Exploring the Marketability and Beneficial Use of BioSolids

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Brianne Cooper
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1 Exploring the Marketability and Beneficial Use of BioSolids

2 City of Midland Background City of Midland owns and operates POTW and Landfill (compost facility) Residual management program Approved sub surface land app. Class B / Class A compost(winter belt press) WWTP (2).5MG prim dig. (1) 1.0 MG sec. dig. /1MG bio holding /belt filter press

3 Bio-solid Recycling and Beneficial use Bio-solids can be beneficial to soils and plants Improved soil physical properties are the results of the addition of organic matter and plant nutrients

4 What are Bio-solids Bio-solids are mostly organic solids resulting from the treatment of wastewater that has undergone treatment to kill pathogens and have been approved by EPA for land application as a fertilizer and soil supplement

5 Class A and Class B Bio-solids Bio-solids can be in several forms including liquid, dried or pellet form or compost Any bio-solids used on land application should be described by the degree of stabilization. Michigan recognizes 2 levels of sludge stabilization; labeling as Class A and B biosolids Liquid application to farm fields is the most widely used application process in the U.S.

6 Regulations EPA 40 CFR 503 Regulations Michigan Administrative Rule Part 24 All Bio-solids require pathogen reduction, pollutant and nutrient analytical Facilities that land apply in Michigan are permitted by MDEQ to recycle class A and B bio-solids Annual reports are required by MDEQ

7 Could we market biosolids as a product? Could we sell? Should we sell? How would we sell? Class A or B? Liquid or dry? Liability? Could we market as a fertilizer? Soil Amendment? Could we bid out to farmers? Landscape Co.? Could we provide Service? Can we recover our cost of land application? Could we maintain budget?

8 Midland WWTP Class A Bio-solid Recycling Midland s class A EQ bio-solid is derived from the liquid class B product but is further processed by dewatering and composting. In 2005 RMP modification approved by MDEQ composting bio-solids and yard clippings, and distribution of such product as a soil amendment we researched the viability of this product for use in the agricultural industry and future use in the landscaping industry.

9 Midland Composted Bio-solids Process Class A bio-solids are produced by dewatering the digested solids then blending with wood chips and leaves and composted at city landfill. The composting process takes approx. 16 weeks to accomplish during the summer months.

10 MCB Process The blended material is windrowed to manage the biological process Windrows are turn by the landfill staff on a routine basis to help aerate the process Temperatures of the windrows are monitored to verify the biological process

11 MCB Process Upon achieving the optimum temperature of 130 degrees (approx. 10 weeks weather dependent) staff continues temperature monitoring and turning of the windrows After 2 weeks of optimum temps the windrows remain idle

12 MCB Process After composting staff rough screens and sample the product to verify Class A EQ compost. The class A product has been used in city flower bed, golf course and ground restoration projects. Staff performed a demonstration project for amending agricultural soils.

13 Demonstration of Class A bio-solids Need to demonstrate viable product if going to market Keep MDEQ involved with demonstrations of bulk use Determine how to market, bulk or less than bulk or bag Determine if rough screen product is feasible to use as landscape soil amendment

14 Class A Compost in City Flower Beds

15 Agriculture Demonstration Plot 1 20 acre soy bean field: 2.2% Organic content of soil/cec 3.9 pre application (sand) 12 yd/ac MCB applied and worked into soil on 10 acres of the field 10 acres untreated

16 Demonstration Results Plot 1 Yield increase of 5 bushel per acre on the 10 acres treated Improved organic content up to 2.7% CEC increased from 3.9 to 5.9 Improved root structure of crop

17 Commentary

18 Demonstration Results 10 acre corn field: 1.4% organic pre application (sand) 40 yd/ac applied and worked into soil ph 7.8 Nitrogen value of compost equal agronomic needs Plot 2

19 Demonstration Results Plot 2 Yield: 200 bushel per acre Organic content of soil improved to 2.4% ph improved to 7.5% CEC improved from 5.4 to 9.4 MDEQ Bio-solid division staff in corn field July 7, 2006

20 Commentary Kris Meyer farmer /land owner: The 10 acres in which we applied in the spring of 2006 had improved water retention (reffering to the low volume of rain received) I expected reduced crop production as in years past with such little rain but the opposite has occurred.

21 Why use a MCB Soil Amendment Long Term improvement of the physical properties of the soil translates into $$$$$$$ When improving the organic matter in soil we improve: Nutrient retention, Water retention, Improved CEC, Permeability, Aeration and Microbial activity

22 Why Class A Bio-solids Marketable soil amendment product which can be used by the general public with little or no requirements Less liability Easier to handle and distribute Easier to store Improve water quality

23 Class A Bio-solids Reduced Regulations Class A EQ bio-solids being used,sold or marketed in volume of less than 1 ton (approx 2 yards) have no regulation in regards to use Class A EQ bio-solids being used in bulk form of greater than 1ton can be permitted to require only record keeping of whom received such product and location where used

24 Product Marketability Market segments - landscapers /agriculture Bag or bulk Demand for the product / Competition Appearance Product/Application soil amendment, topdressing

25 Midland Bio-solid Compost (MBC) Midland Bio-solid compost rich organic matter Midland Bio-solid Compost enhances soil rooting media providing Characteristics better water retention and increases the ability of soil to hold nutrients. The organic Organic Matter 48% and long lasting and break down usable ph 7.0 nitrogen over a 8 10 week period. C:N Ratio 14:1 Midland Bio-solid Compost is derived from stabilized anaerobic digested sludge. Nutrients The bio-solids are mixed with residential Total Nitrogen 2.0% yard waste and wood chips and composted Total Phosphorus 1.7% to create MBC. All MBC is tested and per EPA Total Potassium.30% MDEQ guidelines are classified as exception quality bio-solids. MBC also contains trace Micronutrients amounts of micronutrients including iron, Copper.04% zinc, copper, magnesium, molybdenum Zinc.05% and manganese. Direction: Avoid direct application in areas that flood, on wetlands or into surface water. Wash hands after use. Lawns: On established lawns apply top dressing ¼ to ½ and rake into soil, new lawns apply ½ to 1 of MBC for every 4 of soil being conditioned. Trees & Shrubs: For established shrubs scatter approx. 20 lbs. of MBC per 100 sq uniformly over the soil and work into soil. For transplanting shrubs use approx. 2lbs. of MBC per foot of shrub height and mix with soil at the bottom of the hole when shrubs are transplanted. For transplanting container grown trees use 3lbs. per foot or tree height and mix with loose soil at bottom of hole when trees are transplanted from containers. Potting Soil: For potting soil use blend 20 to 50% MCB with soil or growing media and fill container with MBC blend to about 2 from the pot rim and pat down firmly. Form hole in MBC blend and place the root ball into soil at about the same depth as in the original container. Agriculture use: For home garden use apply 30 lbs. of MBC per 100 sq. uniformly over the soil and work into soil. For large field crop use consult your local farm coop or compost distributor. Analytical results are available upon request. Manufactured by: City of Midland Utilities Department, 2125 Austin, Midland Mi

26 Cost for Class A Class A approx $270 per dry ton to produce Class B approx $150 per dry ton Class A does not include maint. cost. Proposed upgrades transportation, conveyor system, fine screener, bag system, upgrade press?

27 Class B Bio-solids Recycling Some of the Class B site restrictions: All application sites are permitted at least 10 days prior to application Health department and township officials must be notified prior to application Distance restrictions to wells and open stream waters Applied at agronomic rates Soil testing Crop restrictions

28 Michigan Land Application Typical utilization of the class B liquid bio-solids product is accomplished through subsurface land application of agricultural fields Could also be surfaced applied with proper permit approval

29 Class B Value Typical Application Crop : Corn Average application rates based on agronomic needs per acre 160 lb Nitrogen 35 lb Phosphorous 70 lbs.potassium Current state wide average of fertilizer cost per the MDA Nitrogen= $.50 /lb Phosphorous= $.40/lb Potassium= $.30/lb

Cost Savings Nitrogen: 160 lbs. = $ 80.00 Phosphorous: 35 lbs.

30 Cost Savings Nitrogen: 160 lbs. = $ Phosphorous: 35 lbs. = $14.00 Potassium: 70 lbs. = $ Fertilizer value = $115 per acre

31 Cost to the City of Midland MG land application cost: $ 96,200 MDEQ permit fee: $ 8,534 Recycling cost: $104, land application cost: $67,925 MDEQ permit fee 01-02: $3,855 Recycling cost: $71,780 Cost increase per year of approx. $6,581 per the last 5 years

32 Maintaining Cost Goal: Maintain established bio-solid program and current budget cost for recycling class B biosolids Proposal: Implement an application fee to farmer receiving class B bio-solid subsurface application.

33 The Proposed Program for Class B Bio-solids The city of Midland WWTP generates enough Class B bio-solids to treat approx. 300 acres per year Potential fertilizer value to a farmer for 300 acres = $34,500 Program guarantee to adhere to EPA 503 rules and Mi. Part 24 rules and regulation in associated to bio-solids and the application site management Application would occur 3-4 times per year (as is status)

34 The Proposed Program for Class B Bio-solids Bio-solids will be applied at agronomic rates After each application the farmer would invoiced and pay fee per acres applied Farmer selection year one of application fees: Present new program to farmers currently utilizing the city of Midland Biosolid program and request application fee Suggested starting fee of a minimum of $20 per acre starting 2009 spring haul out Require contract

35 So God made a Farmer! * Do you know the farmers in your program? * Farmers for 3 or more generations! * They know the bang for the buck from biosolid application! * Even for the hobby farmer - it s a business! * Dollars and sense!

36 The Future of recycling Bio-solids Bio-solids are being produced and sold in different region of the U.S. Wisconsin, Ohio, Indiana and Virginia are a few of the states that are producing and marketing different types of bio-solids products No facility in Michigan is marketing or applying fees to such products To sustain a feasible recycling process we the generators should view bio-solids as a valued product and not a waste product

37 Gas to Energy Bioreactor 2009 City landfill required to install methane collection system Power plant at WWTP and use digester methane with landfill methane Gas pretreatment at landfill Install hot water pipeline to WWTF use for heat / install Thermal sludge drying create class A bio-solids $11,000,000

38 Project Re-design to Achieve Budget Goal Eliminate gas pretreatment Eliminate Thermal sludge drying and Class A bio-solids Develop bio-reactor using liquid biosolids Budget $8,500,000 Stimulus Funds used to finance substantial portion off the project (Shovel ready)

39 Timeline 2009 plans and gas collection system and compressor facility construction 2010 gas pipeline from LF to WWTP & power plant construction 2011 power plant start-up 2012 request for bio-reactor permit 2013 operating license issue and startup of bioreactor

40 Active Gas Collection System Closed Area 10 vertical gas wells 6 lateral extraction trenches Active Area Co-Disposal WWTP Sludge with MSW (Reinhart, D.R. et al, , Florida Study) Possible solutions for odor issue Cover as soon as possible Collect gas earlier in the life of the landfill Use mulch as daily cover 19 vertical gas wells 3 lateral extraction trenches Avoid disposal on or near side slopes 2 extraction wells on leachate collection pipes Possible solutions for slope stability issue Mix in well with other material or with landfill MSW Avoid spreading in thick layers 3 temporary trenches (using recirculation lines) Gas is sent to GTE Plant located at WWTP for electricity generation and heat recovery

41 Beneficial Use?

42 Proposed Bioreactor Project Demonstrate the benefit that liquid sludge addition has on decomposition Develop operational guidelines for sludge bioreactor landfills Develop operational guidelines for gas and odor control in sludge bioreactors Evaluate the general effectiveness of sludge bioreactor landfill approach

43 Approach Use non-dewatered sludge from the WWTP digester to increase moisture level in MSW, add inoculation(microorganisms), add nutrients (phosphate) Surface application at active work face Target application rate 10 to 25 gl. sludge / ton MSW (1000 to 3000 gl/dy)

44 Goals Improve quantity and quality of LFG Accelerate waste decomposition increasing LFG generation rate Accelerate waste settlement Airspace recovery Improve leachate quality

45 Increase methane production

46 Co-Disposal WWTP Sludge with MSW Average MSW 150 t/day Sludge additive of approx 1 dry/ton per week Appears to have advantages associated with geotechnical properties of the MSW / sludge mixture, ease of operation and increase moisture content of the MSW

48 Bio-solids A Valuable Resource

BIOREACTOR LANDFILLS: AN INNOVATIVE TECHNOLOGY FOR SUSTAINABLE MANAGEMENT OF SOLID WASTE. Rao Y. Surampalli

BIOREACTOR LANDFILLS: AN INNOVATIVE TECHNOLOGY FOR SUSTAINABLE MANAGEMENT OF SOLID WASTE Rao Y. Surampalli Bioreactor Landfills Municipal solid waste landfills that utilize bulk liquids in an effort to