Montana Malting Facility
History:
Gener-Ox MTS-100-20 Unit (150 GPM)A major Malting Facility in Montana State produces approximately 1.5 million gallons per day of wastewater. The facility is located within a major Barley growing area. The plants primary effluent stream is transported approximately 5.5 miles to the local POTW and contains very high levels of anaerobic organic compounds. These anaerobic organisms result in high concentrations of Hydrogen Sulfide (H2S) in the force main transporting the plant’s effluent to the local POTW. Concerns related to these dangerously high H2S values forced the facility to explore all available options for the control of the high H2S levels in the effluent stream. Because of the significant transport distance, the effluent becomes highly concentrated with H2S and other VOA compounds as it travels toward the receiving facility. These volatile gases escape from the solution upon exposure to turbulence at the point of force main break to gravity. The toxic gases then enter the air stream, creating a high risk to personnel for exposure to dangerous levels of toxic H2S.

Prior to considering IER’s Gener-Ox™ System, the company had attempted to control the H2S problem by using a nitrate-bearing chemical formulation.  This was a very costly approach to H2S control and resulted in annual costs in excess of $100,000. The never-ending chemical costs that were associated with treating the symptoms rather than attacking the basic source of the H2S (anaerobic conditions), forced the processor to investigate many other treatment options, including the IER Gener-Ox™ technology.

Solution:

IER has developed a proprietary super-oxygenation technology which is designed to convert anaerobic effluent streams to a fully aerobic environment. By converting these problem systems from anaerobic to fully aerobic conditions, anaerobic organisms are unable to survive and simply expire. The innovative technology, which is trademarked as Gener-Ox™ was installed at the above facility in January of 2009. The result was an immediate and full conversion of the system’s entire 5.5 mile wastewater transport network from an anaerobic, H2S-producing environment to a fully aerobic, non-sulfur reducing environment. Plant effluent wastewater, prior to discharge to the pressurized force main was treated with high concentrations of fully dissolved oxygen and then pumped into the pressurized force main. The resulting benefit has been that all manhole odors downstream from the injection point have been eliminated and H2S values at all downstream manhole sample points have consistently ranged between zero and 3 PPM. Previous corrosion issues resulting from H2SO4 have also been greatly reduced. 

These benefits have been achieved with absolutely zero requirement
for any other chemical feed. The system operates exclusively by utilizing Mother Nature’s oxygen supply.  The only costs associated with the Gener-Ox™ system are represented in the initial capital, system installation and utility costs. The utility costs associated with this system’s operation are limited to that necessary to operate a 20 HP centrifugal supply pump, a 30 HP air compressor and a 115 volt oxygen concentration technique which is based on molecular sieve resin exchange. Together at full load conditions, the result is a monthly operational cost of approximately $2000.00 based on electrical costs of $0.065 KWH. That cost of $24,000 per year is compared to previously required costs in excess of $100,000 per year for chemical treatment products alone.

In brief, the IER’s Gener-Ox system gave this client:

  • A substantial dissolved oxygen (DO) residual maintained at the most distant manhole points which are approximately 5.5 miles from the point of the Gener-Ox treatment location.
  • A reduction in Hydrogen Sulfide to non-detectable levels within minutes of initializing the Gener-O™x system resulting in reduced acid corrosion within pumps, transport lines, and lift stations throughout the network and reduced H2S values to near zero  throughout the entire force main
  • A savings of $100,000 per year in chemical costs alone by elimination of the nitrate-bearing chemical treatment. This savings resulted in a return on investment (ROI) of less than two years for the customer.