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Project Scope

A sugar processing facility was experiencing hydrogen sulfide (H2S) odor issues in their process water stabilization ponds due to anaerobic conditions. The facility’s four identical ponds are 2,500 feet long, 400 feet wide and up to 12 feet deep, with a finger dike down the middle making each pond C-shaped. Each pond can hold approximately 80 million gallons when completely full. Anaerobic conditions develop in the lower layers of these ponds, leading to H2S generation and volatilization. The facility faces stringent seasonal perimeter ambient air quality standards for H2S concentration and is subject to escalating fines with every violation.

In addition, the pond treatment needs are highly variable as high chemical oxygen demand (COD) slugs and/or factory upsets mean that treatment decisions need to be made in real-time, based on measured and expected levels of sulfide, dissolved oxygen, ORP, COD, pH and temperature. Previously, the facility had been utilizing various chemicals, including peracetic acid and catalyzed hydrogen peroxide (H2O2) in totes to mitigate H2S, however, the facility was experiencing difficulty maintaining control of the H2S and was concerned with violating their permit. Given the large surface area and volume of the ponds it was essential that a cost-effective control method be identified and implemented. USP Technologies (USP) was contacted to provide a long term, viable solution.

Technology

Hydrogen sulfide (H2S) is a colorless gas with the characteristic foul odor of rotten eggs; it is heavier than air, poisonous, corrosive, flammable, and explosive. Many facilities, such as this sugar processor, have limits imposed on H2S emissions. Sulfide is generated by sulfate reducing bacteria (SRB’s) in the anaerobic layers of the ponds. H2O2 treats H2S by creating a zone of oxidation in which sulfides are oxidized before being released to the atmosphere. The reaction is as follows:

H2O2 + H2S → S0 + 2H2O

Sufficient dosing of H2O2 also prevents the formation of H2S by boosting dissolved oxygen and creating aerobic conditions hostile towards SRB’s per the following reaction:

2 H2O2 → O2 + 2 H2O

Solution

The sugar facility conducted an extensive survey of possible control methods and evaluated options on a lab scale prior to pilot testing. H2O2 was found to be the most cost-effective sulfide control agent in the ponds because of its low H2S treatment cost, ability to preferentially oxidize sulfide, including iron sulfide (FeS)

present in the water, permitting long-acting sulfide control by regenerating free ferrous iron (Fe+2) to bind more H2S.

USP provided a program demonstration in 2014, which first involved bringing in tanker truck quantities of H2O2 and pumping this directly into the ponds through fabricated floating distribution nozzles. The desired amount of H2O2 was pumped into specific sections of the ponds, which had anaerobic conditions prevailing, and then the truck would move on to the next section requiring treatment. This provided improved mixing, a lower cost of treatment per gallon, better sulfide control and lowered staff labor costs.

Building off of the success of the tanker treatment method, USP developed an engineered storage and dosing equipment system for H2O2 on each of the four ponds. This allows for treatment to be conducted whenever and wherever conditions warranted. Each of the systems have two floating manifold dosing lines, dubbed PeroxidonsTM, into which H2O2 and pond water are pumped. These lines stretch along the length of each half of the C-shaped ponds, with outlets spaced to distribute H2O2 across the surface of the entire pond. In addition, on each pond 6 – 8 additional dosing lines were installed that allow for concentrated treatment of hotspots including dead zones and the incoming flows. As a result, performance, ease of operation and cost-effectiveness could be improved with the ability to target treatment to specific sections of the pond.

Overall, USP’s full-service hydrogen peroxide program has saved the plant a significant amount of money in fines and operations. USP also maintains a consistent presence on-site, aiding in the daily collection of water and air data, which unburdens plant staff and improves the sulfide control decision-making process. In a collaborative and results-focused approach, USP continues to work closely with plant staff to find ways to improve the program’s effectiveness and to continue lowering the overall cost of treatment.

Treatment results include significant reductions in H2S, increased dissolved oxygen, cost savings compared to previous year’s solutions, reduced in-house labor associated with pond treatment and improved safety over tote handling.

Read More Download Large Ponds Hydrogen Sulfide Odor Control (pdf)[/vc_column_text][/vc_column][/vc_row]

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On a late Friday afternoon in June, a call came in to USP Technologies: a major poultry processing plant in the Southeast was in danger of violating their wastewater discharge permit.  They needed a solution fast or face fines, a temporary shutdown of operations and significant lost revenue.

The poultry plant’s 3.5 million gallon aerated wastewater treatment lagoon was unable to maintain sufficient dissolved oxygen (DO) and was unable to achieve ammonia and biological oxygen demand (BOD) removal requirements.  These conditions were brought about by a combination of warm seasonal temperatures of over >90 F, (lower O2 solubility) and higher than normal chemical oxygen demand (COD) loading to the treatment system.  In addition, the oxygen depleted lagoon was generating significant hydrogen sulfide (H₂S) odors.

The solution was a turn-key hydrogen peroxide dosing program to supplement the plant’s aeration equipment and get the lagoon DO levels back to a target range of 2 – 3 mg/L .  (See Supplemental Dissolved Oxygen for chemistry details on use of H2O2 for supplemental dissolved oxygen in biological treatment systems)

The USP Technologies’ Engineering team reacted quickly, working over the weekend to prepare an appropriately designed storage and dosing system and overnight shipping it to the site for installation in the field. The Team mobilized on Sunday to install and prepare the systems for a Monday start-up.  By Monday afternoon, the hydrogen peroxide system was fully installed and dosing started at about 3:00 pm, a mere 72 hours from the initial phone call from the poultry plant.

Sampling of the lagoon by USP Technologies demonstrated that, within 24 hours, the hydrogen peroxide addition to the aerated lagoons resulted in measurable increases in DO and elimination of H2S odors.  With continued dosing of hydrogen peroxide, the DO levels increased incrementally over the next several days. By the following weekend, DO levels were back in the 2 – 3 mg/L target range and the ammonia and BOD levels were trending downward.  The plant was out of discharge violation danger.  This poultry plant continued to use hydrogen peroxide for supplemental DO throughout the summer and early fall until cooler temperatures and lower COD loading to the lagoons allowed their aeration systems to maintain required DO levels on their own.  USP Technologies removed the storage and dosing systems at the conclusion of the project.

Read More Download our Case Study for Lagoon Supplemental DO (pdf)[/vc_column_text][/vc_column][/vc_row]

[vc_row][vc_column][vc_column_text]Two nitrate products producers were looking for a solution to their visual NOx emission plumes during frequent plant start-ups that would satisfy both public and regulatory expectations. USP Technologies was brought in to design a proprietary technology solution which introduces dilute H2O2 into the NOx absorber during start-ups to reduce emissions of NOx compounds such as NO and NO2. Removals of >90% are achieved, with the NOx being converted to high quality HNO3 product. The process is offered under license designed to minimize risk and disruption to operations. The license includes chemical storage and feed equipment, piping and instrumentation, process safety controls, installation and maintenance, training and documentation as well as H2O2 supply service. USP performed a thorough Process Hazards Analysis on the process, which has resulted in several interlocks and controls being incorporated into the basic design. The process is currently used safely in over 30 start-ups per year at two HNO3 manufacturing units. All piping, components, and controls needed to operate the process safely are included with the license and are installed by experienced H2O2 specialists. The H2O2 storage and feed systems are of modular design and are code-compliant, with years of safe operating history.[/vc_column_text][/vc_column][/vc_row]