RESEARCH REPORTING SERIES. Research reports of the Office of Research and Development, U.S Environmental Protection Agency, have been grouped into nine series These nine broad cate- gories were established to facilitate further development and application of en- vironmental technology. Elimination of traditional grouping was consciously planned to foster technology transfer and a maximum interface in related fields The nine series are Environmental Health Effects Research Environmental Protection Technology Ecological Research Environmental Monitoring Socioeconomic Environmental Studies Scientific and Technical Assessment Reports (STAR) Interagency Energy-Environment Research and Develapment Special” Reports Miscellaneous Reports This report has been assigned to the ENVIRONMENTAL PROTECTION TECH- NOLOGY series. This series describes research performed ta develap and dem: onstrate instrumentation, equipment, and methodology to repair or prevent en- vironmental degradation from point and non-point sources of pollution. This work provides the new or improved technology required for the control and treatment Of pollution sources to meet environmental quality standards, This document is available to the public through the National Technical Informa- tion Service, Springfield, Virginia 22161EPA-600/2-77-156 September 1977 APPRAISAL OF POWDERED ACTIVATED CARBON PROCESSES FOR MUNICIPAL WASTEWATER TREATMENT by A. J. Shuckrow Battelle-Northwest Richland, Washington 99352 and G. L. Culp Clean Water Consultants El Dorado Hills, California 95630 Contract No. 68-03-2211 Project Officer James J. Westrick Wastewater Research Division Municipal Environmental Research Laboratory Cincinnati, Ohio 45268 MUNICIPAL ENVIRONMENTAL RESEARCH LABORATORY OFFICE OF RESEARCH AND DEVELOPMENT U.S. ENVIRONMENTAL PROTECTION AGENCY CINCINNATI, OHIO 45268DISCLAIMER This report has been reviewed by the Municipal Environmental Research Laboratory, U.S. Environmental Protection Agency, and approved for publication. Approval does not signify that the contents necessarily reflect the views and policies of the U. S. Environmental Protection Agency, nor does mention of trade names or commercial products constitute endorsement or recommendation for use.FOREWORD The Environmental Protection Agency was created because of inereasing public and government concern about the dangers of pol- lution to the health and welfare of the American people. Noxious air, foul water, and spoiled land are tragic testimony to the deterioration of our natural environment. The complexity of that environment and the interplay between its components require a concentrated and integrated attack on the problem. Research and development is that necessary first step in problem solution and it involves defining the problem, measuring its impact, and searching for solutions. The Municipal Environ- mental Research Laboratory develops new and improved technology and systems for the prevention, treatment, and management of waste water and solid and hazardous waste pollutant discharges from municipal and community sources, and to minimize the adverse economic, social, health, and aesthetic effects of pollution This publication is one of the products of that research; a most vital communications link between the researcher and the user community. The information herein deals with an evaluation of the use of powdered activated carbon as a means of treating municipal wastewater. It serves to explore the strengths and weaknesses of this new technology and identify those areas where improvements would be of greatest value. As such, it fulfills the need for continuing technology assessment in emerging areas. Prancis T. Mayo, Director Municipal Environmental Research Laboratory iiiABSTRACT Powdered activated carbon has been the subject of several developmental efforts directed towards producing improved methods for treating municipal wastewaters, Granular activated carbon has proven itself as an effective means of reducing dissolved organic contaminant levels, but is plagued with specific oper- ational problems which can be avoided with powdered carbon. ‘The work reported herein was aimed at puttimy powdered activated carbon (PAC) treatment in proper perspective relative to competing tech- nology. All work with PAC and PAC regeneration was reviewed and representative process approaches selected for comparison with activated sludge, activated sludge with nitrification, and granular activated carbon. While no one PAC approach is clearly superior from a performance standpoint, biophysical processes are attractive because they can be incorporated into existing biolog- ical plants. Comparison of capital and operating costs were made for plants with throughput rates of 1, 5, 10, 25, and 50 MGD Cost relations were generated in curvilinear relations to allow interpolation. Based on these estimates, it was determined that independent physical-chemical PAC systems are not economically competitive with other modes of treatment. PAC may offer advan- tages for specific cases where highly variant flows are experienced such as plant receiving flows of a seasonal nature or areas with combined storm sewer systems. A sensitivity analysis was also conducted to determine where improvements could be made to make PAC competitive. Lower carbon doses and/or inexpensive throwaway carbon would be needed to successfully challenge the other systems evaluated. This report was submitted in fulfillment of Contract No. 68-03-2211 by Battelle-Northwest under the sponsorship of the U.S. Environmental Protection Agency. Work was subcontracted to Clean Water Consultants. This report covers a period from June 1975 to July 1976. ivCONTENTS gues es rate ay ee ee Acknowledgements 122222 Dt 1. Introduction. . Bt Oe sumaryfandconclustonst ete ee Performance.» . - ee ee ee ee Economics. 2 6. ee ee ee ee eu Recommendations: gS oe 4. Powdered Carbon Treatment Systems . oo Independent Physical-Chemical (IPC) systems. | Battelle-Northwest Study... .. Sas Eimco Study... ee le Infilco Studies... . ao Jet Propulsion Laboratory (JPL) Stuay |] | Combined Biological-Carbon (CBC) Systems . . . DuPont Pact Process... .- eee eee ICI United States Studies... . 1. é Polyols and Derivatives Waste Treatment Facility. .... oe Boo Combined Waste Treatment Facility. |] | Solids Settling-Extended Aeration. . . . Norfolk, Nebraska, Water Pollution Control Plant... . eee ee ee ee gimpro Studies... . 2.2... 5 6 Contact Stabilization ~ Carbon Systems. | | 5. Powdered Carbon Regeneration. . Atomized Suspended Technique (AST) |). 1 1! Biological Regeneration... .. 2... 00 Fluid Bed Furnace... 2... eve eee SPL Pyrolysis. «2. 2. ee ee Multiple Hearth Furnace... 2... 0.0. Transport System... ee ee Wet Air Oxidation... . ee ee 6. Base Case Selection... ... 2. eee eC Syetemee se ee ee CBC Systems. ©. ee ee Regeneration Systems... ee ee 7. Processes Evaluated... ee ee ee 8. Process Economics... 1... ee ee ee ee Basis for Cost Estimates fee Activated Sludge, Conventional) 11221! Design Basis... ee ee eee ee ee v . iv ova wxidi ow . 4 24 fol . 8 + 10 + 10 10 a le = 1S) 2 22 + 26 + 29 paz - 32 + 32 + 32 34 : 34 - 37 + 40 + 40 242 . 42 + 46 + 52 co . 357 . 61 + 62 s + 63 + 65 + 68 + 68 69 + 69CONTENTS (CONTINUED) Coste ee es es eal Gaplealicostet nt fe 3 Operation and Maintenance Costs. |) 11) 76 Activated Sludge, Single Stage for Nitrification... . as fe ol Activated Sludge with Chemical Coagulation and Filtration... Go 008 eee 1 Granular Carbon Treatment of Chemically” Coagulated, Settled, and Filtered Raw Wastewater so. ee eee ee OL Powdered Carbon, Eimco. ss... ee ee ee 129 Powdered Carbon Feed. ss). ee ee ee 129 Flocculator-Clarifier .. 2... . 2.2... 147 Reactor-Clarifier ...... ee a7, Fluidized Bed Regeneration Furnace. | 1) | 1] 147 Powdered Carbon, Battelle... .... +... . 148 Powdered Carbon, Bio-Physical. .. 2... 2... 148 9. Evaluation of Relative Economics... 2... ... 19 Activated Sludge and Granular Carbon Systems |. 194 Biological Nitrification, Two Stage... ... . 195 Eimco System... ee ee ee ee ee 195 Battelle Process...) ee ee te ee 200 Bio-Physical Process... .. Bo5o645 Het Cost Sensitivity to Carbon Losses. |) 12) 1) ) 204 Composition of Process Costs... ....... 207 Carbon Regeneration Costs... . 2... +... 207 Sensitivity to Sludge Disposal Method. .... . 207 Comparison of Total Annual Cost Components for 10 MGD IPC Systems... 1... .. e+ 21h Eimco vs Granular Carbon... . 2... 22. 211 Battelle vs Granular Carbon... 2.2... 211 Sensitivity of Granular Carbon Costs to Carbon Dosage. . . pe eis Multiple-Hearth Regeneration o£ Powdered Carbon . ' ge 21 ico te Battelle. se ee 216 Bio-Physical. » ss. ee eee ee ee 216 References © 6. 6 ee ee ee ee ee ee ee OB Puppets ee ee Se e235) viNumber 10 11 12 13 14 15 16 FIGURES Process Flow Sheet, Battelle-Northwest Powdered Activated Carbon Treatment system. Schematic Flowsheet of Mobile Pilot Plant, Battelle-Northwest Powdered Activated Carbon Treatment System... . eee ee Fluidized Bed Regeneration Unit for Powdered Rotivated: Cacbonses | jis Gees cs cece mes Regeneration System Schematic Flowsheet, Battelle-Northwest Powdered Activated Carbon Pilot Plant... ee ee ee ee Process Flow Diagram for Eimco Pilot Plant. OPL-ACTS Process for OCSD...... 2... Pilot Plant Schematic... .. 2... Effect of Powdered Carbon on BOD Removals . Effect of Powdered Carbon on COD Removals . Effect of Powdered Carbon on BOD Removals . Activated Sludge Process... ....... Full-Scale Powdered Carbon Treatment at Rothschild, Wisconsin §.T.P... 2... + AST Regeneration System... 1.1... 0% Fluidized-Bed Regeneration Furnace, Eimco Pilot Study... ee ee ee ee ee Modified Eimco Fluidized-Bed. ... 1... Cross-Sectional View of Multiple Hearth pucnsces eee eee vii 13 14 15 17 22 30 33 33 35 35 38 41 45 47 54Number 47 18 19 20 au 22 23 24 26 27 FIGURES (CONTINUED) Schematic of the Westvaco Powdered Carbon Regeneration System. . 1... 4 = Zimpro Carbon Regeneration Flow Diagram... . Activated Sludge Process Schematic. Activated Sludge with Chemical Coagulation and Filtration Schematic. ..... Granular Carbon System Schematic. . Eimco System Process Flow Sheet . . Powdered Activated Carbon Feed system (5-50 MGD) Powdered Carbon Storage and Feeding Powdered Carbon Storage and Feeding Battelle Process Flow Sheet . . . Flow Sheet for Bio-Physical Process Wet Air Oxidation. . 6... . 0 viii (1 McD) . (5-50 MGD). Page 55 58 70 107 124 141 144 145 146 162 17Number 10 1 12 13 14 15 ‘TABLES JPL Pilot Plant Operated at Orange County Sanitation District Plant No.l... .... JPL Pilot Plant Results... ....--.- JPL Pilot Plant Results (Operation by Sanitation District Staff)... ...... Carbon Loading and COD Removal... ~~... Average Pilot Plant Performance... ... Summary of Results... - ee ee eee Sludge Handling Summary. 2-1... eee Full-Scale Powdered Carbon Treatment at Rothschild, Wisconsin S.7.P... 1... 4 - FPluidized-Bed Furnace Results Eimco Pilot Study. 2... ee ee eee Pyrolysis and Activation of Carbon-Sewage HineedlOep tog’! Bqalpaones oe eee: Gas Chromatograph Analysis of Carbon-Sewage Pyrolysis and Activation Off-Gas..... - Properties of Regenerated Carbon from a Bio-Physical Process... + +e se ees Properties of Carbon Regenerated from a Chemical Bio-Physical Process... ....- Assumed Composition of Raw Wastewater. . Estimated Process Effluent Quality Grarignetp ee aqgc0 400004 ix 23 24 25 27 a1 36 36 38 48 50 53 60 60 66 67TABLES (CONTINUED) Number Page 16 Design Conditions for Activated Sludge Primary Sedimentation Unit... .... 2+... 72 7 Activated Sludge System Design Parameters... . 72 18 unit Process Sizes, Activated Sludge... ... = 7: 19 Capital Costs, Activated Sludge... ...... 78 20 Activated Sludge, 1 MGD O&M... ........ 80 21 Activated Sludge, 5 MGD O&M. . 2... 2... . 81 22 Activated Sludge, 10 MGD OSM... . 1... +... © 82 23 Activated Sludge, 25 MGD OSM... ....-.- 83 24 Activated Sludge, 50MGD O&M... ....... 84 25 Activated Sludge, 1 MGD.....- eee ee ee 85 26 Activated Sludge, 5MGD.... 2... 2+ +4. 86 27 Activated Sludge, 1OMGD.... +... .- 2-5 87 28 Activated Sludge, 25.MGD... 2.2.2.2... 88 29 Activated Sludge, 50MGD....- 2... eee 89 30 Activated Sludge Annual Cost Summary... ... 90 a1 Single Stage Activated Sludge Nitrification System Design Parameters... . ++. +++ s+ 92 32 Unit Process Sizes, Single Stage Activated Sludge Nitrification... 2. ee ee ee ee 88 33 Capital Costs, Single Stage Activated Sludge Nitrification... ..........- 94 34 Single Stage Activated Sludge Nitrification, LTMGD OSM... ee ee ee ee 35 Single Stage Activated Sludge Nitrification, OROMMGS Gago eee aoe Ge ene ean EY 36 Single Stage Activated Sludge Nitrification, 1OMGD OSM... ee ee ee ee ee ee 8BNumber 37 38 39 40 41 42 43 44 45 46 a7 48 49 50 51 52 53 TABLES (CONTINUED) Single Stage Activated Sludge Nitrification, 25MGD OM... 1. ee ee et ee ee Single Stage Activated Sludge Nitrification, SOMGD OSM... ee ee ee Single Stage Activated Sludge Nitrification, FMD ese ee Single Stage Activated Sludge Nitrification, SHG... eee et et et te et Single Stage Activated Sludge Nitrification, AIO] McD ce) eee ee Single Stage Activated Sludge Nitrification, rile) Ga 65566506 50400005 00 Single Stage Activated Sludge Nitrification, SO McD Single Stage Activated Sludge Nitrification, annual) Cost ssusmiar yo) eases ernie Activated Sludge with Chemical Coagulation and Filtration, Design Parameters... .... Unit Process Sizes... 1 ee ee ee capital Costs, Activated Sludge with Chemical Coagulation and Filtration... ......-. Activated Sludge with Chemical Coagulation and Filtration, 1 MGD... 2. eee ee eee Activated Sludge with Chemical Coagulation and Filtration, 5MGD....-. +. e+e ee Activated Sludge with Chemical Coagulation and Filtration, 10MGD. 1... eee eee Activated Sludge with Chemical Coagulation and Filtration, 25MGD....... 04.05 Activated Sludge with Chemical Coagulation and Filtration, 50MGD... 1. ee ee eee Activated Sludge With Chemical Coagulation and Filtration, 1 MGD.. 2... ee ee eee xi 100 101 102 103 104 105 106 108 110 112 113 114 15 116 17 118Number 54 55 56 57 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 16 TABLES (CONTINUED) Activated Sludge with Chemical Coagulation and Filtration, 5MGD........-+.-- Activated Sludge with Chemical Coagulation and Filtration, 1OMGD.......-.-- Activated Sludge with Chemical Coagulation Pilsgukey ste oto 5 G60 0 0 0 6 Oo Activated Sludge with Chemical Coagulation and Piltration, 50MGD........+.+. Activated Sludge with Chemical Coagulation and Filtration Annual Cost Summary... .. Design Parameters for Granular Carbon System Granular Carbon Systems Unit Process Sizes . Capital Costs, Granular Carbon... . - Granular Carbon, 1 MGD OSM... 12. eee Granular Carbon, 5 MGD 06M... 1. +... Granular Carbon, 10 MGD O&M... 1... . Granular Carbon, 25 MGD O&M... 2... Granular Carbon, 50 NGD O&M... 1... e Granular (Carbon) Gps | tse ee Granulac,Cacbon, 5 MGDe. 2 tee. ce Grenular (Carbon, 1O-MGDse) et cts8 se te Granular (Carbon, 25°MGDee) | tee ce. Granular Carbon, 50 MGD..... « Granular Carbon Annual Cost Summary. . . . Design Parameters for Bimco System... . Unit Process Sizes, Eimco Process. . .. . Capital Costs, Eimco.... 2... 2.08 Eimco, 1 MGD OSM... ee ee ee ee 120 121 122 123 125 127 128 130 131 132 133 134 135 136 137 138 139 140 142 149 150 151TABLES (CONTINUED) Number Page 77 imicot 5 MCD OGM se 78 Eimco, 10 MGD OSM... ee ee ee ee ee 158 79 Eimco, 25 MGD O&M... + eee ee ee ee ee 18M 80 Eimco, 50 MGD OSM... eee ee ee ee ee 18S el Eimco, LMGD. «ee ee ee ee ee ee ee 156 82 Eimco, SMGD. . ee eee ee ee ee ee ee 1ST 83 Eimco, 1OMGD.. ee ee ee ee ee ee ee e158 84 Eimco, 25 MGD. 6. ee ee ee ee ee ee ee 159 85 Eimco, 50 MGD. 6. ee ee ee eee eee ee 160 86 Eimco Annual Cost Summary... ... +++. + 16L 87 Battelle Process System Design Parameters... 163 88 Unit Process Sizes, Battelle Process... ... 164 89 Capital Costs, Battelle-Northwest Process... 165 90 Battelle-Northwest, 1 MGD OSM... .... ~~. © 166 a1 Battelle-Northwest, 5MGD OSM... ...... 167 92 Battelle-Northwest, 10 MGD O&M... . ~~... © 168 93 Battelle-Northwest, 25 MGD O&M... ...... 169 94 Battelle-Northwest, 50 MGD O&M... 2... + 170 95 Battelle Process, 1MGD.. +. .- e+ eee 0 172 96 Battelle Process, 5MGD....-.-+....+ 172 97 Battelle Process, 1OMGD.......-...-+ 173 98 Battelle Process, 25 MGD.......+....- 174 99 Battelle Process, 50 MGD..-......-+..+.+ 175 100 Battelle Process, Annual Cost Sumary...... 176 101 Design Parameters for Bio-Physical Process with Wet Air Oxidation... ... 2... © 178 xiiiNumber 102 103 104 105 106 107 108 109 110 111 112 113 114 11s 116 117 118 119 120 121 TABLES (CONTINUED) Unit Process Sizes, Bio-Physical. . . . Capital Costs, Bio-Physical Process . . Bio-Physical, 1 MCD OSM... .. 1... Bio-Physical, 5MGD OSM... ..-... Bio-Physical, 10 MGD O&M. . 2... 2. Bio-Physical, 25 MGD O&M... ..... Bio-Physical, 50 MCD OSM... . 2.2... Bio-Physical Process, Annual Cost Summary, 1MGD.. . ee. ee ee Bio-Physical Process, Annual Cost summary, 5MGD... eee ee ee ee Bio-Physical Process, Annual Cost Summary, 10 MCD... - +e ee ee eee Bio-Physical Process, Annual Cost Summary, 25MGD... 2... ee ee ee Bio-Physical Process, Annual Cost Summary, 50MGD.. 0... ee eee Bio-Physical Process, Annual Cost Summary Annual Cost Summary Two-Stage Nitrification. 2... ee ee ee ee Annual Cost Summary Eimco ~ Single Stage. Annual Cost Summary Eimco System at 100 MG/L Carbon... ee ee Annual Cost Summary Eimco System with Throwaway (5¢/1b) Carbon (300 mg/l)... Annual Cost Summary Eimco Systems with FBF Loading = 3 PSF/HR..... 1... Annual Cost Summary Eimco, 50% Reduction ing Uabone Powers rae] sso: eeeseee Battelle Process with 200 mg/l Carbon ana 125 mg/l Alum. eee ee ee oe xiv Page isi 182 183 184 185 186 187 188 189 1g0 ig. 192 193 196 197 198 199 201 202 203Number 122 123 124 125 126 127 128 129 130 131 132 ‘TABLES (CONTINUED) Annual Cost Summary Bio-Physical Process, Carbonaceous Criteria... + ee - + e Process Costs Sensitivity to Carbon Loss. . Composition of Process Costs, 10 MGD. . . Carbon Regeneration Costs... 1... Comparison of Total Annual Cost Components, 10 MGD IPC Systems... .-....--- Granular Carbon Process at 750 1b Carbon Der Ge Granular Carbon Process at 200 lb Carbon ery Ge Eimco Annual Process with Multiple Hearth Regeneration... .-. eee ee Battelle Process with Multiple Hearth Regeneration. ©... ee ee ee ee Bio-Physical Process with Multiple Hearth Regeneration... .-. 1-2 e ee eres Conversion Factors for the Units Employed . xv 205 206 208 209 212 214 215 217 218 219 340ACKNOWLEDGEMENTS The authors wish to extend their gratitude to Daniel J. Hinrics of Culp/Wesner/Culp and Gaynor W. Dawson of Battelle-Northwest for their contributions to this work. Special thanks go to James J. Westrick of the EPA Municipal Environmental Research Laboratory for his able advice and assis- tance during the course of this work. The secretarial and typing efforts of Nancy Painter are grate- fully acknowledged. xviSECTION 1 INTRODUCTION over the past 15 years, a great deal of effort and resources have been invested in wastewater treatment process research and develop- ment. This has been the result of recognition of the need for more highly polished effluents from wastewater treatment facilities in order to meet higher receiving water quality requirements and in some instances for reuse purposes. Treatment process research and development has focused both on improvement of the effective- ness and reliability of existing wastewater treatment schemes and on development of entirely new treatment processes. Sorption on activated carbon has emerged as an integral part of many of the new process developments. In fact, activated carbon sorption is the most efficient process yet known for the reduction of dissolved organic substances in wastewater to very low levels. Activated carbon can be employed either in a granular or powdered state to effect complete or tertiary treatment of wastewaters. Granular carbon applications are by far the more common and, of the two, are the only systems presently utilized in any full-scale municipal wastewater treatment facilities. Development of powdered carbon technology has lagged behind largely as a result of a lack of efficient regeneration systems. Interest in powdered carbon has remained high, however, because of potential advantages over granular carbon systems including: * the cost of powdered carbon on a per pound basis is substan- tially less than that 9f granular carbon; * powdered carbon will equilibrate with soluble wastewater organics in a fraction of the time required by granular car- bon; * powdered carbon is easily slurried and transported, and can be supplied on demand by metering pumps; * powdered carbon dosage can be rapidly changed to meet varying feed organic strength; * a powdered carbon system requires a fraction of the carbon inventory required by granula. carbon systems;* a powdered carbon adsorption system has considerably less headloss than a granular carbon system; and * hydrogen sulfide formation problems associated with many granular carbon systems can be easily avoided in powdered carbon systems. With continued interest in upgrading wastewater treatment systems through conversion to or addition of physical chemical modules, these potential advantages over granular carbon have led to several process development and modification activities focused on powdered activated carbon. ‘These efforts have been further encouraged by the successful pilot-scale demonstration of regen- eration and reuse of powdered carbon employed to treat municipal wastewater and the full-scale regeneration of spent industrial powdered carbon routinely carried out by two commercial concerns. In order to assess the technical and economic viability of powdered activated carbon technology in the municipal treatment field, the Environmental Protection Agency (EPA) commissioned Battelle- Northwest (BNW) and Clean Water Consultants (CWC) to undertake the current study. The objective of the program was to perform a detailed evaluation of the body of data generated in the afore- mentioned process development activities. ‘The literature was reviewed and a series of personal interviews with workers in the field was conducted. Information thus collected was evaluated and three base case treatment processes were selected for further study. Each of these selected processes was subject to a detailed economic analysis for treatment plant sizes of 1, 5, 10, 25, and 50 MGD. Economic comparisons were developed for several activated sludge alternatives and for a granular activated carbon system in the same size range of plants. In each of the base case systems the sludge handling and regeneration processes examined were those utilized in the original development work for the particular pro- cess. One additional regeneration scheme (multiple hearth furnace was subsequently selected and examined for all of the powdered carbon treatment processes in all size ranges. Due to the fact that the various powdered carbon treatment pro- cesses are still in the developmental stage, a number of assump- tions were inherent in the analysis. Thus, a sensitivity analysis was performed for certain of the key assumptions to evaluate their potential impact on the relative economics. Although this analysis is based upon limited data in some cases and assumptions have been necessary, it is believed that a valid picture of the relative feasibility of powdered activated carbon treatment pro- cess technology in the municipal area has emerged. It should be noted that, although laboratory and bench scale studies were included in the literature review, only processes which had been developed on the pilot plant scale were considered for inclusion in the economic analysis 2In the following sections of this report, bon process development activities in the treatment are described, selection of the discussed, and the technical and economic powdered activated car- area of municipal waste base case systems is analysis is presented.SECTION 2 SUMMARY AND CONCLUSIONS PERFORMANCE Independent physical chemical systems utilizing powdered activated carbon are unaffected by toxic substances in the influent stream. Powdered activated carbon in bio-physical processes reduces the sensitivity of the system to toxic substances and seems to stimulate quicker recovery of some systems after a toxic material has passed through the system. In general, powdered activated carbon systems can be uti- lized over a broader range of influent BOD conditions, while producing high quality effluents than more conventional systems. Powdered activated carbon systems are less subject to upset from changes in influent composition than are more conven- tional systems. From a process performance point of view, none of the develop- mental powdered activated carbon municipal treatment systems was found to be clearly superior to the others. Developmental work on the various powdered activated carbon treatment processes has been carried out under widely dif- ferent conditions which makes direct comparison difficult. All of the pilot studies reported in the literature indicate that each of the processes is capable of producing a high quality effluent. Bio-physical processes are attractive in that they offer the possibility of implementation at existing activated sludge plants with no modification of existing facilities other than the addition of powdered carbon handling and feeding systems and a regeneration system Laboratory scale studies of a combined contact stabilization- powdered activated carbon process indicate good potential for this approach.* A full scale plant employing the duPont PACT process for treatment of industrial waste is currently under construction. Another full-scale bio-physical plant utilizing the Zimpro approach is planned for a municipal system in Medina, Ohio These projects should commercialize the approach and should provide valuable full-scale operational experience. * Publicly available data did not lead to a clear choice of a powdered carbon regeneration system based upon technical con- siderations. * Two regeneration systems, the AST system and the transport system, have been operated routinely in regeneration of powdered activated carbon used in corn syrup refining. No such experience exists for carbon used in municipal waste treatment. ¢ Wet oxidation appears attractive since this approach does not require dewatering prior to regeneration or collection of dry powdered activated carbon after regeneration. * Two powdered activated carbon regeneration approaches, the multiple hearth furnace and wet oxidation, will be imple- mented in the full-scale applications in the foreseeable future. Both will regenerate powdered carbon used in bio- physical waste treatment processes. ECONOMICS The following summary table presents the costs for the several alternative processes evaluated in this study. The conclusions of the economic study are: * Independent physical-chemical (IPC) systems (using either granular or powdered carbon) are not cost competitive with conventional activated sludge for removal of BOD in normal municipal applications * The granular carbon IPC system is comparable in costs to conventional activated sludge followed by coagulation and filtration at a carbon dosage of 1,500 1b/MG. At a carbon dosage of 750 1b/MG, the granular carbon system would be slightly lower in cost than activated sludge followed by coagulation and filtration. * The IPC powdered carbon systems with the specified design criteria are not competitive in cost with the granular car- bon system.The Battelle process approach (single clarifier ~ combined sludge handling) would offer savings in costs over the granular carbon system if a carbon dosage of 200 mg/l and an alum dosage of 125 mg/l provides a satisfactory degree of treatment. The two-stage Eimco process cost is comparable to the granu- lar carbon system (1,500 1b/MG) cost at a powdered carbon dosage of 100 mg/l. The cost would also be comparable at the specific dosage of 300 mg/l if a cheap, throwaway carbon were available at a cost of 1¢/1b, an unlikely circum- stance. A single-stage Eimco system with 100 mg/l powdered carbon would be comparable in cost to a granular carbon system operating at a dosage of 750 1b/G A reduction in powdered carbon price from that used in this report (32.5¢/1b) to 16¢/1b would have an insignificant effect on the competitive position of the IPC powdered car- bon systems. The cost of the bio-physical approach where powdered carbon is added to the aeration basin of the activated sludge pro- cess is intermediate in cost between single-stage nitrifi- cation and two-stage nitrification. If the approach pro- vides a comparable degree of reliability of nitrification it would offer an economic advantage over two-stage acti- vated sludge. A proposed version of the bio-physical pro- cess where the design criteria are modified so as to provide only BOD removal appears comparable in cost to conventional activated sludge. The IPC powdered carbon system regeneration costs are based on fluidized bed furnace loading rates recommended indepen- dently by two manufacturers. These rates (5-7 lb/ft2/hr are higher than those originally determined (3 1b/£t2/nr by Battelle-Northwest. Should the lower loading rate be necessary, a significantly adverse cost impact would result. Multiple hearth regeneration of powdered carbon resulted in slightly higher capital costs (including costs of pressure filtration for carbon dewatering), substantially higher fuel requirements in the larger capacity plants, and substantially lower power requirements for all capacity plants. Effects of labor and maintenance materials were not significant. The net cost effect of using multiple hearth regeneration in conjunction with pressure filtration was not significant (i.e., within the probable limits of accuracy of these pre- liminary estimates) for the Eimco and Battelle processes but the addition of a carbon dewatering process in the bio- physical process resulted in a cost increase.The areas offering the potential for the most favorable eco- nomic results are: 1) determining the minimum carbon dosages compatible with satisfactory performance of the Battelle pro- cess for a variety of wastewater characteristics, 2) maxi~ mizing the loading rates on the FBF regeneration process. Power, fuel, and labor costs compose such a small portion of the overall IPC process costs that there is little potential gain from reductions in the assumptions used for these variables. suwwaae nasue Costs/1,000 gations (Doltars) activated sh Los Sout lo mse md 50 mad se reationat ieee avin oul tre | oan Single Stage Mtrificatien 110 0.51 ddl OSL 0.26 ‘wo Stage Nitrsficataon 1219-59048 0350.28 Conventional wath coagula- Sion g Filerasiont 1.490.719.5548 0.37 Granular Carbon Syaten® 1,500 Ibs carbon aa 1 0.73 088 0.46 750 bs earpon/aa bw ores sz ade 200 ibe cazbon/e 1 O64 0480.36 Powlered carton Systane Basic Process Mo Single Stage Hee 0880.72, 608 two Stage With 100 59/1 Carbon ao 0.72087 0420.27 ‘wo stage Wien 300 g/1 Throwawey (Se/Ib) carbon 1.68.8 0.68 0.530. teitet Basic Process 0.97 0.87 on. 200 ag/1 carbon, 125 mg/l aun 1289.58.48] 1200 na/1 Carbon Wsenout faleration 0.98 0.48 Odt 0950.33 Sio-thysieal Basie Process 14s 0.85 odd Carbonaceous Criteria 1.63 0:52 0.380130 0.26 Bftect of 50% seduction in 2.02 0.88 asa 018s Blo-Physscat ies) = fared Effect of multapte dearth fegeneration on Basic Procesa Eines Pe i) Or | Battelle igs ols, 080287 Blo-Physical Ve6 0.63 Osa 0380 Filtration 0.22 0.07 0.050.034 0.024 emese processes include effluent filtration 7SECTION 3 RECOMMENDATIONS, It appears that processes involving powdered activated carbon addition to the activated sludge process are being commercialized by the private sector. ‘wo firms are independently engaged in projects which will lead to full-scale plants using this basic approach but with different regeneration techniques An IPC system, that being developed by JPL, will be operated on the 1 mgd scale in the near future. This project should provide the basis for commercialization or abandonment of the approach dependent upon the results of the demonstration program. The economic analysis conducted in this study indicate that the Eimco approach is not cost competitive with granular carbon systems unless a very cheap throwaway carbon becomes available or unless the carbon dosage requirements were much lower than the 300 mg/l assumed here, The Battelle-Northwest process also requires a drastic reduction in carbon dosage below the assumed value of 600 mg/l for economic viability. However, the required reduction would result in a carbon dosage comparable to that assumed in the Eimco process Laboratory studies of contact stabilization-powdered activated carbon systems indicate good potential for development of a high performance, low residence time process. Such a process would offer the potential of significant cost savings. None of the classic tests such as iodine, methylene blue, phenol erythrosin, molasses, or BET can be used to accurately predict the performance of activated carbon in any of the wastewater treatment processes studied. This makes comparison of different regeneration systems operated at different locations extremely difficult. In view of the above considerations, the following recommendations are made: 1. The Battelle-Northwest process should be reexamined to determine if the carbon and alum dosage can be reduced to make the process economically competitive while maintaining good process performance. In addition, consideration shouldbe given to substitution of a cheaper coagulant such as lime with no coagulant recovery or abandonment of alum recovery in the basic process. Stukenoerg** reported that such modi- fications in the basic Battelle process appeared feasible. Developmental efforts on the contact stabilization-powdered activated carbon process should be undertaken on the pilot scale. A standard test by which to measure the activity of virgin and regenerated powdered activated carbon should be developed if possible. Consideration should be given to parallel operation of several pilot powdered activated carbon regeneration systems oper- ating in concert with one or more treatment systems in order to obtain comparable regeneration data.SECTION 4 POWDERED CARBON TREATMENT SYSTEMS Process development activities for application of powdered acti- vated carbon to municipal waste treatment have been directed toward both independent physical-chemical (IPC) systems and com- bined biological-carbon (CBC) systems. In addition, some work has been conducted on the use of powdered activated carbon in a tertiary treatment mode. Much of the developmental work with powdered activated carbon systems has been with industrial wastes. Although this work can- not be directly translated to municipal use, the body of data generated for industrial applications has been drawn upon to assist in the current evaluation. INDEPENDENT PHYSICAL-CHEMICAL (IPC) SYSTEMS There have been four recent major investigations of the use of powdered activated carbon for the treatment of raw municipal wastewaters and one major study on the treatment of secondary effluent, The various developmental programs are described below. Battelle. thwest Study! The Battelle-Northwest study developed the process shown sche- matically in Figure 1. The process involves contacting raw sewage with powdered activated carbon to effect removal of dis- solved organic matter. An inorganic coagulant, alum, is then used to aid in subsequent clarification. addition of polyelec- trolyte is followed by a short flocculation period. Solids are separated from the liquid stream by gravity settling, and the effluent is then disinfected and discharged or can be filtered prior to disinfection. Carbon sludge from the treatment process is thermally regenerated by a fluidized bed process. Alum is recovered by acidifying the regenerated carbon-aluminum oxide mixture to pH 2 with sulfuric acid. This reclaimed alum is then reused in the treatment process. A pH adjustment, accomplished with a lime slurry, is required to raise the pH to 6.5-7.0 for aluminum hydroxide precipitation when reclaimed alum is recycled. 10WALSAS INSWLVEUL NO@EYD AIIWATLOY CHYAGMOd USEMHLYON-STISLLVE ‘LAMHS MOTA SSEOOdd *T auNoTa NMoaMo18 uSy LMNT aowNund 39NdTYLN3D a3g aaziarnts aanaane wn a310A038 z Hd 01 Yosty Ferry) ONTTLLIS NOILYT XIW <—____ NOLLWAL ILA gent [*7)-n99075/FJorave ALIN Sao yNas MV UIWAT0d Nogavo a3LVATLOV (AW) gauaqmod AN3WLSACOY 68 WHY nd an atv 1The process was first evaluated in a nine-month laboratory study Aqua Nuchar A (product of Westvaco) was selected for use after screening 15 different commercial carbons. Based upon the favorable results of the laboratory study, a 100,000 gpd mobile treatment plant was constructed (see Figure 2). This pilot plant was operated in Albany, New York, from June to October, 1971, and April to June, 1972. The pilot plant was com- posed of two major systems: a liquid treatment system was con- tained, almost entirely, in a forty-foot mobile trailer van. It was designed for a nominal capacity of 100,000 gpd. Carbon, alum and polyelectrolyte were added in a pipe reactor, providing rapid mixing of the chemicals, preceding flocculation and separation in a tube settler. Clarified effluent was chlorinated and released with the option of routing through a gravity filter prior to chlorination. Sludge was dewatered in a centrifuge Carbon was regenerated in a fluidized inert sand bed unit (the development of which is discussed later in this report) which was 36 inch ID, refractory lined, and self supported. As illustrated in Figure 3, this unit consisted of three main sections: a fire- box housing the burner, 30 inches ID by 20 inches high; a bed section containing inert sand, 27 inches ID bottom, 36 inches ID top by 60 inches high; and a freeboard 36 inches ID by 72 inches high. A schematic diagram of the carbon regeneration system is shown in Figure 4. The pilot furnace used in the Battelle study was built by Nichols Research and Engineering Corporation. ‘The pilot study confirmed that proper control of pH within the system was critical. A pH of 4 or less in the first few minutes of carbon contact was found necessary to prevent excessive carry- over of carbon particles from the downstream clarifier. The pH was adjusted to near neutral with lime prior to flocculation The tube clarifier was found to perform well (effluent turbidity <2 JTU) at overflow rates as high as 2880 gpd/ft?. Filter runs averaged 10 hours at a loading rate of 4.4 gpm/ft?. No polymer filter aid was normally used. Three different high molecular weight anionic polyelectrolytes were used in the pilot study: Atlasep 2A2 (product of ICI America, Inc.), Decolyte 930 (product of Diamond Shamrock Chemi- cal Company), and Purifloc A-23 (product of Dow Chemical Company) . All of these polymers were observed to produce large, rapidly settling floc particles. Each of these polyelectrolytes performed satisfactorily at a dosage of 2 mg/l. The carbon sludge was found to readily dewater in a six inch solid bowl centrifuge. The dewatered sludge ranged from 20-35 percent solids at 70 percent recovery with no conditioning polymer. Use of polymers increased the solids recovery to 95 percent. 12WAHLSAS LNAWLVGUL NOY GALWAILOW GTHaGMOd USIMHINON-ITIGLIVG ‘LNWId LOTId FIIGOW JO LAMHSMOTA OLLYWHHOS *% quNDIZ JOWNUNS OL 390075 oau3Lvnad 39v¥ols —- 39VYOLS 39GNTS aalym o3a31 4d inan1433) t i ¥o1v1n99074 " i 1 i 1 1 1 1 i l awit 3LTYOTHIOdAK 314108193734 100 13WATER OR RECYCLE GAS OBSERVATION PORT RY | AND SAND FEED BIN NX J—36" 1p ——of SAND LEVEL FLYIDIZED LLLLLLLLL. SAND LEVEL STATIC i L Ht SLURRY INJECTION 3 ‘ PORT | f xs voors co see | | mb SAND CLEANOUT 6 3 _ \ t— BURNER RECYCLE GAS INLET FLUIDIZED BED REGENERATION UNIT FIGURE 3. FOR POWDERED ACTIVATED CARBON 14Posty Nogyy2 dn3yvn now anayvn ate, on 0334 INWId LOTId NOY GALVAILON aTusaMOa ISGMHIYON-STISLIVE ‘LEXHSMOTS OILVWIHOS WHLSAS NOILWYaNaOTY syo 320Ag78 nogaya ayd3s 307943 onan Or Ley3N3034 Sy uegnyds Tan. *y manora ary WOrssnaKod aN¥é0¥e 39007, oau3LwaaaThe pilot system was operated on both storm flows from a combined sewer and on dry weather, municipal wastewater flows. Excellent degrees of wastewater purification were achieved in both cases During the dry weather conditions, average plant effluent BOD, COD, and suspended solids concentrations for the 1971 studies were 17.8, 35, and 7.7 mg/l, respectively. This represents removals of 82.3 percent BOD, 87.3 percent COD, and 94 percent suspended solids. Plant operational data for the 1972 studies were comparable to those observed in the 1971 portion of the program. During the 1972 operations, the average effluent turbidity, suspended solids COD, and BOD concentrations were 0.67 JTU, 3.1 mg/1, 39 mg/l, and 17 mg/l, respectively. This represents average removals of 98.1 percent suspended solids, 82.6 percent COD and 81.3 percent BOD. The results described above were achieved at total plant deten- tion times which averaged slightly less than 90 minutes. Recovery of 91 percent of the powdered carbon was achieved. The operation of the carbon regeneration facility is described in a subsequent section. Eimco Study? Eimco Corporation constructed a 100 gpm pilot plant in Salt Lake City, Utah, for evaluation of powdered activated carbon treatment of raw sewage. The pilot plant is shown schematically in Figure 5. It was operated for 16 months to evaluate lime, alum, and ferric iron coagulation and single and two-stage counter-current carbon treatment. Aqua Nuchar A was the carbon selected for use in this work. A second follow-on study of 15 months duration was subsequently conducted. Screened and comminuted raw wastewater was obtained from the main Salt Lake City pump station discharge line. The desired flow was pumped to the chemical treatment unit, a 12 ft diameter solids-contact clarifier provided with a surface skimmer. Chem- icals were added to achieve coagulation-precipitation and aid flocculation and clarification. The settled solids were removed and collected for gravity thickening and vacuum dewatering tests. The chemically treated effluent then flowed by gravity to the carbon contactors which could be operated either single-stage (parallel) or two-stage counter-current (series). The carbon con- tactors were 10 ft diameter solids-contact units. Powdered acti- vated carbon was fed and maintained as a concentrated slurry. Spent carbon was periodically withdrawn to control slurry concen- tration. The spent carbon removed was gravity thickened in a 5 ft diameter unit and then dewatered on a 3 ft by 3 ft vacuum filter. 16the effluent from carbon treatment was filtered through a 3.5 ft diameter granular media filter, The filter bed consisted of 1.5 ft of 1 to 1.5 mm coal over 1.0 ft of 0.6 to 0.8 mm sand. The backwash water, containing spent carbon, was collected and recycled back to the carbon contactors. The final effluent was collected in a clear well and used for backwashing the filter and as plant water. It was found that single stage carbon contact in a slurry con- tactor actually provided the equivalent of 2-4 contacts due to the biological action occurring in the slurry contactor. Hydrogen sulfide problems developed but could be controlled by maintaining the solids detention time in the clarifier to three days or less. However, the process developers concluded that two-stage counter- current carbon contacting required less carbon than single-stage carbon contacting to produce a given effluent quality in terms of soluble COD and thus recommended the latter approach. Although this appeared to be the case, the pilot plant results were not precise enough to define the difference between the two types of contacting modes with a significant level of statistical con- fidence. A clear choice of chemical for the chemical pretreatment step did not emerge from the study. Lime was identified as the chemical of choice for wastewaters low in alkalinity and high in phosphorus. For a high alkalinity-low phosphorus wastewater either alum or ferric chloride were deemed acceptable. It was noted that lime had no consistent effect on soluble COD removal while both alum and ferric chloride reduced the soluble COD by 40 to 50 percent Although the lime sludge produced in the primary was found to thicken and dewater more easily than the other chemical-primary sludges, five to six times as much sludge was produced by lime treatment than by alum or ferric chloride treatment. For the Salt Lake City case, alum appeared to be the chemical of choice Effluent phosphorous concentrations of as low as 0.4 mg/l were achieved at an Alt3 dosage of 13 mg/l. A carbon dosage of 75-300 mg/l was employed throughout this work and was found to produce an effluent soluble COD of 15-30 mg/l During the period June to September 1973, the pilot plant oper- ating on a weak influent at a carbon dosage of approximately 100 mg/l was able to produce an effluent which averaged 3 mg/l soluble COD. Anaerobic biological action in the carbon contactors was believed to contribute significantly to the removal of soluble COD in the treatment system. Thickening and dewatering of spent carbon were effectively accomplished. ‘The spent carbon concentration of 25 to 50 g/l in the carbon contactor blowdown was increased to 70 to 100 g/l in a gravity thickener with a solids loading averaging 10/1b/ft2/day 18The thickened material then was readily dewatered to 78 per- cent moisture in a yacuum filter at rates of 6 to 9 1b/ft2/hr About 0.2 percent cationic polyelectrolyte by weight was required for conditioning to obtain about 90 percent solids recovery across the vacuum filter and produce a readily dischargeable filter cake. The Eimco pilot plant carbon furnace was of the same basic design as used in the Battelle pilot plant, but was constructed by BSP Division of Envirotech. Infilco Studies7/®)"* The Infilco Company conducted evaluations of the powdered carbon treatment of secondary effluents and raw sewage. The first in- vestigation, high rate solids-contact treatment units embodying internal slurry recirculation were operated singly and in series as powdered activated carbon sorption systems. Secondary (acti- vated sludge) sewage treatment plant effluent was treated in a 30,000 gpd pilot plant using a slurry of activated carbon and a cationic polyelectrolyte flocculation agent. A two-stage counter-current system was used. Application of the process involved series operation of two solid-contact clarifiers of a type used widely for water treatment. Carbon was fed to the second unit and a first-stage slurry was developed from car~ bon advanced from the second contact-clarifier. Spent carbon was withdrawn from the system by blowdown from the first unit. To protect the receiving stream from carbon lost during process disruption, post filtration was provided. Preliminary laboratory study of three powdered activated carbons resulted in selection of Atlas Chemical Industries’ Darco S-51 for the pilot plant program and it was found that polyelectrolyte flocculation was required to produce floc which settled well. A study of 26 compounds disclosed that Dow Chemical Company's Puri- floc C-32 was the most effective and it was used throughout the pilot plant work. A polyelectrolyte dosage of 6-7 mg/l was required for effective flocculation at carbon feed rates up to 140 mg/l while a dosage of 10 mg/l of C-32 was required at carbon feed rates of 266 mg/l. Slurry settling rates far exceeded requirements at the pilot plant which was operated at hydraulic loads from 0.4 to 1.6 gpm/ft2 of clarification area. In spite of this, it was nec- essary to reduce the pilot plant throughput when influent sus- pended solids were high because of an inability to remove solids as rapidly as they were accumulated within the system during these periods. The volume of system blowdown ranged from 0.05-0.1 percent of the throughput. Its solids content of 13-22 percent by weight should enable economical recovery of carbon for reuse by reactivation without further concentration. 19Pilot plant influent filtered COD averaged 27.2 mg/l and ranged from 23-34 mg/l during the study. Two-stage counter-current treatment with 67, 146, and 266 mg/l of carbon achieved respec- tive reductions of 60, 72, and 84 percent, and residual CoD con- centrations were 10.8, 7.4, and 4.4 mg/l. A COD reduction of 65 percent and an effluent COD of 9.7 mg/l was obtained in a one unit contactor system with a carbon dosage of 140 mg/l. Carbon loadings for the two-stage systems ranged from 9-24 mg of BOD per 100 mg of carbon and a loading of 13.1 percent by weight was obtained during single unit treatment. In later work with screened and degritted raw sewage, Infilco again utilized a two stage counter-current system composed of solids contact clarifier units. This was essentially the same 30,000 gpd system utilized in the prior work with secondary effluents. Laboratory studies preceeded the pilot plant investigation in order to facilitate selection of a powdered activated carbon and a coagulant for use in the pilot studies. As a result of the laboratory studies, Aqua Nuchar A was selected for use in the major portion of the study, primarily on the basis of the price differential between Aqua Nuchar A and Darco S-51. None of the polymers studied in the laboratory were found to be consistent in reducing supernatant turbidity to 10 JTU except at very high dosages. Four polyelectrolytes were judged to be superior to the others tested: Purifloc C-31, Purifloc C-32, Primafloc C-7, and CAT-FLOC. Based upon price and handling con- siderations, C-31 was selected as the primary flocculating agent Later pilot plant operations incorporated alum as an auxiliary flocculant in some instances. During the pilot plant operations, each of the contactors was operated at throughput rates of 0.5-1.5 gpm/ft? which corresponded to carbon contact times of 35-12 minutes. Carbon (Aqua Nuchar A) dosage was varied from 100-250 mg/1, polymer dosage was varied from 2 mg/1-20 mg/l, and alum dosage was varied from 0-50 mg/l, with high alum dosage corresponding to low polymer dosage. Mean values of the influent CoD to the pilot plant for the various operating periods ranged from 82.4 percent at a carbon dosage of 100 mg/l to a high of 92.2 percent at a carbon dosage of 200 mg/l. It was noted that the final effluent had a perceptible and dis- tinctive sour odor (not hydrogen sulfide) which was quite dis- agreeable. In one comparative run using Darco S-51 carbon, no substantial difference in effluent quality was evident. 20No attempt to regenerate spent carbon was made in the course of this investigation. Jet Propulsion Laboratory (JPL) Study! The JPL process is a two-stage counter-current adsorption system using powdered activated carbon. A block flow diagram is shown in Figure 6. Fresh activated carbon is mixed with wastewater in the second mixing basin, settled and the entire mixture of settled sewage solids and activated carbon is transferred to the primary mixing basin. Settled solids and carbon are removed from the primary settling basin, dewatered and transferred to a pyrolysis reactor. The reactor produces activated carbon and a burnable gas. The activated carbon is then recycled to the secondary mixing basin. Activated carbon is intended to serve two functions: 1) adsorp- tion of organics and other pollutants, and 2) settling aid in both the primary and secondary sedimentation basins. It is also believed that the carbon acts as a filtration aid and prevents compression of sewage solids during dewatering. A trailer mounted pilot plant was constructed by JPL in Pasadena and operated at Orange County Sanitation District Plant No. 1 in Fountain Valley, California beginning February 1974. Typical operating conditions for the pilot study are shown in Table 1. Results reported in the paper by Humphrey et al.,% are summarized in Table 2. These results were achieved with carbon from the pyrolysis reactor at dosages from 300 to 600 mg/l. The staff of the Orange County Sanitation District analyzed seven runs in July-August 1974. ‘The results of the test data are sum- marized in Table 3. The secondary effluent shown in the table is unfiltered and it is believed by the Sanitation District staff that secondary effluent standards (BOD = 30 mg/l, suspended solids = 30 mg/l) could be achieved by chemical treatment with ferric chloride and polymers or filtration; or by removal of fine carbon in the feed. A sample of activated carbon was dry screened into the following size fractions: Above 100 mesh 100 - 200 mesh 200 - 300 mesh Below 325 mesh Samples of degritted raw wastewater were treated with 600 mg/1 of carbon from these four size fractions and analyzed for COD at various times from 0 to 30 minutes after addition of the carbon The results of this test showed that, in the size ranges studied 21abana usw aso0 Hod SSa00u¥d StoV-Tar “9 guNDIE (uoqae9, + AbrougT dnaxew) Teop 93 7ubTT ' ' (worseariod ! x0Kzxq pur stsdtoz4a)} useta Hourotes Axeaod SPETOS Serres (Sutxezem0q) ssetq 1931Td (SPTTOS ¥0S~) SpTTOs ebemag + -uoqzed sours -SPTTOS , abenos | (eTpew pextH) aoTsTAeTD uotzequauTpas ta &3taew! Kavu sr tt Graeres | Aaepuoses feSTy BUTT (4ra0TS_ SOT) (SPTTOS &6~) (P933T Hea) uogze) pozeatjoy — epnts abemes abemas + woqre 22TABLE 1 JPL PILOT PLANT OPERATED AT ORANGE COUNTY SANITATION DISTRICT PLANT NO. 1 Capacity: 7 gpm Primary mixing: 6.25 hp mixer @ 1725 rpm detention time = 28 minutes Primary settling: overflow rate = 335 gpa/ft? detention time = 86 minutes Secondary mixing: 0.33 hp mixer @ 1725 rpm detention time = 28 minutes Secondary settling: equipped with 1 Microfloc settling tube module, 8 ft,long overflow rate = 385 gpd/ft detention time = 86 minutes Solids handling system: No equipment for continuous sludge removal; therefore, system shut down for batch removal of sludge from primary and secondary settling basins Dewatering: (1) Rotary vacuum filter, or (2) Netzsh plate filter: ll plates, 14 x 14 in. a total filter area = 32.7 ft Pyrolysis reactor: 8 in. ID stainless steel tube equipped with an external gas fired jacket bed temperature = 1800°F 23£6 L070 To°T putz 88 z00°0 9t0°0 AeATTS £9 €T'0 zero TexOTN el so°o Tz'0 eet L6 Lt0°O blo aeddop on 9e70 670 wn qwo2rys v8 92070 ogo wn tupes 46 9 eT zet pueursd uebixo [eotueyoota s6 z L be eseorp oot 0 ToT 86z SPTTos pepuedsns eTT3eTOA 66 T Ltt vor SPTTOS pepuadsns Te30% Tesowsy stesteq —(PezeaTTa) JeNTIIa auentssa = UONTFUT weqsweIed Axepuoses Axepuooes T/pu “UOT FeT\USOUOD «SLINSHY LNVId LOTId Tar @ aleve 24sutseq 5uTT33e5 Arepuooes wory vogreo pue spTTOs eHemes peT339S - IS 9eSe stp cer . zeyonN zs L6 vLT 86 yet 7SS 98 zet 49k 3 oozed oozed oT 9% “baw THe 69s RySDN Ts 9 922 88 vet vee SE ze TES oozed TS 998 L 6t ‘Baw r6e ozo zeyonNn tS L6 «= 9@Z_—s5-10 percent). Refuse when pyrolyzed and activated results in significant ash concentrations in the product carbon (>70 percent). Lignite coal was selected for use in the process since it represents a source of low ash carbon with activation comparable to commercial activated carbons and also provides at low cost the necessary makeup energy to the system for operation of the calciner and flash dryer 46Sight Glass r/c ee Preeboara Tc Thermocouple we Dewatered’ Carbon Cake Injection To P/L I r/c & [meee P/T (Pressure Indicator) ) P/E Natural Gas Z|. Burner Chamber Fire Box Off-Gas RecycleTABLE 9 FLUIDIZED-BED FURNACE RESULTS EIMCO PILOT STUDY Run_ Number 6 2 8 9 a une July Sept Oct Tov Run Date, (1973) 37-18, 18-20, 1413, 8-10, 223, Pretreatment chemical Alun Feciy_—=«Fecly_—«Fecly— Alum Operation Principal GR? OGR ocr (OG, cock, Feed Point (from Bed Floor), ine. 18 18 a8 as 18 Sand Bed Depth, in: Static 2 22 36 . . Plaiai: - aay 48+ 7 7 Sand Size, US Mesh 16x30 16x30 «16x30 16x30 16x30 Gas Flow, Sceu: Burner Air 80 90 8s 90 93 Burner Gas 8 9 9.2 10 10 Off Gas Recycle 70 60 75 80 90 Gas Velocity, ft/sec: Botton of Bed 2.0 2.2 22000 27 29 Preeboard? oe Lo tgs! tT Lat Run Length, hr 0rd 2 egos cir 2 eter aero) Feod Fate, dry Ib/hr 1 27 37 16 a Moisture in Feed, ¥ by weight 78 16 ices Er Average Temperature, ce Frecboara uu3o-«1330- 7014701470 Sand Bee 4250 1400-1250 1ss0 1850. Firebox 1900 1970602000» 2000 Average Pressure, in. of 0: Freeboard “4 3 3 a ° Firebox 37 64 n 70 68 Average 02 Content of Stack Gas, ¥ by Volune 0.3 o3 0.3 0.0 on Fixed Carbon Recovery, ’ 200 78 93 100 16 3 off cas recycle b= includes water vapor ce - estimated 48‘the inclusion of a flash dryer is considered extremely important for achieving high thermal efficiencies (70 percent) for carbon~ se age sludge drying, pyrolysis and activation with an indirect- fired rotary calciner. JPL concluded that although direct~fired furnaces such as rotary kilns and multiple-hearths provide high thermal efficiencies independent of a flash dryer, they are sub- ject to high powdered carbon losses in the stack gases as well as high carbon oxidation losses from air leaks and/or oxidation flames. In addition, they felt that the multiple-hearth units are expensive relative to rotary calciners. Preliminary cost evalu- ations suggested a factor of 2 to 3 difference in installed equipment costs. Other cost factors such as equipment life and maintenance charges alter the impact of initial equipment cost differences on the overall process economics Pyrolysis and activation tests were conducted in pilot test equip- ment including direct fired rotary kiln, indirect-fired rotary calciners and multiple-hearth reactor, Table 10. Initial testing was conducted at Versa-Tech, Louisville, Kentucky, in a 6 1/2 inch I.D. by 7-foot long by 3-foot electrically heated rotary calciner. Feed rates were at 5.7 to 9.7 lb/hr of wet (31-48 percent mois- ture) carbon-sewage with a retention time of 9 to 14 minutes at wall temperatures of 650-760°C. Steam activation was low because of operational problems with the amount and temperature of steam injected. However, despite the mechanical problems of operation carbon-sewage sludge was pyrolyzed and activated. Activation was low. Iodine absorption was measured at 288 to 367 mg/gram carbon The low activation was accompanied by a corresponding high yield of carbon, 98 to 127 percent based on the activated carbon feed Later tests were conducted at the Combustion Engineering test facility at Springfield, Ohio. An uninterrupted 50 hour test was conducted on a 6 1/2 inch I.D. by 11-foot long, 6-foot natural gas fired rotary calciner. Feed rates were 8 to 10 lb/hr with a very wet (73 percent moisture) carbon-sewage. Temperatures were varied from 600 to 900°C, solids retention time from 10 to 20 minutes and steam rates from 0 to 1.3 lb/hr. The resulting carbon activation had an iodine adsorption of 330-590 mg/gram carbon. Yields were from 65 to 125 percent based on activated carbon feed. Hourly samples were taken of product carbon and analyzed for iodine adsorption and ash content, Product dis- charge was segregated and weighed on an hourly basis. Very close monitoring of the operation was achieved. Initial operation was at 600°C and then increased by 100°C increments. It was readily evident that temperatures below 800°C were inadequate for pyrolysis and activation. The product carbon especially at the lower temperatures of 600 and 700°C retained some of the sewage odor and showed very low activation. Test results in the region of 800 to 900°C were very promising for obtaining good pyrolysis and activation. At 15-minutes retention time and 830-850°C there appeared to be a threshold rondition for carbon activation 49set-oe 009-086 fuon obser pue axeor aye wend sainsay oATaeban ser-so oss-ore ayat 9 - ems Deosé-or9 = “dae se) TWrOR/qT 9005 “24/aT SL pw dee worswoqoN 9 evens ‘amaeTon worreredo o-2-5:0 sber0s/,uoRte D.080 - “dss, ayat o€ une on. woyseunen #prTos veg - armasrow woraezefo m2 fonts "beng uae) [ny/¢33 1-1 ‘usfoxatH Swat ¢°1-0 Taras 2006-009 = “hess, $PTTOS svat 0 uyw de-or worqaved sPFTOS neg = eames woraesodo 24 05 8°T-9°0 *968n9s/,uo9rD eas ot *abox4eH ‘ri/at pono “wean e094. '059"~ uae 50 2.098 '000 = “dru 11H aya U6 = 15 uuu FE-6 ‘uoFauoe sPtL0s Mes assim ot * (ur uoqzes 290 WORE) = BIOTA AZ (wez6,t yop = “sae ourper) 09-9 szea-1 perta 529 reamsen ao9z1a “20etd UE sunawou 2/t z Wanm soeuang waren 9 x ca “Ur oe no *proys6urs4s Serzsourbug uorasnceog “uTTa ‘Kavioy partde#09 TEIN boot az ate “arn “ur St 0 provséurids ‘buyseout6e3 uoynencmen aUsOTED AI0I08 remen 7 9 suot az tex a'r “ur ct 9 poveon Arteatssoora 33 Loe-n02 omi/s c= teu SCT Feet tOBEROS/ uORED BIO AT Cx “OT “UT z/t 9 ¥ 57tay BIT RIO SF OTA HST pen curpor Sbenos-oaze9 aararaow ToS FUPTTNOSH INGWAINOI LS LOIId NI GOWMAS-NOMYVO JO NOILWAILOW GNW SISATONAE ot sTav, 50A temperature of 850°C indicated significantly higher activation and lower yields than operation at 830°C. Increased retention time (20 minutes) at 830°C was found to increase the extent of activation but not as greatly as a temperature increase from 830 to 850°C. A short duration test was attempted in a 15-inch diameter by 12- foot long natural gas, direct-fired rotary kiln. Feed was 30 1b/ hr for a 10 minute retention time at 850°C. This test was unsuc- cessful but it did emphasize some negative aspects of the direct- fired rotary kiln for carbon-sewage pyrolysis and activation. Approximately 5000 pounds of wet carbon-sewage sludge (58-72 per- cent moisture) was used for 66 hours of operation of a multiple- hearth reactor at Nichols Engineering and Research Company, Belle Mead, New Jersey. Tests were conducted in a 36-inch I.D. by 6 hearth reactor with the top 3 1/2 hearths removed. This change allowed operation at a feed rate of 75 lb/hr. A dry cyclone on the exhaust gases provided for capture of powdered carbon leaving the multiple hearth with the exhaust gases. This was followed by a water scrubber and afterburner. Operation of the multiple hearth was carried out with the after-burner both "on" and "off." Approximately 5 to 20 percent of the product carbon was recovered in the dry cyclone and wet scrubber as carry~ over from the multiple hearth by the exhaust gases. Initial operation of the multiple-hearth was conducted at a com~ bustion gas temperature of 950°C with the bed temperature 100°C lower. Under these conditions, activation of the carbon was high iodine adsorption was greater than 1000 mg/gram carbon, but yields were low (70 percent or less, yield based on activated carbon feed). To improve carbon yield, gas temperatures were reduced to 840°C. Carbon activation was accordingly reduced, iodine adsorp- tion was reduced to 350 mg/gram carbon, and yields increased up to 126 percent (activated carbon feed). The combination of feed rate and rabble arm rotation at 1 RPM provided approximately 30 minutes solids retention in the multiple hearth. Care was exer- cised to maintain the multiple hearth at a slightly positive pressure to eliminate air leaks. Burners were kept slightly fuel rich (up to 10 percent excess fuel) to maintain a reducing flame. With these provisions, the test results of carbon acti- vation and yield from the multiple-hearth reactor corresponded to that obtained in the rotary calciner. Since the combustion gases firing the multiple hearth contained approximately 20 percent moisture, no need was found for separate steam injection Achieving carbon activation was not a problem with proper acti- vation temperatures. Gas samples of off-gas were obtained from the gas holder at Versa~ Tech in the operation of the electrically heated rotary calciner and also from the off-gas line of the gas-fired rotary calciner 51at Combustion Engineer's test facility. The gas analyses are presented on a dry and nitrogen free basis in Table 1l. The energy value of this gas was approximately 300 Btu/ft3. MULTIPLI EARTH FURNACE Multiple-hearth furnaces of the type illustrated in Figure 16 have been used extensively for the regeneration of granular acti- vated carbon, Although it is known that Nichols Engineering and Research have carried out some studies on regeneration of spent powdered activated carbon used in municipal wastewater treatment no published information could be discovered on the use of this system to regenerate powdered activated carbon. However, a multiple-hearth furnace is under construction at DuPont's Chambers Works Plant for regeneration of spent carbon from the PACT pro- cess. DuPont selected this method after detailed study of several alternative regeneration techniques. TRANSPORT sysTEM?‘~36 Westvaco Corporation has developed and commercialized a patented method for powdered carbon regeneration (U. S. Patent 3,647,716). A 20,000 1b per day unit was placed in operation at Covington, Virginia, in early 1971 to regenerate spent carbon from corn syrup refineries. A schematic of the system is shown in Figure 7s Spent carbon feed at Covington is a sticky solid of approximately 50 percent moisture exhibiting extremely poor flow properties To assure reliable feeding, a bin activator is utilized to with- draw spent carbon from a 24 hour storage tank. The bin activator serves a weigh belt feeder which in turn discharges the metered feed through a rotary air lock and into a pneumatic mixing tube. ‘The carbon is dispersed and suspended by a metered oxidizing air stream and pneumaticaly conveyed to the top of a vertical venturi- type section inside the furnace. Steam may also be utilized as the oxidizing stream on carbons with low organic loading. High velocity, high-temperature flue gas enters just below the venturi section and intensively mixes with the carbon-water-air stream above the venturi, resulting in instantaneous heat transfer and optimum gas/solid contacting. The reactor process steps are drying, volatilization of organics, burning of volatiles, and steam activation of residual carbon These steps occur almost simultaneously in the reactor above the venturi section in the space of a few seconds. The steam selectively activates any carbon residue left in the carbon micro- pore structure. Overall reactor temperature for these steps is 1,750 to 1,850°F, depending on spent carbon loading 52+s3Insoy qsey SutzecuTbua ‘UOTysNquod ‘CL/6Z/p FSRTNSOY YOSL-eSISA 'GL/EC-0Z/Tas TOyEM /UIBhOTITN TOF Po3D2ITIODy 186 9"s8 S76 er98 ores 68e Butgunosoy Te30% £70 - - - - - ufo ere - we - - - Pye - zo zo - zo - urs wet TLt Loot zat Lt0z eret 9 €-0T ort vet zret “79T so-et Yu UT v0 zo zo z0 zo Zo zyy Lr8e ortp orve roe 6It en ead zat oret T6t srt - “00 SL 762, SL/EC/-S__SU7ee7t=b _ L747 T=E__ Loe 7-2 __ SL7oz7T=T- TW TON) ¥SO5ED-376 sv9-da0 yvoved 3S9L NOLLVAILOV GNY SISATOWAG SOWMAS-NOgYVO JO SISATIVNY HaVEDOLVWONHD sv Tl aTave 53CARBON GAS IN out HEARTH 1 RABBLE ARM 2 3 RABBLE TEETH CARBON FIGURE 16. CROSS-SECTIONAL VIEW OF MULTIPLE HEARTH FURNACE 54WHESAS NOTLWYENEDAY NOMYVO GAYIGMOd OOVALSEM SHL dO OTMWWSHOS “LT auNOTE (91sd $) arent 38NL ONTXIN DLLvWn aNd 907 ¥I¥ 4303341739 HOTaM YOLYATLOW NIg 39v¥OLS 0334In the 10-ton per day unit at Covington, no more than 1 1b of carbon is suspended in the furnace at any instant, allowing almost immediate response to control changes. Good control of the sorptive activity of the regenerated carbon is maintained by careful attention to temperature, feed rate, and the air-to-feed ratio in the reactor. Once the proper con- ditions of feed rate, temperature and firing rate have been set. the process is reported to be extremely steady, and only minute trimming adjustments are necessary to hold the activity and yields in the desired range. Loadings of organic impurities in the range of 10-50 percent of the weight of the original carbon can be burned off with very little loss. It is generally possible to keep yields in the range of 75-95 percent, with lower loadings favoring higher carbon yields. For corn syrup spent-carbon, a yield relative to the amount of original carbon used in the pro- cess is about 80-90 percent. Suspended particles at 1,800°F exit the reactor via a horizontal refractory-lined duct to a downflow evaporative cooler in which the gas stream is cooled to 450°F with a three-compartment glass- cloth bag filter. The carbon is continuously discharged by air locks, conveyed by a water-cooled screw conveyor, and screened for any foreign material. A pneumatic conveyor then delivers the regenerated carbon to bulk storage tanks. Due to the high steam volume, all interior surfaces in the bag filter must be kept above the gas dewpoint. Dry collection was selected at Covington because the product is shipped to users by rail. Wet scrubber collection is considered practical and should result in capital savings if carbon is used onsite and stored in slurry form. By July 1973, the Covington operation was treating 12.5 tons per day of carbon from two corn syrup refineries with plans to serve as many as seven refineries in the near future. The operation of the regeneration furnace is now considered routine and is con- sidered to be a part of the production capacity at Covington. The major problem, now overcome, arose during the initial oper- ation and was related to slagging. Some of the slag was resulting from silica filter aids used in the corn industry This problem was resolved by shutting down the furnace once per week and removing the slag (about 100 1b per week) from the bottom of the furnace as a routine function. The other initial source of slag was found to be caused by leaching of nickel from the stainless-steel shell. This has been solved by instal- ling refractories within the shell. The Westvaco transport system for powdered carbon regeneration was piloted in conjunction with a pilot study of the DuPont PACT process. In this application, a mixture (approximately 5650-50) of waste activated sludge and powdered carbon were supplied to the furnace. No data on the pilot study were made available for use in this study. WET ATR O: zimpro, Inc., has investigated the feasibility of applying their Wet Air Oxidation process to regeneration of powdered activated carbon used in wastewater treatment. The regeneration process developed by Zimpro is shown in Figure 18 The flow scheme for carbon regeaeration is similar to that used by Zimpro in the wet air oxidation of sewage sludge and industrial wastes. Spent carbon is withdrawn from the wastewater contact system and concentrated by gravity thickening. Thickened spent carbon slurry at approximately 6-8 percent solids is pressurized to system pressure, mixed with compressed air and heated to a reaction temperature in the heat exchangers. Heated air and spent carbon slurry are conveyed to a reactor where selective oxidation and a consequent temperature rise occurs. Hot spent gases and regenerated slurry continuously pass out of the reactor through the heat exchangers where they are cooled while heating the incoming slurry and air. Cooled gases and regenerated carbon slurry are released directly back into the wastewater flow stream via a pressure control valve. The regen- eration system is designed to be thermally self sustaining so steam injection from an auxiliary boiler is required only during start-up. The system temperature is maintained in the 390-470°F range at a pressure of 700-750 psi. Temperature can be controlled by bypassing the heat exchanger or by multiple point air addition Turbulence created by air addition is thought to prevent and breakdown scale in the system, thus providing a self cleaning feature. Tt also improves the heat transfer zimpro has reported on several pilot and full scale projects which have involved the use of wet air oxidation for carbon regeneration. n one of these the wastewater treatment involved a CBC process that utilized powdered activated carbon and bacteria indigenous to sewage in a conventional activated sludge type flow scheme. The raw waste was a domestic sewage with a variety of industrial contributions. Spent carbon, consisting of about three parts of activated carbon solids to one part bio- mass was regenerated in a con:inuous wet air oxidation unit During an in-process study, several regeneration conditions were applied, the one of maximum severity resulting in a fixed carbon loss of less thsa nine percent. Solids were isolated from the regenerated carbon slurries, dried and examined for response to four selected chemical tests. ‘able 12 shows the results. 57WWHOVIG MOTd NOT“VUSNGOTY NOGYVO OXEWIZ “gl aUNDTa WALSAS LNSWLV38L ( > Nasu? OL yOLvavdas sve $$3140109 BOLYYIN39 woLovay dund NOTLY¥3N3934 y Noguyd sontv WuOLs KYU TS juugis Noguvd LN3dS 58The progressive increases in all relative efficiencies shows that the activated carbon, although loaded with impurities and mixed with biomass, can be processed by a continuous wet air oxidation reactor to give regenerated solids responding well to classical activated carbon tests. Relative efficiencies for methylene blue erythrosin, and molasses color are restored to a greater extent than that of iodine. The ash content change was from 6.0 percent to about 11.0 percent in each case. In the second study, a full-scale chemical-CBC treatment was con- ducted by slightly modifying the conventional primary-activated sludge plant. The wastewater was a domestic sewage heavily loaded with a paper mill waste containing clays, titanium dioxide, and polymer latex. ‘Treatment with alum and soda ash to neutralize the alum was accomplished prior to the CBC process The spent carbon slurry was regenerated by a continuous, full- scale wet air oxidation unit under three conditions with fixed carbon recoveries of 97, 97, and 91 percent. Table 13 shows the results of the four chemical adsorptions and BET total specific surface determination. 59TABLE 12 PROPERTIES OF REGENERATED CARBON FROM A BIO-PHYSICAL PROCESS Condition A B ¢ D E Adsorbate Relative Efficiencies, % Todine 24.0 29.2 30.4 52.9 56.3 Methylene Blue 24.2 24.2 31.2 63.3 65.3 Erythrosin 38.8 35.6 50.6 82.0 129.0 Molasses Color 65.7 74.2 83.5 9447 95.7 Percent Ash in* 100% Dry Solid Ulel 0 11-1 10.8 11.0 1.4 *Parent Carbon percent ash, 100 percent dry solid basis = 6.08 TABLE 13 PROPERTIES OF CARBON REGENERATED FROM A CHEMICAL BIO-PHYSICAL PROCESS Condition A B c Adsorbate Relative Efficiencies, & Iodine 32.8 48.9 57.6 Methylene Blue 68.5 95.7 119.6 Erythrosin 46.5 91.0 95.4 Molasses Color 85.6 90.8 93.9 Recovery of BET Surface, % 58.6 52.8 74.8 % Ash, 100% Dry Solid Basis 68.0 68.2 75.3 60SECTION 6 BASE CASE SELECTION At the beginning of the program, available published literature on powdered activated carbon wastewater treatment and regeneration technology was reviewed and pertinent data extracted. Following review of the data, personal contacts were made with firms and researchers responsible for original development studies on powdered activated carbon treatment and regeneration systems. These personal contacts involved both telephone interviews and site visits. Organizations contacted during the course of the program are as follows: cPc International EI DuPont de Nemours & Company Envirotech Corporation Facet Enterprises, Inc ICI United States Infilco Jet Propulsion Laboratory Neptune Microfloc Nichols Research and Engineering Orange County Sanitation District University of Washington Westvaco Corporation Zimpro Incorporated The activities of these organizations as related to powdered activated carbon technology have been previously discussed Interviews with individuals active in the field provided addi- tional insight into the intricacies of the various technologies. 61Prior to commencing the study, it had been hoped that a single base case could be selected for the economic analysis. This selection was to be based on technical evaluations of the merits of the various technologies. It soon became obvious, however, that selection of a single base case, while possible, would not provide the comprehensive analysis desired. No one process scheme clearly exceeded all others in performance. In fact, most of the processes reportedly were capable of producing high quality effluents. Moreover, the characteristics of the various processes are vastly different and the development efforts have proceeded along distinctly different lines at different locations. Therefore, it was decided to perform the economic analysis for at least one IPC system and one CBC system. After more detailed evaluation, two IPC systems and one CBC system were finally selected as discussed below. A similar problem exists with regard to evaluating the quality of carbons regenerated by different techniques. Although data exist on losses and recoveries of quantities of carbon in different regeneration systems and under different operating conditions, no standard test exists by which the effectiveness of regenerated carbons in wastewater treatment can be measured. None of the classic tests such as iodine, phenol, methylene blue, erythrosin molassess color, or BET can be used to accurately predict the performance of activated carbon in any of the wastewater treatment processes studied. ‘Therefore, the evaluation of various carbon regeneration studies carried out at different locations under different circumstances is extremely difficult. IPC SYSTEMS ‘Two stage countercurrent contacting theoretically provides for the most efficient use of powdered activated carbon. Both Infilco, in their work and Eimco, in their work on chemically clarified raw sewage, employed this approach as did studies on secondary effluent treatment conducted by the EPA at Lebanon, Ohio.?® Thus, it was considered important to include a two stage countercurrent system in the economic analysis. Of the development efforts incorporating this approach, the Bimco study represented the largest scale pilot operation, generated the largest body of data operated for the longest period of time, and was the only program in which carbon regeneration was carried out on a large scale It also represented a system in which phosphorous removal was accomplished. Therefore, one of the base case systems was patterned after the Eimco flowsheet, The Battelle-Northwest process was also selected as a base case system because it represented a widely different approach which had been successfully piloted on a large scale. This process being a single stage, short detention time type system represented a low capital cost approach. In addition, a large body of data existed for use in this study. 62The JPL system was not chosen as one of the base cases for several reasons. Only a limited quantity of data was available to this study. In addition, a larger scale demonstration program will be underway in the near future. This program should generate much better information on design and operating parameters, and process performance than is presently available. Thus, it was concluded that detailed analysis of the JPL system should be delayed until completion of the demonstration program. cBC_SYSTEMS Only a limited quantity of data, much of it unpublished and most of it on the bench scale, is available at this time on the contact stabilization-powdered activated carbon system. Based on work to date, this approach appears to be very promising but was not considered to be at a stage of development for consideration in this analysis. DuPon't PACT process, Zimpro's bio-physical process, and ICI's several studies have many similarities. The liquid treatment scheme is the same basic concept in all cases. However, most of duPont's work has been with industrial wastes. Zimpro, on the other hand, has generated much data on municipal waste. Therefore, the base case selected for the economic analysis was patterened most closely after Zimpro's bio-physical system. It should be recognized, however, that the main difference is in the regeneration systems and thus the economic analysis of the liquid treatment system should provide insight into the PACT process economics and activated sludge-powdered carbon systems in general. REGENERATION SYSTEMS For each of the base systems, the regeneration system utilized in the original developmental work was maintained for the economic analysis. This provided a system for which actual field data existed for a regeneration system working in concert with a treatment system. Thus, a FBF was selected for the Battelle and Eimco systems, and a wet oxidation system in the case of the CBC system. Although pilot data was generated for the transport system, work- ing in conjunction with the DuPont PACT process, it was not made available for use in this study. Nichols Research and Engineering provided information which enabled an economic analysis to be performed for the multiple hearth furnace for all of the base case processes. CPC International did the same for the AST system. Tt should be noted, however that actual pilot plant experience for these two systems working in conjunction with the various wastew-‘or treatment systems does not exist and that ther: in 1 tree e of uncertainty 63in the economic analyses in these latter cases. For the multiple hearth furnace full scale operational experience will soon be forthcoming at duPont's Chambers Works. In summary, three thermal regeneration processes and the wet oxidation process are included in the analysis. 64SECTION 7 PROCESSES EVALUATED In order to determine the economic competitiveness of powdered activated carbon processes in the municipal wastewater treatment field, the costs of the following processes were evaluated for plant capacities of 1, 5, 10, 25, and 50 MGD * Activated sludge, conventional. * Activated sludge, single stage for nitrification * activated sludge, conventional followed by chemical coagulation, sedimentation, and filtration. ¢ Granular carbon treatment of chemically coagulated, settled, and filtered raw wastewater * Powdered carbon treatment of raw wastewater in a two- stage system as developed by Eimco. * Powdered carbon treatment of raw wastewater in a single-stage system as developed by Battelle-Northwest. © Powdered carbon addition to the aeration basin of the activated sludge process in a bio-physical process. The assumed raw wastewater composition is shown in Table 14. Table 15 presents estimated effluent quality parameters for pri- mary treatment and for the other processes evaluated. This table should be used with caution since the values given are only esti- mates. A higher degree of uncertainty exists in the case of the powdered carbon systems since the estimates were derived on the basis of extrapolations of data generated in developmental studies Process flowsheets and design parameters are given in the next section with the corresponding economic data. 65TABLE 14 ASSUMED COMPOSITION OF RAW WASTEWATER (VALUES IN mg/l UNLESS INDICATED) Raw Sewage Solids, Total 700 Dissolved Solids, Total 500 Fixed 300 volatile 200 Suspended Solids, Total 200 Fixed 50 volatile 150 Settleable Solids ml/1 10 BoD,-20°C 200 ‘toc 200 cop 500 Total N 40 Organic N 15 Free Ammonia 25 Nitrites 0 Nitrates 0 Total P 10 Organic P 3 Inorganic P 7 66Bt - - - - & - - (1/pu) x-fon € ez ez ee ez 1 €@ sz (pa) nan Be sz sz sz se sz sz ze (r/suy N Te20% “9 “9 £0 ca) To “9 we 86 (1/600) @ Teron oz or ot L so st se o (1/50) sprites © popusdsns oz oz oz oz st st sz ort = T/u) cos Sseoorg ~Sse00xd Bees0%d “WeISAS wOTIETITTT pue WOTIEOTITATIN “SBPATS JuSuyeOTT Teotséyd-org oTTea3eq cout —uoge)_-—=—sUoFaeTNBEOD e6pnts peveataoy Azewr za aeqnuez) ue eBpnts poqearaow poqeatiow, SOTLSTUSLOWAWHD ALITWAO INSNTSST SsaOOUa GALWWILSE ST STavLSECTION 8 PROCESS ECONOMICS BASIS FOR COST ESTIMATES The Appendix contains the cost curves used as the basis for cost estimates in this report. Some of these curves were developed for EPA by CWC under Task Order 3 of EPA Contract 68-03-2186. Many other curves were developed specifically for this evaluation The cost curves are based on fourth quarter 1975 cost levels. The capital cost curves for each unit process do include an allowance (25 percent) for contractors overhead and profit and a 15 percent contingency allowance. In addition, each includes an allowance for a proportional share of overall plant electrical system costs. Experience indicates that a 15 percent allowance for electrical system costs is reasonable. Blanket application of this allowance to each unit process may result in some inequities in electrical system cost allocation among the unit processes but when the treatment system cost components are added together, any such inequities will be balanced. Also, each unit process includes a 15 percent allowance for miscellaneous items to account for items associated with a unit process that would be defined in a unit takeoff from construction drawings for the entire plant but which cannot otherwise be accurately defined. Construction labor was estimated from the Richardson Estimating and Engineering Standards. In some cases, the labor required to install manufactured equipment was estimated by the manufacturer. Where such estimates were not available, the cost of labor for equipment installation was estimated as 35 percent of the equip- ment costs. ‘The capital cost curves presented do not include an allowance for costs of engineering, legal, fiscal, administrative financing during construction, or yardwork related to inter- connecting the various unit processes. These factors are added to the subtotals determined from the curves. The following sections present the detailed cost estimates for each of the processes evaluated. The report then concludes with a section which analyzes the relative economics of the various processes. Because the powdered carbon processes have not been widely applied and experience is largely on the pilot scale, the potential effects of changes in the assumed critical design or operating parameters and costs are also discussed. 68Some assumptions are common to all of the processes. It was assumed for the comparative, base cases that all sludges would be incinerated for all alternative processes. The potential impact of other methods of waste sludge disposal on the relative economics is discussed in the last eral administrative O&M costs (management analysis, yardwork, etc.) were not natives. The differences in these would be small (or non-existant in significant effect on the relative Land costs are not included in the discusses the impact that relative various alternatives could have on section of the report. Gen- clerical, laboratory included in any of the alter- costs between alternatives many cases) and would have no economics of the processes. base cases but the last section space requirements of the the relative economics based on varying land values. ACTIVATED SLUDGE, CONVENTIONAL Design Basis The activated sludge system schematic is shown in Figure 19. The major unit processes are primary sedimentation, activated sludge aeration and secondary sedimentation, chlorination, gravity thickening of primary sludge, dissolved air flotation thickening of waste activated sludge, vacuum filtration of the two thickened sludges, and incineration of the dewatered sludges. Effluent filtration and ultimate sludge ash disposal were not included in this analysis. Provisions for standby units were not included. The design conditions for raw wastewater characteristics and the primary sedimentation tank design with expected primary effluent quality are shown in Table 16. Using these primary effluent data and McKinney's model,*? the activated sludge system design criteria were developed. The aeration system design was limited to a maximum oxygen uptake rate of 70 mg/l/hr. A mean cell residence time of five days was used. ‘The return activated sludge pumps were sized for a one percent sludge concentration and completing a system solids balance. The secondary sedimentation basins were sized based on hydraulic overflow rate of 600 gal/ft2/day at average flow. The resultant design parameters are shown in Table 17. The chlorine contact basins are sized for a 30 minute detention time at peak dry weather flow (PDWF, 1.5 times design flow). A dosage rate of 10 mg/l was applied to the PDWF for sizing feed equipment. The gravity thickener sizing is based on a solids loading of 20 1b/£t2/day. Solids concentrations of five percent (influent and ten percent (underflow) were assumed. 69OLIWWEHOS SSAOO¥d AOGNIS GELWAILOV ‘6T TuNTS ‘TWsodsi OL HS¥ + 1 L NOLvYSNIONI T 300MS 03431VM30) wand wona¥A wagon asams enavonl von romana ay Te ee sin sans ivy ais TE __snems oarmusy wnios L a ree LN ae fu NouwaNamaas ‘#0N093S anamas3 aaiv3uL /NouMiNawas UaAVAaIsYR AU wee 1 ' 1 wounse Lb NOUN 70TABLE 16 DESIGN CONDITIONS FOR ACTIVATED SLUDGE PRIMARY SEDIMENTATION UNIT Raw Wastewater: Suspended Solids Volatile Content BoD, TemBerature Peaking Factor (Dry Weather Primary Sedimentation Design Parameters: Surface Loading @ Average Flow Suspended Solids Removal Sludge Concentration BOD, Removal Eetfuone Bob, 7 200 mg/l 75 percent 200 mg/l 20°C 1.5 800 gpd/ft2 65 percent 5 percent 30 percent 140 mg/1TABLE 17 ACTIVATED SLUDGE SYSTEM DESIGN PARAMETERS Design Parameters Activated Sludge Aeration Basins F/M, lb BOD,/1b MLVSS 6.355 MLVSS, mg/1. 3,150 Hydraulic detention time, hr 4 Mean Cell Residence Time (MCRT) days 5 Sedimentation Basins e Surface loading, gpd/§t” @ ADWF 600 Solids loading, 1b/ft*/day @ PDWF <35 Return activated sludge, percent of influent flow 46 Return activated sludge concentration percent 1 Chlorination Detention time @ PDWF, minutes 30 Dosage, mg/1 lo Gravity Thickener (Primgry Sludge Solids load, 1b/£t*/day 20 Solids concentration in, percent 5.0 Solids concentration out, percent 10.0 Dissolved Air Flotation Thickener (Waste Activated Sludge) Solids loading, 1b/ft?/day 20 Solids concentration in, percent 1 Solids concentration out, percent 3 vacuum Filtration o Solids loading 1b/ft*/hr hr 3 Polymer dosage 1b/ton 18 Solids concentration out, percent 16 Run time, hr/day 20 Multiple Hearth Incjneration Loading, 1b/£t*/hr 6 Downtime, percent 30 72The dissolved air flotation thickener sizing is also based on a 20 1b/f£t2/day solids loading. This solids loading was chosen so as to avoid the need for chemical thickening aids. Solids concentration of one percent (influent) and three percent (float are assumed. The vacuum filter sizing is based on a 3 1b/ft?/day solids loading and a 20 hr/day runtime. The polymer feed systems for the vacuum filters were sized based on 18 lb of polymer/ton of ary solids. Using a dewatered sludge concentration of 16 percent, the multiple hearth incinerators were sized for a 6 1b/ft?/hr loading (wet! solids basis) and a 70 percent operation runtime Unit process component sizes are summarized in Table 18. The only exceptions to the above criteria are the solids thickening and dewatering equipment for the 1 MGD design. The thickeners sized for the 1 MGD plant were smaller than available equipment so both primary and waste activated sludges are combined and thickened by gravity. Costs The capital and operation costs for the unit processes shown are developed through a review of the costs of actual plant construc- tion and operation, equipment cost data from manufacturers, and published cost data, These generalized cost curves should not be used for estimating a given plant cost but are readily usable for comparing alternative processes as in this report. Individ- ual plant costs must be developed based on the specific waste~ water treatment plant design, local labor and material costs, and local climatic and site conditions. Some of the limitations, in addition to the general local con- ditions discussed above, include no standby provisions, no specific modular sizing other than minimum available sizes, and no adjustments for local regulatory agency design restrictions. Capital Costs Sedimentation. The source of the construction cost curve for sedimentation was the report to EPA, "Costs of Chemical Clarification of Wastewater," January 1976." These cost data were developed from quantity takeoffs and equipment manufactures's estimates. ‘The cost curve in the Appendix shows construction cost as a function of clarifier surface area. 73+AybuTpao09e parsn(pe sy wa3sks paos romAToa “2VA4/ay Zes'Z TO YOIM/IU S*BY OG TTT ouya uorsexedO "23g ETT Jo woe soBJans © Sey YOTUN 9 X 9 P ST Pash ayUN aSOTTEUS ., setduexe dow T UT zeUeyDTYI Agzawrb Aq pousrxotys SebpRTs poreayaoe a3sea pu Arewyrd y208 (2) *auoueatnbea Zoqey pue 3802 uoTzoNz3sSUOD oUTUIEZ9p 03 pasn st AQTORdeD yeog “3502 sTeTIOIeU souvuaqureu pue quauerTNbex reMod ayy auyUIeI9P 02 pEsN ST MOTJ eBes9Ay ~ Aeog/obEIEAY 1) ov0'9 oz0’e otz’t $09 Tet za3 ‘uotaexourour wy zz ze'e we (ey 98°% 2Y/T ‘p83 xouktoa of9/T ste oze cot (eyeTT 233 ‘wore xoattz unnoen ost'z 560'T eer ere - gag "wore sovgans ‘z0uexOTUS uorge30Ta TY peATossta wz sse'T eos ue (2) 86 gaz ‘Pore eDe3zns ouayoyua AaTaes5 OPT'T/09% © oLS/oBE —BLZ/ZST_—HTT/94_ (8 'Ze/e"ST yeod/operoae xe0K/suoy ‘aueultnbe peed 000602 00S ’POT-— 008 Th 006/02 ost’ 33 ‘HUea 30eRuOD 33 ‘unto ‘uoraeuTzoTYO ose see ost se st ud6 ‘sduma o6pnts osz'z ser't ost see sb udb ‘sdumd ova S'PE/OEZ B°LT/S*TT 06°9/09° Sb"E/OE"Z (7) 69°/96" cow ‘sdumd sya ost‘es sist 0L9’9t see’e 1991 gaa ‘are ooesans syueg uoraequewTpas Arepuoces 000'z 000'T oor 002 ov dy ‘s202e70¥ O00‘STI’T O0S‘LSS 0OD’EZ_—=OOSTIT —ovEEZ £33 ‘eumTon syuEL UOTIeIEy 00s'z9 osz‘Te o0s'zt ose'9 osz'T 233 "Bere Boeyans syurg, uoTsequeupes AxewTIg quoucdwog 310 ssaoozg Tun oS ot or $ T gow ‘Aaqoedeg @OGNIS GSLVATLOY ‘SaZIS ssao0ua ZINA et save 74Aeration Basins. Historical aeration basin cost data has been updated with results of other detailed cost studies by CWC and recent costs obtained by Black & Veatch and CH2M-Hill. All data have been adjusted to the last quarter of 1975, Bureau of Labor Standards (BLS) wholesale price index for concrete products Construction cost as a function of aeration basin volume is shown in the Appendix. Mechanical Aeration Equipment. Cost data for instal- Ted mechanical equipment have been derived from experi- enced cost data and equipment costs supplied by manufac- turers. Return Activated Sludge Pumping station. The cost Felationshine for recyele pumping developed by Black & Veatch'! were adjusted and used as a basis for esti- mating the cost of the return activated sludge pumping stations in this study. The costs shown by Black & Veatch have approximately doubled due to inflation, stricter OSHA requirements, and regulatory agency reliability standards. The pumping stations are assumed to employ vertical diffusion vane pumping units with attendent valves, piping, and control facilities. The pump is suspended in the wet well and motors and motor control centers are housed in a superstructure. Waste Sludge Pumping Stations. Waste sludge pumping equipment costs are based on the use of intermittent sludge pumping with positive displacement pumps. The cost data presented in the Black & Veatch cost curves were updated for this study. Included in the pump station cost is an underground structure which houses the pumps and piping and is constructed adjacent to and in conjunction with the sedimentation basin. Also included is a superstructure which houses electrical control equipment. This curve is applicable to both primary and waste activated sludge pumping. Chlorination. The chlorine contact basin cost curve is based on the same construction used for the aeration basin cost curve. The chlorine feed equipment cost curve is based on chlorine gas feed and is taken from the draft report by CWC for the EPA "Estimating Initial Investment Costs and Operating and Maintenance Require- ments of Stormwater Treatment Processes. 15Gravity Thickening. These costs were developed using the samé approach used in the earlier CWC work.? Dissolved Air Flotation Thickening. The flotation thickener cost curve was taken from the CWC report.“? Steel fabricated units are available with surface areas up to 450 square feet. The concrete basin costs include the tank, flotation cell equipment, air compressor, and controls. Vacuum Filtration Costs. Vacuum filtration costs were obtained from equipment manufacturers and include the basic filter, associated vacuum and filtrate pumps internal piping, and other appurtenant equipment and controls. The costs for polymer feed and storage equip- ment associated with the vacuum filter were taken from the CWC report. Operation and Maintenance Costs The operation and maintenance costs consist of labor, power and maintenance materials. The individual cost curves were developed through a variety of resources including recent CWC work for the EPA and the Black & Veatch study."! In some instances, oper- ating plants were consulted for information on labor requirements. Sedimentation Basins. OSM requirements are based on the Black & Veatch report."! Mechanical Aeration. Operation and maintenance require- ments of the aeration system are expressed in terms of the installed aerator horsepower. Labor requirements are based on the Black & Veatch report."! The power requirements were calculated on the basis of an assumed oxygen transfer of 2 1b 02/hp-hr or 3.0 1b 02/kwh. Maintenance material costs are based on the Black & Veatch report. Return Activated Sludge Pumping Station. ‘The return TF —————— are based on the Black & Veatch report.*! The power requirements were developed using a head of ten feet and the pumping efficiencies shown in the Appendix. The maintenance material cost curve is an update of the Black & Veatch curve.*? Waste Sludge Pumping Station. Labor requirements for the waste sludge pusping stations are based on the Black & Veatch report. ‘The power requirements were based on a pumping head of 25 feet and a pumping efficiency of 40 percent (progressing cavity pumps) . Maintenance material costs were updated from the Black & Veatch report.*! 76Chlorination. Labor requirements and maintenance mate- yial costs for chlorination are based on the Black & Veatch report. The chlorine costs are based on recent suppliers quotes for one ton cylinders and tank car lots Gravity Thickening. Gravity thickener labor require- ments are based on data presented in the EPA Technology Transfer manual on sludge treatment and disposal,"? assuming a loading of 20 1b/ft2/day. The maintenance mate- rial costs were based on the sedimentation basin data. Flotation Thickening. O&M cost curves for flotation do not include chemical feed. The thickeners for this project were sized so as to require no chemical addi- tives. All three cost curves (labor, power, and maintenance materials) were taken from recent CWC work." Vacuum Filtration. The O&M cost curves were based on recent CWC work" but adjusted for 20 hr/day operation. These curves were developed with information obtained from Metropolitan Denver Sewage Disposal District experience, manufacturer's data, and the Black & Veatch report. ‘1! Polymer Feeding. The O&M cost curves for polymer feeding and mixing were based on recent CWC work.*® Labor requirements were based on actual plant experi- ence at Metro Denver. Power requirements were based on the use of plunger metering pumps and 6.4 hp-hr for mixing 100 pounds of polymer. Annual maintenance mate- rial costs were assumed to be three percent of the equipment cost. Multiple-Hearth Incineration. Labor requirements for multiple-hearth incineration were taken from recent cwc work'” and adjusted for 70 percent operation run- time (6,132 hr/year). The fuel requirements were pro- vided by equipment manufacturers for combined raw pri- mary and waste activated sludges, vacuum filtered to 16 percent solids. Power requirements were developed in the same manner. The Black & Veatch incineration maintenance material cost curve"! was converted to a square foot of hearth basis by assuming a loading rate of 6 lb/ft2/hr (wet), updated, adjusted to 70 percent operation runtime. Tables 19-29 present the cost estimates which are then summarized in Table 30. 7000/08T 000’0tT 000/09 000'Le o00/2t 000'0es 000’ ove 000’00z 000 ort 000'TS 000062 000’ 00z 000’ort 000'€6 000'ry 000/06» 000/09¢ 000'0zz 000’ 0Lt 000/sL 000’0rs 000’ 06¢ 000’ 0€z 000’ 09 00004 000'0s0'z 000’00z‘T 000’06s 000’0e€ 000/06 000'00z'T 000008 000‘ 06€ 000‘ Ez 000/29 000'00%'T 000006 000’0Es 000’09€ 000'ovt 000’009't 000'0%6 000‘ ovr 000’ 092 000"04 0S Se oT Ss T cow SOQNIS GEGVAILOY ‘S%SOO TwLTavo 6 aTava quoud nba uot eUTZ0TUD sutseg 30e]u09 auTroTUD uotaeis Sutduma eépnts Arewrza uoTieas Sutdumg eSpnts paaeataoy aaseM uoTaeas butdumg ebpnts pezeata0y wInzey sxueg, uoT3eqUSeUIT peg Azxepuooas auowdtnba uoTaer0y sutseg uoTIezEy syueg, uot qequoUTpes Axewy ag 78000'8TS‘zz 000/8ZL' FT 000‘0ns's 000'see's 000‘6t8‘z 00075ra’T 0007L0z7T 007007 0007zer 0007 Tez 000‘STz‘z 000‘ 6rb'T 000‘ ove 000’6us 000'2z ooo'Lsr ‘at 000‘zL0‘zt 000‘000'% 000‘bz8'b 000‘TtE‘z 000'L9z'z 000‘z8p°T 000098 000° z6s 000’ 8bz 000‘06T‘9T 000/06s‘0T 000‘opT'9 000‘zez‘b 000°4z0'z 00070007S 0007001’ 00070097@ 0007006'T 000700T'T 000° 06€ 000‘00z 00006 000/0s 000/LE 000‘000'T 000/09 000‘0LE 000‘0sz 000‘soz 000/09€ 000‘ o8z 000/06T 00008t v/N 000/09T 000‘ o¢T 000‘06 000/zL 000‘99 05 a oT $ T cow (*p, 3409) 6T stays SZS09 TWLTa¥O IWLOL woT3onz3su0D butang 3sezeqUT [eset ‘Testa “BupreauT Sug 1S09 NOTLONYTSNOD ‘TeLOL yZOMpIRR Tez03qs uoTaeroupouT abezoag pure peed rauktoa seaTTs wnnoe, zousyoTUL uorae30Ta ATW Peatossta qeusyoTUL Aytavig 79sos‘at ose se ose’ wn ovr SHOT eoueueaurey 30 aso Tenuuy aes oradamsuos Teng Tenwwy ze0'ore ous'9 TOE wT z9 oot o09're 209 wt wn ov0't oo» we 00s ws wn ove © 008 sot o00'0t oze ove'e ozo coo'orz o'r wt wn ove'e ous —a- ee woradumsne3 Tens xenog Tenuuy WO GOW T ‘SDaNIs aTLVATIOW oz atave aon voysezouyour pbexo3s pu poeg soatioa sestra umnoey, soUaOTYL UOTIEROTE ATY PeaTOSSTS ouoxoqus £37409 auoudtnbs uoraeurzoT49 surseg 3oe2u09 eutzoTUD Serding efpnts Azewtza Supdimg OSpNts peseATIOY |aseH burdung SSpnts poavayaoy ureaey uorarauowrpos Axepvoo9s auowdynbg uoraez9¥ surseg uoyez0y voyaeauowypes Azeupza 80eeeey ar ov 00°2t oz oer os’, we 006" o00'F ove 002 c00'9 we 009° eoueuaqurey 30 as0p Tenuuy aT ost’es9'T TOOT - 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oor'z ore obexoas pue poss xouktos o00'zs - 000'04s ove" seateg ene oot - 000"008 oor'e eusyoyua uoTaeaoTd 2T¥ peAToRETa our - 000'9 our seuexoyun Aa¥A025 000" _ ooe’e ueusyoba uoraeurz0THD we - ws wa superna 2983809 euTsOTKD 009's - 00s’ ose suydung obpnts Azeuyza ooo'et - oos'zz suydang ofpnts peataraoy o3seH os’ - 00‘0ut Suydimg ofpnts peseayioy uznaey 00" - uoraesuourpas Azepucoas 000’ 7 5 corte aueadenbg worseaey wn 7 we sureea vossezey 09's a o06'6 oot’e woyseauauypas Areutza soueeauyen 30 woradenaues woradumeuon ‘Tenuy so Tenuuy {ena teruy zoned (eRuUy WO GOW SZ ‘S9aNTS asLVATLOW €@ aTava 83096'6et TO 000'08 SReTTOd STE SOTH osueuoauren 30 3809 Tenuuy got * 008 008’ sse/Pr got ¥ 0ae DON" BOTT - ooe'z - 200'000'T - 00/0081 - ooo'et - ye - 00st - 000" - voo'ove - 0007 - 200’002 ‘ot - wa - 0007 TES | orsduneucy vor3dumsuco Teng Tens xonog Tenuuy 00" 08's o00*et wa 006" TOE SORT ‘enue WSO GOW 0S ‘SDaNIS aaLVAILOY ve aTeva aon vorsexoufour sBexoag pue peas zouttoa soaTta wmnoe, OUDXOTGL YOTAPR0TE AT poaToSsTa ouOxOTHE ArzaezD quoudtnbs voyaeurzoTa supeeg 39"3u09 oufz0TNO surdung efpnts Axestza Bupdung *6pnts peveayioy 92cm surduma oSpnts poreaaoy umaey uoraequoutpes Axepuesas juondinbz uorsez0y suysea uorsez0y uoraequowrpes Axeutca 84ACTIVATED SLUDGE, TOTAL ANNUAL COSTS Amortized Capital @ 7 2,819,000 x 0.0943: Labor 6,970 Hours @ $9/H Power 310,092 kWh @ $0.0 Fuel 6 3.8 x 10° scr @ $1 Maintenance Materials Chemicals Chlorine 15.2 Tons @ $220/1 Polymer 6430 1b @ §2/1b TOTAL Cost/MG @ Capacity TABLE 25 %, 20 Years 9 jour 2/ kwh -50/TCF on $373, 330 365 x 1 85 1 McD $266,000 62,730 6,200 5,700 16,500 3,340 12,860 $373,330 §1,023/MG‘TABLE 26 ACTIVATED SLUDGE, 5 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 5,885,000 x 0.09439 $555,000 Labor 16,590 Hours @ $9/Hour 149,310 Power 1,658,150 kWh @ $0.02/kWh 33,160 Fuel é 24 x 10° SCF @ $1.50/TCF 36,000 Maintenance Materials 43,340 Chemicals Chlorine 76 Tons @ §220/Ton 16,720 Polymer 32,193 1b @ $2/1b 64,380 TOTAL $897,910 $897,910 Cost/MG @ Capacity = $492/MG 365 x 5 86TABLE 27 ACTIVATED SLUDGE, 10 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 8,540,040 x 0.09439 $806,000 Labor 24,170 Hours @ $9/Hour 217,530 Power 3,128,200 kwh @ $0.02/kWh 62,565 Fuel 6 50 x 10° scF @ $1.50/TCF 75,000 Maintenance Materials 57,070 Chemicals Chlorine 152 Tons @ $220/Ton 33,440 Polymer 64,386 1b @ $2/1b 50 128,770 TOTAL $1, 380,375 Cost/MG @ Capacity = $42380.375 = sa78/uc 87TABLE 28 ACTIVATED SLUDGE, 25 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 14,728,000 x 0.09439 $1,390,000 Labor 43,960 Hours @ $9/Hour $ 395,640 power 7,598,200 kWh @ $0.02/kWh $ 151,965 Fuel 6 140 x 10° SCF @ $1.50/TCF $ 210,000 Maintenance Materials $ 120,710 Chemicals Chlorine 380 Tons @ $100/Ton $ 38,000 Polymer 160,600 1b @ $2/lb $321,200 TOTAL eee costs/u ¢ capacity = $2627.55 = s2e0/no 88TABLE 29 ACTIVATED SLUDGE, TOTAL ANNUAL COSTS Anortized Capital @ 7%, 20 Years 22,518,000 x 0.09439 Labor 70,510 Hours @ $9/iour Power 14,854,000 kWh @ $0.02/kWh Fuel G 300 x 10° ScF @ $1.50/TCF Maintenance Materials Chemicals Chlorine 760 Tons @ $100/Ton /Ton Polymer 321,200 lb @ $2/1b 2/1b TOTAL $4,415,060 Cost/MG @ Capacity = S$¢2t5+06 89 50 MGD = $242/MG $2,125,000 $ 634,590 $ 297,090 $ 450,000 $ 189,980 $ 76,000 $642,400 $4,415,060TABLE 30 ACTIVATED SLUDGE ANNUAL COST SUMMARY Annual Cost ($1,000) Amortized Capital Labor Power Fuel Maintenance Materials Chemicals Chlorine Polymer TOTAL Costs/1,000 Gals (Operating @ Capacity) 266 S |e $1.02 555 149 33 36 43 $0.49 90 MGD 210 806 218 62 15 57 33 129 1,380 $0.38 25 1,390 396 152 210 121 2,628 $0.29 50 2,125 635 297 450 190 $0.24ACTIVATED SLUDGE, SINGLE STAGE FOR NITRIFICATION The design of this system is based on a mean cell residence time of ten days to achieve nitrification in a single stage activated sludge system. Table 31 presents the design parameters for the nitrification system. Table 32 presents the resulting unit pro- cess sizes. Capital and O&M costs are based on the same sources described in the preceding section for the conventional acti- vated sludge system. Tables 33-44 present the results of the cost calculations. ACTIVATED SLUDGE WITH CHEMICAL COAGULATION AND FILTRATION This system consists of the activated sludge design previously described with downstream chemical coagulation and filtration. The chemical coagulation and filtration designs are the same as used for the granular carbon system described in detail later in this report. The process schematic is shown in Figure 20 and the design criteria are summarized in Table 45. Unit process sizes are shown in Table 46. Table 47 presents the capital costs. Costs for the chemical clarification, sludge handling, chlorination, and filtration portions of the system were obtained from work conducted by CWC under EPA Contract 68-03-2186. Appropriate cost curves are presented in the Appen- dix O&M costs are summarized in Tables 48-52. These costs were taken from component costs determined previously in the study. ‘Tables 53-57 summarize total annual costs for each capacity and Table 58 is an overall summary. GRANULAR CARBON TREATMENT OF CHEMICALLY COAGULATED, SETTLED, AND FILTERED RAW WASTEWATER The process schematic is shown in Figure 21. The design criteria are shown in Table 59. Gravity filters were used at all capac- ities. Pressure filters may be more economical in capacities of five mgd or less, but for comparative purposes, gravity filters were used in all cases. Filter costs were obtained from the earlier CWC report.‘ A minimum of four filters were provided to insure reliability. The other criteria are self-explanatory. Unit process sizes are shown in Table 60, Table 61 presents the capital costs. Costs for the chemical clarification, sludge handling, chlorination, and filtration portions of the system were obtained from work conducted by CWC under EPA Contract 68- 03-2186."° Capital costs for the carbon influent pumping and the carbon contacting system were obtained by updating the curves from the EPA Technology Transfer Manual, "Process Design Manual 91TABLE 31 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION SYSTEM DESIGN PARAMETERS Design Parameters Activated Sludge Aeration Basins P/M, Ib BODs/Ib MLVSS 0.20 MLSS, mg/1 3,270 Ayaraulic Detention Time, he 7 Mean Cell Residence Time (MCRT), Days 10 Sedimentation Basins Surface Loading, gpd/ft? @ xDWr 600 Solids Loading, 1b/ft2/day @ POWF 35, Return Activated Sludge, Percent of Influent Flow 6 Return Activated Sludge Concentration, Percent 0.8 Chlorination Detention Time @ PDWF, Minutes 30 Dosage, mg/1 10 Gravity Thickener (Primary Sludge) Solids Load, 1b/ft?/day 20 Solids Concentration in, Percent 5.0 Solids Concentration out, Percent 10.0 Dissolved Air Flotation Thickener (Waste Activated Sludge) Solids Loading, 1b/ft?/day i Solids Concentration in, Percent z Solids Concentration out, Percent 3 Vacuum Filtration Solids Loading 1b/ft?/nr 3 Polymer Dosage 1b/ton 18 Solids Concentration out, Percent 16 Run Time, hr/day 20 Multiple Hearth Incineration Loading, 1b/ft2/nr (Wet Solids) 6 Downtime, Percent 30 92jowosenbox s0geT pue 3609 Yor3en: ‘pue sqoasaynbex aanod es _ woehs poos aoektog “2804/4 s62'7 30 990K ing Bey worn 9 x9 8 #F pomN Fyn FeaTTOUS rus so6pnts posentaar sTmem pue Asmwyad Wee ep aroede> eo "3809 3 B6erONY — AeOA/ABOIONT oos's ose'z tort oss ort 23 ‘uorrexourour oo o core wo cess 2 suyat *p908 zeRktoa err ae use ove were pay feoay seatta mown osu't sue ose ser 23F ‘een osesang ‘soveXSTUE worexora aY poatoserg owe sse't as ue (260 zaz teary soezme oussoruy Arar) ort"tyos —_ons/one ez/est prion ereese-st syeoa/oser30 seon/suey nba peed 00%60 —005"For 0001 006 '02 vere £27 Sew 2eIH yo simran uoraeurset49 ost ser ost se st wod6 ‘sain ofpers 0081 006 oor ont 9 235 ‘edna oem srts/srre erse/eut — CrOL/0S"9 aI “s/sb-e cort/69 ‘oom ‘oduna svat osetra — su9tty oso seca es0't 2a7 tesa soegan5 ques woraeauomypes Arepuoses 00s’ ose't oe ose ot 84 ‘exoye20y vo0%es6"T —000'ses 00000 000" s6t 000"6e 27 ‘aupqon ‘HUE woTLeFOY oos'z9 —se’te oostet oes ose’ a3 teas 2983205, squey uofaeruoetpes Krew sa OE oe —T Far a eesoezg run NOTIVOIAINLIN FOGNIS GHLVAILOV SOVGS STONIS ‘sazIS sSaOo¥a LIND ze aTavL 93000'09T, 000‘ oat 000’0es 000 ‘062 000/009 000'099 000’0s0'z 000‘00z'z 000’ o0t’z 000‘009'T os 000‘0Et 000 “ort 000‘ ove 000 ‘002 000/0er 0000s 000‘ 00z't 000‘o0s't 000’ 00%/t 000 ‘ore sz 000/06 000’09 000’ 00z 000‘ovt 000’0Lz 000‘00¢ 000065 00008 000’0s8 000‘o»r ob ‘cow 000 ze ooo’Le 000’ ort 000/86 00006T, 000 ‘007 000‘oce, 0000s 000’ ors 000097 000's9 000'zt, 000'TS 00°99 000’06 000'98 00006 000’0et 000’ ozz 000'04 xeuoyOTUL Aatarig quowdrnba woTaeETZOTUD sutseg 3023009 ‘euTzoTUD voqze3s Surdung Sbpnts Axeutza uoqaeas Sutduma eSpnTs peweaTapy e3sey uoTaeas, Sutdumg o6pnts pesvataoy uznaoy sxury uoTqequewrpas Axepucoos, quowd nby, uoTzez0y suyseg woyaezoy sxueg uoyaequeuTpes Axeutaa NOLIVOIGINLIN SDGNTS GHLVATLOY ADVIS ATONIS ‘S~soo TwLTdvo e€ HTaVL 94000‘ ts6’ rz 000‘ store 000’ rsp'z 000'zsp‘oz o00'zts‘z 900'ov6 "et 000'o0a's 0000s 000 0r6 000'oEe 000'ztz‘9r WoO vEET 000'009't o00'sce*eT 000’ae9’T 000’ 00L'TT 000'006e 000’ sz 000'009 coo'osz 000'z09"6 00" TLE 000'sz6 000‘ 902°¢ 000'9%6 000'092'9 000008'z 000‘00t 000’ ore 000’o8t (7,340) 000’sez’9 000’090/e doOTTs DOO" Tse 000’eT9 000’ toe. ooo’ztt’s 000’s0s’z s1s02 ‘TETaKO THIOL uoTzonr3su0) Buying 3sezequT yeboq ‘Testa ‘uyaoouy6ua soo NOTLONEESNOD TWLOT. o00’sz9 000’ Boe 000r8b‘» 000'002/z 000'004'T 000’00T'T 000'zs o00Le o00'0ez —000’soz 00009T wn e€ aTava yzompreg Tex03ans uorsezeuToUr abero3§ pur peeg TeuKTOR 03TTd umnoea FOMOAOTUL uoraeaoTa ayW peatorsta 95obe‘oT got XE p96'6SP zIz'k 00n7E got * LE 0007SE 009°T on - 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000’000'zt 000° Tz wn - wn we 00s ‘6 - 000'0z 006’ ‘Baetiod ‘sterseven = S85 Teanyen “aos TE SanOn soueuequTeW 30 uoTadumsucg uoradunsuog —_z0qe ysoo Tenuuy Teng Tenuuy gomog Tenuuy = Tenuuy Tercn uorgezouTour aBex03$ pue peed xouXtoa oatta wnnsep ROUDyOTUL votze30Ta 7TV peaTossta xeuayorur Aypaez9 auomdynbg uoTzeUTZOTHD suyseg 3983009 eUTTOTED Surdang obpats Axewrra surduma afpnts perearaoy 22seH suydung S6pnTs peqeaTaoy wznaoy uoqaequeurpes Arepuoses quowdinbg woTzez0N sutsvg woper0y uorzequewrpes Areurag ‘NOTINOIGIUGIN BOANIS GHLVAILOW HOVLS TIONS ee aTaws 100TABLE 39 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION, 1 MGD TATAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 3,060,000 x 0.09439 Labor 7,212 Hours @ $9/Hour Power 459,964 kWh @ $0.02/kWh Fuel 6 3.7 x 10° scr @ $1.50/TCF Maintenance Materials Chemicals Chlorine 15.2 Tons @ $220/Ton Polymer 5,851 lb @ $2/1b TOTAL $40,272 Cost/MG @ Capacity = $1,097/MG 365 x 1 101 $288,833 $ 64,908 $ 9,199 $ 5,550 $ 16,840 $§ 3,340 $§ 11,702 $400,272TABLE 40 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION, 5 MGD TOTAL ANNUAL COSTS Ammortized Capital @ 7%, 20 Years 6,236,000 x 0.09439 Labor 17,010 Hours @ $9/Hour Power 2,317,100 kwh @ $0.02/kith Fuel 6 22 x 10° ScF @ $1.50/TCF Maintenance Materials Chemicals Chlorine 76 Tons @ $220/Ton Polymer 29,298 lb 8 §2/1b TOTAL $939,868 Cost/MG @ Capacity = S¢e-te- = $515/MG 102 $588,616 $153,090 $ 46,340 § 33,000 $ 43,510 § 16,720 $58,592 $939,868TABLE 41 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION, TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 9,402,000 x .09439 $ Labor 25,650 Hours @ $9/Hour $ Power 4,612,200 kWh @ $0.02/kWh $ Fuel 7 46 x 10° scr @ $1.50/1CF $ Maintenance Materials $ Chemicals Chlorine 152 Tons @ $220/Ton $ Polymer 58,59. lb @ $2/1b $ TOTAL sl, Cost/MG @ Capacity = S}¢g°6.501 = saio/me 103 10 MGD 887,455 230,850 92,244 69,000 66,330 33,440 117,182 496,501TABLE 42 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION, 25 MGD TOTAL ANNUAL COSTS Amortized Capital @ 78, 20 Years 16,272,000 x .09439 Labor 46,890 Hours @ $9/Hour Power 10,913,800 kWh @ $0.02/kWh Fuel 6 130 x 10° scF @ $1.50/TCF Maintenance Materials Chemicals Chlorine 380 Tons @ $100/Ton Polymer 146,146 lb @ $2/1lb TOTAL Costs/MG @ Capacity = *3.5Aoe5= 104 $2,022,111 = $309/MG $1,535,914 $ 422,010 $ 218,275 $ 195,000 $ 120,620 $ 38,000 $242,292 $2,822,111TABLE 43 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION, 50 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 24,951,000 x .09439 $2,355,125 Labor 77,490 Hours @ $9/Hour $ 697,410 Power 21,293,000 kWh @ $0.02/kWh $ 425,860 Fuel 6 280 x 10° scF @ $1.50/TCF $ 420,000 Maintenance Materials $ 180,460 Chemicals Chlorine 760 Tons @ $100/Ton $ 76,000 Polymer 282,292 lb @ $2/1b $584,584 TOTAL $4,739,439 Cost/MG @ Capacity = 54,139. 489 = $260/MG 105TABLE 44 SINGLE STAGE ACTIVATED SLUDGE NITRIFICATION ANNUAL COST SUMMARY Annual Cost ($1,000) le amortized Capital 289 Labor 65 Power 6 Fuel 6 Maintenance Materials 17 Chemicals Chlorine 3 Polymer 12 TOTAL 400 Costs/1,000 gals. 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000'00rT 000 FT uoTaexaTTa wnnoeA oos - 000'00r'T 0059 SuyuexoTuL UOTIeIOTE 008'T - 000'2t 0r'T BuruexoTus AaTAez 000° - 000/98 oze burduma oSpnts TeoTWSUD 000'6t - 000'S% ors Surdima o6pnts poyeaTaoy easem 000’6 - 000’St ore surdung efpnts Areutza o08’T - 000'bz oot’z e6pnts ‘xouktoa ose - 00's oz reqenaasem ‘ xeuATOR 000'z - 00/9 000'z wnty. sBurpesa TeOTWEUD oos’€ - 000'st ooe’z juewdynba woraeurzoTuO - - - - suTseg 39equ09 oUTIOTUD 000/02 - 000" ove 000'8 uoraex3TTa 000/0T - ooz‘et 00'S OTSTIETO 006'€ a 00008 ose worseTnos0Ta oo8’z - 000/00z'T 008 surxta prded 00'S - 000/ ove 000’ Butdumg s6pnts peavataow umMI0u 000'et - 00002 006’s syuey uoTaequaWTpes Axepuoses 000'8T - 000'00z’0T 000" T yuoudmba uorzer0¥ - - - - sutseg uoTaez0y 00s'6 - 000'0z 006'P syuez uoyequeurpes Aremysa Swiied “stersereN “Se TeANTEN HT ‘SanOH FUSISTMOD SS050RE soueussuTeH 30 woradunsucy uoradunsuco = z0qe7 yso Tenuuy Tong Tenuuy xonog Tenuuy — Tenuuy dow 0S ‘NOTLWELIIG GNY NOILWINOWOD ‘TYOIWSHD HLIM SOan1s agLWATZOW zs Sav 17TABLE 53 ACTIVATED SLUDGE WITH CHEMICAL COAGULATION AND FILTRATION, 1 MGD TOTAL ANNUAL CosTS Amortized Capital @ 7%, 20 Years 3,733,000 x 0.09439 $352,357 Labor 13,578 Hours @ $9/Hour $122,202 Power 473,400 kwh @ $0.02/kWh $ 9,470 Fuel a 5.1 x 10° crs @ $1.50/TCF $ 7,650 Maintenance Materials $ 19,830 Chemicals Alum 190 Tons @ $70/Ton $ 13,300 Polymer 8,329 1b @ $2/1b $ 16,600 761 1b @ $0.30/1b $ 230 chlorine 4.6 Tons @ $220/Ton $_1,012 TOTAL $544,067 Cost/MG @ capacity = $344:967 ~ s1, as0/me 118TABLE 54 ACTIVATED SLUDGE WITH CHEMICAL COAGULATION AND FILTRATION, 5 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 8,059,000 x 0.09439 $ 760,689 Labor 25,130 Hours @ $9/Hour $ 226,170 Power 2,102,100 kith @ $0.02/kWwh $ 42,040 Fuel a 33 x 10° SCF @ $1.50/TCF $ 49,500 Maintenance Materials $ 57,990 Chemicals Alum 950 Tons @ $70/Ton $ 66,500 Polymer 41,659 1b @ $2/1b $ 83,300 3,805 1b @ $0.30/1b $ 1,140 Chlorine 23 Tons @ $220/Ton $5,060 TOTAL $1,292,389 Cost/MG @ Capacity = $4,292,389 - s7oa/uc 119TABLE 55 ACTIVATED SLUDGE WITH CHEMICAL COAGULATION AND FILTRATION, 10 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 12,419,000 x 0,09439 Labor 35,000 Hours @ $9/Hour Power 3,851,000 kWh @ $0.02/kWh Fuel fe 66 x 108 scr @ $1.50/rTcF Maintenance Materials Chemicals Alum 1,900 Tons @ $70/Ton Polymer 83,317 1b @ $2/1b 7,610 1b @ $0.03/1b chlorine 46 Tons @ $220/Ton TOTAL Cost/MG @ Capacity = $2,020,954 _ sssanuc 120 $1,127,394 $ 315,000 $ 77,020 $ 99,000 90,520 133,000 166,600 2,300 10,120 2,020,954TABLE 56 ACTIVATED SLUDGE WITH CHEMICAL COAGULATION AND FILTRATION, 25 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 21,761,000 x 0.09439 $2,054,020 Labor 60,850 Hours @ $9/Hour $ 547,650 Power 9,315,800 kWh @ $0.02/kWh $ 186,315 Fuel 190 x 106 scr @ $1.50/TCF $ 285,000 Maintenance Materials $ 168,450 Chemicals Alum 4,750 Tons @ $70/Ton $ 332,500 Polymer 208,294 lb @ $2/lb § 416,600 19,025 lb 4 $0.30/1b $ 5,700 Chlorine 115 Tons @ $100/ron $11,500 ‘TOTAL $4,007,735 cost/tg @ capacity = £4:907.735 ~ g439/u 121TABLE 57 ACTIVATED SLUDGE WITH CHEMICAL COAGULATION AND FILTRATION, 50 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 33,785,000 x 0.09439 Labor 97,420 Hours @ $9/Hour Power 17,991,000 kWh @ $0.02/kWh Fuel 400 x 106 scr @ $1.50/7c Maintenance Materials Chemicals Alum 9,500 Tons @ $70/Ton Polymer 416,589 lb @ $2/1b 38,050 1b @ $0.30/1b chlorine 230 Tonss @ $100/Ton TOTAL = $6,830,361 _ Cost/MG @ Capacity = 235° 24S5= = $374/MG 122 s s a jn ne a 3,188,966 876,780 359,820 600,000 272,180 665,000 833,200 11,415 23,000 6,830,361Leros beros ss*0s TL08 oy Ts T9E‘OEB‘9S SEL‘LOO’DS Gh6'OzO'7S EBE‘ZEZ‘TS L90 DHSS 007% oos7TT Oet70T 0907 zt0"T ST9‘ PPB ooe‘zzp 006’89T Opp rs ogg ‘9T 000/s99 oos‘zee o00‘eeT 00S'99 oe ‘eT ost ‘ZLz ost ‘89T ozs’06 0664S oe ‘et 000/009 000’sez 000'66 005 ‘6r oso’e oza‘6se ste‘98t ozo’Le ovo‘zp oLr'6 ogL‘9L8 os9’Les 000’ste oLt‘9zz zoz‘zzt 996/S8T’E SEL‘L00'F = HGE*LZT‘T —-6 89094 use‘zse 0s sz oT S T NOTLWINOWOD TWOIWSHO HLIM HOGNTS GaLVAILOW Gow “A;toedea (000/T$) 3809 Tenuuy RIVAWNS LSOD TWANNY NOILWULIIG Ny 8s aTawL (A3T0edeo @ Surqesedo) STeD 000‘T/s3500 TWLOL eurz0Ty xowk Toa unre ssTeOTUOYD STeTIO3eN souvusquT eH qeng wemoa zoqet Teatdeo peztzz0uy 123OLLWWEHOS WHLSAS NOSUVD UWINNVED ‘Tz oraezouyour| a ae3Tta unnoen f aeq3Tae1D mina 124TABLE 59 DESIGN PARAMETERS FOR GRANULAR CARBON SYSTEM Chemical Treatment Coagulant, Coagulant Dose, mg/1 Polyelectrolyte Dose, mg/1 Flash Mix Time, Min Ploceulation Time Clarifier . Hydraulic Loading, gpm/ft* (peak) Gravity thickener Solids Loading, 1b/ft”/day Underfiow Solids, Vacuum Filter (20 hr/day operation) Feed Solids, % yield, 1b/ft?/nr Cake Moisture Content, ¢ Lime Dose, * by Weight Multiple Hearth Incinerator Loading Rate Downtine, * Granular Media Filter type Average Hyaraulic Loading gpn/tt? Nunber of Filters, Minimum Average Backwash Recycle, § of Filtrate Carbon ‘Treatment Carbon Contactor Average Contact Time Carbon Dose, 1b/mg 125 Alum 125 0.25 L 15 (G = 70, Vertical Turbine) 5 2.8 75 40 7 UW (wet) /ar/ee? 30 Gravity, Tri Media 5 4 3 Upflow, Countercurrent, Expanded 30 Min 1,500Chlorination TABLE 59 (Cont'd.) Contact Time @ PDWF, Min 30 Dosage, mg/l carbon Regeneration Furnace Type Downtime, Loading Rate Carbon loss 5 (max) (3 ave) Multiple Hearth 30 2 40 Ib carbon/ft*/aay 88 /cycle 126ous azz 000’ 60z ooL’z osy'est se o00't oce't os'h osz‘z oos’z ossT ose ‘or oot oot’ss ose'69 sez tt oos’ Pot ose’T szu'9e sue oos sus sere S2t't osz'T 826 sut's oos’e oss'ze sis're ott Osh 008 ‘te ors o69‘oe st coz ose 06°0 ose cos ove oo'z con't ozo'et os6'et veuy3 yo qusczed og ung ‘oowurng ozts umuTUTHy, ores yt Brze osc 006/02 ost’y ouz (use sve'st 690/e su st oot oz set se sro 60°0 sez Sh osz os sat Le seo'T Loz oz ovt ots’9 zoe'T su6'9 see't sop 6 3 z aq wee ebezeny BA/suoy, *p80q SUTZOTYO £93 ‘30R;U09 ourzoTYD ‘aoeuang uotqezouabioy uoqzeD 93 ‘Ton 70308309 wogzeD eATIO055q IH ‘Buydumg quentgur uoqzeo dB ‘Bur mg obpats Areupza su/qy ‘out ebpats Azeupza xu/at ‘Atoa ayqt woTY aageacisem, Feeg TeoTusyD 233 ‘Zoxex0uyour zak ‘x0aTta wensen Zag, RouDyOTUS sepats Axewpza zag ‘xeatts ga9 (3eTsTzeTO 33 ‘z03eTND90TS 33 TH prder SHZIS SSA00Nd LINN SWHLSAS NOGYYO YWIANWED 09 arava 127000‘o68'8e 0007S8T"e o00'sze’e. 000‘ Lia‘ ve Goo" Stee 000’ 29642 Dao OTT 000‘0¢s 000’006'¢ 000’00s “oT 000’000'T 000’02b 000‘ 00r 000/z9 000’ 00¢ 000’ 004€. 000’ 002‘, 000’ oor 000'006/z 000‘ 0022 000'09T 000‘ DET 05 000‘ t98'zz ooo tat 000’ 6r2'z oo0‘aec ‘et ooo TOE 000‘Le6*9t 900769 000‘ ore 000‘ 009'z 000’00r's. 000/095 000‘ oze 000/08z 000‘ ze 000'09T 000’ 009'z 000" 002 000‘ 00z 000‘ 006‘T 000‘ 00T‘T 000‘ 00t 000/92 se 000’L99/2r ooo" BEOT 000’ 9v2't o00’e8e ‘oT worse 000*80t'6 ‘DOOR 000*002 000’008't 000*008 ‘z 000‘o8e 000‘002 000‘ 09t 000‘@t 000" ot 000’ 006'T, 000‘ 00% 000’ 09T 000‘0s0'T 000‘ orp 000‘ss 000‘ Le OF asi o00'sze's ‘00 zes 000’ 6ts 000'rz8"9 ‘000 SEE 000'986"s oo07zz 000‘ ort 000‘ 00r‘T 000/002‘T 000'09T 000‘ 0st 000‘ 00t 000’ eT 00's 000’ oon’ T 000‘ 0zz 000‘ oTT 000's89 000’ 0¢z 000‘ se 000'ez g o00'LeL' 0007 Bee 000‘998 000’ ces"e v00"Cie 000’ 90P'e 007% 00'S 000‘ 0st'T 000‘ 0sz 000'sb 000's9 000’ 0% 000‘ ot 000‘ oe 000'000't 000‘ o6T 000'04, 000/06e 000'se o00'et 000'0T T Nomavo UVTANYUD ‘SLSOD TwLIavo 19 sav 1800 TWLIavO TwLOL uoTzonz3su05, butang 3sez03ur Tebor ‘qeosta ‘6uTZeauTbus S09 NOTLONYTSNOD TwLOL yx0mpreR, ‘Twzonens peed auTZ0TUD 30e3U09 oUTZOTYD waqshs uoTzeT8UDbey UOqTeD weqSshg 1039eqU0D uogreD futdumg quentzur uoqze3 ebpnts Azeuyza Sutdumg e6pnts. ouTT eppnts Arewrza toa wnt aqena3sey, peag TeoTuoyD zo3ereuTOUT xeqTTa umnoea TeUsyOTUL ebpnts Ameurza x0aTTa ZOq3TIETO qo3eTNS20Ta xTH prdey 128for Carbon Adsorption." Analysis of the regeneration costs in the TT Manual indicated that they were low when updated by the EPA STP index. Recent bids indicate that the EPA index does not adequately reflect the inflation of mechanically complex systems such as regeneration furnaces. Thus, data developed by CWC for multiple-hearth furnace systems under EPA Contract 68-03-2186 were used as the basis for capital costs of the carbon regener- ation systems. Tables 62-66 summarize O&M costs. Activated carbon costs were obtained from manufacturers. Labor and maintenance materials for carbon adsorption were obtained from the TT Manual curves. Power requirements for pumping through the carbon system were calculated based on a total head of 50 feet. The TT Manual curves for car- bon regeneration labor are in error (i.e., 24,000 manhours/year for 6,000 pounds a day for carbon is obviously far too high). Discussions were held with the authors of that portion of the TT Manual. Based on this, it was decided to use the CWC labor curve for multiple-hearth furnaces. The TT Manual curves were used for regeneration power and maintenance materials. Regeneration fuel requirements are based on the following data furnished by a carbon manufacturer during a recent design project to estimate on-site regeneration energy requirement: Btu Per 1b Carbon Reactivated Furnace Gas 3,000 Steam 1,250 Afterburner 2,400 ‘TOTAL 6,650 Tables 67-71 summarize total annual costs for each capacity and Table 72 is an overall summary. It was found cheaper to regen- erate carbon even at the one MGD scale rather than use the car- bon on a one time basis. POWDERED ;ARBON, EIMCO The process schematic for this process is shown in Figure 22. The design criteria are shown in Table 73. Incineration was assumed as the means of ultimate sludge disposal for the primary sludge in this base case. Most sources of unit process costs have already been described. Unit process costs not previously discussed are covered below. Powdered Carbon Feed Costs for powdered carbon feed were developed specifically for this project. Figures 23-25 describe the powdered carbon feed system design. The carbon is stored and fed in a slurry 129oe8’8r 000% oos't oe 008 o0z oot o0z 000'b 000%e oot o0s‘t ose oop osz ‘SHeTTOT 7STeTIOTEH soueuequTeW 30 3809 Tenuuy, OT ¥ STE oot’ vee got X OT 0007S S 000’ 04 - o0s's - 000' - oot’ - oop’ got ¥ STZ 000’08 - 000’ss - 000'T - 000'88 - ove 'e - ove’ - 000/42 “sep Teangen “aos Pi uoTydumsuep uoT3dumsucg Teng Tenuuy zemoa Tenuuy W830 GOW T ‘NOY¥D UWIANYED z9 aTava sso'zt ee ose ose se ooz't o0e 002 00s'T 002'T ore oos'z oss oot't ost SanOH soqeT renuuy AWOL uoTqereuebey uogzeD uotsdzospy uoqzeo uOFIeUTIOTYD eépnts Axeurza buydumg pnts peed ourT ebpnts Areurza Aqoa unty zazeme3seH, peag TeoTWEND zoyexourour aaaTFa unnoep, qoUaxOTUL eépnts Axeutza x0aTTs 20q3TIETO zoqeTnos0TE xtk prdew 130o0s’ue got * 9°6E oo9’ziz't —ote'zz 00r7S got e Ter ‘0007008 o00'F 008’ - 000" ose o08’t 008’t - - oro o0z'z - 000'zz oot 002 - 000’6 006’t oot - o0L'z oor ose - 009'z oor 00044 got * STZ 000" 0sz 006’e 000'02 - 000" 08T ooz'e oor - 008’ oor 002" - 000’stt 009’€ o08’T - 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000’ ose 'T - oos’e - 000'0zT - 000/09 ~ oos'e ~ 000’ o0T * EL 000/006 - 000’ 008 - 000/21 - 000'o6t - 009/9 - 000/ ov - 000‘ ozs “Se TemIeN dos Ux uoTzdumsucs, uoT3dumsuey eng renuuy zemog Tenuuy WO GOW SZ ‘NOMYVO BVTANWED s9 qTava ore ‘Ts 0007et 002’ 009/T o0€ oot’z oor o0z't 000/0T 005'6 009 o02's ove 'e oez oo anon roqeT Tenuy MLOL uoyaersuebey vogreD uotadzospy uogzeo woTqeUTZOTUD efpnts Axeurza Suydumg ebpnts peed ourT espnts Areuraa toa unty xoqEMoisen pasa TeoTueyD xoqez0UTSUT 393TTa umnoep AOUOYOTUL ebpnts Axewtig x03TT FOTETIETO zo3eTNOD0TE arn prdey 133000'stz got * ITE 00z‘vo0‘oT —0L0'z8 000°9T got ¥ Tet 0007009"T = 000"6T ozs‘Tt - 000’00s"€ — 000’9 00s’ - 000'st ooe'e 000'0t - 000 oez oor 008'z - 000'zs 00u'2 ose - 00's oer 000'2 - 000’9 000'2 000/0€ OT * OFT 000%0su‘T 000’8T 000'00r - 000’00s‘T —000'9T oor'z - 000'97 oot't 000'0z - 000'Lz, 0008 000'ot - o0z‘et 00's 006'¢ - 000'08 ose 008'z - oo0'ooz‘t 008 SyeTrod “STeqweven «= SED TeanaeN HS Ga ~«= Sano eouewoquTeH Jo uoTsdumstico votadumsoy —oqeT ysop Tenuuy Teng Tenuuy wemog Tenuuy — Tenutny WSO GOW OS ‘NOmIvO AVTONWID 99 aTava ‘TNLOL uorqexeuebay uoqre) uoradzospy uoqze9 uoyaeUTZOTYO espnts Arewtza buyduma e6pnts peog surT ebpnts Axewrza toa umty eqemezsem, peeg TeoTWeyD zozer9uToUL x03TTa umnoea FOUDyOTUL ebpats Axeutaa 03TTs A9y5TIETO x03eTRO90TI xTW prdey 134TABLE 67 GRANULAR CARBON, 1 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 4,737,000 x 0.09439 Labor 12,055 Hours @ $9/Hour Power 384,100 kWh @ $0.02/kWh Fuel 31.5 x 106 scr @ $1.50/TCF Maintenance Materials Chemicals Makeup Carbon 22 Tons @ $1,000/Ton Alum 190 Tons @ $70/Ton Polymer - Wastewater 7e1 1b @ $0.30/1b Lime - Primary Sludge 153 Tons @ $37/Ton Chlorine 4.6 Tons @ $220/Ton TOTAL Cost @ Capacity = eUete = $1,839/MG 135 $447,125 $108,495 $ 7,680 § 47,250 18,830 22,000 13,300 230 5,660 1,012 nile onan a 671,582TABLE 68 GRANULAR CARBON, 5 MGD TOTAL ANNUAL COSTS ® Amortized Capital @ 7%, 20 Years 8,325,000 x 0.09439 Labor 22,310 Hours @ $9/Hour Power 1,272,600 kiwh @ $0.02/kWh Fuel 39.6 x 10© scF @ $1.50/TCF Maintenance Materials Chemicals Makeup Carbon 109 Tons @ $1,000/Ton Alum 950 Tons @ $70/Ton Polymer - Wastewater 3,805 1b @ $0.30/1b Lime - Primary Sludge 766 Tons @ $37/Ton Chlorine 23 Tons @ $220/Tor TOTAL $1,238,977 _ Cost/MG @ Capacity = *'4725.977 = s728/mc 136 785,797 200,790 25,450 59,400 47,500 109,000 66,500 1,140 28,340 5,060 1,328,977TABLE 69 GRANULAR CARBON TOTAL ANNUAL CosTS Amortized Capital @ 7%, 20 Years 12,667,000 x 0.09439 Labor 31,550 Hours @ $9/Hour Power 2,275,200 kWh @ $0.02/hWh Fuel ie 68.4 x 10° ScF @ $1.50/TCF Maintenance Materials Chemicals Makeup Carbon 219 Tons @ $1,000/Ton Alum 1,900 Tons @ $70/von Polymer - Wastewater 7,610 1b @ $0.30/1b Lime ~ Primary Sludge 1,532 Tons @ $37/Ton chlorine 46 Tons @ $220/Ton ‘TOTAL cost /uc @ capacity = $24125.378 137 + 10 GD = $582/MG $ 1,195,638 283,950 45,500 102,600 76,570 219,000 133,000 2,300 56,700 10,120 2,125,378TABLE 70 GRANULAR CARBON, 25 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 22,861,000 x 0.09439 Labor 51,330 Hours @ $9/Hour Power 5,219,600 kwh @ $0,02/kih Fuel 164 x 10° scr @ $1.50/TCF Maintenance Materials Chemicals Makeup Carbon 547 Tons @ $1,000/Ton Alum 4,750 Tons @ $70/Ton Polymer - Wastewater 19,025 1b @ $0.30/1b Lime - Primary Sludge 3,830 Tons @ $37/Ton chlorine 115 Tons @ $100/Ton TOTAL Cost/MG @ Capacity = 244356542 = suse /uc 138 $ s 2,157,850 461,970 104,372 246,000 148,050 547,000 332,500 5,700 141,700 11,500 4,156,642TABLE 71 GRANULAR CARBON, 50 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 38,840,000 x 0.09439 $3,670,827 Labor 84,070 Hours @ $9/Hour $ 738,630 Power 10,004,200 kwh @ $0.02/kWh $ 200,100 Fuel 311 x 106 scr @ $1.50/TcF $ 466,500 Maintenance Materials $ 215,000 Chemicals Makeup Carbon 1,096 Tons @ $1,000/Ton $1,096,000 Alun 9,500 Tons @ $70/Ton $ 665,000 Polymer - Wastewater 38,050 lb @ $0.30/1b $ 11,415 Lime - Primary Sludge 7,660 Tons @ $37/Ton $ 283,420 Chlorine 230 Tons @ $100/Ton $23,000 TOTAL $7,369,892 Cost/MG @ Capacity = $14369+892 - saoasuc 139ov'os za69e‘L wee ovEez brit 0-99 0°960'T o°sTz S°99F T*00z 9°8eL B0L9e Os 9p 08 z9°9sT'h cut os*tt us Sze OrLbs So" 8PT o-9nz Le" POT orzo BrLsT'z don ALTOWAWS estos ey S2t'e 0798 zt°0t ez oreet or 6tz oon 9°z0T s'sh or rez 9°S6T'T 0 €L0$ 6Leze'T ve Bz 90's PUT s*99 0°60T slp bres syrsz 8°00 g7see s (000’TS) &soo TwANNY ze aay pe-Ts Ly TL €8°8T Step we s*g0T Lop T (Aq 7Oede9 qe Burqeredo) STPD 000‘T/S3800 TwLOD abpnts Axewrza - owpT SUuTIOTYO zoqemoysem - xowATod unTy uogqzep dnoxew sTeOTUBYD sTeqTxe7eW soueUszUTEH Teng xemoa qOgeT Teatdeo pezt3a0uy AYWHWOS SOD TYANNY NOs¥vo UvTANYES 140ISGHS MOT SSAQOUd WALSAS COWIE uoqzed paaezsuobay umopnora ousboy| pee poztprata ‘ee aunola (aoxezowrour) qesodere o2 afpnts, poxeaeneg agezatta || 241 o10/351 5 . 3 oe 4 i cs Sts 120 Stytact | 330309 goeac0s spree sores t ce mee Y soae Taos roT3 7701, uogaea n-092KTABLE 73 DESIGN PARAMETERS FOR EIMCO SYSTEM Chemical Treatment Coagulant Coagulant Dose, mg/l Polyelectrolyte Dose, mg/1 Flash Mix Time, Minute Clarifier ‘Type Hydraulic Loading, gpm/ft? (Peak) Gravity Thickener A Solids Loading, lb/day/ft Underflow Solids, % Vacuum Filter Feed Solids, % Yield, 1b/hr/ft? Cake Moisture Content, % Lime Dose, % by Weight Carbon Treatment Carbon Contactor Peak Hydraulic Loading, gpm/ ft Carbon Dose, mg/1 Carbon Slurry Concentration, g/l Underflow Concentration, % Gravity Thickener 2 Solids Loading, lb/day/ft Underflow Solids, % Vacuum Filter Feed Solids, % Polyelectrolyte Dose, 1b/Ton Dry Solids), Yield, lb/hr/ft Cake Solids, % Granular Media Filter Type Average Hydraulic Loading gpm/ft? Average Backwash Recycle, % of Filtrate 142 Alum 125 0.25 Flocculator-Clarifier 0.8 10 5 5 2.8 15 40 Internal Solids Recycle 0.8 300 10 20 12 12 10 8 27 Tri Media 5TABLE 73 (Cont'd.) Pluidized Bed Furnace Solids Loading, 1b/hr/£t? 3 Freeboard Velocity, ft/sec 1.2 Firebox Temperature, °F 2000 Operating Temperature, °F 1250 Carbon Recovery, & 90 Blowdown, % 5 Primary Sludge Incineration Multiple Hearth, Loading Rate 7 lb/ét2/nr (wet’ Basis) Chlorination Contact Time @ PDWF, Minutes 30 Dosage, mg/1 5 (Max), 3 (Ave) 143(pBul 0S-S) WHLSAS Gadd NO@YVO GALVAILOW GauaqMod 430334 © BovuOLS av aHw3n0 ‘ez muneTa ‘Auinie voao3 wing aovNo1s AWIMS NOEMYD Gnnowses20Nn fuing_ vou paiosausdeu yoni 40 30> pooaios wea) 1w0qi02 cranes 144(pS T) ONTGSad ANY SOWHOLS No@uvO daysaMod “Fz gUNOTa Ss duind paeg Lem 145(pBw 0$-S) ONIGSad ONY SOWYOLS NO@¥WO GausaMOd “sz syNOTE se yp paeds /Q0100N 1-00) IGA 1:001 146consisting of one pound of carbon per gallon of water. The major elements of the 5 to 50 MGD systems include 1. Carbon slurry pumping from regeneration furnace to underground storage basin. 2, Underground slurry storage and mixers with bulk unloading facilities. 3. Carbon slurry pumping from underground storage to elevated feeders. 4. Slurry feeders in elevated structure The one McD system includes only carbon slurry storage with mixers and a slurry metering feed pump The underground storage volume was varied with plant size with the following minimum storage provided: 1 MGD ~ 20 days; 5 MGD - 5 days; 10 MGD - 3.5 days; 25 MGD - 3 days; and 50 McD - 2.5 days The previously developed cWC curves*® for rapid mixing basins (G = 600) were used to estimate the costs of the underground storage basins. Pump and feeder costs were obtained from manu- facturers. Flocculator-Clarifier Manufacturer supplied equipment cost information coupled with CWC estimates of basin costs provided the basis for the flocculator- clarifier construction cost curve. O&M requirements were based on the previously developed" cwC information on flocculation and sedimentation. Reactor-Clarifiers These curves were obtained from the earlier CWC report." Fluidized Bed Regeneration Furnace Fluidized bed furnace (FBF) regeneration of powdered carbon has been demonstrated only on a pilot scale. Thus, there is a degree of uncertainty about the design criteria and any estimates of costs for full scale systems. Because of this uncertainty, the FBF costs receive added attention in the later analysis of economic sensitivity. Independent estimates of capital and OsM costs for full scale systems were obtained from two manufacturers (Envirotech and Copeland Systems). Both manufacturers rated their FBF systems at higher capacities (from 5 1b/ft2/hr in the smaller furnaces to 7 lb/ft?/nr in the larger furnaces than shown in Table 73. With the exception of power requirements, the data from the two manufacturers were in close agreement. The 147cost curves in the Appendix are based upon the capacities of the FBF systems as rated by the manufacturers rather than the 3 1b/ hr/sq €t. shown in Table 73. Fuel requirements vary with the size of the FBF system and range from 9,000 Btu/pound of carbon at 100 lb/hr to 5,500 Btu/pound at 10,000 lb/hr. The manu- facturers agreed closely on fuel requirements. Power requirements as estimated by Envirotech, ranged from 0.82 kwh/pound of carbon at 100 lb/hr to 0.6 kWh/pound of carbon at 3,400 lb/hr. Cope- land's estimates were 0.2 kwh/pound of carbon. The power curve is based on Envirotech's estimates with the potential impact of lower power requirements discussed later. Labor and maintenance material requirements were extrapolated from CWC's earlier work on multiple hearth furnaces. The FBF sizing for the plant examples was based on 30 percent downtime. It was found cheaper to regenerate carbon at the one MCD size rather than use the carbon on a one-time basis. Tables 74-86 present the results. POWDERED CARBON, BATTELLE Figure 26 represents a schematic of this process. Table 87 pre- sents the design criteria. The basis of most unit costs has been discussed in previous sections. Costs for centrifuging, sulfuric acid feeding, and tube settling were obtained from the earlier cwe report. ‘The carbon contactor costs were determined using the flocculator cost curve (G = 70). Rapid mixing costs are based on G = 300. It was found to be lower in cost to regen- erate carbon in the one MGD plant than to use the carbon on a one-time basis. Thus, regeneration facilities are included for all capacities. Alum feed costs represent only the makeup alum since the recovered alum is recycled with the powdered carbon. Credit of 9,500 Btu/lb of raw sewage solids was taken into con- sideration in determining the supplemental fuel requirements of the FBF furnace. This heat value essentially balances the heat required to vaporize the added water found in the Battelle pro- cess sludge relative to the Eimco process sludge (6.5 1b water/ 1b carbon vs 2.7 1b water/lb carbon). The heat required to bring the added water vapor up to 1500°F is equivalent to an added 2690 Btu/lb of carbon for the Battelle process sludge relative to the Eimco process sludges. Curve 101 reflects these differences in heat requirements POWDERED CARBON, BI! HYSICAL Figure 27 presents a schematic of this process. Table 101 pre~ sents the design criteria. Air quantities (mechanical aeration used as basis for cost estimates) are adequate for nitrification Costs for the wet oxidation system for carbon regeneration were obtained from Zimpro. The regeneration system was sized based upon 30 percent downtime -- consistent with the assumption made for other regeneration techniques. 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000'sz0"se = aT - 0000e2 - 000'0E ; 0007s 7 000*00u"» a 00's ; 200'9 (000/006 g0T * 008 (000*000"t ; 00°92 g0T X oF - 000'06t ; 000*000"2 - 000*082 - 000'002"T ST woTadmeuey woradimsveg Teng Tenney erg TRULY WO GOW OS ‘OOWIE 0g STavE oz0'68 cnot oe s8prts toqze9 oor sbpnts Axewy2a supdima 96eRTs 006 peog Area efpnts Loar oon pooa sur eepnts Areurxa oou'e uoazy3 oze. oa o00'z unty peed 120) 000'9 aaa 00'Tt seat Te unnoen, oor't xousxoTus, ‘s6pats woaze9, espars Areurza o0z's serra 000" er sxersTae TD 3o"au09 SPTTOS oor's —-zersFeTO-290T2 008 aw Pde, OH 2097 enuey 155TABLE 81 EIMCO, 1 MGD TOTAL ANNUAL COSTS amortized Capital @ 7%, 20 Years 4,918,000 x 0.09439 Labor 15,515 Hours @ $9/Hour Power 1,183,100 kWh @ $0.02/kivh Fuel 19 x 10© scF @ $1.50/TCF Maintenance Materials Chemicals Powdered Carbon 69 Tons @ $650/Ton Alum 190 Tons @ $70/Ton Polymer - Wastewater 761 1b @ $0.30/1b Polymer - Carbon Sludge 4,380 lb @ $2.00/1b chlorine 4.6 Tons @ $220/Ton Lime - Primary Sludge 153 Tons @ $37/Ton TOTAL $757,569 365 x 1 Cost/MG @ Capacity = $2,078/MG 156 $464,210 $139,635 § 23,662 28,500 $ 26,750 44,850 13,300 230 1,012 $ $ s $ 9,760 $ $5,660 $ 757,569TABLE 82 BIMCO, 5 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 8,863,000 x 0.09439 Labor 26,430 Hours @ $9/Hour Power 4,455,900 kwh @ $0.02/kWh Fuel 56.5 x 106 scr @ $1.50/TCF Maintenance Materials Chemicals Powdered Carbon - Makeup 345 Tons @ $650/Ton Alum 950 Tons @ $70/Ton Polymer - Wastewater 3,805 lb @ $0.30/1b Polymer - Carbon Sludges 35,040 1b @ $2.00/1b chlorine 23 Tons @ $220/Ton Lime - Primary Sludges 766 Tons @ $37/Ton TOTAL Cost/mc @ Capacity = £4,7264237 ~ soaojuc 157 836,579 237,870 89,118 84,750 72,550 224,250 66,500 1,140 70,080 5,060 28,340 1,716,237TABLE 83 EIMCO, 10 TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 13,610,000 x 0.09439 Labor 36,400 Hours @ $9/tiour Power 7,805,900 kWh @ $0.02/kWh Fuel A 95 x 10° scr @ $1.50/TCF Maintenance Materials Chemicals Powdered Carbon ~ Makeup 690 Tons @ $650/Ton Alum 1,900 Tons @ $70/Ton Polymer - Wastewater 7,610 lb @ §0.30/1b Polymer - Carbon Sludge 70,080 1b @ $2.00/1b chlorine 46 Tons @ $220/Ton Lime - Primary Sludge 1,532 Tons @ $37/Ton TOTAL $2,823,616 Cost/MG @ Capacity = 23p.43e05 158 MGD = $774/MG $ $ 1,284,648 327,600 156,118 142,500 121,970 448,500 133,000 2,300 140,160 10,120 56,700 2,823,616TABLE 84 BIMCO, 25 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 23,818,000 x 0.09439 $2,248,181 Labor 57,720 Hours @ $9/Hour $ 519,480 Power 19,228,500 kWh @ $0.02/ktIh $ 384,570 Fuel 227 x 106 scr @ $1.50/TCF $ 340,500 Maintenance Materials $ 240,850 Chemicals Powdered Carbon 1,725 Tons @ $650/Ton $1,121,250 Alum 4,750 Tons @ $70/Ton $ 332,500 Polymer - Wastewater 19,025 1b @ $9.30/1b $ 5,700 Polymer - Carbon Sludge 175,200 lb @ $2.00/1b $ 350,400 Chlorine 115 Tons @ $100/ron $ 11,500 Lime - Primary Sludge 3,830 Tons @ $37/Ton $__141,700 TOTAL $5,696,631 = $5,696,631 Costs/MG @ Capacity = *3e2°0s52) = s624/uc 159TABLE 85 EIMCO, 50 MGD TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 40,886,000 x 0.09439 Labor 89,020 Hours @ $9/Hour Power 34,025,000 kWh @ $0.02/kWh Fuel iE 430 x 10° SCF @ $1.50/TCF Maintenance Materials Chemicals Powdered Carbon 3,450 Tons @ $650/Ton Alum 9,500 Tons @ $70/Ton Polymer - Wastewater 38,050 1b @ $0.30/1b Polymer - Carbon Sludge 351,000 1b @ $2.00/1b chlorine 230 Tons @ $100/Ton Lime - Primary Sludge 7,660 Tons @ $37/Ton TOTAL $10,293,025, 365 x 50 Cost/MG @ Capacity $564/MG 160 $ 3,859,230 $ 801,180 $ 680,500 $ 645,000 $ 379,780 $ 2,242,500 $ 665,000 $11,415 $ 702,000 $ 23,000 $283,420 10,293,025TABLE 86 EIMCO ANNUAL COST SUMMARY Annual Cost ($1,000) Amortized Capital Labor Power Fuel Maintenance Materials chemicals Powdered Carbon Alun Polymer - Wastewater Polymer - Carbon Sludge Chlorine Lime - Primary Sludge ‘TOTAL Costs/1,000 Gals (Operating @ Capacity) 27 45 13 0.2 10 787 $2.08 161 837 238 a9 as 73 224 66 1a 70 28 1,716 $0.94 190 1,285 328 156 142 122 448 133 a 140 10 57 2,824 $0.77 25 2,248 520 384 340 241 1,121 332 5.7 350 11.5 142 5,697 $0.62 50 3,859 801 680 64s 380 2,242 665 qa 702 23 283 10,293 $0.56LZaHS MOT SSz00¥a ATIELLVE “92 gunDdIa eee fa | aoams | osziams | ZHe OL 'g wev : | aie NoLLWNo Hoh | mm eo Nolaw7n99013 eae u3wA0d Nosuvo CaLVALLOe o3¥30Mod eB Amv env 162TABLE 87 BATTELLE PROCESS SYSTEM DESIGN PARAMETERS Treatment System Carbon Contact - Minutes Time at pi 4 10 Time at pi 7 3 Flocou)ation Velocity Gradient - fps/ft 70 Tine = Minutes 10 Tube Settler Loading Rate - gpa/rt? 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006'T o0s‘T - 000'92 o08't o0s’e - 000" 00t 000% 000’ oe - 00/0006 —g0T'9 ose - 000'€ 000 Saettod “Stepzeqen StS Temaen “Gos ca ‘SNOW soueuequTen JO uoTsdunsucs uoyadumsuoy —-x0qeT 3509 TenuUy Teng Tenuue xonoa Tenuuy — Tenuuy “USSMHLNON-STTILIVE v6 STAVE xouktod Azq, repeez pedumd ‘owrtyo1nd, z umte prnbr Te PINT TE Twin uoraesatta uoTaeUTZOTUD soeumg peg poztprnTs e6ng7a3Ua9 sdung eBpnts TeoTweyD uotaequourpes uorseTns00T3 xT prdew yoeques uogzeD prow otangtas 26pnTs - xouATog c7e78no3seN - XomATOR out udgze9 ny peaa TeOTWSYD 170TABLE 95 BATTELLE PROCESS, 1 MGD TOTAL ANNUAL COSTS Amortized Capital 2,936,000 x 0.09439 Labor 13,370 Hours @ $9/Hour Power 1,673,000 kWh @ $0.02/kWh Fuel 21 x 106 scF @ $1.50/TCF Maintenance Materials Chemicals Makeup Alum 42 Tons @ $70/Ton Makeup Carbon 127 Tons @ $650/Ton Lime 228 Tons @ $37/Ton Polymer, Wastewater 6,044 lb @ $0.30/1b Polymer, Sludge 5,183 lb @ $2/1b Sulfuric Acid 456 Tons @ $57.30/Ton chlorine 4.6 Tons @ $220/Ton TOTAL Cost/MG @ Capacity = 2$2-515 ~ §1, 700/uc a7 $277,129 $120,330 $ 33,460 $ 31,500 $ 24,400 2,940 83,000 8,436 1,813 10,366 26,129 1,012 nin on nv nv 620,515TABLE 96 BATTELLE PROCESS, 5 MGD TOTAL ANNUAL CosTSs Amortized Capital 6,166,000 x 0.09439 Labor 22,860 Hours @ $9/Hour Power 6,262,700 kwh @ $0.02/kWh Fuel 6 84 x 10° SCF @ $1.50/TCF Maintenance Materials Chemicals Alum 210 Tons @ $70/Ton Carbon 635 Tons @ $650/Ton Lime 1,140 Tons @ $37/Ton Polymer, Wastewater 30,220 1b @ S0.30/1b Polymer, Sludge 25,915 1b @ $2/1b sulfuric Acid 2,280 Tons @ $57.30/Ton Chlroine 23 Tons @ $220/Ton TOTAL = $1,773,454 Cost/MG @ Capacity = =3¢5—S*5—— = $972/MG 172 582,000 205,740 125,254 126,000 49,180 14,700 431,800 42,180 9,066 51,830 130,644 5,060 1,773,454TABLE 97 BATTELLE PROCESS, 10 MGD TOTAL ANNUAL COSTS Amortized Capital 10,016,850 x 0.09439 Labor 33,200 Hours @ $9/Hour Power 13,123,300 kiwh @ $0.02/kWh Fuel 168 x 10° @ $1.50/TcF Maintenance Materials Chemicals Alum 420 Tons @ $70/Ton carbon 1,270 Tons @ $650/Ton Lime 2,280 Tons @ $37/Ton Polymer, Wastewater 60,440 1b @ $0.30/1b Polymer, Sludge 51,830 1b @ $2/lb Sulfuric Acid 4,560 Tons @ $57.30/Ton Chlorine 46 Tons @ $220/Ton TOTAL Cost/HG @ Capacity = 532262.726 — sa67/uc 173 nin ww nv nia 945,490 298,800 262,466 252,000 71,510 29,400 825,500 84,360 18,132 103,660 261,288 10,120 3,162,726TABLE 98 BATTELLE PROCESS, 25 MGD TOTAL ANNUAL COSTS Amortized Capital 20,353,000 x 0.09439 $1,921,120 Labor 72,900 Hours @ $9/Hour $ 656,100 Power 27,281,000 kWh @ $0.02/kWh $ 545,620 Fuel 385 x 10© scr @ $1.50/TCF $ 577,500 Maintenance Materials $ 113,390 Chemicals Alum 1,050 Tons @ $70/Ton $ 73,500 Carbon 3,175 Tons @ $650/Ton $2,063,750 Lime 5,700 Tons @ $37/Ton $ 210,900 Polymer, Wastewater 151,100 lb @ $0.30/1b $ 45,330 Polymer, Sludge 129,575 lb @ $2/1b $ 259,150 Sulfuric Acid 11,400 Tons @ $57.30/Tor $ 653,220 Chlorine 115 Tons @ $100/rTon $11,500 TOTAL $7,131,080 Cost/MG @ Capacity = $22131,080 ~ g7g1 m6 365 x 25 174TABLE 99 BATTELLE PROCESS, 50 MGD TOTAL ANNUAL COSTS Amortized Capital 36,293,000 x 0.09439 $ 3,425,696 Labor 90,290 Hours @ $9/Hour $ 812,610 Power 47,497,000 kWh @ $0.02/kWh $ 949,940 Fuel 630 x 106 SCF @ $1.50/TCF $ 945,000 Maintenance Materials $ 159,250 Chemicals Alum 2,100 Tons @ $70/Ton $ 147,000 Carbon 6,350 Tons @ $650/Ton $ 4,127,500 Lime 11,400 Tons @ $37/Ton $ 421,800 Polymer, Wastewater 302,200 lb @ $0.30/1b $ 90,660 Polymer, Sludge 259,150 1b @ $2/lb $ 518,300 Sulfuric Acid 22,800 Tons @ $57.30/Ton $ 1,306,440 Chlorine 230 Tons @ $100/Ton $ 23,000 TOTAL $12,925,196 = $12,925,196 _ Cost/MG @ Capacity = “365 x 507 $708/MGTL-08 Sz6‘zt iad 90e'T gis Té zee “ety Lvt 6st sve ose eTs gee en BL Tet TT €s9 6sz st wz 790 be eI 8s 9s 9s9 16 Sz os = L8"0S = L608 ‘2 g9T 19 vot at v8 ‘t see 6z ze ese z9z 66z ‘T $6 cow RWNWWAS LSOD TvANNY oT fe €LL'T oT s Tet zs 6 ww Ten st 6 92T Set 90% z9¢ ca (000/T$) asop Tenuuy Oot sTavs oL'ts oz9 9z ot ot 8 bz ze ce ot Luz (Aaqoedeo Q ButT3zer8do) STD 000'T/S3800 TwLOL euTzOTYO prow ofangtns abpnts ‘zeuwAToa zoqeneasem /x0WATOS euET uogze9 uate sTeoTweyD STeTIOgeW soURUERUTEH Teng reMod zoqet Teatdeo pezt3z0uv ‘ssa00ud STISLLVE 176NOTIVGIXO BIW TAM HLIM SSHDOUd TYOISAHd-O1G WOU LAGHS MOTE ‘LZ aUNIA encprora peat otezoas L ow uoravzsueboy z [— “eben o13ku auentg33 39"u09 worseurz0r%9 sustazes, paseo 295 — ee ere suze 108 woqae> 177TABLE 101 DESIGN PARAMETERS FOR BLO~PHYSICAL PROCESS WITH WET AIR OXIDATION Primary Sedimentation Surface Loading Rate, gpd/ft® Detention Time, Hour Solids Removal Efficiency, % Sludge Moisture, % Sludge Specific Gravity Activated Sludge Air Rate, scfm/MGD Recycle, & Mixed Liquor Solids, mg/1 Volatile Carbon Total Growth Yield Coefficient, 1b vs/lb BoD Return Sludge Solids, mg/l vss Carbon Total Detention Time, Hour Sludge Age, Days Secondary Sedimentation Overflow Rate, gpd/ft Polymer Dose, mg/1 Flow to Thickener, gal Mc Gravity Thickener Loading Rate, 1b/ft2/ day Thickened Sludge, % Solids Wet Oxidation system Temperature, °F Pressure, psi Blowdown Volume, gal/1G Solids, 1b/MG Ash Content of Solids, @ 178 800 2.5 65 95 1.03 1,275 50, 4,000 8,000 13,000 0.5 12,000 24,000 39,000 4.5 12.5 400 5,000 450 700 100 166 75TABLE 101 (Cont'd) Carbon Losses mg/l Blowdown oxidation Effluent Carbon Dose mg/l Makeup Carbon Regenerated Carbon Primary Sludge Dewatering Vacuum Filtration, 1b/ft?/nr Polymer, 1b/Ton Primary Sludge Disposal Multiple Hearth Incinerator, 1b/ft?/hr/hr 179 WwW 103Zimpro were adjusted to reflect housing, miscellaneous, and con- tingency costs. The costs of carbon handling and storage included by Zimpro were deducted and the CWC costs for this item were used. zimpro's estimates of labor, power, and fuel were used for OsM costs. Zimpro felt the regeneration system would be thermally self-sustaining except for startup and shutdown periods. Thus, fuel requirements are minimal. ‘Table 102 presents the unit process sizes. 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= $554/MG 189TABLE 111 BIO-PHYSICAL PROCESS, ANNUAL COST SUMMARY, TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 9,804,000 x 0.09439 Labor 25,960 Hours @ $9/Hour Power 5,316,400 kwh @ $0.02/kWh Fuel é 15.09 x 10° scF @ $1.50/TCF Maintenance Materials Chemicals Carbon 260 Tons @ $650/Ton Polymer 152,205 1k @ $0.30/1» chlorine 46 Tons @ $220/Ton ‘TOTAL $1,580,383 Cost/MG @ Capacity = 27,380.38 = $433/MG 190 10 MGD $ 925,400 $ 233,640 $ 106,328 $ 23,635 $ 67,600 $ 169,000 $ 45,660 $10,120 $1,580,383TABLE 112 BIO-PHYSICAL PROCESS, ANNUAL COST SUMMARY, TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 17,536,000 x 0.09439 Labor 44,140 Hours @ $9/Hour Power 13,464,800 kWh @ $0.02/kWh Fuel fe 40.2 x 10° SCF @ $1.50/TCF Maintenance Materials Chemicals Carbon 650 Tons @ $650/Ton Polymer 280,512 lbs @ $0.30/1b Chlorine 115 Tons @ $100/Ton TOTAL Cost/Ns @ capacity = £2,052.232 = §334/MG 25 MGD $1, $ § s $3, 655,223 397,260 269,296 60,300 122,000 424,500 114,153 11,500 052,232TABLE 113 BIO-PHYSICAL PROCESS, ANNUAL COST SUMMARY, TOTAL ANNUAL COSTS Amortized Capital @ 7%, 20 Years 28,015,000 x 0.09439 Labor 71,460 Hours @ $9/Hour Power 25,001,200 kWh @ §0.02/kWh Fuel B 88.4 x 10° SCF @ $1.50/TCF Maintenance Materials Maintenance Materials Chemicals Carbon 1,300 Tons @ $659/Ton Polymer 761,025 lbs @ $0.30/1b chlorine 230 Tons @ $100/Ton TOTAL $5,203,099 $5,203,099 _ S65 BGS = $286/MG Cost/MG @ Capacity 192 50 MGD $2,634,335, $ 643,140 $ 500,024 $ 132,600 $ 132,600 $ 196,700 $ 845,000 $ 228,300 $23,000 $5,203,0996z"0$ 07's ee Bzz Svs Let eet oos £09 peo'z “Os ee70s zsoe or IT zp zt 09 69% Lee ss9/T “st evros ogs‘T oT oF 69T 89 €@ 90T vee S76 “OT Ss'os TiLOaT $ ez v8 ey ot Ss 99T 929 ~s 9p Ts ees Lt v 6 L Lop T dow “Xayoedey AUWHWNS LSOD ‘TYANNY (000/T$) 3809 Tenuuy vIl aTavE (Aaqoedea 9 Sutzez2d0) STPD 000/T/S3509 ‘TeLOL sutz0TuD rowdtoa uoqre3 isTeOTWoUD STeTI9qeW soULUSIUTEN tena zeMoa zoqet TeyTde peztz10uy ‘$sa00%d ‘TYOISAHa-OTd 193SECTION 9 EVALUATION OF RELATIVE ECONOMICS Because of the fact that the powdered carbon processes are still in the developmental stage, the preceding cost estimates are based on assumptions some of which may prove to be either overly optimistic or pessimistic. Thus, it is the purpose of this section to evaluate the potential impact of some key assumptions on relative costs. ACTIVATED SLUDGE AND GRANULAR CARBON SYSTEMS The following summarized the costs calculated previously for activated sludge and granular carbon systems: $/1,000 SMe 10 50_NGD Activated sludge Conventional M02). 049) | 10%sa | 0r2o8 |= On2d Single Stage Nitrification 1.10 0.51 0.41 0.32 0.26 Two Stage Nitrification 1.21 0.59 0.46 = 0.350.299 Conventional with Coagulation and Filtration 1.49 0.71 0-55 0.4d (0.37 Granular Carbon system rege Ours) 065) 0646) 0.40) Independent physical chemical treatment utilizing the granular carbon system is clearly not economically competitive with con- ventional activated sludge systems. However, if effluent standards require high degrees of removal of phosphorus and suspended solids, then the granular carbon system is comparable in costs to activated sludge treatment followed by coagulation and filtration for plants of 5 mgd or greater in capacity. The potential impact of savings in land costs should also be considered. As an example, if one assumes a land savings of 10 acres for the 10 MGD capacity, the cost savings which result from a land price (land amortized at 7 percent, 20 years) of $1,000/acre would be only $0.00025/1,000 gallons or at $50,000/acre, only $0.0125/1,000 gallons. Thus, unless land costs are extremely high, the cost savings from 194reduced space requirements are not significant in the relative economics of biological processes and purely physical chemical processes. BIOLOGICAL NITRIFICATION, TWO STAGE Detailed estimates of conventional activated sludge and single stage nitrification were presented earlier. In order to determine the potential economic position of the bio-physical powdered carbon process (which is claimed to provide stable nitrification), it proved desirable to also estimate the cost of two-stage biological nitrification -- a commonly used approach. Table 115 summarized the results of this calculation. The costs are based on providing aeration (three hour detention), final sedimentation (600 gpd/ft2), and return sludge pumping (50 percent 0 downstream of conventional activated sludge. Costs were determined using the appropriate cost curves in the Appendix. EIMCO SYSTEM The basic Eimco process is based on two stages of carbon contact preceded by chemical coagulation and sedimentation. Although carbon requirements would increase, capital costs and O&M costs would be decreased by eliminating the second stage contactors. The maximum potential gain for cost savings in a single stage system would be represented by the costs using the same carbon dosage used in the two-stage system -- realizing that some of this potential gain would probably be offset by increased carbon costs. ‘Table 116 summarizes the results of the calculations. Total annual cost savings of 4-6 percent resulted -- not enough to significantly alter the competitive position of the process relative to granular carbon or biological processes. Eimco's work indicated that carbon dosages as low as 100 mg/l may be practical (while producing an effluent quality of 5 mg/l CoD, 5 mg/1 SS, and 0.3 mg/l phosphorus) under some conditions. Thus costs were also calculated for the system based on a 100 mg/l carbon dosage. ‘Table 117 summarizes the results. The lower carbon dosage has a significant impact on the economics and would Place the two-stage system in a comparable but competitive Position with granular carbon systems. Should the single stage system be successful at a 100 mg/l carbon dosage, then the Eimco system would be lower in cost than the granular carbon system Some work is being done on generating powdered activated carbon from waste materials which might provide a carbon low enough in cost that it could be used on a throwaway basis. Table 118 shows the impact that use of 5¢/1b and 1¢/lb throwaway carbon (300 mg/l dosage) would have on the two-stage Eimco system. The cost would have to be 1¢/lb for the system to be competitive with the granular carbon system. It was assumed that the carbon sludge would be dewatered and hauled (40 mile haul) to a disposal site 1956270s se-os 9r08 65°08 Terts SUOTTeD 000'T/S3S09 one’s eez'e s69'T se0'T evp Twrot es Tee Get co T sewkToa 9L ca ce ia € autzoTu sTeoTweyD ve 4st so 8 or sTeTre3eH eoueueqUTEN os oz se 9e 9 Teng Lye Lee 96 BP 6 emg oe te L9z eet aL roqet 608‘T oo'T 69 ste yeatde peztaz0uy of oe OT = T ce (ocoTs) 3809 TeNuUy NOTAVOTATaGIN FOVLS-OML AMWAHNS LsOD ‘TvANNW SIt aTaws 196s30eqU0D UOgreo Jo obeys puooss BuTzeUTUTTS wory sbuTARS TeT3USz0d uUTXeu SUTUIEZeP 0} ZepIO UT wozShs o6eIg OML wWoIZ pebueyouny Y € s s 9 woTzonpeu & 9sros z9"0s LL°08 ve°0S = BO"ZS STD 000‘T/S3509 26e3S OM, vsos 09°0$ €L°0$ 68°0S 96°TS (AyyoedeD § Butzezedo) STED 000'T/s3809 786 Lep's 199'% 9z9'T TL ‘"TwLOL £8e wt ws az 9 ebpnts Axewyzg ‘owrT £@ S°TT ot s c suTIOTYD zoe ose OFT OL ot abpnts uoqzeo ‘rouATod writ us az vUrT zo qoReMazSseM ‘xaUATOS $99 zee eet 99 zt unTy we'z Tet‘T arb vez sb uogze> pezepnog xSTROTWOUD eee ozz €IT 69 9% sTeTz93eW eoURUEqUT EN $99 ove zor $8 8z Teng 099 Le zst 98 ez zomod Bel uly £0€ Tez 8It z0qe 1 Liste ¥90/2 L9t/T Tht ber Teatdeo peztazouy OS SOT aw (000‘T$) 3509 Tenuuy SOWLS J'IONIS - OOWIS AYWWWNS ISOD "TWANNY OTT STavL 197Leros 489'9 eae 4 vez brit 599 ope eze se ore ol 000° a zpos 998’ eet svIt “Tt us zee LE soz €6T o6t 6sb Lee’t se zor 8 ve s6z Ott'T OT caw zL-0s = 68° TS prE‘T 169 Be 9 s 1 &z € aad z0 99 et se st 09 €z 1s ez sb ez Liz ozt ene 9p se TT (000‘T$) 3809 TenuUy (43 70edeD 9g Butzez0do: STeD 000‘T/s3s509 ‘TWLOL ebpnts Arewrza ‘owty suTz0TUD ebpnts Yoqze9 /zeuATOS xoyeMaysem ‘rowATOR unTy YoqzeD perepmod STROTUOUD sTeTZeqeW couRUeqUTEN Tena qemoa zoqet Teatded peztaz0uy NO@YWS T/OW OOT LY WHLSAS OOWIS AUWWWNS JSOD "TWANNY LIT ataws 198Bes ev 'os as‘og TL*0$ aS "TS srs esos 89°08 Teos 89°Ts eels eza‘p aov'z BLp'T v9 E82 bt Ts a 9 4 stl ot s T ZOL ose Ovt on oT vrIT us Gag vUT z0 $99 zee eT 99 £1 Taz‘ Ovt’T osb 8zz oF ozs ooe ost ze se ore vez aad o£ oe set 60T 8p ze et 09z zet 8s ze ’ aL wey ste zzz Tt sio'z 06s‘T 786 zg se 0S oe oT $ T caw (000‘T$) 3809 Tenuuy at /et @ STD 000'T/s3500 (Aatoedeg 9 buTzezedo) STeD 000'T/s3809 ‘TWLOL ebpnts Arewysa ‘owrT BUTIOTUO ebpnts uoqrea ‘rowATOa qaqemeqzsem /xouATOd umTy uoqzed pexzepmoa STROTUSYD SuttpueH eSpnts sTeT197eH souBUEqUTEN Teng zemoa zoqet yeqrdes peztazouy (T/9W ODE) NOMAv (QT/3S) AWMYMOWHL HLIM WILSAS OOWIa AAWWWAS LSOD TwANNY SIT a1avE 199As noted earlier, the FBF regeneration system costs (Appendix curves 28, 99-102) are based on loadings recommended independently by two manufacturers. Because the independently determined loading rates (higher than the three lb/hr indicated by the Battelle-Northwest study’) were virtually identical, they were used as the basis of the FBF costs in the basic cases of each process. Although this assumption appears reasonable, the impact of using a loading rate of three 1b/ft2/hr was determined as shown in Table 119. The impact is quite significant and the process costs would be substantially higher should the lower FBF loading rate prove necessary. The impact that a 50 percent reduction in labor, power, and fuel costs would have on overall costs is shown in Table 120. Such a large reduction is not likely but Table 120 indicates that even such a major reduction would still not place the process in a competitive position with the granular carbon process. Should the cost of powdered activated carbon be reduced by 50 percent approaching the levels of 2-3 years ago, a savings of 6¢/1,000 gallons would result for all capacities. BATTELLE PROCESS A dominant factor in determining the cost of the basic Battelle process is the large carbon (600 mg/l) and alum (200 mg/l dosages specified. These, in turn, affect the cost of sludge handling and regeneration facilities. The costs using the same alum dosages (125 mg/1) used in the Bimco process and a carbon dosage of 200 mg/1 were calculated. Table 121 presents the results. The impact on costs is dramatic -- providing about a 50 percent reduction in capacities of 5 MGD or more. The reduction places the costs significantly (20-34 percent) below the costs of the granular carbon system. The potential for economic gains through use of cheap, throwaway carbon is limited with this process because of the questionable practicality of disposing of the sludge (a mixture of raw sewage solids, alum sludge, and carbon) after merely dewatering. If incineration were practiced (so as to be comparable to the other processes), the savings resulting from elimination of the FBF would be largely offset by the costs of incineration. If the price of carbon were reduced 50 percent, the cost of the basic Battelle process (600 mg/l carbon) would be reduced 12¢/1,000 gallons. At a carbon dosage of 200 mg/l, the lower carbon price would result in a savings of 4¢/1,000 gallons. The Battelle data indicate that the need for effluent filtration is marginal. If effluent filtration were eliminated, the following savings would result (cost/1,000 gallons): 1 mGD - 22¢; 5 MGD - 7¢; 10 MGD - 5¢; 25 MGD - 3.4¢; 50 McD - 2.4¢. 2006z 9s*0s zeros S90‘ET €8z ez zoL wit s99 ee'z 68e spe‘ ozz’T sss oer’s 0s zo ec es a STL os: ze 1 8h ve! z6 re: €€ oe 9 Tz sos LL°08 *0$ £670 TH TIRE T is ot € OFT cae € eet tat arb z ez 9 are 9 asz S ave ore 6e9'T ot cw 6 peros Fg} €s0'z az oe bT'T vez 94 oet 99T rst ceo/T ss 807s 9zrzs 87a 8z ze oz Tet tes (000/T$) 3809 Tenuuy au/zas/aT £ = esearour 8 ysop sseo0xg oouTgy oTseg (atoedeo 9 Butaezedo) STD 000'TS/83800 ‘TeLOL abpnts Azewtza ‘eurT suTIOTU abpnts uoqzes ‘xewAToa wozeMa3seM ‘TOUATOS unTy uoqzeD pezepmog sTeoTUSYD sTeTIeqeW soueUEZUTEN Teng qemoa xoqeT Teqtdes peztaz0uy ONIGYOT ddd HLIM WHLSAS OOWIa RYWWWAS LSOD TYANNY 6 ataws 201ovros TS"0s L22'6 €8e Z0L pit s99 eyez ose zze ove oor 6se’e Os gvos 9s0s €L0's aa s*tt ose us zee Tet We oxt z6t o9z Bree a Tana ‘waMoa as"os e708 69°0$ €8°0s ots’z ots‘T oe Bz oT = OFT OL —— ae —e = Bbr vez er ee ue a BL Sh vot 6IT $8z/T Lee ot = dow parts Tats z99 ot z0 eT sb Le oT zt on vor (000‘T$) 3s09 TenuUy ‘YoavI NI NOTLOnazY eos AAWWWOS “SOD TwANNY ozt atava Su/sqt 00ST 8 sse00rg uoqrep reTNUeID (Kaqoedeg g Sutzezedo STeD 000'T/3800 ‘TWLOL ebpnts Azeutza ‘our auTz0TYO eSpnts uoqred ‘reukTor qezemezsem ‘oUkTOd unty uoqze9 pezepmoa sTeOTWOUD sTerr0zeW SoueusqUTEH eng zemod zoqe Teqrdeo pezt3r0uy ‘OOWIE 202se-0s sze’9 ez 9t8 60z £97 SLe‘T bIT 60F ses sor c9e'T 0s 6E*0$ Las’e TT gop oft Tet 889 og oz 98z stp cet'T sufsea 39e3u0D aUTZOTUD sxoqoequop uoqzeD xeTAUeZD Buyduna uogreo xeTAUeZD uoyaezaT Fa 497Aez5 J9TZTABTO 70798H seTnpon ButTa30s eqnz 40737221) - ZOgBTROOOTI ZOT5TIET) uoraeTnoooTa BuyxTH pre suoyae3s duma +ys ‘a0W wangey pue eyeTpeureqUT uoraeiey TeoTURYOO ‘suyseg uoTzEz0y 226CONSTRUCTION COST, DOLLARS 1,000,000 9| 100 ,009} 2 os eres 24 eres 34 5 878% ooo? * 1,000,000 Volume - Cubic Feet AERATION BASINS CONSTRUCTION COST Curve 1 227CONSTRUCTION COST, DOLLARS us aon 1,000,001 100 ,009) ws & oreo! 34 S87 8S. 2 3 4 Ss e769 2 3 4 56789 100 1,000 Installed Power - Horsepower MECHANICAL AERATION CONSTRUCTION COST Curve 2 228CONSTRUCTION COST, DOLLARS 1,000, 00g | us waxeo 100 ,009| o> a 990! 23 4 8 6769 2s 4 se769 2 3 4 567 1.0 10 Firm Capacity - NGD INTERMEDIATE OR RETURN ACTIVATED SLUDGE PUMPING STATIONS CONSTRUCTION COST Curve 3 229DOLLARS CONSTRUCTION cosTS, 100,00 QI > wove 10,001 > Barco! 2 34 5 6789 23 4s e789 10,000 100,000 Rapid Mix Volume, Cubic Feet RAPID MIXING CONSTRUCTION cosTS 230 23 4 8 6789 Curve 4009} 100, SuvT100 ‘$1809 NOTLINYLSNOD 2s 4 $6780 ¥o0,000 4 678) Flocculator Volume, Cubic Feet 2 10,000 3 8s eres FLOCCULATION, VERTICAL TURBINE CONSTRUCTION COSTS Curve 5 2311,000, 00 CONSTRUCTION COST, DOLLARS, 2 3 4 56788, 2 3 4 56789 2 3 4 Ss e7e9 1,000 10,000, Single Basin Area, Square Feet (Single unit) CLARIFIER CONSTRUCTION CosTS Curve 6 232DOLLARS CONSTRUCTION cosTS, 1,000,009 9| as wove 100,009 w+ wovao 2 3 4 56789 2 3 4 567689 2 3 4 56789 1,000 10,000 Area, Square Feet (Single unit) FLOCCULATOR - CLARIFIER CONSTRUCTION cosTS Curve 7 233100,008) a INSTALLED COSTS, DOLLARS 10,001 2 3 4 56789 23 4 86789 2 3 4 8678 1,000 10,000 Quantity of Modules, Square Feet ‘TUBE SETTLING MODULES CONSTRUCTION CosTS Curve 8 234CONSTRUCTION COSTS, DOLLARS 1,000, 004 100,00 w+ voroo 34 56709 4 5 6789 2S 4 86789 7 f,o00 7 * 70,000 Net Effective Settling Area, ft2 (Single Unit) «-t) REACTOR - CLARIFIERS CONSTRUCTION Costs Curve 9 235DOLLARS CONSTRUCTION costs, 1,000,001 | 100,00 2 34 56789 23 4 s67e9 100 1,000 Media Surface Area, Square Feet GRAVITY FILTRATION CONSTRUCTION CosTS 236 2 4 56789 Curve 10CONSTRUCTION COSTS, DOLLARS 1,000,009 3 100,009 w+ oro! 10,000 7 2 3 #5676, @ 3 #86765, 2 5 4 56769 Pumping Capacity, MGD CARBON ADSORPTION PUMP STATION CONSTRUCTION cosTS Curve 11 237DOLLARS: CONSTRUCTION CosTS, 10,000,000 9 ws wove 1,000,000 | 100,000 T 2 3 456763, 2 8 #86785,, 2 8 456709 Average Design Flow, MGD GRANULAR CARBON CONTACTOR SYSTEM (30 minutes contact at design flow) CONSTRUCTION CosTS Curve 12 238CONSTRUCTION COST, DOLLARS 1,000 ,00g ys 4 56789, 23 4s 6789 10,000 100,000) Volume, Cubic Feet CHLORINE CONTACT BASINS CONSTRUCTION COST Curve 13 239CONSTRUCTION COST, DOLLARS 1,000 ,009 3| 100,000) 2 SA SEO FS A FETED OO Chlorine Use, Tons Per Year CHLORINE FEED EQUIPMENT CONSTRUCTION COST 240 2 x «se 789 Curve 14CONSTRUCTION COST, DOLLARS ws aoreo 1,000 ,009| 9| 100 ,000} 2 3 8 5 678s 2 3 8 56789 23 4 S676S 100 1,000 Firm Pumping Capacity - GPM WASTE SLUDGE PUMPING STATIONS CONSTRUCTION COST Curve 15 241DOLLARS CONSTRUCTION cosTS, us voxou 1,000, 00 ws wore ~ 100,009] us vara ~ z 34 56789 2 5 4 56789 2 3 4 56789 100 1,000 Firm Pumping Cap: city, GPM CHEMICAL SLUDGE PUMPING CONSTRUCTION cosTs Curve 16 242CONSTRUCTION COST, DOLLARS ws worse & 100,000 uw _ > waroe! 2 34 5 6789 2 3 4 56789 2 3 4 86789 100 1,000 Surface Area, Square Feet GRAVITY THICKENING CONSTRUCTION COST Curve 17 243CONSTRUCTION COST, DOLLARS 1,000 , 09; 100,001 Pre fabric: rrits}— i 3a 5 6789, 2s 4 8 6Tes 2s 4 S678. 100 1,000 Surface Area - Square Feet FLOTATION THICKENING CONSTRUCTION COST Curve 18 244CONSTRUCTION COST, DOLLARS 2s 4 S679) 2 3 4 sere Filter Area - Square Feet VACUUM FILTRATION CONSTRUCTION COST 245 2 3 4 s67es Curve 19ws vaxeo ; i i : € 4 i : i g : s g 2 i g B 100,009 i : : : ‘ 2 3 4 s67eo 2s 4 s6789 23 4 s67e9 10 100 Installed Capacity, gpm CENTRIFUGING CONSTRUCTION CosTS Curve 20 246eRe a Steet tinrs gree ee See S 3 3 8 Suv 7100 *1S09 NOILONYLSNOD 34 se 789 2s 4 sores z 1,000 0 1 Single Furnace Hearth Area - Square Feet yas 678s 2 MULTIPLE HEARTH INCINERATION CONSTRUCTION COST Curve 21 247CONSTRUCTION COSTS, DOLLARS 1,000, 00 100, 01 2 3 4 5 6789 2 3 4 86789 2 3 4 5678s 100 1,000 Alum Feed, Pounds/Hour ALUM STORAGE & FEEDING CONSTRUCTION COSTS Curve 22 248DOLLARS CONSTRUCTION COST, uw > garvee 10,000, 004 ‘| 4s wove 1,000, 001 2 3 4 86789 2 5 4 86789 23 4 s6789 1,000 10,000 Powdered Carbon Capacity - lb/hr POWDERED ACTIVATED CARBON F CONSTRUCTION COST Curve 23 249aa: ; 8 6 o 5| 2 4 ° 3 8 : : s > wooo! S 2 3 4 s 6768 2 3 4 86789 10 1,000 ime Feed, 1b/hr LIME STORAGE § FEEDING CONSTRUCTION CosTS Curve 24 250CONSTRUCTION COST, DOLLARS HH +H 348 6789 2 3 4 $6789 2 5 4 56789 10 Polymer Feed - Pounds/Hour POLYMER STORAGE AND FEEDING CONSTRUCTION COST Curve 25 251CONSTRUCTION COSTS, DOLLARS 1,000,009 | 100,009) a _> wore | | 2| 1 | {| 2s 4 8 6789 2 3 4 56769 23 4 5 e7es 1,000 10,000 Sulfuric Acid Peeé, lb/hr SULFURIC ACID STORAGE AND FEEDING CONSTRUCTION CosTS Curve 26 252CONSTRUCTION COST, DOLLARS 100, 00% 9] 10,091 2 34 5 6789 2 3 4 86789 2 3 4 s67e8 100 1,000 Feed Rate, Pounds/Hour DRY CHEMICAL FEED SYSTEMS CONSTRUCTION CosTS Curve 27 253CONSTRUCTION COSTS, DOLLARS us voxoo 10,000,000} ud wore 1,000,009} o> oreo 23 4 56789 2 5 4 56769 2 3 4 56789 Lo 100 1,000 Bed Area, sq/ft FLUIDIZED BED REGENERATION SYSTEM CONS'TRUCTION CosTS Curve 28 254| ; g ; g 4 8 3 3 2] § E 1,000,000 z 3 é : ; ; ; ; ; 2 3 456789.) 2 3 #56789 > @ 3 4 CAPACITY, GPM WET AIR REGENERATION SYSTEM CONSTRUCTION Costs Curve 29SUTIOa ‘51500 NOTLOMYLSNOD £3 Single Press Volume, PRESSURE, FILTRATION CONSTRUCTION COSTS. Curve 298 256ANNUAL MAN-HOURS FOR 0 & M 2 | 34 5 6789, 2 3 4 s6789 2 3 4 56789 100 1,000 Installed Power - Horsepower MECHANICAL AERATION MAN-HOUR REQUIREMENTS Curve 30 257ANNUAL POWER USAGE, MILLION KWH/YEAR Installed Power - Horsepower MECHANICAL AERATION POWER REQUIREMENTS 258 Curve 32ANNUAL COST, DOLLARS 10,0 2 Faery ef FF Sere Installed Power, Horsepower MECHANICAL AERATION MAINTENANCE MATERIAL COSTS 259 ¥ 4 SeTeo Curve 32ANNUAL MAN-HOURS FOR O & M a 2 worooe 2 3 4 8 6789, 2 5 4 5678S 2 3 4 8678s 1.0 10 Firm Pumping Capacity - MGD RETURN ACTIVATED SLUDGE PUMPING STATIONS MAN-HOUR. REQUIREMENTS Curve 33 260POWER CONSUMPTION, MILLION KWH/YEAR wd voyavn a Average Flow - NGD RETURN ACTIVATED SLUDGE PUMPING STATIONS. POWER REQUIREMENTS Curve 34 261WIRE TO WATER EFFICIENCY PERCENT 100 95 90 85 Constant Speed Pumping Unit Variable Speed Drive Pumping Unit (Wound Rotor) 15 20 25 «630 35 40 4550 Pumping Unit Capacity, GPM PUMPING UNIT EFFICIENCY RELATED TO CAPACITY Curve 35 262ANNUAL COST, DOLLARS s ba > oS, Average Flow - MGD RETURN ACTIVATED SLUDGE PUMPING STATIONS MAINTENANCE MATERIAL COSTS Curve 36 263ANNUAL MAN-HOURS FOR O & M 1,000 s4 seres oe Se SerES es 4S eTED Rapid Mix Basin Volume, Cubic Feet RAPID MIXING MAN-HOUR REQUIREMENTS Curve 37 264a s vovoe 1,000,000 9| 100,001 ANNUAL POWER CONSUMPTION, KWH 2S 4 se Tes 2S 4 sees e348 6789) O00 10,000 Rapid Mix Basin Volume, Cubic Feet RAPID MIXING POWER REQUIREMENTS Curve 38 265ANNUAL COSTS, DOLLARS 10,000 8 1 00g wb von 2 s 4 5678s 2 3 4 sere 2 3 4 56769 1,000 10,000 Rapid Mix Volume, Cubic Feet RAPID MIXING MAINTENANCE MATERIAL COSTS Curve 39 266ANNUAL MAN-HOURS FOR 0 & M no » eorvoe 1,009} 7| t= wa soo BS 4 ETE Oe FH SETOCD noe Flocculator Volume, Cubic Feet FLOCCULATION MAN-HOUR REQUIREMENTS 267 34 s67es Curve 40ANNUAL POWER CONSUMPTION, KWH 100,000 9 10,009 sa 36789 FS 4 FETS ogg? 2 4 FETE OOF Flocculator Volume, Cubic Feet FLOCCULATION POWER REQUIREMENTS, Curve 41 268ANNUAL COSTS, DOLLARS ua vance 2 3 4s 6789 2 3 4 s6789 2 3 4 56789 10,000 100,000 Flocculator Volume, Cubic Feet FLOCCULATION MAINTENANCE MATERIAL COSTS Curve 42 269ANNUAL MAN-HOURS FOR 0 & M os varce 10,000 2 34S 6789, 23 4 S678, 2 3 4 sees 1,000 10,000 Surface Area, Square Feet CLARIFIER MAN-HOUR REQUIREMENTS Curve 43 270Ferrif Chhodi ANNUAL POWER CONSUMPTION, KWH 2S 4s S67 89 23 4 se7e9 2s a sere 1,000 10,000 Clarifier surface Area, rt? (single unit) CLARIFIER POWER REQUIREMENTS Curve 44 27.ANNUAL COSTS, DOLLARS 10,000 9 1,009 2 39, 2 3 2 3678 Fs Ser ee og FF TEETER OD Surface Area, Square Feet CLARIFIER MAINTENANCE MATERIAL COSTS. Curve 45 272ANNUAL MAN-HOURS FOR O & M w > gaveo 10,009 9) o> wove 1,009 2 S43 6789, 23 4 se7e9 2 3 4 s67es 1,000 10,000 Area, Square Feet PLOCCULATOR ~ CLARIFTE! MAN-HOUR REQUIREMENTS: Curve 46 273Katt ANNUAL POWER CONSUMPTION, 100, 00 10,00 0 °| sv ora0> 2 3 4 5 eres, 2s 4 se7es 23 4 $6789 1,000 "10,000 Area, Square Feet FLOCCULATOR - CLARIFIER POWER REQUIREMENTS Curve 47 274ANNUAL COSTS, DOLLARS us ware 10,001 ws wares 1,009 2s 4 367 ee 23 4 se7es 23 4 s67e! 1,000 10,000 Area, Square Feet FLOCCULATOR ~ CLARTFIER MAINTENANCE MATERIAL COSTS Curve 48 275ANNUAL MAN-HOURS 0 & M 10, 00% 2 y 4 5678s 2 3 4 5678 2 3 «sere 2,000 10,000 ation Zone Area, ft? (single Unit) REACTOR CLARIFIER MAN-HOUR REQUIREMENTS Curve 49 276ws won z 3s 4 S676 2 3 45678 2 3 4 8 e7ee 1,000 110,000 Separation Zone Area, ft2 ( gle Unit) REACTOR CLARIFIER POWER REQUIREMENTS Curve 50 217ANNUAL COSTS, DOLLARS 10, 00% 2 3 4 56789 2 3 4 sere 23 4 sees 1,000 10,000 Separation zone, ft? (Single unit) REACTOR CLARIFIER MAINTENANCE MATERIAL COSTS Curve 51 278ANNUAL MAN-HOURS FOR O & M 10,06 2 3 4 5 67es 2 3 4 56789 100 1,000 Media Surface area, ft2 GRAVITY ETLTRATION MAN-HOUR REQUIREMENTS Curve 52 279Ken ANNUAL POWER CONSUMPTION, us wove 1,000,009 3 100,000 uw & wore 2s 45 6789 23 4 S6789 23 4 86789 100 1,000 Media Surface Area, Square Feet GRAVITY FILTRATION POWER REQUIREMENTS (Backwash ~ 2/24 Hours) Curve 53 280ANNUAL COST, DOLLARS a 2 aareo 10,000 1,000 2 3a 5 6789 2s 4 Se7e9 2 3 4 86789 ‘100 1,000 Media Surface Area, Square Feet GRAVITY FILTRATION MAINTENANCE MATERIAL COSTS Curve 54 281ANNUAL MAN-HOURS FOR 0 & M 10,000 9| 1,009 aw a aor 100 Design Flow, MGD GRANULAR CARBON ADSORPTION AND PUMPING (30 minutes contact) MAN-HOUR REQUIREMENTS 282 2 3 4 5 6768 2 3 4 86789 10 100 2 3 4 s6789 Curve 55ANNUAL POWER CONSUMPTION, KWH 1,000,000 9 100,009 2 vaswo’ Design Flow, MGD GRANULAR CARBON ADSORPTION AND PUMPING (30 minutes contact) POWER REQUIREMENTS 283 23 4 56789 2 3 4 56789 234 86709 10 "100 Curve 56ANNUAL COSTS, DOLLARS 10,009 o_o wore: 1,000 2 3 4 56788, 23 4 S67 89, 2 3 4 Se7ee 1 10 00 Design Flow, MGD GRANULAR CARBON ADSORPTION AND PUMPING (30 minutes contact) MAINTENANCE MATERIALS Curve 57 284ANNUAL MAN-HOURS FOR O & M 1,000 9| 2S a 56789 2 5 4 se7es 2s 4 86789 "100 1,000 Chlorine use, Tons/Year CHLORINATION MAN-HOUR REQUIREMENTS Curve 58 285ANNUAL COST, DOLLARS 2 34 5 67 es 23 4 56789 23 4 se 708 100 1,000 Chlorine Use - Tons Per Year CHLORINATION MAINTENANCE MATERIAL COSTS Curve 59 286ANNUAL MAN-HOURS FOR O & M ws vax 1,00 S o* woroos 2 2 5 4 86789 2 34 56789 ser es 1,000 Firm Pumping Capacity - GPM WASTE SLUDGE PUMPING MAN-HOUR REQUIREMENTS, Curve 60UYBA/HNY - NOLLANASNOD B3MOd yes 6788 SF SCTE O09 e 2 34 5 67 EN KD 2 Average Flow - GPM WASTE SLUDGE PUMPING POWER REQUIREMENTS Curve 61 288ANNUAL COST, DOLLARS os aovoe 1,009 yas e789; Ty se 789 23 a se res 100 1,000 Firm Pumping Capacity - GPM WASTE SLUDGE PUMPING MAINTENANCE MATERIAL COSTS Curve 62 289ANNUAL MAN-HOURS FOR O & M 1,009 100 w+ waren cr zs 4 56789 zs 4 6789 100 1,000 Firm Pumping Capacity, gpm CHEMICAL SLUDGE PUMPING MAN-HOUR REQUIREMENTS Curve 63 2902| Esco Z § 3 z 3 5 5 5 | 8 3 & 5 2| 3 3 20,009] < 7 a 5 4 | 2 3 4 56789 2s 4s e769 23 4 86761 100 1,000 Volume Sludge Pumped, gpa CHEMICAL SLUDGE PUMPING POWER REQUIREMENTS Curve 64 291DOLLARS ANNUAL COSTS, ws voveo 10, 009| 1,000 wo woroe 2s 4 5676s 2S 4 36789 2S 4 se 7es 100 1,000 Volume Sludge Pumped, gpm CHEMICAL SLUDGE PUMPING MAINTENANCE MATERIAL COSTS Curve 65 292ANNUAL MAN-HOURS FOR 0 & M uw > varee 2 34 8 67 eS 1,000 @ 2 *S87F%S oye 8 De TeR Surface Area - Square Feet GRAVITY THICKENING MAN-HOUR REQUIREMENTS Curve 66 29310,00, ANNUAL POWER CONSUMPTION, KWH us wave! 23 8 S 6789 2s 4 86709 2 3 4 se7ee 1,000 10,000, ‘Thickener Area, SF GRAVITY THICKENING POWER REQUIREMENTS Curve 67 294ANNUAL COST, DOLLARS 2 733 2s 4 sees 234 beTeD F48878S Oy 10,000 Surface Area - Square Feet GRAVITY THICKENING MAINTENANCE MATERIAL COSTS Curve 68 295ANNUAL MAN-HOURS FOR 0 & M 1,004 os waves 109} 2s 4 56789 2s 4 se7es 2 3 4 867eo 100 1,000 Surface Area - Square Feet FLOTATION THICKENING MAN-HOUR REQUIREMENTS Curve 69 296ANNUAL POWER CONSUMPTION, KWH/YEAR us eance 1,,v00 ,009) | o> wove 100 ,009) 2 e788 23 4 S678, 23 a Se res a 100 1,000 Surface Area - Square Feet FLOTATION THICKENING POWER REQUIREMENTS Curve 70 297MAINTENANCE MATERIAL COSTS, DOLLARS ya sees 2 3 @ se7es 1,000 10,000, Surface Area - Square Feet 2 3 4 56789 FLOTATION THICKENING MAINTENANCE MATERIAL COSTS Curve 71 298ANNUAL MAN-HOURS FOR 0 & M 348 5 6789, 2 3 4 se7e9 2 00 1,000 Vacuum Filter Area - Square Feet VACUUM FILTRATION MAN-HOUR REQUIREMENTS (20 hours/day operation) 299 3 4 8678s Curve 72ANNUAL POWER CONSUMPTION, KWH/YEAR 1,000,000 9] 100 ,009} w_® wore z 34 5678 2s 4 S67 8o 2 3 4 5678s 100 1,000 Vacuum Filter Area - Square Feet VACUUM FILTRATION POWER REQUIREMENTS (20 hours/day operation) Curve 73 300ANNUAL COST, DOLLARS 100,009 ees —C— Pee Vacuum Filter Area - Square Feet VACUUM FILTRATION MAINTENANCE MATERIAL COSTS (20 hours/day operation) Curve 74 301ANNUAL MAN-HOURS FOR O 6 M 100, 009, 3| 20,008 2 3 4 56789 2 3 4 86789 2 3 4 8678s 10 "100 Flow, gpm CENTRIFUGING MAN-HOUR REQUIREMENTS (Based on 70% Operation Run Time) Curve 75 302ANNUAL POWER CONSUMPTION, KWH ws vavee 1,000,000 100,000 23 4 56789 2 3 4 86789 2 3 4 86789 100 Flow, gpm CENTRIFUGING POWER REQUIREMENTS (Based on 70% Operation Run Time) Curve 76 303DOLLARS: ANNUAL COSTS, ws cares 100,009 | as wove 10,000 2 34 S67 e9 2s 4 se7es 23s 4 s 6789 10 100 Flow, gpm CENTRIFUGING MAINTENANCE MATERIAL COSTS Curve 77 304ANNUAL MAN-HOURS FOR O & M ws voxeo w_ 2 wore Ss a wore! 17,0001 2 3 4 5 6789 2 3 4 86789 2 3 4 se 78s 100 1,000 Hearth Area - Square Feet MULTIPLE HEARTH INCINERATION MAN-HOUR REQUIREMENTS (70% operation time, 6 pounds/square foot/hour loading-wet basis) Curve 78 305ANNUAL POWER CONSUMPTION, KWH/YEAR 1,000 00 2 #86789 }99 2 3 456785) oo 2 5 4 SETS Hearth Area - Square Feet MULTIPLE HEARTH INCINERATION POWER REQUIREMENTS (70% operation time, 6 pounds/square foot/hour loading-wet basis) Curve 79 306uw > varoo oot wu & wore NATURAL GAS CONSUMPTION, MILLION SCF/YR > vores 2 3 4 56789 2 3 4 86769 23 4 S678 100 1,000 Hearth Area - Square Feet MULTIPLE HEARTH INCINERATION FUEL REQUIREMENTS (70% operation time, 6 pounds/square foot/hour loading-wet basis) Curve 80 307ANNUAL COST, DOLLARS 10,000 2 3 4 56789 23 4 56789 2 3 456768 100 1,000 Hearth Area, Square Feet MULTIPLE HEARTH INCINERATION MAINTENANCE MATERIAL COSTS (70% operation time, 6 pounds/square foot/hour loading-wet basis) Curve 81 308ANNUAL MAN-HOURS FOR 0 & M us aoneo 1,000 2 3 4 5 6789, 2 3 4 86789 23 4 86789 100 1,000 Alum Feed, Pounds/Hour ALUM STORAGE AND FEEDING MAN-HOUR REQUIREMENTS Curve 82 3091,009 ANNUAL POWER CONSUMPTION, KWH r 34s 67 89 23 8 S67 8S 23 4s 6789 : 00 1,000 Alum Feed, Pounds/Hour ALUM FEEDING POWER REQUIREMENTS Curve 83 310ANNUAL COST, DOLLARS ws vavoe 10,000 2 34 5 6789, 2 3 4 56789 23 4S 6769 100 1,000 Alum Feed, Pounds/Hour ALUM STORAGE AND FEEDING MAINTENANCE MATERIAL COSTS Curve 84 311ANNUAL MAN-HOURS FOR 0 & M 10,004 ws wore: 2 3 4 56789 2S 4 86789 2 1,000 10,000 Powdered Carbon Capacity - lb/hr POWDERED ACTIVATED CARBON FEED SYSTEM MAN-HOUR REQUIREMENTS 312 34 sees Curve 85xwH ANNUAL POWER CONSUMPTION, 10,000,000 1,000,009 2 3 4 56769 2 3 456789 2 3 4 86789 1,000 10,000 Powdered Carbon Capacity ~ lb/hr POWDERED ACTIVATED CARBON FEED SYSTEM POWER REQUIREMENTS. Curve 86 313DOLLARS ANNUAL COST, 8 7 6 5 4 3 100,00 10,004 as ao eo: 2 3 4 56789 2s 4 e769 2 3 2 56789 1,000 10,000 Powdered Carbon Capacity ~ Ib/hr POWDERED ACTIVATED CARBON FEED SYSTEM MAINTENANCE MATERIAL Curve 87 314ANNUAL MAN-HOURS FOR 0 & M us goxeo 10, 00g 1,009 oo wore 2 sas eres 2 3 4 5678 2 3 4867 "100 1,000 Lime Feed, lb/hr LIME STORAGE AND FEEDING MAN-HOUR REQUIREMENTS Curve 88 315KWH ANNUAL POWER CONSUMPTION, 100,000 3| 10,009 a wore 2 3 4 3 6789, z 100 34 56789 [Pumped | Feel £ QuigkLi Pumped Ft ‘Slakéd 1 1,000 Lime Feed, Ib/ne LIME FEEDING POWER REQUIREMENTS 316 24 | sa S67 Curve 89DOLLARS ANNUAL COSTS, 10,01 104 a _* ward 2 3 4 8 6789 2 3 4 56789 2s 4 s67es 100 1,000 Lime Feed, Ib/he LIME STORAGE AND FEEDING MAINTENANCE MATERIAL COSTS Curve 90 317ANNUAL MAN-HOURS FOR O & M 10,000 9| yu & wares | 67 ya S67 LY 2 36788 5 Polymer Feed, Pounds/Hour POLYMER FEEDING MAN-HOUR REQUIREMENTS 318 2S 4 8678 Curve 91ANNUAL POWER CONSUMPTION, KWH uw > varee 10,000 9 3 w+ a aro! 2 y 8 8 6769 2 3 4 5678 2 3 4 s6700 10 Polymer Feed, Pounds/Hour POLYMER MIXING AND FEEDING POWER REQUIREMENTS Curve 92 319ANNUAL COST, DOLLARS 2 ys s67es 2 3 4 s6789 2 3 6 86780 10 Polymer Feed, Pounds/Hour POLYMER STORAGE AND FEEDING MAINTENANCE MATERIAL COSTS Curve 93 320ANNUAL MAN-HOURS FOR O 6 M 2s 4 Se7e55, 2 5 4 8e67ea 9 2 3 4 56789 Sulfuric Acid Feed, lb/hr SULFURIC ACID FEED MAN-HOUR REUQUREMENTS Curve 94 321KWH ANNUAL POWER CONSUMPTION, 10,009 9| 1,009) 2 ys 4 B67 ee 2 3 4 86789 1,000 Sulfuric Acid Feed, SULFURIC ACID FEED POWER REQUIREMEN’ 322 10,000 Lb/hr 2 34 se 789 Curve 95ANNUAL COSTS, DOLLARS us vavee 10,091 9 43 678) «367 2 3 #56709 (0 2 3 # ere Ce 5 * 5 67eD Sulfuric Acid Feed, Ib/hr SULFURIC ACID STORAGE AND FEEDING MAINTENANCE MATERIAL COSTS Curve 96 323ANNUAL MAN-HOURS FOR 0 & M ws varoo 1,000 wu _> woreo uw > wore 2 3 4 56789 2 3 4 86789 23 4 86768 100 1,000 Feed Rate, Pounds/Hour DRY CHEMICAL FEED SYSTEMS MAN-HOUR REQUIREMENTS Curve 97 324ANNUAL COST, DOLLARS 1,000) ws wore 2 34 5 6789, 2 3 4 S678 2 3 4 seves 100 1,000 Feed Rate, Pounds/Hour DRY CHEMICAL FEED SYSTEMS MAINTENANCE MATERIAL COSTS Curve 98 325ANNUAL MAN-HOURS FOR O & & os vaxoo us aor80 20,008 a avon 1,000 100 sa 3 678s 3 4 86789 1,000 Pounds Carbon/Hour FLUIDIZED BED REGENERATION SYSTEM MAN-HOUR REQUIREMENTS (Based on Full Time Operation) 326 10,000 Curve 99ANNUAL POWER CONSUMPTION, KWH 10,000,000 ‘| ws wove 2,000,009} ws aor 234 56784 ooo 2 3 #56789, eS 4 S6TeS 100 Pounds Carbon/Hour FLUIDIZED BED REGENERATION SYSTEM POWER REQUIREMENTS (Based on Full Time operation) Curve 100 327NATURAL GAS CONSUMPTION, MILLION SCF/YEAR us wore 109] ws woven ww oveo 2 3 4 5 6709 2 3 4 s67es 100 1,000 10,000 Pounds Carbon/#our FLUIDIZED BED REGENERATION SYSTEM FUBL REQUIREMENTS (Based on Full Time Operation) 328 23 4 Seres Curve 101ANNUAL COSTS, DOLLARS 10,009 2,000! 2 3 6 s6reo 2 3 4 56789 2 3 4 56789 100 1,000 10,000 Pounds Carbon/Hour FLUIDIZED BED REGENERATION SYSTEM MAINTENANCE MATERIALS (Based on Full Time Operation) Curve 102 329ANNUAL MAN HOURS FOR O&M 10,000 1,000 uo vores nu a garse 2S 4 86789 2s 4 8678 10 CAPACITY, GPM WET AIR REGENERATION SYSTEM MAN HOUR REQUIREMENTS 330 23 + oer 100 Curve 103POWER CONSUMPTION - Kwh/YEAR 10,000,000 21,000, 000g 7| 6| 5 4 3 2] 2100 ,000 2 3 4 56789 2 3 4 5678s 2 3 4 86789 10 100 CAPACITY, GPM WET AIR REGENERATION SYSTEM POWER REQUIREMENTS Curve 104 331NATURAL GAS CONSUMPTION, MILLION SCF/YEAR as vores ws woroo yw» waxoo 23 8 56789 23 4 s67es 2 3 4 36768 10 100 CAPACITY, GPM WET AIR REGENERATION SYSTEM FUEL REQUIREMENTS (Based on sludge characteristics shown in Table Curve 105 332DOLLARS: ANNUAL COSTS, 100,000 10,000 mu voveo nu * @avoo > woroo 2 s+ eres 2 3 4 8678 2 3 4 s67ee 100 CAPACITY, GPM WET AIR REGENERATION SYSTEM MAINTENANCE MATERIAL COSTS Curve 106 333W390 Yoa SUNOH-IeW ‘TenNNW 34 s67es a S67 89 3 @ 5 6789 5 1,000 Lao Feet Filter Press Volume, Cubic PRESSURE PILTRATION, LABOR 7 DAY/WEEK OPERATION, 2 HR CYCLE) (BASED ON CONTINUOUS, MENTS MAN-HOUR. REQUIRE Curve 107 334WH ANNUAL POWER CONSUMPTION, 1,000, 00 100, 00) Ac 2 3 4 5678s 23 4 56789 23 4s 6788 100) 1,000 Filter Press Volume, Cubic Feet PRESSURE FILTRATION, POWEK (BASED ON CONTINUOUS, 7 DAY/WEEK OPERATION, 2 HR CYCLE) POWER REQUIREMENTS: Curve 108 335DOLLARS ANNUAL COSTS, | jt “Ty 1 tt | + 2 3 4 5 6789 100 1,000 Filter Press Volume, Cubic Feet PRESSURE FILTRATION (BASED ON CONTINUOUS, 7 DAY/WEEK OPERATION, 2 HR CYCLE) MAINTENANCE MATERIAL COSTS Curve 109 336= - te 9s of ve Tz at/9 13800 Ine eH S a . eH Cf MEW ZT - - 4 ‘omaston eH - - £ - - - 8 fusY 0S'O-zP"0 OF'O-FE"OOFO-VEO SPOTS "0 onro ono so/ub *katsued {TNE UTH 06 = -UTH OL uyH OL 04. oe. 04, ou. ze nuns UT 46 UTH 08 UTH 08 - - - - ooz naun % UR 66 -UTH 66 um ss 66 26 - - OT mu, % ‘ezts eToTIIEE - - ert st ot - - wh/29 foumton e404 - - - - - . _ Zequny euTpoT ve-eT - = S . . - sequmn Tousyd a TH OLT UN Ot = = 36 ov ZeqUNN sesseTOR a 0'8-0°9OG-S*E O'S ors sot sot ad a a “est oost 09 oss ser ub/ uw ‘eoay soezans wea ns ws ee rea) 9 # sorsredorg TeOTaaE aeyoun zeyonn goaea_oozea__oszepozpén _ooreporphH asenaeah SaaS PITT TOT @? SNOSUYO GaLVATZOV agusamoa SIAVITVAY ATTVIONSWWOD JO SOTLSTYALOWUWHD 3377 - - ve-08 be-or at/o "3809 xTa - - - xen z xen z 8 femaston . xen sz xen z xeW #T - 8 fuse p9"O-T9°0 ez"O-Zz"0_ZE“O-Lz"0 - Ts"0-SP"0 do/ub *Aaysueq xTNE 88-8L se-se oL-s¢ sa-s9 06 see noun 8 z6-88 s6-se 8-01 - 86 oe nazun & 66-16 66-S6 66-06 - 66 Oot naus % ‘e2z¥s eToTAIVa OL"0-79°0 zz-BTOre-brT - - 6/99 ‘eumton oz0a OoTz-o06T ooSE-oozE —_009€-008z UH O0L oort-006 oqumy ourpor zt-8 et-1t gt-eT - oer soqumy Towstd - 00€-002 - - - eqmy sosseton a ov e- - - na Oopt-OoeT OOEE-O00E ~—ovFE-008z 008-004 000T-006 ub/ u feory sess WERE eke Teas WOaReS oe ‘soraxedoxg TEOTUAE poztxeatna WO qxoseraTta cog “uoBT ED (7p, 3W0D) 338zw ve ez at/> ‘380 4THE xe ST xen ST xe ST femaston or-s or-s ores suse ov-0-22"0 ovo-zz"0 ov'o~zz"o co/ab "Ayrsueq Tha (388) se-08 (383) s8-o8 ("38a) s8-08 see naun ¢ . e - og nauZ § . - - oot nays & ‘ezts eToTazed - - - uB/o9 ‘ounton azoa Bay 00L Baw ove Say 008 xequn 2uTpoT - . . xequmy Tousua 7 - . Foqumyy SesseToH orot-s-8 orot-s'a orot-s'a Hd 001-059 ost-ose 008-004 uub/,w ‘wey eoezans z Wr ¥ soysaedora TESTEM THIN (+p, at09) 339TABLE 132 CONVERSION FACTORS FOR UNITS Engissh rues? prume/aco. aru oF-0.555 (t7 32) 2 cad some tt/s00 ‘alton spe paste om a 2 spate’ in » ww/any w/ee? /aay w/e? ne we fie-he b/s, are ve pel tone/aay st 055 i = 0,252 kg-eat = 97.63 ay? = 9 kgecala? = 278 afnern'/eay 23 ues 0.585 ksrcal/kg = 0.2048 = = 0,0929 a? = 028 2! me 0.2048 m/sec 3.705 1 = .003785 0? /aay = .0408 a /2ay/n* = .0632 an? /aee = .0532 1/202 = 40.7 da? even 2 40,7 L/man/a 258 oe = stg = 4S ka /0y = 4.830 g/eay/a? > 4.830 9/me/0* = 0.1692 xe/ur = 6484 xo/ken 2 0.92 g/n = 3,705 a? = 3,785 93 /eay = ng/L (approminate) = 0.006898 1/2? = 907 xo/aay st sera (a) +32 e°/sec en? jeec/a® ’ s/tay/s? phen? wn os afac/e? /asy ksreal kgreal/g weal/n? 340 EMPLOYED engisah = 0.2937 in = 15.85 gpm = 0.0288 gpmyse? = .002208 18 = .002205 1/te*sany (002208 byte" me = 1000 pen 9.335 wh/ac = 3.5971 BTu/ne/ieo = 2,205 = 3.966 ere = 1.60 aTu/ap = aan enue? = 2.205 Lbyday = 2.208 kis 5.91 w/the = 9479 stu = .0008308 » oes aruee? 2.342 apne = 0245 ernst? = 15.85 en = 3.28 € = 10.76 «2? sos? = 268.2 ope = 24.52 parte? 3504 tar 3.28 ft/sec (tps) = pre (approximate) > ppayne (approximate) 0.972 pene = 145.03 psiTECHNICAL REPORT DATA (Please read uszracions on ie reverse before completing) | EPA~600/2-77-156 MUNICIPAL WASTEWATER TREATMENT A. J. Shuckrow and G. J. Culp Battelle-Northwest Battelle Blvd. Richland, Washington 99352 Office of Research and Development, U.S. Environmental Protection Agency Cincinnati, Ohio 45268 APPRAISAL OF POWDERED ACTIVATED CARBON PROCESSES FOR — |s. Municipal Environmental Research Laboratory--Cin., OH We REPORT BATE 1977(Tssuing Date) _ is. PERFORMING ORGANIZATION CODE SANIZATION REPORT WO. [iO PROGRAM ELEMENT NO. — 1cell [iy CONTRACT EHARERS—— | 68-03-2211 13, TYPE OF REPORT AND PERIOD COVERED yo fa, SPONSORING AGENCY CODE | EPa/e00/14 Project Officer: James J. Westrick (513-684-7652) fe-masTRACTpGWered activated carbon has been the subject of several developmental efforts directed towards producing imoroved methods for treating municipal wastewaters, Granular activated carbon has proven itself as an effective means of reducing dissolve organic contaminant levels, but is plagued with specific operational problems which can be avoided with powiered carbon. The work reported herein was aimed at putting powdered activated carbon (PAC) treatment in proper perspective relative to competing technology. All work with PAC and PAC regeneration was reviewed and representative process approaches selected for comparison with granular activated carbon. While no one PAC approach is clearly superior from a performance standpoint, biophysical processes are attractive because they can be incorporated into existing biological plants. Comparison of capital and operating costs were made for plants with through- put rates of 1, 5, 10, 25, and 50 M@. Cost relations were generated in curvilinear relations to allow interpolation. Based on these estimates, it was determined that independent physical-chamical PAC systems are not economically campetitive with other modes of treatment, PAC may offer advantages for specific cases where highly variant Flows are experienced such as plant receiving flows of a seasonal nature or areas with cambined storm sewer systans A sensitivity analysis was also conducted to deter- mine where improvenents could be made to make PAC competitive. Lower carbon doses and/or inexpensive throwaway carbon would be needed to successfully challenge the Lather systems evaluated. Iz cosaniF ‘Activated carbon Activated siudge process Cost comparison Economic analysis Estimates Powdered activated car- bon processes 138 Municipal wastewater Granular activated car- bon processes Powder (particles) |Physcial-chemical treat~ Regeneration (engineering) ment RELEASE TO PUBLIC TW BEGURTTY CLASS 7G Repo V WOOF PRTES UNCLASSIFIED 538? Ta ae UNCLASSIFIED EPA Form 22201 1879) esac nme 1157-05705