Mustard WasteDesign Proposal

The “Second Most Ethical” BE Team

SMEBET Members:Matt RosenIan MelvilleCahner JenniceMatt RimerKira Bartlett

Advisor: Caye Drapcho

Table of ContentsCompany Intro

The Problem

-Goals, Constraints, Considerations

Potential Solutions

-Research Analysis, Sustainability.

Future Analysis

-Simulation, Scale Modeling

The Company

Olds Products

Located in Pleasant Prairie, Wisconsin

http://www.oldsproducts.com

Google Maps

Mustard ProductionBatch system (seasonal emphasis)

Ingredients: Mustard seed, Vinegar, Brine, spices and water

-Automatically metered into batch

-Minor Ingredients sometimes added by operator

Slurry is agitated accordingly then pulverized into common known mustard pace, which is then pumped to storage tank to await packaging

Waste ProductionOlds Products is subject to the FDA’s cleaning regulations

Machines are cleaned with each flavor change, which is multiple times per day. Per regulations, machines must be cleaned with water at least 120 degrees F

End of week extensive cleaning with hot water and acid caustic wash

All waste pumped into 6,000 gallon reservoir

The Problem

The Problem

Wastewater cannot be discharged through the sewer system to the Pleasant Prairie municipal treatment plant.

-pH - too acidic - required pH range: 5.5-9 pH (Kenosha)

Current Solution - land application method via a third party company.

-Expensive! $0.07 per gallon ($200,000 annually)

http://www.wrc.org.za

Land Application

Labor Intensive

Seasonal - Can’t apply to snow or frozen land

Potential Odor near residential areas

Excess nutrient runoff contaminate surrounding water

Needs strict monitoring and precise application

Project Goals

Solve immediate problem of waste disposal

-On site treatment

-Make water suitable for off-site treatment

Create/obtain a usable byproduct

Economic and Sustainable viability

Project Goals

Bioprocess- Avoid use of chemical reagent to neutralize pH by using a biologic

Structural - Incorporate current wastewater reservoir (6,000 gallon tank); Design simply & maximize economy of space

Mechanical- Simplicity, keep total energy loss down, strive to be energy neutral

Constraints

Geographic: Pleasant Prairie, WI v. Clemson, SC

Budget

Municipal Codes (Wastewater treatment guidelines)

Current operating procedures

Limited information

Overall lack of team experience with wastewater treatment

ConsiderationSafety

-Working with chemicals and reagents-Industrial food plant Ecological

-Impact of treated water products on environment

-Distinct seasonal change in Wisconsin Ethical

-Olds Product contact is relative of team member

User Perspective

User - hands on consumer of product or operator of system

-How does it work?

-What do I need to do to run it?

-What is the maintenance/upkeep needed?

Client Perspective

Client -Purchaser or implementer of system (the one whose problem is being solved)

-How much will it cost?

-What is the system's size?

-Can it be easily incorporated into other facilities?

Designer Perspective

Designer - Creator of system (subject to client constraints)

-What is the problem with the waste?

-How much waste needs to be processed? At what rate?

-Is there a maximum start up cost or ROI timeframe?

Potential Solutions

Filtration

Filter out mustard particles & other particulates

-Mechanical/Physical

-Biological

-Chemical Coagulant

Increase pH

Chemical Reactions

-Calcium Carbonate

-Sodium Hydroxide

Microorganisms

Electrolysis

Electrolysis

Hydrogen Production from Acetic Acid

Microbial Electrolysis Cell (MEC)

-MFC with external energy input

-Biological Wastewater treatment http://energy.gov/eere

Generate CoProductsHydrogen Gas

Biodiesel

Sinapic Acid

Biopesticide http://blacklemag.com

Recycling Water

2.6 million gallons of waste transported off site

Over 3 million gallons of water used in production and cleaning

Potential reuse of wastewater

http://thumbs.dreamstime.com/

Sustainability Measures

On-site treatment

Biological treatment methods

Recycling water back through facility

Generate coproducts

Future Analysis

Wastewater Testing

pH

HPLC

Best Filtration Mechanism

Wastewater Parameter Testing

-Federal Regulation 40 CFR §136.3 - Test Procedures

Ian Melville

Simulation

Intelligen SuperPRO Designer Solidworks

Stella COMSOL Multiphysics

http://www.genengnews.com/

Scale Modeling

Lab Scale MFC or MEC

Electrolysis using PV Cells

http://pubs.acs.org/doi/pdf/10.1021/es050244p

Schedule

Industry Connection

Students working with industry partners

Potential for actual implementation

Practice with real world engineering economics and communication

References

Kemker, C. 2013. pH of Water. Fundamentals of Environmental Measurements. Available at: http://www.fondriest.com/environmental-measurements/parameters/water-quality/ph/#p8. Accessed 7 September 2015.

(1999). Naked Egg Experiment. Science of Cooking. Available at: http://www.scienceofcooking.com/naked_egg_experiment.htm. Accessed 7 September 2015.

(2011). What is Calcium Carbonate. Industrial Minerals Association - North America. Available at: http://www.ima-na.org/?page=what_is_calcium_carb. Accessed 8 September 2015

(2013). Limestone pH Adjustment Systems. Digital Analysis Corporation. Avlailable at: http://www.phadjustment.com/TArticles/Limestone.html. Accessed 7 September 2015

Amin, I. N. H. M., Saffuan, A. F. A., (2015). Preperation of Recycle Mussel Shell as Physical Adsorbent for Restaurant Wastewater Treatment. International Journal of Engineering Sciences & Research Technology. 239-246

References Cont.

(2015). Pubchem Compound Database. National Center for Biotechnology Information. Available at:http://pubchem.ncbi.nlm.nih.gov/compound/Sodium_acetate#section=Top. Accessed 10 September 2015

Leykauf, S. (2015). Magnesium Hydroxide as an Alternative to Caustic Soda for Alkalinity Adjusment. Industrial Waterworld. Available at: http://www.waterworld.com/articles/iww/print/volume-8/issue-4/feature-editorial/magnesium-hydroxide-as-an-alternative-to-caustic-soda-for-alkanity-adjustment.html. Accessed 10 September 2015

Zoulias, E., Varkaraki, E., Lymberopoulos, N., Christodoulou C., Karagiorgis, G. (2012) A Review on Water Electrolysis. Centre for Renewable Energy Sources and Energy Efficiency. Available at: http://www.cres.gr/kape/publications/papers/dimosieyseis/ydrogen/A%20REVIEW%20ON%20WATER%20ELECTROLYSIS.pdf. Accessed 9 September 2015

References Cont.

Kargi, F. and Arikan, S. (2013). ”Electrohydrolysis of Vinegar Fermentation Wastewater for Hydrogen Gas Production Using Different Types of Electrodes.” J. Environ. Eng., 139(6), 881–886.

Cheng, S., Logan, B. (2007). Sustainable and Efficient Biohydrogen Production via Electrohydrogenesis. Proceedings of the National Academy of Sciences of the United States of America. vol. 104. no. 47. 18871-18873

Liu, H., Ramnarayanan R., Logan, B. (2004). Production of Electricity during Wastewater Treatment Using a Single Chamber Microbial Fuel Cell. Environmental Science and Technology. vol. 38. 2281-2285

Questions?

Picture Credit:http://batman.wikia.com/wiki/The_Riddler_(Jim_Carrey)