Acquire and Install Unique Air and Pressurized Ozone Technology at Tofino Fish Processing Plant to Reduce Pathogens and Biological Loading of Processing Wastewater

Final report

Pacific National Processing
AIMAP-2010-P01

Table of contents

Executive Summary
1. Project Description
Introduction
Project Rationale
Methods/Solutions
Project Objectives
2. Results
3. Changes and Revisions during the Project
Technology
4. Future Activities
5. Using Project Data for Development of the Seafood Processing Markets for Muddy River Technologies Inc

Executive Summary

Pacific National Process Ltd. located in Tofino on the west coast of Vancouver Island is an independent processor of farmed Atlantic salmon.  They work exclusively with the 14 Mainstream Canada farms located on the west coast of Vancouver Island processing over 16,000 tonnes of farmed product per year. The plant employs 50 people fulltime and provides a rare opportunity for year round employment for the 1700 residents of Tofino and is an important economic contributor to the area.

The plant produces up to 250m3 of wastewater plant daily that contains solids, blood, viruses and bacteria and other compounds. The wastewater currently flows through the District of Tofino sewage system and is discharged to the marine environment with minimal treatment. This has been a concern for some time and Pacific National Processing has been actively looking for a solution.

In the summer of 2009, three treatment systems were compared on the basis of effluent quality and capital investment and Muddy River Technologies Inc. (MRTI) provided a technology that was both cost effective and would produce effluent of the desired quality. A pilot test was conducted in September 2009 with promising results and the system was approved for full implementation. A contribution application was submitted to the DFO Aquaculture Innovation and Market Access Program (AIMAP) in December 2009 and was approved in March 2010.

The water treatment system was fully installed by March 2011 and commissioned and tested by September 1, 2011. During this time modifications were incorporated to ensure the technology produced effluent that meets water quality requirements. Ongoing revisions include technology changes to ensure large particles are more effectively removed, to reduce system shut down from fluctuating power and that systems are independent reducing the time a trained technician is required.

Muddy River Technologies Inc. in Delta BC manufactures water treatment technology and has provided a unique solution for this project with their proprietary technology. This innovative technology is appropriate for all BC and Canadian seafood processing companies and will support continuous development of the aquaculture industry by enabling the adoption new technologies that enhance environmental performance.  This project is a key demonstration of how this technology fits the aquaculture industry requirements and as such is an essential first step in Muddy River Technologies accessing this new market.

1. Project Description

Introduction

Pacific National Processing Ltd. is a wholly owned subsidiary of EWOS Canada Ltd. of which
Mainstream Canada is a division. Mainstream Canada manages and supplies direction to the operations of Pacific National Processing Ltd. They have the sole purpose of processing Atlantic salmon raised at the 14 Mainstream Canada farm sites on the west coast of Vancouver Island. The plant is located in Tofino on the west coast of Vancouver Island and processes approximately 16,000 tonnes of cultured fish per year and employs 50 people fulltime, a rare opportunity for year round employment for the 1700 residents of Tofino. An estimated 500 indirect jobs are created from the processing and salmon culture operations which are also a considerable economic contribution to the area. Pacific National Processing and the District of Tofino have worked collaboratively in the past and will continue to do so in the future to manage water quality issues, periods of freshwater shortage, and to improve the quality of wastewater entering the municipal collection facilities. This project is just one example of the ongoing cooperation between Pacific National Processing and the District of Tofino.

Project Rationale

The wastewater from the Pacific National Processing plant in Tofino was being discharged through the municipal system to the marine environment with components largely intact. This was not an acceptable situation for the processing plant, Mainstream Canada who operates the processing plant, the District of Tofino who is responsible for disposal of wastewater through the municipal sewage system, nor the community and area residents including First Nations.

Combined with the seawater used to transfer fish from the transport boats and rainwater collected from the site, as much as 250m3 of wastewater can be produced from the processing plant daily. These wastes contain solids, blood, viruses and bacteria and other compounds normally produced by processing facilities.

The raw wastewater from the processing plant is processed through one of two municipal comminutor stations which grind and screen solids and pump remaining sewage to the town’s marine outfall without further treatment. The processing wastewater has significant biological loading (suspended and dissolved solids, ammonia, and phosphate) and there was no ability to reduce these levels just using the municipal system.

Methods/Solutions

This project was a joint undertaking between Pacific National Processing, the District of Tofino and Muddy River Technologies to install and evaluate a water treatment system with unique Air MASS and Pressurized Ozone MASS units to determine efficacy in removing pathogens and harmful substances.

Project Objectives

• Reduce the level of potentially harmful components in the processing plant wastewater being discharged to the marine environment;
• Install treatment method to ensure the wastewater meets the new District of Tofino standards;
• Install treatment method to ensure wastewater meets the Mainstream Canada requirements;
• Expand on the existing collaborative working relationship with the District of Tofino to a full partnership to address wastewater and freshwater issues in the community; and
  
• Communicate the project information to the public and support the adoption of the technology in the aquaculture industry.

This project was designed to ensure Pacific National Processing meets the highest standards for effluent for the District of Tofino. In addition to the District requirements, the processing plant is further required to meet the Mainstream Canada standards for removal of fish pathogens (bacteria and viruses) in all processing wastewater. These requirements are compatible with the Ministry of Environment Biosecurity Procedures for IHNV Positive Farm Sites recommendations which call for 100% removal of pathogens during a disease outbreak.

The first goal of this project is to produce effluent that meets the District of Tofino standards, and equally as important the second goal is to produce effluent without harmful bacteria and viruses. A long term vision for the processing plant is to treat effluent and produce water that can be re-used.

In the pilot project, the Air MASS and Pressurized Ozone MASS system was identified as having the key components that will reduce biological load and destroy pathogens and provide a technology that works most efficiently with a constant flow of wastes, with particles greater than 500 microns removed and operating for 18 hours in a 24 hours period.

2. Results

The technology was fully implemented at the Pacific National Processing plant in Tofino by March 31, 2011 with commissioning and testing completed September 1, 2011. The results show the technology was sufficient for all water effluent quality targets to be reached however ongoing improvements continue to increase consistency of effluent, reduce the system down time, and reduce the time required for a trained technician to be present.

The system performance met or exceeded design criteria for disinfection, suspended solids removal and suspended solids related biological oxygen demand (BOD), after the coagulation and flocculation chemicals used were modified.

Elevated phosphorous levels during the pilot were due to a cleaning compound that was being used on site at the time; it has now been replaced by a phosphate free agent. Elevated ammonia levels are observed in the full scale results due to a cleaning agent used during washdown after fish processing; post processing wastewater was not assessed in the pilot. Total suspended solids (TSS) concentrations in the pilot and full scale effluents are comparable. BOD levels in the waste water treatment plan (WWTP) effluent is significantly higher than suggested by the pilot; possible causes include a higher overflow rate in the air floatation vessel, insufficient pre-screening, and chemical effects from post production cleaning agents.

The system was designed to incorporate all equipment into two shipping containers. Installation of equipment into the shipping containers began during the summer of 2010, and was completed by the end of 2010. During the spring of 2011 the package plant and ancillary systems were installed on site. By early April, the installation was complete, and commissioning commenced.

3. Changes and Revisions during the Project

Technology

The MRTI MASS (Micro Air Separation System) was commissioned in early 2011 and the initial results were very encouraging, however, as the system continued to run, the quality of the effluent did not meet the project goals. During the project, the following modifications were made:

• Modifications to coagulants and polymers used, as well as concentrations
• Elevated pH was required in order to achieve satisfactory effluent quality however the high pH caused excessive foaming in the Ozone MASS section and a reduction of pH was then required at the inlet to the Ozone MASS; and
• To enhance the Ozone MASS performance, a recycle line was installed to re-circulate a portion of clarified, disinfected effluent and co-mingle it with the Ozone MASS inlet stream.

4. Future Activities

Since the completion of the system commissioning, it has been determined that to perform effectively, efficiently and consistently, the system requires a constant, equalized influent flow that is largely devoid of fish scales and solid matter. The following options are being explored to enhance the performance of the MRTI MASS system:

Removal of Large Solid Particles

When excessive heavy solids are pumped into the MRTI Primary MASS the clarified water outlet becomes plugged resulting in water flooding the sludge outlet. This makes it necessary to open the drain valve on the MASS each time the WWTP is started in order to remove the heavy solids and flush the clarified water outlet.

1. The current screen on the rotary drum filter (500 microns) can be changed to a finer mesh screen (250 microns).
2. Solids currently settle on the bottom of the equalization tank and are taken up by the pump causing 1) solids to be introduced into the system and 2) the pump to clog and quit and not provide a consistent flow to the treatment system. One option is to move the pump suction a couple of feet above the bottom of the tank.
   
   Consistent Mixing
   
   Good mixing is essential for efficient operation as it provides for a stable and consistent influent into the treatment system. Also, it is important that the water in the equalization tank is processed on a consistent basis and not allowed to stand for long periods of time.
   
   
3. The mixing device within the equalization tank, used to produce a homogenous mass, does not operate effectively due to power fluctuations. A more efficient method of mixing is being researched.
4. Scales and other solids that accumulate in the bottom of the equalization tank are currently removed manually on a regular basis. The equalization tank suction will be raised so heavy solids build up could be minimized by recycling these solids back to the raw water sump via the existing bottom suction line for reprocessing.
   
   Operation and Maintenance
   
   
5. Plumbing installed exterior to the treatment system enabled efficient and cost effective installation and ease of maintenance but will now require heat tape or other method to keep from freezing during winter.
   
   Chemicals
   
   The MRTI system was designed and constructed to treat the 250m3 of wastewater that the plant produces on a daily basis. The specific design criteria for system hydraulic loading were to ensure that the loading for all anticipated flow rates would not exceed 122 LPM/M2. At a flow rate of 208 LPM the hydraulic loading for the primary MASS is: 90 LPM/M2.
   
   The majority of wastewater treatment systems require the use of chemicals to assist with separating solids from the wastewater stream. Pacific National Processing’s system utilizes three different chemicals to assist in the overall treatment of the plant wastewater and they are: coagulant ferric chloride (43% solution), sodium hydroxide (45% solution) and polyacrylamide polymer. A stock of chemicals is kept on site in drums and totes to provide an uninterrupted supply to the system.
   
   
6. A transfer pump system for restocking the feed tanks has been set up in order to reduce the amount of direct contact the employees have with the chemicals needed for the treatment process.
   
   Electronics and Power Supply
   
   
7. Due to the large number of variables present in the process, additional automation will be installed in order to remove the variables and the need for a trained technology to be present at all times.
8. Undependable power supply has caused some of the electronic components that use low voltage to lose their settings and revert back to factory defaults resulting in poor function of many components and damage to the PLC components requiring replacement. A solution is being researched.

5. Using Project Data for Development of the Seafood Processing Markets for Muddy River Technologies Inc

Given the current state of the farmed fish processing industry in the eyes of the general public and the negative perceptions that exist, it comes as no surprise that the industry as a whole is investing hundreds of thousands of dollars to try and improve its image. While the average person would not normally be aware of the fish processing portion of the cycle of production most people are aware of the potential for disaster that exists on the British Columbia coastline should a blood borne virus escape into the natural environs to infect the wild species.

The Muddy River treatment system which can claim its ability to not only reduce TSS and subsequent BOD, can also offer disinfection which is not only perceived, but is indeed far and away the most critical step.  In addition, the method of disinfection, ozone gas, is recognized as a natural product which, while offering an indiscriminate and highly effective disinfection process, also becomes harmless with a very short half-life and a natural return to oxygen as a by-product.

The Muddy River system has a highly efficient method of mass transfer of gas thereby allowing for safe and effective treatment of waste streams and consequent viral control and disinfection.

It is our intention that we make all farmed fish processors throughout the world aware of this technology as the inescapable reality of blood borne virus is upon us and unlikely to recede anytime in the near future. MRTI will complete this through international tradeshows, industry trade magazines and industry focused direct mail both physical and electronic, incorporating testimonials.

MRTI intends to take a targeted approach starting with Canadian processors, on the west and east coasts and expanding to Europe and South America. Mainstream will play a critical role in assisting MRTI with the marketing of our MASS Ozone System as they host the system and are the source of the data which we will use to promote our technology. We are in the process of developing our marketing plan and we look forward to working with Mainstream in an effort to promote this home grown, innovative and environmentally responsible technology.