Colgate Palmolive Plant

Possibly the most representative treatment facility that handles wastewaters from the production of soaps, detergents, glycerines, and personal care products is Colgate-Palmolive Company's plant at Jeffersonville, IN [3]. The production wastes had received treatment since 1968 [21] in a completely mixed activated sludge plant with a 0.6 MGD design flow and consisting of a 0.5 MG mixed equalization and storage basin, aeration basin, and final clarifier. The treated effluent was discharged to the Ohio River, combined with rain drainage and cooling waters. During operation, it was observed that waste overloads to the plant caused a deterioration of effluent quality and that the system recovered very slowly, particularly from surfactant short-term peaks. In addition, the fact that ABS had been eliminated and more LAS and nonionic surfactants were being produced, as well as the changes in product formulation, may have been the reasons for the Colgate treatment plant's generally less than acceptable effluent quality. (Note that 1 MG=3785 m3, 1 MGD=3785 m3/day.)

Owing to the fact that the company considered the treatment efficiency in need of more dependable results, in 1972-1973 several chemical pretreatment and biological treatment studies were undertaken in order to modify and improve the existing system. As a result, a modified treatment plant was designed, constructed, and placed in operation. A new 1.5 MG mixed flow and pollutant load equalization basin is provided prior to chemical pretreatment, and a flash mixer with lime addition precedes a flocculator/clarifier unit. Ahead of the pre-existing equalization and aeration basins, the capability for pH adjustment and nutrient supplementation was added. Chemical sludge is wasted to two lagoons where thickening and dewatering (normally 15-30% solids) take place.

The intermediate storage basin helps equalize upsets in the chemical pretreatment system, provides neutralization contact time, and allows for storage of pretreated wastewater to supply to the biological treatment unit whenever a prolonged shutdown of the chemical pretreatment occurs. Such shutdowns are planned for part of the weekend and whenever manufacturing stoppage occurs in order to cut down on costs. According to Brownell [3], waste loads to the pretreatment plant diminish during plantwide vacations and production shutdowns, and bypassing the chemical pretreatment allows for a more constant loading of the aeration basins at those times. In this way, the previously encountered problems in the start-up of the biological treatment unit after shutdowns were reduced.

The pollutant removal efficiency of this plant is normally quite high, with overall MBAS (methylene blue active substances) removals at 98-99% and monthly average overall BOD5 removals ranging from 88 to 98% (most months averaging about 95%). The reported MBAS removals achieved in the chemical pretreatment units normally averaged 60-80%. Occasional high MBAS concentrations in the effluent from the chemical pretreatment system were controlled through the addition of FeCl2 and an organic polymer that supplemented the regular dose of lime and increased suspended solids' capture. Also, high oil and grease concentrations were occasionally observed after spills of fatty acid, mineral oil, olefin, and tallow, and historically this caused problems with the biological system. In the chemical pretreatment units, adequate oil and grease removals were obtained through the addition of FeCl2. Finally, COD removals in the chemical system were quite consistent and averaged about 50% (COD was about twice the BOD5).

In the biological step of treatment, removal efficiency for BOD5 was very good, often averaging over 90%. During normal operating periods, the activated sludge system appeared incapable of treating MBAS levels of over 100 lb/day (45.4 kg/day) without significant undesirable foaming. The BOD5 loading was normally kept at 0.15-0.18 g/day/g (or lb/day/ lb) MLVSS, but it had to be reduced whenever increased foaming occurred. Finally, suspended solids concentrations in the secondary clarifier effluent were occasionally quite high, although the overflow rate averaged only 510 gal/day/ft2 and as low as 320 gpd/ft2 (13-20.8 m /day/ m ). The use of polymer flocculants considerably improved the effluent turbidity, reducing it by 50-75%, and because higher effluent solids contribute to high effluent BOD5, it was reduced as well. Therefore, although the Colgate-Palmolive waste treatment plant occasionally experiences operating problems, it generally achieves high levels of pollutant removal efficiencies.

Many analytical procedures have been developed for determination of MBAS [73,75] and COD/DO [61,89-91] concentrations in water and wastewater, in turn, for monitoring the efficiency of treatment processes.

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