University of San Carlos

School of Engineering
Talamban, Cebu City, Philippines

Proposed Wastewater Treatment Facility

for King’s Quality Food Incorporated –
A Meat Processing and Packaging Company

CHE 525N
Management of Industrial Wastes

Submitted to:

Engr. Ramir L. Jarabis

CHE 525N Instructors

Submitted by:

Alexis Margret M. Aberion

Kristian Gregg C. Banaag
Shiela Marie C. Burgos
Christine Jenica U. Dy
Alyssa Fay L. Go

February 22, 2017

Table of Contents
Chapter 1....................................................................................................................................................3
Introduction.............................................................................................................................................3
Chapter 2....................................................................................................................................................5
Review of Existing Industries and Manufacturing Facilities.....................................................................5
2.1 Overview of the Meat Processing Industry and Its Major Products...............................................5
2.2 Meat Processing Industry in the Philippines and Implemented Policies........................................7
2.3 Meat Processing Companies in Cebu...........................................................................................10
Chapter 3..................................................................................................................................................12
Details of Manufacturing Process..........................................................................................................12
Chapter 4..................................................................................................................................................13
Details of Waste Management Processes..............................................................................................13
4.1 Nature and Characteristics of Industrial Wastes..........................................................................13
4.2 Baseline Data and Methodology on Acquisition of Baseline Information....................................13
4.3 Detail of Unit Operations and Processes......................................................................................13
Chapter 5..................................................................................................................................................36
Waste Management Initiatives..............................................................................................................36
5.1 Pollution Prevention/Cleaner Production (P2/CP).......................................................................36
5.2 Environmental Management System (EMS).................................................................................36
Chapter 6..................................................................................................................................................37
Future Trends and Direction..................................................................................................................37
Chapter 7..................................................................................................................................................38
Conclusion.............................................................................................................................................38
Chapter 8..................................................................................................................................................39
Recommendation..................................................................................................................................39
References................................................................................................................................................40
Appendices...............................................................................................................................................41
Appendix A: Material Balance Calculations...........................................................................................41

2
 Chapter 1
Introduction
The global meat processing industry is a growing business, hitting 315 million tons of
meat worldwide in 2014. This means that, on average, each person in the world consumes about
43.4 kilograms of meat annually [ CITATION Wor161 \l 3081 ]. Meat processing is the generic
term used to describe the industry. However, a number of terms are used to describe the facilities
at which meat processing occurs, including abattoirs, slaughterhouses and meat packing plants.
The meat processing industry is changing progressively including a great deal of growth in terms
of technological advancements, automated meat processing systems, meat grading systems,
improved packaging technology and more efficient distribution systems.

The two main driving forces to the industry’s enlarged scope are the technological
advancements and increasing food demand. Technology development in this sector of the
economy brought about more efficient meat processing facilities, benefiting from scale
economies and learning economies. Additionally, changes in food process technology has
allowed for a greater choice of quality meat products available for consumption. Food demand
has switched from cooking-it-all-at-home to easy-to-prepare products. This shift brought about
concerns of nutrition and safety which were not inquired in the old model. In consequence, not
only the meat industry has changed but also its co-participants, the food retailing and livestock
production segments.

3
 Figure 1.1 Meat products sold in a supermarket

In today’s market, consumers are requiring meat products that are easy to prepare,
reliable, dependable, reasonably priced and wholesome. The industry’s process and production
technology evolved to the extent that convenience and versatility are easily taken care of to
accommodate customer preferences and needs.The meat processing industry is now facing
increasing pressure to ensure that company’s activities are safe and environmentally sensitive,
but there is also increasing internal pressure to maintain or increase profitability in the face of
fierce competition. The food-processing industry in general has special concerns about the health
and safety of the consumer.

Key resources used by the food-processing industry include the water, raw materials
andenergy. Traditionally, the food-processing industry has been a large water user. Water is
usedas an ingredient, an initial and intermediate cleaning source, an efficient
transportationconveyor of raw materials, and the principal agent used in sanitizing plant
machinery andareas. Although water use will always be a part of the food-processing industry, it
has becomethe principal target for pollution prevention and source reduction practices. The key
environmental issues for the meat processing industry primarily deal with its wastewater and
solid waste. Primary issues of concern for its wastewater are biochemical oxygen demand
(BOD), total suspended solids (TSS) and excessive nutrient loading. On the other hand, primary
issues of concern for its solid waste include both organic and packaging waste.

For this specific course, we will be focusing on the industry’s wastewater management
system and practices. Our featured meat processing and packaging company is King’s Quality
Foods Inc. The company is one of the leading food processing and distribution organization in
the country with its main plant located in Paknaan, Mandaue City, Cebu. Our objective is to
propose a new and improved wastewater treatment scheme for their production wastewater
which has high nutrient loading and high levels of fats, oils, grease and other insoluble matter.
We wish to design a system that will achieve an effluent meeting DENR Class C standards and a
scheme to recycle their treated wastewater for other plant uses. Basically, the primary goal of this
project is to design and strategize an improved wastewater treatment facility to attain zero
discharge. Additionally, we will be developing a pollution prevention/cleaner production
program, and a feasible environmental management system for King’s Quality Foods Inc.

4
 Chapter 2
Review of Existing Industries and Manufacturing Facilities
2.1 Overview of the Meat Processing Industry and Its Major Products
The meat processing industry is composed of several animal disassembling facilities
which slaughter, break down the animal body into smaller portions, and process the meat for
consumer consumption or further processing. This industry is also composed of several other
meat processing firms, which do not slaughter the animals but manufacture a wide range of fresh
or frozen products and sells for grocery chain stores, meat distributors, wholesalers, restaurants
and hotel chains, foodservice, and further processors as well. These slaughter facilities, also
known as packers, are usually specialized in one or two species such as beef, pork, lamb, veal,
chicken, and turkey. They sell their products as carcass, boxed cuts, case-ready cuts for retail,
portioned whole muscle, portioned formed product, ground patties, whole bird and poultry parts.
On the other hand, meat processing and packing plant will often undertake the cooking, curing,
smoking and pickling of meat and the manufacture of variety of hams and sausages.

Processed meats include bacon, sausage, hot dogs, sandwich meat, packaged ham,
pepperoni, salami and virtually all red meat used in frozen prepared meals. Processed meat
products can be classified according to the processing technology applied. Presented in Figure
2.1 is a classification of processed meat products.

Figure 2.1 Classification of processed meat products.

5
 Fresh processed meat products are meat mixes composed of comminuted muscle meat
with varying quantities of animal fat. Products are salted only, curing is not practiced. Non-meat
ingredients are added in smaller quantities for improvement of flavour and binding, in low-cost
versions larger quantities are added for volume extension. All meat and non-meat ingredients are
added fresh (raw). Heat treatment (frying, cooking) is applied immediately prior to consumption
to make the products palatable. If the fresh meat mixes are filled in casings, they are defined as
sausages (e.g. frying sausages). If other portioning is customary, the products are known as
patties, kebab, etc. Convenience products, such as chicken nuggets, have a similar processing
technology and can also be included in this group. In contrast to the rest of the group, chicken
nuggets etc. are already fried in oil at the manufacturing stage during the last step of production.

Cured meat cuts are made of entire pieces of muscle meat and can be sub-divided into
two groups, cured-raw meats and cured-cooked meats. The curing for both groups, cured-raw
and cured-cooked, is in principle similar: The meat pieces are treated with small amounts of
nitrite, either as dry salt or as salt solution in water. The difference between the two groups of
cured meats is: (a) Cured-raw meats do not undergo any heat treatment during their manufacture.
They undergo a processing period, which comprises curing, fermentation and ripening in
controlled climatized conditions, which makes the products palatable. The products are
consumed raw/uncooked.; (b) Cured-cooked meats, after the curing process of the raw muscle
meat, always undergo heat treatment to achieve the desired palatability.

The product components of raw-cooked meat products are muscle meat, fat and non-meat
ingredients which are processed raw, i.e. uncooked by comminuting and mixing. The resulting
viscous mix/batter is portioned in sausages or otherwise and thereafter submitted to heat
treatment, i.e. “cooked”. The heat treatment induces protein coagulation which results in a
typical firm-elastic texture for raw-cooked products. In addition to the typical texture the desired
palatability and a certain degree of bacterial stability is achieved.

Precooked-cooked meat products contain mixes of lower-grade muscle trimmings, fatty

tissues, head meat, animal feet, animal skin, blood, liver and other edible slaughter by-products.
There are two heat treatment procedures involved in the manufacture of precooked-cooked
products. The first heat treatment is the precooking of raw meat materials and the second heat
treatment the cooking of the finished product mix at the end of the processing stage. Precooked-

6
cooked meat products are distinguished from the other categories of processed meat products by
precooking the raw materials prior to grinding or chopping, but also by utilizing the greatest
variety of meat, animal by-product and non-meat ingredients.

Raw-fermented sausages are uncooked meat products and consist of more or less coarse
mixtures of lean meats and fatty tissues combined with salts, nitrite (curing agent), sugars and
spices and other non-meat ingredients filled into casings. They receive their characteristic
properties (flavour, firm texture, red curing colour) through fermentation processes. Shorter or
longer ripening phases combined with moisture reduction (“drying”) are necessary to build-up
the typical flavour and texture of the final product. The products are not subjected to any heat
treatment during processing and are in most cases distributed and consumed raw.

Dried meat products are the result of the simple dehydration or drying of lean meat in
natural conditions or in an artificially created environment. Their processing is based on the
experience that dehydrated meat, from which a substantial part of the natural tissue fluid was
evaporated, will not easily spoil. Pieces of lean meat without adherent fat are cut to a specific
uniform shape that permits the gradual and equal drying of whole batches of meat. Dried meat is
not comparable to fresh meat in terms of shape and sensory and processing properties, but has
significantly longer shelf-life. Many of the nutritional properties of meat, in particular the protein
content, remain unchanged through drying.

2.2 Meat Processing Industry in the Philippines and Implemented Policies

The country is a net exporter of processed meat products. In 2013, the industry generated
US$ 47.3 million in exports. The local industry imports around 85% of its raw material inputs. In
terms of finished processed meat, majority of its output meets domestic demand. Major export
markets include the United Arab Emirates, Qatar, Saudi Arabia, Kuwait, Japan, the United States,
Canada, Guam, and Taiwan. The market for meat, fish and poultry in Philippines increased at a
compound annual growth rate of 0.9%. The frozen meat products category led the meat, fish and
poultry market in Philippines, accounting for a share of 51%.There are 175 meat processors in
the country, majority of which are located in the National Capital Region, Region III, and Region
IV-A[ CITATION Eur16 \l 3081 ].

7
 According to R.A. 9296, also known as the Meat Inspection Code of the Philippines,
places such as poultry dressing plants, meat cutting plants, meat processing plants, cold storage
warehouses, and slaughterhouses all fall under the title of a meat establishment. As of 2013, the
National Meat Inspection Service (NMIS) has accredited 137 slaughterhouses, 116 poultry
dressing plants, 264 meat-processing plants, 42 meat-cutting plants, and 98 cold storage
warehouses.

Within these meat establishments, the animal is broken down into specific cuts, leaving
behind a carcass, before being sent to the shipper. Cuts usually go to institutional buyers such as
restaurants and hotels, while the carcasses are sent to the wet markets and supermarkets.
Supermarkets receive a bulk of the cattle and poultry from AAA and AA meat establishments.
AAA means that the establishment has been approved and registered by the National Meat
Inspection Services (NMIS) and the respective local government unit. An AAA establishment
can distribute its meat through both domestic and international channels. The AA establishments
have a smaller reach, only able to distribute their meat between provinces or within the province
or city. The lowest label for a meat establishment is the single A, where in the slaughterhouse
may only distribute within the city or municipality of its location.

Unlike AAA establishments, unaccredited slaughterhouses and wet markets usually do

not observe the hygienic slaughtering and handling of the meat. Usually, pigs are hit with a pipe
instead of being stunned, and carcass splitting is done on the floor rather than the recommended
(and more hygienic) practice of hanging the pig above a table. According to the guidelines on
good hygienic slaughtering practices for locally registered meat establishments, the carcass must
be hanging on a rail or placed on top of clean surfaces while being cut. Wet markets also tend to
receive frozen meat meant for supermarkets, hotels, and restaurants, but they lack the proper
storage facilities for these items.

There is no (non-endangered) animal illegal to eat per se, apart from dogs and cats, as
long as these slaughterhouses follow the hygienic practices and guidelines required by law. The
NMIS has even drafted a guideline for the hygienic slaughtering of crocodile, as there are
crocodile farms in Palawan, Cagayan de Oro, and Rizal. Horsemeat is also considered a legal
food animal, but is site specific to markets in Malabon.

8
 Because meat is so prone to bacterial diseases, most governments have strict sanitation
regulations for their respective countries' meat packing facilities. These include frequent
inspections, mandatory cleaning procedures of equipment, and disease prevention measures
among still-living livestock. As the global demand for meat increases, meat producers must be
extra careful to keep fast-moving equipment clean and their animals disease-free.

The Meat Inspection Code of the Philippines, as one among country’s strict law on
protecting the right to health of the people, defines meat and meat product’s safety guidelines and
procedures from production to consumption. NMIS an attached agency of the Department of
Agriculture, is tasked to serve as the national controlling authority on all matters pertaining to
meat and meat product inspection and hygiene. The National Meat Inspection Service
promulgates and implements policies, procedures, guidelines, rules and regulations governing
post-production flow of livestock and meat and meat products (both locally produced and
imported) through the various stages of marketing and proper handling, inspection, processing,
storage and preservation of such products. It protects the interest, health, and general welfare of
the meat consuming public and is responsible for the development of the livestock and meat
industry.

Figure 2.1The different possible paths meat is bought and sold

9
2.3 Meat Processing Companies in Cebu

In Cebu, the top three meat processing and packing companies are Virginia Foods Inc.,
Sunpride Foods Inc., and King’s Quality Foods Inc. Virginia Foods, Inc. originally Virginia
Farms Inc., is a locally started family business with its expansion from animal farming to meat
processing. At present, the company is engaged in manufacturing, distribution, and selling of
processed meat products. It caters to consumers nationwide with bigger concentration in the
Visayas and Mindanao area. Virginia Food, Inc. is continuously improving their manufacturing
facility located in Compostela, Cebu. Among many new developments, the company has
recently invested in a new cold storage facility in the quest of providing customers with the
highest and most dependable quality products.

Sunpride Foods Inc. is a fully integrated meat processor with operations covering
slaughtering and preparation, all the way to the production of frozen processed meats, canned
products, and flavour mixes under the brand names Holiday, Sunpride, Goodmorning, Shoppers
and Kassel. These products are manufactured with its highest quality and top consideration of its
affordabilityto the consumers. Likewise, they cater slaughtering and blast freezing services to its
numerous business partners. Their facilities are strategically located in a 4-hectare, industry-
compliant, and AAA-accredited compound in Paknaan, Mandaue which include: the SFI
Slaughterhouse; the SFI Food Processing Plant that occupies one third of the premises; and the
SFI Main Business Office.

Lastly, King’s Quality Foods Incorporated is fast a growing and competitive meat
processing company. As of 2016, the company is still celebrating its 60 years in the business. The
company is the well-known maker of King’s Longaniza Hamonada and other breakfast products
such as Cooked Ham, Pork Tocino, Premium and Honeycured Bacon. King’s Quality Foods Inc.
is a multi-brand food processing and distribution organization with its plant located in Paknaan,
Manadue City, Cebu.

Among the companies mentioned, our featured company is King’s Quality Foods Inc.
The rationale for choosing such company is that it is one of the country’s fast growing meat
processing companies and distribution organizations and its convenient plant location. Because it
is fast growing, we would want to gain a more knowledge on how the company copes up with

10
the local demand for meat products, how they maintain their product quality, how they comply
with health, safety and environmental standards for their products and plant processes, and lastly
how they manage their wastes. With this actual knowledge in mind, we would like to make a
comprehensive report about their existing manufacturing process and wastewater management
system. In line with this, we would then be proposing a concept for an improved wastewater
treatment facility for their plant.

Figure 2.2 Leading products of King’s Quality Foods Inc.

King’s Quality Foods Inc. is GMP certified, HACCP certified and “AAA” certified. Good
Manufacturing Practice Certification means that the company or plant site and its employed
process methods in the production of its products have been subject to a thorough control
investigation and is certified to be in compliance. On the other hand, the HACCP or Hazard
Analysis and Critical Control Points Certifications means that the company complies with the
food safety requirements to address and prevent biological, chemical, and physical hazards in
production processes and product distribution systems.

The company’s vision is to be the Top 3 meat processing company offering premium
quality and affordable products available in Visayas and Mindanao by 2020. They plan to
achieve this vision by consistently and continuously growing its strong distribution network of
branches and presence in the HRI (hotels, restaurants and institutions) and modern trade markets.

11
 Chapter 3
Details of Manufacturing Process

3.1 General Steps in Meat Processing

After slaughtering and cutting up the animal, the next crucial step is to cool the meat until
it is processed further. Depending on the local circumstances, the meat is transported to the next
processing station in either cooled or frozen form. There, the processes of mincing, cutting,
smoking, simmering, and maturing (depending on whether dry sausage, boiled sausage, or
cooked sausage is being produced) play differing roles. For example, a cooking stage when
producing dry sausage does not exist. Presented below are the general steps employed in meat
processing operation.

1. Cooling

The pH value of meat is considered to be so important because it has a major effect on the meat's
quality factors. The pH value allows conclusions to be drawn on the color, softness, taste, water
binding capacity, and shelf life. This is because, once the animal has been slaughtered,
biochemical processes start to break down the meat and will influence the pH value. Measuring
this value allows you to obtain information about the speed of these processes and the quality of
the meat.

2. Mincing
Mincing is a fundamental process in the meat processing industry. It is carried out using special
devices of different sizes, ranging from manually operated mincers to large industrial versions. It
is important that meat is not exposed to major temperature fluctuations, particularly not in the
range above 7 °C. This is why the cooling chain needs to be ensured when mincing and
additional cooling must be provided if required.

3. Cutting
Vacuum cutters are ideal for ensuring meat has a better color and for cutting the meat more
effectively. The use of a vacuum cooking cutter also means that the separate simmering of the

12
meat is unnecessary, as is the case when producing cooked sausage. Temperature plays a key role
in these devices since it is instrumental in determining the ultimate quality of the sausage .

4. Curing
In its simplest form the word ‘curing’ means ‘saving’ or ‘preserving’ meat and the definition
covers preservation processes such as: drying, salting and smoking. When applied to home-made
meat products, the term ‘curing’ usually means ‘preserved with salt and nitrite.’ When this term
is applied to products made commercially it will mean that meats are prepared with salt, nitrite,
ascorbates, erythorbates and dozens more chemicals that are pumped into the meat. Meat cured
only with salt, will have a better flavor but will also develop an objectionable dark color. Factors
that influence curing:

5. Stuffing
Meat plants need a machine that will stuff, link and portion sausages in one cycle. Sausages must
be of the same length and weight otherwise it would be impossible to estimate costs and run the
business. Such machines are very expensive and can stuff thousands of pounds of sausage in one
hour. The piston is powered by hydraulic pressure and the machine is controlled with a foot or a
knee.

6. Heat Treatment
The heating parameters to be applied in meat processing can vary considerably in temperature
and time depending on the type of product. Heat treatment methods cause various physical-
chemical alterations in meat, which result in the beneficial sensory and hygienic effects on the
processed products. Smoking, drying, and salting of meat and meat products are one of the oldest
methods of food preservation. Smoking has been traditionally used for shelf life extension and
development of the typical sensory flavor associated with smoked meats. Sausages and other
meat products are smoked for flavor and color development and to preserve the product.

7. Maturing/Storing/Drying
When producing dry sausages, the maturing/ drying phase plays the most important role of all.
The products must be dried until they have a residual water content that complies with food

13
regulations. Here, it is important that the water is released evenly and not too quickly, otherwise
a high-quality end product cannot be guaranteed. To prevent drying errors, the relative humidity
must be in balance with the aw value of the dry sausage when drying starts. In addition, the
relative humidity must only be lowered slowly to allow the water to escape from the inside to the
outside of the sausage.

8. Tumbling
Tumbling is a process that mixes and moves the meat. This process generally needs to be
performed below a certain threshold temperature. In the meat processing industry – particularly
so for producing cooked ham – the correct temperature is essential to guarantee that the end
product has the best possible quality

9. Autoclaving
A long-established method of preserving sausages is to boil them in a container. Sausages
processed in this way are filled into sealed vessels (jars or tins). They are then placed in an
autoclave to preserve the product.

3.2 General Equipment used in Meat Processing

1. Meat grinder (mincer)

The meat grinder is a sausage making tool
that forces meat scraps under high pressure
along a horizontally mounted cylinder with
sharp-edged ribs through a series of holes in a
perforated plate. As the compressed meat
extrudes through the holes in the plate, a
revolving four-bladed knife cuts it. The
perforated plate has round holes ranging from
1 to 13 mm. The degree of comminution is
most of all determined by the choice of the
hole-diameter in the perforated plates.

14
 Figure 3.2.1. Meat Grinder

3. Mixer
Mixers are primarily used in obtaining a well-blended mix of ground meat, fat and spices for
coarse-ground sausages. Mixing under a partial vacuum has some advantages, especially in the
preparation of dried sausages. The machine generally consists of a rectangular round-bottom
vessel through which run two parallel shafts equipped with wing-shaped paddles agitating the
meat mass back and forth to give a uniform distribution of fat and lean particles, spices and other
ingredients. Discharge is usually by tilting the mixer 90 degrees. Overloading the mixer prevents
good mixing.

4. Tumbler (massager)
Tumbling, on the other hand, is a more rigorous physical treatment and involves the impact
energy from forcing meat pieces to fall from the top of a rotating drum. It has been suggested
that the meat needs to drop at least three feet in a rotating tumbler to get the maximum effect.
The rigorous tumbling action causes foaming of the exudate which suggests the need for
vacuumizing the tumbler contents. There are also two basic types of tumblers: the rotating drum
and the end-over-end tumbler. The rotating drum is gentler in treatment and uses less space per
volume of capacity.

5. Cutter (chopper)
Cutters are designed to comminute meat materials very finely by revolving them in a bowl with
rapidly rotating knives. Modern cutters usually have dual-speed knives and a variable bowl
speed; they are often equipped with a special device for emptying the bowl as well as a
thermometer over the bowl to help in controlling meat temperature during chopping. They can
operate under vacuum which contributes to a better colour and improves the water binding
capacity of the meat.

6. Emulsifying mill
In recent years, new equipment such as an emulsifying mill has been designed for preparing meat
emulsion. The emulsifying mill has proved itself in the meat processing industry all over the

15
world. It usually includes a perforated plate on which a two-edged blade rotates, i.e. cutting knife
or knife rotor. Immediately below the plate is a centrifugal pump that forces material through the
perforated plate. Compared to the cutter, the emulsifying mill operates at a much higher speed,
producing a finer emulsion. Normally, the emulsion is ready for stuffing by one passage through
the machine.

Figure 3.2.2. Stainless Steel Colloid mill/Emulsifying and Grinding Machine

7. Frozen meat cutting machines

The most common machines for cutting frozen meats are guillotines and rotting cutting
machines. Guillotines are relatively simple, not too expensive space-saving cutting devices that
can be adjusted to give different thicknesses of meat cuts. Machines operating on the blade-
rotating principle are cutters, flakers and dicing machines. Cutters can produce a desired uniform
size reduction of the frozen raw material (meat or fat) without smearing it. Flakers are equipped
with beak-shaped cutting blades to chip or peel off the frozen meat block into flakes. The dicing
machines are used in the manufacture of cooked sausages for giving a dice-or disc-shaped form
to different raw materials.

16
 8. Stuffer
There are two well-known and proved systems used for stuffing of the emulsion in casings or in
other containers. First, the piston stuffer is a cylinder, equipped with an easily movable cover and
a piston moving upward pushing the mix into the casing through a stuffing tube or horn of
suitable size. The larger the diameter of the stuffing horn, the lesser will be the smearing of the
mix. Attachments (twist-off or dividing devices) are provided to permit stuffing of desired
amounts of sausage mix in the production of small, uniform-weight sausages. The second system
of stuffing the meat emulsion or mixture into casings is the continuously-working stuffing
machine. This type of stuffer has a great advantage for large-scale producers: its filling funnel
may be refilled without stopping the machine.

Figure 3.2.3. Meat Stuffer

17
 9. Linker
Linking of filled casings by hand is done on a
stuffing table; this manual operation is particularly
practised for large diameter sausages.
Semiautomatic clipping machines are also available
to close the end of large diameter sausages. Linking
machines tie the stuffed small-and medium-diameter
casings (with thread or twist) into units of desired
uniform length; this method greatly reduces the
labour cost when the size of operation justifies its
use. Machines that stuff and link are today the
accepted practice in medium- and large-scale
production. After the sausages have been linked,
Figure 3.2.4. Sausage Linker
they are placed on rods which are hung either on
racks or cages suspended from overhead rails or
upon trucks.
9. Smokehouse
There are two basic types of smokehouse: the simple or natural-air-circulating smokehouse and the modern or air-conditioned
located either outside or directly inside the smokehouse at one end. In any case, the circulation should be so directed that the
humidity is controlled by steam injectors or by varying the amount of outside air introduced into the smokehouse. Air temperat

18
 10. Cooker
Cooking of sausages, particularly the large kind
can be done by submerging them in hot water in
steel tanks or in a steam-jacketed round-bottomed
kettle. To avoid heat loss and shrivelling,
sausages that are not cooked in the smokehouse
should be moved immediately after smoking to
the cooker. Another method, used for small-
diameter sausages, is cooking in special cooking
cabinets; after cooking, sprays of cold water chill them to an internal temperature slightly above
room temperature.

19
 Chapter 4
Details of Waste Management Processes

4.1 Nature and Characteristics of Industrial Wastes

The generation of wastewater in the food industry is inevitable. Wastewater effluents
from a meat processing industry are usually organic in nature. They emit odors caused by the
decomposition of protein and lipid organic matter. In compliance to R.A. 9275 Philippine Clean
Water Act of 2004, the company is required to treat their generated wastewater prior to disposal.
This comes along with both economic and environmental effects.

The important characteristic that need to be identified in order to determine the treatment
methods for the wastewater are total volume produced daily and the water characteristics such as
total suspended solids, biological oxygen demand and fats, oils and grease.

King’s Quality Food, Inc. produced 105.84 – 120 m3 of wastewater a day. The table
below summarizes the wastewater characteristics of the company.

Table X. Wastewater Characteristics of King’s Quality Food, Inc. (2016)

Influent Effluent
Parameter
July July August September October Average Min Max
DO (mg/L) - 7.9 6.6 4.5 9.6 7.15 4.5 9.6

BOD (mg/L) 290 1.4 12 2.3 25 10.18 1.4 25

COD (mg/L) 775 47 67 59 159 83 47 159

TSS (mg/L) 433 1 13 9 43 16.5 1 43

True Color (CU) 300 5 20 15 25 16.25 5 25

Oil and Grease

26.3 0.1 1.9 1.3 6.3 2.4 0.1 6.3
(mg/L)
pH 6.4 8.56 8.57 8.18 8.1 8.35 8.1 8.57

4.2 Baseline Data and Methodology on Acquisition of Baseline Information

Include influent and effluent data
Range of influent volumetric flow rates (volume of wastewater treated daily; daily/hourly
volumetric flow rate of influent)

20
 Space Availability for WWTF
4.3 Process Equipment/ Technology and Materials of Construction Selection Criteria
4.3.1 Process Equipment Selection

In this project, the designers will either be replacing or adding a new process step or equipment
to improve the wastewater treatment system of a meat processing and packing plant. In line with
this, the designers have set a criteria for selection of the process technology/equipment to be
employed in the new design for logical and critical evaluation of the said proposal. Presented in
Table X is a criteria for process equipment selection. Additionally, presented in Table X is a
rating guideline for fair assessment and evaluation of considered process
technologies/equipment.

Table 4.3.1. General Criteria for Equipment/Process Technology Selection

Factors Description Weight

Technological Maturity
Capital and Operating Cost and It is desirable that the capital cost for
Energy Utilization
Space Requirement
Equipment Efficiency
Scientific background of the technology is
well-understood. One of the key indicators
of a mature technology is the ease of use
for both small-scale and industrial-scale
operation. A mature technology is a 20%
technology that has been in use for long
enough that most of its initial faults and
inherent problems have been removed or
reduced by further development.
installing the technology or needed
equipment is low. Operating and
maintenance cost must be reasonable. Cost
consideration include the initial cost of
purchase and the life cycle costs of 20%
equipment. Life cycle costs include
maintenance, replacement, demolition and
disposal of the equipment.
Minimal land space is desired since the
wastewater treatment facility land area is 30%
very limited.
Technology must produce high percent
removal of BOD, TSS and FOG at the
shortest amount of time possible. 30%

21
 TOTAL: 100%

Table 4.3.2. Rating Guideline for the Evaluation of Considered Process Technologies/Equipment

Criteria
Factors 1 2 3
(Undesirable/unsuitable) (Moderately desirable/ (Very desirable/Suitable)
Suitable)
Technological  Few available  Considerable data  Numerous data
Maturity literature and literature and literature
 Not yet tested in available to available and
large scale support operation and
treatment technological design of
 Relatively new efficiency and equipment has
and still claims already been
developing  Has been used in optimized
some industries  Has been used in
successfully many industries
 Has been existing successfully for a
and been used in long time
the industry for
some time
Capital and  High costs for  Moderate costs  Relatively low
Operating purchase, associated with costs associated
Cost and construction and the purchase with the
Energy installation construction and purchase,
Utilization  High costs installation construction and
required for  Moderate costs installation
power, required for  Relatively low
maintenance power, costs required for
requirements and maintenance power,
additional raw requirements and maintenance
materials that additional raw requirements and
might be needed materials that additional raw
might be needed materials that
might be needed
Space  Requires a large  Requires a  Requires a small
Requirement area for relatively amount of space
construction moderate amount for construction
additional of space for and for the
supporting construction and additional
equipment for for the additional supporting
pre-reatment or supporting equipment
further treatment equipment

22
Equipment  Low removal  Moderate removal  Very high
Efficiency efficiencies efficiencies (70- removal
(FOG (<70%) or 90%) and requires efficiencies
Removal) requires long a moderate (>95%) with
residence times amount of time short residence
times

4.3.2. Selection of Materials of Construction

Material selection for construction in engineering equipment is a critical aspect of design. The
choice of material poses major influence on performance, safety, reliability, cost and life of
equipment. For the design of the modified grease trap, induced air flotation unit, flow
equalization tank and storage tank (for recycle), the following criteria will be considered in
choosing the best suited materials of construction.

Table 4.3.3. Selection Criteria for Material of Construction

Consideration/Factor Description Weight

Compatibility and Resistance
to Corrosion
Material Strength and
Structural Capability
Ease of Fabrication and
Construction
Material Sources and
Availability
Installation and Maintenance
The material must be resistant to chemicals
or other solvent/chemical reactions and
abrasiveness, compatible with the type of 30%
wastewater contained in the vessel and has
low corrosion rate.
The chosen material for construction must
be adequately strong to withstand pressure
differences between the equipment interior
and exterior environment, and sudden
30%
changes in flowrate. The material selected
must be able to support the loads imposed
on the vessel over the whole length of its
use.
The materials must be easily fabricated and
must be flexible for on-site or prefabricated
construction. Complicated installations with
10%
close tolerances can result in greater wastage
or even rework being required and will not
be desired.
The source of materials must be considered
to keep transport costs and resultant
emissions to a minimum. Additionally, it is 10%
desired that material is readily available to
avoid delays and construction hold-ups.
Installation and maintenance cost must be 20%

23
Cost reasonable. Cost consideration include the
initial cost of purchase and the life cycle
costs of materials. Life cycle costs include
maintenance, replacement, demolition and
disposal.
TOTAL: 100%

4.4 Detail of Unit Operations and Processes

4.4.1. Existing Wastewater Treatment Process Scheme

Figure 4.4.1. Existing Wastewater Treatment Process Scheme of King’s Quality Foods Inc.

24
4.4.2. Proposed Wastewater Treatment Process Scheme

INSERT INTRODUCTION/OVERVIEW ON THE PROPOSED WWTF

25
 and pretreatment is
required to initially
minimize the FOG
material levels; not
practical for full-
scale industrial
operation
*requires prior treatment or should be used in conjunction with other primary treatment systems

Using the general criteria for equipment/process technology selection and rating
guideline for the evaluation of considered process technologies/equipment shown in Table X and
X, the considered primary treatment systems are rated accordingly.

Table 4.4.2. Rating Evaluation of the Considered Primary Treatment Systems

Chemical
Grease Gas Biological
System coagulation and Filtration
Trap Flotation Treatment
sedimentation
Technological
3 (0.6) 3 (0.6) 3 (0.6) 2 (0.4) 2 (0.4)
Maturity (20%)
Capital and
Operating Cost
2 (0.4) 1 (0.2) 1 (0.2) 1 (0.2) 1 (0.2)
and Energy
(20%)
Space
Requirement 2 (0.6) 2 (0.6) 2 (0.6) 2 (0.6) 2 (0.6)
(30%)
Equipment
Efficiency 1 (0.3) 3 (0.9) 2 (0.6) 2 (0.6) 2 (0.6)
(30%)
Total (100%) 1.9 2.3 2.0 1.8 1.8

As presented in Table X, the systems that have acquired the highest rating evaluation are
the gas flotation and grease trap systems. Both of these systems will be considered in this design
report, especially since the company is already employing a grease trap system.

In this design report, the designers intend to incorporate a gas flotation system with the
current wastewater treatment facility of the company for optimal removal of total suspended
solids. However, it is noted that the available space is limited. In order to integrate the two

28
systems, the designers propose to modify the grease trap system and add a gas flotation system
which will serve as a befitting design for the company.

As for the secondary treatment, the available SBR units of the company will still be
utilized. However, in order to regulate the flowrate and water composition of the water effluent
of the gas flotation system, an equalization tank shall be designed to situate prior to the SBR
units.

One of the goals of the company is recycling 20% of the treated water for other uses such
as washing lavatories or equipment. To address this goal, the designers proposed to design a
storage tank that will contain the water to be recycled, since this is currently not yet available in
the company.

29
4.4.2.1. Screen
The removal of relatively large solids (0.7 mm or larger) can be achieved by screening.
Screening is one of the cheapest and simplest wastewater treatment steps used in food processing
plants. Flow-through static screens with openings around 1-mm are among the most popular
configurations.

4.4.2.2. Modified Grease Trap

 Grease Trap Functions

Meat processing facilities produce wastewater with heavy loads of fats, oils, grease and
solids. Before sending that water down the sewer drain, pre-treatment is required to remove as
much of these solids and oils as possible.

 Grease Trap Operation (Equipment Mechanism)

Solids in the wastewater that do not float will be deposited on the bottom of the grease
trap and will need to be removed during routine grease trap cleaning. Oil and grease floats on the
water surface and accumulates behind the baffles, displacing the wastewater from the middle of
the grease trap and into the sanitary sewer or septic system. Air relief is provided to maintain
proper air circulation within the grease trap. Typically, it can remove 85-90% FOG.

 Maintenance Practices
The ability of oil water separators to function properly depends upon the timely
performance of required service and maintenance. Frequent inspections should be made of the
system and all associated piping, valves, etc. to prevent operational and mechanical failures or
inefficiencies. Sludge and oil need to be periodically removed from the oil/water separator to
keep it operating properly (About 25% full).

 Grease Trap Design Issues

Passive grease traps and grease interceptors do not control the inflow of wastewater.
Conventional grease traps do not have enough time to separate FOG from the wastewater
(retention time) resulting to low efficiencies. When the grease trap is full of grease sludge the
trap is incapable of capturing any grease or solids.

30
  Selection of Grease Trap Type and Configuration
Grease interceptors typically come in one of two basic types. The first type is called a
hydromechanical grease interceptor (HGI), previously referred to as a grease trap. These are
prefabricated steel manufactured units, predominately located indoors at a centralized location in
proximity to the fixtures served or at the discharging fixture point of use. They are relatively
compact in size and utilize hydraulic flow action, internal baffling, air entrainment, and a
difference in specific gravity between water and FOG (fats, oils, and grease) for the separation
and retention of FOG from the fixture waste stream. The second type is the gravity grease
interceptor (GGI). These are engineered, prefabricated, or field-formed concrete constructed
units that typically are located outside due to their large size and receive FOG discharge waste
from all required fixtures within a given facility. These units essentially utilize gravity flow and
retention time as the primary means of separating FOG from the facility waste stream prior to it
entering the municipal drainage system [CITATION Ame12 \l 13321 ].

Table X. Rating Evaluation of Considered Types of Grease Interceptors

Rating
Criteria
HGI GGI
Technological Maturity (20%) 1x 0.2= 0.2 3x0.2=0.6
Capital and Operating Cost and Energy 2x0.2= 0.4 3x 0.2= 0.6
Utilization (20% )
Space Requirement (30% ) 3x0.3= 0.9 2x0.3= 0.6
Equipment Efficiency (FOG Removal) (30% ) 3x 0.3= 0.9 2x 0.3=0.9
TOTAL 2.4 2.7

HGIs are typically used for indoor and smaller scale treatments where its typical capacity
is 20 – 50 gallons per minute, can only store 40 – 100 pounds of FOG and are 15 – 60 gallons in
volume. For this reason, it was given a rating of 1 in the technological maturity aspect since
wastewater volume discharge of the chosen company exceeds these ranges thus making the HGI
an unsuitable choice. Thus, for large scale wastewater treatment, the gravity grease interceptor
would be appropriate.

31
  Selection of Material of Construction

In the industry, the common types of materials used in the construction of gravity grease
interceptors are reinforced concrete, plastic and protected steel. However, since the grease
interceptor to be designed is of industrial scale and will be located outdoors, plastic will not be
considered. Presented in Table X is a comparison between the different types of materials
commonly used for the construction of grease interceptors comparing the material’s strength,
corrosion and thermal shock resistance, ease of fabrication and construction, material
availability, and cost. Lastly, presented in Table X is the rating sheet for evaluating which type
of material is the most suitable for the given set of operating conditions (environment) of the
system and type of wastewater considered in the process. Using the selection criteria for
materials of construction, the most suitable type of material to be used in constructing a flow
equalization tank is reinforced concrete.

Table X. Equalization Tank Material of Construction Comparison

Type of material
Property/Characteristic
Reinforced Concrete Steel
Yield Strength 7,000 psi 36,000 psi
Fatigue Strength 6,500 psi 24,000 psi
Corrosion Resistance High Moderate
Thermal Shock Resistance High High
Ease of Fabrication and Construction Moderately Easy Difficult
Material Sources and Availability High Moderate
Installation and Maintenance Cost Moderate High

Table X. Rating Sheet: Equalization Tank Material of Construction

Type of Material
Consideration/Factor Reinforced
Steel
Concrete
Compatibility and Resistance to Corrosion 28% 22%
Material Strength and Structural Capability 27% 30%
Ease of Fabrication and Construction 8% 7%
Material Sources and Availability 9% 7%
Installation and Maintenance Cost 16% 13%
TOTAL: 88% 79%

Reinforced concrete (RC) is a composite material in which concrete's relatively low

tensile strength and ductility are counteracted by the inclusion of reinforcement having higher

32
tensile strength or ductility. Reinforcing schemes are generally designed to resist tensile stresses
in particular regions of the concrete that might cause unacceptable cracking and/or structural
failure. Modern reinforced concrete can contain varied reinforcing materials made of steel,
polymers or alternate composite material. Generally, reinforced concrete has high relative
strength and toleration of tensile strain, excellent thermal compatibility and durability, and high
material stability.

Gravity grease interceptors commonly are made of 4-inch (101.6-mm) minimum

thickness concrete walls, with interior concrete barriers that act to sectionalize the interior into
multiple chambers that dampen flow and retain FOG by flotation [ CITATION Ame12 \l 13321 ].
Application of reinforced concrete is more labor intensive to use but after curing, the reinforced
concrete is strong and resistant to UV, weathering, punctures, and cracking. On average, a
concrete-lined basin has a service life of over 60 years. To keep the stability and performance of
the equipment, the basin should be inspected regularly to identify any necessary repairs due to
environmental stress cracking. Small concrete repairs can be performed relatively easily with
grout when the basin is not in service. It should be noted that frequent cleaning of the
equalization tank will help mitigate odor issues, sediment accumulation, and weed growth in the
reinforced concrete.

 Gravity Grease Interceptor Design and Equipment Specifications

Gravity grease interceptor is a type of grease interceptor with the main purpose of
collecting fats, oil and grease from wastewater, preventing the deposition of pipe – clogging
grease in the wastewater treatment equipment to follow. These are typically located outside due
to larger size. The primary means of separating FOG is essentially dependent on the gravity flow
and retention time. The standard for construction and design of gravity grease interceptors is
IAPMO/ANSI Z1001: Prefabricated Gravity Grease Interceptors. The design typically
incorporates two or more compartments in series and uses its larger volume of water to slow
down the flow of velocity, allowing time required for the buoyancy of FOG to cause separation.

It operates on the principle of separation by flotation alone where the performance of the
system depends on the difference between the specific gravity of the wastewater and that of the

33
grease where rate of separation increases with a larger difference between the two. Since the
grease globules’ rise rate is inversely proportional to the viscosity of the wastewater, the rate of
separation will be faster when the carrier fluid is less viscous and vice versa.

When designing the ideal separation basin, four parameters dictate effective FOG
removal from the water: grease/oil droplet size distribution, droplet velocity, grease/oil
concentration, and the condition of the grease/oil as it enters the basin. The ideal separation basin
is one that has no turbulence, short-circuiting, or eddies. The flow through the basin is laminar
and distributed uniformly throughout the basin’s cross-sectional area. The surface-loading rate is
equal to the overflow rate. Free oil is separated due to the difference in specific gravity between
the grease/oil globule and the water. Other factors affecting the design of an ideal basin are
influent concentration and temperature.

 Gravity Grease Interceptor Sizing Calculation

Assumptions
Gravity separation permits the removal of particles that exhibit densities different from
their carrier fluid. Separation is accomplished by detaining the flow stream for a sufficient time
to permit particles to separate out. Separation, or retention, time (T) is the theoretical time that
the water is held in the basin. A basin must be designed such that even if the grease/oil globule
enters the chamber at the worst possible location (at the bottom), there will be enough time for
the globule to rise the distance needed for capture. By heuristics, the retention time normally
expected for the grease to separate by buoyancy is 30 minutes. The sizing of the gravity grease
interceptor will be carried out using the peak flowrate method. For the geometry, the interceptor
will be designed as a rectangular basin.

Heuristics

A grease trap is most commonly a two-chambered tank positioned along the wastewater
drain pipe. Wastewater slows down as it moves through the compartments of the trap, allowing
time for less dense material to separate and rise to the liquid surface. Liquid and solid grease as
well as light waste particles will be held in the trap while the wastewater below passes out. The
minimum requirements for the grease trap design are as follows:

34
 The length of the trap should be equal to between 1.3 – 2 times the total depth where the
grease trap contents would only occupy 2/3 of the total depth and the remaining 1.3 of the trap is
the head space. The surface area of the trap should be equal to between 1000 – 2000 times the
total depth measured in millimeters. [CITATION Placeholder1 \l 13321 ]

Sizing Calculations

The sizing of the gravity grease interceptor will be carried out using the peak flowrate
method where calculations will be based on the maximum volumetric flowrate of wastewater
influent or the expected maximum flow in gallons per minute that the grease interceptor will
receive thus,

3
120 m 1 day
Q= (
day 10 hours )( 601minutes
hour
)( 264.172
m
3
gal.
)=52.83 GPM
V =QT

V =52.83 GPM ( 30 min. )=1585.032 gallons=6 m3

Where,
V- volume of liquid in interceptor
Vtotal – total volume of interceptor
Q – maximum influent flowrate in GPM
T – retention time
Since the grease trap contents would only occupy 2/3 of the total depth and the remaining
1.3 of the trap is the head space the total volume of the grease interceptor can be calculated as:

V total ( 23 )=V
3 3
V total= V = x 6 m3=9 m3
2 2

As stated previously, the surface area of the trap should be equal to between 1000 – 2000
times the total depth measured in millimeters. In this case a ratio of 2000 times will be used thus,

V total=l·w·h

35
 l·w=2000 h
3
1000 mm
V total =9 m 3 ( m )=2000h 2

h=2121.32mm=2.12 m

By heuristics, the length of the trap should be equal to between 1.3 – 2 times the total
depth. In this case a ratio of 1.3 times will be used to maximize space.

3 2
V total =9 m =l·w·h=2.12 m x 1.3 x w

w=1.81 m
l=1.3 x 1.81 m=2.35 m

Based on chapter 10 of the Uniform plumbing code of 2012 or IAPMO, interceptors

should be installed and connected so that it is accessible at all times for inspection, cleaning and
removal of intercepted grease. For a maximum pipe flow of 52.83 GPM, the diameter of grease
waste pipe should be 3 inches. Specifications for the outlet tees, manhole openings, airspace and
more are presented in the figure below.

36
 Fig. Gravity grease trap sizing specifications
Pumping requirement
Qρgh
P=
3.6 E 6
3
m 1 day 1 hr

P=
120 (
day 10 hr )( 3600 )s ( 1000m kg )( 9.81 ms ) ( 2.12m ) ( 23 ) =1.288E-5 kW
3 2

3.6 E 6

Table. Gravity Grease Interceptor Design Summary

Parameter Calculated Values
Volume 6 m3
Height 2.12 m
Width 1.81 m
Length 2.35m
Pumping requirement 1.3E-5 kW

4.4.2.3. Induced-Ai Flotation (IAF) Unit

 IAF General Functions and Operation

Like any gas flotation system, the induced-air flotation (IAF) is used to remove
suspended solids, fats, oil and grease in wastewater. To do this, bubbles are generated using air as
the typical flotation agent and discharged into the liquid by air distributors such as diffusers and
high-speed rotating impellers. Degner [CITATION Deg75 \n \t \l 13321 ] describes the typical
hydraulic regime in an IAF unit as presented in Figure X.

37
 Figure X. Hydraulic Characteristics in an IAF Unit
Two fluid flow paths, gas and liquid, occur in an IAF unit. This occurs together with three
distinct regions in the unit. Air enters the wastewater from the upper portion, following Path A.
Liquid at the bottom of the unit circulates, Path B, and meets and mixes with the air introduced.
This occurs in the two phase mixing region. The flotation region is situated above the mixing
region. Here, the gas bubbles with particles adhering to them rise. As the bubbles rising collapse,
the particles reach the skim region where it is skimmed off by minimal mechanical disturbance.

 Selection of Process Technology for TSS and FOG Removal

Gas Flotation System

A gas flotation system is an efficient unit operation for the removal of suspended particles
and fats, oil and grease from wastewaters. This is carried out by introducing microbubbles into
the wastewater.

A gas flotation system employs the following process:

1. Bubble generation in wastewater

2. Contact between bubble and suspended particle in the wastewater
3. Attachment of particle to the bubble
4. Rise of bubbles with attached particles to the water surface where they are skimmed off

Gas flotation systems typically use air as the flotation agent. Two common gas flotation
systems are the dissolved-air flotation (DAF) and the induced-air flotation (IAF). DAF systems
involve the injection or dissolving of air in the wastewater while is it under pressure. Following
this is the release of the pressure to the atmospheric level. IAF systems involve aeration at
atmospheric pressure. Air is dispersed or diffused in the wastewater to induce bubble formation
in the liquid. In this context, the DAF and IAF systems are considered for the selection of a gas
flotation system. To compare, Table X presents additional information about these systems.

38
Table X. Characteristics Comparing DAF and IAF

Induced Air Flotation Dissolved Air Flotation

Criteria
(IAF) (DAF)
Capital Cost ($) 115,000 354,000
Operation cost ($/yr) 29,200 52,800
Area Requirements (ft2) 750 3,000
Treatment efficiencies (%)
BOD5 50 55
SS 60 82
Oil and grease 95 96

Using the general criteria for equipment/process technology selection and rating
guideline for the evaluation of considered process technologies/equipment shown in Table X and
X, the considered gas flotation systems are rated accordingly. As presented in Table X, the IAF
system has acquired the highest evaluation rating.

Table X. Rating Evaluation of the Considered Gas Flotation Systems

Induced-Air Flotation Dissolved-Air

SYSTEM
(IAF) Flotation (DAF)
Technological Maturity (20%) 2 (0.4) 3 (0.6)
Capital and Operating Cost and
2 (0.4) 1 (0.2)
Energy (20%)
Space Requirement (30%) 3 (0.9) 2 (0.6)
Equipment Efficiency (30%) 3 (0.9) 3 (0.9)
Total (100%) 2.6 2.3

 Selection of Material of Construction

The flotation system must be constructed in a manner that will enable it to within harsh
environments. The options for the materials of construction for the flotation tank of a flotation
system include concrete, polypropylene, epoxy-coated carbon steel and stainless steel. Table X
summarized the characteristics for each type on material; it categorizes them as advantageous or
disadvantageous for the chosen company.

Table X. IAF Material of Construction Comparison

Material Advantages Disadvantages
Reinforced Concrete -sturdy and leak proof -expensive due to required civil

39

Polypropylene -good strength and stiffness
-broad chemical resistance
Epoxy-Coated -offers the strength of steel
Carbon Steel -generally corrosion-resistant
Stainless Steel -resists rust formation
-holds up in indoor and outdoor
applications
-can be easily modified without
the need to re-apply paint and
coatings
work for large WWTFs
-problematic when placed
outdoors – tertiary carbon bond
breakdown occurs and causes
discoloration and cracks
-not recommended in the food
industry because free fatty acids in
the floats will eat through the
epoxy coatings causing rusting on
the steel
-high price

Table X. Rating Sheet: IAF Material of Construction

Type of Material
Consideration/Factor Reinforced Epoxy-Coated
Polypropylene Stainless Steel
Concrete Carbon Steel
Compatibility and
Resistance to 30% 30% 10% 30%
Corrosion
Material Strength
and Structural 25% 10% 30% 30%
Capability
Ease of Fabrication
10% 5% 7% 7%
and Construction
Material Sources
10% 5% 7% 7%
and Availability
Installation and
18% 10% 15% 15%
Maintenance Cost
TOTAL: 93% 60% 69% 89%
Reinforced concrete (RC) is a composite material in which concrete's relatively low
tensile strength and ductility are counteracted by the inclusion of reinforcement having higher
tensile strength or ductility. Reinforcing schemes are generally designed to resist tensile stresses
in particular regions of the concrete that might cause unacceptable cracking and/or structural
failure. Modern reinforced concrete can contain varied reinforcing materials made of steel,
polymers or alternate composite material. Generally, reinforced concrete has high relative

40
strength and toleration of tensile strain, excellent thermal compatibility and durability, and high
material stability.

For the chosen company, application of reinforced concrete is most suitable. For one, the
wastewater treatment facility of the company is located outdoor which makes reinforced concrete
practical. Although the use of reinforced concrete is labor intensive, since labor in the Philippines
is not as costly as other countries, constructing the flotation system on site will be economical
compared to purchasing the entire system, with its added logistic costs.

On average, a concrete-lined basin has a service life of over 60 years. To keep the
stability and performance of the equipment, the basin should be inspected regularly to identify
any necessary repairs due to environmental stress cracking. Small concrete repairs can be
performed relatively easily with grout when the basin is not in service. It should be noted that
frequent cleaning of the equalization tank will help mitigate odor issues, sediment accumulation,
and weed growth in the reinforced concrete walls.

 IAF Unit Design and Equipment Specifications (Sizing)

A flotation unit may either be circular or rectangular [ CITATION Eck00 \l 13321 ]. Since
the company is limited in space, a rectangular flotation is considered for the design in the
context. Some factors considered in the design of the flotation unit include the concentration of
the suspended solids in the wastewater, influent volumetric flowrate, air flowrate and solids
loading rate. Other factors used will be assumed based on values obtained from heuristics and
literature.

A factor that affects the performance of a flotation system is the ratio of the volume of air
to the mass of solids (A/S) needed to achieve a certain degree of clarification. Typical A/S rations
used in wastewater treatment facilities vary from 0.005 to 0.060 mL/mg [CITATION Tch03 \l
13321 \m Kar13]. For this design, the assumed value for the A/S ratio is 0.060 mL/mg. The
typical retention time of a flotation process used as primary treatment falls within 20 to 30
minutes [ CITATION Eck00 \l 13321 ]. As another factor used in the design, 20 minutes will be
used as the retention time.

41
 In many wastewater system design, one of the principal parameters used is the hydraulic
loading rate. It is defined as the ratio of flow to the surface area of a wet basin. This is an
important parameter for the sizing of the IAF unit. Typical values for the hydraulic loading rate
range from 8 to 160 L/m2·min [CITATION Tch03 \l 13321 ]. For this design, a hydraulic loading
rate of 8 L/m2·min will be assumed.

Surface Area, Length and Weight

As previously mentioned, the hydraulic retention time can be defined as the ratio of flow
to the surface area of a wet basin. As obtained from the company, the maximum volumetric
flowrate of wastewater is 120 m3/day. From this, the required surface area can be obtained.

Q
A= Eq. X
H LR
m3
120
day
A=
1 m3
8 2
L
m · min 1000 L (
1440 min
day )( )
2
A=10.42 m
Based on the layout of the wastewater treatment facility of the company, the length is set
to 5 m for applicability. Correspondingly, the width of the IAF unit can be determined.

A 10.42 m2
W= =
L 5m
W =2.1m

Volume
The volume of the wastewater to be contained in the flotation unit can be determined
from the volumetric flowrate and retention time. This parameter will be further used to obtained
the height of the unit.

V =Q · t R
Eq. X

m3 ( day
V =120
day
20 min ) (
1440 min )
3
V =1.67 m

42
Surface Loading Rate

With the value of total suspended solids in the influent, the solid loading rate can be
determined. As determined from the mass balance calculations presented in the Appendices, the
influent contains 233.75 mg/L of total suspended solids.

SaQ
SLR= Eq. X
A
m3

SLR=
233.75
mg
( 1g
L 1000 mg
1000 L
)(
1 m3 )(
120
day )
10.42m2

g
SLR=2,691.94 2
m · day

Liquid Height

It is essential to determine the liquid height or depth in the flotation unit in order to size
the said unit.

V
h L= Eq. X
A
1.67 m3
h L=
10.42 m2

h L=0.16 m

IAF Unit Height

The total height of the IAF unit can be determined using the liquid height and the
heuristic value of an added freeboard. According to [ CITATION Kar13 \l 13321 ], the typical
height of the added freeboard is 0.3 meters

H=0.16 m+0.3 m

H=0.46 m ≈ 0.5 m

For convenience, the height or depth of the IAF unit is rounded up to 0.5 meters.

43
Air Feed

For efficient an flotation process, it is essential to determine the amount of air required.

A
Air Feed= A x x SLR Eq. X
S
1 m3
(
Air Feed=( 10.42 m2 ) 0.060
mL
)(1L
mg 1000 mL )( 1000 L )( 10001 gmg )( 2,691.94 m ·gday )
2

m3
Air Feed=1.683
day

Table. IAF Design Summary

Parameter Calculated Values
Surface Area 10.42 m2
Length 5m
Width 2.1 m
Height 0.5 m
Surface Loading Rate 2,691.94 g/(m2∙day)
Air Feed 1.683 m3/day

4.4.2.4. Flow Equalization Tank

 Equalization Tank General Functions and Operation

Flow equalization is a process of controlling flow velocity and flow composition. This
process is necessary in many municipal and industrial wastewater treatment processes to dampen
severe variations in flow and water quality. Each unit operation in a treatment train is designed
for specific wastewater characteristics. Improved efficiency and control are possible when all
unit operations are carried out at uniform flow conditions. If there exists a wide variation in flow
composition over time, the treatment efficiency of the overall process performance may degrade
severely. These variations in flow composition could be due to many reasons, including the
cyclic nature of industrial processes and seasonal variations. To dampen these variations,
equalization basins are provided at the beginning of the treatment train.

Equalization tanks serve many purposes. Many processes incorporate equalization basins
in continuous treatment systems to equalize the waste flow so that the effluent at the downstream

44
end can be discharged at a uniform rate. Some of the benefits of employing equalization
basins/tanks in wastewater treatment processes include:

 Equalization of flow rate, organic concentration, pH and temperature fluctuations.

 Improved sedimentation efficiency by improving hydraulic detention time.

 Efficiency of a biological process following an equalization tank can be increased

because of uniform flow characteristics and minimization of the impact of shock
loads and toxins during operation.

 Manual and automated control of flow-rate-dependent operations, such as chemical

feeding, disinfection, and sludge pumping, are simplified.

 Treatability of the wastewater is improved and some BOD reduction and odor
removal is provided if aeration is used for mixing in the equalization basin.

 A point of return for recycling concentrated waste streams is provided, thereby

mitigating shock loads to primary settlers or aeration basin.

 Selection of Material of Construction

In the industry, the common types of materials used in the construction of equalization
tanks are earthen, reinforced concrete, roller-compacted concrete and steel. Presented in Table X
is a comparison between the different types of materials commonly used for the construction of
equalization tanks comparing the material’s strength, corrosion and thermal shock resistance,
ease of fabrication and construction, material availability, and cost. Lastly, presented in Table X
is the rating sheet for evaluating which type of material is the most suitable for the given set of
operating conditions (environment) of the system and type of wastewater considered in the
process. Using the selection criteria for materials of construction, the most suitable type of
material to be used in constructing a flow equalization tank is reinforced concrete.

Table X. Equalization Tank Material of Construction Comparison

45
 Type of Material
Roller-
Property/Characteristic Reinforced
Earthen compacted Steel
Concrete
Concrete
Yield Strength 1,000 psi 7,000 psi 7,000 psi 36,000 psi
Fatigue Strength 400 psi 6,500 psi 4,000 psi 24,000 psi
Corrosion Resistance High High High Moderate
Thermal Shock
Low High High High
Resistance
Ease of Fabrication Moderately Moderately
Easy Difficult
and Construction Easy Easy
Material Sources and
High High Moderate Moderate
Availability
Installation and
Low Moderate Moderate High
Maintenance Cost

Table X. Rating Sheet: Equalization Tank Material of Construction

Type of Material
Roller-
Consideration/Factor Reinforced
Earthen compacted Steel
Concrete
Concrete
Compatibility and
Resistance to 25% 28% 28% 22%
Corrosion
Material Strength
and Structural 20% 27% 27% 30%
Capability
Ease of Fabrication
6% 8% 8% 7%
and Construction
Material Sources
8% 9% 7% 7%
and Availability
Installation and
18% 16% 16% 13%
Maintenance Cost
TOTAL: 77% 88% 86% 79%

Reinforced concrete (RC) is a composite material in which concrete's relatively low

tensile strength and ductility are counteracted by the inclusion of reinforcement having higher
tensile strength or ductility. Reinforcing schemes are generally designed to resist tensile stresses
in particular regions of the concrete that might cause unacceptable cracking and/or structural
failure. Modern reinforced concrete can contain varied reinforcing materials made of steel,
polymers or alternate composite material. Generally, reinforced concrete has high relative

46
strength and toleration of tensile strain, excellent thermal compatibility and durability, and high
material stability.

Application of reinforced concrete is more labor intensive to use but after curing, the
reinforced concrete is strong and resistant to UV, weathering, punctures, and cracking. On
average, a concrete-lined basin has a service life of over 60 years. To keep the stability and
performance of the equipment, the basin should be inspected regularly to identify any necessary
repairs due to environmental stress cracking. Small concrete repairs can be performed relatively
easily with grout when the basin is not in service. It should be noted that frequent cleaning of the
equalization tank will help mitigate odor issues, sediment accumulation, and weed growth in the
reinforced concrete walls.

 Flow Equalization Tank Design and Equipment Specifications (Sizing)

For the proposed wastewater treatment process scheme, a modified equalization tank will
be positioned after the IAF unit (located in-line). The equalization tank shall be equipped with
accessible external valves to permit flow control and ensure proper flow equalization, and will be
operated at variable volume which results in constant outflow/effluent. The tank inlet and
transfer piping size shall be based on the maximum volumetric flow rate of inflow
(approximately 120 m3).

The equalization tank will be watertight and will be constructed as precast concrete (type
of reinforced concrete) with no interior tank wall or floor coatings even in an aggressive
wastewater environment. Precast concrete tanks are not affected by harsh conditions including
extreme fluctuations in temperatures and sudden surges in water inflow. Moreover, precast
concrete tanks are known for their durability and structural robustness so it is assured that
operating and maintenance costs are low.

Volume of equalization tank

According to [ CITATION Env15 \l 13321 ], equalization tanks shall be designed for a
minimum retention time of 2 hours at peak flow. From this retention time, the volume of the
equalization tank can be calculated. The volumetric flowrate of the wastewater treatment facility

47
is given with the value of 120 m3/day and having an operation time of 8 to 10 hours. Averaging
the operation time gives us a value of 9 hours.

V t =Q× t
3
120 m
V t= ×2 hrs
9h
3
V t =26.67 m

Considering a safety factor of 10%

3
V t =26.67 m ×1.1
3
V t =29.33 m

According to[ CITATION Goe05 \l 13321 ], using a cylindrical equalization tank may
have a liquid height equal to the diameter of the tank. The height of the equalization tank is the
sum of the liquid height and the free board height. The free board height is also given by
[ CITATION Arc07 \l 13321 ] which is about 0.7 m.

ht =h+ FB

ht =h L +0.7 m
2
π d ht
V=
4
h
(¿¿ L+0.7 m)
π d2
4
V =¿
h
2 (¿¿ L+0.7 m )
πd
4
3
29.3 m =¿
Since the diameter and the liquid height is equal, the previous equation can be written as

π d 2 (d +0.7 m)
29.3 m3 =
4
d=3.12 m

48
 h L=3.12 m

The total height of the tank can then be computed,

ht =3.12+0.7 m

ht =3.82 m

The area for the equalization tank can also be calculated by

π d2
A=
4

π ( 3.12m )2
A=
4
2
A=7.65 m
The minimum thickness of the concrete as the material of construction used for equalization tank
is 200 mm[ CITATION The15 \l 13321 ]

Table X. Flow Equalization Tank Specifications

Parameter Values
Height 3.82 m
Free board height 0.7 m
Diameter 3.12 m
Volume 29.3 m3
Area 7.65 m2
Flowrate 120 m3
Operating time 8-10 hrs
Safety Factor 10%
Thickness 200 mm

4.4.2.5. Storage Tank for Recycle

 Storage Tank Design

According to[ CITATION Bak11 \l 13321 ], the diameter and height of the tank can be
assumed to be equal. The volume of the tank can be calculated from the equation

π d2
V= h
4
Since the diameter and height of the tank is equal, the equation can also be expressed as

49
 2
πd d
V=
4
Given with the volume of the water entering the tank and a safety factor of 10%, the
diameter and height can now be calculated

π d2 d
V =22.31 m3 ( 1.1 ) =
4
d=3.15 m
h=3.15m

The area needed for the equalization tank can also be calculated to be

2
πd
A=
4

π (3.15)2
A=
4
2
A=7.79 m

Table X. Storage Tank Specifications

Parameter Values
Diameter 3.15 m
Height 3.15 m
Volume 22.31 m3
Area 7.79 m2

50
 Chapter 5
Waste Management Initiatives

5.1 Pollution Prevention/Cleaner Production (P2/CP)

Meat processing in the chosen company is involved with processing of meat into various
specialty products where retail cuts of meat are packaged and further distributed to retail outlets.
Since fresh meat products are highly perishable, storage by refrigeration is required throughout
the life of the product in order to maintain eating appeal and prevent microbiological spoilage.
The life cycle ends with consumption by the consumer and disposal. As with many food
processing industries, the prominent environmental issues that are associated with the operations
in this industry are high water consumption thus generation of waste effluent streams,
consumption of energy and generation of by – products which may carry foul odor. Considering
the environmental responsibilities faced, an environmental management system for the plant is
necessary. Having a management system will help the company comply with regulations more
consistently and effectively as well as help identify and capitalize on environmental
opportunities that go beyond compliance.

Application of pollution prevention or cleaner production program will mean continuous

application of an integrated, preventive, environmental strategy applied to the meat processing,
products and services to increase the overall efficiency as well as lower risks to humans and the
environment. Cleaner production on the other hand can be applied to the production process by
bringing about the conservation of resources, the elimination of toxic/harmful raw materials, and
the reduction of wastes and emissions. It is different to the traditional ‘pollution control’
approach to environmental management. Where pollution control is an after-the-event, ‘react and
treat’ approach, Cleaner Production is a proactive, ‘anticipate and prevent’ philosophy.
Implementation of cleaner production processes and pollution prevention measures can provide
both economic and environmental benefits. For an effective pollution prevention program, the
designers have constructed a table to identify areas in which pollution prevention can be
implemented and the corresponding waste minimization techniques. Presented in Table 5.1.1 are
waste minimization techniques for various target areas.

51
Table 5.1.1. Waste Minimization Techniques
Target and Definition
Water Consumption
Water is used for the watering and
washing of livestock, the washing
of trucks, washing of carcasses
and by-products, and for cleaning
and sterilising equipment and
process areas. Basically, water is
used in all processes involved in
the entire processing of meat
products.
Wastewater Effluent Discharge
The meat industry has the
potential for generating large
quantities of solid waste and waste
waters with high organic loading,
BOD level, and fats and oil.
Air Emission and Odorous
Emissions
Odor controls should be
implemented, where necessary, to
minimize odor impacts on nearby
residents.
Particulate matter emissions of
smoke houses should be kept
below 150 milligrams per normal
cubic meter (mg/Nm3) with a
carbon content of less than 50
mg/Nm3.
Key Strategies and Practices
 Undertaking dry cleaning of trucks and
equipment prior to washing with water
 Reusing relatively clean wastewaters from
cooling systems, vacuum pumps etc. for washing
(Separate cooling waters from process and waste
waters and recirculate cooling water)
 Using dry cleaning techniques to pre-clean
process areas and floors before washing with
water
 Using high pressure rather than high volume for
cleaning surfaces
 Using automatic control systems to operate the
flow of water in hand-wash
 Reduce the liquid waste load by preventing all
solid wastes and all concentrated liquids from
entering the wastewater stream
 Cover collection channels in the production area
with grids to reduce the amount of solids entering
wastewater
 Equip the outlets of wastewater channels with
screens and fat traps, to recover and reduce the
concentration of coarse material and fat in the
combined wastewater stream
 Optimize the use of detergents and disinfectants
in washing water
 Reduce air emissions from ham processing with
some degree of air recirculation after filtering
 Isolate and ventilate all sources of odorous
emissions. Oxidants such as nitrates can be added
to wastes to reduce odor
 Odor reduction is the most important air pollution
issue in meat processing plants and can be
achieved by:
 Minimizing the stock of raw material and
storing it in a cold, closed, well-ventilated
place
 Pasteurizing the raw material before
processing it in order to halt biological
processes that generate odor
 Installing all equipment in closed spaces and
operating under partial or total vacuum.
52
  Keeping all working and storage areas clean

 Implementing switch-off programs and installing

Energy Consumption
Energy is an area where
substantial savings can be made
almost immediately with no
capital investment, through simple
housekeeping efforts. Additional
savings can be made through the
use of more energy efficient
equipment and heat recovery
systems.
sensors to turn-off or power-down lights and
equipment when not in use;
 Improving insulation on heating or cooling
systems and pipework etc.
 Insulating and covering scald tanks/boilers to
prevent heat loss;
 Recovering waste heat from effluent streams,
vents, exhausts and compressors
 Maintaining a leak-free compressed air system
 Favouring more efficient equipment
 Improving maintenance to maximize energy
efficiency of equipment
 Maintaining optimal combustion efficiencies on
boilers
 Eliminating steam leaks

5.2 Environmental Management System (EMS)

Environmental issues are complex, numerous and continually evolving, and an ad hoc
approach to solving environmental problems is no longer appropriate. Companies are therefore
adopting a more systematic approach to environmental management, sometimes through a
formalised environmental management system (EMS). Most EMS models are built on the “Plan,
Do, Check, Act” model introduced by Shewart and Deming.

Figure 5.2.1. Plan, Do, Check, Act model by Shewart and Deming

53
 Even if a company already has a compliance system, having an EMS can help the plant
comply with regulations more consistently and effectively, including helping in identification
and capitalization on environmental opportunities that go beyond compliance. To improve
environmental management, the company needs to focus not only on what things happen but also
why they happen and over time, the systematic identification and correction of system
deficiencies will lead to better environmental and organizational performance. An EMS provides
a company with a decision-making structure and action program to bring Cleaner Production into
the company’s strategy, management and day-to-day operations. One type of cleaner production
option is housekeeping. This deals with improvements on work practices and proper maintenance
which are commonly low cost that however produce significant benefits. Second is process
optimization which is a means by which resource consumption may be reduced. Another option
is raw material substitution where the use of hazardous materials are eliminated through
replacement which might require modification in process equipment. Adopting of new
technology may also be an option as this can reduce source consumption as well as minimize
waste generation though improved operating efficiencies. The last option is new product design
which may bring benefits, aside from the ones previously mentioned, reduce energy consumption
and provide more efficient production process. This is a long term strategy which may require
new equipment as well as increased marketing efforts. The key elements of an EMS as based on
the “plan, do, check, act” model is presented in Figure 5.2.1.

First step is to develop a statement of the company’s commitment to the environment and
use this as the framework for planning and action. Planning involves environmental aspects in
which the environmental attributes of the products, services and activities of the company are
identified and possible significant environmental impacts are determined. In planning, it is
important to pay attention to legal requirements and identify and ensure access to relevant laws
and regulations to which the company must adhere to. Based on the policy, environmental
impacts and other factors, the environmental goals of the company are then established.

The implementation environmental management program will take the plans necessary in
achieving the set objectives and targets in action. One element of the implementation is structure
and responsibility. Here roles and responsibilities the management are established and provided
with appropriate resources. Employees are then trained to ensure their capability in carrying out

54
their responsibilities as well as encouraged to establish internal and external communication on
any management issues. To maintain information on the company’s EMS, documentation must
be employed along with document control.

Figure 5.2.1. Key Elements of an EMS

Following the implementation, there must be monitoring of key activities and track
performance by conduction of periodic assessment of compliance with legal requirements and
identification of problems to prevent their recurrence. The company’s EMS must be periodically
reviewed for continual improvement also through maintained and well managed records.
Presented in Tables 5.2.1-3 are the aspect-impact evaluation for an environmental management
system for a meat processing and packaging company like King’s Quality Foods Inc.

55
Table 5.2.1. General Meat Processing
Activity/Product/Service Aspect
1. Packaging Material Use Use of resource in the
manufacture of products for
storage
Generation of waste from
packaging
2. Preparing/Processing of Air exhaust and particulate
Meat generated from processing
Generation of
noise/vibration
Generation of animal waste
from meat processing
Impact
 Excess water use could lead to depletion of
resources
 Extraction and manufacturing of resources
generating flows of waste at each stage of p
 Hidden impacts associated with the process
soil erosion and degradation
 Increased disposal to landfill sites
 Landfill sites can pollute the air, surface
spoil the scenery and represent an immine
 Disposal from incineration can release toxi
ash that requires disposal in hazardous was
 Pollutants emitted may include sulfur dioxi
carbon monoxide
 Harmful effects depend on their concentrati
exposure to the pollutant
 Physical and chemical processes in an ecos
impacts
 Impacts depend upon the magnitude and fre
vibration
 High levels/intensities can be detrimental to
safety and performance in plant operations
 Some associated health effects may range f
hearing loss to high blood pressure
 Animal by-products presenting a risk relate
residues of toxic substances or environmen
processing, can be disposed of as waste by
 Landfill sites can pollute the air, surface, an
scenery and represent an imminent risk to p
 Airborne emissions from landfills are know
hydrogen sulfide, VOCs, dust and endotoxi
cause health problems including headaches
and burning eyes
 Disposal from incineration can release toxi
ash that requires disposal in hazardous was
 Certain wastes are recycled at a rendering p
tallow, grease and high-protein meat and bo
 Impacts associated with rendering plants m
and air pollution
 Airborne emissions from rendering plants m
health issues
 Harmful viruses and bacteria may not be fu
 rendering and may be transmitted into the e
 Waste generated from rendering plants if re
environment can result in negative environm
3. Storage meat (cold) Use of CFCs and HFCs as  Emission of ozone-depleting substances (O
refrigerants the atmosphere
 Depletion of ozone will increase UVB radia
surface with adverse effects for humans, pla
 ODSs will also have a global warming effe
 Global warming can have multiple effects,
range of tropical pests and diseases but incr
fires and severe weather events such as stor
 HFCs contribute to global warming but hav
potential
Use of (anhydrous)  Ammonia is a dangerous refrigerant if not p
ammonia as a refrigerant  Ammonia is primarily a respiratory toxican
irritation, and in higher concentrations, dea
4. Receiving and shipping Emissions of CO, NOx,  These pollutants collectively impact urban
meat VOCs and particles from  Air pollution from vehicles causes cancer a
vehicles addition to aggravating chronic respiratory
 Vehicles are a major source of carbon mono
warming gas. This pollution has multiple ef
the range of tropical pests and diseases but
of fires and severe weather events such as s
drought
 Pollutants may chemically react in the atmo
secondary pollutants such as acid rain and o
Noise generation from  Impacts depend upon the magnitude of the
vehicles  Noise caused by traffic can endanger health
 The growth and spread of traffic have exace
Waste generated from road  These wastes may impact the environment
and traffic sources surface waters, groundwater and land
 Consumption of huge quantities of gasoline
spills, expansion of offshore oil drilling, tox
underground storage tanks, fallout from aci
roads and highways

Table 5.2.2. Specialized Meat Processing

Activity/Product/Service Aspect Impact
1. Meat cooking Air pollutants generated  Possible odor, and products of combustion
2. Meat smoking Air pollutants generated  Particulate matter (PM), carbon monoxide (
compounds (VOCs), polycyclic aromatic h
organic acids, acrolein, acetaldehyde, forma
oxides are identified pollutants

3. Meat curing (using salt,
sugar, sodium nitrite and
sodium nitrate)
4. Ingredient application
(spices, preservatives,
extenders, etc.)
Table 5.2.3. General Facilities Operation
Activity/Product/Service
1. Fuel use/energy use
 Acetic acid has been identified as the most
present in smoke, followed by formic, prop
acids
 The emission is also dependent on the quan
smoke) used, rather than the quantity of me
 Emissions can impact air quality and pose a
Odors generated  Heating zones in smokehouses are a source
VOCs
 VOCs are considered an odor nuisance in r
proximity to rendering plants
 In the presence of sunlight, VOCs can react
create ground level ozone and photochemic
turn contribute to pollution of the atmosphe
 Some individual VOCs are believed to
health. For example, benzene is classified
causing) to humans and hexane as a cause
 of nervous system disorders
Use of resources (wood) to  Excess use could lead to depletion of a finit
produce smoke resources
 Extraction and manufacturing of resources
generating flows of wastes at each stage of
 Hidden impacts associated with the process
soil erosion and degradation
Water effluent generated  Residual additives used in curing processes
during cleaning steps and processing area w
increased loading in wastewater
 Salts are not removed by normal secondary
therefore ability of treatment works to meet
criteria is limited
Water effluent generated  Residual additives contributing to wastewa
requirements (spices, preservatives,
Aspect Impact
Fuel/energy used in  Increased consumption will deplete a finite
operations resources Extraction and manufacturing of
and generates flows of waste at each stage o
 Hidden impacts associated with the process
resources may include soil erosion and deg
 Carbon dioxide, most of which results from
causes about half of global warming. The
fossil-fuel-derived methane, nitrous oxide,
the nitrogen oxides must also be considered

2. Refrigeration/ Use of CFCs and HFCs as
air conditioning systems refrigerants
Use of (anhydrous) ammonia
as a refrigerant
3. General trash Generation of solid waste
4. Maintenance of plant Use and discharge of water
grounds and for ground maintenance
machinery/equipment
Use of fertilizers, pesticides
and herbicides in
maintenance operations
Use of toxic substances for
cleaning
 Global warming has multiple effects includ
the range of tropical pests and diseases but
of fires and severe weather events such as s
drought
 Emission of ozone depleting substances (O
the atmosphere
 Depletion of ozone will increase UVB radia
surface with adverse effects for humans, pla
will also have a global warming effect
 Global warming can have multiple effects,
range of tropical pests and diseases but incr
fires and severe weather events such as stor
HFCs contribute to global warming but hav
potential
 Ammonia is a dangerous refrigerant if not p
 Ammonia is primarily a respiratory toxican
irritation, and in higher concentrations, dea
 Increased disposal to landfill sites
 Landfill sites can pollute the air, surface
spoil the scenery and represent an immine
 Disposal from incineration can release toxi
ash that requires disposal in hazardous was
 Impact may include excess water use and d
resource
 Modern use of water resources can cause p
 There is a wealth of toxicological and envir
these products
 The main chemicals contained in fertilizers
phosphorus. These two chemicals can cause
aquatic plants leading to oxygen depletion a
 Pesticides and herbicides contain toxic mat
environmental and human health risks. Hu
organisms, and plants can be severely threa
 Hazardous wastes generated from cleaning
air, surface water or groundwater
 Pollution of soil may affect people who live
roots into it and animals that move over it
 Air may become contaminated by direct em
wastes Evaporation of toxic solvents from c
common problem
 River and lake pollution, if it is toxic enoug
plant life Immediately, or it may injure slow
 Underground pollutants can be carried by u
contaminate water supplies
 Water effluent generated from washing can
wastewater treatment plant
 Chapter 6
Future Trends and Direction

As human population continues to grow and urbanize, the challenges for securing water
resources and disposing of wastewater will become increasingly more difficult. Thus,
decentralized wastewater management systems should be more considered in the future to treat
wastewater at or near the points of waste generation.[ CITATION Ang15 \l 13321 ]
According to EPA, recycled water can satisfy most water demands, as long as it is
adequately treated to ensure water quality appropriate for use. Recycled water is commonly used
for non-potable purpose, such as agriculture and cooling water for power plants. In uses where
there is a greater chance of human exposure to the water, more treatment is required. As for any
water source that is not properly treated, health problems could arise from drinking or being
exposed to recycled water if it contains disease-causing organisms or other contaminants
[ CITATION Dan15 \l 13321 ]. UV disinfection, for example, is proving valuable for wastewater
treatment in some advanced facilities. However, the upfront cost of implementing UV systems
makes the technology out of reach for most treatment system operators
For IAF systems, chemical pretreatment is critical to IAF performance. The IAF obtains
excellent particle removal efficiency in a wide range of alum dosage and flocculation time.
Commonly used chemicals include trivalent metallic salts of iron, such as FeCl 2 or FeSO4 or
aluminum, such as AlSO4. Organic and inorganic polymers are often used to enhance the IAF
process. The most commonly used inorganic polymers are the polyacrylamides. [CITATION
Pan17 \l 13321 ]
IAF float often contains 2 to 10 percent solids. The solids may need to be dewatered
before disposal to reduce the sludge volume by reducing water content. Float dewatering is
usually performed by filtration or centrifugation[ CITATION Pan17 \l 13321 ].
Lower flowrate of air for IAF also performs a better particle removal, because smaller
bubble size leads to more bubbles which could ensure a floc attached to a favorable number of
bubbles, that is the collision efficiency is increased[ CITATION Tsu \l 13321 ]. Air pressure also
affects bubble size formation which is at 0.3 MPa and oil and grease removal improved at a
higher coagulation rotation speed[ CITATION Sei11 \l 13321 ].
Another suitable advanced tool that can be used is the membrane technology which can
be used as a different wastewater treatment. This technology can be used for the removal of
bacteria, microorganisms, particulates and organic matter. [ CITATION Alm15 \l 13321 ].
Combined processes have evolved into a reliable technology that is nowadays successfully used
for many types of slaughterhouse wastewater effluents.
Chapter 7
Conclusion
 Chapter 8
Recommendation
 References

Almandoz, M., Marchese, J., Pagliero, C., & Ochoa, N. (2015). Composite ceramic membranes from
natural aluminosilicates for microfiltration applications. Ceramics International.

American Society of Plumbing Engineers. (2012). Plumbing Engineering Design Handbook (Vol. 4).
Chicago, IL: American Society of Plumbing Engineers.

AmericanSociety of Plumbing Engineers. (2012). Plumbing Engineering Design Handbook (Vol. 4).
Chicago, IL: American Society of Plumbing Engineers.

Angelakis, A. N., & Snyder, S. A. (2015). Wastewater Treatment and Reuse: Past, Present, and Future.
Water .

Arceivala, S. J., & Asolekar, S. R. (2007). Wastewater Treatment for Pollution Control and Reuse. McGraw
Hill.

Atlas, W. (2016). All About the Meat Processing Industry.

Bakelli, Y., Arab, A., & Azoui, B. (2011). Optimal sizing of photovoltaic pumping system. Elsevier.

Degner, V. (1979). Dispersed air flotation cell design and operation. In G. Bennett, Water - 1975 AlChE
sympsium series (p. 151). New York.

Eckenfelder, W. W. (2000). Industrial Water Pollution Control 3rd Ed. McGraw-Hill.

Environment Protection Department of Hongkong. (2015, May 19). Environment Protection Department
The Government of the Hong Kong Special Administrative Region. Retrieved from
http://www.epd.gov.hk/epd/english/environmentinhk/water/guide_ref/guide_wpc_stp_3.html

Euromonitor International. (2016). Processed Meat and Seafood in the Philippines.

Goel, R. K., Flora, J. R., & Chen, J. (2005). Flow Equalization and Neutralization. Physicochemical
Treatment Processes , p. 184.

Karia, G., & Christian, R. (2013). Wastewater Treatment: Concenpts and Design Approch. PHI Learning
Pvt. Ltd.

Pan America Environmental. (2017, February 11). Pan America Environmental Industrial Wastewater
Treatment Systems. Retrieved from dissolved-air-flotation: http://www.dissolved-air-
flotation.com/dissolved-air-flotation-theory.html

Sein, L. O. (2011). Removal of total suspended solids and oil and grease using flotation unit.

Tchobanoglous, G., Burton, F., & Stensel, H. (2003). Metcalf and Eddy Inc. Wastewater Engineering:
Treatment and Reuse 4th Ed. McGraw-Hill.

The Constructor-Civil Engineering Home. (2015). The Constructor . Retrieved from the constructor.org:
http://theconstructor.org/tips/minimum-thickness-of-structural-concrete-members/7452/
Theobald, D. L. (2015, September 22). 5 Key Trends that will shape the future of water and wastewater.
Retrieved from Flowcontrolnetwork: http://www.flowcontrolnetwork.com/5-key-trends-that-
will-shape-the-future-of-water-wastewater/

Tsuge, H., Li, P., & Hirofumi, O. (n.d.). Application of Induced Air Flotation on Water Treatment.
Yokohama: School of Science for Open and Environmental Systems.
 Appendices
Appendix A: Material Balance Calculations
For the proposed wastewater treatment process scheme, the influent (meat production
wastewater) will pass through a preliminary screening process to remove large solid particles at a
volumetric flowrate of 120 m3/day. The influent has a concentration of 290 mg/L BOD, 433
mg/L TSS and 26.30 mg/L FOG. After passing through a flow-through screen, the influent then
goes to a grease trap and an induced air flotation unit respectively to remove traces of TSS and
FOG. After removal of fats, oils, and grease, and other insoluble impurities the influent goes to
an equalization tank to equalize flow and wastewater composition. The last step of the process
scheme is the removal of BOD via a sequencing batch reactor (w/ 3-paddle aerator) aided with a
BioAmp system. Presented in Table A.1 is a summary of the equipment efficiencies which will
be used for the detailed material balance calculations around each equipment.

Table A.1 Summary of Process Equipment Efficiencies (Based on BOD, TSS and FOG
Removal)
Equipment Modified Induced Air Equalization Sequential Batch
Parameter Grease Trap Flotation (IAF) Unit Tank Reactor (SBR)
BOD Removal (%) 25 32.50 0 95.30
TSS Removal (%) 45 60 0 94.90
FOG Removal (%) 90 95 0 87.80

A. Material Balance around Modified Grease Trap

Stream 2 (Grease Trap Floats)

Stream 1 (Influent) Stream 3 (Grease Trap Effluent)

MODIFIED GREASE
120 m3/day TRAP
290 mg/L BOD
433 mg/L TSS
26.30 mg/L FOG
Stream 4 (Grease Trap Sludge)

Figure A.A.1 IPO of Modified Grease Trap Unit (Given Influent Data)
Assumptions: Overall Material Balance around IAF Unit:
• BOD removal – 25.00% M T 1=M T 2 + M T 3 + M T 4
 • TSS removal – 45.00% Water Balance:
• FOG removal – 90.00% M H 2 O 1=M H 2 O 2 + M H 2 O 3 + M H 2 O 4
• BOD and TSS removed will be part of V 1 ρ H 2 O=V 2 ρH 2 O +V 3 ρ H 2 O +V 4 ρH 2 O
Stream 4 (Sludge V 1=V 2 +V 3 +V 4
• FOG removed will be part of Stream 2 BOD Balance:
(Floats) M BOD 1=M BOD 3 + M BOD 4
• Stream 2 concentration is assumed to V 1 C BOD 1=V 3 C BOD 3 +V 4 C BOD 4
be 809.50 kg/m3, the average density TSS Balance:
of animal fat and lard M TSS 1=M TSS 3 + M TSS 4
• Stream 4 concentration is assumed to
V 1 C TSS 1=V 3 CTSS 3+V 4 CTSS 4
be at 10,000 mg/L
• Density of water is constant and is FOG Balance:
M FOG 1=M FOG2 + M FOG3
equal to 1,000 kg/m3
V 1 C FOG 1=V 2 C FOG 2 +V 3 C FOG 3

Given the concentration of the influent and the volumetric flowrate, the mass flowrate of each
water quality parameter were calculated. Moreover, based on the BOD, TSS and FOG removal
efficiency of the modified grease trap unit, the mass flowrate for each water quality parameter of
the grease trap effluent was also calculated. The amount of water in the influent stream was also
calculated after.
Stream 1 (Influent) BOD Mass Flowrate:
M BOD 1=C BOD 1 (V 1 )

m3
M BOD 1=290
mg
L
BOD 120
day ( )( 1000
1m
L
3) ( 1 kg
1,000,000 mg )

kg
M BOD 1=34.80 BOD
day
Stream 1 (Influent) TSS Mass Flowrate:
3
M TSS 1=433
mg
L
TSS 120 (
m
day )( 1000
1m 3
L
) ( 1 kg
1,000,000 mg )

kg
M TSS 1=51.96 TSS
day
Stream 1 (Influent) FOG Mass Flowrate:

m3
M FOG 1=26.30
mg
L
FOG 120
day ( )( 1000
1m
L
)3( 1kg
1,000,000 mg )

kg
M FOG 1=3.156 FOG
day
Stream 1 (Influent) Water Mass Flowrate:
 M H 2 O 1=M T 1−M BOD 1−M TSS 1−M FOG 1
3

(
M H 2 O 1= 120
m
day )( 1000m kg )−34.80 daykg BOD−51.96 daykg TSS−3.156 daykg FOG
3

kg
M H 2 O 1=119,910.084 H O
day 2
From the calculated mass flowrates for each water quality parameters in the influent stream,
BOD, TSS and FOG mass flowrates in the grease trap effluent stream were calculated using the
removal efficiency of the modified grease trap unit.
Stream 3 (Grease Trap Effluent) BOD Mass Flowrate:
M BOD 3=M BOD 1 −(%BOD removal)( M BOD 1)

kg kg
M BOD 3=34.80
day (
BOD− ( 0.25 ) 34.80
day
BOD )
kg
M BOD 3=26.10 BOD
day
Stream 3 (Grease Trap Effluent) TSS Mass Flowrate:
kg kg
M TSS 3=51.96
day (
TSS−( 0.45 ) 51.96
day
TSS )
kg
M TSS 3=28.578 TSS
day
Stream 3 (Grease Trap Effluent) FOG Mass Flowrate:
kg kg
M FOG 3=3.156
day (
FOG−( 0.90 ) 3.156
day
FOG )
kg
M FOG 3=0.3156 FOG
day
Based on the given float concentration, the FOG mass flowrate in Stream 2 (Grease Trap Floats)
was calculated. Additionally, based on the set combined BOD and TSS concentration in Stream 4
(Grease Trap Sludge), the BOD and TSS mass flowrate in Stream 4 were also calculated.
Stream 2 (Grease Trap Floats) FOG Mass Flowrate:
Using the FOG balance around the modified grease trap unit,
M FOG 1=M FOG2 + M FOG3

kg kg
M FOG 2 ¿ M FOG 1−M FOG 3=3.156 FOG−0.3156 FOG
day day
 kg
M FOG 2=2.8404 FOG
day
Stream 4 (Grease Trap Sludge) BOD Mass Flowrate:
Using the BOD balance around the modified grease trap unit,
M BOD 1=M BOD 3 + M BOD 4

kg kg
M BOD 4 ¿ M BOD 1−M BOD3 =34.80 BOD−26.10 BOD
day day
kg
M BOD 4 =8.70 BOD
day
Stream 4 (Grease Trap Sludge) TSS Mass Flowrate:
Using the TSS balance around the modified grease trap unit,
M TSS 1=M TSS 3 + M TSS 4

kg kg
M TSS 4 ¿ M TSS 1−M TSS 3=51.96 TSS−28.578 TSS
day day
kg
M TSS 4 =23.382 TSS
day
From the given data and calculated values, the following data can be used for the calculation of
volumetric flowrates for each outgoing stream.

Stream 2 (Grease Trap Floats)

2.8404 kg/day FOG
CFOG2 = 809,500 mg/L

Stream 1 (Influent) Stream 3 (Grease Trap Effluent)

MODIFIED GREASE
120 m3/day TRAP 26.10 kg/day BOD
120,000 kg/day 28.578 kg/day TSS
119,910.084 kg/day H2O 0.3156 kg/day FOG
34.80 kg/day BOD
51.96 kg/day TSS Stream 4 (Grease Trap Sludge)
3.156 kg/day FOG
8.70 kg/day BOD
23.382 kg/day TSS
C(BOD+TSS)4 = 10,000 mg/L

Figure A.A.2 IPO of Modified Grease Trap Unit (With Initially Calculated Values)

Stream 2 (Grease Trap Floats) Volumetric Flowrate:

Assuming that all of the FOG removed from the modified grease trap unit will be part of Stream
2 and that the concentration of this stream is equal to 809.50 kg/m3, the average density of
animal fat and lard, the flowrate of Stream 2 can be calculated.
M FOG 2
V 2=
C FOG 2

kg

( )
2.8404
day
V 2=
kg
809.50 3
m
3
m
V 2=0.0035
day
Stream 4 (Grease Trap Sludge) Volumetric Flowrate:
Assuming that all of the BOD and TSS removed from the modified grease trap unit will be part
of Stream 4 and that the concentration of this stream is equal to 10,000 mg/L the flowrate of
Stream 4 can be calculated.
V 4 C (BOD +TSS ) 4=M BOD 4+ M TSS 4

M BOD 4 + M TSS 4
V 4=
C ( BOD+TSS ) 4

kg kg
8.70
+23.382
day day
V 4=
mg 1 kg 1000 L
10,000 (
L 1,000,000 mg 1 m3 )( )
m3
V 4 =3.2531
day
Stream 3 (Grease Trap Effluent) Volumetric Flowrate:
By taking the water balance:
M H 2 O 1=M H 2 O 2 + M H 2 O 3 + M H 2 O 4

V 1 ρ H 2 O=V 2 ρH 2 O +V 3 ρ H 2 O +V 4 ρH 2 O

V 1=V 2 +V 3 +V 4

V 3=V 1−V 2−V 4

3 3 3
m m m
V 3=120 −0.0035 −3.2531
day day day
 3
m
V 3=116.7434
day
Stream 3 (Grease Trap Effluent) BOD, TSS and FOG Concentration:
With the calculated mass flowrate of a given water quality parameter and the volumetric flowrate
of the treated wastewater stream, BOD, TSS and FOG concentration of the grease trap effluent
were calculated as follows:
BOD Concentration:
kg 1,000,000 mg
M
C BOD 3= BOD 3 =
26.10
day ( 1 kg
=223.57
mg )
BOD
3
V3 m 1,000 L L
116.7434
day 1 m3 ( )
TSS Concentration:
kg 1,000,000 mg
M
CTSS 3= TSS3 =
28.578
day ( 1 kg
=244.79
mg)TSS
3
V3 m 1,000 L L
116.7434
day 1 m3 ( )
FOG Concentration:
kg 1,000,000mg
M
C FOG 3= FOG 3 =
0.3156
day (
1 kg
=2.70
mg
FOG
)
3
V3 m 1,000 L L
116.7434
day 1 m3 ( )
Presented in Figure A.3 is a summary of the calculated volumetric flowrate and composition of
each stream ingoing and outgoing of the modified grease trap unit.

Stream 2 (Grease Trap Floats) 0.0035 m3/day Floats

2.8404 kg/day FOG
CFOG2 = 809,500 mg/L

Stream 1 (Influent) Stream 3 (Grease Trap Effluent)

MODIFIED GREASE
120 m3/day Influent TRAP 116.7434 m3/day GT Effluent
120,000 kg/day 26.10 kg/day BOD (223.57 mg/L)
119,910.084 kg/day H2O 28.578 kg/day TSS (244.79 mg/L)
34.80 kg/day BOD (290 mg/L) 0.3156 kg/day FOG (2.70 mg/L)
51.96 kg/day TSS (433 mg/L) Stream 4 (Grease Trap Sludge)
3.156 kg/day FOG (26.30 mg/L)
3.2531 m3/day Sludge
120 m3/day 8.70 kg/day BOD
290 mg/L BOD 23.382 kg/day TSS
433 mg/L TSS C(BOD+TSS)4 = 10,000 mg/L
26.30 mg/L FOG
 Figure A.A.3 Complete IPO of Modified Grease Trap Unit

B. Material Balance around Induced Air Flotation (IAF) Unit

Stream 5 (IAF Floats)

Stream 3 (Grease Trap Effluent) Stream 6 (IAF Effluent)

INDUCED AIR
FLOTATION (IAF)
116.7434 m3/day GT UNIT
Effluent
26.10 kg/day BOD (223.57 mg/L)
28.578 kg/day TSS (244.79 mg/L)
Stream 7 (IAF Sludge)
0.3156 kg/day FOG (2.70 mg/L)

Figure B.1 IPO of IAF Unit (With Known Concentrations and Flowrates)

Assumptions: Overall Material Balance around IAF Unit:

• BOD removal – 32.50%
• TSS removal – 60.00%
• FOG removal – 95.00%
• BOD and TSS removed will be part of
Stream 7 (Sludge)
• FOG removed will be part of Stream 5
(Floats)
• Stream 5 concentration is assumed to
be 809.50 kg/m3, the average density
of animal fat and lard
• Stream 7 concentration is assumed to
be at 10,000 mg/L
• Density of water is constant and is
equal to 1,000 kg/m3
M T 3=M T 5 + M T 6 + M T 7
Water Balance:
M H 2 O 3=M H 2 O 5 + M H 2 O 6 + M H 2 O 7
V 3 ρH 2 O=V 5 ρ H 2 O +V 6 ρ H 2O + V 7 ρ H 2 O
V 3=V 5 +V 6 +V 7
BOD Balance:
M BOD 3=M BOD 6 + M BOD 7
V 3 C BOD 3 =V 6 C BOD 6 +V 7 C BOD 7
TSS Balance:
M TSS 3=M TSS 6 + M TSS 7
V 3 C TSS 3=V 6 C TSS 6 +V 7 CTSS7
FOG Balance:
M FOG 3=M FOG 5+ M FOG 6
V 3 C FOG 3 =V 5 C FOG 5 +V 6 C FOG 6
 Using the same calculation procedure done previously, the mass flowrate for each water quality
parameter of the IAF effluent was calculated based on the BOD, TSS and FOG removal
efficiency of the IAF unit. Also, based on the given float concentration of Stream 5, the FOG
mass flowrate in Stream 5 (Grease Trap Floats) was calculated. Additionally, based on the set
combined BOD and TSS concentration in Stream 7 (Grease Trap Sludge), the BOD and TSS
mass flowrate in Stream 7 were calculated. Lastly, from the given data and calculated values,
volumetric flowrate for each outgoing stream of the IAF unit can be were calculated.
Correspondingly, BOD, TSS and FOG concentration in the IAF Effluent stream were calculated.
Presented in Table A.B.1 is a summary of the calculated values for Stream 5, 6 and 7.
Table A.B.1 Summary of Calculated Concentration and Volumetric Flowrate Values for Stream
5, 6 and 7 (Outgoing Streams of the IAF Unit)
Parameter Value
Stream 6 BOD Mass Flowrate (kg/day) 17.6175
Stream 6 TSS Mass Flowrate (kg/day) 11.4312
Stream 6 FOG Mass Flowrate (kg/day) 0.01578
Stream 5 FOG Mass Flowrate (kg/day) 0.29982
Stream 7 BOD Mass Flowrate (kg/day) 8.4825
Stream 7 TSS Mass Flowrate (kg/day) 17.1464
Stream 5 (IAF Floats) Volumetric Flowrate (m3/day) 0.00037
Stream 7 (IAF Sludge) Volumetric Flowrate (m3/day) 2.5629
Stream 6 (IAF Effluent) Volumetric Flowrate (m3/day) 114.1801
Stream 6 BOD Concentration (mg/L) 154.30
Stream 6 TSS Concentration (mg/L) 100.12
Stream 6 FOG Concentration (mg/L) 0.14

Presented in Figure B.2 is a complete diagram of the IPO of the IAF Unit with all calculated
concentration and flowrate values.
0.00037 m3/day Floats
Stream 5 (IAF Floats) 0.29982 kg/day FOG
CFOG2 = 809,500 mg/L

Stream 3 (GT Effluent) Stream 6 (IAF Effluent)

INDUCED AIR
FLOTATION (IAF) UNIT 114.1801 m3/day IAF Effluent
17.62 kg/day BOD (154.30 mg/L)
116.7434 m3/day GT Effluent 11.43 kg/day TSS (100.12 mg/L)
26.10 kg/day BOD (223.57 mg/L) 0.02 kg/day FOG (0.14 mg/L)
28.578 kg/day TSS (244.79 mg/L)
0.3156 kg/day FOG (2.70 mg/L) Stream 7 (IAF Sludge)
2.5629 m3/day Sludge
8.48 kg/day BOD
17.15 kg/day TSS
C(BOD+TSS)4 = 10,000 mg/L
 Figure B.2 Complete IPO of Induced Air Flotation (IAF) Unit

C. Material Balance around Flow Equalization Tank

In the flow equalization tank, it will be assumed that there will only be minute changes in the
water quality or composition of the wastewater. Therefore, volumetric flowrate and water
composition will be the same for the ingoing and outgoing stream of the flow equalization tank.

Stream 6 (IAF Effluent) Stream 8 (EQ Effluent)

FLOW EQUALIZATION
114.1801 m3/day IAF Effluent TANK 114.1801 m3/day EQ Effuent
17.62 kg/day BOD (154.30 mg/L) 17.62 kg/day BOD (154.30 mg/L)
11.43 kg/day TSS (100.12 mg/L) 11.43 kg/day TSS (100.12 mg/L)
0.02 kg/day FOG (0.14 mg/L) 0.02 kg/day FOG (0.14 mg/L)

Figure C.1 Complete IPO of Flow Equalization Tank

D. Material Balance around Sequencing Batch Reactor (SBR) Unit

Stream 9 (SBR Floats)

Stream 8 (EQ Effluent) Stream 10 (SBR Effluent)

SEQUENCING BATCH
REACTOR
114.1801 m3/day EQ(SBR)
Effuent
17.62 kg/day BOD (154.30 mg/L)
11.43 kg/day TSS (100.12 mg/L)
Stream 11 (SBR Sludge)
0.02 kg/day FOG (0.14 mg/L)

Figure D.1 IPO of SBR Unit (With Known Concentrations and Flowrates)
Assumptions: Overall Material Balance:
• BOD removal – 95.30% M T 8=M T 9+ M T 10+ M T 11
• TSS removal – 94.90% Water Balance:
• FOG removal – 87.80% M H 2 O 8=M H 2 O 9 + M H 2O 10 + M H 2 O 11
• BOD and TSS removed will be part of V 8 ρH 2 O=V 9 ρ H 2O + V 10 ρ H 2O +V 11 ρH 2 O
Stream 11 (Sludge) V 8=V 9+V 10 +V 11
• FOG removed will be part of Stream 9 BOD Balance:
(Floats) M BOD 8=M BOD 10+ M BOD 11
• Stream 9 concentration is assumed to V 8 C BOD 8=V 10 C BOD 10 +V 11 C BOD 11
be 809.50 kg/m3, the average density
TSS Balance:
of animal fat and lard
M TSS 8=M TSS 10 + M TSS 11
• Stream 11 concentration is assumed to
V 8 C TSS 8 =V 10 C TSS 10+ V 11 C TSS 11
be at 10,000 mg/L
• Density of water is constant and is FOG Balance:
equal to 1,000 kg/m3 M FOG 8=M FOG 9+ M FOG 10
V 8 C FOG 8=V 9 C FOG 9+ V 10 C FOG 10

Using the same calculation procedure done previously, the mass flowrate for each water quality
parameter of the SBR effluent was calculated based on the BOD, TSS and FOG removal
efficiency of the SBR unit. Also, based on the given float concentration of Stream 9, the FOG
mass flowrate in Stream 9 (SBR Floats) was calculated. Additionally, based on the set combined
BOD and TSS concentration in Stream 11 (SBR Sludge), the BOD and TSS mass flowrate in
Stream 11 were calculated. Lastly, from the given data and calculated values, volumetric flowrate
for each outgoing stream of the SBR unit can be were calculated. Correspondingly, BOD, TSS
and FOG concentration in the SBR Effluent stream were calculated. Presented in Table A.D.1 is
a summary of the calculated values for Stream 5, 6 and 7.
Table A.D.1 Summary of Calculated Concentration and Volumetric Flowrate Values for Stream
5, 6 and 7 (Outgoing Streams of the IAF Unit)
Parameter Value
Stream 10 BOD Mass Flowrate (kg/day) 0.8281
Stream 10 TSS Mass Flowrate (kg/day) 0.5829
Stream 10 FOG Mass Flowrate (kg/day) 0.0024
Stream 9 FOG Mass Flowrate (kg/day) 0.0176
Stream 11 BOD Mass Flowrate (kg/day) 16.7919
Stream 11 TSS Mass Flowrate (kg/day) 10.8471
Stream 9 (SBR Floats) Volumetric Flowrate (m3/day) 0.00002
Stream 11 (SBR Sludge) Volumetric Flowrate (m3/day) 2.7639
Stream 10 (SBR Effluent) Volumetric Flowrate (m3/day) 111.4162
Stream 10 BOD Concentration (mg/L) 7.43
Stream 10 TSS Concentration (mg/L) 5.23
Stream 10 FOG Concentration (mg/L) 0.02
 Presented in Figure D.2 is a complete diagram of the IPO of the SBR Unit with all calculated
concentration and flowrate values.

0.00002 m3/day Floats

Stream 9 (SBR Floats) 0.0176 kg/day FOG
CFOG2 = 809,500 mg/L

Stream 8 (EQ Effluent) Stream 10 (SBR Effluent)

SEQUENCING BATCH
REACTOR (SBR) 111.4162 m3/day SBR Effluent
0.8281 kg/day BOD (7.43 mg/L)
114.1801 m3/dayEQ Effluent
17.62 kg/day BOD (154.30 mg/L) 0.5829 kg/day TSS (5.23 mg/L)
11.43 kg/day TSS (100.12 mg/L)
Stream 11 (SBR Sludge) 0.0024 kg/day FOG (0.02 mg/L)
0.02 kg/day FOG (0.14 mg/L)
2.7639 m3/day Sludge
16.79 kg/day BOD
10.85 kg/day TSS
C(BOD+TSS)4 = 10,000 mg/L

Figure D.2 Complete IPO of Sequencing Batch Reactor (SBR)

E. Material Balance around Storage Tank (For Recycle)

The goal of this design project is to be able to treat the wastewater from a meat processing
plant in order to meet Class C water quality standards which can be used for recycling
purposes. In line with this, 20% of the treated wastewater will be sent to a storage tank for
future recycle while the rest will be disposed in the drainage channel.
Stream 12 (Effluent Recycle)
22.8832 m3/day SBR Effluent
SESTORAGE TANK 0.8281 kg/day BOD (7.43 mg/L)
(RECYCLE) 0.5829 kg/day TSS (5.23 mg/L)
0.0024 kg/day FOG (0.02 mg/L)

Stream 10 (SBR Effluent) Stream 13 (Effluent Disposal)

111.4162 m3/day SBR Effluent 91.5330 m3/day SBR Effluent

0.8281 kg/day BOD (7.43 mg/L) 0.8281 kg/day BOD (7.43 mg/L)
0.5829 kg/day TSS (5.23 mg/L) 0.5829 kg/day TSS (5.23 mg/L)
0.0024 kg/day FOG (0.02 mg/L) 0.0024 kg/day FOG (0.02 mg/L)
 Figure E.1 Complete IPO of Storage Tank for 20% Effluent Recycle
Table A.2 Summary of Material Balances for the Proposed Wastewater Treatment Scheme
Stream No. 1 2 3 4 5 6 7 8 9 10 11 12 13
Vol.
Flowrate 120 0.0035 116.74 3.25 0.00037 114.18 2.56 114.18 0.00002 111.42 2.76 22.88 91.53
(m3/day)
BOD Conc.
290 0 223.57 0 154.30 154.30 0 7.43 7.43 7.43
(mg/L)
10,000 10,000 10,000
TSS Conc.
433 0 244.79 0 100.12 100.12 0 5.23 5.23 5.23
(mg/L)
FOG Conc.
26.30 809,500 2.70 0 809,500 0.14 0 0.14 809,500 0.02 0 0.02 0.02
(mg/L)