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Thomas Nangle, P.E.CDM Smith

• 2015 NC AWWA WEA Spring Conference

Meeting Biosolids Management Challenges Through Advanced Technologies & Resource Recovery

2015 NC AWWA WEA Spring Conference

Presentation Outline

• Background

– Franklin, TN

– Drivers for Biosolids Upgrades

– Key Considerations

• Franklin Biosolids Upgrades

– Overview of Process and Equipment

– Closer look at Interesting Design Features

• Questions

2

Background

3

2015 NC AWWA WEA Spring Conference 4

Franklin, Tennessee


Integrated Water Resources Plan (IWRP)

• 30 year plan to address:

– Aging Infrastructure

– Fast Paced Growth

– Increasingly Stringent Regulations

• Holistic infrastructure improvements to:

– Potable Water

– Wastewater

– Storm Water

– Reclaimed Water

5


Goals Defined New Solids Treatment Process

• One of the primary nine goals of the IWRP was a long-term, sustainable biosolids process. To better define the best solution, the following goals were defined by the Steering Committee & Staff:

6Picture: http://mtsgreenway.org/blog/lets-talk-biosolids

– Reduce risk

– Improve operational efficiency

– Earn environmental/public acceptance

– Control odors

– Produce Class A biosolids


Being a Good Neighbor

• Adjacent to:

– High School

– Sport Fields

– Public Park

– Residential Neighborhood

• Sensitive to:

– Odor

– Noise

– Truck Traffic

7


Franklin Water Reclamation Facility (WRF)

Picture Provided by Franklin WRF


Existing Biosolids Issues




Preliminary Design of Biosolids System

• Anticipated Solids Loadings, Phases of Construction

– Phase 1 – 20 MGD through 2025

• 18 dry tons of WAS per day1

• 1,200 dry lb of FOG per day1

– Phase 2 – 32 MGD through 2040

• 30 dry tons of WAS per day1

• 1,800 dry lb of FOG per day1

• Preliminary Engineering Analysis

– Four solids process train alternatives

– Concept-level facility sizing, economic analyses

– Non-cost evaluation

– Scoring of alternatives based on cost & non-cost factors

10

Proposed Biosolids Treatment Process

11


Biosolids Process Flow – Part 1

12

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers

Sludge StrainersWAS Storage

WAS from

Secondary Clarifiers

Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal


Biosolids Process Flow – Part 2

13

Class A

Dried Biosolids

for Beneficial

Use

Partial Solar Drying

Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage

Sludge Recirculation

Future Side

Stream

Treatment

Filtrate to

Plant Drain


Sludge Strainers

14

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers


WAS from


Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal

• 5mm pressurized sludge screens • 2 for Phase 1 (standby) • 3 for Phase 2 (1 standby)


WAS Storage

15

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers


WAS from


Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal 280,000 Gallon Pre-Stressed Concrete Storage Tank

Picture: http://www.cromcorp.com/crom_promo.php


Pre-Dewatering Centrifuges

16

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers


WAS from


Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal

• Min 20” Bowl Centrifuges, • 3 for Phase 1 (1 standby) • 4 for Phase 2 (1 standby)


Pre-Dewatered Cake Bin

17

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers


WAS from


Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal

316 SS Live Bottom Hopper 60 cubic yard cake bin with two progressing

cavity pumps

Picture: http://www.cambi.no/wip4/plant.epl?cat=10643&id=210924


FOG Receiving and Handling

18

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers


WAS from


Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal

• Two FOG Receiving Stations, • 316 SS Storage Tanks with pumped

mixing • (2 for Phase 1, 3 for Phase 2)

• FOG Feed pump Loop.


Thermal Hydrolysis Pre-Treatment (THP)

19

Centrifuge

Dewatering

Pre-THP

Thermal

Hydrolysis

(THP)

Centrate

to Plant Drain

Dilution

Water

Grease from

Local Haulers


WAS from


Pre-Dewatered

Cake Bin

High Pressure

Steam

Dewatered Cake

Bypass to Haulers

Screenings to Off-

Site Disposal

B-2 System Skid with separate Process Gas Unit Skid1

1 This is a picture of the DC Water installation, which consists of 4 trains, each with six B-12 reactors


Sludge Cooling Heat Exchangers (HEXs)

20

Class A

Dried Biosolids

for Beneficial

Use


Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage


Future Side

Stream

Treatment

Filtrate to

Plant Drain

• 316 SS Tube-in-Tube HEXs • Two HEXs for Phase 1, • Three HEXs for Phase 2

Picture: http://www.oti.cc/heat-exchangers/)


Anaerobic Digestion

21

Class A

Dried Biosolids

for Beneficial

Use


Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage


Future Side

Stream

Treatment

Filtrate to

Plant Drain

• 375,000 gallon pre-stressed tanks • Two for Phase 1, Three for Phase 2.


Digester Biosolids Storage

22

Class A

Dried Biosolids

for Beneficial

Use


Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage


Future Side

Stream

Treatment

Filtrate to

Plant Drain

90,000 gallon bolted steel tank

Picture: http://www.midstatetank.com/vertical_tanks.php


Post-Dewatering Screw Presses

23

Class A

Dried Biosolids

for Beneficial

Use


Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage


Future Side

Stream

Treatment

Filtrate to

Plant Drain

• 5 HP Screw Presses• 2 for Phase 1 (1 standby)• 3 for Phase 2 (1 standby)

Picture: http://www.huber-technology.com/products/sludge-treatment/sludge-dewatering.html?L=0


Solar Drying

24

Class A

Dried Biosolids

for Beneficial

Use


Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage


Future Side

Stream

Treatment

Filtrate to

Plant Drain

• Pilot installation of two solar dryers


Biogas to Power Generation

25

Class A

Dried Biosolids

for Beneficial

Use


Remaining Class A

Dewatered

Biosolids to

Beneficial Use

Mesophilic

Anaerobic

Digestion

Screw Press

Dewatering

Post-Digestion

Biogas to Power

Generation

Sludge Cooling

Heat Exchangers

Digested

Biosolids

Storage


Future Side

Stream

Treatment

Filtrate to

Plant Drain

• 2 reciprocating engines• 2 heat recovery steam generators• 2 backup boilers• Gas conditioning System• Gas Storage Membrane(s)• Waste Gas Flare


Biogas Process Flow

26

Biogas to Power

Generation

Biogas Storage

Membranes

Combined

Heat & Power

System

Waste Gas

Flare

Gas

Conditioning

Electricity

to Plant

High Pressure

Steam to THP

Steam

Hot Water to

Treatment Processes

Auxiliary

Boilers

Stea

m

Questions

27

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