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.
Combined brewery and dairy wastewater facility processing 500 m3/day of mixed effluent. Brewery contributes COD 5,500 mg/L, BOD 3,200 mg/L, and suspended solids 1,200 mg/L. Dairy contributes additional COD 3,000 mg/L, fat 800 mg/L, protein 400 mg/L, and calcium 180 mg/L as CaCO3. Combined influent COD 7,500 mg/L, fat 800 mg/L, pH varies 4.5-10.5. Site has no space for advanced biological treatment and requires rapid commissioning. Discharge limit COD <100 mg/L, TSS <10 mg/L, fat <5 mg/L, conductivity <300 µS/cm. The mixed waste creates unique challenges: dairy fat solidifies below 15°C, protein forms stable foam, calcium phosphate precipitates during pH changes, and variable brewery/dairy ratio causes organic loading swings of +/- 40%.
Step-by-step process configuration from raw wastewater to compliant discharge.
Heated DAF at 38°C with ferric chloride (250 mg/L) and high-molecular-weight cationic polymer removes 92% of dairy fats and 78% of brewery solids. Maintaining temperature above fat melting point prevents pipeline clogging. Float sludge at 8% solids — dairy fats recovered for rendering sale. DAF effluent COD reduced from 7,500 to 5,200 mg/L. Protein foam controlled with automated antifoam dosing. Retention 35 minutes at 0.5 MPa saturation pressure.
Effluent acidified to pH 2.8-3.0 for optimal Fenton reaction. FeSO4 (500 mg/L Fe2+) and H2O2 (1,500 mg/L) dosed in 4-hour reaction tank. Hydroxyl radicals (OH*) mineralise brewery humic acids and dairy lactose. COD reduced from 5,200 to 1,400 mg/L (73% removal). Iron hydroxide floc carries co-precipitated organics. Temperature rises 8-12°C from exothermic reaction — heat recovery to DAF influent.
pH raised to 8.0 (not higher) with soda ash to prevent calcium phosphate precipitation. Iron hydroxide precipitates at pH 7.5-8.0. Lamella clarifier captures precipitated solids at 5 m/h upflow. Sequestering agent (polyacrylate 5 mg/L) prevents calcium carbonate scaling on clarifier plates. Effluent COD 1,000 mg/L, TSS <25 mg/L. Calcium maintained <120 mg/L to protect downstream RO.
Two-column lead-lag GAC system adsorbs residual brewery organics and dairy colour. EBCT 30 minutes for thorough adsorption. Lead column breakthrough monitored by UV254 online analyser. Effluent COD reduced from 1,000 to 180 mg/L. Dairy whey-derived colour reduced from 350 to <30 Pt-Co units. Spent carbon regenerated thermally off-site. Biological growth on carbon prevented by upstream AOP ensuring zero biodegradable residual.
Two-pass brackish water RO with anti-scalant dosing prevents calcium and phosphate scaling on membranes. Anti-scalant (SHMP-based, 3 mg/L) plus pH adjustment to 6.5 with CO2. First pass achieves 90% recovery, COD 180 to <30 mg/L, conductivity 1,800 to <200 µS/cm. Second pass polishes to COD <15 mg/L, conductivity <100 µS/cm, TSS <1 mg/L. Permeate meets strictest discharge limits. Concentrate (10%) disposed as controlled waste.
Combined sludge from DAF, Fenton clarification, and RO reject at 4% total solids. Belt press thickens to 18% cake solids for off-site disposal. RO permeate achieves 90% overall water recovery from raw wastewater to final effluent. Daily water balance: 500 m3 raw in, 450 m3 permeate recovered for reuse in cleaning, 50 m3 reject + sludge moisture to disposal. Annual water benefits 146,000 m3.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
DAF 25 m3/h with heating jacket, 38°C operation, ferric/polymer dosing, fat skimmer, 0.5 MPa saturation.
View EquipmentSS baffled reactor 100 m3, FeSO4/H2O2 dosing, pH control, 4h HRT, heat recovery exchanger.
View EquipmentSS clarifier 80 m2, iron hydroxide separation, 5 m/h upflow, automatic desludging, calcium management.
View EquipmentLead-lag columns 3.0 m diameter, 30 min EBCT, UV254 breakthrough monitoring, thermal regeneration.
View EquipmentBWRO 8-inch membranes, anti-scalant dosing, 95% overall recovery, permeate TDS <50 mg/L.
View EquipmentBelt filter press for combined sludge dewatering to 18% cake solids, 150 kg DS/h capacity.
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.
FeSO4, H2O2, soda ash, polymer, antifoam, anti-scalant, and CO2 preparation with day tanks.
View EquipmentMulti-stage acid and alkali dosing for Fenton reaction and RO inlet pH control.
View EquipmentPlate heat exchanger recovering Fenton exothermic heat to pre-warm DAF influent.
View EquipmentDiscover how these treatment processes connect to form complete wastewater treatment solutions.
Fenton AOP for recalcitrant COD destruction in mixed brewery-dairy waste.
Heated DAF for fat and solids removal from dairy-brewery mixed wastewater.
Activated carbon polishing for residual organics and dairy colour removal.
RO polishing for final COD, conductivity, and TSS removal to reuse quality.
Belt press for combined chemical and physical sludge volume reduction.
Calcium phosphate and carbonate scaling prevention in mixed waste.
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.