Irvine Ranch Water DistrictMichelson Water Recycling PlantPhase 2 Expansion

SCAP Water Quality Committee Meeting

Randy Lee, P.E. , Assistant Director of Recycling Operations

September 23, 2014

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1. IRWD Background

2. MWRP Existing Processes Overview

3. MWRP Phase II Expansion

4. Biosolids Project Status Update

Presentation Overview

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IRWD Serves 20% of Orange County

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Water, Wastewater, Water Recycling, and Urban Runoff

California Special District governed by a publicly-elected Board

IRWD customer base:• Residential population: 330,000• Daytime population: >500,000• Service connections: 102,380

IRWD service area:• 181 square miles (20% of Orange County)• All or part of six cities and unincorporated county:

About the Irvine Ranch Water District

IrvineTustin

Orange

Lake ForestNewport Beach

Costa Mesa

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IRWD Services Drinking Water

Sewage Collection

Recycled Water

Urban Runoff Treatment

Phase 2 Expansion Project

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ASCE OC

Water Treatment Project

of the Year - 2013

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• Produces 18 MGD of Title 22 recycled water.

• Phase 2 Expansionincreases capacity to 28 MGD.

• Scheduled completion June 2014.

Michelson Water Recycling Plant

MWRP Aerial View

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Michelson Water Recycling Plant

NORTH IRVINE INTERCEPTOR

SOUTH IRVINE INTERCEPTOR

INFLUENT GRINDERS

PRIMARY SEDIMENTATION

TANKS

FLOW EQUALIZATION

BASINS

ACTIVATED SLUDGE BASINS

SECONDARY SEDIMENTATION

TANKS

DUAL MEDIA

FILTERSCHLORINE

CONTACT TANKS

RECYCLED WATER CUSTOMERS

OCSD

Treatment Process Prior to Expansion

10OCSD

NORTH IRVINE INTERCEPTOR

SOUTH IRVINE INTERCEPTOR

HEADWORKS

PRIMARY SEDIMENTATION

TANKS

FLOW EQUALIZATION

BASINS

ACTIVATED SLUDGE BASINS

SECONDARY SEDIMENTATION

TANKS

DUAL MEDIA

FILTERS

CHLORINE CONTACT TANKS RW

CUST.

HIGH RATE CLARIFIER

UV DISINFECTIONMEMBRANE BIOREACTOR

PRIMARY EFFLUENT

PUMP STATION

Phase 2 Overall Process Train

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Phase 2 Expansion Overview

`

HEADWORKSNEWPSTs

EXISTINGPSTs

PEPS

MEMBRANE BIOREACTOR

FLOWEQUALIZATION

BASINS

EXISTINGBLOWER

ROOM

HIGH RATE

CLARIFIER

UV DISINFECTION

SPENT BACKWASH TANK

CHLORINE CONTACT TANK

EFFLUENT PUMPS

NEW TREATMENT FACILITIES

MODIFIED EXISTING TREATMENT FACILITIES

NEW CHEMICAL FACILITIES

NEW ELECTRICAL FACILITIES

SPENT BACKWASH TANK

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New Headworks

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New Primary Sedimentation Tanks

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New Primary Effluent Pump Station

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Membrane Bioreactor

FINESCREENS

DE-OX ZONE

DE-OX ZONE

ANOXIC ZONE

ANOXIC ZONE

AERATION BASIN

AERATION BASIN

MLP.S.

RASBOX

RA

S C

HA

NN

EL

MEMBRANETANKS

DIPTANK

B.P.TANK

PE

RM

EA

TE

PU

MP

RO

OM

BL

OW

ER

RO

OM

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MBR Process Flow

10 MGD

5 MGD

5 MGD

30 MGD

30 MGD

10 MGD

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MBR Fine Screens & Aeration Basins

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MBR Mixed Liquor Pump Station

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Loading MBR Membrane Cassettes

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MBR Air & Permeate Piping

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Permeate Pump & Blower Rooms

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MBR Photos

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Ultraviolet Disinfection Facility

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New Phase 2 Buildings

High Rate Clarifier Electrical Bldg.

Headworks Membrane Bioreactor

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MWRP Phase 2 Overview

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Floodwall – 200 Yr Flood Protection

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Treatment Process $83

Million

Floodwall

$ 5 Million

Overall Construction Cost: $88 Million

Change Orders:

$ 4 Million 4.5%

Total

$92 Million

Construction Management $14 Million

15%

Phase 2 Construction Cost

Biosolids & Energy Recovery Facilities Project

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Project Objectives

• Beneficially reuse Biosolids and Biogas produced during the treatment process.

• Manage residuals (Biosolids) at reduced costs to IRWD’s customers.

• Construct project to meet IRWD’s future Biosolids handling needs.

• Minimize environmental impacts:Drying and pelletizing reduces export truck loads by factor of four.

• Reduces greenhouse gas effects by beneficially using pellets locally as a fertilizer or e-fuel.

Biosolids & Energy Recovery Project

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Project Description

• IRWD to construct facilities at MWRP for:

• Biosolids digestion, dewatering and drying

• Biogas management and energy recovery

• Odor control systems

• IRWD would no longer export solids to Orange County Sanitation District (OCSD).

• Project would also accept Biosolids trucked in from IRWD’s Los Alisos Water Recycling Plant (LAWRP).

Biosolids & Energy Recovery Project

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Biosolids Facilities Site Location

MWRP

Biosolids and Energy

Recovery Facilities

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EXISTING PRIMARY CLARIFIER

EXISTING SECONDARY CLARIFIER

ACID-METHANE PHASE ANAEROBICDIGESTION

DEWATERINGCENTRIFUGE

DIGESTED SLUDGE STORAGE

MICROTURBINES

BIOGAS ELECTRICITY

CAKESTORAGE & LOADOUT

CLASS BCAKE HAUL(BACKUP)

ROTARYDRUMDRYER

PELLET STORAGE & LOADOUT

CLASS A PELLET HAUL

FATS, OILS & GREASE

CENTRATETREATMENT

TO LIQUID TREATMENT

RECYCLED WATER

PS

WAS

THICKENINGCENTRIFUGE

THICKENINGCENTRIFUGE

DIGESTER GAS CLEANING

Simplified Process Schematic

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Air Permit Process Diagram

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Heat Drying System

Furnace

Mixer

ID Fan

Pellet Cooler

To Storage Silos

Cake from dewatering

Cake BinRecycle Bin

RTO

Venturi Scrubber

Condenser

Furnace

Triple Pass Drying Drum

Gas Recirculation

Pneumatic Transporter

Atmosphere

Preseparator Baghouse

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• Produces a pellet suitable for local beneficial reuse

• Nitrogen for fertilizer

• Btu content for e-fuel

• Dryers in CA:

• Encina (Carlsbad)

• Sacramento

• Corona

Heat Drying System

3-D Model Renderings

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Digestion Facilities

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Egg-Shaped DigestersSludge Holding Tanks

Acid Phase Digesters

Digester Control Bldg.

FOG Foodwaste Receiving.

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Biosolids Handling BuildingDryer and Odor Control

Discharge Stacks

Polymer Storage

Solids Receiving Pellet Loadout

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Biosolids Handling Building

Centrate Treatment

Polymer Storage

Centrifuge Area

Dryer Area

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Biogas Treatment & Microturbines

Biogas Storage

Biogas Conditioning Microturbines

4141

Centrifuge Room

Thickening Centrifuges

Dewatering Centrifuges

4242

Dryer System – Lower Level

Dryer Drum

Pellet Screen

4343

Dryer System – Upper Level

Dryer Drum

Solids/Off Gas Separation

Pellet Mixer

Recycle Bin

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Sub-Surface View of 3,028 Piles

Construction Photos

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Construction Photos

Pile Installation – Digester Area

Completed:• Construction of

structure and

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Construction Photos

Pile Installation – Basement of Solids Handling Building

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Installation of Piles in Methane Digester Area

May 2014 Quarterly Report

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Installation of Piles in Solids Handling Facility

May 2014 Quarterly Report

Project Schedule

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Project Schedule

DATE ACTIVITY

April 29, 2013 Notice of Award

June 3, 2013 Notice to Proceed

Sept. 2013 – March 2014 Pile Driving

January 17, 2016 Anaerobic Digestion Facilities Online

March 2, 2016 Produce Class B Biosolids (Cake)

June 30, 2016 Microturbine Power Generation Online

August 29, 2016 Produce Class A Biosolids (Pellets)

October 28, 2016 Project Completion

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Pile Driving $

10 Million 6%

Digesters $

45 28%

Dryer

$ 13 8%

Biogas & Microturbines $ 8

5%

Sitework $

14 9%

Other

$ 73 45%

Total Bid Amount $ 163

Million

Biosolids Construction Cost

Contact Information:

Randy Lee, P.E.Irvine Ranch Water Districtleer@irwd.com949-453-5780