Presentation Outline...Presentation Outline • Who is Alexandria Renew Enterprises • Process...
Transcript of Presentation Outline...Presentation Outline • Who is Alexandria Renew Enterprises • Process...
5/14/2019
2019 VWEA Education Seminar 1
Optimizing Plant Performance with “Smart” Operations
Presented by:
Kacey King-McRae/AlexRenew
Presented To:
VWEA Education Seminar
Richmond, VA
May 9, 2019
2019 VWEA Education Seminar
Presentation Outline
• Who is Alexandria Renew Enterprises
• Process Monitoring Evolution
• Advanced Mainstream Controls
• Probe Maintenance Program
• Lessons Learned
• Call to Action
2019 VWEA Education Seminar
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2019 VWEA Education Seminar 2
AlexRenew: Small and Mighty!
• Only 35 usable acres
• Designed for 54 MGD and peak flows of 116 MGD
• City of Alexandria needs 58 MGD at buildout
2019 VWEA Education Seminar
Alex Renew Water Transformers
• VA Class 1 Certified Op Techs
• CMRT Certified Mechanics
• Resource Recovery Efforts
• LEED Platinum Certified Facility
• Moxie
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2019 VWEA Education Seminar 3
AlexRenew Liquids Treatment Processes
2019 VWEA Education Seminar
Process Monitoring Evolution at AlexRenew
MONITOR BASIC CONTROL
NON CRITICAL PROCESS CONTROL
CRITICAL PROCESS CONTROL
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2019 VWEA Education Seminar 4
Evolution to SMART Ops: Where We Were
• Aeration - DO probes
• Monitoring and Basic Process
Control
• Supplemental Carbon - NOx Probes
• Monitoring and Manual FeedNH4
+
NO2-
O2
O2
carbon
carbon
AOBs
NOBs
NO3-
N2
NO2-
2019 VWEA Education Seminar
Evolution to SMART Ops: Phased Implementation
NH4+
NO2-
O2
O2
carbon
carbon
AOBs
NOBs
NO3-
NO2-
N2
Preparation for Mainstream Anammox
• Air ON/OFF
• Suppress NOBs/Nitrite Shunt
• Ammonia Probes
• NH3-based DO Control
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NH4+
NO2-
O2
O2
carbon
carbon
AOBs
NOBs
NO3-
NO2-
N2
Evolution to SMART Ops: Phased Implementation
• Automated Carbon Dosing
• Based on NOx Probe Readings
• ORP Interlock
• No Carbon Feed in ORP indicates no NOx
Methanol Dose Table
2019 VWEA Education Seminar
Primary
Effluent
80%
Centrate
3%
Removed
in CPT
17%
Ammonia Loading Secondary
Process with CPT
Primary Effluent Centrate Removed
Evolution to SMART Ops: Phased Implementation
NMF
Secondary Process
Primary Effluent
Flow Diversion
Flow Return
• Dewatering Centrate Pretreatment
• NH3 Loading to Secondary Process
• Nutrient Management Facility
• N Load Balancing2019 VWEA Education Seminar
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2019 VWEA Education Seminar 6
Evolution to SMART Ops: Added Instrumentation
9 Probes
3 Probes
26 Probes
2 Probes
22 Probes
2 Probes2019 VWEA Education Seminar
Smart Operations: Process Air Reduced by 30%
• Savings of $145,000/yr in electricity use (CY2018 vs. CY2014)
NH4+
NO2-
O2
O2
AO
Bs
NO
Bs
NO3-
ABAC in Operation
Average 12,800 scfm Average 9,300 scfm
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
Jan
-14
Ma
r-1
4
Ma
y-1
4
Jul-
14
Se
p-1
4
No
v-1
4
Jan
-15
Ma
r-1
5
Ma
y-1
5
Jul-
15
Se
p-1
5
No
v-1
5
Jan
-16
Ma
r-1
6
Ma
y-1
6
Jul-
16
Se
p-1
6
No
v-1
6
Jan
-17
Ma
r-1
7
Ma
y-1
7
Jul-
17
Se
p-1
7
No
v-1
7
Jan
-18
Ma
r-1
8
Ma
y-1
8
Jul-
18
Se
p-1
8
No
v-1
8
Jan
-19
Ma
r-1
9
Mo
nth
ly A
vera
ge
Air
Use
(sc
fm) CPT Startup &
Low DO in BRBs NMF Startup
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Methanol
Auto-Dose
Smart Operations: Methanol Use Reduced by 50%
• Savings of $300,000/yr in electricity use (CY2018 vs. CY2014)
N2
NO2-
NO3-
c
c
Average 1,050 gpd Average 484 gpd
ABAC in Operation TN < 3 mg/L
0
10,000
20,000
30,000
40,000
50,000
60,000Ja
n-1
4
Ma
r-1
4
Ma
y-1
4
Jul-
14
Se
p-1
4
No
v-1
4
Jan
-15
Ma
r-1
5
Ma
y-1
5
Jul-
15
Se
p-1
5
No
v-1
5
Jan
-16
Ma
r-1
6
Ma
y-1
6
Jul-
16
Se
p-1
6
No
v-1
6
Jan
-17
Ma
r-1
7
Ma
y-1
7
Jul-
17
Se
p-1
7
No
v-1
7
Jan
-18
Ma
r-1
8
Ma
y-1
8
Jul-
18
Se
p-1
8
No
v-1
8
Jan
-19
Ma
r-1
9
Mo
nth
ly M
eth
an
ol U
se (
ga
l)
2019 VWEA Education Seminar
Year mg/L
2014* 3.77
2015* 3.81
2016** 2.65
2017** 2.61
2018 ** 2.76
Average Effluent TN
* Permit Limit per Waste Load
Allocation (~ 4.5 mg/L)
** Concentration-Based Limit of 3
mg/L
Smart Operations: Final TN Reduced by 25%
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2019 VWEA Education Seminar 8
Smart Operations: Automation Roadmap
SMART
OPERATIONS
AT ALEXRENEW
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Swing
Swing
Swing
Anoxic
Air On/Off
BRB
Influent
RAS
to SSTs
BRB 6
Anoxic
Anoxic
Anoxic
Air On/Off
Anoxic
Anoxic
NH3NOx
NH3NOx
NH3NOx
NH3NOx
Swing
NH3NOx
NH3
NH3
NH3ORP
ORP
DO
DO
DO
DO
DO
DO
DO
DO
DO
DO
Swing
Supplemental
Carbon
NH3
SMART Operations: Proven Instrumentation
Secondary Process
33 Sensors Measuring
NH4-N, NO3-N, NO2-N,
pH, DO, ORP
• Ion Selective Probes
• UV Spectral Sensors
• Wet Chem. Analyzers
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• Determines Probe Maintenance
Schedule
• Defines Roles and Responsibilities
• Improves Probe Reliability
• Reduces Equipment Downtime
SMART Operations: Probe Maintenance Program
Key is to Create a Probe Maintenance Team2019 VWEA Education Seminar
Fundamentals of the Probe
Maintenance Program
SMART Operations: Probe Maintenance Program
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SMART Operations: Probe Maintenance Requirements
0
50
100
150
200
250
300
350
400
450
500
Secondary CPT NMF Filtration UV IPS
Annual Man-Hour Equivalents
Annual Field Hrs Annual Lab Hrs
• 1.02 Man-hour Equivalents for ROUTINE Maintenance and Calibration
• Lab and Field Work Required for Probe Value Checks
• Analytical, Electrical and Mechanical Aptitude Required
2019 VWEA Education Seminar
Roles and Responsibilities
SMART Operations: Probe Team
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• Proactive maintenance and probe monitoring are vital to
successfully implementing automated process controls.
• Documentation and data management are crucial in
troubleshooting process issues.
• Increased environmental regulations and advances in water
treatment technology are changing the role and expectation
of today’s operators.
SMART Ops at AlexRenew: Lessons Learned
2019 VWEA Education Seminar
• Don’t be afraid to take a “leap of
innovation”
• Manage risks
• Automation will modify the role of operator
• Not “set it and forget it”
• Take it step-by-step - Start small and build
as you go
• Commit resources needed
SMART Ops at AlexRenew: Key Take Aways
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Coauthors
• Kacey King-McRae/AlexRenew• Paula Sanjines/Jacobs
2019 VWEA Education Seminar
Thanks, and Stay in Touch!
Visit us online: www.alexrenew.com
Email: [email protected]
Alexandria Renew Enterprises
CallMeMoxie
@AlexandriaRenew
Alexandria Renew Enterprises
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2019 VWEA Education Seminar 13
Questions?
2019 VWEA Education Seminar