Urban Water Sustainability Leadership Conference, 2011 Clean Water America Alliance

Resource Recovery: Sustainable Water Reclamation (SeWeR)

Milwaukee Metropolitan Sewerage District

Tim Bate, PE, Director of Planning, Research & Sustainability

Karen Sands, AICP, Manager of Sustainability

Words Matter

A vocabulary of truth and

simplicity will be of service

throughout your life.

-Winston Churchill

Our Talk Today

•MMSD Background

•Visions for the Future

•Energy at MMSD

•Resource Recovery at MMSD

• Regional Agency

• Established by State Law

• Provide water reclamation and

flood management

MMSD Sewers

Municipally Owned Sewers

Private Laterals

Water Pollution Abatement Program (WPAP)

• Treatment Plant Upgrades

• ISS (a.k.a. Deep Tunnel)

• Sewer Rehabilitation

A $3 billion investment

Below Ground

Gallons of Storage

Long

In Diameter

The Deep Tunnel has kept

91 Billion Gallons of pollution out of Lake Michigan

A Path to the Future

MMSD 2035 Vision’s Strategic Objectives

1. Integrated Watershed Management

a) Zero CSOs and SSOs

b) Integrated management of urban and rural stormwater

2. Climate Change Mitigation/Adaptation with an

emphasis on Energy Efficiency

a) Use 100% renewable energy sources, with 80% being

self-produced

b) Reduce MMSD's carbon footprint by 90% from its

2005 baseline

Current MMSD Energy Situation Summary

• Energy costs are significant to MMSD

• MMSD has significant carbon footprint

• Natural gas is most significant energy source:

• Financially

• BTUs

• Carbon footprint

• Reductions in energy use can save money

JI Natural Gas

Energy at MMSD

• Purchased Energy

• Produced Energy

From Effluent

Other On Site

Purchased Energy • Energy Budget (2011): ~$13M

• 16% of O&M budget

• By Cost: 70% gas, 30% electricity

• By BTU: 90% gas, 10% electricity

• Total BTUs purchased at WRFs is

~10,000 Wisconsin residential homes

Produced Energy

• From Treatment Process Waste Heat

Biogas

• Onsite Solar PV

More Solar + Wind on the Horizon…

Produced Energy From Effluent Process

Waste Heat: JI Turbines:

Natural Gas to Electricity

Biogas: SS Digesters + Engine

Generators: Biogas to Electricity +

Heat

Waste Heat

• Turbines are source of waste

heat

• Saves on purchase and use of

natural gas in solids drying

• Generates electricity instead of

purchase

South Shore WRF Biogas • BioGas converted to electrical power by Engine

Generators

• Air Used in Secondary Treatment

• Heat Used in Digestion Process

•Biosolids can be Transferred via 11-mile Pipeline

Future: MMSD Landfill Gas Project • VES Owns Emerald Park Landfill (EPL)

in Muskego, 15 Miles from JIWRF

• Agreement: MMSD + VES

• 16” LFG Pipeline from EPL to JIWRF

• Replace existing NG turbines with

turbines capable of burning LFG

Initially 3 turbines, up to 2 more

• Save $ & Reduce Carbon Footprint

• Gas Now Flared Off

• Total Pipeline Cost ~ $43M

LFG Turbines

• New Turbine building

• 3-5 Solar Mercury 50, 4.8 MW

Turbine-generators

• High Efficiency, Low Emissions

• Lower Temperature Exhaust

• Need to Heat Dryers Using NG,

Along with Using Waste Heat

from Turbines

• Total Cost: $61.5M

Produced Energy

•From Effluent Process •Waste Heat

•Biogas (now & future)

•Onsite •Solar PV

•More Solar + Wind on the Horizon…

Solar PV

•20 kw: Rooftop of D&D Building

•Produced 93,324 kWh

Website: http://view2.fatspaniel.net/PV2Web/merge?&view=PV/standard/Simpl

e&eid=189343

Maximize Use of Renewables

• Landfill Gas

• SS Digester Thickening & Mixing, Co-digestion

• Regional Biosolids/High Strength Waste

• Excess “waste” heat

• Sewer Thermal

• Solar, Wind

• Renewables Project Gap

Minimize Energy Use (Conservation/Technologies) • Energy Management and Controls

• JI Turbines

• Hybrid Fleet Replacement

• Water Conservation (complete)

• HVAC Upgrade (complete)

• Lighting (complete)

• JI Aeration AFP, Aeration/Blowers

• SS Aeration Optimization

• Conservation Project Gap

Nutrient Recovery at MMSD

• Milorganite

• Future

Trading

Other?

Milorganite: A True Original

• Developed in 1926 by Dr. O.J. Noer

• Originally: Commercial Turf & Vegetable

• Milorganite has been a Mainstay in the Turf Industry

for 85+ Years

• MMSD: One of the Nation’s Oldest Recyclers

What is Milorganite?

• Milorganite is Derived from Dried Microbes

• Iron is Added in the Treatment Process

• Iron Becomes Organically Complexed to Microbes

• Dried at 1,200º F for Over 30 Minutes

• Daily and Weekly Laboratory Analysis to

Guarantee Safety and Nutrient Analysis

Benefits of Milorganite

• Non-burning

• Eco-friendly

• Safe for Kids and Pets

• 4% Iron for Deep Greening

• Slow Release Nitrogen

• Can be Used Everywhere

• Inexpensive Organic

Paradigm Change Industry-Wide

• Words

Stop Saying “Waste”

Start Saying “Resource”

• Goals

Energy Independence

Resource Recovery

How We Talk About This Matters!!!!!

Questions?

Extra slides below…insert them wherever (and if) they make sense.

END HERE!!!!!

LFG Project Roles MMSD:

• Design, Construct, Own & Operate 16”

LFG Pipeline from EPL to JIWRF

• Replace existing NG turbine with turbines

capable of burning LFG

Includes a major building addition

Initially 3 turbines, up to 2 more

VES:

• Design, construct, own and operate LFG

treatment and compression system

LFG Pipeline

• 16” Diameter

• 19 Miles Long

5.6 Miles Convert Steel Pipe

13.3 Miles New HDPE

• <100 psi

• Total Cost: ~$43M

2009 Green Energy

Solar Power

Methane

$800,000

Gas

http://v3.mmsd.com/Sustainability.aspx

Landfill Gas -to- Green Power Greenhouse Gas Reduction

500,000 Tons Customer Savings

$10’s of Millions

Existing JI Combined Heat and Power Process

Natural Gas

2-15 MW Natural

Gas Turbines and

Generators Electricity for Plant Needs

(wet weather, 24 hours/day, 5

days/week

Waste heat to

Milorganite dryers WE Electricity, dry

weather,

weekends

Excess waste heat

Natural Gas (when not using turbines

LFG Purchase Contract and Financials

• Full start up in January 2013

• 20 year contract to purchase LFG at 48% of NYMEX

• Net savings: “$10’s of millions”

– Actual savings dependent upon NG price and actual quantity of LFG

LFG Supply

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MM

Btu

Year

Projected MaximumGuaranteed Minimum

3 Turbines

5 Turbines

Jones Island Stationary Combustion Sources Before and After Landfill Gas Project (based on 2007 fuel usage data)

GHG Emissions in Metric Tons of Equivalent CO2

~95% Reduction

Other Projects With Significant $ Savings

• Jones Island Aeration

– High efficiency blowers

– Up to $600K/year savings

• South Shore Process Control

– Control blowers via ammonia and DO probes

– Up to $200K/year savings

• Digester Mixing

– Increase SS digester gas production

– Up to $800K/year savings

Combined Heat and Power Process with Landfill Gas

Electricity for Plant Needs,

Waste heat to

Milorganite dryers

Excess waste heat

3-5 4.8 MW gas

turbines

Natural Gas

Natural Gas

Landfill Gas

Purchase

electricity if not

enough LFG

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