Courtesy of:

CE525

Industrial Wastewater
Management and
Resource Recovery
MAN’S GREATEST
DISCOVERY
IN CHEMISTRY:
MASTERY OF FIRE…
ULTIMATELY LED TO INDUSTRIALIZATION,
OVERPOPULATION AND URBANIZATION…
AND AIR POLLUTION..
…AND WATER POLLUTION
Some Resource Perspectives
• Most countries want to increase their
agricultural production-- why be
dependent on others for food?
• Worldwide crop residue production is
at least 3600 billion pounds/y:
• 800 million tons sugar cane bagasse
• 500 million tons rice straw
• 500 million tons corn stover
NATURAL RESOURCE
RECOVERY
• Natural resources limited
• Importance to development
• Wastes are polluting
• Recover more – less pollution
Composting
 RESOURCE
EXTRACTION
FROM WASTE

Dewatered
orange peel


Citrus oils
and molasses
ORANGE JUICE BYPRODUCTS RECOVERY
 ORANGE JUICE BYPRODUCTS BENEFICIATION

Orange juice, is of course, the most important product from the orange (50%).
Byproducts, all of which are used in food processing, agriculture and electronics
Cold-pressed oils
Oil removed from the peel during the juice extraction process. The major use is for
flavoring juices, beverages and other foods and confections.
Essences and aromas
These are recovered during the evaporation process when the juice is heated under
a vacuum to remove the water. Used to flavor citrus juice and beverage products.
Press liquor
The remaining peel, seeds and membrane are processed through a screw press for
much of the remaining liquid — press liquor. Used to make citrus molasses.
Citrus molasses
The product resulting from the evaporation of the press liquor, it is either sold to local
distillers to make alcohol or mixed with peel pulp to produce cattle feed.
D'limonene
Recovered from the orange peel from conversion of the press liquor to molasses,
d'limonene is used for making everything from adhesives to a solvent used by the
electronics industry as a replacement for ozone depleting chlorofluorocarbons.
Dried peel
90% of the moisture removed by pressing and heating: pressed into pellets that is
used for cattle feed.
Orange Peel: no longer a waste
Other fruits
and vegetables
also provide
opportunities

RECOVERY OF
BYPRODUCTS
FROM PINEAPPLE
WASTES
METAL
RECOVERY
FROM
WASTE
WATERS
METAL ION SOLUBILITIES AS A FUNCTION OF pH
DEPOSITION OF CALCIUM
CARBONATE AS A RESULT
OF DECREASED SOLUBILITY
WITH INCREASE IN
TEMPERATURE
Reuse of Water Softening
Lime Sludge and Coal
Combustion Byproducts
Rob Baker, Research Assistant
J(Hans) van Leeuwen, David J. White
Principal Investigators
 IOWA STATE UNIVERSITY
Dept Civil Construction, and Environmental Engineering
Ames, Iowa

Problem
• Stockpiles of water
treatment lime sludge
in Mid-West
• DNR: No new lagoons
 IOWA STATE UNIVERSITY
Dept Civil Construction, and Environmental Engineering
Ames, Iowa

Lime Sludge in Cement

Production

80t cement produced using 20t lime sludge

Air Pollution Control with Limestone

SO2 + CaCO3  CaSO3 + CO2

AIR POLLUTION CONTROL WITH LIMESTONE
SO2 + CaCO3  CaSO3 + CO2
POWER PLANT BYPRODUCT RECOVERY
Test Embankment
High gas prices!
 Bioprocessing and value-
added products from ethanol
manufacture

J (Hans) van Leeuwen et al.

Ames, December 19, 2006
Roadmap to more effective ethanol

Fungal processing

Food-grade
alcohol
Major Dry Corn Milling Products

Ethanol CO2

Recycled
Water  Stillage  DDGS

$$$$$
MICROBIAL BIOMASS
PRODUCTION
Fungal species
Dedication to work
Rhizopus sp. grown on
wet corn milling wastewater

50 

Research supported by USDA, ADM and P&G

Physical
Selection
Fungal reactor and screening setup
Cultivating Fungi in Attached Mode

The Rhizopus fungi grew very well attached to PCS (an extruded
mix of polyethylene and dried plant biomass) and excluded bacteria.
Easy harvesting by sloughing off and subsequent settling.
 Chemical Selection of Species
Ozone
generators
pH controllers

Desiccators

Bioreactors

Ozonation at 50-60 mg/L

Influent dosing Variac
pumps
Water bath
enhances selection
and production of fungi
and discourages bacteria
Reactor set-up for ozonation
Fungal Treatment of Thin Stillage

Day 0 Day 4 Day 5 Day 8

Fungal
biomass
 Fungal Treatment of Thin Stillage
100 40

Suspended solids (g/L)

80
30
COD (g/L)

60
TCOD 20 TSS
40 SCOD VSS
10
20

0 0
0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9

Day Day

Effluent Fungal biomass with

collected solids attached
Fungal Treatment of Thin Stillage
Feed
After treatment Settled effluent

COD removal 93%

Solids removal 98%

Research into
water reclamation

Huge quality improvements: recyclable water

and harvesting of high protein animal feeds
Potential for revenue generation
• Thin stillage generated at a typical 50 Mgal/y
ethanol dry-mill plant = 550 gpm
With 50% recycle = 1500 m3/day
• Thin stillage strength = 160 g/L COD
• Total COD thin stillage = 120 ton/d
• COD removal 80%
 fungal yield is c. = 0.4 g/g COD
• Fungal biomass yield = 38 m ton/day
• Worth c. $2 million/y @ 7c/lb (high lysine)
 DDGS
Enhancing nutritional Production
value of DDG
• DDG production increasing
rapidly - demand will fall behind
• DDG market limited by poor
amino acid balance for monogastrics
• Adding fungal biomass to DDG will result
in much improved amino acid profile
• Fungal chitosan and oligosaccharides
complex could greatly enhance
monogastric nutrition
 Enhancing nutritional
value for swine with COS

A Body B Body Production

Period mass mass increase

Start 1.37 kg 1.37 kg -

21 days 6.28 kg 6.26 kg -

35 days 8.88 kg 9.5 kg +7.0%

42 days 11.09 kg 12.54 kg +13.1%

61 days 21.43 kg 24.25 kg +14.1%

 No antibiotics required
 Energy savings in
thin stillage treatment
• Heat required for evaporation on a 50
Mgal/y plant would be 3300MBtu/day
• Heat recovered of 90%  330
MBtu/day
• Cost of natural gas New York
Mercantile Exchange was c. $12.5 per
MBTU at the end of 2005 (eia.doe.gov)
• Annual savings in energy c. $1.5M
Simplifying Lignocellulosic Fermentation


H2SO4 Enzymes Pretreatment part of
Heat current technology is
polluting and expensive

Brown Rot Fungus:

Gloeophyllum trabeum
 Fungal Solid State Fermentation Research

• corn fiber coated

on inside of bottles
with brown rot
moulds
• incubation at 30oC
• moist environment
maintained
• multiple bottles
allowed regular
sampling

Source: picture taken in the lab Day 3 Day 5 Day 9

 Solid-State followed by
Submerged Fermentation

Trained cormorants
with neckrings led
to the submergence
of the culture idea


The aerobic SSF was followed by anaerobic conditions

to prevent sugar “poaching” by the fungi
 Solid-State Fermentation
& Ethanol Production
Yeast nutrient solution
with or without yeasts
5
(% of initial fiber)

4 2d SSF, yeasts
Ethanol

3 3d SSF, yeasts

2 3d SSF, Breakthrough:
no yeasts
G. trabeum produced ethanol
1
under anaerobic conditions
0 Sugars released were
0 48 96 144 192 240 288 effectively fermented to
ethanol by yeasts
Anaerobic Incubation (h)

This2could have -far-reaching

d G. trabeum w/ yeast implications – needs further development
Ultrasonication of corn slurry
8.00

7.00 Control
6.00 CEU
SD2020
CEU
SD4040

Volume (%)
5.00
CU 20
SA20
4.00
CU 40
SA40
3.00

2.00

1.00
High power
0.00
0.0 0.1 1.0 10.0 100.0 1000.0 10000.0

Particle Size (um)

 Ultrasonication: sugar release

Uncooked

Cooked
Ultrasonication: Equipment
Ethanol Purification with
Ozonation and GAC

SPME and analyses on GC-MS-O system

 Ethanol Purification to Food-grade
Ozonation removed some undesirable odors
from fuel ethanol, e.g., #10 burnt/
burnt plastic, #13 smoky/medicinal.
• Produced new “winey/sweet” note.
• The GAC treatment removed an
offensive “skunky/rancid” note.
• Both treatments removed (up to 100%) some
potentially/known toxic chemicals, e.g.,
acetaldehyde, hexane, benzene, and styrene.
• The process has great potential in
production of industrial and food-grade
alcohol from fuel ethanol.
 Using Ozone to Control Fungi in
Stored High Moisture Corn

Ozonation requires < 1% of the energy that would be

required for additional drying to prevent fungal growth
 The Team
• J (Hans) van Leeuwen Engineering, O3
• AL Pometto III Fermentation
• Samir Khanal Bioprocess Eng.
• Jacek Koziel Analytical
• Sam Beattie Mycology
• Allan Trenkle Animal nutrition
• Carl Bern Corn storage
• Graduate students (12) Laboratory
Foaming!!
Ankeny
foaming
problem:
Summer 2003
Nocardia
forms
Nocardia, along with 0675 filaments (400x)
Improvement after dosing c. 2g Cl2 per kg biomass per day
Ankeny
bulking
problem:
Spring 2003
Microthrix
parvicella
 Ships’ Ballast Water Treatment

ZAP
the
ZOOPS
..or Hollywood Invaders?
Alien Invaders in
our Coastal Waters
- weirder and risky
ZEBRA MUSSELS
The Target:
Invasive
Marine
Species
RESEARCH ON SHIPS’ BALLAST WATER TREATMENT
NUTECH O3, NOAA, NETSCO, UNCW, UWS, ISU, et al.
Propeller exposed under
unballasted conditions
Into the Tonsina’s ballast tanks
Inside the ozone generator aboard the Tonsina
Side-stream
ozone
injection