix of residual milk product, water, and CIP chemicals with very high levels of Total Dissolved Solids (TDS), Chemical Oxygen Demand (COD) and Total Suspended Solids (TSS). Prior to filtering this waste water with the Kemco CMF/RO filtration system, it was being hauled offsite for disposal.
As shown in the table above and photo below, the Kemco System proved to be very effective in removing the contaminants that prevented this waste stream from being discharged to the municipal treatment system.
The Kemco CMF/RO has reduced the haul costs by 75% and the filtered water is currently being recycled as cooling tower make-up water, or being safely discharged to the municipal system.