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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
2
1. IRWD Background
2. MWRP Existing Processes Overview
3. MWRP Phase II Expansion
4. Biosolids Project Status Update
Presentation Overview
3
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
28
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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
