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Sustainability Incorporated into the Solids Handling Improvements of the Douglas L. Smith Middle Basin Treatment Plant

Sustainability Incorporated into the Solids Handling Improvements of the Douglas L. Smith Middle Basin Treatment Plant. Susan Pekarek and Doug Nolkemper Johnson County Wastewater. Dale Gabel, CH2M HILL Mike Kalis, HDR|Archer Engineers. Johnson County Wastewater (JCW) System.

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Sustainability Incorporated into the Solids Handling Improvements of the Douglas L. Smith Middle Basin Treatment Plant

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  1. Sustainability Incorporated into the Solids Handling Improvements of the Douglas L. Smith Middle Basin Treatment Plant Susan Pekarek and Doug Nolkemper Johnson County Wastewater Dale Gabel, CH2M HILL Mike Kalis, HDR|Archer Engineers

  2. Johnson County Wastewater (JCW) System • Located in Johnson County, KS • Established in 1945 • Serves population of ~500,000 • Seven wastewater treatment plants • Capacity to treat 62 MGD; send ~15 MGD to other municipalities to treat • Over 30 pump stations and 2100 miles of sewer

  3. Douglas L. Smith Middle Basin Wastewater Treatment Plant

  4. Drivers for Solids Handling Project • Solids capacity expansion needed to match liquid capacity expansion • Desire to bring Blue River WWTP solids to Middle Basin (Biosolids Master Plan, 2004) • Desire to provide a disposal facility for fats, oils, and grease (FOG) wastes • Johnson County Governing Body passed resolution to reduce GHG’s 80% by 2050 • Increase solids handling capability while decreasing carbon footprint

  5. FOG Waste Quantities Obtained from Existing County Permit System • Restaurant Greases - 2.2 million gallons/year • 750 facilities (approx.) w/ grease traps • 900 gallons per facility (average) • Traps pumped once every 113 days (average) • Industrial Grease and Sludges –2.1 million gallons/year • Dissolved air flotation thickener (DAFT) sludges from food processing industries for margarine, salad dressing, mayonnaise, and sauces • 41,000 gallons per week (average)

  6. Estimated Quantity of FOG Wastes to be Received at the Middle Basin WWTP • FOG Waste Receiving Facility Sizing • Assumed 75% of all FOG waste generated in Johnson County will be received; 3.23 million gallons per year • 12,400 gpd, annual average (3-4 trucks per day) • 30,000 gpd, peak

  7. FOG Waste Receiving Station Based on Successful Facilities • Sites visited • South Bayside System Authority, Redwood City, CA • East Bay Municipal Utility District, Oakland, CA • Millbrae Water Pollution Control, Millbrae, CA • Information from Gryaab Rya WWTP, Gothenburg, Sweden – cold climate operations • Key Observations for Middle Basin Project • Above ground storage, more user friendly • FOG waste not as difficult to manage as originally thought • Started with a very engineered approach; ended with a much more operator friendly design

  8. South Bayside System Authority’s FOG Waste Receiving Station, Redwood City, CA

  9. East Bay Municipal Utility District’s FOG Waste Receiving Station, Oakland, CA

  10. Millbrae, CA’s FOG Waste Receiving Station

  11. Gryaab, Sweden’s FOG Waste Receiving Station

  12. Middle Basin Project Components Flares Digester Mixing Digester Gas Storage Bubble Gas Cleaning System FOG Waste Receiving Station Cogeneration Units

  13. FOG Waste Enhances Digester Gas Production

  14. Cogeneration System Considerations • Combined heat and power (CHP) system (heat used for building heating) • High-efficiency engines to maximize electricity production’ • Gas cleaning to reduce engine O&M costs • Containerized units to reduce capital costs

  15. Example of Containerized Cogeneration System

  16. Several Cogeneration Engines Evaluated • One 848 kW engine • One 1060 kW engine • Two 1060 kW engines; 1 duty 1standby • Two 1060 kW engines; 2 duty • Two 633 kW engines; 2 duty

  17. Significant Annual Power Savings Provided by Cogeneration System

  18. Multiple Configurations Provide Reasonable Life-Cycle Payback Periods

  19. Middle Basin Solids Improvement Project Additional Enhancements • Sludge from Blue River plant is currently hauled to a point in the Turkey Creek Collection system (approximately I-35 & 75th St) • Hauling to Middle Basin will save approximately 25,000 miles/year, saving thousands in O&M costs

  20. Middle Basin Solids Improvement Project Summary • Anaerobic digestion of 6,700 tons/yr of wastewater treatment plant sludges • Processing of 3.2 million gallons of FOG waste/yr • Electrical power savings of $500,000/yr • Net reduction in carbon footprint of 10,000 tons of CO2eq/yr

  21. Blue River Main Treatment Plant (151st st. and Kenneth Rd)

  22. Carbon Supplementation • Using carbon supplementation at the Blue River Main treatment plant • Essentially turning waste products to feedstock • Make the bugs happy and they do a better job of removing NO3 and PO4

  23. Carbon Supplementation II • Pilot program using 1/3rd of flow capacity has proven concept • Much friendlier and more cost effective than alternatives. • Chemical process (Ferric or Ferrous Chloride, alum) • Biological removal (installation of fermenters or modification of existing equipment)

  24. Carbon Supplementation III Supplemental Carbon • Either purchased or obtained as a waste product (soft drink bottling waste as one example) • Savings in pre-treatment costs to providers

  25. Other JCW Sustainability Initiatives • Electronic plan review • Satellite line cleaning location • Routing analysis of cleaning and inspection crew routes • Video Conferencing (three JCW locations)

  26. Questions? Sustainability Incorporated into the Solids Handling Improvements of the Douglas L. Smith Middle Basin Treatment Plant

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