43. Feasibility Study to Increase Capacity to 340 KW

8/10/2019 43. Feasibility Study to Increase Capacity to 340 KW

1/99


2/99

Feasibility Study to Improve Septage Receiving and Increase Power to 340 kWGeorgian Bluffs/Chatsworth Biodigester Township of Chatsworth/Township of Georgian Bluffs February 2012

GENIVAR OS-03-012-11-OS i

Table of Contents

1.0 INTRODUCTION AND HISTORY...............................................................................................1-1

2.0 EXISTING FACILITIES................................................................................................................2-1

3.0 PROPOSED 3-PHASE POWER LINE EXTENSION..................................................................3-1

4.0 IMPROVED SEPTAGE MANAGEMENT - SEPTAGE STORAGE AND TRASH REMOVALSYSTEM......................................................................................................................................4-1

5.0 ADDITIONAL 240 KW 3-PHASE GAS GENERATOR................................................................5-1

6.0 BIOGAS AND ORGANIC WASTE REQUIRED TO PRODUCE 340 KW OF ELECTRICALPOWER ................................ ................................ ................................ .......................................6-1

7.0 DIGESTATE STORAGE..............................................................................................................7-1

8.0 SUMMARY OF PROPOSED FACILITIES TO UPGRADE TO 340 KW AND IMPROVE SEPTICRECEIVING AND TRASH REMOVAL........................................................................................8-1

9.0 ADDITIONAL ELECTRICAL ENERGY FROM WASTE HEAT...................................................9-1

10.0FINANCIAL ANALYSIS .............................................................................................................10-1

10.1 Capital Costs..........................................................................................................................10-110.2 Revenue and Operating Costs ..............................................................................................10-110.3 Financial Analysis for Payback Period...................................................................................10-1

11.0RECOMMENDATIONS .............................................................................................................11-1

List of TablesTable 1 Estimated Biogas Production and Organic Waste RequiredTable 2 Capital Cost Estimate to Expand Electrical Production at Biodigester to 340 kWTable 3 Revenue for Additional 240 kW of Electricity and Tipping Fees for Organic WasteTable 4 Additional Annual Operating Cost Increase of Electrical Production from 100 kW to 340

kWTable 5 Financial Analysis for Additional 240 kW

List of FiguresFigure 1 Location Map (Grey and Bruce Counties)Figure 2 Existing Facilities at Georgian Bluffs/Chatsworth Biodigester Figure 3 Proposed Routes to Extend 3-Phase Power

Figure 4 Proposed Facilities to Upgrade to 340 kW and Improve Septage Receiving & TrashRemoval

Appendices Appendix A Ontario Ministry of the Environment Amended Certificate of Approval Appendix B Hydro One Estimate for Extension of 3-Phase Power Line Appendix C Covered Concrete Septage Storage Facility Appendix D Septage Receiving Station and Trash Removal System Appendix E Prefabricated Fiberglass Building for the Septage Receiving Station


3/99


GENIVAR OS-03-012-11-OS ii

Appendix F Preliminary Quotation and Materials List for a 240 kW Gas Generator and Heat RecoverySystem

Appendix G FIT Electrical Power Rates for Biogas Projects

Appendix H Two (2) Types of Turbine Engines for Waste Heat


4/99


GENIVAR OS-03-012-11-OS 1-1

1.0 INTRODUCTION AND HISTORY

The Georgian Bluffs/Chatsworth biodigester project was constructed at the Derby wastewater treatment

plant facilities in part of the south half of Lot 4, Concession 6, former Township of Derby, Township of

Georgian Bluffs in the year 2010. The project was substantially completed on January 18, 2011 and the

project produced electrical power to the Hydro One grid starting March 20, 2011. The facility has the

capacity to treat 40 m 3 of septage per day and +5 m 3 per day of organic waste (vegetable waste, fats,

oils, grease, dog food, ice cream waste, sewage sludge, etc.). The facility is constructed to produce 100

kW of electrical energy to the Hydro One grid using a single-phase connection. The digester size is 1,000

m3 and there is a hydrolyzer of 100 m 3 and a 2 m 3 pasteurizer. The treated digestate storage that was

originally constructed was 850 m 3, however, it was found that more storage was needed at the existing

facility and for expansion to 340 kW. Therefore, in October 2011, an additional 5,630 m 3 of digestate

storage was added to the facility. The existing facility is located in the Township of Georgian Bluffs asshown on Figure 1 . The facility continues to produce electricity using organic waste, septage and hauled

sewage.


5/99


6/99



2.0 EXISTING FACILITIES

The existing facilities at the Derby wastewater treatment plant for treating septage and other organic

waste to produce electrical power as of October 2011 are shown on Figure 2 . The facilities have the

capability of treating FOG (fats, oils and grease), in a 2 m 3 pasteurizer before discharge to the digester.

There is a 50 m 3 concrete FOG storage tank. Other organic wastes are placed into the 100 m 3 hydrolyzer

or come from dewatered septage, which is utilized to feed the digester. Septage is unloaded from the

septage haulers at the septage dumping station at the entrance to the facility. An additional digestate

storage facility of 5,630 m 3 was constructed in October 2011, to allow for storage of digestate during the

winter period for the amount of waste required to produce 340 kW of electrical power. The total digestate

storage is 6,480 m 3 which is sufficient to handle 36 m 3 of treated digestate per day for 180 days. The

existing facilities operate motors on single-phase power and produce single-phase power through a 100

kW generator.

The existing facilities operate under an Amended Certificate of Approval for the Derby wastewater

treatment works, No. 2206-8KSQZV, dated August 23, 2011 ( Appendix A ). The rated capacity of the

Derby wastewater treatment plant is 57.5 m 3 per day.


7/99


8/99



3.0 PROPOSED 3-PHASE POWER LINE EXTENSION

In order to produce more electrical power at the existing biodigester site, it is necessary to extend the 3-

phase hydro power line. There is an existing 3-phase Hydro One power line at Sideroad 6, which is the

next concession north of the biodigester site. Three (3) routes were considered; the shortest route would

be 1.8 km directly from Concession 6 across proposed property easements to the site. Although this is

the shortest route it is expected that this is not feasible due to the easements required for an access road

with a hydro power line. Another route considered would be along Concession 5 in the former Derby

Township and Sideroad 3 for a distance of approximately 3.58 km. This would be the longest alternative

route as shown on Figure 3 . The preferred route for the 3-phase power is shown in red on Figure 3 from

Sideroad 6 along Concession Road 7 and Sideroad 3 to the new hydro pole erected on-site. This would

be a distance of 2.81 km.

A proposal was obtained by the Municipalities from Hydro One to extend the 3-phase power line. The

initial estimate is shown in Appendix B . A preliminary cost estimate from Ontario Hydro is $265,200 plus

HST. It is assumed that this is for constructing the power line along the preferred route on Concession 7.


9/99


10/99



4.0 IMPROVED SEPTAGE MANAGEMENT - SEPTAGE STORAGE AND

TRASH REMOVAL SYSTEM

The first design for the biodigester which was tendered in 2009 provided storage for septage before it wasfed into the biodigester. The storage was removed to reduce costs and was replaced with a dewatering

system to reduce the size of the digester. Initially a septage receiving station to remove the trash was

considered, however in order to save costs, a bar screen system was installed instead. There has been

some problems with the bar screen system to remove trash such as plastics and rocks due to clogging

with loads of septage, which have a lot of trash and other materials in them, thus causing other problems

with septage handling at the site. Septage trucks are generally 13.6 to 15.9 m 3 (3,000 to 3,500 IG). The

system was designed to discharge a septage tanker truck tank (+15 m 3) in approximately 11 minutes.

However, when this was checked trucks were unloading as fast as 7 minutes or faster, thus the

dewatering system that was designed has not operated properly. Also there have been problems withsome septage from septic systems that is fairly strong and lots of trash and other holding tank that have

relatively weak hauled sewage from the Sunset Strip, from commercial operations. This hauled sewage

could include waste products such as oil and chemical products from cleaning.

It was discussed recently at the December 2011 Project Team Meeting, that possibly some of the hauled

sewage from some of the commercial operations on the Sunset Strip in the Township of Georgian Bluffs

should be bypassed to the lagoon directly and not dewatered or put into the biodigester. It was also

discussed that a system should be designed to have storage so that the trucks can unload quicker and

operate the dewatering system every two (2) days on a controlled basis. At times we have had up to 6 or 7 truckloads of septage or hauled sewage per day; however the norm is more like 2 to 3 truck loads per

day. It is proposed to allow for existing septage and an expected significant increase in septage volumes.

It is proposed that a septage holding tank for raw septage should be constructed with a capacity of

approximately 230 m 3, which would allow for storage of approximately 14.5 loads of septage at 15.9 m 3

(3,500 IG) per load. A preliminary proposal for a concrete storage tank 9.14 m in diameter and 3.65 m

deep with a concrete cone cover is shown in Appendix C .

The new septage receiving station has a capacity of approximately 1,000 USGPM or 830 IGPM. This

would allow for 3.77 m 3/minute and would allow a 15.9 m 3 septage truck to dump in 4.2 minutes (or less

than 5 minutes).

The proposed septage receiving station will remove the trash and compact it and dewater the trash so

that it can then be taken to the landfill. The septage dewatering system needs to be housed inside of an

insulated building for the winter to allow for cold temperatures so that it can operate during that time. This


11/99



is similar to installations in other municipalities in Ontario for septage receiving stations. A copy of the

proposal for a septage receiving station is shown in Appendix D . A proposed fiberglass prefabricated

building to house the septage receiving station and cost estimate is shown in Appendix E .


12/99


13/99



6.0 BIOGAS AND ORGANIC WASTE REQUIRED TO PRODUCE 340 kW OF

ELECTRICAL POWER

The estimated biogas production required for 340 kW of power is shown in Table 1 . The estimatedsources of waste were septage, DAF and sludge (not dewatered) from Chapman's Ice Cream, FOG (fats,

oils, grease) and vegetable waste. The amount of septage that can be received is 57 m 3/day which is the

capacity of the Derby wastewater treatment plant. The septage is dewatered to approximately 8% solids,

and reduces the input to the biodigester to approximately 7.1 m 3/day. 3,672 m 3 of biogas are required to

produce 340 kW of electrical power from two (2) generators. The estimated amount of DAF and sludge

(non-dewatered) at approximately 4 to 5% solids from Chapman's is 16.5 m 3/day. If this was dewatered it

would be approximately 4 m 3/day. The storage was designed for approximately 36 m 3 of organic waste

per day which also provides the required retention time in the biodigester of 25 to 30 days. At 48.6

m3

/day, there is only approximately 20.5 days of storage. If the dewatered waste was taken fromChapman's, at approximately 4 m 3/day, there would be approximately 36.1 m 3 of waste received per day

to produce the required biogas for 340 kW. It should also be noted that the biodigester should be

operated at 7 to 9% solids for good operation and minimizing the amount of digestate produced.

If some of the higher strength ice cream waste (10% butter fat and 35% solids) could be obtained from

Chapman's Ice Cream, then this would reduce the amount of waste required to 36 m 3/day or less and

produce sufficient biogas since it is estimated that this waste would produce 350 m 3 of biogas/m 3.


14/99

Table 1Estimated Biogas Production and Organic Waste Required

Georgian Bluffs/Chatsworth Biodigester OS-03-012-11-OS

Biogas

1. Septage 7.1 m3/day x 106 m3 of biogas/m 3 (Dewatered to 8%) = 752 m 3/day(57 m 3/day x 13.2 m 3 of biogas/m 3)

2. DAF and Sludge (Chapman's Ice Cream) 4 to 5% solids 16.5 m3/day x 27.6 m3 of biogas/m 3 = 455 m 3/day3. Fats, oils and grease 13.5 m3/day x 124 m3 of biogas/m 3 = 1,674 m 3/day

4. Vegetable waste 11.5m3/day

x 70m3 of biogas/m 3

= 805m 3/day

Total estimated biogas production per day 3,686 m 3 /dayDaily quantity of waste 48.6 m

3 /day

Energy Potential No. of kWH = 3,686 = 8,191 kWH/day

0.45 Power = 8,191 = 340 kW

24

G:\2003\100\103012\reports\feasibility Study\table 1 - Feb 10 2012.xlsx


15/99


16/99



8.0 SUMMARY OF PROPOSED FACILITIES TO UPGRADE TO 340 kW AND

IMPROVE SEPTIC RECEIVING AND TRASH REMOVAL

The following are proposed improvements to increase the electrical production at the biodigester from100 kW to 340 kW and to improve septage receiving and trash removal:

Improve Septage Receiving and Trash Removal

1. New 230 m 3 concrete septage storage tank with meter.

2. Supply and install a new septage receiving station capable of receiving 3.77 m 3/minute (830

IGPM). The septage receiving station will remove the trash, plastics and stones from the

septage.

3. Supply and install a prefabricated insulated fibreglass building 3.7 m wide, 9.6 m long and 4.0 m

high to house the septage receiving station and odour control system.

4. Supply and install a new odour control system for the septage holding tank and septage receiving

station.

5. New water supply to septage receiving station from existing well.

6. On-site piping and valves.

7. Lighting and electricals.

Increase Electrical Power From 100 kW to 340 kW

8. Extend 3-phase power line 281 km from Sideroad 6 to biodigester site.

9. Supply and install a new 240 kW gas generator in a steel container with boiler.

10. Supply and install electricals for 3-phase power production on-site.

11. Upgrade the SCADA system for the 340 kW system.

12. Hydro inter-tie.

The facilities that are proposed are shown on Figure 4 for the upgrade to 340 kW and for improvements

to septage receiving and trash removal. If there are weak loads of hauled sewage from the Sunset Strip


17/99



the system will have the capability to bypass the septage holding tank and discharge directly to the

aerated sewage lagoon.


18/99


19/99



9.0 ADDITIONAL ELECTRICAL ENERGY FROM WASTE HEAT

When the Georgian Bluffs/Chatsworth biodigester is expanded from 100 to 340 kW approximately 340

kW of heat will be produced. It is estimated that only approximately 100 kW or less of heat will berequired to operate the biodigester during the winter time. There will probably be approximately 240 kW

or more of waste heat at 80 degrees Celsius (water) available.

This low grade waste heat of approximately 240 kW at 80 degrees Celsius (water) can be utilized to make

electrical energy using a turbine engine. There are two (2) types of turbine engine that can use waste

heat:

1. Marnoch Thermal Power Turbine Engine being developed out of Port Severn, Ontario and being

partly funded from the federal and provincial governments, including OPA.

2. Organic Rankine Cycle Waste Heat Turbine Engine, which has been developed for years.

Information on these two (2) types of turbine engines for utilizing waste heat can be found in Appendix H.

If the turbine engine is 60% efficient, utilization of waste heat to produce electricity will generate an

additional $190,000 of electricity through the FIT program.


20/99


GENIVAR OS-03-012-11-OS 10-1

10.0 FINANCIAL ANALYSIS

10.1 Capital Costs

The capital cost estimate to expand the electrical production at the biodigester to 340 kW and to upgrade

the septage handling and trash removal system is outlined in Table 2 . The estimated cost, including

engineering, FIT application, amendment to the C of A, connection impact assessment with Ontario

Hydro and soils investigation is $1,815,000 (excluding HST). The estimated project cost for the improved

septage handling, trash removal and septage storage is estimated at $676,700 as shown in Table 2A.

Therefore, the estimated cost to increase the biogas and electrical output from 100 to 340 kW is

$1,138,300.

10.2 Revenue and Operating Costs

The additional revenue for production of 200 kW of electricity at the Township of Georgian

Bluffs/Township of Chatsworth biodigester is outlined in Table 3 . The FIT electrical rates for biogas

projects are shown in Appendix G as $0.16/kwh up to 500 kW. Revenue is obtained from three (3)

sources, electrical sales to the FIT program, tipping fees for organic waste and additional tipping fees for

increased septage. The estimated annual revenue is $832,000.

The additional operating cost to increase electrical production from 100 kW to 340 kW is outlined in Table

4 . The additional annual cost for operation is estimated at $161,300/year. This includes a reserve fund

for upgrading of the additional 240 kW capacity at $25,000/year. There is also a provision for engineering

support for biodigester operation of $16,000/year. Therefore the net annual revenue would be estimated

at $670,700/year.

10.3 Financial Analysis for Payback Period

A financial analysis for the additional 240 kW electrical production plus improvements to the septage

receiving and trash removal system is outlined in Table 5 . As can be seen in Table 5 , the net annual

revenue is $670,700/year and the project costs are $1,815,000 (excluding HST). The payback of the

capital cost using a real interest rate of 3% is less than 3 years.


21/99

Table 2Capital Cost Estimate

toExpand Electrical Production at Biodigester

to 300 kW

Township of Georgian Bluffs/Township of Chatsworth

OS-03-012-11-OS

1. Extend 3-phase power line from Sideroad 6 along Concession 7 and Sideroad 3to the new hydro pole on the biodigester site a distance of 2.81 km.

$265,000

2. Supply new 240 kW gas generator. $355,000

3. Install 240 kW gas generator. $30,000

4. Electrical for 3-phase power production on-site. $100,000

5. New 230 m 3 concrete septage storage tank. $75,000

6. Supply and install mixer for septage holding tank. $20,000

7. Supply and install septage receiving station. $210,000

8. Supply and install prefabricated, insulated fibreglass building for septagereceiving station.

$85,000

9. Install a new odour control system for the septage holding tank. $20,000

10. 63 mm water supply to septage receiving station. $9,000

11. Control valves and on-site piping. $45,000

12. Hydro connection cost. $60,000

13. Hydro One inter-tie. $25,000

14. Electrical for lights, motor, etc. $50,00015. Upgrade to SCADA system. $20,000

16. Site work. $30,000

Construction Sub-Total $1,399,000

Contingency (+ 10%) $140,000

Construction Total $1,539,000

Engineering (+ 15%) $230,000

FIT Application $8,000 Amendment to C of A $5,000

Connection Impact Assessment - Hydro One $23,000

Soils Investigation $10,000

PROJECT TOTAL (excluding HST) $1,815,000

G:\2003\100\103012\Reports\Feasibility Study\table 2.xlsx


22/99

Table 2AEstimated Capital Cost

for Improved Septage Handling, Trash Removal and Septage Storage

Township of Georgian Bluffs/Township of Chatsworth Biodigester

OS-03-012-11-OS

1 New 230 m 3 concrete septage storage tank. $75,000

2 Supply and install mixer for septage holding tank. $20,000

3 Supply and install septage receiving station. $210,000

4 Supply and install prefabricated, insulated fibreglass building for septagereceiving station.

$85,000

5 Install a new odour control system for the septage holding tank. $20,000

6 63 mm water supply to septage receiving station. $9,000

7 Control valves and on-site piping. $45,000

8 Electrical for lights, motor, etc. $50,000

9 Site work. $15,000

Construction Sub-Total $529,000

Contingency (+ 10%) $52,900

Construction Total $581,900

Engineering (+ 15%) $87,300

Amendment to C of A $2,500

Soils Investigation $5,000

PROJECT TOTAL (for septage handling improvements) $676,700

G:\2003\100\103012\Reports\Feasibility Study\Table 2A.xlsx


23/99

Table 3Revenue for Additional 200 kW of Electricity and Tipping Fees for Organic Waste


OS-03-012-11-OS

1. Electrical power sales for the FIT program (240 x 24 x 0.16 x 340) $313,0002. Tipping fees for organic waste (24 x $25 x 365) $291,000

3. Additional tipping fees for septage (25 x $25 x 365) $228,000

Total Estimated Annual Revenue for Additional Electricity (240 kW),Organic Waste and Septage Treatment

$832,000

G:\2003\100\103012\Reports\Feasibility Study\Table 3.xlsx


24/99

Table 4Additional Annual Operating Cost Increase of Electrical Production

from 100 kW to 340 kW


OS-03-012-11-OS

1. 240 kW gas generator maintenance. $25,000 /yr

2. Additional electrical use. $15,000 /yr

3. System operation additional cost (1.5 hr/day @ $35/hr = 365 x $52.50). $19,200 /yr

4. General additional maintenance. $10,000 /yr

5. Land application of biosolid (liquid digestate) (10,220 m 3/year x $5.00/m 3 $51,100 /yr

6. Engineering support for biodigester operation. $16,000 /yr

7. Reserve funding for upgrading of the additional 240 kW capacity $25,000 /yr

Total Estimated Additional Annual Operation Cost for 240 kW $161,300 /yr



25/99

Table 5Financial Analysis

for Additional 240 kW


OS-03-012-11-OS

Project Cost $1,815,000

Annual Additional Revenue $832,000

Annual Additional Operation Cost including Reserve Funding $161,300

Net Annual Revenue ($832,000 - $161,300) $670,700

The payback of the capital cost of $1,815,000 by the Township of Georgian Bluffs and Township of Chatsworth (with no grant) is estimated using 3% real interest rate/year to be (3.091 x 670,700 =$2,073,000) less than 3 years.



26/99


GENIVAR OS-03-012-11-OS 11-1

11.0 RECOMMENDATIONS

The following is recommended based on this Feasibility Study for increasing the capacity of the

biodigester facility to 340 kW and improving the septage receiving and trash removal system:

1. Based on a payback period of less than 3 years with no federal or provincial grants, it is

recommended that the project proceed as outlined in this Feasibility Study at an estimated project

cost of $1,815,000 (excluding HST). The estimated cost for the portion of the total project for

improved septage handling, trash removal and septage storage is $676,700.

2. It is recommended that an application be submitted to the Ontario Power Authority for initial

approval under the FIT program.

3. It is recommended that an Impact Assessment for connection to the Ontario Hydro grid be carried

out and submitted to Hydro One for approval.

4. The Ontario Ministry of the Environment, Approvals Branch, should be contacted to confirm that

this increased production could be carried out under an Amendment to the C of A for the Derby

wastewater treatment plant.

5. Applications for potential grants to increase septage treatment and provide increased green

energy should be investigated.

Respectfully submitted:

GENIVAR Inc.

Ross Slaughter, P. Eng.Senior Water Resources Engineer

Designated Consulting Engineer MRS/dlw


27/99


28/99


GENIVAR OS-03-012-11-OS

Appendix A

Ontario Ministry of the EnvironmentAmended Certificate of Approval


29/99


30/99


31/99


32/99


33/99


34/99


35/99


36/99


37/99


38/99


39/99


40/99


41/99


42/99


43/99



Appendix B

Hydro One Estimate for Extension of 3-Phase Power Line


44/99


45/99


46/99



Appendix C

Covered Concrete Septage Storage Facility


47/99


48/99


49/99



Appendix D

Septage Receiving Station and Trash Removal System


50/99


51/99


52/99


53/99


54/99


55/99



Appendix E

Prefabricated Fiberglass Building for theSeptage Receiving Station


56/99


57/99


58/99


59/99


60/99


61/99


62/99


63/99


64/99



Appendix F

Preliminary Quotation and Materials List for a 240 kW Gas Generator and Heat Recovery System


65/99


66/99


67/99


68/99


69/99


70/99


71/99


72/99



Appendix G

FIT Electrical Power Rates for Biogas Projects


73/99


74/99


75/99


76/99


77/99


78/99


79/99


80/99


81/99


82/99


83/99


84/99


85/99


86/99


87/99


88/99


89/99


90/99


91/99


92/99


93/99


94/99


95/99


96/99


97/99


98/99


99/99

43. Feasibility Study to Increase Capacity to 340 KW

Documents

Transcript of 43. Feasibility Study to Increase Capacity to 340 KW