Idaho Potato Processor
History:
Gener-Ox MTS-100-20 Unit (150 GPM)A major food processor produces around 600,000 gallons per day of wastewater. The facility is located within a major food growing and processing area and the primary digester overflow water is used for irrigation of alfalfa and feed grasses.

Due to the effluent stream being extremely high in anaerobic organics compounds, the untreated water develops high concentrations of Hydrogen Sulfide (
H2S) and highly malodorous volatile organic acids (VOA’s).  

This effluent water is pumped from the plant facility to irrigation points which are up to 7.5 miles from the plant. Because of the significant transport distance, the effluent becomes highly concentrated with H2S and VOA gases. These gases escape from solution at the point of spray application entering the air stream with the aerosol from the spray nozzles. The resulting odor emanating from the spray nozzles was more than enough to attract the attention of residents living nearby as well as others in the vicinity.  

Prior to employing IER’s Gener-Ox™ System, the company had attempted to treat the odor problem with nitrate-bearing chemicals. This process resulted in an inconsistent control and the facility continued to receive complaints from residents within the surrounding area. The never ending cost of chemical treatment resulted in the processer investigating all treatment options.

Solution:

IER offers a proprietary super-oxygenation technology which is designed to convert anaerobic effluent streams to a fully aerobic environment. This technology, trademarked as Gener-Ox™ was installed at the above facility in April 2009 and the result was an immediate and full conversion of the  entire 7.5 mile transport system from an anaerobic, H2S-producing environment to a totally aerobic, non-sulfur reducing environment. Effluent water being discharged into the pressurized line was treated with high concentrations of fully dissolved oxygen while being transported to the land application network of crop circles.  The resulting benefit has been all odors have been eliminated, zero H2S has been detected and the land application points and previous corrosion issues from H2SO4 have been greatly reduced. An additional benefit has been the reduction of digester effluent COD levels by 12%, from 583 mg/liter at the digester effluent point to 510 mg/liter at the end of the force main.  All of this is achieved without the requirement for any chemical feed while only utilizing mother nature’s oxygen supply.  The only costs that are associated with the Gener-Ox™ system are the installation and utility costs which are required to operate the system. In the case of this processor, the resulting electrical consumption associated with the operation of the system involves a 15 HP centrifugal feed pump and a 20 HP compressor. Together at full load conditions they result in a monthly operational cost of ~ $1000.00 based on electrical costs of $0.05 KWH.

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

  • A dissolved oxygen residual has been maintained at the most distant application  point which is 7.5 miles from the point of initial treatment.

  • Odors were reduced to non-detectable within hours of Gener-Ox™ startup.

  • Gas phase Hydrogen Sulfide (H2S) has been totally eliminated.

  • Reduction in corrosion from acid formation within pumps, wet-well and irrigation components.
  • COD/BOD levels were lowered by 12% (This reduction accomplished even considering the low COD residual present in the digester effluent).

  • Operations and maintenance costs reduced to a small fraction of the never ending chemical addition costs, allowing for an accelerated ROI.