39B Hebron Business Park, Hebron Rd,

Kilkenny, R95 C43W Ireland

www.weweng.ie Email: scrickley@weweng.ie Ph: +353872224768

http://ssu.ie/research/watertech/

Wastewaters from the

Pharma-Biopharma Industries

May 2016

Prepared by

Seamus Crickley BE EurIng CEng FIEI WEF

Director, WEW Engineering Ltd

Consulting Engineers

CONCEPTS BEING COVERED Detailed design values outlined below but may be confirmed by

later study and with my assistance.

Inter-related areas of engineering are outlined and each one may be separately addressed in preparing the detailed package.

Preliminary Planning and Discharge Licensing are reviewed as they are determinant of all infrastructural services to follow.

Definition of raw discharges is listed as a process priority – always related to in-house production.

Overall review of Stages of Treatment is summarised.

More specifics on Operations of Treatment are introduced.

Emerging technology demands are suggested.

General agreement with production on irreducible minimum.

Prime loading parameters BOD, COD, TOC, TDS, TSS, FOG, Volatile Organics, TKN, NH₃, NO₃, Chlorides, Bromides, Sulphates, Alkalinity, Colour, Odour, Turbidity, Metals etc.

Rate of Discharge is normally variable with hourly, daily, weekly or monthly trends – possibly with allowance for future extension. Trend Curves are required for parameters over designated periods see over.

Treatability studies may be required if BOD < 40% COD

Possible need for Polytox and/or Nitrotox respiration trial or full pilot study.

Pending Licence Negotiations determine outfall qualities and overall design criteria are then in place.

DEFINITION OF PARAMETERS & SCOPE

DEFINITION OF PARAMETERS & SCOPE

- 500

1,000 1,500 2,000 2,500 3,000 3,500 4,000

Kg

/da

y

Date

Figure 1B : SS Load

-

1,000

2,000

3,000

4,000

5,000

Kg

/da

y

Date

Figure 1A : COD Load

0

50

100

150

200

250

300

350

400

m³/

da

y

Date

Figure 1C: Flow

URS INVESTIGATORY STUDIES Raw wastewater characterisation, viable treatment/disposal systems, preliminary

works design, CAPEX/Total Cost recommendation.

Selected treatment system summary review by the Specialist Consultant forms the basis for negotiating our:

Planning Permission.

DTS/Discharge to sewer (where relevant).

Outfall Licence Negotiations.

Design of feasible process operations for combinations.

Incorporate necessary automatics/control loops to satisfy process performance.

Confirm overall PID with nominated controls and equipment categories for each alternative.

Completion of GA Drawing for each alternative.

Reaffirm associated M/E/C Capex Cost and Total Cost.

Submission of Preliminary Report for discussion and final confirmation of optimum works facility.

PLANNING & LICENSING CRITERIA Following discussions on report:

Straight-forward applications for Planning and Discharge Licences.

Submission of detailed process and works summary with warranty on performance a necessary Appendix.

After discussions, RFI’s and mutual agreement the project may then proceed.

Detailed works design – P, M & E – commences .

The characterisation and allied process requirements take precedence.

PRELIMINARY TREATMENT Each project should be viewed as a one-off depending on in-house production. Typical operations:

Collection of discharges with screening, forward pumping ,grit/silt and FOG removal – if deemed necessary.

Cooling may be necessary. This justifies energy saving versus cost outlay study.

Separate collection and treatment of cooling waters may be viable.

Balancing with auto emergency diversion facility in the event of unacceptable raw wastewater characteristics.

Balancing tanks mixed/aerated with roofing in place and facility to remove gas via a scrubber (biofilter, etc).

Balancing volume is 50% and 200% of daily flow and a stock capacity should be provided.

pH correction before or after balancing with on-line modulating / in-loop control.

Forward pumping to secondary treatment, pH values (6.5 – 8.5).

In-line nutrient addition 100:5: 1 BOD:N:P Ratio.

For extrahigh ingoing phosphorus levels. Where PO₄ exceeds 150 mg/l preliminary P removal using lime coagulation clarification by lamella may be used.

As for main works design the bench confirmation of chemical flocculation and sludge separability optimises selection.

PRELIMINARY TREATMENT

SECONDARY TREATMENT

Objectives : Produce wastewater quality in compliance with a discharge

licence.

Biologically maximise carbon removal , bio-energy recovery : minimise excess sludge and carbon footprint.

Biologically pretreat for direct discharge direct to a POTW.

Full two stage biological treatment to a high quality final discharge.

Cohabitating bacterial synthesis designed to maximise the C and N cycles while normally producing a COHNPS sludge.

SECONDARY TREATMENT (contd.) • Bacterial growing – normally C and N based

• Typical reactors are now based on: Anaerobic Digestion (Conventional low-rate, UASB/ESBR/Hybrid).

Completely Mixed Activated Sludge – Carbon removal only, nitrification-denitrification, ABPR, UCT, AAO, MLE, Whurman process.

Sequencing Batch Reactors (SBR): these are reaction clarifiers.

Attached Growth Systems (fully, partly or reverse-flow)

Membrane Bioreactors: Reaction clarifiers giving high quality at high cost.

Shunt N removal Technology : researched for sidestreams .

SECONDARY TREATMENT (contd.)

• Central criteria for design (known from experience or proven by pointed research) are: • Reaction Rate (t-1 or kg load/kg reacting mass·d).

• SRT (ES / Reacting Mass)

• Oxygen demand: from SOR calculations at the process operating temperature, with wastewater transfer constants.

• Automated rates of recirculation to remove NO₃, etc.

• Clarification utilising the conventional clarifier ( U values 0.3 m/h – 0.6 m/h). Low solids flux applies for this sector of wastes. . DAF clarification as a fitting alternative in certain cases.

• Sludges generated are automatically withdrawn.

HIGH GRADE SECONDARY TREATMENT

TERTIARY AND ADVANCED TREATMENT This operation relates to more demanding licences and/or outfalls

which are being considered for re-use (utility/irrigation/fire).

Normally relate to removal of: TSS

TS

PO₄ below norm

Colour and COD

Turbidity

Pathogens

Tertiary operations now utilised include: Conventional sand or multi-media filters, auto backwash sized at up to 7 m/hr.

Continuously wasted filtration sized at 10m/h – 11m/h

Coagulation to remove PO₄ for removal with TSS.

Activated Carbon for colour, turbidity, TS and COD removal.

Sterilization – normally using UV but, in some cases chlorination of high quality effluents for reuse.

TERTIARY AND ADVANCED TREATMENT Areas of advanced treatment:

Nanofiltration: a non-biological version of MBR and running at approx. 4 Bar; good source of high quality utility/freshwater with efficient tertiary stage.

Reverse osmosis: Ideal for highest quality reuse water with minimum retentate; runs at approx. 7 Bar, turbidity 0.3 NTU, SDI 4 or 5.

EXCESS SLUDGE EMISSIONS Normally combines:

Primary FOG’s: some troubles but high energy.

Settleable’s primary/secondary : 60% VSS – 80% VSS

Inert solids; normally lime based offer P-Removal.

Specific Plant/Process dictates characteristics of solids.

Normally 1% DS – 3.5% DS after thickening .

Ease of dewatering indicated by bench indicators SDI and CPT.

Maximise removal rate of bound water by correct choice /dosage (kg/tDS) of polymer with/without lime.

Alternative dewatering methods: Filter press (12% DS Cake ±)

Decanter (16% DS Cake ±)

Screwpress (10% DS Cake ±)

Plate and Frame Press (25% DS Cake ±)

Cake ultimate disposal a critical Planning/EIS issue.

Agricultural/Contractor disposal is the norm but spreading regulated by SI 31, 2014.

EXCESS SLUDGE EMISSIONS

Conditioning Alternatives relate to solids constitution, pathogen count and characteristics of carrier liquid. Alternatives:

Conventional Solids AD

Composting

Aerobic Digestion/Pasteurisation (ATAD)

Landfilling

Typical solids operations on recent plants on following slides:

PROCESS DESIGN

INLET BALANCING with emergency

dump facility

NITRIFICATION – DENITRIFICATION,

AAO (MBR) plant (with carbon & nutrient dosing

stations)

SLUDGE PLANT – Plate & Frame

Dewatering

FULL ODOUR CONTROL FACILITIES

BIOPHARMA FALL WORKS WWTP

ATAD PASTEURISING ORGANIC SLUDGE

ON-LINE CONTROL & MODULATION Design requires 12.5% - 30% safety factor on process parameters.

Energy minimisation now dictates all design details.

Process design should maximise rates by utilising energy from reaction – Eckenfelder’s theory.

All parameters causing reduced treatability require on-line control.

Auto-Diversion must ensure that the plant is never operated outside its design limits.

Choice of energy-efficient machinery takes precedence.

Modulate control of all prime movers to minimise energy outlay.

Failsafe feedbacks as an indicator of pending works failure passed – if necessary off site – via SCADA to Administrators.

EMERGING TECHNOLOGIES Utilise oncoming micro bio-research giving new bacterial cultures e.g.

granular AD, PAO, Nareda, SO₄ reducing cultures – some at R + D, other awaiting commercial use.

Capacity reduction of reactor/clarifier with equivalent or better performance.

Auto feedback from works loading to in-house production.

Design concepts to minimise, modulate and recycle energy with reduced carbon footprint.

Sludge, properly identified and treated (Class A or B) is an ideal base for organic agriculture.

The Pharma – Biopharma wastewaters are amenable to AD. Characterisation/ pilot works will confirm cost ROI with time. This is the loading challenge for Engineering management in the industry.

Incorporate process development to upgrade outfall quality for subsequent re-use.

TYPICAL REFERRING PROJECTS

HIGH RATE FILATRATION

MODIFIED LUDZAK

ETTINGER

MEMBRANE BIOREACTOR

OVERALL PROCESS

20

, 00

0m

3/DA

Y

FINAL QUALITY –

FOR RECYCLE

BOD5 ≤ 5mg/l

TSS ≤ 2mg/l

TOTAL N ≤ 15mg/l

PO-P4 ≤ 0.6mg/l [approx. 99%

reduction]

30,000kg BOD/d

TYPICAL REFERRING PROJECTS

TYPICAL REFERRING PROJECTS

TYPICAL REFERRING PROJECTS

REFERENCES Reverse Osmosis & Nanofiltration, AWWA Manual M46, 2007.

Integrated pollution Prevention & Control, EC, 2006.

The Microbiology of Anaerobic Digesters, M.H. Gerardi, Wiley 2003.

Biological Treatment of Food Industry Wastewaters, S. Crickley, Teagasc 1992.

Emerging Concepts in Pharma Industry Wastewaters Treatment, S. Crickley, UCC, Nov 2015.

Anaerobic Digestion Text, D.A. Stafford & D.E. Hughes, Applied Science, Sep 1979.

ATAD Digestion Process, USEPA 625/10-90/07

Potasium Sodium and Chloride in Agricultural Soils, Dr. J.H.A.M Steeven voorden, University Bologna, 1993.

Good Agricultural Practice to Protection of Waters, Dept. Agriculture, SI 31 of 2014

Biologival Nutrient Removal, WEF/ASCE/EWRI; MOP N°30:2005

ATV-DVWK Standard – A 131E, ATV DVWK, May 2000.

Biofilm Reactors, WEF MOP 35, 2010

Theory, Design & Operation of Nutrient Removal AS Process, Water Research Communion, University of Capetown, 1984.

ABPR Technology, S. Crickley, Engineers Ireland, 2007

Additional References in main written Document

THANK YOU FOR YOUR ATTENTION

THE END

QUESTIONS? www.weweng.ie Email: scrickley@weweng.ie Ph: +353872224768