PROCEEDINGS
WORKSHOP ON POULTRY PROCESSING PUNT WATER UTILIZATION AND WASTE CONTROL
E d i t e d by Roy E , Carawan
Department of Food S c i e n c e North C a r o l i n a S t a t e U n i v e r s i t y Held i n Greensboro, North C a r o l i n a
September 1 6 , 1971
Sponsored by: A g r i c u l t u r a l E x t e n s i o n S e r v i c e Department of Food S c i e n c e Department of Economics
North C a r o l i n a S t a t e U n i v e r s i t y and t h e
Water Resources Research I n s t i t u t e 0 f
The U n i v e r s i t y of North C a r o l i n a
The p u b l i c a t i o n o f t h i s r e p o r t was s u p p o r t e d i n p a r t by t h e A g r i c u l t u r a l E x t e n s i o n S e r v i c e a n d t h e Department of Food S c i e n c e , NCSU, and by f u n d s p r o v i d e d by t h e United S t a t e s Department o f t h e I n t e r i o r , O f f i c e of Water Resources Research, a s a u t h o r i z e d under t h e Water Resources Research Act o f 1964.
Agreement Number 14-31-0001-3533
iii
POULTRY PROCESSING PLANT WATER UTILIZATION AND WASTE CONTROL Ramada I n n
Greensboro, North C a r o l i n a September 1 6 , 1971
Thursday Afternoon Chairman
D r a Fred R , T a r v e r , Jr. Department of Food S c i e n c e
1:00 p,m, WELCOME o ~ E O O O O E a o O O O O D O Q D O a d ~ e D O e O ID r E I James E, L e g a t e s , Dean School of A g r i c u l t u r e and L i f e S c i e n c e s WORKSHOP OBJECTIVES o o o , c o , P r o f e s s o r David H c Howells, D i r e c t o r
N, C, Water Resources Research I n s t i t u t e ECONOMIC ASPECTS o o , , o c , , o o o , , , , , O , O a O O O e D r , James A, S e a g r a v e s Department of Economics THE GOLD KIST STUDY:
Background and P r o c e d u r e s , o , o e , , o , , , , , , , , . M r , Roy E, Carawan Department o f Food S c i e n c e P r o c e s s and Equipment Changes ,,,,,,,,,,,,
,,
M r , John A, MaconDepartment of Economics B i o l o g i c a l E v a l u a t i o n , , , o , , o o o , , ,,,,,, , , D r , Marvin L o Speck Department of Food S c i e n c e O v e r a l l R e s u l t s e , o o o e , , , e o o , , o , , o , B o dO oO OD Mr, Roy E, Carawan Department of Food S c i e n c e D i s c u s s i o n
3:15 p,m, BREAK
3:30 porno INDUSTRY PROBLEMS AND CONCERNS
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WATER AND WASTE MANAGEMENT: Background , o , o , o o , , , , G G o o , o , , C C a d d O O B O ~ B o C e Mr, Byron HawkinsC i t i e s
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R u l e s and R e g u l a t i o n s-
NOW and F u t u r e 0 , , , , 0 0 0 , 0 0 0 0 0 0 0 , M r , L e s l i e Matthews, D i r e c t o r I n d u s t r i a l Waste Treatment Program Durham, North C a r o l i n a S t a t e and F e d e r a l
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R u l e s andR e g u l a t i o n s
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Now and t h e F u t u r e ,,,,,,,, MY, William C, M i l l s-
R e g i o n a l Engineer I n d u s t r i a l Waste S e c t i o n Water Q u a l i t y D i v i s i o n North C a r o l i n a O f f i c e o f Water and A i r Resources SUMMARY o E0 00 6 00 0 C0 0 00 0 00 0 00 0 00 0 0d OOo Do DOOOo o 0 M r o Byron Hawkins
Gold K i s t P o u l t r y DISCUSSION
Thursday Evening Chaf rman
P r o f e s s o r Gene McJunkin A s s o c i a t e D i r e c t o r
N, C , Watex R e s o u r c e s R e s e a r c h I n s t i t u t e
5 ~ 3 0 p,m, DINNER
INDUSTRY PROBLEMS AND CONCERNS , , , , , , , , Dr, Robert E. Cook, Head Department of P o u l t r y S c i e n c e 6:30 p,m, WORKSHOP SESSION (See a t t a c h e d l i s t of workshop q u e s t i o n s )
TABLE OF CONTENTS
THE GOLD KIST STUDY
Background and Procedures ,
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21 Process and Equipment Changes,
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4 1 INDUSTRY PROBLEMS AN'D CONCERNS-
WATER AND WASTE MANAGEMENT a 53 Background. a 4 e r e r e e e s , e o e s e B e s , s r ~ e o s 55USDA Rules and Regulations
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Now and t h e Future,
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59 Cities-
Rules and Regulations-
Now
and t h e F u t u r e, ,
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63 Spate and F e d e r a l-
Rules and Regulations-
Now and t h e Future,
67INDUSTRY PROBLEMS AND CONCERNS a e
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0 e e e s 9 a n 6 8 e e 73Discussion Group I
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79INTRODUCTION
There i s a growing awareness of t h e need t o a c t now t o i n s u r e adequate e n v i r o n m e n t a l p r o t e c t i o n , Research emphasis i n i n d u s t r i a l problems i s s h i f t i n g from d e s t r u c t k v e measures such as w a s t e t r e a t m e n t toward i n - p l a n t w a t e r and w a s t e management, New knowledge and competence a r e r e q u i r e d f o r e f f e c t i v e implementation of w a t e r and w a s t e management i n p o u l t r y p r o c e s s i n g ,
T h i s workshop w i l l f o c u s on t h e impact of i n - p l a n t p r o c e s s and equip- ment changes on w a t e r u s e and w a s t e abatement i n p o u l t r y p r o c e s s i n g ,
O b j e c t i v e s of t h e workshop a r e t o : (1) s h a r e r e s u l t s o f a r e s e a r c h ,
development and d e m o n s t r a t i o n p r o j e c t conducted i n t h e Gold K i s t p l a n t a t Durham, North C a r o l i n a ; (2) i n t e r p r e t t h e u s e f u l n e s s of t h e s e r e s u l t s f o r improving t h e o p e r a t i o n of your p l a n t ; and (3) d i s c u s s i m p l i c a t i o n s o f t h e r e s u l t s f o r implementation of w a t e r c o n s e r v a t i o n and w a s t e abatement pro- grams by p o u l t r y p r o c e s s i n g f i r m s and enforcement of h e a l t h and environ- m e n t a l programs by r e g u l a t o r y a g e n c i e s ,
A d e t a i l e d s t u d y of o p p o r t u n i t i e s f o r w a t e r and w a s t e r e d u c t i o n w a s made t h r o u g h o u t t h e p l a n t , There h a s been a 30 p e r c e n t r e d u c t i o n i n w a t e r u s e (580,000 g a l l o n s v e r s u s 838,000 g a l l o n s ) and a 65 p e r c e n t reduc-
t i o n i n w a s t e d i s c h a r g e d t o t h e c i t y system (1400 pounds v e r s u s 4000 pounds of BOD), Blood from t h e k i l l i n g room h a s been e f f e c t i v e l y e l i m i - n a t e d from p l a n t e f f l u e n t , and f e a t h e r s i n t h e p l a n t e f f l u e n t have been
c o n ~ r o l l e d , B i o l o g i c a l q u a l i t y of t h e f i n a l p r o d u c t h a s been m a i n t a i n e d , The Water Q u a l i t y O f f i c e , Environmental P r o t e c t i o n Agency, and Gold K i s t s u p p o r t e d t h e s t u d y on a 70-30 c o s t - s h a r i n g b a s i s , North C a r o l i n a S t a t e U n i v e r s i t y p r o v i d e d t e c h n i c a l and r e s e a r c h r e q u i r e m e n t s i n c l u d i n g a b i o l o g i c a l e v a l u a t i o n of a l l p h a s e s , E f f e c t i v e n e s s of t h e p r o j e c t h a s been g r e a t l y enhariced by t h e f u l l c o o p e r a t i o n of t h e P o u l t r y I n s p e c t i o n Group a t a l l l e v e l s ,
WELCOME
D r , James E, L e g a t e s , Dean
School of A g r i c u l t u r e and L f f e S c i e n c e s N o r t h C a r o l i n a S t a t e U n i v e r s i t y
It i s a l m o s t r e d u n d a n t f o r m e t o emphasize t h e need f o r w a t e r ; and y e t , we o f e e n must overemphasize i n o r d e r t o d e v e l o p a p r o p e r p e r s p e c t i v e f o r t h o s e who haven" begun t o t h i n k s e r i o u s l y a b o u t t h i s need, Stop and t h i n k a b o u t how i m p o r t a n t o u r w a t e r s u p p l y i s , We r e a l i z e t h a t i t might be p a i n f u l , b u t w e can go w i t h o u t food as l i v i n g organisms f o r a l o n g e r p e r i o d of t i m e t h a n we can go w i t h o u t w a t e r , A s you f l y a b o u t i n an a i r p l a n e o r t r a v e l i n v a r i o u s c o u n t r i e s , p a r t i c u l a r l y i n v e r y a r i d r e g i o n s , i r i s most i n t e r e s t i n g t o n o t e how t h e p o p u l a t i o n f o l l o w s t h e w a t e r s u p p l y , The b i t s of g r e e n e r y s t a n d o u t where t h e w e l l s and s t r e a m s h a v e burgeoned f o r t h , We%e s o v i t a l l y i n need of water; and y e t , we i n North C a r o l i n a t a k e i t s o much f o r g r a n t e d , We h a v e an abundance of water and a t t h i s time a f r e s h , c l e a n w a t e r s u p p l y t h a t we can p r e s e r v e , A s o u r p o p u l a t i o n i n c r e a s e s and o u r i n d u s t r i a l demands f o r w a t e r i n c r e a s e , and you a r e c o n s i d e r i n g t h e s e demands t o d a y , t h e amount of w a t e r p e r
c a p i t a w i l l c o n t i n u e t o rise, Within r e a s o n a b l e bounds w e h a v e a f i x e d s u p p l y of w a t e r a v a i l a b l e , I t i s e v a p o r a t e d i n t o t h e s k y and t h e n r e t u r n e d t o u s , moving from t h e c o n t i n e n t a l d i v i d e toward t h e c o a s t , We must l e a r n t o u s e t h i s w a t e r r e s o u r c e i n a most e f f i c i e n t and e f f e c -
t i v e way, I n t h e a r e a of i n d u s t r i a l u s e s , we a r e now j u s t b e g i n n i n g t o s e n s e t h e need f o r p r o p e r u s a g e ,
T h i s morning we had t h e good f o r t u n e of v i s i t i n g a p o u l t r y p l a n t s i m i l a r t o t h e o n e you w i l l be d i s c u s s i n g i n your r e p o r t t o d a y , T h i s gave me a f i r s t - h a n d l o o k a t some of t h e problems i n v o l v e d i n your
s t u d y c We must h a v e w a t e r t o p r o v i d e a q u a l i t y p r o d u c t f o r o u r consumer; and y e t , t h e c o s t of p r o v i d i n g t h a t w a t e r can become c r i t i c a l , L t h i n k i t i s most t i m e l y t h a t you have come t o g e t h e r t o c o n s i d e r t h e r e s u l t s of t h i s u n i q u e s t u d y , It i s n ' t a l a b o r a t o r y s t u d y , b u t you have u s e d t h e l a b o r a t o r y as a m o n i t o r , You h a v e a n o p e r a t i o n a l working model which h a s been examined and p e r m i t t e d c e r t a i n changes, T h i s w i l l make
P r o f e s s o r Howells h a s k i n d l y a s k e d t h a t I p a r t i c i p a t e on t h e Water Resources R e s e a r c h I n s t i t u t e Board, By p a r t i c i p a t i n g w i t h you t o d a y , I s h a l l g a i n a n i n t r o d u c t i o n t o t h e program which h i s I n s t i t u t e i s
c o o p e r a t i v e l y s p o n s o r i n g w i t h o t h e r u n i t s of t h e U n i v e r s i t y , T h i s i s a wonderful example of how we can and must work t o g e t h e r t o s o l v e s u c h broad-based problems i n t h e days ahead, A m u l t i - d i s c i p l i n a r y a p p r o a c h
i n v o l v i n g segments of o u r i n d u s t r y and economy, p r o v i d e s t h e o n l y mean- i n g f u l way t o a p p r o a c h problems of such a broad s c o p e ,
WORKSHOP OBJECTIVES
P r o f e s s o r David H, Howells, D i r e c t o r
North C a r o l i n a Water Resources Research I n s t i t u t e
o f t h e U n i v e r s i t y o f North C a r o l i n a
The workshop o b j e c t i v e s a r e c l e a r l y s t a t e d i n t h e f l y e r s h e e t s s o r e a l l y a l l P have t o do i s t o r e p e a t them, But t h i s g i v e s me a chance t o make a c o u p l e of b r i e f p o i n t s t h a t I much wanted t o make, I t h i n k a l l o f u s h e r e a g r e e w i t h o u t any r e s t a t e m e n t t h a t t h e w a t e r r e s o u r c e w e ' r e d e a l i n g w i t h i s r e l a t i v e l y f i x e d i n q u a n t i t y , I n s p i t e of t h e v e r y o p t i m i s t i c r e p o r t s of t h e Bureau sf Census d u r i n g t h e p a s t few weeks c o n c e r n i n g t h e s h a r p d r o p i n r e p r o d u c t i o n i n t h i s c o u n t r y , we have a l o t of p e o p l e i n t h e p i p e l i n e , and 1% s u r e t h e p o p u l a t i o n i s g o i n g t o c o n t i n u e t o grow f o r q u i t e a few y e a r s t o come, Accompanying t h i s , o f c o u r s e , w i l l b e a s t e a d y i n c r e a s e i n i n d u s t r i a l p r o d u c t i o n ,
It s t a n d s , t h e r e f o r e , t h a t w f t h t h e s e c o n t i n u i n g p r e s s u r e s c i t i e s and i n d u s t r i e s i n North C a r o l i n a a r e going t o b e f a c e d w i t h a f u t u r e of i n c r e a s i n g l y s t r i n g e n t c o n t r o l s on t h e w a s t e s t h a t t h e y ' r e p e r m i t t e d t o d i s c h a r g e i n t o t h e a i r , t h e w a t e r and o n t o t h e l a n d , T h i s w i l l b e c o s t l y i f we p e r s i s t i n our p r e o c c u p a t i o n w i t h w a s t e t r e a t m e n t - - c o s t l y , i n d e e d , Our g o a l , however, i s n o t t o b u i l d w a s t e t r e a t m e n t f a c i l i t i e s , and I t h i n k we sometimes l o s e t r a c k o f t h i s , I t i s t o p r e s e r v e and upgrade w a t e r q u a l i t y through t h e most economic combination of a c t i o n s s t a r t i n g w i t h i n - p l a n t r e d u c t i o n s and o t h e r changes i n w a t e r u s e i n t h e i n d u s t r i a l p r o c e s s ,
I n t h e n e a r f u t u r e many of our communities i n North C a r o l i n a a r e g o i n g t o b e f a c e d w i t h p r o v i d i n g a t l e a s t some d e g r e e of advanced w a s t e t r e a t m e n t , p a r t i c u l a r l y i n t h e upper Piedmont c r e s c e n t , A l l w i l l have t o upgrade t h e e f f i c i e n c y of e x i s t i n g w a s t e t r e a t m e n t f a c i l i t i e s , A s o u r communities and i n d u s t r i e s move i n t o t h e s e h i g h e r r a n g e s o f t r e a t - ment e f f i c i e n c y a t h i g h e r u n i t c o s t s , i t becomes v e r y i m p o r t a n t t h a t
our communities and i n d u s t r i e s i m a g i n a t i v e l y s e a r c h f o r t h e l e a s t c o s t a l t e r n a t i v e s , T h i s , I t h i n k , i s of c r u c i a l s i g n i f i c a n c e ,
p r e l i m i n a r y s t e p s which can s h a r p l y r e d u c e t h e c o s t s t o r e a c h o u r common o b j e c t i v e which, of c o u r s e , i s c l e a n w a t e r , Now t h i s can a v o i d o r
d e c r e a s e t h e need f o r new c a p i t a l i n v e s t m e n t and o p e r a t i n g c o s t s f o r b o t h w a s t e treatmen.t and w a t e r s u p p l y , It can i n c r e a s e t h e o v e r a l l e f f i c i e n c y o f w a s t e reduction--and I u s e t h a t term i n l i e u of t r e a t m e n t - - and p o s s i b l y d e f e r t h e need f o r more advanced w a s t e t r e a t m e n t . A l s o , i t can s a v e money f o r i n d u s t r y and t h e c i t i z e n s a t l a r g e ,
The s u c c e s s f u l d e m o n s t r a t i o n of t h e p o t e n t i a l b e n e f i t s from i n - p l a n t changes i n t h e p o u l t r y p r o c e s s i n g i n d u s t r y i s t h e p u r p o s e of t h i s work- shop t o d a y , The o b j e c t i v e s , a s you n o t e d i n t h e f l y e r , a r e : ( 1 ) t o s h a r e t h e r e s u l t s o f a r e s e a r c h , development and d e m o n s t r a t i o n p r o j e c t i n t h e Gold K i s t p l a n t i n Durham; ( 2 ) t o i n t e r p r e t t h e u s e f u l n e s s of
t h e s e r e s u l t s f o r improving t h e o p e r a t i o n s of your p l a n t ; and ( 3 ) t o d i s c u s s t h e i m p l i c a t i o n s of t h e r e s u l t s f o r i m p l e m e n t a t i o n of w a t e r c o n s e r v a t i o n and w a s t e abatement programs by p o u l t r y p r o c e s s i n g f i r m s , T h i s s u c c e s s s t o r y can be r e p e a t e d i n many o t h e r l o c a t i o n s t o t h e b e n e f i t of a l l o f North C a r o l i n a and t h e s t a t e s r e p r e s e n t e d h e r e t o d a y , I t ' s w o r t h n o t i n g , I b e l i e v e , c o o p e r a t i v e i n s t i t u t i o n a l p a r t i c i p a n t s i n t h i s p r o j e c t ; i , e , , t h e Environmental P r o t e c t i o n Agency, t h e S o u t h e r n C o t t o n P r o d u c e r s , and t h e s t a t e l a n d g r a n t u n i v e r s i t y , a l l w i t h t h e b l e s s i n g s of t h e S t a t e Department of Water and A i r R e s o u r c e s , It shows what can be accomplished when p r i v a t e i n d u s t r y , t h e e n v i r o n m e n t a l a g e n c i e s , and t h e u n i v e r s i t y g e t t o g e t h e r and p u t t h e i r c o l l e c t i v e s h o u l d e r s t o t h e wheel, I hope we have a v e r y s u c c e s s f u l program today,
Question: I might a s k , P r o f e s s o r Kowells, i t ' s n i c e t o have a l t e r n a t i v e s , a s you h a v e e x p r e s s e d i n your comments, and I ' m s u r e t h a t c e r t a i n a l t e r n a - t i v e s a r e more e f f e c t i v e t h a n o t h e r s , which of t h o s e a p p r o a c h e s do you f e e l i s most e f f e c t i v e ?
Answer: My p r i n c i p a l r e f e r e n c e h e r e , of c o u r s e , u s i n g t h e Gold K i s t p r o j e c t as an example, i s t h e i n c r e a s e d e f f i c i e n c y i n t h e u s e of w a t e r ,
ECONOMIC ASPECTS D r ,
J,
A, Seagraves Department of Economies North C a r o l i n a S t a t e U n i v e r s i t yT h i s i s a broad title--Economic A s p e c t s - - t h a t l e a v e s me l o t s of leeway, I c o u l d t a l k a b o u t whether p r i n t i n g money i s a good way t o i n c r e a s e o u r g r o s s n a t i o n a l p r o d u c t o r I c o u l d t a l k a b o u t t h e P r e s i - d e n t ' s wage-price f r e e z e , However, I t h i n k I am supposed t o t a l k a b o u t t h e r e l a t i o n s h i p of t h i s Gold K i s t w a s t e r e d u c t i o n p r o j e c t t o t h e
economy and t o o t h e r r e s e a r c h , Dean L e g a t e s and P r o f e s s o r Howells have done a good j o b of r e l a t i n g i t t o e n v i r o n m e n t a l c o n c e r n s , We know t h a t some o f t h e s e e n v i r o n m e n t a l c o n c e r n s a r e e m o t i o n a l and ephemeral, and i t ' s p o s s i b l e t o go o f f t h e deep end, Dean L e g a t e s made r e f e r e n c e t o t h e p h o s p h a t e announcement, The government h a s had t o make a r e v e r s a l on i t s o r i g i n a l s t a n d a g a i n s t p h o s p h a t e s i n d e t e r g e n t s , I t h i n k t h e r e i s a s t r o n g c a s e t o be made f o r b e t t e r c o s t - b e n e f i t a n a l y s e s of regu- l a t i o n s o r more s t u d y of a l l t h e p r o s and cons b e f o r e t h e r e g u l a t i o n s a r e e n f o r c e d ,
Compared t o r e g u l a t i o n s , t h e d e m o n s t r a t i o n g r a n t t h a t w e ' r e con- s i d e r i n g t h i s a f t e r n o o n i s a low-keyed, calm approach t o e n v i r o n m e n t a l q u e s t i o n s , The f e d e r a l government pays 70 p e r c e n t of t h e c o s t of t h e d e m o n s t r a t i o n w i t h t h e company p u t t i n g up 30 p e r c e n t , The way t h i s p r o j e c t g o t s t a r t e d i s t h a t t h e u n i v e r s i t y and t h e company g o t t o g e t h e r , The u n i v e r s i t y a g r e e d t o do t h e p l a n n i n g and s c i e n t i f i c a s p e c t s , and Byron Hawkins w i t h Gold K i s t o v e r i n Durham a g r e e d t o manage t h e
p r o j e c t and make some i n - p l a n t changes, We t r i e d t o a n a l y z e changes i n t h e p l a n t and make s u r e t h a t t h e y would b e p r o f i t a b l e b e f o r e we made them, Byron Hawkins c o u l d v e t o any f a r o u t o r u n p r o f i t a b l e p r o p o s a l s ,
I want t o t a l k a b o u t a n o t h e r approach t o p o l l u t i o n problems which i s a l s o r e l a t e d t o t h e s u c c e s s of t h i s d e m o n s t r a t i o n g r a n t , I r e f e r t o t h e i n d u s t r i a l w a s t e s u r c h a r g e s t h a t Durham and some o t h e r c i t i e s a r e now u s i n g , C i t i e s f a c e d w i t h h i g h e r c o s t s of w a s t e t r e a t m e n t a r e c o n s i d e r i n g s u r c h a r g e s based on t h e s t r e n g t h of t h e w a s t e s t h a t t h e y r e c e i v e , I n t h e p a s t , t h e y have s i m p l y charged f o r sewage o r i n d u s t r i a l w a s t e s on t h e b a s i s of t h e number o f g a l l o n s o r t h e volume of t h e
t r e a t a b l e w a s t e s , They c h a r g e on t h e b a s i s of t h e pounds o f BOD o r suspended s o l i d s t h a t a r e i n t h e w a s t e ,
Maybe i t would b e good t o t h i n k j u s t a l i t t l e about why p o u l t r y p r o c e s s i n g w a s t e s might have been h i g h o r why some p e o p l e might t h i n k t h e y a r e h i g h , "High" i s o n l y a r e l a t i v e t h i n g , What grounds do we have f o r a c c u s i n g t h e p o u l t r y p r o c e s s i n g i n d u s t r y of h a v i n g "high" w a s t e s ? I t ' s r e l a t i v e t o something t h a t we t h i n k s h o u l d be l o w e r , But one r e a s o n t h a t t h e s e w a s t e s might a c t u a l l y be r e l a t i v e l y h i g h compared w i t h what i t ' s p r o f i t a b l e t o do c o u l d be t h a t t h e s e c o s t s a r e i n s i g n i f i c a n t i n t h e t o t a l c o s t p i c t u r e of t h e p r o c e s s i n g p l a n t ; w a t e r i s a v e r y s m a l l p o r t i o n o f c o s t , Yet, water i s one p l a c e where i n d u s t r y h a s a h i g h i n t e r r e l a t i o n s h i p w i t h s o c i e t y s o t h e r e i s a l o t of concern f o r t h e amount of w a t e r used and t h e q u a l i t y of t h e w a t e r t h a t comes back,
Another r e a s o n p o u l t r y p r o c e s s i n g p l a n t s might h a v e seemingly 11
h i g h " wastes i s t h a t some c i t i e s have n o t been g i v i n g u s any s i g n a l s as t o what i t c o s t s t h e c i t y t o t r e a t t h e wastes, I n o t h e r words, i f w e ' r e n o t b e i n g c h a r g e d on a b a s i s of what i s i n t h e wastes, why s h o u l d
t h i s b e o f c o n c e r n t o u s ? So t h i s t i e s i n w i t h my main t o p i c , t h e r e l a t i o n s h i p of t h e s u r c h a r g e s t o t h e s e w a s t e s ,
T a b l e 1 shows t h e c i t i e s i n North C a r o l i n a t h a t have s u r c h a r g e s now, C h a r l o t t e was t h e f i r s t c i t y t o a d o p t s u r c h a r g e s back i n 1956. They c h a r g e around $60 p e r thousand pounds of BOD i n t h e i r w a s t e s , T h i s s u r c h a r g e i s j u s t f o r t h e pounds of BOD o v e r 250 p a r t s p e r m i l l i o n which i s d e f i n e d a s t h e normal l e v e l covered by t h e r e g u l a r sewer
s e r v i c e b i l l , F o r t h e C i t y of Durham t h e r e i s a c h a r g e o f $80 a
Table
1
S u r c h a r g e R a t e s as of January 1941
Went I n t o E f f e c t
C h a r l o t t e
Greensboro
b i l l f o r t h e p a r t o f t h e w a s t e s under 250 o r 300 p a r t s p e r m i l l i o n , Now you can a l s o s e e from t h i s t a b l e t h a t t h r e e of t h e s e c i t i e s have j u s t adopted t h e i r s u r c h a r g e s i n t h e l a s t y e a r , and you c a n o b s e r v e t h a t Greensboro and C h a r l o t t e were two of t h e c i t i e s t h a t adopted them e a r l y , They a r e a l s o two of t h e c i t i e s t h a t had t h e h i g h e s t w a s t e t r e a t - ment problems, t h e h i g h e s t l e v e l o f w a s t e t r e a t m e n t demanded by s o c i e t y , and t h e h i g h e s t c o s t of w a s t e t r e a t m e n t , I t ' s v e r y l o g i c a l t h a t t h o s e c i t i e s a d o p t e d t h e s u r c h a r g e s f i r s t , The c u r r e n t emphasis on h i g h e r waste t r e a t m e n t i s one r e a s o n why t h e s e o t h e r t h r e e c i t i e s have adopted s u r c h a r g e s , Another r e a s o n i s t h a t t h e f e d e r a l government h a s announced t h a t i t ' s n o t w i l l i n g t o c o o p e r a t e w i t h t h e c i t i e s i n c o n s t r u c t i o n g r a n t s i f t h e y d o n ' t c h a r g e i n d u s t r i e s t h a t d i s c h a r g e l a r g e amounts of t r e a t a b l e w a s t e s a c c o r d i n g t o l o a d i n g o r w a s t e s t r e n g t h i n a d d i t i o n t o c h a r g i n g on
t h e b a s i s of volume, Are t h e r e any q u e s t i o n s now a b o u t t h e magnitude of t h e s e s u r c h a r g e s o r how t h e y a r e l e v i e d ?
: You've been t a l k i n g a b o u t d o i n g i t on t h e b a s i s of t o t a l s t r e n g t h h e r e and t h e n t a l k a b o u t volume, D o you do b o t h ?
Answer: Yes, There i s
a
volume c h a r g e made t h r o u g h t h e r e g u l a r w a t e r-
c o n s i d e r t h i s f i r i n a s b e i n g 1000 pounds above normal f o r e v e r y 1,000,000 pounds o f w a t e r p u r c h a s e d , The s u r c h a r g e would b e $60 p e r 1000 pounds,
L e t ' s d i s c u s s now t h e l o g i c of s u r c h a r g e s , I t h i n k t h a t you b u s i - nessmen u n d e r s t a n d t h e i n c e n t i v e s of c h a r g e s v e r y w e l l s o I ' l l t r y n o t
t o b e l a b o r t h e s e p o i n t s ,
P r i v a t e and S o c i a l E f f e c t s of S u r c h a r g e s
S u r c h a r g e s make t h e i r c o n t r i b u t i o n t o s o c i a l e f f i c i e n c y by making i n d u s t r y aware o f t h e c o s t of w a s t e t r e a t m e n t i n t h e most d r a m a t i c way p o s s i b l e - - t h r o u g h t h e pocketbook, F i g u r e 1 w i l l h e l p i l l u s t r a t e t h e e x p e c t e d r e s p o n s e o f a n i n d u s t r i a l f i r m t o a s u r c h a r g e , B e f o r e t h e s u r - c h a r g e , w a s t e s i n pounds of BOD p e r y e a r a r e i n d i c a t e d by Q Q The
0 3 "
cuxve r e p r e s e n t s t h e c o s t p e r u n i t of removing BQD i n t h e p l a n t r a t h e r t h a n s e n d i n g i t t o t h e c i t y , A t f i r s r . t h e c o s t s a r e n e g a t i v e o r
i n d i c a t e t h a t p r o f i t s can a c t u a l l y be i n c r e a s e d by r e c o v e r i n g some
by-products r a t h e r t h a n l e t them g e t i n t h e c i t y sewer, I n o t h e r words, i f t h e f i r m were j u s t a l i t t l e more c o n s c i e n t i o u s a b o u t w a s t e s and
l o o k i n g f o r s m a l l p r o f i t s , i t would r e d u c e i t s w a s t e s from QOQ3 t o QOQZe The p r o f i t i t would g a i n i s r e p r e s e n t e d by t h e small shaded a r e a A
below t h e a x i s , With a s u r c h a r g e of S i t would pay t h i s f i r m t o f u r t h e r r e d u c e i t s w a t e r - c a r r i e d w a s t e s t o Q Q Beyond t h e p o i n t R i t i s l e s s
0 1"
e x p e n s i v e f o r t h e f i r m t o buy w a s t e t r e a t m e n t from t h e c i t y t h a n make f u r t h e r i n - p l a n t r e d u c t i o n s i n w a s t e s , The amount t h e c i t y would s a v e by n o t h a v i n g t o t r e a t t h e w a s t e s Q Q would b e r e p r e s e n t e d b y t h e a r e a
1 3
RQlQ3S, That p a r t of t h e w a s t e r e d u c t i o n t h a t can p r o p e r l y b e a t t r i b u t e d t o t h e s u r c h a r g e i s o n l y Q1Q2"
Now F i g u r e 2 i s t h e same as F i g u r e 1 b u t s t r e s s e s t h e n e t r e t u r n s t o s o c i e t y a s s o c i a t e d w i t h t h e i n - p l a n t removal of w a s t e s Q Q 1 2 and Q2Q3" The movement from
Q
t o Q would b e o p t i m a l w i t h a s u r c h a r g e and c a n b e3 2
d e s c r i b e d a s t h e r e s u l t of an i n f o r m a t i o n program o r "awareness campaign," The c i t y s a v e s area B and t h e f i r m a r e a A , The f u r t h e r movement from Q
2
F i g u r e 1 , E ~ p e c t e d e f f e c t of a s u r c h a r g e on a t y p i c a l f i r m
Curve shows added u n i t c o s t s of w a s t e removed
S u r c h a r g e
< "Waste d i s c h a r g e d t o c i t y i n pounds of BOD I n - p l a n t removal of w a s t e s -.
S u r c h a r g e = a v e r a g e
c o s t t o c i t y of removing a pound of BOD
P r e s e n t Q O = t o t a l
w a s t e s
QOQ1 = o p t i m a l d i s c h a r g e of w a s t e t o c i t y w i t h s u r c h a r g e .
QOQZ o p t i m a l d i s c h a r g e of w a s t e t o c i t y w i t h o u t s u r c h a r g e . Q0Q3
=
d i s c h a r g e o f w a s t e s t o c i t y by t y p i c a l f i r m t h a t was n o tw a s t e c o n s c i o u s , T h i s i s a non-optimal p o s i t i o n and t h e s h a d e d a r e a r e p r e s e n t s d o l l a r l o s s e s t o t h i s i n d u s t r y
t h a t c o u l d b e avoided by o p t i m a l r e c o v e r y o f b y - p r o d h c t s . RQ Q S = c o s t t o c i t y of w a s t e t r e a t m e n t t h a t c o u l d b e a v o i d e d by
12
Figure
2.Social returns to information programs about industrial
- -wastes and to surcharges
Curve shows added unit
costs of waste removed
by a particular
industrial firm
S
0
I--
In-plant removal of wastes
-- >Wastes discharged to city
Surcharge
=
average cost
to city
o fremoving
apound of BOD
Present
J O
=total.
wastes
A
=returns to informaticn program which this firm can capture for itself
simply by removing waste Q2Qy
B =
returns to society from an information program assuming this industry
moves to its optimal position, Q2.
C
=returns to society from surcharge if this firm moves to new optimal
position
Qwhere it is removing Q
Q pounds of BOD
each time period.
1
1 3
D
=added cost of in-plant waste reduction by firm per time period.
C
+
D =savings to city from not having to treat wastes Q
Q1 2'
B
+
C+
D =savings to city from information campaign and surcharge.
c o s t l y p l a c e - - i s a r e a C, The g a i n s t o s o c i e t y from b o t h t h e i n f o r m a t i o n program and t h e s u r c h a r g e a r e t h e sum of a r e a A, B and C,
A more c o n v e n t i o n a l way t o view t h i s same c o s t c u r v e f o r i n - p l a n t
w a s t e removal i s a s a demand c u r v e f o r w a s t e t r e a t m e n t by t h e c i t y , I n F i g u r e 3 t h e c u r v e from F i g u r e 2 h a s been t u r n e d o v e r s o t h a t Q i s on
0
t h e l e f t and QOQl r e p r e s e n t s w a s t e t r e a t m e n t purchased from t h e c i t y i n pounds of BOD p e r y e a r , The m a r g i n a l c h a r g e f o r added pounds of w a s t e t r e a t e d by t h e c i t y i s Q R, and t h i s i s a l s o t h e m a r g i n a l c o s t of
1
f u r t h e r i n - p l a n t w a s t e removal, But t h e whole a r e a RQ Q T i s n o t p a i d 1 0
t o t h e c i t y , S u r c h a r g e s a s t h e y a r e n o r m a l l y l e v i e d a r e j u s t on w a s t e s above some d e f i n e d normal s t r e n g t h , NW, M u l t i p l y i n g t h i s d e f i n e d normal
(pounds p e r m i l l i o n pounds) t i m e s t h e q u a n t i t y of w a t e r ( c o n v e r t e d t o m i l l i o n s of pounds) i n d i c a t e s t h e q u a n t i t y of w a s t e t r e a t m e n t purchased
through t h e normal w a t e r and sewer c h a r g e , The amount of s u r c h a r g e p a i d t o t h e c i t y i s i n d i c a t e d by t h e a r e a E, The a r e a marked "Free" w a s t e s a r e o n l y f r e e i n t h e s e n s e t h a t no s u r c h a r g e i s p a i d on them and t h a t t h i s a r e a depends on t h e volume of w a t e r bought, n o t on t h e pounds of w a s t e s , The volume of w a t e r bought c o u l d i n c r e a s e o r d e c r e a s e i n r e s p o n s e t o such a s u r c h a r g e ,
F i g u r e 4 i s i n c l u d e d t o i l l u s t r a t e t h e demand and s u p p l y f o r w a t e r , The s u p p l y o r c o s t c u r v e of m u n i c i p a l w a t e r t o t h e f i r m i s a s t a i r - s t e p p e d f u n c t i o n w i t h a l o n g f l a t s e c t i o n i n d i c a t e d by
S,
The demand c u r v e b e f o r e s u r c h a r g e s i s D and t h e optimum q u a n t i t y of w a t e r f o r1
t h i s f i r m t o buy was Wl, Immediately a f t e r c o n v e n t i o n a l s u r c h a r g e s a r e imposed, w a t e r t a k e s on a n added dimension of u t i l i t y i n d i c a t e d by t h e c r o s s - h a t c h e d a r e a ; t h a t i s , t h e demand c u r v e s h i f t s upward t o D
2 b e c a u s e a d d i t i o n a l w a t e r purchased p r o v i d e s what we c a l l e d " f r e e " w a s t e s , With D2, t h e optimum q u a n t i t y of w a t e r purchased p e r y e a r would be W2: S u r c h a r g e s would a l s o t e n d t o r e d u c e t h e u t i l i t y of w a t e r
i n p l a n t s as d r y p r o c e s s e s and more by-product r e c o v e r y a r e adopted, U l t i m a t e l y , t h e demand c u r v e f o r w a t e r might f a l l t o D and t h e q u a n t i t y
3
demanded t o W I n t e r e s t i n g l y enough, a r e d u c e d u s e o f w a t e r make some
3 "
Waste d i s c h a r g e d by i n d u s t r y o r demand f o r w a s t e t r e a t m e n t by c i t y 3-
F i g u r e 3 . Demand and s u p p l y c u r v e s f o r m u n i c i p a l t r e a t m e n t o f w a s t e s by a t y p i c a l f i r m showing s u r c h a r g e s p a i d
Demand c u r v e f o r m u n i c i p a l t r e a t m e n t
of w a s t e s
Shaded a r e a , E , shows s u r c h a r g e a c t u a l l y p a i d .
NW i s t h e d e f i n e d l e v e l o f n o r m a l w a s t e s i n p a r t s p e r m i l l i o n .
(NW)W r e p r e s e n t s t h e a l l o w a b l e l e v e l o f w a s t e (pounds o f BOD) c o v e r e d by t h e n o r m a l b i l l i n g f o r w a t e r and s e w e r .
W 1 i s t h e amount o f w a t e r p u r c h a s e d from t h e c i t y b e f o r e t h e s u r c h a r g e . Water demanded c o u l d i n c r e a s e t o W2 when s u r c h a r g e i s i n s t i t u t e d s o a s
t o r e d u c e o r e l i m i n a t e E , b u t t h e demand f o r w a t e r c o u l d a l s o d e c r e a s e t o W as d r y methods o f w a s t e removal a r e s u b s t i t u t e d f o r w e t m e t h o d s .
F i g u r e 4. Demand and s u p p l y c u r v e s f o r w a t e r by
a
t y p i c a l f i r mWater p u r c h a s e d from c i t y
Dl = demand f o r ( u t i l i t y o f ) w a t e r b e f o r e s u r c h a r g e on i n d u s t r i a l w a s t e . D2 = demand c u r v e f o r w a t e r i m m e d i a t e l y a f t e r s u r c h a r g e . The u t i l i t y of
added u n i t s o f w a t e r h a s i n c r e a s e d b e c a u s e of d e f i n e d "normal" i n s u r c h a r g e .
(NW)W2
= pounds o f BOD t h a t w i l l n o t h a v e t o pay s u r c h a r g e . Dg = demand f o r ( u t i l i t y o f ) w a t e r a f t e r s u r c h a r g e and a f t e r f i r m h a smade i n - p l a n t c h a n g e s t o r e d u c e w a t e r - c a r r i e d w a s t e s .
We made a s t u d y of f i v e p o u l t r y p l a n t s i n t h e U n i t e d S t a t e s t h a t have been p a y i n g s u r c h a r g e s f o r more t h a n f i v e y e a r s e a c h , We o b t a i n e d
twenty-seven o b s e r v a t i o n s from t h e s e f i v e f i r m s , We used r e g r e s s i o n a n a l y s i s t o e s t i m a t e t h e e f f e c t of changing b o t h t h e p r i c e of w a t e r and t h e s u r c h a r g e , A s was i n d i c a t e d by c u r v e D i n F i g u r e 4 , we found t h a t
3
h i g h e r s u r c h a r g e s were a s s o c i a t e d w i t h l e s s demand f o r w a t e r , Higher p r i c e s f o r w a t e r a l s o had t h e e f f e c t of r e d u c i n g t h e pounds of w a t e r - c a r r i e d w a s t e s p e r 1000 b i r d s , These e f f e c t s a r e summarlzed a s e l a s t i c f t i e s i n T a b l e 2 ,
T a b l e 2
E l a s t i c i t i e s from E t h r i d g e v s r e g r e s s i o n a n a l y s i s of f i v e p o u l t r y p r o c e s s i n g f i r m s t h a t have been p a y i n g s u r c h a r g e s d u r i n g r e c e n t y e a r s (twenty-seven o b s e r v a t i o n s )
Normal w a t e r and sewer c h a r g e S u r c h a r g e on BOD and SS
A one p e r c e n t i n c r e a s e i n t h e p r i c e of w a t e r was a s s o c i a t e d w i t h a ,63
p e r c e n t d e c r e a s e i n u s e , A one p e r c e n t i n c r e a s e i n t h e s u r c h a r g e was a s s o c i a t e d w i t h a , 5 1 p e r c e n t d e c r e a s e i n w a t e r - c a r r i e d w a s t e s , I do n o t have a h i g h l e v e l o f c o n f i d e n c e i n r e s u l t s o b t a i n e d from o n l y
twenty-seven o b s e r v a t i o n s , b u t t h e c o e f f i c i e n t s i n v o l v e d were s i g n i f i - c a n t l y d i f f e r e n t from z e r o a t t h e f i v e p e r c e n t l e v e l , The r e s p o n s e t o t h e s u r c h a r g e by p o u l t r y p r o c e s s i n g f i r m s p r o b a b l y h a s been under- e s t i m a t e d by t h e s e p r o c e d u r e s ,
b r o i l e r s and a l a r g e i n c r e a s e i n c u t t i n g - u p o p e r a t i o n s , Data on s e a s o n a l o u t p u t of t u r k e y s would be needed t o i n t e r p r e t t h e d a t a on w a s t e s from C e n t r a l s o y a ' s p l a n t ,
Background and Procedures Mr, Roy E , Carawan Department of Food Science North Carolina State University
The background of this study is very unique.
I
would like to give a couple of comments on the background and explain how the project developed.All of our previous speakers have mentioned the increasing emphasis on environment, and their comments reassure me that it is an important fact; and that indeed, we do and should have this increasing environmental emphasis.
I'm
sure that if we had this meeting five years ago no one would have mentioned the environment. This emphasis has prompted new regulations and more vigorous enforcement of all regulations, We have new state regulations regarding waste discharges, We have the Corps permit program and the Environmental Protection Agency, You heardDr, Seagraves mention that all cities who receive federal funds to build a facility--and
I
believe that just about all cities do receive these funds--will have to start charging equitable costs for waste treatment. Also, we're faced with the rising costs of production,I
don't thinkthis is any secret to the people in the poultry processing industry, We began this study with the realization that the cost of water and wastes could be very significant in poiltry processing, Although they're
small, they're still significant. When only approximately 7,3q per pound exists for live hauling, processing, selling, delivery and profit and you take a cost of 0.1 to 1~ per bird, it becomes very significant. Byron Hawkins can tell you when the costs go up at the same time they put a surcharge on you, it becomes a lot more significant. The management of water and wastes in the poultry processing industry has long been disregarded because it could be disregarded. It was too small to profitably manage, We began developing the project with the premise or the belief that management in poultry processing would act provid- ing they had the necessary knowledge, We didn't believe that plants knew how much water they were using, We also didn't believe they knew how much wastes were being discharged or where they were coming from,
t h e y a r e n ' t t o o r e a s o n a b l e , They were developed f i f t e e n o r twenty y e a r s ago, and t h e p o u l t r y i n d u s t r y h a s expanded v e r y r a p i d l y i n t h e l a s t t e n t o twenty y e a r s , t h e p l a n t s have been modernized and have become l a r g e r , We now have some tremendous s i z e p o u l t r y p r o c e s s i n g p l a n t s t o d a y ,
I p r e f a c e d t h i s w i t h t h e f a c t t h a t management would a c t p r o v i d i n g t h e y had t h e n e c e s s a r y knowledge, I have t o a g r e e t h a t p o s s i b l y a s u r - c h a r g e g i v e s them a l i t t l e i n c e n t i v e t o do t h i s , I ' m n o t recommending them, b u t i t does g i v e an i n c e n t i v e , We began d e v e l o p i n g t h i s s t u d y a s a r e s e a r c h p r o j e c t a t t h e u n i v e r s i t y w i t h t h e f e e l i n g t h a t something needed t o be done i n t h e p o u l t r y p r o c e s s i n g i n d u s t r y , T h e r e was enough w a t e r u s e d a n d w a s t e g e n e r a t e d t h a t we t h o u g h t we c o u l d make a n i m p a c t , D r , B i l l C r o s s w h i t e r e a l l y h e l p e d b e g i n t h e p r o j e c t , We began e a r l y w i t h a s m a l l p r o j e c t from t h e Water Resources Research I n s t i t u t e of The Univer-
s i t y of North C a r o l i n a , and from t h e r e we proceeded t o go t o t h e Environmental P r o t e c t i o n Agency, A t t h a t t i m e we were o f f e r e d
t h e o p p o r t u n i t y t o do a d e m o n s t r a t i o n g r a n t w i t h t h e p o u l t r y p r o c e s s i n g p l a n t , and t h i s i s when we approached t h e Gold K i s t o r g a n i z a t i o n and M r , Byron Hawkins t o a c t w i t h u s on t h i s d e m o n s t r a t i o n g r a n t , The
way a d e m o n s t r a t i o n g r a n t works i s t h e f e d e r a l government i s w i l l i n g t o p u t d o l l a r s i n t o a n a r e a where t h e r e i s no knowledge, where you need m o d i f i c a t i o n s and where you need c h a n g e s , T h i s i s what we f e l t was
t r u e i n t h e p o u l t r y p r o c e s s i n g i n d u s t r y , We needed t o t i e t o g e t h e r t h i n g s t h a t were t h e r e ; we needed t o t i e t o g e t h e r t h e new p r o c e s s i n g s t e p s t h a t were a v a i l a b l e ,
W i l l someone t u r n on t h e p r o j e c t o r ? I work w i t h t h e A g r i c u l t u r a l E x t e n s i o n S e r v i c e a t North C a r o l i n a S t a t e U n i v e r s i t y , and t h a t ' s o u r famous B e l l Tower, 1 ' m i n t h e Department of Food S c i e n c e ,
hat's
o u r new b u i l d i n g on t h e campus, If y o u ' r e e v e r t h e r e , come and v i s i t u s , Our p r o j e c t was e n t i t l e d , W a t e r and Waste Management i n P o u l t r y P r o c e s s i n g , " This i s a p r e t t y broad and p r e t t y a l l - e n c o m p a s s i n gt i t l e , I hope by t h e t i m e we g e t t h r o u g h t h a t y o u ' l l b e t t e r under- s t a n d o u r p r o j e c t ,
U n i v e r s i t y (NCSU) r o l e , which i s v e r y u n u s u a l i n a r e s e a r c h p r o j e c t o f t h i s t y p e , was i n v o l v e d w i t h Gold K i s t i n what we c a l l a sub-
c o n t r a c t c F i r s t o NCSU was r e s p o n s i b l e t o t r a i n t h e o p e r a t i n g p e r s o n n e l i n t h e p l a n t which were p r o v i d e d by t h e Gold K i s t o r g s n f z a t i o n t o manage t h e p r o j e c t , t a k e s a n p l e s , do t h e l a b t e s t i n g , and t o be t h e r e and do t h e a c t u a l work, Also, we were r e s p o n s i b l e f o r s u p e r v i s i n g t h e sampling p r o c e d u r e s t h a t went on i n t h e p l a n t , The t h i r d t h i n g was c o o r d i n a t i n g t h e development of t h e s p e c i a l i z e d equipment; t o h e l p d e c i d e what t y p e s of equipment would go i n and where and h e l p d e v e l o p i t ; p r o v i d e t e c h n i - c a l a s s i s t a n c e i n t h e i n - p l a n t changes, and t h i s was l a r g e l y t h r o u g h t h e e f f o r t s of M r , John Macon who you w i l l h e a r from i n a few m i n u t e s ; and t o make a s y s t e m e v a l u a t i o n i n b e n e f i t - c o s t a n a l y s i s , If we p u t i n some changes, j u s t what would t h e y c o s t a n o t h e r p o u l t r y p l a n t t o i n s t i t u t e and what c o u l d t h e y e x p e c t t o g a i n from t h e s e changes? We a l s o need t o d e v e l o p some management g u i d e s , These can t e l l you how t o d e v e l o p t h e equipment and how t o m o t i v a t e t h e p e o p l e t o u s e l e s s w a t e r and g e n e r a t e l e s s w a s t e ,
One of t h e s p e c i a l f e a t u r e s of t h i s p r o j e c t was t h e j o i n t develop- ment of t h e p r o j e c t , We had t h e Department of Economics w i t h Dr, Cross- w h i t e and M r , John Macon, and we had t h e Food S c i e n c e Department w i t h m y s e l f , D r , Speck and D r , T a r v e r gave u n l i m i t e d a s s i s t a n c e , and t h i s l e d t o t h e i n t e r d i s c i p l i n a r y r e s e a r c h team, A l s o , as I mentioned b e f o r e , we had a f u l l - t i m e i n - p l a n t p r o j e c t s t a f f which c o n s i s t e d of Mr, Lawrence C a r t e r t h r o u g h most of t h e p r o j e c t , and h e was t h e one t h a t h e l p e d
sample and keep r e c o r d s of t h e d a i l y p r o j e c t s , Mr, Hawkins s u p e r v i s e d him, and a l s o t h r o u g h o u r e f f o r t s we h e l p e d s u p e r v i s e him and t e l l him which samples t o p i c k up and where, But h e was t h e one who was i n t h e p l a n t and had t o do t h e work, Then, t h e a p p l i e d s y s t e m s a n a l y s i s
c l e a r l y t h e c o o p e r a t i o n we have r e c e i v e d , There were t h e employees of t h e Environmental P r o t e c t i o n Agency; t h e s t a t e w a t e r r e s o u r c e p e o p l e , t h e Water Resources Research I n s t i t u t e and a l l t h e u n i v e r s i t y s t a f f , We've had p e o p l e from a l l o v e r working w i t h u s on t h i s p r o j e c t ,
The d e m o n s t r a t i o n p r o j e c t , a l t h o u g h conceived by t h e u n i v e r s i t y and
EPA,
was a s k e d f o r and g r a n t e d t o t h e Gold K i s t o r g a n i z a t i o n , The a c t u a l t e s t s a r e b e i n g r u n a t t h e i r Durham p l a n t , The D u r h a m f a c i l i t y was managed by M r , Byron Hawkins and M r , Lawrence C a r t e r was t h ei n - p l a n t p r o j e c t d i r e c t o r , P o u l t r y a r e p r o c e s s e d i n t h e p l a n t on two l i n e s w i t h a combined c a p a c i t y of 12,000 b i r d s p e r hour, The coopera- t i o n e x p e r i e n c e d w i t h i n t h e u n i v e r s i t y was c o n t i n u e d w i t h t h e Gold K i s t o r g a n i z a t i o n ,
Now, g e t t i n g t o t h e s p e c i f i c o b j e c t i v e s of t h e p r o j e c t : (1) t o i n s t a l l a n d / o r modify t h e p r o c e s s i n g equipment i t s e l f , What could we do i n modifying t h e equipment t h a t was i n t h e p l a n t t o e n a b l e i t t o u s e l e s s w a t e r , t o g e n e r a t e l e s s w a s t e s ? ( 2 ) t o e v a l u a t e t h e impact o f t h e s e changes, How much w a t e r r e d u c t i o n would a change make? How much w a s t e would one of o u r changes e l i m i n a t e ? ( 3 ) t o determine t h e economic i m p l i -
c a t i o n s o f t h e s e changes, Could a p o u l t r y p l a n t j u s t i f y t h e e x p e n s e s of t h e p r o c e s s m o d i f i c a t i o n ? I n o t h e r words, would we s a v e enough w a t e r and would we e l i m i n a t e enough w a s t e s t o j u s t i f y s p e n d i n g t h e money t o make t h e changes? Not a l l of our changes panned o u t , We d i d n ' t e x p e c t them t o , and t h i s i s why we had t h e d e m o n s t r a t i o n g r a n t , I f we had t h e answers b e f o r e we s t a r t e d , we w o u l d n ' t have had t o do t h e work, ( 4 ) t o f o r m u l a t e t h e management g u i d e s which I d i s c u s s e d
p r e v i o u s l y ,
Now o u r b a s i c p l a n of work was f i r s t t o o b t a i n bench mark i n f o r - m a t i o n , By bench mark i n f o r m a t i o n , we mean j u s t how much w a t e r was
used i n t h e p l a n t , Where a r e t h e w a s t e s coming from i n t h e p l a n t ? T h i s was j u s t t o g i v e u s a n o v e r a l l f e e l f o r what was going on, The second
t h e w a s t e s b e f o r e t h e y g o t o u t o f t h e p l a n t , S l i d e A r e p r e s e n t s t h e p l a n t , I f y o u 2 1 f o l l o w t h e p o t a b l e w a t e r from t h e l e f t and t h e b i r d s from t h e t r u c k g o i n g t o r e c e i v i n g , t h e k i l l i n g s t a t i o n , s c a l d i n g ,
d e f e a t h e r i n g , t h e whole b i r d wash, e v i s c e r a t i o n , t h e f i n a l b i r d wash, c h i l l i n g and t h e n i n t o g r a d i n g , weighing and p a c k i n g , you can s p o t t h e u s e s o f w a t e r and a r e a s of by-products r e c o v e r y , You have f e a t h e r s from d e f e a t h e r i n g ; you have your blood; you a l s o have o f f a l t h a t w i t h t h e f e a t h e r s n o r m a l l y g o e s t o a p o u l t r y r e n d e r i n g p l a n t , and t h e y a r e b o t h conveyed i n t h e p l a n t by w a t e r , T h i s i s one of o u r problems, When t h e s e go i n t o t h e w a t e r , you g e t a l l t h e s o l u b l e s u b s t a n c e s i n t h e o f f a l Leaking o u t ; you g e t f e a t h e r s , b i t s and p i e c e s and e v e r y t h i n g e l s e t h a t h a s been going t o t h e w a s t e t r e a t m e n t system, One o f t h e problems you h a v e i s how t o e l i m i n a t e t h e w a t e r i n g e t t i n g t h e s e o u t of t h e p l a n t , I t ' s v e r y e a s y t o throw i t away i n t h e w a t e r , b u t what a r e t h e problems you run i n t o ?
The way we approached t h e bench mark d a t a and t h e b i o l o g i c a l work was t o go t o d i f f e r e n t p o i n t s i n t h e p l a n r a s shown i n S l i d e A , But we
t o o k each u n i t o p e r a t i o n i n t h e p l a n t and looked a t i t i n i t s e n t i r e t y , For example, we t o o k t h e s c a l d e r e x i t ; t h e c h i l l e n t r y and t h e p r e - c h i l l e r ,
t h e whole b i r d wash, and a t e a c h p o i n t we t o o k w a t e r f l o w and w a s t e w a t e r samples t o d e t e r n i n e where t h e w a s t e s a r e g e n e r a t e d , Then we added t h e s e up f o r t h e t o t a l w a s t e s t r e a m of t h e p l a n t , A l s o , we d i d t h e same t h i n g f o r t h e b i o l o g i c a l work,
Now i f you wonder what t h i s means i n North C a r o l i n a , l a s t y e a r , i f my f i g u r e s a r e c o r r e c t , we produced somewhat o v e r 300 m i l l i o n b i r d s , Using a v e r a g e w a t e r u s e f i g u r e s , t h i s amounts t o o v e r 3,60 b i l l i o n g a l l o n s of w a t e r t h a t was used i n North C a r o l i n a l a s t y e a r from t h e pro- c e s s i n g of p o u l t r y , From two t o t e n m i l l i o n pounds of BOD were d i s -
5
charged from t h e p l a n t s , You w i l l n o t i c e I used a wide r a n g e t h e r e , I t a l l depends on whose f i g u r e s y o u ' r e u s i n g f o r what p l a n t , We do n o t have f i g u r e s on most of t h e p l a n t s s o I ' m a v e r a g i n g t h e s e myself, But I ' d s a y somewhere i n t h e two t o t e n r a n g e , and t h i s shows you t h e mag- n i t u d e of t h e problem, 1 t ' s q u i t e a l a c k of i n f o r m a t i o n i n t h i s a r e a and t h i s i s one o f t h e problems and one of t h e r e a s o n s t h a t we s t a r t e d
o t a b l 26 .e Water
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F e a t h e r s
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R e f r i g e r a t e d D e l i v e r y T r u c k s
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Sample P o i n t P r o d u c tI
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By-product---) P o t a b l e Water
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P r o c e s s Water---)(+
Waste WaterP r o c e s s and Equipment Changes discussion w i t h S l i d e s by
M r , John A. Macon Department of Economics North C a r o l i n a S t a t e U n i v e r s i t y
I t ' s a p l e a s u r e t o b e h e r e , U s u a l l y , a t t h e u n i v e r s i t y we w o u l d n ' t t h i n k o f d o i n g a s t u d y w i t h o u t g o i n g t h r o u g h a l a b o r a t o r y model, a p i l o t p l a n t and t h e n s c a l e - u p t o a f u l l o p e r a t i n g u n i t , When we proposed t h i s r e s e a r c h s t u d y t o Washington, Washington wasn' t i n t e r e s t e d a t a l l . They s a i d , "No, i f w e ' r e g o i n g t o g e t t h e j o b done, we want i t now." That i s , t h e y wanted a c t i o n , T h a t ' s a l s o what we wanted, So t h e y t u r n e d u s down i n t h e v e r y b e g i n n i n g and s e n t u s back home. It was a t t h a t p o i n t , r e a l l y , t h a t t h e p r o j e c t g o t s t a r t e d a s a r e s e a r c h and d e m o n s t r a t i o n g r a n t , I n r e v i s i n g t h e p r o j e c t we d i d e x a c t l y what we would have done a t t h e u n i v e r s i t y w i t h one e x c e p t i o n , I n s t e a d o f b u y i n g a t e s t t u b e o r a f l a s k , we bought t h e whole t h i n g and p u t i t i n t h e p l a n t no m a t t e r what i t was. I f i t d i d n ' t work, we had p a i d o u t more money t h a n we s h o u l d h a v e , But w i t h a l l t h e e f f o r t t h a t was made, t h e p r i m e p u r p o s e b e i n g - - a n d we hope t h a t t h i s w i l l b e t r u e - -
t o make changes t h a t c o u l d b e i n s t a l l e d n a t i o n w i d e upon c o m p l e t i o n of
o u r p r o j e c t w i t h a t l e a s t a two-year o r b e t t e r g a i n i n t i m e o v e r t r a d i t i o n a l t y p e r e s e a r c h .
I f you w i l l l o o k a t i t from t h a t s t a n d p o i n t , we a r e t h i n k i n g p r i m a r i l y o f u s i n g o u r p l a n t a s a " l a b o r a t o r y i n a c t i o n , " We made m i s t a k e s ; we
p u r c h a s e d m a t e r i a l s t h a t went t o w a s t e ; b u t i n making o u r m i s t a k e s , we were a b l e t o s a y t h e s e m i s t a k e s l e d t o s u c c e s s , I t h i n k t h e y s h o u l d h a v e changed t h e t i t l e of my s u b j e c t t o "The Problems of G e t t i n g These Changes Made" b e c a u s e t h e r e were some problems. F i r s t of a l l , I r e a l i z e t h a t i t ' s h a r d enough t o measure t h e q u a n t i t y o f goods g o i n g o u t of a p l a n t , b u t w a t e r was s q u i r t i n g o u t o f s o many p l a c e s i n t h i s p l a n t I b e l i e v e i t would h a v e b e e n i m p o s s i b l e t o have measured a l l of t h e w a t e r g o i n g o u t . A t t h a t t i m e i t was c l o s e t o a million g a l l o n s a day, and you d o n ' t p u t t h a t i n y o u r p o c k e t o r b u c k e t e i t h e r ,
Question: Where were t h e s e g a l l o n s s q u i r t i n g o u t ?
Answer: Well, i f t h e y w e r e n ' t s q u i r t i n g o u t , t h e y were g o i n g some p l a c e , They were r u n n i n g through t h e m e t e r ,
So t h a t l e d u s t o b e l i e v e t h a t we'd b e t t e r s t a r t some fmplementa- t i o n on i t which we d i d , Of c o u r s e , we went r i g h t d i r e c t l y t o o u r P a r s h a l l f l u m e , which i s n o t h i n g more t h a n
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measuring d e v i c e , That and t h e V-notch w i e r were u s e d w i t h c o n s t a n t r e c o r d e r s , I r e a l i z e t h a t many of you a r e n o t f a n i l i a r w i t h t h e s e i t e m s , b u t maybe we can show a few s l i d e s a s we go along, The t h i n g t h a t I c a r r y around w i t h me from now on i s n o t o n l y my watch, b u t my stopwatch. With a bucketand a stopwatch you can f i n d o u t how much w a t e r i s s q u i r t e d o u t i n t h o s e p l a c e s ,
S t a r t i n g h e r e w i t h a P a r s h a l l flume, which i s j u s t one view, i t i s a r e s t r i c t i o n where you can measure t h e volume of w a t e r by m e r e l y t a k i n g a measurement of t h e d e p t h of w a t e r f l o w i n g through t h e
r e s t r i c t e d a r e a of a m e t a l c o n t a i n e r which i s j u s t l i k e a p i p e l i n e , Following t h a t w i t h a sampler--and I r e a l i z e t h a t i t i s v e r y d i f f i c u l t t o g e t good p i c t u r e s of t h e s e units--but t h i s was a composite s a m p l e r t h a t t a k e s samples c o n t i n u o u s l y f o r twenty-four h o u r s , T h i s sample of t h e e f f l u e n t gave u s some r e p r e s e n t a t i o n o f what was i n t h e vol.ume o f w a t e r t h a t w a s p a s s i n g t h r o u g h t h e p l a n t , Housed above t h i s P a r s h a l l
flume i s a Thompson r e c o r d e r t h a t r e c o r d e d t h e t o t a l f l o w o f t h e w a t e r , Measuring t o g e t t h e o r i g i n a l volumes was one of t h e f i r s t t h i n g s done
t h r o u g h o u t t h e p l a n t . We p u t i n w a t e r m e t e r s i n j u s t a b o u t e v e r y l o g i c a l p l a c e t o measure t h e d a i l y volume o f w a t e r , We knew t h e n what was happening i n e a c h i n d i v i d u a l p r o c e s s , Meters were a v e r y i m p o r t a n t p a r t of o u r t e s t i n g program,
p l a n t , we had t o s e t t l e i t down and g e t a t l e a s t some u n i f o r m i t y of o p e r a t i o n ; b e c a u s e l i t e r a l l y , i t was s o i r r e g u l a r t h a t I c o u a d n ' t keep up w i t h i t , So one of t h e t h i n g s we had t o do was t r y t o f i n d o u t i f we c o u l d g e t some r e g u l a t i o n .
I have h e r e t h r e e i t e m s t h a t a r e common t o everybody. On y o u r r i g h t i s a w a t e r p r e s s u r e gauge, I know y o u ' v e s e e n them on e v e r y home w e l l system i n t h e c o u n t r y , and y o u ' v e s e e n them i n many o t h e r p l a c e s , t o o . S l i g h t l y t o your l e f t i s a g a t e v a l v e t h a t i s a s common a s t h e day i s l o n g , You c a n r e g u l a t e t h e amount of w a t e r by s h u t t i n g t h e
v a l v e down t o a p o i n t where t h e gauge shows a c e r t a i n amount of p r e s s u r e . T h i s p r e s s u r e i s u n i f o r m h e r e g i v i n g u s a c e r t a i n flow. When u s i n g t h e p r e s s u r e gauge and g a t e v a l v e , you a r e r e l y i n g on t h e o p e r a t o r t o make t h a t change o r t o check t h a t f l o w e v e r y day, I n t h i s c a s e we added a f e a t u r e . We wanted t o s h u t t h e w a t e r o f f and come back t h e n e x t day and have t h e same f l o w a s t h e day b e f o r e , So we bought t h e t h i r d v a l v e a n d p u t i t i n s e r i e s w i t h t h e o n e s t h a t a r e s u p p l y i n g t h e s p r a y n o z z l e s . T h i s a s s u r e s a c o n s t a n t f l o w each t i m e t h e g a t e v a l v e i s opened.
I n t h i s s l i d e i s a view of t h e q u i c k s h u t - o f f v a l v e which I recommend w h o l e h e a r t e d l y b e c a u s e o f t h e s a v i n g i n t i m e i n o p e n i n g and c l o s i n g i t .
of poor q u a l i t y b i r d s , So i n s p i t e of how w e l l you have your a u t o m a t i c k i l l e r s g o i n g I hope you s u c c e s s , and 1 hope t h a t some of you can show me how i t s t i l l b e a t s t h e hand k i l l i n g , At t h i s p o i n t t e c h n i q u e i s something t h a t n e e d s t o be c h a l l e n g e d , and a good k i l l i n g machine pro- v i d e d , For t h e w o r k e r s d o i n g hand k i l l i n g we p r o v f d e d s p l a s h s h i e l d s a t t h e o t h e r end o f t h i s t r o u g h t h a t a r e n o t v i s i b l e i n t h i s p i c t u r e ; t o keep a l l t h e blood p o s s i b l e c o n t a i n e d and t o keep i t o f f t h e w o r k e r s , The environment had been improved i n such a way t h a t a t t h e t i m e we had t o remove t h e s h i e l d s f o r e x p e r i m e n t a l p u r p o s e s t h e workers t h r e a t e n e d n o t t o hand k i l l c h i c k e n s t h a t day, So you can s e e i t w a s n o t o n l y f o r t h e b e n e f i t o f w a t e r r e d u c t i o n and w a s t e c o n t r o l , b u t i t was an e n v i r o n m e n t a l and human r e s o u r c e advancement,
Along w i t h t h e s h i e l d s we have a s t a i n l e s s s t e e l , s h e e t m e t a l t r o u g h c o n t a i n e r , You w i l l n o t i c e how c l e a n and w h i t e t h e s e b i r d s a r e , T h i s i s because r i g h t a f t e r t h e b i r d s a r e killed--and i f you've e v e r been around t h e home o p e r a t i o n , you know t h a t t h e y f l o p a l l o v e r t h e place-- t h e y p a s s o v e r a s e r i e s of e l e c t r i c a l s h o c k i n g b a r s and a r e s t i l l e d by t h e s h o c k i n g machine e a r l y a f t e r b e i n g k i l l e d , You w i l l n o t i c e t h a t t h e body and t h e f e a t h e r s a r e k e p t c l e a n , t h e b l o o d i s w e l l c o n t a i n e d i n o u r trough; t h e r e f o r e , we a r e c o l l e c t i n g n o t o n l y t h e w o r s t p o l l u - t a n t s of o u r p l a n t b u t i t i s now a good by-product, M r , Hawkfns s a y s h e l i k e s t h e way h e g e t s t h e money back, So from t h a t p o i n t w e ' l l go now on i n t o t h e n e x t s e r i e s ~ f s l i d e s which i s t h e d e f e a t h e r i n g
department ,
Question: The w a l l s shown t o t h e right--were t h e y t h e o r i g i n a l w a l l s ? Answer:
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Yes, s i r , i t ' s t r u e and you w i l l s e e a p i c t u r e l a t e r showing what t h e w a l l looked l i k e , 'There h a s been a d r a s t i c change i n t h e amountof l o s s of m a t e r i a l s a t t h i s p o i n t ,
I n t h i s s l i d e
