Rose Hulman Environmental Rose Hulman Institute of Technology CM 1537 5500 Wabash Ave Terre Haute Indiana 47803 April 7 2008 Ryujiro Tsuchihashi Metcalf Eddy Inc 605 Third Avenue New York NY 10158 212 984 7332 Dear Mr Tsuchihashi Our team at Rose Hulman Environmental RHE is pleased to present the final report for your wastewater plant upgrade and expansion We have utilized our education in codes and regulations hydraulics unit processes and computer applications We have completed our designs for the Modified Ludzack Ettinger Process Step Feed Preanoxic Process Bardenpho Four Stage Process and the total suspended solids removal We then performed an economic analysis and an assessment of each configuration Our final design recommendations were determined with the help of a decision matrix In the following report you will find a summary of all our information and our recommendation for the upgrade and expansion Thank you for your assistance with this expansion and upgrade design We are extremely excited about the completion of this project We look forward to presenting our final recommendations to your committee Thank you again for your time and please contact Andrea Bollinger at 812 760 8717 if you have any questions concerns or comments Sincerely Josey Daugherty Jeremy Burch Project Manager Project Engineer Project Editor Andrea Bollinger Project Engineer Client Liaison Liam Moll Project Engineer Final Report WWTP Upgrade and Expansion for Metcalf Eddy Academic Design Competition Problem 1 Rose Hulman Institute of Technology Terre Haute IN Josey Daugherty Jeremy Burch Andrea Bollinger Liam Moll April 7 2008 Disclaimer The contents of this engineering design report were prepared by civil engineering students at Rose Hulman Institute of Technology for their senior capstone design class Rose Hulman Environmental is a fictitious company created by students Andrea Bollinger Jeremy Burch Josey Daugherty and Liam Moll for the purpose of this class These students are not registered professional engineers All material presented herein should be reviewed and stamped by a professional engineer prior to construction A liability waiver has been signed by the client and copies are available from the client and from Rose Hulman Institute of Technology i Executive Summary Metcalf Eddy M E has hired Rose Hulman Environmental RHE to upgrade and expand a wastewater treatment plant WWTP located in New Jersey The current treatment process utilizes a suspended growth activated sludge extended aeration process with surface aerators The facility is to be expanded from 12 million gallons per day MGD to 16 MGD The Environmental Protection Agency EPA is beginning to tighten regulations on wastewater treatment plants to meet their set effluent goals Two of the most common concerns regarding a wastewater treatment plant are the effluent nitrogen and biochemical oxygen demand BOD RHE evaluated three process configurations the Modified Ludzack Ettinger process Step Feed process and the Bardenpho process to adapt into the existing facility RHE assessed each configuration based on process performance capital costs and operational costs Though each process met the effluent limits set forth by M E RHE s cost analysis found the MLE was economically the best process An additional benefit to the MLE process is it can be easily adapted into existing wastewater treatment plants RHE has proposed that the existing treatment plant be upgraded expanded and configured into a Modified Ludzack Ettinger MLE process This process will achieve effluent nitrogen and BOD of less than five mg L as requested by M E The new process will also be able to produce water for beneficial reuse To achieve this high quality effluent from wastewater RHE has added a rapid sand filter capable of producing a total suspended solids effluent of less than five mg L Construction of the upgraded facility will cost approximately 615 000 and annual operational costs are estimated at 82 000 ii TABLE OF CONTENTS 1 0 PROJECT DESCRIPTION 1 2 0 DESIGN SOLUTIONS 4 2 1 Codes and Regulations 4 2 2 Process Configuration Designs 4 2 3 Cost Analysis of Design Options 4 2 4 Assessment of Design Options and Selection of Design 5 3 0 SELECTED DESIGN 7 3 1 BOD and Nitrogen Removal 7 3 2 Sensitivity Analysis 8 3 3 Suspended Solids Removal 9 3 4 Drawings 10 APPENDICES APPENDIX A Current Process Configurations A 1 Overview A 1 A 2 Primary Treatment A 1 A 3 Secondary Treatment A 3 A 4 References A 4 APPENDIX B Codes and Regulations B 1 Overview B 1 B 2 Permitting Codes and Regulations B 1 B 3 References B 5 APPENDIX C Design of Modified Ludzack Ettinger Process C 1 Overview C 1 C 2 Analysis of Modified Ludzack Ettinger Process C 1 C 3 Calculations of Modified Ludzack Ettinger Process C 3 C 4 Conclusions C 27 C 5 References C 29 APPENDIX D Design of Step Feed Preanoxic Process D 1 Overview D 1 D 2 Analysis of Step Feed Preanoxic Process D 1 D 3 Calculations of Step Feed Preanoxic Process D 3 D 4 Conclusions D 20 D 5 References D 21 iii APPENDIX E Design of Bardenpho Four Stage Process E 1 Overview E 1 E 2 Analysis of Bardenpho Four Stage Process E 1 E 3 Calculations of Bardenpho Four Stage Process E 4 E 4 Conclusions E 31 E 5 References E 31 APPENDIX F Economic Analysis F 1 Overview F 1 F 2 Economic Analysis F 1 F 3 Calculations of Economic Analysis F 2 F 4 Conclusions F 5 F 5 References F 5 APPENDIX G Assessment of Process Configuration Options G 1 Overview G 1 G 2 Weighting for Grading Criteria G 2 G 3 Grading Criterion for Process Performance G 2 G 4 Grading Criterion for Capital Cost G 3 G 5 Grading Criterion for Operating Cost G 3 G 6 Scoring of Processes G 4 G 7 References G 4 APPENDIX H Sensitivity Analysis H 1 Overview H 1 H 2 Values of Sensitivity Analysis H 1 H 3 Conclusions H 10 H 4 References H 11 APPENDIX I Design of Total Suspended Solids Removal System I 1 Overview I 1 I 2 Beneficial Reuse I 1 I 3 Options for Total Suspended Solids Removal I 2 I 4 Design of Total Suspended Solids Removal System I 5 I 5 Conclusions I 12 I 6 References I 12 APPENDIX J Drawings of Selected Configuration J 1 Overview J 1 J 2 Site Plan of Modified Ludzack Ettinger Process J 2 J 3 Flow Diagram of Modified Ludzack Ettinger Process J 3 APPENDIX K References K 1 References K 1 iv APPENDIX L Rose Hulman Environmental Team Member Resumes L 1 Overview L 1 L 2 Project Manager s Resume Josey Daugherty L 2 L 3 Project Engineer and Editor s Resume Jeremy Burch L 3 L 4 Project Engineer and
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