Left: Untreated wastewater with hazardous chestnut color (COD 2,150 mg/L). Right: Ozone-treated water achieving drinking-grade clarity (COD 89 mg/L) using OX-80 generator and V6 Off-Gas Valve.
A Picture Worth 1,000 Data Points: Decoding the Transformation
The side-by-side images submitted by Customer. aren’t just marketing visuals – they’re a forensic map of ozone’s oxidation power. Let’s dissect what each frame reveals:
Left – The Problem (Pre-Treatment):
- Color: Opaque chestnut brown (Hex #6B4226) caused by:
▶︎ Roasted nut tannins (UV254 absorbance: 0.87/cm)
▶︎ Protein-laden washwater (Kjeldahl Nitrogen: 85 mg/L) - Foam: 6-inch stable foam layer (surface tension <45 mN/m)
- Regulatory Risk: Exceeded local discharge limits for:
▶︎ BOD₅ (610 vs. 30 mg/L max)
▶︎ Oil & Grease (190 vs. 10 mg/L max)
Right – The Solution (Post-Ozone):
- Color: NSF/ANSI 61-certified clarity (UV254: 0.12/cm)
- Operational Wins:
▶︎ 100% foam elimination within 18-minute retention time
▶︎ 94% BOD₅ reduction enabling direct reuse in boilers
▶︎ Zero chemical additives – ozone residual self-neutralizes
This transformation was achieved not just by their OZY-80 Oxygen-fed Ozone Generator (80g/h), but through precision integration with the V6 Intelligent Off-Gas Valve. Here’s how these systems synergized:
The Oxygen-Ozone-OffGas Trifecta: Engineering Breakdown
1. Why Oxygen-Fed Beats Air-Fed for Food Wastewater
| Parameter | OZY-80 (Oxygen) | Typical Air-Fed | Benefit Realized |
|---|---|---|---|
|
Ozone Concentration |
12% wt. |
5% wt. |
60% faster COD oxidation |
|
Energy Efficiency |
2.8 kWh/kg O₃ |
6.1 kWh/kg O₃ |
$15,600/year saved |
|
NOx Byproducts |
<0.1 ppm |
2.3 ppm |
Avoided $8k/month denitrification costs |
Client’s ROI Calculation:
Annual Savings = (Energy Savings) + (Chemical Cost Avoidance) + (Regulatory Penalty Prevention)
= ($15,600) + ($42,000) + ($150,000)
= $207,600
System Payback Period = Capital Cost / Annual Savings = $198,500 / $207,600 ≈ 11.5 months
2. Off-Gas Valving: The Silent Multiplier
The V6 Valve enhanced performance through:
- Gas Recycling Loop: 28% unreacted ozone redirected to pretreatment stage
- Pressure-Tuned Injection: Maintained 0.4-0.6 ppm dissolved ozone despite flow surges
- Fail-Safe Protocols: Auto-vent upon pump failure (tested 0.3s response time)
NutriFoods’ Performance Metrics:
| Metric | Without V6 Valve | With V6 Valve |
|---|---|---|
|
Ozone Utilization |
12% wt. |
92% |
|
Energy Efficiency |
18h/day |
12h/day |
|
Maintenance Stops |
Biweekly |
Quarterly |
Selecting Your System: 5 Must-Ask Questions
What’s Your Contaminant Profile?
- Food wastewater requires ozone doses 2-3× higher than municipal due to:
▶︎ Fats/Oils (C≥20 chains need 4g O₃/g contaminant)
▶︎ Proteins (Breakdown requires ORP >800mV)
- Food wastewater requires ozone doses 2-3× higher than municipal due to:
Oxygen or Air Feed?
Choose oxygen-fed if:
✔️ Discharging to sensitive ecosystems (no nitrates)
✔️ Processing >10 tons/day organics
✔️ Seeking >90% pathogen killOff-Gas Strategy?
- Catalytic destroyers vs. Thermal
- Closed-loop vs. Vent-to-atmosphere
Peak vs. Average Load?
NutriFoods sized their OX-80 using:Ozone Demand (g/h) = [(Q_peak × C_peak) – (Q_avg × C_avg)] × SF
= [(35m³/h × 2500 mg/L) – (20m³/h × 1200 mg/L)] × 1.5
= 79.8 → OX-80 selected
Material Compatibility?
- 316L stainless steel for ozone contact zones
- Kalrez® seals for valve assemblies
