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Biosolids Facility Update In the Final Stretch
August 12, 2015
City of Detroit, Water and Sewerage Department
| City of Detroit Water & Sewerage Department
Biosolids Management Needs
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• Historical solids management challenges resulted in
permit violations
• ACO requires peak biosolids capacity of 850 DTPD
• New MACT air quality rules – effective March 2016
• Incineration Complex I obsolete
• High O&M costs to manage biosolids
• Ongoing capital costs for
equipment rehabilitation,
replacement and upgrade
| City of Detroit Water & Sewerage Department
Existing Solids Processes at the WWTP
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Primary Sludge Secondary Sludge
Gravity Thickening Gravity Thickening
Thickened Sludge
Storage
Dewatering Centrifuges/BFPs
Incineration Ash Disposal
Off-Load Facility
Lime Stabilization
Land Application
Landfill
MHI Complex I
MHI Complex II
| City of Detroit Water & Sewerage Department
Background Biosolids Decision
Based on March 2012 Biosolids Symposium: • Retire C-I Incinerators
• Construct Biosolids Dryer Facility (PC-792)
• Bring C-II Incinerators into Air Quality Compliance
with 2016 regulations (PC-791)
• Biosolids peaks managed with
land application, land-filling
and C-II Incinerators
• Competitive Procurement • 3 Proposers
• 9 Proposals
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| City of Detroit Water & Sewerage Department
Background Biosolids Decision
• NEFCO Alternate 2 Selected for PC-792
• Lowest costs
• Spare dryer train
• Provides dewatering
• Does not significantly constrain plant operations
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| City of Detroit Water & Sewerage Department
Primary Sludge Secondary Sludge
Gravity Thickening Gravity Thickening
Thickened Sludge
Storage
Dewatering Centrifuges/BFPs
Incineration Ash Disposal
Off-Load Facility
Lime Stabilization
Land Application
Landfill
MHI Complex I
MHI Complex II
Existing Solids Processes at the WWTP
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New Biosolids Drying Facility
Beneficial Reuse of Dried
Fertilizer Product
| City of Detroit Water & Sewerage Department
PC-792 Contract Facility
• 20 year operation and maintenance contract
• 316 DTPD Firm Capacity
• Contract approved by Board March 27, 2013
• Substantial Completion required by March 29, 2016
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| City of Detroit Water & Sewerage Department
Biosolids Drying Facility
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4 Dryer Trains • 110 dtpd each
• 440 dtpd (peak)
8 Dewatering
Centrifuges • 66 dtpd each
• Two centrifuges
per dryer train
Centrifuges
Dryer
| City of Detroit Water & Sewerage Department
Drying Process
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Liquid Sludge Dewatering and Mixing
Weigh
Belt
Mixer
Cake
Bin
Centrifuges
(2 Per Dryer – Total 8) Lobe
Pumps
Total 8
To
Dryer
Sludge Grinders
(2 Per Dryer – Total 8)
WWTP
Sludge Feed
Pumps
3 & 4
12” Line
Across
Jefferson
Ave
16” Line
Across
Jefferson
Ave
Polymer
WWTP
WWTP
Blended
Sludge
Tanks
3 & 4
Biosolids Dryer Facility
| City of Detroit Water & Sewerage Department
Drying Process
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Air Handling &
Emission Controls
Solids System
Components
| City of Detroit Water & Sewerage Department
Triple Pass 110 DTPD Dryer
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| City of Detroit Water & Sewerage Department
Biosolids Dryer Facility Equiment
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Cake Bin Tray Scrubber
Regenerative
Thermal Oxidizer
Recycle Bin
Biosolids Dryer
Dryer Furnace
| City of Detroit Water & Sewerage Department
Biosolids Dryer Facility Equipment
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Product Silo Cyclone Separator
Odor Scrubbers
Hypochlorite and Caustic
Tanks for Odor Control
Dry Polymer
Silo Polymer Mix
Tanks
| City of Detroit Water & Sewerage Department
Dryer Facility Benefits
Retire 1940’s era Complex I incinerators to improve reliability of operations and avoid upgrade and rehabilitation costs Reduced reliance on aging Complex II incinerators and landfills • Increased reliability • Reduced energy
(natural gas) consumption • Reduced emissions • Extended equipment life
– reduced costs
Firm capacity of 316 dry tons per day - 70% of average daily biosolids
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| City of Detroit Water & Sewerage Department
Dryer Facility Benefits
Dewatering capability supplements WWTP • Improved reliability
• Addresses prior challenges in meeting permit
Improves ability to manage peak biosolids • Reduced WWTP off-loading
• Reduces or eliminates need
to store peak biosolids
• Sufficient capacity for all
peak loads when used with
limited incineration and
off-loading to land application
or land fill
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| City of Detroit Water & Sewerage Department
Dryer Facility Benefits
Environmentally beneficial use for biosolids
Dryer product lower in odors and safe - pathogens
killed
Preserve landfill capacity and reduces trucking
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| City of Detroit Water & Sewerage Department
Dryer Facility Benefits
Lower impact on community • Odor control scrubbers and building sealed to contain odors.
• Only dried biosolids with little odor will be trucked
• Noise control – quieter than Complex I fans being retired
• Fewer trucks – reduces volume to be trucked by 75%
• Located farther from residential areas
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| City of Detroit Water & Sewerage Department
Air Emissions Are Lower For Dryers than for Incinerators Emissions Limits Established in MDEQ Permit to Install
Pollutant
Complex II Incinerators
Emissions Limits
(8 Incinerators
360 DTPD Firm)
Biosolids Dryer Facility
Emissions Limits
(4 Dryers
316 DTPD Firm)
Percent
Reduction
Particulate Matter 46.6 tpy 20.0 tpy 57.1%
Particulate Matter - PM2.5 58.3 tpy 19.2 tpy 67.1%
Particulate Matter - PM10 59.6 tpy 26.9 tpy 54.9%
Carbon monoxide 1,522.4 tpy 65.7 tpy 95.7%
Volatile Organic Compounds
(Per incinerator or dryer) 3.20 lb./hr. 1.68 lb./hr. 47.5%
Nitrogen oxides 663.4 tpy 71.5 tpy 89.2%
Carbon Dioxide Equiv. (CO2e) 237,275 tpy 90,361 tpy 61.9%
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PC-792 Uses Best Available Control Technology
Air Emissions
| City of Detroit Water & Sewerage Department
Summary of Contract: 20 Year O&M Period
Contractor Responsibilities • All required operation & maintenance services –
dewatering, drying, beneficial reuse, hauling, disposal
• All repairs, maintenance and equipment replacements
needed to maintain operation – No more DWSD capital
requirements for 20 years
• Continuous processing at any flow
rates required by DWSD (within
contractual range)
• Beneficial reuse of biosolids and all
residuals disposal costs
• Performance guarantee
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| City of Detroit Water & Sewerage Department
Summary of Contract: 20 Year O&M Period
Contractor Responsibilities • Provide chemicals, hauling, and beneficial reuse
• Pay for utility usage above guaranteed amounts
• Coordinate operations with DWSD
• Provide DWSD and MDEQ with required records
• Maintain O&M records in CMMS
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| City of Detroit Water & Sewerage Department
Summary of Contract: 20 Year O&M Period
Contractor Responsibilities • Provide property insurance
• After 20 years turn over equipment in “as-new” condition
except for reasonable and normal wear and tear.
• Train DWSD to take over at end of 20 years
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| City of Detroit Water & Sewerage Department
Summary of Contract
DWSD Responsibilities • Provide utilities within usage guarantees.
• Provide liquid sludge within specified range
Coordinate sludge operations with Contractor
Monthly payments
22
| City of Detroit Water & Sewerage Department
Contract Cost Status
*Subject to escalation at Detroit CPI rate: 0.06% to date since March 2013
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Item Contract Price
Construction Fixed Cost
(94.1% Complete)
$132,000,000
Authorized Changes $2,724,143
Unencumbered Allowances $8,285,444
Monthly O&M Cost
(Includes 73,000 Annual Dry Tons)
$1,079,000*
Added Cost/DT
(Above 73,000 to 115,340 Annual DT)
$76.60*
Added Cost/DT
(Above 115,340 to 140,000 Annual DT)
$88.93*
| City of Detroit Water & Sewerage Department
Current O&M Costs v. Reductions Presented In March 2013 First Year O&M Costs ($ x 1000)
Prior Existing
(March 2013)
Dryers Estimate
(March 2013)
Current Existing
(No Drying)
Aug. 2015
Incineration DTPY 111,000 28,439 94,000
Landfilling DTPY 39,000 17,412 62,200
Land Application DTPY 13,000 5,804 8,800
Drying DTPY 111,345 -
Solids Manpower (Positions) 298 127 143
Dewater, Incinerate, Offload
Labor $25,401 $10,716 $11,499
Natural Gas $10,595 $2,715 $7,421
Electricity $2,574 $689 $2,528
Dewatering Polymer $5,640 $1,787 $5,240
Lime $1,646 $735 $1,987
Land Filling & Land Application $10,086 $4,337 $11,848
Parts, Supplies, Services, Other $12,411 $6,985 $13,355
Subtotal WWTP $68,353 $27,964 $53,879
WWTP Unit Cost per Dry Ton $419.35 $541.35 $326.54
Biosolids Dryer Facility
O&M Payments $15,885
Natural Gas $5,475
Electricity $2,165
Subtotal Dryer Facility $23,525
BDF Unit Cost Per Dry Ton $211.28
Total Cost $68,353 $51,488 $53,879
Savings Base $16,865
Overall Unit Cost Per Dry Ton $419.35 $315.88 $326.54
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| City of Detroit Water & Sewerage Department
O&M Cost Reductions Now Expected to Improve on Prior Plans First Year O&M Costs ($ x 1000)
Prior Existing
(March 2013)
Dryers Estimate
(March 2013)
Current Existing
(No Drying)
Aug. 2015
Firm Capacity
Drying
Aug. 2015
Incineration DTPY 111,000 28,439 94,000 45,160
Landfilling DTPY 39,000 17,412 62,200 4,000
Land Application DTPY 13,000 5,804 8,800 500
Drying DTPY 111,345 - 115,340
Solids Manpower (Positions) 298 127 143 91
Dewater, Incinerate, Offload
Labor $25,401 $10,716 $11,499 $7,318
Natural Gas $10,595 $2,715 $7,421 $3,565
Electricity $2,574 $689 $2,528 $1,115
Dewatering Polymer $5,640 $1,787 $5,240 $1,577
Lime $1,646 $735 $1,987 $162
Land Filling & Land Application $10,086 $4,337 $11,848 $887
Parts, Supplies, Services, Other $12,411 $6,985 $13,355 $8,127
Subtotal WWTP $68,353 $27,964 $53,879 $22,752
WWTP Unit Cost per Dry Ton $419.35 $541.35 $326.54 $458.15
Biosolids Dryer Facility
O&M Payments $15,885 $16,202
Natural Gas $5,475 $4,310
Electricity $2,165 $1,962
Subtotal Dryer Facility $23,525 $22,474
BDF Unit Cost Per Dry Ton $211.28 $194.85
Total Cost $68,353 $51,488 $53,879 $45,226
Savings Base $16,865 Base $8,654
Overall Unit Cost Per Dry Ton $419.35 $315.88 $326.54 $274.09
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| City of Detroit Water & Sewerage Department
Analysis of Potential Operating Strategies is In Progress First Year O&M Costs ($ x 1000)
Prior
Existing
(March
2013)
Dryers
Estimate
(March
2013)
Current
Existing
(No Drying)
Aug. 2015
Maximize
Drying
Aug. 2015
Firm
Capacity
Drying
Aug. 2015
Minimize
Dryers &
Maximize
Incineration
Aug. 2015
Minimize
Dryers &
Maximize
Land Appl.
Aug. 2015
Minimize
Dryers &
Maximize
Landfilling
Aug. 2015
Incineration DTPY 111,000 28,439 94,000 40,000 45,160 87,500 6,000 6,000
Landfilling DTPY 39,000 17,412 62,200 4,000 4,000 4,000 28,700 86,000
Land Application DTPY 13,000 5,804 8,800 500 500 500 57,300 -
Drying DTPY 111,345 - 120,500 115,340 73,000 73,000 73,000
Solids Manpower (Positions) 298 127 143 91 91 91 91 91
Dewater, Incinerate, Offload
Labor $25,401 $10,716 $11,499 $7,318 $7,318 $7,318 $7,318 $7,318
Natural Gas $10,595 $2,715 $7,421 $3,158 $3,565 $6,908 $474 $474
Electricity $2,574 $689 $2,528 $990 $1,115 $2,147 $435 $435
Dewatering Polymer $5,640 $1,787 $5,240 $1,413 $1,577 $2,922 $2,922 $2,922
Lime $1,646 $735 $1,987 $162 $162 $162 $4,637 $2,783
Land Filling & Land Application $10,086 $4,337 $11,848 $871 $887 $1,022 $11,893 $14,713
Parts, Supplies, Services, Other $12,411 $6,985 $13,355 $7,767 $8,127 $8,127 $7,478 $7,478
Subtotal WWTP $68,353 $27,964 $53,879 $21,679 $22,752 $28,605 $35,157 $36,122
WWTP Unit Cost per Dry Ton $419.35 $541.35 $326.54 $487.16 $458.15 $310.92 $382.14 $392.63
Biosolids Dryer Facility
O&M Payments $15,885 $16,661 $16,202 $12,956 $12,956 $12,956
Natural Gas $5,475 $4,503 $4,310 $2,728 $2,728 $2,728
Electricity $2,165 $2,050 $1,962 $1,242 $1,242 $1,242
Subtotal Dryer Facility $23,525 $23,214 $22,474 $16,926 $16,926 $16,926
BDF Unit Cost Per Dry Ton $211.28 $192.64 $194.85 $231.86 $231.86 $231.86
Total Cost $68,353 $51,488 $53,879 $44,892 $45,226 $45,531 $52,083 $53,048
Savings From Current Base $16,865 Base $8,987 $8,654 $8,348 $1,796 $831
Overall Unit Cost Per Dry Ton $419.35 $315.88 $326.54 $272.07 $274.09 $275.94 $315.65 $321.50
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| City of Detroit Water & Sewerage Department
Biosolids Dryer Facility Capital Funding
PC-792 avoids capital cost for: • Rehabilitation of remaining Complex I incinerators under
PC-774 ($6.5M)
• Complex I air quality MACT upgrades ($26M)
• Future periodic rehabilitation/upgrades of Complex I
• Centrifuge replacement project (deferred) ($25M)
• Dewatered biosolids storage
facility ($12.2M)
• Reduced periodic rehabilitation
or replacement of C-II &
dewatering equipment
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| City of Detroit Water & Sewerage Department
Biosolids Dryer Facility Capital Funding
PC-792 Debt Service • Segment 1 SRF Loan for $81M
• Debt service ~$5.2M/yr. for 20 years at 2.5%
• Bond funding for balance
• Debt service ~$4.7M/yr. for 30 years at 5.5%
• Segment 2 SRF loan being
discussed with MDEQ
• Replace bond funding for ~$21M
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| City of Detroit Water & Sewerage Department
Construction Status
• Equipment and systems needed for operation are installed
and vendor checked
• Lighting, site work and finishes being completed
• Corrections as required during shake-down
• Punch list, touch-up and final documentation
29
| City of Detroit Water & Sewerage Department
Current Start-up Schedule
Over Six Months Ahead of Schedule (Testing and Shake-down Continue)
31
Current Plan
Contract
Requirement
Control System Acceptance Test and Screens Being finalized
Start-up and Issue Resolution Ongoing
Field Testing to Confirm Equipment
Performance
Aug. 5 to 13
Demonstration Testing of Trains 1 to 3 Aug. 14 to
Sept. 2
Substantial Completion of Trains 1-3 Sept. 2, 2015 Mar. 14, 2016
Demonstration Testing of Train 4 Sept. 2 to 12
Substantial Completion of Trains 4 Sept. 14, 2015 Mar. 29, 2016
| City of Detroit Water & Sewerage Department
Operation
Marketing – NEFCO developing market • Dried product for use as farm fertilizer • Product name will be “MichiGreen” Approved by MDEQ for use in Michigan Also pursuing approval in Ohio, Indiana, Ontario and other states
32
| City of Detroit Water & Sewerage Department
Operation
DWSD role: Monitoring of NEFCO performance to contract • DWSD coordinator • Capacity available • Invoices • Maintenance • Permit compliance
33
| City of Detroit Water & Sewerage Department
Changes to WWTP
Shutdown of Complex I incinerators at Dryer Substantial Completion Dewatering and disposal operating scenarios are being evaluated Re-assignment of staff • Overall reduction of about 52 positions currently
anticipated • MDEQ approval of staffing adjustments required • Performance based placement of incinerator operators
(title plant tech) • Evaluation of staffing needs to effectively operate and
maintain Complex II as dryers come on-line • Interim use of staff to decommission Complex I • DWSD liaison appointed to coordinate with the Contractor
34
| City of Detroit Water & Sewerage Department
Dryer Facility Tour
Date and Time to be Set At Board’s Convenience
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