Expansion of the
Newcastle Water Pollution
Control Plant
WEAO Student Design Competition 2013
Contents
Introduction
Stage 3 Design
Stage 3 Extras
Stage 4 Layout
Conclusions
Questions?
Introduction
Who are we?
Bradley
Free
5 th Year Water
Resource
5 th
Kyle
Lockwood
5 th Year Environmental
Tanzeel
Ahmed
Year Environmental
Robyn
Thompson
4 th Year Mechanical
Introduction
Background
 An expansion is planned for the Durham Region Newcastle Water Pollution
Control Plant (WPCP), in the Municipality of Clarington, Newcastle, Ontario
 The expansion of the WPCP is planned in four stages, to ultimately increase the
capacity to six times that of the current operating capacity
University of Guelph
The Objectives:
1.Preliminary Design and layout for Newcastle WPCP
for Stage 3 expansion including biosolids handling and
energy recovery
2.Conceptual layout for Newcastle WPCP expansion
for Stage 4 expansion
Clarington, Ontario
Stage 3 Design
Population Analysis
Stage 3
Design
 Population Analysis
 Selection of Processes
 Based on previous growth data from the
municipality of Clarington
 Stage 3 to be completed when Stage 2
average day capacity reaches 75% of ADF
 Peak Flow rates were estimated using the
Harmon formula
 Expected service capacity according to
population growth against time
 The Layout and Design
45000
 Secondary Treatment
 Tertiary Treatment
 Biosolid Handling and Treatment
Average Inflows (m3/d)
 Receiving Station and Headworks
 Primary Clarification
Average Inflow Rates
40000
Peak Inflow Rates
35000
30000
Stage 3 Completed: 2034
25000
20000
15000
10000
5000
0
2000
2020
2040
Population
2060
2080
Stage 3 Design
The Layout
1. Office Building
2. Headworks
3. Primary Clarifiers
5. Secondary Clarifiers 9. Dewatering Units
6. Disinfection
10. Chemical Storage
7. Cloth Filters
11. Anaerobic Digesters
4. Aeration Tanks
8. Digester Gas Flaring 12. CHP System
Stage 3 Design
Receiving Station and Headworks
Mechanically Cleaned bar screen installed
Installed parallel to existing systems
Increases existing treatment capacity
Two additional aerated grit tanks installed
Will be able to process Stage 3 flows of 39,300 m3/d
Extra unit provided for redundancy and maintenance
Stage 3 Design
Primary Clarification
 Circular Primary Clarification tank installed
 Existing clarifier tank will be modified during stage 3
installation as a circular tank
 Will eliminate maintenance issues of gross solids
buildup in corners of existing square clarifiers
 Performed during stage 3 installation
 Will reduce BOD and TSS sufficiently for ADF and PDF
Stage 3 Design
Secondary Treatment
Two aeration tanks will be installed in parallel to existing tanks
Aeration
will operate
as awill
staged
CAS process
to allow
Two newtanks
secondary
clarifiers
be installed
in parallel
to existing
operational
flexibility
clarifiers
 have
First astage
fitted
withofjet50%
aeration and diffuser grid
 Will
recycle
ratio
 Second
has
diffuser
grid installed
 Clarifiers
are stage
sized to
treat
the maximum
daily flow of 39,300 m3/d
 Can perform nitrification-denitrification for alkalinity recovery
 Will be consistent with existing plant systems
 Stage 3 of system will have an operational MLSS of 3500 g/m3
 Will have an SRT of 12 days to achieve nitrogen removal
Stage 3 Design
Tertiary Treatment
Alum
Addition
UV system
UV3000Plus™)
selected
as best
method
eliminating
Three
Cloth (Trojan
Filtration
Units (AquaDISK
Tertiary
Filtration
system)installed
 TSS
Will
reduce
the
influent
phosphorus
by over 85%
current
chlorine
disinfection
methods

reduced
below
5mg/L
for ADF
 Will
Added
atchlorine
thetoaeration
tank
effluent
Current
contact
tank
will
act as
a bypass

be able
process
Stage
3
flows
of 39,300
m3channel
/d
 Extra
Chosen
because
it monthly
was
most
effective
treatment
for the
Achieves
desired
geometric
density of

unit
provided
for the
redundancy
andmean
maintenance
lowest
cost of Escherichia Coli
150cfu/100mL
 Low Pressure/ High Intensity (LP/HI) lamps
 Horizontal Parallel to flow lamp configuration
 Automatic chemical/mechanical cleaning
 Weighted Gate Automated Level Controller
Stage 3 Design
Sludge and Biosolid Treatment
TM
2
Single stage
highDisposal
rate
mesophilic
anaerobic system
digesters
installed
ROTAMAT
(HUBER
) Screw
Press dewatering
chosen
Processed
Sludge
parallel
Stage agricultural
2 Digesters
 approved
2toDewatering
units installed
Stage
 On
land site for
under
the3Durham
Digesters
will
treat
the throughout
wasted
solids
from the
primary
clarifier and
 Have
a total
dry
solids
capacity
of 280
kg Dry/h
Region
Works
Department’s
Biosolids
Management
the WAS
from
secondary
clarifier centrifugal dewatering system
 O/M
costs
arethe
smaller
than traditional
Program
 Operates
SRT of 20at
days
<1.5 rpm screw rotation speed
 Requires
External pump
recirculation
mixing
<20 min/d
of operator
attention
 Produces
Biogas collection
for Combined
Heat and Power (CHP) energy
18 – 25%tocake
solids
recovery
The Extras
CHP Energy Recovery
The
Extras
 CHP Energy Recovery
 Noise and Odour Control
 Hydraulic Profile
 Modelling
 Process Control and
Instrumentation
 Construction Implementation
 Cost Analysis
 Captures the biogas produced from the
Digesters and generate renewable energy
 Primary mover of the CHP system is 2
microturbines
 CHP Economic Feasibility
 Generate approximately
$130,000/year in energy savings
 11 Year Payback Period
 Dependent upon obtaining Electricity
Contracts
 Fuel Gas Conditioning System will reduce
H2S, CO2, PM extending the lifespan of the
microturbines and reducing greenhouse
gases
 Flare located southwest of the facility in
case of CHP system failure
The Extras
Noise and Odour Control
Problem: Development of surrounding residential area of great concern
Solution?
 Adequate buffer areas around the facility
 Housing facilities with adequate noise depletion technology (for pumps,
generators, etc.)
 All noise and odour sources will maintain the minimum separation distance of
100 meters in agreement to MOE odour and noise guidelines.
The Problem
Source: Google Maps
111m
The Extras
Hydraulic Profile
E.L. 84.75m
Available Head of 4.0m
E.L. 80.75m
The Extras
Modelling
STOAT®
 WRc’s waste water modelling software
 BOD, TSS and NH3 was modelled within the simulation
 At an operational temperature of 10oC, the effluent objectives
were well below target
Parameter
BOD5 (10 mg/L)
TSS (10 mg/L)
(Ammonia + Ammonium) Nitrogen*
Proposed Effluent
Objectives
Simulated
Mean Effluent
10 mg/L
10 mg/L
9 mg/L
15 mg/L
4.76 mg/L
6.61 mg/L
0.49 mg/L
*The simulated ammonia effluent is assumed to be representative of both ammonia and ammonium
* Concentration listed are for summer and winter objective respectively
The Extras
Process Control and Instrumentation
 Supervisory Control and Data Acquisition (SCADA)
 Provides operational ease by reducing monotonous tasks for operators
 Overall efficiency of the plant improved by maintaining steady state
process
The
Controls
Headworks and Clarifiers
 Monitoring and pumping control
Aeration Basin
 Dissolved oxygen monitoring
 Aeration efficiency improvements of
up to 50%
 Monitoring and Pumping
Tertiary Treatment
 Flow monitoring and splitting
Digesters
 Monitoring performance
 Controlling temperature, pressure,
recirculation and feed rates
CHP
 Monitoring and controlling flow rates
and energy production
The Extras
Construction And Implementation
2034
Dec
Nov
Oct
Sep
Aug
Jul
Jun
May
Apr
Mar
Feb
Jan
Dec
Nov
Oct
Sep
Aug
Construction Period
Mobilization and Erosion Control Systems
Site Preparation
Concrete Placing, Formwork and Reinforcing Steel
Piping and Mechanical Equipment Installation
Support Facilities
Electrical Work, Instrumentation and Controls
Landscaping and Final Clean-up
Commissioning
Duration
(months)
Task Name
2033
15
1
1
4
6
2
6
2
3
Minimizing Environmental
Impact
The completion date of Stage 3 is
accordance
with Local Municipalities, by-laws
and MOE Standards
PlantInDesign:
12 months
established
as year-end of 2034
Permits and
Approvals:
12 months
 Using current data in the
 Noise
Control
Tendering/Awards: 2 months
population analysis

Dust
Control
Construction Period: 15 months
 Recommended that population
Commissioning:
2 months
 Protection
of Surface Water
growth trends are rechecked
every 5 years
 Erosion Control
The Extras
Cost Analysis
Total Capital Cost:
$26,350,000.00
9% 8%
19%
64%
The Extras
Cost Analysis
Annual Operation and
Maintenance Cost: $898,000.00
22%
53%
15%
6%
4%
The Extras
Stage 4 Layout
Stage
1&2
Stage
43
Conclusions
Conclusion
Recommendations
Acknowledgements
Questions
Further
investigation
should
be conducted
The proposed
processes
for Stage
3 includewith
respect to the integration of the microturbine CHP
Hongde
Zhou, Ph.D.,
P.Eng. – Faculty
Advisor

Additional
headworks
improvements
system
for
biogas
handling
Professor of the School of Engineering – University of Guelph
Issues clarification
such as the availability
of
 1
primary
tank
obtaining contracts
from the Advisor
Ontario
Miles MacCormack
, P.Eng. – Consultant
 2 Manager
two-staged
aeration
Project
– Stantec
Inc.
Energy
Board
(OEB)tank
and the Local
Distribution
Company (LDC)
are of

1
secondary
clarification
tank
Rafiq Qutub
, M.Eng., P.Eng.
concern
Subcommittee Chair, Student Design Competition – Water
 3
cloth
filters
Green
incentive
grants should be
Environment
Association
of Ontario
to determine
possible
 1 UVassessed
disinfection
unit
alleviation
Kirill Cheiko
, EIT. of total capital cost and further
Water
– Stantec Inc.
 2EIT
additional
anaerobic
digesters
evaluation
of the systems
feasibility
Questions
and…
 2 screw
press
Yashar
Esfandi
, EIT.dewatering units
Population growth trends are rechecked every
Inside Sale Representative – SPD Sales Limited
5 years to determine if the completion of Stage 3
Stage 3 is toschedule
be completed
by year-end of 2034
construction
requires
Hussein
Abdullah, Ph.D.,
P.Eng. –adjustment
Director
The School of Engineering – Guelph University
 present cost of $26.3 Million
Obtain additional specific order costing
 O/M of $0.9
annually
information
fromMillion
manufacturers
Conclusions
The Credits