Southerly Renewable Energy Facility

Ohio Water Environment Association

December 3, 2015 Biosolids Workshop

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

4

Southerly

Avg: 126 MGD

Easterly

Avg: 94 MGDWesterly

Avg: 26 MGD

NEORSD Wastewater Treatment Plants

Biosolids Force Main

Pumps 1.3 billion gallons

of wastewater solids to

Southerly each year for

processing and disposal

Largest WWTP in

Ohio. Can treat

up to 736 MGD.

Skim

min

gs

Bio

so

lids

Skim

min

gs

WWTPs, Service Areas, Major Sewers

E

W

S

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

Biosolids Handling Before REF

Gravity

Thickening

Zimpro

TCSTs

De-

wateringMHIs

Gravity

Belts

DPS

EAS

To Ash

Lagoons

NORTH

Sludge

Storage

Southerly Biosolids Handling

(before REF)

• Thermal Conditioning System (Zimpro) produced

Class A biosolids; 5 equipment trains

• 300 - 340 psig; 320 - 400 ºF; 140 - 280 gpm

• 4 Thermally Conditioned Sludge Thickeners

• 6 Humboldt 53 DTPD High Solids Centrifuges

~ 47% solids

• 4 Multiple Hearth Incinerators

3.6 DTPH permitted feed rate;

2.7 DTPH actual capacity

• 4 Waste Heat Boilers produce 425 psi HP steam,

primarily for Zimpro

EAS

Gravity

Thickening

Renewable

Energy

Facility

Gravity

Belts

DPSTo Ash Lagoons

Biosolids Handling After REF

NORTH

Sludge

Storage

Facilities Decommissioned After REF

NORTH

ZIMPRO

DEWATERING &

CONVEYANCE

MHIs

2

VCUs

2 VCUs

2 VCUs

SLUDGE STORAGE

TANKS

DIGESTER

TANKS

MAINT.

BLDG.

GRAVITY BELT

THICKENERS

THERMALLY

CONDITIONED SLUDGE

THICKENERS

HUB,

OFFICES

WASTE

HEAT

BOILERS

Also Decommissioned:

Skimmings-only FBI at

Easterly WWTP

Site of REF

Truck

Loading

IncinerationDewatering

Renewable Energy Facility Layout

Hub, OfficesNORTH

Turbine

Generator

Bldg.

Substation,

MCC

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

• Average biosolids production was projected to increase

by about 40% because volatile solids would no longer be

thermally destroyed. Actual increase is probably closer to

20%.

• %TVS with Zimpro ranged between 41 and 69 with an

average of 58.

• From Jan. 1, 2015 through Sept. 30, 2015, %TVS (without

Zimpro) ranged between 52.6% and 80.1% with an average

of 65.5%.

Biosolids Production After Zimpro

Decommissioning

Biosolids Incinerated Per Year (DT)

The annual avg.

for 2014-2015 is

20% greater than

the annual avg.

for 2009-2013

Anticipated Characteristics of

Dewatered Biosolids Pumped to FBIs

Parameter

Chemically

Conditioned

(Polymer)

Design Total Solids (%) 28

Total Solids Range (%) 26-35

Design Volatile Solids (% VS) 68

Volatile Solids Range (% VS) 54-72

Design Higher Heating Value (Btu/lb VS) 10,500

Higher Heating Value Range (Btu/lb VS) 9,500-12,000

68%

28%

2015 Monthly Averages - %TS & %TVS

BTU/lb VS during Stack Tests

10,243

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

Renewable Energy Facility

What’s inside?

The 50,600 SF multi-story REF Building houses the

following new systems:

• Three 100 DTPD Infilco Degremont FBIs; FBIs

process Southerly and Easterly WWTP biosolids

and skimmings from all 3 WWTPs

• Biosolids dewatering and conveyance: three Andritz

50 DTPD high solids centrifuges, one 32 CY

receiving bin and two Schwing 50 DTPD dual piston

pumps per FBI

• Steam produced by waste heat boilers in FBI trains

turn Elliot turbine generator to produce electricity

(2 - 3.5 MW)

Dewatering &

Conveyance

Skimmings

(1- 2 gpm typ.)

Skimmings

HMI Screen Capture for FBI Train

100°F

1075°F

1550°F

1200°F

Biosolids

Natural Gas

Waste

Heat

Boiler

Induced

Draft Fan

Fluidizing Air

Blower

Steam

Boiler

Feed

Water

Hot

Wind box

Sand Bed

425°F

350°F

300°F

125°F

Freeboard

Fluidized

Bed

Incinerator

200°F

700°F

635 psig

Incineration System Process Flow Diagram

Natural Gas

1375°F

1550°F

Incineration System Plan View (Typ. of 3)

FBI

WSCWHB SHX

PHX

STACK

IDF

Fluidized Air

BlowerFBI

PHX

Fluidized Bed

Incinerator

Roof Sprays

Natural Gas

Fluidizing Air

Biosolids,

Skimmings

Refractory Dome

Fluidized Bed Incinerator

20 Ports4 Ports

6 Ports

Windbox

Upper Freeboard

Lower Freeboard

Primary Heat Exchanger

Exhaust

Gas from

FBI

Heated

Fluidizing

Air to FBI

Windbox

Exhaust

Gas to

WHB

Fluidizing

Air from

FAB

Waste Heat Boiler

Exhaust

Duct on

Economizer

Waste Heat Boiler

Steam

Drum

Waste Heat Boiler

Economizer

Steam Drum

Secondary

Heat

Exchanger

Exhaust Gas

from WHB

Scrubbed

Gas to Stack

Scrubbed

Gas from IDFExhaust Gas

To WSC

Wet

Scrubber

Pre-Cooler

Wet

Scrubber

Exhaust

Gas From

SHX

Scrubbed

Gas To

IDF

Induced

Draft Fan

Scrubbed

Gas from

WSC

Scrubbed

Gas To

SHX

Stack

Pre-Cooler

Monthly Operating Data for 2015

Jan

Feb

Marc

h

April

May

June

July

Aug

Sept

Oct

Nov

Dec

To

tal

FBI 1 27 10 0 0 16 26 0 13 29 121

FBI 2 31 26 25 30 29 21 28 16 0 206

FBI 3 3 4 31 30 11 3 31 31 30 174

1 Operating 2 14 6 0 6 10 3 2 1 44

2 Operating 28 13 25 30 25 20 28 29 29 227

3 Operating 1 0 0 0 0 0 0 0 0 1

• Number of days with 0 FBIs in operation: 1 (2/11/15)

• Number of days with 1 FBI in Operation: 44 (16% of the time)

3,292.23 DT processed; 74.82 DT/day/FBI

• Number of days with 2 FBIs in operation: 227 (83% of the time)

27,990.53 DT processed; 61.53 DT/day/FBI

• Number of days with 3 FBIs in operation: 1

Dry Tons per Day During 2015 (Monthly Avg.)

January

Febru

ary

Marc

h

April

May

June

July

August

Septe

mber

Octo

ber

Novem

ber

Decem

ber

FBI 1 58.5 72.6 - - 75.6 80.1 - 56.6 53.9

FBI 2 54.1 57.7 53.9 65.5 57.3 73.7 55.6 47.0 -

FBI 3 102.2 74.6 71.5 70.1 55.6 81.9 66.6 60.7 61.2

Hours of Autogenous Operation Per Month

During 2015

Jan

Feb

Marc

h

April

May

June

July

Aug

Sept

Oct

Nov

Dec

To

tal

FBI 1 25 49 - - 78 127 - 9 77 365

FBI 2 70 84 147 218 105 126 38 31 - 819

FBI 3 21 21 233 385 100 0 117 124 205 1,206

• Best performance by a single FBI: 93 hours of autogenous operation for FBI 3

over a 96 hour period on April 9 - 12, 2015

~ 327.96 DT processed; 81.99 DT/day; %TVS = 62.24 to 65.83

• Best performance of two FBIs concurrently: 23 hours of autogenous operation

for FBIs 1 & 3 on September 27, 2015.

~ 40.55 DT to FBI 1; 67.17 DT to FBI 3; %TVS = 73.01

• No. of calendar days FBIs operated autogenously: 16

~ FBI 1 - 0 days; FBI 2 - 4 days; FBI 3 - 12 days

• No. of calendar days FBIs operated autogenously for at least 12 hrs/day: 86

~ FBI 1 - 11 days; FBI 2 - 26 days; FBI 3 - 49 days

0

100,000

200,000

300,000

400,000

500,000

600,000

2009 2010 2011 2012 2013 2014 2015

Total Gas Usage at SWWTC in MCF

200,000 MCF @ $5.30/MCF = $1.06 Million in annual savings

1.86 MCF

Comparison of MHI & FBI Emissions

Year Type of

Incineration

Tons of

Pollutants*

Dry Tons of

Biosolids

2010 MHI 153.7 34,381

2011 MHI 169.7 37,002

2012 MHI 171.2 34,168

2013 MHI 171.0 35,483

2014 MHI & FBI 65.20 40,844

2015

(Jan. – Sept.)

FBI 34.0 31,469

2015

(12 month est.)

FBI 45.3 41,959

* Summation of the following pollutants: CO, NOx, SO2, PMf, OC & Pb.

For the FBIs, its VOC instead of OC, and PMf plus PMc instead of PMf.

Pollutant

FBI 1

Emission

Factors

(9/23/14)

FBI 2

Emission

Factors

(9/3/14)

FBI

Emission

Factors

(10/7/14)

Avg.

Emission

Factors

for the 4

MHIs

CO 0.02 0.28 0.04 0.9640

NOx 1.54 0.97 1.02 6.5650

SO2 0.77 0.97 0.46 1.0018

PMf 0.06 0.08 0.06 0.5600

PMc 0.05 0.09 0.06 -

VOC 0.002 0.02 0.069 0.0248

Pb 0.00002 0.00001 0.000008 0.0036

Comparing FBI and MHI Emission

Factors (in lbs/DT)

PollutantTons for

FBI 1

Tons for

FBI 2

Tons for

FBI 3

Tons for

all FBIs

CO 0.08 1.68 0.23 1.99

NOx 6.08 5.82 5.90 17.8

SO2 3.04 5.82 2.66 11.52

PMf 0.24 0.48 0.35 1.07

PMc 0.20 0.54 0.35 1.09

VOC 0.01 0.12 0.40 0.53

Pb 0.00008 0.00006 0.00005 0.00019

Totals 9.65 14.46 9.89 34.00

DT of

Biosolids7,895 12,010 11,564 31,469

2015 Southerly FBI Emissions(Jan. 1 through Sept. 30)

• Original 2008 PTI contained the following requirements

which where deleted in 2014 and 2015 revisions

FBIs shall incinerate no more than 82,500 DT of biosolids annually

FBIs shall consume no more than 100,000 MCF of natural gas

annually

• All other requirements of the PTI are being met

Air Pollution Permit-to-Install

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

• The steam turbine generator is designed to work in

conjunction with two FBIs. If the third FBI is in operation,

excess steam will be directed to the auxiliary condenser

• The steam turbine generator can produce up to 3.5 MW, but

is currently producing 1.25 MW. At $0.066/KWH, the retail

cost of this power is $1,980 daily, and $722,700 annually

• The power produced by the steam turbine generator is fed

to Substation 21, the main substation for the REF

• The REF uses 6 to 8 MW on average

• The entire Southerly WWTC used 11.1 MW on average in

2015 (monthly averages in 2015 have ranged from 10.3 MW

to 11.8 MW).

Energy Production by the Steam

Turbine Generator

Steam System For Power Generation

Process Flow Diagram

STEAM

TURBINE

CO

ND

EN

SA

TE

TA

NK

DEAERATOR

BOILER

FEED

WATER

PUMPS

AUXILIARY

CONDENSATE

PUMPS

WHB

MAIN

CONDENSATE

PUMPS

MAIN

CONDENSER

AUXILIARY

CONDENSER

GEN

COOLING

WATER

PUMPS

HEAT

EXCHANGERS

CONDENSATE

SUPPLY

PUMPS

Additional

deaerator and

boiler feed

water pump

being installed

to improve

redundancy

MAKE UP

WATER

PUMPS

MAKE UP

WATER

STORAGE

TANK

Energy ProductionTurbine

Auxiliary

Condenser

Main

Condenser

Generator

Agenda

• Introduction to Southerly WWTC

• Biosolids Handling Before & After REF

• Changes in Biosolids

• FBI Performance

• Energy Production

• Future Improvements

Pollutant Units LimitFBI

1

FBI

2

FBI

3

PM mg/dscm 18 Y Y Y

HCl ppmvd 0.51 Y Y Y

CO ppmvd 64 Y Y Y

Dioxans/

furans TEQng/dscm 0.10 Y Y Y

Hg mg/dscm 0.037 N N Y

NOx ppmvd 150 Y Y Y

SO2 ppmvd 15 N N N

Cd mg/dscm 0.0016 Y Y Y

Pb mg/dscm 0.0074 Y Y Y

40 CFR Part 60 Subpart LLLLEmission Limits for FBIs

Compliance required by March 21, 2016!

Envirocare Mercury Scrubber(installed on top of existing wet scrubbers)

Sorbent Polymer

Composite

Sorbent Polymer Composite (W. L. Gore of Gore-Tex fame)

Guaranteed to meet FBI

emission limits for Cd, HCl,

Hg, Pb, PM and SOx with

the following conditions:

Cd concentration ≤ 4.7

mg/Kg in dry biosolids

Pb concentration ≤ 140

mg/Kg in dry biosolids

Sulfur concentration ≤

0.9% in dry biosolids

PM concentration ≤ 10

mg/dscm @ 7% dry O2 at

mercury scrubber inlet

Hg concentration ≤ 0.07

mg/dscm @ 7% dry O2 at

mercury scrubber inlet

So In Conclusion…

• Biosolids Production is up 20% due to Zimpro

decommissioning; a desired %TS easy to maintain;

%TVS affected by factors beyond our control

• Autogenous operation is not the norm, but gas

usage is down significantly, and Operations will

continue to improve FBI performance

• FBI emissions are 26% of MHI emissions; mercury

scrubber will further decrease emissions to meet

new SSI standards

• Steam turbine generator is routinely in operation

and producing electricity for REF; Operations will

continue to improve performance and increase MW

Questions?