0. Irvine Ranch Water District Michelson Water Recycling Plant Phase 2 Expansion
SCAP Water Quality Committee Meeting
Randy Lee, P.E. , Assistant Director of Recycling Operations
September 23, 2014

1. Presentation Overview
IRWD Background
MWRP Existing Processes Overview
MWRP Phase II Expansion
Biosolids Project Status Update

2. IRWD Serves 20% of Orange County

3. Water, Wastewater, Water Recycling, and Urban Runoff
About the Irvine Ranch Water District
Water, Wastewater, Water Recycling, and Urban Runoff
California Special District governed by a publicly-elected Board
IRWD customer base:
Residential population: 330,000
Daytime population: >500,000
Service connections: 102,380
IRWD service area:
181 square miles (20% of Orange County)
All or part of six cities and unincorporated county:
Irvine
Tustin
Orange
Lake Forest
Newport Beach
Costa Mesa

4. IRWD Services Drinking Water Sewage Collection Recycled Water
Urban Runoff Treatment

5. Phase 2 Expansion Project
ASCE OC Water Treatment Project of the Year

6. Michelson Water Recycling Plant
Produces 18 MGD of Title 22 recycled water.
Phase 2 Expansion increases capacity to 28 MGD.
Scheduled completion June 2014.

7. MWRP Aerial View

8. Michelson Water Recycling Plant
Treatment Process Prior to Expansion
FLOW EQUALIZATION BASINS
DUAL MEDIA FILTERS
PRIMARY SEDIMENTATION TANKS
SECONDARY SEDIMENTATION TANKS
ACTIVATED SLUDGE BASINS
CHLORINE CONTACT TANKS
NORTH IRVINE INTERCEPTOR
INFLUENT GRINDERS
RECYCLED WATER CUSTOMERS
SOUTH IRVINE INTERCEPTOR
OCSD

9. Phase 2 Overall Process Train
OCSD
NORTH IRVINE INTERCEPTOR
SOUTH IRVINE INTERCEPTOR
HEADWORKS
PRIMARY SEDIMENTATION TANKS
FLOW EQUALIZATION BASINS
ACTIVATED SLUDGE BASINS
SECONDARY SEDIMENTATION TANKS
DUAL MEDIA FILTERS
CHLORINE CONTACT TANKS
RW CUST.
HIGH RATE CLARIFIER
UV DISINFECTION
MEMBRANE BIOREACTOR
PRIMARY EFFLUENT PUMP STATION

10. Phase 2 Expansion Overview
NEW TREATMENT FACILITIES
MODIFIED EXISTING TREATMENT FACILITIES
FLOW
EQUALIZATION
BASINS
NEW CHEMICAL FACILITIES
NEW ELECTRICAL FACILITIES
EXISTING
BLOWER
ROOM
HIGH RATE
CLARIFIER
MEMBRANE BIOREACTOR
UV DISINFECTION
PEPS
SPENT BACKWASH TANK
SPENT BACKWASH TANK
EXISTING
PSTs
NEW
PSTs
HEADWORKS
CHLORINE CONTACT TANK `
EFFLUENT PUMPS

11. New Headworks

12. New Primary Sedimentation Tanks

13. New Primary Effluent Pump Station

14. Membrane Bioreactor ANOXIC ZONE DE-OX ZONE PERMEATE PUMP ROOM
BLOWER ROOM
PERMEATE PUMP ROOM
ANOXIC ZONE
RAS CHANNEL
DE-OX ZONE
MEMBRANE
TANKS ML
P.S.
AERATION BASIN
FINE
SCREENS
RAS
BOX
AERATION BASIN
ANOXIC ZONE
DE-OX ZONE
DIP
TANK
B.P.

15. MBR Process Flow
30 MGD
5 MGD
10 MGD
5 MGD
10 MGD
30 MGD

16. MBR Fine Screens & Aeration Basins

17. MBR Mixed Liquor Pump Station

18. Loading MBR Membrane Cassettes

19. MBR Air & Permeate Piping

20. Permeate Pump & Blower Rooms

21. MBR Photos

22. Ultraviolet Disinfection Facility

23. New Phase 2 Buildings Headworks Membrane Bioreactor
High Rate Clarifier
Electrical Bldg.

24. MWRP Phase 2 Overview

25. Floodwall – 200 Yr Flood Protection

26. Phase 2 Construction Cost
Treatment Process $83 Million
Floodwall $ 5 Million
Overall Construction Cost: $88 Million
Change Orders: $ 4 Million 4.5%
Total $92 Million
Construction Management $14 Million 15%

27. Biosolids & Energy Recovery Facilities Project

28. Biosolids & Energy Recovery Project
Project Objectives
Beneficially reuse Biosolids and Biogas produced during the treatment process.
Manage residuals (Biosolids) at reduced costs to IRWD’s customers.
Construct project to meet IRWD’s future Biosolids handling needs.
Minimize environmental impacts: Drying and pelletizing reduces export truck loads by factor of four.
Reduces greenhouse gas effects by beneficially using pellets locally as a fertilizer or e-fuel.

29. Biosolids & Energy Recovery Project
Project Description
IRWD to construct facilities at MWRP for:
Biosolids digestion, dewatering and drying
Biogas management and energy recovery
Odor control systems
IRWD would no longer export solids to Orange County Sanitation District (OCSD).
Project would also accept Biosolids trucked in from IRWD’s Los Alisos Water Recycling Plant (LAWRP).

30. Biosolids Facilities Site Location
MWRP
Biosolids and Energy
Recovery Facilities

31. EXISTING PRIMARY CLARIFIER
Simplified Process Schematic
DIGESTER GAS CLEANING
MICROTURBINES
BIOGAS
ELECTRICITY
FATS, OILS & GREASE
EXISTING PRIMARY CLARIFIER
DEWATERING
CENTRIFUGE
THICKENING CENTRIFUGE
PELLET STORAGE & LOADOUT
CLASS A PELLET HAUL
ROTARY DRUM DRYER PS
CAKE
STORAGE & LOADOUT
CLASS B CAKE HAUL
(BACKUP)
EXISTING SECONDARY CLARIFIER
DIGESTED SLUDGE STORAGE
ACID-METHANE PHASE ANAEROBIC DIGESTION
WAS
RECYCLED WATER
TO LIQUID TREATMENT
CENTRATE TREATMENT

32. Air Permit Process Diagram

33. Triple Pass Drying Drum Pneumatic Transporter
Heat Drying System
Furnace
Mixer
ID Fan
Pellet
Cooler
To Storage Silos
Cake from dewatering
Cake Bin
Recycle
Bin
RTO
Venturi Scrubber
Condenser
Triple Pass Drying Drum
Gas Recirculation
Pneumatic Transporter
Atmosphere
Preseparator
Baghouse

34. Heat Drying System
Produces a pellet suitable for local beneficial reuse
Nitrogen for fertilizer
Btu content for e-fuel
Dryers in CA:
Encina (Carlsbad)
Sacramento
Corona

35. 3-D Model Renderings

36. FOG Foodwaste Receiving.
Digestion Facilities
Egg-Shaped Digesters
Sludge Holding Tanks
Digester Control Bldg.
Acid Phase Digesters
FOG Foodwaste Receiving. 36

37. Dryer and Odor Control Discharge Stacks
Biosolids Handling Building
Dryer and Odor Control Discharge Stacks
Polymer Storage
Solids Receiving
Pellet Loadout

38. Biosolids Handling Building
Dryer Area
Centrifuge Area
Polymer Storage
Centrate Treatment 38

39. Biogas Treatment & Microturbines
Biogas Storage
Biogas Conditioning
Microturbines

40. Centrifuge Room
Thickening Centrifuges
Dewatering Centrifuges 40

41. Dryer System – Lower Level
Pellet Screen
Dryer Drum 41

42. Solids/Off Gas Separation
Dryer System – Upper Level
Solids/Off Gas Separation
Recycle Bin
Pellet Mixer
Dryer Drum 42

43. Sub-Surface View of 3,028 Piles

44. Construction Photos

45. Construction of structure and
Construction Photos
Pile Installation – Digester Area
Completed:
Construction of structure and

46. Construction Photos
Pile Installation – Basement of Solids Handling Building

47. Installation of Piles in Methane Digester Area
May 2014 Quarterly Report
Installation of Piles in Methane Digester Area

48. Installation of Piles in Solids Handling Facility
May 2014 Quarterly Report
Installation of Piles in Solids Handling Facility

49. Project Schedule

50. Project Schedule DATE ACTIVITY April 29, 2013 Notice of Award
June 3, 2013
Notice to Proceed
Sept – March 2014
Pile Driving
January 17, 2016
Anaerobic Digestion Facilities Online
March 2, 2016
Produce Class B Biosolids (Cake)
June 30, 2016
Microturbine Power Generation Online
August 29, 2016
Produce Class A Biosolids (Pellets)
October 28, 2016
Project Completion

51. Biosolids Construction Cost
Pile Driving $ 10 Million 6%
Digesters $ %
Dryer $ %
Biogas & Microturbines $ %
Sitework $ %
Other $ %
Total Bid Amount $ 163 Million

52. Contact Information: Randy Lee, P.E. Irvine Ranch Water District