eco/Tech Sludge Recycling System (SRS)

NEIWPCC – FOG ConferenceConcord, NH & Sturbridge, MA

February 15-16, 2005

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S The eco/Tech Sludge Recycling System: A Local FOG Disposal Alternative

♦Introduction♦Sludge Recycling System (SRS)

Operations and Maintenance♦Air Emission Test Results♦Market Conditions and Challenges♦Design Enhancements♦Summary

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S Introduction

♦Biosolids and FOG♦SRS Development♦SRS Modules

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S Biosolids and FOG

♦Definitions♦U.S.Generation♦Disposal Methods♦An Opportunity

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S Definition

♦“Biosolids, historically known as sewer sludge, are the solid organic matter produced from private or community waste water treatment processes….”

US EPA, September 1999

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S Definition

♦Fats, Oils and Grease -Commonly knows as FOG, is the by-product of cooking. Domestic and commercial sources are: meat fats, lard, cooking oil, shortening, butter, food scraps, sauces and dairy products. Industrial sources include the manufacturing of ice cream, soy products, food flavorings and food processing.

WEF Publication “Fat Free Sewers”

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S U.S. Generation

♦8 million dry tons of biosolids

♦Restaurant yellow and brown grease– 25 pounds/person/year

in metropolitan areas♦Other sources♦Growing faster than

population

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S Sludge and FOG Disposal Methods

♦Land Application♦Compost♦Landfill Cover♦Burned♦Burial in Land Fill♦Surface Disposal♦Rendered♦Conversion to Bio-Fuel

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S An Opportunity

♦A New Disposal Option♦Producer Benefits♦SRS Owner Benefits

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S SRS Development

♦Heat Balance of Combustion System♦R&D at eco’s Pittsfield RRF

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S SRS Development (Cont’d.)

♦Installed at eco’s Agawam, Massachusetts Facility

♦Start-up was April 2002

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S SRS Modules

♦Transportation♦Receiving & Mixing♦Injection ♦Controls

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S Transportation Module

♦High Solids Tanker♦Commercial Tanker

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S Receiving & Mixing Module

♦Unloading Area

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S Receiving & Mixing Module (Cont’d.)

♦Preparation Equipment

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S Receiving & Mixing Module (Cont’d.)

♦Storage

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S Receiving & Mixing Module (Cont’d.)

♦Odor Control

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S Basketball Hall of Fame

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S Injection Module

♦Injection Pump♦Rack♦Injector

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S Controls

♦Integrated into Distributed Control System

♦User Friendly

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S SRS Operations History

♦Volume Combusted

♦Sludge Types

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S Volume Combusted

♦Over 12,000,000 gallons♦Over 2,800 dry tons♦Trend: Higher solids – Less water♦More volatile content

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S Sludge Types

Sludge Type Percent Solids BTU/Lb (dry)

W aste Activat ed (W AS) 2- 10% 8,400W AS with Pr imary Skimmings 3% 9,500Digested Sludge 19% 4,500

FOG (ice cream) 13 - 30% 13,700FOG (soy) 4% 8,000Paper M ill 10% 6,500

Textile Mill 7% 10,000

C oal Pile S lurry 20% 14,300Food Flavors 8% 7,000

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S SRS Maintenance History

♦Reliability vs. Expectations

♦Cost per Ton

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S Reliability vs. Expectations

♦Pumping Equipment♦Tanks – Level Detectors

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S Reliability vs. Expectations (Cont’d.)

♦Carbon System Limitations♦Rack Components

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S Reliability vs. Expectations (Cont’d.)

♦Nozzle♦Balance of Plant

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S O&M Cost per Dry Ton

2002 Actual 2003 Actual 2004 Actual

Labor $39,900 $49,400 $46,900

Contracted Lab Fees $8,700 $6,400 $7,300

Parts $22,100 $23,700 $30,900

Dry Tons Processed 1,149 1,158 1,714

Cost/Dry Ton w/o Labor $27 $26 $22

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S Air Emissions

♦Pioneer Valley RRF Air Pollution Control

♦21H Tests♦Results – Excellent!

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S Results – Excellent!

♦PM10 down 80%♦NOx down 10%♦SOx no change♦Multiple Metals &

Dioxins -insignificant changes

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S Market Conditions and Challenges

♦Solids Level– WAS

♦Industrial FOGs♦Yellow & Brown Grease

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S Design Enhancements

♦Nozzle and Retractor♦Next Generation Odor Control♦Level Sensors♦Equipment for Unloading and Storing

Grease Waste♦Controls♦Next Site…

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S Design Enhancements (cont’d.)

Pittsfield Resource Recovery Facility

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S Summary

♦Co-Combustion Commercially Proven♦Documented NOx and PM10 Reduction♦Local, Competitive Cost Disposal for

Non-hazardous Liquid Wastes♦Protective of Employees Health &

Safety

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SPresented by: Edward P. Champagne

Project Manager

eco/Technologies, LLC

An Company

(518) 434-1227

echampagne@energyanswers.com

DLM