“WE DON’T NEED NO… INCINERATION” LESSONS LEARNED …• Final Clarification ... particularly non-Newtonian • Non-Newtonian – a fluid whose viscosity is dependent on shear

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

2

COLUMBUS’ BIOSOLIDS MANAGEMENT STRATEGY

3

Southerly Wastewater Treatment Plant

Columbus, OH

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

• 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

29 June 2016Black & Veatch

4

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

PREVIOUS SOLIDS MANAGEMENT PROGRAM OVERVIEW (2009)

5


UNCLASSIFIEDSOLIDS

CLASS BBIOSOLIDS

THICKENING DEWATERING DEWATERING

LANDAPPLICATION

INCINERATION COMPOST FACILITY

(JP Only)

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

PREVIOUS SOLIDS MANAGEMENT PROGRAM OVERVIEW (2014)

6


UNCLASSIFIEDSOLIDS

CLASS BBIOSOLIDS


LANDAPPLICATION

OHIO MULCH

INCINERATION OFF SITEDIGESTION

COMPOST FACILITY

(JP Only)

Southerly WWTP Multiple Hearth Incinerator (MHI)

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

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


7

Southerly WWTP Multiple Hearth Incinerator (MHI)

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

• Southerly Incinerator Catastrophic Failure March 2015

• Title V MACT Standards effective March 21, 2016

• Jackson Pike Incinerator shutdown March 8, 2016

MACT COMPLIANCE


8

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

29 June 2016

9

Black & Veatch

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

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

FUTURE 100 % BENEFICIAL REUSE PROGRAM

10


UNCLASSIFIEDSOLIDS

CLASS BBIOSOLIDS


LANDAPPLICATION

OHIO MULCH

INCINERATION OFF SITEDIGESTION

COMPOST FACILITY

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

• 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

29 June 2016

11

Black & Veatch

CO

LUM

BU

S’ B

IOSO

LID

S M

AN

AG

EM

EN

T S

TR

AT

EGY

Need storage to make the system work.

SEASONAL LAND APPLICATION PERIODS

29 June 2016

12

Black & Veatch

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

13

SCH

ED

ULE

AN

D K

EY

DE

CIS

ION

S

• 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

14

Black & Veatch

SCH

ED

ULE

AN

D K

EY

DE

CIS

ION

S

• 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

29 June 2016

15

Black & Veatch

BIOSOLIDS LAND APPLICATION FACILITY

16

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

LAND APPLICATION SOLIDS PROCESS FLOW


17

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

BIOSOLIDS LAND APPLICATION FACILITY (BLAF)

29 June 2016

18

Black & Veatch

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)

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

• 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

19

Black & Veatch

8-10% Thickened Biosolids Sample Collection

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

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

20

New Thickened Biosolids Pump

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

• 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


21

Land Application Control Building

Biosolids Truck Loading Pump Construction

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

Largest units that Moyno makes

• 8 Progressing Cavity Pumps• 2 stage• 1,000 gpm @ 100 psi• 125 hp motor

TRUCK LOADING AND TANK RECIRCULATION


22

BIO

SO

LID

SLA

ND

AP

PLI

CA

TIO

N F

AC

ILIT

Y

BIOSOLIDS LAND APPLICATION FACILITY (BLAF)

29 June 2016

23

Black & Veatch

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

LAND APPLICATION CONTROL BUILDING

29 June 2016

24

Black & Veatch

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

25

Black & Veatch

Biofilter – Smoke Testing

Access Bridge Aluminum Tank Cover

Biofilter – Lava Rock and Pine Bark

BIO

SOLI

DS

LAN

D A

PP

LIC

AT

ION

FA

CIL

ITY

26

BIO

SO

LID

SLA

ND

AP

PLI

CA

TIO

N F

AC

ILIT

Y

27Truck Loading Station

LESSONS LEARNED

28

Centrifuge OptimizationPipe Supports Tank Mixing

LESS

ON

S LE

AR

NE

D

CENTRIFUGE OPTIMIZATION

29


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

LESS

ON

S LE

AR

NE

D

• 8% 10%

• Centrifuge Operational Parameters• Solids Feed Rate• Polymer Quality• Relative Speed• Pond Depth

• Very tight TS tolerances are tricky to achieve

CENTRIFUGE OPTIMIZATION


30

LESS

ON

S LE

AR

NE

D

• 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


31

LESS

ON

S LE

AR

NE

D

• 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

32


Keep the material moving!

LESS

ON

S LE

AR

NE

D

TANK RECIRCULATION AND GEOMETRY


33

Minimize SuctionPiping

Minimum 4:1 Floor Slope

Tank Recirculation

LESS

ON

S LE

AR

NE

D

TANK RECIRCULATION AND GEOMETRY


34

LESS

ON

S LE

AR

NE

D

35

WHAT’S AT THE END OF THE RAINBOW?


LESS

ON

S LE

AR

NE

D

BIOSOLIDS LAND APPLICATION FACILITY (BLAF)29 June 2016Black & Veatch

36

www.bv.com

Documents

“WE DON’T NEED NO… INCINERATION” LESSONS LEARNED …• Final Clarification ... particularly non-Newtonian • Non-Newtonian – a fluid whose viscosity is dependent on shear