AECOM Water Sludge Dewatering Improvements at Gulf Coast Waste Disposal Authority s Bayport Facility TACWA - May 29, 2009
Agenda Background & Plant Overview Project Objectives Existing & Proposed Facilities Process Overview Process by Area Cost Saving Measures Conclusion
GCA Bayport Plant Belt Press Project Area
Plant Overview Peak Flow: 30 MGD >50 industrial, 2 municipal customers Bayport Industrial Complex Industrial high strength waste Average BOD: 1,300 mg/l Two step activated sludge process 1 st Step: High purity oxygen in covered tanks, designed to eliminate any organic emissions from wastewater 2 nd Step: Conventional aeration Three 180-foot final clarifiers
Project Design Objectives Increase sludge dewatering capacity from 94 dry tons/day to 188 dry tons/day, with expansion capability to 235 dry tons/day Add dry polymer capabilities Include cost saving opportunities Optimize use of operator time Create safe and workable environment
Existing Facilities CWA Meter Enclosure Existing A-Plant 500,000 gallon Sludge Tank Incinerator Foundations PS Truck Bay Existing Press Bldg First Step Aeration Tank 4
Proposed Facilities CWA Meter Enclosure CWA Tanks & Booster Pumps Existing A-Plant 500,000 gallon Sludge Tank Prop Sludge Feed FPS Proposed Press Bldg PS Truck Bay Polymer Bldg Existing Press Bldg First Step Aeration Tank 4
Overview Schematic CWA Water Dry Polymer Water Tank Tote Booster Pumps Stormwater Pump Station Filtrate Pump Station Belt Press Belt Conveyor Blower Liquid Polymer Neat Polymer Tank Polymer Mix Tank POLYMER SLUDGE Air Sludge HoldingT ank Aged Polymer Feed Tank Sludge Grinder Strainer Spool Prog Cavity Pump Pump Inline Mixer Belt Press Belt Conveyor Conveyor Trailers Loading / Truck Bay
Sludge Feed Area Grinders vs Strainers Sludge Pumps / VFDs Containment Containment Wall Grinder Pump Pump Pump Magnetic Flowmeters (4) Grinder Pump Plan View Section A
Sludge Feed Area
Polymer Building CWA Storage Tanks & Booster Pumps Reserved for Future Tank Polymer Mix Tank & Aged Polymer Feed Tank Polymer Feed Pumps Loading Dock Forklift / Dry Polymer Tote Storage
Polymer Building Mix Tank Aged Feed Tank Future Future CWA Tank Booster Pumps
Polymer Building
Polymer Make-up System CIBA Fab 2b Polymer System Capable of receiving either dry or emulsion (liquid) polymer Polymers special handling due to moisture absorbency New Polymer Building
Polymer Feed Dry Powder 2,200 lb SS totes, forklift Infrared heat lamps Blower
Polymer Feed - Liquid Phasing with dry polymer Existing storage tank, truck offloading, dessicant, and recirculation system remain in place
Polymer Dilution Water Supply Coastal Water Authority (CWA) Non-potable water backup supply Polyethylene storage tank Back-pressure valve
Dilution (Polymer Makeup Tanks) Mix: 3,000 gallons, Fiberglass Aged: 4,500 gallons, Stainless Steel Uncoiling time (30 min)
Polymer Feed Pumps Initial setting percent solids, polymer usage Ratio control (sludge/polymer) VFDs
Inline Mixers Importance of good mixing (polymer/water/sludge) Manufacturer claimed benefits (polymer savings: 25-40%, slight increase in cake solids) Komax vs Koflow: Komax static selected Considered plugging, savings, head loss Ashbrook mixer post-injection to sludge
Belt Press New Building
Belt Press New Access Platform
Belt Press Gravity & Wedge Sections High pressure rollers pressure and shear is increased gradually Filtrate & washwater collection/recycle
Conveyor Walkways Weigh Scales trailer switch/stop Drain pan & flush
Conveyor
Filtrate Pump Station 7,600 gallon wet well Four 780 gpm submersible pumps Existing vs New
Truck Bay / Sludge Disposal Haul to commercial landfill (paid by truckload) Ultimate disposal by a contractor Additional truck paving/access Importance of Percent Solids, water
Cake Percent Solids Two existing presses: 14%-17% solids Two new presses: 17%-20% solids Ashbrook Winklepress 14 high pressure section, released 10/06 Potential retrofit for existing presses
Hauling & Disposal cost per year ($) Cake Solids vs Disposal Cost Per Year $1,400,000 $1,300,000 $1,200,000 $1,100,000 $1,000,000 $900,000 $800,000 $700,000 $600,000 $500,000 $400,000 $300,000 $200,000 $100,000 $330,000 Savings Annually $0 10% 11% 12% 13% 14% 15% 16% 17% 18% 19% 20% 21% 22% 23% 24% 25% Cake percent solids (%)
Cost Savings Measures Potential Project Cost Savings Polymer: ~ $100K/year Hauling & Disposal: ~ $330K/year Conveyor scales optimize trailer loading - hauling & disposal: truck-load basis Upgraded, newer technology, belt press Opportunity to utilize dry polymer Significant long term savings possible, especially with escalating cost of materials, fuel
Very Special Thanks to Ricky Clifton Leonard Levine, Carl Hennagir, Peter Janes Jack Wahlstrom and the Bayport Plant staff
Questions?