Energy Efficiency Projects for Aeration Systems:
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1 Energy Efficiency Projects for Aeration Systems: A Case Study of the Fox River Water Reclamation District James Kerrigan, P.E. Fox River Water Reclamation District Ryan Christopher, P.E. Greeley and Hansen Laurissa Cubbage, P.E. Greeley and Hansen
2 Presentation Topics Overview of Energy Usage at WRF Overview of the Fox River Water Reclamation District West WRF High Efficiency Aeration Improvements Albin D. Pagorski WRF Aeration System Improvements Grant Funding Availability Summary
3 Overview of Energy Usage at WRF AERATION 54.1% Source: Zahreddine, Phil, USEPA. Innovative Energy Conservation Measures at Wastewater Treatment Facilities. Power Point Presentation.
4 Fox River Water Reclamation District Provides wastewater treatment services to over 180,000 residents in service area (City of Elgin, Village of South Elgin) FRWRD treats average of 26 MGD across 3 WRFs North West Albin D. Pagorski
5 West Water Reclamation Facility Online in 2004 Design average flow 5.0 mgd Current average flow 3.1 mgd Designed for expansion up to 25 mgd
6 West WRF Aeration System Background 3 Existing Multi-Stage Centrifugal Blowers Blowers were oversized for low flow situations Excess air was sent to offline aeration tank Infrastructure Available for Denitrification Tanks setup for denitrification Equipment purchase required (mixers and recycle pump)
7 West WRF Existing Blower Room
8 West WRF Aeration Blower Technology Evaluation Comparison Between Turbo Blowers and Existing Equipment Energy efficiency Operation and maintenance costs Capital costs Payback period Option 1 New Turbo Blower, continue to send excess air to aeration tank Option 2 New Turbo Blower, no excess air Option 3 New Turbo Blower, no excess air and install denitrification
9 Air Flow Frequency Air Flow Frequencies 20.00% 18.00% 16.00% 14.00% Option 3 Option 2 Option % 10.00% 8.00% 6.00% 4.00% 2.00% 0.00%
10 Evaluation Recommendation Recommended Option 3 Install One 150 hp Turbo Blower and install pump and mixers to operate denitrification Total Construction Cost = $177,000 $30k in annual energy savings $153,318 grant was awarded from two agencies 87% of construction cost for project came from grants Payback reduced to under 1 year with grant funding
11 High Efficiency Aeration Blower Project
12 High Efficiency Aeration Blower Project
13 West Plant Blower Power Reduction Approx. 40% Reduction in Power Usage Old Blower Operation BNR Online New Blower Online
14 Albin D. Pagorski WRF Aeration System Improvements Albin D. Pagorski WRF Daily average flow 16.0 mgd Design average flow 25.0 mgd Peak flow 50 mgd Existing blowers were past useful life and have become maintenance intensive No D.O. Controls, labor intensive process New industrial load to plant with high BOD concentration
15 ADP Aeration System Efficiency Evaluation Comparison between existing equipment and new equipment Energy efficiency Operation and maintenance costs Capital costs Payback period Option 1 New Turbo Blowers Option 2 New Turbo Blowers with new diffusers Option 3 New Turbo Blower, with new diffusers and D.O. controls
16 Air Flow Frequencies Air Flow Frequency 20.00% 18.00% 16.00% New DO and Diffusers New Diffusers Only Existing Aeration System 14.00% 12.00% 10.00% 8.00% 6.00% 4.00% 2.00% 0.00%
17 ADP Aeration System Improvements Updated Plant Basis of Design Analyzed plant firm capacity, resulting reduction 27,000 scfm to 20,800 scfm Evaluated blower combinations New DO Control System Pressure Based Dual Loop Control Sequencing Minimizing WRF interruption
18 Air Flow, scfm Blower Combination Selected 30,000 28,000 26,000 Neuros 300 HP Option at Design Flow (25 mgd) with Fresh Express Peak Flow (0.80 mgd) (Dirunal Variations Shown by Dashed Lines) DAILY AVERAGE FLOW DAILY MAXIMUM FLOW, 40% ABOVE AVERAGE DAILY MINIMUM FLOW, 50% BELOW AVERAGE BLOWER RANGE 300HP: 2,353 to 5,369 scfm 24,000 22,000 Firm Capacity 20,000 18,000 Maximum Flow Envelope 4-300HP 16,000 14,000 12, HP 10,000 8, HP 6,000 4, HP 2,000 Minimum 0 Flow Envelope 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Percentile Frequency
19 ADP ASI Project Update $2.4 million construction cost 5 Turbo Blowers with associated electrical upgrades Dissolved oxygen control system Fine bubble diffusers (under separate contract) Substantial Completion April 2015 Final Completion May 2015 Grant Funding
20 ADP ASI Project Update
21 ADP ASI Project Update
22 ADP WRF Power Reduction Old Blowers Operation All New Blowers Online
23 Grant Funding Both projects received grant funding through ICECF and DCEO West WRF $45k from ICECF $108k from DCEO ADP Aeration System Improvements $208k from ICECF $612k from DCEO (Diffuser replacement required to receive full funding) Total Grant Funding $973k awarded to both projects
24 Summary Aeration system efficiency improvements can greatly reduce operational costs Grant funding is available to push projects that fight for funding with more conventional projects FRWRD Projected Annual Energy cost savings Total = $167,400 Simple Payback Under 10 years
25 Lessons learned Blower Manufacturer Differences Controls of blowers, valve operation Selected blower more cost effective even with slightly lower efficiency Integration Needs Careful Consideration Design to Include Staging of Demolition Staff Training Flow Meters New Check Valves
26 Questions Acknowledgments Fox River Water Reclamation District Bob Trueblood Beth Vogt Doug Haacker Dave Green Greeley and Hansen Andy Martin
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