Are You Getting Your Money’s
Worth?
Dividends of Performance-Based Polymer Procurement
Keller Schnier, PE
November 2015
Acknowledgements
Maggie Macomber, PE – Charlotte Water
Jackie Jarrell, PE – Charlotte Water
David Wagoner, PE – CDM Smith
Presentation Take Aways
 Key steps in the polymer selection program
 Importance of:




Proper polymer selection
Planning the process
Qualified participation
Maintaining control of the process
 Polymer selection determination
 Lowest cost polymer = best value?
 Relationship between performance and overall cost
3
Importance of Proper Polymer Selection
 Cost Control




Equipment
Operations
Polymer - type
Biosolids - end use/disposal
 Quantity
 Dewatering performance
 Quality
 Handling
 Odors
4
Polymer Selection Goal
 Produce the best biosolids product for the lowest cost
 Best product  fits your program needs
 Lowest Cost 
 Polymer cost (selection and usage based)
 Operations and maintenance cost (operator and equipment)
 Reuse/disposal cost (performance based)
5
Polymer Selection – Step-Wise Approach
 Step 1 – Consider 3rd party Project/program manager
 Step 2 – Develop Customized Approach




Baseline criteria development
Establish ground rules and polymer selection criteria
Testing plan and schedule
Vendor Solicitation/selection
 Step 3 - Conduct Testing




Selected vendors
Bench-scale testing
Full-scale testing
Performance data development/handling
 Step 4 - Bid document/Polymer Selection
6
Step 1 – 3rd Party Project Manager





Administers Polymer Trial program
Time – coordination - responsiveness
Manage the process and the vendors
Single point of contact
Multiple plants create challenges
 Uniformity and consistency
 Control of all data
7
Step 2 – Customized Approach
 Baseline criteria development
 Historical performance
 Equipment capacities
 Establish ground rules and polymer selection criteria
 Detailed testing plan and schedule
 Vendor selection




8
Advertise details
Request submission of Notification of Interest
Pre-submission meeting
Selection of vendors for Trials
Establishing Baseline Criteria
 Goal - Set boundaries/criteria for equipment
operation, polymer use and required
performance
 System review - conditions and limitations
 Polymer mixing
 Feed concentrations
 Feed capacity/ranges
 Dewatering system performance and
information
 Capacity of dewatering equipment
 Historic performance data
 Special concerns
 Odors
 Fecal coliform reactivation or regrowth
9
Plant Information and Data Summary Sheets
Facility Name
Polymer storage/mix/feed
Type of Device
NSF Standard 60 Certification required
Make/Model - Attach Specification
Dedicated to thickening or combined with dewatering
Number of units operational
Polymer delivery - drum, tote, bulk
Dewatering Feed, gpm
Combined
Bulk
Polymer mixing system type - batch, continuous Batch, DW/TK Combo
Current Daily average flow rate per unit
Operating Range Min/Max per unit
320
Batch tank mixer type
250 / 390
Mix tank volume & batches per day
Dewatering Feed Solids, % solids
4500 g X 3/13 M-F &
1.5 S-S
Average
2.7
Make-up water source; plant or potable
Minimum
2.3
Polymer feed system type
Prog. Cavity Pump
Maximum
3.3
Feed capacity range, gpm
10-35 gpm
Desired
22
Dewatered Solids, % Solids
Maximum polymer feed concentration
Historical
Lower Limit
18.5
Active polymer content, %
Potable
1.00%
41
Neat Polymer Usage per day / year (gal)
310 / 80,600
18
Neat Polymer per batch (gal)
Filtrate/ Centrate/Supernatant Solids, mg/L TSS
Desired
100
Historical
150
Upper Limit
500
Operating schedule
days of the week
hours/day
Number of units normally operated
10
No
5
24
1
Current Polymer mix feed conc, %
0.70%
Polymer feed rate, gpm
Current Average
30
Design Min/Max
0 / 35
Maximum Polymer dosage to achieve cake solids and
centrate/filtrate/supernatant specified,
lb total polymer/dry ton solids
60
SUBJECT: SOLICITATION OF INTEREST FOR POLYMER SUPPLY CONTRACT
To Whom It May Concern:
The ________is currently contacting polymer manufacturers that may be interested in supplying polymer
for a twelve (12) month period. The polymer will be used in the sludge thickening and dewatering
processes at the following facilities ______. Prequalification testing of polymer products will begin in
_______. Interested Manufacturers are required to provide a Notification of Interest to:
Notifications will be accepted until ___________. All information listed in the Applicant Qualification
must be submitted in the Notification. Incomplete or partial submittal of information will not be accepted.
A prequalification testing protocol, containing manufacturer qualifications, existing feed equipment
description, polymer type specification, sludge characteristics, and evaluation criteria, is attached to this
letter for reference. Please read the prequalification testing protocols very carefully.
The polymer supplied shall be suitable as a conditioner for:
 anaerobically digested sludge prior to centrifuge or belt filter press dewatering,
 water treatment plant alum sludge prior to gravity thickening followed by belt filter press
dewatering and
 secondary sludge centrifuge and gravity belt thickening prior to anaerobic digestion.
The polymer supplied by the manufacturer shall be an anionic or cationic emulsion type. No gel, dry or
liquid polymers will be accepted. The polymer shall be compatible with the City's existing equipment
and treatment scheme and cause no impacts to effluent quality.
The prequalification testing process includes:
Bench-scale Laboratory Jar Testing: All manufacturers who express an interest will be given an
appointment between ______________ to perform jar tests to screen their polymers. Each manufacturer
may prequalify more than one product, but only one polymer will be chosen for full scale testing.
Designated plant staff (or the city's representative) will be available to assist with jar testing in accordance
with the polymer testing protocol.
Full-scale Performance Testing: Manufacturers submitting products for full-scale testing will be given
eight (8) to ten (10) hour appointments to demonstrate performance. Full-scale testing will be conducted
during the months of ________________________. Manufacturers shall provide sufficient quantity of
polymer to perform the full-scale tests using plant polymer feed systems on the designated thickening
and/or dewatering equipment at no cost to the City.
Minimum acceptable performance conditions are provided in the attached information.
11
Manufacturers whose polymers have proven to be effective and acceptable based on achieving the
minimum acceptable performance requirements during the full-scale performance tests will be invited to
offer a sealed bid.
Control the Number of Vendors
Seek Strong Technical Experience
1. The manufacturer must be the manufacturer of the polymer(s) and owner of the equipment used in the
manufacturing of polymer(s) from component ingredients. Proof of manufacturing and ownership of the
equipment must be submitted.
2. The manufacturer must provide current listing of ISO certifications such as 9001 and 14001 and other
relative certifications such as designation from the American Chemistry Council as a Responsible Care®
industry to demonstrate its dedication to quality control and environmental stewardship.
3. The performance testing shall be conducted under the direction of a designated technical representative
(TR) provided by the manufacturer at no cost to the City. Manufacturer shall list the name, address and
contact information for the proposed TR. Upon award of contract, the designated TR must be responsible
to quickly address the needs of CMU regarding polymer supply and quality, and provide polymer use
technical assistance. Accordingly, the residence of the TR must be within a 50 mile radius of _____.
4. Manufacturers shall certify that they have sufficient (existing) manufacturing capacity for the polymer
products offered to the City. A detailed list, describing manufacturing capacity and location and a list of
existing commitments shall be provided. This information will be used by the City to determine the
capability of the prospective polymer manufacturer to supply polymer products in quantities adequate to
meet processing requirements of the City.
5. Manufacturers shall include a list of at least three (3) municipal customers, with current contact
information, that are currently using or have used the proposed polymer product(s) within the last three
(3) years. This information will be provided to CMU and its representative using the form provided in
Exhibit 1.
6. Qualified manufacturers while on plant sites with polymers shall maintain product information for all
polymers that will be considered for the bench-scale and full-scale tests. At a minimum, product
information shall include polymer name, product number, a current material safety data sheet (MSDS)
and product specification indicating % active polymer content.
12
Other Key Items in the Solicitation
 Full-Scale testing and sampling details
 Procedural approaches
 Performance data development
 Polymer Performance Evaluation Calculations
 Calculations to be used
 Full transparency
 Avoid questions/contested conditions later
13
Full-Scale Test and Sampling Details
1. Full-scale testing will be allowed by appointment only.
2. A meeting will be held individually with each manufacturer before initiation of full-scale testing to review the
goals, conditions, and responsibilities for the testing.
3. A maximum of two (2) people from the polymer manufacturer will be allowed on-site during the test.
4. A minimum of eight (8) hours, and a maximum of ten (10) hours per day of testing. Under no circumstances
shall tests be continued past 5:30 P.M.
5. Minimum of five (5) acceptable polymer dosages with at least 30 minutes of run time per dosage.
6. Maximum of eight (8) acceptable polymer dosages with at least 30 minutes of run time per dosage.
7. Five (5) defined doses (minimum requirements) to be run as close as possible to:
a. Lowest possible dosage (lbs/dry ton) to achieve performance goals, the next higher integer dosage
(lbs/dry ton), and three (3) more dosages in 2 to 5 lbs/dry ton increments (total of 5 dosages);
b. Each of the defined doses will be run twice for a maximum of ten (10) sample sets, and a maximum of
sixteen (16) sample sets.
8. Average of the five (5) best acceptable sample sets will be used for evaluation
9. Plant personnel will collect and composite samples for the 30 min run period for each dosage.
a. The first sample shall be collected 10 minutes after thickening/dewatering device startup;
b. Thereafter samples shall be collected every 10 minutes (3 samples in 30 minutes).
10. Plant personnel will analyze samples and split samples will be analyzed by CMUs state certified laboratory.
14
Polymer Performance Evaluation Criteria
Solids Feed Rate, SF, (lb/d)
SF = 8.34 x QF x CF
Where:
QF = sludge feed rate (gpm)
CF = sludge feed concentration (mg/L)
Polymer Usage, PU, (lb polymer/dry ton)
PU = SP / (SF/2,000)
Polymer Feed Rate, SP, (lb/d)
Sp = 8.34 x QP x CP
Solids Recovery, R (%)
Where:
R =100 x C x (F-B)/(F x (C-B))
QP = polymer feed rate (gpm)
CP = polymer feed concentration (mg/L)
Polymer Feed Concentration (Neat), CP, (mg/L)
CP = 120,090 x M / (VP+ VW)
Where:
M =Mass of neat polymer per test batch (lbs)
VP =Volume of polymer per test batch (gallon)
VW = Volume of water per test batch (gallon)
15
Where:
C =Total cake solids (%)
F =Sludge feed solids (%)
B =Centrate solids (%)
Example Polymer Performance Calculation
Biosolids Production (avg):
Land Application Costs:
Polymer Dose (avg):
Polymer cost:
Dewatered Cake Solids (avg):
% recovery (avg):
10 dry ton/day
$15/wet ton
20 lb/dry ton
$1.00/lb
20% solids
98%
(from polymer trials)
(current contract rate)
(from polymer trials)
(from polymer bid)
(from polymer trials)
(from polymer trials)
Polymer cost per day =
5 dt/d x 20 lb/dt x $1.00/lb / 0.98 recovery = $102.04/day
Land Application Costs =
5 dt/d x $15/wt / 0.20 % solids = $375/day
Total Cost =
$102.04 + $375 = $477.04/day
16
Selection of Qualified Vendors
 Pre-submittal meeting with interested Vendors
 Receive and review Letters of Interest
 Select 3 to 4 most qualified vendors
17
Step 3 – Conduct Testing
 Facility tours with Vendors
 Equipment review
 polymer measurement, mixing, and feed rate/control arrangements
 Q&A
 Refine Testing Schedule
 Bench-Scale Testing
 Full-Scale Testing
18
Bench-Scale Testing
 Conducted at plant site - lab setting
 Vendor conducts, Owner/PM observes
 One vendor at a time
 Sludge samples provided by Owner
 Owner keeps samples of polymers being considered for fullscale trials
 Vendor chooses polymer to advance to full-scale trial
 Projects and presents dosage rates for full-scale testing
 lb polymer/dry ton of solids
 Must fall within acceptable dosage range criteria
19
Full-Scale Testing
 Set dewatering machine operating conditions
 based on equipment operation ranges ~ mid range
 test all polymers under same conditions – level playing field
 Sample collection, control and testing - by Owner
 Microwave % solids analyzer
 Data management by Project Manager
 Performance criteria – pass/fail and range limitations
 Maximum allowed polymer dosage
 minimum solids capture % or max TSS levels
 minimum/maximum cake solids
 Performance data finalization
20
Step 4 – Vender Bid Price Submittal and Polymer
Selection
 Facility: WWTP
 Address:
 ITB 269-0131-010
Manufacturer
A
B
C
D
21
Product
NC 101
K290FLX
8846FS
SE 757
Price Per Pound
$ 0.96
$ 1.185
$ 1.11
$ 0.84
Vendor A
Polymer Data
Polymer Sp Gr
Polymer lb/gal
Vendor X
Product input
Polymer Feed Mix % (total),
Ferric, $ per gallon
Ferric, lb/gal
Sludge disposal, $ per wt ton
Polymer Bid Price, $/lb
Sludge feed Poly Feed
Rate, gpm Rate, gpm
251
251
251
251
251
251
251
251
251
251
20.5
22.0
23.5
24.5
24.5
23.5
22
20.5
20.0
19.5
22
Sludge Feed Cake
Solids, %
Solids, %
2.36
2.31
2.27
2.31
2.34
2.34
2.30
2.28
2.28
2.35
18 min
18.57
19.97
20.25
20.44
21.30
21.77
20.08
19.54
18.46
17.26
Centrate
Solids, %
.05 max
0.0163
0.0168
0.0154
0.0147
0.0198
0.0105
0.0198
0.0175
0.0194
0.0160
Centrate
solids, lb/hr
20.47
21.10
19.34
18.46
24.87
13.19
24.87
21.98
24.37
20.10
Feed
Solids,
lb/hr
2964
2901
2851
2901
2939
2939
2889
2864
2864
2952
Feed
Solids,
DT/hr
1.482
1.451
1.426
1.451
1.470
1.470
1.444
1.432
1.432
1.476
input
input
input
input
Polymer
Feed,
lb/hr
79.71
85.54
91.37
95.26
95.26
91.37
85.54
79.71
77.76
75.82
1.04
8.67
0.78%
$0.79
11.2
$15.00
$0.96
Polymer batch mix
Polymer, gal Water, gal
33.82
4500
Polymer
lb/DT
feed solids
60 max
53.78
58.96
64.09
65.66
64.82
62.18
59.22
55.67
54.31
51.37
Capture
1=100%
Solids
Lost
lb/hr
0.994
0.994
0.994
0.994
0.992
0.996
0.992
0.993
0.993
0.994
17.89
18.68
17.19
16.39
22.16
11.78
22.04
19.43
21.38
17.38
Net
Polymer
solids,
lb/DT
produced,net solids
DT/hr
produced
1.473
1.441
1.417
1.442
1.458
1.464
1.433
1.422
1.421
1.467
54.11
59.35
64.48
66.04
65.31
62.43
59.68
56.05
54.72
51.68
Ferric Feed
lb per
lb polymer
0.169
0.157
0.147
0.141
0.141
0.147
0.157
0.169
0.173
0.177
Polymer
Cost
per DT
net solids
$51.94
$56.97
$61.90
$63.40
$62.70
$59.93
$57.29
$53.80
$52.53
$49.61
Ferric
cost
per DT
solids
Cake
Disposal
Cost
per DT
$38.61
$80.78
$39.46
$75.11
$40.14
$74.07
$39.43
$73.39
$39.00
$70.42
$38.86
$68.90
$39.68
$74.70
$40.00
$76.77
$40.02
$81.26
$38.77
$86.91
Avg cost lowest 5 =
Total
Cost
per DT
$171.33
$171.55
$176.12
$176.21
$172.12
$167.69
$171.67
$170.57
$173.81
$175.29
$171.78
Vendor D
Polymer Data
Polymer Sp Gr
Polymer lb/gal
Vendor Y
Product input
Polymer Feed Mix % (total),
Ferric, $ per gallon
Ferric, lb/gal
Sludge disposal, $ per wt ton
Polymer Bid Price, $/lb
Sludge feed
Rate, gpm
250
250
250
250
250
250
250
250
250
250
Poly Feed Sludge Feed
Rate, gpm Solids, %
26.5
25
23
21
20
20.5
21
21.5
22
22.5
23
2.27
2.35
2.29
2.24
2.3
2.42
2.34
2.36
2.28
2.35
Feed
Cake
Centrate Centrate
Solids,
Solids, % Solids, % solids, lb/hr lb/hr
18 min
19.6
19.43
19.42
18.17
17.1
18.11
18.47
18.97
18.6
19.02
.05 max
0.0162
0.0125
0.013
0.014
0.0423
0.0125
0.0168
0.0158
0.0119
0.0119
20.27
15.64
16.26
17.51
52.92
15.64
21.02
19.77
14.89
14.89
2840
2940
2865
2802
2877
3027
2927
2952
2852
2940
Feed
Solids,
DT/hr
1.420
1.470
1.432
1.401
1.439
1.514
1.464
1.476
1.426
1.470
input
input
input
input
Polymer
Feed,
lb/hr
102.04
96.27
88.57
80.86
77.01
78.94
80.86
82.79
84.71
86.64
1.03
8.59
0.770%
$0.79
11.2
$15.00
$0.840
Polymer batch mix
Polymer, gal Water, gal
33.82
4500
Polymer
lb/DT
feed solids
Capture
1=100%
Solids
lost
lb/hr
60 max
71.87
65.49
61.83
57.71
53.53
52.15
55.25
56.08
59.40
58.94
0.994
0.995
0.995
0.995
0.984
0.996
0.994
0.994
0.995
0.996
17.93
13.76
14.35
15.37
45.92
13.56
18.37
17.32
13.07
13.06
Net
Polymer
solids,
lb/DT
produced,net solids
DT/hr
produced
1.411
1.463
1.425
1.393
1.416
1.507
1.454
1.468
1.420
1.463
72.32
65.80
62.14
58.03
54.40
52.38
55.60
56.41
59.67
59.20
Ferric
Feed
lb per
lb polymer
7.9
8.4
9.1
10.0
10.5
10.2
10.0
9.7
9.5
9.3
Polymer
Cost
per DT
net solids
$60.75
$55.27
$52.20
$48.75
$45.70
$44.00
$46.70
$47.39
$50.13
$49.73
Ferric
cost
per DT
solids
Cake
Disposal
Cost
per DT
$40.31
$76.53
$38.88
$77.20
$39.91
$77.24
$40.82
$82.55
$40.18
$87.62
$37.75
$82.83
$39.11
$81.21
$38.76
$79.07
$40.07
$80.65
$38.87
$78.86
Avg cost lowest 5 =
Total
Cost
per DT
$177.60
$171.35
$169.35
$172.12
$173.49
$164.58
$167.02
$165.22
$170.84
$167.46
$167.02
Performance Conditions + Polymer Price =
Lowest Cost Outcome
Cake
Polymer
Solids, % lb/DT
Vendor A
Vendor D
19.3
18.6
Polymer
Bid, $/lb
56.4 $
56.4 $
Polymer
Cost,
$/DT
0.96 $
0.84 $
Cake
Polymer +
Disposal Disposal
$/DT
$/DT
54.51 $
47.59 $
77.72 $
80.52 $
132.23
128.11
Based on performance conditions, Vendor A could have won
the contract with a bid of $0.875/lb
Performance data provides documentation of the expected
performance….once selected polymer is used
24
Summary
 All polymer is not created equal
 purchase polymer based on $/lb polymer alone - risky
 Polymer Trials can provide competitive, performance based
polymer selection
 Qualify polymer vendors with technical expertise
 Set clear instructions and guidelines
 Control the process
 Trials protocol, sampling, testing, selection criteria
 Develop performance data for each polymer
 consistent testing conditions for all
 Apply bid price to performance conditions for lowest cost
outcome
25
Questions
schnierkw@cdmsmith.com