1. Wastewater Management at an Animal Protein Rendering Facility J.B. Hess, W.A. Dozier, J. Spann and B. Thomas Poultry Science Department, Auburn University and American Proteins, Hanceville, AL

2. Rendering Industry Recycling Inedible Human Food – Useful Products Removed from Poultry Meat Production Waste Stream Protein Meals for Pet Food and Agriculture Oil (Fat) Recovery for Biodiesel and Animal Feed Usage

3. Rendering Industry Input Intensive Transportation of Raw Product Cooking – Energy Usage – Water Usage and Recovery Waste Management – Air – Water

4. American Proteins Hanceville Alabama Rendering – Regional Poultry Plants – Offal – Frozen Farm Mortalities Poultry Products – Pet Food Animal Proteins – Feed Grade Animal Proteins – Oils

5. American Proteins Largest Poultry Rendering Plant in the US Offal from 20 Poultry Processing Plants 2 Billions Pounds per Year 1000 Truck Loads of Offal per Day Odor Control and Waste Management Compliance are First Order Issues

6. American Proteins Odor Control Scrubbers Anaerobic Lagoon Cover Biofilter Bed – Cooker Gas Exhaust – After Scrubbers

7. American Proteins Wastewater Facility Pretreatment Anaerobic Lagoon Two Aerobic Lagoons Four-Stage Activated Sludge System Tertiary Filtration Ultraviolet Disinfection

8. American Proteins Wastewater Treatment System Pretreatment 235,000 gpd Condensate 600,000 gpd Anaerobic Lagoon Aerated Lagoon Aerated Lagoon Anoxic Reactor #1 Activated Sludge Oxic Reactor #2 Activated Sludge Clarifier Disk Filter UV Disinfection Waste Sludge Lagoon Mulberry Fork Warrior River Cooling Lagoon Reuse Lagoon Feed Grade & Pet Food 6,000,000 gpd 30,000,000 gpd Make up Water Up to 800,000 gpd Averages 450,000 gpd Reclamation of Fats & Solids Bio Gas

9. Pretreatment Process - Mechanical Surge Wet Well Fine-Mesh Drum Screen First DAF Treatment Second DAF Treatment – Polyamine – Cationic – Anionic Pumped into the Anaerobic Lagoon

10. DAF Units After Hycor Fine Mesh Drum DAF #1 – Floating Solids – Mainly Fats – Back to Rendering Flow Equilizational Basin DAF #2 – Flocculation Tube - Polymers To Anaerobic Lagoon

11. Anaerobic Lagoon Solids and flocculated Fats Returned to Protein and Fat Recovery Lagoon - Covered Biogas Harvest – Used to Heat Boilers

12. Biogas Harvested from Anaerobic Lagoon 2 Million Cubic Feet per Week 70% Methane (carbon Dioxide, Hydrogen Sulfide) Biogas mixed with natural gas at a 10% rate to fuel boilers Could use more

13. Aerobic Lagoons

14. Activated Sludge Process Four Reactors Two Anoxic – Denitrification Two Aerobic – BOD Reduction, Nitritfication Clarifier – Removes Final Solids Tertiary Filtration Disk

15. Bioreactors 3 (anoxic) and 4 (oxic)

16. Clarifier/Tertiary Filtration/ Ultraviolet Disinfection

17. Water Use/Recovery/Reuse Potable Water Intake – 90,000 Gal/Day 50,000 Gal. is for Boiler Makeup Inflow of 900,000 Gal/Day – 2/3 Condensate from Cooking Process – 300,000 Gal/Day Rendering Process

18. Water Use/Recovery/Reuse Production Reuse Rate of 6 Million Gal/Day Cooling Water System Recycles 30 Million Gallons/Day – Condensing Vapors from Cooking Discharge Rate of 400,000 Gal/Day Discharge – Mulberry Fork of Warrior River

19. Water Reuse

20. Supervisory Control and Data Acquisition Monitoring System Inline Ammonia Nitrates MLSS pH ORP

21. Nutrient Reductions Through System Biological Oxygen Demand – 99.96% Chemical Oxygen Demand – 99.65% Total Suspended Solids – 99.81% Total Kjeldahl Nitrogen – 99.52% Ammonia – 99.95% – From 2,500 mg/L to <0.5 mg/L Oil and Grease – 99.90%

22. Some Comparisons Organic Loading – City of 900,000 People Hydraulic Loading – City of 10,000 People Cullman County – 80,000 People

23. Value of Reclamation Reclaimed Materials Proteins and Fats 400,000 Pounds/Week $500,000 per Year Waste Disposal Cost Avoidance – $350,000 Per Year

24. Awards 2001 Excellence in Industrial Wastewater Treatment (Physical/Biological Treatment) - Alabamas Water Environment Association 2003 Clean Water Award Honorable Mention, Full Treatment Category – U.S. Poultry and Egg Association 2004 Clean Water Award, Full Treatment Category –U.S. Poultry and Egg Association 2007 Honorable Mention for Facility of the Year Award –Environment Protection 2008 Excellence in Industrial Wastewater Treatment (Biological Advanced Treatment) - Alabamas Water Environment Association 2010 Clean Water Award, Full Treatment Category –U.S. Poultry & Egg Association, March 2010

25. Conclusions American Proteins Rendering Plant Starts with Large Loads in Waste Water Handling Proven Systems in Mechanical and Biological Control Handle that Load Waste Solids are Recycled Odor Control Systems are Important as Well Consistent Quality has led to Industry Awards

26. Wastewater Management at an Animal Protein Rendering Facility J.B. Hess, W.A. Dozier, J. Spann and B. Thomas Poultry Science Department, Auburn University and American Proteins, Hanceville, AL