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Application of water treatment technology

POLYCO GROUP’S introduction

Sewage treatment system for breweries

With a consumption of 3.8 billion liters in 2015, Vietnam is one of the largest beer
markets in Asia. According to brewing industry, in 2015, beer consumption in Viet Nam
is 41 liters per person, just behind Korea and Japan in Asia. Beer industry with annual
growth rate in the past 10 years is 6.4% and the last 5 years is 5.7% and accounted for
94% of the consumption of alcohol, so in recent years there are more and more breweries
invested. In addition, the state policy encourages brewing industry as a strong economic
sector to increase state budget revenues. However, in addition to the growth of brewing
industry, sewage is one of the problems that need solving.

Sewage from breweries

Beer contains mostly water (> 90%), ethanol (3 - 6%), CO2 and other solvents. The
brewing industry is one of the largest users of water, the average water use of Sabeco and
Habeco is about 4.6 to 6.0 liters per liter of beer. Brewing is therefore one of the
industries that requires a lot of water, so it emits a very large amount of sewage. Sewage
from breweries usually includes the following types:

1. Cooling water, condensate. This type of water is not polluted so it can be pre-treated
and re-used;

2. Water using for sanitary equipment such as washing pot cooking, tank, floor of
manufacturer. This sewage contains a lot of organic matter which needs to be treated to
clean the environment and re-use;

3. Sanitary water and fermentation equipment, pipeline containers, fermented floors.


This type of sewage contains many yeast carcasses, the yeast is easy to decay causing
serious pollution. This type of sewage requires special treatment to reduce the risk of
contamination;

4. Sanitary water using for washing beer bottle s. This type causes seriously polluted,
this includes not only organic substances but also many color compounds from labels and
metal.

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Picture 1. Diagram of production technology and emissions breweries

Suitable technology

Sewage from breweries is highly organic pollution which decomposes very quickly so
sewage is black and it causes serious pollution plus additives and chemical process of
production such as CaSO4, H3PO4 , NaOH, Na2CO3 etc If not being treated, these

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substances will cause seriously environmental pollution when the sewage is discharged
directly to the receiving source without being treated well.

Based on the above analysis, sewage treatment in beer production to reuse is the most
effective solution. Sewage from brewery’s operations has high nutrient content and
traditional treatment methods by introducing sewage into urban or industrial sewage
treatment plants, both wasteful and pressurized to the downstream source. In addition,
sewage treatment of urban sewage treatment plants or industrial zones greatly increases
the cost of breweries.

Because of the potential value of sewage from brewery rich in carbon and nutrients (N /
P), the choice of optimal technology can save costs, can use renewable energy and reuse
to reduce cost is an urgent need.

Table 1. Characteristics of sewage from brewery

Parameter Unit sewage from


brewery
Flow - - 2-8 hL sewage/hL
beer
COD mg/L 2000–6000 0.5-3 kg COD/hL
beer
BOD mg/L 1200–3600 0.2 – 2kg BOD/hL
beer
TSS mg/L 200–1000 0.1-0.5 kg TSS/hL
beer
pH 4.5–12
Nito-N mg/L 25–80
Photpho-P mg/L 10–50
Heavy metal mg/L Very low

There are many technologies to treat sewage from breweries. However, with the current
conditions, current breweries such as Sabeco and Habeco choose anaerobic and aerobic
treatment technologies. The use of this technology results in lower operating costs and
stable discharge quality and high system safety.
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With a high organic content, the BOD5 / COD> 0.5 ratio should be treated with anaerobic
and aerobic combined bioreactors. Sewage treatment technologies commonly used are:
UASB (Upflow Anaerobic Sludge Blanket), combined with SBR (Sequencing Batch
Reactors).

Table 2. Comparison between anaerobic and aerobic systems

Anaerobic technology Aerobic technology


Eliminate COD 65–90% 90–98%
Generate energy High: CH4 is produced as Low: CO2 only
biogas
Low energy consumption Low High
Sludge Low High
Remove (N / P) Low High
Space requirements Low High
Operation Simple Complex

Technology Introduction

UASB anaerobic treatment process (Upflow Anaerobic Sludge Blanket):

In UASB tank, sewage is evenly distributed on bottom of the tank and goes from the
bottom to the suspended sediment, then through mud layer (microorganism), anaerobic in
tank will mix absorbs organic matters. (BOD, COD etc) dissolve in sewage, and break
down and convert them into biogas (about 70-80% of methane and 20-30% of carbon
dioxide and other gases). Output biogas is collected for Biogas steamer [Installed for
wastewater treatment system of Sai Gon - Hanoi Brewery]

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Picture 2. UASB system and collecting biogas to supply steamer
Advantages of UASB technology:

COD removal efficiency up to 90%

Sewage treatment with very high levels of organic pollution

Very low energy consumption during operation.

Sequencing Batch Reactors (SBR):

As a reactor works in the form of activated sludge treatment, two periods of aeration and
gasification take place in the same tank. SBR system is a system for treating of
biological sewage containing organic compounds and high nitrogen. Continuous
operation system includes the following process:

Anoxic Fill Phase: Sewage at this stage is distributed throughout the tank with activated
sludge at the bottom of the tank. Bioprocesses occurring simultaneously in this stage are

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anaerobic and aerobic. Sewage flowing into the tank to the level indicator, the sensor
signal level signaling the valve closed again.

Reaction: After finishing Anoxic Fill Phase, sewage is continuously aerated with stirring.
In this stage, sewage is treated until sewage is treated to the permitted level. This process
creates a biochemical reaction between activated sludge and activated sludge. The length
of ventilation and aeration are dependent on the quality of sewage and the level of
treatment required.

Sedimentation process: Aeration process and stirring stop, activated sludge is settled to
the bottom of the tank. Sedimentation occurs in a static environment, the hydraulic effect
of the tank reaches 100%.

Water splash in: Inner water is collected in the disinfection tank through decanter.

Activated sludge collection / retention: The tank is ready for loading. Activated sludge is
pumped into the slurry tank.

Cycle work cycles are installed through intelligent and flexible control software.

Picture 3: SBR technology system (Sequencing Batch Reactors)

Advantages of SBR technology:

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The flexible SBR system can handle a variety of sewage with a variety of components
and high loads.

Easy to maintenance, maintenance of equipment.

The system can be controlled completely automatically

Low output TSS, high phosphorus removal efficiency, nitrification and high
denitrification

The process of cotton is good because there is no system of mechanical mud

The deposition process in the static state is highly effective

Ability to upgrade the system

The sewage treatment system is controlled by a SCADA system - an automated


management system. Through the use of measuring instruments (such as flow meters,
dissolved oxygen meters), the system is fully programmed to control the output water
quality and optimize the process. to reduce energy consumption.

Picture 4. Scada control system model

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After treating, sewage is QCVN 40: 21011 / BTNMT, column A is used for watering
plants, washing toilets, cleaning factories, washing cars, washing sugar etc for the factory
to save cost for production.

Established in 1995, POLYCO has had over 30 general contractor projects for
Vietnamese and foreign breweries. Modern technology and constant innovation has won
the most demanding customers from all over the world such as Germany, Japan, Holland.
In addition to modern technology, POLYCO also has experienced and dedicated
technicians to the profession. Every year, the technical committee is sent to seminars and
equipment fair to improve knowledge as well as update new brewing technology in the
world.

POLYCO has improved the technology and programmed the control system through
control devices to operate the brewery waste water treatment system efficiently and
economically, especially the reuse of energy from the gas. Biogas of the anaerobic
process UASB.

Add some achievements: certificates of merit, medals:

- Ho Chi Minh Award for Science and Technology is exceptionally appreciated for
the group of works: "Research, application and development of mechanical
technology - Automation in food processing industry" 2015.
- Gold Medal of the World Intellectual Property Organization (WIPO) for excellent
science and technology in 2004.
- 02 First prizes in VIFOTEC Science and Technology Award 2000 - 2004.
- First-class Labor Medal 2014
- Second-class Labor Medal 2009.
- Third-class Labor Medal 2006
- Second-class Labor Medal for CEO in 2013
- Third-class Labor Medal for General Director in 2008
- Key products of Hanoi People's Committee from 2007 to present
- Excited Government Excellence in 2012 and 2015
- Excellent emulation flag awarded by the Prime Minister in 2012
- Many Certificates of Merit from the Government, Ministries, Branches and Cities
awarded over the years.
Some images of sewage treatment system which POLYCO GROUP has constructed and
installed and transferred technology:

1. Sewage treatment system Sai Gon - Quang Ngai Brewery Capacity 2.500m3 / day.

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2. Sewage treatment system Sai Gon - Kien Giang Brewery Capacity 1,200m3 / day.

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