Sonication Retention Time Reference

Commonwealth Energy Biogas/PV Mini-Grid
Renewable Resources Program

Making Renewables Part of an Affordable and
Diverse Electric System in California
Contract No. 500-00-036

Site Selection and Test Plan Report
Project 2.2 Enhanced Energy Recovery through Optimization
of Anaerobic Digestion and Microturbines
Task 2.2.2 Final Report
Prepared For:
California Energy Commission
Public Interest Energy Research Renewables Program
Prepared By:
Bill Kitto, CH2M HILL, Santa Ana, California

3 Hutton Centre Drive, Suite 200
Santa Ana, CA 92707
And
LEGAL NOTICE
This report was prepared as a result of work sponsored by the California Energy
Commission (Commission). It does not necessarily represent the views of the
Commission, its employees, or the State of California. The Commission, the State of
California, its employees, contractors, and subcontractors, make no warranty, express or
implied, and assume no legal liability for the information in this report; nor does any
party represent that the use of this information will not infringe upon privately owned
rights. This report has not been approved or disapproved by the Commission, nor has the
Commission passed upon the accuracy or adequacy of the information in this report.
USR040230003.DOC
1104 Main Street, Suite 630

Vancouver, WA 98660
March 26, 2004
Contents
Section
Page
Preface................................................................................................................................................. v
Executive Summary.................................................................................................................... ES-1
1
Introduction ......................................................................................................................... 1-1

1.1 Background ................................................................................................................ 1-1
1.2 Results of Project 1.1Planning and Analysis...................................................... 1-1
1.3 Overview of Project 2.2 ............................................................................................. 1-2
1.4 Report Content and Organization........................................................................... 1-2
Enhanced Anaerobic Digestion Site Selection.............................................................. 2-1

2.1 Site Description .......................................................................................................... 2-1
2.1.1
City of Riverside ......................................................................................... 2-1
2.1.2
Potential Test Sites at the Plant................................................................. 2-1
2.1.3
Recommended Location ............................................................................ 2-5
2.2 Ultrasound Pilot System ........................................................................................... 2-5
2.2.1
Introduction................................................................................................. 2-5
2.2.2
IWE Tec Equipment Description .............................................................. 2-5
2.2.3
Sonico Pilot Equipment Description ........................................................ 2-6
2.2.4
Scope of Supply........................................................................................... 2-6
2.2.5
Required Ancillary Equipment................................................................. 2-7
2.3 Expanded Process Flow Diagram ........................................................................... 2-7
2.4 Test Plan...................................................................................................................... 2-9
2.4.1
Process Description .................................................................................... 2-9
2.4.2
Rationale for Test ........................................................................................ 2-9
2.4.3
Predicted Performance............................................................................. 2-10
2.4.4
Test Objectives and Technical Approach .............................................. 2-10
2.4.5
Test Matrix................................................................................................. 2-11
2.4.6
Facilities, Equipment, Instrumentation to Conduct Test .................... 2-11
2.4.7
Test Parameters and Procedures ............................................................ 2-12
2.4.8
Data Analysis Procedures ....................................................................... 2-15
2.4.9
Quality Assurance Procedures ............................................................... 2-15
2.4.10 Contingency Measures............................................................................. 2-16
2.5 Existing Data Summary Table ............................................................................... 2-16
2.6 Mass and Energy Balance ....................................................................................... 2-17
2.7 Test Recommendations and Schedule .................................................................. 2-17
Microturbine Gas Cleaning .............................................................................................. 3-1

3.1 Site Description .......................................................................................................... 3-1
3.1.1
General Map, Address, Contact Information, Plant Layout................. 3-1
3.1.2
Potential Sites at RP-1 ................................................................................ 3-1
3.2 Gas Cleaning Pilot System ....................................................................................... 3-1
USR040230003.DOC
III
CONTENTS, CONTINUED
Section
3.3
3.4
3.5
3.6
3.7
Page
3.2.1
Gas Drying ...................................................................................................3-3
3.2.2
H2S Removal ................................................................................................3-3
3.2.3
Package Siloxane Treatment System ........................................................3-3
Expanded Process Flow Diagram ............................................................................3-4
Test Plan ......................................................................................................................3-4
3.4.1
Process Overview........................................................................................3-4
3.4.2
Rationale for Test ........................................................................................3-4
3.4.3
Predicted Performance ...............................................................................3-6
3.4.4
Test Objectives and Technical Approach.................................................3-6
3.4.5
Facilities, Equipment, Instrumentation to Conduct Test.......................3-7
3.4.6
Test Procedures ...........................................................................................3-8
3.4.7
Data Analysis Procedures ..........................................................................3-9
3.4.8
Quality Assurance Procedures ................................................................3-10
3.4.9
Contingency Measures .............................................................................3-10
Existing Data Summary Table................................................................................3-10
Energy Balance .........................................................................................................3-10
Test Recommendations and Schedule...................................................................3-11
Appendix
RP-1 Gas Production 2002 Data
Tables
2-1
2-2
2-3
2-4
2-5
3-1
3-2
3-3
Enhanced Anaerobic Digestion Test Matrix .................................................................... 2-11

Baseline Solids Handling Data Collection ....................................................................... 2-13
Baseline Data Collection for Biogas and Co-gen System ............................................... 2-14
Plant Data ............................................................................................................................. 2-16
Enhanced Anaerobic Digestion Test Schedule ................................................................ 2-18
Project Team Members Contact Information..................................................................... 3-2
Sampling Plan ...................................................................................................................... 3-11
Microturbine Gas Cleaning Test Schedule....................................................................... 3-14
Figures
2-1
2-2
2-3
3-1
3-2
3-3
3-4
3-5
3-6
IV
Riverside Process Flow Schematic ...................................................................................... 2-3

City of Riverside Sewage Plant Layout .............................................................................. 2-4
Process Flow Diagram .......................................................................................................... 2-8
Location Map for RP-1 and Vicinity ................................................................................... 3-2
Plant Layout for IEUA RP-1 Facility................................................................................... 3-3
Potential Sites For Locating Test Equipment..................................................................... 3-5
Process Flow Diagram for Biogas Drying System ............................................................ 3-8
Process Flow Diagram for Biological H2S Removal System............................................ 3-8
Process Flow Diagram for Biogas Cleaning Package System.......................................... 3-9
USR040230003.DOC
Preface
The Public Interest Energy Research (PIER) Program supports public interest energy
research and development that will help improve the quality of life in California by bringing
environmentally safe, affordable, and reliable energy services and products to the
marketplace.
The PIER Program, managed by the California Energy Commission (Commission), annually
awards up to $62 million to conduct the most promising public interest energy research by
partnering with Research, Development, and Demonstration (RD&D) organizations,
including individuals, businesses, utilities, and public or private research institutions.
PIER funding efforts are focused on the following six RD&D program areas:
Buildings End-Use Energy Efficiency

Industrial/Agricultural/Water End-Use Energy Efficiency
Renewable Energy
Environmentally-Preferred Advanced Generation
Energy-Related Environmental Research
Strategic Energy Research
For more information on the PIER Program, please visit the Commissions Web site at:
http://www.energy.ca.gov/research/index.html or contact the Commissions Publications
Unit at 916-654-5200.
For Commonwealth Program-specific information, please visit
http://www.pierminigrid.org.
What follows is a report for the California Energy Commission, Public Interest Energy
Research Program, Contract Number 500-00-036, conducted by the Commonwealth Energy
Team. The report is entitled Site Selection and Test Plan Report. This project contributes to
the Renewable Energy component of the PIER program.
USR040230003.DOC
Executive Summary
Background
The Project Prioritization Assessment, delivered under Task 1.1.10 of this PIER program,
recommended prioritized sites and technologies for research testing and evaluation to
advance renewable energy. Sites for testing of technologies for enhanced anaerobic
digestion and gas cleaning for microturbines at wastewater treatment plants ranked highly
in that prioritized list.
The Process Selection Report for Wastewater Treatment Plants, delivered under Task 2.2.1 of
this PIER program, recommended an ultrasound process for enhanced anaerobic digestion
and a package of combined treatment technologies for gas cleaning, to be carried into a site
selection and test phase.
This site selection and test plan report carries forward the conclusions from the abovementioned reports and provides specific site recommendations, further definition of the
processes and their integration into the host facilities at the recommended sites, and test
plans for the recommended processes.
Enhanced Anaerobic Digestion

Site Selection
The ultrasound process selected in Task 2.2.1 is recommended for testing at the City of
Riverside Water Quality Control Plant. A specific location on the south side of digesters #1
and #2 at that plant is recommended and described on a plant layout in Section 2.1.
Process Definition and Equipment Vendors

Two vendors of ultrasound systems, IWE Tec and Sonico, were selected to provide
equipment. Their scope of supply and recommended ancillary equipment for pilot testing is
described in Section 2.2 of this report. An expanded process flow diagram of integration into
the existing host facility is shown and discussed in Section 2.3.
Test Plans, Operating Data, and Schedule

Test plans and procedures, including equipment needed, predicted performance, and data
gathering and analysis procedures, are provided in Section 2.4. Existing plant operating data
are summarized in Section 2.5. A baseline mass-energy balance for performance
comparisons of existing and new systems is discussed in Section 2.6, and a schedule for
testing that starts in February 2004 and ends in February 2005 is defined in Section 2.7.
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ES-1
EXECUTIVE SUMMARY
Gas Cleaning for Microturbines

Site Selection
The gas cleaning process package selected in Task 2.2.1 is recommended for testing at the
Inland Empire Utilities Agency (IEUA) Regional Plant #1 (RP-1) facility. Three location
options for placement of equipment at that facility are discussed in Section 3.1:
Next to the existing treatment equipment (iron sponges and gas compressors) at that
facility
North of digester No. 4 (the manure digester)
Close to the energy recovery building, southeast of the digesters
Process Definition and Equipment Vendors

The recommended gas cleaning processes include a refrigerated dryer for moisture removal,
a biological process using bacteria for hydrogen sulfide removal, and a package siloxane
removal system as manufactured by Applied Filter Technologies or Pioneer Air Systems.
These processes are described further in Section 3.2 and expanded process flow diagrams
are provided in Section 3.3.
Test Plans, Operating Data, and Schedule

Test plans and procedures, including equipment needed, predicted performance, and data
gathering and analysis procedures, are provided in Section 3.4. Existing plant operating data
are summarized in Section 3.5. A baseline mass-energy balance for comparison of
performance of existing and new systems is discussed in Section 3.6, and a schedule for
testing that starts in February 2004 and ends in December 2004 is defined in Section 3.7.
ES-2
USR040230003.DOC
SECTION 1
Introduction
In June 2001, the Commonwealth Energy Team was awarded a programmatic contract
under the California Energy Commissions Public Interest Energy Research (PIER) Program
to conduct research on strategies for making renewable energy more affordable in
California. The Commonwealth Energy approach involves assessing the combined potential
of biogas and photovoltaic (PV) resources in a defined study area and identifying how these
resources could be developed in a complementary and cost-effective manner. The
Commonwealth Energy Team conducted this research in a real world setting so that the
findings could be applied elsewhere in California and thereby benefit more California
ratepayers. The local area Commonwealth Energy selected for its renewable energy research
activities is the Chino Basin, referred to in this report as the study area.
1.1 Background
The Chino Basin is rich in PV and biogas resources. Moreover, it is a rapidly growing area
with substantial and increasing electrical loads. The underlying goal of the Commonwealth
Energy PIER Renewables Mini-Grid Program is to identify potential Building Integrated PV
(BIPV) and biogas energy projects, bring innovative technologies and business practices to
these projects, assess the benefit to the local electricity distribution system (the mini-grid),
and then use the findings to develop a business model for siting cost-effective, renewable
energy projects. A description of the Commonwealth Energy PIER Program, including the
results of some of the work undertaken to date, is presented on the project Web site,
http://www.pierminigrid.org.
An important element of the Commonwealth PIER Renewables Mini-Grid Program is a
project devoted to research on improving energy recovery from biogas derived from
anaerobic digestion. This project is identified as Project 2.2, Enhanced Energy Recovery
Through Optimization of Anaerobic Digestion and Microturbines. The work summarized
in this report (Task 2.2.2) is the second activity of Project 2.2, and carries forward the results
of the Process Selection Report completed for Task 2.2.1.
1.2 Results of Project 1.1Planning and Analysis

Project 1.1 (Planning and Analysis Report) confirmed that projects and technologies for gas
cleaning for microturbines and enhanced digestion systems should be examined further.
Also, it became clear during the research that because of high power costs, projects designed
to maximize energy recovery from digesters and generation equipment are important and
potentially economical. These projects were therefore ranked highly in the Project
Prioritization Assessment Report (Task 1.1.10). Those results were carried into Project 2.2.
USR040230003.DOC
1-1
INTRODUCTION
1.3 Overview of Project 2.2

The objectives of Project 2.2 are:
Increase and optimize digester gas production through thermal hydrolysis and
ultrasound processes.
Develop and optimize cost-effective gas cleanup systems.
Evaluate and quantify environmental benefits that result from using microturbines at
sewage treatment plants.
Evaluate performance and cost during operation so sewage treatment plants have
greater certainty on cost and reliability of using microturbines.
The first task, 2.2.1, evaluated several different processes and selected an ultrasound process
for enhanced anaerobic digestion and a custom treatment package for gas cleaning for
microturbines, to be carried further to site selection and testing.
This report fulfills the scope of Task 2.2.2, which includes a report on selection of the best
sites at which to deploy the technologies and processes for enhanced anaerobic digestion
and gas cleaning that were selected in Task 2.2.1. The report also provides (1) expanded
process flow diagrams that further define the selected processes and show their integration
into the selected host facilities, and (2) test plans for the new systems.
1.4 Report Content and Organization

This report is organized as follows:
Section 1 introduces the Commonwealth Energy program, provides background

information on the Chino Basin, presents an overview of the Commonwealth PIER
project for Enhanced Energy Recovery through Optimization of Anaerobic Digestion
and Microturbines, and describes the objectives and content of this report.
Section 2 describes the selected test site for the enhanced anaerobic digestion process.
Expanded process flow diagrams are presented, and process definition, test plans,
recommendations and schedule are discussed.
Section 3 describes the selected test site for the microturbine gas cleaning process.
Expanded process flow diagrams are presented, and process definition, test plans,
recommendations and schedule are discussed.
1-2
USR040230003.DOC
SECTION 2
Enhanced Anaerobic Digestion Site

Selection
This section evaluates the selected test site for the ultrasound pilot test. The ultrasound
technology to be tested is designed to increase the production of biogas from digestion of
organic solids. The City of Riverside is well suited to host the ultrasound pilot test.
2.1 Site Description

2.1.1 City of Riverside
The City of Riverside is the recommended location for the ultrasound pilot testing program.
The City of Riverside Water Quality Control Plant address is 5950 Acorn Street in Riverside,
CA 92504. The point of contact for the testing is Stephen Schultz, Wastewater Systems
Manager for the City of Riverside. The wastewater plant has two primary and secondary
treatment trains within the same site, referred to as Plant 1 and Plant 2. Currently, the
primary sludge is thickened at each plant and then pumped into a common line to the
digesters. The waste activated sludge (WAS) from the two activated sludge plants is sent to
one pair of dissolved air flotation thickeners (DAFTs) from where the thickened waste
activated sludge (TWAS) is sent to the digesters.
The wastewater treatment plant has five existing digesters, of which three will be in
operation during the test period. The pilot systems will be located south of Digesters #1 and
#2 for ease of access and to minimize the temporary piping and electrical cable lengths. The
City of Riverside operates standard mesophilic digesters at 100F, and the results from the
ultrasound pilot test will be applicable to treatment plants across California. The City of
Riverside process schematic is shown in Figure 2-1, and the plant layout is shown in
Figure 2-2.
A third digester, Digester #4, is planned to be brought online in early 2004, and will be fed
primary solids and TWAS from Plant 2. Therefore, the feed to this digester may be slightly
different than the feed to the other digesters. In addition, Digester #4 is slightly larger than
the other two digesters. Performance of Digester #4 will be monitored during the test as a
check on the performance of the test digesters, although it will not be a true control digester,
owing to the differences between this and the other two digesters.
2.1.2 Potential Test Sites at the Plant

The City of Riverside is currently using two of its five digesters, Digesters #1 and #2
(previously labeled Digesters #6 and #7). These two digesters are adjacent to each other and
share the same pump room and electrical room. They are also the closest digesters to the
DAFTs that provide the TWAS feed to the digesters, and to the dewatering building.
Figure 2-2 shows the location of test digesters and DAFTs. The City has been operating
these two digesters since the 1980s and extensive background data are available for
USR040230003.DOC
2-1
ENHANCED ANAEROBIC DIGESTION SITE SELECTION
performance of these digesters, which may be referred to during this test as necessary.
Digesters #1 and #2 are similar in size, design, and mixing and heating equipment and have
been in operation for the same duration. Plant data (provided in Section 2.5) show that the
digesters have similar performance, although plant staff have recommended a more
detailed evaluation of the two digesters prior to testing. The similarities between these two
digesters and the background data available make these suitable for side-by-side testing of
two different ultrasound systems.
Three locations of the ultrasound equipment were considered. The evaluation criteria
included ease of supply of TWAS to the ultrasound systems, routing of the sonicated solids
from each system to the respective digester, piping for bypassing the ultrasound systems in
case of a shutdown, and electrical hookup for the test equipment. The TWAS feed line to the
digesters is buried for most of its length, and is only accessible at the DAFT pump room, or
in the digester pump room basement, where the digester feed pipe header and valve
systems are located. The three locations considered were:
Adjacent to the DAFT pump room

On the north side of Digesters #1 and 2
On the south side of Digesters #1 and 2
The location next to the DAFTs provided easy access to the feed TWAS line, but produced
complications as it required routing of multiple temporary pipelines to convey sonicated
TWAS from each ultrasound system to the respective digesters, as well as bypass lines,
across an onsite roadway that plant staff would need to use. This location significantly
increased the total pipe length that would be required.
Location of the test equipment on the north side of the digesters was also considered. At this
location, a single TWAS feed line could be installed from the DAFT pump room to the
equipment, which would reduce the pipe length and access issued associated with the first
location. Alternatively, the TWAS feed to the test equipment could be connected to a T
section on the feed header in the digester pump room basement. This avoided having to run
lines across the access road, but the line from the pump room basement required routing it
up the main access staircase, which could cause a potential safety issue for plant staff. The
sonicated TWAS from the test equipment to the digesters could be routed into the external
digester mixing lines on the north side of the digesters. However, electrical connections
would have to be routed from a control room on the opposite side of an access road.
Location of the test equipment on south side of the digesters was also considered. There is
an existing electrical control room adjacent to the digester pump room on this side, which
has spare capacity and could accommodate electrical needs of the test equipment. The
TWAS feed to the test equipment could be accessed at the same T-connection in the
basement that was considered for the above location. However, by locating the equipment
on the south side, the line could be run up an existing ladder, rather than the main access
stairway, and would not be a safety concern. There are mixing line access points on the
external digester walls on the south side that could be used for routing the sonicated TWAS
into the digesters.
2-2
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FIGURE 2-1
Riverside Process Flow Schematic
USR040230003.DOC
2-3
FIGURE 2-2:
City of Riverside Sewage Plant Layout
2-4
USR040230003.DOC
2.1.3 Recommended Location

Three potential test equipment locations were considered and discussed with the plant staff.
It was clear that the third location, on the south side of Digesters #1 and #2, would be the
best in terms of maintaining access to the plant facilities, minimizing the length of
temporary piping and electrical lines, and minimizing potential health and safety issues.
2.2 Ultrasound Pilot System

2.2.1 Introduction
Different ultrasound systems and manufacturers are evaluated as part of the Process
Selection Report. Two manufacturers, IWE Tec and Sonico, were selected to provide
ultrasound systems for pilot testing. This section briefly describes the technologies and the
equipment to be provided by each manufacturer.
2.2.2 IWE Tec Equipment Description

The IWE Tec approach to ultrasound application for municipal sludges is based on partial
treatment of the secondary sludge stream. The premise is that, for this system, partial
treatment is the most cost-effective approach. The ultrasound system consists of individual
cascade probes, each within an individual cylindrical reactor. The cascade probe is a
patented development of the common rod-shaped probe. The IWE Tec system operates at
sonication times of 30 to 60 seconds. The systems are usually designed to run between 50 to
75 percent of the maximum power, to provide a buffer and prevent the units from cutting
out because of power overloads. Because this ultrasound system operates close to the
maximum amplitude, the operating power draw can only be varied by changing the load,
which may be achieved by changing line pressure, feed flow rate, or solids concentration of
the feed sludge. Some of the recent advances made to improve the cost-effectiveness of the
IWE Tec system are:
Increase in the maximum amplitude from 25 m to 50 m
Increase in probe power, from 4 kW to potentially 16 kW. Probes over 4 kW have a new
water cooling system
Change in probe design from a single-cast piece to a two-piece probe to allow the lower
portion, which has the most wear, to be replaced more frequently, while the upper
portion can be replaced less frequently
Data from IWE Tec ultrasound systems in Germany show that the older design, using 2-kW
probes at the lower amplitude range, typically provided improvements in anaerobic
digestion as follows:
Increase in volatile solids destruction of 20-25 percent

Increase in gas production of 25-30 percent
Improved dewaterability of 0-5 percentage points
Actual results vary depending on digestion performance without ultrasound, digester

retention times, and the proportion of secondary solids in the digester feed.
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2-5
2.2.3 Sonico Pilot Equipment Description

The Sonico ultrasound system consists of individual radial horns that are shaped like a
ring donut. The horns are mounted in series in a reactor that typically contains three or five
horns. The reactor is designed with flanges at either end that connect to a 6-inch diameter
pipe. The radial horn and reactor designs are covered by patents.
The Sonico approach to ultrasound application for municipal sludges is based on treatment
of the entire secondary sludge stream. The Sonico system operates at sonication times of
around two seconds. Recent tests conducted by Sonico show that maintaining the desired
power draw is key to achieving the optimal ultrasound dose and intensity. The system does
this by adjusting amplitude and line pressure to maintain the set power draw. This prevents
the units cutting out on overload, and prevents performance dropping when changes in the
sludge feed system would otherwise have reduced the power draw. The system is designed
to typically run at 70 to 75 percent of the maximum amplitude, which provides buffering for
changing loads. Some of the recent advances made by Sonico to improve the costeffectiveness of the system are:
Increase in the maximum amplitude from 12 m to 16 m

Increase in power, from 3 kW to 6 kW horns
More cost-effective horn manufacturing process
Improvements in the transducer cooling system
Data from Sonico ultrasound systems show that the older design, using 3 kW probes at the
lower amplitude range, typically provided improvements in anaerobic digestion as follows:
Increase in volatile solids destruction of 30-50 percent

Increase in gas production of 30-50 percent
Improved dewaterability of 0-2.5 percent
Actual results vary depending on digestion performance without ultrasound, digester

retention times, and the proportion of secondary solids in the digester feed.
2.2.4 Scope of Supply

The manufacturers will provide the ultrasound demonstration equipment as an integrated
operating system consisting of an equipment skid or container, necessary horns,
transducers, generators to treat the specified TWAS flow; cooling system; flowmeter(s); two
pressure sensors; interconnecting pipes, bypass line, valves, instrumentation, control panels;
sample stations; and interconnecting power and control wiring and associated raceways.
The manufacturers will be responsible for designing their ultrasound demonstration system;
delivering to the plant; providing installation instruction, assistance, and training for the
City of Riverside staff; commissioning; acceptance testing; and decommissioning.
The manufacturers will be responsible for acceptance testing of individual items of
equipment prior to demonstration testing. The City of Riverside will install the equipment
in accordance with the manufacturers requirements and will provide manpower during
startup.
Section 2.4.6 lists the equipment provided by each manufacturer.
2-6
USR040230003.DOC
2.2.5 Required Ancillary Equipment

The required ancillary system will include a 10,000-gallon TWAS holding tank with low,
high, and high-high level controls to allow continuous flow through the ultrasound
equipment systems; temporary piping between the TWAS feed line, the ultrasound
demonstration systems and the digesters; TWAS progressive cavity feed pump for IWE Tec
Ultrasound train; emergency bypass line and automatic valving to prevent overflow of the
TWAS holding tank by diverting the TWAS feed flow to Digesters #1 and #2; plug valves to
isolate demonstration equipment from the sewage treatment plant; temporary power and
control cable to connect to the plant system; and digester gas flowmeters. Additional
services and utilities that will be required include power supply; plant effluent for cooling;
daily staffing and monitoring; and sampling and laboratory analysis during the testing
period.
2.3 Expanded Process Flow Diagram

Two ultrasound supplier systems will be installed for a side-by-side comparison of the
technology. Ultrasound is most effective on the TWAS, which is harder to break down in the
conventional digestion process. The test equipment will be installed on the TWAS feed to
the digesters. The TWAS feed from the DAFTs is not continuous throughout the day, as the
pumps cycle on and off depending on levels in the TWAS tanks. However, as ultrasound
systems are primarily sized on flow, it is preferable to provide a consistent feed to the
ultrasound systems, to maximize the use of the test units. Therefore, the test setup, as shown
above in Figure 2-3 , includes a TWAS holding tank that provides buffering and a more
continuous flow to the ultrasound units. One ultrasound demonstration system will feed
digester #1; the other will feed digester #2. As the IWE Tec system only treats part of the
flow, this unit has a bypass line through which the unsonicated portion will be routed to the
digesters. The holding tank and demonstration equipment will be located outside, on the
south side of the test digesters and temporary piping will feed the system.
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2-7
FIGURE 2-3
Process Flow Diagram
(Please see attached .pdf file)
2-8
USR040230003.DOC
2.4 Test Plan

2.4.1 Process Description
A demonstration trial will be conducted to investigate the economic, practical and technical
benefits of using ultrasound to increase gas production on existing anaerobic digesters at the
City of Riverside Sewage Treatment Plant. The Sonico system will treat all the TWAS to
Digester #1, with a design average sonication retention time of around two seconds. The
IWE Tec system will provide partial treatment (30 percent of TWAS flow) to Digester #2,
and the remaining TWAS flow will bypass the ultrasound system. The IWE Tec system
typically is designed for a sonication retention time of 30 seconds. Descriptions of the two
ultrasound systems have been provided in Sections 1.2.1 and 1.2.2 of this report. Flow rates
to each system and the power draw of each will be monitored. Parameters that provide
indications of the impact of ultrasound on the TWAS will be measured, including soluble
COD release, viscosity and microscopic analysis of cellular material.
The TWAS from each ultrasound system will mix with the primary sludge in the digester. In
all other respects the operation of the digesters will continue as usual, with the temperature
at around 100F. Ultrasound, through improved hydrolysis, is expected to provide
measurable improvements in digestion, including increased solids destruction, increased
gas production, and improvements in dewaterability.
As with any test that seeks to measure improvements in a process, it is vital that the baseline
performance is well established. This is even more important when comparing two different
systems as part of a side-by-side test, where the merits of one system will be contrasted with
the merits of the other system. To ensure that both test digesters are operating under similar
conditions, primary and TWAS flow rates and solids loading rates for each digester will be
monitored. In addition, the operating volumes of each digester will be checked through
tracer tests, so that the true hydraulic retention time may be calculated. The main digestion
performance parameters will be measured through volatile solids destruction, and gas
production. Additional parameters will be monitored, to verify stability of the digestion
process and downstream impacts such as dewaterability improvements. Section 1.4.7
provides more detail on the parameters that will be monitored.
As the digester gas is used for generation of electricity through the on-site IC engines, the
quality of gas, and the proportion of energy generated from the digester gas will be
monitored as part of the test process.
2.4.2 Rationale for Test

Ultrasound technology for improved anaerobic digestion was tested at laboratory scale as
early in the 1960s. However, at that time, ultrasound generating technology was not
sufficiently developed to provide a process that could cost-effectively be implemented at
full-scale. In the last five years, advances in ultrasound equipment have generated renewed
interest in this technology for hydrolysis of municipal solids. The technology provides an
easy retrofit option for existing wastewater treatment plants, and has a relatively low cost
compared with options such as thermal hydrolysis. The simple installation and operation of
this technology make it particularly attractive as a potentially cost-effective method for
PDX\040230003.DOC
2-9
optimizing gas production at municipal plants. There are three primary suppliers with
systems developed for municipal applications, and these suppliers are continuing to
develop and optimize their equipment to improve cost-effectiveness. Most of the work to
date has been conducted in Europe, and there is a need to develop this technology for
application in the United States.
The longest-running ultrasound installation at a municipal treatment plant is around three
years using low power probes (2 kW). Most of the work to date has been done in Europe,
where conditions at municipal plants are often different from plants in the U.S., and as
mentioned earlier, digester performance in Europe tends to be lower than in the U.S.
Sonico has conducted trials at Orange County Sanitation District (OCSD), and is currently
testing the same equipment at a Los Angeles County Sanitation District plant, which is very
similar to OCSD. The testing was done with 3 kW probes and was on a biological sludge
produced from Pure Oxygen Activated Sludge Process. Additionally, data needs to be
collected with sludges produced at air aerated sludge plants, which are the most common
biological treatment processes in the U.S. The secondary solids from air aerated sludge
plants are more highly oxidized and the structure of the solids may be stronger. Therefore,
the biogas production potential with ultrasound treatment may be different, and the
required energy input to achieve sufficient disintegration might be higher.
The presence of multiple vendors is beneficial for the market, as the suppliers are seeking to
improve life-cycle costs for their systems to be increasingly competitive. Each of the three
suppliers in the market has a very different approach to the application of their ultrasound
systems and very different operational parameters, which make direct comparison of the
systems difficult. Testing of the different suppliers at the same site would enable such a
comparison to be done for the first time, and the potential advantages of each system to be
verified.
2.4.3 Predicted Performance

As there is no operating experience with the ultrasound equipment in California on a typical
sewage treatment plant, a conservative estimate of 20% improvement in gas production
from the TWAS is predicted. Electricity generation is expected to be increased as a result of
the digested gas production improvement. As the City of Riverside will bring on line a third
digester before the pilot test, only 2/3rds of the TWAS will be treated through the
ultrasound systems. It is anticipated that during the pilot test, the electricity generated by
biogas will increase by approximately 125 kW, offsetting natural gas use.
2.4.4 Test Objectives and Technical Approach

The aim of the enhanced anaerobic digestion test is to evaluate the cost-effectiveness of
using ultrasound to increase digester gas production at sewage treatment plants. The test is
being conducted at the City of Riverside sewage treatment plant, as this has primary and
secondary treatment processes that are typical of those found in California. Two different
ultrasound systems will be tested side-by-side to compare different approaches to
application of this technology for enhanced digestion. To achieve this, the objectives of this
test are:
2-10
Establish robust baseline performance data for the test digesters
USR040230003.DOC
Evaluate performance of two digesters, each with a different ultrasound system

Evaluate operability of the two ultrasound systems (downtime, energy draw etc.)
2.4.5 Test Matrix

To achieve the test objectives, the test will be conducted in four phases, briefly described
below and summarized in Table 2-1.
1. Pretest Phase - During this phase, a number of checks will be carried out at the City of
Riverside sewage treatment plant, to ensure that the data collected during the test will
be robust and reliable. This includes calibration of all flowmeters (sludge flows and gas
flows), evaluation of mixing systems on the test digesters, tracer tests to determine
digester operating volume, and collection of plant data for the past year.
2. Baseline Phase - During the first three months of the test, detailed baseline data will be
collected with the newly calibrated instrumentation and following the test procedures
described in Section 1.4.7 (excluding those relevant to the ultrasound systems).
3. Ultrasound Test Phase - Once the two ultrasound systems are installed, the ultrasound
systems and digesters performance will be monitored, as per the test procedures
described in Section 1.4.7.
4. Continuation Phase After the ultrasound systems have been shut down at the end of
phase three, the digesters will continue to be monitored for another two to three months,
to follow the change in digester performance back to the baseline. This confirms that
improvements seen during the ultrasound testing phase can truly be attributed to the
use of the equipment.
TABLE 2-1
Enhanced Anaerobic Digestion Test Matrix

Digester #1
Digester #2
No Ultrasound
With Sonico
Ultrasound
No Ultrasound
With IWE Tec

Ultrasound
Pretest Phase
1 month
1 month
Baseline Phase
3 months
3 months
6 months
6 months
3 months
3 months
Phase
Ultrasound Phase
Continuation Phase
2.4.6 Facilities, Equipment, Instrumentation to Conduct Test

The ultrasound demonstration system will be provided as a complete, integrated, and fully
operating system starting from inlet flanges of the TWAS feed pump and ending at inlet of
the temporary piping to the digester, and will consist of the following subsystems:
PDX\040230003.DOC
2-11
Complete ultrasound equipment, including but not limited to reactor chamber, horns/
probes, boosters, extenders, transducers, generators, and cooling system, to treat the
specified TWAS flow to one digester.
One container or skid system to house the ultrasound equipment and all appurtenances,
to be located outside and adjacent to the digesters.
One acoustic sound enclosure, if required.
Two pressure indicators.
Flowmeter(s) and required motorized valves (if needed) to control and protect
demonstration equipment.
Bypass line and valves to proportion flow for IWE Tec Ultrasound System
TWAS Progressive Cavity Pump for each Ultrasound train.
Interconnecting pipes, valves, and sample stations.
Instrumentation and control panel.
Interconnecting power and control wiring and raceways.
The required ancillary system will include:
A 10, 000-gallon TWAS holding tank with low, high, and high-high level controls to
allow continuous flow through the ultrasound equipment systems.
Temporary piping between the TWAS feed line, the ultrasound demonstration systems
and the digesters.
Emergency bypass line to prevent overflow of the TWAS holding tank.
Isolation valves to isolate demonstration equipment from the plant.
Digester Gas Flowmeters.
Power supply, temporary power and control cable to be connected to plant system.
Daily staffing and monitoring.
Sampling and laboratory services during the testing period.
2.4.7 Test Parameters and Procedures

This section outlines the test parameters for the baseline, ultrasound and continuation
phases of the program, including solids data, biogas and electricity data and data specific to
the ultrasound systems.
Solids Handling Parameters

Table 2-2 provides the solids handling parameters that will be monitored during the test.
One week prior to the start of the ultrasound systems, more intensive dewatering tests
should be conducted, by isolating each digester, to assess the difference in performance
2-12
USR040230003.DOC
between them. This will then be repeated towards the end of the ultrasound phase, after the
digesters are at steady state operation and again during the continuation phase.
TABLE 2-2
Baseline Solids Handling Data Collection
Parameter
Daily Flow (mgd)
Primary Sludge
To Each
Digester
TWAS To
Each Digester
Digested Sludge
From each
Digester
Quantity (wtpd)
Dewatered
1
Cake
Frequency
daily
daily
TS (%)
3 x week
VS (%)
3 x week
Alkalinity (mg/l)
3 x week
pH
3 x week
1 x month
3 x week
Viscosity
VFA (mg/l)
Ammonia (mg/l)
3 x week
Nitrate (mg/l)
3 x week
3 x week
TKN (mg/l)
Sulfate (mg/l)
3 x week
daily
daily
Temperature (F)
Iron Salts (mg/l)
Polymer (lb/ton)
daily
Capture rate (%)
daily
Operation (hr/d)
daily
# of Duty Units
daily
1 Conduct 1 week of more intensive dewatering tests to characterize dewatering variability between each
digester.
2 If bottom sludge is withdrawn from the digesters, the volume and solids should be recorded.
Biogas and Co-Generation System Parameters

Table 2-3 provides the data to be collected to develop the baseline prior to installation of the
ultrasound systems. Gas flows, flared gas and electricity generation should be recorded
daily. Gas composition may be analyzed two to three times a week.
PDX\040230003.DOC
2-13
TABLE 2-3
Baseline Data Collection for Biogas and Co-gen System

Digester Gas from
each digester
Landfill
Gas
Natural
Gas
Total (entire
Co-gen)
Frequency
Daily Flow (scfd)
daily
Methane (%)
weekly
H2S (ppm)
weekly
BTU
End of each phase
Daily electricity (kW)
Daily amount Flared (scfd)
Parameter
Ultrasound System Parameters

During the phase when the ultrasound systems are on line, the testing described above in
the baseline section will be continued. In addition, weekly tests will be conducted for the
following additional parameters:
COD, soluble COD, and viscosity in an out of each ultrasound system

Microscope analyses for filaments in an out of each ultrasound system
City of Riverside plant staff assistance will be required to check operation of the ultrasound
systems. Both units will be provided with control panels for automated operation. A log
sheet will be provided for once daily monitoring of the systems, which will include:
Electricity used by each ultrasound system;

Daily recording of line pressure in and out of the ultrasound systems;
Number of units operational;
Power draw for each unit; and
Flow rate through the two ultrasound systems
Test Procedures
The parameters listed in Table 2-2 and Table 2-3 will be measured using existing plant
equipment and sample procedures. Flow measurements will be made with existing solids
flow and gas flowmeters, which will be calibrated before the start of the test, and will be
cross-checked with strap-on flowmeters. The flowmeters will be checked every six months
during the test. Chemical data for the digester feed and exit sludges and biogas will be
conducted using the standard methods for laboratory analysis of the listed parameters.
Tests that the City of Riverside laboratory is not certified to conduct will be sent to a
certified external laboratory.
Digester temperature measurements will be taken from on-line temperature sensors on the
digester recirculation lines, with additional daily manual readings, as currently done by
plant staff. Iron salt addition and dewatering polymer use will be calculated from the volumes and concentration of chemicals used, as currently monitored at the plant. Dewatering
capture rate will be calculated from solids measurements in the feed biosolids and in the
2-14
USR040230003.DOC
filtrate. The hours of operation and number of dewatering units in use will be recorded by
plant staff, and cross-checked with digested biosolids flows to the dewatering facility.
Ultrasound operating parameters will be recorded by the plant staff in a daily operating log,
using meters installed on the two systems. Chemical and microscope analyses of the
sonicated TWAS will be conducted by the City of Riverside laboratory, or by a certified
external laboratory.
2.4.8 Data Analysis Procedures

A detailed procedure will be developed to analyze the extracted data during the testing
phases. This will include development of a daily log sheet for recording operational
parameters of the ultrasound units and digesters. Information from the log sheets will be in
a format that can be easily input into an Excel spreadsheet. On-line data collected by the
plant, such as flow rates, and laboratory data will input into Excel spreadsheets. Data
analysis will consist primarily of monitoring trends in digester performance (volatile solids
reduction, biogas production - quality and quantity) using daily data, as well as moving
averages to provide long term trends. In addition to the digester performance, the
dewaterability of the biosolids will be documented and the energy demand of the
ultrasound system will be documented. Data will be updated and reviewed at least every
two weeks, as the laboratory analysis data becomes available.
Another excel spreadsheet will be created with the raw data and the calculations to
determine the operational cost for each ultrasound pilot system.
2.4.9 Quality Assurance Procedures

There are two important aspects with experimental quality assurance and control. The first
is the assurance of good sample collection and shipping methods. The appropriate sample
collection points and collection times will be demonstrated to the plant operators. The
samples will be collected by the operators in appropriate bottles provided by the laboratory
that will be conducting the tests. For samples sent to an external laboratory, the sample
bottles should be stored on ice and shipped in coolers on the same day if possible, or before
10:00 a.m. the next morning for samples taken later in the day. When same day shipping is
not possible (usually weekends and evenings), the sample bottles will be preserved, stored
(usually at 4C) and shipped the next morning to ensure that the appropriate procedures
and holding times are met, as specified by the analytical laboratory.
The second aspect lies with the laboratorys procedures and QA/QC methods. As the
laboratory analysis will be conducted by the Plants certified laboratory or by an external
certified laboratory, the laboratory staff should be familiar with standard sample storage,
analysis and QA/QC procedures. When immediate analysis is not possible (usually
weekends and nights), the sample bottles will be preserved, stored (usually at 4C) and
delivered to and analyzed in accordance with appropriate procedures and holding times, as
specified by the analytical laboratory. Replicate samples and split sample analysis will be
conducted occasionally to verify reliability of results.
PDX\040230003.DOC
2-15
2.4.10 Contingency Measures

As shown on the Process Flow Diagram, a bypass line will divert the TWAS flow to the
digesters when triggered by a high level signal on TWAS holding tank or plants shutdown.
Sonico ultrasound unit employs redundant horns to maintain the normal operation in case
of failure of the other horns. IWE Tec will have spare horns and parts available to allow
bringing the system back-on-line in the event of equipment malfunction.
The testing period will be extended up to two months (3 HRT Cycles), if the ultrasounds
units happen to be offline for more than two weeks.
2.5 Existing Data Summary Table

Table 2-4 provides a summary of available plant operating data for January through midNovember 2003. During this period, Digesters #1 and 2 were in operation. Once Digester #4
is brought online, it is anticipated that approximately one-third of the TWAS and primary
sludge flows will be sent to this digester, reducing the loading rates on the current digesters,
and increasing the overall retention time.
TABLE 2-4
Plant Data
Description
Unit
Min
Max
Avg
MGD
0.08
0.19
0.12*
PS % TS
Percent
2.55
5.85
4.35
PS % VS
Percent
43.82
85.57
79.89
DAF In Flow
MGD
0.16
0.79
0.55
DAF Eff Flow*
MGD
0.04
0.17
0.11*
DAF % TS
Percent
2.99
5.62
3.74
DAF % VS
Percent
63
90
78.13
MGD
0.124
0.27072
0.23*
Dig 1 pH
SU
6.94
7.81
7.49
Dig 1 VA
mg/l
26
425
82
Dig 1 Alk
mg/l
2,777
3,916
3,447
Dig 1 VA/Alk
ratio
0.01
0.13
0.02
Dig 2 pH
S.U.
7.3
7.8
7.5
Dig 2 VA
mg/l
23
367
70
Dig 2 Alk
mg/l
2,882
4,239
3,588
Dig 2 VA/alk
ratio
0.01
0.11
0.02
Dig In % TS
Percent
3.1
5.1
4.0
Dig In % VS
Percent
72
86
79
AVG VS Reduction
Percent
4.01
66
50
DIG 1&2 Eff % VS
Percent
54
79
65
Primary Solids Flow*
Total Dig Flow*
2-16
USR040230003.DOC
TABLE 2-4
Plant Data
Description
Unit
Min
Max
Avg
BP In Flow
MGD
0.43
0.23
BP In % TS
Percent
1.5
2.6
2.2
BP dtpd
Tons
42
21
BP wtpd
Tons
342
171
BP CAKE % TS
Percent
10.6
16.4
12.5
Dig 1 Temp
Deg. C
36
41
39
Dig 2 Temp
Deg. C
36
41
39
Dig Detention
Days
12
26
14
Combined Dig H2S
ppm
25
111
73
Landfill Gas H2S
ppm
91
10
Total H2S
LBS/Day
1.340
6.877
3.523
Landfill Gas H2S
LBS/Day
0.6
2.6 Mass and Energy Balance

As part of the baseline test phase, a mass and energy balance will be conducted to ensure
that the data being collected are robust. The energy balance will reflect planned operational
changes at the plant, including use of a third digester and addition of polymer to the DAFTs
to increase thickness of the TWAS.
2.7 Test Recommendations and Schedule

The test recommendation is to proceed with side-by-side evaluation of two different
ultrasound systems for enhanced biogas production at the City of Riverside sewage
treatment plant. The two systems will be installed on Digesters #1 and 2, which are
currently the only two digesters in operation. A pretest phase will be conducted to verify
accuracy of on-site equipment and ensure the digesters are operated under similar
conditions and loads. This will be followed by the baseline phase, with the digesters
operated under similar conditions as the ultrasound testing phase. It is necessary that
Digester #4 be operational prior to the start of the baseline phase. The ultrasound testing
phase will be followed by a continuation phase, to track the return of the digesters to preultrasound performance once the units are turned off. Table 2-5 summarizes the schedule
for the four phases.
PDX\040230003.DOC
2-17
TABLE 2-5
Enhanced Anaerobic Digestion Test Schedule

Phase
Duration
Date
Pretest Phase
1 month
April 2004
Baseline Phase
3 months
May July 2004
Ultrasound Phase
6 months
August 2004 January

2005
Continuation Phase
3 months
February April 2005
2-18
USR040230003.DOC
SECTION 3
Microturbine Gas Cleaning
The purpose of the microturbine gas cleaning pilot test is to collect and analyze data for
different technologies to determine their efficacy in removing hydrogen sulfide and
siloxane. This section discusses the pilot testing site location, the technologies to be tested,
the process flow diagram, the testing plan, and the test recommendations and schedule.
The biogas used for operating microturbines must meet stringent quality requirements
(maximum of 150 parts per million [ppm] moisture, 25 ppm hydrogen sulfide [H2S], and 10
ppbv siloxanes) to prevent early deterioration of the microturbines. The biogas produced in
the digesters at a wastewater treatment plant is typically saturated and contains
approximately 500 to 2,000 ppm H2S, and 2 to 5 ppm siloxane. Biogas from manure
digestion is also saturated, contains approximately 500 to 2,000 ppm H2S and typically no
siloxanes. The content of each of these contaminants needs to be decreased to meet the
biogas quality stated above.
3.1 Site Description

The IEUA has microturbines at RP-1. RP-1 is located toward the center of the mini-grid and
has seven anaerobic digesters, an iron sponge system to remove H2S, biogas compressors
and storage, an energy recovery building, a waste gas burner, and eight microturbines. Six
of the seven digesters at RP-1 process the solids from municipal waste. Digester No. 4 is
used to process dairy manure.
The RP-1 facility has been selected to conduct the biogas cleaning pilot test program because
it has microturbines and biogas generated using both municipal waste and manure. To
control H2S in the biogas from digestion of municipal waste, iron salts are being added at
the Headworks to minimize H2S formation during digestion. The biogas is further treated
using an iron sponge. There is no siloxane removal for the internal combustion engines, but
carbon filters are used to reduce H2S levels in the biogas used in microturbines. The biogas
produced from manure typically is saturated and has high H2S concentration, but is
typically free of siloxanes. To reduce H2S levels in the manure digester biogas, iron salt is
added directly to the digesters and the biogas is further treated through an iron sponge.
3.1.1 General Map, Address, Contact Information, Plant Layout

The selected site, RP-1, is located at 2450 E. Philadelphia, Ontario, CA, 91761. Figure 3-1
contains RP-1 location and vicinity maps. The main contacts for the Biogas Cleaning Pilot
Test Program are listed in Table 3-1.
Figure 3-2 contains the overall plant layout for RP-1. This layout shows the location of the
existing digesters (northwest quadrant of the site); iron sponges, gas compressors and gas
storage (southeast of the digesters) and microturbines (north of the Control Building).
USR040230003.DOC
3-1
MICROTURBINE GAS CLEANING
FIGURE 3-1
Location Maps for RP-1 and Vicinity

The push-pin indicates the location of RP-1.
Location Map
Vicinity Map
TABLE 3-1
Project Team Members Contact Information

Name
Eliza Jane Whitman
Ryan Gross
Company
IEUA
6075 Kimball Ave

Chino, CA 91710
CH2M HILL
825 NE Multnomah,
Suite 1300, Portland,
OR 97232
CH2M HILL
3 Hutton Centre Dr.,

Suite 200, Santa
Ana, CA 91707
Bill Kitto
Fred Soroushian
Carmen Quan
3-2
Address
Telephone
909-993-1685
909-993-1699
Fax
909-357-3884
E-mail
Ewhitman@ieua.org
rgross@ieua.org
Bkitto@ch2m.com
714-435-6232
714-424-6232
Fsoroush@ch2m.com
714-435-6117
714-424-2063
Cquan@ch2m.com
USR040230003.DOC
FIGURE 3-2
Plant Layout for IEUA RP-1 Facility
USR040230003.DOC
3-1
3.1.2 Potential Sites at RP-1

Figure 3-3 shows the sites for locating the test pilot equipment. These sites are identified as
A, B and C. Site A is located next to the existing iron sponges and gas compressors, which
makes it suitable for installing the pilot test equipment for the gas drying system. The main
biogas header is buried west of the Energy Recovery Building and becomes exposed (above
ground) south of the iron sponges. The gas compressors are located only a few feet north of
the iron sponges and the exposed main biogas header with low levels of H2S and high
pressure is located East of the compressors and easily available for tapping and feeding the
gas drying pilot test equipment. The location of utilities in the area will require further
investigation.
Site B is located north of digester No. 4 (the manure digester). The H2S removal pilot test
equipment could be located in this area to test the H2S removal efficiency. This location has
number of advantages. One advantage is that digester No. 4 is isolated from the H2S
pretreatment system at RP-1, which consists of injecting ferric chloride at the Headworks.
The H2S pretreatment is required to reduce the content of H2S in the biogas to comply with
the emissions established by the South Coast Air Quality Management District (SCAQMD).
Digester No. 4 has a dedicated ferric chloride injection system that can be turned on and off
without affecting the rest of the biogas quality. Another advantage is that the biogas
produced in digester No. 4 is from 100 percent manure digestion and contains high H2S
content (once the iron salt addition to the digester is stopped).
Site C is located close to the energy recovery building, south-east of the digesters. This site is
suitable for installing the packaged siloxane treatment system. The existing biogas header
feeding the existing microturbines is located near site C. This header could be isolated from
the existing system to allow operating the existing microturbines with the cleaned biogas
from the packaged system.
3.2 Gas Cleaning Pilot System

The treatment process at RP-1 includes ferric chloride injection at the headwork to control
the H2S concentration in the biogas produced at anaerobic digesters No. 1 through 3 and 5
through 7. The amount of H2S in the biogas from these digesters is less than 100 ppm. Ferric
chloride is directly injected into digester No. 4 to maintain the amount of H2S in the biogas
at an average of 60 ppm. After the biogas is collected from all the digesters, it is treated with
iron sponges to further reduce the amount of H2S to approximately 5 ppm. The biogas
compressors are located downstream of the iron sponges and increase the biogas pressure to
40 pounds per square inch gauge (psig) before it is stored in the biogas storage system.
From the storage system the biogas is distributed to the engine generators, boilers and the
microturbines.
The proposed Gas Cleaning Pilot System consists of testing technologies that have the
potential to remove moisture, siloxanes and H2S; but that are neither being used in the USA
nor have been applied at the scale needed for microturbine gas treatment. These
technologies are gas drying, biological H2S removal system and a package system for
siloxane treatment. The proposed Gas Cleaning Pilot System equipment is described in the
next sections.
USR040230003.DOC
3-1
FIGURE 3-3
Potential Sites for Locating Test Equipment
3-2
USR040230003.DOC
3.2.1 Gas Drying

The selected technology for pilot testing is a refrigerated dryer for moisture removal and its
effects on siloxane removal through the condensate.
The refrigerated dryer system is skid mounted, suitable to handle biogas and consists of a
refrigeration unit, a vertical heat exchanger and a control. The heat exchanger module
utilizes a plate-to-plate precooler that lowers the refrigeration energy requirements. This
unit performs 3 functions, gas chilling, moisture separation, and condensate removal. The
unit is suitable to handle pressurized biogas between 20 and 300 psig. It handles biogas with
an inlet temperature of 150 degrees F and cools it to 40 degrees F dew point. The pressure
drop across the unit is 2 psig. The unit has a Class 1, Division 1 classification. The control
panel is explosion-proof rated.
The refrigerated dryer for this pilot test program will be sized to treat 50 standard cubic feet
per minute (scfm) of biogas. This is enough biogas to run four of the existing 30-kW
microturbines (12 scfm per microturbine).
3.2.2 H2S Removal

The H2S found in biogas can be removed through a biological process by bacteria. The
bacteria in this process oxidizes the sulfide to produce both elementary sulfur and sulfur
acid. The bacteria live naturally in nearly all substrates (soil, water, sludge and manure) and
require nutrients, oxygen/air, and humidity to live. The biological activity is temperature
dependent, and this process works more efficiently at a temperature of approximately 35C
(95F).
The biogas flows from the digester to the H2S removal tank, which is partially filled with
plastic or ceramic filter chips as growing media for the bacteria. The filter chips are
supported by grating at the tanks bottom. The removal tank also contains a mixture of
water and nutrient solution (N, P, and K with micronutrients), which is recirculated and
sprayed over the media. Artificial addition of substrate to the system is typically not
required because the bacteria enter the process tank with the biogas. Air is also added to the
biogas to provide the required oxygen for the bacteria. Since biogas/air mixtures with over
10 percent oxygen are combustible or explosive, less than 10% air is added to the biogas. For
safety reasons, the oxygen (O2) concentration and pH are continuously measured and
transmitted to the computer control system. The tank is provided with drain and overflow
nozzles (one each) to remove the surplus fluid.
The system for the pilot test will be sized to treat up to 100 scfm at 1,500 ppm H2S with turn
down to 50 scfm at 500 ppm H2S content.
3.2.3 Package Siloxane Treatment System

There are two companies that manufacture packaged systems to clean biogas. Applied Filter
Technology offers the SAGPack series. These are customized units designed and built to
match specific biogas cleaning requirements. These systems can include any combination of
compression, chilling, condensing/coalescing, siloxane removal, organic sulfur removal,
desiccation, and particulate filters.
PDX\040230003.DOC
3-3
The other company is Pioneer Air Systems, Inc. The gas drying unit in the Pioneer system
consists of cyclic refrigeration capable of achieving an outlet temperature of 20 degrees F.
The removal of siloxanes in the Pioneer system depends on liquid condensation (by
adsorption with the condensed water) and polishing with activated carbon.
Both these companies will be contacted to determine if a unit can be rented or obtained for a
low capital cost. If available, the unit will be tested and used to compare technologies for
siloxane removal.
The package system for this pilot test program will be sized to treat 50 scfm of biogas, which
is enough to run 4 of the existing 30-kW microturbines at RP-1.
3.3 Expanded Process Flow Diagram

Figures 3-4 and 3-5 contain the process flow diagram for the gas drying system and
biological H2S removal system, respectively. These diagrams include the major components
and instrumentation required for each of pilot test units. Figure 3-6 contains the process
flow diagram for the package system.
3.4 Test Plan

3.4.1 Process Overview
As part of the Public Interest Energy Research (PIER) Program, a demonstration trial will be
conducted to investigate the economic, practical and technical benefits of microturbine gas
treatment technologies for removing moisture, siloxane and H2S.
The gas drying system for moisture removal will be installed downstream of the existing
gas compressors and will be physically located east of the existing gas compressors and iron
sponges. The biological H2S removal system will be installed north of digester No. 4 and this
technology will be compared to the existing chemical H2S removal system using ferric
chloride. The packaged siloxane treatment system will be located south-east of the digesters,
close to the energy recovery building. The pilot test equipment will be installed outdoors
and temporary piping will feed each of the systems.
3.4.2 Rationale for Test

Use of biogas in microturbines requires removal of moisture, H2S, and siloxane. Most of the
gas treatment technologies currently in use are either too costly or not available at the scale
needed for microturbines. Some technologies could potentially remove multiple
contaminants from biogas. For example, moisture removal through refrigeration also allows
condensation of the siloxanes in the biogas. This removal efficiency needs to be investigated
to determine if using refrigerated gas drying would significantly reduce the size of the
required siloxane removal system.
3-4
USR040230003.DOC
FIGURE 3-4
Process Flow Diagram for Biogas Drying System

BIOGAS REFRIGERATED DRYER
FIQ
PI
TI
PI
TI
BIOGAS
FROM EXST
GAS
COMPRESSORS
DRIED
BIOGAS
TO
HEADER
SAMPLE
POINT
SAMPLE
POINT
REFRIGERATION
CIRCUIT
CONDENSATE
SAMPLE POINT
FIGURE 3-5
Process Flow Diagram for Biological H2S Removal System
BIOLOGICAL H2S REMOVAL SYSTEM

CONDENSER
/ DRYER
S
WATER
SUPPLY
FIQ
PI
TI
BLOWER
NPK
NUTRIENTS
H2S REMOVAL
TANK
PI
RECIRC PUMP
BIOGAS
FROM
DIGESTER No. 4
SAMPLE
POINT
TI
H2SREDUCED
BIOGAS
TO
BIOGAS
HEADER
SAMPLE
POINT
TO
DISPOSAL
CONDENSATE
SAMPLE POINT
PDX\040230003.DOC
3-5
FIGURE 3-6
Process Flow Diagram for Biogas Cleaning Package System
BIOGAS GAS CLEANING PACKAGE

SYSTEM
FIQ
BIOGAS
FROM EXST
GAS
COMPRESSORS
PI
PI
TI
TI
CLEANED
BIOGAS
TO
MICRO
TURBINES
SILOXANE
REMOVAL
MODULE
GAS COOLING
MODULE
SAMPLE
POINT
SAMPLE
POINT
CONDENSATE
SAMPLE POINT
SAMPLE
POINT
Current technologies for H2S removal require either chemical feed (i.e., iron salts) or media
replacement (i.e., iron sponge), which typically result in high operating costs. Local
experience in operating the biological H2S removal system (level of difficulty and
operational labor requirements) needs to be acquired and documented to analyze this
system. This is also the case for the packaged siloxane removal system.
The proposed technologies (refrigerated dryer and biological H2S removal) for this pilot test
program have the potential of substantially reducing the gas treatment cost. However, the
available data for these systems is not comprehensive to allow analysis of their efficiency or
cost effectiveness.
The purpose of the Digester Gas Cleaning Pilot Test program is to collect the necessary
information to determine the removal efficiency and cost effectiveness of these technologies.
3.4.3 Predicted Performance

The expected removal performance for the proposed technologies is based on available
empirical data.
Experimental data shows that existing biogas cleaning units can reduce H2S concentration
by 90 percent99 percent. This means that an H2S concentration in the 2,000 ppm range
before treatment can be reduced to lower than 20 ppm after treatment. Bench scale testing
for siloxane removal using refrigeration and condensation, indicate a reduction of over
50 percent of the siloxane concentration.
3.4.4 Test Objectives and Technical Approach

There are 2 main test objectives for this pilot program. One of them is to obtain the
necessary data to determine the contaminant removal efficiency for each of the technologies.
3-6
USR040230003.DOC
The other is to obtain the necessary data to determine the cost effectiveness of operating
each of these technologies.
The pilot test equipment and system design will include sample ports and instrument ports
to facilitate the collection of samples and measuring of parameters necessary to achieve the
goals of this program. Before starting the design of the digester cleaning pilot test system, it
will be necessary to analyze the composition of the biogas in the main header and in
Digester No. 4. This is required to optimize the size of the pilot test equipment.
For the gas drying system, samples of the biogas will be taken upstream and downstream of
the refrigerated dryer once a week. These samples will be sent to the laboratory to test the
moisture and siloxane content in the biogas samples and the results recorded. Samples of
the condensate will also be collected once a week and sent to the laboratory to test its
composition and pH and the results will be recorded. Condensate testing will help in
determining the alternatives for its disposal. In addition, the pressure and temperature of
the biogas and the power consumed by the refrigerated dryer will be recorded daily. A
flowmeter with a totalizer will be provided upstream of the gas drying system to measure
and record the biogas flow daily. The daily amount of condensate will also be measured and
recorded.
The influent and effluent pipes of the biological H2S treatment system will be provided with
ports to collect biogas samples once a week. These samples will be sent to the lab to test the
H2S content in the biogas and the results recorded. The temperature and pressure of the
biogas and the amount of air supplied to the system will be recorded daily. The amount of
power consumed by the entire system (recirculation pump, motorized valves and the air
compressor supplying the air to the system) will be measured and recorded daily. A
flowmeter with a totalizer will also be provided upstream of the biological H2S treatment
system to measure and record the biogas flow daily.
The packaged siloxane treatment system pilot unit will be furnished with ports upstream
and downstream of each of its main elements to collect samples of biogas to test the
moisture and siloxanes content. If the package unit produces condensate, a sample will be
collected and its composition tested, as well. These samples will be collected and send to the
laboratory once a week and the results recorded. The pressure and temperature of the
biogas and the power consumed by each of the elements in the package unit will be
recorded daily. A flowmeter with a totalizer will also be provided upstream of the gas
drying system to measure and record the biogas flow daily. The daily amount of condensate
will also be measured and recorded.
3.4.5 Facilities, Equipment, Instrumentation to Conduct Test

The equipment required to collect a biogas sample is a Tedlar bag or a field test kit supplied
by the laboratory where the testing will be conducted. Each of the sample ports will require
a manual valve to fill the biogas container for the sample. A request for proposal will be sent
to laboratories with the capability to test for siloxanes, moisture, H2S, and other common
biogas constituents. The laboratory to conduct the biogas testing for this pilot program will
be selected based on the technical merits and cost included in the submitted proposals.
A power meter with totalizer will be used to measure the electricity consumed by each of
the systems. The reading and recording of this parameter will be done manually.
PDX\040230003.DOC
3-7
Pressure gauges and thermowells will be used to measure the pressure and temperature of
the biogas. The reading and recording of this parameter will be done manually.
A thermal mass flowmeter with totalizer will be used to measure the flow of biogas. The
reading and recording of this parameter will be done manually.
3.4.6 Test Procedures

Biogas testing needs to be performed once a week for each of the pilot testing equipment.
The procedure will be as follows: a biogas sample will be collected at each of the sample
ports (identified under Article 2.4.3) and sent to the laboratory for testing. The laboratory
will perform three primary testsEPA TO-14 to test for volatile organics, ASTM Procedure
D-5504 GC/SCD for sulfur species, and SIL GC/MS test for individual siloxane species. The
test results will be recorded. It is expected that the biogas samples will be collected by
personnel from the laboratory.
For all pilot systems, the testing program also will include daily monitoring and recording
of biogas flow, temperature and pressure, and equipment power consumption.
The testing program for the gas drying and the package system will require weekly
collection and analysis of the condensate as well as recording of these results. The
condensate from the drying equipment will be collected in a container and its volume
measured and recorded daily. The temperature of the condensate will be measured and
recorded before disposal.
Table 3-2 contains a summary of the recommended sample collection, tests, data
monitoring, data recording, and a schedule for each.
TABLE 32
Sampling Plan
Sample/Parameter Monitored
Test
Frequency
Biogas upstream of equipment
Moisture/siloxane
Once a week
Biogas downstream of equipment
Moisture/siloxane
Once a week
Temperature
--
Once a day
Pressure
--
Once a day
Flow
--
Once a day
System power consumption
--
Once a day
H2S
Once a week
H2S
Once a week
Temperature
--
Once a day
Pressure
--
Once a day
Flow
--
Once a day
System power consumption
--
Once a day
Gas Drying System
Biological H2S Removal System
3-8
USR040230003.DOC
TABLE 32
Sampling Plan
Sample/Parameter Monitored
Test
Frequency
Siloxane
Once a week
Siloxane
Once a week
Temperature
--
Once a day
Pressure
--
Once a day
Flow
--
Once a day
Motor 1 power consumption
--
Once a day
Motor 2 power consumption
--
Once a day
Package System
Each of the equipment systems that will be used in this pilot testing program is provided
with its own proprietary control system for proper and safe operation. The refrigerated
system contains the controls for the refrigeration cycle. The packaged siloxane removal
system is provided with controls for the condensation cycle (the siloxane removal process
uses media and does not require control).
The biological H2S removal system is provided with equipment, instrumentation,
appurtenances and a PLC unit to control the process. The air compressor supplying the
necessary air to the process is controlled by an oxygen sensor. If the oxygen sensor reaches
the high level setpoint, the air compressor stops operation. The pH of the fluid is also
measured on-line and allows water to enter the tank if the pH sensor reaches the low
setpoint. The system is also equipped with Drgertubes for local measurement of H2S.
The laboratory must follow the equipment calibration recommendations to meet the ASTM
and EPA requirements for the tests that are required above. Pressure gauges, thermowells
and power meters will require calibration every year. Thermal mass flowmeters will require
calibration every 3 months.
Other data that will be collected are the cost of supplies for each system and the labor hours
dedicated to the operation and maintenance of each system. The time to inspect instruments
and collect and record parameters will be documented separately for each system.
3.4.7 Data Analysis Procedures

The data will be input into an excel spreadsheet which will contain the necessary
calculations for the required analysis. The expected calculations are removal percentages for
H2S, moisture, and siloxanes.
Another excel spreadsheet will be created with the raw data and the calculations to
determine the operational cost for each pilot system.
PDX\040230003.DOC
3-9
3.4.8 Quality Assurance Procedures

The proposals from the laboratories will require submission of their quality assurance
program for sample collection and testing. As a minimum, the laboratories quality
assurance programs will be required to meet EPA and ASTM standard.
In the field, the collection of the condensate samples will be done using sterilized containers.
Immediately after collecting the sample, the container will be labeled with the sample
number, source, date and time.
The person performing the daily collection of data from instruments will be required to fill
in the form: the area where the instruments are located, the date, and time. The order in
which the person collects the data also will be established to ensure all readings are taken
and recorded. An hour prior to collecting data, the person will be required to check the
instruments to ensure they are in working order. Repair of the non-operating instruments
will be required prior to taking any readings.
3.4.9 Contingency Measures

The size of the biogas samples will be large enough to allow performing two of each of the
three tests required. The unused portions of the biogas samples will need to be refrigerated,
in case the tests have to be performed a second time. The pilot systems will be provided
with the bypass lines to prevent disruption of plant operation in case of an equipment
malfunction.
3.5 Existing Data Summary Table

The appendix contains the tables summarizing the monthly biogas production at RP-1.
3.6 Energy Balance

An energy balance will be performed for each of the systems being piloted. The power
consumed by the equipment for each of the pilot systems will be considered a parasitic load
when performing the energy balance for each pilot system.
For instance, for the gas drying system, the power consumed by the refrigeration unit will
be recorded and subtracted from the net energy generated by the microturbines. The
parasitic loads of the microturbines will be included in the calculation, but their effects kept
separately from that of the refrigeration value.
The same procedure will be used to calculate the energy balance for the biological H2S
removal system and the packaged system. The power consumption for the biological H2S
removal system will be measured at the control panel and will be recorded as a total
number. For the packaged system, the power consumption for each motor will be recorded
to allow preparing separate energy balances for each of the treatments.
3-10
USR040230003.DOC
3.7 Test Recommendations and Schedule

The test recommendation is to proceed with pre-testing of the biogas to optimize the size of
the different equipment for the pilot test program (Gas Drying, Biological H2S Removal
System and Package System equipment).
The existing method for removal of H2S in Digester No. 4 (ferric chloride injection) needs to
be tested to establish the removal efficiency baseline for this H2S removal technology. Once
the baseline is established, the Biological H2S Removal testing phase will start.
For the Gas Drying and Packaged System, the baseline and actual testing will be done
concurrently. Samples will be taken upstream and downstream of each pilot system and
each existing system. The baseline for the Gas Drying system will be the series of existing
biogas storage tanks and for the Package system the baseline will be the existing carbon
units on the microturbines.
For the Microturbine Gas Cleaning pilot program, a continuation test phase is not required.
Table 3-3 summarizes the schedule for the different technologies and corresponding phases.
TABLE 3-3
Microturbine Gas Cleaning Test Schedule

Phase
Duration
Date
Pretest Phase (all pilot technologies)
1 month
May 2004
Baseline Phase for Biological H2S Removal
1 month
June July 2004
Biological H2S Removal Phase
4 months
October 2004
February 2005
3 months
October 2004
January 2005
Gas Drying and Package System Phase
(1)
(1)
Baseline and technology phase testing for these technologies will be done concurrently.
A continuation phase is not required for any of these technologies.
PDX\040230003.DOC
3-11
Appendix
RP-1 Gas Production 2002 Data
USR040230003.DOC
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Commonwealth Energy Biogas/PV Mini-Grid

Renewable Resources Program

Contract No. 500-00-036

Bill Kitto, CH2M HILL, Santa Ana, California

1104 Main Street, Suite 630

Introduction ......................................................................................................................... 1-1

Enhanced Anaerobic Digestion Site Selection.............................................................. 2-1

Microturbine Gas Cleaning .............................................................................................. 3-1

Enhanced Anaerobic Digestion Test Matrix .................................................................... 2-11

Riverside Process Flow Schematic ...................................................................................... 2-3

Buildings End-Use Energy Efficiency

Enhanced Anaerobic Digestion

Process Definition and Equipment Vendors

Test Plans, Operating Data, and Schedule

Gas Cleaning for Microturbines

North of digester No. 4 (the manure digester)

Close to the energy recovery building, southeast of the digesters

Process Definition and Equipment Vendors

Test Plans, Operating Data, and Schedule

1.2 Results of Project 1.1Planning and Analysis

1.3 Overview of Project 2.2

Develop and optimize cost-effective gas cleanup systems.

1.4 Report Content and Organization

Section 1 introduces the Commonwealth Energy program, provides background

Enhanced Anaerobic Digestion Site

2.1 Site Description

2.1.2 Potential Test Sites at the Plant

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

Adjacent to the DAFT pump room

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

Riverside Process Flow Schematic

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

City of Riverside Sewage Plant Layout

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

2.1.3 Recommended Location

2.2 Ultrasound Pilot System

2.2.2 IWE Tec Equipment Description

Increase in the maximum amplitude from 25 m to 50 m

Increase in volatile solids destruction of 20-25 percent

Actual results vary depending on digestion performance without ultrasound, digester

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

2.2.3 Sonico Pilot Equipment Description

Increase in the maximum amplitude from 12 m to 16 m

Increase in volatile solids destruction of 30-50 percent

Actual results vary depending on digestion performance without ultrasound, digester

2.2.4 Scope of Supply

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

2.2.5 Required Ancillary Equipment

2.3 Expanded Process Flow Diagram

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

Process Flow Diagram

(Please see attached .pdf file)

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

2.4 Test Plan

2.4.2 Rationale for Test

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

2.4.3 Predicted Performance

2.4.4 Test Objectives and Technical Approach

Establish robust baseline performance data for the test digesters

ENHANCED ANAEROBIC DIGESTION SITE SELECTION

Evaluate performance of two digesters, each with a different ultrasound system

2.4.5 Test Matrix

Enhanced Anaerobic Digestion Test Matrix

With IWE Tec