Project Information
- Location: Wisconsin
- Project Type: Food Processing Plant Wastewater Treatment
- Completion Date: July 2016
Treatment Objectives
- Design Flow:
0.08 MGD - Effluent Objective:
< 1.3 mg/L TAN (winter)
< 1.6 mg/L TAN (summer)
< 20 mg/L BOD
< 20 mg/L TSS
PROJECT BACKGROUND & CHALLENGES
The southern Wisconsin shore of Lake Michigan is home to many large industrial companies valuing the proximity to both Milwaukee and Chicago, which can put a strain on the area’s wastewater treatment infrastructure. At the same time, protecting local watersheds and ecosystems is a priority; even the city of Kenosha, located in the heart of this region, is named for the indigenous word for a local species of fish. As a result, regulators and regional treatment plants are pushing the responsibility back on industry.
THE NEI ANSWER
All upgrades to the wastewater treatment facilities needed to be contained within the existing property boundaries, so a compact solution was the key. We and the engineering firm Snyder and Associates, proposed utilizing the existing lagoons as part of an upgrade to include SAGR® cold water nitrification. This would allow Colesburg to realize cost savings in the construction, long-term operation, and overall maintenance of the system, while maintaining their existing footprint and allowing for key additions to enable the WWTF to meet its new ammonia limits.
The proposed upgrade would combine the two plants into one. The first existing lagoon was divided into two cells, both of which were then aerated using our technology – optAER® aeration system. The second existing lagoon was also divided, converting one half into two additional cells (a partial mix aerated cell and an unaerated settling cell), followed by a two-train aerated horizontal flow SAGR® for nitrification (ammonia removal) in the other half.

The company in question explored all their options. At first, they considered upgrading to a mechanical plant in order to achieve their ammonia limits (right), until a conversation with our engineers offered a more cost-effective solution.
Solving the Phosphorus Deficiency Problem:
Following initial commissioning in 2017, the system operated as expected, capably meeting the ammonia requirement of < 1 mg/L by achieving a 0.07 mg/L in the effluent. However, although the SAGR appeared to be operating normally, the ammonia levels began to increase. While initially not a concern, the ammonia levels eventually rose to the point where the plant was briefly out of compliance and it was necessary to resume trucking a portion of their wastewater out for treatment.



UPGRADED SYSTEM PERFORMANCE
The SAGR system for the food processor’s wastewater treatment plant was first commissioned on July 6, 2017.