Biosolids Dryer Technology Types, Product Types and Market Value By Todd O. Williams, PE, BCEE

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1 VWEA Education Seminar Collaborative Biosolids: Fuel for Thought Richmond, Virginia May 11, 2017 Biosolids Dryer Technology Types, Product Types and Market Value By Todd O. Williams, PE, BCEE

2 Biosolids Dryer Technology Types, Product Types and Market Value Acknowledgements: Brian Owsenek, UOSA Rodney Lloyd, Leesburg Tim Gallagher, CH2M Tim Bauer, CH2M Peter Burrowes, CH2M Ron Alexander, Alexander Associates _WWGST_RRR_PPT_Template_01.pptx

3 Outline Drying Technologies Overview Product Marketing Issues Virginia Case Studies Summary _WWGST_RRR_PPT_Template_01.pptx

No. of Trucks/Day Why Dry Biosolids? Mass & Volume reduction Trucks for Hauling 12 10 8 6 4 2 Trucks for Hauling Cake (No.

4 No. of Trucks/Day Why Dry Biosolids? Mass & Volume reduction Trucks for Hauling Trucks for Hauling Cake (No./Day) Trucks for Hauling Dry Product (No./Day) _WWGST_RRR_PPT_Template_01.pptx 0% 25% 50% 75% 100% Percent of Solids Dried (2030 Basis)

5 Why Dry Biosolids? Produces a Class A product (under Part 503 rules) unrestricted use flexible usages commercial fertilizer blend (prepared) fertilizer amendment (direct land application) fuel cement kilns Can be stored easily (well, sort of.) _WWGST_RRR_PPT_Template_01.pptx

Drying Technologies Rotary Drums (Direct) Jones Island, WI; UOSA, VA; Changi, Singapore; Louisville, KY; Corona, CA; Bonita Springs, FL; Leesburg, VA; Blue Lake, MN; Stamford, CT;

6 Drying Technologies Rotary Drums (Direct) Jones Island, WI; UOSA, VA; Changi, Singapore; Louisville, KY; Corona, CA; Bonita Springs, FL; Leesburg, VA; Blue Lake, MN; Stamford, CT; Philadelphia, PA Advantages Product quality High capacity Operating experience Disadvantages High cost High safety provisions Complexity, O&M _WWGST_RRR_PPT_Template_01.pptx

7 Typical Direct Drum Dryer _WWGST_RRR_PPT_Template_01.pptx

(moderate) Safety (lower temp & low dust) Waste heat provisions Can use waste heat from CHP

8 Drying Technologies Belt Dryers (Direct) Kenosha, WI Low temperature air is used to heat, absorb moisture recycle optional heated by furnace or heat exchanger Advantages Product quality (moderate) Safety (lower temp & low dust) Waste heat provisions Can use waste heat from CHP Disadvantages Large footprint vs capacity Moderate complexity, O&M _WWGST_RRR_PPT_Template_01.pptx

dryers are horizontal single-pass Advantages Good for smaller plants Lower complexity

9 Drying Technologies Paddle & Screw (Indirect) Wilsonville, OR; Wilmington, DE hot oil or steam are used to heat hollow paddles and shaft recycle not typical variable speed rotors dryers are horizontal single-pass Advantages Good for smaller plants Lower complexity Disadvantages Product quality Sludge quality adaptability Neutral Safety _WWGST_RRR_PPT_Template_01.pptx

Drying Technologies Continuous Batch (Indirect) Fayetteville, AR Hot oil is used to heat rotor Recycle not typical Mixing augers and drum Fill Dry Discharge

10 Drying Technologies Continuous Batch (Indirect) Fayetteville, AR Hot oil is used to heat rotor Recycle not typical Mixing augers and drum Fill Dry Discharge cycle Advantages Good for smaller plants Lower complexity Disadvantages Product quality Neutral Batch operation Safety _WWGST_RRR_PPT_Template_01.pptx

Drying Technologies Solar Drying Lincoln, Rio Vista, Salida CA; Kent

airflow and mole Advantages Good for smaller plants Lower complexity

used in tandem with thermal dryers to reduce energy use by half Chamber

11 Drying Technologies Solar Drying Lincoln, Rio Vista, Salida CA; Kent County, MD Sun and forced ventilation used Climatic sensors control airflow and mole Advantages Good for smaller plants Lower complexity Disadvantages Large space required Neutral Batch operation Safety Can be used in tandem with thermal dryers to reduce energy use by half Chamber filling End of batch ready for unloading Drying _WWGST_RRR_PPT_Template_01.pptx

12 Drying Technologies..and others Thin film (Green Bay, WI) _WWGST_RRR_PPT_Template_01.pptx

13 Drying Technologies..and others Fluid Bed Tray Flash Electric Etc. Dryer Types (2011) Number of Facilities USA Canada Drum 38 6 Belt 7 Indirect 78 1 Solar 15 Total _WWGST_RRR_PPT_Template_01.pptx

dryers Indirect dryers Hardness Dust Size Uniformity Contaminants (Metals, Fiber, Plastics) Odors Digested or

14 Product Marketing and Quality and End Use Issues Seasonality of Production and Use Especially apparent in northern climates Storage in winter is an issue Pellet Quality Big difference in product uniformity Direct dryers Indirect dryers Hardness Dust Size Uniformity Contaminants (Metals, Fiber, Plastics) Odors Digested or not Nutrient Content (N-P-K) Generally N = 5 to 6 Generally P = 3 to 8 Generally K = _WWGST_RRR_PPT_Template_01.pptx

Product Marketing and Quality and End Use Issues Fertilizer Blenders Require High Degree of Uniformity and will pay top $ Agricultural Users Do not require

15 Product Marketing and Quality and End Use Issues Fertilizer Blenders Require High Degree of Uniformity and will pay top $ Agricultural Users Do not require uniformity and will pay much less, if at all Soil Blenders? Are they really interested in the products and willing to pay? _WWGST_RRR_PPT_Template_01.pptx

16 WEF RBC Conducted a Survey in 2016 and Published a Fact Sheet of Operating Dryer Facilities in _WWGST_RRR_PPT_Template_01.pptx

17 WEF Survey/Fact Sheet Highlights Virtually all dryer facilities sell granulated product Half of respondents sell product for $1-$20/ton One third of respondents sell product for greater than $20/ton Most (>75%) market product in bulk only _WWGST_RRR_PPT_Template_01.pptx

Recent Survey Results from Several California Dryer Facilities (Corona, Encina, Sacramento, Ventura) Only high quality pellets can be sold for substantial price.

18 Recent Survey Results from Several California Dryer Facilities (Corona, Encina, Sacramento, Ventura) Only high quality pellets can be sold for substantial price. High quality pellets are being sold in relatively small quantities to golf courses and nurseries for $100 - $120/ton in super-sacks High quality pellets are sold in bulk to landscapers, nurseries and greenhouses range from $40 - $85/ton Bulk sales to fertilizer blenders and brokers in the $20 - $40/ton range Bulk sales to farmers/agriculture value between $12 - $17/ton and used mainly to prevent on site storage _WWGST_RRR_PPT_Template_01.pptx

Case Study UOSA, Virginia Berlie/Swiss Combi (3265) installed in 2004 Andritz DDS 40 installed in 2014 Operate 24/5 Process digested primary blended with undigested WAS Process about 6,000 DT/Year

19 Case Study UOSA, Virginia Berlie/Swiss Combi (3265) installed in 2004 Andritz DDS 40 installed in 2014 Operate 24/5 Process digested primary blended with undigested WAS Process about 6,000 DT/Year N-P-K = Market product by third party 50/50 share in product revenues Sold in bulk only Wintertime, mostly agriculture at $20/T Summer to fertilizer blenders at $40/T After $15/T Admin fee, net +$5/T when sold to blenders, net -$5/T when sold to ag/farmers _WWGST_RRR_PPT_Template_01.pptx

20 Case Study Leesburg, Virginia Andritz DDS 20 installed in 2002 Operate 2 shifts, 5 days per week (5 am- 10 pm) Process digested primary blended with undigested WAS Process about 1,000 DT/Year N-P-K = Market product themselves Giveaway in bags to residents Sold in bulk and in bags Published information on website _WWGST_RRR_PPT_Template_01.pptx

21 Leesburg TLC Product Sales in 2016 Tons # bags Revenue (including delivery) Net Revenue ($/ton) Net Revenue ($/bag) % product distributed 50 lb bags sold $26,400 $ $ % Bulk sold 575 $41,713 $ % 50 lb bags giveaway % Bulk giveaway % Total $68,113 $ % _WWGST_RRR_PPT_Template_01.pptx

22 Summary Thoughts There are many drier types that create many different product types Understand your objectives Know what the local market is Before selecting a technology! Higher quality uniform products are sold at higher prices Markets are generally good for dried products Brokers have capacity to move product quickly and efficiently but will pay significantly less for product Utilities that market their own product require dedicated staff, but reap higher profits on product sales Build flexibility into your program! _WWGST_RRR_PPT_Template_01.pptx

23 Biosolids Dryer Technology Types, Product Types and Market Value QUESTIONS? Todd O. Williams, PE, BCEE _WWGST_RRR_PPT_Template_01.pptx

Biosolids Management Utilizing Solar and Thermal Processes

Biosolids Management Utilizing Solar and Thermal Processes By Chris Enloe-Instrument & Supply, Inc. And Shannon Jones, P.E.-Utilities Engineer City of Fayetteville What are biosolids? Biosolids are the