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Kenosha Wastewater Treatment Plant -Energy Optimized Resource Recovery
Project
Prepared By:
Curt Czarnecki, P.E. Kenosha Water Utility
Presented By: Joseph Hughes, P.E.
Centrisys Corporation
MIWEA June 21st, 2016
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• The entire Kenosha Water Utility (KWU) Staff, including:
• Ed St. Peter, Curt Czarnecki, Melissa Arnot, Katie Karow, &
Tom Tetzlaff
• J. F. Ahern – General Contractor
• Pieper Power – Electrical Contractor
• CD Smith – Civil Contractor
• Donohue & Associates – Engineer including Dennis Dineen &
Allen Williams
• Centrisys Corp. including Geoff Harvey & Christine Smith
• CNP – Gerhard Forstner
Thanks & Acknowledgement
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• Kenosha Water Utility (KWU) and Wastewater Treatment Plant
(WWTP) Overview
• Drivers for Energy Optimized Resource Recovery Project
• Technology Overview
• Preliminary Results
• Economics (Added Value)
• Conclusion
Presentation Outline
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WWTP Service Area Overview
• Population: 110,000
• Service Area: 85.7 mi2 (222 km2)
• Collection System – Gravity Sewer System: 332 mi (535 km)
– Lift Stations: 13
• Permitted Annual Average Daily Flow: 28.6 MGD (1.253 m3/s)
• 2015 Annual Average Daily Flow: 21.9 MGD (0.961 m3/s)
• Effluent Discharge: Lake Michigan
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WWTP Loadings Average Day (Current Loadings Based on 2015 Data): • BOD
– Influent: 32,910 lbs/day (180 mg/l) – Effluent: 2,475 lbs/day (13 mg/l) – 92% Removal
• TSS – Influent: 32,863 lbs/day (180 mg/l) – Effluent: 1,415 lbs/day (8 mg/l) – 96% Removal
• Ammonia – Influent: 4,881 lbs/day (27 mg/l) – Effluent: 530 lbs/day (3 mg/l) – 89% Removal
• Phosphorus – Influent: 533 lbs/day (3 mg/l) – Effluent: 85 lbs/day (0.5 mg/l) – 84% Removal
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Sludge Characteristics Primary Sludge:
– Average Flow: 68,620 gal/day (260 m3/day) – Solids Concentration: 3.3% – Solids Production: 19,020 lbs/day (8,626 kg/day) – Volatility: 77%
Waste Activated Sludge (WAS): – Average Flow: 151,350 gal/day (570 m3/day) – Solids Concentration: 1.05% – Solids Production: 13,010 lbs/day (5,900 kg/day) – Volatility: 72%
Digested Sludge – Solids Concentration: 2.7% – Volatile Solids: 54% – Volatile Solids Reduction: 60% – Sludge to Landfill (2015): 2,500 dry US tons, 2,270 dry metric tons
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Motivation Behind Project
• Aging WWTP infrastructure
• An effort to combat ever rising utility costs:
– Natural Gas
– Electricity
• Reduce or eliminate landfill disposal fees
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Project Objectives
• Increase biogas production
• Generate electricity from biogas
• Achieve 90% dry and Class A biosolids
• Utilize waste heat as the main thermal energy supply
• Maintain existing effluent quality
• Maintain or decrease noise, odor and particulate levels
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Design Approach • Wisconsin allows for design/build approach on
resource recovery projects • Design/Build was utilized due to the varying
technologies and complexity of the project. • In the RFP the design/builder was tasked with the
following: – Preparation of the design – Assisting KWU in obtaining all necessary permits – Procuring, constructing and installing all components – Integrating the new system with the existing plant
SCADA network – Startup and commissioning – Preparation of O & M manuals – Warrantying the system
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Anaerobic Digestion Modifications
Before Project After Project
Digesters 4 primary
2 secondary
2 primary
1 secondary
Total Capacity 633,550 ft3 319,650 ft3
Mixing Condition Unmixed Fully mixed with mechanical
hydraulic mixing
Sludge Feed
Operation
Batch feeding operation based
on 8-hour shifts Continuous feed
Feed Primary (3.3% TS)
WAS (5.0% TS)
Primary (7% TS)
WAS (7% TS)
HRT in digesters Primary=30 days
Current operation:
Primary=17 days
Ultimate Operation:
Primary=22 days
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Mechanical Hydraulic Mixing Rotamix by Vaughan Company
System consists of: • Chopper pump • Internal piping • Six nozzles (per digester) Benefits: • More even heating of
contents • Improved volatile solids
reduction • Increased gas production
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Primary Sludge Thickening Centrifuge THK 200 by Centrisys Corporation
Before Project: Gravity thickened sludge (3.3% TS) pumped directly from the clarifiers into the digesters Operational Characteristics • Sludge Feed: 3.1% TS • Cake Material: 6.1% TS • Avg. Power Consumption:
5.7 kW • Capture Rate
• Without Polymer: 89% • With Polymer: 98%*
*Emulsion Cationic Polymer 46% active
@ 0.5 gallons/hour
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WAS Thickening Centrifuge THK 200 by Centrisys Corporation
• Prior to our partnership: A DAFT system was utilized to thicken the WAS flow stream from 1% TS to 3.5-4.0% solids before being pumped into the digesters
• A WAS thickening centrifuge was previously pilot tested and installed in 2011 – Due to downstream
limitations the WAS flow stream was thickened to roughly 5% solids with the thickening centrifuge
– This project allowed us to further thicken the WAS flow stream to 7% solids
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WAS Thickening Centrifuge Installation
Operational Characteristics • Sludge Feed: 1.1 - 1.3%
TS • Cake Material: 6.9% TS • Average Power
Consumption: 13.6 kW • Capture Rate: • Without Polymer: 90% • With Polymer: 97%*
*Emulsion Cationic Polymer 46% active @ 0.2 gallons/hour
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Thermo-Chemical Hydrolysis PONDUS by CNP-Technology Water and Biosolids Corporation
Components of Hydrolysis Process:
• Thermo: TWAS is heated to 140 - 160oF (60 - 70oC)
• Chemical: 1.5 to 2.0 liters of caustic soda (50% concentration) is injected per 1 m3 of TWAS
• Detention Time: Circulation through the reactor and heat exchanger for 2 to 2.5 hours.
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Thermo-Chemical Hydrolysis
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Thermo-Chemical Hydrolysis
pH
• Upon addition of caustic soda pH = 11 (+/-)
• Following hydrolysis process pH = 6.8 to 7.0
• Hydrolysis process breaks down the cell walls and releases internal organic acids which brings the pH of the flow stream back to neutral.
• Hydrolysis causes the pH adjustment and therefore no additional chemical addition is necessary prior to anaerobic digestion process.
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Thermo-Chemical Hydrolysis
Thermal Efficiency • The blending of hydrolyzed TWAS and unheated
thickened primary sludge results in a final temperature of roughly 40oC (100oF) which is ideal for the mesophilic anaerobic digestion process
• All thermal energy required for the hydrolysis process is transferred into the digesters.
Atmospheric Pressure • The entire hydrolysis process is completed at
atmospheric pressure Additional Volatile Solids Reduction • Volatile solids reduction of 60% (before) and 65%
(currently) Increased Dewaterability of Digested Sludge
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PONDUS Reactor Installation
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PONDUS Heat Exchanger
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Thermo-Chemical Hydrolysis
• Reduced Viscosity Provides for: – Lower mixing energy requirements
– Higher digester loading rates
1
10
100
1000
10000
0 4 8 12 16 20
Dra
ina
ge
tim
e (
se
c)
Nozzle diameter in mm
Sludge viscosity tests at KWU (compensated for sludge density)
water 1 mPa s 20,0 °C 1000,0kg/m³
glycerol 99,5 %tig, 1480 mPas 19,6 °C, 1260,0 kg/m³
WAS Kenosha 19,6 °C, TS6,5% , GV 70,0% , 1026,3kg/m³
drain flow hydrolysisc138/input 15 gpm 71,0 °C,TS 6,5% , GV 70,0% ,1005,3 kg/m³
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Biogas Production
149,012
155,826 152,956 155,384
192,502
181,039 185,771
176,316 184,358
178,676
0%
4% 3% 4%
23%
18% 20% 15%
19% 17%
0%
10%
20%
30%
40%
50%
100,000
120,000
140,000
160,000
180,000
200,000
220,000
240,000
2012 2013 2014 2/22/16 -3/6/16
3/7/16 -3/20/16
3/21/16 -4/3/16
4/4/16 -4/17/16
4/18/16 -5/1/16
5/2/16 -5/15/16
5/16/15 -5/29/16
Cu
bic
fe
et
pe
r d
ay
Additional Biogas Production
2-Week Average Daily Biogas Production
Increased Biogas Production from 2012 level (Contract Base Year)
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Biogas Conditioning Gas conditioning and siloxane removal by Unison Solutions
• Before Project: Raw biogas was utilized by – Raw water pump engines
– Hot water boilers
– Flared to the atmosphere
• A package system was incorporated to condition and compress the biogas – moisture
– particulates
– siloxane
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Electric & Thermal Energy Generation
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Electric & Thermal Energy Generation CHP Generators by Kraft Power
• Before Project: – All electricity was purchased exclusively from the local utility. – All heat was provided by our boilers using either natural gas or biogas
as their fuel source.
• Two combined heat and power (CHP) generators were installed to utilize the biogas as a fuel source to generate electrical as well as thermal energy.
• The CHP units are each capable of producing: – 330 kW of electrical energy – 422 kW of thermal energy
• The electricity produced will power the new system as well as supply the excess electricity to the main plant power network for beneficial use elsewhere throughout the plant.
• The thermal energy will be utilized by the PONDUS system, the compact belt dryer and the central WWTP heating loop.
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Isometric Project Overview Heat Biogas Electricity Biosolids
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Biosolids Dewatering CS 21-4HC Centrifuge by Centrisys Corporation
• The centrifuge was installed in 2009 & replaced three plate and frame presses.
• This project met or exceeded all design criteria and provided a payback of one year!
• The dewatering centrifuge has historically been fed digested sludge with a 2.7% TS concentration and consistently achieved 26-29% TS on the cake material.
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Centrifuge Room
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Drying of Biosolids Compact belt dryer by Sulzle-Klein
• Previously dewatered biosolids went to local landfill
• Now, biosolids are dried using the recovered heat from the co-generation units as the thermal supply.
• The belt dryer achieves all the requirements of Class-A and KWU is currently in the process of getting our final biosolids product re-classified with the Wisconsin Department of Natural Resources.
• The dried product is discharged into a conveyor system and automatically deposited into the bed of a dump truck.
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Drying of Biosolids
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Drying of Biosolids
Distributor extrudes the biosolids into noodle-like strands to maximize the surface area for maximum evaporation capacity
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Drying of Biosolids
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Odor Control KWT 1000/1300 by Sulzle-Klein
• Treats the exhaust air from the belt dryer, the buffer & mix tanks, the PONDUS reactor, and the thickening & dewatering centrifuges.
• Water cools the exhaust air and removes particulates.
• Sulfuric acid neutralizes ammonia odors.
• Caustic soda neutralizes sulfur compounds such as mercaptans.
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Other Items Incorporated Into Project
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Other Items Incorporated Into Project
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Other Items Incorporated Into Project
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Other Items Incorporated Into Project
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Other Items Incorporated Into Project
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Other Items Incorporated Into Project
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Other Items Incorporated Into Project
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Estimated Added Value Criteria Daily Annual Unit Cost Unit Annual Savings
On-Peak Electricity
(kWh) 4,752 1,734,480 $0.07660 per kWh $132,861
Off-Peak Electricity
(kWh) 8,448 3,083,520 $0.05238 per kWh $161,515
Electric Demand (kW) 550 6,600 $12.65 per kW $83,490
Electrical Total $377,866
Cake Sludge
(wet tons) 25 9,249 $38.01 per ton $351,554
Disposal Total $351,554
TOTAL Value $729,420
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Grant from Local Utility
• Due to the nature of the project KWU was awarded over $500,000 in grants for implementing the new biosolids process from Focus on Energy.
• The installation of the thermo-chemical hydrolysis system, co-generation units, and LED lighting all qualified for the largest grant this organization awards to an individual project.
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Conclusion
Through innovative thinking KWU was able to:
–Become more energy efficient
–Less reliant on purchased electrical and thermal energy, reducing operating costs
–Produce a higher quality end product (Class A Biosolids)
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Questions? Curtis Czarnecki, P.E.
Director of Engineering Services
Kenosha Water Utility
4401 Green Bay Road
Kenosha, WI 53144
Phone (262)653-4306
Joe Hughes Project Manager Centrisys Corp.
Phone: (262) 716-9949 [email protected]