Task

A dairy company in southern Germany processes whey into high-quality whey protein and lactose powder. The end products are used in the food industry worldwide - including as ingredients for dairy products, sausage products, baked goods and confectionery, baby food, sports nutrition and drinks.

In 2023, ALMAWATECH was awarded the contract to build a wastewater treatment plant to treat the vapor condensate produced during the manufacture of whey protein and lactose powder.

Design data

Preparation quantity:

  • Max. 600m3/d

Objective:

  • Pre-treatment to reduce biofouling on the membranes in reverse osmosis systems, resulting in significant savings in operating costs and increased operational stability

Solution & implementation

Our vapor water treatment includes a 2-stage biofiltration (ALMA BioFil Compact) with denitrification, nitrification and carbon degradation. Special clay balls are used as filter material and growth bodies for microorganisms in the biofiltrations. The many pores allow the formation of a multi-layered biofilm with aerobic and anoxic areas, which enables efficient degradation of various substances and a stable biocenosis.

Three biofiltration stations connected in series were built. The first biofilter is used for denitrification, while ammonium is converted into nitrate (nitrification) and carbon compounds are broken down in the following biofiltration stations. The treated water from biofilters II and III is fed back into biofilter I (upstream denitrification).

To ensure a sufficient supply of micronutrients and to guarantee the biodegradation of nitrogen and carbon compounds, a nutrient solution specially adapted to the composition of the vapor condensates is dosed ( ALMA AQUA series operating fluid).

After biological treatment, the treated wastewater is passed through gravel filters (ALMA FIL)to remove sludge flocs and microorganisms. The wastewater is then treated further in reverse osmosis systems.

The purpose of the ALMA BioFil Compact is the pre-treatment of water that is to be further treated in reverse osmosis systems .

Pre-treatment enables cost-efficient and space-saving treatment of the water. This significantly reduces the operating costs for membrane replacements and membrane cleaners to prevent biofilms on the membranes. The profitability of pre-treatment using the ALMA BioFil biofiltration process varies depending on the system and water composition and can be achieved within 2 to 6 years through savings in operating resources and higher system efficiency.

References cheese dairies & dairies

Customer Dairy
Commissioning May 2024
Location Southern Germany
Process Biofiltration,
Filtration
Product ALMA BioFil Compact,
ALMA FIL

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