Presentation Outline...Presentation Outline • Who is Alexandria Renew Enterprises • Process Monitoring Evolution • Advanced Mainstream Controls • Probe Maintenance Program

5/14/2019

2019 VWEA Education Seminar 1

Optimizing Plant Performance with “Smart” Operations

Presented by:

Kacey King-McRae/AlexRenew

Presented To:

VWEA Education Seminar

Richmond, VA

May 9, 2019

2019 VWEA Education Seminar

Presentation Outline

• Who is Alexandria Renew Enterprises

• Process Monitoring Evolution

• Advanced Mainstream Controls

• Probe Maintenance Program

• Lessons Learned

• Call to Action


5/14/2019


AlexRenew: Small and Mighty!

• Only 35 usable acres

• Designed for 54 MGD and peak flows of 116 MGD

• City of Alexandria needs 58 MGD at buildout


Alex Renew Water Transformers

• VA Class 1 Certified Op Techs

• CMRT Certified Mechanics

• Resource Recovery Efforts

• LEED Platinum Certified Facility

• Moxie


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AlexRenew Liquids Treatment Processes


Process Monitoring Evolution at AlexRenew

MONITOR BASIC CONTROL

NON CRITICAL PROCESS CONTROL

CRITICAL PROCESS CONTROL


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Evolution to SMART Ops: Where We Were

• Aeration - DO probes

• Monitoring and Basic Process

Control

• Supplemental Carbon - NOx Probes

• Monitoring and Manual FeedNH4

+

NO2-

O2

O2

carbon

carbon

AOBs

NOBs

NO3-

N2

NO2-


Evolution to SMART Ops: Phased Implementation

NH4+

NO2-

O2

O2

carbon

carbon

AOBs

NOBs

NO3-

NO2-

N2

Preparation for Mainstream Anammox

• Air ON/OFF

• Suppress NOBs/Nitrite Shunt

• Ammonia Probes

• NH3-based DO Control


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NH4+

NO2-

O2

O2

carbon

carbon

AOBs

NOBs

NO3-

NO2-

N2


• Automated Carbon Dosing

• Based on NOx Probe Readings

• ORP Interlock

• No Carbon Feed in ORP indicates no NOx

Methanol Dose Table


Primary

Effluent

80%

Centrate

3%

Removed

in CPT

17%

Ammonia Loading Secondary

Process with CPT

Primary Effluent Centrate Removed


NMF

Secondary Process

Primary Effluent

Flow Diversion

Flow Return

• Dewatering Centrate Pretreatment

• NH3 Loading to Secondary Process

• Nutrient Management Facility

• N Load Balancing2019 VWEA Education Seminar

5/14/2019


Evolution to SMART Ops: Added Instrumentation

9 Probes

3 Probes

26 Probes

2 Probes

22 Probes

2 Probes2019 VWEA Education Seminar

Smart Operations: Process Air Reduced by 30%

• Savings of $145,000/yr in electricity use (CY2018 vs. CY2014)

NH4+

NO2-

O2

O2

AO

Bs

NO

Bs

NO3-

ABAC in Operation

Average 12,800 scfm Average 9,300 scfm

0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

18,000

20,000

Jan

-14

Ma

r-1

4

Ma

y-1

4

Jul-

14

Se

p-1

4

No

v-1

4

Jan

-15

Ma

r-1

5

Ma

y-1

5

Jul-

15

Se

p-1

5

No

v-1

5

Jan

-16

Ma

r-1

6

Ma

y-1

6

Jul-

16

Se

p-1

6

No

v-1

6

Jan

-17

Ma

r-1

7

Ma

y-1

7

Jul-

17

Se

p-1

7

No

v-1

7

Jan

-18

Ma

r-1

8

Ma

y-1

8

Jul-

18

Se

p-1

8

No

v-1

8

Jan

-19

Ma

r-1

9

Mo

nth

ly A

vera

ge

Air

Use

(sc

fm) CPT Startup &

Low DO in BRBs NMF Startup


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Methanol

Auto-Dose

Smart Operations: Methanol Use Reduced by 50%

• Savings of $300,000/yr in electricity use (CY2018 vs. CY2014)

N2

NO2-

NO3-

c

c

Average 1,050 gpd Average 484 gpd

ABAC in Operation TN < 3 mg/L

0

10,000

20,000

30,000

40,000

50,000

60,000Ja

n-1

4

Ma

r-1

4

Ma

y-1

4

Jul-

14

Se

p-1

4

No

v-1

4

Jan

-15

Ma

r-1

5

Ma

y-1

5

Jul-

15

Se

p-1

5

No

v-1

5

Jan

-16

Ma

r-1

6

Ma

y-1

6

Jul-

16

Se

p-1

6

No

v-1

6

Jan

-17

Ma

r-1

7

Ma

y-1

7

Jul-

17

Se

p-1

7

No

v-1

7

Jan

-18

Ma

r-1

8

Ma

y-1

8

Jul-

18

Se

p-1

8

No

v-1

8

Jan

-19

Ma

r-1

9

Mo

nth

ly M

eth

an

ol U

se (

ga

l)


Year mg/L

2014* 3.77

2015* 3.81

2016** 2.65

2017** 2.61

2018 ** 2.76

Average Effluent TN

* Permit Limit per Waste Load

Allocation (~ 4.5 mg/L)

** Concentration-Based Limit of 3

mg/L

Smart Operations: Final TN Reduced by 25%


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Smart Operations: Automation Roadmap

SMART

OPERATIONS

AT ALEXRENEW


Swing

Swing

Swing

Anoxic

Air On/Off

BRB

Influent

RAS

to SSTs

BRB 6

Anoxic

Anoxic

Anoxic

Air On/Off

Anoxic

Anoxic

NH3NOx

NH3NOx

NH3NOx

NH3NOx

Swing

NH3NOx

NH3

NH3

NH3ORP

ORP

DO

DO

DO

DO

DO

DO

DO

DO

DO

DO

Swing

Supplemental

Carbon

NH3

SMART Operations: Proven Instrumentation

Secondary Process

33 Sensors Measuring

NH4-N, NO3-N, NO2-N,

pH, DO, ORP

• Ion Selective Probes

• UV Spectral Sensors

• Wet Chem. Analyzers


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• Determines Probe Maintenance

Schedule

• Defines Roles and Responsibilities

• Improves Probe Reliability

• Reduces Equipment Downtime

SMART Operations: Probe Maintenance Program

Key is to Create a Probe Maintenance Team2019 VWEA Education Seminar

Fundamentals of the Probe

Maintenance Program

SMART Operations: Probe Maintenance Program


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SMART Operations: Probe Maintenance Requirements

0

50

100

150

200

250

300

350

400

450

500

Secondary CPT NMF Filtration UV IPS

Annual Man-Hour Equivalents

Annual Field Hrs Annual Lab Hrs

• 1.02 Man-hour Equivalents for ROUTINE Maintenance and Calibration

• Lab and Field Work Required for Probe Value Checks

• Analytical, Electrical and Mechanical Aptitude Required


Roles and Responsibilities

SMART Operations: Probe Team


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• Proactive maintenance and probe monitoring are vital to

successfully implementing automated process controls.

• Documentation and data management are crucial in

troubleshooting process issues.

• Increased environmental regulations and advances in water

treatment technology are changing the role and expectation

of today’s operators.

SMART Ops at AlexRenew: Lessons Learned


• Don’t be afraid to take a “leap of

innovation”

• Manage risks

• Automation will modify the role of operator

• Not “set it and forget it”

• Take it step-by-step - Start small and build

as you go

• Commit resources needed

SMART Ops at AlexRenew: Key Take Aways


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Coauthors

• Kacey King-McRae/AlexRenew• Paula Sanjines/Jacobs


Thanks, and Stay in Touch!

Visit us online: www.alexrenew.com

Email: [email protected]

Alexandria Renew Enterprises

CallMeMoxie

@AlexandriaRenew

Alexandria Renew Enterprises


5/14/2019


Questions?


Documents

Presentation Outline...Presentation Outline • Who is Alexandria Renew Enterprises • Process Monitoring Evolution • Advanced Mainstream Controls • Probe Maintenance Program