Producing Class A Biosolids Producing Class A Biosolids The Chicago Way – A Unique The Chicago Way – A Unique PFRP Equivalency ProcessPFRP Equivalency Process

Dr. Lakhwinder S. HundalDr. Lakhwinder S. Hundal

Sr. Environmental Soil ScientistSr. Environmental Soil ScientistEM&R Department EM&R Department

Metropolitan Water Reclamation District of Greater ChicagoMetropolitan Water Reclamation District of Greater Chicago

NWBMA Conference, Chelan, WA Sept 19 – 21, 2010

Metropolitan Water Reclamation District of Greater ChicagoMetropolitan Water Reclamation District of Greater Chicago

Protecting Our Water Environment

Metropolitan Water Reclamation District of Greater ChicagoMetropolitan Water Reclamation District of Greater Chicago

Protecting Our Water Environment

Metropolitan Water Reclamation District of Greater ChicagoMetropolitan Water Reclamation District of Greater Chicago

Founded in 1889 to protect water quality of Lake MichiganFounded in 1889 to protect water quality of Lake Michigan

Services Cook County Illinois including city of Chicago and Services Cook County Illinois including city of Chicago and 125 suburban communities125 suburban communities

Service area covers 875 sq. miles and includes 5.5 million Service area covers 875 sq. miles and includes 5.5 million people + industry equivalent to 5.7 million people people + industry equivalent to 5.7 million people

Operates seven water reclamation plants handling daily Operates seven water reclamation plants handling daily flow of 1.5 billion gallonsflow of 1.5 billion gallons

– – Fill 450 acre swimming pool 10 ft. deep dailyFill 450 acre swimming pool 10 ft. deep daily

Produces ~180,000 dry tons biosolids annuallyProduces ~180,000 dry tons biosolids annually–– Takes ~ 15,000 semi trailers to haul annual Takes ~ 15,000 semi trailers to haul annual

productionproduction

About The MWRDAbout The MWRD

It is a Big Pile of Poop!!

Solids management was not

an issue in 1889

Became a necessity in 1920s

Constructed Imhoff Tanks

• Calumet WRP in 1922

• Stickney WRP in 1930

Imhoff tanks provided sludge

storage and digestion

Evolution of Solids Evolution of Solids Management …Management …

Installed lagoons in 1937 to handle IHS, WAS, & PS

Long-term storage discontinued in 1970sLong-term storage discontinued in 1970s

• Due to horrific odor and public outcryDue to horrific odor and public outcry

• Dwindling lagoon capacityDwindling lagoon capacity

Evolution of Solids Management … Evolution of Solids Management … contd.contd.

Disposal in lagoons Disposal in lagoons – Not a good – Not a good optionoption

Evaluated feasibility and economics of three

alternatives:

• IHS drying on sand beds

• Separate digestion in heated tanks and drying on

sand beds

• Mechanical dewatering IHS, heat drying & incineration

Adopted the 3rd alternative; built a mechanical

dewatering facility, a heat drying, and an

incineration plant in 1937

Evolution of Solids Management … Evolution of Solids Management … contd.contd.

Era of Nitroganic Era of Nitroganic TankageTankage

Sold as:

•Bulk to citrus farmers in Florida

•In bags as Nitrorganic Tankage Heat drying abandoned in 1981

•Energy shortage in 1979

•O&M costs too high

•Environmental awarenessEnvironmental awareness

Air-dried Imhoff sludge “Give Away” Air-dried Imhoff sludge “Give Away” program program

Used in home gardens as a “soil Used in home gardens as a “soil builder”builder”

Public loved itPublic loved it

Era of Nu Earth (1930s – 1987)

Promoting Nu EarthPromoting Nu Earth

Discontinued in 1987 due Discontinued in 1987 due

to:to:

High metal content – High metal content –

Cd > >300 mg/kgCd > >300 mg/kg

Bad pressBad press

The District commit to The District commit to

distribute biosolids distribute biosolids

only under controlled only under controlled

practicepractice

Demise of Nu Earth

Using Liquid Sludge For Using Liquid Sludge For Reclamation of Strip-Reclamation of Strip-

Mined LandMined Land

Barging Liquid Sludge 200 miles Down the Illinois River to Fulton

County

“Prairie Plan” Fulton County, IL

- 1971

Won the engineering award of 1974 – Competition was BART in

San Francisco, CA and Sears Tower in Chicago

No biosolids to site since 2004 because:No biosolids to site since 2004 because: Production of air-dried EQ biosolidsProduction of air-dried EQ biosolids

Ability to find local outlets for EQ biosolidsAbility to find local outlets for EQ biosolids

Plain economics – Cost savingsPlain economics – Cost savings

Air-dried EQ biosolids readily accepted as topsoil Air-dried EQ biosolids readily accepted as topsoil substitute for daily and final covers in municipal substitute for daily and final covers in municipal landfillslandfills

Increased local demand for air-dried EQ biosolidsIncreased local demand for air-dried EQ biosolids

“ “Prairie Plan” Fulton County, Prairie Plan” Fulton County, ILIL

Common Beneficial UsesCommon Beneficial Uses

Soil Amendment / Soil ConditionerSoil Amendment / Soil Conditioner Improve soil fertility and soil tilthImprove soil fertility and soil tilth

Substitute for Commercial FertilizersSubstitute for Commercial Fertilizers Top dressing golf coursesTop dressing golf courses

Fertilizing agricultural crops Fertilizing agricultural crops

Substitute for TopsoilSubstitute for Topsoil Construction of recreational facilitiesConstruction of recreational facilities

Landfill Cover – Daily and final coverLandfill Cover – Daily and final cover

Cinder Ridge Golf Links

Area: 100 acres, 18-hole

course

Quantity = 500 – 600 ton/yr

Savings: >$25,000

Harborside International Golf Harborside International Golf CourseCourse 453-acre site including two 18 hole

courses and golf academy

Over 500,000 dry tons of District’s biosolids used in final cover of landfill

Hosted Georgia-pacific senior PGA pro Am and SBC senior open

Voted third best municipal golf course in USA by the golf week magazine

?

Harborside International Golf Harborside International Golf CourseCourse

Chicago River Chicago River

Sculpture Park in Sculpture Park in

ChicagoChicago

Area: 4 acres

Application rate = 650 ton/ac

Savings: >$75,000

BIOSOLIDS Utilization SUMMARY

Farmland (80%

)

Daily & Final

Cover (7%) LandfillCo-disposal

(3%)

Golf Courses, Parks (10%)

PFRP-Equivalent Class A PFRP-Equivalent Class A CertificationCertification

Increase Research and Increase Research and Demonstration ActivitiesDemonstration Activities

Major Initiatives Undertaken Major Initiatives Undertaken to Attain Current Programto Attain Current Program

After 1993 the District started evaluating After 1993 the District started evaluating its solids processing trains for Class A PFRPits solids processing trains for Class A PFRP

Evaluated pathogen analyses of 344 Evaluated pathogen analyses of 344 samples from 1991-1996 monitoring samples from 1991-1996 monitoring

Filed a petition to USEPA’s Pathogen Filed a petition to USEPA’s Pathogen Equivalency CommitteeEquivalency Committee

Pathogen analysis on additional 1,400 Pathogen analysis on additional 1,400 samplessamples

Stickney and Calumet WRPs processing Stickney and Calumet WRPs processing trains granted Class A PFRP equivalency in trains granted Class A PFRP equivalency in July 2002July 2002

PFRP-Equivalency Certification

1.1. Anaerobic DigestionAnaerobic Digestion Temperature – 95Temperature – 95ººF minimumF minimum Retention time – minimum 20 days Retention time – minimum 20 days

2.2. Centrifugation (High Solids Processing Centrifugation (High Solids Processing

Train)Train) Solids content – 25 to 30 percentSolids content – 25 to 30 percent

3.3. Lagoon AgingLagoon Aging Holding time – 18 months minimum after last Holding time – 18 months minimum after last

additionaddition

4.4. Air-Drying Air-Drying Agitation frequency – 3 to 4 times per weekAgitation frequency – 3 to 4 times per week Solids content – 60 percent minimumSolids content – 60 percent minimum

PFRP-Equivalent Codified Operation

Cost of helminth & virus testing for each PCost of helminth & virus testing for each Projectroject

Eliminates logistics associated with 4-6 wk Eliminates logistics associated with 4-6 wk turnaround for helminth ova testingturnaround for helminth ova testing

Good PR Good PR

PFRP Certification Requirements

Demonstrate compliance by testing 12 samples per year for helminth ova & virus

Report data semi-annually

Annual PFRP compliance audit

Benefits

Lessons Learned

Good working relationship with state Good working relationship with state and federal regulatorsand federal regulators

Establish good public relations program

Low tech processing trains very effective in pathogen reduction

Air-drying and stockpiling subject to will of “Mother Nature” and can severely affect coordinating timing of production and demand

Codify PFRP-equivalent processing to allow more operational flexibility

Modify processing trains by blending to with other materials to address odors, salinity, and excess nutrients

Lessons Learned

QuestionsQuestions