DAF Float – Cost to Profit
NAMI ENVIRONMENTAL
CONFERENCE
Atlanta, GA 2016
KEITH BAILEY
SMITHFIELD
Tar Heel Plant
90 Million Gallon
Effluent Storage Basin
8,500–Head
2-4 Hour Hog
4 MGD WW
Facility
Resting Area
Rendering
/Pretreatment
1 Million Sq. Ft
Facility
Tar Heel Plant
• Size
– 1,000,000 sq. ft.
• Employees
– 5,000
• WW Treatment
– 4 MGD, Nitrogen Removal Capability – Discharge to Cape Fear
River
• Production
– 32,500 Head/Day
• Utilities
– 6 MGD Surface Water Treatment Plant, Groundwater Well
System, 1 MGD Reclaimed Water System, 2.3 MGD Water
Reuse System.
Tar Heel
• Existing Situation
– DAF Float Dewatered with Belt Filter Press
and landfilled.
– Volume = 12,400 tons/year
– Costs = $300,000/year
Basis of Design
Yield Projections
• 20,000 lbs./hr. DAF Float
– 40 gpm
• 25,000 lbs./day Solids
– 0.75 lbs./head
– 25,000 lbs. x $0.23 = $5,750/day
• 14,500 lbs./day 98% Brown Grease
– 0.50 lbs./head
– 14,500 lbs. x $0.20 = $2,850/day
• Potential Revenue = $2,504,230!
Project
• Project Description
–
–
–
–
–
–
–
–
Two NX 438 3 Phase Alfa Laval Centrifuges
15,000 gallon DAF Float Tank w/Mixer (existing)
500 Gallon Balance Tank
Two Inline Steam Injection Heaters
PLC Control System
Building
Conveyors
Brown Grease Tank
Costs
• Capital Costs
– $1,749,945
•
•
•
•
•
•
•
•
Alfa’s
Electrical
Mechanical
Building
Solids Handling
Grease Tank
Piping
ATC Application
= $978,893
= $191,546
= $56,132
= $149,112
= $41,900
= $40,000
= $50,000
= $50,000
Projected Profit
•
•
•
•
•
•
•
•
•
Belt Press Rental
Electricity
Nat Gas
Chemicals
Grease
MBM
Landfill
Manpower
Maintenance
• Total
($98,000)
$45,000
$391,575
($28,000)
($855,000)
($1,638,750)
($296,400)
$100,000
$50,000
$2,327,775
Payback
• Cost =
• Profit =
• Payback =
$1,749,945
$2,327,775/Year
9 months
DAF
DAF Float Tank
Balance Tank
Steam Heater
Decanters
Decanters
PLC Display?
PLC Display Work Around
PLC Control
Solids Auger
Solids Auger
Grease Tank
Odor Control
Solids
Brown Grease
Actual Yield FY13
• Grease
2,566,913 lbs.
– $1,026,765@$0.40/lb.
– 0.32 lbs./head @8,020,766 head
• MBM
2,863,403 lbs.
– $687,217@$0.25/lb.
– 0.37 lbs./head @ 8,020,766 head
• Total Profit = $1,737,926 vs. Projected
Profit of $2,327,775
Questions?