City Council Agenda Packet 03-14-2005 Special
SPECIAL MEETING - WASTEWATER TREATMENT PLANT ISSUES.
GROWTH PROJECTIONS AND RELATED ISSUES
--
5 P.M. AT THE WWTP CONFERENCE ROOM
I. Growth Projections and Related Issues - Presented by Jeff O'Neill
- Building Trends 2004 and 2005
Building Development Trends - Single Family and Townhomes
2002 - 203 units
2003 - 206 units
2004 - 250 units
- Lot Development Projections
- Population Projections
II. Wastewater Treatment Plant Issues
1. Introduction - John Simola
2. Existing Operating Conditions at the WWTP Including Biosolids (Power Point)
PSGNEOLA (See Annual Report 2004 in three-ring binder distributed to Council
in January)
III. Alternatives - Presented by Bolton & Menk, Inc. (Power Point)
~
IV.
Summary - Presented by John Simola
V. Tour of BioSolids Portion of Plant (time permitting)
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YEAR
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
CITY OF MONTICELLO
POPULATION PROJECTIONS
POPULATION
10961.55
11770.65
12705.30
13803.50
14989.25
16300.55
17737.40
19299.80
20987.75
22801.25
UNITS PER YEAR
245
290
335
380
425
470
515
560
605
650
TOTAL UNITS
3729
4019
4354
4734
5159
5629
6144
6704
7309
7959
3484 Units as of 2004
2.79 Residents per Unit
Calculation:
(Units per Year x 2.79) + Population from previous year.
1----. ---------------l
I POPULATION PROJECTIONS - CITY OF MONTICELLO
25000.00
20000.00
.
15000.00
10000.00
LO.OO
.
5000.00
I_POPULATION I
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 _TOTALUNI~
_._-"--_.._--,._-_.._-~_.~
F:\ADMIN\$pread\-JOHN\POPULA TIONPROJECTIONS03-05..>:ls: 3/1012005
Special Council Agenda - 03/14/2005
.
Introduction of Waste Water Treatment Plant Issues - Presented bv John Simola.
II-I
A.
BioSolids
BioSolids is the most important issue facing the operation of Monticello Waste Water Treatment
plant today. Although the Waste Water Treatment Plant is operating and meeting all permit
parameters, all solids removed during treatment of the waste water have to be properly reused or
properly disposed of. Each year, the City generates approximately 1.4 million gallons of liquid
biosolids. This is down trom 2 million gallons prior to the installation of the gravity belt thickener.
The amount of actual dry solids in the biosolids is approximately 4% which equals approximately
180 dry tons per year. Prior to 1996, the City had hand shake agreements with a few farmers in the
area and individual Minnesota Pollution Control Agency site permits for the land application of
Class B biosolids.
.
In 1989, the City Council authorized City staff to begin searches for land to purchase for biosolids
application as, at any time, on a farmer's whim or township regulations, we would have no place to
apply the biosolids and would have to dry and land fill biosolids which is very expensive. In 1995,
we narrowed our search to larger sites due to grov.'th and buffer area requirements. We spent a great
deal of time trying to purchase a large site on County Road 106. This, however, did not work out.
In 1996, the City entered a purchase agreement with the Bohanan's to purchase a 158 acre farm at
the corner of Briarwood and West County Road 39 in Monticello Township. The purchase, of
course, was dependant upon the City acquiring a permit from the Minnesota Pollution Control
Agency to operate a land spreading biosolids facility on that site. A significant amount of research
was performed, engineering studies were performed, test borings and ground water monitoring wells
were put in, and many special public informational meetings were held and the site was finally
approved for biosolids applications in the fall of 1996.
The City uses the services ofPro-Ag Crop Consultants to assist with monitoring the application of
biosolids, the crop irrigation, the plant up take of nitrogen and yields of the crops as well as carry
over nitrogen for the next year. The farm is leased to Spring Brook Farms of Big Lake for an
estimated $20,000 per year some of which is applied toward a state of the art irrigation system on
the site. Those leases go into the year 2006 cropping season. The City also rents the existing
farmhouse for $10,000 per year. Two pole barns on the farm house city equipment, including
biosolids application and hauling equipment. We recently received permanent permit status for our
facility from the MPCA.
As part ofthe plan for biosolids applications, the City included a Class A biosolids process with the
construction of the WWTP in 1996 that system, however. failed to operate properly and the City
settled out of court for a sum of approximately $700,000 to put towards a working Class A process
or additional farm land.
.
Today we find ourselves in the need for additional biosolids land or a process to produce Class A
biosolids. Especially exceptional quality Class A biosolids which has a minimal amount of
.-
.
Special Council Agenda - 03114/2005
pathogens, meets vector attraction requirements, and is low in metals. A change in operations at the
Monticello WWTP has temporarily used up the remaining capacity of the faml, as the biosolids
produced from the process changes are extremely high in nitrogen and nitrogen is one of the limiting
factors for applying biosolids to crop land as you cannot put on more nitrogen than the crop can take
up. While the process is being reversed at the WWTP and we expect to get back to having at least
20% reserve capacity in the farm, we still need to move ahead with solving our biosolids problems
for the future. It has been com Carting to have the farm as we have not had to worry about a place to
go with the biosolids for the last nine years. We have generated $30,000/year in income from rents
and the land has probably more than quadrupled in value. We have controlled this part of our
operations rather than it controlling us.
Today at this meeting you will hear from PSG with a summary of operating conditions at the WWTP
today, as well as projected needs for expansion of the WWTP itself, which is our second big issue
at the WWTP. In addition, you will have a Class A alternatives presentation from Bolton & Menk,
an engineering firm that helped us through our court cases over the Class A process. At the end of
the meeting we will sum up our options and also discuss the possible regional facilities that may be
built in the future.
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Special Council Meeting: 03114/2005
IV.
SUMMARY
From the above information and presentations by PSG and Bolton & Menk, Inc., we hope it has been
demonstrated that the City of Monticello needs additional options for biosolids almost immediately.
The options are, of course, to buy and permit additional land so the City can control its own destiny,
the land would escalate in value, rents would help offset operational costs at the farm, and the
investment in land would return several fold in the future back to the City with the increase in value
of/and. It is important to have a disposal site where the biosolids can be reused and farming is a
good alternative. However, farming may not be the long term single solution for the City. Wc can't
continue to buy land forever. As the City doubles, triples or quadruples in size, our needs for land
would also do the same.
The alternatives to go to an exceptional quality Class A biosolids our self are attractive in that we,
again, would be able to control our own operations and would not have to depend on some outsiders.
A system such as the A TAD or belt drying system do have benefits in that regard. Both of them have
somewhat high capital investment costs, probably the A TAD more than the belt drying system.
While the AT AD system allows us to continue with our liquid system, the belt drying system allows
us to go to a system with much less need for storage and, ultimately, the biosolids could be further
dried or incinerated, so that we can dispose of the inert grit in many places. The costs of operation
of some of those systems, however, are dependent on fossil fuels and if they don't work as planned
we could have high operational costs.
The possibility exists of joining with other cities in a regional facility such as with Delano, Princeton,
Otsego, Zimmerman, etc. It appears at this time that the city of Buffalo and the city of Big Lake
believe it's in their best interest to build a system themselves to handle their own biosolids so they're
not dependent on someone else. There is an indication, though, that they are over sizing their
systems and may have room for the City of Monticello in the future if things work out. How long
a period of time that would be until they need the additional capacity for themselves is not known.
I have given you a lot to think about in regards to biosolids. We also need to start planning for thc
next expansion of the WWTP, adding the fourth tank at the bare minimum so that we take a
proactive approach towards that rather than a reactive approach to emergency situations at the plant.
There are no decisions to be made today but we can't put this on the back burner, so at an upcoming
meeting we will talk about the summary and the alternatives again and look more into the pros and
cons of each one. Also at that time we will have a little more information on the regional facility
being built possibly within 20 miles of the City of Monticello.
.
Wastewater Biosolids Treatment
Information
*
K)N1'lCf.J...U}
March 14,2005
Presented by
.
Items to be Presented
. Background on Existing Biosolids Treatment Facilities
. Class B vs. Class A Biosolids
. Class A Biosolids Treatment Process Alternatives
. Criteria for Selection of Class A Biosolids Treatment
System
. ATAD System
. Belt Drying System
. Questions
e-
.
.
1
.
Background
. Thickening, anaerobic digestion, storage and land
application site
. Class B biosolids
. City owns 158 acres of agricultural land for
biosolids disposal
. Approx. 1.4 million gallons ofbiosolids applied to
agricultural land per year
. Supplemental fertilizer
.
.
.
Gravity Belt Thickener (GBT)
.
.
.
2
.
.
.
Anaerobic Digesters and Storage
.
.
.
3
.
Anaerobic Digesters and Storage
.
.
.
Biosolids Land Application Site
..
.
.
4
.
Biosolids Land Application Site
.
..
.
5
Class B Biosolids
. Pathogen reduction less than 2 million fecal coliform
. Vector attraction 35% reduction in volatile solids or
incorporation into soils
. Land application is primary disposal method
. Land application sites have to be approved by MPCA
. Land application ofbiosolids in winter months is
prohibited
.-
.
.
.
.
.
-...
Class A Biosolids
· Pathogen reduction less than 1000 fecal coliform
· Vector attraction is met with Class A biosolids treatment
process (does not require incorporation into soils)
· Greater flexibility in final disposal options/year around
land application on agricultural lands and can use non-
agricultural lands
· Permitting process is less regulated - "exceptional
quality"
· Better public acceptance
· Regulation trends are to provide Class A biosolids
.
..
Class A Biosolids Treatment
Process Alternatives
· EP A Regulations 40CFR Part 503 (pathogen, vector
and pollutant limits)
· Autothermal Thermophilic Aerobic Digestion
(ATAD)
· Heat and lime treatment (RDP)
· Temperature Phased Anaerobic Digestion (TPAD)
. Heat drying
.
..
6
.
Criteria for Selection of Class A
Biosolids Treatment System
. Proven track record
. More than one manufacturer of equipment
. Maximizing the utilization of existing biosolids facilities
. Minimum space required
. Low operation and maintenance costs
. Low energy costs
. Control system automation for maximizing the utilization
of existing staff
. Cost effective life cycle costs
. Public acceptance
.
.
.
Definition of ATAD
Autothermal Thermophilic Aerobic Digestion (ATAD):
A self heating aerobic digestion process with
microorganisms that grow in a temperature range from
500 C to 650 C and a hydraulic retention time of 7-10 days.
.
..
.
7
.
AT AD History
. Studied in the 60's
. Developed in the early 70's
. Operational in the mid to late 70's
.
.
.
40 CFR Part 503
Class A Sludge Criteria
. Pathogen reduction requirement
. Time/Temperature equation
. Vector attraction reduction
. Pollutant limits
.
.
.
8
.
.
.
9
.
.
AT AD Benefits
. Minimum space required
. Low 0 & M costs
. Self heating system (low energy use)
. Automatic control system
. Numerous facilities installed with performance data
. EP A approved technology
. May be able to utilize existing anaerobic digester
tanks for AT AD
.
..
.
10
-
.
List of ATAD Facilities
Installed in Minnesota
. New Ulm
. Lakefield
. Green Lake Sanitary Sewer and Water
District, Kandiyohi County
. Waseca
.
.
.
New VIm, Minnesota
Wastewater Treatment Facility
.
11
.
New VIm, Minnesota
ATAD Facility
.
.
.
.
..
.
12
.
Fecal Coliform ATAD Process
New Vim, Minnesota
1200
"
:!! 1000
'0
E~ 800
o J!
- g
o~ 800
0
.. E
" l! 400
..",
Z
... 200
!.
0
Fecal Limit
~ ~ ~ I I I I i ~ ~ ~ e i i ~ ~ ~ ~ ~ ~ I I
! i ~ ~ ~ ~ ~ ~. ~ ~ .~ ~ i ~ ~ i ~ i ~ ~ ~ i
. .
.
Lakefield, Minnesota
ATAD Wastewater Treatment Facility
.
.
.
13
.
AT AD Biosolids Treatment
.
.
.
Fecal Coliform
A TAD Process
Lakefield, Minnesota
1200
..
:2 1000
'0
~~ 800
,g,g
:= -
0... 600
o 0
- E
5 l! 400
.f 01
Z
0. 200
!.
Fecal Limit
0
'" ~ C> C> ~ ~ .. .. '" '" ... ~
':1 ! t ! t ! t c;> t !
'"
~ 0. 0. 0. .. 0. 0
<( 0 <( 0 <( 0 :Ii 0 <( z
.-- .
.
14
-
.
Green Lake Sanitary Sewer
& Water District
.
.
Green Lake Sanitary Sewer
& Water District
.
.
.
..
15
.
Fecal Coliform
AT AD Process
Green Lake SSWD-Kandiyohi County, Minnesota
1200
"
:2 1000
"0
~~ 800
,gJ!
=.9
0_ 600
(.) 0
- E
~ I! 400
...'"
Z 200
...
!.
0
.. .. 0 0 - - .. .. '"
l!! l!! Ii! Ii! Ii! Ii! Ii! Ii! Ii!
~ ~ - - i ~ ~ - i
~ ~ ~ Ii! ~ ~
..
0 0
.
Fecal Limit
.. ~ ~
Ii!
~ ~ -
~ ~ ~
0
.
.
Preliminary AT AD Site Layout
,",;' :'I'~~;'~:,\
& . ;""..I'\...,
,'''"'-:, ~'o<I',"""""",(~~
. ~ ,'--" .r-...,. ,
1;(
"!i;
I
,'7
L_
.
.
16
.
Review of Heat Drying Process
. Why consider heat drying?
. Large volume reduction (60-80%)
. Process requires small space requirements
. Produces a nice dry product people can handle
easily and use
. Odors can be completely contained in small space
. Reliable process to meet Class A requirements
.
.
.
Review of Dryer Technologies
Technology
Continuous Feed Rotary
Drum Dryer System
Batch Feed Rotary Drum
Dryer System (Fenton)
Continuous Feed Belt
Dryer System (Kruger,
Andritz)
.
.
Comment
High volume systems
technology
Modification of rotary
drum technology to
smaller scale application
"Next" generation of
small scale dryer
technology
.
17
18
.
Why Sludge Drying?
e.g. town 500,000 Inhabitants
-
.........
... ... ... ... ...
... ... ... ... ...
......... ... ...
............ ...
............ ...
... ......... ...
...
-
.........
Mech dewatenng
-...-...
c_~~~-~~
.....
A _
31 Silo trucks
1 truck
.
..
.
Kruger BioCon Description
. Safe, Simple & Efficient
. Indirect Convection Belt Dryer
. Stainless steel, variable speed mesh belts
. Large biosolids drying surface
area (thin strings)
. Enables low temperature drying
.
. Two stages
. First stage: 15 minutes at
< 1800C (3560F)
. Second Stage: 45 minutes at
< 850C (1 850F) .
.
.
Kruger BioCon Description
.
.
. Heat supplied by indirect heat
exchangers
. Transferred to the sludge via circulated
air ( axial fans)
. Closed Loop
. Recirculatiou of drying air
. Heat recovered from wet drying air after
passing through a condenser
. Dehumidified air retorned to the system
as new drying air
. Drying occurs under slight vacuum
(no odor release)
.
Kruger BioCon Dryer System
Wet SlUdge
SoIds: to-30%
.
at ~ '-TH:~::'~~c~ I
~ Warm Sedlon
T_75-85"C
I '
~ ~~f~Iji:ILt~i
(heat 1S(I1JlUl) 10 c:ondenaer D=d heat SOUfCM
a1udga.
.
.
.
19
-
.
Biocon Dryer Unit
.
.
Biosolids on Discharge Auger
,
..
.
.
.
.
20
.
Biosolids End Product
.
.
.
Finished Product
Dried
Pellets
.
.
.
21
.
Andritz Belt Drying Systems BDS
Development targets concerning the new drying generation
..
.
Andritz Functional Principle BDS Dryer
. Belt drying system, product flow, air circulation, heat
generation & exhaust air treatment
--
Orylngulr!oap
--
..... end
-
ElchlluSl:Alr
I
.....
hlel'~~I~.~
ICUN:tl
.
.
.
22
-
.
Andritz Dryer Unit
.
.
Andritz Dryer (Inside)
.
.
.
.
23