Biosolids SPOTLIGHT

Biosolids SPOTLIGHT: A focus on the people of biosolids who work in our region

September 2024 - MABA Biosolids Spotlight 

Provided to MABA members by Bill Toffey, Effluential Synergies, LLC 

SPOTLIGHT on BLOOM

DC Water’s biosolids product, Bloom, “sparks joy!” While influencer Marie Kondo’s “spark joy” tips no longer focus on tidiness, she now advises on the “little activities that bring peace and joy on a deeper level.”  Any biosolids manager who reviews the case studies and testimonials of Bloom users, easily found on Blue Drop websites and social media, cannot help but enter a zone of peace and joy. The District’s plan for a first-in-the-U.S. technology embraced some 15 years ago envisioned “biosolids product(s) that will have maximum potential use in the marketplace” (WEFTEC 2010, “Development Criteria in the Age of Sustainability – DC Water’s New Paradigm for Biosolids and Energy Management”).  That dream has been actualized, and that “sparks joy.”

The birth of Bloom as a soil product followed closely upon completion at DC Water’s Blue Plains Advanced Wastewater Treatment Plant of the biosolids treatment process that combined the Cambi Thermal Hydrolysis Process with new mesophilic anaerobic digesters and new belt filter presses. On January 17, 2017, the DC Water Blog offered this announcement: “One Drop Begets Another: We launched [Blue Drop] 54 days ago with the goal of marketing products and services DC Water has already developed – to generate revenue and improve the state of the water sector.”  This brought the “new paradigm for biosolids” to reality.

Seven years of market development have brought Bloom to a peak place among biosolids products. But for the venerable Milorganite, nearing its 100th anniversary (1926 to 2026), Bloom, with its tagline “Good Soil, Better Earth,” has developed an unexcelled breadth of its product reach compared to exceptional quality biosolids worldwide. Its markets range from city sites to rural lands, from community gardens to large farms, from homeowners to highly esteemed professionals. Bloom is available in its “fresh” form (Fresh Bloom) and in two blends, the Woody Blend and the Sandy Blend. Specification sheets are available for all three forms, describing physical and chemical characteristics, and use information sheets are available for each. Market segments have coalesced into landscaper and resellerscontractorsfarmers, and homeowners.  For all markets, Blue Drop prepares a photographic gallery and testimonials of successful product uses, many backed up by 18 webinars viewable on YouTube.

As is true for most successful ventures, committed, forward-thinking champions comprise the Bloom production and marketing enterprise.  At the head of the enterprise is Chris Peot, who for 25 years has been one of the nation’s foremost advocates for biosolids recycling and high-quality product formulation. He arrived at the DC Water and Sewer Authority when the agency was knee-deep in substandard, odor-prone residuals, determined to change its off-kilter course and poor reputation. He was a key advocate for the treatment train announced in 2010 to create a product with the promise that was to become Bloom. He helped conceive the marketing program for the Bloom biosolids product that would launch Blue Drop. Chris now serves the dual role of Interim President of Blue Drop and the Director of Recovery and Wastewater Treatment for the District of Columbia Water and Sewer Authority (DC Water). 

spotlight 1

Chris Peot, Director of Resource Recovery, giving a tour of Cambi Thermal Hydrolysis Process units at DC Water’s Blue Plains AWTP

Chris Peot’s pledge was to create the highest value biosolids product that would yield the District and its ratepayers the highest returns. To accomplish this, he would have DC Water create versatile products and markets.  DC Water would turn to soil and plant experts, notably Ron Alexander, to assist customers on technical issues, and the agency would support related practical and university end use research, as with Drs. Greg Evanylo and Gary Felton.  Peot needed a vehicle, Blue Drop, to assist with marketing, engaging a staff of problem-solvers and passionate advocates for the product. Today in 2024, Bloom is supported by the brilliance of April Thompson, Holly Kiser and Victoria Alleyne. 

Marketing Bloom has become a unique success with April Thompson, who leads the Bloom marketing and sales efforts. April holds an MBA and an MA in International Development from American University and a BA from the University of Virginia, which led her to work in more than a dozen countries. She has worked in non-governmental organizations on important causes, such as food security and child labor. She is also a freelance journalist, particularly on sustainable lifestyle topics, and is passionate about urban agriculture and conservation, having completed the master gardener and naturalist programs. April now brings these commitments to important issues and these talents in marketing, communication and project management to her position as Senior Director for Bloom. And she does so in the context of a strong effort at DC Water to make a great product.  "The team at DC Water deserves a ton of credit," April is quick to say, "as they actually blend our beautiful product in house, they help deliver to our customers and they work literally day and night to get trucks loaded."

spotlight 2

April Thompson, Senior Director, bragging about the results of Bloom

April holds up golf courses as a growing type of customer for Bloom, overseen by Bloom Sales Manager Victoria Alleyne. Victoria is the Bloom Sales Manager working with landscapers, contractors, land resellers.  While born in the US, Victoria was raised in Barbados, the origin of her love of plants.  She earned a BS in Environmental Sciences and her MBA from the University of Maryland Global Campus.  Prior to Bloom, Victoria spent more than four years at Maryland Environmental Services, where she was part of MES organics diversion, composting, and recycling, including the marketing and distribution of Leafgro.

Golf courses are by no measure easy customers for Victoria, as Bloom is not a familiar soil amendment, and much is at stake in successful product performance. The expectations by golf course superintendents for their soil products is for even, deep green landscape, for spotless, disease-free turf, and for the precise balance of good drainage yet adequate moisture holding characteristics. Over the past several years, Bloom has managed to earn the trust and respect of expert consultants in the golf industry, who help tailor the Bloom product to the exacting, dependable performance needed by courses.  

April and Victoria have come to appreciate the expert voice of Jeff Michel, Vice President of M&M Consulting, who in a recent training webinar spoke alongside Allen Turner, Superintendent of Four Streams Golf Course on specific aspects of Bloom that are highly valued. These include sand blends that have a controlled release of nutrients at a pace matching turf needs, not over-fertilizing (which weakens the grass) not resulting in leaching below the roots (which is a waste of money). The result is turf that is deeply rooted, a key to drought resistance and plant health.

spotlight 3

Before and after pictures of green restoration using the Sandy Blend Bloom product at the Four Streams Golf Course

In the “Bloom fan club” also is Ben Ellis, superintendent of the golf course at Andrews Air Force Base. Ellis speaks to how Bloom builds soil cation exchange capacity with its organic matter, how it sequesters carbon for sustainability and how it provides a kick of extra iron and nitrogen for super green color. But it was the cost-effective availability of the Bloom Sand Blend in high volumes that was the lifesaver at a project he managed at Fort Belvoir, when he restored ten acres entirely devoid of topsoil and organic matter. At his post at Andrews, his eye is now on a large delivery of Bloom for development of a driving range.  

Victoria is also responsible for large contractor jobs.  She points to the South Capitol Bridge, the largest Bloom project to date, as a capstone event. Also known as the Frederick Douglass Memorial Bridge project, plans included highly visible landscapes, challenging grades and paths for public accessibility for bikers and walkers. This mandated high quality turf and plant establishment for what was to become a world-class landscape, hence the need for Bloom as a dependable foundation for success. The soil specification for the DC Department of Transportation called for a significant increase in organic matter to bring the existing topsoil to a quality suitable for sustainable plant growth. Landscape architects and soil scientists came together to find an optimal blend that included Bloom for its capability to provide a rich quantity of slow-release nutrients.  The Bloom-amended soil could provide drought resistance through good water holding capacity, disease tolerance from its balance of plant nutrients, and good soil structure for water drainage and storm management control.

spotlight 4

Fresh Bloom applied for in situ incorporation with existing soil fill at South Capitol Bridge project

 spotlight 5

Capitol Bridge South with high value landscape plantings completed

Holly Kiser, Blue Drop’s Agricultural Liaison, calls herself a “farm kid.” She was raised on a dairy farm, and today lives with her farmer husband and two children on Radley Bend, a multi-generational farm producing hay, dairy, and cattle, and of course pigs her kids tend as 4H projects. She has personally witnessed biosolids benefits to crop production and soil health, so is able to compellingly represent Bloom as an affordable and natural fertilizer.

Blue Drop has posted a case study of an agricultural application of Bloom at the Lorn Carlee farm. Carlee’s 600-acre farm in Washington and Frederick Counties in Maryland is on a path to improved soil health, greater crop yields and sustainability with the use of organic matter sources.  Carlee started using chicken litter and then moved to Bloom, committing to transforming his cultural practices over a five-year period. He is using 20 tons per acre of Bloom on sorghum and 10 tons per acre on soybeans, resulting in larger sorghum heads and greener leaves and soybeans that are taller and more productive.  Without Bloom, Carlee had been barely achieving 100 bushels of sorghum per acre, but with Bloom Carleereaches a yield of 135 bushels per acre.  Carlee has discovered that Bloom makes crops more resilient to drought, and he expects that future soil tests will show improvement in his soil’s improved cation exchange capacity. With improved soil health, Carlee expects to move his target of corn production from 200 bushels per acre to 250 bushels.  Through Bloom, Holly has introduced to Lorn Carlee Fresh Bloom as a source of organic matter and natural nutrients that puts into real action sustainable farming.

spotlight 6

Bloom applied to farm fields results in notable improvements in crop vitality

The highly skilled and dedicated Blue Drop sales team has a key foundation of support back at DC Water – James Fotouhi, the Resource Recovery Program Manager. James has been with DC Water for nearly 7 years, providing Blue Drop’s sales team with the regulatory, science and logistical foundation necessary for this unusually wide-ranging and necessarily transparent sales program. James has a civil engineering degree from the University of British Columbia, which engaged his interests in energy and water efficiencies and that propelled him in his early career with Engineers without Borders and with water technology consultants BlueTech Research. At DC Water, James has worked on energy efficiencies, carbon management and greenhouse gas emissions, and he has provided avenues for program efficiencies to reduce costs in the Bloom marketing. His technology and science skills have made him a key staffer, supported by able staffers such as Antoine Wroton, in addressing current issues with microcontaminants.

James underscores the importance of Bloom product quality in the entire recycling enterprise.  James says “one of the keys to Bloom’s success is consistent product quality. When operated correctly, THP can produce a very homogenized, low odor material, and DC Water does a great job keeping it functional. Operations has discovered a lot of flexibility in the system, finding that even with entire digesters or CAMBI trains down for months at a time, the Class A VSR [volatile solids reduction] and time/temperature requirements [for further pathogen reduction] can still be easily met. In 10 years since commissioning, the biosolids treatment process has always met and exceeded our permit requirements.”

Keeping the biosolids treatment process working is a committed team of wastewater treatment professionals at DC Water.  James called out Eric Barnett, in Process Engineering, and Dennis Morris, Program Manager Department of Maintenance Services, as heading the teams that keep the process moving dependably 24-7.  Dennis emphasized: “[Cambi} is not a set-and-forget process. We have good people who really care about their jobs, and they need to be constantly aware. Thermal hydrolysis is a good process, but we have needed continuous improvements for changes to optimize it.” Dennis is always in search of young people to train as the next generation to keep the Bloom product excellent.

DC Water and Blue Drop together are the global leaders in the production, distribution and sales of exceptional quality biosolids for use in urban and nearby agricultural landscapes. The progress across the 15 years from concept to full implementation has been a steady perseverance and commitment to principles of sustainability, circular economy and resource use efficiency.  This endeavor is a shining example for all of us in the biosolids profession, an example that can spark joy.

For more information, contact Mary Baker at [email protected] or 845-901-7905.

 

August 2024 - MABA Biosolids Spotlight 

Provided to MABA members by Bill Toffey, Effluential Synergies, LLC 

SPOTLIGHT on Two New Members and Two Great Programs

Capital Region Water in Harrisburg, PA

The 60 foot by 160 foot covered biosolids storage pad, with a capacity of about 50 truck loads of biosolids cake, has been a family project. The Longnecker family, with patriarch 76-year-old Glenn and wife Sharon, son Jamie and his wife Gail, and son Danny built this framed and fabric covered shed in Elizabethtown, situated within the cluster of homes, barns, garages and roosts that comprise their farm. The shed is complete, the ribbon has been cut and the first deliveries of digested cake have been received from the Capital Region Water (CRW) plant 25 miles upriver on the Susquehanna River. The Longneckers grow field corn, soybean and barley on 300 acres for a herd of 200 steers and flocks of 30,000 chickens and guinea hens. In erecting this storage facility, the Longneckers ensure their ongoing supply of CRW biosolids, and avoid the “mess” that field unloading of cake had been for their nearly 20 years of biosolids use. 

spotlight 1

Three generations of Longneckers all joined in on the construction of the 60’ by 160’ biosolids storage facility on their 300-acre farm outside Elizabethtown, PA, a 25-minute truck ride from CRW’s plant in Harrisburg

 spotlight 2

The covered storage facility can hold upwards of 1,200 tons of biosolids cake for fertilizing field corn, soybeans and barley in support of their herd of steer and their flock of poultry

One big winner in this story is CRW, one of MABA’s newest public utility members, operating a 21 MGD facility in the city of Harrisburg, Pennsylvania. CRW is now rebuilding its land application program after years of landfill co-disposal.  This rebuild is part of a long-range program for reinvestment in its biosolids treatment facilities, the implementation of a biosolids master plan completed in 2018 for this plant. CRW produces approximately 2,500 dry tons of solids annually, a number expected to grow as the agency implements a project to truck-in sources of additional gas-producing organic matter for its digesters. 

Jess Rosentel, Chief Operations Officer, can readily enumerate the series of improvements that have been completed over the past several years.  A capstone of these just broke ground in June 2024, the Energy Recovery Improvements Project. Improvements to solids handling systems include such features as: installation of 1/4 inch screens at its headworks; complete rebuild of its mesophilic anaerobic digesters, including interior surface liners, replacement of gas mixers with linear motion mixers and installation of fixed covers with gas holding capacity; and separate digestion of primary and secondary solids, both sources thickened ahead of digestion by gravity belt thickeners.

spotlight 3

CRW, undertaking a series of solids handling improvements set forth in a 2018 master plan upgraded the anaerobic digesters, including adding a fixed cover in support of linear motion mixers

A key component of the digester project is the hydrolysis pretreatment of thickened waste activated solids. This process decision was supported by a comprehensive solids and energy planning model developed by engineering consultant Arcadis, managed for CWR by Arcadis’s Eric Auerbach, which showed that improved volatile solids destruction would benefit both biogas production and reduced biosolids utilization costs. 

CRW chose for WAS hydrolysis the Pondus alkaline thermal hydrolysis system manufactured by Centrisys in Kenosha, WI, and represented locally by Kappe Associates, both MABA members.  In contrast to the better-known Cambi thermal hydrolysis process that treats combined solids under high temperature and pressure to a Class A level of pathogen reduction, the Pondus system will pretreat the waste activated secondary solids at low temperature and pressure using an alkaline addition. The process will be ahead of thickening and mesophilic digestion, producing instead a Class B biosolids.  CRW did not target Class A treatment, as it is comfortable with its Class B options for utilization. Instead, CRW prioritized improved volatile solids destruction for reduced hauling volumes and increased biogas yield in support of its outlets for Renewable Natural Gas.

Pretreatment of WAS with hydrolysis was a key objective.  CRW had earlier installed Enhanced Nutrient Removal and had witnessed the troubling performance of its Belt Filter Presses (BFPs) to achieve the goal of 20 percent solids.  This is because ENR produces phosphorus accumulating bacteria that under anaerobic conditions release Extracellular Polymeric Substances (EPS) that interfere with release of bound water during press operations.  Hydrolysis promises to disintegrate the EPS to promote a far more dewaterable feedstock to the BFPs and hence significant reduction in total cake production.

Arcadis also guided CRW toward an innovative energy program for its solids treatment, providing two special components. First, a high strength liquid waste receiving station has been built which will allow CRW to accept trucked-in liquid High Strength Organic Waste (HSOW).  This organic loading will supplement the blended primary and hydrolyzed WAS by up to 20 percent of total organic loading. Some of the biogas from anaerobic digestion will still go to boilers for internal energy use, but CRW will not need to replace its 40-year-old ICE generators. Instead, it will process the biogas to standards for Renewable Natural Gas set by UGI Energy Services (UGIES) for injection into a pipeline conveniently situated along its property boundary. CRW will operate the gas clean up equipment, but UGIES will operate the equipment for continuous monitoring of gas quality, a step required for pipeline injection. The revenue from the sale of the RNG to UGIES is nearly double the basic commodity price because of the value of the RINs (Renewable Identification Numbers) assigned to biogas.  CRW will also receive tipping fee revenue for acceptance of HSOW. Nearby Derry Township Municipal Authority (DTMA), featured in the July SPOTLIGHT on Thermal Processes, has many years of experience with HSOW, and substantial additional sources of HSOW have been identified nearby by consultant Material Matters, as this region has a deep agricultural economy and many food processors.

spotlight 4

Recent ground-breaking for the Pondus thermal hydrolysis system will add to the complex of equipment that includes the gas clean up system and the receiving station for the High Strength Organic Waste liquids that provide supplemental biogas production

This comprehensive biosolids system overhaul has taken teamwork. Rosentel gives credit to colleagues throughout the chain of command. Roy Hoke, Operations Supervisor, has championed the efforts to bring the new equipment online and ensure good performance. David Stewart, the Chief Technical Officer, was instrumental in vetting the choice of processes and equipment. CEO Charlotte Katzenmoyer and the board were engaged all along the way in understanding the choices and supporting the investments.  Centrisys had to patiently await the conclusion of the yearlong negotiation between CRW and UGIES over terms of its contract before it could break ground on its Pondus system.  Arcadis remains tied to CRW in its review of equipment installation.  Material Matters is helping CRW set up its agency’s system for monitoring land applications by Longneckers and other farmers that may be attracted to CRW’s improved biosolids quality.

Upper Occoquan Service Authority in Centerville, Virginia

Biosolids dryers are the key feature of the Class A Exceptional Quality management program at Upper Occoquan Service Authority (UOSA). Its two dryers enable UOSA to dependably produce 7,000 dry tons annually of dried biosolids pellets for a wide variety of agricultural and horticultural uses in the northern Virginia region around Manassas.   UOSA operates the Millard H. Robbins Water Reclamation Plant, serving four jurisdictions: Prince William and Fairfax Counties and the cities of Manassas and Manassas Park.  It discharges an average of 42 MGD of effluent to a reservoir watershed, and hence it is tasked with very stringent standards for treatment. UOSA’s culture of innovation and high performance is captured in its solids treatment as well as its liquid treatment components. 

Class A biosolids products have been a commitment of UOSA for several decades, but the dryers were not UOSA’s first venture into production of Class A biosolids.  Windrow composting of its pressed biosolids cake was the original technology UOSA worked with, using to its advantage a remote location.  As the plant was expanded in 2001 from 32 MGD to 54 MGD and its digester capacity was expanded, UOSA moved also to a Swiss Combi closed loop rotary dryer.  The capacity of this innovative dryer, assembled for UOSA in 2004 by Berlie Technologies in Canada (now Groupe Berlie-Falco), was supplemented with the RDP Advanced Alkaline treatment system which had been installed in place of composting. RDP subsequently was kept in place to cover as a backup processing system for UOSA’s dryers if Part 503 requirements for drying were not met by the dryers or if they were down for servicing.  The Swiss Combi dryer, which is a single pass dryer with a 3.5 ton/hour evaporative capacity, could not always meet the solids volumes or meet the drying standard.  UOSA’s drying capacity was then amplified with the installation of an Andritz Rotary Drum Dryer, a triple pass dryer with a 4.4 ton/hour evaporative capacity, which became the primary equipment for Class A treatment. The Swiss Combi is pulled into operation in the Spring season, when the Robbins plant works to draw down its winter accumulation of microbial solids, “culling the herd,” as Solids Supervisor Kevin Gately calls it.

spotlight 5

Kevin Gately, UOSA Solids Supervisor, with a sample of biosolids pellets produced by the Andritz rotary drum dryer

 spotlight 6

UOSA’s rotary dryers produce rounded pellets of uniform size and strength, with a strong market value

Class A heat drying is a necessary biosolids treatment step for UOSA. Brenda Arce, Process Operations Engineer, explains that the biosolids feedstock to the dryer is a blend of digested primary sludge and undigested thickened waste activated sludge (TWAS). Without drying, a blend of TWAS and digested primary solids would not meet Class B standards, so land application of a blended cake is not an option during downtime of the dryers.  UOSA’s three digesters are set up for primary sludge digestion. The primary feed and digested solids drawdown are carefully balanced to keep the anaerobic system stable and free from foaming. Biogas is deployed in multiple ways: for gas mixing of the digester, for boilers to heat the process and to make steam for carbon regeneration, and for fuel for electricity generation in internal combustion engines. The off gas of the engines and boilers is directed back to the liquid treatment process to re-carbonate the flows after high lime chemical treatment for phosphorus capture.  Digestate and thickened WAS are blended and held in a short-term storage tank until called upon for centrifuge dewatering in Westfalia and Alfa Laval (Sharples) centrifuges, which both produce 20 percent cake feed to the dryers. Centrifuges and dryers are operated Monday through Friday.

spotlight 7

UOSA's three primary solids digesters with biogas collection system on their fixed covers

spotlight 8

The control panel for the polymer activation skid for UOSA’s automated polymer feed system

The polymer feed rate is automated, an example of UOSA’s culture of high performance.  Dosage is controlled by real time measurement of total suspended solids with a sensor in the centrate trough.   Operators clean the probes daily. and an instrument technician is on call when operators notice bad readings. A skid mounted polymer mixing system provided by ProMinent Fluid Controls replaced an earlier in-line mixer. Together, these improvements have helped control this costly aspect of solids treatment.

Thermal drying is followed by pellet cooling and screening. Oversized pellets can be crushed and undersized material can be returned for blending back in with fresh cake. The screened pellets are temporarily stored in silos, of which there are four, each with a 200-ton capacity. One of the silos is reserved for pellets that are determined to be not within specification as Class A product by temperature monitoring.  All silos are protected from hot spot development with a nitrogen purge system.  The entire drying operation is kept nearly dust free with the use of sonic air fans mounted in the ceiling and with regular hosing down of all surfaces. According to Gately: “We have had no explosions, knock on wood,” a sentiment to which Lead Operator Jimmy Ojeda quickly agrees. 

A constant in UOSA’s solids program is Synagro, the service company handling biosolids pellets as a soil amendment product for land application. Steve McMahon, Mid-Atlantic Product Sales Manager, arranges pellet distribution to landowners, golf courses, landscapers and soil blenders under the trade name Granulite in Virginia, North Carolina, Pennsylvania, Alabama and South Carolina.  UOSA understands that its pellets, with good uniformity and strength and with low odor, are among the best pellets that Synagro can offer to customers.  Should the pellets be off spec in any way for the fussier customers, McMahon can readily distribute them to farmers eager for the nutrients. Synagro also covers for UOSA the Virginia DEQ regulatory requirements for reporting and site permit compliance.

spotlight 9

Synagro markets UOSA pellets under its Granulite trade name to farmers and landscaping customers

With close attention to excellence in design, operations and maintenance of all steps in the solids treatment process, UOSA has a biosolids recycling program that stands with the best in the Mid-Atlantic region.

For more information, contact Mary (Firestone) Baker at [email protected] or 845-901-7905.

 

July 2024 - MABA Biosolids Spotlight 

Provided to MABA members by Bill Toffey, Effluential Synergies, LLC 

SPOTLIGHT on Thermal Processes in the MABA Region 

We are close, really very close!  There is no risk of jinxing any of the four projects by predicting that, within 24 months of this SPOTLIGHT, the MABA region will have four operating thermal systems for depolymerizing biosolids.  These are the four: BioforcetechEarthcare BethelEcoremedy and CHAR Technologies. Not among these four are those “in the pipeline” projects introduced in other regions (374WaterGenifuelKORE Infrastructure, Heartland HelioStorm). Also not listed are other projects in the MABA region that are either not truly “off-the-ground” (Saratoga Biochar Solutions) or that are awaiting some big actions to revive them (Aries Clean Technologies and Biowaste Pyrolysis Solutions).  But having four on track is amazing, as they are near MABA members, and each holds the possibility of becoming reference facility operations. This is a breakthrough in biosolids technologies. 
 
A special aspect of the four projects in the Mid-Atlantic region is how they allow for useful comparisons. Two are municipal projects (Ephrata and DTMA); two are private ventures (CHAR Technologies and Earthcare Bethel).  Pyrolysis and gasification are both represented. The residuals range in quality from biochar to ash.  A common element is the processes are autogenous, meaning sustained without outside fuel sources. Expected feedstocks range from raw cake to digested cake to digested dried pellets. One technology (CHAR) proposes a mobile unit suited for use by multiple small treatment plants, a second technology (Bioforcetech) is suited for fixed installation at a small plant, a third (Ecoremedy) for installation at a medium size plant, and the largest of the bunch (EarthCare Bethel) is a standalone plant accepting sources of organic residuals from multiple classes of industrial and municipal plants.  Yes, should all of these prove successful, the Mid-Atlantic region will be blessed by an array of options that will be references for the entire U.S., and perhaps beyond. 
 
Earthcare Bethel
Earthcare’s gasification facility in Bethel, Pennsylvania, is the furthest along, as it is getting ready for its first deliveries of biosolids cake the last week of July 2024. Earthcare Bethel, LLC (a venture of Earthcare LLC, Earthcare Solutions LLC and BLDPC Ventures LLC) consists of two gasification units, both sized for 40 dry tons of feed daily, one primarily gasifying an agricultural residual and a second, newer unit committed to biosolids cake.  While connecting to the electric utility delayed start-up, the facility has been able to go through commissioning of both units. Leading the development effort is Sean Sweeney, an engineer and Senior Vice President at Barton Loguidice DPC and now Earthcare Solution’s Executive Vice President. But the vision for this facility is that of company founder Mike McGolden, who has delivered over the past 20+ years on ten thermal facilities in the U.S. and abroad. Earthcare gasifiers accept a variety of organic waste feedstocks, though the Bethel facility is the first with a unit devoted to biosolids.  The “secret sauce” for the Bethel facility is the availability nearby of high carbon poultry litter that, when gasified alone or in combination with biosolids, produces a biochar conforming to standards of the International Biochar Initiative for use as a soil amendment and for use in site remediation, both in collaboration with its allied enterprises, EcoChar LLC and EcoChar Environmental Solutions, LLC.

spotlight 1

Earthcare Bethel has completed installation of its drying and gasification facility in Bethel, PA, for producing biochars from biosolids and agricultural residuals, and shipments of biosolids will begin before the end of July 2024.

Earthcare Bethel will be operated as a merchant facility, accepting deliveries from multiple haulers bringing in dewatered biosolids of varying treatment levels, including raw sludges. Sweeney is looking for biosolids cake that is between 18% to 25% in solids content. Cake will be delivered to a receiving building where it is loaded into a hopper for blending with dried agricultural litter to achieve an optimum moisture and energy content for feed to a triple pass drum dryer.  The discharge goes through a cyclone separator, with the solids directed to the gasifier. The syngas coming off the gasifier is fuel for both the gasifier itself and for the dryer, and the system is operated to allow significant carbon to be fixed in the char rather than completely oxidized.  The gasifiers will eventually run 24 hours a day, seven days a week.  The system includes blending with additives and activating the char so that it is tailored to meet customer requirements. The state Solid Waste facility permit will be tied to production for commercial biochar outlets. During start up, Earthcare will be collecting samples of the feedstock and the final product to demonstrate product conformance to state biosolid standards and IDI biochar standards.  While the system is not designed with PFAS or microplastics in mind, Earthcare believes its system will be shown to mitigate both.
 
Ephrata Borough Authority and Bioforcetech
Ephrata Borough Authority’s installation of the Bioforcetech facility is close behind EarthCare.  Its two Centrisys centrifuges and four proprietary dryer units, called BioDryers (slowly rotating drums that are aerated and heated), are already in operation, and the pyrolysis unit is installed and is in the commissioning stage. The origin of this project was a response to an RFP by Ephrata to design a Class A biosolids stabilization facility at its Treatment Plant #1, a plant with a current flow of 2 MGD and designed for 3.8 MGD, to replace a system that had no stabilization process.  The Borough’s original concept was a temperature-phased anaerobic digester system with centrifuge dewatering, producing a Class A cake that could be used by local farmers. The engineering firm of GHD assembled an alternative proposal, subsequently accepted by the Authority, which followed the success of the Bioforcetech pyrolysis process at Silicon Valley Clean Water in Redwood City, California, which boasted useful biochar products.  The biosolids is first dried in a “BioDryer,” a proprietary system resembling an enclosed composting chamber and then processed through a pyrolysis unit to produce biochar. 

spotlight 2

Ephrata Borough Authority, with centrifuges and the Bioforcetech BIoDryers (pictured here) installed and operating, is now starting up the newly installed pyrolysis unit, with assistance of consultant GHD.

GHD has led the efforts to bring this technology to Ephrata. Charles Winslow is the project manager overseeing the purchase of the system and guiding the installation. The components in place today include centrifuges and BioDryer, which together take solids up to 75%. Start-up is now imminent for the third element, the pyrolysis unit, which will receive a continuous flow of cake for final drying to 95% followed by thermal depolymerization in the absence of oxygen to produce a biochar.  A key aspect is the oxidation of the syngas produced by the pyrolysis unit, using 30% of the heat for operating the pyrolysis and the other 70% for drying the biosolids in the BioDryer and in the storage unit after dewatering. Carbon filters and wet scrubbers are the air control system off the pyrolysis unit. Supplemental fuel is only used for start-up.  The pyrolysis units, now in their second generation of design, are expecting two months of operation before cleaning.  The biochar will be marketed by Bioforcetech, the revenue from which will be shared with the Authority.  PFAS concerns were a secondary, but deciding factor, in Ephrata’s selection of the system; the primary driver was the cost effectiveness of the total operation compared to other advanced stabilization technologies. 
 
Synagro’s CHAR Technologies
CHAR Technologies, out of Ontario, Canada,is manufacturing a demonstration unit of its high-temperature pyrolysis process. This demonstration unit was purchased by Synagro, which saw its role in solids processing at small plants and a potential to scale up to large facilities. The system Synagro purchased from CHAR is skid mounted and mobile, and, without a dryer component, is set up to process dried biosolids pellets. The expected initial trial in the Mid-Atlantic region is Baltimore’s Back River Treatment plant.

spotlight 3

Synagro purchased the mobile pyrolysis unit shown here, designed and built by Canada-based CHAR Technologies, with an eye toward demonstrating it at Baltimore’s Back River plant, where Synagro operates a biosolids dryer.

CHAR Technologies’ Pyrolysis Demonstration Unit (PDU) depolymerizes dried biosolids through pyrolysis, a high temperature thermal process operating in the absence of oxygen in a rotary kiln chamber with an external burner.  Except during start-up, the PDU is autogenous, as it is fueled with the syngas generated during the breakdown of biosolids, a major beneficial feature of the system.  The syngas contains dust, steam, hydrogen, carbon monoxide, carbon dioxide and methane, so the PDU is equipped with scrubbers that convert the syngas for internal use in the pyrolysis unit, with excess syngas combusted, along with exhaust gases from the pyrolysis unit, in a thermal oxidizer unit before being discharged through the stack. The excess syngas will be evaluated for suitability to use as supplemental energy for drying facilities at future installations. At full deployment, the PDU will produce approximately 143 standard cubic feet per minute of high heating value syngas and roughly 4 tons per day of inert carbon-rich biochar that can be used as a soil amendment or used as fill.  Approximately 26 gallons per hour of high Chemical Oxygen Demand ("COD") wastewater will be discharged back to the WRRF for treatment.
 
Derry Township Municipal Authority and Ecoremedy
Derry Township Municipal Authority (DTMA), Hershey, PA, is ready to pull the trigger on constructing the Ecoremedy gasification system, having navigated several complex processing, finance and permitting challenges that would rightfully cause any reasonable wastewater manager to pause.  The story of how Ecoremedy came to be is part of the larger story of DTMA’s biosolids program.  DTMA has “seen it all” with biosolids treatment and use. At one time, Derry had incinerators; these were followed by liquid injection to farmlands of lime stabilized biosolids; in  turn, this program was followed by anaerobic digestion with biogas fueled indirect paddle dryers. But “stuff” happened, such as a flood that damaged cogeneration equipment, irreparable wear and tear to its dryers, and problems with farmer complaints about dusty dried biosolids. While DTMA is back using Class B cake on farms, a master planning effort led by Brown and Caldwell was guided by DTMA’s goal of returning to Class A product and on staying ahead of the regulatory curve, which seemed to be pointing to PFAS regulation and restrictions on Class B use. DTMA also sought to preserve its “net energy positive” reputation with hauled-in organic waste feeding its iconic egg-shaped digester.

spotlight 4

The operator visually checks centrate return from the centrifuges to verify capture rate and polymer dosage, both factors in ensuring performance goals are being met.

Yes, DTMA’s 5 MGD plant has a complex set of moving parts, but Bill Rehkop, Executive Director for DTMA (PA), thrives on complexity.  When Ecoremedy, a local firm that had been experimenting with gasification of manure, turned its focus to biosolids with a demonstration project in southeastern Pennsylvania’s Morrisville STP, Rehkop took note.  He enlisted Brown and Caldwell, a firm with deep biosolids experience, to accompany DTMA in doing the detailed work of ensuring Ecoremedy’s success in delivering a facility that left no aspect to chance, including details of conveyance, storage, ventilation, odor and dust control, and fire/explosion protection. On top of this, Rehkop has consistently held as a core goal that of ensuring reliable flow and use of DTMA’s biosolids should an interruption of the gasification system occur, as he could move on a dime back to the use of Class B biosolids to farmlands.  Rehkop has also been persistent: confronting the intention of state regulators to reclassify its biosolids as industrial residuals; seeking to maximize state financial incentives (Penn Vest revolving fund) and procurement mechanisms (COSTARs); and, designing its gasifier to operate as a regional biosolids facility.  At the end of the process, DTMA will be producing a mineral rich ash, low in carbon because of nearly complete use of carbon for energy production. It will be a system that drives energy efficient drying and depolymerization process to yield a residual with soil building and plant nutrient attributes.

For more information, contact Mary (Firestone) Baker at [email protected] or 845-901-7905.

 
<< first < Prev 1 2 3 4 5 6 7 8 9 10 Next > last >>

Page 1 of 10