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Massachusetts Water Resources Authority Presentation to MWRA Advisory Board MWRA Residuals Processing & Agreement for Operation and Maintenance of the.

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Presentation on theme: "Massachusetts Water Resources Authority Presentation to MWRA Advisory Board MWRA Residuals Processing & Agreement for Operation and Maintenance of the."— Presentation transcript:

1 Massachusetts Water Resources Authority Presentation to MWRA Advisory Board MWRA Residuals Processing & Agreement for Operation and Maintenance of the Fore River Pelletizing Plant with New England Fertilizer Company May 21, 2015

2 Massachusetts Water Resources Authority Residuals Treatment Facilities

3 Massachusetts Water Resources Authority Residuals Processing – Schematic Overview

4 4 Massachusetts Water Resources Authority Residuals Processing Statistics for Deer Island Sludge to Digestion – 246 dry TPD – 70% as Primary sludge – from gravity thickening – 30% as Waste Secondary sludge – from centrifuge thickening Typical sludge makeup of other plants: 50:50 – Time in Anaerobic Digestion: 18-21 days – 62% Volatile Solids destruction (industry ave. is 50%)

5 5 Massachusetts Water Resources Authority Residuals Processing Statistics for Deer Island FY14 Annual Avg digester gas production – 188 kscfh – 96% of gas is beneficially used in boilers – 95% of total boiler heat attributable to Digas Value of gas utilization - $21.3M (heat) & $2.3M (power)

6 6 Massachusetts Water Resources Authority Overview of Current Residuals Processing Sludge to Pellet Plant – 100 dry TPD – On DITP, Digested sludge is stored, then pumped 7 miles to Pellet Plant Methane gas captured, stored, then used in boilers on site – NEFCO dewaters, dries, & pelletizes all digested sludge – All pellets go to beneficial re-use: turf farms golf courses fertilizer blenders cement kiln

7 7 Average Daily Sludge to Pellet Plant (DTPD)

8 Located in Fore River Shipyard Designed, Constructed & Owned by MWRA – Phase I – $88 M – Phase II - $45 M – Total cost - $133 M Since Day 1, has always been a Contract Operation – Contract 1: 1991 – 2001Competitive Bid – NEFCo – Contract 2: 2001 – 2015Competitive Bid - NEFCo MWRA Pellet Plant located in Quincy, MA 8

9 Current contract - S345 – 15-year (2001-2015) Process liquid sludge from DITP – Receive digested sludge – Dewater with centrifuges – Dry with thermal dryers – Produce Class A Fertilizer Pellet – In CY 2014: Processed 100 dtpd Paid NEFCo $14.1M Pellet Plant – Contract O&M Since 1991 (cont.) 9

10 Contractor is responsible for developing & maintaining Diverse Markets for beneficial reuse for all sludge sent to the Pellet Plant – Land Application – Fertilizer Blenders – Alternate Fuels – Bay State Fertilizer Program Maintain Facility & Equipment – Responsible for returning a fully operable plant at the end of the contract to MWRA. Pellet Plant – Contract O&M Since 1991 (cont.) 10

11 State Annual Tonnage Percentage Connecticut 6,81122% New York 5,67818% Indiana 3,09010% Maine 2,1707% Rhode Island 1,8356% Florida 1,6655% Virginia 1,5545% Massachusetts 1,4395% Georgia 1,3324% Vermont 1,1754% Pennsylvania 1,0253% Ohio 9803% Maryland 9803% Missouri 5902% North Carolina 3281% Michigan 2591% Bagged/truck 1060.3% 11 Pellet Distribution by State

12 12 Comparison of Pellet Molybdenum Concentrations to DEP Limit

13 Step 1: Condition Assessment Facility is in excellent condition – 20+ year life remaining with no major capital (with continued maintenance) Step 2: Residuals Technology Assessment Recommendations at DITP – May impact quality & quantity of sludge sent to Pellet Plant Recommendations at Pellet Plant – Limited to energy efficiency gains given condition of facility Pellet Plant – Contract Renewal Preparation 13

14 Technology Assessment Recommendations (cont.) – Consider larger, more efficient Dryer Trains Implemented at Philadelphia & soon Detroit – Evaluate impacts of co-digestion programs at DITP – Given long remaining life, any capital expense decisions must rely on payback – Recommend 5-year extension to quantify impacts of pilots and new dryer ops – Suggested next long-term contract – 15 years Pellet Plant – Contract Renewal Preparation Step 2 (cont.) 14

15 Pellet Plant – Existing Contract with NEFCo 15 Current Contract Cost Structure Fixed Fee first 90 dtpd (32,850 dry tons annually) (~$400/ton) Excess Qty >90 dtpd (>32,850 dry tons annually) (~$280/ton) Fixed yearly capital dollar value (pre-determined) No pass-throughs for utilities –Includes adjustments for inflation FY14 Avg - ~$380/ton

16 Pellet Plant – NEFCo Contract Extension 16 Contract Cost Structure – Sludge Processing (changes) Original ContractContract Extension Change Fixed Fee first 90 dtpd annual (32,850 tons/yr)same base price but for 92.5 dtpd Variable Fee >90 dtpd same incremental price >92.5 dtpd CY2014 Total contract expenses $14,090,654 $13,582,354 for sludge processing $13,334,464 if on extension -$12,574,468 base + = same base + - plus $1,007,886 excess qty plus $759,996 excess qty Savings of $247 K in year. + $508,300 capital expenses

17 Pellet Plant –NEFCo Contract Extension – Capital Program 17 Capital Program - $7.0 Million cap $6.087 K – project awards subject for future Board approvals NEFCo designs all capital projects – paid 15% of awarded project NEFCo responsible for capital costs in excess of $7.0 M cap Must return a fully operational plant at end of contract Drum replacement not included in cap if completed.

18 Pellet Plant – NEFCo Contract Extension Summary 18 Reduced Price for Sludge Processing $1.25 M savings over 5-yr extension Revised Capital Program Structure Retains NEFCo liability (must return fully operating plant at end of contract) Extension authorized for 5-years

19 Pellet Plant – NEFCo Contract Extension Summary 19 Provides MWRA sufficient time to: Evaluate potential energy efficiency improvements (large dryer technology) Stabilize future sludge quantities (co-digestion) Allow for increased competition

20 Word of mouth marketing - 32 transactions in April and May Lawn care “enthusiasts” showering praise upon Bay State Fertilizer Marketing Intern started May 18 th – Goal: Expand retail presence 20 Bay State Fertilizer

21 21 New Bay State Fertilizer Bag – Rita Berkeley

22 Available at no cost MWRA member Communities Pickup at the Pellet Plant in Quincy Contact Carl Pawlowski (617) 773-4295 22 Bay State Fertilizer

23 Massachusetts Water Resources Authority Questions ? 23


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