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Opportunities and Challenges: Update on the WSACC Heat to Energy Project. Thomas Hahn, PE (CH2M HILL) Coleman Keeter (WSACC) Angela Roberts, PE (CH2M HILL). Agenda. Background / Existing Facilities Need for Project Description of Project Features Imported Biosolids Handling Facility

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opportunities and challenges update on the wsacc heat to energy project

Opportunities and Challenges: Update on the WSACC Heat to Energy Project

Thomas Hahn, PE (CH2M HILL)

Coleman Keeter (WSACC)

Angela Roberts, PE (CH2M HILL)

agenda
Agenda
  • Background/ Existing Facilities
  • Need for Project
  • Description of Project Features
    • Imported Biosolids Handling Facility
    • Heat Recovery and Power Generation System
  • Challenges and Opportunities
  • Path Forward
  • Questions
background rrrwwtp facilities
Background / RRRWWTP Facilities
  • Serving Cabarrus County
  • 26.5 mgd capacity
  • High-Purity Oxygen Activated Sludge
  • Solids Handling System
    • Primary and Secondary Clarifiers
    • Gravity Thickeners
    • Dewatering Centrifuges
    • Multiple Hearth Furnace (MHF)
need for project
Need for Project
  • Historically:
    • MHF operating well below permitted capacity
    • Autogenous burn 4 – 5 days / week
    • Maintaining temperature in MHF with fuel oil for remaining days
  • With imported solids
    • Reduced need for fuel oil
    • Optimized MHF operation
    • Revenue from imported solids
    • Solids handling alternative for other utilities
  • Heat Recovery / Power Generation
    • Green energy and revenue for WSACC
imported biosolids handling facility design capacities
Imported Biosolids Handling Facility – Design Capacities
  • Design Maximum Imported Biosolids Delivery/Conveyance Rate = 5.25 wet tons / hour
  • Storage Capacity of Imported Biosolids Handling Facilities = At least 1 day at design maximum imported biosolids delivery/conveyance rate
imported biosolids handling facility truck unloading
Imported Biosolids Handling Facility - Truck Unloading
  • Two unloading “lanes” – one per solids receiving bin
  • Solids analysis
  • Weighing / recordkeeping
imported biosolids handling facility solids receiving bins
Imported Biosolids Handling Facility - Solids Receiving Bins
  • 96 CY each (192 CY total).
  • Electrically actuated retractable covers
  • Leveling screws
  • Live Bottom Screws with Variable Frequency Drives
  • Load cells
  • Extraction screws and sludge mixer
imported biosolids handling facility dewatered sludge pump
Imported Biosolids Handling Facility - Dewatered Sludge Pump
  • 45 gallons per minute (gpm) at 30% total solids
  • Screw feeder integral to dewatered sludge pump
  • Lubrication system (water injection) included to ensure reliable conveyance of imported cake
  • Piping and valving set up for multiple conveyance options.
heat recovery and power generation system heat recovery unit
Heat Recovery and Power Generation System - Heat Recovery Unit
  • Replacement of the existing heat recovery unit at the Incinerator Building
  • Heat recovery unit completely contained within the existing building
heat recovery and power generation system hrsg components
Heat Recovery and Power Generation System – HRSG Components

Steam Drum

Down-Flow Section

Cross-Flow Section

heat recovery and power generation system steam turbine generator
Heat Recovery and Power Generation System - Steam Turbine Generator
  • Installed in new metal building
  • Process piping provided between the existing Incinerator Building and new Steam Turbine Generator Building
  • Overhead power lines to provide the power generated at the site back to the electrical grid.
challenges
Challenges
  • Coordination, scheduling, and procurement for Owner-furnished equipment
    • Solids storage / conveyance equipment for Imported Biosolids Handling Facility
    • HRSG and STG for Heat Recovery and Power Generation System
  • Timing for bid of Heat Recovery and Power Generation System installation work
  • Contractor involvement with Owner-furnished equipment manufacturers
  • Imported dewatered sludge with wide variety of characteristics
    • Handling and controls
  • Incinerator shutdown for installation of Heat Recovery and Power Generation System equipment
opportunities
Opportunities
  • Cost-competitive all-weather biosolids disposal alternative
  • Optimization of biosolids feed quantity / quality to existing incinerator
  • Generation of green energy
  • Generation of revenue at WSACC
path forward
Path Forward
  • Continuing successful Imported Biosolids Handling Facility operations
    • Operating January 2013 – present
  • Heat Recovery and Power Generation System
    • Construction work at site started in August 2013
    • Concrete placement and backfill for STG Building now
    • Continuing mechanical equipment procurement
    • Incinerator shutdown, equipment installation, and startup
    • Anticipated completion of construction in May 2014
considerations for interested surrounding utilities
Considerations for Interested Surrounding Utilities
  • Imported sludge with higher Total Volatile Solids (TVS) preferred for optimum operation of the MHF
    • Surrounding utilities may choose not to digest solids
    • Significant savings in O&M costs for those facilities
opportunities and challenges update on the wsacc heat to energy project1

Opportunities and Challenges: Update on the WSACC Heat to Energy Project

Thomas Hahn, PEthomas.hahn@ch2m.com

NC AWWA-WEA 93rd Annual Conference November 12, 2013