A Case Study for Retrofitting Anaerobic Digestion ......A Case Study for Retrofitting Anaerobic...
Transcript of A Case Study for Retrofitting Anaerobic Digestion ......A Case Study for Retrofitting Anaerobic...
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A Case Study for Retrofitting Anaerobic Digestion Facilities at the City of Waukesha
Presented By Travis Anderson and Jeff Harenda
October 12, 2016
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Outline
• Project drivers at digestion facilities
• Improvements meet current and future needs
• Review of project sequence and construction
• System flexibility allows many operating strategies
• Initial data shows excellent performance
• Lessons learned provide value for WWTPs
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Review of Anaerobic Digestion
Project Drivers
Inefficient Mixing Equipment
Aging Heating System
Grit Accumulation
Digester Foaming
Controls and Instrumentation
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Selected Digestion Alternative Meets
City’s Current and Future Needs
Efficient Mixing Design
Foam Detection and Control System
Minimal Maintenance
Egg-Shaped Digester
Increased Gas Production
Maximized Use of Existing
Infrastructure
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Waukesha CWP Digestion Upgrades
New ESD (Dig. 1) •Mixing / Recirc pumps
•Drain pump
•Heat exchanger
•Foam control
Centrate Storage •Centrate Return
pumps
Gas Handling •Sediment traps
•Foam separator
•SS gas piping
•Relief valve
•Flare
Dig. 2 •Steel cover to remain
•Variable depth (T-valve)
•Pump mix
•Spiral heat exchanger
•Foam control Dig. 3 •Dual membrane cover
•Pump mix
•Spiral heat exchanger
•Foam control
Hot Water Boilers •100% and 50% units
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Egg-Shaped Digester Advantages
May Result in Best Alternative
• Facilities planning should include evaluation of
alternatives to traditional “pancake” digesters:
Higher mixing efficiency
Greater gas production & foam control
Smaller footprint
Digester No. 4 Egg-Shaped Digester
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Foaming Concerns Require Multiple
Solutions
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Grit Accumulation Impacts Plant
Operations and Budget
Egg-Shaped Digester
Digester No. 3
Grit Accumulation
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Space Constraints Required Unique
Approach
Fox River
Main Site Roadway
Major Utilities
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Egg-Shaped Digester Construction is
First on Critical Path
• 1.1 million gallons
• 82 ft tall, 66 ft wide
• Spiral staircase from
existing control building
• 4.5 ft thick foundation
• Pump mix with heat
exchanger
• Internal draft tube
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Existing Digester No. 4 Demolition
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Egg-Shaped Digester Subgrade
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Egg-Shaped Digester Foundation
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Concrete Ring Wall
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Steel Vessel
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Dome Lift
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Painting, Insulation, and Stairs
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ESD Startup
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Retrofit Digester No. 2
New Gas Piping Insulation for Steel
Cover
New Mixing, Heating and Foam
Control System
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Retrofit Digester No. 3
Inner Membrane
Outer Membrane
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System Flexibility Allows Many
Operating Strategies
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Operation in Series Becomes
Normal Sequence
Egg-Shaped Digester
Digester No. 4 Digester No. 3
Digester No. 1 Digester No. 2
Centrate Storage Tank
Digester No. 2 Digester No. 3
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Schematics
TWAS Primary
Dig No. 1
• Reconfigure digesters for series
operation (existing is parallel)
• TWAS and Primary Sludge
pumped to Digester No. 1
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Schematics
TWAS Primary
Dig No. 1
Dig No. 2
• Flow out of Digester No. 1 by
displacement to Digester No. 2
(steel cover)
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Schematics
TWAS Primary
Dig No. 1
Dig No. 2 Dig No. 3
• Flow out of Digester No. 2
through a telescoping valve to
Digester No. 3 by gravity.
• Telescoping valve allows lowering
of Digester No. 2 level for foam
control.
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Telescoping Valve
Digester No. 2 Sludge Well
Telescoping Valve Determines Digester Level
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Schematic
TWAS Primary
Dig No. 1
Dig No. 2 Dig No. 3
Centrifuge
• Digested sludge pumped to the
centrifuge through one of two
pumps.
See Sheet 00-G6.03
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Initial Data Shows Excellent
Performance
0
0.5
1
1.5
2
2.5
1 2 3 4 5 6 7 8 9 10 11 12
Solids Concentration
(%)
Sample
Digester No. 1 Mixing Test
Digester No. 2 Mixing Test
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Lessons Learned Provide Value for
Future Projects
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Coordination with CB&I
• Design requires close coordination with CB&I
Multiple design meetings
Coordination of scope (equipment, controls)
Discuss bidding strategy early (sole source concerns)
• Visit to project with CB&I digester
CB&I Egg-Shaped Digester (Grandville, MI)
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Conclusion
• Improvements meet current and future needs
• System flexibility allows many operating strategies
• Initial data shows excellent performance
• Lessons learned provide value for WWTPs
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Acknowledgements
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Silo-Shaped Digesters
• Tall concrete cylinder
• Advantages
Minimize footprint
Efficient mixing
Not proprietary
• Disadvantages
More difficult to construct
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Egg-Shaped Digesters
• Welded steel vessel
• Advantages
Better foam control
Minimize footprint
Efficient mixing
• Disadvantages
Only one supplier
Chicago Bridge & Iron Egg-Shaped Digester
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Waukesha WWTP Selected Alternative
• Advantages of the selected alternative
Makes maximum use of existing digestion infrastructure.
Relatively low cost with only one new digester
Relatively low maintenance cost with only two digesters
requiring routine maintenance (excluding egg-shaped
digester)
Relatively low energy cost for mixing (one egg-shaped and
one conventional digester)
Improved foam management
Can be configured for co-digestion of high strength wastes
in the future – gas production
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Example - Waukesha WWTP
• Digestion improvement alternatives
One New Egg-Shaped
Digester
Refurbish Existing
Digesters
One new conventional
digester
Two new conventional
digesters
Two new egg-shaped
digesters
Two silo-shaped
digesters
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Review of Project Sequence and
Construction
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Retrofitting Existing Infrastructure
Provides Cost Savings
Conversion of 1960s Digester to Centrate Storage
Digester No. 1 Converted to Gas Holder/Fill & Draw Digester
Digester No. 2 Maintained as Active Digester