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TRANSCRIPT
Thomas Nangle, P.E.CDM Smith
• 2015 NC AWWA WEA Spring Conference
Meeting Biosolids Management Challenges Through Advanced Technologies & Resource Recovery
2015 NC AWWA WEA Spring Conference
Presentation Outline
• Background
– Franklin, TN
– Drivers for Biosolids Upgrades
– Key Considerations
• Franklin Biosolids Upgrades
– Overview of Process and Equipment
– Closer look at Interesting Design Features
• Questions
2
Background
3
2015 NC AWWA WEA Spring Conference 4
Franklin, Tennessee
2015 NC AWWA WEA Spring Conference
Integrated Water Resources Plan (IWRP)
• 30 year plan to address:
– Aging Infrastructure
– Fast Paced Growth
– Increasingly Stringent Regulations
• Holistic infrastructure improvements to:
– Potable Water
– Wastewater
– Storm Water
– Reclaimed Water
5
2015 NC AWWA WEA Spring Conference
Goals Defined New Solids Treatment Process
• One of the primary nine goals of the IWRP was a long-term, sustainable biosolids process. To better define the best solution, the following goals were defined by the Steering Committee & Staff:
6Picture: http://mtsgreenway.org/blog/lets-talk-biosolids
– Reduce risk
– Improve operational efficiency
– Earn environmental/public acceptance
– Control odors
– Produce Class A biosolids
2015 NC AWWA WEA Spring Conference
Being a Good Neighbor
• Adjacent to:
– High School
– Sport Fields
– Public Park
– Residential Neighborhood
• Sensitive to:
– Odor
– Noise
– Truck Traffic
7
2015 NC AWWA WEA Spring Conference 8
Franklin Water Reclamation Facility (WRF)
Picture Provided by Franklin WRF
2015 NC AWWA WEA Spring Conference 9
Existing Biosolids Issues
Picture Provided by Franklin WRF
Picture Provided by Franklin WRF
2015 NC AWWA WEA Spring Conference
Preliminary Design of Biosolids System
• Anticipated Solids Loadings, Phases of Construction
– Phase 1 – 20 MGD through 2025
• 18 dry tons of WAS per day1
• 1,200 dry lb of FOG per day1
– Phase 2 – 32 MGD through 2040
• 30 dry tons of WAS per day1
• 1,800 dry lb of FOG per day1
• Preliminary Engineering Analysis
– Four solids process train alternatives
– Concept-level facility sizing, economic analyses
– Non-cost evaluation
– Scoring of alternatives based on cost & non-cost factors
10
Proposed Biosolids Treatment Process
11
2015 NC AWWA WEA Spring Conference
Biosolids Process Flow – Part 1
12
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal
2015 NC AWWA WEA Spring Conference
Biosolids Process Flow – Part 2
13
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
2015 NC AWWA WEA Spring Conference
Sludge Strainers
14
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal
• 5mm pressurized sludge screens • 2 for Phase 1 (standby) • 3 for Phase 2 (1 standby)
2015 NC AWWA WEA Spring Conference
WAS Storage
15
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal 280,000 Gallon Pre-Stressed Concrete Storage Tank
Picture: http://www.cromcorp.com/crom_promo.php
2015 NC AWWA WEA Spring Conference
Pre-Dewatering Centrifuges
16
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal
• Min 20” Bowl Centrifuges, • 3 for Phase 1 (1 standby) • 4 for Phase 2 (1 standby)
2015 NC AWWA WEA Spring Conference
Pre-Dewatered Cake Bin
17
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal
316 SS Live Bottom Hopper 60 cubic yard cake bin with two progressing
cavity pumps
Picture: http://www.cambi.no/wip4/plant.epl?cat=10643&id=210924
2015 NC AWWA WEA Spring Conference
FOG Receiving and Handling
18
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal
• Two FOG Receiving Stations, • 316 SS Storage Tanks with pumped
mixing • (2 for Phase 1, 3 for Phase 2)
• FOG Feed pump Loop.
2015 NC AWWA WEA Spring Conference
Thermal Hydrolysis Pre-Treatment (THP)
19
Centrifuge
Dewatering
Pre-THP
Thermal
Hydrolysis
(THP)
Centrate
to Plant Drain
Dilution
Water
Grease from
Local Haulers
Sludge StrainersWAS Storage
WAS from
Secondary Clarifiers
Pre-Dewatered
Cake Bin
High Pressure
Steam
Dewatered Cake
Bypass to Haulers
Screenings to Off-
Site Disposal
B-2 System Skid with separate Process Gas Unit Skid1
1 This is a picture of the DC Water installation, which consists of 4 trains, each with six B-12 reactors
2015 NC AWWA WEA Spring Conference
Sludge Cooling Heat Exchangers (HEXs)
20
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
• 316 SS Tube-in-Tube HEXs • Two HEXs for Phase 1, • Three HEXs for Phase 2
Picture: http://www.oti.cc/heat-exchangers/)
2015 NC AWWA WEA Spring Conference
Anaerobic Digestion
21
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
• 375,000 gallon pre-stressed tanks • Two for Phase 1, Three for Phase 2.
2015 NC AWWA WEA Spring Conference
Digester Biosolids Storage
22
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
90,000 gallon bolted steel tank
Picture: http://www.midstatetank.com/vertical_tanks.php
2015 NC AWWA WEA Spring Conference
Post-Dewatering Screw Presses
23
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
• 5 HP Screw Presses• 2 for Phase 1 (1 standby)• 3 for Phase 2 (1 standby)
Picture: http://www.huber-technology.com/products/sludge-treatment/sludge-dewatering.html?L=0
2015 NC AWWA WEA Spring Conference
Solar Drying
24
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
• Pilot installation of two solar dryers
2015 NC AWWA WEA Spring Conference
Biogas to Power Generation
25
Class A
Dried Biosolids
for Beneficial
Use
Partial Solar Drying
Remaining Class A
Dewatered
Biosolids to
Beneficial Use
Mesophilic
Anaerobic
Digestion
Screw Press
Dewatering
Post-Digestion
Biogas to Power
Generation
Sludge Cooling
Heat Exchangers
Digested
Biosolids
Storage
Sludge Recirculation
Future Side
Stream
Treatment
Filtrate to
Plant Drain
• 2 reciprocating engines• 2 heat recovery steam generators• 2 backup boilers• Gas conditioning System• Gas Storage Membrane(s)• Waste Gas Flare
2015 NC AWWA WEA Spring Conference
Biogas Process Flow
26
Biogas to Power
Generation
Biogas Storage
Membranes
Combined
Heat & Power
System
Waste Gas
Flare
Gas
Conditioning
Electricity
to Plant
High Pressure
Steam to THP
Steam
Hot Water to
Treatment Processes
Auxiliary
Boilers
Stea
m
Questions
27