Constructed Wetlands Treatment of an Automotive Bedliner Manufacturers Wastewater Art Kuljian, P.E., BCEE, Kevin Olmstead, Ph.D., P.E., Tammy Rabideau, CPG, Jamie MeikleWEFTEC 2009 October 14, 2009

OutlineBackgroundTimelineConstruction and StartupSystem DescriptionTreatment Cells and LagoonsWetland PlantingsTertiary FiltrationSystem PerformanceSystem ObservationsSummary

BackgroundTruck bedliner manufacturing operation in Lapeer, MichiganMixed sanitary and process wastewater from plastic extrusion and thermoforming operationsPrevious unlined lagoon system ineffectiveRestrictive groundwater discharge limitsSwitched to wetland wastewater treatment First-in-the-State in Michigan for an industrial application

Constructed Wetlands AdvantagesPassive, self-regenerative treatment process, given proper harvesting of dominant plantsLow environmental impactLittle need for operator attentionLarge buffering capacity to accommodate system variancesHabitats for wetland speciesShort implementation schedule

TimelineCharacterization June 1999Pilot Study August 1999Design/Build Proposal January 2000Begin Construction April 2000System Startup August 2000 Phase 2 Expansion April 2006Phase 2 Commissioning October 2006In continuous operation since November 2000

Relative Removals During Pilot Testing

Chart10

95

90

96

90

Mass Removal (%)

90

BOD

1

Effluent BOD

Concentration (mg/L)

Figure 2: BOD Performance of MBR system with oily waste

TSS

1

Effluent TSS

Concentration (mg/L)

Figure 3: TSS Performance of MBR system with oily waste

NH3-N

1

Effluent NH3-N

Concentration (mg/L)

Figure 4: NH3-N Performance of MBR system with oily waste

O&G

1

Effluent Oil & Grease

Concentration (mg/L)

Figure 5: Oil & Grease Performance of MBR system with oily waste

COD

69.7

64.6

64

40.75

57.25

63.25

57.75

45.2

37087

78.5

37148

37178

108

101

34

53

53

41

50

36

31

54

Effluent COD

Concentration (mg/L)

Figure 6: COD Performance of MBR system with oily waste

Sheet1

DateFlow (gpd)HRTBODTSSNH3-NPCODCODBTEXBTEXPNHPNHCdCdCrCrCuCuPbPbHgHgNiNiZnZn

RepRepRep0.020.420.10.140.00130.588.3

130030.20.01040.12740.03560.00430.00270.050.504

Nov-00403021500.1569.7N/AN/A0.020.420.10.140.00130.588.3

Dec-0092070.464.6N/AN/A

Construction and StartupWetland comprised of over 27,000 native plantsInstalled over 160,000 ft2 PVC liner and earth bedSeeded startup with activated sludge from POTWTemporary winter storage of wastewater in HDPE lined lagoons underlain with bentonite-sand layerFinal polishing in 150 ft2 tertiary sand filter buildingUV disinfection prior to surface water discharge

System Description20,000 gallon/day (gpd) design flow rate, 90 day HRT4 acre lined wetland treatment system - 2 winter storage lagoons (900,000 gal.each) - 2 primary cells (0.6 acre capacity) - secondary treatment cell (2.5 acre capacity) - tertiary treatment cell (0.9 acre capacity)Continuous downflow sand filter rated at 5 gpm/ft2Disinfection w/ultraviolet (UV) radiationFlow monitoring structure and discharge to Plum Creek

Process Flow Diagram

PlantingsPrimary Cells

Plantings---Secondary Cells

System PerformanceSignificant treatment occurs in the primary cells: - BOD and TSS are reduced ~ 60% to 70% - NH3-N is reduced ~ 85% to 95% - Total P is reduced ~ 60% to 70%Flowthrough, facultative treatment occurs in the primary cells, with an HRT of ~ 12 daysVegetative growth in the secondary and tertiary cells results in mass removals for all target parameters of 90% to 95%

System Removal Performance

Effluent BOD

Chart11

2500

254025

2

9

36906

39

36967

8

1

1

37087

2

3

2

3

2

19

19

25

6

4

37418

37448

37478

37508

37538

4

28

10

37658

35

6

37748

37778

37808

37838

37868

6

6

12

18

18

11

9

8

8

38182

38212

38242

15

2

15

20

27

25

18

38482

38512

38542

38572

38602

38632

38662

38692

38722

38752

38782

38812

38842

38872

38902

38932

38962

4

2

3

6.4

5.25

2.8

39187

4.12

39247

39277

39307

39337

39367

7.1

4.1

2.1

39487

39517

39547

39577

39607

39637

39667

39697

1.9

1.5

2.1

1.5

39847

39877

39907

39937

3.3746153846

1.5

7.1

Monthly Average BOD

BOD Ave Limit

BOD (mg/l)

End AlumAddition

BOD

1

Effluent BOD

Concentration (mg/L)

Figure 2: BOD Performance of MBR system with oily waste

TSS

1

Effluent TSS

Concentration (mg/L)

Figure 3: TSS Performance of MBR system with oily waste

NH3-N

1

Effluent NH3-N

Concentration (mg/L)

Figure 4: NH3-N Performance of MBR system with oily waste

O&G

1

Effluent Oil & Grease

Concentration (mg/L)

Figure 5: Oil & Grease Performance of MBR system with oily waste

COD

69.7

64.6

64

40.75

57.25

63.25

57.75

45.2

37087

78.5

37148

37178

108

101

34

53

53

41

50

36

31

54

Effluent COD

Concentration (mg/L)

Figure 6: COD Performance of MBR system with oily waste

Sheet1

DateFlow (gpd)HRTBODTSSNH3-NPCODCODBTEXBTEXPNHPNHCdCdCrCrCuCuPbPbHgHgNiNiZnZn

RepRepRep0.020.420.10.140.00130.588.3

130030.20.01040.12740.03560.00430.00270.050.504

Nov-00403021500.1569.7N/AN/A0.020.420.10.140.00130.588.3

Dec-0092070.464.6N/AN/A

Effluent TSS

Chart2

3000

304530

15

20

36906

31

36967

11

9

10

37087

20

13

9

11

8

31

29

39

15

8

37418

37448

37478

37508

37538

20

35

30

37658

36

13

37748

37778

37808

37838

37868

20

18

27

28

29

29

34

15

23

38182

38212

38242

36

36

32

42

42

44

33

38482

38512

38542

38572

38602

38632

38662

38692

38722

38752

38782

38812

38842

38872

38902

38932

38962

20

15

7

11.5

7.67

4

39187

7

39247

39277

39307

39337

39367

15.7

8.8

12.7

39487

39517

39547

39577

39607

39637

39667

39697

11.7

7.1

9.8

5.2

39847

39877

39907

39937

9.4746153846

4

20

Monthly Average TSS

TSS Ave Limit

TSS (mg/l)

End AlumAddition

BOD

1

Effluent BOD

Concentration (mg/L)

Figure 2: BOD Performance of MBR system with oily waste

TSS

1

Effluent TSS

Concentration (mg/L)

Figure 3: TSS Performance of MBR system with oily waste

NH3-N

1

Effluent NH3-N

Concentration (mg/L)

Figure 4: NH3-N Performance of MBR system with oily waste

O&G

1

Effluent Oil & Grease

Concentration (mg/L)

Figure 5: Oil & Grease Performance of MBR system with oily waste

COD

69.7

64.6

64

40.75

57.25

63.25

57.75

45.2

37087

78.5

37148

37178

108

101

34

53

53

41

50

36

31

54

Effluent COD

Concentration (mg/L)

Figure 6: COD Performance of MBR system with oily waste

Sheet1

DateFlow (gpd)HRTBODTSSNH3-NPCODCODBTEXBTEXPNHPNHCdCdCrCrCuCuPbPbHgHgNiNiZnZn

RepRepRep0.020.420.10.140.00130.588.3

130030.20.01040.12740.03560.00430.00270.050.504

Nov-00403021500.1569.7N/AN/A0.020.420.10.140.00130.588.3

Dec-0092070.464.6N/AN/A

Effluent NH3-N

Chart5

99999999090

9999999925920

0

7

36906

20

36967

0

0

0

37087

0

0

2

4.5

4

5

2.5

2

1

0.5

37418

37448

37478

37508

37538

4.5

13

13

37658

27

7.5

37748

37778

37808

37838

37868

2

2.5

4

8

15.5

17

2.5

3

2.5

38182

38212

38242

2

3

4.5

8.5

7.5

12

2.5

38482

38512

38542

38572

38602

38632

38662

38692

38722

38752

38782

38812

38842

38872

38902

38932

38962

0.3

1

0.95

1.08

0.588

0.22

39187

0.14

39247

39277

39307

39337

39367

0.48

0.7

2

39487

39517

39547

39577

39607

39637

39667

39697

0.25

0.5

0.5

0.3

39847

39877

39907

39937

0.6698461538

0.14

2

NH3-N Ave Daily Max

Daily Max Limit (May-Sept only)

NH3-N (mg/l)

End AlumAddition

BOD

1

Effluent BOD

Concentration (mg/L)

Figure 2: BOD Performance of MBR system with oily waste

TSS

1

Effluent TSS

Concentration (mg/L)

Figure 3: TSS Performance of MBR system with oily waste

NH3-N

1

Effluent NH3-N

Concentration (mg/L)

Figure 4: NH3-N Performance of MBR system with oily waste

O&G

1

Effluent Oil & Grease

Concentration (mg/L)

Figure 5: Oil & Grease Performance of MBR system with oily waste

COD

69.7

64.6

64

40.75

57.25

63.25

57.75

45.2

37087

78.5

37148

37178

108

101

34

53

53

41

50

36

31

54

Effluent COD

Concentration (mg/L)

Figure 6: COD Performance of MBR system with oily waste

Sheet1

DateFlow (gpd)HRTBODTSSNH3-NPCODCODBTEXBTEXPNHPNHCdCdCrCrCuCuPbPbHgHgNiNiZnZn

RepRepRep0.020.420.10.140.00130.588.3

130030.20.01040.12740.03560.00430.00270.050.504

Nov-00403021500.1569.7N/AN/A0.020.420.10.140.00130.588.3

Dec-0092070.464.6N/AN/A

Effluent P

Chart9

0.500

0.543

0.15

0.4

36906

2.6

36967

0.1

0.1

0.1

37087

0.3

0.35

0.4

0.6

0.5

0.55

0.5

0.9

0.4

0.45

37418

37448

37478

37508

37538

0.8

2.5

3

37658

4

0.75

37748

37778

37808

37838

37868

0.5

0.6

0.75

1.9

3.3

1.6

0.8

0.9

0.75

38182

38212

38242

0.75

0.5

0.5

1.4

2.2

3.5

0.9

38482

38512

38542

38572

38602

38632

38662

38692

38722

38752

38782

38812

38842

38872

38902

38932

38962

0.2

0.3

0.4

0.36

0.16

0.1

39187

0.25

39247

39277

39307

39337

39367

0.23

0.4

0.4

39487

39517

39547

39577

39607

39637

39667

39697

0.5

0.4

0.2

0.1

39847

39877

39907

39937

0.2923076923

0.1

0.5

Monthly Average P

P Ave Limit

P (mg/l)

Installation of Sand Filter

End AlumAddition

BOD

1

Effluent BOD

Concentration (mg/L)

Figure 2: BOD Performance of MBR system with oily waste

TSS

1

Effluent TSS

Concentration (mg/L)

Figure 3: TSS Performance of MBR system with oily waste

NH3-N

1

Effluent NH3-N

Concentration (mg/L)

Figure 4: NH3-N Performance of MBR system with oily waste

O&G

1

Effluent Oil & Grease

Concentration (mg/L)

Figure 5: Oil & Grease Performance of MBR system with oily waste

COD

69.7

64.6

64

40.75

57.25

63.25

57.75

45.2

37087

78.5

37148

37178

108

101

34

53

53

41

50

36

31

54

Effluent COD

Concentration (mg/L)

Figure 6: COD Performance of MBR system with oily waste

Sheet1

DateFlow (gpd)HRTBODTSSNH3-NPCODCODBTEXBTEXPNHPNHCdCdCrCrCuCuPbPbHgHgNiNiZnZn

RepRepRep0.020.420.10.140.00130.588.3

130030.20.01040.12740.03560.00430.00270.050.504

Nov-00403021500.1569.7N/AN/A0.020.420.10.140.00130.588.3

Dec-0092070.464.6N/AN/A

Original Site

Lagoon Preparation

Cell Preparation

Sand-Bentonite Underlayer

Lagoon Liner Installation

Treatment Cell Liner Installation

Flow Distribution Berm Construction

Initial Planting

Water Plantains and Bulrushes in Secondary Cell

Acclimated Plantings

Winter Storage Lagoon

Artistic Shot of Storage Lagoon

Secondary Cell

Yours Truly on the Berm

Tertiary Cell with Water Depth Gauge

Tertiary Cell

Final Treatment Building

Volcano ContinuousDownflow Sand Filter

UV Disinfection and Flow Monitoring

Toad on Top of Things at the UV Chamber

Site ObservationsNutrient uptake in wetland vegetation was poor during the winter months and good to excellent remainder of the yearOperations labor minimal -

Performance Summary95% removal of BOD5, TSS, NH3-N and P is achievableEffluent NH3-N of 0.5 mg/L and P of 0.2 mg/LPrimary cells provide equalization and treatment prior to discharge to secondary and tertiary cellsEffluent BOD5 has averaged 3 mg/L and TSS has averaged 5 mg/L since installation of the sand filter

Lessons LearnedEnsure C:N:P ratio of 100:5:1 is available in wastewater feedMaintain wetland water temperature >50F (10C); otherwise, winter storage may be neededBackwash of sand filter at 2% to 5% of flow aids insoluble nutrient removalPeriodic lamp cleaning via citric acid and/or sodium hypochlorite every 2 to 3 monthsAnnual harvesting of dominant plants (e.g., cattails) helps ensure variation and quantities of all speciesHarvest duckweed before winter die-off to keep total P inventory in check

Contractor/Supplier AcknowledgementsMs. Joanne Michael, Southern Tier Consulting West Clarksville, NYMr. Dave Bury, North American Lining Services Kalkaska, MIMr. Mark Fisher, Lighthouse Filters Dahlonega, GAMr. Todd Desloover, Debarr Construction Greenwood, MIMr. H. Blair Selover, Tetra Tech Ann Arbor, MI

Questions?

**This is the wastewater storage lagoon (lined)