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BIOSOLIDS ENHANCEMENTS AT THE DOS RIOS WRC SLUDGE BLEND TANKS AND CENTRIFUGES Garrett Kehoe, P.E. September 21, 2018

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BIOSOLIDS ENHANCEMENTS AT THE DOS RIOS WRC SLUDGE BLEND TANKS AND CENTRIFUGESGarrett Kehoe, P.E.

September 21, 2018

Arcadis 2017

Agenda

Background

Issues

Phased Solution Approach

o Phase I Sludge Blend Tank Improvements

o Phase II Thickening Centrifuges

Lessons Learned and Implemented

Arcadis 2017

1984/85 Dissolved Air Flotation Thickening

2006- Gravity Belt Thickeners 1 & 2

2009 Gravity Belt Thickeners 3 & 4

Dos Rios WRC Sludge consists of:

o Excess Activated Sludge (WAS)

o Dos Rios Primary Sludge

o Leon Creek Sludge (Primary + WAS)

Background

Arcadis 2017

The issues

(Prior to Upgrades)

Inconsistent Feed Rate

Inconsistent Thickness

Lack of Automation

Lack of Redundancy

Capacity Limitations

Arcadis 2017

Existing SystemPrimary Sludge

DIGESTERS

DIGESTERS

DIGESTERS

EAS

EAS

EAS

Leon

Primary

Sludge

Leon

Blended

Thickened

Arcadis 2017

The IssuesPrimary Sludge

DIGESTERS

DIGESTERS

DIGESTERS

EAS

EAS

EAS

Leon

Primary

Sludge

Leon

Blended

Thickened

Centrifugal Pumps

(Inconsistent Flow)

Not Being Thickened

In Pipe Sludge Blending

(Inconsistent Thickness)

Arcadis 2017

Phase I Sludge Blending Tank

Fix consistency of flow and thickness

Increase operational flexibility

Phase II Centrifuges

Add redundancy

Add capacity

Automation

Reduce Operational Costs

Phased Approach

Arcadis 2017

New Gravity Belt Thickeners Feed Pump Station

New Recirculation Pump Station

New Blending Tank

Overflow Protection

Bypasses for Operational Flexibility

Phase I Sludge Blend Tank

Arcadis 2017

Primary Sludge

DIGESTERS

DIGESTERS

DIGESTERS

EAS

EAS

EASLeon

Primary

Sludge

Leon

Blended

Thickened

Proposed System

New Feed Pump Station

(Improved Flow Rate Control)

New Blending Tank

(Improved Consistency)

Arcadis 2017

Completion Pictures

Arcadis 2017

Two new Centrifuges

New Polymer System

New Centrate Pump Stations

Automation

Facilities for Future Centrifuges

Phase II

Arcadis 2017

Solids Loading Capacity vs Flow Capacity

Thickening equipment needs to be evaluated for both

Capacity Evaluation

Arcadis 2017

Phase II Sludge Flows

GBTs @ 750 gpm each

0

500

1000

1500

2000

2500

3000

3500

2014 2016 2018 2020 2022 2024 2026 2028 2030 2032

Slu

dge F

low

(gpm

)

Year

2% Growth Sludge Flow

Average Flow (gpm) 3 Operating GBT 4 Operating GBT

Arcadis 2017

Phase II - Solids Thickening Needs

GBTs @ 3750 lb/hr | Centrifuge @ 6500 lb/hr

0

100000

200000

300000

400000

500000

600000

700000

800000

2014 2016 2018 2020 2022 2024 2026 2028 2030 2032

Dry

Solid

s (

ppd)

Year

2% Growth Solids Handling Capabilities

Average Flow Loading Rate (ppd) 3 Operating GBT 4 Operating GBT One Additional Centrifuge Two Additional Centrifuge

Arcadis 2017

Phase II

New Feed Pumps

New Polymer Building

New Electrical Building

New Centrate Pumps

New Centrifuges Future Centrifuges

Arcadis 2017

Ongoing Construction

Arcadis 2017

Ongoing Construction

Arcadis 2017

Scoping/Procurement Differences

General Contractor

Centrifuge

Backwash Pump

Thickened Sludge Pump

Polymer System

TYPICAL

Centrifuge

General Contractor

Backwash Pump

Thickened Sludge Pump

Polymer System

DOS RIOS THICKENING

Lessons Learned

Arcadis 2017

Available underground space extremely limited

Exposed piping can be your friend

Lessons Learned

Arcadis 2017

I&C Workshops, I&C Workshops, I&C Workshops

3 Instrumentation and controls workshops during design

1 Network workshop during construction

1 Control panel workshop during construction

1 Graphics workshop during construction

Lessons Learned

Record drawings are not always right!

Arcadis 2017

Thickened sludge pumping is an art.

Non Newtonian fluid.

Highly recommend viscosity testing sludge for >5% solids.

Lessons Learned

Arcadis 2017

Lessons Learned Control Maps

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Housekeeping and Safety By Design

Confined Space, no access provided

Tapered edge to prevent storm water entry

Grating above entire centrifuge area to clear spilled sludge easily

Arcadis 2017

Questions?