Fremont Water Pollution Control Center Plant Expansion for Nutrient Removal and Wet Weather Flow Treatment
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1 OWEA 2013 Annual Conference June 19, 2013 Fremont Water Pollution Control Center Plant Expansion for Nutrient Removal and Wet Weather Flow Treatment Jeff Lamson, Superintendent, WPCC Robert Hrusovsky, PE, MWH Americas
2 Fremont Water Pollution Control Center 1019 Sand Road Fremont, Ohio
3 Progression of Improvements at WPCC
4 Location for New Liquids Process
5 Plant improvements are being driven by a Requirement of the Federal Clean Water Act Reduce Combined Sewer Overflows (CSO) Develop a Long Term Control Plan (LTCP) Failure to comply could result in enforcement action against the City.
6 Combined Sewer Overflow Combination of raw sewage and storm water discharged to surface waters.
7 COMBINED SEWER OVERFLOWS in Fremont, Ohio Fremont s sewer system is approximately 75% combined. An average of 1 billion gallons of combined sewage is discharged to the Sandusky River every year. An average of 70 events occur per year.
8 LTCP Requirements June 29, 2006 OEPA letter to the City stated that at a minimum 80% solids removal and disinfection were required. However, the City was later told that CSOs would need to be reduced to no more than 4 events/year and water quality standards would need to be maintained.
9 Alternatives
10 LTC Proposal December 2007 Treat 9.2 MGD through current facility (with improvements) and 34.8 MGD through High Rate Treatment and disinfection. (Total 44 MGD) along with common projects. Total cost $67.4 million. OEPA responded by requiring the City to conduct a No Feasible Alternatives (NFA) study to be completed by end of 2010.
11 No Feasible Alternatives Study (NFA) The City had to prove that there were no feasible alternatives to the current proposal that would result in more water being treated biologically, based on technology and the financial capability of the City. Finanacial Capability Had to show that at least 2.1% of the household median income was being spent on sewer services. If not, then other alternatives that would provide additional biological treatment had to be investigated.
12 Results of NFA City could reasonably treat 18 MGD through biological treatment and 33 MGD through HRT (Total 51 MGD) $52.8 million for plant improvements Total LTCP cost $78.4 million OEPA, due to financial capability, felt the City could treat 24 MGD through biological treatment and 36 MGD through HRT. (Total 60 MGD) Wanted this completed at the same time at a cost of $67.4 million for plant improvements Total LTCP cost $94.4 million Current rate schedule puts the cost at 2.06% of household median income
13 Current Plan after Negotiations with OEPA Build new 24 MGD biological process with new Class A solids handling facility for an estimated $57 million. The City has two years to determine if any additional treatment is necessary to meet the CSO requirement of 4 or less events per year. Conduct common projects to reduce the amount of storm water to be treated. Reduce Inflow and Infiltration (County monitoring and surcharge program).
14 Why Build a New Facility? Engineer s estimate based on life cycle costs was $1.4 million less to build new than renovate old and bring up to code. Build new with today s technology and specifications to treat 24 MGD rather than hope the old would meet NPDES requirements. Better position the City for future growth and regulations.
15 Structural issues with existing basins.
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19 Advantages of the New Facility Biological Nutrient Removal Help with algae blooms in Lake Erie Reduce biosolids production lower operating costs Class A biosolids More options for use Environmentally safer Lower or eliminate disposal costs currently > $200,000/year More energy efficient
20 Plant Project Design firm MWH Americas, Cleveland Office Construction Manager at Risk (CMAR) MWH Constructors and Mosser Construction Inc. New law allowing CMAR went into effect April 2012
21 Advantages to CMAR Lower number of change orders Less liability for City Process makes it easier to hire local firms
22 Influent Screen / Pump Station Screening System Manual Coarse Screen (3 spacing to protect mechanical screen from large objects) Mechanical Bar Screen (1/4 spacing) Manual Bypass Reversing Conveyor Screening Washer/Compactor Dumpster
23 Influent Pumps Submersible Split wet well for maintenance. Multiple pump sizes with VFD s for wide range of flow 2-3 MGD 1-6 MGD 2-12 MGD Space for future pumps Dump discharge piping connection for flushing out wet well (resuspend grit)
24 Influent Pumps Dual force mains 24 and 36 for wide range of flow and future flow Flow meters on each force main
25 Grit Removal Submerged Vortex Grit Concentrator Type System 2 Units each rated for 15 MGD Space for 2 future units Grit pumps in basement Flushing water at pump suction for grit suspension Two grit separation/washing units. Water goes back to treatment by gravity.
26 A2O System. Anaerobic/Anoxic/Oxic Biological treatment / Internal recycle. Floating Mixers Fine bubble diffusion system Internal recycle with submersible pumps Multiple blowers with turndown capability Surface Mixers ORP and DO sensors for control. Fine Bubble Air Diffusers Recirculation Pumps
27 Process Alternatives Evaluated Membrane Bioreactor (MBR) Integrated Fixed-film Activated Sludge (IFAS) Oxidation Ditch Three-stage (A2O) biological nutrient removal (BNR) activated sludge Vertical Loop Reactor (VLR)
28 Alternative Evaluation Criteria Compatibility with existing site constraints Constructability Use of existing facilities Operation during construction Proprietary licensing Construction time Wet weather performance
29 Alternative Evaluation Criteria Ease of operation Maintenance requirements Expandability Sidestream (screenings, grit, residuals) impacts Energy consumption Compliance with nutrient removal regulations Odor control
30 Alternative Evaluation Scoring Membrane Bioreactor 395 IFAS 523 Oxidation Ditch 502 Three-stage A2O BNR 558 Vertical Loop Reactor 481
31 Why Three-Stage A2O was Selected Easy to integrate to the existing site Meets current regulatory limits Prepares Fremont for future nutrient removal requirements (TP and TN) Minimal number of bio-reactors
32 Why Three-Stage A2O was Selected Simple operation Can accommodate peak wet-weather flows (stepfeed operation) Lower aeration (energy) requirements Minimal impact to existing operations Primary sedimentation is not required
33 Final Clarifiers 3 at 90 ft diameter 18 deep (ability to store solids) Energy Dissipating Inlet (EDI) Density Current Baffles RAS pump dedicated to each clarifier with flow meter.
34 Tertiary Filter Rotating Disc Filter Automatic backwash Over double the treatment capacity in half the footprint Mudwell to collect backwash and send to A2O influent
35 Disinfection Ultraviolet (UV) system 2 Channels 12 MGD each 1- Bypass Channel Canopy Overhead Peracetic acid as backup / power outage
36 Effluent Pump Station Multiple variable speed submersible pumps 1-3 MGD 2-6 MGD 2-9 MGD Flow to river by gravity until pre-determined river level then turn on pump station.
37 Chemical Systems Settling aid polymer Aluminum Chlorohydrate (ACH) for phosphorous removal Peracetic acid for RAS filaments and backup disinfection Polymer for thickening and dewatering centrifuges Room for future chemical
38 Solids Processing Autothermophilic Aerobic Digestion (ATAD) Gravity thickener Thickening centrifuge ATAD SNDR Biofilter Dewatering centrifuge (liquid or solid Class A product)
39 Overall Site Plan Permanent Grit Pad Septage Receiving Manhole
40 Proposed Construction Phasing Demolition / Dewatering Equip. (Mar 13 June 13 ) Piling (June 13 Aug 13 ) Liquid Phase (July 13 Feb 15 ) Solids Phase (Mar 15 Dec 15 ) *Use Existing Aeration Tanks for Temporary Aerobic Digestion
41 Questions?
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