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 Liam Moll Project Engineer/Client Liaison Project EngineerFinal 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, 2008i 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.ii 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.iii 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