B.O.D. Removal in the Waste Water Lagoon - Case Study
DO2E High Volume Double Flow Aerators Reduce B.O.D. levels from 8,000 # / day down to < 500 #’s / day. (93.75% REDUCTION in BOD)
Kansas Dairy Ingredients (KDI) announced its plans to build a dairy ingredient and cheese plant in Hugoton, Kansas. The company will start construction on the facility next month and begin phase I operation at the middle of the fourth quarter in 2012. The facility will be positioned to expand in 2013 to add cheese production. Kansas Dairy Ingredients will invest $20 million plus over the next 18 months in Hugoton.
When the facility first opens, Kansas Dairy Ingredients plans to begin processing approximately 1 million pounds of milk per day to produce fractionated dairy ingredients. As production builds, the company anticipates eventually processing up to 2.5 million pounds of milk per day by the end of 2013. The company plans to build additional capacity to produce cheese and other dry milk ingredients.
In January 2013, KDI, (Kansas Dairy Ingredients) was faced with fines exceeding $65,000 per month from the City of Hugoton for excess; B.O.D., F.O.G., low pH and High TSS levels. As a means of treating and addressing these and possibly future issues, the city constructed a new 2-acre, poly-lined lagoon, 12feet deep at their facility specifically for the treatment of this waste stream. This lagoon is approximately 2 miles from the KDI facility and currently receives 150,000 to 200,000 gallons per day with a 30-day retention time. Shortly after the plant first started up, discharge issues began to occur. BOD discharge was over 8,000 #’s per day, F.O.G. was over 95 ppm, pH levels were 3.1 to 4.2 ppm, TSS was over 2,900 ppm and odor was horrendous.
In early June 2014, under the direction of engineer Pete Earls, DO2E supplied and installed a 4 Hp. Little John Digester with 4 tubes of Advanced Oxidation Processing (A.O.P.) in a lift station located between the KDI plant and the lagoon. Each tube of ozone produces .50 grams of ozone per hour and is delivered into the waste stream through the Little John Digester. The purpose of this was to pre-treat all effluent as much as possible before it reached the lagoon. As the main source of treatment in the lagoon, DO2E installed eight, 20 Hp. High Volume Double Flow DO2E Aerators in the newly constructed 2-acre lagoon servicing only KDI effluent. Each of the aerators, delivered approximately 650 scfm, transferred 18.9 MGD and produced 2.85 #’s of oxygen / Hp / hour. The Aerators were allowed to run for approximately 30 days before additional testing was conducted. At this point, the aerators were used primarily for mixing lime in an effort to raise and stabilize the pH levels in the lagoon to maximize oxygen transfer. In July 2014, it was determined by consulting engineer Pete Earls that the pH levels were stabilized around 7.65 ppm, and under his direction critical testing was to begin. Our first goal was to condition the effluent where it would hold it’s highest levels of dissolved oxygen. The DO levels quickly increased from .65 ppm to 2.85 ppm and over the following 6 months, steadily climbed to 4.6 ppm where it remains constant today.
GOALS / OBJECTIVES
1) Reduce or Eliminate Fines and penalties
2) Raise pH levels
3) Raise Dissolve Oxygen Levels (4) Reduce BOD by 70%
5) Reduce F.O.G. by 70%
6) Reduce TSS by 75%
1) Fines were eliminated
2) Ph. levels Steady at 7.65 ppm
3) DO levels averaging 4.6 ppm
4) BOD Reduced by 93.75%
5) F.O.G. Reduced by 82.30%
6) TSS Reduced by 87. 5%