1. Newcastle Water Pollution Control Plant
Expansion of the
Newcastle Water Pollution Control Plant
WEF Student Design Competition 2013

2. Contents Introduction Stage 3 Design Stage 3 Extras Conclusions
Questions?

3. Who are we? Introduction Bradley Kyle Lockwood Robyn Thompson
Free
Water Resources Engineering Graduate
Tanzeel Ahmed
Environmental Engineering Graduate
Kyle Lockwood
Environmental Engineering Graduate
Robyn Thompson
Mechanical Engineering Graduate

4. The Objectives: Background Introduction
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:
Preliminary Design and layout for Newcastle WPCP for Stage 3 expansion including biosolids handling and energy recovery
Conceptual layout for Newcastle WPCP expansion for Stage 4 expansion
Clarington, Ontario

5. Stage 3 Design Population Analysis Stage 3 Design
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
Population Analysis
Selection of Processes
The Layout and Design
Receiving Station and Headworks
Primary Clarification
Secondary Treatment
Tertiary Treatment
Biosolid Handling and Treatment
Stage 3 Completed: 2034

6. The Layout Stage 3 Design Office Building Secondary Clarifiers
Dewatering Units
Headworks
Disinfection
Chemical Storage
Primary Clarifiers
Cloth Filters
Anaerobic Digesters
Aeration Tanks
Digester Gas Flaring
CHP System

7. Receiving Station and Headworks
Stage 3 Design
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

8. Primary Clarification
Stage 3 Design
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

9. Secondary Treatment Stage 3 Design
Two aeration tanks will be installed in parallel to existing tanks
Aeration tanks will operate as a staged CAS process to allow operational flexibility
First stage fitted with jet aeration and diffuser grid
Second stage has diffuser grid installed
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
Two new secondary clarifiers will be installed in parallel to existing clarifiers
Will have a recycle ratio of 50%
Clarifiers are sized to treat the maximum daily flow of 39,300 m3/d

10. Tertiary Treatment Stage 3 Design
Three Cloth Filtration Units (AquaDISK Tertiary Filtration system)installed
TSS reduced below 5mg/L for ADF
Will be able to process Stage 3 flows of 39,300 m3/d
Extra unit provided for redundancy and maintenance
UV system (Trojan UV3000Plus™) selected as best method eliminating current chlorine disinfection methods
Current chlorine contact tank will act as a bypass channel
Achieves desired monthly geometric mean density of 150cfu/100mL of Escherichia Coli
Low Pressure/ High Intensity (LP/HI) lamps
Horizontal Parallel to flow lamp configuration
Automatic chemical/mechanical cleaning
Weighted Gate Automated Level Controller
Alum Addition
Will reduce the influent phosphorus by over 85%
Added at the aeration tank effluent
Chosen because it was the most effective treatment for the lowest cost

11. Sludge and Biosolid Treatment
Stage 3 Design
ROTAMAT (HUBERTM) Screw Press dewatering system chosen
2 Dewatering units installed for Stage 3
Have a total dry solids throughout capacity of 280 kg Dry/h
O/M costs are smaller than traditional centrifugal dewatering system
Operates at <1.5 rpm screw rotation speed
Requires <20 min/d of operator attention
Produces 18 – 25% cake solids
Processed Sludge Disposal
On approved agricultural land site under the Durham Region Works Department’s Biosolids Management Program
2 Single stage high rate mesophilic anaerobic digesters installed parallel to Stage 2 Digesters
Digesters will treat the wasted solids from the primary clarifier and the WAS from the secondary clarifier
SRT of 20 days
External pump recirculation mixing
Biogas collection to for Combined Heat and Power (CHP) energy recovery

12. Extras CHP Energy Recovery The Extras The
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
CHP Energy Recovery
Life Cycle Impact Assessment
Noise and Odour Control
Hydraulic Profile
Modelling
Process Control and Instrumentation
Construction Implementation
Cost Analysis

13. Life Cycle Impact Assessment
The Extras
Compares the environmental impact of anaerobic digestion against lime stabilization for sludge treatment
Pré developed SimaPro 7.0 software was used to conduct a comparative study
Life Cycle Impact Results
Lime stabilization is worse in every impact category
Lime stabilization produces more sludge
Anaerobic Digestion for sludge treatment is therefore the most environmentally sustainable solution

14. STOAT® Modelling The Extras 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
Proposed Effluent Objectives
Simulated Mean Effluent
BOD5 (10 mg/L)
10 mg/L
4.76 mg/L
TSS (10 mg/L)
6.61 mg/L
(Ammonia + Ammonium) Nitrogen*
9 mg/L
15 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
Parameter
Proposed Effluent Objectives
Simulated Mean Effluent
BOD5 (10 mg/L)
10 mg/L
4.76 mg/L
TSS (10 mg/L)
6.61 mg/L
(Ammonia + Ammonium) Nitrogen*
9 mg/L
15 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

15. Controls Process Control and Instrumentation The The Extras
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
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
Headworks and Clarifiers
Monitoring and pumping control
Aeration Basin
Dissolved oxygen monitoring
Aeration efficiency improvements of up to 50%
Monitoring and Pumping

16. Hydraulic Profile The Extras Available Head of 4.0m E.L. 84.75m

17. Construction And Implementation
The Extras
Task Name
Duration (months)
2033
2034
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Apr
May
Jun
Jul
Construction Period 15
Mobilization and Erosion Control Systems 1
Site Preparation
Concrete Placing, Formwork and Reinforcing Steel 4
Piping and Mechanical Equipment Installation 6
Support Facilities 2
Electrical Work, Instrumentation and Controls
Landscaping and Final Clean-up
Commissioning 3
Minimizing Environmental Impact
Plant Design: 12 months
Permits and Approvals: 12 months
Tendering/Awards: 2 months
Construction Period: 15 months
Commissioning: 2 months
The completion date of Stage 3 is established as year-end of 2034
Using current data in the population analysis
Recommended that population growth trends are rechecked every 5 years
In accordance with Local Municipalities, by-laws and MOE Standards
Noise Control
Dust Control
Protection of Surface Water
Erosion Control

18. 111m The Problem Solution? Noise and Odour Control Problem: The Extras
Development of surrounding residential area of great concern
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
111m

19. $26,350,000.00 Total Capital Cost: Cost Analysis The Extras 9% 8% 19%
64%

20. $898,000.00 Annual Operation and Maintenance Cost: Cost Analysis
The Extras
Annual Operation and
Maintenance Cost:
$898,000.00
22% 6%
53% 4%
15%

21. $302,442 Annual Savings with the Proposed Solution: Sludge Disposal
Cost Savings
Annual Savings with the
Proposed Solution:
$302,442
Operational Function*
Average Monthly Cost
Average Annual Cost
Stage 1&2 (from 2011 operational data)
$ 9,388.54
$ 112,662.50
Stage 3 (anticipated operation within 2014)
$ 28,038.90
$ 336,466.84
Stage 3 (anticipated operation within 2034) $
$ 34,024.85
*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP
Operational Function*
Average Monthly Cost
Average Annual Cost
Stage 1 (from 2011 operational data)
$ 9,388.54
$ 112,662.50
Stage 2 (anticipated operation within 2014)
$ 28,038.90
$ 336,466.84
Stage 3 (anticipated operation within 2034) $
$ 34,024.85
*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP
Operational Function*
Average Monthly Cost
Average Annual Cost
Stage 1 (from 2011 operational data)
$ 9,388.54
$ 112,662.50
Stage 2 (anticipated operation within 2014)
$ 28,038.90
$ 336,466.84
Stage 3 (anticipated operation within 2034) $
$ 34,024.85
*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP
Operational Function*
Average Monthly Cost
Average Annual Cost
Stage 1 (from 2011 operational data)
$ 9,388.54
$ 112,662.50
Stage 2 (anticipated operation within 2014)
$ 28,038.90
$ 336,466.84
Stage 3 (anticipated operation within 2034) $
$ 34,024.85
*Calculations for disposal are performed on a historical basis that sludge costs $12.50 to haul to the Duffin Creek WPCP

22. Stage 4 Layout
The Extras
Stage 3
Stage 1&2
Stage 4

23. Questions and… Conclusions Conclusion Recommendations Acknowledgements
The proposed processes for Stage 3 include
Additional headworks improvements
1 primary clarification tank
2 two-staged aeration tank
1 secondary clarification tank
3 cloth filters
1 UV disinfection unit
2 additional anaerobic digesters
2 screw press dewatering units
Stage 3 is to be completed by year-end of 2034
present cost of $26.3 Million
O/M of $0.9 Million annually
Conclusions
Further investigation should be conducted with respect to the integration of the microturbine CHP system for biogas handling
Issues such as the availability of obtaining contracts from the Ontario Energy Board (OEB) and the Local Distribution Company (LDC) are of concern
Green incentive grants should be assessed to determine possible alleviation of total capital cost and further evaluation of the systems feasibility
Population growth trends are rechecked every 5 years to determine if the completion of Stage 3 construction schedule requires adjustment
Obtain additional specific order costing information from manufacturers
Hongde Zhou, Ph.D., P.Eng. – Faculty Advisor
Professor of the School of Engineering – University of Guelph
Miles MacCormack, P.Eng. – Consultant Advisor
Project Manager – Stantec Inc.
Rafiq Qutub, M.Eng., P.Eng.
Subcommittee Chair, Student Design Competition – Water Environment Association of Ontario
Kirill Cheiko, EIT.
Water EIT – Stantec Inc.
Yashar Esfandi, EIT.
Inside Sale Representative – SPD Sales Limited
Hussein Abdullah, Ph.D., P.Eng. – Director
The School of Engineering – Guelph University
Questions and…
Conclusion
Recommendations
Acknowledgements
Questions

24. Thank you! Thank you! The Credits Conclusions
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Conclusions
The Credits
Thank you!
Thank you!