Biosolids Facility Update - Water and Sewerage Facility Update ... Biosolids Dryer Facility Equiment...

Biosolids Facility Update In the Final Stretch

August 12, 2015

City of Detroit, Water and Sewerage Department

| City of Detroit Water & Sewerage Department

Biosolids Dryer Facility

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Biosolids Management Needs

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• Historical solids management challenges resulted in

permit violations

• ACO requires peak biosolids capacity of 850 DTPD

• New MACT air quality rules – effective March 2016

• Incineration Complex I obsolete

• High O&M costs to manage biosolids

• Ongoing capital costs for

equipment rehabilitation,

replacement and upgrade


Existing Solids Processes at the WWTP

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Primary Sludge Secondary Sludge

Gravity Thickening Gravity Thickening

Thickened Sludge

Storage

Dewatering Centrifuges/BFPs

Incineration Ash Disposal

Off-Load Facility

Lime Stabilization

Land Application

Landfill

MHI Complex I

MHI Complex II


Background Biosolids Decision

Based on March 2012 Biosolids Symposium: • Retire C-I Incinerators

• Construct Biosolids Dryer Facility (PC-792)

• Bring C-II Incinerators into Air Quality Compliance

with 2016 regulations (PC-791)

• Biosolids peaks managed with

land application, land-filling

and C-II Incinerators

• Competitive Procurement • 3 Proposers

• 9 Proposals

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Background Biosolids Decision

• NEFCO Alternate 2 Selected for PC-792

• Lowest costs

• Spare dryer train

• Provides dewatering

• Does not significantly constrain plant operations

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Primary Sludge Secondary Sludge

Gravity Thickening Gravity Thickening

Thickened Sludge

Storage

Dewatering Centrifuges/BFPs

Incineration Ash Disposal

Off-Load Facility

Lime Stabilization

Land Application

Landfill

MHI Complex I

MHI Complex II

Existing Solids Processes at the WWTP

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New Biosolids Drying Facility

Beneficial Reuse of Dried

Fertilizer Product


PC-792 Contract Facility

• 20 year operation and maintenance contract

• 316 DTPD Firm Capacity

• Contract approved by Board March 27, 2013

• Substantial Completion required by March 29, 2016

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Biosolids Drying Facility

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4 Dryer Trains • 110 dtpd each

• 440 dtpd (peak)

8 Dewatering

Centrifuges • 66 dtpd each

• Two centrifuges

per dryer train

Centrifuges

Dryer


Drying Process

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Liquid Sludge Dewatering and Mixing

Weigh

Belt

Mixer

Cake

Bin

Centrifuges

(2 Per Dryer – Total 8) Lobe

Pumps

Total 8

To

Dryer

Sludge Grinders

(2 Per Dryer – Total 8)

WWTP

Sludge Feed

Pumps

3 & 4

12” Line

Across

Jefferson

Ave

16” Line

Across

Jefferson

Ave

Polymer

WWTP

WWTP

Blended

Sludge

Tanks

3 & 4


http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCPLog4_rjccCFUo0Pgod1CsBDg&url=http://www.enggcyclopedia.com/2011/01/valve-pid-symbols/&ei=X9q_VbK9M8ro-AHU14Rw&bvm=bv.99261572,d.cWw&psig=AFQjCNHFr55lKYj_TAvjk7zqubLZ6UpFig&ust=1438722959168320








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Drying Process

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Air Handling &

Emission Controls

Solids System

Components


Triple Pass 110 DTPD Dryer

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http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCPnJ6OOhl8cCFQw9PgodLdMGjw&url=http://rotarydryer.org/triple-pass-drying&ei=psvEVfneMYz6-AGtppv4CA&bvm=bv.99804247,d.cWw&psig=AFQjCNGynye5VZrwzBgaeUC9XleISgYUAw&ust=1439046869148008


Biosolids Dryer Facility Equiment

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Cake Bin Tray Scrubber

Regenerative

Thermal Oxidizer

Recycle Bin

Biosolids Dryer

Dryer Furnace


Biosolids Dryer Facility Equipment

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Product Silo Cyclone Separator

Odor Scrubbers

Hypochlorite and Caustic

Tanks for Odor Control

Dry Polymer

Silo Polymer Mix

Tanks


Dryer Facility Benefits

Retire 1940’s era Complex I incinerators to improve reliability of operations and avoid upgrade and rehabilitation costs Reduced reliance on aging Complex II incinerators and landfills • Increased reliability • Reduced energy

(natural gas) consumption • Reduced emissions • Extended equipment life

– reduced costs

Firm capacity of 316 dry tons per day - 70% of average daily biosolids

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Dewatering capability supplements WWTP • Improved reliability

• Addresses prior challenges in meeting permit

Improves ability to manage peak biosolids • Reduced WWTP off-loading

• Reduces or eliminates need

to store peak biosolids

• Sufficient capacity for all

peak loads when used with

limited incineration and

off-loading to land application

or land fill

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Environmentally beneficial use for biosolids

Dryer product lower in odors and safe - pathogens

killed

Preserve landfill capacity and reduces trucking

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http://www.mwra.state.ma.us/03sewer/html/baystate.htm



Lower impact on community • Odor control scrubbers and building sealed to contain odors.

• Only dried biosolids with little odor will be trucked

• Noise control – quieter than Complex I fans being retired

• Fewer trucks – reduces volume to be trucked by 75%

• Located farther from residential areas

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Air Emissions Are Lower For Dryers than for Incinerators Emissions Limits Established in MDEQ Permit to Install

Pollutant

Complex II Incinerators

Emissions Limits

(8 Incinerators

360 DTPD Firm)


Emissions Limits

(4 Dryers

316 DTPD Firm)

Percent

Reduction

Particulate Matter 46.6 tpy 20.0 tpy 57.1%

Particulate Matter - PM2.5 58.3 tpy 19.2 tpy 67.1%

Particulate Matter - PM10 59.6 tpy 26.9 tpy 54.9%

Carbon monoxide 1,522.4 tpy 65.7 tpy 95.7%

Volatile Organic Compounds

(Per incinerator or dryer) 3.20 lb./hr. 1.68 lb./hr. 47.5%

Nitrogen oxides 663.4 tpy 71.5 tpy 89.2%

Carbon Dioxide Equiv. (CO2e) 237,275 tpy 90,361 tpy 61.9%

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PC-792 Uses Best Available Control Technology

Air Emissions


Summary of Contract: 20 Year O&M Period

Contractor Responsibilities • All required operation & maintenance services –

dewatering, drying, beneficial reuse, hauling, disposal

• All repairs, maintenance and equipment replacements

needed to maintain operation – No more DWSD capital

requirements for 20 years

• Continuous processing at any flow

rates required by DWSD (within

contractual range)

• Beneficial reuse of biosolids and all

residuals disposal costs

• Performance guarantee

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Contractor Responsibilities • Provide chemicals, hauling, and beneficial reuse

• Pay for utility usage above guaranteed amounts

• Coordinate operations with DWSD

• Provide DWSD and MDEQ with required records

• Maintain O&M records in CMMS

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Contractor Responsibilities • Provide property insurance

• After 20 years turn over equipment in “as-new” condition

except for reasonable and normal wear and tear.

• Train DWSD to take over at end of 20 years

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Summary of Contract

DWSD Responsibilities • Provide utilities within usage guarantees.

• Provide liquid sludge within specified range

Coordinate sludge operations with Contractor

Monthly payments

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Contract Cost Status

*Subject to escalation at Detroit CPI rate: 0.06% to date since March 2013

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Item Contract Price

Construction Fixed Cost

(94.1% Complete)

$132,000,000

Authorized Changes $2,724,143

Unencumbered Allowances $8,285,444

Monthly O&M Cost

(Includes 73,000 Annual Dry Tons)

$1,079,000*

Added Cost/DT

(Above 73,000 to 115,340 Annual DT)

$76.60*

Added Cost/DT

(Above 115,340 to 140,000 Annual DT)

$88.93*


Current O&M Costs v. Reductions Presented In March 2013 First Year O&M Costs ($ x 1000)

Prior Existing

(March 2013)

Dryers Estimate

(March 2013)

Current Existing

(No Drying)

Aug. 2015

Incineration DTPY 111,000 28,439 94,000

Landfilling DTPY 39,000 17,412 62,200

Land Application DTPY 13,000 5,804 8,800

Drying DTPY 111,345 -

Solids Manpower (Positions) 298 127 143

Dewater, Incinerate, Offload

Labor $25,401 $10,716 $11,499

Natural Gas $10,595 $2,715 $7,421

Electricity $2,574 $689 $2,528

Dewatering Polymer $5,640 $1,787 $5,240

Lime $1,646 $735 $1,987

Land Filling & Land Application $10,086 $4,337 $11,848

Parts, Supplies, Services, Other $12,411 $6,985 $13,355

Subtotal WWTP $68,353 $27,964 $53,879

WWTP Unit Cost per Dry Ton $419.35 $541.35 $326.54


O&M Payments $15,885

Natural Gas $5,475

Electricity $2,165

Subtotal Dryer Facility $23,525

BDF Unit Cost Per Dry Ton $211.28

Total Cost $68,353 $51,488 $53,879

Savings Base $16,865

Overall Unit Cost Per Dry Ton $419.35 $315.88 $326.54

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O&M Cost Reductions Now Expected to Improve on Prior Plans First Year O&M Costs ($ x 1000)

Prior Existing

(March 2013)

Dryers Estimate

(March 2013)

Current Existing

(No Drying)

Aug. 2015

Firm Capacity

Drying

Aug. 2015

Incineration DTPY 111,000 28,439 94,000 45,160

Landfilling DTPY 39,000 17,412 62,200 4,000

Land Application DTPY 13,000 5,804 8,800 500

Drying DTPY 111,345 - 115,340

Solids Manpower (Positions) 298 127 143 91


Labor $25,401 $10,716 $11,499 $7,318

Natural Gas $10,595 $2,715 $7,421 $3,565

Electricity $2,574 $689 $2,528 $1,115

Dewatering Polymer $5,640 $1,787 $5,240 $1,577

Lime $1,646 $735 $1,987 $162

Land Filling & Land Application $10,086 $4,337 $11,848 $887

Parts, Supplies, Services, Other $12,411 $6,985 $13,355 $8,127

Subtotal WWTP $68,353 $27,964 $53,879 $22,752

WWTP Unit Cost per Dry Ton $419.35 $541.35 $326.54 $458.15


O&M Payments $15,885 $16,202

Natural Gas $5,475 $4,310

Electricity $2,165 $1,962

Subtotal Dryer Facility $23,525 $22,474

BDF Unit Cost Per Dry Ton $211.28 $194.85

Total Cost $68,353 $51,488 $53,879 $45,226

Savings Base $16,865 Base $8,654

Overall Unit Cost Per Dry Ton $419.35 $315.88 $326.54 $274.09

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Analysis of Potential Operating Strategies is In Progress First Year O&M Costs ($ x 1000)

Prior

Existing

(March

2013)

Dryers

Estimate

(March

2013)

Current

Existing

(No Drying)

Aug. 2015

Maximize

Drying

Aug. 2015

Firm

Capacity

Drying

Aug. 2015

Minimize

Dryers &

Maximize

Incineration

Aug. 2015

Minimize

Dryers &

Maximize

Land Appl.

Aug. 2015

Minimize

Dryers &

Maximize

Landfilling

Aug. 2015

Incineration DTPY 111,000 28,439 94,000 40,000 45,160 87,500 6,000 6,000

Landfilling DTPY 39,000 17,412 62,200 4,000 4,000 4,000 28,700 86,000

Land Application DTPY 13,000 5,804 8,800 500 500 500 57,300 -

Drying DTPY 111,345 - 120,500 115,340 73,000 73,000 73,000

Solids Manpower (Positions) 298 127 143 91 91 91 91 91


Labor $25,401 $10,716 $11,499 $7,318 $7,318 $7,318 $7,318 $7,318

Natural Gas $10,595 $2,715 $7,421 $3,158 $3,565 $6,908 $474 $474

Electricity $2,574 $689 $2,528 $990 $1,115 $2,147 $435 $435

Dewatering Polymer $5,640 $1,787 $5,240 $1,413 $1,577 $2,922 $2,922 $2,922

Lime $1,646 $735 $1,987 $162 $162 $162 $4,637 $2,783

Land Filling & Land Application $10,086 $4,337 $11,848 $871 $887 $1,022 $11,893 $14,713

Parts, Supplies, Services, Other $12,411 $6,985 $13,355 $7,767 $8,127 $8,127 $7,478 $7,478

Subtotal WWTP $68,353 $27,964 $53,879 $21,679 $22,752 $28,605 $35,157 $36,122

WWTP Unit Cost per Dry Ton $419.35 $541.35 $326.54 $487.16 $458.15 $310.92 $382.14 $392.63


O&M Payments $15,885 $16,661 $16,202 $12,956 $12,956 $12,956

Natural Gas $5,475 $4,503 $4,310 $2,728 $2,728 $2,728

Electricity $2,165 $2,050 $1,962 $1,242 $1,242 $1,242

Subtotal Dryer Facility $23,525 $23,214 $22,474 $16,926 $16,926 $16,926

BDF Unit Cost Per Dry Ton $211.28 $192.64 $194.85 $231.86 $231.86 $231.86

Total Cost $68,353 $51,488 $53,879 $44,892 $45,226 $45,531 $52,083 $53,048

Savings From Current Base $16,865 Base $8,987 $8,654 $8,348 $1,796 $831

Overall Unit Cost Per Dry Ton $419.35 $315.88 $326.54 $272.07 $274.09 $275.94 $315.65 $321.50

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Biosolids Dryer Facility Capital Funding

PC-792 avoids capital cost for: • Rehabilitation of remaining Complex I incinerators under

PC-774 ($6.5M)

• Complex I air quality MACT upgrades ($26M)

• Future periodic rehabilitation/upgrades of Complex I

• Centrifuge replacement project (deferred) ($25M)

• Dewatered biosolids storage

facility ($12.2M)

• Reduced periodic rehabilitation

or replacement of C-II &

dewatering equipment

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Biosolids Dryer Facility Capital Funding

PC-792 Debt Service • Segment 1 SRF Loan for $81M

• Debt service ~$5.2M/yr. for 20 years at 2.5%

• Bond funding for balance

• Debt service ~$4.7M/yr. for 30 years at 5.5%

• Segment 2 SRF loan being

discussed with MDEQ

• Replace bond funding for ~$21M

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Construction Status

• Equipment and systems needed for operation are installed

and vendor checked

• Lighting, site work and finishes being completed

• Corrections as required during shake-down

• Punch list, touch-up and final documentation

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Start Up Status

First product on July 30, 2015

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Current Start-up Schedule

Over Six Months Ahead of Schedule (Testing and Shake-down Continue)

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Current Plan

Contract

Requirement

Control System Acceptance Test and Screens Being finalized

Start-up and Issue Resolution Ongoing

Field Testing to Confirm Equipment

Performance

Aug. 5 to 13

Demonstration Testing of Trains 1 to 3 Aug. 14 to

Sept. 2

Substantial Completion of Trains 1-3 Sept. 2, 2015 Mar. 14, 2016

Demonstration Testing of Train 4 Sept. 2 to 12

Substantial Completion of Trains 4 Sept. 14, 2015 Mar. 29, 2016


Operation

Marketing – NEFCO developing market • Dried product for use as farm fertilizer • Product name will be “MichiGreen” Approved by MDEQ for use in Michigan Also pursuing approval in Ohio, Indiana, Ontario and other states

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Operation

DWSD role: Monitoring of NEFCO performance to contract • DWSD coordinator • Capacity available • Invoices • Maintenance • Permit compliance

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Changes to WWTP

Shutdown of Complex I incinerators at Dryer Substantial Completion Dewatering and disposal operating scenarios are being evaluated Re-assignment of staff • Overall reduction of about 52 positions currently

anticipated • MDEQ approval of staffing adjustments required • Performance based placement of incinerator operators

(title plant tech) • Evaluation of staffing needs to effectively operate and

maintain Complex II as dryers come on-line • Interim use of staff to decommission Complex I • DWSD liaison appointed to coordinate with the Contractor

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Dryer Facility Tour

Date and Time to be Set At Board’s Convenience

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Questions?

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Biosolids Facility Update - Water and Sewerage Facility Update ... Biosolids Dryer Facility Equiment...

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