Review of WEFTEC 2016 Challenge & Overview of 2017 Event. Malcolm Fabiyi, PhD, MBA Spencer Snowling, PhD. P.Eng

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1 Review of WEFTEC 2016 Challenge & Overview of 2017 Event Malcolm Fabiyi, PhD, MBA Spencer Snowling, PhD. P.Eng

2 Agenda Review 2016 Challenge Provide overview of updates to 2017 event

3 Frequency WEFTEC Scores 6 Distribution of Team Scores - WEFTEC Score (out of a maximum 1000 points)

4 WEF 2016 Operations Challenge Laboratory Safety Collections Maintenance Process Control

Operator friendly, and easy to use Tracks progress,

5 WEF Operations Challenge 2016 Simulator platform for WEF Operations Challenge Realistic, challenging scenarios Operator friendly, and easy to use Tracks progress, enables scoring WEF Operations Challenge: Simulation as a Process Skill

SimuWorks Layout 2 Clickable Diagram 1 4 3 5 6

6 SimuWorks Layout 2 Clickable Diagram Instructions Data input panel 7 Flyover panel 8 9 Simulation control

7 Instructions - Using the Simulator 1. Click on Unit Process in Plant Diagram 2. Make Changes (repeat for each unit process as necessary) 3. Click on Start 4. Observe Results Step 1: Click on Unit Process Above

8 Instructions - Using the Simulator 1. Click on Unit Process in Plant Diagram 2. Make Changes (repeat for each unit process as necessary) 3. Click on Start 4. Observe Results Step 2: Adjust s

9 Instructions - Using the Simulator 1. Click on Unit Process in Plant Diagram 2. Make Changes (repeat for each unit process as necessary) 3. Click on Start 4. Observe Results Step 3: Press Start

10 Instructions - Using the Simulator 1. Click on Unit Process in Plant Diagram 2. Make Changes (repeat for each unit process as necessary) 3. Click on Start 4. Observe Results Step 4: See Results

15 Questions Challenge 1: High Effluent COD (50 Points) Challenge 2: High Effluent BOD 5 and NH 4 (75 Points) Challenge 3: High TKN with Energy Limit (100 Points) Challenge 4: High Effluent TN in

11 15 Questions Challenge 1: High Effluent COD (50 Points) Challenge 2: High Effluent BOD 5 and NH 4 (75 Points) Challenge 3: High TKN with Energy Limit (100 Points) Challenge 4: High Effluent TN in Cold Weather (50 Points) Challenge 5: High Effluent TP (75 Points) Challenge 6: High BOD5, NH4 and Cold Temperature (50 Points) Challenge 7: High Total Nitrogen (TN) (75 Points) Challenge 8: Low SRT and MLSS (75 Points) Challenge 9: Energy and Chemical Cost Management (125 Points) Challenge 10: High-Strength Wastewater Treatment (50 Points) Challenge 11: SRT Control (75 Points) Challenge 12: Energy Management (75 Points) Challenge 13: Total Nitrogen Removal (50 Points) Challenge 14: Clarifier Maintenance (50 Points) Challenge 15: Cold Weather, No DO Controller (50 points)

12 Calculations Variable MLSS Calculation Solids concentration at the effluent from the aeration tank. mass of solids in bioreactor (Ibs) SRT SRT (days) = mass flow of waste activated sludge (Ibs/day) The dissolved oxygen (DO) concentration is reported from the end of the DO in Aeration Tank aeration tank. The total energy cost includes the following energy costs: Primary sludge pumping Aeration energy (blower power) Energy Cost Internal recycle pumping in aeration tank Recycled activated sludge (RAS) pumping Waste activated sludge (WAS) pumping The total chemical cost includes the following chemical costs: Primary ferric dosage for phosphorus removal Chemical Cost Secondary ferric dosage for phosphorus removal Methanol dosage for enhanced denitrification Sludge Production Sludge production is calculated as the solids concentration times the flow for all sludge (combined primary and secondary) being hauled from the gravity sludge thickeners.

13 Typical Operational s Units Low Range High Range MLSS mg/l 2,000 4,000 Food to Mass Ibs BOD/Ib SS/day SRT Days 2 10 Primary Clarifier Gals/ft 2.day 500 1,500 Hydraulic Loading Secondary Clarifier Hydraulic Loading Gals/ft 2.day

Challenge 1: High Effluent COD The WWTP starts with

14 Challenge 1: High Effluent COD The WWTP starts with low MLSS Effluent COD Dissolved Oxygen (DO) In Reactor < 20.0 mg/l mg/l SRT is reasonable at 5.4 days. 3 secondary clarifiers off-line. DO is clearly very low No ammonia removal despite reasonable SRT Solution Adjust aeration Add secondary clarification

Challenge 1: High Effluent COD Effluent COD Dissolved Oxygen (DO) In Reactor < 20.0 mg/l 1.0-3.

15 Challenge 1: High Effluent COD Effluent COD Dissolved Oxygen (DO) In Reactor < 20.0 mg/l mg/l The targets can be met by making any of the following changes: Challenge 1 Option 1 Option 2 Option 3 Aeration: DO (mg/l) 0.5, 0.5, 2, 2 2,2,2,2 Aeration: Flow (ft3/min) 2,000 Clarifiers Online 2 4 2

Challenge 2: High Effluent BOD 5 and NH 4 Effluent BOD 5 Effluent NH 4

One aeration tank is offline The influent loading is 4 MGD (15,100 m 3

16 Challenge 2: High Effluent BOD 5 and NH 4 Effluent BOD 5 Effluent NH 4 MLSS < 5.0 mg/l < 1.0 mg/l > 2000 mg/l In this case, the WWTP starts with a very low MLSS SRT is a bit low at 4 days. 3 of the 4 secondary clarifiers offline. One aeration tank is offline The influent loading is 4 MGD (15,100 m 3 /d). Solution Resolve DO issues Evaluate need to bring on aeration tank Evaluate need to bring on additional clarifiers Adjust WAS rate

17 Challenge 2: High Effluent BOD 5 and NH 4 Effluent BOD 5 Effluent NH 4 MLSS < 5.0 mg/l < 1.0 mg/l > 2000 mg/l The targets can be met by making any of the following changes: Challenge 2 Option 1 Option 2 Aeration: DO (mg/l) 2, 2, 2, 2 2,2,2,2 Aeration: Flow (ft3/min) Aeration Tank Online 1 2 WAS Pump Rate 52,835 25,000 Clarifiers Online 2 4

Challenge 3: High TKN with Energy Limit DO in Bioreactor MLSS Total Energy Usage

0 mg/l Influent flow has a higher flow rate and higher COD concentration than

The WWTP plant starts off with a very low MLSS and SRT DO concentration is very high at

18 Challenge 3: High TKN with Energy Limit DO in Bioreactor MLSS Total Energy Usage Effluent TKN mg/l > 2000 mg/l $/yr < 5.0 mg/l Influent flow has a higher flow rate and higher COD concentration than Challenges 1 and 2. The WWTP plant starts off with a very low MLSS and SRT DO concentration is very high at 7.7 mg/l. Note that the energy consumption is also exceeding the target of $130,000/yr. Solution Resolve DO issues Evaluate need to bring on aeration tank Evaluate need to bring on additional clarifiers

Challenge 3: High TKN with Energy Limit DO in Bioreactor MLSS Total Energy Usage Effluent TKN 1.0-2.5 mg/l > 2000 mg/l 130000 $/yr < 5.

19 Challenge 3: High TKN with Energy Limit DO in Bioreactor MLSS Total Energy Usage Effluent TKN mg/l > 2000 mg/l $/yr < 5.0 mg/l The targets can be met by making any of the following changes: Challenge 3 Option 1 Option 2 Aeration: DO (mg/l) 0.5, 0.5, 2, 2 Aeration: Flow (ft3/min) 3,000 Aeration Tanks Online 1 1 WAS Pump Rate 40,000 50,000 Clarifier Online 2 4

0 mg/l The influent flow and loading is similar to Challenge 3, but the liquid temperature at the WWTP

20 Challenge 4: High Effluent TN in Cold Weather Effluent BOD 5 Effluent Total Nitrogen (TN) < 5.0 mg/l < 6.0 mg/l The influent flow and loading is similar to Challenge 3, but the liquid temperature at the WWTP is now 53 F (12 C). Note that one of the targets is now total nitrogen (TN) requiring a setup for denitrification. Solution Bring all systems online Set DO levels to enable Nitrification and Denitrification

21 Challenge 4: High Effluent TN in Cold Weather Effluent BOD 5 < 5.0 mg/l Effluent Total Nitrogen (TN) < 6.0 mg/l The targets can be met by making any of the following changes: Challenge 4 Option 1 Option 2 Aeration: DO (mg/l) 0.5, 0.5, 2, 2 0, 2, 2, 2 Aeration: Flow (ft3/min) Aeration Tank Online 2 2 WAS Pump Rate 52, ,000 Internal Recycle (MGD) Clarifiers Online 4 4

22 Challenge 5: High Effluent TP Effluent TSS Effluent Total Phosphorus (TP) Chemical Dosage Cost < 8.0 mg/l < 1.0 mg/l < $65,000 /yr Influent flow and loading is similar to Challenge 4; the liquid temperature at the WWTP is 53 F (12 C). s now include Total Phosphorus (TP), which will require dosing ferric chloride Chemical dosage cost must be under $65,000/yr. Solution Bring all systems online Shut off methanol dosage Apply Ferric to Preliminary and Secondary dosage points

23 Challenge 5: High Effluent TP Effluent TSS Effluent Total Phosphorus (TP) Chemical Dosage Cost < 8.0 mg/l < 1.0 mg/l < $65,000 /yr The targets can be met by making any of the following changes: Challenge 5 Option 1 Option 2 Aeration: DO (mg/l) Aeration: Flow (ft3/min) Aeration Tanks Online 2 2 WAS Pump Rate Methanol Dosage Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifier Online 4 4

24 Challenge 6: High BOD 5, NH 4 and Cold Temperature Effluent BOD 5 Effluent NH 4 < 10 mg/l < 1.0 mg/l Similar to Challenge 5, the influent flow is 4 MGD (15,100 m 3 /d), with a slightly lower COD concentration and temperature of 53 F (12 C). Effluent targets of BOD 5 and NH 4 are not being met when the simulation starts. DO appears to be reasonable at about 1.3 mg/l Solution Bring all systems online Set DO levels to enable Nitrification and Denitrification Adjust Ferric dosage to make P available for bio-treatment

25 Challenge 6: High BOD 5, NH 4 and Cold Temperature Effluent BOD 5 Effluent NH 4 < 10 mg/l < 1.0 mg/l The targets can be met by making either of the following changes: Challenge 6 Option 1 Option 2 Aeration: DO (mg/l) 2,2,2,2 2,2,2,2 Aeration: Flow (ft3/min) Aeration Tanks Online 2 2 WAS Pump Rate Methanol Dosage Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric 1,200 0 Clarifiers Online 4 4

26 Challenge 7: High Total Nitrogen (TN) Total Nitrogen (TN) Chemical Dosage Cost < 8.0 mg/l < 100,000 $/yr Influent is 2.2 MGD (8,300 m 3 /d) at a temperature of 75 F (24 C) Relatively low influent COD of 300 mg/l, but a high influent ammonia of 37 mg/l. The target is for Total Nitrogen removal, so denitrification will be required. The WWTP plant starts off with a very low MLSS and SRT. Solution Bring all systems online Set Aeration levels to enable Nitrification and Denitrification Adjust methanol to reduce cost Adjust WAS to enhance SRT Adjust Internal Recycle

27 Challenge 7: High Total Nitrogen (TN) Total Nitrogen (TN) Chemical Dosage Cost < 8.0 mg/l < 100,000 $/yr The targets can be met by making either of the following changes: Challenge 7 Option 1 Option 2 Aeration: DO (mg/l) 0, 2,2,2 Aeration: Flow (ft3/min) 2,000 Aeration Tanks Online 2 2 WAS Pump Rate (gpd) 50, ,000 Methanol Dosage (gpd) Internal Recycle (MGD) 5 Primary Ferric (Ib Me/day) Secondary Ferric Clarifiers Online 4 4

28 Challenge 8: Low SRT and MLSS Mixed Liquor Suspended Solids (MLSS) SRT Effluent TSS > 2500 mg/l 6-12 days < 10.0 mg/l Influent flow is 5 MGD (18,900 m 3 /d). The concentrations and temperature have been reset to their defaults. WWTP starts out with a reasonable MLSS of ~2,000 mg/l and SRT of 5.4 days. Solution Bring all systems online Adjust aeration settings Adjust WAS rate

29 Challenge 8: Low SRT and MLSS Mixed Liquor Suspended Solids (MLSS) SRT Effluent TSS > 2500 mg/l 6-12 days < 10.0 mg/l The targets can be met by making either of the following changes: Challenge 8 Option 1 Option 2 Aeration: DO (mg/l) 2,2,2,2 Aeration: Flow (ft3/min) 1,500 Aeration Tanks Online 2 2 WAS Pump Rate (gpd) 40,000 25,000 Methanol Dosage (gpd) Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifier Online 4 4

Challenge 9: Low SRT and MLSS Effluent TSS Effluent TKN Effluent Total Phosphorus (TP) <

0 mg/l Energy Cost < $175,000 Chemical Dosage Cost < $65,000 Influent flow is the same

energy and chemical cost. WWTP start with low MLSS and SRT, and several units off-line.

30 Challenge 9: Low SRT and MLSS Effluent TSS Effluent TKN Effluent Total Phosphorus (TP) < 10.0 mg/l < 5.0 mg/l < 1.0 mg/l Energy Cost < $175,000 Chemical Dosage Cost < $65,000 Influent flow is the same as Challenge 8 However there are now 5 target conditions, including limits on both energy and chemical cost. WWTP start with low MLSS and SRT, and several units off-line. The DO in the aeration basin is higher than normal at 7.5 mg/l. Solution Bring all systems online Adjust aeration settings Adjust WAS rate Adjust Ferric dosage

31 Challenge 9: Low SRT and MLSS Effluent TSS Effluent TKN Effluent Total Phosphorus (TP) < 10.0 mg/l < 5.0 mg/l < 1.0 mg/l Energy Cost < $175,000 Chemical Dosage Cost < $65,000 The targets can be met by making either of the following changes: Challenge 9 Option 1 Option 2 Aeration: DO (mg/l) 0.5, 0.5, 0.5, 0.5 Aeration: Flow (ft3/min) 5,000 Aeration Tanks Online 2 2 WAS Pump Rate 70,000 65,000 Methanol Dosage Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifiers Online 4 4

Challenge 10: High-Strength Wastewater Treatment Effluent COD Airflow to Aeration Tanks < 130.

32 Challenge 10: High-Strength Wastewater Treatment Effluent COD Airflow to Aeration Tanks < mg/l < 3500 ft3/min (2375 m3/hr) Influent COD concentration is 750 mg/l, reflecting some high-strength waste in the influent. Influent flow rate is 5 MGD (18,900 m 3 /d), as in Challenge 8. All available reactors and clarifiers are already on-line. The targets include both the effluent COD as well as the airflow rate in the aeration tank. Solution Adjust aeration settings Adjust Ferric dosage Adjust WAS rate

33 Challenge 10: High-Strength Wastewater Treatment Effluent COD Airflow to Aeration Tanks < mg/l < 3500 ft3/min (2375 m3/hr) The targets can be met by making either of the following changes: Challenge 10 Option 1 Option 2 Aeration: DO (mg/l) Aeration: Flow (ft3/min) 3,400 3,500 Aeration Tank Online WAS Pump Rate 80,000 50,000 Methanol Dosage Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifier Online

Challenge 11: SRT Control BOD 5 SRT Effluent Soluble Ortho- Phosphorus <

1 mg/l Influent is 4 MGD (15,100 m 3 /d), with a COD concentration of 520

The goal is to achieve a SRT of 6 to 8 days, while also meeting the BOD5

34 Challenge 11: SRT Control BOD 5 SRT Effluent Soluble Ortho- Phosphorus < 7.0 mg/l 6-8 days < 0.1 mg/l Influent is 4 MGD (15,100 m 3 /d), with a COD concentration of 520 mg/l at 72 F (22 C). The plant starts with a very low MLSS. The goal is to achieve a SRT of 6 to 8 days, while also meeting the BOD5 and soluble phosphorus targets. Solution Bring clarifiers online Set DO control at default values Adjust sludge wastage Adjust Ferric dosage

35 Challenge 11: SRT Control BOD 5 SRT Effluent Soluble Ortho- Phosphorus < 7.0 mg/l 6-8 days < 0.1 mg/l The targets can be met by making either of the following changes: Challenge 11 Option 1 Option 2 Aeration: DO (mg/l) 0.5, 0.5, 0.5, 0.5 2,2,2,2 Aeration: Flow (ft3/min) Aeration Tank Online WAS Pump Rate 65,000 75,000 Methanol Dosage Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifier Online 4 4

Challenge 12: Energy Management BOD 5 TKN Total Energy Cost < 10.0 mg/l < 3.

mg/l), and the temperature is 53 F (12 C).

36 Challenge 12: Energy Management BOD 5 TKN Total Energy Cost < 10.0 mg/l < 3.0 mg/l < $190,000/yr Influent loading is very high (flow = 6 MGD, COD = 520 mg/l), and the temperature is 53 F (12 C). Simulation starts with very low MLSS and SRT, with a high DO of 4.7 mg/l in the aeration basin. s require BOD 5 removal and full nitrification, while keeping the total energy expenditure below $190,000. Solution Bring all systems online Adjust aeration Adjust sludge wastage Adjust RAS flow

37 Challenge 12: Energy Management BOD 5 TKN Total Energy Cost < 10.0 mg/l < 3.0 mg/l < $190,000/yr The targets can be met by making either of the following changes: Challenge 12 Option 1 Option 2 Aeration: DO (mg/l) Aeration: Flow (ft3/min) 4,500 4,450 Aeration Tank Online 2 2 WAS Pump Rate (gpd) 170, ,000 Methanol Dosage RAS Pump Rate (MGD) 4 5 Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifier Online 4 4

Challenge 13: Total Nitrogen Removal Total Nitrogen (TN) Total Chemical

0 mg/l < $75,000/yr Influent flow is 8 MGD, with an ammonia concentration

The Total Nitrogen effluent target of 10 mg/l requires full nitrification

38 Challenge 13: Total Nitrogen Removal Total Nitrogen (TN) Total Chemical Cost < 10.0 mg/l < $75,000/yr Influent flow is 8 MGD, with an ammonia concentration of 40 mg/l. The Total Nitrogen effluent target of 10 mg/l requires full nitrification and denitrification. The simulation starts with a low MLSS and SRT. Solution Bring all systems online Adjust aeration Adjust internal recycle Adjust sludge wastage Adjust RAS flow Adjust methanol dosage

39 Challenge 13: Energy Management Total Nitrogen (TN) Total Chemical Cost < 10.0 mg/l < $75,000/yr The targets can be met by making either of the following changes: Challenge 13 Option 1 Option 2 Aeration: DO (mg/l) 0, 2, 2, 2 0.5, 0.5, 0.5, 0.5 Aeration: Flow (ft3/min) Aeration Tanks Online 2 1 WAS Pump Rate (gpd) 180,000 Methanol Dosage (gpd) Internal Recycle (MGD) RAS (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifiers Online 4 4

Challenge 14: Clarifier Maintenance BOD 5 MLSS < 7.

of service for maintenance & cannot be put back in service.

2 MGD, with default influent characterizations.

40 Challenge 14: Clarifier Maintenance BOD 5 MLSS < 7.0 mg/l > 3000 mg/l Two of the secondary clarifiers are out of service for maintenance & cannot be put back in service. Influent flow is 2.2 MGD, with default influent characterizations. The simulation starts with a very low MLSS of 704 mg/l. Solution Bring one clarifier online Adjust aeration Adjust sludge wastage

41 Challenge 14: Clarifier Maintenance BOD 5 MLSS < 7.0 mg/l > 3000 mg/l The targets can be met by making either of the following changes: Challenge 14 Option 1 Option 2 Aeration: DO (mg/l) 2,2,2,2 2,2,2,2 Aeration: Flow (ft3/min) Aeration Tank Online 1 1 WAS Pump Rate 4,000 5,500 Methanol Dosage RAS (MGD) 1.4 Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifier Online 2

Challenge 15: Cold Weather, No DO Controller SRT Dissolved Oxygen (DO) in Aeration Tank 10-12 days 1.0-3.

temperature of 53 F (12 C). Note that in this question, the DO Controller option is not available.

42 Challenge 15: Cold Weather, No DO Controller SRT Dissolved Oxygen (DO) in Aeration Tank days mg/l Influent flow is 4 MGD (15,100 m 3 /d) with a relatively high COD concentration of 520 mg/l, and temperature of 53 F (12 C). Note that in this question, the DO Controller option is not available. The simulation starts with a low MLSS and DO concentration in the aeration tank. Solution Adjust aeration Adjust sludge wastage

43 Challenge 15: Cold Weather, No DO Controller SRT Dissolved Oxygen (DO) in Aeration Tank days mg/l The targets can be met by making either of the following changes: Challenge 15 Option 1 Option 2 Aeration: DO (mg/l) Aeration: Flow (ft3/min) 3,600 4,000 Aeration Tank Online WAS Pump Rate (gpd) 40,000 45,000 Methanol Dosage Internal Recycle (MGD) Primary Ferric (Ib Me/day) Secondary Ferric Clarifiers Online 1 4

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Virtual Plant Training Manual Introduction to Simulator Based Operator Training

Virtual Plant Training Manual Introduction to Simulator Based Operator Training Hydromantis ESS, Inc. 6 March 2017 1 Table of Contents Preface... 6 Chapter 1: Introduction to the Activated Sludge Wastewater