Industrial Wastewater Treatment
Treatment of high strength waste is the foundation of Pharmer Engineering. We provide services for numerous food processors including Bush Brothers, J.R. Simplot, Kraft, Glanbia and Basic American Foods.
Pharmer Engineering works with the industry to determine the treatment option that is best suited for the application. We provide general design, bid, build services, or we often implement the improvement through a design build team.
We understand the schedule and budgetary demands of the private sector and work with the client to provide the best engineering value for their requirements in an expedited manner.
Industrial Experience
This section presents examples of past industrial projects performed or led by Pharmer's water and wastewater professionals. The projects are divided into the following areas:
Food and Beverage
Meat Products
SSI Wilder, Idaho
Lead Process Engineer: Odor control investigations at a meat processing plant. The recommended solution was improved pretreatment with fine screening and DAF. He was responsible for detailed design, equipment procurement, construction management, and system startup. The project has successfully eliminated the odor problems and lessened the impact associated with wastewater land application.
Swift Foods, Minnesota
Phosphorus Removal and Sludge Handling (Industrial Facility) Project Manager and Lead Process Engineer for the design of wastewater phosphorus removal and sludge handling improvements. The industrial wastewater plant owned by the City serves a prominent pork processor that is the sole discharger to the 2 mgd plant. The chemical phosphorus removal is designed to meet a 1 mg/L total phosphorus limit.
The design included filtration by cloth media to provide assurance of meeting the phosphorus limits. The filter building included office and laboratory areas. Careful attention was paid to building materials to make the facilities attractive and blend into the surrounding area. The solids handling facilities include a gravity belt thickener designed to function as a thickener to minimize storage volume. Waste activated sludge is thickened and stored in two 126 feet diameter bolted-steel sludge storage tanks. The liquid sludge is stored in the tanks until final disposal at land application sites.
Dairy Products
Schreiber Foods, Logan, Utah.
Pharmer was retained to design a new activated sludge treatment system to accommodate a plant expansion and meet POTW discharge limits. The new facility included a new pump station, three plug flow selectors, aeration basin and secondary clarifier. The new treatment facility is currently under construction.
Kraft Foods, Rupert, Idaho.
Pharmer was retained to provide fast-track design for a new water treatment system. The water filtration and softening system was designed in 2 weeks with construction immediately following. In addition, Pharmer provided Kraft with technical specifications for additions to the whey system.
Kraft Foods, Farmdale, Ohio.
Extensive wastewater system modifications were required to adhere to Ohio DEQ permit changes. A conceptual design report was submitted in mid-September and design drawings were produced 2 weeks later for initiation of construction in mid-October. Nine design packages were prepared for bidding and construction of a covered anaerobic pond system followed by an aerobic pond. Temporary system designs kept the plant in compliance during the winter construction. The construction was completed through the winter and operational within 9 months.
Kraft Foods, Lowville, New York.
Pharmer was retained by Kraft to evaluate a pH control system that was not meeting permit requirements. A carbon dioxide system was proposed and subsequently designed to provide effluent buffering and eliminate chemical handling issues with an existing sulfuric acid system.
Glanbia (formerly Avonmore West, Inc.).
Several planning projects were completed, including the following:
- Gooding, Idaho. Prepared Facilities Plan for submission to DEQ as part of land application permit renewal process. Developed feasibility and costs for high-rate anaerobic treatment with gas collection and use in on-site boilers.
- Richfield, Idaho. Prepared Facilities Plan for submission to DEQ as part of land application permit renewal process. Developed feasibility of in-pipe nitrate reduction for land application.
- Twin Falls, Idaho. Developed conceptual plan for anaerobic treatment and prepared cost estimates. The anaerobic treatment concept was developed to pretreat the process waste and avoid a City assessment for wastewater treatment improvements.
Tillamook County Creamery Association, Tillamook, Oregon.
The plant produces cheese, ice cream, and butter and processes over 1.2 million pounds of milk per day. The existing activated sludge plant was improved, including new pump stations, equalization, expanded aeration and clarification capacity, and improved chlorination and sludge storage. A phased construction approach was formulated to serve both immediate and future needs.
Smith's Dairy, Riverside, California.
Design of a pretreatment system for facility that discharges wastewater to the City’s treatment facilities. Prior to discharge, pH needed to be adjusted to conform with discharge requirements. Carbon dioxide was the chemical of choice for pH control, as it is easy to use and non-hazardous.
Nelson Rick’s, Rexburg, Idaho.
The cheese plant was experiencing odor problems in their existing lagoons during the spring. The design implemented aspirating aeration equipment to keep the pond contents aerobic during the winter and shortening the spring turnover.
Snake River Cheese, Blackfoot, Idaho.
Proposed rate increases by the City of Blackfoot prompted an investigation into the feasibility of on-site pretreatment. Several biological systems were evaluated for cost and efficiency and compared to the surcharge. The pretreatment evaluation prompted the City to re-evaluate the surcharge structure and ease the implementation program, thereby negating pretreatment.
LeSeuer Cheese, LeSeuer, Minnesota.
The cheese plant contributed a significant load to a municipal lagoon system. The load caused considerable odor problems and prompted extensive modifications to the City system. A design using an innovative earthen basin aeration system was implemented to better treat the wastewater before discharge into the existing lagoon system.
Canned, Frozen, and Preserved Fruits, Vegetables
Basic American Foods, Las Cruses, Mexico
Wastewater system separation and improvements project. This green chili pepper plant's land application site was cut in half, requiring the plant to discharge half of its waste to the municipal plant. An in-plant sewer separation was necessary to segregate certain prohibited waste and pretreatment was added.
Bush Brothers Cannery, Dandridge, Tennessee
This bean processor land applies its wastewater. Population growth in the area has led to increased odor complaints at the land application sites. In addition, stricter land application loading limits were expected during the facility’s next permit cycle. As a result, Pharmer Engineering evaluated wastewater treatment alternatives for Bush Brothers. Stemming from this evaluation, Pharmer Engineering designed a new high-rate anaerobic treatment system including a new DAFT, sulfide oxidation, biogas utilization and a separate anaerobic digester for the DAFT float. The new treatment system has the ability to treat approximately 75,000 lb/d of COD and is currently under construction.
Del Monte Foods USA, Burley, Idaho
The plant land-applies wastewater to a site that was showing signs of overload. An intensive wastewater sampling program was designed to characterize the wastewater. The sampling showed that wastewater characteristics changed dramatically during the season, depending on crop production (peas, corn, or lima beans). After the wastewater characteristics were established, a study evaluated various methods for treatment on a cost and feasibility basis. The alternatives evaluated included expanding the land application site with and without supplemental storage capacity, discharging to the City-owned treatment facility or to neighboring industrial treatment facilities, treatment and direct discharge to the Snake River, and flow reduction within the factory.
Dickinson Frozen Foods, Fruitland, Idaho
Dickinson Frozen Foods in a major onion processor in Western Idaho. Wastewater generated by this food processor is currently discharged to a municipal treatment facility in the rural Township of Fruitland, Idaho. Due to production expansions, the organic load discharged to the Township reached a level that created problems for the municipal treatment system. As a result, Dickinson retained Pharmer personnel for the planning, design, and construction of a new wastewater pretreatment system.
Pharmer developed an innovative and economical treatment system that included an aerated lagoon with diffused aeration followed by a clarifier. The treated effluent is discharged to the municipal treatment system with a 97% reduction in Biochemical Oxygen Demand. Biological solids generated by the treatment process are applied to adjacent land during the growing season. During winter months, solids are stored in the aerated lagoon.
Food Packaging Plant, Portland, Oregon
Design and construction management for separation of process water and potable water systems and air system modifications.
Heinz Frozen Foods (HFF), Ontario, Oregon
Formally known as Ore-Ida, HFF operates a potato processing facility in Ontario. Pharmer personnel have been associated with the treatment facilities for the last 15 years and were involved with the design, construction, and start-up of the biotower/activated sludge treatment system during the early 1990s.
In September 2000, HFF required modifications to the plant that included the design of a new pumping system that allows primary clarifier effluent to bypass the biotowers. Pharmer was retained for this work and completed the mechanical and electrical design and assisted HFF in the purchase of major equipment items.
Idaho Association of Commerce and Industry (IACI) Potato Research Committee
Completed an overall potato wastewater management study in response to increasing regulations governing land application of wastewater. The objectives were to analyze the performance and cost of wastewater treatment processes that could be used to alleviate nitrogen buildup problems experienced in land application practices.
J.D. Irving, Ltd., St. John, New Brunswick, Canada
Conceptual planning of treatment facilities for Cavendish Farms potato processing facility. The work included wastewater flow and loading projections based on estimated production levels and an evaluation of treatment processes to meet discharge requirements in the Saint John’s River. The treatment systems selected were preliminary screening, anaerobic lagoon treatment, and nitrification in an activated sludge biological selector system. Phosphorus reduction is accomplished by chemical precipitation. Solids generated and/or removed from the flow stream were then to be dewatered and landfilled.
J.R. Simplot, Caldwell, Idaho
Conceptual report addressing short- and long-term wastewater growth factors and continued land application as well as river discharge. The conceptual report evaluated treatment systems including anaerobic pretreatment, secondary activated sludge treatment, and chemical and biological phosphorus removal (for river discharge).
J.R. Simplot, Burley, Idaho
Provided planning, design, and construction services for several projects, including:
- Primary Clarifier. Planning, design, and construction of a new 75-foot diameter primary clarifier. Due the corrosiveness of the potato wastewater, it was determined that the primary clarifier should be constructed out of Type 304 stainless steel.
- Wastewater Facilities Plan. The wastewater treatment plant receives process wastewater from a potato fry plant as well as from an ethanol alcohol plant. The major issues addressed included chemical and biological phosphorus removal, grease removal and handling systems, replacement of an existing primary clarifier, and upgrades to the primary sludge pumping and thickening system.
- Pipeline River Crossing. Design and construction of a pipeline system crossing the Snake River. The pipelines transport wastewater and silt from the potato processing facility located on the north side of the river to the wastewater treatment facility, which is located on the other of the river. The pipeline system consisted of a 10-inch process line, a 6-inch silt line, a 6-inch spare line, and a ballast pipe. All of the pipes were constructed and connected together on shore, floated across the river, and positioned prior to submergence. Services included material analysis and selection, final design, permitting and easement acquisition, bidding, and construction management. The project was performed on a fast-track schedule and coordinated to meet the needs of the potato processing facility, as well as optimum river conditions for construction.
J.R. Simplot, Hermiston, Oregon
Provided planning, design, and construction services on several projects including:
- Primary Clarifier. The project included performing a settleability test to establish clarifier loading criteria, which was used to calculate the optimum size of the primary clarifier. A 55-foot diameter clarifier with steel tank was recommended. A turnkey design package was then prepared and bid to a prequalified list of contractors.
- Nitrogen Removal System Selection. The study evaluated aerobic biological treatment systems that could consistently and economically remove 70 to 90 percent of the nitrogen from the anaerobically treated wastewater prior to land application. Appropriate treatment technologies were rated based on a series of criteria including capital and operating costs, land requirements, full-scale applications, reliability and stability, and complexity of operation. The study led to a pilot study of predenitrification-nitrification in an activated sludge system.
- Solids Contact Anaerobic Treatment System. Design of an anaerobic treatment system consisting of a large 4.2-million-gallon reactor vessel designed to treat up to 80,000 pounds of chemical oxygen demand (COD) per day. Services included preliminary design, detailed design, construction management, resident inspection, and startup assistance. Other facilities included in the design were a biogas handling system, chemical feed facilities, plate settlers, pumping facilities, and laboratory. The treatment system was designed as a pretreatment process (COD reduction) for future nitrogen removal treatment facilities.
J.R. Simplot, Grand Forks, North Dakota
Preliminary design report for potato processing wastewater treatment. The existing wastewater treatment system consists of primary clarification and secondary activated sludge treatment. The treated wastewater is discharged to the municipal treatment plant.
Tasks included in the study were to review current flows and loads to the treatment system and project future flows and loads; review the current treatment objectives and investigate future permit requirements that could impact the capacity of the existing system; estimate the wastewater heat loss using surface aeration and the wastewater heat loss using diffused aeration systems (jet or coarse bubble); calculate process performance for current and future conditions without temperature conservation (surface aeration) and with temperature conservation (diffused aeration); develop aeration requirements for surface aeration, jet aeration, and coarse bubble diffused aeration systems; provide a capital and annual cost estimate for the three aeration systems evaluated; provide recommendations for upgrading the existing treatment system to treat future flows and loads; and meet anticipated permit requirements.
J.R. Simplot Company, Manitoba, Canada
Simplot Food Group built a new plant in Portage la Prairie, Manitoba that turns 2,000,000 pounds per day of fresh potatoes into a million pounds per day of french fries. At full build-out, the plant will generate 60,000 pounds per day of BOD that will be treated in a large low-rate anaerobic reactor. Almost 375,000 cubic feet per day of biogas will be produced that, in turn, can produce 700 kilowatts of electricity, or 250 boiler horsepower.
The biogas is collected, compressed slightly, and piped to the plant’s boilers. The biogas augments natural gas and provides about 10 percent of the plant’s steam demand. Extremely cold winter temperatures in the northern prairies have made the Portage la Prairie biogas design a challenging and exciting project. Pharmer provided planning and design for this design/build portion of the project.
Ocean Spray Cranberries, Inc., Bordentown, New Jersey
The project was prompted by numerous odor complaints by neighbors and required fast-track management to mitigate the problem. Odors were generated by volatile organic acids formed in the process wastewater and stored in equalization basins prior to treatment. During a week-long period, project team members assessed the situation, analyzed options, and prepared a predesign report which was presented to the client at the conclusion of the site visit.
The selected opinion was to cover the equalization basin with a clear span aluminum cover, install mechanical mixing in the equalization, and ventilate the odorous gases to the activated sludge treatment system through an existing diffused aeration system. This option was advantageous to the Owner, as separate odor treatment facilities did not have to be constructed and maintained. In order to ventilate the odorous gases, 400 feet of fiberglass duct was constructed between the covered basin and the existing centrifugal blowers, which supply compressed air to the diffused aeration system. The project was designed and major equipment items were bid and purchased directly by the Owner. The project was completed on schedule and below the estimated budget. Since project start-up, there have been no odor complaints associated with the waste treatment system.
Potato Processor, Blackfoot, Idaho
Bob Pharmer served as project manager for a design-build of a membrane bioreactor (MBR) advanced wastewater treatment facility for a food processor in Blackfoot, Idaho. The process treats a potato wastewater to the equivalent of Class B reuse criteria. The MBR design met client objectives by reducing total nitrogen by 94%. This allowed continued land application on the same site with greater plant output. The MBR system allows future discharge flexibility if direct discharge to the Snake River is pursued. The plant treats an average flow of 1.4 mgd with a peak flow of 1.7 million gallons per day. The population equivalent of the organic load is 70,000 persons. The anoxic and aeration tanks were bolted, baked-epoxy coated steel tanks with fine bubble air diffusers. The three membrane trains were contained in rectangular steel tanks in a separate metal frame building. Transfer of recirculation flow was done with a unique air lift pumping system to provide a twelve times denitrification recirculation flow. The system is fully automated and requires minimal operator attention. Total project cost was approximately $5 million.
Ore-Ida Foods Inc., Boise, Idaho
Provided planning, design, and construction services on several projects including:
- Water Reuse. Completed a water reuse feasibility study and design for treating 300,000 gallons per day (gpd) of final effluent. Part of this water will be made up by defrost water (approximately 50,000 gpd). Using this water directly for reuse eliminates the need for it to flow through the secondary facilities, thereby reducing the hydraulic load on treatment facilities and discharge to the Snake River.
- Wastewater Treatment Upgrades. Design of a new recirculation pump station to be incorporated into an existing biofilter-activated sludge treatment system. The pump station houses three 10,000‑gpm pumps that pump a combination of primary effluent, RAS, and ABF recycle to the distribution system on the biofilters. Other work includes design of a second activated biofilter utilizing redwood media; process design calculations and design for the selector, activated sludge system, and aeration requirements; and replacement of the media in the existing activated biofilter with vertical flow plastic type media.
Ore-Ida Foods, Inc., Plover Wisconsin
Provided planning, evaluation, and design on several projects, including:
- Design of an activated-sludge treatment system at potato processing facility. Used bench-scale testing to calculate process kinetics and sizing parameters and designed a two-basin activated sludge system for nitrification, with a selector channel designed for filament control. In addition, designed the primary treatment system, including solids dewatering, as well as the primary clarification system, the scum-pumping and removal system, and site piping and plumbing.
- Wastewater characterization study that resulted from a 1-mg/L phosphorus limit imposed on the facility’s treated wastewater discharge to the Wisconsin River. Wastewater treatment at this facility includes screening, primary sedimentation, anaerobic treatment utilizing upflow anaerobic sludge bed technology, nitrifying activated sludge, and belt filter press sludge dewatering. The study determined the primary sources of phosphorus in the wastewater, and evaluated methods to control the phosphorus either through changes in factory operations or treatment system modifications. A concept to control phosphorus through a combination of lime precipitation and biological phosphorus removal was developed. The study findings and plan were then used to negotiate a permit relaxation to an effluent phosphorus concentration of 6 mg/L.
- Phosphorus control treatability study and preliminary design to confirm the effectiveness and limitations of the recommended phosphorus control plan and to refine final design criteria.
- Final design of phosphorus control facilities.
Penwest Foods, Inc., Richland, Washington
Design and construction of a pretreatment system, which included an above ground, steel primary clarifier for removal of residual starch with a vacuum drum filter for solids dewatering. The primary effluent was followed by a anaerobic sludge blanket biological treatment system, which was designed to remove 85% of the total Biological Oxygen Demand (BOD) prior to discharge to the municipal treatment works.
Grain Mill Products
Kellogg Company, Battle Creek, Michigan
Provided planning, design, and construction services on several projects including:
- Pilar, Argentina.
Process selection and preparation of a turnkey bid package for a wastewater treatment facility to treat 182 m3/day of process waste, 23 m3/day of sanitary waste, and 22 m3/day of filtrate return flows. Coordination between Kellogg’s corporate headquarters in the U.S. and on-site construction managers was required to ensure that local building and environmental requirements were met. Process selection was based on the client’s desire to have a system that was easy to operate, provided reliable treatment, and was cost-effective. The system selected consisted of pumping, screening, equalization, pH adjustment, activated biotower, activated sludge, clarification, disinfection, and effluent monitoring prior to being discharged to a local river. - Guangzhou, China.
Design of a wastewater pretreatment system required to remove coarse solids and adjust pH prior to discharge to a wastewater treatment facility that serves the industrial area of Guangzhou. - India and Venezuela.
Wastewater treatment process review two breakfast cereal processing facilities. The reviews included verifying flow and loading information, confirming unit process sizing criteria, identifying alternate treatment systems, calculating waste solids production, and verifying that the solids handling and disposal systems were adequate for the anticipated loads. The process reviews were used by Kellogg to initiate required changes in the design of the treatment systems, which resulted in a significant reduction in operational problems during start-up.
Sugar and Confectionery Products
The Amalgamated Sugar Co., Nampa, Idaho
The project involved the treatment of high strength flume water for the reduction of Chemical Oxygen Demand (COD). At the end of the beet processing campaign, flume water is drained into a 12‑million-gallon storage pond for reduction of COD prior to land application. Due to the initially high COD of 25,000 mg/l, organic acids formed in the storage pond, causing severe odor problems and reduced treatment efficiency. Analyses were preformed to determine the oxygen and supplemental nutrient requirements needed to sustain a viable bacteria growth. Recommendations included seeding of the basin with fresh waste sludge from a local treatment plant, the addition of a phosphorus supplement, and adding 600 hp of aspirating aeration.
Bay County Department of Water and Sewer, Bay City, Michigan
Wastewater characterization project involving review of the design basis and operating procedures for this 10 mgd wastewater treatment plant and characterization of a major loading source, the wastewater from a sugar beet processing facility. The study identified the nature and impact of the sugar beet wastewater on the treatment plant and recommended operational practices to minimize these impacts during the sugar beet processing season.
Pacific Northwest Sugar Company, Moses Lake, Washington
Design included clarifier, solids pump station, sediment ponds, condensate pond, and aerated flume pond.
Miscellaneous Food Preparations and Kindred
Frito-Lay, Inc., Rancho Cucamonga, California
Evaluation of pretreatment facilities for appropriate technologies which could achieve a minimum of 35% removal of Chemical Oxygen Demand (COD) and 70% removal of Total Suspended Solids (TSS) from wastewater generated by corn snack food processing. Appropriate treatment technologies evaluated included dissolved air flotation, primary clarification, and fine screening. The evaluation also reviewed cost-effective means of dewatering and disposal of the waste solids removed from the wastewater pretreatment facilities. The recommended system included coarse screens, a 35-foot diameter primary clarifier, and belt filter press for sludge dewatering.
Power Bar Foods, Boise, Idaho
Provided evaluation and design services on the following projects:
- Pretreatment Study - The study was prompted by rising sewer bills, which could have cost up to $800,000 in connection fees plus monthly user charges. This wastewater study was initiated to:
- Determine if the wastewater monitoring station is measuring accurately and pulling representative samples
- Determine if there are cross connections or inflow and infiltration (I&I) problems that have impacted the flows
- Develop processes to minimize flow and loading discharges
- Present pretreatment alternatives and cost comparisons.
This study provided the guidance required to manage their flows and loads more effectively and maintain their sewer lines to prevent unrepresentative sampling. Thus, user rates were reduced dramatically.
- pH Control System Design – Design Modifications to an equalization system to include pH control. Modifications included improved mixing and pH measurement.
StarKist Caribe, Puerto Rico and American Samoa
Reviewed operation and equipment for DAF treatment and conducted on-site studies. The study recommended equipment improvements and chemical dosage refinement.
Weight Watchers Food Company, Pocatello, Idaho
Planning and economic analysis for a new wastewater pretreatment system. The facility discharges wastewater directly to a municipal treatment plant. Based on limited wastewater treatment capacity at the treatment plant and relatively high user rates, Weight Watchers initiated a feasibility analysis for the installation of a pretreatment system to reduce BOD and TSS loadings to the City. The analysis included an economic evaluation based on the cost of the pretreatment system versus the reduction in monthly user charges due to reduced discharge loading.
Multiple-Client Projects
Nampa Industrial User Group, Nampa, Idaho
We were retained by Nestle’ USA, Simplot Meat Products, The Amalgamated Sugar Company, and Sorrento Lactalis (collectively referred to as the Nampa Industrial User Group), to evaluate the feasibility and cost of an industrial pretreatment facility. The work involved flow and load projections; evaluation of a low rate covered anaerobic lagoon system and a high rate up-flow anaerobic reactor system; development of the conveyance and land cost associated with several sites; and a comparison of a City-owned versus an industry-owned pretreatment facility. The study concluded with an estimation of the overall capital and annual costs with and without a pretreatment facility.
Unified Sewerage Agency, Washington County, Oregon
Odor and treatability studies, pretreatment evaluation, and implementation of industrial user process modifications for Forest Grove Wastewater Treatment Facility. The plant suffered from 10:1 COD spikes during corn processing; color episodes and pH excursions during berry processing; excessive sulfide loading from maraschino cherry processing; and high COD discharges from meat processors and computer chip manufacturers.
Chemical/Metals
Davis Monthan Air Force Base, Tucson, Arizona
Design Manager: Design of an industrial wastewater treatment facility. Redesign effort involved directing flow from five building areas for treatment. Treatment included storm water equalization, oil/grease removal, iron co-precipitation for cadmium, filtration, ion exchange, and solids dewatering.
Army Ammunition Plant, Modesto, California
Design Manager: Groundwater cleanup treatment system. The project was conducted for the Army Corps of Engineers and included chromium removal by hydroxide precipitation and cyanide removal by ion exchange.
Pendleton Woolen Mills
Lead Design Engineer: Modifications to activated sludge wastewater treatment process. The rehabilitation design involved reuse of existing treatment units to minimize cost with improvements to the RAS/WAS system and sludge land application system. The solids disposal design included a storage tank, mixing equipment, irrigation pumps, and irrigation system.