Bega Cheese Upgrades To DAF Aeration At Wastewater Lagoon With Excellent Result

Bega Strathmerton EDUR DAF_Main Image

Bega Cheese Strathmerton

DAF & Venturi Aerator Transforms Wastewater Lagoon For Food Processing Company

bega cheese love venturi aerator - it transformed their wastewater lagoon
  • Bega Cheese
  • Strathmerton, VIC
  • 2019
  • Food Manufacturing
  • Wastewater Treatment
  • Venturi-Aerator and Daf Pump
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Project Background

In 2018, the Environmental Manager at Bega, Northern Victoria, Mr Sean Trebley, was given the task of upgrading their Strathmerton Plant’s wastewater aeration system.

The wastewater system consisted of a DAF unit, which flowed into an aerated lagoon, and after this the effluent was stored in 2 non-aerated lagoons during winter, before irrigation in summer.

A reduction in production reduced the wastewater produced, which meant that the existing aerators onsite at Bega Cheese were de-prioritised. This led to them not being maintained as well, until they became almost unusable, but they were difficult to access for repair. This lead to the choice of expensive repairs or finding a new system that was easier to access.

Bega Cheese Management decided to investigate other more efficient methods to aerate the site’s waste water.

Sean Trebley (Recently appointed Environmental Manager for Northern Region) had a positive experience dealing with Hydro Innovations, who are the sole importer for Gorman-Rupp Pumps. Gorman Rupp have a global reputation in the manufacture of efficient pump systems.

The project began in November 2018 and took two months, completed in late January 2019

Wastewater before the new Venturi Aeration system Bega

Image above: How the lagoon and DAF tank looked prior to the upgrade.

November signalled the removal of the old redundant aerators, consisting of 2x30kw and 6x 8kw aerators.

Concurrently, the design of the new switchboard and plans for the operation to run easily and reduce maintenance and control interferences was carried out. The system design incorporates a soft starter for the 30kw motor. A 24hour clock fully automates the system and removes any start up stresses to the drive motor and pump.

The aerator was delivered around a month into the project and placed into position. Next the pipework for the suction line was installed, ready for the inaugural start up.

The Lagoon after installing the Gorman-Rupp EchoStorm Venturi Aerator.

The Solution –EchoStorm Aerator Plus EDUR DAF Pump

In addition to the bank mounted EchoStorm Aerator, Hydro Innovations provided recommendations on how to greatly raise the efficiency and optimize their DAF plant prior to the water being transferred to the lagoon.

An EDUR DAF pump was suggested to replace their existing conventional system, which consisted of: A 7Kw recycle pump; a 3 phase air compressor; and an air saturation pressure vessel. The 1kW EDUR DAF pump replaced this entire set-up, delivering substantial energy cost savings.

It also greatly decreased the required maintenance cost and labour costs because of the reduced amount of equipment in the new system.

By optimising this system, more water can be pre-treated efficiently and effectively before being transferred to the lagoon. The pump draws water from the DAF tank, and creates a negative pressure in the suction line to enable it to draw in atmospheric air with the water. The air is sheered and pumped through a solution line with the water, where the air is forced into solution under pressure, before being released back into the DAF tank. The reduced pressure within the DAF tank draws the air out of solution, to form a tank full of micro-bubbles, which floats fat, oils and grease to the surface.

EDUR DAF Pump “waiting” to be piped into the system

The Result

The Bega Cheese team were happy with their new system. The DO levels in their lagoon had continued to improve and increase from Day 1, and the DAF tank had “transformed” within 15 minutes of start-up. See the before and after images below.

The Bega crew are also very happy that their new investments are much more easily accessed and maintained than the systems they replaced.

More information about Venturi Aerators or Gorman-Rupp pumps can be obtained from info@hydroinnovations.com.au

Download the Brochure | Ask Our Team

The EchoStorm water aerator from Gorman-Rupp offers the benefits of safety, reliability and ease of access to water aeration applications.

Because these units are mounted on the bank [instead of floating on the water or being submerged in it], access is much less complicated and safer, while delivering oxygen transfer outcomes.

The EchoStorm water aerator benefits::

  • No cranes or row boats for maintenance
  • Easily accessed
  • Less downtime
  • Reliable and easy to maintain
  • Easily scalable and low cost of ownership
  • Thorough mixing – no dead spots
  • High SOTR (Standard Oxygen Transfer rate)
  • Oxygenated water

These aeration units are used in conjunction with Gorman Rupp self-priming centrifugal pumps to deliver solutions for the following applications:

  • Lagoon and basin water aerator
  • Oxidation ditch aeration
  • Lake destratification and algae control
  • Odour control
  • Sludge digestion
  • Septage treatment

Download the Brochure | Ask Our Team

The Gorman-Rupp Super T Series self-priming centrifugal wastewater/sewage pump has been the world benchmark for this technology since 1963 (>50 years). They have been designed for economical, trouble-free operation, with superior solids handling capability and a large inspection cover to access pump internals for service or blockage removal. Super T Series pumps now have several variants that either improve solids handling or efficiency.

Advantages include:

  • Self-Priming pump has the ability to mount high and dry above the wet well (not in it)
  • Up to 7.6 metre suction lift
  • Handle spherical solids to 76mm in diameter
  • Low cost of ownership
  • Greatly reduced OH&S issues – no more working over water/heights/cranes/heavy swinging weights
  • Surface-mounted pumps with easy access for monitoring or service
  • Advanced safety features including pressure relief valve to protect operators
  • Improved maintenance features to greatly reduce maintenance time and costs, with removable rotating assembly
  • A variety of materials of construction to handle abrasive and/or corrosive fluids
  • “Eradicator” technology for handling rags, wet wipes, rope etc
  • “Eradicator Plus” technology for extreme-duty stringy materials applications

Super T Series With Eradicator
Super T Series with Eradicator Plus

Download the Brochure | Ask Our Team

The Gorman-Rupp Super T Series pump with Eradicator™ Solids Management System are a series of self-priming centrifugal pumps designed specifically for handling municipal and industrial wastewater containing stringy, difficult-to-pump, solids in suspension (such as wet wipes, rags and feathers).

They have been designed for economical, trouble-free operation, with design features that deliver superior solids handling capability and a large inspection cover to access pump internals for service or blockage removal. Gorman-Rupp Super T Series wastewater and sewage pumps have been used for pumping of WAS and RAS and for digester recirculation with great success in wastewater treatment plants around the country, as well as food process plants, paper mills and other heavy industries. The Eradicator™ system advances the solids handling capabilities of this range.

Advantages include:

  • Ability to mount high and dry above the wet well [not in it]
  • Self-priming to 7.6 metres
  • Low cost of ownership
  • Greatly reduced OH&S issues
  • No cranes or hoists for access
  • Easy access for monitoring or service
  • Advanced safety features to protect operators [such as the lightweight inspection cover-plate]
  • Improved maintenance features to greatly reduce maintenance time and costs, with removable rotating assembly
  • A variety of materials of construction to handle abrasive and/or corrosive fluid.
  • Sizes 2” to 10”, with flows to 200 L/s and heads to 40 metres.

Download the Brochure | Ask Our Team

The EchoStorm water aerator from Gorman-Rupp offers the benefits of safety, reliability and ease of access to water aeration applications.

Because these units are mounted on the bank [instead of floating on the water or being submerged in it], access is much less complicated and safer, while delivering oxygen transfer outcomes.

The EchoStorm water aerator benefits::

  • No cranes or row boats for maintenance
  • Easily accessed
  • Less downtime
  • Reliable and easy to maintain
  • Easily scalable and low cost of ownership
  • Thorough mixing – no dead spots
  • High SOTR (Standard Oxygen Transfer rate)
  • Oxygenated water

These aeration units are used in conjunction with Gorman Rupp self-priming centrifugal pumps to deliver solutions for the following applications:

  • Lagoon and basin water aerator
  • Oxidation ditch aeration
  • Lake destratification and algae control
  • Odour control
  • Sludge digestion
  • Septage treatment

Download the Brochure | Ask Our Team

The EDUR LBU multiphase pump is a multi-stage centrifugal pump with the unique capability of being able to pump a liquid/gas mixture. The centrifugal pump is constructed of either C.I./ Bz/ SS, Nodular Cast Iron, All-Bronze, Stainless Steel, or Super-Duplex Stainless-Steel construction, so may be used to handle a variety of liquids.

Air, Oxygen, Carbon Dioxide and Ozone gases can be introduced into the suction line and transported and used to mix or disperse the gases. This makes the pump ideal for DAF plants, where the multiphase pumps provide the task of air saturation without the use of compressed air (no compressor, air saturation tank or associated controls).

Advantages include:

  • Flows to 16 l/s, able to treat DAF tank inflows up to 150 L/s with a single pump.
  • Pressures to 12 bar
  • Operating pressure max. 40 bar
  • Handle temperatures from -50 °C to 140 °C
  • Gas contents up to 30 %
  • Up to 115 cSt
  • Cast iron/Bronze/Stainless steel, Nodular cast Iron, All-Bronze, Stainless Steel, or Super-Duplex Stainless Steel construction
  • Completely replace the “old” DAF system with a single pump
  • No compressor needed on DAF systems
  • No Air-Saturation [pressure] Vessel needed on DAF systems

Download the Brochure | Ask Our Team

The EDUR PBU multiphase pump is a single-stage peripheral centrifugal pump with the unique capability of being able to pump a liquid/gas mixture. The centrifugal pump is constructed of stainless steel, so may be used to handle a variety of liquids. Air, Oxygen, Carbon Dioxide and Ozone gases can be introduced into the suction line and transported and used to mix or disperse the gases. This makes the pump ideal for DAF plants, where the multiphase pumps provide the task of air saturation without the use of compressed air (no compressor, air saturation tank or associated controls).

Advantages include:

  • Flows to 4.0 l/s, suiting DAF inflows to 40 litres per second
  • Pressures to 9 Bar
  • Operating pressure max. 16 bar
  • Temperature -40 °C to 140 °C
  • Gas contents up to 15%
  • Viscosity up to 115 cSt
  • Stainless steel construction
  • Completely replace the “old” DAF system with a single pump
  • No compressor needed on DAF systems
  • No Air Saturation [Pressure] vessel needed on DAF systems

Our Team is available to answer your pump query within the hour

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Hydro Innovations is proud to distribute a broad range of quality, reliable and industry-leading industrial pumps and aerators.

We are also delighted to share that Hydro Innovations is proud to be the exclusive distributor of Gorman-Rupp Pumps.

Gorman-Rupp is the world leader in self-priming centrifugal wastewater pump technology, and invests heavily in R&D, and in training for their international representatives – like Hydro Innovations.

This puts us in an excellent position to make the very best recommendations for our Australian customers.

Our other suppliers, Ragazzini of Italy and EDUR of Germany, are also world leaders in their respective technologies (Peristaltic Pumps – Ragazzini, and Specialist centrifugal pumps – EDUR).

We carry a very large inventory of pumps and spare parts for all of these brands, to help us to deliver industry-leading service.