R2E2 Project - Wisconsin Wastewater Operators` Association

Resource Recovery and Electrical Energy
(R2E2)
Lake Michigan Regional Meeting
Chilton, WI
December 10, 2015
Bruce Bartel – NEW Water
Who or What is NEW Water?
• Brand of Green Bay Metropolitan Sewerage District
• Wastewater treatment services for 18 municipalities
• Two treatment facilities serving NE Wisconsin 24/7/365
Background Information
2008 – Initiated planning for future of
solids handling
Three main drivers:
• Aging infrastructure
• Environmental regulations
• Increased capacity needs
2011 – Completed the Solids
Management Facility Plan
Alternative Selection
Researched 72 Possible Options
Resource Recovery
and Electrical Energy: R2E2
• Thoroughly evaluated six alternatives
 Alternative 2: Incineration with Energy Recovery
 Alternative 3A: Digestion with Thermal Processing
 Alternative 3B: Digestion with Thermal
Processing and Electrical Generation (known as
R2E2 Project)
 Alternative 11: Composting
 Alternative 14: Incineration and Drying
 Alternative 16: Rehabilitate Existing Solids Handling
System
R2E2 – What is it?
Most cost-effective solution to replace
solids handling at the Green Bay
Facility
Tools to treat wastewater as a resource
Selected Alternative
• R2E2 Project Highlights (Main Components)
 Anaerobic Digestion (mesophilic) for biogas production and solids
reduction
o Two Silo Shaped Digesters
o 110 Feet Tall
o 2.2 MGD Capacity Each
o High Strength Waste Receiving
 Co-generation equipment for electrical energy generation
o Two Caterpillar I/C Engines
o 2.0 MW Each
Selected Alternative
Sectional View of
Deep Cone Silo
at Broad Run WRF
in Loudoun County, VA, USA
Selected Alternative
• R2E2 Project Highlights (Main Components)
 Dewatering
o Three – 21” Centrisys Centrifuges
o One – 26” Centrisys Thickening Centrifuge
Co-Thickening
 Solids Drying
o One – Haarslev Scalping Dryer
o Thermal Oil for Heat Recovery
Selected Alternative
• R2E2 Project Highlights (Main Components)
 Fluid Bed Incineration
o One – SUEZ (IDI)
o 51 Dry Tons per Day
o Heat Recovery
 State of the art air pollution control equipment to reduce air
pollutants and meet new standards
Nutrient Recovery
• Added feature to the R2E2 Project
• Reduces phosphorus and nitrogen from solids processing recycle
stream
 Reduces maintenance to manually remove struvite from equipment
and piping
 Produces a beneficial re-use product
 Multiform Harvest Inc.
Anaerobic Digestion
• Microorganisms produces biogas
• Reduces solids for incineration
• High strength waste to boost
biogas production
Selected Alternative
Silo-Shaped Digesters at Broad Run WRF in Loudoun County, VA, USA
Electrical Energy Generation
•Burns biogas from digestion
•Can blend in natural gas
•Recovery of generated heat
Fluidized Bed Incineration
•Thermal oxidation of solids
•Recover heat from exhaust
•Heat to pre-dry solids
Air Pollution Control Equipment
•Meets new, stricter limitations
•State-of-the-art equipment
Nutrient Recovery System
•Reduces struvite maintenance issues
•Beneficial reuse
•Generates revenue stream
Nutrient Recovery System
•Reduces struvite maintenance issues
•Beneficial reuse
•Generates revenue stream
R2E2 Contracts & Status
• Project Contracts:
 Contract 33: Primary Switchgear & Utility Relocation
Project
o Includes:
New Electrical Substation Building
Electrical Switchgear Equipment
Relocation of Utilities
o Completed Spring 2015
R2E2 Construction
Foundation walls of
Switchgear Building
showing duct bank
penetrations,
waterproofing,
insulation
Electrical Power Distribution &
Switchgear Building Construction
Electrical Switchgear Installation
Electrical Switchgear Installation
R2E2 Contracts & Status (cont.)
• Contract 34: Solids & Digestion Facilities
 Includes:
o Anaerobic Digestion
o New Solids Building
o Centrifuge Dewatering
o Biogas Storage
o Electrical Energy Generation
o Nutrient Recovery
o Ash Dewatering and Storage
o Installation of Fluid Bed Incinerator Equipment
Operational Challenges
• Finding the “Sweet Spot”
– VS reduction to 60 to 65%
– Optimize biogas production
– Optimize electrical energy production
– How far to dry solids
– Autogenous incinerator operation
• Energy Managers
R2E2 Timeline
•
•
•
•
•
•
•
Planning Stage (2008‐2011)
Design Stage (2012‐2015)
Equipment Procurement (2013‐2014)
Construction Project #1 (2014)
Construction Project #2 (2015‐2018)
Implementation (2018)
Construction Project #3 (2019)
R2E2 Costs
Project Phase
Approximate Costs
Engineering Services
Fluidized Bed Incinerator Equipment
Construction Project #1
Construction Project #2
Construction Project #3
Total
$25,000,000
$21,200,000
$6,300,000
$114,000,000
$2,500,000
$169,000,000
R2E2 Benefits
• Addresses the original project drivers:
– Aging infrastructure
– Environmental regulations
– Increased capacity needs
• Lowest cost plan over a 20-year planning period
• Generate about 50% of NEW Water’s energy needs
R2E2 Benefits
• Accept different wastes (i.e. dairy, sugar, and food
processing) that can boost energy production
• Use approx. 90% less natural gas than current system
• Struvite is a slow release fertilizer; $400,000/year
revenue
R2E2 Benefits
• By producing much of its own energy, NEW Water will
be able to minimize expenses as energy costs rise in
future years
• Reduce greenhouse gas (CO2) emissions by approx.
22,000 metric tons per year, which is the same as
removing about 15,000 vehicles from the road
Back to the Future:
Resource Recovery and Electrical Energy (R2E2)
Thank You!
Questions / Comments?
Contact Information:
Bruce Bartel, Treatment Manager
bbartel@newwater.us
(920) 438-1006
For more information please
visit:
www.newwater.us
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