R2E2: How a Biosolids Project Ignited a Utility Transformation

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1 R2E2: How a Biosolids Project Ignited a Utility Transformation 2017 Virginia WEA Education Seminar May 11, 2017 Collaborative Biosolids: Fuel for Thought Tom Sigmund Executive Director NEW Water

2 Agenda Overview of NEW Water and the R2E2 Project Process and Facility Description Energy and Nutrient Recovery Construction Progress NEW Water Transformation

3 NEW Water the brand of the Green Bay Metropolitan Sewerage District Provides collection and treatment for 18 municipalities in Northeast Wisconsin Formed in Owns and operates: GBF, designed to treat 49.2 mgd through secondary treatment DPF, designed to treat 14.3 mgd through tertiary treatment Serves a population of 230,000

4 De Pere and Green Bay Water Resource Recovery Facilities Green Bay Facility De Pere Facility

5 Solids Management Facilities Plan NEW Water and ch2m developed the Solids Management Facility Plan (SMFP) Planning to solids unit processes considered Resource recovery and operations emphasized in evaluation

6 Selected Solids Processing Solution

7 Choices were all expensive Customer Reaction Poor economy made it difficult to understand why this project was being attempted now Rate impact was main concern; drove customer frustration NEW Water formed a customer working group As a team, walked through entire project to explore alternatives in detail

8 Can You Support the R2E2 Project? Understood do nothing wasn t an alternative Customer group helped reduce capital cost by $8 million Bought into benefits of resource recovery No opposition at public hearing

9 Resource Recovery and Electrical Energy Generation (R2E2)

10 Reframe the Conversation through Branding

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14 R2E2 What Is It? Most cost-effective solution to replace solids handling at the Green Bay Facility Treat wastewater as a resource to be recovered

15 NEW Water Expectations of R2E2 Capital cost: $169 million Construction completion in 2018 Initially generate about 60% of GBF power and heating requirements Capacity to generate 90% of GBF power needs

16 Anaerobic Digestion Microorganisms produce biogas Reduces solids for incineration High-strength waste to boost biogas production

17 Resource Recovery: Struvite Nutrient recovery in the form of struvite Converts into a fertilizer product Creates a potential $400,000 revenue stream Reduces maintenance of equipment & piping

18 R2E2 Solids Building Overview Nutrient Recovery Dewatering Pre- Drying Cake Pumping Incineration Cogeneration

19 R2E2 Costs Project Phase Fluidized Bed Incinerator Equipment Approximate Costs $24,900,000 Construction Project #1 $7,400,000 Construction Project #2 $133,800,000 Construction Project #3 $2,900,000 Total $169,000,000 In 2013, NEW Water initiated four years of rate increases to pay for R2E2 debt service.

20 Incineration System Schematic

21 CHP Energy Profile

22 Incineration Energy Profile

23 Thermal Oil Loop Energy Profile Design heat recovery/generation: 9,440 kw Design heat users: 8,940 kw Waste heat exchanger: 5,980 kw

24 Summary of Energy Recovery & Utilization Input energy AD from solids and HSW 13,120 kw Recovered or lost energy Electricity; ~21% Heat recovered (high grade): ~17% Heat recovered (low grade): ~22%

25 Nutrient Recovery MultiWAS

26 Nutrient Recovery Cost Estimate Summary Alternative Capital Cost (2013 Dollars) Annual O&M Cost (2013) 20-year Life-Cycle Cost, including Salvage Value FeCl 3 without bio-p: TP = 0.3 mg/l Fermentation/bio-P combined with a lower FeCl 3 dose: TP = 0.3 mg/l Nutrient recovery with WAS P- release Nutrient recovery without WAS P- release $830,000 $1,367,000 $29,980,000 $15,240,000 $1,062,000 $34,330,000 $12,100,000 $472,000 $16,500,000 $11,860,000 $824,000 $25,280,000

27 Nutrient Recovery Included to reduce phosphorus recycle to help achieve new, lower phosphorus effluent limits and mitigate nuisance struvite formation Estimated annual costs/revenue: Fertilizer revenue: 3.3 DT/day Magnesium chloride addition: $450,000/yr Caustic addition: $70,000/yr

28 Challenges and Opportunities Project became the most expensive in NEW Water s history Rate increases caused significant customer concern Able to implement many Utility of the Future concepts Changing Utility mindset from wastewater treatment to resource recovery

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48 Summary R2E2 was the most cost-effective alternative R2E2 will use AD followed by FBI to process biosolids Use of partial drying and cold windbox to enable autothermal FBI operation R2E2 will utilize recovered heat for heating and cooling applications R2E2 expected performance: Generate >60% GBF projected power in 2035 Generate up to 90% with natural gas addition to engines Accept high strength waste into AD System thermal efficiency will be about 40%

49 R2E2 Enabled Other Utility of the Future Decisions

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51 Photo credit: Steve Seilo April 2011

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65 Protecting our most valuable resource, water Tom Sigmund (920)