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Energy Efficiency Opportunitiesat Wastewater Treatment
Facilities
UW – Madison Class
November 3, 2010
Focus on Energy
Joseph Cantwell, P.E.
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Economic Benefits of Efficiency
• Reduces the need for new power plants
New power plant cost >$3,000/kW
Efficiency program cost <$500/kW
• Reduced environmental impacts,
including $$
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Why?
• Why energy?
– Limited resource– Costs are
increasing– Major component
of facility budgets– Can be managed
• Why Water & Wastewater?
– Facilities consume 35% of energy used by municipalities
– Operation is 24/7
– W/WW energy costs are $9 billion/yr
– W/WW consume 70 billion kWh/yr
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Energy Baseline
Find out where you’re at (baseline)...
…so you can figure out where you want to go (benchmark).
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Implementation Value
Single shift
– (8 hrs/day) (5 days/wk) (52 wks/yr)
= 2,080 hrs/yr Continuous
– (24 hrs/day) (365 days/yr) = 8,760 hrs/yr
8,760 hrs/yr / 2,080 hrs/yr = 4.2
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Electricity Requirement for Typical Activated Sludge Facilities (WEF)
Grit1%
Screens1%
Clarifiers3%
Wastewater Pumping
12%
Lighting and Buildings
6%
Chlorination1%
Belt Press3%Anaerobic
Digestion11%
Gravity Thickening1%
Return Sludge Pumping
1%
Aeration60%
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Water/Wastewater Approach
• Site surveys—How performed
• Data requested• Discussions with
operators• Assessment
approach• Assessment report
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Assessment Approach
• Explore major energy uses
• Address facility operations
• Modify/adjust operations
• Level of interest of operator
• Acceptance of assessment
• Cooperation to implement
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Data to Gather
• Energy bills• Demand consumption• Size of treatment units• Design memorandum• Existing loading information• Effluent limits• Site input• Equipment data
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Basic Assessments
• Plot energy consumption and demand• Percent loading – components and systems• Variability of process equipment• Variation in loading hourly/daily/weekly• Distribution of energy consumption• Obtain Amp, Watt or DO readings• Meet and review operations with site
personnel
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Identified Energy Saving Opportunities
Wastewater Aeration Pumping Variable Speed
Drives Automatic Controls Solids Management Operation Equipment Selection
Water Pressure Throttled Valves Drives Controls Pumps Operation
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Electric Energy Bill Basics
• Kilowatt (kW) = Power or Electric Demand ─ kW is measured over 15-minute periods
(averaged kW)─ Equals KWH measured over 15 minutes * 4
• KWH (Kilowatt hour) = Energy Used─ KWH = kW * hours─ On-peak kWh = kWh used during weekday─ Off-peak kWh = kWh used during weeknight
and weekends
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Demand-side management
Demand
Learn when “on-peak” demand is
Review when changes in equipment occur
Schedule maintenance/equipment tests
Maintenance operations (welding, pump station cleaning, filter backwashing)
Treating hauled in wastes
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Impact on demand
Demand
Change in blowers
Change in pumps
Utilize standby generator
Interior and exterior lighting
Exercising equipment
Stagger large energy processes
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Daily DemandAugust 15, 2001
1600
1620
1640
1660
1680
1700
1720
0:00 3:00 6:00 9:00 12:00 15:00 18:00 21:00 0:00
Time of Day
kWUnderstand Electric Demand
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Understand Electric Demand
WWTP - November 2008 Demand Data
0
10
20
30
40
50
60
70
80
90
100
11/1
/200
8 0
0:15
11/1
1/20
08 1
4:45
11/1
4/20
08 0
5:15
11/1
6/20
08 1
9:45
11/1
9/20
08 1
0:15
11/2
0/20
08 2
3:45
11/2
3/20
08 1
4:15
11/2
6/20
08 0
4:45
11/2
8/20
08 1
9:15
11/3
0/20
08 0
9:45
11/6
/200
8 0
1:00
11/8
/200
8 1
5:30
Dem
and
(kW
)
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Understand Electric Demand
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Aeration
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Aeration
Aeration
Organic loading• Biochemical oxygen demand (BOD)• Ammonia
Mixing• 0.125 cfm/SF• 0.25 cfm/SF
Aeration “capability” to meet code Diffuser density Flexibility of blower selection Existing and design loading
Must assess:
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Effect of bubble size
The smaller the bubbles, the larger the area-to-volume ratio
The smaller the bubbles, the slower the bubble rise rate
Smaller bubbles have more surface area and longer residence time in the liquid.
Both increase the clean water oxygen transfer.
Aeration
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Bubble size comparison
One hundred seventy-five golf balls fit into the volume of a basketball. So, with the same volume, you increase the surface area for O2 transfer by about 5.6 times.434.9/2.5 = 175175 X 8.9 = 1557.5/277.6 = 5.6
Diameter (in)
Surface area (in2)
Volume (in3)
Golf ball 1.7 8.9 2.5
Baseball 2.9 25.8 12.3
Basketball 9.4 277.6 434.9
Aeration
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Energy Savings from DO Management
Actual Setpoint SavingsDO DO Fraction %2 2 - -3 2 1/8 12.54 2 2/8 255 2 3/8 37.56 2 4/8 507 2 5/8 67.58 2 6/8 75
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Aeration
1. Aeration Tank Volume: 50 ft x 250 ft x 18 ft = 225,000 ft3
2. Floor Area: 50 ft x 250 ft x 0.125 cfm/ft2 = 1,563 cfm (Mixing)
3. Code (air rate capability)@ 20 cfm/1000 ft3 = 4,500 cfm (Mixing)
4. Organic Loading: (3.5 MGD) BOD = 4,500 lb/day & NH3 = 625 lb/day (4,500 lb/day x 1.1lbO2/BOD x ft3/0.0172 lbO2/ft3air x day/1440 min)/0.20eff = 1,000 cfm (625 lb/day x 4.6 lbO2/lbNH3 x ft3/0.0172 lbO2/ft3air x day/1440 min)/0.20eff = 580 cfm
1,000 cfm + 580 cfm = 1,580 cfm
EXAMPLE – AERATION CONTROL PARAMETER
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Aeration
Organic Loading Controlled @ 1,580 cfm: 1,580cfm @8.5 psi = 75 hp x (0.746 kWh/hp/0.90eff ) x 8,760 hr/yr x $0.08/kWh =
$43,570/yr
Mixing (use 20 cfm/1000 ft3) 4,500cfm @8.5 psi = 200hp x (0.746 kWh/hp/0.90eff) x 8,760 hr/yr x $0.08/kWh =
$104,240/yr
SAVINGS = $60,670/yr
EXAMPLE – AERATION CONTROL PARAMETER
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Electricity Requirements for Activated Sludge Wastewater
Lighting & Buildings8.1%
Anaerobic Digestion14.2%
Aeration54.1%
Return Sludge Pumping0.5%
Gravity Thickening0.1%
Screens0.0% Grit
1.4%Clarifiers
3.2%
Belt Press3.9%
Chlorination0.3%
Wastewater Pumping
14.3%
Derived from data from the Water Environm ent Energy Conservation Task Force Energy Conservation in Wastewater Treatm ent
Energy Intensive Processes - Pumping
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• Pump performance curve• Drive (if applicable)• Motor specifications• Design information• Amp draw (field-measured)• Existing flow conditions• Discussion with operations personnel• System components
– Static– Dynamic – conveyance
configuration
Pumping Assessment
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Pumping System Efficiency
Rangeof Eff.
Low Ave High
Motor 85-95 .85 .9 .95
Drive 20-98 .20 .6 .98
Pump 30-85 .30 .6 .85
Eff. of System .05 .32 .80
5 to 80%
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Variable speed pump selection
Energy-Intensive Processes - Pumping
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Energy Savings Obtained Through Installed Projects
• Oxidation DitchMonthly Average Energy Savings
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Monthly Average kWh BEFORE Monthly Average kWh AFTER
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Energy Savings Obtained Through Installed Projects
• Package PlantMonthly Average Energy Savings
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan
Monthly Average kWh BEFORE Monthly Average kWh AFTER
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Energy Savings Obtained Through Installed Projects
• Activated SludgeMonthly Average Energy Savings
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep
Monthly Average kWh BEFORE Monthly Average kWh AFTER
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Ensuring a Sustainable Future:An Energy Management Guidebook for Wastewater and Water Utilities
http://www.epa.gov/waterinfrastructure/bettermanagement_energy.html
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Energy Benchmarking
MGD = million gallons per day
Source: Focus on Energy," Water and Wastewater Energy Best Practice Guidebook”
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Energy Savings Identified
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What We Learned with Focus
• Energy Awareness – Management
• Knowledge of energy use is critical
• Energy efficiency w/o impact to effluent limits
• Significant savings available
• System assessment necessary
• Savings are long-term
• Publicize the need for energy efficiency
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What We “Also” Learned with Focus
• Must overcome barriers
• Designers need to become aware of value
• Need to address electric charge rates
• Need to develop more training in energy efficiency
• Require energy efficiency/education for certification
• Agencies need to address energy efficiency
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Design
Design development needs to be energy efficient from start up through design life of system
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Operation
Does all equipment need to be in operation?
Flexibility in equipment selection
Range of operation
Energy efficient throughout range
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Aerated Lagoons
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Wastewater Treatment Facility• An aerated lagoon wastewater treatment facility
consisting of three lagoons (two aerated and one settling).
• The two aerated lagoons work by using helixor aerators with three 40 hp blowers.
• The annual electric consumption was 494,710 kWh/yr, relating to 7,340 kWh/million gallons.
• The village installed a new fine-bubble diffusion system and reduced the speed of the existing blowers.
• Resulting in energy savings of 264,000 kWh/yr
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Installed Projects ….
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
Oct-05
Nov-0
5
Dec-0
5
Jan-
06
Feb-0
6
Mar
-06
Apr-0
6
May
-06
Jun-
06
Jul-0
6
Aug-0
6
Sep-0
6
Oct-06
Nov-0
6
Dec-0
6
Jan-
07
Feb-0
7
Mar
-07
Apr-0
7
May
-07
Jun-
07
Jul-0
7
Aug-0
7
Sep-0
7
Oct-07
Nov-0
7
Dec-0
7
Date
kWh
per
mo
nth
Coarse Bubble DiffusersAvg. Monthly Power Consumption = 45,660 kWh
Fine Bubble DiffusersAvg. Monthly Power Consumption = 21,047 kWh
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Assessed Project…
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Assessed Project…
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Municipal Wastewater Treatment Facility
• An activated sludge facility, oxidation ditch• The WWTF is not loaded at design • The annual electric consumption reduction
potential was forecasted to be 200,000 kWh for aeration and 250,000 for mixing
• The Municipality changed operations to reduce on – peak electric consumption
• The Municipality has additional opportunities to reduce energy through more awareness of operational impact on energy consumption
Assessed Project …
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IF YOU HAVE QUESTIONS, PLEASE CONTACT:
Joseph Cantwell, P.E.Focus on Energy/SAIC
1845 Derrin LaneBrookfield, WI 53045Tel: (262) 786-8221Fax: (262) [email protected]