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CITY OF BALITMORE DEPARTMENT OF PUBLIC WORKS BACK RIVER WWTP

Presentation Outline. Plant OverviewWater ReusePotable Water ConservationElectrical Distribution UpgradesPerformance Based Energy ContractBGE Load Response ProgramOn-Site Bleach GenerationFuture Energy Considerations. Back River WWTP. Built in 1907 on 466-acre tract located in eastern Baltimore CountyDesign flow 180 MGDAverage flow 140 MGD140 sq. mile service area/1.3 million customersTwo outfalls-Back River and Sparrows PointAnnual O

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CITY OF BALITMORE DEPARTMENT OF PUBLIC WORKS BACK RIVER WWTP

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    1. CITY OF BALITMORE DEPARTMENT OF PUBLIC WORKS BACK RIVER WWTP ENERGY INITIATIVES AND INNOVATIVE PRACTICES

    2. Presentation Outline Plant Overview Water Reuse Potable Water Conservation Electrical Distribution Upgrades Performance Based Energy Contract BGE Load Response Program On-Site Bleach Generation Future Energy Considerations

    3. Back River WWTP Built in 1907 on 466-acre tract located in eastern Baltimore County Design flow 180 MGD Average flow 140 MGD 140 sq. mile service area/1.3 million customers Two outfalls-Back River and Sparrows Point Annual O & M budget - $50 million 300 employees % Removal Efficiencies FY-08 BOD 99%, SS 99%, TP 94%, TN 68%

    4. PLANT AERIAL VIEW

    5. BACK RIVER FACILITIES

    6. Water Reuse Overview Sparrows Point approached City to use Back River effluent for process water at steel plant. In 1941 Back River and Sparrows Point Steel Plant entered into a Water Reuse Agreement. SP currently takes approximately 40 MGD of Back River’s final effluent. SP reimburses the City for electrical, chlorine and water costs ~ $950,000 per year. Current steel plant owner is Severstal

    7. BS Sparrows Point Plant Background Built in 1887 on 3500 acre tract of land with frontage on the Patapsco River Location selected so ships could off-load raw materials and transport finished product Produced steel plates, strip steel, sheet steel, and tin plate Plant has downsized since its heyday in the 1950’s when it employed over 30,000 people

    8. Water Reuse Agreement - History Bethlehem Steel needed larger supply of water than available from ordinary sources Original Agreement executed in 1941 Bethlehem Steel constructed 4.5 mile 60” pipeline to convey water Max rate of 50 MGD 1947 amended to 100 MGD max

    9. Water Reuse Agreement - History 1951 amended to 100 MGD min – 200 max - built additional 96” pipeline - built treatment facilities at Back River to further treat effluent Mid-1980’s abandoned treatment facilities. Flow gradually has been reduced over time to the current level of 40 – 45 MGD Agreement can be cancelled by either party with a two year notification.

    10. LIFT PUMPS

    11. Name of creek?Name of creek?

    12. Effluent Water Uses at BS Currently takes ~ 40 MGD of Back River final effluent for process water Used in various steel production processes Cooling and cleaning of hot gas streams After use the water is treated at their Humphrey’s Creek Facility prior to discharge into the Chesapeake Bay

    16. Need to verify numbersNeed to verify numbers

    17. Waste Pickle Liquor Agreement 1979 initial agreement – Bethlehem Steel’s waste product used for P removal at Back River 40,000 gal/day City constructed loading, storage and dosing facilities at Back River Trucking costs were split 1982 amended – City pays 2/3 trucking and Bethlehem Steel 1/3

    18. Waste Pickle Liquor Agreement 1986 amended – City pays 100% trucking December 2000 – changed from ferrous sulfate to ferrous chloride Ferrous chloride a preferred product due to decreased acidy and higher iron content Reduced quantity to less than 10,000 gallons/day Current average usage is 8,000 gallons/day

    21. POTABLE WATER CONSEVATION Plant has converted pump seal water systems and polymer mixing systems from potable water to plant flushing water Saves over 100,000 gpd of potable water Potable water still used as backup source Saves over 36.5 million gallons of potable water per year Annual savings of over $50,000 Need picturesNeed pictures

    22. Seal Water System

    23. Poly-Blend System

    24. ELECTRICAL DISTRIBUTION UPGRADES SC- 9555 Electrical Distribution Upgrade $4,000,000 capital cost Installed four new 34.5 kV capacitor banks to maintain power factor between 0.9 and 0.98 Upgraded the 13.2 and 2.4 kV feeders to 34.5kV Standardize entire plant distribution system to 34.5kV SC- 835 Blower House 2 Controls System Improvement $1,800,000 capital cost Replaced across the line starters with soft starts Replaced blower and guide vane controls These projects improved energy efficiency and increased system reliability

    25. ENERGY PERFORMANCE CONTRACTING Mechanism to implement necessary infrastructure improvements that reduce energy consumption and operating costs. Financed through operating budget utility savings. No impact to capital funding program. Performance and savings guaranteed.

    26. ENERGY PERFORMANCE CONTRACTING PROCESS Preliminary Feasibility Study Share information and identify potential savings Phase 1 Agreement Lists ECMs and potential savings Develops costs for Phase 1 Proposal Phase 1 Proposal Completes detailed energy audit, project scope, savings and final proposal Phase 2 Agreement Complete design followed by construction After construction, measurement and verification data collected and reconciled annually Call Rick or Mark for detailsCall Rick or Mark for details

    27. PROJECT RESULTS Project Cost = $14.1 Million $1.8 Million in Annual Energy and Operational savings in first year Sustainable and reliable solution Funded through savings in operating budget Increased equipment redundancy and reliability Demonstrates BRWWTP’s commitment to energy conservation Check numbers and expandCheck numbers and expand

    28. ENERGY CONSERVATION MEASURES (ECM) ECM #1 - Digester Gas Utilization ECM # 2 - Digester Recirculation Pump Improvements ECM # 3 - HVAC Improvements ECM # 4 - Direct Digital Ventilation Controls ECM # 5 - Lighting Improvements ECM # 6 - Water Conservation

    29. ECM #1 DIGESTER GAS UTILIZATION Digester Gas Conditioning Two new gas conditioning skids for cleaning, drying and siloxane removal Engine Generators Three 1 MW Waukesha Enginators designed for landfill and digester gas Recovery Steam Generators (HRSGs) Capture waste heat from engine exhaust to produce low pressure steam

    30. ECM #1 DIGESTER GAS UTILIZATION Plant biogas needs will be met first and all excess biogas will be used by generators. Generators sized to handle annual average of 1.1 million cubic feet of gas per day. Electricity generated must be used on-site and can’t be fed back to grid (Interconnect Agreement) Cogen Facility will be operated and maintained by JCI under a Maintenance Agreement

    31. ECM #1 DIGESTER GAS UTILIZATION Financial and Operational Benefits Clean gas will be available throughout site. Improved reliability of HVAC and process boilers due to clean gas. Convert wasted flared biogas to electricity. Heat recovery/steam generation results in more digester gas available to engines. Sustainable and reliable solution. Produces 20% of Plant’s electrical requirements

    34. ECM # 2 DIGESTER RECIRCULATION PUMP ESD Recirculation Pump Improvement Replace one vortex pump in each digester Replace with a Hidrostal pump Energy consumption reduced by 55 HP 55 hp each?55 hp each?

    35. ECM #3 HVAC IMPROVEMENTS 320 ton York absorption chiller boiler unit 125 gallon domestic water heater Split system heat pump with programmable thermostat 2 cast iron sectional hot water boilers Benefits More efficient use of digester gas Increased equipment service life Reduced maintenance and improved redundancy

    36. ECM #4 DIRECT DIGITAL CONTROL/VENTILATION OPTIMIZATION Direct Digital Control Metasys energy management system (EMS) Lab exhaust fan monitoring and control Ventilation Optimization Establish schedule and ventilation rates for fan systems Optimize return and outside air ratios Electric Unit Heaters New non-adjustable fixed range thermostats

    37. ECM #5 LIGHTING IMPROVEMENTS Energy efficient electronic ballast Occupancy sensors for low use areas. Re-lamping/ re-ballast existing fixtures with 28W T8 lamps and magnetic ballasts. Replace metal halide & high pressure sodium fixtures with energy efficient high output T5 fixtures. LED exit signs. How many lights changed out?How many lights changed out?

    38. ECM # 6 WATER CONSERVATION Installation of the following water conservation devices Replace 3.5 gpf toilets with 1.6 gpf low flush toilets and flush valves Replace 4 gpm shower heads with 2.5 gpm reduced flow shower heads 0.5 gpm aerators on restroom sinks Water less urinals in Administration Bld.

    39. SUMMARY OF ANNUAL SAVINGS (Year 1) ECM 1 Digester Gas Utilization $1,630,000 ECM 2 ESD Recirculation Pump 15,145 ECM 3 HVAC Improvements 32,250 ECM 4 Digital HVAC Control 46,500 ECM 5 Lighting Improvements 81,350 ECM 6 Water Conservation 1,050 TOTAL $1,806,000

    40. BGE’s RIDER 24 LOAD RESPONSE PROGRAM Customers that can reduce electric loads during peak demands receive credits on bill for enrolling Credits based on amount of load reduction 1,000 kw load reduction worth $70,000/yr Customers can participate by either shutting down equipment or running generators Maximum load response is 10 times per year for up to 6 hours. (Monday-Friday) Average number of activations over past 6 years was1.6 requests per year

    41. WWFD ENROLLMENT Location Capacity (kw) Annual Credit ($) Back River 2,000 144,682 Patapsco 1,366 98,329 Eastern Ave PS 433 31,869 Jones Falls PS 250 18,400 Dundalk PS 115 8,454 TOTAL SAVINGS $301,734

    42. ONSITE BLEACH GENERATION Construction of bleach/chlorine gas generation facility of maximum 15,000 #/day equivalent chlorine. Hybrid system which produces chlorine gas for immediate use, 12 % bleach and excess caustic soda. Estimated project cost $18.5 million Excess caustic use in scrubbers and future ENR Project payback less than 6 years Estimated production cost for #chlorine $0.40 vs. bulk delivery cost of $0.97.

    43. FUTURE ENERGY CONSIDERATIONS Solar Power Hydrogen Gas Utilization from OSBG Digestion Process Enhancements Possible 4th Enginator Biodiesel production from scum and grease

    44. QUESTIONS?

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