How Tyson Foods monitors poultry wastewater with SCADA

The Tyson Foods chicken further processing facility in Russellville, Arkansas, uses a proprietary supervisory control and data acquisition (SCADA) system to manage wastewater pretreatment processes. It includes real-time visual monitoring with cameras.

The operator uses a stylus and digital pad to remotely the control operation of the wastewater treatment system.
The operator uses a stylus and digital pad to remotely the control operation of the wastewater treatment system.

The Tyson Foods further processing plant in Russellville, Arkansas, is the winner of the 2016 U.S Poultry and Egg Clean Water Award in the pre-treatment category. A notable capability of the facility is the remote monitoring and control of wastewater pretreatment processes with a proprietary supervisory control and data acquisition (SCADA) system, which includes real-time visual monitoring with cameras.

Tyson Foods’ wastewater pretreatment system in Russellville relies on an initial screening of raw wastewater followed by two dissolved air flotation (DAF) systems with distributed, aerated flow equalization (EQ tanks) to treat an average of 200,000 gallons per day.

The 24-hour further processing production schedule yields roughly 3 million pounds of finished poultry products each week and results in wastewater containing breading, marination, batter and oils. In varying combinations those constituents are often difficult to treat consistently without constant operator oversight, even with flow equalization.

Dissolved-air-flotation-Tyson-Foods-Russellville

The poultry wastewater treatment system includes two dissolved air flotation units (DAFs) and an equalization tank for distributed, aerated flow of 200,000 gallons per day.

Proprietary SCADA provides flexibility, efficiency

The Tyson Foods further processing facility employs a proprietary supervisory control and data acquisition (SCADA) system to more efficiently manage the wastewater treatment system. In addition to monitoring and control from the onsite control panels, the SCADA provides real-time monitoring and control through the use of a portable pad, onsite, or remotely via the internet.

SCADA systems use various sensors including on/off switches for pumps and motors, pH and flow meters to operate large unit processes such as the screens, dissolved air flotation units, and the equalization tank levels and aerators. Real-time feedback about and control of the overall system operations can be examined and controlled or automated if the appropriate sensors are used.

SCADA allows more constant oversight

Although a variety of SCADA systems are available commercially, the Russellville system was designed by Tyson Foods. A unique aspect of the Tyson Russellville system is that it includes cameras that allow the operator to see more qualitative parameters. These include cameras that show the floated solids moving along the DAF surface and the treated water discharged to the local water reclamation facility.

Wastewater manager Rick Owens said the SCADA allows more constant oversight of the facility’s wastewater pretreatment operations.

Managers are able to remotely control wastewater pretreatment processes through the SCADA system, which includes real-time visual monitoring with cameras.

Remote monitoring on weekends as pretreatment processes restart following sanitation procedures is especially helpful. It allows Owens to monitor the startup of pumps and wastewater levels in equalization tanks from home, including real-time camera views.

Owens explains, “I can log on remotely and look at my pumps, the gallons per minute going through, pH levels and check everything at home.”

Owens can tap into his 16 years of expertise to examine the consistency and color of the DAF float and watch for suspended solids in the discharged water. He noted, “I can make chemical adjustments from home and confirm that the system is operating as designed.”

State officials take notice of innovations

Dave Evans, complex environmental manager, said, “Rick can isolate one of the EQ tanks if he knows a heavy wastewater load is coming from further processing production, or if an alarm occurs, or he sees a high pH from sanitation. He can also manage the first flush storm water from the paved trailer areas during a heavy rain event. It really gives us a step up on compliance and our local and state regulators appreciate that aspect.”

Dave-Evans-and-Rick-Owens

Dave Evans, complex environmental manager, and Rick Owens, wastewater manager, said the supervisory control and data acquisition system (SCADA) provides real-time monitoring and remote control via the internet.

Tyson’s innovations in Russellville have caught the attention of the Arkansas Department of Environmental Quality, which has called on the facility to demonstrate the system to other wastewater operators in the state.

Upgrades to enhance environmental stewardship

Water conservation also serves as a facility touchstone, with regular meetings, performance metrics and reporting usage to help show constant improvement.

A number of upgrades to the wastewater treatment system are planned to enhance environmental stewardship:

  • More advanced valves are to be installed that will allow moving water between EQ tanks.
  • Dry scrubbers on the roof will be upgraded with more efficient wet scrubbers to improve air standards compliance.
  • Weep pads are to be added to trailer holding areas, including the regrading, paving and curbing those areas. The result will be better use of grass swales and other natural best management practices to control storm water volumes and capture contaminants.

Solids captured from the wastewater treatment system are already land applied in a controlled manner to reclaim land that ultimately will become a wildlife habitat.

The focus is on stewardship, according to Evans, who gave an example: “The further processing facility’s production processes have been changed to prevent flour and marinades into the drains.

“All these things working together have revolutionized what we are doing from a money standpoint, from a regulation standpoint and how hard we have to work to do it. If we do it to efficiency, we don’t have to fight to make it work.”

Community involvement at Russellville facility

David Beavers, plant manager, said the facility’s stewardship includes community outreach and support. “At Tyson Foods, we believe in giving back to the community in which we operate. Our local management orchestrates these efforts but it is our team members who make it happen.”

Evans added, “We have helped survivors of natural disasters, most recently for a local tornado and then floods in Louisiana. With the majority of charity events Tyson promotes and those recent disasters, we show up with a cooker, provide the meat and we actually cook it. We are supporting and serving the community.”

Tyson Foods’ further processing facility in Russellville, Arkansas, works hard to conserve water and responsibly return what is used. The environmental stewardship, along with a proud service ethic for giving back to the community, made the facility a 2016 Clean Water Award winner.

The Clean Water Award, which is sponsored by U.S. Poultry & Egg Association, recognizes outstanding wastewater treatment facilities operated by poultry companies and allied industries. The pre-treatment category consists of facilities that discharge processed effluents to municipal water reclamation facilities before final discharge into the environment.

 

 

Read more on Clean Water Award winners: 

Poultry renderer recognized for wastewater reclamation, www.wattagnet.com/articles/28628

Sanderson Farms awarded Clean Water Award, www.wattagnet.com/articles/28585

  

 

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