2017 VWEA Education Seminar May 11 th, 2017

Transcription

1 Kenosha s Energy Optimized Resource Recovery System Joseph Hughes, P.E., Centrisys Corporation Dr. Ing Andreas Dünnebeil, PONDUS Verfahrenstechnik GmbH 2017 VWEA Education Seminar May 11 th, 2017

2 Thanks & Acknowledgement to: The Kenosha Water Utility (KWU) Staff, including: Ed St. Peter, Bob Carlson, Curt Czarnecki, Melissa Arnot, Katie Karow, Tom Tetzlaff & Matt Paul Centrisys Corp. Design/Builder CNP Technology Water and Biosolids Corp. Donohue & Associates Engineer of Record J. F. Ahern General Contractor Pieper Power Electrical Contractor CD Smith Civil Contractor

3 This is not a Suspense Thriller Conclusions Through innovative thinking KWU was able to: Become more energy efficient, reduce operating costs, and now produces a Class A Biosolids. PONDUS increases biogas production by 15% to 30% PONDUS substantially reduces WAS viscosity. PONDUS increased Biosolids dewatering capacity by 2% to 4% and/or decreases polymer usage. KWU Won American Council of Engineering Companies (ACEC) 2017 Grand Award for the Energy Optimized Resource Recovery Project

4 Presentation Outline Motivation Behind Project & Project Objectives KWU Wastewater Treatment Plant Overview Specific Project Challenges Technology Overview Start Up and Optimization Preliminary Results Lessons Learned Conclusion

5 Motivation Behind Project Aging WWTP infrastructure Last major upgrade/expansion was in year old anaerobic digesters in need of upgrade/repair Maximize the beneficial use of biogas in an effort to combat ever rising electricity & natural gas costs Approximately $300,000/yr in 2012 Reduce or eliminate landfill disposal fees Approximately $350,000/yr in 2012

6 Project Objectives Increase biogas production Generate electricity from biogas Generate thermal energy from biogas Achieve 90% dry Class A biosolids Win the $500,000 Focus on Energy Grant Maintain or decrease existing effluent quality, noise, odor, and particulate levels

7 WWTP Overview

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9 Project Specific Challenges

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11 Dewatering Centrifuge The three (3) old plate and frame presses cost approximately $510,000/yr for lime and $100,000/yr for ferric chloride. The single CS21 4HC dewatering centrifuge installed in 2009 eliminated the need for the chemicals, as well as an associated $140,000 in disposal costs, resulting in a total savings of approximately $750,000 per year.

12 Dewatered Solids Load Out Bay

13 Deteriorated Structural Concrete

14 Solids Dewatering Room Modifications

15 Solids Dewatering Room Modifications

16 Solids Dewatering Room Modifications

17 Solids Dewatering Room Modifications

18 Repaired Structural Concrete

19 Solids Dewatering Room Modifications

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21 Temporary Dewatering Building

22 Temporary Dewatering Building

23 Solids Handling Building Basement

24 Solids Handling Building Basement

25 Solids Handling Building Basement

26 Solids Handling Building Basement

27 Solids Handling Building Basement

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29 WAS Thickening Centrifuge A DAFT system was used to thicken the WAS from 1% TS to % TS before being pumped to the digesters until a single WAS thickening centrifuge was installed in 2011, replacing the four (4) DAFT bays.

30 WAS Thickening Centrifuge

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32 Biosolids Dryer and Odor Scrubber

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35 Technology Overview

36 Isometric Project Overview Heat Biogas Electricity Biosolids 60% - 70%

37 Primary Sludge Thickening Centrifuge THK 200 by Centrisys Corporation Before Project: Gravity thickened sludge (3 4% TS) pumped directly from the clarifiers into the digesters Operational Characteristics Sludge Feed: 3.3% TS Cake Material: 6 7% TS Avg. Power Consumption: 5.7 kw Capture Rate Without Polymer: 89% With Polymer: 98%* *Emulsion Cationic Polymer 46% 0.5 gallons/hour

38 Primary Sludge Thickening Centrifuge THK 200 by Centrisys Corporation

39 WAS Thickening Centrifuge THK 200 by Centrisys Corporation Operational Characteristics Sludge Feed: % TS Cake Material: 6 7% TS Average Power Consumption: 13.6 kw Capture Rate: Without Polymer: 90% With Polymer: 97%* *Emulsion Cationic Polymer 46% 0.2 gallons/hour

40 Thickening Centrifuges THK 200 by Centrisys Corporation

41 PONDUS Thermo Chemical Hydrolysis Process (TCHP) PONDUS TCHP by CNP Technology Water and Biosolids Corporation

42 PONDUS TCHP PONDUS TCHP by CNP Technology Water and Biosolids Corporation Components of Hydrolysis Process: Thermo: TWAS is heated to o F (60 70 o C) Chemical: 1.5 to 2.0 liters of caustic soda (50% NaOH concentration) is injected per 1 m 3 of TWAS Detention Time: Circulation through the reactor and heat exchanger for 2.5 hours (+/ ).

43 PONDUS Reactor Installation

44 PONDUS Heat Exchanger

45 PONDUS TCHP PONDUS TCHP by CNP Technology Water and Biosolids Corporation ph Change Through PONDUS TCHP Upon addition of caustic soda ph = 11 (+/ ) Hydrolysis process breaks down the cell walls and releases internal organic acids which brings the ph of the flow stream back to neutral. Following hydrolysis process ph = 6.8 to 7.0

46 PONDUS TCHP NaOH Tank PONDUS TCHP by CNP Technology Water and Biosolids Corporation

47 PONDUS TCHP NaOH Pumps PONDUS TCHP by CNP Technology Water and Biosolids Corporation

48 Anaerobic Digesters

49 Mechanical Hydraulic Mixing Rotamix by Vaughan Company System consists of: 50 HP Chopper pump Internal piping with three (3) dual nozzle discharge assemblies (per digester) Benefits: More even heating of contents More even distribution of hydrolized feed

50 Biogas Conditioning Gas conditioning and siloxane removal by Unison Solutions Before Project: Raw biogas was utilized by Raw water pump engines Hot water boilers Flared to the atmosphere A package system was incorporated to condition and compress the biogas moisture particulates siloxane

51 Combined Heat and Power (CHP) Units CHP s by Kraft Power

52 Electrical Power Generation

53 Hot Water Loop

54 Insulated Hot Water Loop

55 Isometric Project Overview Heat Biogas Electricity Biosolids 60% - 70%

56 CS21 4HC Dewatering Centrifuge Dewatering Centrifuge by Centrisys Corp.

57 CS21 4HC Dewatering Centrifuge Dewatering Centrifuge by Centrisys Corp.

58 Centrifuge Room

59 Dewatered Biosolids

60 Drying of Biosolids Compact belt dryer by Sülzle Klein

61 Drying of Biosolids Compact belt dryer by Sülzle Klein Distributor extrudes the biosolids into noodle like strands to maximize the surface area for maximum evaporation capacity

62 Drying of Biosolids Compact belt dryer by Sülzle Klein

63 Drying of Biosolids Compact belt dryer by Sülzle Klein

64 Dried Biosolids Loadout Bay

65 Dried Biosolids

66 Odor Control KWT 1000/1300 by Sulzle Klein Treats the exhaust air from the belt dryer, the buffer & mix tanks, the PONDUS reactor, and the thickening & dewatering centrifuges. Water cools the exhaust air and removes particulates. Sulfuric acid neutralizes ammonia odors. Caustic soda neutralizes sulfur compounds such as mercaptans.

67 Controls

68 Controls

69 Start Up and Optimization

70 Controls Start Up Schedule

71 Anaerobic Digestion Modifications Digesters Before Project 4 primary 2 secondary After Project 2primary 1 secondary Total Capacity 633,550 ft 3 319,650 ft 3 Mixing Condition Sludge Feed Operation Feed HRT in digesters Unmixed Batch feeding operation based on 8 hour shifts Primary (3.3% TS) WAS (5.0% TS) Primary=30 days Fully mixed with mechanical hydraulic mixing Continuous feed Primary (6 7% TS) WAS (6 7% TS) Current operation: Primary=22 days Ultimate Operation: Primary=17 days

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73 Screenings

74 Screenings

75 Old ½ Bar Screen New ¼ Perforated Plate Screen

76 Preliminary Results

77 Thermo Chemical Hydrolysis Sludge viscosity tests at KWU (compensated for sludge density) water 1 mpa s 20,0 C 1000,0 kg/m³ Drainage time (sec) glycerol 99,5 %tig, 1480 mpa s 19,6 C, 1260,0 kg/m³ WAS Kenosha 19,6 C, TS 6,5%, GV 70,0%, 1026,3 kg/m³ Nozzle diameter in mm Reduced Viscosity Provides for: Lower mixing energy requirements Higher digester loading rates drain flow hydrolysis c138/input 15 gpm 71,0 C, TS 6,5%, GV 70,0%, 1005,3 kg/m³

78 250, , , ,000 50,000 0 Biogas Production Biogas Production of D2+D3 (cfd)

79 Process Stability PONDUS WAS TAKEN OUT OF SERVICE FROM 4:00 pm APRIL 27 TH UNTIL 2:20 pm on MAY 2 ND 200,000 Daily Biogas Production Cubic feet per day (normalized to 25 C and atmospheric pressure) 190, , ,000 No PONDUS 160, ,000 4/24/16 4/25/16 4/26/16 4/27/16 4/28/16 4/29/16 4/30/16 5/1/16 5/2/16 5/3/16 5/4/16 5/5/16

80 Process Stability BIOGAS PRODUCTION CAME BACK WITHIN 24 HOURS AFTER PONDUS WAS RESTARTED Biogas production on May 2nd PONDUS restarted at 14: % increase Biogas flow (cfm) 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 0:00 1:00

81 VSS Destruction Volatile Solids Reduction (%)

82 Biosolids Dewatering Polymer Use

83 Biosolids Dewatering Polymer Use

84 Biosolids increase in Dewatering potential

85 Dryer Feed Pipe Injection Ring

86 Lessons Learned You cannot have enough drains and flushing connections.

87 Lessons Learned Critical spare parts sometimes the smallest part can cause a large problem

88 Lessons Learned Inspect maintenance access prior to start up

89 Positive Results KWU was awarded the $500,000 Focus on Energy grant for implementing the new Energy Optimized Resource Recovery System and the results. The State of Wisconsin Approved KWU Biosolids as being a Class A exceptional quality product in February 2017.

90 Conclusions Through innovative thinking KWU was able to: Become more energy efficient, reduce operating costs, and now produces a Class A Biosolids. PONDUS increases biogas production by 15 to 30% PONDUS substantially reduces WAS viscosity. PONDUS increased Biosolids dewatering capacity by 2% to 4% and/or decreases polymer usage. KWU Won American Council of Engineering Companies (ACEC) 2017 Grand Award for the Energy Optimized Resource Recovery Project

91 Questions? Joe Hughes Project Manager Centrisys Corp. Phone: (262)