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