Expansion of theNewcastle Water Pollution

Control PlantWEF Student Design Competition 2013

Contents

Introduction

Stage 3 Design

Stage 3 Extras

Conclusions

Questions?

Who are we?

Bradley

FreeWater Resources

Engineering Graduate

Kyle

LockwoodEnvironmental Engineering

Graduate

Introduction

Robyn

ThompsonMechanical Engineering

Graduate

Tanzeel Ahmed

Environmental Engineering Graduate

BackgroundIntroduction

 

 

Clarington, Ontario

An expansion is planned for the Durham Region Newcastle Water Pollution Control Plant (WPCP), in the Municipality of Clarington, Newcastle, Ontario

The expansion of the WPCP is planned in four stages, to ultimately increase the capacity to six times that of the current operating capacity

University of Guelph

The Objectives:1.Preliminary Design and layout for Newcastle WPCP

for Stage 3 expansion including biosolids handling and energy recovery

2.Conceptual layout for Newcastle WPCP expansion for Stage 4 expansion

Stage 3 Design

Population Analysis

Selection of Processes

The Layout and Design

Receiving Station and Headworks

Primary Clarification

Secondary Treatment

Tertiary Treatment

Biosolid Handling and Treatment

Population AnalysisStage 3 Design

Based on previous growth data from the municipality of Clarington

Stage 3 to be completed when Stage 2 average day capacity reaches 75% of ADF

Peak Flow rates were estimated using the Harmon formula

Expected service capacity according to population growth against time

2000 2010 2020 2030 2040 2050 2060 2070 20800

5000

10000

15000

20000

25000

30000

35000

40000

45000

Average Inflow Rates

Peak Inflow Rates

Population

Ave

rag

e In

flo

ws

(m3/

d)

Stage 3 Completed: 2034

The LayoutStage 3 Design

1. Office Building

2. Headworks

3. Primary Clarifiers

4. Aeration Tanks

5. Secondary Clarifiers

6. Disinfection

7. Cloth Filters

8. Digester Gas Flaring

9. Dewatering Units

10. Chemical Storage

11. Anaerobic Digesters

12. CHP System

Receiving Station and HeadworksStage 3 Design

Mechanically Cleaned bar screen installedInstalled parallel to existing systemsIncreases existing treatment capacity

Two additional aerated grit tanks installedWill be able to process Stage 3 flows of 39,300 m3/dExtra unit provided for redundancy and maintenance

Primary ClarificationStage 3 Design

Circular Primary Clarification tank installed Existing clarifier tank will be modified during stage 3

installation as a circular tank Will eliminate maintenance issues of gross solids

buildup in corners of existing square clarifiers Performed during stage 3 installation

Will reduce BOD and TSS sufficiently for ADF and PDF

Secondary TreatmentStage 3 Design

Two aeration tanks will be installed in parallel to existing tanksAeration tanks will operate as a staged CAS process to allow operational flexibility

First stage fitted with jet aeration and diffuser grid Second stage has diffuser grid installed Can perform nitrification-denitrification for alkalinity recovery Will be consistent with existing plant systems Stage 3 of system will have an operational MLSS of 3500 g/m3

Will have an SRT of 12 days to achieve nitrogen removal

Two new secondary clarifiers will be installed in parallel to existing clarifiers Will have a recycle ratio of 50% Clarifiers are sized to treat the maximum daily flow of 39,300 m3/d

Tertiary TreatmentStage 3 Design

Alum Addition Will reduce the influent phosphorus by over 85% Added at the aeration tank effluent Chosen because it was the most effective treatment for the

lowest cost

Three Cloth Filtration Units (AquaDISK Tertiary Filtration system)installed TSS reduced below 5mg/L for ADF Will be able to process Stage 3 flows of 39,300 m3/d Extra unit provided for redundancy and maintenance

UV system (Trojan UV3000Plus™) selected as best method eliminating current chlorine disinfection methods

Current chlorine contact tank will act as a bypass channel Achieves desired monthly geometric mean density of

150cfu/100mL of Escherichia Coli Low Pressure/ High Intensity (LP/HI) lamps Horizontal Parallel to flow lamp configuration Automatic chemical/mechanical cleaning Weighted Gate Automated Level Controller

Sludge and Biosolid TreatmentStage 3 Design

ROTAMAT (HUBERTM) Screw Press dewatering system chosen 2 Dewatering units installed for Stage 3 Have a total dry solids throughout capacity of 280 kg Dry/h O/M costs are smaller than traditional centrifugal dewatering system Operates at <1.5 rpm screw rotation speed Requires <20 min/d of operator attention Produces 18 – 25% cake solids

2 Single stage high rate mesophilic anaerobic digesters installed parallel to Stage 2 Digesters

Digesters will treat the wasted solids from the primary clarifier and the WAS from the secondary clarifier

SRT of 20 days External pump recirculation mixing Biogas collection to for Combined Heat and Power (CHP) energy

recovery

Processed Sludge Disposal On approved agricultural land site under the Durham

Region Works Department’s Biosolids Management Program

Extras CHP Energy Recovery

Life Cycle Impact Assessment

Noise and Odour Control

Hydraulic Profile

Modelling

Process Control and

Instrumentation

Construction Implementation

Cost Analysis

The Captures the biogas produced from the

Digesters and generate renewable energy Primary mover of the CHP system is 2

microturbines CHP Economic Feasibility

Generate approximately $130,000/year in energy savings

11 Year Payback Period Dependent upon obtaining Electricity

Contracts Fuel Gas Conditioning System will reduce

H2S, CO2, PM extending the lifespan of the microturbines and reducing greenhouse gases

Flare located southwest of the facility in case of CHP system failure

CHP Energy RecoveryThe Extras

Life Cycle Impact Assessment The Extras

Compares the environmental impact of anaerobic digestion against lime stabilization for sludge treatment

Pré developed SimaPro 7.0 software was used to conduct a comparative study

Life Cycle Impact Results Lime stabilization is worse in every impact category Lime stabilization produces more sludge

Anaerobic Digestion for sludge treatment is therefore the most environmentally sustainable solution

Climat

e ch

ange

Ozone

dep

letion

Photo

chem

ical o

xidan

t for

mat

ion

Partic

ulate

mat

ter f

orm

ation

Ionis

ing ra

diatio

n

Terre

stria

l acid

ificat

ion

Agricu

ltura

l land

occ

upat

ion

Urban

land

occ

upat

ion

Natur

al lan

d tra

nsfo

rmat

ion

Wat

er d

eplet

ion

Met

al de

pletio

n

Fossil

dep

letion

0

10

20

30

40

50

60

70

80

90

100

Land Application following Digestion Land Application following Lime Addition

ModellingThe Extras

WRc’s waste water modelling software

BOD, TSS and NH3 was modelled within the simulation

At an operational temperature of 10oC, the effluent objectives

were well below target

STOAT®

Parameter Proposed Effluent Objectives

Simulated Mean Effluent

BOD5 (10 mg/L) 10 mg/L 4.76 mg/LTSS (10 mg/L) 10 mg/L 6.61 mg/L(Ammonia + Ammonium) Nitrogen* 9 mg/L 15 mg/L 0.49 mg/L*The simulated ammonia effluent is assumed to be representative of both ammonia and ammonium* Concentration listed are for summer and winter objective respectively

Parameter Proposed Effluent Objectives

Simulated Mean Effluent

BOD5 (10 mg/L) 10 mg/L 4.76 mg/LTSS (10 mg/L) 10 mg/L 6.61 mg/L(Ammonia + Ammonium) Nitrogen* 9 mg/L 15 mg/L 0.49 mg/L*The simulated ammonia effluent is assumed to be representative of both ammonia and ammonium* Concentration listed are for summer and winter objective respectively

Process Control and InstrumentationThe Extras

Supervisory Control and Data Acquisition (SCADA)

Provides operational ease by reducing monotonous tasks for operators

Overall efficiency of the plant improved by maintaining steady state

process

Headworks and Clarifiers Monitoring and pumping controlAeration Basin Dissolved oxygen monitoring Aeration efficiency improvements of

up to 50% Monitoring and Pumping

Tertiary Treatment Flow monitoring and splittingDigesters Monitoring performance Controlling temperature, pressure,

recirculation and feed ratesCHP Monitoring and controlling flow rates

and energy production

TheControls

Hydraulic ProfileThe Extras

Available Head of 4.0m

E.L. 84.75m

E.L. 80.75m

Construction And ImplementationThe Extras

Task Name

Duration (

months)

2033 2034

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Construction Period 15 Mobilization and Erosion Control Systems 1 Site Preparation 1 Concrete Placing, Formwork and Reinforcing Steel 4 Piping and Mechanical Equipment Installation 6 Support Facilities 2 Electrical Work, Instrumentation and Controls 6 Landscaping and Final Clean-up 2 Commissioning 3

The completion date of Stage 3 is established as year-end of 2034 Using current data in the

population analysis Recommended that population

growth trends are rechecked every 5 years

Plant Design: 12 monthsPermits and Approvals: 12 monthsTendering/Awards: 2 monthsConstruction Period: 15 monthsCommissioning: 2 months

Minimizing Environmental Impact In accordance with Local Municipalities, by-laws and MOE Standards

Noise Control Dust Control Protection of Surface Water Erosion Control

Noise and Odour ControlThe Extras

Development of surrounding residential area of great concernProblem:

The Problem

Adequate buffer areas around the facility Housing facilities with adequate noise depletion technology (for pumps,

generators, etc.) All noise and odour sources will maintain the minimum separation distance of

100 meters in agreement to MOE odour and noise guidelines.

Solution?

111m

Cost AnalysisThe Extras

8%

64%

9%19%

Total Capital Cost:

$26,350,000.00

Cost AnalysisThe Extras

Annual Operation and Maintenance Cost: $898,000.00

53%

22%6%4%

15%

Sludge Disposal Cost Savings

Janu

ary

Febru

ary

Mar

chApr

ilM

ayJu

ne July

Augus

t

Septe

mbe

r

Octob

er

Novem

ber

Decem

ber

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

$40,000

Disposal Costs for Stage 1 operation as of 2011 Disposal Costs for Stage 3 operation without Sludge Treatment

Disposal Costs for Stage 3 operation with on site Sludge treatment

Operational Function* Average Monthly Cost Average Annual Cost

Stage 1 (from 2011 operational data) $ 9,388.54 $ 112,662.50Stage 2 (anticipated operation within 2014) $ 28,038.90 $ 336,466.84Stage 3 (anticipated operation within 2034) $ 2835.40 $ 34,024.85*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP

Janu

ary

Febru

ary

Mar

chApr

ilM

ayJu

ne July

Augus

t

Septe

mbe

r

Octob

er

Novem

ber

Decem

ber

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

$40,000

Disposal Costs for Stage 1 operation as of 2011 Disposal Costs for Stage 3 operation without Sludge Treatment

Disposal Costs for Stage 3 operation with on site Sludge treatment

Operational Function* Average Monthly Cost Average Annual Cost

Stage 1 (from 2011 operational data) $ 9,388.54 $ 112,662.50Stage 2 (anticipated operation within 2014) $ 28,038.90 $ 336,466.84Stage 3 (anticipated operation within 2034) $ 2835.40 $ 34,024.85*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

$40,000

Disposal Costs for Stage 1 operation as of 2011 Disposal Costs for Stage 3 operation without Sludge Treatment

Disposal Costs for Stage 3 operation with on site Sludge treatment

Operational Function* Average Monthly Cost Average Annual Cost

Stage 1 (from 2011 operational data) $ 9,388.54 $ 112,662.50Stage 2 (anticipated operation within 2014) $ 28,038.90 $ 336,466.84Stage 3 (anticipated operation within 2034) $ 2835.40 $ 34,024.85*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP

$0

$5,000

$10,000

$15,000

$20,000

$25,000

$30,000

$35,000

$40,000

Disposal Costs for Stage 1 operation as of 2011 Disposal Costs for Stage 3 operation without Sludge Treatment

Disposal Costs for Stage 3 operation with on site Sludge treatment

Operational Function* Average Monthly Cost Average Annual Cost

Stage 1&2 (from 2011 operational data) $ 9,388.54 $ 112,662.50Stage 3 (anticipated operation within 2014) $ 28,038.90 $ 336,466.84Stage 3 (anticipated operation within 2034) $ 2835.40 $ 34,024.85*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP

Annual Savings with the Proposed Solution: $302,442

Stage 4 LayoutThe Extras

Stage 4Stage 3Stage 1&2

Conclusions

Conclusion

Recommendations

Acknowledgements

Questions

The proposed processes for Stage 3 include

Additional headworks improvements

1 primary clarification tank

2 two-staged aeration tank

1 secondary clarification tank

3 cloth filters

1 UV disinfection unit

2 additional anaerobic digesters

2 screw press dewatering units

Stage 3 is to be completed by year-end of 2034

present cost of $26.3 Million

O/M of $0.9 Million annually

Further investigation should be conducted with respect to the integration of the microturbine CHP system for biogas handling

Issues such as the availability of obtaining contracts from the Ontario Energy Board (OEB) and the Local Distribution Company (LDC) are of concern

Green incentive grants should be assessed to determine possible alleviation of total capital cost and further evaluation of the systems feasibility

Population growth trends are rechecked every 5 years to determine if the completion of Stage 3 construction schedule requires adjustment

Obtain additional specific order costing information from manufacturers

Hongde Zhou, Ph.D., P.Eng. – Faculty AdvisorProfessor of the School of Engineering – University of Guelph

Miles MacCormack, P.Eng. – Consultant Advisor Project Manager – Stantec Inc.

Rafiq Qutub, M.Eng., P.Eng.Subcommittee Chair, Student Design Competition – Water Environment Association of Ontario

Kirill Cheiko, EIT.Water EIT – Stantec Inc.

Yashar Esfandi, EIT.Inside Sale Representative – SPD Sales Limited

Hussein Abdullah, Ph.D., P.Eng. – Director The School of Engineering – Guelph University

Questions and…

Conclusions

The Credits

THANK YOU!THANK YOU!