Dairy Processing Wastewater Treatment

Published on by for Fluence Corporation

Dairy Processing Wastewater Treatment

Aeration and Mixing Technologies Well-Designed for Maximum Results

Process Wastewater High in Contaminants

Wastewater from the dairy industry is generated from raw milk receiving stations, bottling plants, cheese factories, butter and casein processing, condensed and dried milk processing, and ice cream facilities.
The wastewater is a mixture of dairy product waste, heating, cooling, and washdown water, and chemicals used in the washing and sanitizing processes. It contains high concentrations of BOD and COD, dissolved and
suspended solids, nitrogen and phosphorous compounds, chlorides, fats, oils, and greases. Dairy wastewater decomposes rapidly and reduces dissolved oxygen in the receiving waters, encouraging fungal growth, odors, and sludge.

Treating Dairy Wastewaters is Demanding

Plenty of challenges confront the treatment of dairy wastewaters

• Wide swings in wastewater loading and discharge rates require equalization upfront

• Sludge accumulates on equipment and tankage

• Bulking and foaming problems arise

• Low temperatures diminish treatment effectiveness

• High dissolved oxygen demands result in expensive aeration energy charges

• Odors from the treatment process can be overwhelming if not managed properly

• Over-aerating activated sludge reduces settling and increases suspended solids concentrations

• Poor treatment results in clogged sewer pipes and increased biomass growth.

 

Fluence Aeration and Mixing Technologies Support Effective Treatment

Fluence offers aeration and mixing technologies ideally suited for dairy process wastewater treatment.

 

TORNADO® Family of Surface Aerators

The Tornado aerator provides superior subsurface directional mixing and oxygen dispersion to wastewater bodies. The intense action of the aerator shears wastewater solids to increase treatment performance by enhancing the surface area for oxygen and bacteria contact. 

• 2 – 100 HP (1.5 – 75 kW) Models

• 1800 rpm at 60 Hz (1500 rpm at 50 Hz)

• Grease-lubricated sealed bearings are ideal for high concentrations of solids, grit, and sand

• Solid shaft; vibration-free design

• Low maintenance and patented replaceable modular seals

• Tapered roller bearings prevent aerator shaft vibration and absorb propeller thrust loads

• Self-heating bearing design is ideal for cold climate locations

• Available in standard 304 stainless steel and optional 316 stainless steel construction

• Premium efficiency motor is designed to work with soft start VFD controllers to eliminate power surge  penalties and reduce energy costs

• Blower-assisted models are available for high oxygen demand applications.

 

HURRICANE® Submersible Aspirating Aerator/Mixer

The Hurricane Submersible aerator delivers high oxygen transfer rates with 360-degree radial mixing to depths of up to 24 feet. This equipment is ideal for a wide range of industrial applications including aerobic digesters,
equalization basins, activated sludge, and post aeration basins. The Hurricane is installed at the base of the tank and does not need anchoring to the tank. It can operate as an aerator/mixer or mixer only.

• 14 model sizes ranging from 5 to 100 HP (3.75-75 kW)

• Impeller and stator are manufactured from single pieces of 17-4 stainless steel hardened to Rockwell 45 HRC for superior abrasion resistance

• Impeller is balanced for minimal vibration and maximum chopping action to crush solids

• The base features large extended adjustable legs for stable wide-radius support; vibration dampening feet help prevent “walking”

• Multiple diffuser tubes adapted to rectangular or circular basins provide uniform air distribution for full-floor coverage

• Mixer or aerator/mixer functionality is created by valving off the air inlet pipe or by changing the water depth in the basin

• Fixed or removable mounting options are available

Dairy Wastewater Treatment Challenges Fluence Equipment  Advantages
Acidic environment due to organic materials or chemicals causes corrosion All components are 304 stainless steel construction—no galvanized parts; 316  stainless steel is available as an option.
The Tornado features sealed grease-lubricated bearings which are not exposed to wastewater.
High solids, sludge build-up, and fats, oils, and grease (FOG) Aeration equipment provides intense horizontal mixing action, maintaining solids in suspension and providing deep aeration and mixing action to help dissolve accumulated sludge.
Foul odors Surface aerators create an air cap at the
water’s surface and provide aeration
and mixing below the surface to avoid
splashing or spraying.
Harsh wastewater environments Fluence aerators are designed for harsh wastewater conditions. Industrial-grade, chemical-duty and explosion-proof motors are available options and are designed to withstand high temperatures associated with some processing applications. Corrosion- and UV-resistant stainless steel construction ensures long-lasting performance.
Energy-intensive treatment Premium efficiency motors, turndown capabilities, and smart aerator technologies.
Maintaining treatment equipment Aerators are easy to install, require little maintenance, and some models are accessible  at the surface, requiring no draining or dredging for regular maintenance.

 

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