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Massachusetts Water Resources Authority Presentation to MWRA Advisory Board MWRA Residuals...
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Transcript of Massachusetts Water Resources Authority Presentation to MWRA Advisory Board MWRA Residuals...
![Page 1: Massachusetts Water Resources Authority Presentation to MWRA Advisory Board MWRA Residuals Processing & Agreement for Operation and Maintenance of the.](https://reader036.fdocuments.net/reader036/viewer/2022062517/56649f095503460f94c1d859/html5/thumbnails/1.jpg)
Massachusetts Water Resources Authority
Presentation to
MWRA Advisory Board
MWRA Residuals Processing & Agreement for Operation and Maintenance
of the Fore River Pelletizing Plant withNew England Fertilizer Company
May 21, 2015
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Massachusetts Water Resources Authority
Residuals Treatment Facilities
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Massachusetts Water Resources Authority
Residuals Processing – Schematic Overview
•
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Massachusetts Water Resources Authority
Residuals Processing Statistics for Deer Island
• Sludge to Digestion – 246 dry TPD– 70% as Primary sludge – from gravity thickening– 30% as Waste Secondary sludge – from centrifuge thickening
• Typical sludge makeup of other plants: 50:50
– Time in Anaerobic Digestion: • 18-21 days
– 62% Volatile Solids destruction • (industry ave. is 50%)
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Massachusetts Water Resources Authority
Residuals Processing Statistics for Deer Island
• FY14 Annual Avg digester gas production – 188 kscfh– 96% of gas is beneficially used in boilers– 95% of total boiler heat attributable to Digas
• Value of gas utilization - $21.3M (heat) & $2.3M (power)
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Massachusetts Water Resources Authority
Overview of Current Residuals Processing
• Sludge to Pellet Plant – 100 dry TPD– On DITP, Digested sludge is stored, then pumped 7 miles to Pellet Plant
• Methane gas captured, stored, then used in boilers on site– NEFCO dewaters, dries, & pelletizes all digested sludge
– All pellets go to beneficial re-use:• turf farms • golf courses • fertilizer blenders • cement kiln
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2005 2006 2007 2008 2009 2010 2011 2012 2013 201490
95
100
105
110
115
Average Daily Sludge to Pellet Plant (DTPD)
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• Located in Fore River Shipyard
• Designed, Constructed & Ownedby MWRA– Phase I – $88 M– Phase II - $45 M– Total cost - $133 M
• Since Day 1, has always been a Contract Operation– Contract 1: 1991 – 2001 Competitive Bid – NEFCo– Contract 2: 2001 – 2015 Competitive Bid - NEFCo
MWRA Pellet Plant located in Quincy, MA
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• Current contract - S345 – 15-year (2001-2015)
• Process liquid sludge from DITP – Receive digested sludge– Dewater with centrifuges– Dry with thermal dryers– Produce Class A Fertilizer Pellet
– In CY 2014:• Processed 100 dtpd• Paid NEFCo $14.1M
Pellet Plant – Contract O&M Since 1991 (cont.)
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• Contractor is responsible for developing & maintaining Diverse Markets for beneficial reuse for all sludge sent to the Pellet Plant– Land Application– Fertilizer Blenders– Alternate Fuels– Bay State Fertilizer Program
• Maintain Facility & Equipment– Responsible for returning
a fully operable plantat the end of the contractto MWRA.
Pellet Plant – Contract O&M Since 1991 (cont.)
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Land Application
Fertilizer Blenders
Alternate Fuel
Bay State Fertilizer Program
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State Annual Tonnage Percentage
Connecticut 6,811 22%New York 5,678 18%Indiana 3,090 10%Maine 2,170 7%Rhode Island 1,835 6%Florida 1,665 5%Virginia 1,554 5%Massachusetts 1,439 5%Georgia 1,332 4%Vermont 1,175 4%Pennsylvania 1,025 3%Ohio 980 3%Maryland 980 3%Missouri 590 2%North Carolina 328 1%Michigan 259 1%Bagged/truck 106 0.3%
Pellet Distribution by State
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Comparison of Pellet Molybdenum Concentrations to DEP Limit
Jan
'12
Apr'12
Jul'12
Oct '12
Jan
'13
Apr '13
Jul '13
Oct '13
Jan
'14
Apr '14
Jul '14
Oct '14
0%
50%
100%
150%
200%
Monthly Pellet Molybdenum Concentrations(Expressed as a % of DEP Type I Limit)
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Step 1: Condition Assessment• Facility is in excellent condition
– 20+ year life remaining with no major capital
(with continued maintenance)
Step 2: Residuals Technology Assessment• Recommendations at DITP
– May impact quality & quantity of sludge sent to Pellet Plant
• Recommendations at Pellet Plant– Limited to energy efficiency gains given
condition of facility
Pellet Plant – Contract Renewal Preparation
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Technology Assessment Recommendations (cont.)
– Consider larger, more efficient Dryer Trains• Implemented at Philadelphia & soon Detroit
– Evaluate impacts of co-digestion programs at DITP
– Given long remaining life, any capital expense
decisions must rely on payback
– Recommend 5-year extension to quantify impacts
of pilots and new dryer ops
– Suggested next long-term contract – 15 years
Pellet Plant – Contract Renewal Preparation Step 2 (cont.)
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Pellet Plant – Existing Contract with NEFCo
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Current Contract Cost Structure
• Fixed Fee first 90 dtpd (32,850 dry tons annually) (~$400/ton)• Excess Qty >90 dtpd (>32,850 dry tons annually) (~$280/ton)
• Fixed yearly capital dollar value (pre-determined)• No pass-throughs for utilities
– Includes adjustments for inflation
• FY14 Avg - ~$380/ton
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Pellet Plant – NEFCo Contract Extension
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Contract Cost Structure – Sludge Processing (changes)
Original Contract Contract Extension Change• Fixed Fee first 90 dtpd annual (32,850 tons/yr) same base price but for 92.5 dtpd• Variable Fee >90 dtpd same incremental price >92.5 dtpd
• CY2014 Total contract expenses $14,090,654
$13,582,354 for sludge processing $13,334,464 if on extension- $12,574,468 base + = same base + - plus $1,007,886 excess qty plus $759,996 excess qty
Savings of $247 K in year.+ $508,300 capital expenses
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Pellet Plant –NEFCo Contract Extension – Capital Program
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• Capital Program - $7.0 Million cap
• $6.087 K – project awards subject for future Board approvals• NEFCo designs all capital projects – paid 15% of awarded project
• NEFCo responsible for capital costs in excess of $7.0 M cap• Must return a fully operational plant at end of contract• Drum replacement not included in cap if completed.
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Pellet Plant – NEFCo Contract Extension Summary
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• Reduced Price for Sludge Processing
• $1.25 M savings over 5-yr extension
• Revised Capital Program Structure
• Retains NEFCo liability (must return fully operating plant at end of contract)
• Extension authorized for 5-years
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Pellet Plant – NEFCo Contract Extension Summary
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• Provides MWRA sufficient time to:
Evaluate potential energy efficiency improvements (large dryer technology)
Stabilize future sludge quantities (co-digestion)
Allow for increased competition
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• Word of mouth marketing - 32 transactions in April and May
• Lawn care “enthusiasts” showering praise upon Bay State Fertilizer
• Marketing Intern started May 18th
– Goal: Expand retail presence
Bay State Fertilizer
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New Bay State Fertilizer Bag – Rita Berkeley
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• Available at no cost MWRA member Communities
• Pickup at the Pellet Plant in Quincy
• Contact Carl Pawlowski (617) 773-4295
Bay State Fertilizer
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Massachusetts Water Resources Authority
Questions ?
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