August 2015

Technology Deep Dive: Phosphorus removal innovation PAGE 58

tpomag.com AUGUST 2015

In My Words: Knowing residuals markets PAGE 56

Tailgating to

Chuck Smithwick District Manager Grifton, N.C.

Excellence CONTENTNEA MSD TEAM GETS THE MOST FROM A NEW BNR PROCESS PAGE 42

Sustainable Operations: Low-risk biogas power PAGE 28

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Aerzen USA .............................. 41 ❒

JDV Equipment Corporation 47 ❒

AllMax Software, Inc. ............. 47 ❒

JWC Environmental ................ 29 ❒

Aqua Ben Corporation ............. 59 ❒

Keller America Inc. .................. 7 ❒ Komline-Sanderson ................ 31 ❒

AQUA-Zyme Disposal Systems, Inc. ........................ 67 ❒

Kuhn North America, Inc. ........ 69 ❒

Bilfinger Water Technologies, Inc. ............... 73 ❒ Booth 1016

Blue-White Industries ............ 2 ❒ Bright Technologies, div. of Sebright Products, Inc. ....... 69 ❒

Carylon Corporation ................. 17 ❒ CB&I .......................................... 21 ❒ Centrisys Corporation ............ 59 ❒ CST Industries .......................... 19 ❒ Eagle Microsystems, Inc. ......... 31 ❒ Enviro-Care Company ...........

4 ❒

FKC Co., Ltd. ............................ 25 ❒

Flo Trend Systems .................. 54 ❒

Lovibond Tintometer .............. 35 ❒ Parkson Corp. ........................... 37 ❒ Roto-Mix, LLC ............................. 71 ❒ Schreiber LLC ............................ 35 ❒ Screenco Systems LLC ............ 73 ❒ SEEPEX Inc. ............................... 39 ❒ Smith & Loveless, Inc. ............. 79 ❒ SUEZ ENVIRONNEMENT ........ 78 ❒

8 ❒

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Grace Industries, Inc. ............. 61 ❒

USABlueBook .......................... 80 ❒

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contents

top performers:

August 2015

WATER: PLANT Page 32

Beyond the Normal

An Illinois water treatment plant improves water quality and operations with a major upgrade and a team that thrives on challenges. By Trude Witham WASTEWATER: OPERATOR Page 22

Beautiful Music

32

22

Frank D’Ambrosia hits all the right notes conducting plant operations and training programs while building an award-winning career as a clean-water plant superintendent. By Jack Powell

on the cover Chuck Smithwick and the team at the Contentnea Metropolitan Sewerage District (North Carolina) hold informal morning “tailgate” gatherings where ideas are broached, solutions discussed and experiences shared. Says Smithwick: “Everybody works together. We don’t let any good ideas go to waste.” (Photography by Stuart Jones)

42

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WASTEWATER: BIOSOLIDS Page 12

Doing It by the Book

A Maine sanitary district demonstrates that no agency is too small to benefit from creating and following a formal biosolids management plan. By Ted J. Rulseh WASTEWATER: PLANT Page 42

Tailgating to Excellence

Operators at North Carolina’s Contentnea MSD quickly learn to get the most performance from a new biological nutrient removal facility. By Jim Force

LET’S BE CLEAR Page 8

BUILDING THE TEAM Page 40

PRODUCT NEWS Page 72

What if the U.S. had a strategic energy policy, defining roles for each energy source and backed by major funding? What might that mean for clean-water plants and biogas?

New York’s Southern Cayuga Lake Intermunicipal Water Commission faces recruitment challenges while keeping the leadership pipeline filled.

Product Spotlight – Wastewater: Sampler controller provides single-screen programming, USB transfer capability Product Spotlight – Water: Hydraulically balanced diaphragm pump designed for long life

By Ted J. Rulseh, Editor

By Ann Stawski

By Ed Wodalski

@TPOMAG.COM Page 10

Headworks and Biosolids Management Directory Page 48

2016 WWETT Show Invites Seminar Proposals Page 75

IN MY WORDS Page 56

INDUSTRY NEWS Page 75

Lise LeBlanc helps organic residuals suppliers connect with their customers. Her success with municipal and private-sector clients holds lessons for biosolids recycling programs.

People/Awards; Education; Events

Pure Recognition

By Ted J. Rulseh

FOCUS:

San Diego Public Utilities picks up honors for effective communication about its Water Purification Demonstration Project for indirect potable reuse.

TECHNOLOGY DEEP DIVE Page 58

Hey, a Guy Can Dream

Visit daily for exclusive news, features and blogs. HOW WE DO IT: WASTEWATER Page 20

May-December Marriage

A Massachusetts plant team takes heroic measures to integrate a new biogas-fueled CHP system with an older treatment process. By Scottie Dayton HEARTS AND MINDS Page 26

By Craig Mandli SUSTAINABLE OPERATIONS Page 28

Next in Line

Residuals as Resources: Knowing the Market

Nutrient Solutions

An innovative process combines chemical treatment and membrane separation to extract and recover phosphorus from wastewater biosolids.

Low-Risk Biogas Power

By Ted J. Rulseh

A power purchase agreement lets a California agency benefit from a fuel-cell-based generation system without investing up-front capital.

WWETT SPOTLIGHT Page 60

By Doug Day PLANTSCAPES Page 30

Roots of Preservation A wide variety of trees beautify the landscape and put the brakes on stream bank erosion at a Missouri clean-water plant. By Jeff Smith

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Simple Screening

Dewatering plant owner markets his receiving station to the industry.

WORTH NOTING Page 76

coming next month: September 2015 Digital Technology, WEFTEC Pre-Show Issue �� Let’s Be Clear: Hire the resume? Or the person? �� Top Performer – Wastewater Plant: Fisherman’s work ethic in Petersburg, Alaska �� Top Performer – Biosolids: John Donovan, P.E., CDM Smith �� Top Performer – Water Operator: Michael Ramsey, Westmont (Illinois) Water Treatment Plant �� Top Performer – Wastewater Operator: Benjamin Carver, Fairfield-Suisun Sewer District, California

By Craig Mandli

�� How We Do It: Edge-retentive coating in Springfield, Illinois

PRODUCT FOCUS Page 62

�� Sustainable Operations: Biogas to energy in Thousand Oaks, California

Headworks and Biosolids Management CASE STUDIES Page 68

Headworks and Biosolids Management

�� In My Words: Planning for and responding to climate change �� Tech Talk: Managing data with mobile technology �� Technology Deep Dive: Kruger’s AnoxKaldnes Hybas process for SBRs

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Hey, a Guy Can Dream WHAT IF THE US HAD A STRATEGIC ENERGY POLICY, DEFINING ROLES FOR EACH ENERGY SOURCE AND BACKED BY MAJOR FUNDING? WHAT MIGHT THAT MEAN FOR CLEAN-WATER PLANTS AND BIOGAS? By Ted J. Rulseh, Editor

T

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Published monthly by COLE Publishing, Inc. 1720 Maple Lake Dam Rd., PO Box 220, Three Lakes, WI 54562 Call toll free 800-257-7222 / Outside of U.S. or Canada call 715-546-3346 Mon.-Fri., 7:30 a.m.-5 p.m. CST Website: www.tpomag.com / Email: [email protected] / Fax: 715-546-3786 SUBSCRIPTION INFORMATION: A one year (12 issues) subscription to TPOTM in the United States and Canada is FREE to qualified subscribers. A qualified subscriber is any individual or company in the United States or Canada that partakes in the consulting, design, installation, manufacture, management or operation of wastewater and water treatment facilities. To subscribe, return the subscription card attached to each issue, visit tpomag.com or call 800-257-7222. Non-qualified subscriptions are available at a cost of $60 per year in the United States and Canada/Mexico and $150 per year to all other foreign countries. To subscribe, visit tpomag.com or send company name, mailing address, phone number and check or money order (U.S. funds payable to COLE Publishing Inc.) to the address above. MasterCard, VISA and Discover are also accepted. Include credit card information with your order. ADDRESS CHANGES: Submit to TPO, P.O. Box 220, Three Lakes, WI, 54562; call 800-2577222 (715-546-3346); fax to 715-546-3786; or email [email protected]. Include both old and new addresses. Our subscriber list is occasionally made available to carefully selected companies whose products or services may be of interest to you. Your privacy is important to us. If you prefer not to be a part of these lists, please contact Nicole at [email protected]. ADVERTISING RATES: Call 800-994-7990 and ask for Phil or Kim. Publisher reserves the right to reject advertising which in its opinion is misleading, unfair or incompatible with the character of the publication. EDITORIAL CORRESPONDENCE: Address to Editor, TPO, P.O. Box 220, Three Lakes, WI, 54562 or email [email protected]. REPRINTS AND BACK ISSUES: Visit www.tpomag.com for options and pricing. To order reprints, call Jeff Lane at 800-257-7222 (715-546-3346) or email [email protected]. To order back issues, call Nicole at 800-257-7222 (715-546-3346) or email nicole.labeau@ colepublishing.com. CIRCULATION: 71,813 copies per month. © 2015 COLE PUBLISHING INC. No part may be reproduced without permission of publisher.

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he other night I had a dream. I dreamed I woke up one morning to find out that our federal government had adopted a comprehensive energy policy. (OK, I didn’t really have this particular dream, but bear with me.) This policy was not some hodgepodge of here-today/gone-tomorrow grants, loans and incentives for this or that form of green or sustainable energy. It was an actual policy with defined roles for coal, nuclear, natural gas, diesel gasoline, wind, solar, geothermal and, yes, biogas. And what a great thing it was. No longer would major energy decisions be based on private companies’ short-term economic considerations — like closing and tearing down a perfectly good, newly refurbished and relicensed nuclear plant near my hometown, because right now it’s cheaper to make electricity with natural gas and coal. Instead, long-range thinking would apply. In the above example, the federal government would subsidize the nuclear plant’s power to keep it open, since in time we’d need that reliable, clean, greenhouse-gas-free energy, and at some point its price would again be market-competitive.

RUDE AWAKENING But of course I woke up to reality. The nuclear plant was still gone. And as far as the eye could see we’d continue, as a nation, making stupid decisions about energy. I wonder, if we had an actual energy policy, what that would mean for biogas from the nation’s clean-water plants — those with anaerobic digestion, anyway. This one seems like the ultimate no-brainer. Clean-water plants all over the country have anaerobic digesters that produce methane. Many do not use them to produce energy. What stands in their way? More often than not, it’s the up-front investment in enginegenerators or combined heat and power (CHP) systems. Treatment plants increasingly are recognized as resource recovery facilities. One of their resources clearly is energy. Biogas-to-energy systems, based on what I have seen and

read, yield a pretty good return on investment and relatively attractive simple payback times.

WHERE’S THE DOWNSIDE?

OF

It stands to reason that a national energy policy would aggressively encourage biogas-fueled CHP. Digestion of biosolids alone can produce substantial gas and energy. The gas burns clean and in many or most cases would displace power from more-polluting sources like coal-fueled power plants. And once a facility has digesters, it’s natural to feed them food waste, FOG and other high-BOD waste products, yielding even more gas. That brings the extra benefit of keeping those materials out of landfills, with all the cost and environmental risk they can entail. How much potential is there for biogas-to-energy? How much biogas do we produce today versus what we could produce if the resource was fully developed? Well, a few years ago, the North East Biosolids and Residuals Association (NEBRA) collected data on biogas production at cleanwater plants across the United States. The survey found that 1,238 treatment plants use anaerobic digestion and produce biogas, mostly at larger facilities (flows exceeding 1 mgd). On the other hand, two-thirds of the 3,300 or so plants above that size threshold do not produce biogas. And only a small number of plants with flows below 1 mgd do so. So only a fairly small percentage of the nation’s 15,000 to 16,000 permanent treatment facilities produce and use biogas. To be fair, some of these are small package plants, but the survey did find some small facilities with anaerobic digestion — plants with flows from 1 to 5 mgd, and even some with less than 1 mgd. Some of these use biogas to generate electricity.

C

lean-water plants all over the country have anaerobic digesters that produce methane. Many do not use them to produce energy. What stands in their way? More often than not, it’s the up-front investment in engine-generators or combined heat and power (CHP) systems.

Get it Right at the HEADWORKS Mission Critical Processes Downstream Perform Better

WHAT’S THE POTENTIAL? Another study, the 2014 Biogas Market Snapshot from XPRT Media, said the United States had the world’s greatest untapped biogas potential, and that from all sources — cleanwater plants, farms and others — this country could produce nearly 70 million MWh of electricity per year from biogas. That won’t solve all the country’s energy challenges, but it does compare to the output from several 1,000 MW utility power plants, and that’s a substantial amount of renewable energy. So if our country had a real energy policy, maybe we’d see incentives put in place to encourage anaerobic digestion and biogas-to-energy. Such incentives could include lowinterest loans structured so that the loan repayment would “cash flow” from the energy cost savings (and revenue). Then perhaps we’d have this valuable resource on the way to being fully developed. That would be a boon to our energy supply, the environment and our economy — not to mention a dream come true.

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tpomag.com August 2015

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@tpomag.com

Visit the site daily for new, exclusive content. Read our blogs, find resources and get the most out of TPO magazine.

SOCIAL CONNECTION

7 Wastewater Groups to Follow on LinkedIn Some days, you might wonder why you need more social media. Isn’t Facebook enough? But if you’re not using LinkedIn, you could be doing your career a disservice. Dive into the world of LinkedIn with this list of water and wastewater discussion groups. Before you know it, your newsfeed will be flooded with industry-specific information. Tpomag.com/featured

PINTEREST WORTHY

How to Upcycle Old Water Meters When an Iowa water utility replaced its manual water meters, creativity broke loose. See how the team repurposed old equipment, turning one fine example into an office aquarium. (Hint: Some trial and error was involved at the expense of Bertha the Betta.) Take a look at these Pinterestworthy ideas, and let us know if your team has found new uses for retired equipment. Tpomag.com/featured

EXPERT ADVICE

“

5 Tips to a Newbie from a Seasoned Veteran

OVERHEARD ONLINE

“Unlike our traditional water resources that are stressed by dry weather and population growth, wastewater is a drought-resistant water resource that is too valuable to waste.”

“

Forward Thinking: Citizen’s Group Drives Flagstaff’s Wastewater Initiatives Tpomag.com/featured

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When you’re new to wastewater, nothing is more important than listening to a plant’s seasoned operators. Here, contributor Marcel Tremblay shares what he would tell a newcomer, pointing out some sound advice for the next generation of wastewater plant employees. Tpomag.com/featured

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top performer wastewater: BIOSOLIDS

Doing It

by the Book A MAINE SANITARY DISTRICT DEMONSTRATES THAT NO AGENCY IS TOO SMALL TO BENEFIT FROM CREATING AND FOLLOWING A FORMAL BIOSOLIDS MANAGEMENT PLAN STORY: Ted J. Rulseh | PHOTOGRAPHY: Gabe Souza

BEING SMALL IS NO REASON TO CUT CORNERS. That’s a reason the Mechanic Falls (Maine) Sanitary District has a formal biosolids management plan, even though it serves just 3,100 people and moves just 23 dry tons of material per year. “It’s about saying what you do and doing what you say,” says Nicholas “Nick” Konstantoulakis, district director. “It’s a booklet that tells exactly

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TREATMENT PLANT OPERATOR

what we do, where we do it and how we do it. When regulators know that you have a program in writing for anybody to see and you have a history of following it, you’re fine.” The plan is built in the model of the National Biosolids Partnership Environmental Management System (EMS) program. The district land-applies liquid, lime-stabilized biosolids on a farm 6 miles from its 490,000 gpd

LEFT: Chlorination levels are logged daily at the Mechanic

Falls Sanitary District plant. BELOW: Nick Konstantoulakis, director, and Brian Ahlquist, operator.

‘‘

When regulators know that you have a program in writing for anybody to see and you have a history of following it, you’re fine.” NICK KONSTANTOULAKIS

career change. “I was bored with what I was doing,” he recalls. “When you work in a lab, you pretty much do the same thing day in, day out.” He and 11 others applied for an opening at the Mechanic Falls district. Then-director Tom Schultz chose Konstantoulakis largely because he was familiar with the ISO 9000 international quality standard, similar in character to National Biosolids Partnership’s EMS: “Tom wanted to do the EMS, and I was a perfect fit.”

EFFICIENT TREATMENT Mechanic Falls, in southern Maine, has a 33-year-old activated sludge treatment facility using a racetrack-style oxidation ditch. The community is all residential and light commercial, which means flows rates and influent quality are consistent year-round.

(design) clean-water plant. The management plan spells out every detail of procedures. All land application takes place in October. The entire process — lime addition, hauling, spreading, testing, recordkeeping — costs about $15,000 a year.

HOMEGROWN TALENT Konstantoulakis, a Maine native, has been with the district for 10 years and director for two. He served in the U.S. Air Force for four years after high school, lived in Texas for nine years working and attending Sam Houston State University, then returned to Maine, where he put his industrial technology studies to work in laboratory positions with electronics manufacturers. His quality assurance experience from those jobs helped him make a

Mechanic Falls (Maine) Sanitary District FOUNDED: |

1982

POPULATION SERVED: |

3,100 (700 sewer connections) 0.49 mgd design, 0.25 mgd average BIOSOLIDS PROCESS: | Oxidation reactor, lime stabilization BIOSOLIDS VOLUME: | 23 dry tons per year BIOSOLIDS USE: | Agricultural land application CITY WEBSITE: | www.mechanicfalls.govoffice.com GPS COORDINATES: Latitude: 44° 6’37.94”N; longitude: 70°23’7.55”W PLANT FLOWS: |

tpomag.com August 2015

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The Mechanic Falls plant uses an oxidation ditch secondary treatment process (Lakeside Equipment). The aerators are controlled automatically to sustain optimum dissolved oxygen.

HOSTING THE YOUNG ONES As director of the Mechanic Falls Sanitary District, Nicholas “Nick” Konstantoulakis has emphasized public outreach. “I’m trying to get the community more involved,” he says. “When I started here 10 years ago, this district was the best-kept secret in town. You could drive by and you weren’t even sure what it was. When I bring people here, they can’t believe how beautiful it is. There’s no odor. My predecessor, Tom Schultz, ran the operation like a military base in terms of being neat and clean. I’ve kept that up. We plant flowers. I planted 111 tulips, and 88 came up. For a plant that’s 33 years old, this place is looking pretty good.” Konstantoulakis loves to bring in local fifth graders once a year: “They’re so much fun because they’re interested. I start by opening the manhole at the headworks and letting them look down there. They think that’s so cool. I have a safety barrier around it, and I say, ‘If you ever see a manhole open, make sure you call somebody.’ “I take them to the aeration basin and tell them, ‘This is as much a living thing as all of us here. It needs air, it needs oxygen, it needs food.’ Then I tell them that every time they flush the toilet, this is where it goes. I say, ‘Does anybody want to guess what’s out there?’ Always, some little girl will say, ‘Poop?’ And I’ll say, ‘That’s right — 288,000 gallons. And that’s good, because it’s in here and not in the river. We’re a wastewater treatment plant and proud of it.’” As for adults around his own age, Konstantoulakis reminds them of days of the first Clean Water Act. “I’ll jokingly say, ‘Remember when you were a hippie in the 1970s and you wanted clean water? That’s what you’re paying for.’”

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TREATMENT PLANT OPERATOR

Wastewater (250,000 gpd average flow) passes through a Worthington comminutor for preliminary treatment and then directly into the 288,000-gallon oxidation ditch (Lakeside Equipment). A set of grooved, motor-driven, rotating paddles beat air into the mixed liquor. Konstantoulakis and assistant Brian Ahlquist achieve optimum removal of volatile solids by holding dissolved oxygen in the ditch at 0.8 mg/L, with help from oxygen sensors (ABB Automation). “We can control it manually, but generally we use our SCADA system,” Konstantoulakis says. “If it starts raining heavily or if the DO starts dropping for any reason, the paddles kick in automatically. Our SCADA pretty much takes care of it all.” Water from the aeration process passes to two final clarifiers (Lakeside Equipment). After chlorine disinfection, final effluent averaging about 8 mg/L BOD and TSS is discharged to the Little Androscoggin River. “If you put a glass of drinking water beside a glass of our effluent, you couldn’t tell the difference,” Konstantoulakis says.

TO THE FIELDS On the solids side, waste activated sludge is pumped to a pair of 150,000-gallon storage tanks, where it accumulates until land application season in October. Two Sutorbilt blowers (Gardner Denver) mix the material; there is no digestion. Material enters the tanks at about 3 percent solids, and periodic decanting raises the solids content to 4 percent. Just before land application the tank contents are lime stabilized. After an initial pH reading on the material, lime slurry is delivered to the tanks by a trash pump until the pH reaches 12, a process that takes about 30 minutes. The pH is held at that level for two hours and rechecked the next day. A year’s biosolids production is typically about 140,000 gallons. (continued)

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A contractor delivers biosolids to the farm in a 4,000-gallon tank truck and surface-applies it to the field as directed by the landowner. The farm has 109 acres of corn and hay land permitted by the state Department of Environmental Protection. The lime-stabilized material, applied in cool autumn conditions, presents no odor issues. “We don’t use all 109 acres,” Konstantoulakis says. “We apply about 600 pounds per acre. We do a chemical analysis on the material we spread, and about a month to six weeks later we take a soil sample and send it to the University of Maine for laboratory analysis.” The biosolids are tested for 25 parameters, including pH and nutrients, as well as heavy metals, which are nearly nonexistent. The contractor, at the district staff’s direction, observes required setbacks from roads (100 feet) and the farmer’s well (300 feet). No other homes are nearby. “Our farmer loves the material,” Konstantoulakis says. “A brick cheese that was made from milk he supplied recently won an award. The cheesemakers were so impressed with the product that they put a picture of his farm on one of the packages.”

ACCORDING TO PLAN The district’s process is fully documented in the biosolids management plan. The district joined the National Biosolids Partnership EMS program in 2007 and is also a member of the North East Biosolids and Residuals Association. An EMS is a management framework that helps treatment facilities constantly improve in key areas, such as quality management, regulatory com-

‘‘

A colorimeter is used to test a water sample for chlorine levels (Lovibond Tintometer).

pliance, environmental performance and relations with interested parties. “Our plan tells who the director is and who the helper is,” Konstantoulakis says. “It has sections on roles and responsibilities for each one of us. It describes our public participation plan, our process controls, our internal audits. There’s a section on management review and a section on chemical (continued)

It’s a win-win program that benefits us all. It helps us continue to ensure that our biosolids are of the highest quality and that our recycling program remains cost-efficient.”

NICK KONSTANTOULAKIS

Brian Ahlquist checks the facility’s sludge blanket early in the morning as part of his daily rounds.

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TREATMENT PLANT OPERATOR

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17

‘‘

If you put a glass of drinking water beside a glass of our effluent, you couldn’t tell the difference.” NICK KONSTANTOULAKIS

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Lakeside Equipment Corporation analysis. If we encounter a problem, 630/837-5640 we’re required to describe it in www.lakeside-equipment.com writing and tell what we plan to do (See ad page 3) about it.” To Konstantoulakis, the plan is Lovibond Tintometer Plant effluent and plant influent. Visitors to the Mechanic Falls facility are 800/922-5242 helpful on various levels: “Because impressed by the quality of water discharged to the Little Androscoggin River. www.lovibond.us we have our procedures in writing, (See ad page 35) if I get hit by a bus tomorrow, the RUNNING SMOOTHLY person I work with could easily take over. When we’re inspected by the DEP, For now, Konstantoulakis, Ahlquist and office manager Carrie White they can look at our plan and see putting it into practice.” are keeping the biosolids program and the treatment plant running smoothly. The plan also helps the district run a consistent, clean operation and “Our goal right now is to keep things as they are, business as usual,” Konavoid alarming the public: stantoulakis says. “Our No. 1 goals are to continue with preventive main“It’s a win-win program that benefits us all. It helps us continue to ensure tenance and to make our community more knowledgeable about us. that our biosolids are of the highest quality and that our recycling program “My colleagues are in their 40s. They’re computer-smart, they have posremains cost-efficient. There are a handful of people who are against land itive energy and it’s great. I plan to work until I’m 70. I really like what I’m application, but they tend to be the same people who will go to a hardware doing. This is the first time in my life where I don’t need an alarm clock to store and buy fertilizer from another country, not even knowing where it get up and go to work.” comes from. We don’t look over our shoulder when we do this, but we do understand that members of the public who don’t understand it or have been misinformed might raise concerns.”

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TREATMENT PLANT OPERATOR

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wastewater: HOW WE DO IT

May-December Marriage A MASSACHUSETTS PLANT TEAM TAKES HEROIC MEASURES TO INTEGRATE A NEW BIOGAS-FUELED CHP SYSTEM WITH AN OLDER TREATMENT PROCESS By Scottie Dayton

H

undreds of pounds of solids slipped downstream through worn equipment at the Fairhaven (Massachusetts) Water Pollution Control Facility. The volume made it difficult for the plant to meet its discharge permit. Looking for solutions, the town took part in a pilot study on anaerobic digestion and combined heat and power (CHP) systems. “It concluded that although we are a small plant, the process could be cost-effective if we used glass-fused-to-steel tanks instead of concrete structures,” says Linda Schick, sewer and wastewater superintendent. The $8 million project was financed by a principal-forgiveness loan through the American Recovery and Reinvestment Act (federal stimulus) and the State Revolving Fund Green Infrastructure. “We had two years to deploy the system or face repaying the money with 2 percent interest,” says Schick. Challenges accompanied the integration of new technology with 28-yearold equipment, requiring operators to be constantly on call at first. “We almost didn’t make it,” says Schick. “Besides the generation gap, small-scale digestion is most successful on farms, where there are no other processes to integrate or sidestreams to absorb.” The team’s two-year effort made Fairhaven the second wastewater facility in the state to generate its own heat and energy.

The installation includes two fixed-cover Aquastore digester tanks (CST Industries) and dual membrane DuoSphere container (WesTech Engineering).

SETTING THE TABLE Built in 1969 and upgraded in 1989, the 5 mgd (design) activated sludge facility averages 3 mgd. Three 1987 plunger pumps on timers (Komline-Sanderson) feed primary sludge to two fixed-cover Aquastore digestion tanks (CST Industries). Two chopper pumps (Vaughan Co.) circulate solids through mixing nozzles in the tanks. Two other pumps move material through the heat exchangers to maintain a constant 98 degrees F in the digester. A gas conditioner removes water from the gas before it enters the MAN 100 kW CHP generator (Kraft Power Corporation), which runs on natural gas, biogas or a mix. Excess biogas is stored in a dual-membrane DuoSphere containment (WesTech Engineering) or flared through a burner stack (Varec Biogas, a division of Westech Industrial). Digested biosolids are treated with ferric chloride, then dewatered in two 1-meter gravity belt thickeners (Komline-Sanderson). The resulting cake is incinerated by a vendor.

INTO THE FRAY Plant designers were present during the CHP system’s startup in September 2012, but Tom Bienkiewicz, director of the Massachusetts State Board of Certification of Operators of Wastewater Treatment Facilities, was pivotal in providing technical and moral support.

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TREATMENT PLANT OPERATOR

LEFT: Assistant superintendent Rene Robillard (left) and Bob Gomes, CHP operator, connect a hose to the grease receiving tank. RIGHT: Gomes and Linda Schick, sewer and wastewater superintendent, monitor energy production from the MAN generator (Kraft Power Corporation).

“He spent a lot of time and energy explaining to state Department of Environmental Protection officials why it was taking so long to get the process going,” she says. “Tom was our moral support. We even had his personal number, and he’d talk us through problems no matter when we called.” Most repairs involved shutting down the digester, then starting up again from square one — a time-consuming process. It began the first day of startup when solids in the feed system never reached the digester. Increasing pressure burst an underground pipe, sending the material bubbling to the surface. After investigating for weeks, Bob Gomes, CHP operator, Joe Frates,

plant mechanic, and Ray Paczosa, plant electrician, pinpointed the cause. Rags had clogged a static mixer on the feed line in the CHP building, creating back-pressure on the line. Once they removed the mixer, solids flowed to the digester. They also retrofitted the plunger pumps, rerouted piping and installed new timers. “Bob came to the plant every weekend to check on the digester,” says Schick. “Without his commitment, I doubt we would have been as successful. While others lost faith, Bob always rose to the challenge.”

SEVERE INDIGESTION More challenges were in store. A miscalculation placed the sludge level too close to the top of the digester tanks, causing violent agitation. The burping, foaming material infiltrated and then blocked the output lines. Seeking an escape route, the material entered the gas piping, forcing operators to open pressure release valves instead of flaring the gas. “After we reduced the sludge level by 10 to 15 percent, Joe Frates installed drainlines on the gas piping, enabling operators to flush the system,” says Schick. “Assistant superintendent Rene Robillard was the lead on purging the entire gas system, beginning at the top of the digester and working back to

EVALUATING PERFORMANCE Because the system is still in its infancy, projected savings are moving targets. The process generates only enough biogas to heat the digester tanks and power pumps in the digester building. To increase methane production and reduce purchased gas from a third to less than a quarter, the town is considering adding restaurant grease to supercharge the system. Electric rates doubling in March also moved the number. “My normal electricity budget is $300,000,” says Schick. “I’m probably realizing a 20 percent savings from the CHP system and solar panels on three buildings after deducting maintenance and other costs.” One solid benefit is the 50 percent reduction in biosolids sent for incineration. “We had 10 to 12 trucks hauling it away every week,” says Schick. “That’s down to four or five, reducing hauling costs by $130,000 last year.”

Gomes (left), and Matt Manzone, maintenance craftsman, work on the DuoSphere container blowers.

the CHP generator.” The fire department stood by to assist in case of an emergency. The struggle to meet the startup deadline heightened the operators’ stress. After learning new techniques, they had to relearn them as components and processes were re-engineered from within. Schick’s team spent two years modifying piping, adding chemical feed sites and reformulating how the facility wasted sludge. While the adjustments benefited the digester, they often were not conducive to the main plant’s treatment train. Wastewater usually entered the primary settling tanks at about 50 degrees F, but mixing it with hot solids from the digester’s return sidestream adversely affected the process. “We’re trying to balance how we optimize the digester to get the profit we were hoping for, but also minimize the effect it has on the other side of the plant,” says Vincent Furtado, Board of Public Works superintendent. The successful marriage of new with old was hard-won. “The town had budgeted $500,000 for startup adjustments, but they cost an additional $1.5 million,” says Schick.

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top performer wastewater: OPERATOR

BEAUTIFUL

MUSIC

FRANK D’AMBROSIA HITS ALL THE RIGHT NOTES CONDUCTING PLANT OPERATIONS AND TRAINING PROGRAMS WHILE BUILDING AN AWARD-WINNING CAREER AS A CLEAN-WATER PLANT SUPERINTENDENT STORY: Jack Powell | PHOTOGRAPHY: Amy Voigt

LIKE A MASTER MUSICIAN, A WASTEWATER TREATMENT PLANT

procedures for taking readings on sludge blankets, grit removal procedures and lab analysis.” As for D’Ambrosia’s reaction, “I was very surprised,” he says in an accent that gives away his New Yorker background. “It’s quite an honor and one that reaffirms my belief that wastewater has been a great career that I’ve had the good fortune to pursue for the last 35 years.”

superintendent must make sure everything works in harmony — from equipment to operators. That’s what Frank D’Ambrosia has been doing successfully for 11 years as superintendent at the Village of Archbold (Ohio) Wastewater Treatment Plant. Since March 1, 2004, this easygoing former EXPANSION EXPERIENCE music teacher and traveling musician has overD’Ambrosia started work life as a music seen a major expansion at the plant, 40 miles teacher. Later, while touring with a five-piece southwest of Toledo. He has also ensured that the band (see sidebar), he met his wife, Susan, who 2.5 mgd facility meets all federal and state envihad family in Defiance, a city of 16,500 in northronmental regulations, kept the collections syswestern Ohio. In 1979, D’Ambrosia found a job tem functioning, and made sure his operators at the city wastewater treatment plant, which get the training they need to keep their certifica“went from work-and-a-paycheck to a career.” tions. Such diligence has earned D’Ambrosia a “A year later, we went down to south Florida, rewarding career and an industry lifetime where I worked for about a year and a half,” says achievement award. D’Ambrosia. “I first worked at a 2 mgd wastewaLast year D’Ambrosia received the William ter facility for a private utility and got my Class D. Hatfield Award from the Northwest Ohio A wastewater license. Then I moved to the BroWater Environment Association (NWOWEA). ward County Wastewater Treatment Plant just The award recognizes outstanding performance Frank D’Ambrosia, superintendent, Village of Archnorth of Miami. When I started there the facility and professionalism over a career. bold Wastewater Treatment Plant. was under construction to expand from 20 mgd The awards program said, “Frank D’Ambrosia to 60 mgd. While in Florida, I gained a lot of truly embodies what it means to be a consumvaluable knowledge that I brought back to Defiance.” mate wastewater professional.” Citing how he organized and taught the D’Ambrosia worked his way up from operator to assistant superintenNWOWEA’s semiannual Operator Education Day, which prepares operadent and experienced a plant expansion from 4 mgd to 6 mgd. He then tors to take state wastewater certification tests, the writeup mentioned that moved to Archbold, a village of 4,300. Along the way, he got his Class III D’Ambrosia has opened the plant to host many hands-on workshops for certification in wastewater. area operators and “routinely provides training to employees in many areas, The Archbold plant underwent a $6 million upgrade in 2006-07. The including digester operations, secondary system DO control and proper

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TREATMENT PLANT OPERATOR

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Communication up and down is very important. So is delegating — letting people take ownership of their work and become part of what’s being done, rather than wait to be told what to do.”

ABOVE: D’Ambrosia oversaw a major upgrade of the Archbold facility in 2006-07. BELOW: D’Ambrosia,

FRANK D’AMBROSIA

shown with Randy Volkman, plant operator, is a big believer in training. He provides classes at his own facility as well as through the Ohio Water Environment Association.

Frank D’Ambrosia, Village of Archbold (Ohio) Wastewater Treatment Plant POSITION: |

Wastewater treatment plant superintendent 35 years in clean-water industry DUTIES: Oversee plant and collections system operations, supervise 6 employees EDUCATION: Bachelor’s degree, music education – Queens College, New York CERTIFICATIONS: Class III municipal wastewater operator MEMBERSHIPS: Water Environment Federation, Ohio Water Environment Association, Northwest Ohio Water Environment Association GOALS: Continue to serve village residents, contribute to a better environment and promote wastewater as a career choice GPS COORDINATES: Latitude: 41°30’26.57”N; Longitude: 84°18’49.84”W EXPERIENCE: |

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Frank D’Ambrosia, a former music teacher and traveling musician, has enjoyed a rewarding career and earned an industry lifetime achievement award as superintendent at the Village of Archbold Wastewater Treatment Plant.

A TALE OF TWO CAREERS Frank D’Ambrosia’s career in clean water had the most unlikely of starts. Growing up in New York City, D’Ambrosia wanted to be a music teacher. He went to a Catholic high school in Brooklyn, earned a bachelor’s degree in music education from Queens College and got some credits toward a master’s. “I taught music in the New York school system in the mid1970s, but after only a year, the city had to lay off 5,000 teachers,” he says. “If you were teaching less than eight years, you got laid off.” Always resourceful, D’Ambrosia formed a five-piece band with some other unemployed teachers. Called Frequency, and later Touch, they played Top 40 songs and covered groups like Steely Dan, Pablo Cruise and Foreigner. D’Ambrosia played the keyboard. After successful gigs at various New York resorts, the band moved to hotels and lounges along the East Coast, from Boston to Miami. One night, while playing at a bar in Jacksonville, Florida, D’Ambrosia’s future wife, Susan, came in and liked what she heard. Soon the couple started dating. Shortly thereafter, they moved to Defiance, Ohio, her hometown, and D’Ambrosia’s three-year music career ended. He began putting down roots and working at the wastewater treatment plant. Does he have regrets? “Wastewater certainly has been a good career for me,” D’Ambrosia says. “The more I got into it, the more I saw that there was advancement and that I could make a good career for myself. Plus, you’re doing something that’s good not only for the environment but also for people in the community. Every day you have a chance to learn something new. There’s always something different going on, so yes, I definitely think it’s a good career choice for young people.” While running the Archbold plant, D’Ambrosia still keeps his musical chops, playing clarinet and saxophone as well as piano. He performs on weekends with community groups, at churches and with the Defiance College Jazz Band.

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renovation increased capacity from 1.75 mgd to 2.5 mgd with 5 mgd peak flow. It also added a grease removal system, new final clarifiers, a new ferrous chloride storage tank, new chlorination and dechlorination systems, a new process monitoring and control system, and a new operations building. The project also included modifications to a tertiary lagoon to create an overflow basin that retains diverted influent over 5 mgd. Today, the plant’s activated sludge process treats an average daily flow of 1.6 mgd and removes 96.8 percent of TSS, 99.1 percent of CBOD, 92.4

‘‘

Everybody has a lot of respect for Frank. If you can’t get along with him, it’s your problem. Frank fits in with our vision of being proactive in keeping our wastewater operators trained and their skills sharp.”

DENNIS HOWELL

percent of ammonia and 90.5 percent of phosphorus. Effluent discharges to Brush Creek, which flows into the Tiffin River, a 55-mile-long tributary of the Maumee River. Class B biosolids are applied to farm fields. During the renovation, D’Ambrosia worked closely with the city’s engineering team and with Jones & Henry Engineers of Toledo. Five years ago, D’Ambrosia and his team added two biosolids lagoons, bringing the total to five and providing a year’s storage. In 2013, the facility added an air diffusion system to its wet-weather retention lagoon, keeping solids suspended until the water is treated. Last spring, the plant added a larger and more efficient grit removal, washing and dewatering system.

THE RIGHT TOUCH Orchestrating these projects, while maintaining 40 miles of sewer lines, nine lift stations and an industrial pretreatment program, requires a deft touch and strong management skills. D’Ambrosia displays those qualities in abundance, says Dennis Howell, village administrator. “Frank is an interesting guy,” says Howell. “He has a lot of interests and talents, including being a fine musician, and he’s very knowledgeable and astute in the wastewater field. Everybody has a lot of respect for Frank. If you can’t get along with him, it’s your problem. Frank fits in with our vision of being proactive in keeping our wastewater operators trained and their skills sharp.” Of the plant’s seven operators (one a nearly full-time lab technician), five have Class III certifications and one has a Class I certification. Three know how to operate the plant’s combination cleaning truck to vacuum the sewer lines. D’Ambrosia sees that they get the continuing education they need to keep their certifications, learn new technologies and maintain plant equipment. “I do my own training,” says D’Ambrosia. “Through NWOWEA, I set up a half-day of training that we invite people in the community to come to. Plus, I do training with the operators, such as bringing in chlorine people to talk about chlorine application. Also, through the Ohio WEA, I set up a review session twice a year for young operators planning to take the wastewater certification exam. We have three sessions that day. I teach the basic wastewater course and have experts who teach advanced wastewater and do a review of the collections system.”

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Frank is an easy guy to work for. When we have bigger projects, we tell him and he gives us the green light to proceed. He’s very supportive and gives us every chance to get the training we need to do our jobs better.”

RANDY VOLKMAN

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PRAISE FOR TRAINING The operators are grateful for the education D’Ambrosia provides and for his collaborative management style, which encourages them to take responsibility and run with good ideas. They credit him with keeping morale high and fostering a team environment. “He’s a real good boss who lets us do what we need to do to get the job done,” observes Mike Short, assistant superintendent and maintenance chief. “Frank gives us free rein and doesn’t micromanage,” says Short, a Class III operator and 28-year plant veteran. “Frank is excellent when it comes to getting us training. If we get an email message about a program, say a motor or pump class, he’ll let us go, juggling the schedule so we’ll have people here to run the plant. We can go pretty much anywhere in Ohio. It’s an asset to everybody.” Randy Volkman, a Class III operator who has been at the plant for 19 years, adds, “Frank is an easy guy to work for. When we have bigger projects, we tell him and he gives us the green light to proceed. He’s very supportive and gives us every chance to get the training we need to do our jobs better.” For D’Ambrosia, it’s all part of being a good leader, as is a strong work ethic. That means getting in at 6:30 in the morning, checking the SCADA system, overseeing lab tests and addressing issues, from balky equipment to a homeowner with a backed-up sewer. “Communication up and down is very important,” he says. “So is delegating — letting people take ownership of their work and become part of what’s being done, rather than wait to be told what to do. It’s what makes the job rewarding.” FREE INFO – SEE ADVERTISER INDEX

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HEARTS AND MINDS

Pure Recognition SAN DIEGO PUBLIC UTILITIES PICKS UP HONORS FOR EFFECTIVE COMMUNICATION ABOUT ITS WATER PURIFICATION DEMONSTRATION PROJECT FOR INDIRECT POTABLE REUSE By Craig Mandli

Y

ou could say the San Diego Public Utilities Department started in a deep hole. “Toilet to Tap” was the original negative idea the department was saddled with selling to the public for adding purified wastewater to the drinking water supply. But a program facelift and innovative community education programs, all while dealing with severe drought, helped convince residents that wastewater reclamation can be a solution for the area’s water shortage. In late 2014, the Public Relations Society of America San Diego/Imperial Counties Chapter presented the department with the Edward L. Bernays Silver Award of Merit for Public Affairs for its Water Purification Demonstration Project public outreach program.

CREATING DIALOGUE The demonstration project’s goal was to confirm the feasibility of purifying recycled water to supplement drinking water supplies. The outreach program for the demonstration project included presentations, booths at community events, facility tours, informational materials, advertisements and social media. After an outpouring of support, the San Diego City Council unanimously adopted the project’s findings in April 2013 and set forth directives for implementing the Pure Water San Diego program, which when complete will divert some 100 mgd from the Point Loma Wastewater Plant to What’s Your Story? three future water purification facilities. Those plants will treat TPO welcomes news about your the water with membrane filtrapublic education and community tion, reverse osmosis and UV disinoutreach efforts for future articles fection/advanced oxidation before in the Hearts and Minds column. Send your ideas to editor@tpo delivery to existing reservoirs. mag.com or call 877/953-3301.

Outreach tools include infographics and handouts on the safety of recycled water and the final report of the Water Purification Demonstration Project.

“It was really a comprehensive communication plan and outreach strategy that encouraged public involvement and fostered active community dialogue,” says Alma Rife, senior public information officer. “The result was an increase in understanding and a general approval rating of water purification that went from 26 percent in 2004 to 73 percent in 2012.”

THE BEGINNING After several years of study, the council in October 2007 chose indirect potable reuse as the best way to maximize use of recycled water. The council commissioned the Water Purification Demonstration Project to determine the feasibility of turning recycled water into purified water. For a year beginning in 2012, the Advanced Water Purification Facility reclaimed 1 million gallons of effluent daily and treated it to a level clean enough to drink. The project included extensive testing at each step of the process, along with a multipronged education program inviting people to take virtual and actual tours of the facility.

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The result was an increase in understanding and a general approval rating of water purification that went from 26 percent in 2004 to 73 percent in 2012.” ALMA RIFE

“City staff participated in a variety of community events, including community street fairs, health fairs and expos, events on college campuses, and events with a focus on the environment and science, such as the annual San Diego Festival of Science & Engineering EXPO Day at Petco Park and Earth Fair at Balboa Park,” says Rife. “The city also reached out to the multicultural communities at events such as Linda Vista Multicultural Festival, Juneteenth Celebration, Asian Cultural Festival and Fiesta del Sol.” The yearlong demonstration project included more than 9,000 waterquality tests that determined no contaminants were present in the purified water. The California Department of Public Health and the San Diego Water Board approved the city’s water purification concept. According to Rife, the city received a positive response from the public at events. “Most people did not have much previous knowledge of purifying water, but once the water purification process was explained to them in detail, they are generally supportive of potable reuse,” says Rife. “The public realizes that the city needs a reliable and drought-proof local water supply.”

PHOTOS AND GRAPHICS COURTESY OF THE CITY OF SAN DIEGO PUBLIC UTILITIES

Pure Water San Diego had a presence at the annual San Diego Festival of Science & Engineering EXPO Day at Petco Park.

YOUTH COMPONENT Rife says the city considers educating children at least as important as informing adults. In her mind, the next generation will make decisions about future water supply solutions and needs information about the longterm benefits of water reuse. “The city offers free tours of our North City Water Reclamation Treatment Plant to Boy Scout and Girl Scout troops, elementary schools and various youth organizations,” says Rife. “Additionally, the staff participates in events at schools and with youth organizations such as the YMCA. We focus on creating content that involves lots of engagement. This includes handson activities, easy-to-understand visuals that are eye-catching, and asking questions to keep their attention.” That includes answering questions that are not always positive. While people have embraced the idea of drinking recycled wastewater as they receive more information, some adults and children remain skeptical. Rife says city employees answer the tough questions with transparency and honesty: “If one of our staff members does not know the answer to a question, they take down the person’s contact information and get back to them in a timely manner with an accurate response.”

THE NEXT STEP In November 2014, backed by the findings of the outreach program, the City Council unanimously voted to advance the Pure Water San Diego program. The program has support from several environmental groups, city officials and community leaders, many of whom recently served as members of the Pure Water Working Group behind the Water Purification Demonstration Project. The immediate goal is the construction of a full-scale purification facility that will process 15 mgd by 2023. By 2035, if all goes as planned, nearly 30 percent of San Diego’s water (83 mgd) will come from local sources or treated wastewater. Public outreach campaigns will play a large part and include infographics and handouts on the safety of recycled water. “This is a very diverse area, and we can reach a broader multicultural audience by translating materials into additional languages,” Rife says. “In addition, we plan to increase our audience on all social media platforms, seek more partnerships with youth-based organizations, and partner with colleges and universities to offer tours and presentations.” Youth-oriented materials will include fact sheets, presentations, activity pages and trading cards. Virtual events such as video contests and social media polls will help educate the tech-savvy crowd. The city’s outreach program has served as a model to other agencies seeking to implement water purification. Water agencies from as far away as Japan and Australia have visited to learn more. “We’ve come a very long way from the idea of drinking water from the toilet,” says Rife. “We’ve been proactive from the start, and it has paid off. The people here now know that recycled wastewater is a viable and needed remedy for California’s water issues.” (For more information about San Diego’s water purification efforts and the findings of the Water Purification Demonstration Project, visit www.purewatersd.org.)

Pure Water San Diego staff give a youth presentation during an Earth Fair event. tpomag.com August 2015

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PHOTOS COURTESY OF INLAND EMPIRE UTILITIES AGENCY

SUSTAINABLE OPERATIONS

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TPO welcomes news about environmental improvements at your facility for the Sustainable Operations column. Send your ideas to [email protected] or call 877/953-3301.

By Doug Day

A

California clean-water plant has moved closer to a vision of being off the grid by 2020 through a partnership that now fulfills about 50 percent of its power needs. Regional Water Recycling Plant No. 1 (RP-1), located in the City of Ontario and operated by Inland Empire Utilities Agency (IEUA), delivers biogas to run a privately owned fuel cell installation, then buys the power at rates below utility grid prices. The 44 mgd (design) tertiary plant treats an average of 28 mgd. Its effluent, along with that of IEUA’s other three wastewater treatment plants, goes into the utility’s reclaimed water system, where it is used for in-house processes; for irrigation of parks, golf courses and farms; for industrial purposes; and for groundwater recharge. Its biosolids system uses three-phase digestion, which provides some 700,000 cubic feet of biogas every day for the fuel cells. The biosolids are trucked to an IEUA composting facility in Rancho Cucamonga that produces more than 230,000 cubic yards of SoilPro Premium Compost per year.

CLEANER ELECTRICITY IEUA needed a new plan when air-quality regulations required a reduction in output of RP-1’s two 1.4 MW cogeneration engines. While their total

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ABOVE: About half of the electricity for the Regional Water Recycling Plant No.1

comes from this 2.8 MW fuel cell power plant. A 20-year power purchase agreement sets a price for the power for the life of the contract.

In exchange, IEUA signed a 20-year power purchase agreement (PPA) to buy all the electricity the fuel cells generate. “Most of the biogas is used by the fuel cells,” says Pietro Cambiaso, IEUA senior engineer for environmental compliance. “Excess gas is used in boilers to heat the digesters.” Heat from the fuel cells is also recovered. Switching to fuel cells, which don’t require combustion, greatly reduced emissions: • Carbon monoxide (CO) by 92 percent • Nitrogen oxides (NOx) by 6 percent • Volatile organic compounds (VOCs) by 91 percent • Sulfur oxides (SOx) by 72 percent • Particulate matter by 86 percent A small amount of gas from the acid phase of digestion is flared because it is low in heating value and would require substantially more cleanup of hydrogen sulfide and siloxanes than the rest of the digester gas.

NO CAPITAL INVESTMENT The PPA gives IEUA a set cost for electricity into the future without having to fund the project from its capital budget. “There was no capital outlay,” says Cambiaso. “We’re only purchasing the power at an established rate. We didn’t want to assume the risk, so the PPA was a good solution.” Jesse Pompa, senior associate engineer in environmental compliance, adds that the PPA addresses some issues the agency had heard of with other projects. “With other agencies, we had seen that the gas conditioning skid and the fuel cells would be from separate manufacturers, and there would be a lot of finger-pointing if there was any downtime. The fuel cells can also be powered with natural gas, in which case RP-1 still pays the guaranteed starting rate for the power: 12.6 cents per kWh with a 2.5 percent annual escalation. That is comparable to the price now paid to Southern California Edison. “The assumption is that Edison’s rates will

There was no capital outlay. We’re only purchasing the power at an established rate. We didn’t want to assume the risk, so the PPA was a good solution.” PIETRO CAMBIASO

output capacity was the same as the new 2.8 MW fuel cell installation, the agency was limited by emissions standards to operating just one of engines. The agency decided on a partnership with a private firm, which owns and operates the fuel cell plant and handled its design, financing and construction. The system uses a DFC3000 Direct FuelCell power plant from FuelCell Energy, which calls the project the largest digester gas fuel cell installation operating in the United States. It went online in January 2013.

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increase between 4 and 6 percent based on historical data,” says Cambiaso. “Over time, we’re going to see the savings.”

SUPPLY AND DEMAND RP-1’s electrical demand ranges from 3.5 MW in winter to just above 4 MW in summer. “There is some parasitic load for the 2.8 MW fuel cell plant, so we see a maximum of around 2.4 MW,” says Pompa. The fuel cells are supplemented by a 4-acre, 800 kW solar array, installed in 2008, that uses both fixed and tracking solar panels. IEUA installed similar

The gas conditioning system is covered by Inland Empire Utilities Agency’s power purchase agreement.

The wastewater treatment plant’s biosolids system uses three-phase digestion, which provides some 700,000 cubic feet of biogas every day for the fuel cells.

systems at all its locations through a PPA with SunPower, for a total of 3.5 MW solar generating capacity. The solar installations provide 8 percent of the utility’s electrical needs, replacing power previously purchased off the grid. “We’re still working on implementing some efficiency projects at RP-1 to conserve energy,” says Cambiaso. “Ultimately, the goal is to be self-sufficient. We have higher demand in summer, so we need to work on that. In winter, we make some excess power and are working with the local utility to export that power back to the grid.” At present, biogas generation matches up well with the need for gas on site, but the agency is considering adding gas storage. “The demand may change or the production may change,” says Cambiaso. “So we’re looking to see if it would be cost-effective to add gas storage.” FREE INFO – SEE ADVERTISER INDEX

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PLANTSCAPES

Operators planted oak and walnut saplings in the area farther from the creek.

Roots of Preservation A WIDE VARIETY OF TREES BEAUTIFY THE LANDSCAPE AND PUT THE BRAKES ON STREAM BANK EROSION AT A MISSOURI CLEAN-WATER PLANT By Jeff Smith

O

perators and staff of the 1.8 mgd Perryville (Missouri) Wastewater Treatment Facility planted more than 1,400 trees last spring to halt erosion along the banks of the Cinque Hommes Creek, which passes in front of the plant and is its receiving water. In the bargain, they’re beautifying the landscape. “We sure hope it works and the trees take hold before a gully washer rain comes along,” says Jeremy Meyer, water and wastewater superintendent at the two-stage trickling filter facility. A portion of creek bank near the plant has eroded away at least 10 to 12 feet in the last decade.

AN INSIDE JOB Using a planting machine pulled by a 108 hp John Deere model 6415 tractor, operators Robert Brown and Dave Myer planted 14- to 16-inch-tall cottonwood, bald cypress and sandbar willow cuttings, spaced 10 feet apart and in rows with 10 feet of separation. Operator Wendell Valleroy drove the tractor.

‘‘

Tree plantings are designed to curtail erosion on the bank of the Cinque Hommes Creek.

The idea is to have the slower-growing trees mature to provide shade in an area where a planting attempt several years ago partially failed.”

area farther from the creek. “The idea is to have the slower-growing trees mature to provide shade in an area where a planting attempt several years ago partially failed,” says Meyer.

JEREMY MEYER

The idea of planting the trees grew out of a request from the Missouri Department of Conservation (MDC). Staff members spotted the severe erosion while surveying the creek for Japanese hops, an invasive species that can quickly choke off a waterway. “I asked them if the hops could be used to make beer,” Meyer recalls jokingly. The creek empties into the Mississippi River, where the Japanese hop vine is most commonly found. In recent years it has been increasing its range into streams and tributaries. The MDC worked with the city and Meyer to negotiate a cost-sharing agreement that provided 90 percent funding for the nearly $7,000 project. A portion of the funding was to revisit and

In eight hours over two days, the men covered nearly 11 acres of field and the embankment near the creek, assisted by Neil Bert, plant operations foreman, and Mike Compte, operator. Meyer used a dibble bar to handplant 100 willow stakes on the eroded portion of the stream bank. He plans to plant 300 more next spring. “We are counting on the root structure of the trees to stop the erosion,” says Meyer. The operators also used a dibble bar to hand-plant 3-foot-tall saplings of pin oak, red oak, shumard oak, white oak, bur oak and black walnut in the

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Features: Plant personnel involved in the project include, from left, Jeremy Meyer, water/wastewater plant superintendent; Neil Bert, plant operations foreman; Mike Compte and Dave Myer, plant operators; and Wendell Valleroy, plant operator/electrician. Not shown: Robert Brown, plant operator.

update the previously failed planting. The cost also included field preparation by chemical application to eradicate competing vegetation around newly planted and existing trees. As a condition of the agreement, plant operators will be responsible for the maintenance, mowing and weed-control spraying of the newly planted field for 10 years. Meyer says the project was worthwhile and an efficient team effort: “Once we all got going and figured out how to do it the best way, we got it done quickly. We hope the roots of the new trees will stabilize the creek bank and stop the erosion.”

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top performer water:

PLANT

Beyond

the Normal

AN ILLINOIS WATER TREATMENT PLANT IMPROVES WATER QUALITY AND OPERATIONS WITH A MAJOR UPGRADE AND A TEAM THAT THRIVES ON CHALLENGES STORY: Trude Witham

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TREATMENT PLANT OPERATOR

PHOTOGRAPHY: Stephen Haas

In 2013, a UV/advanced oxidation process disinfection system was added to take care of seasonal taste and odor issues. The operators’ learning curve is ongoing. “I’m happy with the length of time these projects took, as it gave the operators time to focus on each new system and provide input,” says Ross. “Throughout construction, the team faced a different daily challenge. They had to keep up with constant changes, but they took it on, and I think they actually enjoyed the challenge.” The new system is more efficient. “The clarifiers operate without moving parts,” says Ross. “The old system had paddles, chains, gears, shear pins and so on. Our maintenance went from a daily disaster to near zero. The old plant had a small chlorine room that was converted to a lab, but that was When we started also the main plant entrance. So, we up the new plant, upgraded to a new lab with enough room for all the proper equipment the sludge blanket we we need to perform routine lab work.” Today, the 3.5 mgd (1.8 mgd averneeded was already in the age) conventional treatment plant cones, so we were able produces finished water with 0.03 to 0.10 NTU and 184 mg/L hardness to make water that met for 17,000 customers.

‘‘

our permit the first day.”

MAKING IMPROVEMENTS

DENNIS ROSS

The Otter Lake treatment plant and the 765-acre Otter Lake were built in 1969 in response to water shortages from the City of Springfield, the area’s previous water supplier. The plant is operated by the Otter Lake Water Commission, which serves the communities of Auburn, Divernon, Girard, Pawnee, Thayer, Virden, Nilwood and Tovey, the South Palmyra Rural Water District and Henderson Water. “None of these towns or districts could afford to have a water plant of their own, so the towns got together in the early 1960s and designed this plant,” says Ross. The commission is run by an eight-member board of directors, one appointed by the leadership of each member community. Joe Hogan, Class A operator, checks one of the sensors inside a TrojanUVSwift reactor during routine maintenance at the Otter Lake Water Commission treatment plant.

Otter Lake Water Treatment Plant, Girard, Illinois FOUNDED: |

1969

POPULATION SERVED: |

17,000 8 communities, 2 water districts SOURCE WATER: | Otter Lake TREATMENT PROCESS: | Conventional DISTRIBUTION: | 40 miles of pipeline SYSTEM STORAGE: | 1.1 million gallons KEY CHALLENGE: | Keeping up with new regulations WEBSITE: | www.otterlakewater.net GPS COORDINATES: | Latitude: 39°26’5.95”N; longitude: 89°53’48.68”W SERVICE AREA: |

OPERATORS AT THE OTTER LAKE WATER TREATMENT

Plant have a lot to be happy about — improved water quality and operations after an $8.5 million upgrade, a supportive water commission and general manager Dennis Ross. Ross brought his operations team through an 18-month improvement project at the plant, in Girard, Illinois. Completed in 2010, it included adding solids contact clarifiers, two new multimedia filters, a new control room and laboratory, and a million-gallon clearwell.

tpomag.com August 2015

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‘‘

One thing that really stands out is when someone offers to work a holiday for an operator with young kids. That shows how much we are like a family here.”

DENNIS ROSS Team members at the Otter Lake Water Commission treatment plant include, from left, Stan Crawford, Jeff Stanley, Joe Hogan, Brian Durbin, Rudy Rodriguez, Dennis Ross, Bob Dill and Tim Walter.

chose ClariCone solids contact clarifiers from CB&I for ease of operation and low maintenance. “We visited other plants that were using those and talked to the operators,” says Ross. “We spent a lot of time doing our homework.” Water from Otter Lake is pumped to the plant where it is fed powdered activated carbon and a preoxidant before entering the head tank for mixing. From there, it enters the ClariCone units (two, for redundancy). Treated water overflows into a weir and is piped to multimedia filters (Leopold - a Xylem Brand). Peroxide is added for advanced oxidation to eliminate taste and odor issues. The water is sent to the UV system (TrojanUV) and then disinfected with sodium hypochlorite gas before entering the clearwell. “The new clearwell is baffled to meet Illinois EPA contact time requirements before the water is sent to our second clearwell,” says Ross. A MOSCAD SCADA system (Motorola Solutions) ties the plant together. Plant equipment includes a pair of ClariCone solids contact clarifiers supplied by CB&I.

The board decided in 2007 to upgrade the water plant to replace aging equipment and accommodate growth. The existing flocculation/sedimentation basins were not automated and were wearing out. “It was a good system back then, but new regulations required lower turbidity, which we had a difficult time meeting,” says Ross. The board hired Hurst-Rosche Engineering to look at equipment options. The commission

34

TREATMENT PLANT OPERATOR

SMOOTH STARTUP The ClariCone clarifiers provide mixing, tapered flocculation and sedimentation in one hydraulically driven vessel. There are no mixers, scrapers, recycle pumps or other continuous moving parts. The system maintains a dense, suspended, rotating slurry blanket that provides solids contact, accelerated floc formation and solids capture. The conical concentrator maximizes slurry discharge concentration and enables operators to visually monitor the slurry discharge. “The cones look like a wine glass, narrow at the base and larger at the (continued)

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top, basically an upside-down cone,” says Ross. “Water comes in the bottom, where it is mixed with caustic and polymer, turning at a pretty high rate. As the water makes its way up the cone, the surface is larger, so the water turns at a much slower rate. A blanket is formed in the lower portion of the cone, and clean water comes off the top.” The operators’ learning curve was smooth. “Our lead operator, Jeff Stanley, received hands-on training at another plant, then returned after a week and trained the others,” says Ross. Bob Dill, operations supervisor, helped ensure a successful startup. “He did his homework, and we tested new chemical feeds in the old plant so we knew what rates we would need to feed,” recalls Ross. Since the clarifiers need to have a sludge blanket to perform, the operators pumped lime sludge from the old plant into the new clarifiers with a 3-inch trash pump. “When we started up the new plant, the sludge blanket we needed was already in the cones, so we were able to make water that met our permit the first day. This would not have happened without Bob’s upfront work.”

BETTER TASTE The $2.3 million upgrade to UV/AOP technology allows the plant to comply with the Cryptosporidium rule and produces better-tasting water. “We had just gone through about eight months of algae in the lake and were getting calls about taste and odor,” recalls Ross. “We looked at other plants’ UV/AOP systems and talked to operators to find out what they liked and didn’t like.” Although the new system uses significant electricity, Ross feels it is a better way to reduce taste and odor. “The system looks simple, but there is a whole set of automated controls, separate from the SCADA,” Ross says. “Operators must calibrate the in-line meters and check the sensors as part of the state-required verification process. “The UV system looks at several things to ensure that the water is getting the correct dose of light. We have to verify that the systems are working

WATER BUFFALO Dennis Ross, Otter Lake Water Commission general manager, has dedicated his adult life to the water industry. At 17, he began working for Missouri Cities Water Company in St. Charles. After getting his certification, he moved into management and worked for several water systems. He reached a high point in 2014 when he received the AWWA George Warren Fuller Award from the Illinois Section of AWWA. “I didn’t feel that I was in the same class as others I know who had received this award,” he says. “It was very emotional. Besides my family, the chairman of my board, Jake Rettberg, was there.” Ross credits his mentors for his success: “My main mentor was the late Max Wells, who was the division manager for the St. Charles division of Missouri Cities Water. I was working as a draftsman, and Max asked if I would like to move to meter reading, which is where everyone starts. Max taught me how to deal with customers and mentored me while on that job.” Another mentor was Lynn Bultman, vice president of Missouri Cities, who promoted Ross to division manager in Warrensburg, Missouri. “He was willing to put a 29-year-old kid in a management position, even though everyone else in that operation was older than I was,” Ross says. “I don’t think either of these gentlemen knew they were my mentors, but they enjoyed sharing their knowledge with the next generation, and I was lucky enough to be there to soak it up.”

Dennis Ross, general manager

Today, Ross mentors others: “When I came to the Otter Lake plant, I missed having peers to talk to in a larger water system, so I got involved with ISAWWA.” He ended up chairing the Education Committee and met people from other water plants, helping them with treatment issues. Ross also serves on the Diversity Committee, chairs the Water for People Committee and serves on the Water Utility Council. His hobby is riding his 2009 Harley Davidson Ultra Classic motorcycle as part of the Water Buffaloes (www.ridewithpurpose. org). He does the annual Ride with Purpose to the AWWA ACE conference to raise money for Water for People. He has ridden to Dallas, Denver and Boston.

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TREATMENT PLANT OPERATOR

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37

properly. UV transmittance is important. The in-line meter feeds this information to the UV system, so that’s why we have to calibrate it every week.” Sensors in the reactor tell the system how much power is needed for the correct dose of light. Operators check the sensors monthly by comparing them to three reference sensors kept in storage. Each unit has two reference sensors, which TrojanUV verifies and calibrates yearly. The quartz sleeves that house the bulbs are automatically cleaned at startup and shutdown and every eight hours. The lubricant must be refilled and checked every six months. Magmeters that report the flow of water to the system are calibrated monthly.

LOOKING AHEAD Future challenges for the Otter Lake team include keeping up with EPA regulations, fixing line breaks in the aging distribution system and preparing for weather events. An ice storm in the early 1980s knocked out power for three days; the plant now has standby generators. “We also have cots and sleeping bags tucked away, and in the winter we stock canned goods just in case,” says Ross. More plant improvements are in the works. New high service pumps and two new backwash pumps should be in place by summer 2016. Variable-frequency drives will save about $40,000 a year on electricity.

‘‘

The UV system looks at several things to ensure that the water is getting the correct dose of light. We have to verify that the systems are working properly.” DENNIS ROSS

HIGH MORALE High productivity and morale define the plant operations team. “I believe they’re happy here because they are encouraged to make suggestions and to come up with things that are beyond the normal job,” says Ross. The operators use their talents to everyone’s advantage; they even remodeled the plant’s bathroom. “Moving the lab allowed us to convert the old lab into a break area for the microwave, coffee maker and refrigerator,” says Ross. “All of these were in the filter room before. The operators welcomed that change.” The job offers substantial variety: lab work, maintenance, meter Plant team members like Jeff Stanley, lead operator, routinely take initiative in offering ideas and providing labor to reading, grounds maintenance. Operimprove the facility. ators also help protect the Otter Lake watershed by planting trees and laying riprap along the shoreline. Otter Lake is the only lake in the state with The team will continue its watershed preservation work and community its own mechanical barge, according to Ross. It can haul 17 tons of riprap outreach. “We’re very involved with the ISAWWA, and we hosted a plant and place it along the shoreline at a rate of about 100 feet per day with a crew tour for them in September 2014,” says Ross. The plant also offers tours to of three. local schools: “Even if those students don’t go on to become operators, they The operators support each other, helping new hires understand a treatmay be our customers some day, so it’s important for them to know who we ment process or prepare for the next exam. “One thing that really stands out are and what we do.” is when someone offers to work a holiday for an operator with young kids,” says Ross. “That shows how much we are like a family here.” from: Ross, a commission team member since 1997 and general manager since CB&I Motorola Solutions 1998, holds a Class A water treatment license. Besides Dill (Class A, 16 years) 832/513-1000 847/576-5000 and Stanley (Class A, 17 years), the team includes Rudy Rodriguez, crew www.cbi.com www.motorolasolutions.com foreman (Class D, 18 years); Class A operators Stan Crawford, Otis Foster, (See ad page 21) Joe Hogan and Tim Walter; Class C operator Eric Walsh; and Brian Durbin. TrojanUV Leopold - a Xylem Brand 888/220-6118 Customer service representatives Laura Sommerfeld and Andrea Hanney 855/995-4261 www.trojanuv.com handle tasks that include billing, human resources, public relations, IT, www.fbleopold.com recordkeeping and bookkeeping.

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BUILDING THE TEAM

Next in Line NEW YORK’S SOUTHERN CAYUGA LAKE INTERMUNICIPAL WATER COMMISSION FACES RECRUITMENT CHALLENGES WHILE KEEPING THE LEADERSHIP PIPELINE FILLED By Ann Stawski

I

n 2011, the Southern Cayuga Lake Intermunicipal Water Commission suddenly found itself with open positions for general manager and production manager. Besides filling those two roles, the commission had to fill the newly created positions of assistant distribution manager and assistant production manager at the Bolton Point Municipal Water System. That meant four key leadership positions open. The commission responded not by rushing to fill the slots but by taking the long view and developing training and succession plans to help ensure a full pipeline of leadership candidates for the future.

ON THE CAREER PATH

PHOTOS COURTESY OF BOLTON POINT MUNICIPAL WATER SYSTEM

The Southern Cayuga commission, based in Ithaca, New York, operates the Bolton Point system, which serves just under 7,000 metered connections in the towns of Ithaca, Dryden and Lansing and the villages of Cayuga Heights and Lansing. Without a succession plan in place, it was difficult to move existing personnel into the open leadership slots. The Bolton Point system has a staff of 17, including four distribution operators, four water treatment plant operators, instrument and control mechanic operators, water maintenance specialists and a GIS/IT specialist.

tell us about your team Joan Foote was appointed general manager May 30, succeeding the retiring Jack Rueckheim.

This feature in TPO aims to help clean-water plant leaders develop strong, cohesive operating teams. We welcome your story about team-building at your facility.

The most likely internal candiSend your ideas to editor@ date for general manager was Jack tpomag.com or call 877/953-3301 Rueckheim, then distribution manager and a 33-year employee of the Southern Cayuga commission. However, he felt ill equipped for that role and was focusing on retirement. Still, in 2011, he agreed to step in as general manager for up to five years or until a replacement could be named. Rueckheim took charge, immediately identifying opportunities to collect and standardize information and align training for all staff. “I kind of stumbled into this as a career years ago,” he says. “I never thought, ‘Oh, I want to work in a water treatment facility,’ but it has proven to be solid, dependable work.”

‘‘

As we recruit and bring in candidates, we focus on people who want advancement and want to learn more and move up. That’s important for us to build our succession planning. That’s the best way for this kind of facility.” JUDITH DRAKE

Judith Drake, human resources manager for the Town of Ithaca and the Southern Cayuga commission, agrees that people do not always consider work in water facilities as a career option: “It’s not always a calling one thinks about in high school, but once they are introduced to the occupation, most tend to stay for the long haul.”

RECRUITING CHALLENGES A succession plan has helped the Bolton Point Water System prepare for a future of capable and stable leadership.

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TREATMENT PLANT OPERATOR

Drake finds recruiting for the water facility to be a challenge in that many professionals don’t want to jump from one water plant to another. The Bolton Point system advertised nationally for its open positions and received only eight responses.

The succession plan includes methods for identifying talented people who are interested in increasing responsibility.

ments as time allows. We want to develop our staff into leaders.” Since Rueckheim’s appointment as general manager, he and his team have worked diligently to update facility procedures so that information does more than sit on a shelf. “We took the information out of our heads and put it on paper,” he says. “When someone asks a question, we pull out the manual and find the answers. That makes the team stronger and smarter.” Leaders hope that by creating a plan and cultivating internal candidates, the commission will be able to create a dependable pipeline of leadership prospects. Drake observes, “In developing our succession program and managing open recruitment, Bolton Point focuses on people who want to move up. This means making our entire staff the strongest it can be on all levels.” “People like stability and staying at one facility or municipality,” says Drake. “They don’t always want to uproot their lives and their families’ lives for a job.” That makes it all the more critical to hire people who fit into a succession plan for the long term. “As we recruit and bring in candidates, we focus on people who want advancement and want to learn more and move up,” says Drake. “That’s important for us to build our succession planning. That’s the best way for this kind of facility.” Aside from traditional recruitment, the commission looks to local programs to generate awareness of the industry and its facilities. Tompkins Cortland Community College offered a New York State Health Department Water Operator IIA license course in which the Bolton Point system water staff helped teach a section. The students toured the water plant facility and interacted with staff in the laboratory. A professor from Cornell University brings in students from his environmental engineering course. Earlier this year, he produced a video of the treatment plant. Extending and promoting the facility’s activities in the community helps make prospective employees aware of the career opportunities.

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PROMOTING INTERNALLY While Rueckheim stepped in as general manager, the Southern Cayuga commission found a suitable production manager from an internal source. While a leadperson, Joan Foote had been performing some work normally done by the production manager; she was able to transition into that role. Drake acknowledges challenges in enticing employees to advance through the ranks: “Some people understand that by moving up to a manager level, there is more responsibility to undertake. Sometimes it means being on call and making quick decisions at two in the morning. Some people just don’t want to step up to that level.” To help promote from within, the Southern Cayuga commission launched extensive supervisory and management training to employees who show interest and potential to become managers or supervisors. In addition, employees receive operational training beyond what is required to maintain their licenses. “The training and tests taken by our staff is a strong point of the commission,” says Rueckheim. “Employees receive cross-training in other depart-

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top performer wastewater:

PLANT

Tailgating to

Excellence

OPERATORS AT NORTH CAROLINA’S CONTENTNEA MSD QUICKLY LEARN TO GET THE MOST PERFORMANCE FROM A NEW BIOLOGICAL NUTRIENT REMOVAL FACILITY STORY: Jim Force PHOTOGRAPHY: Stuart Jones

AT THE CONTENTNEA METROPOLITAN SEWERAGE

District, tailgating doesn’t mean getting together for beer and burgers before a football game. It refers to the informal morning gatherings of the eight-member operations staff before they head out for their daily tasks. Ideas are broached. Solutions discussed. Experiences shared. “We’re a team,” says Chuck Smithwick, manager of the district, based in Grifton, North Carolina. “Everybody works together. We don’t let any good ideas go to waste.” Adds Renee Smith, operator in responsible charge, “We’re small. Each day we might be doing something different. You put on whatever hat you need to wear that day.” The daily exchange of ideas and observations helps because the district is operating a brand-new wastewater treatment plant, the culmination of more than $33 million in improvements and upgrades over the last 10 years, driven by new requirements from state and federal environmental agencies. The result? The district meets all discharge parameters, including nutrient reductions.

STEP UP TO BNR The Contentnea district serves the communities of Winterville (population 10,000), Ayden (5,000) and Grifton (2,800). Average daily flow to the 4 mgd (design) treatment plant is 2.14 mgd. Effluent flows into Contentnea Creek, a part of the Neuse River watershed. In the old days before the improvement project, the district operated a

42

TREATMENT PLANT OPERATOR

Plant operators including Stephen Berry (left) and James Woodard received training to ensure proper functioning of the facility’s BNR oxidation ditch (Ovivo).

2 mgd multistage aerationcl a r i f ic at ion facility designed to reduce BOD and TSS and convert ammonia to nitrite in a partial nitrogen removal process. “Our operators did a fantastic job of making the old plant work, but the flow had gone beyond what the old plant could handle, and it couldn’t meet the new nutrient limits,” Smith says. “It wasn’t designed to do what we needed it to do.” To meet the tighter nutrient requirements, the new treatment works is anchored by a five-stage biological nutrient removal (BNR) Bardenpho oxidation ditch process (Ovivo). The new headworks includes a screen and cyclone grit removal system (Parkson Corp.). The flow then passes through a Parshall flume where flow is monitored. The headworks is designed for a maximum wet-weather flow of 8 mgd. Smithwick says infiltration and inflow is a problem in the collections sys-

tem. Each community is responsible for the integrity of its own system. “We’re working with our communities on reducing I&I,” Smithwick says.

OUT WITH N In the Bardenpho system, the first phase of the oxidation ditch operates in the anaerobic mode for luxury uptake of phosphorus. It is followed by an anoxic zone for nitrogen removal, an aerobic aeration stage for nitrification, a second anoxic stage for further denitrification, and a post-aeration stage to promote settling in the clarifier. Return activated sludge is directed back to both anoxic zones. Two 90-foot-diameter, 16-foot-deep clarifiers settle solids and produce a clear overflow that passes to a tandem of deep bed sand denitrification filters.

Methanol is the carbon source. The filters are “bumped” periodically to release nitrogen in its gaseous form. The filter also polishes the wastewater. Filter backwash water is returned to the head of the plant. TSS is not an issue, as the plant easily meets its requirement of less than 30 mg/L. Total nitrogen isn’t an issue anymore: In 2014, the plant effluent averaged just 1.69 mg/L total nitrogen. Final effluent is UV disinfected (WEDECO) before discharge. Biosolids are aerobically digested, gravity thickened to 2 percent solids and dewatered on two new 800 Series incline screw presses (Huber Technology) rated at 90 gpm. Cake averaging 18 to 20 percent solids is hauled to a compost facility about 90 miles away. The district owns 70 acres surrounding the treatment plant where liquid biosolids can be applied. tpomag.com August 2015

43

‘‘

We’re a team. Everybody works together. We don’t let any good ideas go to waste.”

CHUCK SMITHWICK

Contentnea Metropolitan Sewerage District, Grifton, North Carolina BUILT: |

1976 (new plant 2010-2014) POPULATION SERVED: | 17,000 FLOWS: | 4 mgd design, 2.14 mgd average TREATMENT PROCESS: | Biological nutrient removal, denitrification filters TREATMENT LEVEL: | Tertiary RECEIVING WATER: | Contentnea Creek (feeds Neuse River) BIOSOLIDS: | Land-applied ANNUAL BUDGET: | $2.28 million GPS COORDINATES: | Latitude: 35°21’24.02”N; longitude: 77°24’56.96”W

“We started operating the screw presses in March 2014, with the goal of reducing land application of biosolids to our property by 50 percent,” says Smithwick. “We typically apply about 2.2 million gallons to our fields annually.” In 2014, the property received 800,000 gallons, fertilizing Bermuda grass and coastal hay for livestock feed. Material is applied from mid-March through October. About 1.5 million gallons was dewatered in the presses in 2014.

KEEPING CONTROL The control system (Ovivo) ramps the aerators up and down to control dissolved oxygen in the BNR process and optimize chemical and energy use.

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TREATMENT PLANT OPERATOR

The CMSD staff includes, front row, from left, Harriett Pridgen, Windy Sammond and Renee Smith; back row, Jimmy Edwards, Stephen Berry, James Woodard and Chuck Smithwick. Not shown: Ricky Barrow.

PLCs on the individual pieces of equipment provide further process control, and the plant uses a telemetry system to oversee all processes and alert operators to an issue if necessary. “The ditch is very operator-friendly,” Smith says. “We essentially turn it on and let it run.” The new plant capped a 10-year outlay in capital improvements to the treatment system and the wastewater collections system, including interceptor and pump station work. Much of the funding came from outside sources and zero- or low-interest loans. About 30 percent came as grants from the U.S. Department of Agriculture and Rural Development and the North Carolina Rural Center. Other money came from the state’s Clean Water Management Trust Fund. “Without their help, none of this would have been possible,” Smithwick says. The district bills the communities it serves, and they in turn bill customers. Smithwick says individual sewer bills have increased slightly, and the communities are implementing flow-based billing over the next two years.

USING THE OLD PLANT While the former treatment plant is gone, it is not forgotten. In fact, it serves a purpose. The district uses space in the old plant for solids processing and storage. “Four of the old circular clarifiers have been converted to aerobic digesters for processing solids,” he says. These small tanks (150,000-gallon capacity) have been retrofitted with diffused air blowers. They are used in rotation, week by week.

Chuck Smithwick inspects a valve actuator (AUMA Actuators) in the plant’s filter gallery.

oxygen entering the second anoxic zone. “The manufacturer gave us the idea, and we’ve learned how to operate with the DO a bit lower and get better denitrification in the ditch,” says Smith. “That means less methanol needed in the denitrification filters and less cost. We’ve been able to optimize the efficiency of the denitrification process.” Plant operators have made another adjustment that improved phosphorus removal. “Weather and mixed liquor suspended solids play a big part in phosphorus removal,” Smith says. During summer, the staff maintains the MLSS at 3,000 mg/L or less and increases the DO content of the basin. In winter, the MLSS increases to about 4,000 mg/L. “We’ve found the lower MLSS in summer results in better phosContentnea Metropolitan Sewerage District PERMIT AND PERFORMANCE INFLUENT

EFFLUENT

PERMIT

143 mg/L

2.26 mg/L

15 mg/L

TSS

165 mg/L

< 2.5 mg/L

30 mg/L

Phosphorus

3.79 mg/L

0.66 mg/L

2.0 mg/L

Total nitrogen

24.19 mg/L

1.69 mg/L

37,100 lbs/yr

BOD

“We pump biosolids into one of the digesters for a week, then switch to a second digester and pump into that one for a week,” Smithwick says. It’s a batch operation: Each digester holds solids for about a month to condition the material before it is transferred to the dewatering facility or spread on land. “By using the old plant, we’ve been able to increase our storage from 1 milThe (oxidation) lion gallons to 2.4 million gallons,” Smithwick says. “From an operations standpoint, ditch is very we can’t have enough storage space.” The operator-friendly. We increased capacity enables the plant to remove, stabilize and properly recycle its biosolids. essentially turn it on

‘‘

and let it run.” RENEE SMITH

OPERATING INNOVATIONS

The Contentnea team’s ingenuity has helped the plant perform effectively. Besides Smithwick and Smith, the team includes James Woodard, Ricky Barrow and Stephen Berry, operators; Jimmy Edwards, mechanic; Windy Sammond, lab assistant; and Harriett Pridgen, administrative officer. As is typical with new treatment processes, the staff received training from the equipment manufacturers, but Smith and her staff have made their own adjustments to meet their specific needs. “Each facility is different,” Smith says. “We learned the new processes together and we brainstormed with all our operators on how to optimize operations.” One of the most important lessons learned was that the BNR oxidation ditch system can be most effectively controlled by monitoring dissolved

James Woodard changes the effluent flow chart.

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45

James Woodard cleans the RoS 3Q 800 screw press (Huber Technology) after processing a batch of biosolids.

‘‘

Each facility is different. We learned the new processes together and we brainstormed with all our operators on how to optimize operations.”

RENEE SMITH

phorus removal,” Smith says. In hot weather, increased DO reduces the tendency of phosphorus to release back into the water. The plant also adds alum during summer to increase phosphorus removal.

PEAK PERFORMANCE The tweaks make a difference. The district produces outstanding effluent, averaging well under permitted levels for BOD, TSS, phosphorus and total nitrogen. Effluent phosphorus averaged 0.66 mg/L for all of 2014; total nitrogen averaged 1.69 mg/L.

The plant’s nitrogen permit limit is stated in pounds released per year. “Our permit limits us to no more than 37,100 pounds of nitrogen on an annual basis,” Smithwick says. “In 2014, our actual was 10,492 pounds.” The district has gone from near the bottom of the list to first in nitrogen removal among the members of the Neuse River Compliance from: Association, a regional nutrient AUMA Actuators, Inc. trading group formed to reduce 724/743-2862 nitrogen into the sensitive Pamlico www.auma-usa.com Sound estuary. Huber Technology, Inc. Before installation of the new 704/949-1010 treatment processes, the district diswww.huberforum.net charged more than 6 mg/L of total (See ad page 9) nitrogen at the midyear points of Ovivo USA, LLC 2008 and 2009, and more than 8 512/834-6000 mg/L in 2010. In 2014, the midyear www.ovivowater.com number was 1.52 mg/L, lowest in the Parkson Corp. compliance association. “It’s much 888/727-5766 easier now,” says Smithwick. “It’s www.parkson.com better for our operators and for the (See ad page 37) environment.” WEDECO – a Xylem Brand

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855/995-4261 www.wedeco.com Windy Sammond, lab assistant, performs regular tests to help keep the process in control and on track.

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TREATMENT PLANT OPERATOR

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Alfa Laval Ashbrook Simon-Hartley 5400 International Trade Dr., Richmond, VA 23231 866-253-2528 [email protected] www.alfalaval.us/wastewater

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Aqualitec Screening Equipment 3415 S Sepulveda Blvd., Ste. 1100, Los Angeles, CA 90034 855-650-2214 [email protected] www.aqualitec.com BDP Industries, Inc. 354 Rte. 29, Greenwich, NY 12834 518-695-6851 Fax: 518-695-5417 [email protected] www.bdpindustries.com

See ad page 73

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Bilfinger Water Technologies, Inc. 1950 Old Hwy 8 NW, New Brighton, MN 55112 800-833-9473 651-636-3900 Fax: 651-638-3171 [email protected] www.water.bilfinger.com Blue-White Industries 5300 Business Dr., Huntington Beach, CA 92649 714-893-8529 Fax: 714-894-9492 [email protected] www.blue-white.com

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Bright Technologies Specialty div. of Sebright Products, Inc. 127 N Water St., Hopkins, MI 49328 800-253-0532 269-793-7183 Fax: 269-793-4022 [email protected] www.brightbeltpress.com

See ad page 17

Carylon Corporation 2500 W Arthington St., Chicago, IL 60612 800-621-4342 312-666-7700 Fax: 312-666-5810 [email protected] www.caryloncorp.com

See ad page 21

CB&I 2103 Research Forest Dr., The Woodlands, TX 77380 832-513-1000 Fax: 832-513-1005 [email protected] www.cbi.com

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Centrisys Corporation 9586 58th Pl., Kenosha, WI 53144 877-339-5496 262-654-6006 Fax: 262-764-8705 [email protected] www.centrisys.us CNP - Technology Water and Biosolids Corp. 9535 58th Pl., Kenosha, WI 53144 262-764-3651 Fax: 262-764-8705 [email protected] www.cnp-tec.com

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Underdrain Filter Bottoms

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CST Industries 498 N Loop 336E, Conroe, TX 77301 936-539-1747 [email protected] www.cstindustries.com

Bio Tre solids a Ap tmen plic t / ati on Ce ntr Se ifug par es ato / rs Che Feemical d E /Po qui lym pm er ent Co agu Flo lan c Po cula ts/ lym nts ers / Co m Equ post ipm ing ent Co nve yor s

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DEL Tank & Filtration Systems 436 Hwy 93 N, Scott, LA 70583 800-468-2657 337-237-8400 Fax: 337-266-7800 [email protected] www.deltank.com Duperon Corporation 1200 Leon Scott Ct., Saginaw, MI 48601 800-383-8479 989-754-8800 Fax: 989-754-2175 [email protected] www.duperon.com

See ad page 31

See ad page 4

Eagle Microsystems, Inc. 366 Circle of Progress Dr. , Pottstown, PA 19464 610-323-2250 Fax: 610-323-0114 [email protected] www.eaglemicrosystems.com Enviro-Care Company 1570 St. Paul Ave., Gurnee, IL 60031 815-636-8306 Fax: 815-636-8302 [email protected] www.enviro-care.com

See ad page 25

FKC Co., Ltd. 2708 W 18th St., Port Angeles, WA 98363 360-452-9472 Fax: 360-452-6880 [email protected] www.fkcscrewpress.com

See ad page 54

Flo Trend Systems, Inc. 707 Lehmen St., Houston, TX 77018 713-699-0152 [email protected] www.flotrend.com

See ad page 8

See ad page 61

See ad page 9

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Fournier Industries, Inc. 3787 Frontenac Blvd. W, Thetford Mines, QC G6H 2B5 CANADA 418-423-6912 Fax: 418-423-7366 [email protected] www.rotary-press.com Grace Industries, Inc. 305 Bend Hill Rd., Fredonia, PA 16124 724-962-9231 Fax: 724-962-3611 [email protected] www.graceindustries.com Huber Technology, Inc. 9735 NorthCross Center Ct., Ste. A, Huntersville, NC 28078 704-949-1010 Fax: 704-949-1020 [email protected] www.huberforum.net Hydro International 2925 NW Aloclek Dr., Ste. 140, Hillsboro, OR 97124 866-615-8130 503-615-8130 Fax: 503-615-2906 [email protected] www.hydro-int.com JDV Equipment Corporation 1 Princeton Ave., Dover, NJ 07801 973-366-6556 www.jdvequipment.com JWC Environmental 290 Paularino Ave., Costa Mesa, CA 92626 800-331-2277 949-833-3888 Fax: 949-833-8858 [email protected] www.jwce.com

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Grease Receiving

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Headworks/Biosolids Management Komline-Sanderson 12 Holland Ave., Peapack, NJ 07977 800-225-5457 908-234-1000 Fax: 908-234-9487 [email protected] www.komline.com

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Kuhn North America, Inc. PO Box 167, Brodhead, WI 53520 608-897-2131 Fax: 608-897-2561 [email protected] www.kuhnnorthamerica.com

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Lakeside Equipment Corporation 1022 E Devon Ave., Bartlett, IL 60103 630-837-5640 Fax: 630-837-5647 [email protected] www.lakeside-equipment.com

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Noxon North America, Inc. 4-470 N Rivermede, Concord, ON L4K 3R8 CANADA 416-843-6500 [email protected] www.noxon.com

See ad page 37

Ovivo USA, LLC 2404 Rutland Dr., Austin, TX 78758 512-834-6000 Fax: 512-834-6039 [email protected] www.ovivowater.com

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Parkson Corp. 1401 W Cypress Creek Rd., Ft. Lauderdale, FL 33309 888-727-5766 954-974-6610 Fax: 954-974-6182 [email protected] www.parkson.com

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PWTech (Process Wastewater Technologies) 9004 Yellow Brick Rd., Ste. D, Rosedale, MD 21237 443-648-3300 Fax: 410-238-7559 [email protected] www.pwtech.us

See ad page 71

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Roto-Mix, LLC 2205 E Wyatt Earp Blvd., Dodge City, KS 67801 620-225-1142 Fax: 620-225-6370 [email protected] www.rotomix.com Schreiber LLC 100 Schreiber Dr., Trussville, AL 35173 205-655-7466 Fax: 205-655-7669 [email protected] www.screiberwater.com Screenco Systems LLC 13235 Spur Rd., Genesee, ID 83832 208-790-8770 [email protected] www.screencosystems.com

See ad page 39

SEEPEX Inc. 511 Speedway Dr., Enon, OH 45323 937-864-7150 Fax: 937-864-7157 [email protected] www.seepex.com

See ad page 79

Smith & Loveless, Inc. 14040 Santa Fe Trail Dr., Lenexa, KS 66215 800-898-9122 913-888-5201 [email protected] www.smithandloveless.com

See ad page 78

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SUEZ ENVIRONNEMENT 8007 Discovery Dr., Richmond, VA 23229 800-446-1150 804-756-7600 [email protected] www.degremont-technologies.com

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Continuous Deflection Separation

Sludge Incineration

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Tank Connection Affiliate Group 3609 N 16th St., Parson, KS 67357 620-423-3010 Fax: 620-423-3999 [email protected] www.tankconnection.com

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USABlueBook PO Box 9006, Gurnee, IL 60031 800-548-1234 847-689-3000 Fax: 847-689-3030 [email protected] www.usabluebook.com USP Technologies (US Peroxide) 900 Circle 75 Pkwy., Ste. 1330, Atlanta, GA 30339 877-346-4262 404-352-6070 Fax: 404-352-6077 [email protected] www.usptechnologies.com

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Vaughan Company, Inc. 364 Monte-Elma Rd., Montesano, WA 98563 888-249-2467 360-249-4042 Fax: 360-249-6155 [email protected] www.chopperpumps.com VFOLD INC. 15700 Robins Hill Rd., Unit 2, London, ON N5V 0A4 CANADA 877-818-3653 Fax: 519-659-6523 [email protected] www.vfoldinc.com WesTech Engineering, Inc. 3665 S West Temple, Salt Lake City, UT 84115 801-265-1000 Fax: 801-265-1080 [email protected] www.westech-inc.com

FREE INFO – SEE ADVERTISER INDEX

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Fine Tuners

Finicky, Fastidious and Fussy In common with most water engineers we meet, at Hydro we are shamelessly persistent in fine-tuning the best from our technology. Obsessing over the finest details is essential for optimum design and operation. Using the proven principles of Advanced Grit Management ®, we demand 85-95% removal of grit entering wastewater treatment plants. In a small footprint, the Eutek HeadCell® protects downstream processes from abrasion and deposition so the plant functions as designed.

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55

IN MY WORDS

Residuals as Resources: Knowing the Market LISE LEBLANC HELPS ORGANIC RESIDUALS SUPPLIERS CONNECT WITH THEIR CUSTOMERS. HER SUCCESS WITH MUNICIPAL AND PRIVATE-SECTOR CLIENTS HOLDS LESSONS FOR BIOSOLIDS RECYCLING PROGRAMS. By Ted J. Rulseh

L

ise LeBlanc started a consulting career 18 years ago, helping farmers in Canada’s Atlantic provinces develop crop management programs. Along the way, she saw a critical need to manage nutrients on land, “to ensure that we don’t have excessive nutrients leading to environmental issues, or not enough nutrients so that farmers don’t get good crop yields and quality.” It was then her business, LP Consulting in Mount Uniacke, Nova Scotia, took an additional direction. Today, she helps businesses and municipalities turn organic waste materials into resources and market them, usually as farm fertilizers and soil amendments. She sees big potential for residuals of many kinds, including municipal biosolids, as commercial fertilizers grow more expensive and as the farm community looks to more sustainable practices. She believes the biggest key to successful farm-based waste-to-resource programs is understanding the market: To be viable, a product must deliver provable economic value and fit in with farmers’ existing practices. LeBlanc shared a broad picture of Canada’s residuals market in an interview with TPO. Many of her insights translate well to biosolids recycling projects. : What triggered your interest in residuals as a viable product for farmers? LeBlanc: I’m really interested in the economics of growing crops: How much money are we putting in, and what are we getting out? It became clear that straight inorganic commercial fertilizers were becoming more expensive. Farmers were cutting back. Soil pH and nutrient levels decreased. So I started asking what was out there that could improve my farm clients’ crop production. : What was your first venture into the residuals area? LeBlanc: We started with the Brooklyn Power utility here in in Nova Scotia. They were taking wood ash to a landfill and paying a tipping fee. That was very expensive. They were interested in reducing expenses but also in whether this material could be a resource. We did tests on the material, secured environmental permits and conducted research on 26 farm fields to look at the soil health over time. We found we were increasing yield, improving soil pH and increasing nutrients. I encouraged my farm clients to use the wood ash in their crop production programs. As they saw improvements in their fields, neighbors noticed, and it grew from there. : How exactly is the wood ash beneficial? LeBlanc: It has a lot of nutrients, in particular potash, phosphorus, sulfur and calcium. It also acts like lime by increasing soil pH. It was like a huge multivitamin. All of a sudden, farmers were greatly increasing production at a fraction of the cost of commercial lime and fertilizer. On really poor soils, we more than doubled yield and quality.

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: What is the scope of your company’s services on projects like this one? LeBlanc: We work for the company on testing, permits and regulator y compliance. We handle marketing, with demonstration sites, booths and farm meetings to make farmers aware. Then we work with the farmers. How much do you need? What’s the best way to use it? Put in front of corn? Apply it in fall or spring? We determine the tonnage to send to each farm and work with trucking companies to make sure they deliver on a timely basis. If issues with the public arise, we put on public meetings and talk to the media. : Have you been involved with municipal biosolids projects? LeBlanc: Halifax Regional Municipality had been putting wastewater sludge into the harbor, which Lise LeBlanc, with a soil amendment was not acceptable. They looked at made from alkaline-stabilized bioalternatives in what they called the solids from the Halifax (Nova Scotia) Clean Harbor Solution. They decided Regional Municipality. on an alkaline-stabilization program through N-Viro Systems Canada, which is now owned by Walker Industries. They approached me for help in working with farmers. I looked at the product analysis and thought it was great. We had nitrogen and phosphorus in the biosolids, high potash from the cement kiln dust, and lime to increase soil pH. We did have pushback from environmental groups and went through our painful years, but now we have a waiting list of farmers. We secured a CFIA (Canadian Food Inspection Agency) label for the product. Because it’s sold as fertilizer, it doesn’t have to follow provincial biosolids guidelines. : What are some keys to a successful waste-to-resource program? LeBlanc: It’s important to understand the market. It’s not enough to say your product has N, P and K in it and farmers should take it. The agriculture community will only embrace a product if there is a good return on their dollar. Take the Halifax product, for example. To buy lime and com-

About LP Consulting LP Consulting, based in Mount Uniacke, Nova Scotia, works to develop sustainable solutions for farmers, businesses and the environment. The company’s four staff professionals offer expertise in nutrient, soil and waste management, crop production, land reclamation, education, training and research. The company also partners with municipal and industrial clients to develop, manage and sustain waste-to-resource programs involving biosolids, wood ash, compost, anaerobic digestate, offshore drilling waste, rendering plant effluent, fishery waste, paper mill sludge, and construction and demolition waste. LP also works with crop and livestock producers to increase yields and profitability. That includes helping them make use of local soil amendments that improve crop production and soil health. Company principal Lise LeBlanc holds a bachelor’s degree in agriculture from Dalhousie University, along with a bachelor’s degree in education and a Master of Science degree from Acadia University. Both institutions are in Nova Scotia.

mercial fertilizer to replace a tonne of N-Viro product, farmers would have to spend $125 to $150. So if they’re paying $40 to $50 a tonne for the product, that’s a significant return. It takes somebody to show them that — a lot of presentations and penciling out the economics at the table. : Apart from pure economics, what factors influence success? LeBlanc: What’s the soil type in your locality? If farms already have a high soil pH, then an alkaline-stabilized biosolids will not have a market. If the soil already has good organic matter, then organic matter in a compost is not a selling feature. You need to understand the growing season farmers are working with. During peak times when the farmers need the product, you need to have a lot of trucks lined up. Some residuals companies will have just a couple of trucks going. Farmers can’t wait and will just cancel. They’ll apply commercial fertilizer because it’s faster. It’s important to have a good relationship with the farm community. If you don’t have one, work with somebody who does. I recommend finding a local agrologist who is highly respected among farmers — someone who knows what will sell and what won’t. : How do you recommend approaching community relations? LeBlanc: The way farmers manage the product is important. You want to reduce neighbor conflicts as much as possible. Make sure you don’t apply it on weekends. Make sure you don’t apply it in the heat of summer when you could generate odors, because odors will shut you down. Instead of having farmers store material on the fields, ship it when they’re ready to use it. In our programs, once we adopted these practices, essentially 99 percent of calls and concerns stopped. If something does go wrong, deal with it up front. Don’t hide it, because it will come out, and then it’s difficult to get trust back. One thing most people don’t think about is: Your first face to the public is your truckers. They don’t need to be your PR people, and they shouldn’t be; that’s not their training. But spend some time with them to at least let them know what the product is that they’re hauling. Give them brochures so if someone stops and asks a question, they can say, “This is a biosolids compost (or whatever it is); here’s some information, and you can call the person listed on the back.” The key to communication is being honest. I’ve conducted public meetings. I prefer one-on-ones because public meetings can be hijacked. Meet one on one with people who have concerns. Provide information. Listen to them. You’ll have those who’ve heard bad things about residuals and aren’t

sure. With information, you can bring them around. You also have those who, whatever you give them or tell them, will never change their minds. : Besides the products you’ve already mentioned, what other programs has your company been involved with? LeBlanc: We run a wood ash program for the J.D. Irving forest products company out of New Brunswick. Our wood ash programs are booked now about two years in advance, before the product is even made. We’re looking at moving chicken manure and livestock manure that farmers can’t use on their own land. We’re also looking at soil blending and composting. : What are some other residual products that you see as having potential? LeBlanc: One is pulp and paper sludge. Some companies try to burn it, but it has high water content, so that’s very inefficient. Some years ago, a company tried a land application program, but it wasn’t well managed, and odors shut it down. But I’ve seen it on agricultural land, and it works fantastic. I think it has big potential. Fish waste is an excellent source of nitrogen and other nutrients for farms, but again, there’s a need to address odor. You could co-compost it. Biofuel is another potential market for using residuals. To the general public, if they’re uncomfortable with biosolids, if there is an “ick factor,” well, you’re not using it to grow food. You’re using it to grow energy. There’s probably residual material out there that we don’t even know about yet that could be excellent for waste-to-resource programs. : What’s the benefit of co-composting? LeBlanc: Co-composting can increase the value of a compost and make it easier to move. Suppose you have a material that has a nutrient value of $5 or $10 per tonne. That’s not going to be very attractive to the farm community. But what if there’s another residuals company nearby that has a different product, so that if you blended those two together, it’s worth $50 a tonne? Now you certainly can go back to the table and talk about moving that product. : What are some examples of residuals that could be profitably mixed? LeBlanc: Adding biosolids to compost can greatly increase the nutrient value, but then you have to deal with public concern about biosolids. That’s not difficult in the agricultural sector, but then farmers have to deal with their neighbors. Another material that can be composted is digestate from food waste, or food waste mixed with animal manure. : How would you characterize the future potential for residuals? LeBlanc: I think there is huge potential for residuals. The price of fertilizer continues to go up. The ability to easily extract phosphorus from the earth is decreasing. In the next 30 years, that phosphorus will be extremely expensive. Phosphorus is key to plant growth, so it’s important that governments support residuals for land application. If we’re to be sustainable in the future, we can’t keep putting these residual nutrients into landfills. : Can regulatory agencies play a role in advancing residuals programs? LeBlanc: Departments of environment need to improve their approaches if we’re to move ahead on these sustainable programs. Many departments say they support sustainable programs, but in reality they make it very difficult. Many don’t like to look at research conducted in other areas. They say, “We’re different here.” But in reality they’re not so different. Why do we set programs back by decades because their first response is to say no, regardless if there are similar successful programs elsewhere? That’s not supportive of sustainability. I understand they need to ensure that a product is safe, but when they have all the data to show that it’s safe, they shouldn’t put up roadblocks to making programs successful. That’s frustrating for companies that want to provide sustainable programs. It all comes back to sustainability: reducing waste, changing waste to resources and using those resources. tpomag.com August 2015

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TECHNOLOGY DEEP DIVE

1) Biosolids are pumped into Tank 1 and acidified to lower the pH, thus solubilizing the phosphorus.

5) Lime is added to the phosphorus-rich solution in Tank 2 to raise the pH and precipitate the phosphorus.

2) Low-pH material is pumped through a ceramic membrane, allowing only liquid and solubilized materials to pass.

6) A second ceramic membrane separates the precipitated phosphorus from the liquid stream, allowing phosphorusfree liquid to pass, and leaving behind extracted phosphorus.

3) Low- or no-phosphorus material is pumped to dewatering. 4) Solubilized phosphorus solution passes through membrane and is pumped to Tank 2.

Nutrient Solutions AN INNOVATIVE PROCESS COMBINES CHEMICAL TREATMENT AND MEMBRANE SEPARATION TO EXTRACT AND RECOVER PHOSPHORUS FROM WASTEWATER BIOSOLIDS By Ted J. Rulseh

P

hosphorus can be a challenge not only in clean-water plant effluent but in biosolids. For facilities looking to land-apply biosolids in areas with naturally phosphorus-rich soils, high P in the material can be an obstacle. Now, Renewable Nutrients, based in Pinehurst, North Carolina, offers a process that can remove phosphorus from the solids and capture it downstream. The results are crop- and soil-friendly biosolids and a granular calcium phosphate product that can be used as fertilizer. The Quick Wash process chemically separates phosphorus from the biosolids in one tank, then chemically precipitates it in another tank. The company offers a mobile, trailer-mounted pilot treatment unit that can be installed at clean-water plants to test how the process could be configured to operate at a commercial scale on the site. Jeff Dawson, CEO, and Larry Sandeen, chief engineer, talked about the process in an interview with Treatment Plant Operator. : What need in the marketplace drove development of this technology? Dawson: Around the country and the world, there is an issue with the amount of phosphorus being land-applied with biosolids. Excess phosphorus can run off into waterways and cause algae blooms. On the other side, the world

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has reached its peak in extraction of phosphorus, a nonrenewable resource that is also essential to growing food. Our technology creates biosolids with a more desirable nitrogen-to-phosphorus ratio while capturing the extracted phosphorus in a product that can be directed to other beneficial uses. : How is the phosphorus extracted from the biosolids stream? Sandeen: We acidify the solids to a pH of roughly 2.5 to lyse some of the cells, dissolve the phosphorus and make it available to be carried forward in a liquid stream through a separation process. There we capture the low-phosphorus solids, which can be land-applied without affecting surface waters. The low-pH, high-phosphorus liquid moves to another tank. : How is the phosphorus recovered from that liquid stream? Sandeen: We add lime to that liquid to a pH of about 10.5, causing calcium phosphate solids to precipitate out. After another separation process, the high-pH, relatively clean liquid stream can be returned to the treatment plant headworks or to a point in the process that requires alkalinity. The precipitated solids can then be processed further — concentrated, dewatered or dried, depending on the intended use and the specific market we would be delivering the product to.

: Where in a wastewater treatment plant process would this process be deployed? Sandeen: Most commonly, it would be installed before sludge dewatering. Our system could function as the thickening process. It could also be implemented on a phosphorus-rich sidestream. There are ample opportunities to customize it to the specific needs of a facility. : What is the typical solids content of the biosolids created from this process? Sandeen: We typically target about 4 percent, but it depends on how we apply the technology. That’s one reason we have our pilot plant — so we can look at different plants, different scenarios, different points in the process to pull the sludge from. You can work this process with digested biosolids, waste activated sludge or almost any solids stream.

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Customers don’t buy a ‘black box’ from us. They buy the technology, and all the parts along the chain are off-the-shelf, proven technologies that have been around the waste treatment business for quite some time.”

JEFF DAWSON

Ideas Ahead See us at WEFTEC booth 2674

THK Thickening System WEF Innovative Technology Award Winner

Attacking key challenges with new thinking. At Centrisys, that’s how we’ve been moving the wastewater industry forward for more than 25 years. From more efficient dewatering, to polymer-free thickening, to the next valuable breakthrough, we continue to advance innovations that save money, increase

: How would you describe your pilot unit? Sandeen: It’s a trailer-mounted unit that we can move from location to location to demonstrate the technology. It receives flows on the order of 3 to 5 gpm. The point is to model the extraction process on site and collect data that will inform full-scale implementation. We can also collect samples of the two solids streams and send them to dewatering vendors to see how their equipment would handle the materials. For an existing facility considering a retrofit of our process, we can send samples to the manufacturers of the dewatering equipment they currently use to get an assessment of how operations would be affected by our process. : What degree of phosphorus removal can your process achieve? Dawson: We can customize the amount of extraction depending on what the customer wants the solids to look like on the back end. So if you need a 2-to-1, 3-to-1 or 4-to-1 nitrogen-to-phosphorus ratio in your biosolids because in your region that’s what you need for land application, we can do that. We have a technology that extracts more than 80 percent of phosphorus, but that can be dialed down if the customer so desires. : What does this technology look like in terms of the equipment deployed on a site? Dawson: We’re agnostic in terms of the equipment that’s needed. Customers don’t buy a “black box” from us. They buy the technology, and all the parts along the chain are off-the-shelf, proven technologies that have been around the waste treatment business for quite some time. We’re agnostic in how we put a process together to meet the needs of a facility. : What are prospective customers saying about this technology? Dawson: As we have conversations with consulting engineering firms and end users, there are dynamic discussions about changing how the industry deals with nutrient issues and nutrient extraction and how this could be a game-changing technology. There’s a need for it because states are getting much more restrictive in the land application of phosphorus in biosolids. And the reality is that as a society we have to start reusing phosphorus as that resource becomes scarcer and prices continue to go up.

uptime and advance your success.

Get ahead today at Centrisys.com/IdeasAhead.

Road Trip and a Tour – Sunday, September 27, 2015 Join us on a tour of the Kenosha Wastewater Treatment Plant, and see how this 1938 facility has been transformed into a plant for the future. Unable to make the tour? Come visit Centrisys at WEFTEC Booth 2674 or CNP Technology Water and BioSolids Corp. at WEFTEC Booth 2593.

FREE INFO – SEE ADVERTISER INDEX

Coagulants and Flocculants for Septic, Grease, Municipalities and Industry

Save Money • Save Time • Save Polymer

Call Toll-free:

877.771.6041

• Dewatering polymers for all dewatering equipment • All forms: Dry and Emulsion • Variety of packaging sizes to meet customer needs • Both East & West coast shipping points • Expert technical staff • Specific solutions for our customers

1390 N. Manzanita St. Orange, CA 92867 www.aquaben.com • [email protected]

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spotlight

PHOTO BY CRAIG MANDLI

Scott Meyer, right, owner of Screenco Systems and inventor of the Dual Screen System, discusses the features of his receiving station with an attendee at the 2015 WWETT Show. The gravity system dewaters septage, filtering out garbage that collects atop screens and is manually raked into a collection device.

Simple Screening DEWATERING PLANT OWNER MARKETS HIS RECEIVING STATION TO THE INDUSTRY By Craig Mandli

S

filtered garbage that collects atop the cott Meyer was stuck. An increase in material volume at his Idaho screens can be raked into a wheelseptage dewatering plant, along with tighter regulations on the cleanWater & Wastewater Equipment, barrow or other collection device. liness of land-applied biosolids, left him struggling to keep up. That’s Treatment & Transport Show The unit comes with a stainless steel when he took matters into his own hands. www.wwettshow.com rake. “Our screening system was constantly plugging with hair and rags, and Education Day: Feb. 17, 2016 “We built and tested multiple having to stop periodically to clean it meant I couldn’t filter septage at the Exhibits: Feb. 18-20, 2016 Indiana Convention Center, Indianapolis designs, and have been beta testing volume I needed to,” says Meyer. “I started tinkering with my own design, this current version in commercial and that’s how Screenco Systems was born.” applications for the past 18 months,” says Meyer. “We use it every day at our Meyer’s high-capacity Dual Screen System, which made its commercial dewatering plant, and we’ve seen cleaner biosolids, faster off-load times and debut at the 2015 Water & Wastewater Equipment, Treatment & Transport improved productivity. We’ve run 35,000 gpd through our screen, and the (WWETT) Show, is constructed of aluminum with stainless steel screens, biosolids are virtually garbage-free.” with a collection sump and a high-capacity 6-inch drain. The system has two While he’s been to several past WWETT Shows, the 2015 show was Mey3/8-inch gapped stainless steel bar screens at opposing angles; the front er’s first as an exhibitor. He says his goal was simply to introduce the indusscreen is virtually self-cleaning. It is a non-mechanical, simple way to remove try to his product. “We aimed this large pieces of trash, rocks and other system at people like me — private debris from the flow stream. We’ve run 35,000 gpd through our screen, contractors who do their own dewa“It’s really a simple design with and the biosolids are virtually garbage-free.” tering and small municipalities that no moving parts,” says Meyer. “When SCOTT MEYER dewater as part of their pretreatthe septage is pumped in, trash and ment,” he says. “I’m hoping to show them that there is a product out there debris hits the deflector and ends up on the bottom of the screen. Once it that is simple and affordable. Judging by the positive reaction, a lot of guys starts draining slower, the operator manually rakes it clean.” have been dealing with the same issues I was.” This unit has a 4-inch telescoping inlet hose that moves laterally and can Meyer was excited by the response and sold several units while on the be connected to a vacuum truck or other flow stream. The system is portafloor. He’s already thinking about WWETT 2016 and promises to be back ble; and the 19.5 square feet of screening area allows for continued use and with a “bigger and even better” dual-screen design. is easy to rake clean to the garbage drain tray. It can treat over 500 gpm. Var“I have a couple upgrade ideas, including adding forklift skids to make ious screen gap sizes are available. the station more portable,” he says. “The guys I talked with at WWETT told The unit can be mounted above an open-pit settling pond or as a standme it was a great design at a good price. Hearing that kind of feedback is alone application that can be stationed almost anywhere. The station is easexciting!” 208/790-8770; www.screencosystems.com. ily cleaned with water; catwalk access enables easy cleaning and raking. The

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TREATMENT PLANT OPERATOR

FREE INFO – SEE ADVERTISER INDEX

10,000 Attendees from 53 Countries

Over 80 Educational Sessions

Ideas to Boost Profits

www.wwettshow.com | 866.933.2653 Water & Wastewater Equipment, Treatment & Transport Show

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product focus

FKC SKID-MOUNTED DEWATERING SYSTEM

Headworks and Biosolids Management By Craig Mandli

Aftermarket Parts/Service AGC CHEMICALS AMERICAS AFLAS FLUOROELASTOMERS

FKC skid-mounted dewatering systems can be set up strictly for dewatering or used to heat-pasteurize biosolids while dewatering to achieve a Class A product. Lime is added before dewatering Skid-mounted dewatering to raise the pH to 12 in a separate agitated systems from FKC tank. The liquid biosolids are then pumped with polymer to the flocculation tank on the skid. Flocculated biosolids overflow from the tank into the rotary screen thickener and are gravity fed into the screw press, where steam from a small boiler is injected, heating the biosolids to meet the time and temperature requirements. 360/4529472; www.fkcscrewpress.com.

ML SPIRALS SHAFTLESS SCREWS

AFLAS Fluoroelastomers for pumps, valves and seals from AGC Chemicals Americas enable parts and components to withstand taxing conditions and help reduce downtime in potable water/wastewater operations. AFLAS Fluoroelastomers from AGC Chemicals Americas They enhance performance and extend the life of pumps, seals and valves used in harsh chemical processing applications. They are resistant to acids, bases, solvents, hydrocarbons, sour oil and amines, as well as extreme temperature ranges and highpressure environments. They are copolymers of tetrafluoroethylene and propylene with high molecular weights. Classified by ASTM D 1418-01 as FEPM, they don’t deteriorate under prolonged exposure above 392 degrees F. 800/424-7833; www.agcchem.com.

CONVEYOR COMPONENTS COMPANY VA AND VAX Model VA and VAX bucket elevator alignment controls from Conveyor Components Company are designed to indicate when the head or boot section of a bucket elevator drifts too far out of alignment. They can be used to signal a problem Model VA and VAX bucket elevator alignment controls from Conveyor or simply shut down the bucket elevaComponents Company tor leg. This control device has a sequential two-pole double-break microswitch rated for 20 amps at 120, 240 or 480 VAC. The switch actuation is field adjustable with a simple 3/32 hex wrench adjustment. The metal roller is sturdy and bidirectional, and designed to survive in difficult environments. The housing is a rugged polyester powder-coated steel frame with a specially designed non-accumulating pocket. The microswitch is rated NEMA 4 weatherproof, or NEMA 7/9 explosion-proof. Epoxy coating is available. 800/233-3233; www.conveyorcomponents.com.

ENVIRONMENTAL DYNAMICS INTERNATIONAL AERATION WORKS The Aeration Works Division of Environmental Dynamics International was created to give operators of aeration systems a source for fast, reliable installations and maintenance. Made up of experienced installers and field service professionals, personnel are experts at the installation and maintenance of aeration systems. These expert installers know what tools are needed, how to do it quickly and how to ensure it is done to manufacturers’ specifications. When doing maintenance, the group has the experience to evaluate the degree of work needed. If a construction crew is lined up, Aeration Works can provide supervision to ensure the work is done to any manufacturer’s specifications. 573/4749453; www.aerationworks.com.

Shaftless screws from ML Spirals are constructed from high-strength Swedish alloy steel with high wearing ability and the torque requirements for various spiral applications. They are cold formed in a multitude of close-tolerance Shaftless screws diameters and pitches up to 30 inches in diamefrom ML Spirals ter, and in a variety of bar sizes as large as 4.8 by 1.2 inches. They can be used to transport wet, sticky and difficult materials with a high risk of clogging. 416/277-4262; www.ml-spirals.com.

Belt Filter/Rotary Presses ALFA LAVAL SCREW PRESS The Screw Press from Alfa Laval uses moderate rotational speed for low power consumption, providing a positive impact on operational costs. Its controls ensure consistent continuous operation with minimal Screw Press from Alfa Laval need for supervision. The moderate rotational speed also results in a low noise level, ensuring a positive working environment, and low spare parts demand. Applications include dewatering of municipal wastewater plant sludge (primary, secondary, mixed or digested sludge), as well as industrial biosolids and biogas residues. It reduces sludge volume for lower transportation and disposal costs. 866/2532528; www.alfalaval.us/wastewater.

ANDRITZ SEPARATION LOW-PROFILE BELT PRESS The low-profile dewatering belt press from Andritz Separation has SmarTrax technology that lowers the costs of ownership. The Center of Competences of Arlington with Low-profile dewatering belt collaboration of specialists of the French press from Andritz Separation ANDRITZ facility developed the press, which is engineered with the operator in mind. The low-profile design provides modular flexibility, a smaller footprint, quality of construction and easy maintenance without compromising performance. 800/433-5161; www.andritz.com/separation.

BRIGHT TECHNOLOGIES BELT FILTER PRESS Belt filter press unit from Bright Technologies

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TREATMENT PLANT OPERATOR

The 1.7-meter, trailer-mounted belt filter press unit from Bright Technologies has an insulated control room with FRP walls, air conditioning, electric heat, a refrigera-

tor, stainless steel desk, tool storage, locker, closed-circuit TV and remote operator controls. The modular design allows the room to be custom manufactured to fit most single-drop trailers. Units are made for rapid setup, with folding conveyor and operator walkways. No special lifting equipment is required. 800/253-0532; www.brightbeltpress.com.

eliminating the possibility of partially hydrated polymer molecules. The chamber has a flushing valve for the mechanical seal pocket to extend the life of the seal. The standard unit is able to handle 20 gpm through the chamber. An optional post dilution line can be used to provide an additional 20 gpm. 855/328-9200; www.ipm-sys.com.

FOURNIER INDUSTRIES ROTARY PRESS

LUTZ-JESCO AMERICA LJ-POLYBLEND POLYMER SYSTEM

The rotary press from Fournier Industries uses two slowly rotating screens to create a 2-inch channel that biosolids pass through as they dewater. A pressure restrictor on the Rotary press from outlet allows the operator to vary the degree Fournier Industries of cake dryness in the final product. It has few components and is designed for ease of maintenance. The totally enclosed design mitigates odors and allows the operator to stay out of direct contact with the sludge. The robust control system allows for unattended operation, and it can be equipped with a single dewatering channel, expandable up to six channels on a single machine. It offers low power usage, low noise levels, very little water use and a compact footprint. 952/288-5771; www.rotary-press.com.

The LJ-PolyBlend Polymer System from LutzJESCO America Corp. is a dependable, motorized mixing machine with a corrosion-resistant housing, large turbine and multi-zone mixing chamber that provides uniform dispersion energy at the moment of initial polymer wetLJ-PolyBlend Polymer System ting. The prime mixing zone from Lutz-JESCO America Corp. fully activates the polymer, while the second mixing zone promotes gentle polymer activation via a small turbine, lessening molecule fracturing. Its stainless steel injection valve prevents agglomerations and reduces the need for extended mixing time. The system includes a clear mixing chamber that provides visual monitoring of mixing polymer feed. Its compact design – only 1 to 1.5 square feet – means it’s light and allows for easy installation and transportation. It has automatic pump speed adjustment via 4-20 mA input, water flow sensor and priming port. 800/5542762; www.lutzjescoamerica.com.

Chemical/Polymer Feeding Equipment EAGLE MICROSYSTEMS VF-100 The VF-100 polymer feeder from Eagle Microsystems is constructed of stainless steel and uses a direct drive to ensure optimum performance and durability in harsh chemical feed environments. It can be optimized for any dry-feed application with options like dust collectors, flex-wall agitation, explosion-proof motors, VF-100 polymer feeder wetting cones, solution tanks, flow pacing confrom Eagle Microsystems trol, extension hoppers and multiple screw and motor ranges to accommodate any required feed rate. The chemical feed rate is controlled by electronic SCR speed control for increased accuracy and control. With no external gears, pulleys, chains, belts or lubrications required, it is user-friendly and low-maintenance. 610/323-2250; www.eaglemicrosystems.com.

FORCE FLOW MERLIN CHEMICAL DILUTION SYSTEM Merlin Chemical Dilution Systems from Force Flow enable automatic adjustment of chemical strength on site to keep a metering pump operating in the ideal speed range, regardless of changes in seasonal chemical demand. Operators can save money by purchasing standard high-strength chemical, then diluting on site as needed. Merlin Chemical Dilution 925/686-6700; www.forceflow.com.

Systems from Force Flow

IPM SYSTEMS PARADYNE The ParaDyne liquid polymer activation system from IPM Systems includes a polymer check spring located outside the path of polymer flow to eliminate the polymer from gumming or clogging around the spring. A non-impinging rotor is used to pull polymer through the mixing zone to provide efficiency and eliminate damage to the polymer. There ParaDyne liquid polymer activation is no need to recirculate the polymer system from IPM Systems solution through the mixing zone,

PULSAFEEDER PULSATRON SERIES HV The Pulsatron Series HV from Pulsafeeder is designed for high-viscosity applications up to 20,000 CPS for precise and accurate metering control. It offers manual control over stroke length and stroke rate as standard, with the option to choose between 4-20 mA and external pace inputs for automatic control. Five models are available, having pressure Pulsatron Series HV capabilities to 150 psi at 12 gpd, and flow capacfrom Pulsafeeder ities to 240 gpd at 80 psi, with a turndown ratio of 100-to-1. It comes with a reliable timing circuit, circuit protection against voltage and current upsets, panel-mounted fuse, solenoid protection by thermal overload with auto-reset, water resistance, and guided ball check valve systems to reduce backflow and enhance priming characteristics. 800/333-6677; www.pulsatron.com.

Coagulants/Flocculants BASF CORPORATION – WATER SOLUTIONS DIVISION ZETAG ULTRA The Zetag Ultra flocculant range from BASF Corporation – Water SoluZetag Ultra flocculant range tions Division is a high molecular from BASF Corporation – weight cationic product designed Water Solutions Division to improve dewatering efficiencies. It has been shown to offer improvements in cake solids of up to 20 percent while reducing effective doses by as much as 40 percent. Originally designed specifically for dewatering municipal sludges by centrifuge, the range has also found positive results in thickening applications, including gravity belts and dissolved air, as well as in other industries where sludge is processed at high temperatures and extremes of pH. 800/322-3885; www.watersolutions.basf.com. (continued)

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product focus

Headworks and Biosolids Management

Composting Equipment BIONETIX INTERNATIONAL BCP85 COMPOST ACCELERATOR BCP85 Compost Accelerator from Bionetix International is a blend of bacteria, yeast, enzymes and nutrients that accelerate and optimize degradation of organic BCP85 Compost Accelerator from Bionetix International wastes. Microorganisms and nutrients enrich the material to be degraded and yield an enriched fertilizer. The product provides microbial diversity for maturation and degradation of compost. It contains minerals, amino acids, peptides and vitamins for growth and metabolic activity of microorganisms, including bacteria, yeast and fungi, providing basic element nutrients often missing in organic waste. 514/457-2914; www.bionetix-international.com.

KUHN NORTH AMERICA KNIGHT VT VERTICAL MAXX The Knight VT Vertical Maxx twinauger mixer from Kuhn North America is available in four mid-sized trailer modKnight VT Vertical Maxx els in sizes from 320 to 680 cubic feet. twin-auger mixer from Truck model units are available in 440- to Kuhn North America 680-cubic-foot capacities, with the 440-cubicfoot unit available in a stationary model. Improvements to the mixing chamber and redesigned augers provide aggressive processing of virtually all food waste materials, as well as efficient blending with other organic materials. Faster auger speeds result in improved auger cleanoff and more complete clean-out of the mixer with each batch. The rugged, dependable drive system helps ensure reliable service and long life. Multiple discharge options offer increased versatility, and a variety of conveyor choices are available to match most discharging situations. 608/897-2131; www.kuhnnorthamerica.com.

ROTO-MIX INDUSTRIAL COMPOST SERIES Industrial Compost series mixers from Roto-Mix have a GeneRation II Staggered Rotor that combines gentle tumbling with quick complete mixing to Industrial Compost series ensure rapid decomposition and quality mixers from Roto-Mix compost. Ingredients are lifted up to the side augers that move the material end-to-end for a fast, thorough mix. Total movement of material in the mixing chamber eliminates dead spots. The rotor lifts the material past the wedging point of the lower side auger, providing a fluffier mixture while lowering power requirements. The conveyor is used to build windrows or static piles. They are available in 16.7-, 23-, 27.8- and 34.1-cubic-yard capacities as stationary, trailer- or truck-mount units. 620/338-0090; www.rotomix.com.

Dewatering Equipment AQUA-ZYME DISPOSAL SYSTEMS 30-YARD OPEN-TOP ROLL-OFF DEWATERING UNIT The 30-yard Open-Top Roll-off Dewatering Unit from AQUA-Zyme Disposal Systems can be filled with 22,000 to 25,000 gallons of biosolids at 1 to 2 percent solids in about two hours. After draining 24 hours, the unit can be picked up using a standard-capacity roll-off truck and

transported for solids disposal. Sludge volume can be reduced by 80 percent with reductions to 98 percent in BOD, COD, FOG and TSS. It has few moving parts, and the size of the filter media can be selected according to the particulars of the job. Standard equipment Roll-off Dewatering Unit from includes a roll-over tarp system; side, AQUA-Zyme Disposal Systems floor and center screens; 1/4-inch floor plate; seven-gauge side plates; four door binder ratchets; eight drain ports; two inlet ports; and a long-handle scraper. The average life span is 12 to 14 years. Units are also available in a 15-yard size. 979/245-5656; www.aqua-zyme.com.

Grinders/Shredders HYDRA-TECH PUMPS S4SHR-LP The S4SHR-LP 4-inch hydraulic submersible shredder pump from Hydra-Tech Pumps continuously rips and shears solids with a 360-degree shredding action. The carbide-tipped impeller and hardened macerator suction plate work together to produce a violent shredding action that keeps the discharge open. It is narrower in S4SHR-LP shredder pump size at 21.5 inches, which allows it to fit through from Hydra-Tech Pumps most manholes. Depending on the application, there is a version for portable or fixed installations. A guide rail assembly is available for stationary applications. Combined with HT15 to HT35 power units, it is capable of flows up to 810 gpm. The safe and variable-speed hydraulic drive can be used where electric power is hazardous or impractical. 570/645-3779; www.hydra-tech.com.

JWC ENVIRONMENTAL 7-SHRED The 7-SHRED industrial grinder from JWC Environmental can be quickly configured in a variety of sizes with cutter and motor options tailored to meet exact requirements. It is available with up to a 100 hp drive motor and 29-to-1 cycloidal reducer to turn the hardened steel dual cutting shafts. The 28,000 ft-lbs of available torque can produce forces up to 69,000 pounds at the cutting tips, providing the strength to grind up to 1,000 cubic feet per hour. It can grind imperfect consumer goods, materials for recycling, organics for waste-to-energy, meat and seafood processing waste, and high-volume delumping applications. It 7-SHRED industrial grinder incorporates individual steel scrapers from JWC Environmental between each spacer to increase solids throughput for maximum grinding efficiency. The standard 30-, 40- and 50-inch sizes meet a wide range of output requirements. Standard feed hoppers are available to accommodate a variety of material conveyance methods to the grinder. Customers can choose from 3-, 7- or 17-tooth cutter combinations. 800/331-2277; www.jwce.com.

VAUGHAN COMPANY TRITON Triton screw centrifugal pumps from Vaughan Company handle thick biosolids, large or stringy solids, shearsensitive fluids, and delicate or highly abrasive materials. They have non-overloading power characteristics, heavy-duty power frames and a flushless mechanical seal. A water-flushed mechanical seal or packing is available. 888/249Triton screw centrifugal pumps 2467; www.chopperpumps.com. from Vaughan Company

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Grit Handling/Removal/Hauling PAXXO LONGOFILL The Longofill continuous bag system from Paxxo can connect to the discharge point of machines used to move, dewater or compact screenings, grit and biosolids. Material is then deposited in a 90-meterlong continuous bag for odor containment and spillage control. The cassette bag is easy to seal, and the material and odors are trapped inside, cutting down development of bacteria and fun- Longofill continuous bag system from Paxxo gus spores. 770/502-0055; www.paxxo.us.

SCHREIBER GRIT & GREASE The Grit & Grease removal system from Schreiber consists of two rectangular concrete channels that separate and collect grit and grease. One channel settles particles while the other collects grease. A rotating spiral flow pattern washes organics from the grit, then deposits it in a trough at the bottom of the chanGrit & Grease removal nel. A grit pump mounted to a traveling bridge system from Schreiber then pumps the grit to an elevated trough sloped at one end to transfer the slurry to a classifier for further washing and dewatering. Floating grease is transported to one end of the channel by an air skimming system. Air is directed onto the surface of the grease channel in the direction of a rotating screw conveyor. The screw conveyor rotates, lifting the grease for disposal in a collection container. 205/655-7466; www.schreiberwater.com.

Screw Conveyors SPIROFLOW SYSTEMS FLEXIBLE SCREW CONVEYOR Flexible Screw Conveyors from Spiroflow Systems can help accurately meter chemicals used for pH, bacteria, taste and odor control. Chemicals such as hydrated lime, activated carbon and soda ash can be accurately dosed using either loss-in-weight or volumetric metering, while eliminating dust and environmental contamination. They easily Flexible Screw Conveyors convey dosing chemicals from silos, bulk from Spiroflow Systems bags or bin hoppers to achieve accurate dosing rates as low as 2 pounds per hour. They are flexible and can convey in any direction from horizontal to vertical, routed around fixed obstacles and equipment, and from one room to another through small wall openings. They require minimal maintenance, are easy to clean and dust-free, and can operate at rates of 2 to 88,000 pounds per hour. 704/246-0900; www.spiroflowsystems.com.

Septage Receiving Stations BIO-MICROBICS MYFAST HS-STP MyFAST HS-STP (High-Strength Sewage Treatment Plant) wastewater treatment systems from Bio-Microbics use an enhanced aeration pretreatment zone, adding the LIXOR XD MyFAST HS-STP Submerged Aeration System and MyTEE wastewater treatment Grit Vault as an effective pretreatment systems from Bio-Microbics zone to reduce the levels of BOD and

TSS. Engineered to fit most residential and commercial property applications, systems provide alternative wastewater treatment options for those residing outside the reach or in lieu of municipal treatment plants. The technology, with its 100 percent submerged, fixed-film, packed-bed media bioreactor for low/peak, toxic shock or heavy loading is ideal for septage receiving stations. 800/753-3278; www.biomicrobics.com.

LAKESIDE EQUIPMENT RAPTOR SEPTAGE ACCEPTANCE PLANT The Raptor Septage Acceptance Plant and Raptor Septage Complete Plant from Lakeside Equipment CorpoRaptor Septage Acceptance Plant ration help manage the unloadand Complete Plant from Lakeside ing process and protect Equipment Corporation downstream equipment. The system, with security access and hauler management and accounting software, provides municipalities the tools needed to maximize revenue generation and produce more energy with minimal maintenance. 630/837-5640; www.lakeside-equipment.com.

Screening Systems AQUALITEC CORP. RAKETEC The Raketec multi-rake bar screen from Aqualitec Corp. is capable of huge flow capacity, with low operational costs and hassle-free maintenance. It offers up to 80 mgd flow capacity and is resistant to clogging and Raketec multi-rake bar screen debris damage because it has no subfrom Aqualitec Corp. merged moving parts. The design helps increase debris capture efficiency, prevent costly downtime and repairs, and allow safer and more efficient wastewater treatment plant operation. 855/650-2214; www.aqualitec.com.

E & I CORPORATION CATENARY BAR SCREEN The Catenary Bar Screen from E & I Corporation, A Div. of McNish Corporation, is used for the screening of solids from the influent of wastewater treatment plants. It is a heavy-duty, reliable and easy-to-maintain unit for the protection of pumps in stormwater pump stations, especially in lowlying areas. It has since been utilized extensively in both municipal and industrial Catenary Bar Screen from wastewater treatment plants. Its chain E & I Corporation, A Div. of and rakes form a natural catenary loop McNish Corporation at the bottom of the screen to eliminate the need for any sprockets or chain guides below the liquid surface. This allows all maintenance to be performed from the operating-floor level. 614/899-2282; www.eandicorp.com.

JDV EQUIPMENT CORPORATION SCREW SCREEN The Screw Screen from JDV Equipment Corporation is a reliable self-cleaning method for the removal of solids from industrial or municipal wastewater. It is designed for in-channel or septage receiving applications with low to moderate flow rates. It provides screening, conveying and dewatering in one compact and efficient

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product focus

Headworks and Biosolids Management

design. Influent enters the screen, and solids are captured by the filter media per design requirements. The solids are then transported by the shaftless screw to the compaction zone and finally the discharge point. The optional wash zone removes organic material from the screenScrew Screen from JDV ings prior to compaction and discharges Equipment Corporation into a container or discharge bag. The product can be installed inclined in an existing channel or as a septage receiving station. 973/366-6556; www.jdvequipment.com.

KUSTERS WATER, DIVISION OF KUSTERS ZIMA CORP., PROTECHTOR ProTechtor multi-rake screens from Kusters Water, division of Kusters Zima Corp., can be used in nearly any screening application. ProTechtor multi-rake screens The multiple rake design, lubrication-free from Kusters Water, division lower bearings, automatic jam reversing of Kusters Zima Corp. and individually replaceable bars provide reliable, low-maintenance operation. Materials of construction include 304 or 316 stainless steel. They are manufactured in the USA at a ISO 9001:2008 certified facility. 800/264-7005; www.kusterswater.com.

REE PRODUCTS STATIONGUARD The StationGuard removable bar screen from REE Products filters non-organic debris that can typically be hard on pumps. It is quickly installed, either directly on the pipe or on the wall in a lift station or treatment plant. It could even be used in a manhole situation. It is compatible with dif- StationGuard removable bar screen from REE Products ferent types of pipe, including PVC, SDR, DI, IP, AC and CP. It comes in two adjustable sizes, either for 4to 10-inch or 12- to 20-inch pipes. It effectively removes plastics, diapers, rags and rocks. 888/959-6999; www.ree-nc.com.

SCREENCO SYSTEMS DUAL SCREEN SYSTEM The high-capacity Dual Screen System from Screenco Systems is constructed of aluminum with stainless steel screens, with a collection sump and a high-capacity 6-inch drain. The screen has two 3/8-inch gapped stainless steel bar screens at opposing angles, with the front screen virtually self-cleaning. It is a non-mechanical, simple way to remove large pieces of trash, rocks and other debris from the flow stream. This unit has a 4-inch Dual Screen System from telescoping inlet hose that moves laterally and Screenco Systems can be easily connected to any vacuum truck or other flow stream. The system is portable, and the 19.5 square feet of screening area allows for continued use and is easy to rake clean to the garbage drain tray. It can treat over 500 gpm. Various-gapped screen sizes are available. 208/790-8770; www.screencosystems.com.

SMITH & LOVELESS SCHLOSS MARK CI PIN RACK SCREEN The SCHLOSS Mark CI Pin Rack Screen from Smith & Loveless can be used for coarse screening at medium- to large-sized treatment plants and CSO applications up to 100 mgd. The system’s climbing rake

arm uses a motorized drive system that raises and lowers the rake to screen materials against a stationary bar rack inside the channel. Cleaning from the front side of the rack, the rake arm swings wide open to engage screenings with teeth long enough to fully penetrate SCHLOSS Mark CI Pin Rack the rack. Only the rake head and arm Screen from Smith enter the water, ensuring durable perfor& Loveless mance of the motor, chain, sprocket, bearings and other carriage elements. A telescopic arm adjusts itself to effectively screen large or rake-clogging objects, including consumer flushables. Multiple housing options promote operator safety, while a submersible motor enclosure option protects against flooding. 913/8885201; www.smithandloveless.com.

WESTECH ENGINEERING CLEANFLO MONOSCREEN The CleanFlo Monoscreen from WesTech Engineering is a highly efficient, self-cleaning fine screen that can be used in a wide variety of wastewater and process water treatment applications. Using a reliable blade and drive system, it creates a progressive step motion that allows the screenings to be evenly distributed while minimizing water level surges. The result is a screenings capture ratio of 82.5 percent. CleanFlo Monoscreen from When matched with a CleanWash SWP/CPS WesTech Engineering dewatering unit, the combination maximizes the solids capture rate while minimizing the amount of solids for disposal. 801/265-1000; www.westech-inc.com.

Sludge Handling/Hauling/ Disposal/Application FLO TREND SYSTEMS SLUDGE MATE Sludge Mate container filters from Flo Trend Systems can be used to dewater a variety of sludge and waste, including alum, ferric, lagoon and digested sludge, septic tank, grease-trap and slaughterhouse waste, wastewater residual, and Sludge Mate container filters sump bottoms. The closed-system design from Flo Trend Systems provides total odor control, no spillage, reduced maintenance and weather independence. It has 10-gauge reinforced walls and a seven-gauge carbon steel floor. Available designs have peaked roofs with gasketed bolted-down access hatches, drainage ports, inlet manifolds, floor filters and side-to-side rolling tarps. They produce cake that passes the paint-filter test, and transports straight to landfills for dumping. They dewater on site and are available in roll-offs, trailer mounted and tipping stand mounted in 5- to 40-cubic-yard sizes. 713/6990152; www.flotrend.com.

Sludge Heaters/Dryers/Thickeners KRUGER USA BIOCON The BioCon thermal dryer from Kruger USA processes wastewater treatment plant biosolids into a marketable biosolids end product specific to local market needs. It is a dual-belt dryer designed for safe and efficient operation, creating an end product dried to a minimum solids content of 90 percent that meets Class A requirements. The end product

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SOLEX THERMAL SCIENCE PELLET COOLER The pellet cooler from Solex Thermal Science ensures particle thermal stabilization using indirect heat transfer, creating conduction through each pellet to stabilize the particles to prevent decomposition and possible smoldering. It uses process effluent water as the heat transfer medium with no emissions since fans or blowers are not required. It requires minimal space and is available in capacities ranging from 1,000 to Pellet cooler from 25,000 pounds per hour, with incoming temSolex Thermal Science peratures up to 200 degrees F. 403/254-3500; www.solexthermal.com.

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is suitable for final disposal via most agricultural routes, providing economic benefits to municipalities. The end product can be enhanced with particle-sizing equipment that can alter characteristics such as density. The BioCon thermal dryer enhanced dried product is then screened from Kruger USA to meet specific size requirements. The unit can be paired with an end product storage system such as a bagging station or silo system for handling the dried product. 919/677-8310; www.krugerusa.com.

www.aqua-zyme.com

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❒ AGC Chemicals Americas AFLAS Fluoroelastomers ❒ Conveyor Components Company Model VA and VAX bucket elevator alignment controls

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❒ FKC skid-mounted dewatering systems ❒ ML Spirals shaftless screws Belt Filter/Rotary Presses ❒ Alfa Laval Screw Press ❒ Andritz Separation low-profile dewatering belt press ❒ Bright Technologies belt filter press unit ❒ Fournier Industries rotary press Chemical/Polymer Feeding Equipment ❒ Eagle Microsystems VF-100 polymer feeder ❒ Force Flow Merlin Chemical Dilution Systems ❒ IPM Systems ParaDyne liquid polymer activation system ❒ Lutz-JESCO America Corp. LJ-PolyBlend Polymer System ❒ Pulsafeeder Pulsatron Series HV Coagulants/Flocculants ❒ BASF Corporation – Water Solutions Division Zetag Ultra flocculant range Composting Equipment ❒ Bionetix International BCP85 Compost Accelerator ❒ Kuhn North America Knight VT Vertical Maxx mixer ❒ Roto-Mix Industrial Compost series mixers Dewatering Equipment ❒ AQUA-Zyme Disposal Systems 30-yard Open-Top Roll-off Dewatering Unit

Grinders/Shredders ❒ Hydra-Tech Pumps S4SHR-LP shredder pump ❒ JWC Environmental 7-SHRED industrial grinder ❒ Vaughan Company Triton screw centrifugal pumps Grit Handling/Removal/Hauling ❒ Paxxo Longofill continuous bag system ❒ Schreiber Grit & Grease removal system Screw Conveyors ❒ Spiroflow Systems Flexible Screw Conveyors Septage Receiving Stations ❒ Bio-Microbics MyFAST HS-STP wastewater treatment systems ❒ Lakeside Equipment Corporation Raptor Septage Acceptance Plant and Complete Plant

Screening Systems ❒ Aqualitec Corp. Raketec bar screen ❒ E & I Corporation, A Div. of McNish Corporation, Catenary Bar Screen ❒ JDV Equipment Corporation Screw Screen ❒ Kusters Water, division of Kusters Zima Corp., ProTechtor screens ❒ REE Products StationGuard bar screen ❒ Screenco Systems Dual Screen System ❒ Smith & Loveless SCHLOSS Mark CI Pin Rack Screen ❒ WesTech Engineering CleanFlo Monoscreen Sludge Handling/Hauling/Disposal/Application ❒ Flo Trend Systems Sludge Mate container filters Sludge Heaters/Dryers/Thickeners ❒ Kruger USA BioCon thermal dryer ❒ Solex Thermal Science pellet cooler

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case studies

HEADWORKS AND BIOSOLIDS MANAGEMENT

By Craig Mandli

Scrapers clean solids from intake system

Problem

Thickening centrifuge operates more efficiently and in a smaller footprint

Problem

Backwash strainers at a wastewater treatment plant in Toronto, Ontario, Canada, were consistently clogging with oversized solids that made it past the intake bar screens. Downstream pumping equipment experienced high failure rates, and subsequent treatment stages were overwhelmed.

The Kenosha (Wisconsin) Water Utility Wastewater Treatment Facility faced a decision to repair an aging dissolved air flotation treatment (DAFT) system or move forward with emerging sludge thickening technology.

Solution

Solution

The plant installed two 16-inch Automatic Scraper Strainers from Acme Engineering Products, rated for 6,000 gpm each. The scrapers use aggressive brushes that clean out the slots of the wedge-wire screen. They operate automatically, using line pressure to intermittently purge accumulated solids. Maintenance is infrequent and requires simple replacement of the scraper blade and brush.

RESULT The plant has more uptime as the strainers effectively remove large solids, and downstream treatment equipment operates within normal parameters. Maintenance is reduced on related equipment in the pumping system. 518/236-5659; www.acmeprod.com.

Biosolids treatment system saves significant costs at naval station

Problem

The U.S. Naval Air Station (NAS) Jacksonville in Florida needed to meet the U.S. Navy’s aggressive energy reform targets.

Solution

NuTerra’s detailed financial analysis compared the base’s aerobic digestion operating data to BCR Environmental’s CleanB system. NuTerra installed a unit to treat waste activated sludge from the clarifier to Class B standards before dewatering; the final product is suitable for land application.

RESULT The project delivered $75,000 in energy savings, a 95 percent reduction in energy for biosolids treatment, and a total operating cost savings of $105,000. Payback on equipment is projected at five years (six and a half years including installation). Projections indicate a reduction in greenhouse gas emissions of 480 tons annually. Improved dewatering reduced the total biosolids volume by 12 truckloads annually, saving more than $10,000 per year in hauling costs. Polymer consumption was reduced by 71 percent. 904/819-9170; www.bcrenv.com.

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TREATMENT PLANT OPERATOR

Kenosha installed the Centrisys THK 200 Thickening Centrifuge. The unit uses a smaller footprint and can be easily installed in a 1,000-square-foot building. Its enclosed process nearly eliminates odors. It produces material at 5 percent solids and has the capability to produce 7 percent solids. The thicker sludge improves digester operation and produces more biogas. It requires minimal operator oversight and less maintenance.

RESULT The system, in place for three years, uses no polymer and saved $80,000 to $100,000 in pump and equipment upgrades. Electricity consumption is low, as it incorporates a 10 hp feed pump, a 50 hp main drive and a 20 hp scroll drive, all tied into variable-frequency drives. The city installed a second THK 200 for primary sludge thickening to improve digester performance. 262/654-6006; www.centrisys.com.

City contracts to replace rectangular clarifier parts

Problem

Five wastewater treatment facilities in New York City faced various rectangular clarifier components wearing out due to age and fatigue. The city issued a contract to address replacement of nonmetallic and metallic chain, segmented sprockets, laminated wood and FRP flights, screw conveyor assembly, metallic and nonmetallic wear strips and wear shoes, wall bearings, safety collars, shafting, torque limiters, gear reducer drives, and miscellaneous hardware.

Solution

Fairfield Service Company provided OEM replacement of all those components with a contract value of $5 million.

RESULT Fairfield is in the final stages of completing the order, assuring the facilities of uninterrupted service. The city will issue the company another contract for replacement of additional clarifier components at other facilities. 219/872-3000; www.fairfieldservice.com.

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FOOD WASTE

Problem

WOODCHIPS

PLASTIC PELLETS

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Fine bar screen removes high amount of solids from headworks

BIOSOLIDS

Dewatering press produces drier cake solids, runs more efficiently

Problem

The Andover (Kansas) Wastewater Treatment Plant serves a community of 12,000 next to Wichita. The original plant was built in 1977 and upgraded four times. In 1993, a coarse bar screen with 3/4-inch bar spacing was installed at the headworks. By 2012, the plant began investigating fine bar screens for greater solids removal.

The Chestnut Ridge Area Joint Municipal Authority in New Paris, Pennsylvania, required an upgrade from an aging belt press. High operation and maintenance requirements had to be as low as possible to keep life cycle costs down, and dry cake solids were critical to reducing disposal expenses even as plant throughput rose.

Solution

Solution

“The best kind of process improvement is one that pays for itself,” says Brian Walls, wastewater superintendent. “In this case, the ongoing cost of cleaning the aeration basin, removing rags from diffuser tubes, unclogging return activated sludge pumps and improving the overall performance of the process had an obvious payback calculation.” The city selected the EnviroCare Flo-MultiRake Fine bar screen with 1/4-inch bar spacing.

RESULT The plant staff estimates the new screen is removing two and a half times more solids than the old coarse screen. “We had specified the bar screen to be a turnkey, plug-and-go setup,” says Walls. “When we got it, it was. We did the install ourselves and had an electrician run the conduit and wiring to code. The control panel was preprogrammed and only needed minor adjustments. The bar screen fit perfectly in the pre-existing channel.” 815/636-8306; www.enviro-care.com.

Doug Vitovitch, chief facility operator, personally sourced and supervised the installation of a Volute ES302 following the results of a free pilot study. PWTech and local representatives from EnviRep included all necessary pumps and polymer preparation equipment, and provided both remote and on-site installation assistance to enable Vitovitch to complete the entire municipal project from project inception to installation and successful startup in just over six months.

RESULT Chestnut Ridge began realizing immediate operational cost savings as the Volute press can run unattended while producing drier cake than the old belt press. The 2 hp unit uses significantly less power and wash water. The first two-hour maintenance is scheduled for February 2020, if needed. 443/648-3300; www.pwtech.us. (continued) tpomag.com August 2015

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case studies

HEADWORKS AND BIOSOLIDS MANAGEMENT

Screw press helps plant add efficiency to dewatering process

Screw press helps dewater biosolids quickly

Problem

Problem

For years, the Williamson (New York) Wastewater Treatment Plant had placed anaerobically digested biosolids from a contact stabilization treatment process into two drying beds or four reed bed lagoons. Typically, every five to seven years the town would allow the reed beds to dry and remove the deposited solids via shovels into trucks. The material was unloaded and bulldozed into the nearby property the plant owned. This was time-consuming and labor-intensive, and rain made matters worse. There was also concern about damaging the liners during the operation. Plant leaders decided on a permanent dewatering operation and in the short term hauled the dewatered material to a composting facility in nearby Ontario, New York.

Solution

BDP Industries conducted on-site demonstrations with its belt press and a screw press. For financial and operational reasons, town leaders chose the screw press. To save on installation costs, the unit was skid-mounted with all accessories and piped and wired at the BDP factory. The press offers a small footprint, low operation labor and expected lower maintenance costs due to few moving components.

RESULT The 12-inch-diameter screw press has met performance expectations. Throughput averages 25 gpm at an average of 2.15 percent influent solids concentration, representing 260 pounds per hour of dry solids. It produces a cake averaging 17.3 percent solids. Williamson is now exploring its own composting operation. 518/527-5417; www.bdpindustries.com.

The wastewater treatment plant in the Town of Middlebury, Indiana, treats an average daily flow of 0.99 mgd. The plant had been using beds of pea gravel to dry biosolids. This process yielded biosolids at 5 to 8 percent solids but was proving labor-intensive, costly and time consuming with the increasing plant flows.

Solution

The plant installed a Schwing Bioset Screw Press, selected by the town and a consulting engineer after it outperformed other equipment pilot trials. The feed pump draws material from the aerobic digesters and feeds it to the screw press under low pressure. A simple control system allows unattended operation, and the resulting cake exceeds 19 percent dry solids.

RESULT The press has improved operations and accommodates increasing plant flows by allowing the plant to quickly dewater the material with less labor, reduced odors and lower hauling costs, all within a smaller footprint. 715/247-3433; www.schwingbioset.com.

Dewatering system decreases energy demand

Problem

A septage dewatering facility in California wanted to become more energy-efficient. Facility leaders decided to replace an aging vacuum filter, which had a high energy demand and required significant time and expense to keep operating.

Solution

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They chose a 20-foot dewatering drum from In The Round Dewatering. A cement pad was poured outside the building under a roof overhang, which allows dewatering to take place outside. The process is similar to a gravity dewatering box, as with the box the material must be mixed with a polymer to achieve the waste stream floc. The inside of the drum is lined with interlocking PVC tiles. The difference is that once the drum is full, it rotates one turn every two hours, allowing all free liquids to filter out overnight. The drum is mounted on a roll-off frame and can be loaded on a rolloff truck for transport to the landfill. Once unloaded, it can be washed out quickly with a garden hose and is ready to be filled again.

RESULT The facility can dewater 20,000 to 24,000 gpd with virtually no maintenance. The 1/4 hp motor creates large energy savings and eliminates the diatomaceous earth used in the old process. 317/539-7304; www.itrdewatering.com.

Reverse aeration evens out temperature differentials

Problem

The City of Arlington, Washington, population 18,000, shifted its biosolids process to composting from land application to produce compost for city road improvements, ball fields, parks, a cemetery and a community garden. The challenge was to keep target temperatures within best management practice (BMP) range in the face of variable moisture content in the dewatered cake arriving at the facility, and variable moisture content in wood waste used as an amendment.

Solution

Arlington installed an Aeration Static Pile System (ASP) from Engineered Compost Systems (ECS). The system has automatically reversing aeration for primary and secondary composting and a biofilter to control odors. The facility produces eight batches of compost mix each weekday, or 40 batches a week, for a total of 2,100 cubic yards per year. Roughly 70 percent of the biosolids (800 cubic yards) are processed into Class A Exceptional Quality compost. The process takes five to six weeks.

RESULT The reversing aeration system allows the operator to better control temperature and odor. Operator Kevin Bleeck says his ideal mix is 2 yards of biosolids cake, 3 yards wood waste and 2.5 to 3 yards of compost overs (larger wood particles that remain after product screening, providing porosity and a source of carbon). 206/634-2625; www.compostsystems.com.

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1. KSB DRY-INSTALLED SOLIDS HANDLING PUMP The Sewatec dry-installed solids handling pump from KSB is designed to handle stormwater, wastewater and sludge. Sealing technology enables the pump to operate in a dry environment. Because the pump doesn’t require a source of clean water or the recirculation of pumped liquid to lubricate the seals, the pump can run dry without damage. 804/222-1818; www.ksbusa.com.

2. BAF HIGH-AIRFLOW PORTABLE FAN The Black Jack portable high-airflow fan from Big Ass Fans is designed for indoor and outdoor use. The 6.5-foot frame fits through standard interior doorways and plugs into any 110-volt power supply. The fan moves air up to 120 feet, has a matte-black finish and is wet rated for easy cleaning. Other features include a 25-foot power cord, gearless direct-drive motor for quiet operation, variable-speed controller and locking wheels. 877/244-3267; www.bigassfans.com.

dual-tube assembly is engineered for optimum performance and pressure capability (110 psi). The intelligent control permits connection to SCADA systems and other remote controllers. Optional advanced SCADA communications command and status capabilities include start, stop, motor status, prime and setpoint speed. Protocols include Profibus, DPV1, Modbus RTU, Modbus-TCP, Ethernet/IP and Profinet RT I/O. 714/893-8529; www.blue-white.com.

6. FOSTER TRANSFORMER MULTI-VOLTAGE TRANSFORMER The Model 16531 multi-voltage isolation transformer from Foster Transformer Co. is designed for control panel and lighting applications. The UL-listed transformer accepts all common North American singlephase voltages and provides an isolated 120-volt output up to 0.625 amps. Input voltages include 120/208/240/277/480/60, 50/60 Hz with 120-volt 0.075 kVA output. 800/963-9799; www.foster-transformer.com.

7. McELROY SOCKET FUSION TOOL

3. KROHNE RADAR LEVEL METER The Optiwave 5200 C/F, 10 GHz FMCW radar level meter from Krohne is designed for liquid applications in up to a 98-foot measuring range. The two-wire, loop-powered device measures level and volume in storage or process tanks, with process conditions up to 482 degrees F and pressures to 580 psi in general purpose or hazardous locations (Class I, Division 1). 800/356-9464; http://us.krohne.com.

4. MAGNETROL GUIDED WAVE RADAR TRANSMITTER The Eclipse Model 706 guided wave radar transmitter with Modbus protocol from Magnetrol International is compatible with industry standard RTUs. The complete probe line ensures reliable performance in every application, regardless of media. 800/624-8765; www.magnetrol.com.

5. BLUE-WHITE PERISTALTIC METERING PUMP Designed for smaller municipal water and wastewater systems, the ProSeries-M M-2 peristaltic metering pump from Blue-White Industries injects aggressive and/or viscous chemicals. The Flex-A-Prene,

The Spider 125 socket fusion tool with universal clamping from McElroy Manufacturing is designed for installations using 63 mm to 125 mm PP pipe in overhead, vertical and tight workspaces. Universal clamping accommodates any size pipe or coupling, eliminating the need for inserts. The 15-pound tool comes with a carrying case and full assortment of heaters and heat adapters. 918/836-8611; www.mcelroy.com/fusion.

8. BJM SUBMERSIBLE EXPLOSION-PROOF PUMPS XP-KZN submersible pumps from BJM Pumps are designed for heavy slurries containing coal, ash, sand, gravel or other abrasives. The agitator keeps solids suspended in liquid and prevents clogging. The impeller, wear plate and agitator are made of abrasive-resistant 28 percent chrome iron. The replaceable wear plate’s hardened surface on the suction side prevents erosion. The pump delivers up to 665 gpm, heads to 61 feet and is able to pump a sump or pit within inches of the bottom. 877/256-7867; www.bjmpumps.com.

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1 1. Johnson Screens TRITON underdrain

wastewater:

2. CONTRA SHEAR / RT Rotating screen drums 3. MID/V Integrated Screen, Screw and Washing Compactor

product spotlight

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Sampler controller provides single-screen programming, USB transfer capability 2

By Ed Wodalski The AS950 sampler controller from Hach Company features a full-color, 2 1/2- by 3-inch display for intu it ive, single screen programming, USB drive compatibility, error alert and status screen to simplify troubleshooting in wastewater treatment. Single-screen programming eliminates the need for AS950 from scrolling through the menu, says Hach Company Jamie English, product manager, Hach Company. “The other benefit is the status screen,” she says. “If you want to know what’s going on with the sampler — has it missed any samples, when’s the next program going to start — all you have to do is hit the status button and all that information comes up.” Logged data such as sample history, cabinet temperature and sensor measurements can be downloaded directly from multiple samplers onto a USB drive, eliminating the need for special cables or having to carry a laptop to sampling locations in inclement weather. The USB port also enables users with multiple samplers to program one sampler, download the settings to a flash drive and upload it to the next controller, eliminating the need to reprogram each sampler. “It saves a lot of time when you have the same program on multiple samplers,” she says. The AS950 works with existing Hach sampler bases and bottle configurations. It includes connections for several digital Hach sensors, enabling pH samples to be taken at the discharge site or when levels reach designated setpoints. Digital sensors can also measure rate of flow. The high-speed, dual-roller sample pump has a 3/8-inch I.D. by 5/8-inch O.D. pump tube and flow rate of 1.25 gpm at 3 feet vertical lift. Sample intervals can be set in single increments from 1 to 9,999 flow pulses or 1 to 9,999 mins in one-minute increments. The memory stores up to 4,000 history entries for sample time stamp, bottle number and sample status, up to 325,000 entries for selected measurement channels and 2,000 events. Optional IO9000 input/output modules can be used to set up relays and alarms that can be set for system diagnostics and logging, such as program end, sample complete, missed sample and full bottle. The compact, portable sampler, designed for use in 18-inch manholes, can also be used to measure stormwater runoff and pretreatment by industrial users to ensure permit requirements are being met. 800/227-4224; www.hach.com. FREE INFO ON THIS PRODUCT — RETURN FOLLOWING FORM

WE MAKE WATER WORK Bilfinger Water Technologies has a comprehensive, cost-effective, tailor-made range of equipment for water /water treatment, sludge treatment and industrial applications.

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water:

product spotlight Hydraulically balanced diaphragm pump designed for long life By Ed Wodalski Other features include powder-coated housing for corrosion resistance, plus/ minus 1 percent accuracy regardless of pipeline pressure fluctuations, separate or combined capacity adjustment for maximum turndown and finetuned control from SCADA systems or other process signals. Depending how the pump is used, Carling recommends annual maintenance of the wetted parts, primarily the check mROY series of metering pumps from Milton Roy valves and diaphragm. “Many people can go years without maintenance, it really depends on the service,” he says. “Is it operating 24/7? Are there a lot of particulates in the pump that are being pumped where it might cause wear? Annual maintenance is always recommended as a preventive, but the diaphragm will last about 10 years.” Pump options include motors and variable-speed drives based on system requirements and installation condition, electronic capacity adjustment for remote control and advanced technology diaphragm leak detection system. “It’s really a unique item in the world of industrial products,” Carling says of the pump. “Its fundamental design has been around for many years, and yet, the mROY continues to evolve and is still an innovative technology.” 215/441-0800; www.miltonroy.com.

The mROY series of metering pumps from Milton Roy is the little pump that can. Featuring a design life of 20 years, the low-maintenance pumps are available in PVC, PVDF, 316 stainless steel and alloy 20 with flow rates from 0.017 to 170 gph. “While improvements have been made over the years with various materials, advanced casting technologies, coating systems and control interfaces, the pump has at its core the dependable design that the industry relies on,” says Jim Carling, global product line manager for Milton Roy. Applications include the injection of coagulants, flocculants, filter aids, pH control chemicals, chemicals for taste and odor control, dechlorination and disinfectants such as sodium hypochlorite in the municipal water treatment process. Weighing about 65 pounds, the pump is 8 inches wide, 12 inches deep and 18 inches high (including motor). Key features include a hydraulically balanced diaphragm with a 96,000hour design and turndown ratios up to 100-to-1 for a full range of adjustments based on plant treatment requirements. “Most diaphragm pumps used in water treatment, or even peristaltic pumps, are pressurized on one side, or in the case of a tube, on the inside,” he says. “On the outside or backside of the diaphragm it’s atmospheric. So the diaphragm or tube is containing all of the pressure. With the hydraulically balanced diaphragm you have the process fluid on one side and hydraulic fluid on the other. So the diaphragm is balanced between two pressurized fluids. It’s under very low stress. You’re not stretching anything. You’re not compressing anything. All you’re doing is flexing a piece of Teflon.”

FREE INFO ON THIS PRODUCT — RETURN FOLLOWING FORM

For FREE information on these products, check the box(es) below: ❒ 1. KSB Sewatec dry-installed solids handling pump ❒ 2. Big Ass Fans Black Jack portable high-airflow fan ❒ 3. Krohne Optiwave 5200 C/F radar level meter ❒ 4. Magnetrol International Eclipse Model 706 guided wave radar transmitter ❒ 5. Blue-White Industries ProSeries-M M-2 peristaltic metering pump ❒ 6. Foster Transformer Co. Model 16531 transformer ❒ 7. McElroy Manufacturing Spider 125 socket fusion tool ❒ 8. BJM Pumps XP-KZN submersible pumps ❒ Hach Company AS950 sampler controller ❒ Milton Roy mROY series of metering pumps

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The team members are the greatest resource at this plant. They do the work. I’m support staff. I coordinate what they do, and the best way for me to do that is to listen to what they have to say.”

Nate Tillis Operations and Maintenance Supervisor Beloit (Wis.) Water Pollution Control Treatment Facility

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2016 WWETT Show Invites Seminar Proposals

industry news WAMGROUP names Enviro-Care Company president WAMGROUP named Philip A. Thompson president of WAM North America, doing business as Enviro-Care Company. WAMGROUP purchased Enviro-Care in February. Thompson had been vice president of sales and marketing under the previous owners.

Lined Valve Co. celebrates 20th anniversary Lined Valve Co. celebrates the 20th anniversary of its founding by Jeff Bowman, P.E., in 1995. Beginning in Beaverton, Oregon, the company moved to Woodland, Washington, and opened a second manufacturing facility in Ocala, Florida. In 1999, Bowman purchased A-C Valve, merging the two companies with A-C Valve, doing business as LVC.

Like something? Hate something? Agree? Disagree? Share your opinions about TPO articles through our Letters to the Editor. Send a note to [email protected]

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The 2016 Water & Wastewater Equipment, Treatment & Transport (WWETT) Show is seeking proposals for educational seminars. The show, Feb. 17-20 in Indianapolis, features dozens of presentations given by industry experts. To offer a presentation, send a completed seminar proposal form by Aug. 1. Forms may be completed online at www.wwettshow.com/cfp. Presentations should be 60 minutes long covering topics in a generic manner, without promoting a specific company or product. Seminar topics are: • Septage collection, treatment and disposal • Grease collection, treatment and disposal • Municipal wastewater collection, treatment and disposal • Onsite wastewater treatment system installation, components and maintenance • Sewer and drain cleaning, inspection, repair, lining, locating and detection • Biosolids dewatering, treatment and technology • Portable sanitation – special events and restroom service • Business – marketing, financials and social media • Safety • Trucks and service vehicles – DOT regulations, service and maintenance • Technology and software • Excavation Those whose submissions are accepted will receive four full registration passes to the 2016 WWETT Show. For more information, call 866/933-2653.

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EDUCATION

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RoyCEU.com: We provide continuing education courses for water, wastewater and water distribution system operators. Log onto www. royceu.com and see our approved states and courses. Call 386-574-4307 for details.(oBM)

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Looking for experienced operators & technicians in Florida. Florida-based sewer, wastewater treatment & pipe cleaning company looking for experienced operators and technicians. Travel, clean CDL license, drug-free workplace. Competitive pay based on experience. Please call 407-8095556 x102. (o08)

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Various locations, Texas SouthWest Water Company has openings for Water and Wastewater Operators in Austin, Benbrook, Conroe, Mabank and Pottsboro, Texas. Performs routine checks of the facilities, maintenance and field customer service; helps ensure compliance with governing agencies regulations. Requirements: TCEQ C or above water and/or wastewater license, advanced skills and technical knowledge of water and wastewater treatment, HS diploma or GED, 1-2 years’ related experience; water / wastewater operations and maintenance experience. Apply: http://swwc.applicantpro.com/jobs/ o08

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worth noting

people/awards The Village of Roberts received the Wastewater System of the Year award from the Wisconsin Rural Water Association. The City of Eustis Wastewater Treatment Plant received the 2015 Earle B. Phelps First Place Award (advanced facilities less than 5 mgd category) from the Florida Water Environment Association for outstanding performance and professionalism. Michael Finoia was named the new wastewater treatment superintendent for the plant in Southington, Connecticut. He replaces John DeGioia, who retired after 37 years. Finoia had been the wastewater treatment superintendent in Fairfield, Connecticut. Bhavani M. Rathi was named project manager for the Wastewater Practice Group of Wright-Pierce, a water, wastewater and infrastructure engineering firm serving the Northeast. Caitlyn S. Butler, an assistant professor at the University of Massachusetts, received a $500,000 five-year grant from the National Science Foundation to conduct research on algae and bacteria and ways to improve wastewater treatment. The grant funds her work on algal-sludge granules, which can produce oxygen during wastewater treatment, reducing electricity use while also cleaning the wastewater. Brett Morgan was named the head of the wastewater treatment plants at Hazel Hurst and Lantz Corners, Pennsylvania. Jim Schreiber retired as director of the Hudson (Wisconsin) Wastewater Utility after serving there for nearly 40 years.

events Aug. 13-14 Rocky Mountain Water Environment Association/Grand Junction Water/Wastewater Conference, Two Rivers Conference Center, Grand Junction, Colorado. Call 970/249-3369. Aug. 24-28 Caribbean Water and Wastewater Association Conference and Exhibition, InterContinental Hotel, Miami, Florida. Visit www. fsawwa.org.

Gerald Plank, wastewater supervisor in Fort Smith, Arkansas, earned the Water Environment Federation’s William D. Hatfield Award. Van Buren Municipal Utilities received the Arkansas Water Environment Association Safety Award for cities with a population greater than 20,000. Buddy Burns, water and wastewater superintendent for the City of Glenwood Springs, Colorado, retired in May after 38 years with the city. Allen Schreiber was elected 2015-16 president of the Texas Water Utilities Association. He is supervisor of field services for Fort Bend County, Texas. Richard Kruse, water treatment supervisor with the Taupo District Council in Australia, received the Water Industry Operations Group Operator of the Year award. He supervises the district’s 20 water treatment plants.

Johnny Brean, water operations superintendent for the Ramona Municipal Water District in Southern California, retired after nearly 30 years with the district.

TPO welcomes your contributions to this listing. To recognize members of your team, please send notices of new hires, promotions, service milestones, certifications or achievements to [email protected].

The Florida Section of AWWA named Collier County as the winner in its annual Best Tasting Drinking Water Contest in southwest Florida.

education

Nels Halgren of Devils Lake received the Outstanding Water Works Employee award from the North Dakota Rural Water Systems Association.

AWWA

The City of Wichita Falls, Texas, received the Alan Plummer Environmental Sustainability Award for its water reuse project. The Pace Water System in Florida received the Excellence Award from Water Company of America for billing accuracy and high standards of excellence in ratepayer equity and resource management. Powdersville Water in South Carolina received the Directors Award in the Partnership for Safe Water’s Distribution System Optimization Program.

The American Water Works Association is offering these webinars: • Aug. 5 – Optimizing Collection Systems Data for Capital Investment Planning and Prioritized Cleaning • Aug. 12 – Treatment Tips and Tricks: Filtration • Aug. 19 – What We Know of Cyanotoxins: Research and Advisories • Aug. 26 – Optimizing Filters: Assess Conditions, Rehabilitation and Management Visit www.awwa.org/store/webinars.aspx.

Arkansas

The Wisconsin Rural Water Association (WRWA) honored Dan Mulhern of the Arlington Water Utility as 2015 District Operator of the Year.

The Arkansas Environmental Training Academy is offering these courses: • Aug. 4-5 – AETA Train-The-Trainer, Camden • Aug. 17-21 – Backflow Assembly Tester, Fayetteville • Aug. 18 – Backflow Assembly Tester Recertification, Fayetteville • Aug. 18-20 – Advanced Water Treatment, Lowell • Aug. 25-27 – Basic Water Treatment, North Little Rock Visit www.sautech.edu/aeta/.

Fred Partin retired in June after 33 years as executive director of Bonita Springs Utilities (formerly Bonita Springs Water System) in Florida.

The Arkansas Rural Water Association is offering these courses: • Aug. 4-6 – Intermediate Water Treatment, Midway

The Environmental Utilities Department of the City of Roseville received the California Municipal Utilities Association Resource Efficiency Award for its water-use efficiency program in partnership with WaterSmart software.

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• Aug. 11 – Basic Math, Springdale • Aug. 12 – ADH Compliance, Springdale • Aug. 13 – Applied Math, Springdale • Aug. 13-14 – Plumbing Inspectors School, Lonoke • Aug. 18-20 – Backflow Repair, Lonoke Visit www.arkansasruralwater.org.

California The California-Nevada of Section of AWWA is offering these courses: • Aug. 3 – Groundwater Workshop, West Sacramento • Aug. 4 – Customer Service Workshop, West Sacramento • Aug. 7 – Backflow Refresher, West Sacramento • Aug. 8 – Exam BF, Fresno • Aug. 8 – Exam BF, West Sacramento • Aug. 14 – Exam BF, Pleasanton • Aug. 14 – Sustainability 101 Workshop, Rancho Cucamonga • Aug. 17 – Introduction to Water Treatment, Rancho Cucamonga • Aug. 17 – Water Quality Workshop, West Sacramento • Aug. 18 – Regulations Workshop, West Sacramento • Aug. 22 – Exam BF, Carson City, Nevada • Aug. 22 – Exam BF, Sunnyvale • Aug. 24 – Backflow Tester Course, Rancho Cucamonga • Aug. 25 – Water Use Efficiency Grade 2 Workshop, West Sacramento • Aug. 29 – Exam BF, Rancho Cucamonga Visit www.ca-nv-awwa.org.

Florida

• Aug. 27 – NCWTFOCB Exams, Morganton, Snow Hill and Raleigh Visit www.ncsafewater.org.

Ohio The Ohio Water Environment Association is offering a One Water Utility Management Workshop Aug. 18 in Lewis Center. Visit www.ohiowea.org.

Oklahoma The Oklahoma Environmental Training Center in Midwest City is offering these courses: • Aug 3-4 – C Water Operator • Aug. 5-6 – C Wastewater Operator • Aug. 17 – Trenching and Shoring • Aug. 17-20 – A/B Wastewater Operator • Aug. 19 – Confined Space Entry • Aug. 24-28 – OSHA 40-Hour HAZWOPER Class • Aug. 31-Sept. 4 – Operator Bootcamp Visit www.rose.edu. Accurate Environmental in Oklahoma is offering these courses: • Aug. 4-6 – D Water & Wastewater Operator, Stillwater • Aug. 7 – Open Exam Session, Tulsa • Aug. 12 – General Refresher for Water Operators, Tulsa • Aug. 12-13 – C Water Operator, Tulsa • Aug. 14 – Open Exam Session, Stillwater • Aug. 18-20 – D Water & Wastewater Operator, Tulsa Visit www.accuratelabs.com/classschedule.php.

The Florida AWWA is offering an ISA Water/Wastewater and Automatic Controls Symposium Aug. 4 in Orlando. Visit www.fsawwa.org.

Texas

Illinois

The Water Environment Association of Texas is offering a Biosolids and Odor and Corrosion Conference Aug. 5-6 in San Marcos. Visit www.weat.org.

The Illinois AWWA is offering these courses: • Aug. 11 – Water Main Rehabilitation Alternatives, Decisions and Design, Westmont • Aug. 13 – Water Operator Exam Refresher for Class C and D, Elgin • Aug. 20 – Distribution System O&M – Hydrants, Valves, Water Service Lines, Morris • Aug. 25 – Pumps and Pump Maintenance, Benton • Aug. 25 – Chemical Properties, Safety and Security, Macomb Visit www.isawwa.org.

New Jersey The New Jersey Agricultural Experiment Station Office of Continuing Professional Education is offering these courses: • Aug. 11 – Study and Exam Skills for Licensing and Professional Certification Testing, North Brunswick • Aug. 18-19 – Fundamentals of Generators and Transformers, New Brunswick • Aug. 19 – Water Sampling and Laboratory Procedures, Dover • Aug. 25 – O&M of Water Treatment Filters, North Brunswick Visit www.cpe.rutgers.edu.

New York The New York Section of AWWA is offering a Distribution System O&M course Aug. 5 in Melville. Visit www.nysawwa.org.

North Carolina The North Carolina Section of AWWA-WEA is offering these courses: • Aug. 3-5 – Advanced Management and Supervisory Leadership Training, Greensboro • Aug. 24-28 – Eastern Biological Wastewater Operators School, Raleigh • Aug. 25-28 – 2015 Physical/Chemical Wastewater Operators School, Raleigh

The Texas Water Utilities Association is offering these courses: • Aug. 3 – Activated Sludge, Corpus Christi • Aug. 5 – Utilities Safety, Terrell • Aug. 18 – Utilities Safety, Victoria • Aug. 18 – CSI/CCC, Gatesville • Aug. 18 – Basic Water, online Visit www.twua.org.

Utah/Colorado The Intermountain Section of AWWA is offering an Administrative Professionals Training – Women in Industry seminar Aug. 13 in West Jordan, Utah. Visit www.ims-awwa.org.

Wisconsin The University of Wisconsin-Madison Department of Engineering Professional Development is offering a Purchasing and Inventory Control course Aug. 26 in Madison. Visit www.epdweb.engr.wisc.edu. The Wisconsin Rural Water Association is offering these courses: • Aug. 6 – Cross Connection Hazards and Your Water System, Kaukauna • Aug. 6 – Emergency Response Plan/Waiver Assessments, Kaukauna • Aug. 13 – Cross Connection Hazards and Your Water System, Mount Horeb • Aug. 13 – Emergency Response Plan/Waiver Assessments, Mount Horeb Visit www.wrwa.org. The Wisconsin Section of the Central States Water Environment Association is offering a Pretreatment Seminar Aug. 11, location to be determined. Visit www.cswea.org. TPO invites your national, state or local association to post notices and news items in this column. Send contributions to [email protected]. tpomag.com August 2015

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SPA-110815-00 8_August - PolyBlend Systems (Decatur, TX - R2)_Layout 1 6/24/15 4:04 PM Page 1

Joe Guinn

Wastewater Superintendent City of Decatur WWTP Decatur, TX

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In Decatur, TX, Wastewater Superintendent Joe Guinn and his team are dedicated to the efficient operation of the city’s wastewater treatment plant. He’s proud of his crew, and the hard work they put in every day at their 700,000-gpd facility. “I have the best operators in the state of Texas,” said Joe.

“When we needed a new belt for our filter press, you guys were right on top of it. You got us exactly what we needed.” According to Joe, one of their facility’s greatest sources of pride is the condition of their filter belt press. “It takes a good operator to keep a belt press as clean as ours,” he praised. While proper maintenance is critical, so is timely replacement of filter belts due to their inevitable wear and tear. “When we needed a new belt for our filter press, you guys [at USABlueBook] were right on top of it. You got us exactly what we needed, in no time at all.”

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