News from Schwing Bioset

Southerly Sets The Standard with Sludge Disposal Efforts

 

Schwing Bioset Application Report 14, Columbus, Ohio

Written by Larry Trojak, Trojak Communications

Version also published in WE&T Magazine (click to view)

 

Pumps and sliding frames allow options for effective disposal of cake from Columbus, Ohio, operation.

Wastewater treatment plants can distinguish themselves in any number of ways: by the volumes they can handle, by the number of industry awards they have earned, by the manner in which they handle an interruption in “business-as-usual”, and so on. They can also do so by demonstrating a creative, effective and successful effort to use or dispose of the biosolids they generate. Given those criteria alone, the Southerly Wastewater Treatment Plant could likely be seen as one of the premier WWTPs in operation today. Just coming off a five-year, $350 million expansion which nearly tripled its peak capacity from 114 mgd to about 330 mgd (built-in contingencies for further expansion can take the plant as high as 550 mgd), the plant services the majority of the greater Columbus area. State-of-the-art in every regard, Southerly is poised to build upon an already impressive reputation that has won them numerous National Association of Clean Water Agencies (NACWA) awards for plant and employee performance.

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But it is also its innovative sludge disposal program that separates Southerly from super-plant wannabes. Using a quartet of heavy-duty pumps and a number of sliding frame components (all from Schwing Bioset, Inc. [SBI] Somerset, WI) cake can either be routed directly for incineration or sent to a pair of storage silos. Once in the silos, the material is readily available for truck-loading and transport, either to an already-successful composting operation run by the department or directly to the landfill.  Options, it seems, are the hallmark of this successful operation. 

Change They Can Use

Built in 1967, the Southerly WWTP is one of two plants serving the Columbus metropolitan area (the other being the nearby Jackson Pike WWTP). The current plant expansion which so dramatically increased overall capacity, also increased volumes in the solids handling area. New centrifuges, installed a number of years in advance of that expansion, handle that increase nicely, according to Jeff Hall, Assistant Plant Manager.

“That upgrade was implemented both to replace aging equipment, as in the case of the centrifuges, and to add functionality to other areas like the transportation of solids,” he says. In the past, primary solids were gravity thickened while older centrifuges thickened the waste activated sludge (WAS). The new units now thicken both the primary solids and the WAS. This new approach boosts the solids content of the resulting dewatered cake to about 20-25%, a nice improvement over the 17-21% solids content with the older system.”

Additional changes brought about in that initial upgrade included installation of new cake pumps, a pair of storage silos, and sliding frames at two points in the solids handling process. 

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The Route To Disposal

Getting cake to the point where disposal options are available is a function of Southerly’s pumps and silos. As material exits the centrifuges, it is routed to any of four Schwing KSP 45V(HD)L-SFMS pumps which direct it to the appropriate area. Where that is, varies greatly according to need.

“Even though incineration is the most efficient method of disposal, we still try to keep the compost operation fed with as much as it needs, since that is the better use of the product,” says Carmon “Skip” Allen, Solids Supervisor 2. “Obviously that can vary from day to day. The balance of the material—we can do anywhere from 5.5 tons up to 9 tons an hour—is then sent for incineration. But we know at all times what is going to the silos for storage and what’s getting burned.”

The sludge pumps at Southerly are designed to generate a force sufficient to move cake the long distances needed for either incineration or storage. He says it is easily 300 feet to the multi-hearth incinerators (which have operating temps of 1400°F), and about 400 feet to the storage silos. Equipped with Schwing Bioset’s Sludge Flow Measuring System, the pumps are able to measure to within +/-5% the amount of sludge that is pumped to the incinerator. This simplifies their USEPA reporting requirements for their incinerator operations.

“Material headed to the silos, however, has an additional challenge to overcome,” says Allen. “Once there, the cake has to go straight up another 100 feet to enter the top of the structures, so the force needed to do that is really pretty impressive. I don’t think any regular equipment would be up to a task like that; these are definitely the right pumps for the job.”

Giving it the Slip

Despite maximum operating pressures of 1,100 psi for each pump, those extended distances at Southerly prompted Schwing Bioset to make accommodations to help move the sludge along. To do so, they added a “slip ring,” or pipeline lubrication system. Schwing Bioset’s unique design includes a 360 degree annular groove that evenly injects a thin film of water around the entire annulus of the pipe that separates viscous and sticky materials from the inner wall of the pipeline. The end result is a reduction in friction loss in the pipeline, and lower—in some cases better than 50% less—pipeline operating pressures.

Additional benefits include a savings in energy by reducing the demand on each pump and hydraulic unit, and, because of the reduction in pipeline friction, an increase in wear part life. While other systems try to address the friction issue through the use of as many as four drilled ports which inject more fluid, this offsets a percentage of the gains made by the centrifuges. Still other designs mix polymer with the water to help reduce pressure which, while effective, adds both up-front and perpetual costs to the operation.

Tom Thomas, Maintenance Supervisor 2 at Southerly, says the reduction in friction has also shown benefits in wear part life for the pumps—a fact that is borne out in similar results at Jackson Pike. “We run these pumps round the clock and, even with that 24/7 operation, parts such as the pumping rams, poppet valve discs and seats are getting six months of wear. That’s about 4,000 hours of wear part life, which is outstanding given what they’re being asked to pump.”

Silo Efficiency

As mentioned, the SBI sliding frame silos offer a storage option for cake headed either to the landfill for disposal or to the compost site. Prior to their installation, Southerly relied upon a smaller holding vessel known as “the pit,” a belt-fed, hopper-equipped component that used a series of screws to feed a truck sitting under the discharge chute. City officials say the new silos are larger (providing about 75% more capacity) as well as far more efficient, thereby reducing truck loading times from 45 minutes with “the pit,” down to only five minutes. This was an important criterion when selecting equipment.

Because the City pays a contractor to haul the biosolids, reducing loading times lowers overall hauling costs—the trucks now spend more time hauling and less time waiting to be loaded. The net result is more trucks loaded per day (and a lower cost to do so.) In addition, because of that added storage capability, the composting operation now has the option of drawing material solely from Jackson Pike, if necessary. "Anytime you can reuse something rather than just burying it or burning it, you are making a positive impact," says Assistant Plant Manager Jeff Hall.

“Today, we are reusing about one-third of the solids we handle through the composting operation,” says Hall. “That’s obviously good from an economic standpoint, since we are generating revenue from a product that was once simply discarded. However, it is also a plus from an environmental perspective."

The concept of the sliding frame silo is simple, yet very effective. Hydraulic cylinders move an elliptical frame across the silo floor. The frame’s action not only breaks any bridging that can occur over the extraction screw, it also pushes and pulls material towards the silo extraction screws for discharge into trucks.

Allen says the sliding frame silos were a nice addition to the operation. “Each silo holds better than 1,500 tons of cake, so even if one of the incinerators went down and there was an interruption in the trucking operation, we’d still have a nice short-term storage option while things get back up again. It’s really all about flexibility and these silos afford us that.”

Due to the sheer size of the silos, they are each equipped with three extraction screw conveyors at the bottom which allows the trailers to be evenly loaded without having to be jockeyed back and forth.

The silos also include an odor and splash control shroud that pulls fumes directly off the trailer, thereby minimizing the need for odor control in the truck loading building. In addition, it helps reduce the chance of material splatter during load-out, and confines any such instances to the area immediately adjacent to the trailer, which makes periodic cleanup of the area much easier.

Allen adds that they also use SBI sliding frames on hoppers in advance of the pumps which feed the incinerator. Doing so provides a wide spot in the process line enabling them to maintain steady incinerator operations for several hours in the event of any upset condition with the centrifuges.

Sibling Growth

Southerly WWTP’s growth is being mirrored in the expansion of its sister plant, Jackson Pike WWTP, located a mere seven miles from Southerly’s facility. That plant also installed SBI equipment for similar end uses, but because its capacities are less, scaled down the size of that equipment. So today, Jackson Pike uses a quartet of KSP 25 V(HD)L pumps, rather than the 45s in use at Southerly and powers them with a 100hp power pack compared to its 150hp counterpart. The silos, though smaller in height, are of the same design and offer the same performance benefits as Southerly’s. Once the expansion at Jackson Pike is complete, the two plants will effectively meet all of Columbus’s wastewater treatment needs for decades to come. For Skip Allen, seeing construction at Southerly come to an end after nearly six years is a welcome relief.

“We are all really happy about the changes that have taken place here; there’s no doubt about that. But it feels like we will now finally be able to get back into the treatment plant business. With construction done, we have a big headache behind us, we have a great operation in place, and we’re doing good things for the residents of Columbus. That’s not a bad place to be.”

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To download the entire #14 application report for Columbus, Ohio, click here.

To learn more about Schwing Bioset, our products and engineering, or this project specifically, please call 715-247-3433, email marketing@schwingbioset.com, view our website, or find us on social media.

 

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Tags: Sliding Frame Silos, Municipal Pumps, Truck Loading, Wastewater Treatment, Biosolids

Upgrading a Reliable Necessity - Piston Pumps at the Greeley WWTP

 

Written by Joshua DiValentino, December 2, 2015

The City of Greeley, Colorado, wastewater treatment facility recently implemented a series of strategic upgrades and major improvements were made to the Biosolids Facility. The Greeley facility repurposes its dewatered biosolids cake by trucking it for land application into remote Northern Colorado. The existing Schwing Bioset piston pump located in the sludge dewatering building had been in operation for 20 years and was a key component of this process.

The Greeley facility had relied on its sole Schwing Bioset KSP 25 cake pump for two decades prior to the upgrades. During that time, the existing pump was the only means of transportation for dewatered biosolids between the centrifuge dewatering equipment and the truck loading bin. The piston pump could have been a “bottle-neck” for a facility with limited storage capacity. However, the existing pump provided an exceptionally high level of uptime over its operational life at Greeley, with minimal wear part consumption.   

By 2014-15 the sole KSP 25 had been in operation since the mid 90’s. The City of Greeley facility, working on a larger plant upgrade, decided to implement a new pumping system for the coming decades. Greeley once again chose to invest in a Schwing Bioset KSP Piston pump.

In order to be as cost effective as possible, but also provide maximum redundancy for the foreseeable future, Greeley chose to purchase a new KSP 25, as well as upgrade the existing KSP unit to modern standards. The existing pump was upgraded to match the new KSP unit with control modifications, and upgraded safety features offer easier remote operation and even longer wear part life. The existing unit was also outfitted with a new Hydraulic Power Unit, offering modern hydraulic feed pumps and unlimited control variability.  The two pumps provide redundancy and additional capacity for growth, as well as a modern control network with the current plant SCADA.

Schwing Bioset KSP Municipal Piston Pump  Schwing Bioset Hydraulic Power Pack

The new pump system included a Hydraulic Power Pack, a Twin Screw Feeder, the Control Panel, and of course the Piston Pump. The Schwing Bioset services team worked with the installing contractor and Greeley personnel to integrate the updated control system features on both pumps with the plant MCC.  The new Schwing Bioset KSP cake pumping system (complete with two fully-operational pumps) was turned over to the City of Greeley in the fall of 2015.       

To learn more about this project specifically or learn more about our pumps, please contact this blog’s author, Josh DiValentino, call 715.247.3433, and/or visit our website here: SBI Municipal Pumps.

 

Tags: Piston Pumps, Biosolids, Wastewater Treatment, Pumps, Municipal Pumps

City of Stockton WWTP - Enduring Performance, Replacing a Legacy

 

Written by Joshua DiValentino, August 27, 2015

 

The City of Stockton wastewater treatment facility has seen its fair share of challenges in recent years. When financial resources were limited, the burden fell upon the operations/maintenance staff and the existing equipment to continue operations with aging infrastructure. At this point, the piston pumps supplied by Schwing Bioset, Inc. (SBI), located in the sludge dewatering building, had been in operation for over 20 years.

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The pair of KSP 25 pumps moved dewatered sludge cake from the dewatering building out to the truck loading building, several hundred feet away. The two systems were the only means of transporting dewatered sludge cake for the 30 MGD facility. Regardless of the operational circumstances, with a resourceful operations/maintenance staff and the help of SBI technical support, the pumps remained in service with over 129,900 hours on the meter.

By 2014-15 the pair of KSP 25’s had been in operation since early 90’s, and were now nearly 25 years old. The City of Stockton facility was now emerging from a turnaround and making critical investment upgrades. Stockton once again chose to invest in Schwing Bioset Piston Pumps and replace the aged pumps with brand new KSP 25’s in the dewatering building. The new pumps have the same durability to last another thirty years, and with upgraded safety and control features that offer easier remote operation and even longer wear part life.

The SBI field services team was also hired to remove the exiting units and re-install the new pumps. The pump system was replaced by SBI in full including; Hydraulic Power Packs, Twin Screw Feeders, Control Systems, and of course the Piston Pumps. The SBI crew was able to work seamlessly with Stockton personnel to not upset active onsite operations during installation. As such, the pumps were replaced in series to phase out the old system. A completely brand new turn-key cake pumping system will be turned over to the City of Stockton this year.          

To learn more about our piston pumps or this project specifically, contact a Schwing Bioset Regional Sales Manager, call 715.247.3433, email us, and/or visit our website here.

  

Tags: Piston Pumps, Wastewater Treatment, Municipal Pumps, Dewatered Sludge Cake

Schwing Bioset is Exhibiting at Several Trade Shows in May

 

Posted on Apr 30, 2015 9:33:00 AM

The Schwing Bioset Teams will be traveling nationally and internationally to exhibit at five trade shows during the month of May. 

To learn more about Schwing Bioset pumps (municipal or mining), fluid bed dryers, screw presses, sliding frames, the bioset process, and more, please be sure to find us on the exhibit floor at any of these upcoming shows:

 

California Water Environment Association (CWEA), April 28 - May 1 in San Diego, CA

http://myac15.com/

Florida Water Resources Conference (FWRC), May 3 - 5 in Orlando, FL

http://fwrc.org/

Canadian Institute of Mining (CIM), May 9 - 11 in Montreal, Canada

http://www.miningandexploration.ca/events/article/cim_2015_convention/

Exponor Chile 2015, May 11 - 15 in Antofagasta, Chile

http://www.exponor.cl/en/

Central States Water Environment Association (CSWEA), May 18 - 20 in Oakbrook Terrace, IL

http://www.cswea.org/events/

 

If you'd like to meet with one of our team members, please contact marketing@schwingbioset.com for the name of the contact(s) who is attending the show.

We look forward to seeing you!

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Tags: Announcements, Bioset Process, Events, Biosolids, Wastewater Treatment, Schwing Bioset, Mining Pumps, Municipal Pumps