1. Bergen County Utilities Authority Bergen County Utilities Authority Little Ferry, NJ Superstorm Sandy: BCUA’s Little Ferry WPCF Hazard Mitigation Plan and Facility Improvements Richard M. Cestone, PE, CHMM Dominic L. DiSalvo, PE, BCEE

2. Bergen County Utilities Authority Overview of BCUA’s Little Ferry Water Pollution Control Facility (WPCF) Overview of Superstorm Sandy Impacts Overview of BCUA Mitigation Approach and Energy Resiliency Details on the Combined Heat and Power (CHP) System Upgrade and Additional CHP Black Start Capabilities Questions Agenda

3. Bergen County Utilities Authority BCUA Little Ferry Water Pollution Control Facility In service since 1951 Expanded through the 1970s, 80s and 90s. Design Capacity: 109 MGD Maximum Month Provides secondary treatment. Discharges treated water into the Hackensack River. The BCUA owns and operates seven pumping stations in the Little Ferry WPCF collection (sewer) system. (Municipalities in service area own sewers and combined sewer overflows.)

4. Bergen County Utilities Authority BCUA Service Area Little Ferry WPCF Serves about 536,000 residents. 46 municipalities Commercial/Industrial -METLIFE Stadium -Others

5. Bergen County Utilities Authority 100-Year Flood Impacts Loss of Service Costs: $1M per hour Systems Power/Alternate Power BCUA Preparedness and Successes during Response Impacts of Superstorm Sandy

6. Bergen County Utilities Authority

7. Asset inventory of damage Systems level plan for restoration Scopes of work and cost estimates submitted to FEMA FEMA prepared Project Worksheets Restoration

8. Bergen County Utilities Authority Damages

9. Bergen County Utilities Authority Flood Elevations Superstorm Sandy and the Future Estimated Superstorm Sandy Elevation on site: 9.0 + feet Proposed 100-Year Storm Elevation for the Area: 9.0 feet Proposed 500-Year Storm Elevation: 12.0 feet Design Storm for Mitigation: 100-Year (9.0 feet) + 2-foot freeboard + 1-foot Sea Level Rise = 12.0 feet

10. Bergen County Utilities Authority Proposed plan for improvements to mitigate future impacts Tiered prioritization of “at risk” components Scopes of work and cost estimates submitted to FEMA Plant–wide Mitigation

11. Bergen County Utilities Authority Vulnerability Assessment

12. Bergen County Utilities Authority Mitigation Tiers Tier 1: Moving wastewater (WW) out of the collection system Tier 2: Conveyance through the plant and disinfection Tier 3: Primary and secondary treatment Tier 4: Operations Tier 5: Ancillary

13. Bergen County Utilities Authority Moving WW out of the Collection System: Power Supply - Main Substation, Switchgear Building, CoGen Building, Generators, Fuel Tanks Substations 2 and 3 Bar Screens Main Pump Stations Collection System Pumping Stations Tier 1

14. Bergen County Utilities Authority BCUA Power Supply Power supply is critical to maintaining service to the community. Loss of power supply: No wastewater (sewage) treatment Wastewater will remain in the collection system. -Backup into the community -Local health and safety issues According to FEMA, lost wastewater service is equivalent to $45/person/day: - At 536,000 residents = $24M per day ($1M per hour) Poor power quality: Potential damage to plant equipment

15. Bergen County Utilities Authority BCUA Power Supply Existing BCUA Power Supply: PSE&G electrical grid Biogas powered generators (natural gas from PSE&G available) Backup emergency generators (kerosene fuel) During Superstorm Sandy: Power fluctuations in PSE&G electrical grid Equipment damage BCUA took itself off the PSE&G electrical grid BCUA operated emergency generators

16. Bergen County Utilities Authority Power Supply Mitigation Goal: Maintain wastewater service at all times, including outage/fluctuations in the PSE&G electrical power grid. Approach: Create a new power supply microgrid as the primary source of electricity. The PSE&G electrical power grid will be the secondary or standby source. Based on the expansion of existing biogas powered CHP electric generator system. Use sustainable primary fuel – Biogas from the on-site digestion of sewage sludge (biosolids), brown grease and food organics. Use natural gas from the PSE&G piping network as the secondary or standby fuel for CHP.

17. Bergen County Utilities Authority Power Supply Backup Mitigation New Power Supply Microgrid Project will include: New third CHP electric generator New energy efficient aeration blowers Upgrades to the digester system to enhance on-site biogas fuel production and provide storage New brown grease and food waste receiving and processing system to augment biogas production

18. Bergen County Utilities Authority Other Power Supply Mitigation Protect key power supply assets from flooding at the design flood elevation. Main Substation: Raise electrical components. Switchgear Building and Cogeneration Building: Dry proof walls. Install flood-resistant entrances. Install a flood wall around the building. Raise the transformer outside the Cogeneration Building.

19. Bergen County Utilities Authority PS DOORS - EzDam

20. Bergen County Utilities Authority Purpose: Provide power to Bar Screen Buildings, Main Pump Stations and other facilities Major damage: weeks to 2 months to repair/replace Impact: WW pumping, treatment, permit compliance Substations 2 and 3

21. Bergen County Utilities Authority Replace and raise substations Replace feeders and distribution wiring and conduit Substations Mitigation Approach

22. Bergen County Utilities Authority Screen Building No.’s 1 and 2: Provide screening of influent WW before pumping into rest of the plant Major Damage: Up to 2 months to repair Impact: No screening, River water in wet well and potentially WW in community Bar Screens

23. Bergen County Utilities Authority Dry proof walls Install Flood Proof Entrances Install Flood wall Screen Buildings Mitigation

24. Bergen County Utilities Authority Main Pump Stations No.’s 1 and 2: Pump WW into rest of the plant 400+ MGD capacity Major Damage: weeks to months to repair Impact: WW in community Main Pump Stations

25. Bergen County Utilities Authority MPS No.’s 1 and 2 Dry Proof Walls Install Flood Resistant Entrances Install Flood Wall Install submarine door at Gallery entrances MPS No.1: Raise some electrical assets in basement Install standard plant sump pump Main Pump Station Mitigation Presray

26. Bergen County Utilities Authority Pink Avenue Pumping Station: Pumps WW from community to interceptors Site below DFE Major Damage: weeks to months to repair Impact: WW in community Collection System Pumping Station

27. Bergen County Utilities Authority Pink Avenue Pumping Station: Flood proof entrances Install flood wall around perimeter Meter Chambers (with Sandy impact) Raise or replace meters in submersible enclosure Collection System Mitigation

28. Bergen County Utilities Authority Blower Building Substations 1, 4, 5 and 6 Secondary Sludge Pumping Stations Primary Sludge Pumping Stations Sludge Processing Assets Grit Building 2 Control Building Admin Building Other Mitigation

29. Bergen County Utilities Authority BCUA Proposed Hazard Mitigation Plan under FEMA review Mitigation for Tiers 1 - 4 Systems BCUA has initiated implementation of the first phase of microgrid project: CHP Installation Status of Mitigation

30. Bergen County Utilities Authority The microgrid project warrants an expansion of the CHP cogeneration unit which will entail: Redundancy to existing cogeneration unit. Increased biogas generation due to use of Fats Oils and Grease (FOG) in anaerobic digestion. Provide a basis of black start capability at the Little Ferry WPCF. Status of Mitigation

31. Bergen County Utilities Authority In 1995, the BCUA installed 1.3 MW Caterpillar gas fired engines for their air blower system providing air to their aeration tanks. The engines were designed to burn natural gas and biogas. However NOx and CO emission concentrations were constantly exceeding levels established by their existing air permit. BCUA was forced to temporarily shut down these engines to investigate the problem. BCUA’s History of Biogas Use

32. Bergen County Utilities Authority BCUA’s History of Biogas Use

33. Bergen County Utilities Authority BCUA’s History of Biogas Use

34. Bergen County Utilities Authority Siloxanes that are in hair care products get entrained in the biogas during anaerobic digestion. Combustion of siloxanes generates silicone dioxide (SiO2) which is sand or glass. The buildup caused by SiO2 in the engines caused an increase in NOx and CO. BCUA’s History of Biogas Use

35. Bergen County Utilities Authority A carbon absorption unit was installed to remove the siloxanes and other impurities from biogas. Once installed and operational, the NOx and CO emissions were in compliance with little or no SiO2 generated. SUCCESS!!! BCUA’s History of Biogas Use

36. Bergen County Utilities Authority CHP Cogeneration Facility The BCUA blower engine success was the model for installation of other engines burning biogas. Based on the lessons learned from the blower engines, the BCUA constructed an CHP Cogeneration Facility at their Little Ferry WPCF in 2006. Two 1.4 MW General Electric (GE) Jenbacher internal combustion engines were installed and have the capability of burning both natural gas and biogas generated from the anaerobic digesters.

37. Bergen County Utilities Authority CHP Cogeneration Facility

38. Bergen County Utilities Authority CHP Cogeneration Facility The CHP facility located next to the Blower Engine Building commenced operation in 2008. The facility was able to save over $11 million to date in what would’ve been the cost for natural gas and electricity. In 2009, the BCUA developed an Energy Master Plan to examine energy savings throughout the facility. The centerpiece of the Energy Master Plan was the CHP facility. The BCUA CHP facility was deemed a great success and won awards from the NJDEP, Association of Environmental Authorities (AEA) and Board of Public Utilities (BPU). However, there is always room to improve.

39. Bergen County Utilities Authority Air Pollution and Greenhouse Gas Reduction The CHP cogeneration unit was able to reduce air pollutants like oxides of nitrogen (NOx) and carbon monoxide (CO) and volatile organic compounds (VOC) due to more efficient burning of the biogas instead of burning in the flares. Note that NOx and CO can photochemically react to form ground level ozone. Also it was able to reduce greenhouse gases include carbon dioxide (CO2) and methane (CH4). Note that the aforementioned gases are all either products of combustion or incomplete combustion. CHP Cogeneration Facility

40. Bergen County Utilities Authority Air Pollution and Greenhouse Gases The CHP Cogeneration facility has a twofold way of saving air pollutants and greenhouse gases. The engines have more efficient burning of the gas than if burned in flares. Thus there are less products of incomplete combustion generated (CO, CH4 and VOC). Because the CHP Cogeneration burns its own gas to generate electricity, that saves pollutants and greenhouse gases from being generated at the power plant where the equivalent amount of electricity would have been purchased. CHP Cogeneration Facility

41. Bergen County Utilities Authority Air Pollution and Greenhouse Gases NOx, CO and VOC emissions are approximately the same for both the flares and the cogen unit for biogas combustion. Greenhouse gas savings from burning biogas for 2013 is 123 tons of equivalent carbon dioxide. CHP Cogeneration Facility

42. Bergen County Utilities Authority Air Pollution and Greenhouse Gases The biogas generated over 13 million kilowatt hours of electricity for BCUA during 2013. This results in greenhouse gas savings of 854 tons of equivalent carbon dioxide that would have been generated at a power plant. CHP Cogeneration Facility

43. Bergen County Utilities Authority CHP Cogeneration Facility

44. Bergen County Utilities Authority Air Pollution and Greenhouse Gases In 2013,the BCUA saved over $1.3 million for electricity and gas that would have been purchased instead of burning biogas to generate electricity and heat. This includes $306,000 in thermal savings (natural gas cost), $984,000 in savings from electricity plus an additional $20,500 in Renewable Energy Credits (REC). Since June 2008 the BCUA saved a total of $12.9 million for electricity and gas that would have been purchased. CHP Cogeneration Facility

45. Bergen County Utilities Authority While the CHP cogeneration facility has been a success in energy and pollutant savings, there have been some issues. There have been occasions where one or both engines have been shut down due to repairs or malfunctioning. Currently both engines need to run to effectively consume the biogas. At this time there is no redundancy. CHP Cogeneration Facility

46. Bergen County Utilities Authority The BCUA also wants collects waste substances to increase to biogas generation within the anaerobic digesters. Substances include Fats, Oils and Grease (FOG) and whey. FOG currently generated in Bergen County is currently transported to Gloucester County Utilities Authority and is incinerated. CHP Cogeneration Facility

47. Bergen County Utilities Authority To transport the FOG by truck is about a 200 mile round trip to the GCUA by a diesel fueled truck by the New Jersey Turnpike (expensive tolls). This takes time and money not to mention the end results shows FOG generates additional pollutants and greenhouse gases without any energy recovery. The anaerobic digesters at BCUA will process the FOG with the sludge to generate additional biogas which can be used for the cogeneration unit. Not to mention a closer trip saves time, gas, tolls, and pollutants. CHP Cogeneration Facility

48. Bergen County Utilities Authority In 2013 the BCUA released a report on a pilot study for adding FOG to the sludge and processing it in the anaerobic digesters. The results show that and additional 8.2 cubic feet of biogas will be generated for every gallon of FOG added to the anaerobic digesters. CHP Cogeneration Facility

49. Bergen County Utilities Authority Bergen County generates about 17.6 million gallons of FOG annually from its municipalities. If all of this is processed at BCUA, this will result in 144 million cubic feet of additional biogas generated. These results along with the need for redundancy warrants an expansion of the CHP cogeneration facility. CHP Cogeneration Facility

50. Bergen County Utilities Authority CHP Cogeneration Facility Earlier in 2013 after an 18-year run, the BCUA decided to decommission the gas-fired blower engines. The BCUA currently has three electric engines powering the blowers. The BCUA decided to add a third engine for the CHP unit and located it in the vacated area of the gas-fired blower engines. The engine will be the same 1.4 MW size and will most likely be a GE Jenbacher engine or an engine equivalent in nature.

51. Bergen County Utilities Authority Additions to the CHP Facility Two reasons the BCUA decided to add a third engine: Two engines can constantly operate while one can be serviced (redundancy). The BCUA is setting up a receiving station for fats, oils and grease (FOG) to inject into the anaerobic digester and burn biogas. The BCUA has also planned to receive food wastes, such as whey, to inject into the anaerobic digester to generate additional biogas.

52. Bergen County Utilities Authority Additions to the CHP Facility Even though there are cost savings due to the CHP facility and tipping fees for FOG and food wastes, the BCUA still needed additional funding to install the third CHP engine. In 2013, the BCUA applied for a grant through the New Jersey BPU’s Renewable Energy Incentive Program (REIP).

53. Bergen County Utilities Authority Additions to the CHP Facility On October 25, 2013, the BCUA was awarded a $2.5 million grant to help fund the installation of the third CHP engine. Also the BCUA has been approved of a $7.3 million low interest loan from the New Jersey Infrastructure Financing Program (NJEIFP). These monies are enough to cover the cost of the installation of engine. However, the BCUA is looking at additional funding through grants and loans for future projects.

54. Bergen County Utilities Authority With the engine located in the blower building, the third engine will already have natural gas and biogas lines to be connected easily to this engine. The gas pretreatment system used for the blower engines will be used for the third engine. Expected completion and operation commencement is late April 2015. Additions to the CHP Facility

55. Bergen County Utilities Authority Black Start Capabilities

56. Bergen County Utilities Authority Black Start Capabilities Currently, the BCUA has three kerosene- fired back-up turbines to operate the plant in case of a power outage. The engines have the capability of operating the wastewater treatment areas and sludge processing while the CHP unit is turned off. The CHP engines can operate during extended power outages if kerosene is depleted and cannot be delivered.

57. Bergen County Utilities Authority Conclusion The BCUA can operate with limited outside fuel sources with an CHP system and energy savings based on the tasks provided in their Energy Master Plan. The BCUA will continue to find ways to reduce costs and conserve energy to operate the facility and survive emergency situations.

58. Bergen County Utilities Authority Vice Chairman – Ronald Phillips Executive Director – Robert E. Laux Chief Engineer – Eric Andersen, P.E. Plant Manager – Edward Switay Acknowledgements for BCUA

59. Bergen County Utilities Authority Contact Information Dominic L. DiSalvo, PE, BCEE ARCADIS U.S., Inc. (914) 641-2829 dominic.disalvo@arcadis-us.com Richard M. Cestone, PE, CHMM Remington & Vernick Engineers (856) 795-9595 Richard.Cestone@rve.com

60. Bergen County Utilities Authority Questions?