Expansion of the Newcastle Water Pollution Control Plant WEAO Student Design Competition 2013

Contents  Introduction  Stage 3 Design  Stage 3 Extras  Stage 4 Layout  Conclusions  Questions?

Who are we? BradleyFree 5 th Year Water Resource 5 th Year Water Resource Kyle Lockwood 5 th Year Environmental Introduction Robyn Thompson 4 th Year Mechanical Tanzeel Ahmed 5 th Year Environmental 5 th Year Environmental

Background Introduction Clarington, Ontario Municipality of Clarington, Newcastle, Ontario  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: 1. Preliminary Design and layout 1. Preliminary Design and layout for Newcastle WPCP for Stage 3 expansion including biosolids handling and energy recovery 2. Conceptual layout 2. Conceptual layout for Newcastle WPCP expansion for Stage 4 expansion

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

The Layout Stage 3 Design 1. Office Building 2. Headworks 3. Primary Clarifiers 4. Aeration Tanks 5. Secondary Clarifiers 6. Disinfection 7. Cloth Filters 8. Digester Gas Flaring 9. Dewatering Units 10. Chemical Storage 11. Anaerobic Digesters 12. CHP System

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

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

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

Tertiary Treatment Stage 3 Design Alum Addition reduce the influent phosphorus  Will reduce the influent phosphorus by over 85%  Added at the aeration tank effluent most effective treatment for the lowest cost  Chosen because it was the most effective treatment for the lowest cost Three Cloth Filtration Units Three Cloth Filtration Units (AquaDISK Tertiary Filtration system)installed  TSS reduced  TSS reduced below 5mg/L for ADF  Will be able to process Stage 3 flows of 39,300 m 3 /d  Extra unit provided  Extra unit provided for redundancy and maintenance UV system 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  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

Sludge and Biosolid Treatment Stage 3 Design ROTAMAT (HUBER TM ) Screw Press ROTAMAT (HUBER TM ) Screw Press dewatering system chosen  2 Dewatering units  2 Dewatering units installed for Stage kg Dry/h  Have a total dry solids throughout capacity of 280 kg Dry/h  O/M costssmaller  O/M costs are smaller than traditional centrifugal dewatering system  Operates at <1.5 rpm  Operates at <1.5 rpm screw rotation speed <20 min/d  Requires <20 min/d of operator attention 18 – 25% cake solids  Produces 18 – 25% cake solids 2 Single stage high rate mesophilic anaerobic digesters installed 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  Biogas collection to for Combined Heat and Power (CHP) energy recovery Processed Sludge Disposal  On approved agricultural land site under the Durham Region Works Department’s Biosolids Management Program

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

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

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

Modelling The Extras  WRc’s waste water modelling software  BODTSSNH 3  BOD, TSS and NH 3 was modelled within the simulation effluent objectives below  At an operational temperature of 10 o C, the effluent objectives were well below target STOAT® Parameter Proposed Effluent Objectives Simulated Mean Effluent BOD 5 (10 mg/L)10 mg/L4.76 mg/L TSS (10 mg/L)10 mg/L6.61 mg/L (Ammonia + Ammonium) Nitrogen*9 mg/L15 mg/L0.49 mg/L *The simulated ammonia effluent is assumed to be representative of both ammonia and ammonium * Concentration listed are for summer and winter objective respectively Parameter Proposed Effluent Objectives Simulated Mean Effluent BOD 5 (10 mg/L)10 mg/L4.76 mg/L TSS (10 mg/L)10 mg/L6.61 mg/L (Ammonia + Ammonium) Nitrogen*9 mg/L15 mg/L0.49 mg/L *The simulated ammonia effluent is assumed to be representative of both ammonia and ammonium * Concentration listed are for summer and winter objective respectively

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

Construction And Implementation The Extras Task Name Duration (months) Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Construction Period 15 Mobilization and Erosion Control Systems 1 Site Preparation 1 Concrete Placing, Formwork and Reinforcing Steel 4 Piping and Mechanical Equipment Installation 6 Support Facilities 2 Electrical Work, Instrumentation and Controls 6 Landscaping and Final Clean-up 2 Commissioning 3 completion date 2034 The completion date of Stage 3 is established as year-end of 2034  Using current data in the population analysis rechecked every 5 years  Recommended that population growth trends are rechecked every 5 years Plant Design Plant Design: 12 months Permits and Approvals Permits and Approvals: 12 months Tendering/Awards Tendering/Awards: 2 months Construction Period Construction Period: 15 months Commissioning Commissioning: 2 months Minimizing Environmental Impact In accordance with Local Municipalities, by-laws and MOE Standards  Noise Control  Dust Control  Protection of Surface Water  Erosion Control

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

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

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

Conclusions  Conclusion  Recommendations  Acknowledgements  Questions 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 2034 Stage 3 is to be completed by year-end of 2034 $26.3 Million  present cost of $26.3 Million $0.9 Million  O/M of $0.9 Million annually Further investigation Further investigation should be conducted with respect to the integration of the microturbine CHP system for biogas handling obtaining contracts  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  Green incentive grants should be assessed to determine possible alleviation of total capital cost and further evaluation of the systems feasibility Population growth trends Population growth trends are rechecked every 5 years to determine if the completion of Stage 3 construction schedule requires adjustment additional specific order costing Obtain additional specific order costing information from manufacturers Hongde Zhou Hongde Zhou, Ph.D., P.Eng. – Faculty Advisor Professor of the School of Engineering – University of Guelph Miles MacCormack Miles MacCormack, P.Eng. – Consultant Advisor Project Manager – Stantec Inc. Rafiq Qutub Rafiq Qutub, M.Eng., P.Eng. Subcommittee Chair, Student Design Competition – Water Environment Association of Ontario Kirill Cheiko Kirill Cheiko, EIT. Water EIT – Stantec Inc. Yashar Esfandi Yashar Esfandi, EIT. Inside Sale Representative – SPD Sales Limited Hussein Abdullah Hussein Abdullah, Ph.D., P.Eng. – Director The School of Engineering – Guelph University Questions Questions and…

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