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Newcastle Water Pollution Control Plant

Expansion of the. Newcastle Water Pollution Control Plant. WEF Student Design Competition 2013. Contents. Introduction Stage 3 Design Stage 3 Extras Conclusions Questions?. Introduction. Who are we?. Kyle Lockwood Environmental Engineering Graduate. Bradley Free

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Newcastle Water Pollution Control Plant

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  1. Expansion of the Newcastle Water Pollution Control Plant WEF Student Design Competition 2013

  2. Contents Introduction Stage 3 Design Stage 3 Extras Conclusions Questions?

  3. Introduction Who are we? Kyle Lockwood Environmental Engineering Graduate Bradley Free Water Resources Engineering Graduate Tanzeel Ahmed Environmental Engineering Graduate Robyn Thompson Mechanical Engineering Graduate

  4. Introduction Background • An expansion is planned for the Durham Region Newcastle Water Pollution Control Plant (WPCP), in the Municipality of Clarington, Newcastle, Ontario • The expansion of the WPCP is planned in four stages, to ultimately increase the capacity to six times that of the current operating capacity University of Guelph • The Objectives: • Preliminary Design and layout for Newcastle WPCP for Stage 3 expansion including biosolids handling and energy recovery • Conceptual layout for Newcastle WPCP expansion for Stage 4 expansion Clarington, Ontario

  5. Stage 3 Design Stage 3 Design Population Analysis • Based on previous growth data from the municipality of Clarington • Stage 3 to be completed when Stage 2 average day capacity reaches 75% of ADF • Peak Flow rates were estimated using the Harmon formula • Expected service capacity according to population growth against time Population Analysis Selection of Processes The Layout and Design Receiving Station and Headworks Primary Clarification Secondary Treatment Tertiary Treatment Biosolid Handling and Treatment Stage 3 Completed: 2034

  6. Stage 3 Design The Layout Office Building Headworks Primary Clarifiers Aeration Tanks Secondary Clarifiers Disinfection Cloth Filters Digester Gas Flaring Dewatering Units Chemical Storage Anaerobic Digesters CHP System

  7. Stage 3 Design Receiving Station and Headworks • Mechanically Cleaned bar screen installed • Installed parallel to existing systems • Increases existing treatment capacity • Two additional aerated grit tanks installed • Will be able to process Stage 3 flows of 39,300 m3/d • Extra unit provided for redundancy and maintenance

  8. Stage 3 Design Primary Clarification • Circular Primary Clarification tank installed • Existing clarifier tank will be modified during stage 3 installation as a circular tank • Will eliminate maintenance issues of gross solids buildup in corners of existing square clarifiers • Performed during stage 3 installation • Will reduce BOD and TSS sufficiently for ADF and PDF

  9. Stage 3 Design Secondary Treatment • Two aeration tanks will be installed in parallel to existing tanks • Aeration tanks will operate as a staged CAS process to allow operational flexibility • First stage fitted with jet aeration and diffuser grid • Second stage has diffuser grid installed • Can perform nitrification-denitrification for alkalinity recovery • Will be consistent with existing plant systems • Stage 3 of system will have an operational MLSS of 3500 g/m3 • Will have an SRT of 12 days to achieve nitrogen removal • Two new secondary clarifiers will be installed in parallel to existing clarifiers • Will have a recycle ratio of 50% • Clarifiers are sized to treat the maximum daily flow of 39,300 m3/d

  10. Stage 3 Design Tertiary Treatment • Alum Addition • Will reduce the influent phosphorus by over 85% • Added at the aeration tank effluent • Chosen because it was the most effective treatment for the lowest cost • UV system (Trojan UV3000Plus™)selected as best method eliminating current chlorine disinfection methods • Current chlorine contact tank will act as a bypass channel • Achieves desired monthly geometric mean density of 150cfu/100mL of Escherichia Coli • Low Pressure/ High Intensity (LP/HI) lamps • Horizontal Parallel to flow lamp configuration • Automatic chemical/mechanical cleaning • Weighted Gate Automated Level Controller • Three Cloth Filtration Units (AquaDISKTertiary Filtration system)installed • TSS reduced below 5mg/L for ADF • Will be able to process Stage 3 flows of 39,300 m3/d • Extra unit provided for redundancy and maintenance

  11. Stage 3 Design Sludge and Biosolid Treatment • 2 Single stage high rate mesophilic anaerobic digesters installed parallel to Stage 2 Digesters • Digesters will treat the wasted solids from the primary clarifier and the WAS from the secondary clarifier • SRT of 20 days • External pump recirculation mixing • Biogas collection to for Combined Heat and Power (CHP) energy recovery • ROTAMAT (HUBERTM) Screw Press dewatering system chosen • 2 Dewatering units installed for Stage 3 • Have a total dry solids throughout capacity of 280 kg Dry/h • O/M costsare smaller than traditional centrifugal dewatering system • Operates at <1.5 rpm screw rotation speed • Requires <20 min/d of operator attention • Produces 18 – 25% cake solids • Processed Sludge Disposal • On approved agricultural land site under the Durham Region Works Department’s Biosolids Management Program

  12. The Extras Extras CHP Energy Recovery • Captures the biogas produced from the Digesters and generate renewable energy • Primary mover of the CHP system is 2 microturbines • CHP Economic Feasibility • Generate approximately $130,000/year in energy savings • 11 Year Payback Period • Dependent upon obtaining Electricity Contracts • Fuel Gas Conditioning System will reduce H2S, CO2, PM extending the lifespan of the microturbines and reducing greenhouse gases • Flare located southwest of the facility in case of CHP system failure The CHP Energy Recovery Life Cycle Impact Assessment Noise and Odour Control Hydraulic Profile Modelling Process Control and Instrumentation Construction Implementation Cost Analysis

  13. The Extras Life Cycle Impact Assessment • Compares the environmental impact of anaerobic digestion against lime stabilization for sludge treatment • Pré developed SimaPro 7.0 software was used to conduct a comparative study • Life Cycle Impact Results • Lime stabilization is worse in every impact category • Lime stabilization produces more sludge • Anaerobic Digestion for sludge treatment is therefore the most environmentally sustainable solution

  14. The Extras Modelling STOAT® • WRc’s waste water modelling software • BOD, TSS and NH3 was modelled within the simulation • At an operational temperature of 10oC, the effluent objectives were well below target

  15. The Extras Process Control and Instrumentation • Supervisory Control and Data Acquisition (SCADA) • Provides operational ease by reducing monotonous tasks for operators • Overall efficiency of the plant improved by maintaining steady state process The Controls • Tertiary Treatment • Flow monitoring and splitting • Digesters • Monitoring performance • Controlling temperature, pressure, recirculation and feed rates • CHP • Monitoring and controlling flow rates and energy production • Headworks and Clarifiers • Monitoring and pumping control • Aeration Basin • Dissolved oxygen monitoring • Aeration efficiency improvements of up to 50% • Monitoring and Pumping

  16. The Extras Hydraulic Profile E.L. 84.75m Available Head of 4.0m E.L. 80.75m

  17. The Extras Construction And Implementation Minimizing Environmental Impact • The completion date of Stage 3 is established as year-end of 2034 • Using current data in the population analysis • Recommended that population growth trends are rechecked every 5 years • In accordance with Local Municipalities, by-laws and MOE Standards • Noise Control • Dust Control • Protection of Surface Water • Erosion Control Plant Design: 12 months Permits and Approvals: 12 months Tendering/Awards: 2 months Construction Period: 15 months Commissioning: 2 months

  18. The Extras Noise and Odour Control Solution? Problem: • Development of surrounding residential area of great concern • Adequate buffer areas around the facility • Housing facilities with adequate noise depletion technology (for pumps, generators, etc.) • All noise and odour sources will maintain the minimum separation distance of 100 meters in agreement to MOE odour and noise guidelines. The Problem 111m

  19. The Extras Cost Analysis Total Capital Cost: $26,350,000.00 8% 9% 19% 64%

  20. The Extras Cost Analysis Annual Operation and Maintenance Cost: $898,000.00 22% 6% 53% 4% 15%

  21. Cost Savings Sludge Disposal Annual Savings with the Proposed Solution: $302,442

  22. The Extras Stage 4 Layout Stage 3 Stage 4 Stage 1&2

  23. Conclusions • The proposed processes for Stage 3 include • Additional headworks improvements • 1 primary clarification tank • 2 two-staged aeration tank • 1 secondary clarification tank • 3 cloth filters • 1 UV disinfection unit • 2 additional anaerobic digesters • 2 screw press dewatering units • Stage 3 is to be completed by year-end of 2034 • present cost of $26.3 Million • O/M of $0.9 Million annually • Further investigation should be conducted with respect to the integration of the microturbine CHP system for biogas handling • Issues such as the availability of obtaining contracts from the Ontario Energy Board (OEB) and the Local Distribution Company (LDC) are of concern • Green incentive grants should be assessed to determine possible alleviation of total capital cost and further evaluation of the systems feasibility • Population growth trends are rechecked every 5 years to determine if the completion of Stage 3 construction schedule requires adjustment • Obtain additional specific order costing information from manufacturers Hongde Zhou, Ph.D., P.Eng. – Faculty Advisor Professor of the School of Engineering – University of Guelph Miles MacCormack, P.Eng. – Consultant Advisor Project Manager – Stantec Inc. RafiqQutub, M.Eng., P.Eng. Subcommittee Chair, Student Design Competition – Water Environment Association of Ontario Kirill Cheiko, EIT. Water EIT – Stantec Inc. YasharEsfandi, EIT. Inside Sale Representative – SPD Sales Limited Hussein Abdullah, Ph.D., P.Eng. – Director The School of Engineering – Guelph University Conclusion Recommendations Acknowledgements Questions Questions and…

  24. Conclusions The Credits Thank you! Thank you!

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