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Efficient New Technology to
Improve Missouri’s Largest
Biosolids Composting Operation
Bill Malach, P.E.
City of St. Peters, Missouri
Presentation Overview
Background & History of Facility
Evolution of Organic Resource Recycling in
St. Peters
Implementation of Aerated Static Pile
Composting Facility
Capital Investment, Operating Costs,
Revenues
Sustainable Markets for Biosolids Compost
Biosolids:
The nutrient-rich organic materials resulting
from the treatment of domestic sewage at a
wastewater treatment facility.
When treated and processed, sewage sludge
becomes biosolids which can be safely
recycled and applied as soil amendment to
sustainably improve and maintain
productive soils and stimulate plant growth.
City of St. Peters Population
1970 470
1980 17,029
1990 45,779
2000 51,381
2010 56,500
0
20,000
40,000
60,000
1970 1980 1990 2000 2010
Population
Compost Facility
6 MGD Water Plant
9.5 MGD Wastewater Plant
Compost Facility
Recycling Center/
Transfer Station
Headworks
Oxidation Basins
Aerated Sludge
Holding
Final Clarifiers
UV Disinfection
Dewatering Building
Biofilters
ASP Composting
Evolution of Organic Resource
Recycling Program
Started with Liquid Biosolids Land
Application Program in 1980’s
Pilot Biosolids/Yardwaste Composting
Project 1997 to 2000
Full Scale Windrow Composting in 2001
Aerated Static Pile Composting in 2010
Liquid Land Application
Program (1980 -2009)
Applied 5 Million Gallons Annually
1,200 Dry Tons of Biosolids
Required 450 Acres Annually
Over 1,200 Acres in Program
200 Acre City-owned Farm
Partnership with Farmers
Problems with Liquid Biosolids
Application Program
Dependent on Private Ground
Seasonal Application & Weather Dependent
Class “B” Biosolids Regulation Restrictions
Odors Released During Lagoon Mixing &
Pumping Operations
Benefits of Composting
EPA Approved Process to Further Reduce
Pathogens to Produce Class “A” Material
Creates a Marketable Product
Reduces Dependency on Private Land
Generates Income to Offset Expenses
Sustainable Recycling Process that is
Environmentally Beneficial
St. Peters Organic Feedstocks
30,000 -50,000 CY of Yard Waste
Curbside Collection & Drop-off
Branches, Leaves, Grass
6,000 Wet Tons of Biosolids
Drop-Off Area
First Step is Grinding
Biosolids Dewatering/Mixing
Biosolids Dewatering
Mixing
Mixing by Weight Proportion for
Targeted C/N Ratio
Dewatering Building
Biofilters
ASP Composting
Aerated Static Pile System
Loading Aeration Zone
Temperature Probe
Temperature Probes
Computer Controlled Process
Air Distribution & Biofilter
Curing
Screening Cured Compost
Testing
Aerated Static Pile Composting
Proven Technology
Simple to Operate
Flexible for Future Needs
Benefits of Aerated Static Pile
Composting Process
Aerobic Piles are Less Odorous
Exhaust Air Can be Filtered
Computer Controlled Process Improves
Composting Efficiency
Requires Less Space
Implementation Steps
Selected the “Engineered Compost System”
(ECS) Process
Negotiated a Process Design / Equipment
Procurement Agreement
Selected Local Engineer for Structural &
Sitework Design
Bid Facility Construction & Equipment
Installation
Aerated Static Pile Compost
Facility Costs
Process Equipment & Software $461,000
Site & Structural Engineering $ 99,000
Construction Contract $1,200,000
$1,760,000
Aerated Static Pile Compost
Operation Costs
Salaries & Benefits $ 195,700
Fuel for Equipment $ 66,000
Electric $ 9,100
Equipment Maintenance $ 12,000
Contract Screening $ 30,000
$312,800
Aerated Static Pile Compost
Operation Revenues
Yard Waste Tipping Fees $ 295,000
Compost Sales (Residential) $ 22,820
(Commercial) $ 74,861
Mulch Sales $ 26,806
Topsoil Sales $ 6,206
$425,693
Income from Compost
Operations
Operation Revenues $425,693
Operation Expenses (312,800)
Revenues $112,893
St. Peters GHG Reduction
From Composting
Carbon Sequestering
US EPA Waste Reduction Model (WARM)
-2,790 MTCO2E
533 Passenger Vehicles
6,477 Barrels of Oil
24 Acres of Deforestation
Quality is Essential
USEPA 503 Regulations
US Composting Council Seal of Testing
Assurance (STA) Member
Certified Filtrexx Supplier
Compost Product Markets
Commercial Landscapers
Erosion Control Contractors
Residential Landscaping
Wetland Mitigation Projects
Soil Remediation Projects
Bulk Mulch and Compost Suppliers
Private Customer Loading
Loading Blower Truck
Roadway Re-vegetation
Harvester Road
Wooded Wetland Mitigation Site Area Prepared for Compost 11-2-06
Wooded Wetland Mitigation Site Compost Spreading 11-2-06
Wooded Wetland Mitigation Site Spreading Completed 11-2-06
Wooded Wetland Mitigation Site K Seeding Completed 11-4-06
Planting Trees
Planting
5-Months Later Spring Growth 05-06-07
4 - Years Later (9-24-10)
Benefits of Composting
Combines Organic Resource Streams to
Produce Useful Products
Revenues Help Offset Expenses
Sustainable Process with Negative Carbon
Footprint “Carbon Sink”
Improves Soil Quality & Productivity
City of St. Peters
Organic Resource Recycling
Program
2010 Gold Excellence Award
Composting
US EPA
2008 Exemplary Biosolids
Management
Awards
Organic Resource Recycling is Cost-
Effective and Sustainable
REDUCE
REUSE RECYCLE