Solids Disposal History Primary & Secondary Solids - 1972-1984 - - PowerPoint PPT Presentation

MWEA Process Seminar Kalamazoo Solids Dewatering - Choosing Which Technology Eagle Eye Banquet Facility Bath, MI November 12, 2015

Solids Disposal History

• Primary & Secondary Solids - 1972-1984
• Low Pressure Oxidation (LPO)
• Vacuum Filters
• Incineration (Ash to Landfill)
• 1985 New Secondary Process
• Powdered Activated Carbon (PAC)
• Primary & Secondary solids separated

Primary Solids Disposal History

• Primary Solids – 1985-1992
• Low Pressure Oxidation (LPO)
• Vacuum Filters
• Incineration (Ash to Landfill)
• Primary Solids – 1992-1999
• LPO, Belt Filter Presses, Incineration

(Ash to Landfill)

• Incinerator Shutdown EPA Part 5 Regs
• Primary Solids – 1999-2002
• Belt Filter Presses, Landfilled

Secondary Solids Disposal History

• Secondary Solids – 1985-2001
• Powdered Activated Carbon (PAC)

Added to Treat Industrial Wastes

• Wet Air Regeneration (WAR)

To Destroy Organics & Biomass Regenerate and Reuse PAC

• Differential Sedimentation & Elutriation

(DSE), Remove Ash from WAR Process Plate Press Ash to Landfill Return Carbon to Secondary Process

Current Solids Disposal

• Primary & Secondary Solids - 2002-2007
• Constructed New Solids Handling Facility
• Belt Press All Solids
• Installed RDP (Heat & Lime) Stabilization
• Land-applied Some Class A Biosolids

Mostly Primary Used for Class A

• Landfill All Non-Class A Solids
• Primary & Secondary Solids - 2008-2015
• Belt Press All Solids
• Landfill All Solids

Background

• Biosolids Production
• 240 Wet Tons/day
• 73 % Secondary Dry Solids
• 27% Primary Dry Solids
• Current Technology
• Four 2 Meter Andritz Belt Filter Presses
• Equipment Age 2 @ 13 yrs & 2 @ 23 yrs
• Current Disposal Sites
• Westside Landfill, Three Rivers MI
• Autumn Hills Landfill, Coopersville MI

Costs

• Loading/Hauling/Landfilling
• $2,874,000 in 2014
• Average Cake Dryness 2014
• Primary 26.7% TS
• Secondary 15.5% TS
• Combined Average ~ 20.1% TS

Calculated from Wet Tons

Potential Cost Savings

%TS Increase Savings % Hauling Cost Savings 1 $ 137,256 4.8 2 $ 262,035 9.1 3 $ 375,963 13.1 4 $ 480,397 16.7 5 $ 576,476 20.1 6 $ 665,165 23.1 7 $ 723,294 25.2 8 $ 747,284 26.0 9 $ 823,537 28.7 10 $ 894,532 31.1

Preliminary Fact-Finding

• Bench Scale Evaluations
• WEFTEC Exhibits - Equipment Options
• Vendor Inquiries
• Promising Dewatering Technologies
• Centrifuge
• New Style Belt Press- Klam/Winkle
• 3-Belt Style Belt Press
• Rotary Press
• Screw Press
• Volute Press

Pilot Overview

• Developed Pilot Parameters
• Sent Vendors Operating & Lab Data
• Sent Vendors Samples Prior to Bid
• Sent Request for Proposals to Vendors
• Selected Vendors for Pilot Study
• Cost of Pilot Trailers $ 31,500
• Scheduled 1-2 Week Pilot Trials

Pilot Logistics

Review Pilot Trailer Requirements

• Power Supplies
• Water Connections
• Sludge Feed Connection
• Filtrate/Centrate Discharge
• Cake Disposal Requirements

Pilot Logistics

Coordinating Operations

• Piloting from April-July (pre-ferric)
• Lab Data Sheets / COCs
• Sampling Schedule
• Sample Containers
• Sludge Inventory Consistency
• Data Collection & Compilation
• Staff Coordination

About the Results

• All Results - KWRP Lab
• Samples Collected by KWRP Operations
• All Results are Averages for Each

Technology – The Good and the Bad These Are Not Optimized Results

• Conditions During Tests Varied to

Produce Best Cake

• Additional Results from Vendor Samples

Still Need to be Evaluated

Primary Feed Flow Rate

Company Device Primary Flow gpm

KWRP- Trial Belt Press 100

Alfa Laval Winkle Press

39

Alfa Laval Centrifuge

52

Andritz Centrifuge

48

Fournier Rotary Press

18

Ishigaki Screw Press

5

Hiller Centrifuge

59

BDP 3-Belt Vertical Press

57

PW Tech Volute Press Centrisys Centrifuge

67

Schwing Screw Press

Average Trial Devices 43

Primary Solids Feed

Company Device Primary Feed %TS

KWRP 2014 Belt Press 4.4

Alfa Laval Winkle Press

6.0

Alfa Laval Centrifuge

6.0

Andritz Centrifuge

5.9

Fournier Rotary Press

6.1

Ishigaki Screw Press

5.7

Hiller Centrifuge

5.4

BDP 3-Belt Vertical Press

6.4

PW Tech Volute Press Centrisys Centrifuge

5.5

Schwing Screw Press

Average Trial Devices 5.9

Primary Solids Capture Rate

Company Device Primary Capture %

KWRP 2014 Belt Press N/A

Alfa Laval Winkle Press

99.0

Alfa Laval Centrifuge

97.2

Andritz Centrifuge

96.6

Fournier Rotary Press

97.1

Ishigaki Screw Press

96.2

Hiller Centrifuge

98.6

BDP 3-Belt Vertical Press

99.5

PW Tech Volute Press Centrisys Centrifuge

94.8

Schwing Screw Press

Average Trial Devices 97.4

Primary Filtrate/Centrate P-sol

Company Device P-sol mg/l

KWRP 2014 Belt Press N/A

Alfa Laval Winkle Press

12.6

Alfa Laval Centrifuge

11.3

Andritz Centrifuge

20.5

Fournier Rotary Press

18.8

Ishigaki Screw Press

13.9

Hiller Centrifuge

9.5

BDP 3-Belt Vertical Press

2.6

PW Tech Volute Press Centrisys Centrifuge

21.7

Schwing Screw Press

Average Trial Devices 13.9

Secondary Feed Flow Rate

Company Device Secondary Flow gpm

KWRP- Trial Belt Press 100

Alfa Laval Winkle Press

34

Alfa Laval Centrifuge

36

Andritz Centrifuge

45

Fournier Rotary Press

9

Ishigaki Screw Press

6

Hiller Centrifuge

38

BDP 3-Belt Vertical Press

67

PW Tech Volute Press

3

Centrisys Centrifuge

42

Schwing Screw Press

4

Average Trial Devices 28

Secondary Solids Feed

Company Device Secondary Feed %TS

KWRP 2014 Belt Press 4.3

Alfa Laval Winkle Press

3.5

Alfa Laval Centrifuge

3.5

Andritz Centrifuge

3.6

Fournier Rotary Press

3.7

Ishigaki Screw Press

3.8

Hiller Centrifuge

3.9

BDP 3-Belt Vertical Press

4.0

PW Tech Volute Press

3.8

Centrisys Centrifuge

3.7

Schwing Screw Press

4.1

Average Trial Devices 3.7

Secondary Solids Capture Rate

Company Device Secondary Capture %

KWRP 2014 Belt Press N/A

Alfa Laval Winkle Press

96.5

Alfa Laval Centrifuge

98.4

Andritz Centrifuge

96.0

Fournier Rotary Press

96.3

Ishigaki Screw Press

84.1

Hiller Centrifuge

97.7

BDP 3-Belt Vertical Press

99.1

PW Tech Volute Press

97.7

Centrisys Centrifuge

96.4

Schwing Screw Press

92.2

Average Trial Devices 95.4

Secondary Filtrate/Centrate P-sol

Company Device P-sol mg/l

KWRP 2014 Belt Press N/A

Alfa Laval Winkle Press

6.1

Alfa Laval Centrifuge

9.0

Andritz Centrifuge

29.8

Fournier Rotary Press

23.1

Ishigaki Screw Press

18.9

Hiller Centrifuge

11.6

BDP 3-Belt Vertical Press

11.1

PW Tech Volute Press

17.7

Centrisys Centrifuge

14.7

Schwing Screw Press

15.1

Average Trial Devices 15.9

Primary Solids Results

Company Device Primary %TS

KWRP 2014 Belt Press 26.7

Alfa Laval Winkle Press

36.8

Alfa Laval Centrifuge

32.0

Andritz Centrifuge

35.9

Fournier Rotary Press

38.6

Ishigaki Screw Press

36.0

Hiller Centrifuge

35.1

BDP 3-Belt Vertical Press

34.0

PW Tech Volute Press Centrisys Centrifuge

31.3

Schwing Screw Press

Average Trial Devices 35.0

Secondary Solids Results

Company Device Secondary %TS

KWRP 2014 Belt Press 15.5

Alfa Laval Winkle Press

19.5

Alfa Laval Centrifuge

19.5

Andritz Centrifuge

18.9

Fournier Rotary Press

14.9

Ishigaki Screw Press

20.4

Hiller Centrifuge

18.1

BDP 3-Belt Vertical Press

17.5

PW Tech Volute Press

17.7

Centrisys Centrifuge

19.3

Schwing Screw Press

21.1

Average Trial Devices 18.7

27%-73% Pri/Sec Solids Ratio

Company Device Overall %TS

KWRP 2014 Belt Press 18.6

Alfa Laval Winkle Press

24.2

Alfa Laval Centrifuge

23.2

Andritz Centrifuge

23.5

Fournier Rotary Press

21.3

Ishigaki Screw Press

24.6

Hiller Centrifuge

22.7

BDP 3-Belt Vertical Press

22.0

PW Tech Volute Press Centrisys Centrifuge

22.6

Schwing Screw Press

Average Trial Devices 23.0

Hauling/Loading/Landfilling Potential Annual Savings

Company Device Annual Savings

KWRP 2014 Belt Press

Alfa Laval Winkle Press

$487,329

Alfa Laval Centrifuge

$391,870

Andritz Centrifuge

$418,596

Fournier Rotary Press

$146,017

Ishigaki Screw Press

$533,711

Hiller Centrifuge

$330,486

BDP 3-Belt Vertical Press

$245,135

PW Tech Volute Press Centrisys Centrifuge

$321,389

Schwing Screw Press

Average Trial Devices $359,316

Polymer Considerations

• KWRP Polymer Usage & Costs
• 2014 KWRP Usage 73 gpd
• 2014 Primary $ 91,823
• 2014 Secondary $171,230
• Trial Polymer Usages
• Hard to Calculate
• Different Polymers Trialed
• Variations Can be Costly
• Usage Verification

Primary Polymer Efficiency

Company Device Lbs/ Dry Ton

KWRP 2014 Belt Press 18.2

Alfa Laval Winkle Press

15.8

Alfa Laval Centrifuge

13.5

Andritz Centrifuge

14.5

Fournier Rotary Press

21.5

Ishigaki Screw Press

25.7

Hiller Centrifuge

12.6

BDP 3-Belt Vertical Press

11.2

PW Tech Volute Press Centrisys Centrifuge

21.1

Schwing Screw Press

Average Trial Devices 17.0

Secondary Polymer Efficiency

Company Device Lbs/ Dry Ton

KWRP 2014 Belt Press 12.1

Alfa Laval Winkle Press

17.6

Alfa Laval Centrifuge

30.5

Andritz Centrifuge

37.3

Fournier Rotary Press

22.3

Ishigaki Screw Press

36.0

Hiller Centrifuge

58.7

BDP 3-Belt Vertical Press

12.1

PW Tech Volute Press

42.8

Centrisys Centrifuge

54.2

Schwing Screw Press

18.1

Average Trial Devices 32.9

Additional Considerations

• Verify Polymer Usage
• Verify Energy Usage
• Maintenance Costs
• Annual/Overhaul Costs
• Maintenance Parts/Downtime
• Ease of Maintenance
• Operations Time Requirements

Next Steps

• Create Evaluation Matrix
• Select Top 3 Technologies
• Obtain Equipment Sizing for Basis of Design
• Throughput & Redundancy
• Obtain Installation Cost Estimates
• Building, Structural, Electrical, Process Piping,

Conveyance, Controls (Automation), Etc.

• Calculate Return on Investment (ROI) and

Net Present Value of Alternatives

Questions ???