QUINCY 1WATER UTILITY TDS CONTROL. Lloyd Emil Voges Brown and Caldwell 701 Pike St. Suite 1200 Seattle, WA
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1 QUINCY 1WATER UTILITY TDS CONTROL Lloyd Emil Voges Brown and Caldwell 701 Pike St. Suite 1200 Seattle, WA Abstract The city of Quincy, Washington has an industrial base that includes food processors and data centers (computer server farms). Facing water supply stress, permit changes, and industrial growth, the City is developing the new Q1W Utility that will integrate its industrial and municipal wastewater treatment systems. At the core of the utility are new membrane ultrafiltration and reverse osmosis treatment systems to control total dissolved solids in the reused water. The ultrafiltration system will be used to meet the Washington standards for production of Class A reclaimed water as well as provide pretreatment for the downstream water softener and reverse osmosis systems. Approximately 60 to 65 percent of the ultrafiltered stream will be treated with reverse osmosis to reduce total dissolved solids from a range of 1,300 to 1,400 mg/l to a range of 500 to 600 mg/l for uses such as crop irrigation and groundwater percolation. The Q1W will optimize the benefits of water reclamation and reuse using industrial and municipal wastewater and groundwater to create a system of near-zero environmental discharge and a sustainable water supply for the City s future. It will apply innovative solutions using existing infrastructure to minimize construction costs and stranded assets. 1
2 Introduction The city of Quincy (City) is located in eastern Washington (see vicinity map and inset in Figure 1-1). Its industrial base includes major food processors and data centers (computer server farms). Facing declining water supply, permit changes, and industrial growth, the City is developing a new utility that will integrate its industrial and municipal wastewater treatment systems; it is called the Quincy 1Water Utility (Q1W). The Q1W will optimize the benefits of water reclamation and reuse using industrial and municipal wastewater and groundwater to create a system of near-zero environmental discharge and a sustainable water supply for the City s future. It will apply innovative solutions using existing infrastructure to minimize construction costs and stranded assets. A process flow diagram illustrating how the Q1W will operate is provided in Figure 1-2. QUINCY QUINCY Figure 1-1. Vicinity map 2
3 Figure 1-2. Q1W process flow diagram The multiple activities needed to develop the Q1W include expanding the percolation beds located adjacent to the municipal water reclamation facility (MWRF), increasing capacity at the MWRF to accommodate increasing flows and loads from residential growth, constructing a conveyance system to deliver reclaimed water to a new crop production area north of the city, modifying and expanding components of the industrial wastewater treatment plant (IWTP) and industrial reuse water treatment plant (IRWTP), and installing an aquifer injection well for aquifer recharge. The general locations of these activities are shown in Figure 1-3. These major activities have been grouped into the following five projects. 1. Percolation Expansion 2. MWRF Capacity Upgrade 3. Crop Production 4. IRWTP (Demineralization via reverse osmosis treatment) 5. Aquifer Injection 3
4 Crop Production Area Existing Major Conveyance Corridors Future Major Conveyance Corridor Crop Production Pipeline Estimated Location of Aquifer Injection Well IRWTP Components: -Reverse Osmosis -Water Softeners -Ultrafilters IWTP Headworks MWRF Percolation IWTP Percolation Expansion Figure 1-3. Location of major Q1W activities and components 4
5 This paper describes the core activities needed to develop the Q1W. Section 1 provides a background of the Q1W, including terminology and a summary of the existing systems. Section 2 provides summary descriptions of the major activities. Section 3 provides a discussion of the water balance conducted to evaluate the Q1W system components. Section 4 provides a schedule. 1.1 Background The City serves as an agricultural processing hub for Grant County, Washington, and the surrounding area. Food crops are processed and packaged for distribution at two major food processors located in Quincy. In addition to the MWRF for domestic wastewater, the City operates an IWTP to service food processing and other industries located in Quincy. The IWTP is currently permitted to discharge to an irrigation drainage ditch, or wasteway, under Washington State Department of Ecology (Ecology) National Pollutant Discharge Elimination System (NPDES) Waste Discharge Permit WA Wasteway operation and use is regulated by the United States Bureau of Reclamation (USBR). The City s agreement with USBR for use of the wasteway will expire in September Because of this permitting challenge, the City has been actively working toward developing the Q1W, and has conducted multiple studies and investigations to evaluate and ultimately determine the optimal components that will compose the Q1W. A complete list of these studies and investigations is provided in Appendix A. 1.2 Reuse Water Terminology The term reuse water is used throughout this Paper. This term is defined as water treated for beneficial reuse, and is distinguished from a system that includes disposal of effluent to receiving water or to land disposal. Reuse water includes both reclaimed water and industrial reuse water. Reclaimed water is water generated from the treatment of sanitary wastewater at the MWRF, which treats to the State of Washington s Class A reclaimed water standards. Lower classes (Classes B, C, and D) will not be produced within the Q1W. Reclaimed water use will be limited to crop production/ irrigation and groundwater recharge via percolation. Class A reclaimed water for indirect groundwater recharge via percolation at the percolation beds, which is currently produced using coagulation and filtration, is treated to meet nitrogen limits and is disinfected using ultraviolet treatment. Industrial reuse water is IWTP effluent that will be further treated using coagulation and filtration. Industrial reuse water will be treated to match the standards for reclaimed water, but the wastewater source does not have a sanitary component. Because of the presence of a high concentration of total dissolved solids (TDS), the TDS will be reduced where the usage requires it. Specifically, TDS must be controlled to provide for antidegradation of groundwater. TDS will be controlled for percolation and crop production using reclaimed water by blending with a portion of demineralized industrial reuse water. TDS in water that is directly injected to groundwater will be reduced via partial (side-stream) demineralization using reverse osmosis (RO). 5
6 1.3 Existing System The City currently operates four water and wastewater utilities (municipal wastewater, industrial wastewater, industrial reuse water, and potable water), each of which is an independent system individually permitted and with separate operating funds. Conveyance infrastructure creates partial interties between the industrial and municipal wastewater systems. Figure 1-4 provides the locations of the City s existing wastewater and reuse water facilities. Summaries of the utilities are provided below. Municipal Wastewater. The municipal wastewater utility serves the City s residential customers. A number of industrial users also discharge industrial wastewater to this utility. The utility includes the collection system and the MWRF. The MWRF consists of sequencing batch reactors (SBRs), sand filters, and disinfection using ultraviolet radiation to produce Class A reclaimed water. Reclaimed water is percolated at infiltration beds. There is also a winter storage area for Class A reclaimed water. Industrial Wastewater. The industrial wastewater utility serves two major food processors and includes primary clarifiers, an influent pump station, the IWTP, and the wasteway outfall. The primary clarifiers are located approximately 1 mile north from the IWTP. They formerly provided primary treatment to food processor wastewater, but were replaced when the IWTP was upgraded in 2011 and are now used for redundancy only. An influent pump station is located at the primary clarifier site. The pump station discharges to the IWTP, which includes a covered anaerobic predigestion lagoon, SBRs, equalization (EQ), and tertiary treatment (chlorine disinfection, reaeration, temperature control, and dechlorination). The IWTP also includes sludge storage lagoons. Two double-lined brine evaporation lagoons with leak detection are located at the IWTP, but are a distinct process. They are not connected to the IWTP processes and have no discharge. Industrial Reuse Water. The industrial reuse water utility softens water for industrial use in cooling towers by some of the major industries and consists of several components that make up the IRWTP. The major existing components of this utility include SBR effluent clarifier, filter building, water softener building, and ion exchange (IX) facility to demineralize cooling water. The existing utility currently uses potable water; however, future uses include treating reclaimed and reuse water. The IRWTP also includes two evaporation lagoons for softener brine. Potable Water. The potable water utility supplies potable water to the City s residential and commercial customers. It is also either the primary or backup water supply to a number of major industrial users. Interconnecting Infrastructure. The City s treatment unit processes are linked by a network of piping and conveyance infrastructure, as shown in Figure 1-3. Components of this existing infrastructure include: A 12-inch-diameter pipeline connecting components of the IRWTP to the MWRF. An industrial wastewater pipeline, with 8- and 10-inch-diameter pipes, beginning at the Microsoft Columbia Data Center and terminating at the IWTP brine ponds. The pipeline is used to convey brine between components of the IRWTP and IWTP lagoons in a batch manner. An 18-inch-diameter pipeline from the SBRs at the IWTP to components of the IRWTP, constructed to deliver IWTP secondary effluent to the IRWTP for treatment and eventual use as industrial reuse water. 6
7 Solids Handling Reverse Osmosis Building Primary Clarifiers Brine Lagoons Influent Pump Station IWTP Headworks Industrial Reuse Water Treatment Plant Lagoon 5 (full/in use) SBRs SBR Decant Equalization Lagoon 6 (empty/unused) Anaerobic Lagoon Waste Sludge Lagoons Reed Beds Brine Lagoons Industrial Wastewater Treatment Plant Treatment Systems Percolation Bed Area Municipal Water Reclamation Facility Winter Percolation and Storage Area Figure 1-4. City s existing wastewater and reuse water facilities 7
8 Section 2 Q1W System Projects The objectives of the Q1W are to manage industrial and municipal wastewater treatment capacity to ensure a sufficient level of service for current and future customers, reduce reliance on groundwater supplies by maximizing the use of reclaimed and industrial reuse water, and replenishing groundwater supplies through recharge and direct aquifer injection. This approach will increase the interdependency of the City s four utilities, eventually creating a nearly closedloop regional water cycle, as shown in the process flow diagram, Figure 1-2. This section provides a summary of the multiple activities and projects that will be conducted to develop the various components of the Q1W. 2.1 Percolation Expansion The Percolation Expansion project includes adding a percolation cell to the existing percolation cell system located adjacent to the MWRF, as shown in Figure 2-1. This project will allow the percolation system to accommodate increased flows from the MWRF reclaimed water system and the IRWTP reuse water system. Design of the percolation bed expansion is intended to increase the bed capacity to approximately 2.0 million gallons per day (mgd) or more during the 4-month non-growing period. Water percolated at the percolation beds will meet Class A reclaimed water standards of 10 milligrams per liter (mg/l) biochemical oxygen demand (BOD), 15 mg/l total suspended solids (TSS), and 2 nephelometric turbidity units (NTU) average/5 NTU maximum turbidity. The annual average TDS concentration will be limited to provide for antidegradation of groundwater TDS. However, TDS of percolated water is expected to fluctuate on a monthly basis depending on the proportions of Class A reclaimed and industrial reuse water. 2.2 MWRF Capacity Upgrade In response to wastewater influent flow and load conditions that are approaching the MWRF s rated capacity, the City has been evaluating modification options to achieve a capacity expansion. As of the preparation of this Paper, recommended modifications are not known, but the expansion will likely result in an increased flow rating in the MWRF permit. Although the MWRF receives industrial discharge that will be eventually rerouted to the IWTP, the recent increases in flow and load are also attributable to residential discharge that is above that projected by the sanitary sewer plan. The sewer plan will thus be updated and that plan s flow projections will be incorporated into the Q1W water balance and the percolation and crop receiving capacities will be evaluated accordingly. Due to the current high flow and load conditions, the MWRF expansion needs to occur as soon as feasible. 8
9 Q1W Plan Section 2 Existing Percolation Cells P Road NW Existing Winter Storage Areas New Percolation Cell Figure 2-1. Location of Percolation Expansion project 2.3 TDS Monitoring A number of industrial users with the potential to discharge high-tds industrial wastewater are connected to the municipal and industrial collection systems. In response to high-tds discharges to the system, the City has enacted a high-tds wastewater ordinance, termed the brine ordinance. To monitor and control discharges from these users, the City will install continuous monitoring stations downstream of the users at the connection point to the collection system. The stations will consist of a monitoring manhole, flow and conductivity monitoring instruments, telemetry equipment, and a power supply. Sampling by the City will develop a relationship between TDS and conductivity for each user, so that continuous conductivity measurements can be used to estimate TDS from conductivity. 2.4 Crop Production The Crop Production project entails the construction of a pump station and pipeline that will convey reclaimed water 2 miles north of the city to the crop production area, as shown in Figure 2-2. The City is currently working with farmers on potential crop production land to determine the number of acres that will be included in this project. Previous studies have identified 350 to 650 acres of available land for forage crop production that currently does not already have available water supply. 9
10 Q1W Plan Section 2 Using this range of potentially available crop production acreage, water demands were calculated in order to evaluate the feasibility of this Crop Production project. Water demand during the growing season (March through October) is calculated to be 1.4 mgd average for 350 acres and 2.7 mgd average for 650 acres. Peak demand, which will occur during the hottest days of the summer, is expected to be 2.2 mgd for 350 acres and 3.7 mgd for 650 acres. Conveying water to the crop production area will require approximately 3 miles of force main and a pump station. The pipeline will terminate at an EQ pond, at which point the farmers will withdraw water. Prior to construction of the pipeline, casings will be installed under USBR canals at the locations where the pipeline will cross canals. This will facilitate efficient construction of the pipeline. The pump station and pipeline will convey reclaimed water with a TDS limit of a nominal 500 mg/l to protect soil quality. At minimum, water will meet Class A reclaimed water standards requirements of 30 mg/l BOD, 30 mg/l TSS, and 2 NTU average/5 NTU maximum turbidity. Additionally, BOD, total nitrogen, and nitrates will be limited by agronomic loading rates, unless more stringent parameters are required for one of the other beneficial uses. Future Crop Production Areas Existing Major Conveyance Corridors Future Major Conveyance Corridor Approximate Location of EQ Pond Future Crop Production Pipeline Future Crop Production Pumping Figure 2-2. Location of Crop Production project 10
11 Q1W Plan Section IRWTP Several components of the IRWTP currently exist, including an available abandoned clarifier, filter building, water softening building (WSB), and RO building. To develop the Q1W, however, several components of the IRWTP will be either added or modified in order to treat the IWTP secondary effluent to various end-user water quality needs. As shown in the process flow diagram, Figure 1-2, the IWTP and IRWTP can incorporate selective treatment applications on various quantities of the wastewater stream depending on the intended end use of the wastewater. As shown in Figure 2-1, all of the wastewater that gets treated at the IWTP will go through filtration. A portion of the filtered water can then go through softening. Water that is softened can be conveyed to industries for use in cooling towers. The remaining softened water can then be demineralized via RO. This demineralized water can be blended with filtered water to meet Class A standards for subsequent use at the percolation beds for groundwater recharge, for use on the crop production, or for aquifer injection. This demineralized water can also be conveyed to other industries to offset groundwater demand; this water can be used by the food processors and other industries. TDS limits for the various reuse water uses will range from 400 to 600 mg/l. The current industrial effluent contain 1,300 to 1,400 mg/l of TDS Cover SBR Effluent Equalization Basin The existing SBR effluent EQ basin is open to the air (Figure 2-3). To upgrade the basin for use with the Q1W IRWTP system, the basin will be covered to prevent dust intrusion and algae growth. Flow routing modifications may also be incorporated. IWTP Tertiary Treatment Components SBR Effluent Equalization Basin Figure 2-3. Location of SBR effluent EQ basin and IWTP tertiary treatment components 11
12 Q1W Plan Section IRWTP Filter Feed Pump Station The IRWTP filters (described below) will be installed at the former IWTP primary clarifier site (Figure 2-4). The flow to the filters will have an average flow rate of 2.3 mgd. To convey flowequalized SBR effluent to the IRWTP filters, a pump station will be constructed at the SBR effluent EQ basin. The pipeline for the SBR effluent is an existing, 18-inch-diameter highdensity polyethylene (HDPE) pipe. Former IWTP Primary Clarifier Site Solids Handling Filter Building Figure 2-4. Location of former IWTP primary clarifier site and filter building IRWTP Filter Installation IRWTP filters will be installed in an existing building, herein referred to as the filter building, at the former IWTP primary clarifier site and will treat SBR biological process effluent, as shown in Figure 2-4. The primary purpose of the IRWTP filters is to provide pretreatment for both softening and RO treatment. The primary parameter of concern is TSS. All of the SBR effluent will be filtered Primary Clarifier Modification One of the former IWTP primary clarifiers will be converted for use as part of the filtration system, and will be used to settle solids prior to filtration (Figure 2-4). Anticipated work includes the addition of a chemical coagulant handling system Reverse Osmosis Installation An RO unit will be installed in the WSB, located adjacent to the brine lagoons (Figure 2-5). The WSB currently houses the IX system, which will be replaced by the RO unit. 12
13 Q1W Plan Section 2 The RO system will provide additional treatment to reduce TDS to a portion of the industrial reuse water produced by the IRWTP filters. Microsoft, as well as other potential future industrial reuse water customers, do not require reduced TDS and can use filtered SBR effluent directly. However, for beneficial uses that potentially put industrial reuse water in contact with groundwater, it is expected that TDS reduction will be a regulatory requirement. These uses include aquifer recharge via percolation, crop production, and aquifer injection. It is expected that full demineralization is not required for these beneficial uses. The planningbasis target water quality criterion for TDS is 500 mg/l, which is consistent with state drinking water standards and would comply with state antidegradation standards. Based on these parameters, and a crop production area range of 350 to 650 acres, the RO system is currently being designed with a flow rate between 1.2 and 1.7 mgd. Water Softening Building Brine Ponds Figure 2-5. Location of RO site (WSB) Decommission IWTP Tertiary Treatment The existing IWTP tertiary treatment system consists of chlorination disinfection, temperature control (used to meet summer effluent temperature limits), dechlorination, and reaeration. Each of these unit processes is used to meet surface water discharge standards and will no longer be necessary following the transition to the Q1W system. Each of these unit processes, identified as IWTP Tertiary Treatment Components in Figure 2-3, will be decommissioned. 13
14 Q1W Plan Section Aquifer Injection A part of the plan is to develop an Aquifer Injection program that will also provide the framework for eventual development of an aquifer storage and recovery (ASR) program. This project was developed to provide a viable alternative for discharging excess treated water that may not otherwise be able to be applied to crop production, percolation, or industrial reuse. The City is currently in the process of conducting the hydrogeologic, engineering, and permitting work necessary to complete this project. An approximate location of the aquifer injection well is provided in Figure 2-6. The City will focus its Aquifer Injection program on the Wanapum and/or Grande Ronde basalt formations. While the City does not currently have a need to recover water discharged to aquifer storage, as the generator of the reuse water, the City has the right to the water until it commingles with groundwater of the state. To help the City maintain the ability to legally recover water discharged to aquifer storage, the intent to recover the water must be demonstrated from the outset of the program. Figure 2-6. Location of proposed aquifer injection well 14
15 Section 3 Water Balance A water balance was developed to demonstrate feasible reuse water distribution coordination across multiple Q1W water uses. The water balance includes all of the system components shown in Figure 1-2 and considers the individual inflow and outflow volumes of each component, including water quality constituents. These Q1W projects (Section 2) and their capacity requirements are being developed within the constraints of the master water balance while modeling several scenarios that use varying flow rates depending on the overall Q1W program. For example, scenarios have been developed that assume varying amounts of acres that will be included in the Crop Production project. The water balance assumes the following key average system annual inflow and outflow conditions, as illustrated in Figures 3-1 and 3-2: Inflows: Average IWTP influent flow rate of 2.3 mgd (this value is 10 percent above the current average inflow rate of 2.1 mgd, to account for growth) Average MWRF effluent flow rate of 1.1 mgd, with plans for an increased flow rating Outflows: Crop production area on the order of 450 acres requiring an average of 1.8 mgd between the growing-season months of March through October Average reuse water flow of 0.5 mgd to industries for cooling tower use 2.0 mgd per month in the non-growing season (November through February) sent to the percolation beds (note that the Percolation Expansion component of the Q1W is expected to increase the capacity of the percolation beds to 2.0; they currently have an assumed rating of 1.54 mgd to match the MWRF permit but have an actual capacity closer to 1.1 mgd) Average reuse water outflow of 0.5 mgd to the aquifer via aquifer injection Average reuse water outflow of 0.3 mgd to the food processors for other industrial use Approximately 1.4 mgd of water treated with RO Average unavoidable outflows due to losses from the anaerobic lagoon waste activated sludge and evaporation and seepage at the SBRs and EQ basin is approximately 0.1 mgd 15
16 3.50 Inflows 3.00 Average Flow (MGD) IWTP Influent (Planning) MWRF Effluent Figure 3-1. System influent flows 3.00 Outflows, including system losses 2.50 Average Flow (MGD) Irrigation Water Aquifer Injection MWRF Percolation Industrial (Cooling Tower) Reuse IWTP Uavoidable Discharge Figure 3-2. System effluent flows and losses 16
17 Section 4 Schedule The City is actively working on various aspects of these projects and is working with the applicable regulators and stakeholders to see the projects completed successfully. As discussed in Section 1, this document was developed as a guide for understanding the multiple elements of the projects. The City has met with the primary regulator, Ecology, to discuss the permitting process that the City will undergo to develop the Q1W and to identify the major reports that would need to be submitted. Based on the City s current understanding, the following engineering reports will be developed on behalf of the major Q1W projects and submitted to Ecology: 1. Percolation Expansion 2. MWRF Capacity Upgrade 3. Crop Production 4. IRWTP 5. Aquifer Injection Note that the TDS Monitoring project is not considered as a key component of the Q1W. In discussions that the City has had with Ecology to date, Ecology recommends that one master permit be developed for the Q1W, herein referred to as the Q1W Permit, which will be iteratively updated as each report is approved. As such, an overall understanding of the Q1W planning is essential to establishing a framework for obtaining regulatory approvals for the individual project components. Regulatory coordination will be multi-track for the different end uses, corresponding to the project groups described above. The estimated completion dates for each project are as follows. Percolation expansion permitted and operating: February 2017 MWRF capacity upgrade: mid 2016 Crop production in operation: Spring 2017 IRWTP filters and RO: Winter 2017 Aquifer injection:
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