Biosolids & Energy Recovery Facilities

Biosolids & Energy Recovery Facilities


Biosolids 05 2018

The Biosolids Energy & Recovery Facilities Project integrates a new state-of-the-art organics-handling system at the Michelson Water Recycling Plant. This new system includes biosolids processing, biogas management, and energy recovery systems. The system makes efficient and sustainable use of locally generated renewable resources by creating a beneficial use of biosolids and biogases that are produced during the wastewater treatment/recycling process. This project aligns with green and sustainable business practices, while at the same time creating an effective cost management of wastewater services for IRWD customers.Total Resource Management

The project is co-located at the existing MWRP, at 3512 Michelson Drive, Irvine, CA 92612. The biosolids project is being constructed within a 4.6-acre rectangular-shaped site adjacent to the MWRP. The MWRP is part of a larger property owned by IRWD, which is approximately 452 acres and includes the San Joaquin Wildlife Sanctuary.

Contact information: For questions or concerns, please email info@irwd.com or call 949-453-5500. For emergencies during non business hours please call 949-453-5300 (24 hours).

 

What are Biosolids?
 

Biosolids are a nutrient rich natural by-product of converting wastewater into the recycled water used throughout Irvine for landscape irrigation. Biosolids are the organics removed during the water treatment process. Biosolids contain energy that can be harnessed in two ways: The biosolds undergo further biological and heat treatment to be converted into pellets. Pellets may be used for fertilizer or an e-fuel. The biological treatment also produces biogas that will be used to generate electricity.

Biosolids Pellets

 

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Project Updates+

Week of Nov. 19, 2018:

The tunnel floor is being sealed at Digester 1, and conduit is being installed at the Digester Gas Conditioner. Pump motors are being tested at the Dewatering Feed Pump Station, and scaffolding is being installed at the Solids Handling Building to allow access to HVAC equipment.

Week of Nov. 12, 2018:

Conduit is being installed throughout the tunnels at the Methane Digester, and hot water supply pumps are being tested in the boiler room. Pump motors are also being tested at the Dewatering Feed Pump Station.

Week of Nov. 5, 2018:

Temporary fencing is being removed this week and a start-up test of the boiler equipment is planned. Several HVAC systems are also being tested and balanced. Work stations in the control room are being wrapped up this week, and installation of laboratory cabinetry and an exhaust canopy has been completed.

Week of Oct. 29, 2018:

Second gas meters were installed for the boilers, dryer, and flare, and the staircase on the east side of the Solids Handling Building and steel roof decking of the building were completed.  The final architectural panels have been installed on the Digester Control Building tower and Methane Digesters. Planning is underway for a start-up and testing phase of the project, which will begin later this year.

Week of Oct. 8, 2018:

Crews are testing and balancing HVAC systems this week, and floor sealer is being applied to the elevator and stair shaft. Testing of electrical and systems integration should be completed this week, and handrailing and fencing will be installed at the Andritz facility. Control room workstations will also be completed this week.

Week of Sept. 25, 2018:

Mineral oil instruments were installed at the Andritz Dryer Room, and painting was done at the Area 20 Solids Handling Building (second floor). Cathodic protection and grading were completed at various locations, and concrete poured at the Acid Digesters.

Week of Sept. 14, 2018:

Crews are completing panels on the exterior of Methane Digester No. 1 and on the Digester Control Building. Loop checks are being performed on limit switches in the acid phase digesters, and level indicators are being calibrated for the Centrate Treatment Tanks. Chain hand wheels are being installed on valves in the Digester Gas Conditioner and Holder, and pump motors being tested for the Dewatering Feed Pump Station. The Solids Handling Building has been placed on permanent power.

Week of Aug. 27, 2018

Thickening centrifuges are being installed. Several punch list items are being completed in the Dryer Room, including installation of dryer system equipment, piping, electrical and fencing. Drywall and painting work is taking place in the Solids Handling Building, and chipped concrete is being repoured at the Acid Digesters, where flashing is also being installed. An air compressor is being installed within the flare, and gas treatment electrical is being installed at the micro turbines.

Week of Aug. 13, 2018

Low roof cap flashing is being installed on the exterior parapet walls of the Digester Control Building. Crack injection will be required to repair a minor leak observed in the concrete wall between the two east tank sections. Pump motors in the Dewatering Feed Pump Station are being tested, and glass domes are being formed at the Sludge Holding Tanks. Registers were installed on the HVAC duct on the east side of the Solids Handling Building.

Week of June 30, 2018

Panels are being installed on the catwalk for the Methane Digester Complex; ID tags are being installed on equipment in the Digester Conrol Building; exterior piping is being painted at the Acid Phase Digesters. Pump motors are being tested at the Dewatering Feed Pump Station. In the dryer room of the Solids Handling Building, a dust collector line is being connected to the manifold, scrubber lines are being fitted to the scrubber, and other work is underway. Cameras have been installed on buildings and light poles around the site.

Week of June 23, 2018:

Cathodic protection boxes are being installed in the solids handling building and CCTV cables have been installed. Doors and glass have been installed in the digester control building, and a jib crane has been installed in the dewatering feed pump station. Metal decking has been installed for the silos, and electrical for micro turbines at Area 43 has been completed.

Week of June 4, 2018:

Electrical was completed for the lab, office and restrooms, and bathroom tile was installed this week. At the Digester Control Building, boiler stack installation and supports have been completed, and scaffolding removed. Entrance canopy to the Solids Handling Area and tile in the entrance have been installed. Membranes have been installed in the Area 50 Centrate.

Week of May 22, 2018:

Methane digester No. 2 is being painted, and a digester gas line and acid gas line are being installd at the foam separator for the digester control building. Pump motors at the dewatering feed pump station are being stationed and the domes of the sludge holding tanks are being formed. Roll-up doors to the solids handling building are being installed and work is continuing on the restroom facilities.

Week of April 23, 2018:

Pellet silos have been installed. Evacuation and installation of intake/outtake valve for the drain pump station has been completed.

Week of April 9, 2018:

Good progress has been made in the past month. Steel panels were installed on the methane digesters, elevated walkways and digester tower, where the elevator was also installed. Fabrication of two pellet silos is underway. Over the next several months, work will be focused on the centrifuges and odor control system.

Week of March 12, 2018:

To date, piping and supports have been installed in Digester No. 1. Knee pipe support and sump plumbing have been installed in Digester No. 3. Plumbing is being installed in the Digester Control Building. 

Week of June 12, 2017:

The Solids Handling Building is quickly taking shape as the pre-finished metal panels are being installed on the upper areas. Other work in the Solids Handling Building includes the installation of the roof decking, the electrical circuits to the thickening centrifuges, the large motor control center for the dryer, structural steel for the dryer, as well as the large air ducts and the liquid chemical facilities. Site work such as storm drains, catch basins, light poles, and water pipes are being installed and tested so that curbs, gutters, and paving may occur in the near future. 

Week of June 19, 2017:

At the methane digester complex, eight and 10-inch digested sludge and eight-inch cool methane sludge piping and supports are being installed on digester #1. At digester #3, knee pipe supports and sump plumbing are being installed and exterior scaffolding is being removed.

Week of June 5, 2017:

The contractor worked on the piping installation in the tunnel at Methane Digester No. 1. Pipe supports are being installed in the digester control building. Exposed conduit is being installed in the centrate treatment tanks.Various equipment was wired in the dewatering feed pump station basement. The FOG tanks are undergoing leak testing.

Week of May 22, 2017:

The new SCADA system integrator successfully performed a witnessed bench test of the computer programs to control the odor control chemical pumps. Various items currently being installed include power and control wiring for the thickening centrifuges, polymer control systems, odor control instruments, storm drain catch basins, light poles and duct banks, green metal panels on the exterior of the Solids Handling Building, gas piping on top of the acid digesters, insulation foam on the exterior of the last methane digester, sludge piping in the methane digester tunnels, support structures for the sludge dryer system, and piping at centrate treatment. The microturbines and biogas treatment equipment has been delivered and is being installed. The contractor successfully pressure tested the natural gas lines to the boilers, flare, microturbines, and dryer.

Week of May 8, 2017:

Sandblasting, painting, piping installation taking place at the methane digester complex, digester control building, acid phase digesters and centrate tanks. Electrical work underway at digester gas conditioning, and dewatering feed pump station.

Week of April 24, 2017:

The contractor sandblasted the exterior of the Methane Digester No. 3 and worked on the piping installation in the tunnel. The microturbines were delivered to the site last week. At the solids handling building, the decking was installed on the canopies on the south side of the building. At the biosolids site, the contractor set the concrete formwork and reinforcing steel for the curb opening catch basin in north road. Removable bollards were installed  at the liquid chemical storage truck slab.

Week of April 10, 2017:

The contractor installed the acid gas piping and appurtenances on top of each of the three acid phase digesters. Scaffolding was covered on digester no. 3. Piping and appurtenances are being installed on the west end of the tank deck on the centrate treatment tanks. Removable bollards were installed at the liquid chemical storage area.

Week of March 27 2017:

Various work is taking place at the methane digester complex, the digester control building, the acid phase digesters, the dewatering feed pump station, solids handling building and more.

Week of March 13, 2017:

The tops of the digesters at the methane digester complex were surveyed. Various equipment was wired in the basement of the dewatering feed pump station. Welding is taking place on the roof of the solids handling building. Removable bollard were installed at the truck slab at the liquid chemical building.

Week of February 27, 2017:

Although impacted by frequent rain, recently completed tasks include pouring the concrete pad for the Digester Gas Preliminary Treatment System. Steel bridges have been set in place from the tower above the Digester Control Building to each of the three egg-shaped digesters and applying the thermal insulation on the egg-shaped digesters continues. Digester gas booster pumps were successfully tested at the factory in Toronto and will be shipped to the site shortly. 

Week of February 13, 2017:

Spray foam insulation was cleaned from the scaffolding at the methane digester complex. Electrical work is taking place throughout the complex.

Week of January 30, 2017:

The contractor terminated the electrical conductors for various equipment and installed electrical conduits in the digester control building. Electrical work continues in various aspects of the project.

Week of January 16, 2017:

The contractor cleaned the spray foam insulation from the scaffolding at the methane digester complex. Electrical work is underway at various aspects of the facility. SoCal Gas installed a three-inch gas line along the east side of the Michelson plant entrance. They will be installing the gas meters in the near future.

Week of January 2, 2017:

The contractor is installing foam on the exterior of Methane Digester No. 2; sludge and heated water piping in the Digester Control Building; sludge, chemicals, and odor control piping in the Solids Handling Building; and structural steel for the building walls above the dryer room. Electrical and instrumentation testing of the Andritz Dryer equipment was performed in early December.

Week of December 19, 2016:

In the Boiler Room of the digester control building, the contractor worked on the hot water and heated sludge piping installations. The contractor wired various equipment in the basement in the dewatering feed pump station. The electrical contractor worked on the electrical conductors for the mixers’ motors on both tanks at the sludge holding tanks. Multiple tasks are underway in the solids handling building. SoCal Gas installed a three-inch gas line along the east side of the MWRP entrance.

Week of December 12, 2016

At Methane Digester No. 1, PCI completed application of the foam insulation and is starting application of the primer to protect the foam from UV exposure. At Methane Digester No. 2 PCI covered and tented the construction scaffolding around the outside of the digester and the contractor sandblasted and primed the digester’s exterior. Electrical work is taking place throughout the complex. SoCal Gas installed a three-inch gas line along the east side of the MWRP entrance from Gate 2. They will be installing their gas meters in the near future.

Week of November 7, 2016

At Methane Digester No. 1, GTE started the aluminum railing installation in the tunnel area.  PCI covered and tented the construction scaffolding around the outside of the digester. At the digester control building, FBB placed the concrete for the equipment on the outside of the south side of the east stairway.  SoCal Gas installed a three-inch gas line along the east side of the MWRP entrance from Gate 2.

Week of October 24, 2016

Milestone 1 (MS #1) testing is currently underway to meet the completion goal of October 31, 2016.  The final on-going step includes running a seven-day test of the computerized control system and four pumps in the process that send sludge to the sludge screens to remove fibers that may interfere with the dryer's pellet formation. .  This is the first of seven milestones that follow the sludge treatment process, including thickening centrifuges and odor control (MS #2), anaerobic digestion (MS #4), dewatering centrifuges and sludge loadout to trucks (MS #5), biogas conditioning and microturbine power generation (MS #6), and producing pellets (MS #7). 

Week of October 10, 2016

The contractor worked on the bridges between the Digester Control Building and each methane digester. The ductwork was installed in the boiler room of the mezzanine in the digester control building. The contractor is installing insulation on the refrigerant lines from the air handlers in the west mezzanine to the condensing units outside the north side of the solids handling building.

Week of September 26, 2016

The contractor worked on electrical conductors for mixers on both sludge holding tanks. The electrical contractor is installing power and control cables on the overhead cable tray.  Another contractor is planning work for HVAC controls.At the methane digester No. 1, the fire sprinklers were painted in the tunnel area, and the ductwork support was installed in the tunnel area.  At Methane Digester No. 2, the exterior above grade section of the digester was sandblasted, and the contractor worked on the spray foam insulation in the tunnel area.

Week of September 12, 2016

The contractor worked on the bridges between the Digester Control Building and each methane digester. Ductwork was installed on the mezzanine of the digester control building. The aluminum stair railing for the stair tower at the dewatering feed pump station was worked on and sections were painted. The contractor is installing insulation on the refrigerant lines from the air handlers in the west mezzanine to the condensing units outside the north side of the solids handling building.

Week of August 29, 2016

The top of the gas dome at acid digester No. 2 was adjusted. At acid digester No. 3, the contractor set the concrete formwork for the equipment pad on the digester. In the liquid chemical storage, the contractor is installing conduit, wiring and shut-off switches for the pumps at the sulfuric acid bay. 

Week of August 22, 2016

The contractor continues to make progress on the Solids Handling Building including the masonry and decorative external veneer around the perimeter of the building.  In the methane digester area, the contractor is in the process of applying the foam insulation to the underside of the methane digesters, and in the acid phase digester area, the contractor has completed installation of the handrail and inter-connecting bridges between the digesters.

Week of August 15, 2016

The contractor worked on the spray foam insulation installation on the exterior of Methane Digester No. 1 in the tunnel area.  They also trimmed down the high spots on spray form insulation applied to the exterior of the Methane Digester No. 2 in the tunnel area.  Drain piping was installed in Methane Digester No. 3.

Week of August 3, 2016

Spray foam insulation was applied on the exterior of Digester No. 2 in the tunnel area. Scaffolding was removed from the inside of Digester No. 2. Fire sprinklers inside the solids handling building are being coated. Wiring of various components in the solids handling building is taking place.

Week of July 18, 2016

The contractor installed the masonry veneer on the outside of the walls digester control building.  The electrical contractor installed the electrical conduit on the south side of the building.  The walls were painted in the boiler room.

Week of July 4, 2016

The contractor is performing the fire sprinkler installation in the tunnels of the methane digester complex.  Another contractor worked on the bridges that span between the Methane Digesters and the Digester Control Building. In the solids handling building, the contractor is installing copper lines for air conditioning equipment. The contractor is installing the ladder on the northwest side of the tank.

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