This is an illustrative scenario showing how Reynolds & Bauhm equipment can be configured for this application. Every site has unique requirements — contact us for a solution tailored to your specific wastewater characteristics.
Large mixed brewery-dairy wastewater plant processing 800 m3/day with combined COD 9,000 mg/L. Brewery contributes high-strength effluent from craft beer production (small batches, frequent recipe changes). Dairy adds whey permeate, cream, and CIP chemical consumption. Unique challenges: variable pH 3.5-11 from recipe changes and CIP, emulsified fats stabilised by brewery proteins, iron contamination from brewery equipment (up to 80 mg/L Fe), and seasonal volume swings of 50-120%. Discharge requires COD <50 mg/L, fat <3 mg/L, iron <0.5 mg/L for direct reuse as boiler feed makeup. Electrocoagulation chosen to eliminate external chemical dosing and use existing iron in wastewater as sacrificial anodes.
A six-stage hybrid train — from raw brewery + dairy effluent to boiler-feed-quality reuse water. Each stage links to the relevant equipment or process page.
400 m³ equalization tank with mixing and online pH monitoring. Acidic brewery batches (pH 3.5–5) mix with alkaline dairy CIP (pH 10–11) for natural buffering to pH 6.5–8.0. 12-hour retention smooths flow and load; automated acid/caustic trimming holds pH 7.0 ±0.3. Hot dairy streams blended with cooler brewery waste keep 25–30°C, preventing thermal shock and keeping fat liquid.
Heated DAF at 36°C with dissolved air at 0.45 MPa. Brewery proteins act as natural surfactants — no polymer needed. Ferric chloride (150 mg/L) enhances phosphate precipitation. Float at 15% solids (65% fat, 25% protein, 10% solids) sold to a biogas plant as high-calorific feedstock. Skimmings removed continuously to prevent re-entrainment.
Electrocoagulation with iron anodes (20 A/m²) generates Fe²⁺ in-situ — no external iron dosing. A 30-min EC cell destabilises emulsified fats and coagulates colloidal proteins; electrolytic hydrogen micro-bubbles assist flotation. Fe(OH)₃ precipitate adsorbs organics, and sludge volume is 40% below chemical coagulation.
Medium-pressure UV (1.5 kW per m³/h) with H₂O₂ at 800 mg/L. UV photolysis generates hydroxyl radicals that break down brewery hop compounds (alpha/beta acids) and dairy lactose derivatives. UV fluence 800 mJ/cm² gives 4-log coliform reduction. UVT is monitored — if it drops below 65% from colour, H₂O₂ dose rises automatically. No chemical sludge produced.
Lead-lag GAC columns (3.5 m diameter, 25 min EBCT) adsorb residual UV oxidation by-products and trace organics. Critically, GAC also captures residual dissolved iron from electrocoagulation — polishing 2 mg/L to <0.3 mg/L to protect the RO membranes from iron fouling. Iron breakthrough is flagged by a yellow tint; carbon is replaced every 14 months.
Two-stage RO with iron-fouling-resistant low-charge (LFC) membranes, anti-scalant 3 mg/L at pH 6.5. First pass: 92% recovery, COD to <20 mg/L, iron to <0.05 mg/L. Second pass: conductivity 1,500 to <50 µS/cm, silica <0.5 mg/L. Final effluent meets boiler-feed standards (BS EN 12953) at 88% overall recovery; concentrate recycles to the equalization tank.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
400 m3 mixer tank, pH/temp monitoring, acid/caustic trimming, 12h retention.
View EquipmentDAF 35 m3/h, 36°C, protein-enhanced flotation, 0.45 MPa, continuous skimming.
View EquipmentIron anode EC, 20 A/m2, 30 min HRT, 2.5 kWh/m3, H2 micro-flotation.
View EquipmentLead-lag 3.5 m diameter, 25 min EBCT, iron polishing function, 14-month life.
View EquipmentLFC iron-resistant membranes, 88% recovery, boiler feed quality output.
View EquipmentRepresentative performance data based on typical operating conditions for this equipment configuration.
Explore the full range of equipment used in this and similar applications.
Multi-point acid/caustic dosing for equalization and RO inlet pH control.
View EquipmentH2O2 day tank with metering pump, anti-scalant, and caustic preparation.
View EquipmentThyristor-controlled DC rectifier for EC cell, 0-500A, auto current control.
View EquipmentDiscover how these treatment processes connect to form complete wastewater treatment solutions.
Iron anode EC using existing wastewater iron, eliminating external chemicals.
Photochemical oxidation for hop compounds and lactose derivatives.
Heated DAF leveraging natural brewery proteins for flotation.
GAC with iron polishing to protect RO membranes from fouling.
Two-stage RO with iron-resistant LFC membranes for boiler feed.
pH and flow balancing between acidic brewery and alkaline dairy.
Our engineers will adapt this equipment configuration to your specific wastewater analysis, flow rate, and discharge requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.