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Innovative Tools for Energy Savings
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Transcript of Innovative Tools for Energy Savings
Innovative Tools forEnergy Savings
T. Allbaugh, P.E., S. J. Kang, Ph.D., P.E. , K. Williams, P.E., W. Kramer, P.E., G. Jones, P.E.,
K. P. Olmstead, Ph.D., P.E., L. Thomas, M. Jessee, S. Westover, P.E.
in Municipal WWTPs
Typical Energy Usage in U.S.Wastewater Treatment Plants
• Electricity at Average Plant: – 1500 kWh/Million Gallons (MG) treated for
secondary treatment–Advanced Treatment Plant: 2000 to 3000
kWh/MG
• Other Energy Use– External supply of Carbon; methanol; Micro-C–Natural gas
Reasonable Expectations
Typical Power Use Distribution
Case History: Energy Optimization Study at 46 MGD Tertiary Treatment Plant
• Energy Optimization Team: Operation, safety, maintenance, administration
• Process optimization• Utility bill and energy use analysis• Develop alternatives and assess feasibility • Life-cycle costing• Priority ranking by team votes• Funding decisions
YCUA WWTP
• Recently expanded for 46 MGD average design flow
• Tertiary treatment (biological P removal, filters, UV disinfection)
• Belt presses and fluid bed incinerator
• All flow is pumped to the site
Base Line Energy Costs
• $2.7 M at WWTP/year• $0.4 M at pump stations/year• Average 9 cents/KWH
• Team Goal : Save 5% or more
Power Consumption in KW Before
1538
798
750
189180107 146 boiler
aeration
solids
lighting
incineratordrywell vent
Misc.
Average Power Use Before the Project3708 KW
1418701
370
91 015
65 0
KW after
Boiler(7.7%)AerationSolidsLightingIncin RmDrywell VentMisc
Average Power Use After Implementation2655 KW
Aeration Blowers
• A centrifugal blower system supplies air to aeration, filter backwash, and clear well
• At current loadings, the power requirement could be reduced from 1,070 to 940 hp for one blower modification– COST: $76,000– SAVINGS: $68,000 per year
• Payback in 14 months
Demand Anticipation
• Demand Charge = Single highest 30-minute integrated reading of the demand meter during on-peak hours
• In place for 12 months• $13.75 per kilowatt • Target decrease 300KW ($49,500/year)• Defined protocol for operator response
Demand HistoryYCUA WWTP - Maximum Electrical Demands
0
500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
4,500
5,000
Mar-08
Apr-08
May-08
Jun-08Jul-0
8
Aug-08
Sep-08
Oct-08
Nov-08
Dec-08
Jan-09
Feb-09
Months
Max
imum
Dem
and
(kW
)
HV Controls in Solids and PSST Building
• Original HV equipment controls have been disconnected; system is presently being run manually
• Upgrade controls to Direct Digital Controls (DDC) with METASIS system– COST: $240,000– SAVINGS: $140,000 per year
• Payback in < two years
Intermittent Ventilation for Process Areas
• Dewatering area, cake trucking area, and blower building not always occupied; continuous ventilation unnecessary
• Install local controls, METASYS programming, and H2S/O2 alarm systems to only turn on HVAC when areas are occupied– COST: $40,000– SAVINGS: $43,000 per year
• Payback < one year
Incinerator Room Heat Recovery
• Space above fluid bed always HOT• Boiler combustion air un-tempered in winter• Adjacent dewatering area requires 12 air
changes per hour• Project provides additional heated ventilation
to dewatering, and pre-heated combustion air for boilers
Building Lighting Philosophy
• Original design incorporated highly efficient lights on 100% of the time in galleries and process areas
• Changes incorporate slightly less efficient lights but provide immediate illumination
Lighting System Retrofit
• Fixtures are original, 1970s T12 fluorescent and metal halide High-Intensity Discharge (HID) lights
• Replace all T12 with T8 lamps– Non-HID fluorescent tubes with electronic ballasts– COST: $265,000– SAVINGS: $110,000 per year
• Payback in < three years
Intermittent Ventilation of Drywells at Four Pump Stations
• Crews enter once per week for two hours• Engineering standards call for:– Six air changes per hour , or– Thirty air changes for ten minutes
• Upgrade controls with SCADA– COST: $40,000– SAVINGS: $21,000 per year
• Payback in two years
Adopted Plan
• Optimization Study Cost: $59,000• SRF Project Plan for $1.0M approved with 40%
forgiveness of the loan principal, July 2009• Design and construction underway, 2010-11• Annual Cost Savings: $450,000, or 11%
savings
Summary of Selected ProjectsDescription Annual
SavingsEst. Capital
CostPayback Current
UsageExpected Usage % Reduction
Aeration Blower
$68,000 $76,000 14 months 800 kW 700 kW 12.1
Demand Anticipation
$50,000 $160,000 3 years, 3 months
N/A N/A N/A
Intermittent Process Area Ventilation
$43,000 $40,000 11 months 47 kW 14 kW 70
HV Control Upgrades
$140,000 240,000 1 year, 9 months
750 kW 370 kW 51
Incinerator Room Heat Recovery
$19,000 $65,000 3.5 years - - 5
Lighting System
$110,000 $265,000 2 years, 6 months
189 kW 91 kW 52
Intermittent Drywell Ventilation
$21,000 $40,000 2 years 107 kW 15 kW 86
TOTAL $451,000 $886,000 --- 1891 kW 1191 kW 37
Questions?