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PORT DARLINGTON WPCP EXPANSION PROJECT

PORT DARLINGTON WPCP EXPANSION PROJECT. WEAO Student Design Competition. Ryerson University Design Team : Nancy Afonso Ruston Bedasie Kirill Cheiko Andrew Iammatteo. Introduction. Regional Municipality of Durham has identified a need to expand the Port Darlington WPCP in two phases

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PORT DARLINGTON WPCP EXPANSION PROJECT

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  1. PORT DARLINGTON WPCPEXPANSION PROJECT WEAO Student Design Competition Ryerson University Design Team: Nancy Afonso Ruston Bedasie KirillCheiko Andrew Iammatteo

  2. Introduction • Regional Municipality of Durham has identified a need to expand the Port Darlington WPCP in two phases • Port Darlington WPCP – services the Bowmanville Urban Area Port Darlington WPCP • Objectives: • Develop preliminary design and layout for Phase I expansion • Conceptually design the Phase II expansion • Adhere to design philosophy and limit usage of chemicals • Achieve innovation based on field proven projects, with environmental sustainability and cost awareness always in mind. (Courtesy of Google Maps)

  3. Outline • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Design Basis and Challenges • Process Selection and Facility Design: • Headworks • Primary Treatment • Secondary Treatment • Disinfection • Solids Handling • Additional Considerations • Process Control • Phase I Economic Analysis • Recommendations and Closing Remarks

  4. DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Design Basis and Challenges

  5. Plant Loading • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Hydraulic Loading: • Pollutant Loading:

  6. Effluent Criteria • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS

  7. Design Challenges • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • An alternative method of disinfection • Nitrification • Technologies selected must integrate into the existing plant • Al2(SO4)3 for P removal must be reconsidered • Phase I design and layout must take into account space limitations for Phase II

  8. DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Process Selection and Facility Design

  9. PFD – Phase I • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Primary Treatment Secondary Treatment Disinfection Preliminary Treatment Phase I Sludge Thickening Existing Sludge Stabilization

  10. Plant Layout • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS (Courtesy of Google Maps)

  11. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS

  12. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Headworks

  13. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Primary Clarifiers

  14. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS BNR Bioreactors

  15. DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Phase I Expansion Secondary Clarifiers

  16. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS UV Facility

  17. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Fermenter

  18. Phase I Expansion • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Gravity Belt Thickener

  19. Hydraulic Profile • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Conduit from Headworks Outfall Pipe L.L.EL. 79.66 m Available head = 3.0 m L.L.EL. 76.64 m

  20. Headworks • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Headworks

  21. Headworks • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Installation of two 94 kW raw sewage pumps • Commissioning of third headworks channel • Commissioning of aerated grit tank

  22. Primary Treatment • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Primary Clarifiers

  23. Primary Treatment • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Four (4) rectangular clarifier installation • Total Volume: 1960m3 • BOD Removal: 30% • TSS Removal: 55% • HRT: 3.5h @ ADF • Chain & flight scum/sludge collection

  24. Secondary Treatment • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS BNR Bioreactors

  25. Process Selection • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Activated Sludge with incorporated biological nutrient removal (BNR) • Reduced chemical dependency • Reliable effluent quality • Low sludge production • Sludge has higher levels of bioavailable nutrients • Reduced aeration requirements • Improved sludge settleability • Environmentally sustainable

  26. Process Selection: WESTBANK • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS VFAs Influent BNR Bioreactor Secondary Clarifier Secondary Effluent ANOXIC AEROBIC PREANOXIC ANAEROBIC NMLR WAS RAS

  27. Equipment Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS 40% 20% 40% = Anaerobic = Anoxic = Aerobic

  28. Equipment Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Mechanical Mixers Fine Bubble Diffusers = Anaerobic = Anoxic = Aerobic

  29. Equipment Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Total Bioreactor Volume: 1,782m3 • SRT: 12 days • HRT: 12.5 hours @ ADF • Average MLSS: 3,000 mg/L • Required VFA concentration: 15 – 25 mg/L 7.8% 8% 4.8% 79.4% Mechanical Mixers Fine Bubble Diffusers = Anaerobic = Anoxic = Aerobic

  30. DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Secondary Treatment Secondary Clarifiers

  31. Secondary Clarifiers • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Based on the solids loading rate • “Gould II” type clarifiers • Common sludge collector between sets of two clarifiers

  32. Disinfection • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS UV Facility

  33. Process Selection • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Provide additional hydraulic capacity and meet new compliance criteria • Selection between chlorination/dechlorination and UV disinfection • UV disinfection selected: • Effluent toxicity and safety issues with chlorination • Costs of two processes are becoming comparable • UV capable of the same process reliability, performance track record, and full automatic control capability • Minimal space requirements

  34. Design Basis • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Open – channel, modular design with horizontal, LP-HI lamps • Design Objective: 100 E.Coli/100 mL at PDF • UV Transmittance of 65% (Courtesy of Trojan Technologies Inc.)

  35. Automatic Level Controller ∆ Water Level = 0.881m PDC and Hydraulic Manifold UV Banks 48 lamps/bank UV Facility Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • UV Dose of 30 mW.s/cm2 using LP-HI lamps • 3 channels constructed: 1 Duty and 1 Redundant (equipped); 1 for Phase II (channel only) Automated quartz sleeve cleaning system Variable output electronic ballasts (Courtesy of Trojan Technologies Inc.)

  36. Solids Handling • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Fermenter

  37. Fermenter • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Bio-P removal requires VFAs as a source of energy • Insufficient VFA supply during winter • Addition of a static fermenter will accomplish two goals: • Provide a source of additional VFA’s • Increase sludge solids concentration

  38. Fermenter Schematic • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Influent Sludge from Primary Clarifiers VFA VFA VFA VFA Rich Supernatant to Anaerobic Zones Effluent Sludge to Digesters (Courtesy of www.gc3.com)

  39. Fermenter Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Design Basis: • SRT required: 3-5 days • Sludge loading: 1517 kg/d or 36.8 m3/d (PMF) • Fermenter Design Summary: • Volume: 157 m3 (10 m diameter, 2 m tall) • Sludge solids concentration increased from 4% to 6% • Additional VFAs supplied to the BNR process: 11.2 mg/L

  40. Solids Handling • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Gravity Belt Thickener

  41. Thickening • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Construction of a new digester incurs large capital investments • Thickening can reduce the volume of sludge and allow the use of the existing digesters • Gravity Belt Thickener • Good control capabilities • High cake solids concentration • Relatively low capital and operating costs

  42. Gravity Belt Thickener • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS - Sludge - Separated water

  43. Gravity Belt Thickener • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Design Basis: • Peak solids loading: 13,784 kg/d • Peak hydraulic loading: 675 m3/d • Desired cake solids concentration: 7% • GBT Design Summary: • Length-Width-Height: 5.1 m : 1.7m : 1.5 m • Belt width: 1.2 m • Solids capture: ~95% • Polymer Usage: 2-4 kg/tonne of sludge

  44. Additional Considerations Phase II Conceptual Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Noise & odour control • Septage receiving station • Backup generator • Phase II Conceptual Design Phase II Liquid Facility Courtesy of Envirocan

  45. Phase II Conceptual Design • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Phase II Solids Facility

  46. DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS Process Control

  47. Highlights of Process Control • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Plant to be operated with minimum supervision required • Process Control will rely on automation and plant operators • Existing SCADA system is to be upgradedto include control in addition to monitoring (Courtesy of Port Darlington WPCP)

  48. MOE Requirements • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS • Compliance Sampling required by the MOE • (To be done by the operators)

  49. Process Control • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS 1 2 3 4 5 6 • Performance monitoring Sampling • (To be done by the operators)

  50. Process Control • DESIGN BASIS AND CHALLENGES • PROCESS SELECTION AND FACILITY DESIGN • PROCESS CONTROL • ECONOMIC ANALYSIS • RECOMMENDATIONS AND CLOSING REMARKS 1 2 3 4 5 6 7 1 2 3 4 5 6 7 • Automatic Monitoring and Control (SCADA)

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