Deposition Velocities of Newtonian and Non-Newtonian Slurries in ...
“WE DON’T NEED NO… INCINERATION” LESSONS LEARNED …• Final Clarification ... particularly...
Transcript of “WE DON’T NEED NO… INCINERATION” LESSONS LEARNED …• Final Clarification ... particularly...
29 Ju
ne 2
016
WASTEWATER RESIDUALS MANAGER, CITY OF COLUMBUSBRANDON FOX
“WE DON’T NEED NO… INCINERATION”LESSONS LEARNED AS COLUMBUS TRANSITIONS TO 100% BENEFICIAL RE-USE OF BIOSOLIDS
SIERRA MCCREARY ENGINEERING MANAGER, BLACK & VEATCH
AGENDA
1 – Columbus’ Biosolids Management Strategy2 – Schedule and Key Decisions 3 – Biosolids Land Application Facility 4 – Lessons Learned
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COLUMBUS’ BIOSOLIDS MANAGEMENT STRATEGY
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Southerly Wastewater Treatment Plant
Columbus, OH
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• Traditional Activated Sludge Type Plants• Primary Clarification• Secondary Biological Treatment (aeration)• Final Clarification
• Solids Treatment System• Combined 24,000 dry tons per year
• Unclassified• Anaerobic Digested Class B • Class A Exceptional Quality Biosolids
JACKSON PIKE AND SOUTHERLY WWTP SOLIDS TREATMENT
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PREVIOUS SOLIDS MANAGEMENT PROGRAM OVERVIEW (2009)
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UNCLASSIFIEDSOLIDS
CLASS BBIOSOLIDS
THICKENING DEWATERING DEWATERING
LANDAPPLICATION
INCINERATION COMPOST FACILITY
(JP Only)
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PREVIOUS SOLIDS MANAGEMENT PROGRAM OVERVIEW (2014)
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UNCLASSIFIEDSOLIDS
CLASS BBIOSOLIDS
THICKENING DEWATERING DEWATERING
LANDAPPLICATION
OHIO MULCH
INCINERATION OFF SITEDIGESTION
COMPOST FACILITY
(JP Only)
Southerly WWTP Multiple Hearth Incinerator (MHI)
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EGY • Maximum Achievable Control Technology
(MACT)• MHI Condition Assessment and BCE
• Initial Goal: Determine what incinerator repairs are necessary at both plants.
• Revised Goal: Determine the optimal number of incinerators to improve based on available capacity of ALL management outlets.
• Comprehensive system approach
• Findings• Incineration improvements not necessary
with an expanded beneficial reuse program (Land Application)
MACT COMPLIANCE
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Southerly WWTP Multiple Hearth Incinerator (MHI)
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• Southerly Incinerator Catastrophic Failure March 2015
• Title V MACT Standards effective March 21, 2016
• Jackson Pike Incinerator shutdown March 8, 2016
MACT COMPLIANCE
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Incineration2,47510%
Liquid LA2,277
9%
Compost8,42434%
quasar3,74115%
Deep Row Hybrid Poplar
6,96028%
Landfill1,044
4%
COLUMBUS BIOSOLIDS DISTRIBUTION 2015, DRY TONS
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FUTURE 100 % BENEFICIAL REUSE PROGRAM
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UNCLASSIFIEDSOLIDS
CLASS BBIOSOLIDS
THICKENING DEWATERING DEWATERING
LANDAPPLICATION
OHIO MULCH
INCINERATION OFF SITEDIGESTION
COMPOST FACILITY
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• EPA Part 503 - Biosolids Rule
• Approximately 50% of all biosolids produced in the United States are applied to land to improve soils.
• Applied to less than 1% offarm fields.
LAND APPLICATION
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Need storage to make the system work.
SEASONAL LAND APPLICATION PERIODS
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JANUARY FEBRUARY MARCHSun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat
1 2 1 2 3 4 5 6 1 2 3 4 5
3 4 5 6 7 8 9 7 8 9 10 11 12 13 6 7 8 9 10 11 12
10 11 12 13 14 15 16 14 15 16 17 18 19 20 13 14 15 16 17 18 19
17 18 19 20 21 22 23 21 22 23 24 25 26 27 20 21 22 23 24 25 26
24/31 25 26 27 28 29 30 28 29 27 28 29 30 31
APRIL MAY JUNESun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat
1 2 1 2 3 4 5 6 7 1 2 3 4
3 4 5 6 7 8 9 8 9 10 11 12 13 14 5 6 7 8 9 10 11
10 11 12 13 14 15 16 15 16 17 18 19 20 21 12 13 14 15 16 17 18
17 18 19 20 21 22 23 22 23 24 25 26 27 28 19 20 21 22 23 24 25
24 25 26 27 28 29 30 29 30 31 26 27 28 29 30
JULY AUGUST SEPTEMBERSun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat
1 2 1 2 3 4 5 6 1 2 3
3 4 5 6 7 8 9 7 8 9 10 11 12 13 4 5 6 7 8 9 10
10 11 12 13 14 15 16 14 15 16 17 18 19 20 11 12 13 14 15 16 17
17 18 19 20 21 22 23 21 22 23 24 25 26 27 18 19 20 21 22 23 24
24/31 25 26 27 28 29 30 28 29 30 31 25 26 27 28 29 30
OCTOBER NOVEMBER DECEMBERSun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat Sun Mon Tues Wed Thur Fri Sat
1 1 2 3 4 5 1 2 3
2 3 4 5 6 7 8 6 7 8 9 10 11 12 4 5 6 7 8 9 10
9 10 11 12 13 14 15 13 14 15 16 17 18 19 11 12 13 14 15 16 17
16 17 18 19 20 21 22 20 21 22 23 24 25 26 18 19 20 21 22 23 24
23/30 24/31 25 26 27 28 29 27 28 29 30 25 26 27 28 29 30 31
• Two 28 day application periods per year
• Mon – Sat 10 hour shifts
• Actual application period is closer to 16-20 days per period due to weather limitations
SCHEDULE AND KEY DECISIONS
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• August 2014 - Award of Design Contract
• March 2015 - Advertisement for Construction • June 2015 - Notice to Proceed • Construction Milestones (8 total)
• January 2016 - Land Application Tanks No. 1 and 4 ready for storage
• March 2016 - MACT Compliance; incinerators offline, cake piping modifications complete
• May 2016 - Land Application Tanks No. 2 and 3 ready for storage
SCHEDULE CHALLENGES29 June 2016
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• 1 – Biosolids Thickening Operation Evaluation
• 2 – Liquid Biosolids Volume Evaluation
• 3 – Liquid Biosolids Storage Siting Evaluation
• 4 – Liquid Biosolids Truck Load-Out Evaluation
• 5 – Stored Biosolids Consistency Evaluation
• 6 – Biosolids Odor Mitigation Evaluation
• 7 – Cake Loadout Silo Operation Evaluation • 8 – Biosolids Cake Storage Evaluation
2 MONTHS OF TECHNICAL MEMOS –DECISIONS IN RAPID SUCCESSION
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BIOSOLIDS LAND APPLICATION FACILITY
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LAND APPLICATION SOLIDS PROCESS FLOW
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BIOSOLIDS LAND APPLICATION FACILITY (BLAF)
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Repurposed existing thickening centrifuges
3 bay truck loading station(~86 truck loads per day)
Centralized pump and control building
for truck loadout
4 biofilters for odor control and tank ventilation
Four 2 million gallonthickened 8-10% TS
biosolids storage tanksNew thickened
biosolids pumps and repurposed conveyance
(~1000 lf)
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• City of Columbus has a contractual agreement with their land application vendor to provide 8-10% thickened solids• Higher solids % is preferred to minimize trucking costs
• 8-10% TS is atypical for the industry • Typical programs utilize either liquid injection of 5-6%
TS, or mechanical spreading of dewatered cake (20-35% TS)
• Non-Newtonian fluid • Difficult to determine the exact operational characteristics
8 – 10% CLASS B THICKENED BIOSOLIDS29 June 2016
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8-10% Thickened Biosolids Sample Collection
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Collected data on site specific solids characteristics
• Rheology – the science of the deformation and flow of fluids, particularly non-Newtonian
• Non-Newtonian – a fluid whose viscosity is dependent on shear rate
• Solids samples were collected and sent to the ATS Rheo Systems for analysis
• Rheological data used to calibrate hydraulic calculations and model • Coefficient of Rigidity • Yield Stress
• Field pump test results were used to verify model
RHEOLOGY TESTING29 June 2016Black & Veatch
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New Thickened Biosolids Pump
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• Pump testing concluded much higher system pressures than original hydraulic calculations• Replace existing rotary lobe
thickened biosolids pump equipment with new progressing cavities• 4 Stage Progressing Cavity Pumps• 225 gpm @ 200 psi
• Field Observations:• Large harmonic vibrations
(pipe supports)
PUMP AND SYSTEM TESTING RESULTS
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Land Application Control Building
Biosolids Truck Loading Pump Construction
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Largest units that Moyno makes
• 8 Progressing Cavity Pumps• 2 stage• 1,000 gpm @ 100 psi• 125 hp motor
TRUCK LOADING AND TANK RECIRCULATION
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BIOSOLIDS LAND APPLICATION FACILITY (BLAF)
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LAND APPLICATION CONTROL BUILDING
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Biofilter – Smoke Testing
Access Bridge Aluminum Tank Cover
Biofilter – Lava Rock and Pine Bark
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27Truck Loading Station
LESSONS LEARNED
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Centrifuge OptimizationPipe Supports Tank Mixing
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CENTRIFUGE OPTIMIZATION
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THICKENED BIOSOLIDS PUMP DATA
Flow (gpm) Pressure (PSIG)
Solids Percentage
Modeled 225 185 9.5%
Field Measured 150 150 8.5%
FieldMeasured 60 200 Slightly
Above 10%
UNEXPECTED VARIATIONEXCEEDED PUMP
PRESSURE INTERLOCK
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• 8% 10%
• Centrifuge Operational Parameters• Solids Feed Rate• Polymer Quality• Relative Speed• Pond Depth
• Very tight TS tolerances are tricky to achieve
CENTRIFUGE OPTIMIZATION
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• Large harmonic vibrations noticed during pump testing
• Concerns for existing and new systems
• Contractor contingency was provided to analyze existing support systems due to design deadline constraints
• Performed dynamic analysis for vibration for new and existing systems conveying 8-10% thickened solids
PIPE SUPPORT DESIGN
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• Minimize slugs of non-uniform biosolids
• Provide uniform characteristics within each truck• Avoid discrepancies in % solids samples taken for reporting
and actual % solids applied• Difficulty with truck loading (getting solids to the pump inlet)• No mixing systems identified that will guarantee
performance at 8-10% solids
• … Tank Recirculation
DRIVERS FOR TANK MIXING
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Keep the material moving!
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TANK RECIRCULATION AND GEOMETRY
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Minimize SuctionPiping
Minimum 4:1 Floor Slope
Tank Recirculation
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TANK RECIRCULATION AND GEOMETRY
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WHAT’S AT THE END OF THE RAINBOW?
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BIOSOLIDS LAND APPLICATION FACILITY (BLAF)29 June 2016Black & Veatch
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