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Waste Product to Resource Waste Product to Resource Biosolids Biosolids Handling at City of Handling at City of Wisconsin Rapids Wisconsin Rapids Wisconsin Wastewater Operators Wisconsin Wastewater Operators Association 46 Association 46 th th Annual Conference Annual Conference October 11, 2012 October 11, 2012 Presented by Phil Presented by Phil Korth Korth

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  • Waste Product to Resource Waste Product to Resource BiosolidsBiosolids Handling at City of Handling at City of

    Wisconsin RapidsWisconsin Rapids

    Wisconsin Wastewater OperatorsWisconsin Wastewater Operators Association 46Association 46thth Annual ConferenceAnnual Conference

    October 11, 2012October 11, 2012Presented by Phil Presented by Phil KorthKorth

  • 2006 Wastewater Facility2006 Wastewater Facility

    Screening/Grit RemovalScreening/Grit Removal Primary ClarificationPrimary Clarification Conventional Activated SludgeConventional Activated Sludge Final ClarificationFinal Clarification UV DisinfectionUV Disinfection

  • 2006 Wastewater Facility2006 Wastewater Facility Sludge HandlingSludge Handling

    Anaerobic Sludge Digestion Anaerobic Sludge Digestion 2 Primary 2 Primary DigestersDigesters

    Gravity Belt Thickener for WASGravity Belt Thickener for WAS Liquid Sludge StorageLiquid Sludge Storage Contract Haul DisposalContract Haul Disposal

  • 2006 WWTP Design Capacity2006 WWTP Design Capacity

    Average Daily FlowAverage Daily Flow 5.16 mgd5.16 mgd BOD LoadBOD Load 8,927 lbs/day8,927 lbs/day TSS LoadTSS Load 9,272 lbs/day9,272 lbs/day

  • 2006 WWTP Flows and Loads2006 WWTP Flows and Loads

    Average Daily FlowAverage Daily Flow 4.0 mgd4.0 mgd BOD LoadBOD Load 11,177 lbs/daylbs/day TSS LoadTSS Load 7,063 lbs/day7,063 lbs/day

  • 2006 Capacity Limitations2006 Capacity Limitations

    Limited Activated Sludge CapacityLimited Activated Sludge Capacity Sludge Storage Tank Limited to 132 Days Sludge Storage Tank Limited to 132 Days

    StorageStorage

  • What Happened?What Happened?

    Ocean Spray Added Larger Juice LineOcean Spray Added Larger Juice Line High Strength Cranberry Waste Discharged High Strength Cranberry Waste Discharged

    to Sewerto Sewer No Communication from Ocean SprayNo Communication from Ocean Spray

  • Communication RestoredCommunication Restored

    Ocean Spray Planned Dried Cranberry Ocean Spray Planned Dried Cranberry ProductionProduction

    Industrial Agreement ReachedIndustrial Agreement Reached Second Cranberry Company Requested Second Cranberry Company Requested

    Annexation for Wastewater ServiceAnnexation for Wastewater Service

  • Design ConditionsDesign Conditions

    5.28 MGD5.28 MGD BOD Load BOD Load 18,386 lbs/day18,386 lbs/day TSS Load TSS Load 10,994 lbs/day10,994 lbs/day TKN TKN 1,181 lbs/day1,181 lbs/day P P 177 lbs/day177 lbs/day

  • City Design PhilosophyCity Design Philosophy

    Design for Projected ConditionsDesign for Projected Conditions Allow for Expansion on Site and in Allow for Expansion on Site and in

    StructuresStructures Include Sustainable Features Where Include Sustainable Features Where

    PracticalPracticalWWTP to be a Resource to CityWWTP to be a Resource to CityAttract Industry/JobsAttract Industry/JobsCapture Value in WasteCapture Value in Waste

  • Sludge Treatment AlternativesSludge Treatment Alternatives

    Expand Mesophilic Anaerobic DigestionExpand Mesophilic Anaerobic Digestion Convert Anaerobic Digestion Process to Convert Anaerobic Digestion Process to

    Temperature Phased Anaerobic Digestion Temperature Phased Anaerobic Digestion (TPAD)(TPAD)

    Class A vs. Class BClass A vs. Class B

  • TPADTPAD

    ProsProsReduce Fecal Coliforms to Class A LevelReduce Fecal Coliforms to Class A LevelHigher VSS DestructionHigher VSS Destruction

    More BiogasMore Biogas

    Less Sludge for DisposalLess Sludge for Disposal

    ConsConsHigher Initial CostHigher Initial Cost

  • TPADTPAD

    Design for Class ADesign for Class AConvert Existing Mesophilic Digesters to Convert Existing Mesophilic Digesters to

    Thermophilic DigestersThermophilic DigestersUse Time/Temperature Criteria to Meet Class Use Time/Temperature Criteria to Meet Class

    A RequirementsA RequirementsNew Mesophilic DigesterNew Mesophilic Digester

  • Sludge Handling/Storage Sludge Handling/Storage AlternativesAlternatives

    Liquid Sludge StorageLiquid Sludge Storage Dewater Sludge/Cake StorageDewater Sludge/Cake Storage Dewater Sludge/Sludge Drying and StorageDewater Sludge/Sludge Drying and Storage

  • Sludge Handling/Storage Sludge Handling/Storage AlternativesAlternatives

    Liquid Sludge StorageLiquid Sludge Storage4% 4% -- 5% Solids5% SolidsTwo Large New Tanks RequiredTwo Large New Tanks RequiredHigh Cost DisposalHigh Cost Disposal

    Dewater Sludge/Cake StorageDewater Sludge/Cake Storage18% 18% -- 22% Solids22% SolidsRemote Site RequiredRemote Site RequiredLower Cost DisposalLower Cost Disposal

  • Sludge Handling/Storage Sludge Handling/Storage AlternativesAlternatives

    Dewater Sludge/Sludge Drying and StorageDewater Sludge/Sludge Drying and Storage75% 75% -- 90% Solids90% SolidsRemote Site Remote Site Drying PadDrying PadLowest Cost DisposalLowest Cost DisposalClass A Class A Use as Soil Conditioner/LandscapingUse as Soil Conditioner/Landscaping

  • Sludge HandlingSludge Handling

    Dewater and Drying SelectedDewater and Drying Selected Dewater at WWTPDewater at WWTP Store and Drying Pad in Industrial ParkStore and Drying Pad in Industrial Park Class A Sludge to be Used in City Class A Sludge to be Used in City

    LandscapingLandscapingReduced CostReduced CostWaste to ResourceWaste to Resource

  • Biogas Utilization EvaluationBiogas Utilization Evaluation

    TPAD Increases VSS Destruction and TPAD Increases VSS Destruction and Biogas ProductionBiogas Production

    Biogas Production Exceeds the Need for Biogas Production Exceeds the Need for Digester Heating Digester Heating

  • Biogas Utilization AlternativesBiogas Utilization Alternatives

    Digester Heating in Biogas BoilerDigester Heating in Biogas Boiler Biogas Engine Driven Equipment Biogas Engine Driven Equipment

    (Blowers/Pumps)(Blowers/Pumps) Electrical GenerationElectrical Generation Combined Heat and PowerCombined Heat and Power

  • Biogas UtilizationBiogas Utilization

    Combined Heat and Power SelectedCombined Heat and Power Selected Engine Generator Selected Based on Engine Generator Selected Based on

    EfficiencyEfficiencyMicroturbines Evaluated but Had Lower Microturbines Evaluated but Had Lower

    Overall EfficiencyOverall Efficiency

  • Engine GeneratorEngine Generator

    Dual Fuel Operation Possible (Biogas and Dual Fuel Operation Possible (Biogas and Natural Gas)Natural Gas)

    Heat Recovery from Engine CoolantHeat Recovery from Engine Coolant Heat Recovery from Engine ExhaustHeat Recovery from Engine Exhaust Overall Energy Efficiency = 83%Overall Energy Efficiency = 83% Biogas Boiler Available as BackBiogas Boiler Available as Back--upup

  • TPAD Process OperationTPAD Process Operation

    Volatile Solids Reduction Volatile Solids Reduction 63.7%63.7%10% Improvement from Mesophilic Operation10% Improvement from Mesophilic Operation

  • TPAD Design FeaturesTPAD Design Features

    Two Thermophilic TanksTwo Thermophilic Tanks Feed One Tank Each 24 HoursFeed One Tank Each 24 Hours Automated Feed SystemAutomated Feed System Complex PipingComplex Piping Simple OperationSimple Operation Sludge Feed Small Amounts Each HourSludge Feed Small Amounts Each Hour

  • TPAD Design FeaturesTPAD Design Features

    Common Feed TankCommon Feed TankPrimary SludgePrimary SludgeThickened WASThickened WAS

    Piped to Accept High Strength WastePiped to Accept High Strength Waste Caustic Feed for pH ControlCaustic Feed for pH Control

  • TPAD Design FeaturesTPAD Design Features

    Automated Withdrawal SequenceAutomated Withdrawal SequenceMesophilic Sludge to DewateringMesophilic Sludge to DewateringThermophilic A Sludge to MesophilicThermophilic A Sludge to MesophilicFresh Sludge to Thermophilic AFresh Sludge to Thermophilic AThermophilic B Holds at 131Thermophilic B Holds at 131

    FF..

    Mesophilic Digester Has Cooling Heat Mesophilic Digester Has Cooling Heat ExchangerExchanger

  • Biogas ProductionBiogas Production

    Biogas Production = 70,000 cubic feet/dayBiogas Production = 70,000 cubic feet/day48,000 cubic feet/day From Volatile Solids 48,000 cubic feet/day From Volatile Solids

    DestructionDestruction22,000 cubic feet/day From High Strength 22,000 cubic feet/day From High Strength

    Cranberry Waste Fed Directly to DigestersCranberry Waste Fed Directly to Digesters

  • Electrical GenerationElectrical Generation

    Biogas Engine Provides 29% of Total Biogas Engine Provides 29% of Total Electrical DemandElectrical Demand

    Biogas Engine Operates During Peak Biogas Engine Operates During Peak Demand Hours (8 AM to 9 PM)Demand Hours (8 AM to 9 PM)

  • Hot Water UsageHot Water Usage

    Waste Heat from Biogas Engine Used for Waste Heat from Biogas Engine Used for Process Heat in BuildingProcess Heat in BuildingSludge HeatingSludge HeatingBuilding HeatBuilding Heat

  • Sludge DewateringSludge Dewatering

    Rotary Press SelectedRotary Press Selected Enclosed System Enclosed System Low OdorLow Odor Low Water UseLow Water Use Can be Stopped For Truck UnloadingCan be Stopped For Truck Unloading

  • Sludge DewateringSludge Dewatering

    Land Available in Industrial Park for Land Available in Industrial Park for Storing and Air Drying SludgeStoring and Air Drying Sludge

    Asphalt Pad Built by CityAsphalt Pad Built by City Runoff Collected in Basin with Outlet to Runoff Collected in Basin with Outlet to

    Sanitary SewerSanitary Sewer Sludge Stored and Dried in WindrowsSludge Stored and Dried in Windrows

  • Sludge DewateringSludge Dewatering