Update - NEORSD Southerly WWTC Biosolids Combustion Optimization

Problem Since the startup of the three fluidized bed incinerators (FBIs) at the Northeast Ohio Regional Sewer District (NEORSD) Southerly Wastewater Treatment Center (Southerly WWTC) in 2014 greater than expected auxiliary fuel, that is natural gas, usage has been observed. The original FBI design assumed no auxiliary fuel would be necessary during typical operations. This abstract updates the paper submitted for the 2020 RBC, which was unfortunately cancelled due to the pandemic, with additional data obtained during the interim. Background The NEORSD owns and operates three FBIs at the Southerly WWTC, each design to process 100 dry tons per day (dtpd) at 28 percent solids and 68 percent volatile solids. The FBIs are fed dewatered sludge cake consisting of primary and waste activated sludges generated at the Southerly WWTC. Sludge from the Easterly WWTC managed by NEORSD, discharges into the headworks at the Southerly WWTC for ultimate processing by the FBIs. Typically, FBIs do not require auxiliary fuel when operated near the design condition. Auxiliary fuel is required during startup and sometimes during shutdown operations. Continued use of auxiliary fuel throughout all operations indicates the system is not operating as designed. Objective This study evaluated the existing conditions the FBIs operate under to determine which parameters might be adjusted for more efficient operation. NEORSD can then adjust, as possible, to reduce auxiliary fuel use. Historical Operation Evaluation NEORSD originally provided one year of hourly (average) data from April 2016 to March 2017, see Table 1 for the operational averages. The data was evaluated to determine which parameters impact autogenous operation. The screened parameter set included the following six which were likely to have the greatest impact on autogenous operation. Sludge feed Sludge percent solids Sludge percent volatiles Windbox temperature (preheated air from heat exchanger) Bed temperature Fluidizing airflow All these parameters statistically correlated with autogenous operations at specific levels per the t-test results in Figure 1. So, BC further evaluated this list using NEORSD's existing operating strategy as a guideline. In the end, BC determined the sludge feed rate was the most readily adjustable parameter to achieve more reliable autogenous operation. The sludge feed provides all the heat, when operated close to design values, to heat the combustion air and evaporate the water from the sludge without natural gas addition. When averaging all three FBIs the average sludge feed rate is 1.2 wet tons per hour (wtph) higher during autogenous conditions. It should be noted that the average sludge feed rate, during these autogenous conditions, was roughly 64 percent of the incinerator capacity (13.9 wet tons per hour at 30 percent total solids [TS]). The data suggests that operating the FBIs at higher feed rates will result in autogenous conditions more often. Operational Alternatives Two distinct operational changes could increase the sludge feed rate per FBI. Each option increases the number of thermal cycles, that is the frequency the system goes from operating temperatures to a significantly cooler level. Revised Operations — Option 1 - The first option utilizes storage capacity to provide consistent incinerator operations. Each storage tank holds approximately 1.5 days' solids processing capacity of one incinerator. There are three storage tanks available for operational storage with a fourth one for emergency storage. This option uses one sludge storage tank with one FBI to handle the solids with excess flowing into a second sludge storage tank. When the second sludge storage tank becomes half full and climbing a second FBI can be brought on line to help deplete the incoming and stored solids until one FBI can again handle the solids production. This option includes some concerns about placing additional thermal cycles on the equipment. Revised Operations - Option 2 - The second option operates two FBIs at a higher capacity. This is accomplished by placing one of the operating FBIs in hot standby mode for 6 to 8 hours every day. Though the FBI internals would likely see a relatively small thermal cycle, downstream equipment will undergo a larger cycle or temperature range. Option 2 would also likely not yield the same natural gas savings due to heating if the standby FBI required intermittent heating during downtime. Revised Operation Implementation An industry survey was conducted to better understand thermal cycling on sewage sludge incineration systems and impacts on equipment. Based on the survey Option 1 would likely result in less thermal cycle impacts due to relative infrequency compared to Option 2. Furthermore, discussions with the key equipment supplier (primary heat exchanger and waste heat boiler) indicated the equipment was designed for far more thermal cycles than practical over the anticipated service life of the equipment. After reviewing the two options NEORSD selected and began planning to implement Option 1. NEORSD operates three sludge storage tanks, two are normally used with a third for peak demands. At an assumed 5 percent solids concentration each tank holds roughly 230 dry tons of solids. Each cycle from 1 FBI to 2 FBIs and then back to 1 FBI should take approximately 30 to 40 days, depending on the sludge generation rate, the sludge incineration rate, and the sludge solids concentration achieved in thickening and storage. Based on this approach the FBI sludge feed rate will exceed 80 percent of the design capacity, greatly increasing the chances for autogenous operation. NEORSD conducted multiple full-scale trails, with a month-long campaign in April of 2019 providing the most representative operations of the selected option. Other trials in May 2019, September/October 2019, and August 2020 resulted in shorter durations and experienced other complications resulting in higher energy consumption. Table 2 presents the comparison between the trials and historical costs spanning 2016 through 2018. Costs in the table represent annual values. The trial values were projected to annual operations for comparison. The results of the trials indicate energy and economic savings will result from the revised operating strategy. The April 2019 trial most represents the anticipated revised operating strategy and would result in an annual savings of $390,000. Conclusions This study initially investigated the alternatives to minimize the use of auxiliary fuel during normal operations. This effort identified that recommended increasing the sludge feed rate reduces auxiliary fuel demand and presented two options to achieve a higher FBI throughput. NEORSD opted to manage the sludge in the SSTs to operate the FBIs at a higher sludge feed rate which requires alternating between one and two FBIs in service. The recent April 2019 full-scale trial showed significant energy reductions from the revised operating strategy. Based on this effort NEORSD will continue to pursue operating in the revised manner full time. NEORSD will also continue to closely monitor equipment condition to prevent unplanned outages and whether the slight increase in thermal cycles have any effect. Status NEORSD continues to test the revised operating strategy to verify the operational savings and gain experience. Ultimately the strategy will be implemented as the standard operating procedure.