Aerobic Treatment Plant for Poultry Processing Effluent

Without stopping production, Fluence upgraded a major poultry producer's wastewater treatment to meet discharge limits

A large poultry processing plant in Brazil was relying on an outdated aerobic lagoon wastewater treatment system that was unable to meet new government effluent standards. Without interrupting production, Fluence converted it into an activated sludge wastewater treatment system with low energy consumption and the ability to meet regulations.

Background
BRF is one of the largest agro-industrial companies in the world, thanks to the growth of its more than 30 international brands. It was established with the 2009 merger of two of Brazil's largest food-processing companies, Perdigão and Sadia.

BRF's plant in Dois Vizinhos, in the state of Paraná, processes approximately 700,000 birds a day for domestic consumption and export.

Challenges
The existing wastewater treatment at the plant was rudimentary: Three dissolved air flotation (DAF) systems separated suspended solids from the effluent before it was discharged into an aerobic lagoon. The treatment didn't meet new, stricter discharge standards, particularly limits for nitrogen and phosphorus.

The main challenge was to build and commission a compliant plant by the effective date of new regulations, without interrupting operations.

Solutions
With extensive experience designing wastewater treatment solutions for meat processors, Fluence was able to deliver a plant with efficient performance and low energy consumption.

Aerobic Treatment for Poultry Plant Effluent

As you can see in the process flow diagram above, the plant consists of two parallel nitrification-denitrification lines that receive effluent from the existing DAF systems. A clarification tank was installed downstream, before the point of discharge.

The oxygen required for nitrification is delivered by a fine-bubble air-diffuser system. Membrane diffusers, the most efficient and economical type used in wastewater treatment plants, don't suffer from fouling problems due to the low alkalinity of the effluent. The system design features airflow higher than normally needed to prevent overloading.

When maintenance is required, a system of gates allows one nitrification line to be closed while the other line operates without interruption, allowing treatment to continue. Diffusers are typically replaced after 10 years.

Results and Project Data
Production    700,000    chicken/d        
Flow    16,800    m³/d        
After flotation        Treated water    
COD    600-1,000    mg/L    

Taxonomy

• Poultry Farming
• Poultry Processing