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NYWEA ENERGY SPECIALTY CONFERENCE November 20, 2014 Towards Net-Zero Energy in Wastewater Treatment Demonstration of ClearCove’s Enhanced Primary Treatment Technology Alex Wright, ClearCove Systems & Mark Greene, O’Brien & Gere
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Enhanced Primary Treatment Benefits –Divert digestible material from secondary treatment to anaerobic digestion –Higher TSS and BOD removal –Coagulant addition leads to phosphorus removal Key Impact Areas of Evaluation –Chemical costs –Hydraulic profile –Readily degradable organics for N-removal 11/20/2014 1
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Demonstration CCS EPT Pilot Anaerobic Digestion Pilots Biochemical Methane Potential Testing 11/20/2014 2
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EPT Pilot 20,000 gal/day Equalizes the flow Stops the Flow Removes 100% of the grit Removes 100% of the fibers Settles the high value organics –Phys/Chem: chemical dosing and gravity –Colloidal capture Filters the effluent – 50 micron screen –Membrane Operation Benefit Removes the sludge to a classifying press –Removes additional digestible organics –Removes and dewaters gross matter 11/20/2014 3
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EPT Pilot Wastewater pumped from influent channel of IAWWTF Wastewater enters both sides of the tanks through the Influent Feed Chamber. Grit and dense solids settle out Wastewater flows over 70 degree weirs into the main chamber of the tank where the lighter solids settle out 11/20/2014 4
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EPT Pilot Screen box is lowered into low BOD, low solids supernatant after the settling period Wastewater flows through the screen and down a central effluent hose 50 micron stainless steel screen Air scour to deflect any floating material from coming in contact with screen 11/20/2014 5
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Ithaca Influent Wastewater Ithaca NY Results ClearCove’s EPT Effluent The Best Biomass gets destroyed! Suspended “Fuel” 6 ClearCove Results Ithaca Primary Effluent 11/20/2014
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Sludge Classifying Press Sludge from the EPT unit is processed through SCP SCP “cleans” sludge, removing inorganic solids and releasing encased organics. 11/20/2104 7
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Pilot Digesters 4 Fixed Volume Reactors –300-gallon, cone bottom –100-gallon operating volume Hydraulic Mixing Heating using IAWWTF hot water Data logging for biogas flow and digester temperature Biogas measurements taken every 10 seconds (over 1 million readings over the course of the project) 11/20/2104 8
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Pilot Digesters Four (4) Feed Tanks Hydraulic Mixing Solenoid valve diversion to digester Feedstock transfer by buckets 11/20/2104 9
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BMP Bioprocess Control –Automatic Methane Potential Test System (AMPTS II) (15) 640 ml reactors including controls Used to validate and correlate the digester pilot data 11/20/2104 10
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Results CCS EPT Pilot Anaerobic Digestion Pilots Biochemical Methane Potential Testing 11/20/2014 11
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11/20/2104 12 EPT/SCP Pilot Flow Schematic
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11/20/2104 13
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Mini-Digester Flow Schematic Two test units and two control units 11/20/2104 14
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10/2/2014 15
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10/2/2014 16
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Plant Impacts CCS EPT Pilot Anaerobic Digestion Pilots Biochemical Methane Potential Testing 11/20/2014 17
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11/20/2104 19 Actiflo BACKWASH
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Chemical Impact Current use –400-500 GPD Ferric Chloride Actiflo process 700 GPD peak –50-100 GPD Ferrous Sulfate Headworks Estimated use with EPT –400 GPD Ferric Chloride 11/20/2104 20
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Reduction in Aeration Electricity IAWWTF uses 9,400 kWh/day Aeration accounts for 48% (submetering) 72% for BOD removal (O 2 demand) 28% for nitrification (O 2 demand) BOD removal in existing aeration 5,960 lb/day, 3,275 kWh/day Energy = 0.55 kWh/lb rem BOD removal with EPT 2,290 lb/day, 0.55 kWh/lb rem Energy = 1,260 kWh/day 11/20/2104 21 -62%
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Volatile Solids Current 11/20/2104 23 Mass Balance Thousand Lb/day Gravity Primary Clarifiers 28% VS capture Gravity Thickener 43% VS capture Thickened Solids 67% primary 33% secondary 7.3 18.8 26.1 6.1 9.5 17.0 30.0 13.0 19.5 60,000 scfd
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Volatile Solids EPT 11/20/2104 24 Mass Balance Thousand Lb/day Enhanced Primary Clarifiers 84% VS capture Gravity Thickener 43% VS capture Thickened Solids 82% primary 18% secondary 7.3 18.9 26.2 1.5 5.0 17.0 30.8 13.6 24.7 100,000 scfd EPT
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11/20/2104 25 26%-45%2.4x
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11/20/2104 26 Energy Production Potential 2.4 times 4.X times
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EPT Demonstration Summary Sufficient amount of data collected Pilot EPT:84% TSS removal 67% BOD 5 removal 76% TP removal Primary sludge fraction of digester feed –67% current –82% with EPT 11/20/2104 27
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Digestion Demonstration Summary BMP Results –IAWWTF Primary Sludge 4.4 scf methane per lb VS fed –Enhanced Primary Sludge 6.6 scf methane per lb VS fed –Statistically different with 95% probability 11/20/2104 28
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Digestion Demonstration Summary Pilot Results –IAWWTF Primary Sludge 4.1 scf methane per lb VS fed 13.4 scf methane per lb VS destroyed –Enhanced Primary Sludge 8.3 scf methane per lb VS fed 28.4 scf methane per lb VS destroyed –Statistically different with 95% probability 11/20/2104 29
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IAWWTF Impacts Summary Secondary Treatment Costs –Decrease by 62% –Savings of approx. $125,000/year Methane Generation from Primary Sludge –Increase by 2.4x $325,000/year in kWh value –Optimized upside potential is 4.5x $625,000/year in kWh value * CNG economic $ value would be ~2x –Potential for greater amount Improved thickening 11/20/2104 30
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Thank you! 11/20/2104 31
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Rethink. Reduce. Renew. Alex Wright, awright@clearcovesystems.com, (585) 269-8176awright@clearcovesystems.com Mark Greene, mark.greene@obg.com, (315) 956-6271mark.greene@obg.com
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