Poultry Processing Plant MBR
Dynatec Systems’ installed a HiBrid™ UF for MBR service at a poultry processing plant that processes 800,000 gallons per day. The Membrane Bioreactor (MBR) operates at high flux which means less membrane surface area is required and ultimately saving capital cost. Dynatec Systems has installed over 600 membrane systems providing wastewater solutions since 1979. The HiBrid™ MBR UF combines sound engineering and effective process design with state-of-the-art materials of construction.
Outsource your wastewater service! Dynatec will design-build-own-operate-maintain (DBOOM) your wastewater treatment plant allowing you to concentrate on your core business.
The industrial MBR is the ideal bioreactor configuration for treatment of organic or inorganic contaminants present in industrial wastewaters. MBR’s operate at a higher efficiency while achieving consistent design performance objectives. This makes MBR a more cost effective method of industrial wastewater treatment when performance and tank requirements are considered.
Industrial Membrane Bioreactors Benefits:
- Higher flux
- Lower costs
- Better membranes
- Improved permeate quality
- Less operator attention and maintenance
Industrial Membrane Bioreactor (MBR) Applications
Dynatec’s industrial MBR is the ideal biological system for industrial wastewater treatment. It is designed to handle high strength wastewater containing high concentrations of:
- Biochemical Oxygen Demand (BOD)
- Chemical Oxygen Demand (COD)
- Oil & Grease (FOG)
- Volatiles
- Metals
- Ammonia
- Nitrate
- Inorganic
The performance is not affected by changes in sludge settleability like the conventional systems, making it the wise choice for industrial wastewater treatment systems that have difficult-to-treat waste streams. Dynatec’s MBRs can effectively handle industrial wastewater streams that would otherwise be toxic or inhibitory to other biological treatment systems.
Backed by decades of experience with MBRs, Dynatec has developed many unique process solutions necessary for industrial wastewater treatment applications such as:
- Landfill leachate
- Hazardous landfill leachate with metals removal
- Automotive manufacturing wastewater
- Food manufacturing wastewater
- Titanium processing wastewater
Contact Dynatec Systems today to discuss your wastewater solutions.
https://www.dynatecsystems.com/industries/food-and-beverage/poultry-processing-wastewater-treatment/
Chemical plant wastewater treatment
Chemical plant wastewater treatment was failing to meet discharge limits, installed a Dynatec UF system to separate emulsified fats, oils, and grease (FOG) from their permeate. The raw wastewater has more than 2,000ppm of emulsified FOG with peaks much higher at times. The system consists of four UF units and related components. The system currently treats 66gpm, but all 4 units are expandable. The permeate is free of FOG and is acceptable for discharge.
https://www.dynatecsystems.com/technologies/membrane-technologies/ultrafiltration-systems/
Chemical wastewater treatment utilizing membrane systems that range from selective separation of product to wastewater treatment and reuse. Dynatec Systems has provided many different chemical wastewater solutions.
Chemical Wastewater Treatment Solutions
- Ultrafiltration (UF), Nanofiltration (NF) and Reverse Osmosis (RO) for selective separation of product for recovery
- MBR biological treatment
- Wastewater reuse with MBR
- Conversions of existing systems to MBR
- Expand existing bioreactor treatment capacity
- Improve discharge quality
- Produce water for reuse
- Reduce surcharge
- High purity reuse with MBR and RO
Contaminants Removed
- Organics
- Inorganic solids
- Phenol
- Solvents
- Oils
- Acids
Ultrafiltration offers the following advantages over conventional separation:
- No chemical required
- Very little labor required
- Simple mechanical process
- Less sludge
- Ability to concentrate the retentate for beneficial use
- Less space required
- Overall lower operating costs
Dynatec specializes in extensive RO and NF membrane systems to remove soluble components of wastewater that may not have been removed by primary treatment. In most cases, the purified water can be reused.
RO is capable of rejecting soluble constituents of aqueous streams, such as:
- Bacteria
- Salts
- Sugars
- Proteins
- A wide range of organics and colors
- Improves the color, taste and properties of the fluid
RO can be used to purify fluids such as ethanol, which will pass through the reverse osmosis membrane, while rejecting other ions and contaminants from passing.
RO/NF systems
The most common use for reverse osmosis is in purifying water. It is used to produce water that meets the most demanding specifications. This differs significantly from other RO systems that are often only designed to treat potable water. Our system is specifically designed to accommodate:
- Minimize reject volume
- Variable characteristics
- Minimize fouling
RO and NF Technology
RO uses a membrane that is semi-permeable, allowing the fluid that is being purified to pass through it, while rejecting the contaminants that remain. Most NF and RO systems are operated in crossflow to allow the membrane to continually clean itself.
Integrated clean-in-place (CIP)
The membrane skid has an integrated CIP system on the skid. This is especially important for wastewater reuse systems because the cleaning frequency of the skid is often higher than in other RO applications. With an integrated CIP system, cleaning is fast and easy, minimizing the operator’s time.
Tubular Configuration:
- Higher permeate rate
- Lower rates of fouling
- Higher concentration of retentate
- Easier to clean
- Longer membrane life
- Low operating cost
To discuss your wastewater treatment solution, please contact us today.
Wastewater reuse
Wastewater reuse is achieved at an automotive plant. Wastewater equipment to treat both sanitary and production
wastewater that included oily waste was designed and installed in a new transmission manufacturing facility. The goal was to treat and purify water for reuse.
Dynatec met these demands by providing a membrane bioreactor (MBR) followed by a reverse osmosis (RO) system. The MBR reduced BOD, TSS, and oil and grease to non-detect levels. The RO is used to polish the MBR effluent so that it is suitable for reuse. It is reused in cleaning operations, cooling tower, and all production applications.
80%-90% of the wastewater is purified for reuse. Additional industrial park wastewater (after primary clarification at the industrial park) is introduced to the system for treatment and purification. The system is designed to receive 300,000gpd and purify 250,000gpd for reuse.
This novel approach greatly reduced the total amount of wastewater discharged by this plant. It provided the water needed for production using a comprehensive system that Dynatec designed, supplied and installed.
Ultrafiltration (UF), Membrane Bioreactor (MBR), Nanofiltration (NF) and Reverse Osmosis (RO) are employed by Dynatec for these wastewater projects. Wastewater recovery and reuse has been successfully implemented with industrial and sanitary wastewater streams for:
- Cooling tower make up
- Boiler feed
- Irrigation
- Toilet flushing
- Direct potable reuse
- Cleaning/wash applications
- Rinse processes
- Painting processes
- Other plant processes
For more information on wastewater reuse, please contact us today.
https://www.dynatecsystems.com/technologies/recovery-and-reuse/
High Quality Discharge MBR
Dynatec provides High Quality Discharge MBR system for Retirement Home
The retirement community consists of independent living homes and apartment homes in rural Maryland. The facility is in horse country, in a valley among rolling hills, and shares the area with high-end homes.
Previously, the facility had two septic tanks, and a recirculated sand bed filtration system. This created odors and caused mosquito infestations in summer. The facility chronically missed discharge limits, and thus was paying frequent fines. The sand bed filtration system was high maintenance, constantly flooding and requiring maintenance.
Replacement Criteria
In deciding on a replacement system, several criteria were important to the facility and to State regulators. The plant must be aesthetically pleasing. Odors must be minimized and if possible, eliminated. The plant had to achieve high levels of treatment to meet present and future discharge requirements. Future use of the treated water for irrigation is planned. The plant had to be operator friendly, and be capable of being monitored remotely, since full-time staff would not be available. The plant must be cost effective, from both capital and operating standpoints. Finally, the plant must be modular, in that future expansion of the facility must be accommodated in the design.
The initial plant sizing was nominally for 50,000 gallons per day of treatment capacity and has been expanded to 100,000 gallons per day.
System Design
After a review of the available treatment options, the owners of the facility decided on the (MBR) Membrane Bioreactor option. Due to the modular design of the system, they also chose the out-of-basin membrane module concept provided by the Dynatec MBR system. This process combines ease of use with all the requirements of both the owners and the regulators.
Odor control is achieved by using closed tanks vented to atmosphere. Air from the screening room is used to provide aeration to the reactors and the membranes, using the biomass as a biofilter. The negative pressure in the screen room ensures that there are no fugitive odors from the area. Mixing and aeration of the EQ tanks (the existing septic tanks) ensures no odors from that area.
Design Compatibility with the area: due to the nature of the area, the plant was designed to be installed in a “horse barn”, or at least a building that looks like a horse barn, but in fact, contains both the treatment plant and space for landscaping and other equipment.
High Levels of Treatment have been achieved since the plant’s inception in early 2007. Performance has been maintained since that time. Future plans include treatment for Total-N and Total-P to comply with Maryland’s “flush tax” requirements.
Cost Effective Installation was achieved using standard above-ground HDPE tanks, rather than the more common concrete tanks
Plant Expandability was achieved by the installation of one half of the plant, and the addition of a second membrane rack. No modifications to tanks or other work were required in 2009.
Conclusions:
Since completion and startup in early 2007, the plant has reliably performed, always producing high-quality water.
The Dynatec MBR concept provides economic advantages due to the modular design and the use of standard tanks. The cost of operation is modest when compared to alternatives.
Contact Dynatec Systems today to discuss your sanitary wastewater solution.
https://www.dynatecsystems.com/industries/sanitary-wastewater/
MBR for transmissivity improvement
MBR for transmissivity improvement – Dynatec provided a low pressure nanofiltration (NF) system to remove humic and fulvic acid to improve the transmissivity (UVT) of treated water discharge. The NF system also minimizes the reject volume making the membrane approach practical.
Demands for development of membranes with specific performance continue to increase as water quality requirements tighten and water treatment system designs become more complex.
Where UV is employed for disinfection the requirement for transmissivity improvement has become important at many facilities.
The NF membrane typically rejects only larger polyvalent cations and anions and as a result produces a very small volume of reject.
MBR for transmissivity
Nanofiltration systems are typically used for:
- Color removal from surface water sources including removal of disinfection precursors
- Retention of humic and fulvic acids in landfill leachate to improve UV transmissivity
- Pharmaceutical solvent recovery and management
- Removal of tar compounds in petroleum industry
- Separation of blood compounds in medicine
- Water softening
Dynatec specializes in extensive industrial reverse osmosis (RO) membrane systems and nanofiltration (NF) membrane systems to remove soluble components of wastewater that may not have been removed by primary treatment. In most cases, the purified water can be reused.
RO is capable of rejecting soluble constituents of aqueous streams, such as:
- Bacteria
- Salts
- Sugars
- Proteins
- A wide range of organics and colors
- Improves the color, taste and properties of the fluid
This process is commonly used to purify water and remove salts and other impurities. It can be used to purify fluids such as ethanol, which will pass through the reverse osmosis membrane, while rejecting other ions and contaminants from passing.
Industrial Reverse Osmosis/Nanofiltration systems
The most common use for reverse osmosis is in purifying water. It is used to produce water that meets the most demanding specifications. This differs significantly from other RO systems that are often only designed to treat potable water. Our system is specifically designed to accommodate:
- Minimize reject volume
- Variable characteristics
- Minimize fouling
RO and NF Technology
RO uses a membrane that is semi-permeable, allowing the fluid that is being purified to pass through it, while rejecting the contaminants that remain. Most NF and RO systems are operated in crossflow to allow the membrane to continually clean itself.
Integrated clean-in-place (CIP)
The membrane skid has an integrated CIP system on the skid. This is especially important for wastewater reuse systems because the cleaning frequency of the skid is often higher than in other RO applications. With an integrated CIP system, cleaning is fast and easy, minimizing the operator’s time.
For more information on nanofiltration, please contact us today.
Chemical Manufacturer Wastewater Treatment
A chemical manufacturer issued a PO for a new wastewater treatment system from Dynatec. Our customer is in the process of a major plant expansion and needed to meet new, stricter discharge limits. The wastewater is high in oil and grease, BOD, and COD. The new system will consist of an ultrafiltration system followed by a membrane bioreactor (MBR). The performance of this system was proven over several months of piloting. The results confirmed the selection of UF followed by MBR. The BOD in the permeate was regularly non-detect, down from as high as 40,000ppm in the raw wastewater. All other discharge limits were easily met.
Chemical wastewater treatment utilizing membrane systems that range from selective separation of product to wastewater treatment and reuse. Dynatec Systems has provided many different chemical wastewater solutions.
- Ultrafiltration (UF), Nanofiltration (NF) and Reverse Osmosis (RO) for selective separation of product for recovery
- MBR biological treatment
- Wastewater reuse with MBR
- Conversions of existing systems to MBR
- Expand existing bioreactor treatment capacity
- Improve discharge quality
- Produce water for reuse
- Reduce surcharge
- High purity reuse with MBR and RO
Contaminants Removed
- Organics
- Inorganic solids
- Phenol
- Solvents
- Oils
- Acids
Ultrafiltration offers the following advantages over conventional separation:
- No chemical required
- Very little labor required
- Simple mechanical process
- Less sludge
- Ability to concentrate the retentate for beneficial use
- Less space required
- Overall lower operating costs
Dynatec specializes in extensive RO and NF membrane systems to remove soluble components of wastewater that may not have been removed by primary treatment. In most cases, the purified water can be reused.
RO is capable of rejecting soluble constituents of aqueous streams, such as:
- Bacteria
- Salts
- Sugars
- Proteins
- A wide range of organics and colors
- Improves the color, taste and properties of the fluid
RO can be used to purify fluids such as ethanol, which will pass through the reverse osmosis membrane, while rejecting other ions and contaminants from passing.
RO/NF systems
The most common use for reverse osmosis is in purifying water. It is used to produce water that meets the most demanding specifications. This differs significantly from other RO systems that are often only designed to treat potable water. Our system is specifically designed to accommodate:
- Minimize reject volume
- Variable characteristics
- Minimize fouling
RO and NF Technology
RO uses a membrane that is semi-permeable, allowing the fluid that is being purified to pass through it, while rejecting the contaminants that remain. Most NF and RO systems are operated in crossflow to allow the membrane to continually clean itself.
Integrated clean-in-place (CIP)
The membrane skid has an integrated CIP system on the skid. This is especially important for wastewater reuse systems because the cleaning frequency of the skid is often higher than in other RO applications. With an integrated CIP system, cleaning is fast and easy, minimizing the operator’s time.
Tubular Configuration:
- Higher permeate rate
- Lower rates of fouling
- Higher concentration of retentate
- Easier to clean
- Longer membrane life
- Low operating cost
To discuss your wastewater treatment solution, please contact us today.
https://www.dynatecsystems.com/technologies/membrane-bioreactors/mbr-conversion-r…pgrade-solutions/
Reuse Water with MBR
High-quality discharge and reuse from MBR
Dynatec Provides Reuse Water for Cereals Plant
Dynatec Systems, Inc. has installed a water reuse system in a major cereals plant in Georgia.
The complete treatment system, consisting of a membrane bioreactor (MBR), followed by reverse osmosis (RO), provides a net savings to the plant of more than $3,000 per day in water and sewer charges after deduction of the plant operating costs. The water is reused for cleaning, in scrubbers and in boilers.
Previously, the facility discharged all the wastewater to a municipal treatment plant at a rate of up to 0.5 mgd, and paid both volume and load charges
Quality Criteria
Since the plant produces a food product, ultimate water quality is vital. The two-stage membrane system (MBR + RO) and final sterilization with ultraviolet (UV) treatment provides the quality assurance that plant management requires. In addition, the membranes used in the MBR system are external to the aeration basin and are tubular. This type of membrane is much less susceptible to failure than the immersed type.
System Design
After a review of the available treatment options, the owners of the facility chose the Dynatec bioreactor option. This process combines aerated biological treatment with an out-of-basin ultrafiltration (UF) system. In combination with reverse osmosis treatment, Dynatec was able to provide the client with the necessary assurances that the water quality would not be compromised, and that the water would be suitable for process purposes, such as boiler feed water.
Dynatec’s design consisted of the following components:
- Internally fed rotary screen
- 500,000 gallon above-ground stainless steel equalization tank with jet aeration and duplex PD blowers
- 500,000 gallon above-ground stainless steel aerated biological reactor with jet aeration and triplex PD blowers
- Four membrane skids with a common automated CIP (clean-in-place) system, one skid operates in standby mode
- Reverse Osmosis system
- Final UV (ultraviolet) sterilization
- Sludge dewatering decanter centrifuge
- Completely integrated control system managing all system functions
System Advantages:
- The system provides many advantages for the operators and owners.
- Redundant membrane skids for ease of operation and cleaning.
- Simple automated cleaning operations with membranes in place.
- High mixed liquor concentration ensures the lowest possible sludge production, and requires smallest possible footprint.
- Simple, low maintenance system.
- Long-lasting tubular membranes with 0.03 μm membrane, ensuring removal of bacteria and viruses.
Results:
The system has produced high quality water for reuse. Consistently, the water quality from the MBR has been as follows:
| Analytic | Units | Influent | MBR Effluent |
| BOD5 | Mg/L | 1200 | <5 |
| COD | Mg/L | 20 | |
| TSS | Mg/L | No data | ND |
State Award
The facility received an award from the State of Georgia Association of Water Professionals presented an award to the
facility for Outstanding Operation of a facility in the category of Water Conservation.
Project Conclusion:
The project was completed on time and within budget, and has exceeded the estimates that were initially made for cost savings.
The Dynatec system has proved to be reliable and efficient, and has exceeded the customer’s requirements, based on the initial
projected performance.
Technology Benefits
Biological treatment using Membrane Bioreactors provides several benefits:
- Consistently high-quality water
- No upsets, since the membrane provides a positive barrier to bacteria and viruses
- Smaller footprint than conventional systems, due to operation at high levels of mixed liquor
- Better system kinetics than conventional systems, due to long sludge age
- Complete removal of bacteria and viruses
- High quality water for reuse
- Dynatec Out-of-Basin MBR Systems:
- Operators never come in contact with biomass
- Easy clean-in-place without moving membranes
https://www.dynatecsystems.com/industries/food-and-beverage/
ZLD wastewater treatment system
ZLD wastewater treatment system for a food processing company was provided by Dynatec. The primary treatment is provided by a tubular membrane bioreactor (MBR) followed by reverse osmosis (RO). Membrane bioreactor permeate is reused for cooling tower make up. Reverse osmosis permeate is re-used for high-quality users and reverse osmosis (RO) reject is used for irrigation.
ZLD wastewater treatment system
Recovery and reuse systems have been provided by Dynatec Systems to many industries. The ability to recover and reuse water has many benefits.
- Saving on water costs
- Saving on wastewater disposal charges
- Decreased environmental impact
- Protection from regulatory changes
- Decrease dependence on water provider/source
- Ability to expand without affecting water demand
- Overcome water scarcity issues
- Consistently high-quality for water reuse
Ultrafiltration (UF), Membrane Bioreactor (MBR), Nanofiltration (NF) and Reverse Osmosis (RO) are employed by Dynatec for water reuse projects. Water recovery and water reuse has been successfully implemented with industrial and sanitary wastewater streams for:
- Cooling tower make up
- Boiler feed
- Irrigation
- Toilet flushing
- Direct potable reuse
- Cleaning/wash applications
- Rinse processes
- Painting processes
- Other plant processes
Recovery and reuse systems provided by Dynatec Systems:
- Resorts, hotels, and retirement homes
- Golf courses
- Automotive companies
- Food and beverage companies
- Apartment buildings
- Landfills
- Mines
- Metal finishing plants
- Aerospace companies
Membrane Bioreactors
Membrane bioreactors offer a unique and effective solution for the treatment and reuse of industrial wastewater in industries such as landfills, automotive, aerostructures, distilleries and dairies. Our industry-leading designs and innovation also deliver superior performance for sanitary wastewater and biological nutrient removal applications.
The MBR configuration has proven to be optimal for treatment of many industrial wastewaters when treatment efficiency is an important consideration.
The MBR is the ideal bioreactor configuration for treatment of organic or inorganic contaminants present in industrial wastewaters. MBRs operate at a higher efficiency while achieving consistent design performance objectives. This makes MBR a more cost effective method of treatment when performance and tank requirements are considered.
Bioreactor systems such as the conventional activated sludge system, sequencing batch reactor system and trickling filters are typically designed for operation at a lower volumetric removal rate, requiring larger tanks and more space. These conventional systems often experience upsets that inhibit settling and therefore require much more operator attention than a membrane bioreactor.
The MBR has proven to be optimal for treatment of many industrial wastewaters because it is less susceptible to upsets. The MBR’s performance is not affected by changes in sludge settleability like the conventional systems, making MBR a wise choice for industrial systems that have more difficult to treat waste streams. Dynatec has over 45 years experience in dealing with difficult to treat industrial wastewaters using membrane filtration.
For more information on zero-liquid discharge (ZLD) wastewater treatment systems, please contact us today.
https://www.dynatecsystems.com/technologies/recovery-and-reuse/
SBR to MBR Conversion
SBR to MBR Conversion
Dynatec provided tubular ultrafiltration systems as part of an SBR to MBR conversion. The upgraded treatment system allowed the facility to meet all discharge requirements and increased the capacity of the plant. The SBR could treat 4,000 barrels per day and the upgraded plant utilizing an out-of-basin MBR treats up to 10,000 barrels of wastewater per day.
To meet direct discharge limits, the oil refinery needed to upgrade their treatment system. The existing SBR could not handle the volume of wastewater and was not consistently meeting the discharge quality limits.
The MBR reduced the COD to below 50ppm and phenols are reduced from over 750ppm to non-detect.
The solution for this plant was an oil water separator followed by out-of-basin membrane bioreactor (MBR). The permeate from the MBR met all requirements for discharging to sea water. COD in the permeate was less than 300ppm. Phenols in the permeate were consistently less than 1ppm.
Dynatec provided containerized systems for easy and fast installation at site.
Significant Savings
- Simple process
- Fewer chemicals needed
- Low maintenance
Technology Benefits
- Consistent high-quality water
- Low operating costs
- Minimal operator intervention required
- Reduced sludge disposal costs
Contaminants Removed
- Oil and grease
- Heavy metals
- COD
- BOD
- Suspended solids
- Phenols
Flexible Retrofits
Since the membranes were installed outside the reactor, the membranes allowed for easy retrofit to any bioreactor configuration (circular, rectangular, above or below ground), . Frequently, the existing infrastructure and building space can be reused with little or no changes.
Expandability
The membrane system is easy to expand, since the out of basin configuration allows for simple addition of more membranes, or membrane skids.
Better Performance
The MBR System eliminates many of the unit processes associated with conventional treatment systems. The bioreactor tanks degrade constituents normally considered recalcitrant and they eliminate solids carry-over from occurring, allowing long sludge retention times.
Contact Dynatec to discuss your application.
https://www.dynatecsystems.com/technologies/membrane-bioreactors/mbr-conversion-r…pgrade-solutions/
Silver Recovery at Microcircuit Plant
The Problem
A microcircuit materials production facility produces high purity silver in their process. The process produces a wastewater stream containing valuable dissolved silver compounds. The plant had an existing membrane treatment system to recover the silver from the wastewater, but the system had performance problems, required excessive maintenance and chemical cleaning costs were high.
The Solution
When the plant expanded its operations, they performed an evaluation. The choice was between expanding the existing membrane system or installing a Dynatec membrane system designed for simple automatic operation with low operating costs. Dynatec was ultimately selected to provide a complete system because the Dynatec design offered a more reliable, easier to operate process. The installation includes transfer pumps, two reaction tanks, three ultrafiltration skids designed for 25 gpm each with room for expansion, a sludge conditioning system, and a filter press.
The Process
Wastewater from the process is stored in an equalization tank. Transfer pumps deliver the equalized wastewater to the first reaction tank where DTC (dithiocarbamate) is added to react with the aqueous silver compounds to form insoluble metal salts. The water then enters another reaction tank where the pH is adjusted to optimize precipitation of the silver compounds.
The precipitated silver compounds are then filtered in one of the three ultrafiltration skids. The ultrafiltration system, using tubular PVDF membranes are designed for automatic operation. When the membranes become fouled, the operator initiates an automatic cleaning, and the system performs a chemical membrane cleaning and the ultrafiltration skid is brought back into service.
The permeate from the ultrafilter is discharged and the concentrated silver is sent to a sludge conditioning tank where a high molecular weight cationic polymer is added to aid in filterability of the sludge. The sludge is then sent to a filter press and the cake is sent to a silver reclamation facility.
Conclusion
The installation of the new system was successful. The system has been operating for several years. Current operation at the plant consists of operating two filtration skids at a time with one as a standby. The system is designed to add capacity by simply adding membranes to the existing UF skids. Operators are happy with the system’s operation and the lower amount of maintenance and chemicals required.
Contact Dynatec to discuss your wastewater application.
https://www.dynatecsystems.com/industries/heavy-metals-removal/