Genesee County Drain Commissioner Division of Water & Waste Services District # 3 Water Resource Recovery Facility PATH TO ENERGY REDUCTION

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1 Genesee County Drain Commissioner Division of Water & Waste Services District # 3 Water Resource Recovery Facility PATH TO ENERGY REDUCTION Brian J. Ross, Genesee County Water & Waste Services Mark Earl, Genesee County Water & Waste Services October 13 th, 2016

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4 ENERGY FACTS This is a Test! of your knowledge About Energy

5 ENERGY FACTS 1. Which End-Use Sector consumes the most Energy in Michigan?

6 ENERGY FACTS 1. Which End-Use Sector consumes the most Energy in Michigan? Residential Commercial Industrial Transportation

7 ENERGY FACTS 1. Which End-Use Sector consumes the most Energy in Michigan? Residential

8 ENERGY FACTS 1. Which End-Use Sector consumes the most Energy in Michigan? Residential

9 ENERGY FACTS 2. Michigan homes use 123 million Btu of energy per home/yr which is:

10 ENERGY FACTS 2. Michigan homes use 123 million Btu of energy per home which is: -The National average -More than the National Average -Less than the National Average

11 ENERGY FACTS 2. Michigan homes use 123 million Btu of energy per home which is: -More than the National Average

12 ENERGY FACTS 2. Michigan homes use 123 million Btu of energy per home which is: -More than the National Average Michigan Homes use 38% more energy than the National Average

13 ENERGY FACTS 3. How much do Michigan Households spend for energy?

14 ENERGY FACTS 3. How much do Michigan Households spend for energy? 31% more than the National Average 6% more than the National Average The same as the National Average 3% Less than the National Average

15 ENERGY FACTS 3. How much do Michigan Households spend for energy? 6% more than the National Average

16 ENERGY FACTS 3. How much do Michigan Households spend for energy? High consumption, combined with low costs for heating fuels compared to states with a similar climate, result in Michigan households spending 6% more for energy than the U.S. average.

17 ENERGY FACTS Michigan residents consume a great deal of energy but also create some energy potential.

18 ENERGY FACTS 4. How many dry tons of Biosolids were produced in Michigan last year?

19 ENERGY FACTS 4. How many dry tons of Biosolids were produced in Michigan last year? 78,000 Dry Tons 163,000 Dry Tons 276,000 Dry Tons 315,000 Dry Tons

20 ENERGY FACTS 4. How many dry tons of Biosolids were produced in Michigan last year? 315,000 Dry Tons

21 ENERGY FACTS 4. How many dry tons of Biosolids were produced in Michigan last year? In 2015 there were 315,000 Dry Tons of Biosolids were Produced in Michigan with only 76,000 Dry Tons applied to agricultural land.

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23 You are Here!

24 You are Here!

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34 11 MGD Design Flow 4.5 MGD current daily average flow BNR Facility using A/O process

35 Raw Sewage

36 Influent Pump Station Flow Screening and Grit Removal

37 Primary Flow

38 Secondary Treatment

39 Nitrification Towers

40 Flow Equalization

41 DESIGN FLOW 11 MGD AVERAGE FLOW 4.2 MGD 450 MILLION GALLONS

42 Right-Sized two (2) Aeration Blowers with addition of VFDs (Custom) Right-Sized two (2) RAS Pumps (Prescriptive) Tune-Up for Process and Heating Boilers (Prescriptive)

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44 Largest of the three (3) projects (greatest savings) Replaced two (2) 250 h.p. Hoffman blowers Installed two (2) 150 h.p. Lamson blowers Remanufactured with all new parts Outer shells were used Right sized the blowers Sufficient air flow 90% of the time (w/ smaller blower)

45 Replace Blowers - two (2) blowers were already broken - replaced with two (2) new lower Hp blowers Save Energy Consumption Save actual $

46 Project cost estimate = $154,471 Included in the Project: Two (2) 150 hp Lamson multi-stage blowers (with trade-in ) Two (2) Rotork electrically actuated inlet control valves (460V) Two (2) series 40 Elektrim motors (1.4 service factor) (later replaced with Hyundai) Two Allen-Bradley variable frequency drive units Two (2) monitoring cabinets flow measurement ( in cfm) inlet & outlet bearing temperature readings (in degrees F) inlet & outlet bearing vibration readings All associated piping/electrical work/rigging/and removal Three (3) year warranty Engineering cost estimate = $9,000

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67 Metering services were performed by Consumers Energy Business Solutions. Before the work is done, an estimate needs to be made of how much energy will be saved from the project. The estimate determines amount of funding to be placed in reserve.

68 Pre Application Reservation Period Final Application Payment

69 Pre-Application 69 Information gathering Determine the strategy for quantifying savings Review information with Consumers Energy Advisor In this case, we metered for two weeks, got average kw

70 Reservation 70 How much funding to reserve? Based on anticipated energy savings. Need to calculate energy requirements of equipment. Used Tetra Tech s calculations (Air flow required and estimated Hp.) Consumers Energy reserved $37,200 for GCDCWWS

71 Final Application 71 New ability to control motor speed with VFD Demand was determined by monitoring electrical consumption at various air flow rates.

72 Post: Metering at Various Air Flow Points "PERIOD" FLOW (CFM) kw Time Recorded: ONE :50:51-7:54:48 TWO :55:30-7:57:30 THREE :58:12-7:59:57 FOUR :00:24-8:01:51 FIVE :02:24-8:03:33 SIX :04:12-8:05:42

73 Average kw Post: kw per CFM kw per CFM y = x R² = CFM

74 New Energy Requirements Air Flow and Run Time Data Submitted with Application (calculated by Brent Bode of Tetra Tech; based on nutrient loadings). Air Flow (SCFM) Run Time kw* kwh/year 1,950 15% , ,400 20% , ,650 25% , ,900 20% , ,150 10% , ,400 5% , ,400 5% , , total kwh/year * Anticipated kw Based on Curve of Metered Data on 7/25/2014: y = X where x = air flow in CFM and y = kw at that flow rate

75 Final Calculations 75 PRE ANNUAL ENERGY CONSUMPTION Average demand (metered over the course of 2 weeks) Average Annual Energy Consumed ( kw x 8760 hrs/year) POST ANNUAL ENERGY CONSUMPTION Average Annual Energy Consumed (see table shown previously) kw 1,476, kwh 913, kwh ANNUAL ENERGY SAVINGS Difference = 1,476, kwh- 913, kwh 563, kwh Incentive (@ $0.08/kWh reduced) 45,066.37

76 Blower Project Payback Initial estimate was 465,000 kwh/yr Final calculated energy savings of 563,330 kwh/yr 2.81 years (without rebate) simple payback Greater than a 10% savings in the facility s total annual electrical budget (saving approx. $45,000/year)

77 Consumers Energy Rebate Check for: Linden Resource Recovery Facility

78 Customer Participation Consumers Energy 110,000 $100 million Number of commercial & industrial customers that have participated Total incentive dollars paid to customers since 2009

79 Historically overdesigned treatment facilities Excess capacity exists Need for downsizing of equipment Next step: Future automate control of blowers at District #3 (based on D.O. levels and Nitrification)

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81 Linden had four (4) 32 h.p. KSB RAS pumps Replaced two (2) old 32 h.p. KSB pumps Installed two (2) new 7.5 h.p. KSB pumps We right sized the pumps We were throttling the discharge valve too much We were wasting electricity Incentive = $10,455 Prescriptive incentive (now it is a custom incentive)

82 32 h.p. motor / pump Discharge valve operated at 8-10% open

83 7.5 h.p. motor / pump Handles 90% of required flow demand Discharge valve operated at 50% open

84 Operate one 7.5 h.p. RAS pump 90% of the time Right sizing the pumps saves approx. $10,500 / year Throttling the discharge valve less Project cost = $27,207 Rebate Incentive = $10,455 Simple payback = 2.6 years (without rebate)

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86 Boiler Tune-Ups (Prescriptive) - Worksheet 8 6

87 One (1) Process Boiler (for Anaerobic Digester) Two (2) Heating Boilers (for Building Heat) Both Prescriptive Incentives Incentive was based on boiler size Incentive total (3 boilers) = $800 Outcome: Cleaner emissions, saves money

88 Digester boiler (process) 1 boiler every other year

89 Heating boilers (2)

90 Communication Consumers Energy Ask about the Municipalities Pilot Program for catalog, application Call Consumers Energy Business Solutions at Arrange for an energy advisor to meet with you!

91 Genesee County Drain Commissioner Division of Water & Waste Services District # 3 Water Resource Recovery Facility Brian J. Ross, Genesee County Water & Waste Services Mark Earl, Genesee County Water & Waste Services

92 Genesee County Drain Commissioner Division of Water & Waste Services District # 3 Water Resource Recovery Facility PATH TO ENERGY REDUCTION Brian J. Ross, Genesee County Water & Waste Services Mark Earl, Genesee County Water & Waste Services