Massachusetts Water Resources Authority

Presentation to

MWRA Advisory Board

MWRA Residuals Processing & Agreement for Operation and Maintenance

of the Fore River Pelletizing Plant withNew England Fertilizer Company

May 21, 2015

Massachusetts Water Resources Authority

Residuals Treatment Facilities

Massachusetts Water Resources Authority

Residuals Processing – Schematic Overview

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Massachusetts Water Resources Authority

Residuals Processing Statistics for Deer Island

• Sludge to Digestion – 246 dry TPD– 70% as Primary sludge – from gravity thickening– 30% as Waste Secondary sludge – from centrifuge thickening

• Typical sludge makeup of other plants: 50:50

– Time in Anaerobic Digestion: • 18-21 days

– 62% Volatile Solids destruction • (industry ave. is 50%)

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Massachusetts Water Resources Authority

Residuals Processing Statistics for Deer Island

• FY14 Annual Avg digester gas production – 188 kscfh– 96% of gas is beneficially used in boilers– 95% of total boiler heat attributable to Digas

• Value of gas utilization - $21.3M (heat) & $2.3M (power)

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Massachusetts Water Resources Authority

Overview of Current Residuals Processing

• Sludge to Pellet Plant – 100 dry TPD– On DITP, Digested sludge is stored, then pumped 7 miles to Pellet Plant

• Methane gas captured, stored, then used in boilers on site– NEFCO dewaters, dries, & pelletizes all digested sludge

– All pellets go to beneficial re-use:• turf farms • golf courses • fertilizer blenders • cement kiln

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2005 2006 2007 2008 2009 2010 2011 2012 2013 201490

95

100

105

110

115

Average Daily Sludge to Pellet Plant (DTPD)

• Located in Fore River Shipyard

• Designed, Constructed & Ownedby MWRA– Phase I – $88 M– Phase II - $45 M– Total cost - $133 M

• Since Day 1, has always been a Contract Operation– Contract 1: 1991 – 2001 Competitive Bid – NEFCo– Contract 2: 2001 – 2015 Competitive Bid - NEFCo

MWRA Pellet Plant located in Quincy, MA

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• Current contract - S345 – 15-year (2001-2015)

• Process liquid sludge from DITP – Receive digested sludge– Dewater with centrifuges– Dry with thermal dryers– Produce Class A Fertilizer Pellet

– In CY 2014:• Processed 100 dtpd• Paid NEFCo $14.1M

Pellet Plant – Contract O&M Since 1991 (cont.)

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• Contractor is responsible for developing & maintaining Diverse Markets for beneficial reuse for all sludge sent to the Pellet Plant– Land Application– Fertilizer Blenders– Alternate Fuels– Bay State Fertilizer Program

• Maintain Facility & Equipment– Responsible for returning

a fully operable plantat the end of the contractto MWRA.

Pellet Plant – Contract O&M Since 1991 (cont.)

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Land Application

Fertilizer Blenders

Alternate Fuel

Bay State Fertilizer Program

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State Annual Tonnage Percentage

Connecticut 6,811 22%New York 5,678 18%Indiana 3,090 10%Maine 2,170 7%Rhode Island 1,835 6%Florida 1,665 5%Virginia 1,554 5%Massachusetts 1,439 5%Georgia 1,332 4%Vermont 1,175 4%Pennsylvania 1,025 3%Ohio 980 3%Maryland 980 3%Missouri 590 2%North Carolina 328 1%Michigan 259 1%Bagged/truck 106 0.3%

Pellet Distribution by State

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Comparison of Pellet Molybdenum Concentrations to DEP Limit

Jan

'12

Apr'12

Jul'12

Oct '12

Jan

'13

Apr '13

Jul '13

Oct '13

Jan

'14

Apr '14

Jul '14

Oct '14

0%

50%

100%

150%

200%

Monthly Pellet Molybdenum Concentrations(Expressed as a % of DEP Type I Limit)

Step 1: Condition Assessment• Facility is in excellent condition

– 20+ year life remaining with no major capital

(with continued maintenance)

Step 2: Residuals Technology Assessment• Recommendations at DITP

– May impact quality & quantity of sludge sent to Pellet Plant

• Recommendations at Pellet Plant– Limited to energy efficiency gains given

condition of facility

Pellet Plant – Contract Renewal Preparation

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Technology Assessment Recommendations (cont.)

– Consider larger, more efficient Dryer Trains• Implemented at Philadelphia & soon Detroit

– Evaluate impacts of co-digestion programs at DITP

– Given long remaining life, any capital expense

decisions must rely on payback

– Recommend 5-year extension to quantify impacts

of pilots and new dryer ops

– Suggested next long-term contract – 15 years

Pellet Plant – Contract Renewal Preparation Step 2 (cont.)

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Pellet Plant – Existing Contract with NEFCo

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Current Contract Cost Structure

• Fixed Fee first 90 dtpd (32,850 dry tons annually) (~$400/ton)• Excess Qty >90 dtpd (>32,850 dry tons annually) (~$280/ton)

• Fixed yearly capital dollar value (pre-determined)• No pass-throughs for utilities

– Includes adjustments for inflation

• FY14 Avg - ~$380/ton

Pellet Plant – NEFCo Contract Extension

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Contract Cost Structure – Sludge Processing (changes)

Original Contract Contract Extension Change• Fixed Fee first 90 dtpd annual (32,850 tons/yr) same base price but for 92.5 dtpd• Variable Fee >90 dtpd same incremental price >92.5 dtpd

• CY2014 Total contract expenses $14,090,654

$13,582,354 for sludge processing $13,334,464 if on extension- $12,574,468 base + = same base + - plus $1,007,886 excess qty plus $759,996 excess qty

Savings of $247 K in year.+ $508,300 capital expenses

Pellet Plant –NEFCo Contract Extension – Capital Program

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• Capital Program - $7.0 Million cap

• $6.087 K – project awards subject for future Board approvals• NEFCo designs all capital projects – paid 15% of awarded project

• NEFCo responsible for capital costs in excess of $7.0 M cap• Must return a fully operational plant at end of contract• Drum replacement not included in cap if completed.

Pellet Plant – NEFCo Contract Extension Summary

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• Reduced Price for Sludge Processing

• $1.25 M savings over 5-yr extension

• Revised Capital Program Structure

• Retains NEFCo liability (must return fully operating plant at end of contract)

• Extension authorized for 5-years

Pellet Plant – NEFCo Contract Extension Summary

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• Provides MWRA sufficient time to:

Evaluate potential energy efficiency improvements (large dryer technology)

Stabilize future sludge quantities (co-digestion)

Allow for increased competition

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• Word of mouth marketing - 32 transactions in April and May

• Lawn care “enthusiasts” showering praise upon Bay State Fertilizer

• Marketing Intern started May 18th

– Goal: Expand retail presence

Bay State Fertilizer

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New Bay State Fertilizer Bag – Rita Berkeley

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• Available at no cost MWRA member Communities

• Pickup at the Pellet Plant in Quincy

• Contact Carl Pawlowski (617) 773-4295

Bay State Fertilizer

Massachusetts Water Resources Authority

Questions ?

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