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Case Study

Chicken Processing Plant Grease Trap and Aeration Ponds

Total Suspended Solids, Biological Oxygen Demand, Ammonia, Hydrogen Sulfide, and Sludge Reduction

Problem

A large chicken processing and rendering plant in Southeast Georgia faced numerous problems associated with the treatment of wastewater on site for a daily flow of 1.8 million gallons. The 1st problem was a heavy fat, grease and oil build up on the surface of a 10 thousand gallons grease trap located down-line from the rendering building. The solids build up on the surface of the grease pit exceeded 2.5 ft. and forced the plant to remove the cap with a backhoe once the thickness reached the pit’s overflow level. A 2nd problem was high TSS (750-1,100 ppm), COD/BOD (1,400-1,800 ppm), and ammonia nitrogen (50-70 ppm) in the plant’s two aeration ponds. The ponds are in sequence with the first pond’s capacity at 4.5 and the second at 14 million gallons. The plant has a land application permit allowing for irrigation of hay fields with treated wastewater. The 3rd problem was high H₂S levels from the aeration ponds.

Solution

To address the sludge cap problem on the grease pit, an Organic Product was applied through a pressure sprayer at a rate of 6-8-oz./gal. directly onto the surface of the cap. One quart of concentrated product was applied per treatment. The cap was treated twice each day. Within 7 days the cap was reduced to ~5 in. of tan foam. Treatment continued at same rate twice daily.

To address TSS, COD/BOD, ammonia nitrogen, and hydrogen sulfide problems in the aerated ponds, the Organic Product was applied. Pond #1 (4.5 million gallons) was shocked with 75 gal. and Pond #2 (14 million gallons) was shocked with 175 gal. This 10-20 ppm shock treatment was applied with a high-pressure hose to provide uniform coverage of the pond surface area and allow for better blending of the product into the wastewater. A daily maintenance program of 5-gal. (3-5 ppm of daily flow rate) of product would be metered into Pond #1 at the influent point. There was significant reduction in hydrogen sulfide odors with 48 hours of treatment. After 30 days of treatment the TSS and COD/BOD levels were reduced by 60-65%. The ammonia nitrogen levels were reduced by ~ 85%. The maintenance application rate of 5 gal./day continued.