innovative delivery yields innovative technical solutions · 2020. 5. 27. · innovative delivery...
TRANSCRIPT
Innovative Delivery Yields Innovative Technical Solutions 2018 One Water Ohio
30-August-2018
Phil Cummings, Medina CountyMike Hanna, Black & Veatch
Outline
• The Problem
• The Approach
• The Solution
2
3
In 2015, After 35 years of Zimpo Operations we analysed the viability of our operations for the future
• Increasing COD Loading in the Raw Sewage
• Increasing problems due to internal waste stream recirculation• Maintenance issues with high pressure equipment
• The high cost of energy required for the current sludge process
• Future capabilities of the current aeration system• Maintaining and improving our BNR systems
KEN HOTZ WATER RECLAMATION FACILITY 2015
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Areas of concern
INCR
EASI
NG
CO
D L
OA
DIN
G I
N R
AW
SEW
AG
E
5
The Cod loadings to the plant have steadily increased while the flows have remained stable
This was a strong indication that our efforts would need to be in the area of solids handling
Thermal Hydrolysis• Lysis – breaking stuff apart• Thermal – with heat• Hydro – with water (solubilization)
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Complex Organics SimplerCarbohydrates
Our Zimpro Process is a Thermal Hydrolysis
Unit
INT
ER
NA
L W
AST
E S
TE
AM
RE
CIR
CU
LAT
ION
7
In 2015 we conducted an intensive two week sampling campaign at multiple locations throughout our plant and sewer system
One of the most interesting findings was the significant percentage of recycle loading from our Zimpro process
HIG
H C
OST
OF
EN
ER
GY
8
Our Zimpro operations currently consumes 17
percent of our electrical power use
By shutting down Zimpro our average Electrical power use would drop to 1.01 MW. This power could be provided by one of our existing gas generators
Zimpro consumes 85 percent of our natural gas
This natural gas could be diverted to run one generator for 13 hours per day. While supplying hot water and
Steam to a new process
MA
INT
EN
AN
CE
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Maintenance of high pressure equipment has been a constant issue.
Some of our equipment is no longer functional.
FUT
UR
E C
AP
AB
ILIT
YS
OF
TH
E C
UR
RE
NT
AE
RA
TIO
N S
YST
EM
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With the loadings increasing we considered adding more aeration tanks
Our projections however, showed that even adding three more aeration tanks would not provide enough
capacity by 2038
Liverpool WWTP – Existing Plant
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FOOD WASTE
DOMESTIC SEWAGE
LONG SEWERHEAD
WORKSPRIMARY
CLARIFIERS AERATIONANOXIC / ANAEROBIC
SECONDARY CLARIFIERS
FILTRATION & DISINFECTION
SIDESTREAMTREATMENT
CLARIFIER
PRIMARYTHICKENER
WAS/SPENTTHICKENER
LOW PRESSURE OXIDATION
WET AIR REGENERATION
PLATE & FRAME
PRESSES
ASH SEPARATION
ASH
FILTRATE
OUTFALL
REGEN. CARBON
NATURALGAS
45961 # per day of RAW CODBioP
ENERGY!
ENERGY!
ENER
GY!
3472
2 #
Per d
ay o
f sid
estr
eam
COD
High energy requirements for Zimpro and aerationHowever………..VFA is available for BioP
Legend
Existing Liquid Stream
Existing Solids Stream
Our concern would be what would happen to our Bio P process if the VFA supply was reduced if the Zimpro process was shut down
ENERGY SAVINGS PERFORMANCE CONTRACTS (ESPC)
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EN
ER
GY
SA
VIN
GS
PE
RFO
RM
AN
CE
CO
NT
RA
CT
ING
DELIVERY MODEL
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REQUEST FOR QUALIFICATIONS
PROPOSED ESPCAGREEMENT
INVESTMENTGRADE AUDIT
PROJECTEXECUTION
MEASUREMENT & VERIFICATION
• Qualifications-based selection• Select team for entire project
• Project Goals• Scope/Project Definition• Preliminary Design
• Guaranteed Lump Sum Price• Guaranteed Savings
• Final Design• Procurement• Construction
• Verify Performance• ESCO Corrects or Reimburses
Underperformance
12345
PROJECTS CAN BE IMPLEMENTED WITH NO RATE INCREASE
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DebtService
Energy
Chemicals
Maintenance
Labor
SAVINGS
DebtService
Energy
Chemicals
Maintenance
Labor
Savings applied to capital payments
to fund project
Efficiencyproject creates
savingsR
ATES
DebtService
Energy
Chemicals
Maintenance
Labor
SAVINGS
SAVINGS
SAVINGS
EXCESS SAVINGS
Typicaloperating
budget
Annual Payment
Energy Savings Performance Contracting15
Design-Bid-Build
Performance Contract
RFPPreliminaryEngineering
Report
Design30-60-90-100% Bid Construction Start
Up
CONTRACT• Engineer
CONTRACTS• Multiple Trades• Engineer
RFPProject Scope Development(30% Design)
Construction
Start Up
Design60-90%
CONTRACT• ESCO (Project
Development)
FINAL PRICE & SAVINGS
CONTRACT• ESCO (Energy Savings
Performance Contract)
DELIVERING THE LIVERPOOL PROJECT THROUGH ESPC
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26 December 2018
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Black & Veatch
Oct Nov Dec Jan Feb Mar Apr May June July
Initital Framework
Process Development
Initial Development of ECMs
ECM Screening
Project Definition
Basis of Design/GMP Development
2015 2016
1
2
ECM Walkthrough2
Project Kick-Off1
ECM Screening3
Configuration Confirmation4
Project Definition5
3
4 5
GMP/ESPC6
6
1
1 Process Finalization Work Session
1
2
3
Framework Memo1
Initial ECM List2
Proposed ECM List3
Final ECM List4
Proposed Configuration5
Project Definition Memo6
Basis of Design7
ESPC/GMP Proposal8
4
5
6
7 8
/ Digester Alternatives
A COLLABORATIVE PROCESS
• ECM Walkthrough
• ECM Screening
• Project Definition
• Process/Configuration Finalization
FINANCIAL PROFORMA
$(500,000)
$-
$500,000
$1,000,000
$1,500,000
$2,000,000
$2,500,000
$3,000,000
$3,500,000
$4,000,000
$4,500,000
2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038
Medina County Sanitary EngineersLiverpool Investment Grade Audit
Cash Flow Proforma
Guaranteed Savings Annual Guaranteed Cash Flow Annual Calculated Cash Flow
Managing Risk
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• B&V at risk for aggregated savings
• Looked closely at our risk using Monte-carlo type analysis (using @Risk software)
• Polymer was by far the biggest risk
• In the end the client removed savings guarantee to reduce project cost
Proposed guarantee point$1.54m savings
INNOVATIVE RESULTS
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Liverpool WWTP – New Plant
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COD / energy is redirected to anaerobic digestion. Engine generators converted to CHP to run on biogas and produce steamRAS fermenter to maintain stable bioP operation with less influent VFAStruvite removal to prevent PO4-P recycle
FOOD WASTE
DOMESTIC SEWAGE
LONG SEWERHEAD
WORKSPRIMARY
CLARIFIERS AERATIONBAR SECONDARY CLARIFIERS
FILTRATION & DISINFECTION
PRIMARYTHICKENER
WAS THICKENER
OUTFALL
DAF
SCREENINGPRE
DEWATERING
CAKE BIN
THP
DIGESTERS
FINAL DEWATERING
STRUVITEREMOVALIMPORTED CAKE
RAS FERMENTER
HSW / FOGRECEIVING
HSW TO LIVERPOOL
STRUVITE FERTILIZER
CLASS ACAKE
HRSG
ANO-XIC
PR
OJE
CTI
ON
S FO
R T
HE
YEA
R 2
038
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2015
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INNOVATIVE PROCESSRAS Fermenter Struvite Precipitation
(Airprex)
• 0.7 MG• 2 day SRT
• 41,000 gpd• > 85% PO4-P
removal
THP and Digesters
• 1,100 gph throughput (THP feed)
• 2 x 0.87MG digesters (1 primary, 1 secondary)
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CODIGESTION/COGENERATION
HRSG & Steam Accumulator HSW Tank
• 1,800 lb/hr steam at 175PSIg
• Existing steam generator as auxiliary boiler
• 67,000 gallon high strength waste tank
• Drum screen• Single DAF unit• 240 gpm
DAF Plant (Marks Rd PS)
Liverpool WWTP• Lipp Digesters
• Rolled stainless steel construction
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CURRENT STATUS
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As of August 30, 2018
• Aeration Control
• RAS Fermenter
• Bioagmentation Reactor (BAR)
• BNR
• Cogen Engine Controls
• Construction Complete and Mechanical Systems Commissioned – November 2018
• Digester Seeding – November 2018
• THP Start-up – December 2018
• Gas Cleaning and CHP – January 2019
• Airprex, Dewatering, Polymer – February 2019
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