c
EPA-600/2-82-001d
cNVIKONMtNTAk
PROTECTION
AGENCY
DALLAS, TEXAS
LIBRARY
TREATABILITY MANUAL
VOLUME IV. COST ESTIMATING
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
APRIL 1983
(REVISED)
-------
PREFACE
In January, 1979, USEPA's Office of Enforcement and Office of Water
and Waste Management requested help from the Office of Research
and Development in compiling wastewater treatment performance
data into a "Treatability Manual."
A planning group was set up to manage this activity under the
chairmanship of William Cawley, Deputy Director, Industrial
Environmental Research Laboratory - Cincinnati. The group in-
cludes participants from: 1) the Industrial Environmental
Research Laboratory - Cincinnati; 2) Effluent Guidelines Divi-
sion; 3) Office of Water Enforcement and Permits; 4) Municipal
Environmental Research Laboratory - Cincinnati; 5) R.S. Kerr,
Environmental Research Laboratory - Ada; 6 Industrial Environ-
mental Research Laboratory - Research Triangle Park; 7) WAPORA,
Incorporated; and 8) Burke-Hennessy Associates, Incorporated.
The objectives of this program are :
• to provide readily accessible data and information on
treatability of industrial waste streams;
• to provide a basis for research planning by identifying
gaps in knowledge of the treatability of certain pollut-
ants and waste streams.
The primary output from this program is a five volume, Treatabil-
ity Manual. This was first published in June 1980, with revisions
made in September 1981 and August 1982. This publication re-
places Volume I in its entirety, and updates Volumes II, III,
IV, and V. The individual volumes are named as follows:
Volume I
Volume II
Volume III
Volume IV
Volume V
Treatability Data
Industrial Descriptions
Technologies
Cost Estimating (In the process of re-
vision for later publication)
Summary
i i i
-------
ACKNOWLEDGEMENT
The development of this revision to the Treatability Manual has
resulted from efforts of a large number of people. It is the
collection of contributions from throughout the Environmental
Protection Agency, particularly from the Office of Water Enforce-
ment, Office of Water and Waste Management, and the Office of
Research and Development. Equally important to its success were
the efforts of the employees of WAPORA, Inc., and Burke-Hennessy
Associates, Inc., who participated in this operation.
A list of names of contributors would not adequately acknowledge
the effort expended in the development of the manual. This
document exists because of the major contributions of numerous
individuals within EPA and the EPA contractors, including:
Effluent Guidelines Division
Office of Water Regulations and Standards, Office of
Water
Permits Division
Office of Water Enforcement and Permits, Office of
Water
National Enforcement Investigation Center
Office of Enforcement
Office of Research and Development
Center for Environmental Research Information
Municipal Environmental Research Laboratory
Robert S. Kerr Environmental Research Laboratory
Industrial Environmental Research Laboratory
Research Triangle Park, NC
Industrial Environmental Research Laboratory
Cincinnati, OH
As Committee Chairman, I would like to express my sincere appre-
ciation to the Committee Members and others who contributed to
the success of this effort.
William A. Cawley, Deputy Director,
lERL-Ci
Chairman, Treatability Coordination
Committee
i v
-------
TABLE OF CONTENTS
PREFACE ii
ACKNOWLEDGEMENT iii
IV.1 Introduction IV.1-1
IV.2 Cost Analysis Approach IV.2-1
IV.2.2 General Factors in Cost Analysis IV.2-1
IV.2.2.1 Standard Elements of a Cost Analysis. . IV.2-1
IV.2.2.2 Basic Levels of Capital Cost Estimating IV.2-2
IV.2.2.3 Consideration of Retrofit Costs .... IV.2-5
IV.2.3 Cost Data Format IV.2-6
IV.2.3.1 Technology Cost Sections IV.2-6
IV.2.3.2 Work Sheets IV.2-9
IV.2.3.2.1 Technical Work Sheet IV.2-9
IV. 2. 3. 2.2 Summary Work Sheet IV. 2-16
IV.2.3.2.3 Summary on the Use of
Work Sheets IV.2-17
IV.2.4 Cost Index IV.2-17
IV.3
Technology Cost Data
IV. 3
IV. 3
. 1 Physical/Chemical
IV.3.1.1A Activated Carbon Adsorption . .
IV. 3.1. IB Carbon Regeneration ,
IV.3.1.2A Chemical Oxidation
IV. 3. 1.3 Reserved
IV. 3. 1.4 Reserved
IV. 3. 1.5 Precipitation and Coagulation/
Flocculation
IV. 3. 1.6 Reserved
IV. 3. 1.7 Reserved
IV. 3. 1.8 Reserved
IV. 3. 1.9 Filtration
IV. 3. 1.10 Flotation
IV. 3. 1.11 Flow Equalization
IV. 3. 1.12 Reserved
IV.3.1.13A Neutralization
IV.3.1.13B Liming to High pH
IV. 3.1.13C Lime Handling
IV.3.1.14A Oil Separation
IV. 3. 1.15 Reserved
IV. 3. 1.16 Reserved
IV. 3. 1.17 Reserved
IV. 3. 1.18 Sedimentation
IV. 3. 1.19 Stripping
.2 Biological
IV.3.2.1A Activated Sludge
IV. 3. 2. IB Aeration
IV. 3. 2. 1C Nutrient Addition
IV. 3. 2. ID Heating/Cooling
IV. 3. 2. 2 Reserved
. . . IV. 3-1
-IV.3.1.1-A1
. IV.3.1.1-B1
.IV.3.1.2-A1
IV.3.1.5-A1
.IV.3.1.9-A1
IV.3.1.10-A1
IV.3.1.11-A1
IV.3.1.13-A1
IV.3.1.13-B1
IV.3.1.13-C1
IV.3.1.14-A1
IV.3.1.18-A1
IV.3.1.19-A1
IV.3.2.1-A1
IV.3.2.1-B1
IV.3.2.1-C1
IV.3.2.1-D1
Date: 4/1/83 v
-------
TABLE OF CONTENTS (CONCLUDED)
IV.3.2.3A Nitrification , . IV.3.2.3-A1
IV.3.2.3B Denitrification IV.3.2.3-B1
IV.3.3 Reserved
IV.3.4 Disposal
IV.3.4.1
IV.3.4.2
IV.3.4.3A
IV.3.4.4
IV.3.4.5A
IV.3.4.5B
IV.3.5 Miscell
IV. 4 Industry Cost Data IV. 4-1
IV. 5 Computer Cost Models IV.5.1-1
IV.5.1 General Discussion IV.5.1-1
IV.5.2 Contractor Developed Design and Cost
Model-Overview IV.5.1-1
IV. 5. 2.1 Model Operating Sequence IV. 5.1-3
IV.5.2.2 Major Files IV.5.1-4
IV.6 References IV.6-1
Gravity Thickening . . .
Digestion
Dewatering
Combustion
Landfill
Outside Contractor.
teous Costs
. . . IV.3.4.1-A1
. . . IV.3.4.2-A1
. . . IV.3.4.3-A1
. . . IV.3.4.4-A1
. . IV.3.4.5-A1
. . . IV.3.4.5-B1
. . . IV.3.5-A1
Date: 4/1/83 vi
-------
CO
«*
— PO PO PO PO PO PO PO PO M PO rt PO PO PO PO ro PO PO PO PO PO PO PO PO ro PO co PO co
•o
CO
»*
— UJ
— CO
.a
3
a.
cocococococococo
CO —
•p p
CO _
o o
o
COPOCOCOCOCOCOPOCOCOCOPOPOPO
OOOOCOOOCOCOCOCO000000000003
pOcOrOPOPOcococoPOcOPOcoroco
oooocooococooocooocooocooooo
copococoPOeocopOPOfOPOPO
oooocococooococococococo
o
O>-CMCOJ3-
r- CM PO d- IfN VO t- 00 ON T- T- r- I- r-
CQ CO CO CD 00 CO CO CO CO CD CO CO CO CO
I I I I I I I I I I I I I I
O i— CM
T- CM CO rf ITN \O h- 00 ON r- I- r-
<««<«««
I I I I I I I I I I I I
CM CM CM CM CM CM CM £M CVJ CM CM CM
CO CO PO PO CO CO CO CO CO (O CO CO CO CO PO PO PO PO CO CO CO CO CO CO CO CO PO PO CO CO CO PO CO CO PO CO CO PO PO PO
T3
*
— eg
Q.
co co co
c c c
Ol Ol Ol
C- £- t-
000
CO CO
c c
0101
!_ <_
00
CO CO CO CO
c c c c
Ol Ol Ol Ol
i. i. £- S-
0000
CO CO CO
c c c
Ol Ol Ol
i- i_ !_
000
cccccccccccccccccc
O) D^ O) Ol C^ Ol C7^ Ol CTl Cft Ol Ol Ol Ol Ol O) O> Ol
ooooooooooooooooooo
co
C
c
01
c
o
tl—
O
0)
o —
P
co _
a o
o
o
cc
a.
Ci.POPOCOPOCOCOCOCOPOPOPOPOCOCOCOCOCOPO
< CO
O co o co
CO—00
oo
ON
CD
4J
— — — X X r- r-
O
o o T- CM PO a- m vo r- co
CMCO ....--
ii i i i i i i i i i i i i i i i i i i
1-1- CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM
CO PO CO CO
Date; A/1/83
vii
-------
•o
CD
.C CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO -.-.-. . --_.____-,-_.,___-_.,.___
«* CCCCCCCCCCCCCCCCCCC CCCCCCCCCCCCCCCCCCCC
— w
— CO
£1
O- O O O O O O O O OOO O O O OO OO O OOOOOOOOOOOOOOOOOOOO
c
o
c*- — cooocococococococococococococococococo copocococococoeococococococococococococo
O -P CO «« W 00 00 00 00 00 00 CO 00 00 00 00 00 CO 00 00 00 CO 00 00 00 00 CO 00 00 CO OO CO 00 00 00 CO 00 00 00 CO
a> —
•P Q
co E
Q O
o
>— CMco-a-irNvor-oooNr
*- I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
CD 00 oo 00 00 00 00 00 CO 00 00 00 CO 00 00 00 CO 00 CO CO ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON
.Q r- t— f— t— r- i— f— r- t— T— r- r- T— T-r-r-r— r- r- f— r- r- r- r- r- r- T— r- r- r- r- r-t— r- r- r-T— r- 1—
E
z *~I *"1 *"I . . ""!"~. '". *"I *"! "~1 "~I *^"~. *"I "^"~. *"! "~I"~. *~. *"I"~. *"1 *~I
POCOcOCOPOCOCOPOPOPOPOfOPOCOcOcOcocOco cOrOPOPOCOcococOcococOPOPOcOcocococococo
CD
O
CO
O_
CO
^^ COCOCOCOCQCOCOCOCOCOCOCO COroCOCQCOCOCGCOCOCOCOCOCOCO (OCOCQCOroCDCCCUCOCOCOCOCQ
«* cccccccccccc cccccccccccccc ccccccccccccc
~~ co en en en en en en en en ^n en en en en en en en en en en en 01 CT en en CT en en en en en en en en en en en en 01 en
Q- OOOOOOOOOOOO OOOOOOOOOOOOOO OOOOOOOOOOOOO
to c
o o
^f €>- •"• PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO CO PO PO PO PO CO PO PO
>, O -4J 00 GO 00 00 00 CO 00 00 00 00 CO CO 00 OO CO CO 00 CO 00 00 00 00 00 00 00 00 CO CO OO CO CO 00 00 00 00 CO CO CO 00
°- Q)
o S«
0 co E
^ °3
—' CM CO d" IT\ NO r-CO ON T-r-i-r- r- CM CO J" iTl NO r- CO ON i- i- i- r- r-
COCO COCDCOCO CO CO COffi CO 03 OOOOOOOOOOOOOO
-. i. I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
^ CD COCOCOCOCOCOCOCOCOCOCOCO CO CO CO CO CO CO CO CO CO CO CO CO CO CO .3" J" J" ^ J" J" J" J" J" ^ J" J± J"
~ ^3 r- J- r- I-T-I- r- t- .-i- r- r- r- r- r- r- •- r- ,- r- i- r- r- r- r- r- i- t- r- r- r- i- ^ t- T- ^ ^ ^ r-
I i -:-»»:-:-:H-»: ->:H-:H-:-:-:-:-:-:-:-:-: ->»»»:•:-:-:•=-:
i PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO PO rO PO PO PO PO PO PO PO rO PO PO PO PO PO PO PO PO PO PO PO PO
o 5
^ co
a.
QJ —-_«._ .^____ — ___ — — — -_ _ _ — ____.«.____ — —,_«_ — ™._ —
J3 co co co 03 cococococococorococococococo COCOCOCOCOCOCOCOCOCOCOCOCOCOQCOCOCOCOCO co
u>* cccc cccccccccccccc cccccccccccccccccccc c
3 t-S-tltl iZs-S-S-t-Zs-t-i-S-S-S-S-S- 5.5.i.i_S-S-S.S.U!_S-i-!_!_S-S-i-!_S-!- 8-
OL OOOO OOOOOOOOOOOOOO OOOOOOOOOOOOOOOOOOOO O
c
o
C(_ — COCOCOCO COCOCOCOCOCOCOCOCOCOCOCOCOCO COfOCOCOCOCOCOCOCOCOCOCOCOCOCOCOCOCOCOCO CO
O -P COCOCOCO CO CO CO CO 00 CO 00 OO CO CO CO CO CO 00 CO 00 CO OO 00 OO CO OO CO OO CO 00 00 CO CO CO 00 CO CO 00 OO
Q) ............
a> —
Q O
o
T— ^- r- f— r— CMCO^lTNVOf^OOCTN*— 1— T— r-t— r-OJCO^'LfNVOr*^OOONr-r~T~r"'~r~'~'r~T~r~CNj ^~
i- I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
CO OOOO i- r- r-i- r-^- r- T-T-i- r- r- r- r- PO CO PO PO CO CO PO PO CO PO PO CO PO PO PO PO CO CO PO CO CO
jQ r- r- r- r- t- r- i- r- I- t- r- r- r-r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- r- t- r- r- r- r-
D r-r-r-r- r- r-1- r- r- r- I-I- r- r- r- r- t- r- r- r- r- r- r- r- r- r- r- r- T- r- r- r- r- r- r- r- t- r- t-
z
COCOCOCO COCOCOCOCOCOCOCOCOCOCOCOCOCO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO
0)
CO —
a.
Date; 4/1/83
viii
-------
•o
a>
^Z TO TO 03 TO TO TO TO TOTOTOTOTOTOTOTOTOTOTOTOTO Q3TOTOTOTOTOCDTOTOTOTO TO TO TO TO CO TO TO
<0* CCCCCCC CCCCCCCCCCCCC CCCCCCCCCCC CCCCCCC
— TO en en en en en en en cncncncncncncncncncncncncn cncncncncncncncncncncn en en en o) en en en
3 £- S- S- S- 1. S- S- I-S_I_I-t-!-!-l-!_!-S_!_I_ S_S_t-S-£_!_t_S_ZZs- t. Z Z Z Z Z Z
Q- OOOOOOO OOOOOOOOOOOOO OOOOOOOOOOO OOOOOOO
c
o
<»- — cococococococo cococococococococococococo cococococococococococo cococococococo
O 4-1 CO 00 00 00 00 00 00 00 OO 00 00 CO 00 00 00 00 CO 00 OO 00 00 CO 00 00 00 CO CO 00 00 OO CO 00 00 00 00 CO CO CO
eo —
•P Q
o o
O TO
o
O T— CM CO -d" IT\ O r— CM CO CL O *~
OX^T—^^r—r- ^ CVJ CO if Lft \O f"- CO O\ ^~ *~ r— *"" c/3 t— CM CO 43" lAVOr*—COON^~^~ CO II I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
— .Q r-f— T—r-T—r-t—r-f—f—r-r- f—r-r-T—i—f— r-t—*—t—r-r-t—t—t—r-»—t—f— COCOCOCOCOCOCOCO
^ 3 CVICM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CVI CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CM CVI CM CM
^ COCO COCOCOCOCOCOCOCOCOCO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO CO COCOCOCOCOCOCOCO
^ w
Cu
T3
OJ
^Z CCCQCOCO(OCQCOnCQCO(OCOCOCOQC(ICtICQCO(OCQCQCOCOCOnCOCQ CQCOmCGCQCOCOCOCOCQCCCQ
-------
— CTI cji tjt
woooooooooooooooooo
i-i.S-i.i-
O O O OO
to CD
C C
i. i.
OO
ci
o
(,—
O P
CD
CD —
p Q
to _
O O
O
o
o
eoeocoeoeococococotocotococoeoeotoeo
OoOOOOOOOCOCOOOCOCOOOOOCOCOOOCOOOOOcO
I- CO
—cvi co j-invo r-oo
COO\!-i— i— CM CO d" iTi \O r~ 00 O ' r- i— r- r- i— i- i- i— CM CM CM CM CM CM CM CM CVJ r- CVJ CO it \f\ VO h- 00
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I
CVJCV1CVJCV1 totococococococococofocococotorocototototocococococococo
to to co co co co co to to to co co to co co to to co eo co co co to co co eo co co to co to to co co eo co co eo to co
Date; 4/1/83
-------
IV.I INTRODUCTION
This volume presents procedures and cost data for estimating the
cost of industrial wastewater treatment systems on a unit process
basis. The emphasis in this volume is cost, with supporting
technical information concerning process design and performance
included only as necessary to develop costs from these data.
A brief overview of the cost estimating procedure used in this
volume is presented as a framework for understanding subsequent
cost data presentations. The unit process cost presentations are
grouped according to physical-chemical, biological, sludge treat-
ment, and disposal technologies and are numbered to correspond to
the technology descriptions in Volume III. A chapter has been
reserved for the possible future presentation of waste treatment
system cost data for various levels of treatment on an industry
by industry basis. Information is also presented on computer
based cost estimating models.
Chapter 2 presents a brief overview of some of the major con-
siderations involved in the preparation of a cost analysis and
detailed instructions on the use of the cost estimating data
presented in Chapter 3. In addition, information on appropriate
levels of detail for a cost estimate and a table summarizing the
CE Plant Construction Cost Index are provided.
Information for estimating the costs of a variety of wastewater
treatment unit processes is presented in Chapter 3. Table IV.1-1
shows those technologies included in Chapter 3 as well as those
technologies which are addressed in Volume III but not in Volume
IV at this time.
The unit process data were derived from the BAT Effluent Limita-
tion Guidelines engineering study for the Organic Chemicals/
Plastics and Synthetic Fibers Industries. Each unit process
section contains two major sections. First is a description of
the design procedure and the steps and procedures required to
determine the capital and 0 & M costs for the unit process. Each
presentation follows a standard format:
1. Basis of Design
2. Capital Costs
3. Operation and Maintenance Costs
4. Miscellaneous Costs
5. Modifications
Each unit process section includes descriptions of the key design
parameters, a flow diagram, capital cost curves, equations for
calculating the fixed and variable 0 & M requirements, and explana-
tions of possible variations on the design procedures presented.
Date: 4/1/83 IV.1-1
-------
TABLE IV.1-1. TECHNOLOGIES INCLUDED IN VOLUME IV CHAPTER 3
Section
IV.3.1.1A
IV. 3.1. IB
IV.3.1.2A
IV. 3.1'. 4
IV.3.1.5A
IV. 3. 1.6
IV. 3. 1.7
IV. 3. 1.8
IV.3.1.9A
IV.3.1.10A
IV. 3. 1.11
IV. 3. 1.12
IV.3.1.13A
IV.3.1.13B
IV.3.1.13C
IV. 3. 1.14
IV. 3. 1.15
IV. 3. 1.16
IV. 3. 1.17
IV. 3. 1.18
IV.3.1.19A
IV.3.1.19B
IV. 3. 1.20
IV. 3. 1.21
IV.3.2.1A
IV. 3. 2. IB
IV. 3. 2. 1C
IV. 3. 2. ID
IV. 3. 2. 2
IV.3.2.3A
IV.3.2.3B
IV. 3. 2. 4
IV. 3. 2. 5
IV. 3. 3.1
IV. 3. 3. 2
IV. 3. 3. 3
IV. 3. 3. 4
IV. 3. 4.1
IV.3.4.2A
IV.3.4.3A
IV. 3. 4. 4
IV.3.4.5A
IV.3.4.5B
IV. 3. 5
Category
Activated Carbon Adsorption
Carbon Regeneration
Chemical Oxidation
Chemical Reduction
Precip. and Coag/Floc
Distillation
Electrodialysis
Evaporation
Multi-Media Filtration
Flotation
Flow Equalization
Ion Exchange
Neutralization
Liming to a High pH
Lime Handling
Oil Separation
Polymeric Adsorption
Reverse Osmosis
Screening
Sedimentation
Ammonia Stripping
Steam Stripping
Solvent Extraction
Ultrafiltration
Activated Sludge
Aeration
Nutrient Addition
Heating/Cooling
Lagoons
Nitrification
Denitrification
Rotating Biological Contactors
Trickling Filters
Deep Well Injection
Incineration
Land Application
Recycling
Gravity Thickening
Aerobic Digestion
Vacuum and Pressure Filtration
Incineration (sludge)
Landfill
Outside Contractor
Miscellaneous Costs
Included
X
X
X
X
X
X
X
X
X
X
X
X
X
a
X
X
X
X
X
X
X
X
X
X
X
X
X
a) May be available at a later date.
Date: 4/1/83 IV. 1-2
-------
The second major section presented for each unit process is a
programmed worksheet designed to assist the user in making the
necessary calculations to estimate capital and 0 & M costs. Each
worksheet set includes a Summary Work Sheet which focuses on the
development of capital cost estimates and yearly 0 & M costs from
the components that contribute to the unit process costs. Also
included is a technical Work Sheet or series of technical Work
Sheets and work tables which provide the detailed equations and
tabulation formats for developing the design and cost factors
needed to complete component costs in the Summary Work Sheet.
The Summary and technical Work Sheets are each separated into six
identical sections:
I. DESIGN FACTOR
II. CAPITAL COST
III. VARIABLE 0 & M
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
A separate set of worksheets is included under the unit process
heading of Miscellaneous Costs to assist the user in calculating
common plant costs and in making final adjustments to cost esti-
mates.
All unit process cost estimating methods have been verified to
the extent feasible by comparing the hand estimated results
against information from the BAT engineering study [4-2]. This
test does not necessarily guarantee the results of the method
will reflect "real world" costs, only that the study and the work
sheet approach yield similar results.
Cost data for various levels of treatment by industry will be
presented on a unit cost basis as they are compiled. These data
will be presented in Chapter 4.
Chapter 5 presents information on computer based cost estimating
methods. Specifically it presents an overview of the model from
which the technology cost sections in Chapter 3 were derived.
Information on other models may be presented in the future.
Date: 4/1/83 IV. 1-3
-------
IV.2 COST ANALYSIS APPROACH
IV.2.1 INTRODUCTION
This chapter provides a brief overview of the major elements of
cost analysis for industrial wastewater treatment facilities and
information on their presentation in the Treatability Manual.
This is not a complete reference on cost analysis; the user is
encouraged to study additional references if a more complete
understanding of the subject is required.
This chapter focuses on the major elements and various levels of
detail of a cost analysis. It also introduces the unit process
based cost estimating procedure in Chapter 3 of this volume.
The source of information for developing the Chapter 3 technology
costing procedures was mainly the technical study performed for
the Organic Chemicals Branch at Effluent Guidelines Division of
the USEPA. The proposed method for developing the cost estimates
is based largely on the computerized method used by the contrac-
tor's model for estimating costs for the Organic Chemicals/
Plastics and Synthetic Fibers Industries technical studies. The
cost estimating method for all of the technology sections has
been simplified to some extent to allow the easy calculation by
hand. The cost estimating method presented for several technol-
ogies in Chapter 3 has been simplified to a very significant
degree. These technologies include: Activated Carbon Adsorption
(3.1.1A), Chemical Oxidation (3.1.2A), Coagulation/Flocculation
(3.1.5A), and Activated Sludge (3.2.1A). The cost estimates
developed using the methods in Chapter 3 may lead to slightly
different results than would be achieved using the cost model
(when it is available). The significance of any differences
would have to be determined on the basis of the situation under
consideration.
IV.2.2 GENERAL FACTORS IN COST ANALYSIS
This overview of the standard elements of a cost analysis is
intended to provide the reader with an idea of the context within
which cost information such as that in Chapter 3 is typically
used. Special emphasis is placed on the relative levels of
detail and reliability of cost estimates prepared during the
planning stages of a project and on the additional costs involved
in retrofit projects versus new construction.
IV.2.2.1 Standard Elements of a Cost Analysis
A cost estimate should provide sufficient information to allow a
good understanding of the basic project, the major technical and
cost assumptions, the estimated costs, and the overall economic
and financial merits of the project [4-3]. The level of detail
of this information may vary depending on the projected use or
Date: 4/1/83 IV.2-1
-------
relative stage of development of the project, but the same types
of information are generally required for any cost analysis. For
purposes of this discussion, a complete cost analysis is con-
sidered to be composed of the following six elements:
Element 1 Project Background Information
Element 2 Specified Cost Factors
Element 3 Capital Cost Estimate
Element 4 Annual Cost Estimate
Element 5 Project Feasibility Assessment
Element 6 Reliability Assessment
The general nature and scope of each of these elements is indi-
cated in Table IV.2-1. This document will focus only on Element 3
(Capital Cost Estimates), Element 4 (Annual Cost Estimates), and
to a limited degree Element 2 (specified cost factors such as the
construction cost index). However, it should be kept in mind
that all of the elements should be addressed in a complete cost
analysis.
IV.2.2.2 Basic Levels of Capital Cost Estimating
A cost estimate includes capital cost, annual cost, and financial
cost elements. Of these, the capital cost estimate is generally
the most difficult to make and has the greatest overall variability
[4-3]. Therefore, the level of effort involved in the capital
investment estimate usually determines the level of effort for
the entire cost analysis. The annual cost and financial aspects
of the estimate are also subject to variation, but are not as
site-specific or as difficult to analyze at the early stages of a
project as are the capital costs.
In general there are five basic levels of capital cost estimates.
The general characteristics and relative degree of accuracy of
each of the levels is described in Table IV.2-2.
The information presented in Chapter 3 of Volume IV is suitable
for developing Level 1 order-of-magnitude or Level 2 study level
cost estimates. This level of accuracy and effort is appropriate
for cost estimates developed during the early or conceptual
stages of a project since technical process information is typi-
cally not sufficient to warrent a greater level of effort.
The cost information in Chapter 3 is unit process based.. The
Level 2 study estimate can be developed when there are sufficient
data on the wastewater characteristics and the application of the
technologies available in Chapter 3 to allow full use of the cost
factors presented in the methods. When there are insufficient
data on the wastewater or the treatment technology use in the
specific industry does not agree well with the methods in Chapter 3,
then the best estimate that can be developed would be the Level 1
order-of-magnitude estimate.
Date: 4/1/83 IV.2-2
-------
TABLE IV.2-1. STANDARD ELEMENTS OF A COST ANALYSIS
Element 1. Project Background Information
Includes basic facility description, performance specifications,
and project status assessment
Element 2. Specified Cost Factors
Identifies key financial factors such as interest rates, depre-
ciation assumptions, reference year for costs, and cost index
Element 3. Capital Cost Estimate
a) Direct Costs - equipment, structures, ancillary facilities
b) Indirect Costs - engineering, contingencies, fees
c) Financial and Other Costs
Element 4. Annual Costs Estimate
a) Variable 0 & M - varies with rate of throughput
b) Fixed 0 & M - fixed by the size of facilities
Element 5. Project Feasibility Analysis
Presents an assessment of the profitability or financial feasi-
bility of undertaking the proposed project
Element 6. Reliability Assessment of the Cost Estimate
Presents an assessment of the overall reliability of the cost
estimate based on known and unknown factors, available data
correlations, sensitivity analysis, or other formal assessment
techniques
Date: 4/1/83
IV.2-3
-------
*5
PM
H
o
CO
25
w
PH
3
co
W
PL,
CJ
1— 1
CO
2
w
M
O
S3
O
1—4
H
H
S3
M
W
P i— >
1
CN «— '
tN H
> 0
M CJ
1
H
^
x
> —
co n
CC —
CC
o
a
t_
3
a.
o
V)
l.
O
CO
O
_
tf) V)
CO C
£ O
U CO
ra c
UJ Ol
CO
— (5
fl) U
> 0
CJ >
-I Q
Ifl
O
to
•f
38"%
00
< 1
C *-
o o
-p
co X
O O
c — o
— 3 £
CO
c c -o
— 0 0
E —
— O CO
<- JZ G
a-OXJ
c
Ol
3
O
£
u
a.
ec
0
o
3
C
W
i
1
O
t- 0
II
,J
o
+1
c
o
01
t — 1
v) *> C
coo
o oi —
** C 0
CO— 0)
3 —
£ flj (A
flj 4J (A
C (A
•O 3 0)
N ^ 0 -
— o ao
CO C*- C
t_ 1_ n
o o o-o
c oft--
0) C 3
Ol CO V) Ol
0 3 co«B
U. O CO CC
CD tf)
N C
Ol
CO W —
— to
(-•DO)
0) CT3
*J CO
co V)
E 0) «
E 4-> 0
t- -ex
oia>
(0 0 *»
•one
oS t-
— 0
ft- X
oi*J
W i- C
eg!
— O
C (/> — V 0)
3 <- a.
o-o «
O •£ OJ 1
C 3— 4->
C — flj — —
O »- w «
— 0) *J (-
W OJ O 0) t-
— C Oi C O
o — -o a) ft- •
CD O>3 O» C
•o ca xo
o *
t. t. o — **
OT3 Oft- <0 CO
ft- V ft- 3 —
— 0) V) —
«— «,n 3 co
co 4) (0 co 3 C
CO T? O O iQ '~
CB 1
C— 1
C fl) CO 01
O 0) ft- —
— c —
*»— c
CO 01 O ->
EC— w
a> « a>
O co t-
— o o o
(A a 3
CJ « t.
•o c w
O c co v>
aco (-
*j (A «r
X -Ol
O 0) (fl C
C 3 — —
O W ** —
CO 3 •
** tfl XI O O
— 0) C «
•O -O 3 -fl)
•O 3 O V)
O — Ol
— — o
c
o
CO
N
0 I-
ca 3
c<
E ^
— o
— 01
«-o
1- 3
«
Q
>-
+1
•o
** o — c
fl) t-— O
was —
•o rtig~
1- fl) CO
o-o o jj
<*.— W M
v) O ** —
— u o
via. o o
a O4-
v c ao
CO 0
4J — ft- a
** O VI
O N CD 0)
6— ***J
— L. (0 —
U0 E «
S3 « O
CD 01 U.
s §
fl, 1 .-
01 ac i- co
c e — a) N
•- o JC a— •
»- 0 «- X C X
U O fl) co co
OJft- J 01—
CO « <- 4J
— -0 tj) 0 3
O14J C t- O
C <- CO — 01
0) O 3 C —
£ tfl o1— co
•O (fl C fl) ** —
a> o ce co w
— X— E C
CO — CO . « W
4-> eg O tfl tfl (fl
fl) 3— oiOJ3
•0 (flft- C 3
£0 J 4)
*•» fl) (0 OT3
£ A (fl T) fl) co
I
c
o o
~°
— o
C 0)
— — J
«2
o a.
,.;
X
\t\
^1
*J O
'T~
aa
(0
°s
M VI
o
u u
o
— u.
8 .»
c *» o
o — —
o — «
3 cq
o ^ —
01 CO
fl) C **
co fl) C
X.O —
1
o
Q)
a i
(A >
CO
• L,
«T3
!.£
3^
v> t.
s°
w «"
c
fl) o
fl) 4J
— (0 •
to ifl
— 01
o — —
V)
L.
o
fl) o
— CO
— t_
co E **
*J «- C
o— o
QUO
in
c
CO
Q.
n **
*J C
o o
*J —
t. a
o —
W c.
o
(A V)
O fl)
I u
4J O
Q) *>
0 C
(fl
0 (0
§0)
a
0)
5 a>
CO
ft- E
o —
4J (A
V) fl)
~0
> jj
(A n
c e
0) 3
£ C
E +J
8c
CO
Oft^
b-
c —
o-o
4J (A
CO 4J
U (A
c —
o —
(A
£x:
0
0.3
£V)
L.
O 4J
0
M
(A *J
— ifl
£ O
CO
i
tfl
0)
CO
L.
1
V
0>
o
o
c
£
o
Q)
(A
ss
« E
c —
L. (A
0 «
u.
0
tf) (A
O V
~ a
Cl>>
o -^
o «
S5
w
•o «
g> 1.
i£
CO -W
4J
VI L.
«£
? —
l_
y for i
tm cu I a
— L.
aw
aa
(0
(A 0)
0) -o
£ —
£
£
V)
(0
E
V)
Q)
CO
3
a
fl)
o
c
o
o
s
0)
o
(A
(0
{_
«
0)
n
E
(fl
0)
o
tfl
§
»
I
^
V)
u
a>
£
0
Date: A/1/83
IV.2-4
-------
IV.2.2.3 Consideration of Retrofit Costs
Many outside factors can affect the magnitude and accuracy of a
cost estimate. Factors such as location, climate, and inflation
can significantly alter a cost estimate. Such factors may be
considered by the person making the estimate as appropriate for
the intended use of the estimate.
One of the most significant factors which should be considered is
whether the project under consideration is a retrofit of an
existing facility or new construction. This can have a very
significant effect on the final costs. When an addition is made
to an existing plant, it is termed a retrofit and the cost nor-
mally is more than for the construction of the same unit at a new
plant. The considerations regarding retrofit costs apply when a
unit process type cost estimate is prepared. Besides the complex
design problems, there is also the physical difficulty of inte-
grating the process into the design scheme and constructing the
retrofit unit on the plant site. Some of the factors that con-
tribute to the additional costs are as follows:
Plant Age - May require structural modifications to plant and
process alterations.
Available Space - May require extensive steel support construc-
tion' and site preparation. Existing equipment may require re-
moval and relocation. New equipment may require custom design to
meet space allocations.
Utilities - Electrical, water supply, waste removal, and waste
disposal facilities may require expansion.
Production Shut-down - Loss of production during retrofit must be
included in overall costs.
Direct (Field) Labor - If retrofitting is accomplished during
normal plant operations, installation time and labor hours will
be increased. If installation occurs during off-hours, overtime
wages may be necessary.
Engineering - Increased engineering costs to integrate control
system into existing process.
As a rule of thumb, equivalent retrofit installation costs from
25 to 40 percent more than that for construction on a new facility
[4-3].
In cases where there are multiple trains of the same unit process
the cost of installing the second and third trains is about 90 to
95 percent of the cost of the first one [4-3], This reduction in
cost per unit results from the common series of engineering,
Date: 4/1/83 IV.2-5
-------
purchasing, supervision, and administration of construction for
the multiple train facility.
IV.2.3 COST DATA FORMAT
Chapter 3 presents a unit process based cost estimating method
for wastewater treatment processes. The user of this information
must have available a preliminary design of the wastewater treat-
ment facility to be costed, including a list of unit processes
which are to be used, their relative order in the system, and
necessary influent and effluent conditions. The Chapter 3 tech-
nology cost presentations can then be used to estimate the capital
and operation and maintenance costs of the wastewater treatment
system or units under consideration. Each of the technology cost
presentations includes two types of information; a text section
and a cost worksheet. A patterned description of the steps and
procedures required to determine the capital and 0 & M costs is
included as text for each technology. This text includes the
required design parameters for using the cost estimating method,
a flow diagram of the unit process, capital cost curves, and
variable O & M cost factors. The second type of information
included for each technology cost presentation is a programmed
worksheet series to assist the user in calculating the capital
and 0 & M costs for the specific treatment application using the
methodology for that technology. It is anticipated that the
typical user of these technology cost sections could work mainly
from the worksheets, relying upon the text for reference and
background information.
IV.2.3.1 Technology Cost Sections
Each major technology cost section begins with an introduction
that identifies the techology, its general application, and
references the corresponding section in Volume III for more
detailed technical information. This is followed by a standard
five element presentation that identifies the design basis and
capital cost basis, presents the cost curves, presents the vari-
able and fixed O & M elements and useful factors for their calcu-
lation, and indicates methods to estimate quantities of items
which will affect the subsequent design and costing of other
units (e.g., land required, sludge generation). A generic tech-
nology cost section is presented in Table IV.2-3 illustrating the
type of information that is typically contained in each of the
five standard sections. NOTE: COMMON PLANT COSTS SUCH AS ENGI-
NEERING, YARD PIPING, AND ADMINISTRATION BUILDINGS ARE NOT IN-
CLUDED IN THE CAPITAL COSTS FOR INDIVIDUAL UNIT PROCESSES.
COMMON PLANT COSTS MUST BE CALCULATED AS A SEPARATE ITEM, SEE
MISCELLANEOUS COSTS, IV.3.5.
Date: 4/1/83 IV. 2-6
-------
TABLE IV.2-3. GENERIC TECHNOLOGY/COST SECTION
Al Basis of Design
Focuses on the development of the primary factor needed to use the cost
curves but also gives a general description of the design procedure.
a) Source
Identifies the source of the information and industry for which this
cost estimating method was developed.
b) Required Input Data
Identifies the data that the user must have in order to cost
the system using this method.
c) Limitations
Identifies circumstances under which the technology was not
considered applicable in the original study from which it was
developed.
d) Pretreatment
Identifies required pretreatment systems and criteria for
application.
e) Design Factor
Identifies the procedure and equations in both metric and
English units needed to determine the primary factor(s) used in
the cost curves. In addition any scale factors or correction
factors required to properly use the cost curves are described.
f) Subsequent Treatment
Identifies any subsequent units which are required when the
technology is used (e.g., clarification following activated
sludge).
A2 Capital Costs
Introduces the cost factor and references the cost curves.
a) Cost Data
Identifies equipment included in the capital cost estimates for each
of the systems used to develop the cost curve. The size of the equip-
ment also is described.
Date: 4/1/83 IV.2-7
-------
TABLE IV.2-3. GENERIC TECHNOLOGY COST SECTION (CONCLUDED)
b) Capital Cost Curves
Identifies the basis (e.g., size of systems) and scale of the cost
curves. The specific cost points used to develop the cost curve are
identified in the text, and these points are indicated on the cost
curve (as a boxed point).
c) Cost Index
Identifies the date of the cost estimate and a standard engineering
cost index for that date.
A3 Operation and Maintenance Costs
Introduces the major elements of the fixed and variable 0 & M costs.
a) Variable Cost
Presents the equations and performance variations necessary to
determine the variable 0 & M costs (e.g., those costs that will vary
in magnitude according to the type and quantity of wastewater treated)
This includes costs such as power, chemicals, process water, steam,
and fuel. This section is often the most technically complex part
of a technology cost section since variable costs are significantly
influenced by the performance and scale of the unit process.
b) Fixed Cost
Presents the fixed 0 & M cost factors such as labor, supervision,
overhead, maintenance, and taxes, which are not influenced by the
performance of the unit. These factors are based on the original
study with the base year and unit cost information included.
A4 Miscellaneous Costs
Introduces the need for computing required miscellaneous costs such as
yard piping, engineering, and buildings that are not directly associated
with any one unit process. The computation of these normally required
costs are deferred to a separate technology cost presentation on Mis-
cellaneous Costs (Section IV.3.5). The most important information pro-
vided by this section relates to computing sludge quantities, aeration
requirements, land requirements, and other items which are not directly
costed for the unit process in question but which affect the costing of
subsequent systems such as sludge dewatering units.
A5 Modifications
Presents supplemental information on design factors and costing methods
which may be of assistance to the user.
Date: 4/1/83 IV.2-8
-------
IV.2.3.2 Worksheets
Each technology cost section is accompanied by worksheets de-
signed to assist the user in developing cost estimates. Although
the Technology cost sections' present both metric and English
versions of the design and 0 & M equations, the worksheets present
only the English versions. Basically each worksheet set consists
of a Summary Work Sheet which focuses on development of capital
cost estimates and yearly 0 & M costs for the unit process, and a
technical Work Sheet or series of technical Work Sheets and work
tables which provide detailed equations and tabulation formats
for developing the design and cost factors needed to complete the
Summary Work Sheet. The Summary Work Sheet is separated into six
major parts:
I DESIGN FACTOR
II CAPITAL COST
III VARIABLE 0 & M
IV FIXED O & M
V YEARLY 0 & M
VI UNCOSTED ITEMS
The technical Work Sheet includes the same six headings as the
Summary but also includes a Section in which to list any cost
factors and unit costs. Generic examples of both a Summary Work
Sheet and technical Work Sheet are presented in Tables IV.2-4 and
IV.2-5 respectively illustrating their typical order and format.
In the following sections, a general introduction is provided on
the content and use of the worksheets.
IV.2.3.2.1 Technical Work Sheet (Table IV.2-4)
Use of the worksheets should start with the technical Work Sheet
for the technology of interest. The name of the technology will
appear at the top of the page. In general, technical computa-
tions will be completed on this worksheet and the results trans-
ferred to the Summary Work Sheet for costing. Following is a
step-by-step walkthrough of the sections of the technical Work
Sheet (Table IV.2-5) and a discussion of its use in costing.
Required Cost Factors and Unit Costs
This section is provided for the user to identify the cost factors
such as labor rates, cost index, and chemical costs which will be
used when completing the Summary Work Sheet. A current capital
cost index must be selected to adjust the costs derived using the
capital cost curve (e.g., based on July 1977, St. Louis, CE Plant
Index = 204.7) to the time and place of current interest. The
next group of factors concerns unit costs for chemicals and
utilities. These factors are highly variable depending on loca-
tion and quantity purchased so some discretion is advised in
selecting a unit cost. As a point of reference Table IV.2-6
Date: 4/1/83 IV. 2-9
-------
TABLE IV.2-4. GENERIC SUMMARY WORK SHEET
1.
a.
b.
II.
Cost
III.
a.
b.
c.
d.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
TECHNOLOGY NAME
SUMMARY WORK SHEET
REFERENCE: Section No.
DESIGN FACTOR CAPITAL
Factor = units
Scale Factor if required
CAPITAL COST
= x ( T 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
Chemical = x
Ib/day $/lb
Fuel = x
gal/day $/gal
Steam = x
Ib/day $/lb
FIXED 0 & M
Labor: x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor : x %
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
$/day
$/day
.
.
X
day/yr sum, $/day
$
0 & M
•g
$/yr
UNCOSTED ITEMS
Land ft2 b. Sludge = Ib/day
Date: 4/1/83
IV.2-10
-------
TABLE IV.2-5. GENERIC technical WOSK SHEET
TECHNOLOGY NAME
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. Chemical =
4. Fuel =
5. Steam =
6. Labor =
7. Supervision =
8. Overhead =
9. Lab Labor =
,0. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor sum =
11. Service Water =
Capital Cost Index
$/Kw-hr
$/lb
$/gal
$/lb
$/hr
$/hr
% Labor * 100 =
$/hr
% Capital
% Capital
% Capital
% f 100 =
%/100
%/100
$/thou gal
I. DESIGN FACTOR
a. Factor =
x equation =
units
Unit
b. Scale factor
II. CAPITAL COST
III. VARIBLE 0 & M
a. Power Requirements
HP =
x equation = Hp
factor, unit
b. Other factors
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Factors as required
Date: 4/1/83
IV.2-11
-------
TABLE IV.2-6. BASE UNIT COSTS FOR UTILITIES AND CHEMICALS
(YEAR 1977) [4-2]
ITEM UNIT COST
POWER $0.02/kw-hr
FUEL OIL $0.46/gal
STEAM $0.0045/lb
LIME $0.0149/lb
SULFURIC ACID $0.0215/lb
AMMONIA $0.0789/lb
PHOSPHATE $0.604/lb
SODIUM SULFIDE $0.1375/lb
FERRIC CHLORIDE $0.045/lb
ALUM $0.0645/lb
POLYMER $2.00/lb
ACTIVATED CARBON $0.52/lb
METHANOL $0.0696/lb
WASTE HAULING $0.0004/lb-mile
RESIDUE DISPOSAL $0.018/lb
SOLVENT-UNDECANE $0.137/lb
SOLVENT-TRICRESYL $0.76/lb
CAUSTIC $0.1575/lb
CHLORINE $0.0713/lb
P. PERMANGANATE $0.48/lb
H. PEROXIDE $0.386/lb
SODIUM CHLORIDE $0.0199/lb
Source - These costs are derived from the BAT Effluent Limitations
Guidelines Engineering Study for the Organic Chemicals/Plastics and
Synthetic Fibers Industries [4-1].
Date: 4/1/83 IV.2-12
-------
provides the 1977 values for chemicals, electricity, steam,
contract hauling, etc., which were used in the original cost
source [4-1]. The user may either scale these costs to a current
date or use unit cost data available from other sources (e.g.,
local utilities, equipment supply vendors).
The final group of factors is concerned with labor and other
"fixed" operation costs. Here again current local rates may be
used if known or the labor rates used by the original source may
be scaled. The fixed 0 & M factors used by the source are indi-
cated in a Fixed 0 & M table in each technology cost section. A
generic fixed O & M table is shown in Table IV.2-7 to illustrate
the information provided in each technology cost section. Infor-
mation on items such as Maintenance, Services, and Insurance and
Taxes, which are typically calculated as a percent of capital
cost, is also contained in the fixed 0 & M table. The values
included with the Chapter 3 text may be used unless substitute
values more suited to local conditions are available. In any
case, the percentages for maintenance, service, and insurance and
taxes would be summed and this sum divided by 100 as indicated in
Table IV.2-5 in order to obtain the factor which will subse-
quently be used to determine part IV e. of the O & M costs on the
Summary Work Sheet.
I DESIGN FACTOR
This section provides a programmed approach to determining the
key design factor that is used to estimate costs from the capital
cost curve. For example, surface area is the key design and cost
factor for sedimentation units. Therefore, a fill-in-the-blanks
equation is provided in this section to determine surface area in
English units. It is expected that if the user has any questions
about the meaning of the equations, reference would be made to
the technology cost section where the equations and terms are
defined in detail.
The effort involved in determining the key design factor varies
widely from one technology to another. In many cases the key
factor is simply the influent flow adjusted by a simple scale
factor. In other cases, the design factor is specific to the
influent waste requiring more difficult calculations. In such
cases Work Tables are provided in which each component of the
influent waste matrix is analyzed separately in determining the
overall value of the key design factor for the unit process.
When Work Tables are used, detailed instructions are presented in
the DESIGN FACTOR section and space is provided for performing
final computations or listing the design factor which will be
transferred to the Summary Work Sheet for costing purposes.
Date: 4/1/83 IV. 2-13
-------
TABLE IV.2-7.
GENERIC FIXED 0 & M TABLE FROM A TECHNOLOGY COST
SECTION.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR TECHNOLOGY [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Cost Basis Base Unit Cost
(Equivalent Unit Quantity) (July 1977)
Weeks (
% Labor (
% Labor Cost
hr/day) $ 9 . 80/hr
hr/day) $11.76/hr
NA
Laboratory
Labor (3)
Maintenance
Services
Insurance & Taxes
Service Water
NA - not applicable
Thou gpd
hr/day) $10.70/hr
NA
NA
NA
$ 0.50/thou gal
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.2-14
-------
II CAPITAL COST
Capital cost computations rarely require any additional space in
the technical Work Sheet. However, for some technologies a scale
factor may be computed under the capital cost section. The cost
from the cost curve and any scale factor are entered and adjusted
using a current index on the Summary Work Sheet.
Ill VARIABLE 0 & M
Variable 0 & M calculations in the technical Work Sheet may be
simple or complex. The horsepower requirements are presented as
a regression function of the design factor computed in the DESIGN
FACTOR section. Other variable 0 & M items such as chemical
requirements may require extensive calculations to reflect the
specific influent waste characteristics. In such cases supple-
mental work tables are provided along with detailed instructions
on their use.
IV FIXED 0 & M
As in the case of capital cost computations, fixed 0 & M estimates
are relatively simple and are rarely addressed in the technical
Work Sheet. Using the unit cost factors for each unit process
(see Table IV.2-7) or the revised factors from the REQUIRED COST
FACTORS AND UNIT COSTS section, most fixed O & M cost computa-
tions may be performed on the Summary Work Sheet. However, in a
few cases such as for landfill operations and for unit processes
consisting of several distinct units (e.g., ammonia stripping and
ammonium sulfate recovery) some computation may be required to
determine the fixed 0 & M factors for the unit process as a
whole. In these cases programmed calculation formulas are pro-
vided, with the results to be transferred to the Summary Work
Sheet for final cost calculations.
V YEARLY O & M
This calculation is always performed on the Summary Work Sheet
for the technologies in this report. This heading is included in
the technical Work Sheet in the event that a separate estimate is
developed.
VI UNCOSTED ITEMS
Uncosted items include land requirements and sludge generation
which do not directly enter into the cost computations for the
unit process but which affect the cost of subsequent unit pro-
cesses (e.g., sludge handling) or the cost of the plant as a
whole. The kinds of calculations involved in quantifying the
uncosted items are similar to those involved in quantifying the
design factors and variable 0 & M factors. Once calculated, the
uncosted items are transferred to the Summary Work Sheet from
Date: 4/1/83 IV. 2-15
-------
which they can be easily located and transferred when needed for
subsequent costing operations.
IV.2.3.2.2 Summary Work Sheet (Table IV.2-4)
Almost all of the costing calculations for an individual unit
process are performed on the Summary Work Sheet (see Table IV.2-4).
As noted previously, the design factors and required quantities
of 0 & M items are calculated on the technical Work Sheet and
transferred to the Summary Work Sheet for costing. Following is
an introduction to the Summary Work Sheet and a discussion of its
use in costing.
I DESIGN FACTOR
The key design factor as computed in the technical Work Sheet is
transferred to this section along with any necessary scale factor.
This provides a quick reference point for verifying the factor to
be used when selecting the capital cost from the cost curve.
II CAPITAL COST
The capital cost of the unit process as designed is computed in
this section. The capital cost from the cost curve in the asso-
ciated technology cost section is entered along with the current
cost index, with the current capital cost estimate for the unit
process computed. In those instances wliere the scale factor is
applied to the cost rather than to the design factor, a space for
entering it will also be shown in the capital cost equation.
Ill VARIABLE 0 & M
The daily cost of the variable O & M items are computed in this
section. The required quantities of power, chemicals, etc., are
transferred from section III of the technical Work Sheet and
multiplied by the current unit cost from the REQUIRED COST FACTORS
AND UNIT COSTS section to yield daily cost.
IV FIXED 0 & M
Fixed 0 & M item costs are estimated as a daily cost in a manner
very similar to variable O & M. The exception is that the quanti-
ties of labor, supervision, laboratory labor, and service water
must be transferred from the Fixed O & M table in the technology
cost section (see Table 4 for example) rather than from the
technical Work Sheet. The cost quantities are then multiplied by
the current unit costs from the REQUIRED COST FACTORS AND UNIT
COSTS section to yield daily cost. Maintenance, Services, and
Insurance and Taxes are determined as a specified percentage of
capital cost. For these items the capital cost is multiplied by
the sum of percentages from the REQUIRED COST FACTORS AND UNIT
COSTS section and divided by 365 to yield daily cost.
Date: 4/1/83 IV. 2-16
-------
V YEARLY 0 & M
Yearly 0 & M is the sum of the daily variable and fixed 0 & M
costs multiplied by 365 days/yr. Note that this sum may not
reflect the actual 0 & M cost for the unit process, since several
of these O & M cost items may be adjusted to reflect the size of
the treatment facility. This is addressed in Miscellaneous
Costs, Section IV.3.5.
VI UNCOSTED ITEMS
The quantities of uncosted items computed in the technical Work
Sheet are recorded in this section for subsequent cos*ting opera-
tions.
IV.2.3.2.3 Summary on the Use of Work Sheets
The work sheets are provided to facilitate the use of costing
information provided in the technology cost sections. Calcu-
lations and decision points in the work sheets are often abbrevi-
ated or combined, for the sake of conciseness and do not show all
of the elements individually that contribute to the equation
(e.g., several conversion factors or design factors will be
combined into one number). Thus, the work sheets are not in-
tended to stand alone as a cost estimating tool but need to be
used in conjunction with the technology cost section in order to
clarify the meaning of variables and variable names, fixed 0 & M
cost factors, and critical decision points in system design.
IV.2.4 COST INDEX
The cost curves presented in Chapter 3 are based on CE Plant
construction cost index of 204.7. This reflects construction
costs in St. Louis in July 1977. The CE Plant index appears
bimonthly in Chemical Engineering Magazine and an annual update
is published in April of each year. It is a useful indicator of
changes in construction costs for process type projects requiring
steel and skilled erection labor. The CE Plant index reflects a
weighting of current costs as follows: equipment, machinery and
supports, 61%; erection and installation labor, 22%; buildings,
material and general labor, 7%; and engineering and supervision
A summary of recent values for the CE Plant construction index is
presented in Table IV.2-8.
Date: 4/1/83 IV. 2-17
-------
s
H
H
CO
8
a
o
H
H
O
3
H
CO
o
CJ
H
S3
J
PH
W
O
-
o
2
1
co
oo
I
CN
•
5
i
§
H
HI
— 01
32
E >
o
0
z
4J
s
G.
V
V)
I
>»
3
~)
0)
>
i
~
£
<
£
M
E
i
A
V
u.
c
10
I
1
I-CMCM.-,,,.,.
incMt^.ffincMCMd'
CMPOro.T'\oeOOxO
PO
o
CM
.,
o
CM
o
CTI
0
CM
to
s
CJ
*
8
CM
(S.
O
CM
f>
3
CM
Jf
,J
S
PO
§
CM
m
2
0-CM-ia-mNOi-
ONCT.ONO.ONOVWON
03
CO
ON
(M
M
^
3-
W
CM
in
CO
CM
W
»
(VJ
M
«
C\j
OJ
<\l
m
«o
o
m
in
CO
CM
S
o
f*
ON
CM
NO
in
o
NO
S
PO
j.
CO
o
PO
CO
o
PO
CM
m
o
PO
,-
O
PO
CM
CO
CM
in
ox
CM
PO
s
CM
m
CM
in
o
CO
CM
NO
NO
p-
CM
-
ON
ON
ro
«~
NO
PO
^
in
CO
PO
NO
PO
NO
in
PO
in
PO
CM
PO
PO
PO
PO
m
y
PO
CM
PO
PO
*
fO
r-
O
PO
*
»- in
PO PO
« s
ON ON
V)
0)
«
t.
t
o
0}
•o
c
fl)
s
tructif
tA
C
S
CO —
— ra
3 C
O —
_J
1?
Date; 4/1/83
IV.2-18
-------
IV.3 TECHNOLOGY COST DATA
Cost data are presented in this chapter for industrial wastewater
unit processes. The format used in these Technology cost sections
is described in Chapter 2. The user who is not familiar, with the
format of these sections is advised to review the Chapter 2
information to fully understand the limits and use of these cost
data.
Date: 4/1/83 IV. 3-1
-------
IV.3.1.1 ACTIVATED CARBON ADSORPTION
Introduction
Activated carbon adsorption is a physical separation process in
which organic and inorganic materials are removed from wastewater
by sorption onto the carbon surface. The typical process may use
either a granular carbon in a fixed or moving bed for the sorbent
or may use a powdered carbon in a slurry system. Further details
describing this process can be found in Volume III, Section
III.3.1.1 of the Treatability Manual. Costing methodologies and
cost data for industrial wastewater treatment applications are
presented below.
IV.3.1.1-A. Granular Activated Carbon Adsorption
A 1. Basis of Design
This cost estimate is for a granular activated carbon adsorption
system using fixed beds. The primary cost factor is the bed
volume required for attaining the desired pollutant removal. A
small bed system (volume <34 m3 (£1200 ft3)) and a large bed
system (volume >34 m3 (>1200 ft3)) of the type considered are
illustrated in Figure IV.3.1.1-A1 and Figure IV.3.1.1-A2, re-
spectively.
Bed volume may be estimated based on the empty column hydraulic
contact time. It is assumed that for low order systems (bed
volume £34 m3 (£1200 ft3)) the contact time with all units operat-
ing is 30 min while for high order systems (bed volume >34 m3
(>1200 ft3)) the contact time with all units operating is 20 min
[4-2]. Hydraulic surface loadings were used to develop column
designs with respect to depth and surface area. Surface loadings
were assumed to be in the range of 3.4 L/s/m2 (5 gpm/ft2) for
high order systems and 1.15 L/s/m2 (1.7 gpm/ft2) for low order
systems. The lower surface loading for low order systems is due
to the fact that a minimum of three columns is used and each
column is designed on the basis of a 3.4 L/s/m2 (5 gpm/ft2) sur-
face loading rate for the entire flow [4-2].
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries
[4-2].
Date: 4/1/83 IV.3.1.1-A1
-------
H
<
> •—•
M rH
H I
M
w
pCi
13
O
Date: 4/1/83
IV.3.1.1-A2
-------
U
Q
W
8
H
H
u
W
S Q
< «
K O
O
< ffi
H O
Q H
2
fe O
H
03 EH
O O
O Cfi
05 Q
PM <;
CM
I
H
•
•H
•
CO
ID
O
H
Pn
Date: 4/1/83
IV.3.1.1-A3
-------
b) Required Input Data
Wastewater flow, L/s (mgd)
Carbon use rate, Kg carbon/L (Ib carbon/1,000 gal)
Priority pollutants of concern (mg/L)
Oil and grease (mg/L)
TSS (mg/L)
c) Limitations
Granular activated carbon adsorption is not considered applicable
if all treatable pollutants including...organic priority
pollutants are present in concentrations less than their lowest
expected effluent value.
d)" Pretreatment
Pretreatment should be provided as indicated for the following
conditions:
i) If influent TSS >25 mg/L, then multi-media filtration
should be provided upstream of carbon adsorption.
ii) If influent oil >35 mg/L, then oil removal should be
provided upstream of carbon adsorption.
(e) Design Factor
The primary capital cost factor used for the granular activated
carbon adsorption system is the bed volume required. Bed volume
is determined from the flow and the hydraulic contact time as
follows:
Metric
BV = (FLOW x CT x 60 x 0.001)
where: BV = bed volume, m3
FLOW = influent flow, L/S
CT = contact time, min
60 = seconds/min
0.001 = m3/L
English
BV = (FLOW x 106 x CT) T (1440 x 7.48)
where: BV = bed volume, ft3
FLOW = influent flow, mgd
106 = conversion factor, mgd to gpd
CT = hydraulic contact time, min
1440 = min/day
7.48 = gal/ft3
Date: 4/1/83 IV.3.1.1-A4
-------
The low order cost curve (Figure IV.3.1.1-A3) reflects vertical,
downflow type systems designed with an empty column hydraulic
contact time of approximately 30 minutes while the high order
curve (Figure IV.3.1.1-A4) reflects pulsed bed upflow type systems
designed with an empty column hydraulic contact time of approx-
imately 20 minutes (Range 17 to 29). This should be taken into
account during column sizing and costing.
(f) Subsequent Treatment
None specified, but spent carbon must be regenerated or replaced.
A 2. Capital Costs
The activated carbon adsorption capital cost estimate is based on
the bed volume required. The capital cost may be estimated using
Figure IV.3.1.1-A3 for low order systems (bed volumes £34 m3,
1200 ft3). The capital cost for high order systems may be esti-
mated using Figure IV.3.1.1-A4 (bed volumes >34 m3, 1200 ft3).
Costs estimated using these curves must be adjusted to a current
value using an appropriate current cost index.
a) Cost Data
The items included in the capital cost estimates are as follows
[4-2]:
i) Low Order Systems Bed Volume £34 m3 (£1200 ft3)
Carbon columns (pressurized, steel, rubber lined, downflow
with 100% bed expansion volume)
0.876 L/s - 3@ 0.61 m diam, 7.32 m height, 60 min contact
(0.02 mgd - 3@ 2 ft diam, 24 ft height, 60 min
contact)
4.38 L/s - 3@ 1.22 m diam,. 4.88 m height, 30 min contact
(0.10 mgd - 3@ 4 ft diam, 16 ft height, 30 min
contact)
8.76 L/s - 3@ 1.83 m diam, 4.27 m height, 30 min contact
(0.20 mgd - 3@ 6ft diam, 14 ft height, 30 min
contact)
17.5 L/s - 3@ 2.59 m diam, 4.27 m height, 30 min
contact
(0.40 mgd - 3@ 8.5 ft diam, 14 ft height, 30 min
contact)
Carbon holding tanks (2)
Backwash holding tank
Initial carbon charge 0.762, 3.81, 7.58, and 15.1 Mg, re-
spectively (0.84, 4.2, 8.36, and 16.7 tons, respec-
tively)
Dave: 4/1/83
IV.3.1.1-A5
-------
N
suv-noa ONvsnom oauowrw Isoo
HI
HI
U.
2
01
u
* s
CO
HI
O
o
111
Date: 4/1/83
IV.3.1.1-A6
-------
Pumps (feed, backwash, surface spray, carbon transfer,
backwash return)
Agitators for carbon holding tanks
Instruments, piping, electrical
ii) High Order Systems Bed Volume >34 m3 (>1200 ft3)
Carbon columns (pulsed bed, steel, rubber lined, upflow)
21.9 L/s - 2 plus spare @ 2.59 m diam, 4.88 m height,
39 min contact
(0.5 mgd - 2 plus spare @ 8.5 ft diam, 16 ft height,
39 min contact)
43.8 L/s - 3 plus spare @ 2.59 m diam, 4.88 m height,
29 min contact
(1.0 mgd - 3 plus spare @ 8.5 ft diam, 16 ft height,
29 min contact)
219 L/s - 7 plus spare @ 3.35 m diam, 4.27 m height,
20 min contact
(5.0 mgd - 7 plus spare @ 11 ft diam, 14 ft height,
20 min contact)
876 L/s - 21 plus spare @ 3.66 m diam, 3.96 m height,
17 min contact
(20.0 mgd - 21 plus spare @ 12 ft diam, 13 ft height,
17 min contact)
Spent carbon holding tank
Regenerated carbon holding tank
Initial carbon charge 37.2, 49.9, 145, and 440 Mg,
respectively (41, 55, 160, and 485 tons,
respectively)
Pumps (feed, spent carbon, regenerated carbon)
Instruments, piping, electrical
b) Capital Cost Curves
i) Low Order Systems (bed volume £34 m3 or £1200 ft3) - Figure
IV.3.1.1-A3.
Cost (hundred thousand dollars) vs. bed volume (m3
or ft3)
Curve basis, cost estimate on four systems at flow
rates of 0.876, 4.38, 8.76, and 17.5 L/s (0.02, 0.10,
0.20, and 0.40 mgd) (carbon bed volumes 3.17, 7.88,
15.8, and 31.6 m3 (112, 278, 557, and 1,115 ft3))
ii) High Order Systems (bed volume >34 m3 or >1200 ft3) -
Figure IV.3.1.1-A4.
Cost (millions of dollars) vs. bed volume (m3 or ft3)
Curve basis, cost estimate on four systems at flow
rates of 21.9, 43.8, 219, and 876 L/s (0.5, 1.0,
5.0 and 20 mgd) (carbon bed volumes 51.3, 77, 263
and 874 m3 (1,814, 2,721, 9,310, and 30,870 ft3)
Date: 4/1/83 IV.3.1.1-A7
-------
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component of operating cost is the power for pumps.
Costs for simple replacement of carbon for a small system may
be calculated as shown in Section A4. Costs for carbon re-
generation are estimated as shown in Carbon Regeneration (Section
IV.3.1.1-B). Fixed operating costs include labor, supervision,
overhead, maintenance, laboratory labor, services, insurance and
taxes, and service water. All fixed and variable operating costs
should be adjusted to current levels using an appropriate index
or unit cost factor.
a) Variable Costs
i)
Power Requirement - pumps, low order systems (bed volume
£34 m3 (£ 1200 ft3)) [4-1]. This equation was developed
using regression analysis procedures.
Metric
where:
KW = (0.564 x BV) +4.75
KW = power, kilowatts
BV = bed volume, m3
English
where:
HP = (0.0214 x BV) + 6.37
HP = power, Hp
BV = bed volume, ft3
ii)
Power Requirement - pumps, high order systems (bed volume
>34 m3 (>1200 ft3)) [4-1]. This equation was developed
using regression analysis procedures.
Metric
where:
KW = (0.116 x BV) + 11.1
KW = power, kilowatts
BV = bed volume, m3
English
HP = (0.00441 x BV) + 14.9
Date: 4/1/83
IV.3.1.1-A8
-------
where: HP = power, Hp
BV = bed volume, ft3
iii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost, $/KW
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
EC = electricity cost, $/Kw-hr
24 = hr/day
0.746 = KW-hr/Hp-hr
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.1.1-A1, including the cost basis and unit costs [4-11]
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after design and costing for all unit
processes are completed (see Section IV.3.5).
The amount of carbon required by the system is calculated to
facilitate design and cost estimates for subsequent systems.
Spent carbon must be regenerated or replaced. The decision
whether to replace or regenerate is based on the carbon use rate.
Carbon regeneration may be appropriate (see Section IV.3.1.1-B)
for systems using more than 454 Kg/day (1000 lb/day)' of carbon.
For smaller systems exhausted carbon may be replaced and dis-
carded. The carbon use rate is highly dependent on the charac-
teristics of the waste being treated. Carbon use rates observed
for wastewaters from several different industrial categories are
presented in Table IV.3.1.1-A2 for guidance. Also see Section
III.3.1.1 of Volume III for more information on this subject.
i) Quantity of Carbon Use
Metric
CU = FLOW x CUR x 86,400
Date: 4/1/83
IV.3.1.1-A9
-------
TABLE IV.3.1.1-A1. FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR ACTIVATED CARBON ADSORPTION
[4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.30 Weeks (7.20 hrs/day)
10% Labor (0.72 hrs/day)
75% Labor Cost
0.25 Shifts (1.43 hrs/day)
5.5% Capital
0.40% Capital
2.50% Capital
0.16 L/s
(3.56 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou. L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts-
(3) One shift = 40 hours
"Date: 4/1/83
IV.3.1.1-A10
-------
H
Q
Z '—'
or~
— i
wst
a""1
to
ZUJ
o —
HO
Ci-O
CC LJ
OH
to <
GO
_l
z<
O —
CQCC
ir H
< to
O 13
Q
bJ Z
> —
H CO
O
HO
LU CC
to<
LJ >
CC
Q.CC
bJO
ecu.
.
CM
1
r-
ro
.
>
—
bJ
_j
CO
^
H
CO
o>
CD O
in o
= o
cSfc
o -uLo
.Q CO —
t- ccl--
co
0 -1
CJ1
1 C
c —
0 £
0
^
•O O CD
CO •— E
CO
>>co
4J i- 4J
Q.T3 O
E >>CO
bJ X 4J
•^
C —
— .00
CLO **" " ^
t-O co
O H OTO
in x:
^ \_
< O)
-, A
c —
0 V.
o c
4J o— O
ac— J3
t. CD i-
o sz roco
« Q- i£ O
•Q ^^
< Ol
—
CO >J
— L.
S- 0
4J 01
U) 0)
3 -P
"O CO
c o
CD
UT3
— O
to o
O
o
•d-
i
ON
00
VO
r-
0
in
1
o
it
o
,
o
it
o
o
o
co in
._ _
!- 0 CO
4->— O
U) C —
D CO E
•D O1CD
C S. ^
-00
VO
00
CM
CO
it
^^
VO
m
o
VO
i
CM
r-
r-
O
,
0
ef)
O
O
in
CD
T3
O
4-1
(A
CD
a.
r-
00
CM
1
O
ON
1
o
CO
1
ON
O
O
o
in
0
4J
in
CO
a.
CM
00
CM
^
^^
O 1 II
CM
d
ON
o
r- O CM ON
1 VO
O ON
VO 00 00
ro O O
1
o o o
1 1 1
in
>> CD
>, 4J in > in
i. — U — CD
CD co — in —
c — c o —
— O CO — P
<>- CD 01 a x
co at- x CD
ce to o ui H
i- ON CM CM
i- ON o P-
ON 00 00 CM
CM CM CM CM
in
CO
•~r
1
o
CM
^
O VO
CM i-
i— i—
1 1
1 1
in
P
O
3
Ol CO"O
D JC O
S- 01-
Q O Ct-
ON
CO ^h
00 ON
CM CVI
Date: 4/1/83
IV.3.1.1-A11
-------
where: CU = carbon use, Kg/day
FLOW = influent flow, L/s
CUR = carbon use rate, Kg carbon/L
86,400 = s/day
English
CU = FLOW x CUR x 1000
where: CU = carbon use, Ib/day
FLOW = influent flow, mgd
CUR = carbon use rate, Ib carbon/1000 gal
(see Table IV.3.1.1-A2)
1000 = conversion, mil gal to 1000 gal
ii) Cost of Carbon Replacement
• if CU >454 Kg/day (>1000 Ib/day) see Section
IV.3.1.1-B, Carbon Regeneration
• _if CU <454 Kg/day (<1000 Ib/day) estimate cost of
replacement carbon as shown below
CRC = CU x CP
where: CRC = carbon replacement cost, $/day
CU = carbon use, Kg/day or Ib/day
CP = price of replacement carbon, $/Kg or $/lb
A 5. Modifications
None required.
Date: 4/1/83 IV.3.1.1-A12
-------
I.
a.
II.
Cost
III.
a.
b.
IV.
a.
b.
c.
d.
e.
£.
V.
VI.
a.
ACTIVATED CARBON ADSORPTION
SUMMARY WORK SHEET
REFERENCE: IV. 3. 1.1 -A
DESIGN FACTOR CAPITAL
Bed Volume = ft3
CAPITAL COST
x ( f 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
Carbon Cost = x
CU, Ib/day CP, $/lb
FIXED 0 & M
Labor : x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor : x
hr/day $/hr
Maint, Service, x f 365
I&T: capital, $ %/100 day/y
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
day/yr
$/day
=
.
.
.
r
x
sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Carbon Use (to be regenerated) = Ib/day
Date: 4/1/83
IV.3.1.1-A13
-------
ACTIVATED CARBON ADSORPTION
WORK SHEET
REQUIRED COST FACTORS AND UNIT
1. Current Index =
2. EC: Electricity Cost =
3. CP: Replacement
Carbon =
4. Labor =
5. Supervision =
6. Overhead =
7 . Lab Labor
8. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
9. Service Water =
COSTS
Capital Cost Index
$/Kw-hr
$/lb
$/hr
$/hr
% Labor * 100 = %/100
$/hr
% Capital
% Capital
% Capital
% r 100 = %/100
$/thou gal
I. DESIGN FACTOR
1 . Hydraulic Contact Time
CT = min
2. Bed Volume
BV = ( x
FLOW, mgd
) x 92.8 = ft3
CT, min
II. CAPITAL COST
Date: 4/1/83 IV.3.1.1-A14
-------
III. VARIABLE 0 & M
a. Power Requirements, low order systems
HP = (0.0214 x ) + 6.37 = Hp
BV, ft3
b. Power Requirements, high order systems
HP = (0.00441 x ) + 14.9 = Hp
BV, ft3
c. Carbon replacement cost, for carbon use less than 1000 Ib/day
CRC = x
CU, Ib/day CP, $/lb
see part a. VI.2 for determination of carbon use (CU)
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Carbon Requirement
1. Carbon Use Rate
CUR = Ib carbon/1000 gpd
2. Daily Carbon Use Requirement
CU = x x 1000 = Ib/day
FLOW, mgd CUR lb/1000 gpd
• If CU >1000 Ib/day, see Section IV.3.1.1-B to
estimate cost of carbon regeneration.
• If CU <1000 Ib/day, see III c. above to estimate cost
of carbon replacement.
Date: 4/1/83 IV.3.1.1-A15
-------
IV.3.1.1-B. Carbon Regeneration
B 1. Basis of Design
This cost estimate is for the thermal regeneration of granular
activated carbon using a hydraulic conveyance system and a
multiple-hearth regeneration furnace. A system of the type con-
sidered is illustrated in Figure IV.3.1.1-B1. The primary cost
factor is the required surface area of the regeneration furnace.
A maximum furnace size of 48.3m2 (520 ft2) is used, with the number
of furnaces varied to provide the total required furnace capacity.
The total carbon use is the basis for determining the required
hearth surface area for the furnace, based on an assumed carbon
loading rate of 195 Kg/day/m2 (40 Ib/day/ft2).
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
b) Required Input Data
Carbon use Kg/day (Ib/day) from the carbon adsorption unit
process
c) Limitations
Carbon regeneration is used only when carbon usage exceeds 454
Kg/day (1000 Ib/day). Below that level, spent carbon is disposed
to landfill and replaced with unused carbon.
d) Pretreatment
None specified.
e) Design Equation
The principal factor used to estimate capital costs is the re-
quired hearth surface area for the carbon regeneration furnace.
This is computed based on the carbon usage as follows:
Metric
TFSA = 1.2 x CU * RRATE
where: TFSA = total furnace surface area, m2
CU = carbon usage, Kg/day (see Section 4a of
Carbon Adsorption)
Date: 4/1/83 IV.3.1.1-B1
-------
§
H
EH
w
12
\*s
8
s
Q
W
EH
$
H
EH
O
En
a
H
Q
W
u
§
D
O
H
Date: 4/1/83
IV.3.1.1-B2
-------
RRATE = rate of carbon loading in furnace, Kg/day/m2
(195 Kg/day/m2 is the default value)
1.2 = allowance factor for 20% down time
English
TFSA = 1.2 x CU r RRATE
where: TFSA = total furnace surface area, ft2
CU = carbon usage, Ib/day (see Section 4a of Carbon
Adsorption)
RRATE = rate of carbon loading in furnace, lb/day/ft2
= 40 lb/day/ft2 (default value) (see Table
IV.3.1.1-A1) [4-2]
1.2 = allowance factor for 20% down time
The number of furnaces must be adjusted so that the average size
is less than 48.3m2 (520 ft2).
Metric
CN = TFSA * 48.3
where: CN = computed number of furnaces
48.3 = maximum individual furnace size, m2
English
CN = TFSA * 520
where: CN = computed number of furnaces
520 = maximum individual furnace size, ft2
The actual size of each furnace is computed after rounding to the
next highest whole unit (N)
DFSA = TFSA * N
where: DFSA = design furnace surface area, m2 or ft2
N = design number of furnaces
CN rounded up to next whole number
f) Subsequent Treatment
None specified, although scrubber water from the air cleaning
system might require treatment.
A 2. Capital Costs
The design surface area for each regeneration furnace is the
primary cost factor necessary for estimating capital costs. The
number of furnaces required is used to determine a scale factor
Date: 4/1/83 IV.3.1.1-B3
-------
for adjusting the total capital cost, based on the cost estimate
per furnace presented in Figure IV.3.1.1-B2.
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-2]:
Multiple Hearth Incinerator Package including feed hopper,
dewatering screw, blowcase, afterburner, venturi, and
scrubber (sizes 3.34, 7.9, 17.7, 40.3, and 48.3 m2 hearth
area (36, 85, 191, 434, and 521 ft2 hearth area))
Oil Storage Tank
Venturi Recirculation Tank
Caustic Storage Tank
Pumps (venturi recirculation, caustic transfer, carbon
transport, carbon slurry sump, fuel oil)
Agitators
Piping
Instrumentation
b) Capital Cost Curves
i) Curve - Figure IV.3.1.1-B2.
- Cost per furnace (thousands of dollars) vs.
hearth area (square meters or square feet).
- Curve basis, cost estimate for five systems
designed with hearth surface areas of 3.34, 7.9,
17.7, 40.3, and 48.3m2 (36, 85, 191, 434, and
521 ft2)
ii) Scale factor to convert cost per furnace to total
capital cost
COST = CPF x (N) °'8
where: COST = total capital cost
CPF = cost per furnace based on design furnace
surface area (DFSA)
N = design number of required furnaces
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable operating costs include power, steam, fuel oil, and
service water. Fixed operating costs include labor, supervision,
overhead, maintenance, laboratory labor, services, insurance and
Date: 4/1/83 IV.3.1.1-B4
-------
'AREA. SQUARE METERS
66.0
18.6 27,9 37.2 46.4
200
300 400 600
AREA. SQUARE FEET
600
700
FIGURE IV.3.1.1-B2.
CAPITAL COST ESTIMATE FOR CARBON
REGENERATION[4-10]
Date: 4/1/83
IV.3.1.1-B5
-------
taxes, and service water. All fixed and variable operating costs
should be adjusted to current levels using an appropriate index
or unit cost factor.
a) Variable Costs
i) Power Requirements - combustion air blower, shaft cooling
blower, venturi recirculation pumps, caustic transfer
pumps, carbon transfer pumps, carbon sump pumps, and fuel
oil pump agitator. The following equation was developed
using regression analysis procedures [4-1].
Metric
KW = (0.5 x TFSA) +2.93
where: KW = power, kilowatts
TFSA = total furnace surface area, m2
English
HP = (0.0623 x TFSA) +3.93
where: HP = power, Hp
TFSA = total furnace surface area, ft2
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power, kilowatts
24 = hour/day
EC = electricity cost, $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = power, Hp
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iii) Steam Requirements - steam is added to the furnace at
the rate of one pound of steam per pound of carbon
STEAM = 1.0 x CU
Date: 4/1/83 IV.3.1.1-B6
-------
where: STEAM = 'steam usage, Kg/day or Ib/day
CU = carbon usage, Kg/day or Ib/day
1.0 = Kg steam/Kg carbon or Ib steam/lb carbon
iv) Steam Cost
TSC = STEAM x CPP
where: TSC = total steam cost, $/day
STEAM = steam usage, Kg/day or Ib/day
CPP = cost per Kg or Ib of steam, $/Kg or
$/lb
v) Fuel Requirement - this is based on total heat,
supplied with fuel oil
Metric
FUEL = JPD * (41900 x 0.869)
where: FUEL = fuel, L/day
JPD = heat required, KJ/day
= CU x 18600 x 1.2 x 1.1
CU = carbon usage, Kg/day
18600 = KJ/Kg carbon
1.2 = allowance for 20% downtime
1.1 = allowance for 10% carbon loss during
regeneration
41900 = fuel heating value, KJ/Kg
0.869 = conversion factor, Kg fuel/L fuel
English
FUEL = BTU T (18000 x 7.25)
where: FUEL = fuel, gal/day
BTU = heat required, BTU/day
= CU x 8000 x 1.2 x 1.1
CU = carbon usage, Ib/day
8000 = BTU/lb carbon
1.2 = allowance for 20% down time
1.1 = allowance for 10% carbon loss during
regeneration
18,000 = fuel heating value, BTU/lb
7.25 = conversion, Ib fuel/gal fuel
vi) Fuel Cost
TFC = FUEL x FCPG
Date: 4/1/83 IV.3.1.1-B7
-------
vii)
where: TFC = total fuel cost, $/day
FUEL = fuel, L/day or gal/day
FCPG = fuel cost, $/L or $/gal
Service Water Requirements - this is for scrubber water
and for carbon quenching
• Scrubber Water
Metric
SCRWT = ACFM x 2.01 * 60
where: SCRWT
ACFM
FUEL
0.869
1440
0.5
24.2
367 * 294
1.1
2.01
60
= scrubber water, L/s
= furnace air requirement, m3/min
= (FUEL x 0.869 * 1440) x 0.5 x 24.2 x
(367 * 294) x 1.1
= fuel required, L/day
= conversion factor, Kg fuel/L fuel
= min/day
=0.5 Kg-mole air/Kg fuel
= m3 air/Kg-mole air (at 21°C)
= volumetric ratio, 93°C to 21°C
(367°K to 294°K)
= 10% excess air factor
= L water/m3 air
= seconds/minute
English
where:
660
SCRWT = ACFM x 0.015 x 1440 * 1000
SCRWT = scrubber water, thousand gal/day
ACFM = furnace air requirement, ft3/min
= (FUEL x 7.25 * 1440) x 0.5 x 387 x
(660 * 530) x 1.1
FUEL = fuel required, gal/day
7.25 = conversion factor, Ib fuel/gal fuel
1440 = conversion, min/day
0.5 = 0.5 Ib-mole air/lb fuel
387 = ft3 air/lb-mole air (at 70°F)
T 530 = volumetric ratio, 200°F to 70°F
(660°R to 530°R)
1.1 = 10% excess air factor
0.015 = gal water/ft3 air
1440 = conversion, min/day
1000 = conversion, gal to thousand gal
• Quench Water
Metric
QUNWT = JPD * (2400 x 1.0 x 86400)
ate: 4/1/83 IV.3.1.1-B8
-------
where: QUNWT = quench service water, L/s
JPD = heat required, KJ/day [see (v)
Fuel Requirement]
2400 = heat of vaporization, KJ/Kg water
1.0 = Kg water/L water
86400 = conversion, s/day
English
QUNWT = BTU * (1030 x 8.34 x 1000)
where: QUNWT = quench service water, thousand
gal/day
BTU = heat required, BTU/day [see (v) Fuel
Requirement]
1030 = heat of vaporization, BTU/lb water
8.34 = Ib water/gal water
1000 = conversion, gal to thousand gal
viii) Service Water Cost
Metric
WC = (SCRWT + QUNWT) x WCPL x 86400
where: WC = service water cost, $/day
SCRWT = scrubber water, L/s
QUNWT = quench water, L/s
WCPL = water cost, $/L
86400 = seconds/day
English
WC = (SCRWT + QUNWT) x WCPG
where: WC = service water cost, $/day
SCRWT = scrubber water, thousand gal/day
QUNWT = quench water, thousand gal/day
WCPG = water cost, $/thousand gal
ix) Carbon Replacement - a 10% loss of carbon per cycle
is assumed during regeneration.
CR = CU x 0.1
where: CR = carbon replacement rate, Kg/day or Ib/day
CU = carbon use, Kg/day or Ib/day
0.1 = 10% replacement factor
Date: 4/1/83 IV.3.1.1-B9
-------
x) Carbon Cost
CRBCOST = CR x CCPP
where: CRBCOST = cost of replacement carbon, $/day
CR = carbon replacement rate, Kg/day or
Ib/day
CCPP = carbon cost per pound, $/Kg or $/lb
b) Fixed Costs
The fixed 0 & M components for this technology are listed in Table
IV.3.1.1-B1, including the cost basis and the unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering and common plant items such as land, piping,
and buildings, are calculated after completion of costing for
individual units (See Section IV.3.5).
A 5. Modifications
None required.
Date: 4/1/83 IV. 3.1.1-BIO
-------
TABLE IV.3.1.1.-B1.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR CARBON REGENERATION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.30 Weeks (7.20 hrs/day)
10% Labor (0.72 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
6.32% Capital
0.40% Capital
2.50% Capital
0.08 L/s
(1.72 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.1-B11
-------
I.
a.
b.
II.
Cost
III.
a.
b.
c.
d.
e.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
DESIGN FACTOR
CARBON REGENERATION
SUMMARY WORK SHEET
REFERENCE: IV. 3.1. I -B
CAPITAL
Design Furnace Surface Area = ft2
Scale Factor =
CAPITAL COST
-
x x ( T 204.7)
Cost from curve F current index
VARIABLE 0 & M
Power =
Hp
Steam =
STEAM
Fuel
FUEL,
Water =
WATER
Carbon =
x x 17.9
EC, $/Kw-hr
x
, lb/day $/lb
X
gal/day $/gal
X
, thou gal $/thou gal
X
CR,lb/day $/lb
FIXED 0 & M
Labor:
Supervision:
Overhead:
Lab Labor:
Maint, Service,
I&T:
Service Water:
X
$/hr hr/day
X
$/hr hr/day
X
LABOR, $/day %/100
X
$/hr hr/day
x r 365
capital, $ %/100 day/yr
x
thou gpd $/thou gal
YEARLY 0 & M
UNCOSTED ITEMS
365
$/day
=
=
x
day/yr sum, $/day
$
0 & M
S2
$/yr
Date: 4/1/83
IV.3.1.1-B12
-------
CARBON REGENERATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. Steam Cost =
4. Fuel cost =
5. Water Cost =
6. Activated Carbon Cost =
7. Labor =
8. Supervision =
9. Overhead =
10. Lab Labor =
11. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
12. Service Water =
Capital Cost Index
$/Kw-hr
$/lb
$/gal
$/thou gal
$/lb
$/hr
$/hr
/100
$/hr
% Capital
% Capital
%
Capital
% T 100 =
%/100
$/thou gal
I. DESIGN FACTOR
a. Total Furnace Surface Area
TFSA = 1.2 x (
T 40) =
ft2
_ _
*CU, Ib/day
*See Section 4a of Activated Carbon Adsorption, IV.3.1.1-A
b. Number of Furnaces Required
CN =
T 520 =
TFSA, ft2
The number of furnaces (CN) should be rounded up to the nearest whole
number (N) : N = _ .
c. Individual Design Furnace Surface Area (DFSA)
DFSA =
ft2
TFSA, ft2
N
Date: 4/1/83
IV. 3*1.1-613
-------
d. Scale Factor for Costs
SF=( )°'8=
N
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = (0.0623 x ) + 3.93 = Hp
TFSA, ft2
b. Steam Requirement
STEAM = 1.0 x = Ib/day
CU, Ib/day
c. Fuel Requirement
FUEL = ( x 0.0809) = gal/day
CU, Ib/day
d. Scrubber Water
SCRWT = x 0.0288 = thou gal/day
FUEL, gal/day
e. Quench Water
QUNWT = x 0.0012 = thou gal/day
CU, Ib/day
f. Total Water
WATER = + = thou gal/day
SCRWT,thou gal/day QUNWT, thou gal/day
g. Carbon Replacement
CR = x 0.1 = Ib/day
CU, Ib/day
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83 IV.3.1.1-U14
-------
IV.3.1.2 CHEMICAL OXIDATION
Introduction
Chemical oxidation processes are used to chemically break down
pollutants such as cyanides, sulfides, and formaldehydes which
are not amenable to biological or other traditional means of
treatment. Powerful oxidants such as chlorine, peroxide, or
permanganates are used for chemical oxidation depending on the
specific pollutant to be treated and concern over toxic chlori-
nated residuals. Cyanide treatment by an alkaline chlorination
process is now widely used and can achieve nearly complete cya-
nide destruction. Chemical oxidation processes are described in
more detail in Volume III of the Treatability Manual, Section
111.3.1.2. Costing methodologies and cost data for this technol-
ogy are presented below.
IV.3.1.2-A. Chlorine Oxidation of Cyanide
A 1. Basis of Design
This presentation is for estimating costs for oxidation of
cyanide, by the alkaline chlorination process. A system of the
type considered is represented in Figure IV.3.1.2-A1. The capi-
tal cost factor is the volume of the two stage reactor vessel.
The principal design factors for cyanide oxidation systems are
wastewater flow and influent cyanide concentration. Influent oil
and grease and TSS are checked to determine if pretreatment is
necessary. Chlorine is supplied to the system at a mass ratio of
15 parts chlorine to 1 part cyanide and caustic is added to
control pH between 8.0 and 9.5 and to subsequently neutralize any
excess chlorine. The reaction vessel is sized for 10 minutes
residence time in the first stage and 30 minutes in the second.
a) Source
The unit cost information in this section was derived from the BAT
Effluent Limitation Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries [4-2]. The
method for developing the design factor is based on assumptions
and procedures in the Contractor Developed Design and Cost Model
[4-1].
b) Required Input Data
Wastewater flow L/s (mgd)
Wastewater characteristics
cyanide (mg/L)
oil and grease (mg/L)
TSS (mg/L)
PH
Date: 4/1/83 IV.3.1.2-A1
-------
O
H
I
H
X
O
O
H
g
w
w
u
s
H
Q
CO
CO
w
u
O
rt
CM
CM
D
O
H
)ate: 4/1/83
IV.3.1.2-A2
-------
c) Limitations
Chlorine oxidation is not considered applicable if cyanide is
present at less than 10 mg/L.
d) Pretreatment
Pretreatment should be provided as indicated for the following
conditions:
i) Equalization if necessary, due to flow variations.
ii) If influent oil and grease >50 mg/L, use oil removal
process.
iii) If influent TSS >50 mg/L, use multi-media filtration.
e) Design Equation
The primary cost factor for alkaline chlorination of cyanide is
the volume of the reaction vessel. The required basin volume for
a chemical oxidation system is calculated based on a standard
hydraulic detention time of 40 minutes (10 min. first stage and
30 min. second stage).
Metric
VOL = (FLOW x 40 x 60) * 1000
where: VOL = basin volume, m3
FLOW = average influent flow, L/s
40 = detention time, min.
60 = seconds/minute
1000 = conversion factor, L/s to m3/s
English
VOL = (FLOW x 40) * 1.44
where: VOL = basin volume, thousand gallons
FLOW = average influent flow, mgd
40 = detention time, min.
1.44 = conversion factor, mgd to thousand gallons/min
f) Subsequent Treatment
None specified
g) Chlorinated Organics
Possible formation of chlorinated organics from alkaline chlori-
nation of cyanide should be carefully considered.
Date: 4/1/83 IV.3.1.2-A3
-------
A 2. Capital Costs
The volume of the two stage oxidation tank is the primary factor
for estimation of capital cost using the capital cost curve
(Figure IV.3.1.2-A2). Costs estimated using this curve must be
adjusted to a current value using an appropriate current cost
index.
a) Cost Data
Items included in the capital cost estimate for alkaline chlori-
nation of cyanide are as follows [4-2]:
Two stage concrete reaction vessel
Agitators (2)
Chlorine feed systems
chlorine vaporizer
chlorinator
circulation pumps (2)
Piping, instrumentation, electrical
Metal shed
pH control
ORP (oxidation/reduction potential) control
b) Capital Cost Curves
Curve - see Figure IV.3.1.2-A2.
- Cost (thousands of dollars) vs.
basin volume (cubic meters or thousand gallons).
- Curve basis, cost estimates on four volumes:
105, 526, 1050, and 2100 m3 (27.8, 139, 278, and
556 thousand gallons) 43.8, 219, 438, and 876 L/s
(1, 5, 10, and 20 mgd) at 40 minute detention.
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable operating costs include power, chlorine, and caustic.
Fixed operating costs include labor, supervision, overhead,
laboratory labor, maintenance, services, insurance and taxes, and
service water. All fixed and variable operating costs should be
adjusted to current levels using an appropriate index or unit
cost factor. Miscellaneous plant costs and caustic costs are
developed in subsequent Sections.
Date: 4/1/83 IV.3.1.2-A4
-------
BASIN VOLUME, THOUSANDS OF LITERS
378 767 1136 1614
1802
1600>
BASIN VOLUME,
300
THOUSANDS OF
400
GALLONS
500
FIGURE IV.3.1.2-A2. CAPITAL COST ESTIMATE FOR CHEMICAL
OXIDATION [4-10]
Date: 4/1/83
IV.3.1.2-A5
-------
a) Variable Costs
i) Power Requirements - includes agitators, recirculation
pumps. The following equation was developed using
regression analysis procedures [4-1].
Metric
KW = (0.166 x VOL) +23.6
where: KW = power, kilowatts
VOL = basin volume, m3
English
HP = (0.845 x VOL) +31.6
where: HP = power, Hp
VOL = basin volume, thousand gallons
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost, $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = power, Hp
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iii) Chemical Requirements
• Chlorine
Metric
CL = FLOW x 0.086 x CN x 15
where: CL = chlorine requirement, Kg/day
FLOW = influent flow, L/S
Date: 4/1/83 IV.3.1.2-A 6
-------
0.086 = conversion factor
CN = influent cyanide (as NaCN), mg/L
15 = ratio, Kg chlorine/Kg influent cyanide
English
CL = FLOW x 8.34 x CN x 15
where: CL = chlorine requirement, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
CN = influent cyanide (as NaCN), mg/L
15 = ratio, Ib chlorine/lb influent cyanide
• Caustic (needed to maintain pH between 8.0 and 9.5)
- If influent pH <8.0:
Metric
CR = [(CN x 17) + (8 - pH)3 x 15] x 0.086 x FLOW
English
CR = [(CN x 17) + (8 - pH)3 x 15] x 8.34 x FLOW
- If influent pH £8.0:
Metric
CR = CN x 17 x 0.086 x FLOW
where: CR = required amount of caustic, Kg/day
17 = Kg caustic/Kg CN'
English
CR = CN x 17 x 8.34 x FLOW
where: CR = required amount of caustic, Ib/day
17 = Ib caustic/lb CN'
iv) Chemical Costs (except caustic):
Once the total requirements for chlorine has been estab-
lished, the associated cost may be estimated as follows:
CC = CL x N
Date: 4/1/83 IV.3.1.2-A7
-------
where: CC = chlorine cost ($/day)
CL = calculated requirement for chlorine
Kg/day or Ib/day
N = unit cost of chlorine, $/Kg or $/lb
Capital and 0 & M costs for caustic addition may be cal-
culated for individual add-on technologies or for whole
plants which use a central handling and distribution
system by using Section IV.3.1.13-C. For new plants or
expansions involving several treatment units which use
lime, a central lime/caustic unit may be considered to
serve all of them. For single unit add-on's a small
caustic or lime system may be considered. In either case,
the total quantity of caustic or lime required should be
determined and carried forward to Section IV.3.1.13-C to
determine costs.
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.1.2-A1, including values for the cost basis and the
unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5).
A 5. Modifications
None.
Date: 4/1/83 IV.3.1.2-A8
-------
TABLE IV.3.1.2-A1. FIXED 0 & M COST BASIS AND UNIT COST FACTORS
FOR CHEMICAL OXIDATION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.20 Weeks (4.80 hrs/day)
10% Labor (0.48 hrs/day)
75% Labor Cost
0.15 Shifts (0.86 hrs/day)
3.93% Capital
0.04% Capital
2.50% Capital
0.075 L/s
(1.72 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.2-A9
-------
I.
CHEMICAL OXIDATION
SUMMARY WORK SHEET
REFERENCE: IV.3.1.2-A
DESIGN FACTOR CAPITAL
Basin Volume = thousand gallons
II.
Cost
III.
a.
b.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
CAPITAL COST
= x ( f 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
Chlorine = x
CL, Ib/day NCL, $/lb
FIXED 0 & M
Labor : x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor: x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100 day/yr
Service Water: x x 1000
thou gpd $/gal
YEARLY 0 & M 365
$/day
.
x
day/yr sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Caustic = Ib/day
Date: 4/1/83
IV.3.1.2-A10
-------
CHEMICAL OXIDATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. NCL: Chlorine Cost =
4. Labor =
5. Supervision =
6. Overhead =
7. Lab Labor =
8. Maintenance =
Services =
Insurance/Taxes =
Other O&M Factor Sum =
9. Service Water =
Capital Cost Index
$/Kw-hr
$/lb
$/hr
$/hr
% Labor T 100 =
%/100
$/hr
% Capital
% Capital
% Capital
f 100 =
%/100
$/thou gal
I. DESIGN FACTOR
Basin Volume =
x 27.8 =
FLOW, mgd
thousand gallons
II. CAPITAL COST
III. VARIABLE O&M
a. Power Requirements
HP = (
x 0.845) + 31.6 =
basin volume, thou. gal.
b. Chlorine Requirement for Cyanide Oxidation
HP
CL =
x 125 =
FLOW, mgd CN, mg/L
Ib/day
Date: 4/1/83
IV.3.1.2-A11
-------
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Caustic Requirement for Cyanide Oxidation
If influent pH <8.0
CR = [( x 17) + (8 - _)3 x 15] x 8.34 x
CN, mg/L pH FLOW, mgd
Ib/day
If influent pH >8.0
CR = x
x 142 =
CN, mg/L FLOW, mgd
Ib/day
Date: 4/1/83
IV.3.1.2-A12
-------
IV.3.1.5 PRECIPITATION AND COAGULATION/FLOCCULATION
Introduction
Chemical precipitation, coagulation, and flocculation are em-
ployed to help remove heavy metals and colloidal and dissolved
solids from wastewater streams. Various coagulants such as alum,
lime, ferric chloride, organic polymers, and synthetic polyelec-
trolytes are used in the process depending on the specific waste
material to be removed. The coagulants are rapidly mixed with
the wastewater and the colloidal particles are allowed to agglom-
erate into a floe large enough to be removed by subsequent sedi-
mentation or filtration processes. Precipitation is a chemical
process by which soluble metallic ions and certain anions are
converted to an insoluble form for subsequent removal from the
wastewater stream. Coagulation/Flocculation is often included to
aid in the removal of the insoluble precipitates. The perfor-
mance of the process is limited by chemical interactions, temper-
ature, solubility variances, and common ion and mixing effects.
This process is discussed in more detail in Volume III of the
Treatability Manual, Section III.3.1.5. Costing methodologies
and cost data for this technology are presented below.
IV.3.1.5-A. Precipitation and Coagulation/Flocculation
A 1. Basis of Design
This presentation is for precipitation and coagulation/floccu-
lation of priority and conventional pollutants in wastewater
streams. The basic factor for estimating the capital cost of a
precipitation/coagulation/flocculation system with this method is
wastewater flow. The system is designed with separate mixing and
flocculation chambers having two minutes and 20 minutes detention
time respectively at 120% of average daily flow. A flow diagram
of such a system is presented in Figure IV.3.1.5-A1.
A standard dose of 200 mg/L of alum is assumed in all cases
unless otherwise specified. If different coagulant(s) and/or
different dose rate(s) are considered more appropriate by the
user, they may be substituted for the standard alum dose. A
dosage of one mg/L of polyelectrolyte is assumed in all cases
except when the unit is used to coagulate and flocculate an acti-
vated sludge waste stream. In that case, alum is not used and
only a 5 mg/L dose of polyelectrolyte is used. If precipitation
of some priority pollutant(s) is desired an appropriate precip-
itant dose must be assumed by the user. For more information see
Section III.3.1.13 of Volume III. Sludge generation from this
unit process is accounted for by summing the amount of coagulants
added and precipitates removed. Final conditioning and disposal
of sludg-e as well as provisions for lime handling, if needed, are
accounted for in subsequent unit processes.
Date: 4/1/83 IV.3.1.5-A1
-------
inn nnn
j u u I u u u
nnn nnn
ami
nnnlnnr
uuuluuu
mra
nnn nnr
uuuluuu
nnn nnn
a-
JUD"miu
pnn nnn
JUUIUUU
?.'
J: 1
§
o u
iJ O
fe O
t/a PH
Pi H
p* <3
H
M
-H PH
<3 M
I U
^g
ro Pi
• O
> fn
H
W ^
°D O
O <
l-l M
Pn Q
Date: 4/1/83
IV.3.1.5-A2
-------
a) Source
The unit cost information in this section was derived from
the BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
b) Required Input Data
Wastewater flow L/s (mgd)
Influent TSS and precipitable pollutant concentrations
(mg/L)
c) Limitations
Precipitation/coagulation/flocculation may not be suitable if:
i) Precipitable pollutants not present or present at
concentrations below treatable levels.
ii) No precipitable pollutants and influent TSS <30 mg/L.
d) Pretreatment
Neutralization is required when influent pH £2.5 or pH £9.0.
Depending on the coagulant used, the suitable ranges of pH may be
much smaller.
e) Design Equation
Average daily wastewater flow is the primary capital cost factor
for coagulation/flocculation systems. The design of the system
is based on two minutes detention in the mixing chamber and twenty
minutes detention in the flocculation chamber at 120% of average
daily flow.
f) Subsequent Treatment
Subsequent treatment involves a solids separation process (multi-
media filtration or sedimentation depending on TSS concentration
and floe characteristics).
A 2. Capital Costs
Flow is the primary capital cost factor for this unit process.
Capital cost can be estimated using the capital cost curve
(Figure IV.3.1.5-A2). This curve is based on the addition of one
coagulant chemical plus polyelectrolyte. The cost for a system
which uses more than one coagulant should be adjusted as indi-
cated in Section A 5, b. Costs estimated using this curve must
be adjusted to a current value using an appropriate current cost
index.
Date: 4/1/83 IV.3.1.5-A3
-------
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-2]:
Concrete mixing chamber (2)
Concrete flocculation chamber (2)
Polyelectrolyte addition system (1)
Coagulant holding tank (1)
Coagulant feed pumps (2)
Agitators (2)
Horizontal paddle wheel flocculators
Sluice Gates (2)
b) Capital Cost Curve
Curve - see Figure IV.3.1.5-A2.
- Cost (thousands of dollars) vs flow (liters per
second or million gallons per day).
- Curve basis, cost estimates on four flow rates:
17.5, 87.6, 438, and 876 L/S (0.4, 2.0, 10.0, and
20 mgd).
Scale Factor - for more than one coagulant, see Section A
5,b
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable operating costs include power, coagulants, and poly-
electrolyte. Fixed operating costs include labor, supervision,
overhead, laboratory labor, maintenance, services, insurance and
taxes, and service water. All fixed and variable operating costs
should be adjusted to current levels using an appropriate index
or unit cost factor. Byproduct handling and miscellaneous common
plant costs must be estimated separately.
a) Variable Costs
i) Power Requirements. This equation was developed using
regression analysis procedures [4-1].
Metric
KW = (0.054 x FLOW) +1.79
Date: 4/1/83 IV.3.1.5-A4
-------
PLOW. LITERS KM SE€Oflft
O
o
£
s
1
I
o
o
Ann.
Ann.
dnn.
0
)
f
,
f
/
8-
I/
(
r ;
i6 1
f
^
,
^
x
i <
'5 2<
x
^
X
X
^
( (
!3 3
X
^
^
!
'
*•
$ (
•0 *
^
*
^
f
) 1
8 5
f
]
X
^
y«
0 1
6 6
«<
^"
^
^1
2 1
3 *
<
^
^
K
^
4 1
j>1
X
*'
»•"
71
10
^
6 1
10
»•
*
X
8I
I
d
••1
8 2(
FLOW, MILLION GALLONS PER DAY
FIGURE IV.3.1.5-A2. CAPITAL COST ESTIMATE FOR PRECIPITATION
AND COAGULATION/FLOCCULATION [4-10]
Date: 4/1/83
IV.3.1.5-A5
-------
where: KW = power, kilowatts
FLOW = influent flow, L/s
English
HP = (3.17 x FLOW) +2.40
where: HP = power, Hp
FLOW = influent flow, mgd
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iii) Chemical Requirements
Chemical requirements for this unit process include the
coagulant and polyelectrolyte.
• Requirement for Coagulant or Precipitant
Metric
CHEM(n) = COGDOSE(n) x FLOW x 0.086
where: CHEM(n) = amount of coagulant (n) needed,
Kg/day
COGDOSE = coagulant dose, mg/L
FLOW = influent flow, L/S
0.086 = conversion factor
English
CHEM(n) = COGDOSE(n) x FLOW x 8.34
Date: 4/1/83 IV.3.1.5-A6
-------
where: CHEM(n) = amount of coagulant (n) needed,
Ib/day
COGDOSE(n) = coagulant dose, mg/L
(standard 200 mg/L alum dose or
see Section A 5, a)
FLOW = influent flow, mgd
8.34 = conversion factor
• Requirement for Polyelectrolyte
Polyelectrolyte is added in an amount sufficient to
achieve a concentration of 1.0 mg/L.
Metric
POLY = PDOSE x FLOW x 0.086
where: POLY = amount of polyelectrolyte required,
Kg/day
PDOSE = polyelectrolyte dose, mg/L
FLOW = influent flow, L/S
0.086 = conversion factor
English
POLY = FLOW x PDOSE x 8.34
where: POLY = amount of polyelectrolyte required,
Ib/day
FLOW = influent flow, mgd
PDOSE = polyelectrolyte dose, mg/L
8.34 = conversion factor
If coagulation/flocculation is being used only to
aid in the settling of waste activated sludge, it
is assumed that a polyelectrolyte dose of 5 mg/L is
required and no other chemicals are used [4-1].
iv) Chemical Cost (except lime*)
The chemical cost may be estimated as follows:
CC (n) = I (CHEM (n) x N (n))
where: CC (n) = cost of chemical (n), $/day
CHEM (n) = requirement for chemical (n), Kg/day or
Ib/day
N (n) = unit cost of chemical (n), $/Kg or $/lb
*Costs for lime are based on total plant needs rather
than on the needs of an individual unit. Lime is
assumed to be stored and distributed through a central
Date: 4/1/83 IV.3.1.5-A7
-------
lime handling system. Therefore, lime requirements
should be totaled for each unit process but costs for
handling systems and chemicals should be estimated
separately after the design of all unit processes
requiring lime is completed (See Section IV.3.1.13C).-
If lime is required for an add-on technology, lime
handling and material costs may also be estimated from
information in Section IV.3.1.13C.
b) Fixed Costs
The fixed 0 & M components for this technology are listed in Table
IV.3.1.5-A1, including values for the cost basis and the unit
costs [4-2].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as land, yard
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5).
Sludge handing and treatment facilties are not included in the
cost estimates for this technology but should be designed and
costed separately according to the individual technologies re-
quired (see Section IV.3.4). The nature and quantity of sludge
generated by each wastewater treatment process should be esti-
mated for use in the design and costing of sludge treatment
processes. Sludge generation by this technology is determined
from chemical use and influent pollutants removed (including
solids and precipitable pollutants). A rough estimate of sludge
generation may be made using the equation indicated below:
Metric
SLDG (n) = I [CHEM (n) + MPPT (i)]
where: SLDG (n)
CHEM (n)
MPPT (i)
sludge of type n, Kg/day
coagulant (n) added, Kg/day
pollutant (i) removed, Kg/day
= POL (i) x FLOW x 0.086
POL (i) = pollutant (i) removed (solids or pre-
cipitable pollutant) influent concen-
tration, mg/L
FLOW = influent flow, L/s
0.086 = conversion factor
English
SLDG (n) = Z [CHEM (n) + MPPT (i)]
Date: 4/1/83
IV.3.1.5-A8
-------
TABLE IV.3.1.5-A1. FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR PRECIPITATION AND COAGULA-
TION/FLOCCULATION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.25 Weeks (6.00 hr/day)
10% Labor (0.60 hr/day)
75% Labor Cost
0.20 Shifts (1.14 hr/day)
3.53% Capital
0.40% Capital
2.50% Capital
0.08 L/S
(1.81 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.5-A 9
-------
where: SLDG (n) = sludge of type n, Ib/day
CHEM (n) = coagulant (n) added, Ib/day
MPPT (i) = pollutant (i) removed, Ib/day
= POL (i) x FLOW x 8.34
POL (i) = pollutant (i) removed (solids or pre-
cipitable pollutant) influent con-
centration, mg/L
FLOW = influent flow, mgd
8.34 = conversion factor
This is an estimate of sludge generation that could be either
too high or too low. Factors that will tend to make this
estimate too high include the amount of the chemical added that
remains in solution, the precipitable pollutants that remain in
solution, and the solids that cannot be removed (e.g., too fine).
Factors that may cause this estimate to be too low include side
reactions such as the precipitation of alkalinity in the waste-
water. It is also helpful to identify the nature of the sludge
according to coagulant (e.g., alum sludge) as this information
will be used in the sizing and costing of required sludge handling
systems.
A 5. Modifications
a) Coagulant Dose
If the user determines that a precipitant or coagulant and/or
dose rate other than the standard 200 mg/L of alum is more appro-
priate, it may be substituted into the design. Chemicals such as
lime, ferric chloride and sodium sulfide also have been found to
be effective in precipitating many priority pollutants (see
Section 3.1.5 of Volume III for representative data). The coagu-
lant dose, or doses selected should be sufficient to precipitate
the pollutant(s) of concern, coagulate the resulting precipitate,
and overcome any side reactions such as hydrolysis which might
compete with the desired reaction. In addition, each coagulant
has an optimum pH range and pH adjustment using acid or base may
be required.
b) Capital Cost Scale Factor
The capital cost curve (Figure IV.3.1.5-A2) is based on feed
equipment for one coagulant and a polyelectrolyte. If more than
one coagulant is used, the capital cost should be adjusted by a
scale factor to account for the additional feed equipment. The
scale factor used for this process is the square root of the
number of coagulants and is applied to the flow prior to esti-
mating the capital cost from the cost curve [4-1].
Date: 4/1/83 IV.3.1.1-A10
-------
Scale Factor (applies to flow prior to cost estimation)
Flow for cost purposes = FLOW x (n) *
where: Flow = influent flow, L/s or mgd
n = number of coagulant chemicals, not including
polyelectrolyte
Note that the scale factor does not change the design flow, it is
only a capital cost adjustment.
Date: 4/1/83 IV.3.1.1-M1
-------
I. DESIGN FACTOR
a . FLOW =
COAGULAT ION/ FLOCCULAT I ON
SUMMARY WORK SHEET
REFERENCE: IV.3.1.5-A
CAPITAL
mgd
II. CAPITAL COST
Cost =
Cost from
x ( r 204.7) $
curve current index
III. VARIABLE 0 & M
a. Power
Hp
b. Chemical, Alum =
c. Chemical,
d. Chemical,
e. Polyelectrolyte =
x x 17.9
EC, $/Kw-hr
x
AL, Ib/day NAL, $/lb
= x
Ib/day $/lb
= X
Ib/day $/lb
x
POLY, Ib/day NP, $/lb
IV. FIXED 0 & M
a. Labor:
b. Supervision:
c. Overhead:
d. Lab Labor:
e. Maint, Service,
I&T:
f. Service Water:
X
hr/day $/hr
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
X r 365
capital, $ %/100 day/yr*
X
thou gpd $/thou gal
V. YEARLY 0 & M
365
day/yr
$/day 0 & M
=
.
.
.
X =
sum, $/day $/yr
VI. UNCOSTED ITEMS
a. Lime Requirement
b. Alum Sludge =
c. Chemical Sludge,
d. Chemical Sludge,
Ib/day
Ib/day
Ib/day
Ib/day
Date: 4/1/83
IV.3.1.5-A12
-------
COAGULATI ON/ FLOCCULAT I ON
WORK
SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. NAL: Alum Cost =
4. NFC: Ferric Chloride
Chemical Cost, =
5. NP: Polymer .Cost =
6. Labor =
7 . Supervision =
8. Overhead =
9 . Lab Labor =
LO . Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
LI. Service Water =
Capital Cost Index
$/Kw-hr
$/lb
$/lb
$/lb
$/hr
$/hr
% Labor * 100 = %/100
$/hr
% Capital
% Capital
% Capital
r 100 = %/100
$/1000 gal
J. DESIGN FACTOR
a. Standard Dose, 200 mg/L Alum
FLOW = mgd
b. If more than one coagulant used,
Flow for cost purposes =
not including polyelectrolyte
x ( )°'5 = mgd
FLOW, mgd n
n = number of coagulant chemicals not including polyelectrolyte,
see III B,3
II. CAPITAL COST
Date: 4/1/83
IV.3.1.5-A13
-------
III. VARIABLE 0 & M
a. Power Requirements
HP = (3.17-x ) + 2.40 = Hp
FLOW, mgd
b. Chemical Requirements
1. Standard 200 mg/L Alum Dose
CHEM (Alum) = 1670 x = Ib/day
FLOW, mgd
2. Nonstandard Coagulant Dose (indicate coagulant and dose rate)
CHEM = x x 8.34 = Ib/day
COGDOSE,mg/L FLOW,mgd
CHEM = x x 8.34 = Ib/day
COGDOSE,mg/L FLOW,mgd
3. Number of coagulant chemicals required (n) =
4. Polyelectrolyte Addition
If activated sludge is not being treated (1 mg/L)
POLY = x 8.34 = Ib/day
FLOW, mgd
IJ activated sludge is being treated (5 mg/L)
POLY = x 41.7 = Ib/day
FLOW, mgd
IV. FIXED 0 & M
a. Sludge Generation
1. Pollutants Removed
Indicate coagulant and sum of pollutant concentrations removed by
coagulant
• Pollutants removed by Coagulant 1
MPPT = x x 8.34 = Ib/day
E POL (i) FLOW
• Pollutants removed by Coagulant 2
MPPT = x x 8.34 = Ib/day
Z POL (i) FLOW
Date: 4/1/83 IV.3.1.5-A14
-------
2. For standard 200 mg/L alum dose
SLDG (Alum) = +
MPPT(Alum) CHEM(Alum)
Ib/day
3.
For nonstandard coagulant dose
Indicate coagulant, sludge type, total Ib/day pollutant removed
(MPPT) and total Ib/day chemical coagulant added (CHEM).
SLDG =
SLDG =
MPPT
MPPT
CHEM
CHEM
Ib/day
Ib/day
Date: 4/1/83
IV.3.1.5-A15
-------
IV.3.1.9 FILTRATION
Introduction
Granular-media filtration involves the passage of a stream con-
taining suspended matter through a bed of granular material with
a resultant capture of solids. In most common filter designs,
the liquid flows downward through a static bed. Mechanisms
operative within the filter bed that contribute to solids removal
include: physical straining, sedimentation, inertial impaction,
interception, and adhesion. Further details describing this
process can be found in Volume III of the Treatability Manual,
Section III.3.1.9. Costing methodologies and cost data for this
technology are presented below.
IV.3.1.9-A. Multi-Media Filtration
A 1. Basis of Design
This presentation is for the multi-media filtration of waste-
water, with a sludge byproduct generated. A process flow diagram
for this technology is presented in Figure IV.3.1.9-A1. The
principal design factors for multi-media filtration are wastewater
flow, TSS concentration, and filter surface area. The filter
surface area is also the principal capital cost factor for this
technology. Influent TSS and oil and grease are checked to
determine if pretreatment is necessary. The surface hydraulic
loading rate for the filter is selected based on the influent TSS
concentration, floe characteristics, run length, and bed depth.
From these data and the influent flow, the required filter sur-
face area is calculated for a run time of eight hours at a bed
depth of 1.5 m (5 ft). An appropriate safety factor is applied
to account for backwash time and down time for operating units
[4-1].
a) Source
The unit cost information in this section was derived from the BAT
Effluent Limitations Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries [4-2].
b) Required Input Data
Wastewater flow, L/s (gpm)
Influent total suspended solids (TSS), (mg/L)
c) Limitations
Multi-media filtration is not used if influent TSS concentration
<5 mg/L.
Date: 4/1/83 IV.3.1.9-A1
-------
4-
! \J
Ttt
1 H>
in
iO
/r
si
it
y
ill
a 61
a d)i
o
H
§
H
M
fn
o
CO
to
M
u
§
PM
(Ti
i—I
CO
H
Date: 4/1/83
IV.3.1.9-A2
-------
d) Pretreatment
Pretreatment should be provided as indicated for the following
conditions:
i) If influent oil >35 mg/L, an oil removal process should
be used.
ii) If influent TSS >100 mg/L, then clarification should
be used.
e) Design Factor
The filter surface area is the primary factor used to estimate
cost by this method. Multi-media filters are assumed to have a
bed depth of 1.5 m (5 ft) and operate on an 8 hour run cycle
[4-2]. The user should select an appropriate.hydraulic loading
rate between 1.4 and 5.4 L/s/m2 (2 to 8 gpm/ft2) and calculate
the required filter surface area including the necessary safety
margins. The surface loading rate is affected by the influent
TSS concentration, the relative strength of the floe, and other
factors. For further information see Volume III, Section
III.3.1.9.
Metric
SA = FLOW
Q
where: SA
FLOW
Q
surface area, m2
applied average influent flow, L/s
surface hydraulic loading rate, L/s/m2
(see Volume III, Section III.3.1.9 for guidance in
selecting a loading rate)
English
SA = (FLOW x 106) * (1440 x Q)
where: SA
FLOW
Q
106
1440
surface area, ft2
applied average influent flow, mgd
surface hydraulic loading rate, gpm/ft2
(see Volume III, Section III.3.1.9 for guidance in
selecting a loading rate)
conversion factor, mgd to gpd
conversion factor/ day to minute
The following safety margins are included in the final sizing of
the filter surface area to account for continued operation during
backwash and other downtime of filter units:
- If SA £58.3 m2 (628 ft2), add 20% for system non-service
mode operation
Date: 4/1/83
IV.3.1.9-A3
-------
- If SA <58.3 m2 (628 ft2), add 50% for system non-service
mode operation
f) Subsequent Treatment
None specified.
A 2. Capital Costs
The total surface area of the multi-media filtration units is the
principal factor in the capital cost estimate. Presented in
Figure IV.3.1.9-A2 are installed costs for multi-media filters as
a function of surface area. The filter systems represented by
the curve are sized on an assumed loading rate of 3.4 L/s/m2
(5 gpm/ft2), for a bed depth of 1.5 m (5 ft) and a run length
of 8 hours. They are assumed to use a hydraulic backwash rate
of 13.6 L/s/m2 (20 gpm/ft2) and an air scour rate of 0.22 L/s/m2
(5 ft3/m/ft2) for a period of 15 minutes. Costs estimated using
these curves must be adjusted to a current value using an appro-
priate current cost index.
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-10]:
For the 5.2, 19.5, and 65 m2 (56, 210, and 700 ft2) design units -
Vertical pressure downflow sand filters, maximum individual
unit size of 9.29 m2 (100 ft2)
Feed pumps
Backwash pumps
Air compressor for air scour
Backwash holding tank
Piping, insulation
Instrumentation
For the 260 m2 (2800 ft2) design unit -
Four compartment horizontal filter (four units)
Backwash pumps, air scour compressors, and backwash
holding tank are not required for this equipment
Feed pumps
Piping, insulation
Instrumentation
b) Capital Cost Curves
Curve - see Figure IV.3.1.9-A2.
- Cost (thousands of dollars) vs surface area (square
meters or square feet).
Date: 4/1/83 IV.3.1.9-A4
-------
V)
EC
til
Ul
Ul
o
(0
111
DC
Ul
c
UJ
Ul
u.
UJ
K
O
to
Ul
o:
ui
S
H
,-J
H
H
I
w
H
H
V)
O
3
51
8 8
-------
- Curve basis, cost estimates for the filtration
systems based on total filter surface areas of 5.2,
20, 65, and 260 m2 (56, 210, 700, and 2800 ft2)
based on flows of 8.76, 43.8, 219, and 876 L/s (0.2,
1, 5, and 20 mgd).
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component of the operating cost is the power requirement
for the filtration system. Fixed operating costs include labor,
supervision, overhead, laboratory labor, maintenance, services,
insurance and taxes, and service water. All fixed and variable
operating costs should be adjusted to current levels using an
appropriate index or unit cost factor.
a) Variable Cost
i) Power Requirements - feed pumps, compressors, backwash
pumps [4-1]. This equation was developed using regression
analysis procedures.
Metric
KW = [71.4 x (logn FLOW)] - 140
where: KW = power required, kilowatts
FLOW = influent flow, L/s
log = natural logarithm
English
HP = [95.8 x (logn FLOW)] + 174
where: HP = power, Hp
FLOW = influent flow, mgd
log = natural logarithm
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
24 = hours/day
EC = electricity cost, $/Kw-hr
Date: 4/1/83 IV.3.1.9-A6
-------
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
EC = electricity cost, $/Kw-hr
24 = hr/day
0.746 = Kw-hr/Hp-hr
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.1.9-A1, including values for the cost basis and the
unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after completion of costing for indi-
vidual units (see Section IV.3.5).
The amount of sludge accumulated by the system should be account-
ed for in order to facilitate cost estimates for subsequent
sludge handling systems. Sludge production from filtration is
based on an assumed solids removal efficiency which must be
selected by the user based on conditions.
Metric
SP = FLOW x 0.086 x E x TSS
where: SP
FLOW
0.086
E
sludge production, Kg/day (dry)
applied flow, L/s
conversion factor
solids removal efficiency, fraction
(see Volume III, Section III.3.1.9 for guidance)
TSS = influent suspended solids, mg/L
English
SP = FLOW x 8.34 x E x TSS
where: SP
FLOW
8.34
E
sludge production, Ib/day (dry)
applied flow, mgd
conversion factor
solids removal efficiency, fraction
(see Volume III, Secton 3.1.9 for guidance)
TSS = influent suspended solids, mg/L
Date: 4/1/83
IV.3.1.9-A7
-------
TABLE IV.3.1.9-A1.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR MULTI-MEDIA FILTRATION
[4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.15 Weeks (3.60 hrs/day)
10% Labor (0.36 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
4.09% Capital
0.40% Capital
2.50% Capital
0.23 L/s
(5.18 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.9-A8
-------
A 5. Modifications
The total surface area calculation is outlined in Section A l,e,
Design Factor. A minimum of two operating filters and one stand-
by is specified for most applications with the system sized to
accommodate 150% of average daily flow. For very small systems,
two filters each sized to accommodate 100% of flow may be accept-
able. For systems with a total filter surface area greater than
58.3 m2 (628 ft2), no designated spare filter is required, but the
total surface area should be designed to accommodate 120% of
average daily flow [4-1].
Date: 4/1/83 IV.3.1.9-A9
-------
MULTI -MEDIA FILTRATION
SUMMARY WORK SHEET
I. DESIGN FACTOR
Filtration Surface Area = SA =
(including safety margin)
REFERENCE: IV.3.1.9-A
CAPITAL
ft*
II. CAPITAL COST
Cost = x (
r 204.7)
Cost from curve current index
III. VARIABLE 0 & M
a. Power = x
x 17.9
Hp EC, $/Kw-hr
IV. FIXED 0 & M
a. Labor: x
hr/day
b. Supervision:
hr/day
c. Overhead:
Labor, $/day
d. Lab Labor: x
hr/day
e. Maint, Service,
I&T: capital, $
f. Service Water: x
thou gpd
V. YEARLY 0 & M
$/hr
x
$/hr
X
%/100
$/hr
x * 365
%/100 day/yr
$/thou gal
365
$/day
.
X
day/yr sum, $/day
$
0 & M
££
$/yr
VI. UNCOSTED ITEMS
a. Filter Backwash Solids =
Ib/day
Date: 4/1/83
IV.3.1.9-A10
-------
MULTI-MEDIA FILTRATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Labor = $/day
4. Supervision = $/hr
5. Overhead = % Labor * 100 = %/100
6. Lab Labor = $/hr
7. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other O&M Factor sum = * 100 = %/100
8. Service Water = $/thou gal
I. DESIGN FACTOR
a. Wastewater characteristics
Influent flow = mgd (FLOW)
Influent total suspended solids = mg/L (TSS)
b. Hydraulic loading rate (must be selected by user)
Q = gpm/ft2
c. Filtration Surface Area
SA = ( x 106) r ( x 1440) = ft2
FLOW mgd Q, gpm/ft2
d. Safety Margin
If SA > 628 ft2, then: Design SA = 1.2(SA) = ft2
If SA < 628 ft2, then: Design SA = 1.5(SA) = ft2
II. CAPITAL COST
Date: 4/1/83 IV.3.1.9-A11
-------
III. VARIABLE 0 & M
a. Power Requirements
HP = 95.8 x (logn ) + 174 = Hp
FLOW, mgd
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Filter Backwash Solids
SP = x x x 8.34 = Ib/day
FLOW, mgd TSS, mg/L E, fraction
Date: 4/1/83 IV.3.1.9-A12
-------
IV.3.1.10 FLOTATION
Flotation is used to treat wastewaters containing suspended
solids, colloidal material, or oils that have a specific gravity
close to that of water. Dissolved air flotation (DAF) is a
process by which suspended solids, free and emulsified oils, and
grease are separated from wastewater by releasing gas (air)
bubbles into the wastewater to aid separation. DAF is discussed
in more detail in Volume III, Section III.3.1.10 of the Treat-
ability Manual. Costing methodologies and cost data for these
technologies are presented below.
IV.3.1.10-A. Dissolved Air Flotation
A 1. Basis of Design
This presentation is for the removal of oil and solids from
wastewater by the dissolved air flotation (DAF) process. This
process is represented schematically in Figure IV.3.1.10-A1. The
principal design factor for this technology is the influent
wastewater flow.
The dissolved air flotation system is sized according to the in-
fluent flow rate and design overflow rate. The design overflow
rate for this DAF unit process is 1.36 L/s/m2 (2880 gpd/ft2),
based on design flow plus 50% effluent recycle. The main feed
influent of the DAF unit undergoes pre-flotation flocculation
using lime to aid in the separation of oils and to coagulate and
stabilize the floe. The design flow rate, in all cases, is 120
percent of the average wastewater flow. A minimum of two units,
each at 50% of design capacity, are provided.
Free oil is readily removed by DAF systems but further treatment
is generally required to improve removal of emulsified and soluble
oil. The system presented in this section includes lime floccu-
lation of the DAF influent to aid in the separation of oils and
to coagulate and stabilize floe. Oil and solids removal also may
be enhanced by other chemical and physical means as well. Varia-
tions on the DAF process and information on emulsion breaking
techniques are presented in Sections III.3.1.10 and III.3.1.14 of
Volume III respectively.
a) Source
The unit cost information in this section was derived from the BAT
Effluent Limitations Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries [4-2], The
method for developing the design factor is based on assumptions
and procedures in the Contractor Developed Design and Cost Model
[4-1].
Date: 4/1/83 IV.3.1.10-A1
-------
O
H
E-i
<
EH
O
^
PM
<
Q
co
H
Q
O
<
H
Q
w
u
O
O
rH
oo
H
O
H
Date: 4/1/83
IV.3.1.10-A2
-------
b) Required Input Data
Average and peak wastewater flow L/s (mgd)
Characteristics of the wastewater stream (mg/L)
- oil and grease
- TSS
- floating solids
- floating organic pollutants
c) Limitations
DAF is not considered applicable for treating influent oil con-
centrations of less than 10 mg/L.
d) Pretreatment
For influent oil concentrations greater than 35 mg/L DAF may be
preceded by gravity oil separation.
e) Design Equation
Average influent wastewater flow rate in liters per second
(million gallons per day) is the primary capital cost factor for
DAF systems. The cost factor (flow) is adjusted by a scale
factor (Section A 2 b) to account for peak flow prior to esti-
mating costs.
f) Subsequent Treatment
Sludge and oil and grease removed from the wastewater stream are
usually treated by thickening, stabilizing and dewatering pro-
cesses before being disposed.
A 2. Capital Costs
The primary cost factor for DAF is the design influent wastewater
flow rate. This parameter is the independent variable in the
cost curves for the unit process (Figure IV.3.1.10-A2). For
flows greater than 4.38 L/s (0.1 mgd), a scale factor is applied
to adjust the flow prior to selection of a cost from the cost
curve. The scale factor is used as a means of adjusting capital
cost to account for peak flow capacity.
a) Cost Data
Items included in the capital cost estimates for the DAF units
are as follows [4-2]:
Pre-flotation flocculation tanks (2)
Flotation clarifier, rectangular
Vertical turbine flocculators (2)
Date: 4/1/83 IV.3.1.10-A3
-------
Splitter box, concrete (2)
Polymer holding tank
Polymer feed pumps (2)
Sludge pumps, progressive cavity (2)
Air compressor, centrifugal (2)
Sluice gates
Piping
Instrumentation
b) Capital Cost Curve
i) Curve - Figure IV.3.1.10-A2
- Cost (millions of dollars) vs. wastewater flow
(liters per day or million gallons per day).
- Curve basis, cost estimates for system at six
flow rates: 2.33, 8.39, 21, 25.2, 219, and 437
L/s (37, 133, 333, 400, 3467, and
6933 gpm).
ii)' Scale factor: applies to flow prior to selection of a
cost from the cost curve
• if Avg Flow <4.38 L/s (< 0.1 mgd), scale factor:
SF = 1.0
• if Avg Flow >4.38 L/s (> 0.1 mgd), scale factor:
SF = peak flow + average flow
» 2 x average flow
iii) Flow for Cost Purposes (DFLOW) = FLOW x SF
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs are comprised of both variable and fixed compo-
nents. Power requirement is the only variable operating cost
component. Fixed operating cost components include labor, super-
vision, overhead, laboratory labor, maintenance, services, insur-
ance and taxes, and service water. All fixed and variable oper-
ating costs should be adjusted to current levels using an appro-
priate index or unit cost factor.
a) Variable Cost
i) Power Requirements, DAF - sump pumps, flocculators,
DAF package, sludge pumps, polymer package feed pumps
and air compressors [4-1]
Date: 4/1/83 IV.3.1.10-A4
-------
FLOW, LITERS PER SECOND
(
9 n
i a
o
0
2 1 .Q^
_J
4
1
• OB-
8
o
o
1
5
t
r
-»•
r
&
j3
3-
*
<>
^
^
•J
•*
8
i
<
8
**•
I
i
^«
^
r*
^
pe
-*
V
4
S
i
•*•
*n*
£
r
^
*
2
^
(
13
i
t*
!•»
««<
••
•^
^-
}J
^
1
»0
r
^
x
•**
^
^
^
4
^*
43
r
*
n
PLOW. MILLION GALLONS PER DAY
FIGURE IV.3.1.3.0-A2. CAPITAL COST ESTIMATE FOR
DISSOLVED AIR FLOTATION [4-1]
Date: 4/1/83
IV.3.1.10-A5
-------
Metric
KW = (0.198 x FLOW) +5.28
where: KW = power, kilowatts
FLOW = average influent flow/ L/s
English
HP = (11.6 x FLOW) +7.08
where: HP = horsepower required, Hp
FLOW = average influent flow, mgd
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where.- PC = power cost, $/day
HP = horsepower required, Hp
24 = hrs/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iii) Lime Requirements
Lime is used in this DAF unit for preflocculation and to
help reduce the solubility of some oils. The amount of
lime required varies according to flow and influent
conditions.
Option 1 I_f oil and TSS are the only pollutants present
with no floating materials.
Metric
LIME = 1.5 x (IOIL - EOIL) x 0.086 x FLOW
Date: 4/1/83 IV.3.1.10-A6
-------
where: LIME = daily lime requirement, Kg/day
1.5 = 150% excess dose factor
IOIL = average influent oil concentra-
tion, mg/L (when DAF follows oil
separation, IOIL = 35 mg/L)
EOIL = expected effluent oil, mg/L
(default value 10)
0.086 = conversion factor
FLOW = average influent flow, L/s
English
LIME = 1.5 x (IOIL - EOIL) x 8.34 x FLOW
where: LIME = daily lime requirement, Ib/day
1.5 = 150% excess dose factor
IOIL = average influent oil concentra-
tion, mg/L (when DAF follows oil
separation, IOIL assumed = 35
mg/L)
EOIL = expected effluent oil, mg/L
(default value 10)
8.34 = conversion factor
FLOW = average influent flow, mgd
Option 2
Metric
If oil, TSS and floating materials are present.
Two intermediate variables (A&B) are calculated
and the lime requirement is equal to the larger
of the two.
A = (IFLT - EFLT) x 1.5 x 0.086 x FLOW
where: A
IFLT
EFLT
1.5
English
intermediate estimate of lime re-
quired for floating material, Kg/day
average influent floating materials,
mg/L
expected effluent floating materials,
mg/L (default value 30)
150% excess dose factor
A = (IFLT - EFLT) x 1.5 x 8.34 x FLOW
where : A
IFLT
EFLT
1.5
intermediate estimate of lime re-
quired for floating material, Ib/day
average influent floating materials,
mg/L
expected effluent floating materials,
mg/L (default value 30)
150% excess dose factor
Date: 4/1/83
IV.3.1.10-A7
-------
Metric
B = 1.5 x (10IL - EOIL) x 0.086 x FLOW
where: B = intermediate estimate of lime re-
quired for oil removal, Kg/day
English
B = 1.5 x (IOIL - EOIL) x 8.34 x FLOW
where: B = intermediate estimate of lime re-
quired for oil removal, Ib/day
• If B > A, LIME = B, Kg/day or Ib/day
• If A > B, LIME = A, Kg/day or Ib/day
Option 3 Ij only floating materials are present in the
influent
Metric
LIME = IFLT x 0.086 x 1.5 x FLOW
where: LIME = daily lime requirement, Kg/day
IFLT = average influent floating
materials, mg/L
1.5 = 150% excess dose factor
English
LIME = IFLT x 8.34 x 1.5 x FLOW
where: LIME = daily lime requirement, Ib/day
IFLT = average influent floating mate-
rials, mg/L
1.5 = 150% excess dose factor
iv) Lime Cost
Costs for lime are based on total plant needs rather than
on the needs of individual unit processes. Lime require-
ments should be summed for all systems, but costs for
lime handling systems and chemicals will be estimated
after design of all unit processes requiring lime (see
Section IV.3.1.13-C, Lime Handling).
b) Fixed Costs
The fixed 0 & M components for a DAF system are listed in Table
IV.3.1.10-A1 including the cost basis and the unit costs [4-11].
Date: 4/1/83 IV.3.1.10-A8
-------
TABLE IV.3.1.10-A1.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR DISSOLVED AIR FLOTATION
[4-11]
Dissolved Air Flotation
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.25 Weeks (6.00 hrs/day)
10% Labor (0.60 hrs/day)
75% Labor Cost
0.20 Shifts (1.14 hrs/day)
7.53% Capital
0.40% Capital
2.50% Capital
4.6 L/s
(105.4 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/thou L
($0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.10-A9
-------
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after completion of costing for indi-
vidual units (See Section IV.3.5). The required quantity of land
and expected sludge generation from the unit process are calcu-
lated below to facilitate subsequent cost estimates.
a) Land
The following equation estimates the amount of land required for
DAF based on the overflow rate, scale factor and cost factors.
Metric
where:
LAND = SF x FLOW x (1.2 * 1.36)
LAND = land requirement, m2
SF = scale factor (see Section A2, b)
FLOW = average influent wastewater flow rate, L/s
1.2 = factor for accessories
1.36 = overflow rate, L/s/m2
English
where:
LAND = SF x FLOW x (1,200,000 * 2,880)
LAND = land requirement, ft2
SF = scale factor (see Section A2, b)
FLOW = average influent wastewater flow rate, mgd
1,200,000 = mgd x 1.2 factor for accessories, gals/
day
2,880 = overflow rate, gpd/ft2
b) Sludge and Float Production
DAF may produce waste byproducts consisting of oil, solids, or
oily solids. Sludge or float production varies according to
flow, the influent conditions, and whether or not the DAF unit is
preceded by gravity oil separation. Two cases are considered
corresponding to the influent options examined under the Lime
Requirements Section (A3, a, iii). The total amount of float
produced by DAF may be generally estimated as follows:
FLOAT = OFLOAT + SFLOAT + FFLOAT
where: FLOAT
OFLOAT
SFLOAT
FFLOAT
total float produced, Kg/day or Ib/day
oil float from DAF unit, Kg/day or Ib/day
suspended solids float, Kg/day or Ib/day
floating materials float, Kg/day or Ib/day
The amount of float varies according to the type of waste being
treated. Three options for estimating total float production are
Date: 4/1/83
IV.3.1.10-A10
-------
shown below for situations in which only oil and TSS are removed,
others where oil, TSS, and floating materials are removed, and last
where only floating materials are removed.
i) Option 1 DAF Unit Float - if oil and TSS are the only
pollutants
Oil Float
Metric
OFLOAT = LIME + [0.086 x FLOW x (IOIL - EOIL)]
where: OFLOAT = oil float from DAF unit, Kg/day
LIME = daily lime requirement, Kg/day
(see Section A3 a, iii, option 1)
IOIL = influent insoluble oil, mg/L (assumed
to be 35 mg/L)
EOIL = expected effluent oil concentration
from DAF unit, mg/L (default value 10)
English
OFLOAT = LIME + [8.34 x FLOW x (IOIL - EOIL)]
where: OFLOAT = oil float from DAF unit, Ib/day
LIME = daily lime requirement, Ib/day
(see Section A3, a, iii, Option 1)
IOIL = influent insoluble oil, mg/L (assumed to
be 35 mg/L)
EOIL = expected effluent oil concentration from
DAF unit, mg/L (default value 10)
TSS Float
Metric
SFLOAT = 0.086 x FLOW x (TSSI - TSSE)
where: SFLOAT = suspended solids float, Kg/day
TSSI = influent TSS, mg/L
TSSE = effluent TSS, mg/L (assumed to be
30 mg/L if DAF preceded by gravity
oil separation)
English
SFLOAT = 8.34 x FLOW x (TSSI - TSSE)
where: SFLOAT = suspended solids float, Ib/day
TSSI = influent TSS, mg/L
TSSE = effluent TSS, mg/L
(assumed to be 30 mg/L if DAF preceded by
gravity oil separation)
Date: 4/1/83 IV.3.1.10-All
-------
ii) Option 2 DAF Unit Float - if oil, TSS, and floating
solids are present
If there are oil, TSS, and floating solids in the influent
the following equations are used to determine the amount
of float produced by the DAF unit.
Oil Float and Floating Materials
OFLOAT = LIME x 1.67
where: OFLOAT = float from DAF unit, Kg/day or Ib/day
LIME = daily lime requirement, Kg/day or
Ib/day (see Section A3,a, iii, Option 2)
TSS Float
Metric
SFLOAT = 0.086 x FLOW x (TSSI - TSSE)
where: SFLOAT = suspended solids float, Kg/day
TSSI = influent TSS, mg/L
TSSE = effluent TSS, mg/L (assumed to be
30 mg/L if DAF preceded by gravity
oil separation)
Engi sh
SFLOAT = 8.34 x FLOW x (TSSI - TSSE)
where: SFLOAT = suspended solids float, Ib/day
TSSI = influent TSS, mg/L
TSSE = effluent TSS, mg/L
(assumed to be 30 mg/L if DAF preceded
by gravity oil separation)
iii) Option 3 DAF Unit Float - if only floating solids are
present
FFLOAT = LIME x 1. 67
where: FFLOAT = floating solids, Kg/day or Ib/day
LIME = daily lime requirement, Kg/day or Ib/day
(see Section A3, a, iii, Option 3)
A 5. Modifications
DAF is often used in series with gravity oil separation to treat
combination waste streams of oils, suspended solids, and colloidal
materials.
Date: 4/1/83 IV.3.1.10-A12
-------
I.
a.
II.
DISSOLVED AIR FLOTATION
SUMMARY WORK SHEET
REFERENCE: IV.3.1.10A
DESIGN FACTOR CAPITAL
Flow for cost purposes = mgd
DFLOW
CAPITAL COST
Cost = x ( f 204.7)
III
a.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
c.
Cost from curve current index
. VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
FIXED 0 & M
Labor : x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor: x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
$/day
.
X
day/yr sum, $/day
*1
0 & M
$/yr
UNCOSTED ITEMS
Land = ft2 b. Lime = Ib/day
DAF Float = Ib/day
Date: 4/1/83
IV.3.1.10-A13
-------
DISSOLVED AIR FLOTATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Labor = $/hr
4. Supervision = $/hr
5. Overhead = % Labor T 100 = %/100
6. Lab Labor = $/hr
7. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = % r 100 = %/100
8. Service Water = $/thou gal
I. DESIGN FACTOR
a. Scale Factor for DAF:
I_f average wastewater flow (FLOW) < 0.1 mgd. Scale Factor = 1
If average wastewater flow (FLOW) > 0.1 mgd, Scale Factor =
( + ) * [2 x ( )] =
Peak flow, mgd Avg FLOW, mgd Avg FLOW, mgd SF
b. Wastewater Flow for Costing Purposes:
DFLOW = x = mgd
Avg FLOW, mgd Scale factor
II. CAPITAL COST
III. VARIABLE 0 & M
Power Requirements (DAF)
HP = (11.6 x ) + 7.08
Avg FLOW, mgd
Date: 4/1/83 IV.3.1.10-A14
-------
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. LAND = x x 417 = ft2
SF FLOW, mgd
b. Lime Requirements for DAF
1 Option 1 (oil and TSS only pollutants, no floating material)
LIME = x 12.5 x ( - ) = Ib/day
FLOW, mgd IOIL, mg/L EOIL, mg/L
2 Option 2 (oil, TSS, and floating materials present)
A = x 12.5 x ( -
FLOW, mgd IFLT, mg/L EFLT, mg/L
B = x 12.5 x - ) =
FLOW, mgd IOIL, mg/L EOIL, mg/L
If B > A, LIME = B = Ib/day
If A > B, LIME = A = Ib/day
3 Option 3 (Floating materials only)
LIME = x 12.5 x = Ib/day
IFLT, mg/L FLOW, mgd
c. Waste Solids from DAF Unit
1 Option I (oil and TSS only pollutants, no floating material)
DAF Oil Float
OFLOAT = + [8.34 x x ( - )]
LIME, Ib/day FLOW, mgd IOIL, mg/L EOIL, mg/L
= Ib/day
DAF Suspended Solids Float
SFLOAT = 8.34 x ; x ( - )
FLOW, mgd TSSI mg/L TSSE mg/L
= Ib/day
Date: 4/1/83 IV.3.1.10-A15
-------
Total Option I DAF Float
FLOAT(l) = + = Ib/day
DFLOAT, Ib/day SFLOAT, Ib/day
2 Option II (oil and floating solids present)
DAF Oil and Floating Solids Float
OFLOAT = 1.67 x = Ib/day
- LIME, Ib/day
Note: for LIME see Section III,b
Suspended Solids Float from DAF
SFLOAT = 8.34 x x ( - ) = Ib/day
FLOW, mgd TSSI, mg/L TSSE, mg/L
Total Option II DAF Float
FLOAT(l) = + = Ib/day
OFLOAT, Ib/day SFLOAT, Ib/day
3 (Floating solids only)
FLOAT = FFLOAT = 1.67 x = Ib/day
LIME, Ib/day
Date: 4/1/83 IV.3.1.10-A16
-------
IV.3.1.11 FLOW EQUALIZATION
Introduction
Flow equalization is used to reduce variations in wastewater
flow/ and achieve a more constant flow rate through the down-
stream treatment processes. A secondary objective of flow equal-
ization is to reduce fluctuations in concentration and mass flow
of wastewater constituents. Flow equalization can significantly
improve the performance of wastewater treatment facilities and
can reduce the required size of downstream facilities. Flow
equalization is described in more detail in Volume III of the
Treatability Manual, Section III.3.1.11. Costing methodologies
and cost data for industrial wastewater treatment applications
are presented below.
IV.3.1.11-A. Equalization
A 1. Basis of Design
Wastewater flow is the principal design factor for equalization.
High, average, and low flowrate estimates are used to size the
equalization basin to maintain a detention time of at least 24
hours. The surface area of the equalization basin is used as a
factor in estimating the land required for diking, access roads,
piping, miscellaneous associated facilities, and a spill-contain-
ment basin. A spill-containment (surge storage) basin with a
detention time of 12 hours is included unless the equalization
basin capacity is less than 757 m3 (200,000 gal). A flow equali-
zation system of the type considered is represented in Figure
IV.3.1.11-A1.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
b) Required Input Data
Wastewater flowrate L/s or (mgd) (high, average, low)
c) Limitations
None indicated.
d) Pretreatment
None specified; however, neutralization may precede equalization
if the wastewater is excessively corrosive.
Date: 4/1/83 IV.3.1.11-A1
-------
UJ
03
CL
ix
o
z
a
UJ
VI
UJ
ui
UJ
>-
O
•z
o
H
Date: 4/1/83
IV.3.1.11-A2
-------
e) Design Equation
The design flow is calculated based on influent high, average,
and low flows:
FLOW = AVG x SF
where: FLOW = design flow, L/s or mgd
AVG = average influent wastewater flow, L/s or mgd
SF = scale factor
The scale factor (SF) is computed in one of two ways
depending on the way in which the average influent flow
is determined:
If AVG is calculated as a daily average,
SF = [(RATIO - 2.0) + l.O]0'5
If AVG is calculted as a monthly average,
SF = [(RATIO - 1.5) + l.O]0'5
The flow ratio (RATIO) is the greater of the high flow
to average flow ratio or the average flow to low flow
ratio. The scale factor (SF) calculated from the flow
ratio (RATIO) cannot be greater than 3 nor less than 1.
RATIOH = HIGH * AVG
RATIOL = AVG T LOW
where: RATIOH = high to average flow ratio
RATIOL = average to low flow ratio
HIGH = high flow, L/s or mgd
AVG = average flow, L/s or mgd
LOW = low flow, L/s or mgd
If RATIOH > RATIOL, set RATIO = RATIOH
If RATIOL > RATIOH, set RATIO = RATIOL
If SF > 3.0, set SF = 3.0
If SF < 1.0, set SF = 1.0
f) Subsequent Treatment
None specified.
A 2. Capital Costs
The cost factor for equalization is the wastewater flow rate.
One of two different cost curves is used to estimate capital
costs depending on the design volume of the equalization basin.
Small equalization basins (<8.76 L/s (<0.20 mgd)) may be costed
using Figure IV.3.1.11-A2 and large equalization basins (8.76 to
Date: 4/1/83
IV.3.1.11-A3
-------
876 L/s (0.2 to 20 mgd)) may be costed using Figure IV.3.1.11-A3.
Costs estimated using these curves must be adjusted to a current
value using an appropriate current cost index.
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-2]:
Low Order Equalization Basins <8.76 L/s (<0.20 mgd)
Pumps, piping, valves
Electrical
Tank and pump foundations
Carbon steel tank with liner
Instrumentation
Sump, sump liner
Insulation
Fiberglass grating
High Order Equalization Basins 8.76 to 876 L/s
(0.20 to 20 mgd)
Pumps, piping, valves
Electrical
Concrete diversion chamber,equalization
basin, and surge storage basin
Instrumentation
Sluice gates
Floating agitator
Protective coating
b) Capital Cost Curves
Low Order Basin Curve - see Figure IV.3.1.11-A2.
- Cost (thousands of dollars) vs. design flow (liters
per second or thousand gallons per day)
- Curve basis, cost estimate on design flows of 0.044,
0.219, 2.19 and 8.76 L/s (1, 5, 50, and 200
thousand gallons/day)
High Order Basin Curve - see Figure IV.3.1.11-A3.
- Cost (millions of dollars) vs. design flow (liters
per second or million gallons per day)
- Curve basis, cost estimate on design flows of 8.76,
43.8, 219 and 876 L/s (0.2, 1.0, 5.0, and 20 mgd)
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
Date: 4/1/83 IV.3.1.11-A4
-------
FLOW, LITERS PER SECOND
0 0.876
0 2*0 40 60 80 100 120 140 100 180 200
FLOW. THOUSANDS OF GALLONS PER DAY
FIGURE IV.3.1.11-A2. CAPITAL COST ESTIMATE
FOR FLOW EQUALIZATION
(LOW ORDER) [4-10]
FLOW, LITERS *>ER SECOND
219 438 €57
876
CC
o
CO
i
CO
o
o
6 10 16
FLOW. MILLION GALLONS PER DAY
20
FIGURE IV.3.1.11-A3. CAPITAL COST ESTIMATE FOR
FLOW EQUALIZATION (HIGH
ORDER) [4-10]
Date: 4/1/83
IV.3.1.11-A5
-------
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component of operating cost for equalization is power.
Fixed operating costs include labor, supervision, overhead,
laboratory .labor, maintenance, services, insurance and taxes, and
service water. All fixed and variable operating costs should be
adjusted to current levels using an appropriate index or unit
cost factor.
a) Variable Cost
i) Power Requirements - Low Order Basins
This equation was developed using regression analysis
procedures [4-1].
Metric
KW = (0.346 x FLOW) +0.71
where: KW = power, KW
FLOW = design flow, L/s
English
HP = (20.3 x FLOW) +0.95
where: HP = power, Hp
FLOW = design flow, mgd
ii) Power Requirements - High Order Basins
This equation was developed using regression analysis
procedures [4-1].
Metric
KW = (0.553 x FLOW) -2.17
where: KW = power, KW
FLOW = design flow, L/s
English
HP = (32.5 x FLOW) - 2.91
where: HP = power, Hp
FLOW = design flow, mgd
iii) Power Costs
Metric
PC = KW x 24 x EC
Date: 4/1/83 IV.3.1.11-A6
-------
where: PC = power cost, $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = horsepower required, Hp
EC = electricity cost, $/Kw-hr
24 = hr/day
0.746 = Kw-hr/Hp-hr
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.1.11-A1 including the cost basis and the unit costs
[4-111.
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as yard piping
and buildings, are calculated for the plant as a whole after the
completion of costing for individual unit processes (see Section
IV.3.5). The equalization process requirements for land are
estimated separately for low and high order basins.
a) Land - Low Order Basin ( <8.76 L/s or <0.20 mgd)
Metric
LAND = 1.2 x AREA
where: LAND = land requirement, m2
1.2 = factor to account for land required for
diking, access roads, piping, and miscel-
laneous associated facilities
AREA = surface are of basin, m2
= (FLOW x 86400 x 1) T (1000 x 3.05)
FLOW = design flow, L/s
86400 = sec/day
1 = one day detention
1000 = liters per cubic meter
3.05 = assumed basin depth, m
English
LAND = 1.2 x AREA
Date: 4/1/83 IV.3.1.11-A7
-------
TABLE IV.3.1.11-A1. FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR FLOW EQUALIZATION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.15 Weeks (3.60 hrs/day)
10% Labor (0.36 hrs/day)
75% Labor Cost
0.25 Shifts (1.43 hrs/day)
1.34% Capital
0.40% Capital
2.50% Capital
0.0 Thou L/s
(0.00 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.11-A8
-------
where: LAND = land requirement, ft2
1.2 = factor to account for land required
for diking, access roads, piping, and
miscellaneous associated facilities
AREA = surface area of basin, ft2
= (FLOW x 10s) T (7.48 x 10) x 1
FLOW = design flow, mgd
106 = gallons/million gallons
7.48 = gallons/cubic foot
10 = assumed basin depth, ft
1 = one day detention
b) Land - High Order Basin (8.76 to 876 L/s or 0.20 to 20 mgd)
Metric
where:
LAND = 1.2 x 1.5 x AREA
LAND = land requirement, m2
1.2 = factor to account for land required for
diking, access roads, piping and miscel-
laneous associated facilities
1.5 = factor to account for the land area of the
spill-containment (surge storage) basin
AREA = surface area of basin, m2
= (FLOW x 86400 x 1) ? (1000 x 3.05)
FLOW = design flow, L/s
86400 = sec/day
1 = one day detention
1000 = liters per cubic meter
3.05 = assumed basin dept, m
English
LAND = 1.2 x 1.5 x AREA
where: LAND
1.2
land requirement, ft2
factor to account for land required
for diking, access roads, piping, and
miscellaneous associated facilities
1.5 = factor to account for the land area of
the spill-containment (surge storage) basin
AREA = surface area of basin, ft2
= (FLOW x 106) * (7.48 x 10) x 1
FLOW = design flow, mgd
106 = gallons/million gallons
7.48 = gallons/cubic foot
10 = assumed basin depth, ft
1 = one day detention
Date: 4/1/83
IV.3.1.11-A9
-------
A 5. Modifications
In addition to variations in wastewater flow rate, the following
adjustments are made but not addressed in detail in this presen-
tation.
a) Dampening
High and low flow estimates for a wastewater treatment system may
be made by summing the high and low flows for the individual
waste streams entering the plant. This will indicate the poten-
tial extreme flow, but fails to take into account internal dampen-
ing effects. The effect of dampening in the equalization basin
due to mixing of short-term variations is accounted for by the
scale factor (Section A l,e). The probability of second dampen-
ing (the simultaneous occurrence of high or low flows from in-
dividual sources within the plant) is taken into account by the
use of several adjustments. One factor (ADJUST) is applied to
all streams depending on the amount of daily flow variation and
upstream dampening information. Another factor (EXTRA) is only
applied when less than five streams are being equalized to account
for the mismatching of high peak and extreme low flow values. In
addition to flow, it is assumed that variations in pollutant
concentration are equalized and dampened to the same extent
[4-1].
b) Temperature
A heat balance is performed over the equalization basin to de-
termine exit temperature as follows [4-1]:
Heat Gain = Heat Loss
QA + QB + QC = RA + RB + RC + RD
where: QA = influent heat, Joules/hr or BTU/hr
QB = mechanical heat, Joules/hr or BTU/hr
QC = solar radiation, Joules/hr or BTU/hr
RA = effluent heat, Joules/hr or BTU/hr
RB = evaporation loss, Joules/hr or BTU/hr
RC = surface convection loss, Joules/hr or BTU/hr
RD = sidewall conduction loss, Joules/hr or BTU/hr
Date: 4/1/83
IV.3.1.11-A10
-------
I.
DESIGN FACTOR
EQUALIZATION
SUMMARY WORK SHEET
REFERENCE: IV. 3. 1.11 -A
CAPITAL
Design Flow Rate = mgd
II.
Cost
CAPITAL COST
=
(FLOW)
x ( T 204.7) =
Cost from curve current index
III.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
VARIABLE 0 &
Power =
Hp
FIXED 0 & M
Labor:
Supervision:
Overhead:
Laboratory:
Maint, Service,
I&T:
Service Water:
YEARLY 0 & M
UNCOSTED ITEMS
Land =
M
x x 17.9
EC, $/Kw-hr
x
hr/day $/hr
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x T 365
capital, $ %/100 day/yr
X X
thou gpd $/thou gal
365
day/yr
$/day
—
X
sum, $/day
$
0 & M
$/yr
ft2
Date: 4/1/83
IV.3.1.11-A11
-------
EQUALIZATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Capital Cost Index =
2. EC: Electricity Cost =
3. Labor =
4. Supervision =
5. Overhead =
6. Laboratory =
7. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor =
8. Service Water =
Capital Cost Index
$/Kw-hr
$/hr
$/hr
% Labor r 100 =
$/hr
fc/100
% Capital
% Capital
% Capital
f 100 =
fc/100
$/thou gal
I. DESIGN FACTOR
a. Compute the following:
RATIOH =
High Flowrate, mgd Average Flowrate, mgd
RATIOL =
Average Flowrate, mgd Low Flowrate, mgd
b. Determine the value of RATIO as follows:
1. If RATIOH > RATIOL,
set RATIO =
RATIOH
2. If RATIOL > RATIOH,
set RATIO =
RATIOL
c. Determine the value for the scale factor (SF) as follows:
1. From I b above: RATIO =
Date: 4/1/83
IV.3.1.11-A12
-------
2. If the average flow was computed over 24 hours,
set SF = [( - 2.0) + 1.0]°'5 =
RATIO SF
3. If the average flow was computed over 30 days,
,0.5 _
set SF = [( - 1.5) + 1.0]
RATIO SF
d. If SF (from I c above) is grater than 3.0,
set SF = 3.0
e. If SF (from I c above) is less than 1.0,
set SF = 1.0
f. Determine the design flow as follows:
1. From I c, Id, or I e, SF =
2. Calculate design flow (FLOW)
Design Flowrate (FLOW) = x = mgd
SF Average Flowrate, mgd
II. CAPITAL COST
Based on the design flow determined in I f 2, select a cost from one of the
capital cost curves.
a. Low Order (FLOW <200 thousand gallons/day), use Figure IV.3.1.11-A2
b. High Order (FLOW >0.20 mgd), use Figure IV.3.1.11-A3
III. VARIABLE 0 & M
a. Power Requirements - Low Order (<0.20 mgd)
HP = (20.3 x ) + 0.95 = Hp
FLOW
b. Power Requirement - High Order (0.20 to 20 mgd)
HP = (32.5 x ) + 2.91 = Hp
FLOW
Date: 4/1/83 IV.3.1.11-A13
-------
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Land Requirement
1. Calculate Basin Surface Area (AREA)
AREA = (
x 106) r (7.48 x 10) =
ft*
FLOW, mgd
2. Low Order (Flow <200 thousand gallons/day)
LAND = 1.2 x
ft*
AREA
3. High Order (FLOW >0.200 mgd)
LAND = 1.2 x 1.5 x
AREA
ft2
Date: 4/1/83
IV.3.1.11-A14
-------
IV.3.1.13 NEUTRALIZATION
Introduction
Neutralization involves adjusting the pH of a waste stream to
make it suitable for subsequent treatment or disposal. Generally
this means adjusting an excessively acidic or basic waste stream
to an acceptable range by the addition of an appropriate base or
acid. Further details about the neutralization process may be
found in Volume III, Section 3.1.13 of the Treatability Manual.
Costing methodologies and cost data for this technology are
presented below.
IV.3.1.13-A. Neutralization
A 1. Basis of Design
This presentation is for the neutralization of acidic or basic
wastewater streams by base or acid addition. The system as
represented in Figure IV.3.1.13-A1 consists of a chemical addi-
tion system and a two stage neutralization tank with a design
detention time of 5 minutes in the first chamber and 20 minutes
in the second. The principal design and cost factor for this
technology is wastewater flow. A scale factor is used to adjust for
the presence or lack of flow equalization upstream of the unit.
Other important factors include influent acidity, alkalinity, pH,
TDS, and TSS. Three alternative methods of estimating the neu-
tralization chemical requirements are provided corresponding to
the types of information typically available. The preferable
method is to base the design dosage of sulfuric acid or base
(lime or caustic) required to neutralize the wastewater stream on
influent acidity or alkalinity data (in mg/L CaC03 equivalents).
If these data are not available, the required reagent additions
may be approximated based on pH data. For streams where no
alkalinity, acidity, or pH data are available a standard chemical
dose estimate may be used based on best engineering judgement.
However, it should be kept in mind that use of these last two
methods can introduce considerable error. The neutralization
process is assumed to achieve a control to an average pH of 7.0,
with a pH range of 6.5 to 8.0.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
Date: 4/1/83 IV.3.1.13-A1
-------
i
ffl-
r-
2E
O
H
EH
O
g
CO
CO
w
u
o
«
OH
I
ro
ro
H
CO
3
D
S =5
•
Date: 4/1/83
IV.3.1.13-A2
-------
b) Required Input Data
Wastewater Flow L/s (mgd)
Alkalinity, acidity (in mg/L CaCO3 equivalents) pH
TDS, TSS (mg/L)
c) Limitations
None specified.
d) Pretreatment
Neutralization is usually preceded by flow equalization except
when neutralization is needed first to avoid severe corrosion of
downstream units.
e) Design Equation
Average daily wastewater flow in L/s (mgd) is the primary design
and capital cost factor for neutralization systems. The design
residence times of the reaction and attenuation chambers are five
and 20 minutes, respectively, at 120% of average daily flow. A
scale factor is applied to the capital cost estimate if the
neutralization unit precedes flow equalization to account for
sizing the units for 200% of average daily flow instead of 120%.
f) Subsequent Treatment
None specified.
A 2. Capital Costs
Influent flow is the primary capital cost factor for this unit
process. Capital costs can be estimated for neutralization sys-
tems less than or equal to 8.76 L/sec (0.2 mgd) in capacity
using the low order cost curve (Figure IV.3.1.13-A2) and for
systems between 8.76 and 876 L/S (0.2 and 20 mgd) in capacity
using the high order cost curve (Figure IV.3.1.13-A3). A scale
factor of 1.67 is applied to the capital cost if the neutrali-
zation unit is not preceded by an equalization unit. Costs
estimated using these curves must be adjusted to current values
using an appropriate current cost index.
a) Cost Data
Items* included in the capital cost curve estimates are as fol-
lows [4-2]:
i) Low Order <8.76 L/s, (0.2 mgd)
Mixing tank, fiberglass
Attenuation tank, fiberglass
Date: 4/1/83 IV.3.1.13-A3
-------
Acid storage and feed
Agitators (2)
Piping, electrical
Instrumentation
ii) High Order, 8.76 to 876 L/s (0.2 to 20 mgd)
Mixing tank, concrete, acid brick lined
Attenuation tank, acid brick lined
Acid storage and feed
Agitators (2)
Piping, electrical
Instrumentation
*Note that the lime or caustic handling and feed equipment is de-
signed to serve the entire plant's needs and is sized and costed
separately (see Lime Handling, Section IV.3.1.13-C).
b) Capital Cost Curves
i) Low Order Curve - See Figure IV.3.1.13-A2
- Cost (thousands of dollars) vs. flow (liters per
second or million gallons per day)
- Curve basis, cost estimates on four systems with
flow rates of 4.38, 8.76, 17.5, and 26.3 L/s (0.1,
0.2, 0.4, and 0.6 mgd)
ii) High Order Curve - See Figure IV.3.1.13-A3
- Cost (hundred thousand dollars) vs. flow (liters
per second or million gallons per day)
- Curve basis, cost estimates on four systems with
flow rates of 8.76, 43.8, 219, and 876 L/s (0.2,
1.0, 5.0, and 20.0 mgd).
ill) Scale Factor - If neutralization is not preceded by
equalization, a scale factor of 1.67 is
applied to standard capital cost.
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable components of operating cost are power and chemical
costs. Fixed operating costs include labor, supervision, over-
head, laboratory labor, maintenance, services, insurance and
Date: 4/1/83 IV.3.1.13-A4
-------
FLOW, LITERS PER SECOND
S.S 13 18
22
26
120
06
FIGURE IV.3.1.13-A2
FLOW. MILLION GALLONS PER DAY
CAPITAL COST ESTIMATE FOR NEUTRALIZATION
(LOW ORDER) [4-10]
FLOW. LITERS PER SECOND
175 35O 525 701
876
12 16
FLOW. MILLION GALLONS PER DAY
20
FIGURE IV.3.1.13-A3. CAPITAL COST ESTIMATE FOR NEUTRALIZATION
(HIGH ORDER) [4-10]
Date: 4/1/83
IV.3.1.13-A5
-------
taxes, and service water. All fixed and variable operating costs
should be adjusted to current levels using an appropriate index
or unit cost factor.
a) Variable Costs
i) Power Requirements, Low Order (Flow <8.76 L/s (0.2 mgd))
- pumps, agitators [4-1]. These equations were
developed using regression analysis procedures.
Metric
KW = (0.55 x FLOW) + 0.657
where: KW = power requirement, kilowatts
FLOW = influent flow, L/s
English
HP = (32.3 x FLOW) + 0.881
where: HP = power requirement, Hp
FLOW = influent flow, mgd
ii) Power Requirements, High Order (Flow 8.76 to 876 L/s (0.2
to 20 mgd)) [4-1]. These equations were developed
using regression analysis procedures.
Metric
KW = (0.266 x FLOW) +6.49
where: KW = power requirement, kilowatts
FLOW = influent flow, L/s
English
HP = (15.6 x FLOW) +8.70
where: HP = power requirement, Hp
FLOW = influent flow, mgd
iii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power required, kilowatts
24 = hours/day
EC = electricity cost, $/Kw-hr
Date: 4/1/83 IV.3.1.13-A6
-------
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = horsepower required, Hp
24 = hours/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iv) Chemical Requirements
The chemical requirements for neutralization may be
estimated in one of three ways depending on the influent
wastewater quality data available. The preferred method
is to use acidity/alkalinity data (Case I), but methods
using only pH data (Case II) or a standard dose (Case
III) can be used.
• CASE I - Influent Acidity and Alkalinity Data Available;
- If both acidity and alkalinity are present in the
influent, determine the dominant characteristic.
A = AP - (a T 2)
where: A = modified dominant acidity or alkalinity,
mg/L (CaC03 equivalents)
AP = influent measured dominant acidity or
alkalinity factor, mg/L
a = influent concentration of other factor,
mg/L
This modified alkalinity or acidity should be used in
subsequent calculations where applicable in place of the
dominant influent value.
1) Lime and topping acid requirements based on acidity.
If the influent wastewaters dominant characteristic is
acidic, lime is added to neutralize the acid and topping
acid is added to cover minor acidity fluctuations.
Metric
LIME = 0.74 x AC x FLOW x 0.086
where: LIME = lime requirements, Kg/day
0.74 = stoichiometric ratio of Ca(OH)2 to CaCO3
AC = modified influent acidity, mg/L (CaC03
equivalents)
Date: 4/1/83 IV.3.1.13-A7
-------
FLOW = influent flow, L/s
0.086 = conversion-factor
English
LIME = 0.74 x AC x FLOW x 8.34
where: LIME = lime requirements, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
Topping acid requirements are based on modified
influent acidity as follows:
Metric
TA = ADOSE x FLOW x 0.086
where: TA = topping acid, Kg/day
ADOSE = acid dose, mg/L
FLOW = influent flow L/s
(ADOSE determined from the following table)
Acidity Topping Acid Dose (ADOSE)
(mg/L) (mg/L)
AC > 150 50
100 < AC <, 150 200 - AC
AC < 100 100
English
TA = ADOSE x FLOW x 8.34
where: TA = topping acid, Ib/day
ADOSE = acid dose, mg/L (from above table)
FLOW = influent flow, mgd
2) Acid and topping lime requirements based on alka-
linity
If the influent wastewater is predominantly alkaline,
sulfuric acid is added to neutralize the waste and
topping lime is added to cover minor alkalinity fluctua-
tions .
Metric
ACID = 0.98 x ALK x FLOW x 0.086
where: ACID = acid (H2S04) requirements, Kg/day
0.98 = stoichiometric ratio of H2S04 to CaCO3
equivalents
Date: 4/1/83 IV.3.1.13-A8
-------
ALK = modified influent alkalinity, mg/L,
(CaC03 equivalents)
FLOW = influent flow, L/s
0.086 = conversion factor
English
ACID = 0.98 x ALK x FLOW x 8.34
where: ACID = acid (H2SO<, ) requirement, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
Topping lime requirements are based on modified influent
alkalinity as follows:
Metric
TL = LOOSE x FLOW x 0.086
where: TL = topping lime requirement. Kg/day
FLOW = influent flow, L/s
LOOSE = lime dose, mg/L
(LOOSE determined from the following table)
Alkalinity Topping Lime Dose(LOOSE)
(mg/L) (mg/L)
ALK > 150 50
100 < ALK £ 150 200 - ALK
ALK < 100 100
English
TL = LOOSE x FLOW x 8.34
where: TL = topping lime requirement, Ib/day
LOOSE = lime dose, mg/L (from above table)
FLOW = influent flow, mgd
• CASE II - Only pH Data Available
If influent alkalinity and acidity data are not available,
the lime and acid requirements for a neutralization
system may be estimated based on the following influent
pH ranges. Estimates derived using this method should be
scrutinized for reasonableness; particularly when dealing
with highly buffered wastewaters.
1) If. (low pH) >7.0, then acid and topping lime are
required:
Date: .4/1/83 IV.3.1.13-A9
-------
ACIDC = [(low pH) - 7.0]2 x 20 or
50 mg/L whichever is larger and
TLC =50 mg/L
where: ACIDC
(low pH)
TLC
acid (H2SO<, ) requirement, mg/L
minimum influent pH value
topping lime requirement, mg/L
2) Lf (low pH) <7.0 and (avg pH) >7.0, then lime
and topping acid are required:
LIMEC
TAG
[7.0 - (low pH)]3 x 20 or
50 mg/L whichever is larger and
{[((avg pH) + (high pH) ) * 2] - 7}2 x 20 or
50 mg/L whichever is greater
where: LIMEC
(avg pH)
(high pH)
TAG
•lime requirement, mg/L
average influent pH value
highest influent pH value
topping acid requirement, mg/L
3)
Lf (low pH) £7.0 and (avg pH) £7.0 and (high pH)
£7.0, then lime and topping acid are required:
LIMEC = {7.0 - [((avg pH) + (low pH))
50 mg/L whichever is greater;
TAG = [(high pH) - 7.0]2 x 20 or
50 mg/L whichever is greater
* 2]}3
and
x 20 or
4) Lf (low pH) £7.0 and (avg pH) £7.0 and (high pH)
£7.0, then lime only is required:
LIMEC = [7.0 - (avg pH)]3 x 20 or
100 mg/L whichever is greater; and
TAG = 0
5) To convert chemical requirements to daily weight
basis;
Metric
where:
ACID = ACIDC x FLOW x 0.086
TL = TLC x FLOW x 0.086
LIME = LIMEC x FLOW x 0.086
TA = TAG x FLOW x 0.086
ACID = acid required, Kg/day
TL = topping lime required,
LIME = lime required, Kg/day
TA = topping acid required,
FLOW = influent flow, L/s
0.086 = conversion factor
Kg/day
Kg/day
Date: 4/1/83
IV.3.1.13-A10
-------
English
ACID = ACIDC x FLOW x 8.34
TL = TLC x FLOW x 8.34
LIME = LIMEC x FLOW x 8.34
TA = TAG x FLOW x 8.34
where: ACID = acid required, Ib/day
TL = topping lime, Ib/day
LIME = Lime required, Ib/day
TA = topping and, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
• CASE III - No Data Available
For streams where no pH, acidity, or alkalinity data are
available, a standard dose of 100 mg/L of acid and 100
mg/L of lime may be assumed. These additions are con-
sidered suitable to neutralize occasional pH swings [4-1].
For streams of an essentially neutral pH, a minimum standard
dose of 50 mg/L of acid and 50 mg/L of lime may be used.
Metric
LIME = SDL x FLOW x 0.086
where: LIME
SDL
FLOW
0.086
lime required, Kg/day
standard dose of lime, mg/L
(100 mg/L or 50 mg/L minimum)
influent flow, L/s
conversion factor
ACID = SDA x FLOW x 0.086
where: ACID
SDA
acid required, Kg/day
standard dose of acid, mg/L
(100 mg/L or 50 mg/L minimum)
English
LIME = SDL x FLOW x 8.34
where: LIME
FLOW
8.34
ACID
where: ACID
lime required, Ib/day
influent flow, mgd
conversion factor
SDA x FLOW x 8.34
acid required, Ib/day
Date: 4/1/83
IV.3.1.13-A11
-------
v) Chemical Costs (except lime*)
AC = ACID x N
where: AC = acid cost, $/day
ACID = acid requirement, Ib/day
N = unit cost of sulfuric acid, $/lb
*Cost for lime is based on total plant needs rather than on
the needs of an individual unit process. Lime requirements
should be accounted for but costs for handling systems and
lime should be estimated separately after design of all unit
processes requiring lime (see Lime Handling, Section
IV.3.1.13-C).
b) Fixed Costs
The fixed O & M components of this technology are listed in Table
IV.3.1.13-A1, including the cost basis and the unit costs the
Model [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as land, piping,
and buildings, are calculated after completion of costing for in-
dividual units (see Section IV.3.5).
A 5. Modifications
The effluent stream may be adjusted to account for changes in
total dissolved solids (TDS) and TSS which result from the neu-
tralization process. TDS is expected to change as a result of
additions of acid and lime. If both sulfate and calcium are
present in the wastewater and additional amounts are added during
neutralization, additional TSS may be formed as the solution
reaches the solubility limit for calcium and sulfate. The forma-
tion of TSS from the wastewater is of some interest for cost con-
siderations since it could affect the volume of sludge which
would eventually be collected and disposed of in subsequent unit
processes.
a) TDS Increase due to Neutralization
Metric
TDSE = TDSI + {[LIME x (40 * 74) + ACID x (96 * 98)]
* (FLOW x 0.086)}
where: TDSE = average effluent TDS, mg/L
TDSI = average influent TDS, mg/L
LIME = lime added, Kg/day
40 * 74 = mass ratio of Ca to Ca(OH)2
Date: 4/1/83 IV.3.1.13-A12
-------
TABLE IV.3.1.13-A1. FIXED 0 & M COST BASIS AND
UNIT COST FACTORS FOR NEUTRAL-
IZATION [4-11].
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.20 Weeks (4.80 hrs/day)
10% Labor (0.48 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
2.50% Capital
0.40% Capital
2.50% Capital
0.00 L/s
(0.00 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.13-A13
-------
ACID = acid added, Kg/day
96 * 98 = mass ratio of S04 to H2S04
FLOW = influent flow, L/s
0.086 = conversion factor
* 74) + ACID x (96 * 98)]
English
TDSE = TDSI + { [LIME x (40
* (FLOW x 8.34)}
where: LIME = lime added, Ib/day
ACID = acid added, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
b) TSS Increase due to Neutralization
If calcium, sulfate, and carbonate are present in the wastewater,
then additional suspended solids may be produced [4-1]. The
user should check first to determine if calcium sulfate may
be generated (Step 1), and then check for calcium carbonate
generation (Step 2) [4-1].
i) Step 1. If calcium and sulfate are present in the
influent in excess of the triggering values (1000
and 2000 mg/L respectively are used to trigger the
need for this modification), the effluent TSS is
calculated as follows:
Metric
TSSE = (CAL + SUL - 2500) + TSSI
where: TSSE = effluent TSS, mg/L
CAL = total calcium dissolved solids, mg/L
= [LIME * (FLOW x 0.086)] x (40 * 74) + CALI
LIME = lime added, Kg/day
FLOW = influent flow, L/s
0.086 = conversion factor
CALI = influent calcium dissolved solids, mg/L
40 * 74 = mass ratio of Ca to Ca(OH)2
SUL = total sulfate dissolved solids, mg/L
= [ACID * (FLOW x 0.086)] x (96 * 98) + SULI
ACID = acid requirement, Kg/day
SULI = influent sulfate dissolved solids, mg/L
96 T 98 = mass ratio of SO,, to H2S04
2500 = solubility limit of calcium sulfate, mg/L
= 800 mg/L calcium plus 1700 mg/L sulfate,
[4-2]
Date: 4/1/83
IV.3.1.13-A14
-------
TSSI = influent TSS, mg/L
0.086 = conversion factor
English
TSSE = (CAL + SUL - 2500) + TSSI
where: CAL = total calcium dissolved solids, mg/L
= [LIME * (FLOW x 8.34 )] x (40 * 74) + CALI
LIME = Lime added, Ib/day
FLOW = influent flow, mgd
SUL = total sulfate dissolved solids, mg/L
= [ACID * (FLOW x 8.34)] x (96 t 98) + SULI
Note that the effluent values of calcium and sulfate may
be set at their solubility limits after computing the
TSS increase.
ii) Step 2. If calcium >200 mg/L and carbonate >200 mg/L
and no sulfate:
Metric
TSSE = (CARI + CAL - 200) + TSSI
where: TSSE = effluent TSS, mg/L
CARI = influent carbonate dissolved solids, mg/L
CAL = total calcium dissolved solids, mg/L
= [LIME * (FLOW x 0.086)] x (40 * 74) + CALI
LIME = lime added, Kg/day
FLOW = influent flow, L/s
0.086 = conversion factor
CALI = influent calcium dissolved solids, mg/L
2OO = solubility limit for calcium carbonate,
mg/L
TSSI = influent TSS, mg/L
English
TSSE = (CARI + CAL -200) + TSSI
where: TSSE = effluent TSS, mg/L
CAL = total calcium dissolved solids, mg/L
= [LIME * (FLOW x 8.34)] x (40 * 74) + CALI
LIME = lime added, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
Date: 4/1/83 IV.3.1.13-A15
-------
NEUTRALIZATION
SUMMARY WORK SHEET REFERENCE: IV.3.1.13-A
I.
a.
b.
II.
DESIGN FACTOR
Flow =
Scale Factor, if
CAPITAL COST
Cost =
III
a.
b.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
c.
CAPITAL
mgd
required =
x x ( r 204.7)
Cost from curve scale factor current index
. VARIABLE 0 & M
Power =
x x 17.9
Hp EC, $/Kw-hr
ACID = x
Ib/day $/lb
FIXED 0 & M
Labor:
Supervision:
Overhead:
Lab Labor:
Maint, Service,
I&T:
Service Water:
YEARLY 0 & M
UNCOSTED ITEMS
LIME =
Effluent TDS =
X
hr/day $/hr
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x T 365
capital, $ %/100 day/yr
X
thou gpd $/thou gal
365
$/day
.
.
x
day/yr sum, $/day
$
0 & M
$/yr
Ib/day b. Effluent TSS =
mg/L
mg/L
Date: 4/1/83
IV.3.1.13-A16
-------
NEUTRALIZATION
WORK SHEET
REQUIRED COST FACTORS' AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Sulfuric Acid = $/lb
4. Labor = $/hr
5. Supervision = $/hr
6. Overhead = % Labor r 100 = %/100
7. Lab Labor = $/hr
8. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = % f 100 = %/100
9. Service Water = $/thou gal
I. DESIGN FACTOR
a. Flow = mgd
b. Scale factor
i) IJE neutralization precedes equalization, scale factor = 1.67
otherwise scale factor = 1.0
II. CAPITAL COST
Select: low order or high order cost curve
£0.2 mgd 0.2 to 20 mgd
III. VARIABLE 0 & M
a. Power Requirements, Low Order Systems (<0.2 mgd)
HP = (32.3 x ) + 0.881 = Hp
Flow, mgd
b. Power Requirements, High Order Systems (0.2 to 20 mgd)
HP = (15.6 x ) + 8.70 = Hp
Flow, mgd
Date: 4/1/83 IV.3.1.13-A17
-------
c. Chemical Requirements Case I: Influent Acidity and Alkalinity Data
Available
1. Determine dominant characteristic, alkalinity (ALK), or acidity (AC)
A = - ( * 2) = mg/L
larger of smaller of modified
alkalinity alkalinity alkalinity
or acidity or acidity or acidity
2. If wastewater is predominantly acidic:
LIME = x x 6.17 = Ib/day
AC, mg/L FLOW, mgd LIME
TA = x x 8.34 = Ib/day
ADOSE, mg/L FLOW, mgd Topping Acid
3. If^ wastewater is predominantly alkaline:
ACID = x x 8.17 = Ib/day
ALK, mg/L FLOW, mgd ACID
TL = x x 8.34 = Ib/day
LOOSE, mg/L FLOW, mgd Topping Lime
d. Chemical Requirements Case II: Only pH Data Available
(method used when data are insufficient to use method C above)
1. If (low pH) >7.0:
ACIDC = [ - 7.0]2 x 20 = mg/L
(low pH)
p_r minimum value for ACIDC = 50 mg/L
TLC = 50 mg/L
2. If (low pH) <7.0 and (avg pH) >7.0:
LIMEC = [7.0 - ]3 x 20 = mg/L
(Low pH)
p_r minimum value for LIMEC = 50 mg/L .
TAG = {[( + ) f 2] - 7>2 x 20 = mg/L
(avg pH) (high pH)
or minimum value for TAG = 50 mg/L
Date: 4/1/83 IV.3.1.13-A18
-------
e.
3. If (low pH) <7.0 and (avg pH) <7.0 and (high pH) >7.0:
LIMEC = {7.0 - [(
T 2]}3 x 20 =
(avg pH) (low pH)
or minimum value for LIMEC = 50 mg/L
TAG = (
- 7.0)2 x 20 =
mg/L
(high pH)
or minimum value for TAG = 50 mg/L
4. If (low) pH £7.0 and (avg) pH <7.0 and (high) pH £7.0:
LIMEC = (7.0 -
)3 x 20 =
mg/L
(avg pH)
or minimum value for LIMEC = 100 mg/L
TAG = 0 mg/L
5. Convert to daily weight basis
If (low pH) >7.0 (method 1 above), then:
ACID =
x 8.34 =
ACIDC,mg/L FLOW, mgd
LIME = x x 8.34 =
TLC,mg/L FLOW, mgd
If method 2, 3, or 4 used above, then:
LIME =
x 8.34 =
LIMEC,mg/L FLOW, mgd
ACID = x x 8.34 =
TAG,mg/L FLOW, mgd
Chemical Requirements Case III: No Data
Available (standard 100 mg/L doses assumed)
Ib/day
Ib/day
Ib/day
Ib/day
LIME =
x 8.34 =
SDL, mg/L FLOW, mgd'
ACID =
x-8.34 =
SDA, mg/L FLOW, mgd
Ib/day
Ib/day
mg/L
IV. FIXED 0 & M
V. YEARLY 0 & M
Date: 4/1/83
IV.3.1.13-A19
-------
VI. UNCOSTED ITEMS
a. Effluent IDS (TDSE) =
+ [((0.54 x ) + (0.98 x )) f ( x 8.34)]
TDSI,mg/L LIME,lb/day ACID,lb/day FLOW,mgd
= mg/L
b. Effluent TSS (TSSE)
1. Step 1, Calcium (CALI >1000 mg/L) and sulfate (SULI >2000 mg/L)
present
CAL = {[ f ( x 8.34)] x 0.54} +
LIME,lb/day Flow,mgd CALI,mg/L
= mg/L
SUL = {[ * ( x 8.34)] x 0.98} +
ACID,lb/day FLOW,mgd SULI,mg/L
= mg/L
TSSE = ( + - 2500) +
CAL,mg/L SUL,mg/L TSSI,mg/L
= mg/L
Note - after this TSSE adjustment,
CALI = 800 mg/L
SULI = 1700 mg/L
2. Step 2, Calcium (CALI) >200 mg/L and carbonate (CARI) >200 mg/L
and sulfate (SULI) <2000
CAL = {[ T ( x 8.34)] x 0.54} +
LIME,lb/day FLOW,mgd CALI,mg/L
= mg/L
TSSE = ( + - 200) +
CARI,mg/L CAL,mg/L TSSI,mg/L
= mg/L
Date: 4/1/83 IV.3.1.13-A20
-------
IV.3.1.13-B. Liming to High pH
B 1. Basis of Design
This presentation is for the liming of influent wastewater streams
to high pH as a pretreatment process for ammonia stripping. The
principal design factors are the influent flow, alkalinity,
acidity, and pH characteristics of the influent. When alkalinity
and/or acidity data are known, the lime dosages for softening,
dealkalizing, and neutralizing are calculated based on this
information. When the influent acidity or alkalinity is not
known, a generalization based on pH is used to compute the lime
required. When no data are specified, the influent stream is
assumed to possess negligible alkalinity or acidity, and a pH
close to neutral. The minimum amount of lime added is in all
cases 230 mg/L with an average target value for the effluent pH
of 11.0. The mixing time for liming is 5 minutes and residence
time is 20 minutes.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
b) Required Input Data
Wastewater flow L/s (mgd)
Alkalinity, acidity, mg/L (not required but preferred if
known), pH
Ca, CO3, TSS, TDS (mg/L)
c) Limitations
None specified.
d) Pretreatment
None specified
e) Design Factor
Average daily wastewater flow is the primary design and cost
factor for liming to high pH. The facilities for liming to high
pH are similar to neutralization systems, consisting of a two
stage reaction tank and a chemical feed system. The design
residence time of the reaction and attenuation chambers is 5
and 20 minutes respectively at 120% of average daily flow.
Date: 4/1/83 IV.3.1.13-B1
-------
f) Subsequent Treatment
This unit process always precedes ammonia stripping and a clari-
fier is required to remove excess lime prior to going to the
stripper.
B 2. Capital Costs
The principal cost factor for liming to high pH is the wastewater
flow rate. A low flow (<26.3 L/s, 0.6 mgd) cost curve (Figure
IV.3.1.13-B1) and a high flow (£26.3 L/s, 0.6 mgd) cost curve
(Figure IV.3.1.13-B2) have been developed for lime feed and
monitoring systems required for liming to high pH. The quanti-
ties of lime including minimum quantity and safety factor require-
ments are computed using the methodologies presented in Section
B 3. Costs estimated using these curves must be adjusted to a
current value using an appropriate current cost index.
a) Cost Data
Items included in the capital cost curve estimates are as follows*
[4-2]:
i) Low order (<26.3 L/s, 0.6 mgd)
Mixing tank, fiberglass
Attenuation tank, fiberglass
Agitators (2)
Piping, electrical
Instrumentation
ii) High order (>26.3 L/s, 0.6 mgd)
Mixing tank, acid brick lined
Attenuation tank, acid brick lined
Agitators (2)
Piping, electrical
Instrumentation
*It should be noted that lime storage and handling facilities are
not included in these estimates. Once the lime requirements for
all unit processes have been determined, a central lime storage
and handling facility is designed to serve the whole plant. The
lime handling and storage facilities are therefore costed sep-
arately (see Lime Handling, Section IV.3.1.13-C).
b) Capital Cost Curves
i) Low Order Curve - Figure IV.3.1.13-B1
- Cost (thousands of dollars) vs. flow (liters per second
or million gallons per day)
Date: 4/1/83 IV.3.1.13-B2
-------
- Curve basis, cost estimates for four systems with
design flows of 4.38, 8.76, 17.5, and 26.3 L/s
(0.1, 0.2, 0.4, and 0.6 mgd)
ii) High Order Curve - see Figure IV.3.1.13-B2
- Cost (thousands of dollars) vs. flow (liters per second
or million gallons per day)
- Curve basis, cost estimates for four systems with
design flows of 8.76, 43.8, 219, and 876 L/s (0.2,
1.0, 5.0, and 20.0 mgd)
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
B 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable components of the operating cost are the lime and power
requirements. Fixed operating costs include labor, supervision,
overhead, laboratory labor, maintenance, services, insurance and
taxes, and service water. All fixed and variable operating costs
must be adjusted to current levels using an appropriate index or
unit cost factor.
a) Variable Costs
i) Power Requirements Low Order (FLOW <26.3 L/s, 0.6 mgd)
- pumps and agitators. These equations were developed
using regression analysis procedures [4-1].
Metric
KW = (0.55 x FLOW) + 0.286
where: KW = power, Kilowatts
FLOW = influent flow, L/s
English
HP = (32.3 x FLOW) + 0.384
where: HP = power, Hp
FLOW = influent flow, mgd
ii) Power Requirements High Order (FLOW £26.3 L/s,
0.6 mgd) - pumps and agitators. These equations
were developed using regression analysis procedures
[4-1].
Date: 4/1/83 IV.3.1.13-B3
-------
4.4
FLOW. LITERS PER SECOND
B.8 13 1«
22
26
01
0.2 0.3 04
'LOW. MN.LION GALLONS PER DAY
0.6
FIGURE IV.3.1.13-B1. CAPITAL COST ESTIMATE FOR LIMING TO A HIGH
pH (LOW ORDER)[4-10]
FLOW. LITERS PER SECOND
176 360 62« »6>i
676
1200-
100Q
4 6 12 16
FLOW. MLUON GALLONS PER DAY
FIGURE IV.3.1.13-B2. CAPITAL COST ESTIMATE FOR LIMING
TO A HIGH pH (HIGH ORDER) [4-10]
Date: 4/1/83
IV.3.1.13-B4
-------
Metric
KW = (0.266 x FLOW) +6.11
where: KW = power, Kilowatts
FLOW = influent flow, L/s
English
HP = (15.6 x FLOW) +8.19
where: HP = power, Hp
FLOW = influent flow, mgd
iii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power requirement, Kilowatts
24 = hr/day
EC = electricity cost, $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iv) Lime Requirements*
The lime requirements are calculated based on the infor-
mation available about the influent stream characteris-
tics (i.e., no data, alkalinity and/or acidity data, or
pH data).
• CASE I; No Data.
When no alkalinity, acidity, or pH values are speci-
fied, a soft or neutral wastewater is assumed and a
minimum lime dose of 230 mg/L plus a 25% safety factor
is used.
Metric
LIME = 230 x 0.086 x FLOW x 1.25
Date: 4/1/83 IV.3*1.13-85
-------
where: LIME = required lime, Kg/day
230 = minimum lime dose, mg/L
0.086 = conversion factor
FLOW = influent flow, L/s
1.25 = factor for 25% excess
English
LIME = 230 x 8.34 x FLOW x 1.25
where: LIME = required lime, Ib/day
8.34 = conversion factor
FLOW = influent flow, mgd
If the assumption of an essentially soft or neutral
wastewater is correct, the final solution will have a
pH of approximately 11.5.
• CASE II; Alkalinity and/or Acidity Data Specified.
When either alkalinity or acidity is specified, but
not both, the other is assumed negligible and taken
as zero. Otherwise the influent values for both are
used. The amount of lime required is found using the
following relationship:
Metric
LIME = 1(0.9 x ALK) + (0.74 x ACD) + 230]
x 0.086 x FLOW
where: LIME = required lime, Kg/day
ALK = influent alkalinity, mg/L (CaC03
equivalent)
ACD = influent acidity, mg/L (CaCO3
equivalent)
230 = minimum lime dose, mg/L
0.086 = conversion factor
FLOW = influent flow, L/s
English
LIME = [(0.9 x ALK) + (0.74 x ACD) + 230]
x 8.34 x FLOW
where: LIME = required lime, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor,
Date: 4/1/83 IV.3.1.13-B6
-------
• CASE III: pH Data Specified.
When only pH is specified, the required lime is
calculated using the following equation:
Metric
LIME = 20 x [11.0 - (avg pH)]3 x 0.086 x FLOW
where: LIME = required lime, Kg/day
avg pH = the average influent pH
0.086 = conversion factor
FLOW = influent flow, L/s
English
LIME = 20 x [11.0 - (avg pH)]3 x 8.34 x FLOW
where: LIME = required lime, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
*Costs for lime are based on total plant needs rather
than on the needs of an individual unit process. Lime
requirements should be accounted for but the cost for
lime and handling and storage systems are estimated
separately after design of all unit processes using
lime.
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.1.13-B1, including the cost basis and the unit costs
[4-11].
B 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as
piping and buildings, are calculated after completion of costing
for all unit processes (see Section IV.3.5).
B 5. Modifications
The addition of large amounts of lime affects the effluent con-
centrations of TDS, TSS, calcium, and carbonate. The generation
of additional TSS is of particular interest since it would effect
the subsequent design and handling of clarification and sludge
handling facilities.
a) Effluent TSS Adjustment
TSS = TSSI + Q
Date: 4/1/83
IV.3.1.13-B7
-------
TABLE IV.3.1.13-B1.
FIXED 0 & M COST BASIS AND
UNIT COST FACTORS FOR LIMING
TO HIGH pH [4-11] .
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.20 Weeks (4.80 hrs/day)
10% Labor (0.48 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
2.50% Capital
0.40% Capital
1.92% Capital
0.00 L/s
(0.00 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.13-B8
-------
where: TSS = average effluent TSS, mg/L
TSSI = average influent TSS, mg/L
Q = intermediate variable determined as follows:
i) Case I: If GARB >200 mg/L
and [LIM x (40 * 74)] >200 mg/L, then:
Metric
Q = LIM x (40 * 74) + GARB - 200
where: GARB = average influent CO3, mg/L
LIM = average lime requirement, mg/L
= LIME * (0.086 x FLOW)
LIME = lime requirement, Kg/day
(see section B3,a,iii)
40 r 74 = ratio of Ca to Ca(OH)2, Kg/Kg
English
Q = LIM x (40 * 74) + GARB - 200
where: GARB = average influent C03/ mg/L
LIM = average lime requirement, mg/L
= LIME T (8.34 x FLOW)
LIME = lime requirement, Ib/day
(see Section B 3,a,iii)
40 * 74 = ratio of Ca to Ca(OH)2, Ib/lb
ii) Case II; Lf GARB >200 mg/L
and [LIM x (40 * 74)] 5200 mg/L, then:
Q = 0.2 x LIM x (40 * 74)
iii) Case III; All other conditions.
Q = O
b) Effluent Ca and C03
Following liming to high pH the following effluent concentrations
of Ca and C03 are assumed:
Ca = 80 mg/L
CO3 = 120 mg/L
c) Effluent TDS
Metric
TDS = TDSI + Y
Date: 4/1/83 IV.3.1.13-B9
-------
where: TDS
TDSI
Y
LIM
LIME
Q =
0.086
FLOW
English
average effluent TDS, mg/L
average influent TDS, mg/L
intermediate variable
LIM - Q
LIME * (0.086 x FLOW)
lime requirement, Kg/day
(see Section B 3,a,iii)
intermediate variable
(see Section B 5,a)
conversion factor
influent flow, L/s
TDS = TDSI + Y
where: Y
LIM
8.34
FLOW
LIM - Q
LIME r (8.34 x FLOW)
conversion factor
influent flow, mgd
Date: 4/1/83
IV.3.1.13-B10
-------
LIMING TO HIGH pH
SUMMARY WORK SHEET REFERENCE: IV.3.1.13-B
I.
a.
II.
Cost
III.
a.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
DESIGN FACTOR CAPITAL
Flow = mgd
CAPITAL COST
x ( f 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
FIXED 0 & M
Labor: x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor : x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
day/yr
$/day
x
sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
LIME = Ib/day b. Effluent TSS =
mg/L
Date: 4/1/83
IV.3.1.13-B11
-------
LIMING TO HIGH pH
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Labor = $/hr
4. Supervision = $/hr
5. Overhead = % Labor
6. Lab Labor = $/hr
7. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = % * 100 = %/100
8. Service Water = $/thou gal
I. DESIGN FACTOR
a. Flow =
FLOW, mgd
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements, Low Order (<0.6 mgd)
HP = ( x 32.3) + 0.384 = Hp
FLOW, mgd
b. Power Requirements, High Order (>0.6 mgd)
HP = ( x 15.6) + 8.19 = Hp
FLOW, mgd
c. Chemical Requirements, Case I - No Data Specified
LIME = x 2400 = Ib/day
FLOW, mgd
Date: 4/1/83 IV.3.1.13-B12
-------
d. Chemical Requirements, Case II - Alkalinity/Acidity Data Specified
LIME = [(0.9 x
ALK,mg/L
x 8.34 =
) + (0.74 x
) + 230] x
ACD,mg/L
Ib/day
FLOW,mgd
e. Chemical Requirements, Case III - pH Data Specified
LIME = (11.0 -
(avg)pH
)3 x
x 167 =
FLOW,mgd
Ib/day
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Effluent TSS
1. Necessary Input Data
CARB =
mg/L
LIM =
avg influent CARB
* (
x 8.34) =
LIME,lb/day FLOW,mgd
Intermediate variable = LIM x (40 * 74) =
mg/L
mg/L
2. Case I. If CARB >200 mg/L and [LIM x (40 * 74)]) >200 mg/L
TSS =
x 0.54) +
- 200]
TSSI,mg/L
LIM,mg/L
mg/L
C03,mg/L
3. Case II. If CARB >200 mg/L and [LIM x (40 * 74)] <200 mg/L
TSS =
x 0.11) =
TSSI,mg/L LIM,mg/L
4. Case III. All other conditions
TSS =
mg/L
TSSI, mg/L
Date: 4/1/83
IV.3.1.13-B13
-------
IV.3.1.13-C Lime Handling
C 1. Basis of Design
This presentation is for a central lime handling and distribution
system designed to provide the needs of an entire industrial
wastewater treatment facility. Lime or caustic may be required
by such unit processes as dissolved air flotation, nitrification,
ion exchange, chemical coagulation, filtration (vacuum and pres-
sure), neutralizaton, and liming to a high pH. This system is
designed after the total requirement for lime has been determined
(i.e., after the unit process treatment train design is com-
plete).
The basis for the design is the type of lime handling system and
the total quantity of lime required. The type of lime handling
system depends on whether neutralization is included in the
treatment process and on the quantity of lime needed in the
treatment process. Three handling systems are available. If
neutralization is the only unit process requiring lime and if the
lime requirement is less than 227 Kg/day (500 Ib/day), then a
liquid caustic system is installed. Where the treatment system
requires 3630 Kg/day (8,000 Ib/day) of lime or less, lime require-
ments are met using hydrated lime as illustrated in Figure
IV.3.1.13-C1. For treatment systems requiring over 3630 Kg/day
(8,000 Ib/day) of lime, the lime requirements are met using
quicklime and a slaking system as illustrated in Figure
IV.3.1.13-C2.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
b) Required Input Data
Lime requirements for all individual unit processes.
c) Limitations
None specified.
d) Pretreatment
None specified.
Date: 4/1/83 IV.3.1.13-C1
-------
O
EH
M
Q
H
Q W
&4 Q
w
CO EH
w 2
U Q
O >H
rH
U
I
D
O
H
Date: 4/1/83
IV.3.1.13-C2
-------
n
4 *•
H
i-1
SA
H t— i
J O
H
« EH
O H
En Q
Q
OS
< H
H J
Q W
u
5 H
O D
cn tc
en &
w
O W
O O
tf H
PU ffi
u
I
g
Date: 4/1/83
IV.3.1.13-C3
-------
e) Design Equation
The primary design and cost factor for lime handling systems is
the total daily lime requirement for the plant as a whole. This
is found by summing the calculated lime requirements for all unit
processes as follows:
TOTLIME = Z LIME(u)
where: TOTLIME = total lime requirement in terms of
Ca(OH)2/ Kg/day or Ib/day
LIME(u) = lime requirement for a single unit pro-
cess (u) included in the treatment design
in terms of Ca(OH)2/ Kg/day or Ib/day
Based on the total lime requirement (TOTLIME), the type of lime
handling system is determined as follows:
i) Liquid Caustic
If the only unit process is neutralization and if TOTLIME
£227 Kg/day (<500 Ib/day), then a liquid caustic handling
system is considered adequate to meet the wastewater
treatment facility lime requirement (i.e., caustic require-
ment) . The factor used for costing the liquid caustic
system remains the equivalent lime requirement expressed
in Kg Ca(OH)2/day (Ib Ca(OH)2/day).
ii) Hydrated Lime
If unit processes other than neutralization are used
alone or in combination (with or without neutralization)
and if TOTLIME <3630 Kg/day (£8000 Ib/day), then a bagged
hydrated lime handling system is considered appropriate.
The factor used for costing the lime handling system
remains the lime requirement expressed in Kg Ca(OH)2/day
(Ib Ca(OH)2/day).
iii) Slaking System Using Quicklime
If TOTLIME >3630 Kg/day (>8000 Ib/day), then a slaking
system using quicklime is considered appropriate. Be-
cause the molecular weight of quicklime (CaO) differs
from the molecular weight of hydrated lime [Ca(OH)2],
lime requirements in terms of kilograms or pounds per day
of quicklime are adjusted as follows:
QLIME = TOTLIME x 28 *• 37
Date: 4/1/83
IV.3.1.13-C4
-------
where: QLIME = the lime requirement expressed as Kg
CaO/day or Ib CaO/day
TOTLIME = the lime requirement expressed as Kg
Ca(OH)2/day or Ib Ca(OH)2/day
28 = equivalent weight of CaO
37 = equivalent weight of Ca(OH)2
The cost factor is the lime requirement expressed in Kg
CaO/day or Ib CaO/day.
f) Subsequent Treatment
None required.
C 2. Capital Costs
The cost factor used to determine capital costs is the total lime
requirement. The capital cost curve (Figure IV.3.1.13-C3) is
used to cost three types of lime handling systems as follows:
liquid caustic; hydrated lime; and a slaking system using quick-
lime. The capital cost curve is presented in terms of dollars
vs. lime requirement for systems below 3630 Kg/day (8000 Ib/day),
but shifts to dollars vs. quicklime requirement for systems with
a lime requirement greater than 3630 Kg/day (8000 Ib/day).
a) Cost Data
The capital cost estimates include the following items for each
of the lime handling systems indicated below [4-2]:
i) Liquid Caustic
Steel storage tank
Insulation, electrical, pumps, and piping
Agitators
Instrumentation
ii) Hydrated Lime
Storage silo
Lime slurry tanks
Lime feeders
Bin activator for storage silo
Insulation, electrical, pumps, and piping
Agitators
Instrumentati on
iii) Quicklime With Slaker
Storage silo
Date: 4/1/83 IV.3.1.13-C5
-------
Lime slurry tank
Bin activator for storage silo
Insulation, electrical, pumps, and piping
Agitators
Instrumentation
Combination slakers
Dust filter
b) Capital Cost Curve [4-2]
Curve - see Figure IV.3.1.13-C3
- Cost (thousands of dollars) vs. lime required (thousand
kilograms per day or thousand pounds per day)
Kg Ca(OH)2 for lime <3630 Kg/day; Kg CaO/day for
lime >3630 Kg/day (Ib Ca(OH)2 for lime <8000 Ib/day;
Ib CaO/day for lime >8000 Ib/day)
- Curve basis, cost estimate for five systems with lime
requirements of 45.4, 227, 560, 2,800, and 8,470
Kg/day (100, 500, 1235, 6170, and 18,680 Ib/day)
c) Cost Index
Base period, July, 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
C 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component includes power, while the fixed component
includes labor, supervision, overhead, laboratory labor, main-
tenance, services, insurance and taxes, and service water. All
fixed and variable operating costs should be adjusted to current
levels using an appropriate index or unit cost factor.
a) Variable Cost
i) Power Requirements - pumps, agitators, feeders. The
following equation was developed using regression analysis
procedures [4-1].
Metric
KW = (TOTLIME x 1.32 x 10'«) + 1.72
where: KW = power, kilowatts
TOTLIME = lime required, Kg/day
English
HP = (TOTLIME x 3.93 x 10'4) + 2.30
where: HP = power, Hp
TOTLIME = lime required, Ib/day
Date: 4/1/83
IV.3.1.13-C6
-------
c
III
Q.
III
o
H
I
O
55
H
H
en
CO
O
u
g
ro
O
I
CO
§
§
H
JO SQNVSnOHl *18OO
Date: 4/1/83
IV.3.1.13-C7
-------
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost/ $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
iii) Process Water Requirement (TOTLIME >500 Ib/day)
Metric
PW = TOTLIME x 10 * (1.0 x 86400)
where: PW = process water, L/s
TOTLIME = total lime requirement, Kg/day
10 = Kg H20/Kg Lime
1.0 = conversion factor
86400 = s/day
English
PW = TOTLIME x 10 * 8.34 * 1000
where: PW = process water, thousand gpd
TOTLIME = total lime requirement, Ib/day
10 = Ib water/lb lime
8.34 = conversion factor
1000 = gal/thousand gal
iv) Lime Requirement
• Liquid Caustic System
CAUSTIC = TOTLIME x 40 * 37
where: CAUSTIC = Kg/day or Ib/day of caustic
LIME = total lime requirement as Ca(OH)2,
Kg/day or Ib/day
40 = equivalent weight of caustic (NaOH)
Date: 4/1/83 IV.3.1.13-C8
-------
37 = equivalent weight of hydrated lime
[Ca(OH)2]
(two equivalents per Kg-mole or Ib-mole)
• Hydrated Lime System
HYDRATED LIME = TOTLIME
where: HYDRATED LIME = Kg/day or Ib/day of hydrated lime
TOTLIME = total lime requirement as Ca(OH)2,
Kg/day or Ib/day
• Quicklime with Slaker System
QUICKLIME = TOTLIME x 28 * 37
where: QUICKLIME = Kg/day or Ib/day of quicklime
TOTLIME = total lime requirement as Ca(OH)2,
Kg/day or Ib/day
28 = equivalent weight of quicklime (CaO)
37 = equivalent weight of hydrated lime
[Ca(OH)2]
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.1.12-C1, including the cost basis and the unit costs
[4-11].
C 4. Miscellaneous Costs
Cost for engineering, and other common plant items such as piping
and buildings, are calculated for the entire plant after comple-
tion of design and costing of all individual unit processes (see
Section IV.3.5).
C 5. Modifications
None indicated.
Date: 4/1/83 IV.3.1.13-C9
-------
TABLE IV.3.13-C1.
FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR LIME HANDLING FACILITIES
14-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.20 Weeks (4.80 hrs/day)
10% Labor (0.48 hrs/day )
75% Labor Cost
0.00 Shifts
4.19% Capital
0.40% Capital
2.50% Capital
0.41 L/s
(9.26 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours = 4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.13-C10
-------
I.
LIME HANDLING
SUMMARY WORK SHEET
REFERENCE: IV.3.1.13-C
DESIGN FACTOR CAPITAL
Total Lime Required = Ib/day (Type = )
II.
Cost
III.
a.
b.
c.
d.
e.
IV.
a.
b.
c.
d.
e.
V.
VI.
CAPITAL COST
x ( r 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
Process Water = x
thou gpd WC, $/thou gal
Caustic = x
Ib/day CC, $/lb
Hydrated Lime = x
Ib/day HLC, $/lb
Quicklime = x
Ib/day QLC, $/lb
FIXED 0 & M
Labor : x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor : x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100 day/yr
YEARLY 0 & M 365
day/yr
$/day
.
.
.
x
sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Date: 4/1/83
IV.3.1.13-C11
-------
LIME HANDLING
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. WC: Process Water Cost = $/gal
4. CC: Caustic Cost = $/lb
5. HLC: Hydrated Lime Cost = $/lb
6. QLC: Quicklime Cost = $/lb
7. Labor = $/hr
8. Supervision = $/hr
9. Overhead = % Labor * 100 = %/100
.0. Lab Labor = $/hr
11. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = r 100 =%/100
I. DESIGN FACTOR
a. Determine the total lime requirement in Ib/day as follows:
Complete the following table by inserting the quantity of lime required
for each unit process listed.
Unit Process Lime Required, Ib/day
Neutralization
Dissolved Air Flotation
Chemical Coagulation ~
Vacuum Filtration
Pressure Filtration
Liming to High pH
TOTLIME = Ib/day
Date: 4/1/83 IV.3.1.13-C12
-------
b. Determine the type of lime handling system as follows-.
1. If the total lime required (TOTLIME) >8000 Ib/day, the handling
system is quicklime with slakers. (TYPE = QUICKLIME)
2. If the total lime required (TOTLIME) <500 Ib/day, and if neutrali-
zation is the only unit process requiring lime, the handling
system is liquid caustic. (TYPE = CAUSTIC)
3. All other lime requirements are met using the bagged hydrated
lime. (TYPE = HYDRATED)
II. CAPITAL COST
a. Adjust the lime requirement for use with the cost curve as follows:
Lime Required = x = Ib/day
TOTLIME, Ib/day Factor
(from I a)
1. If TYPE = QUICKLIME,
FACTOR = 56 r 74 = 0.76
2. If TYPE = HYDRATED,
FACTOR =1.00
3. If TYPE = CAUSTIC,
FACTOR = 1.00
III. VARIABLE 0 & M
a. Power Requirements
HP = ( x 3.93 x 10'4) + 2.30 = Hp
Lime Required, Ib/day
b. Process Water Requirements
If TOTLIME (from I a 2) >500 Ib/day
PROCESS WATER = T 834 = thou gal
TOTLIME, Ib/day
(from I a 2)
c. Lime Requirements
1. If TYPE (from I b) = CAUSTIC,
Date: 4/1/83 IV.3.1.13-C13
-------
CAUSTIC =
HYDRATED LIME '
QUICKLIME •
2. If TYPE (from
CAUSTIC ••
HYDRATED LIME •
TOTLIME, Ib/day
(from I a 2)
= 0 Ib/day
= 0 Ib/day
I b) = HYDRATED,
= 0 Ib/day
= Ib/day
TOTLIME
(from la)
= 0 Ib/day
x (40 f 37) =
QUICKLIME =
3. If TYPE (from I b) = QUICKLIME,
CAUSTIC
HYDRATED LIME
QUICKLIME =
0 Ib/day
0 Ib/day
x (28 T 37) =
TOTLIME, Ib/day
(from I a 2)
Ib/day
Ib/day
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83
IV.3.1.13-C14
-------
IV.3.1.14 OIL SEPARATION
Introduction
Oil separation involves the removal of free oils and grease from
a wastewater stream. Gravity separation is designed to allow the
separation to occur based only upon the differences in the spe-
cific gravities of oil and water. For further details on the
gravity oil separation process, refer to Volume III, Section
III.3.1.14 of the Treatability Manual. Costing methodologies and
cost data for this technology are presented below.
IV.3.1.14-A. Gravity Oil Separation
A 1. Basis of Design
This presentation is for the removal of free oil from wastewater
by the gravity oil separation process. This process is repre-
sented schematically in Figure IV.3.1.14-A1. The basic design
and cost factor for the technology is the influent wastewater
flow. Gravity oil separation tanks are sized for an overflow
rate of 0.47 L/s/m2 (1000 gpd/ft2) at 120% of the average daily
wastewater flow rate. A minimum of two units, each at 50% of
design capacity, are provided. Horizontal velocity is limited to
a maximum of 0.9 m/min (3 ft/min).
Gravity oil separation as presented in this discussion is not
assumed to remove soluble or emulsified oil. Emulsions may be
broken to enhance gravity oil separation by chemical or thermal
means. For more information on emulsion breaking see Section
III.3.1.14 of Volume III. In addition other unit processes such
as dissolved air flotation (see Section IV.3.1.10-A) which are
more effective in removing emulsified oils may be considered for
use in combination with or instead of gravity oil separation.
a) Source
The unit cost information in this section was derived from the BAT
Effluent Limitations Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries [4-2]. The
method for developing the design factor is based on assumption
and procedures in the Contractor Developed Design and Cost Model
[4-1].
b) Required Input Data
Average and peak wastewater flow, L/s (mgd)
Characteristics of the wastewater stream (mg/L)
- oil and grease
- TSS
- floating solids
- floating organic pollutants
Date: 4/1/83 IV.3.1.14-A1
-------
i-J
M
O
1
O
-tf
o
tu O
M
CO H
CJ
O
CO
M
w
od
s
CJ
Date: 4/1/83
IV.3.1.14-A2
-------
c) Limitations
Gravity oil separation is not considered applicable for treating
influent oil concentrations of less than 35 mg/L
d) Pretreatment
None specified
e) Design Equation
An adjusted influent wastewater flow rate in liters per second
(million gallons per day) is the primary capital cost factor for
gravity oil separation systems. The cost factor (flow) is first
multiplied by a scale factor (see Section A 2) to account for
peak flow prior to use for cost estimating purposes.
f) Subsequent Treatment
i) Sludge and oil and grease removed from the wastewater
stream are usually treated by thickening, stabilizing and
dewatering processes before being disposed.
ii) Oil separation may be used prior to solvent extraction to
treat wastewater streams containing supersaturated con-
centrations of organic pollutants which are lighter than
water.
A 2. Capital Costs
The primary cost factor for oil separation is the wastewater flow
rate. This parameter is the independent variable in the capital
cost curve for the unit process (Figure IV.3.1.14-A2). For flows
greater than 4.38 L/s (0.1 mgd), a scale factor is applied to
adjust the flow prior to selection of a cost from the cost curve.
The scale factor is used as a means of adjusting capital cost to
account for pealf flow capacity. Costs estimated using these
curves must be adjusted to a current value using an appropriate
current cost index.
a) Cost Dptta
Items included in the capital cost estimates for the oil separa-
tion units are as follows [4-2]:
Two-chamber separation tank with baffles,
concrete (2)
Slop-oil holding tank, covered, fiber reinforced
plastic
Splitter box, concrete
Oil pumps, progressive cavity (2)
Sludge pumps, progressive cavity (2)
Date: 4/1/83 IV.3.1.14-A3
-------
Oil skimmer mechanism (2)
Sluice-gates
Piping, electrical
Instrumentation
b) Capital Cost Curve
i) Curve - Figure IV.3.1.14-A2.
- Cost (millions of dollars) vs. wastewater flow
(liters per second or million gallons per day).
- Curve basis, cost estimates for system at four
flow rates: 8.76, 43.8, 219, and 876 L/s (0.2, 1.0,
5.0, and 20.0 mgd).
ii) Scale factor: applies to flow prior to selection of a
cost from the cost curve
• if Avg Flow <4.38 L/s (< 0.1 mgd), scale factor:
SF = 1.0
• if Avg Flow £4.38 L/s (£ 0.1 mgd), scale factor:
SF = peak flow + average flow
2 x average flow
iii) Flow for Cost purposes = Avg Flow x SF
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs are comprised of both variable and fixed compo-
nents. Power requirement is the only variable operating cost
component. Fixed operating cost components include labor, super-
vision, overhead, laboratory labor, maintenance, services, insur-
ance and taxes, and service water. All fixed and variable oper-
ating costs should be adjusted to current levels using an appro-
priate index or unit cost factor.
a) Variable Cost
i) Power Requirements, Oil Separation - belt skimmer,
sludge pumps, flight skimmers and oil pumps [4-1].
Metric
KW = (0.052 x FLOW) +2.6
where: KW = power, kilowatts
FLOW = average influent flow, L/s
Date: 4/1/83 IV.3.1.14-A4
-------
FLOW. LITERS PER SECOND
(
< 2 O-
_j
_J
o
O
•. 4 K~
Ik l.O
•9
I
21 0-
H QS-
§»~ O.5
0
>
7
•
.
Ji
r1
f
i>
Xl
^
x
-
J
'
I
2
^
9
^
G
-
LI
]
r
*
^
•
j
*•
1
x1
,^
41
L
X
a
X
^-
*•
pX
i
^
2
«<
X*
t
•
*•
Bi
(
7
X
,
1
^
6
*
X1
^
'
^>
8
2
'6
T
0
FLOW. MILLION GALLONS PER DAY
FIGURE IV.3.1.14-A2. CAPITAL COST ESTIMATE FOR
GRAVITY OIL SEPARATION [4-10]
Date: 4/1/83
IV.3.1.14-A5
-------
English
HP = (3.04 x FLOW) +3.45
where: HP = horsepower required, Hp
FLOW = average influent flow, mgd
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power required, KW
24 = hrs/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where.- PC = power cost, $/day
HP = horsepower required, Hp
24 = hrs/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
b) Fixed Costs
The fixed 0 & M components for gravity oil separation are
listed in Table IV.3.1.14-A1 including the cost basis and
the unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after completion of costing for individ-
ual units (See Section IV.3.5). The required quantity of land
and expected sludge generation from the unit process are calcu-
lated below to facilitate subsequent cost estimates.
a) Land
The following equation estimates the amount of land required for
oil separation based on the overflow rate, scale factor, and cost
factors.
Metric
LAND = SF x FLOW x 1.2 * 0.47
Date: 4/1/83 IV.3.1.14-A6
-------
TABLE IV.3.1.14-A1.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR GRAVITY OIL SEPARATION
[4-11]
Dissolved Air Flotation
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.25 Weeks (6.00 hrs/day)
10% Labor (0.60 hrs/day)
75% Labor Cost
0.20 Shifts (1.14 hrs/day)
7.53% Capital
0.40% Capital
2.50% Capital
4.6 L/s
(105.4 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/thou L
($0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.14-A7
-------
where: LAND = land requirement, m2
SF = scale factor (see Section A2,b)
FLOW = average influent flow, L/s
1.2 = factor for accessories
0.47 = overflow rate, L/s/m2
English
LAND = SF x FLOW x (1,200,000 * 1,000)
where: LAND = land requirement, ft2
SF = scale factor (See Section A2,b)
FLOW = average influent flow, mgd
1,200,000 = mgd x 1.2 factor for accessories,
gal/day
1,000 = overflow rate, gpd/ft2
b) Sludge and Float Production
Oil separation may produce waste byproducts consisting of oil,
solids, or oily solids. Sludge or float production varies accord-
ing to flow and the influent conditions. In general the quantity
of sludge and float produced by gravity oil separation may be
estimated as follows:
FLOAT = PFLOAT + OFLOAT + SLDG
where: FLOAT = total float and sludge produced Kg/day or Ib/day
PFLOAT = organic pollutant float, Kg/day or Ib/day
OFLOAT = oil float from oil separation unit, Kg/day or
Ib/day
SLDG = suspended solids sludge, Kg/day or Ib/day
Pollutant Float (PFLOAT)
This includes partially soluble pollutants that are flotable
(These are normally removed by solvent extraction, but may
be present at levels above their solubility limit at this
point in the treatment process). This does not include oil
float due to oil removal and TSS.
Metric
PFLOAT = 0.086 x FLOW x Z(PC(i) - PS(i))
where: PFLOAT = pollutant float, Kg/day
0.086 = conversion factor
FLOW = influent flow, L/s
PC(i) = influent concentration of extractable
pollutant (i), mg/L
Date: 4/1/83 IV.3.1.14-A8
-------
PS(i) = solubility of pollutant (i), mg/L (see
Section IV.3.1.20-A, Solvent Extraction)
English
PFLOAT = 8.34 x FLOW x Z(PC(i) - PS(i))
where: PFLOAT = pollutant float, Ib/day
8.34 = conversion factor
FLOW = influent flow, mgd
PC(i) = influent concentration of extractable
pollutant (i), mg/L
PS(i) = solubility of pollutant (i), mg/L
(see Section IV.3.1.20-A, Solvent
Extraction)
Oil Float (OFLOAT)
This includes floating oil removed by the process.
Metric
OFLOAT = 0.086 x FLOW x (SEPOIL - EFOIL)
where: OFLOAT = oil float from oil separation unit,
Kg/day
FLOW = influent flow, L/s
SEPOIL = total influent insoluble oil, mg/L
EFOIL = expected effluent oil concentration from
gravity oil separation unit, mg/L (default
value 35 mg/L)
English
OFLOAT = 8.34 x FLOW x (SEPOIL - EFOIL)
where: OFLOAT = oil float from oil separation unit,
Ib/day
FLOW = influent flow, mgd
SEPOIL = total influent insoluble oil, mg/L
EFOIL = expected effluent oil concentration
from gravity oil separation unit, mg/L
(default value 35 mg/L)
Sludge (SLDG)
This includes suspended solids removed by the process.
Metric
SLDG = 0.086 x FLOW x (TSSI - TSSE)
Date: 4/1/83 IV.3.1.14-A9
-------
where:
SLDG = suspended solids float, Kg/day
FLOW = influent flow, L/s
TSSI = influent TSS, mg/L
TSSE = effluent TSS, mg/L
English
where:
SLDG = 8.34 x FLOW x (TSSI - TSSE)
SLDG = suspended solids float, Ib/day
FLOW = influent flow, mgd
TSSI = influent TSS, mg/L
TSSE = effluent TSS, mg/L
A 5. Modifications
Gravity oil separation and dissolved air flotation (DAF) are
often used in series to treat combination waste streams of oils,
suspended solids, and colloidal materials.
Date: 4/1/83
IV.3.1.14-A10
-------
I.
a.
II.
Cost
III.
a.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
b.
DESIGN FACTOR
OIL SEPARATION
SUMMARY WORK SHEET
REFERENCE: IV.3.1.14A
CAPITAL
Flow for cost purposes = mgd
CAPITAL COST
—
DFLOW
x ( r 204.7) $
Cost from curve current index
VARIABLE 0 &
Power =
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service
I&T:
Service Water:
YEARLY 0 & M
M
x x 17.9
Hp EC, $/Kw-hr
x
hr/day $/hr
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x * 365
capital, $ %/100 day/yt
X
thou gpd $/thou gal
365
day/yr
$/day
.
X
sum, $/day
0 & M
$/yr
UNCOSTED ITEMS
Land =
Oil Separation
ft*
Float = Ib/day
Date: 4/1/83
IV.3.1.M-A11
-------
OIL SEPARATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Labor = $/hr
4. Supervision = $/hr
5. Overhead = % Labor r 100 = %/100
6. Lab Labor = $/hr
7. Maintenance = % Capital
Services = ~ % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor = % f 100 = %/100
8. Service Water = $/thou gal
I. DESIGN FACTOR
a. Scale Factor for Gravity Oil Separation:
If average wastewater flow (FLOW) < 0.1 mgd, Scale Factor = 1
I_f average wastewater flow (FLOW) > 0.1 mgd, Scale Factor =
( •>- ) * [2 x ( )] =
Peak flow, mgd Avg FLOW, mgd Avg FLOW, mgd SF
b. Wastewater Flow for Costing Purposes:
DFLOW = x = mgd
Avg FLOW, mgd Scale factor
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements (Gravity Oil Separation)
HP = (3.04 x ) + 3.45 = Hp
Avg FLOW, mgd
IV. FIXED 0 & M
Date: 4/1/83 IV.3.1.14-A12
-------
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. LAND =
x 1200 =
ft*
SF Avg FLOW, mgd
b. Float from Gravity Oil Separation Unit
1. Pollutant Float (solvent extractable pollutants removed by oil separation)
PFLOAT = 8.34 x
K
FLOW, mgd PC(i), mg/L PS(i), mg/L
2. Oil Float from Gravity Oil Separation
OFLOAT = 8.34 x x (
FLOW, mgd SEPOIL, mg/L EFOIL, mg/L
3. Suspended Solids Sludge from Gravity Oil Separation Unit
SLDG = 8.34 x x (
FLOW, mgd XSSI, mg/L TSSE, mg/L
4. Total Gravity Oil Separation Float Component
FLOAT = + +
PFLOAT, Ib/day OFLOAT, Ib/day SLDG, Ib/day
Ib/day
Ib/day
Ib/day
Ib/day
Date: 4/1/83
IV.3.1.14-A13
-------
IV.3.1.18 SEDIMENTATION
Introduction
Gravity sedimentation is the most widely used system for removing
suspended solids from wastewater streams. Typical applications
include separation of chemically precipitated solids and/or
biological or other solids from wastewater streams. The type of
process or treatment preceeding a sedimentation system (e.g.,
coagulation, flocculation, and activated sludge) affects the
nature and settleablity of the influent wastewater solids and
thereby affects the design, performance, and cost of the system.
Sedimentation systems are described in more detail in Volume III
of the Treatability Manual, Section III.3.1.18. Costing methodo-
logies and cost data for this technology are presented below.
IV.3.1.18-A. Clarification
A 1. Basis of Design
This is a presentation of costs and necessary design factors for
wastewater clarification using rectangular and dual circular
clarifiers. The principal cost factor is the surface area of the
clarifiers, and the principal design factors are influent flow
and the appropriate overflow rate, given the influent suspended
solids concentration and the nature of the influent solids.
Design of the unit is begun by selecting an appropriate surface
overflow rate from Table IV.3.1.18-A1 based on the source and
type of solids entering the clarification unit. Also, depending
on the type of influent solids, it is possible to select either a
biological solids type clarification system (Figure IV.3.1.18-A1)
or a chemical solids type clarification system (Figure IV.3.1.18-A2)
This distinction will be used in the costing of the system in
Section 2b. The surface area of the clarification units is
calculated with a 20% safety margin based on the average influent
flow and the selected overflow rate. The design is then checked
to assure that the solids flux does not exceed 146 Kg/m2/day (30
Ib/ft2/day).
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries
[4-2]. The method for developing the design factor is based on
assumptions and procedures in the Contractor Developed Design and
Cost Model [4-1].
b) Required Input Data
Wastewater flow, L/s (mgd)
Influent TSS (mg/L)
Influent oil and grease (mg/L)
Date: 4/1/83 IV.3.1.18-A1
-------
TABLE IV.3.1.18-A1. DESIGN AND APPLICATION CRITERIA FOR SEDIMENTATION
SYSTEMS [4-1]
Preceding
Treatment or
Type of Solids
1.
2.
3.
4.
5.
Raw, or untreated
chemical waste
Activated Sludge
Nitrification,
Denitrification
Chemical Coagulation
Alum
Sulfides
Iron
Liming (pH Adjustment)
Followed by Chemical
Coagulation
Clarifier
Type
Chemical
Biological
Biological
Chemical
Chemical
Chemical
Chemical
Overflow Rate
L/s/m2(gpd/ft2)
0.377 (800)
0.236 (500)
0.189 (400)
0.236 (500)
0.236 (500)
0.330 (700)
0.377 (800)
Date: 4/1/83
IV.3.1.18-A2
-------
o
H
u
H
ft,
H
04
U
O r-l
fa I
K CO
O Q
rtC H
H ,-q
Q O
en
J <
fa U
M
CO O
CO O
W t4
U O
O H
« CQ
I
cx>
D
O
H
Date: 4/1/83
IV.3.1.18-A3
-------
L?
t
I (T~
SH Q]
a=—QJ
O-
a
o
H
s
u
H
a
U
OS
o
fa '
H Q
Q H
^
SO
O CO
J
fa J
-------
Preceding unit process and influent solids type
(see Table IV.3.1.18-A1)
c) Limitations
i) If influent TSS <50 mg/L, clarification is not re-
quired.
ii) Solids flux on the sedimentation units is limited to a
maximum of 146 Kg/m2/day (30 Ib/ft2/day) [4-1].
d) Pretreatment
None specified.
e) Design Factor
The design surface area is initially calculated based on influent
wastewater flow and the surface loading factors presented in
Table IV.3.1.18-A1 corresponding to the nature of the influent
solids. This design is then adjusted to a standard clarifier
size based on unit diameter increments of 1.52 m (5 ft).
i) Initial estimate of Surface Area
Metric
SA = 1.2 x FLOW * OVFL
where.- SA = surface area, m2
1.2 = 20% safety margin for SA
FLOW = influent flow, L/s
OVFL = overflow rate, L/s/m2
(see Table IV.3.1.18-A1)
English
SA = FLOW x (1.2 x 106) * OVFL
where: SA = surface area, ft2
FLOW = influent flow, mgd
OVFL = overflow rate (Table IV.3.1.18-A1),
gpd/ft2
1.2 x 106 = conversion factor, including 20% safety
margin for SA
OVFL depends on the preceding treatment and solids type. The
computed SA for a primary solids clarifier may have to be increased
if the influent TSS concentration is excessively high.
Date: 4/1/83 IV.3.1.18-A5
-------
ii) Clarifier Diameters
Dual circular clarifiers are considered for biological
and high order (SA >20.9 m2 (>225 ft2)) chemical clari-
fication systems. These units are adjusted to standard
1.52 m (5 ft) diameter increments with a maximum unit
diameter of 61 m (200 ft). Low order (SA <20.9 m2 (£225
ft2)) chemical applications call for single rectangular
units and are not adjusted.
DM = [ (4 x SA) * (M x ir) ] °'5
where: DM = individual clarifier diameter, m or ft
(maximum = 61 m (200 ft))
4 = conversion factor, radius2 to diameter 2
SA = total required surface area, m2 or ft2
M = number of equal sized clarifiers, (two or
more)
ir = 3.1417
iii) Design Surface Area
After the standard diameter and number of clarifier
units has been determined the design surface area for
cost purposes is computed.
DSA = M x IT x DM2 * 4
where: DSA = design surface area, m2 or ft2
M = number of equal sized clarifiers
it = 3.1417
DM = individual clarifier diameter, m or ft
4 = conversion factor, radius2 to diameter2
f) Subsequent Treatment
None specified.
A 2. Capital Costs
The design surface area of the sedimentation units is the primary
factor for the estimation of capital costs. One of three differ-
ent cost curves is used to estimate capital costs depending on
the relative size of the units and whether the influent solids
are primarily chemical or biological in nature. Small sedimenta-
tion systems (0.46 to 20.9 m2) (5 to 225 ft2) for chemical or raw
solids may be costed using Figure IV.3.1.18-A3 while larger
systems (20.9 to 2790 m2) (225 to 30,000 ft2) for chemical or raw
solids may be costed using Figure IV.3.1.18-A4. Systems for
settling treated biological solids may be costed using Figure
IV.3.1.18-A5. Costs estimated using these curves must be ad-
justed to a current value using an appropriate current cost
index.
Date: 4/1/83 IV.3.1.18-A6
-------
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-2]:
i) Low order chemical, (0.46 to 20.9 m2) (5 to 225 ft2)
Single, concrete rectangular basin with hopper bottom
Progressive cavity pumps (two)
Piping, electrical
Instrumentation
ii) High order chemical, (20.9 to 2790 m2) (225 to 30,000
ft2)
Splitter influent and effluent boxes
Sluice gates (two)
Dual, concrete circular basins with hopper bottom
Horizontal centrifugal pumps (two)
Scrapers, skimmers, weirs
Piping, electrical
Instrumentation
iii) Biological
Splitter, influent, effluent, and scum boxes
Sluice gates (two)
Dual, concrete circular basins with hopper bottom sump
Rapid sludge withdrawal, skimmer, baffle, weir
Scum sump pumps (two)
Piping, electrical
Instrumentation
b) Capital Cost Curves
i) Low Order Chemical Curve - see Figure IV.3.1.18-A3.
- Cost (thousands of dollars) vs. surface area (m2 or
ft2).
- Curve basis, cost estimate on single rectangular
, units of 2.32, 4.65, 9.29, and 20.9 m2 (25, 50,
100, and 225 ft2).
ii) High Order Chemical Curve - see Figure IV.3.1.18-A4.
- Cost (thousands of dollars) vs. total surface area
(m2 or ft2).
- Curve basis, cost estimate on dual circular units of
32.5, 131, 730, and 2859 m2 (350, 1,410, 7,860, and
30,770 ft2) total surface area.
iii) Biological Curve - see Figure IV.3.1.18-A5.
- Cost (thousands of dollars) vs. total surface area
(m2 or ft2).
- Curve basis, cost estimate on dual circular units
with diameters of 4.57, 10.67, 24.4, and 48.8 m (15,
35, 80, and 160 ft).
Date: 4/1/83 IV.3.1.18-A7
-------
(
IOLLARS
•>! C
» c
THOUSANrS OF T
« V
X O <
1
CO
O
o
i
— i
— 1
2.T2
-i
—
i —
— .
, —
(
~
—
^_
—
—
G
i
1 I !
0
: i
4.1
i
i !
i
--
r
-
*^
r--1
p
*
25
i '
-
TOTAL
4 &!
i
!
!
1
j
-
—
U
t—
i ,
r*
^
—
_
i
1
—
[ ! j —
SURFAC
7 9.:
-
^»
—
\
-
f^
-
dO 75
TOTAL
i —
_
r
--
i
—
L
—
__
,E A
9
RE«
1
' 1
>-
i i
^
!
1
H
-— i—
_4_
, SOUAF
.6 1:
^
—
r*
— -
k^
i ' !
, i
I
; i
IE METERS
91CO
lw>&
^*«
' :
I ,
I
"
i
-
I—
U
' J-^f^T^
-
! ! i
-
—
1
- —
(60 I&5 ISO 175
SURFACE AREA, SQUARE FEET
—
L6
I*"
_!
2(
4
J-H-r-
I i I
, j
— i~
i
-H-
i
, f
i — . — i — i
I
—
)S
3
200 22*5
FIGURE IV.3.1.18-A3. CAPITAL COST ESTIMATE FOR CLARIFICATION
OF CHEMICAL WASTE (LOW ORDER)* [4-10]
Date: 4/1/83
IV.3.1.18-A8
-------
en
«
n
CM
CO
f
^_
f
n
0)
0
^
c
t>
-
-
>
^
^
*
-
^
\
i
~
--
V
\
\
-
C
ir
^
\
-
>
>
\
\
\
\
\
-
'
k
\
>
v
>
-
-
<
II
c
\
>
-
—
[>
VI
\
\
\
~
~
\
\
-
\
>
•-
V
\
-
-
-
C
C
-
L-
>
>
\
\
--
^
\
\
\
c
u
c
K
•-
-
)
•>
^
\
-
X
.
V
_
k,
-
c
c
u
-
\
--
)
)
•>
„
s
._
-
\
r
-
^
•
K
c
u
c
-
•)
o
•
-
-
-
-
-
-
c
o
10
in
CM
o
CM
3
u
U.
O
(O
(0
O
ff>
UJ
s
(0
-J
u
H
w
u
o
H
EH
S
H
h
H
K
-
33
co Q
00
H
•
n
savmoa jo saNvsnoHi 'isoo
O
H
fc,
Date: 4/1/83
IV.3.1.18-A9
-------
(0
cc
111
U
UJ
cc
v>
K
111
U
2
K
(A
ui
ui
o
V)
tu
K
UI
U
1?
cc.
z>
(O
_l
s
H
O
o
o
H
m
§
H
8
H
H
U
rt
o
W
H
EH
CO
EH
CO
O
O
EH
H
a
o
m
<
oo
§
H
Date: 4/1/83
SMV110Q JO SQNVSnOHl '1SOO
IV.3.1.18-A10
-------
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component of operating cost is power for clarifier
mechanisms and pumps. Fixed operating costs include labor,
supervision, overhead, laboratory labor, maintenance, services,
insurance and taxes, and service water. All fixed and variable
operating costs should be adjusted to current levels using an
appropriate index or unit cost factor. Byproduct handling and
miscellaneous plant costs are developed in subsequent routines.
a) Variable Cost
i) Power Requirements - primary and chemical sedimentation
[4-1]. This equation was developed using regression
analysis procedures.
Metric
KWC = [(1.39 x 1C'3) x SA] + 2.06
where: KWC = power required, kilowatts
SA = design surface area, m2
English
HPC = [(1.73 x 10'4) x SA] + 2.76
where: HPC = power required, Hp
SA = design surface area, ft2
ii) Power Requirements - biological sedimentation [4-1].
This equation was developed using regression analysis
procedures
Metric
KWB = t(1.99 x ID'4) x SA] + 1.53
where: KWB = power required, kilowatts
SA = surface area, m2
English
HPB = {(2.48 x ID"5) x SA] + 2.05
where: HPB = power required, Hp
SA = surface area, ft2
Date: 4/1/83 IV.3.1.18-All
-------
iii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = KWC or KWB, kilowatts
24 = hr/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = HPC or HPB, Hp
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.1.18-A2, including values for the cost basis and unit
costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after completion of costing for indi-
vidual units (see Section IV.3.5). Land requirements, and sludge
collection for clarifiers are not costed here but are calculated
as indicated below in order to facilitate subsequent design and
cost estimates.
a) Sludge Collection
Wastewater solids collected by clarification are computed as
follows.
Metric
SLDG = FLOW x ATSS x 0.086
where: SLDG = sludge collected, Kg/day (dry)
FLOW = influent flow, L/s
ATSS = influent TSS - effluent TSS, mg/L
0.086 = conversion factor
English
SLDG = FLOW x 8.34 x ATSS
Date: 4/1/83 IV.3.1.18-A12
-------
TABLE IV.3.1.18-A2.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR CHEMICAL AND BIOLOGICAL
CLARIFICATION SYSTEMS [4-11]
Chemical Clarification
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.10 Weeks (2.40 hr/days)
10% Labor (0.24 hrs/day)
75% Labor Cost
0.25 Shifts (1.43 hrs/day)
2.84% Capital
0.40% Capital
2.50% Capital
0.06 L/s
(1.38 Thou gpd)
Biological Clarification
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.10 Weeks (2.40 hr/days)
10% Labor (0.24 hrs/day)
75% Labor Cost
0.25 Shifts (1.43 hrs/day)
3.52% Capital
0.40% Capital
2.50% Capital
0.02 L/s
(0.51 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/thou L
($ 0.50/thou gal)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.1.18-A13
-------
where: SLDG = sludge collected, Ib/day (dry)
FLOW = influent flow, mgd
8.34 = conversion factor
ATSS = influent TSS - effluent TSS, mg/L
The cost of sludge treatment is not presented here but is deter-
mined for all sludges generated by the treatment facility depend-
ing on the processes required.
b) Land
The clarification process requirement for land is estimated as
twice the surface area of the sedimentation units.
LAND = 2 x SA
where: LAND = land requirement, m2 or ft2
SA = design surface area, m2 or ft2
Land requirements are summed and costs estimated after completion
of unit process costing.
A 5. Modifications
a) Flux Restriction
Sedimentation unit design should be checked to insure that a
solids flux of 146 Kg/m2/day (30 Ib/ft2/day) is not exceeded
Metric
Flux = (ATSS x FLOW x 0.086) * SA
where: FLUX = solids flux, Kg/m2/day
ATSS = influent TSS - effluent TSS, mg/L
FLOW = influent flow, L/s
0.086 = conversion factor
SA = design surface area, m2
English
Flux = ATSS x 8.34 x FLOW * SA
where: FLUX = solids flux, Ib/ft2/day
ATSS = influent TSS - effluent TSS, mg/L
8.34 = conversion factor
FLOW = influent flow, mgd
SA = surface area, ft2
Exceeding this flux requires that the surface area be increased.
Date: 4/1/83 IV.3.1.18-A14
-------
b) Sludge Removal Adjustment for Influent TDS and MLSS
The presence of excessive levels of dissolved and suspended
solids in the wastewater affects the performance and sludge
accumulation of the system by changing the density gradient and
settling velocity of the wastewater solids. The user should
adjust performance to compensate for the presence of excessive
suspended solids and for total dissolved solids. These factors
should be taken into account in the reduced solids capture.
c) Supplemental Chemical Addition
If the user is considering increasing the size of clarifier units
to increase solids capture, the alternative of supplemental
chemical addition might also be considered. Solids capture can
be enhanced by the addition of coagulant chemicals such as alum
without increasing clarifier size. For additional information
see Volume III, Section III.3.1.18, Sedimentation and Section
III. 3.1.5, Coagulation/Flocculation.
Date: 4/1/83 IV.3.1.18-A15
-------
I.
II.
DESIGN FACTOR
Surface Area
CAPITAL COST
Cost =
CLARIFICATION
SUMMARY WORK SHEET
REFERENCE: IV.3.1.18-A
CAPITAL
= ft2, Clarifier Type =
x ( * 204.7) =
cost from curve current index
III
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
b.
. VARIABLE 0 &
Power Cost =
FIXED 0 & M
Labor:
Supervision:
Overhead:
Lab Labor :
Maint, Service
I&T:
Service Water:
YEARLY 0 & M
M $/day
x x 17.9
Hp EC, $/Kw-hr
x
hr/day $/hr
x
hr/day $/hr
x
Labor, $/day %/100
X
hr/day $/hr
x f 365
capital, $ %/100 day/yr
X
thou gpd $/thou gal
365
S;
..
.
.
&
x
day/yr sum $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Sludge Recovery = lb/day; Type
Land
ft*
Date: 4/1/83
IV.3.1.18-A16
-------
CLARIFICATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Capital Cost Index =
2. EC = Electricity Cost =
3. Labor =
4. Supervision =
5. Overhead =
6. Lab Labor =
7. Maintenance =
Services =
Insurance/Taxes =
Other O&M Factor sum =
8. Service Water =
$/Kw-hr
$/hr
$/hr
% Labor* 100
$/hr
% Capital
% Capital
% Capital
%/100
100 =
fc/100
$/1000 gal
I. DESIGN FACTOR
a. Type of influent solids
b. Select corresponding overflow rate, Table IV.3.1.18-A1
c. Surface Area
gpd/ftj
SA = [
(1.2 x 106)] *
ft*
FLOW, mgd
d. Clarifier diameter
OVFL, gpd/ft2
(Note-. If SA £225 ft2 and chemical solids are influent, then go to
step e, since the clarifier is a rectangular unit)
1. Set M = number of clarifiers =
2 or more
2. DM = (
x 1.27
ft2
SA ft2
M
3. If DM >200 ft, increase the number of clarifiers until
DM <200 ft and recompute DM
DM =
ft
Date: 4/1/83
IV.3.1.18-A17
-------
4. Round DM up to the next larger 5 ft increment
DM = ft
5. Recalculate surface ara
Design SA = x 0.785 x ( )2 = ft2
M DM, ft
e. Flux Check
FC = ( - ) x 8.34 x T
Inf TSS, mg/L Eff. TSS, mg/L FLOW, mgd SA, ft2
Ib/ft2/day
If flux >30 Ib/ft2/day then the surface area should be increased
and the flux rechecked.
If flux <30 Ib/ft2/day, leave SA as calculated
II. CAPITAL COST
Based on the design factor SA, select a cost from one of three
capital cost curves
a. Low order (25 to 225 ft2), chemical solids
Figure IV.3.1.18-A3 ft2 $
b. High order (350 to 30,770 ft2) chemical solids
Figure IV.3.1.18-A4 ft2 $
c. Biological solids, Figure IV.3.1.18-A5 ft2 $
III. VARIABLE 0 & M
a. Power Requirements - primary and chemical sedimentation
HPC = [(1.73 x 10-«) x ] + 2.76 = Hp
SA, ft2
b. Power Requirements - biological sedimentation
HBP = [(2.48 x 10-5) x ] + 2.05 = Hp
SA, ft2
IV. FIXED 0 & M
Date: 4/1/83 IV.3.1.18-A18
-------
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Sludge Collection
SLDG = x 8.34 x ( - ) = lb/day
FLOW, mgd Inf TSS, mg/L Eff TSS, mg/L
b. Land
Land = 2 x = ft2
SA, ft2
Date: 4/1/83 IV.3.1.18-A19
-------
IV.3.1.19 STRIPPING
Introduction
Stripping is used to remove volatile materials from wastewater
using either air or steam as the stripping agent. This process
usually will be designed for removal of a specific constituent,
such as ammonia, phenol, or sulfur compounds. This process is
described in more detail in Volume III of the Treatability Manual,
Section 111. 3.1.19. Costing methodologies and cost data for
industrial wastewater treatment applications are presented below.
IV.3.1.19-A. Ammonia Stripping
A 1. Basis of Design
This presentation is for the steam stripping of ammonia from
wastewater, with recovery as ammonium sulfate. Costs and design
are developed for an ammonia stripping unit as shown in Figure
IV.3.1.19-A1 and an ammonium sulfate recovery unit as shown in
Figure. IV. 3 .1.19-A2 . The cost factor for the ammonia stripping
unit is the wastewater flow rate per two column system and the
cost factor for the ammonium sulfate recovery unit is the ammonia
flow rate from the stripping column to the absorber. The strip-
ping unit design is fixed at 24 trays per column and assumes that
the influent wastewater is at a pH of 10.5 or greater. The
process is assumed efficient up to 99 percent removal of ammonia
nitrogen or a final effluent of 50 mg/L minimum. The process is
not intended for an influent ammonia concentration less than 500
mg/L. Stripping steam is provided at 0.17 Kg steam/liter of
wastewater (1.4 Ib steam/gallon of wastewater). The overhead
stream is assumed to have a 25 weight percent ammonia concentra-
tion. The recovery system uses a 10 percent sulfuric acid feed
at twice the stoichiometric requirement. The ammonium sulfate is
crystallized, dewatered, and dried, with a cake produced for
recovery, sale, or disposal.
a) Source
This cost estimate method was derived from the BAT Effluent
Limitations Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries.
b) Required Input Data
Wastewater flow L/s (gpm)
TSS (mg/L), NH3(mg/L), pH, temperature (°C)
c) Limitations
Ammonia stripping is not used if ammonia <500 mg/L.
Date: 4/1/83 IV.3.1.19-A1
-------
; ; ;
1— ("V—
V
i
1 ! r i < i
t O "^^^
rro,^
- -- A
*
I
1)
t ^
MJ
f|
1
0
df
4W
|?l
»• i
^~
?a.
1
L.
H
PH
to
H
cn
H I
2 «=r
O —
O
EH
O
s w
<, t-3
05 PH
O PH
< w
H P
Q
O
PS
W
W H
u PS
O H
(Ti
Date: 4/1/83
IV.3.1.19-A2
-------
O
3
H
CM
fr
H
«
H
CO -—
i^ O
H
« H
O U
fa D
Q
S O
W
H
Q <
fa
& J
O D
K> CO
CO H
co 2
W O
CN
<
I
O
H
fa
Date: 4/1/83
IV.3.1.19-A3
-------
d) Pretreatment
Pretreatment is provided as indicated for the following condi-
tions:
i) If influent TSS >50 mg/L, then multi media filtration
is required upstream.
ii) If pH <10.5, then liming to high pH (Section IV.3.1.13-B)
is required upstream.
e) Design Equation
i) Stripping Columns
The primary capital cost factor used for ammonia strip-
ping columns is wastewater flow per two column system.
Metric
FPS = (FLOW * NC) x 2
where: FPS = (maximum of 12.6 L/s per column)
flow per two column system, L/s
FLOW = average influent flow, L/s
NC = number of columns
English
FPS = (FLOW T NC) x 2
where: FPS = (maximum of 200 gpm per column) flow per
two column system, gpm
FLOW = average influent flow, gpm
NC = number of columns
The number of columns must be adjusted until the flow
per single column is less than 12.6 L/s (200 gpm). Each
system is required to have at least two stripping columns
(maximum flow of 25.2 L/s (400 gpm) for the pair). When
the influent flow exceeds 25.2 L/s (400 gpm) three or
more equal sized columns will be required until the flow
per individual column does not exceed 12.6 L/s (200
gpm).
ii) Ammonium Sulfate Recovery
The ammonium sulfate recovery system is designed based
on the ammonia feed rate to the absorber from the
stripper.
Date: 4/1/83 IV.3.1.19-A4
-------
Metric
NH3A = Factor x NH3I
where: NH3A
Factor
NH3 =
50 =
NH3I =
FLOW =
3600 =
10'6 =
ammonia to absorber from the stripper,
Kg/hr
0.99, if influent ammonia to stripper
>5000 mg/L
(NH3 - 50) * NH3, if influent
<5000 mg/L
influent ammonia to stripper, mg/L
(minimum 500 mg/L)
minimum effluent from stripper,
ammonia loading to the stripper
NH3 x FLOW x 3600 x 10"6
influent flow, L/s
conversion factor, L/s to Kg/hr
conversion factor mg/L to Kg/L
mg/L
Kg/hr
English
NH3A = Factor
NH3I
where: NH3A
Factor
ammonia to absorber from the stripper,
Ib/hr
0.99, if influent ammonia to stripper
>5000 mg/L
= (NH3 - 50) T NH3, if influent <5000 mg/L
NH3 = influent ammonia to stripper, mg/L (minimum
500 mg/L)
minimum effluent from stripper, mg/L
ammonia loading to the stripper, Ib/hr
NH3 x FLOW x 500 x 10"6
influent flow, gpm
conversion factor, gpm to Ib/hr
conversion factor mg/L to fraction
50
NH3I
FLOW
500
10'6
f) Subsequent Treatment
Byproduct treatment of ammonium sulfate cake is not considered
directly; it is assumed that the value of the recovered material
equals the cost of handling.
Residual ammonia in the wastewater stream probably requires
biological treatment.
A 2. Capital Costs
The stripping column capital cost is based on the flow rate per
column, with at least two columns required for each system.
Where the total system flow is greater than 25.2 L/s (400 gpm),
Date: 4/1/83
IV.3.1.19-A5
-------
then three or more columns are required, since the maximum column
size is 12.6 L/s (200 gpm). The capital cost curve in Figure
IV.3.1.19-A3 for the ammonia stripping columns is based on a two
column system. Therefore, when three or more columns are re-
quired (i.e., total system flow >25.2 L/s), the cost must be
read as the cost per two columns. A scale factor then is used to
adjust the curve cost to the appropriate system cost. (This
scale factor is presented in Section A2, b). The ammonia re-
covery system capital cost curve in Figure IV.3.1.19-A4 is based
on the flow rate of ammonia from the stripping column to the
absorber. Cost estimated using these curves must be adjusted
to a current value using an appropriate current cost index.
a) Cost Data
i) Items included in the capital cost estimates for the
ammonia stripping columns include [4-2]:
Ammonia stripping column, 24 trays (two)
Bottoms column (two)
Dephlegmators (two)
Accumulators (two)
Bottoms flash tank (two)
Pumps, piping
Instrumentation, electrical
ii) Items included in the capital cost estimates for the
ammonium sulfate recovery system include [4-2]:
Spray absorber (one)
Downcomer leg (one)
Crystallizers (two)
Slurry tank (one)
Overflow tank (one)
Acid storage tank (one)
Centrifuge (one)
Feed vibrator (one)
Rotary drum dryer (one)
Pumps, piping
Instrumentation, electrical
b) Capital Cost Curves
i) Stripper system - see Figure IV.3.1.19-A3.
- Cost (thousands of dollars) vs. flow per two column
systems (liters per second or gallons per minute).
- Curve basis, cost estimate on systems at flow rates
of 2.52, 6.31, 12.6, and 25.2 L/s (40, 100, 200,
and 400 gpm) (individual column capacities of 1.26,
3.15, 6.31, and 12.6 L/s (20, 50, 100, and 200 gpm))
Date: 4/1/83 IV.3.1.19-A6
-------
ii) Scale Factor for more than two stripping columns
- Capital Cost (two columns) = (cost from curve)
- Capital Cost (more than two columns) = (cost from
0 8
curve) x (No. columns/2)
iii) Ammonium sulfate system - see Figure IV.3.1.19-A4.
- Cost (thousands of dollars) vs. ammonia to the absorber
from the stripper (kilograms per hour or pounds per
hour)
- Curve basis, cost estimate on four systems designed
at rates of 44.9, 112, 225, and 450 kilograms (99,
248, 495, and 991 pounds) ammonia per hour
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable components include chemical (sulfuric acid), utilities
(steam, cooling water), and power. Fixed operating costs include
labor, supervision, overhead, laboratory labor, maintenance,
services, insurance and taxes, and service water. All fixed and
variable operating costs should be adjusted to current levels
using an appropriate index or unit cost factor. Byproduct hand-
ling may be required for the ammonium sulfate residue, but this
is considered to be offset by the value of the byproduct.
a) Variable Costs
i) Power Requirements - Total power requirements for an
ammonia stripping system consist of power for the centri-
fuge, dryer, and pumps [4-1]. The following power
equations were developed using regression analysis
procedures.
• Total Power
TP = CP + DP + FP + BP + AP
where: TP = total power required, KW or Hp
CP = power required for centrifuge, KW or Hp
DP = power required for dryer, KW or Hp
FP = power required for feed pumps, KW or Hp
BP = power required for bottoms pumps, KW or Hp
AP = power required for acid and slurry pumps,
KW or Hp
Date: 4/1/83
IV.3.1.19-A7
-------
800-
eoo-
09
a
o
a
u.
O
•9
O
Z 400-
I 200-
FLOW, LITERS PER SECOND
9.81 12.9 18.9
26.2
I-
09
O
o
0-
100
200 300
FLOW, GALLONS PER MINUTE
400
FIGURE IV.3.1.19-A3. CAPITAL COST ESTIMATE FOR
AMMONIA STRIPPING [4-10]
KILOGRAMS AMMONIA PER HOUR TO THE ABSORBER
90.T 191 272 899
464
•9
flC
O
O
Ik
o
01
o
z
O
X
H
<9
O
*0« 400 «°0 900
POUNDS AMMONIA PER HOUR TO THE ABSORBER
1000
FIGURE IV.3.1.19-A4. CAPITAL COST ESTIMATE FOR AMMONIUM
SULFATE REMOVAL [4-10]
Date: 4/1/83
IV.3.1.19-A8
-------
• Centrifuge Power
Metric
CP = 0.029 x NH3A
where:
CP = centrifuge power, KW
0.029 = factor based on 75% dry cake
and 5.08 KW-hr/metric ton dry solids,
KW-hr/Kg
NH3A = ammonia to absorber, Kg/hr
CP = 0.0173 x NH3A
CP = centrifuge power, Hp
0.0173 = factor based on 75% dry cake and 5
Kw-hr/ton dry solids, Hp-hr/lb
NH3A = ammonia to absorber, Ib/hr
• Dryer Power
Metric
DP = 6.0 x (DRYDI)2
English
where:
where:
English
where:
DP = dryer power, KW
10.8 = factor, KW/m2
DRYDI = dryer diameter, m
= 1.95 x (ER)0'5
1.95 = factor
ER = evaporation rate, Kg/hr
= ASP x 2.67
ASP = ammonium sulfate produced, Kg/hr
= 3.88 x NH3A
3.88 = Kg ammonium sulfate/Kg ammonia
2.67 = Kg water evaporated/Kg ammonium sulfate
DP = 0.75 x (DRYDI)2
DP = dryer power, Hp
0.75 = factor, Hp/ft2
DRYDI = dryer diameter, ft
= 4.3 x (ER)0'5
4.3 = factor
ER = evaporation rate, Ib/hr
= ASP x 2.67
ASP = ammonium sulfate produced, Ib/hr
= 3.88 x NH3A
Date: 4/1/83
IV.3.1.19-A9
-------
3.88 = Ib ammonium sulfate/lb ammonia
2.67 = Ib water evaporated/lb ammonium sulfate
• Feed Pump Power
Metric
FP = 1.17 x ID'4 x 3600 x FLOW
where: FP = feed pump power, KW
1.17 x 10"4 = factor relating power to mass flow,
KW/Kg/hr
3600 = conversion factor L/s to Kg/hr
FLOW = wastewater flow, L/s
English
FP = 7.16 x 10 "5 x 500 x FLOW
where: FP = feed pump power, Hp
FLOW = wastewater flow, gpm
7.16 x 10"5 = factor relating power to mass flow,
Hp/lb/hr
500 = conversion, gpm to Ib/hr
• Bottoms Pump Power
Metric
BP = 6.91 x 10"4 x BTM
where: BP = bottoms pump power, KW
3.7 x 10"3 = factor relating power to mass flow,
KW/Kg/hr
BTM = flow from bottom of column (effluent)
including condensed steam and excluding
overhead vapors, Kg/hr
= (1.17 x 3600 x FLOW) - (NH3I x 4)
1.17 = allowance for effluent to include 0.168 Kg
steam per liter feed
3600 = conversion L/s to Kg/hr
FLOW = wastewater flow, L/s
NH3I = ammonia loading to stripper, Kg/hr
= NH3 x FLOW x 3600 x 10"6
NH3 = influent ammonia concentration, mg/L
FLOW = wastewater flow, L/s
3600 = conversion factor, L/s to Kg/hr
10"6 = conversion factor, mg/L to Kg/L
English
BP = 4.21 x 10"4 x BTM
Date: 4/1/83 IV.3.1.19-A10
-------
where: BP = bottoms pump power, Hp
BTM = flow from bottom of column (effluent)
including condensed steam and excluding
overhead vapors, Ib/hr
= (1.17 x 500 x FLOW) - (NH3I x 4)
1.17 = allowance for effluent to include 1.4 Ib
steam per gallon feed
conversion, gpm to Ib/hr
wastewater flow, gpm
ammonia loading to stripper, Ib/hr
NH3 x FLOW x 500 x 10 "6
influent ammonia concentration, mg/L
conversion factor, gpm to Ib/hr
conversion factor, mg/L to fraction
500
FLOW
NH3I
NH3
500
10"6
• Acid and Slurry Pumps Power
Metric
AP = 1.8
10
- 4
x ACID
where: AP = acid pump power, KW
1.8 x 10" 4 = factor relating power to mass flow,
KW/Kg/hr
ACID = 10% sulfuric acid recirculation, Kg/hr
= 57.6 x NH3A
57.6 = stoichiometric factor including 2
times required acid
NH3A = ammonia to absorber, Kg/hr
English
AP = 1.08 x 10
- 4
x ACID
where:
1.08 x
ii)
AP = acid pump power
10" 4 = factor relating power to mass flow,
Hp/lb/hr
ACID = 10% sulfuric acid recirculation, Ib/hr
= 57.6 x NH3A
57.6 = stoichiometric factor including 2 times
required acid
NH3A = ammonia to absorber, Ib/hr
Chemical Requirements - Sulfuric acid makeup is required
to compensate for the reaction with the ammonia removed.
This is calculated on the basis of 7% makeup for the
recirculated acid feed to the absorber.
Metric
AMUP = 0.07 x 57.6 x NH3A
Date: 4/1/83
IV.3.1.19-A11
-------
where: AMUP = acid makeup, (10% sulfuric acid)
Kg/hr
0.07 = % makeup
57.6 = stoichiometric factor
NH3A = ammonia to absorber, Kg/hr
English
AMUP = 0.07 x 57.6 x NH3A
where: AMUP = acid makeup, (10% sulfuric acid) Ib/hr
0.07 = % makeup
57.6 = factor
NH3A = ammonia to absorber, Ib/hr
iii) Utilities - Steam and cooling water are required for the
ammonium sulfate recovery system.
• Cooling Water
Metric
CWF = 7.94 x 10"5 x ACID
where: CWF = cooling water flow, L/s
7.94 x 10"5 = temperature change factor
ACID = 10% sulfuric acid recirculation,
Kg/hr
= 57.6 x NH3A
57.6 = factor
NH3A = ammonia to absorber, Kg/hr
English
CWF = 5.71 x lO'4 x ACID
where: CWF = cooling water flow, gpm
5.71 x 10"4 = temperature change factor
ACID = 10% sulfuric acid recirculation, Ib/hr
= 57.6 x NH3A
57.6 = factor
NH3A = ammonia to absorber, Ib/hr
• Steam for Dryer
Metric
STD = 2.3 x ASP x 2.67
Date: 4/1/83 IV.3.1.19-A12
-------
where: STD = steam required for dryer, Kg/hr
2.3 = factor
ASP = ammonium sulfate produced, Kg/hr
= 3.88 x NH3A
3.88 = Kg ammonia sulfate produced/Kg ammonia
to absorber
NH3A = ammonia to absorber from the stripper,
Kg/hr
2.67 = Kg water evaporated/Kg ammonium sulfate
English
STD = 2.3 x ASP x 2.67
where: STD = steam required for dryer, Ib/hr
2.3 = factor
ASP = ammonium sulfate produced, Ib/hr
= 3.88 x NH3A
3.88 = Ib ammonia sulfate produced/lb ammonia
to absorber
NH3A = ammonia to absorber from the stripper,
Ib/hr
2.67 = Ib water evaporated/lb ammonium sulfate
• Steam for Stripping Column
Metric
STC = 0.168 x FLOW x 3600
where-. STC = steam required for column, Kg/hr
0.168 = Kg steam/liter flow
FLOW = influent flow, L/s
3600 = s/hr
English
STC = 1.4 x FLOW x 60
where: STC = steam required for column, Ib/hr
1.4 = Ib steam/gallon flow
FLOW = influent flow, gpm
60 = min/hr
iv) Cost for variable components includes:
• Chemical Cost (Sulfuric Acid)
Metric
SAC = AMUP x 0.1 x 24 x SAP
Date: 4/1/83 IV. 3.1.19-A13
-------
where: SAC = cost for sulfuric acid, $/day
AMUP = acid makeup (10% sulfuric acid),
Kg/hr
24 = hr/day
SAP = price for concentrated (100% sulfuric
acid), $/Kg acid
0.1 = conversion factor for 10% acid
English
SAC = AMUP x 0.1 x 24 x SAP
where: SAC = cost for sulfuric acid, $/day
AMUP = acid makeup (10% sulfuric acid), Ib/hr
24 = hr/day
SAP = price for concentrated (100% sulfuric
acid), $/lb acid
0.1 = conversion factor for 10% acid
• Power Cost
Metric
where:
PC = TP x 24 x EC
PC = power cost, $/day
TP = total power, KW
24 = hr/day
EC = electricity cost, $/KW
English
PC = TP x 0.746 x 24 x EC
where: PC = total power cost, $/day
TP = total power, Hp
0.746 = Kw-hr/Hp-hr
24 = hr/day
EC = electricity cost, $/Kw-hr
• Cooling Water
Metric
WC = CWF x 86400 x CPG
where: WC = water cost, $/day
CWF = cooling water flow, L/s
86400 = s/day
CPG = cost of water per liter, $/L
Date: 4/1/83
IV.3.1.19-A14
-------
English
where:
WC = CWF x 1440 x CPG
WC = water cost, $/day
CWF = cooling water flow, gpm
1440 = min/day
CPG = cost of water per gallon, $/gallon
Steam Cost
Metric
where:
English
where:
TSC = (STD + STC) x 24 x CPP
TSC = total steam cost, $/day
STD = steam for dryer, Kg/hr
STC = steam for stripping column, Kg/hr
24 = hr/day
CPP = cost per Kg of steam, $/Kg
TSC = (STD + STC) x 24 x CPP
TSC = total steam cost, $/day
STD = steam for dryer, Ib/hr
STC = steam for stripping column, Ib/hr
24 = hr/day
CPP = cost per Ib of steam, $/lb
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.1.19-A1, including values for the cost basis and the
unit costs.
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5).
A 5. Modifications
Additional information on the design of the various components of
the ammonia stripping columns and ammonium sulfate recovery
systems may be found in Reference [4-1].
Date: 4/1/83
IV.3.1.19-A15
-------
TABLE IV.3.1.19-A1.
FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR AMMONIA STRIPPING AND
AMMONIUM SULFATE RECOVERY [4-11]
Ammonia Stripping
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.25 Weeks (6.00 hrs/day)
10% Labor (0.60 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
5.25% Capital
0.40% Capital
2.50% Capital
0.22 L/s
(5.18 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
Ammonium Sulfate Recovery
Cost Basis
(Equivalent Unit Quantity)
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
0.00 Weeks
10% Labor
75% Labor Cost
0.00 Shifts
7.45% Capital
0.40% Capital
2.50% Capital
0.15 L/s
(3.46 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 8/13/82
IV.3.1.19-A16
-------
I.
a.
b.
II.
a.
Cost
b.
Cost
III.
a.
b.
c.
d.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
DESIGN FACTOR
AMMONIA STRIPPING
SUMMARY WORK SHEET
REFERENCE: IV. 3. 1.19 -A
CAPITAL
Stripping Columns: flow per 2-column system =
Ammonium Sulfate 'System: =
CAPITAL COST
Stripping Columns:
= X
gpm
lb/hr
( ) x (
* 204.7)
cost from curve scale factor current index
Ammonium Sulfate Recovery:
x ( * 204.7)
cost from curve
VARIABLE 0 & M
Power =
HP
Acid =
acid,
Cooling =
water cost water
Steam =
steam.
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service,
I&T:
Service Water:
YEARLY 0 & M
UNCOSTED ITEMS
current index
x x 17.9
EC, $/Kw-hr
x x 2.4
lb/hr SAP, $/lb
x x 1440
, gpm WC, $/gal
x x 24
lb/hr CPP, $/lb
STRIPPING RECOVERY
+
$/day $/day
+
$/day $/day
+
$/day $/day
+
$/day $/day
+
$/day $/day
+
$/day $/day
365
$/day
=
.
.
.
.
.
.
X
day/yr sum $/day
$
$
0 & M
$/yr
Date: 4/1/83
IV.3.1.19-A17
-------
AMMONIA STRIPPING
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Capital Cost Index =
AMMONIA AMMONIUM SULFATE
STRIPPING RECOVERY
2. EC: electricity cost = $/Kw-hr
3. SAP: sulfuric acid price = $/lb
4. WC: water cost = $/gal
5. CPP: steam cost = $/lb
6. Labor = $/hr
7. Supervision = $/hr
8. Overhead* = % Labor*
9. Lab Labor = $/hr
LO. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum* =
LI. Service Water = $/thou gal
ttNote - these must be divided by 100 for use in Part IV of the Work Sheet.
I. DESIGN FACTORS
a. Stripping Columns
Flow per column = f '= gpm*
FLOW, gpm no. columns
* minimum of 2 columns, maximum 200 gpm per column
FLOW per 2-column system = 2 x = gpm**
gpm/column
** Note - this is used to develop cost from Figure IV.3.1.19-A3.
b. Ammonia Feed Rate To Absorber (NH3A)
1. Factor Check
a. If influent ammonia (NH3) to the stripping column
>5000 mg/L, then FACTOR =0.99
Date: 4/1/83 IV.3.1.19-A18
-------
b. If influent ammonia (NH3) to the stripping column
= between 50 and 5000 mg/L, then
FACTOR = (
- 50) T
2.
NH3, mg/L
Ammonia Feed Rate (NH3A)
NH3A = x
NH3, mg/L
2000 =
Ib/hr
NH3, mg/L FACTOR FLOW, gpm
II. CAPITAL COST
Stripping Columns scale factor = (
* 2)
0.8
tt columns
III. VARIABLE 0 & M
a. Total Power =
CP, Hp DP, Hp FP, Hp BP, Hp AP, Hp
Hp
1. CP = 0.0173 x
NH3A, Ib/hr
2. DP = 143 x
NH3A, Ib/hr
3. FP = 0.0358 x
4. BP = (0.246 x
FLOW, gpm
FLOW, gpm
Hp
= Hp
= Hp
= Hp
) - (8.42 x 10"7 x
NH3, mg/L FLOW, gpm
5. AP = 6.22 x 10"3 x
b. Acid makeup =
NH3A, Ib/hr
x 4.032 =
Hp
NH3A, Ib/hr
c. Cooling Water =
x 0.0329 =
Ib/hr
gpm
NH3A, Ib/hr
d. Steam = (23.827 x
) + (84 x
Ib/hr
NH3A, Ib/hr
FLOW, gpm
Date: 4/1/83
IV.3.1.19-A19
-------
IV. FIXED 0 & M
a. AMMONIA STRIPPING
Labor : x =
hr/day $/hr
Supervision: x =
hr/day $/hr
Overhead: x =
Labor, $/day % Labor/100
Laboratory: x =
hr/day $/hr
Maint. , Serv. x f 365 =
I&T: Capital %/100
Water
Service: x =
1000 gal/day $/1000 gal
b. AMMONIUM SULFATE RECOVERY
Labor : x =
hr/day $/hr
Supervision: x =
hr/day $/hr
Overhead: x =
Labor, $/day % Labor/100
Laboratory: x =
hr/day $/hr
Maint., Serv. x T 365 =
I&T: Capital %/100
Water
Service: x =
1000 gal/day $/1000 gal
$/day
$/day
$/day
$/day
$/day
$/day
$/day
$/day
$/day
$/day
$/day
$/day
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83 IV.3.1.19-A20
-------
IV.3.2.1 ACTIVATED SLUDGE
Introduction
Activated sludge processes are designed for the removal of dis-
solved and colloidal organic materials from the wastewater stream
by physical and biological mechanisms. There are numerous vari-
ations of the process in use, but general practice has found that
certain conditions result in stable and economical operating
conditions. The key aspect of activated sludge processes is that
they involve the recycle of active biological sludge solids from
the process discharge back to the aeration basin. The activated
sludge process is discussed in more detail in Volume III of the
Treatability Manual, Section III.3.2.1. Costing methodologies
and cost data for this technology are presented below.
IV.3.2.1-A. Activated Sludge
A 1. Basis of Design
This section presents a cost estimating method for activated
sludge basins and appurtenances not including aeration or nutrient
addition. Aeration and nutrient addition costs are addressed in
Sections IV.3.2.1-B and IV.3.2.1-C, respectively. A schematic
flow diagram of an activated sludge system of the type considered
is presented in Figure IV.3.2.1-A1.
The primary cost factor for this technology is basin volume,
but cost curves are also presented in terms of flow and influent
BOD concentration for certain standardized conditions. The
principal design factors considered in this method are flow,
wastewater characteristics, and detention time. The basic design
approach involves calculation of detention time based on the
influent BOD concentration, a set of appropriate assumptions
regarding the mixed liquor volatile suspended solids (MLVSS)
concentration, and the food to microorganism (F/M) ratio in the
basin. Basin volume is then calculated as the product of the
average daily flow and the detention time. A cost curve based on
basin volume is provided for estimating capital costs. A simpli-
fied cost estimating procedure is also presented for the users
convenience which relates capital costs to flow for a set of
standard influent and operating conditions.
Neither of these methods addresses the performance of the act-
ivated sludge system. However, the user may find it necessary
to make independent estimates of performance in order to esti-
mate sludge generation and to size and cost the aerator and
nutrient addition systems in later sections.
a) Source
The unit cost information in this section was derived from the
Date: 4/1/83 IV.3.2.1-A1
-------
c
,-f
\J
H
6-
X
> — °
)
C
i C
!
O
'
) 1
\ I
/ i
i
— — — o •
91
^B
d
i i
i
I
I
i
«?i
I-
l)
n
Ji
:l!
in ji!
»«!i!
H
O
g
CO
Q
W
H
O
fa
o
<
H
Q
g
w
u
o
CM
•
n
S
ID
O
Date: 4/1/83
IV.3.2.1-A2
-------
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/ Plastics and Synthetic Fibers Industries
[4-2].
b) Required Input Data
Wastewater flow, L/s (mgd)
Temperature (°C)/ pH
BOD (mg/L)
Oil and grease, ammonia, phosphorus, TSS, TDS, phenol (mg/L)
Heavy metals and other priority pollutants (vg/L)
c) Limitations
i) Activated sludge is not considered applicable if
influent BOD < 10 mg/L.
d) Pretreatment
Pretreatment should be provided as indicated for the following
conditions [4-1]:
i) Oil >35 mg/L requires oil separation.
ii) pH >9 or pH <6 requires neutralization.
iii) Ammonia >500 mg/L requires stripping (unless ammonia is
less than 5% of the influent BOD).
iv) TSS >150 mg/L requires solids separation process.
v) Heavy metals greater than the following values require
precipitation (lead = 1.5 mg/L; copper =0.5 mg/L; total
chromium = 1.5 mg/L; zinc = 1.5 mg/L; nickel =0.5 mg/L;
trivalent chromium = 10 mg/L).
vi) Cyanide >3 mg/L requires oxidation.
vii) Phenol >300 mg/L requires solvent extraction.
viii) Phenol >100 mg/L with high value divided by average
value >1.2 requires equalization.
ix) Solvent extraction will be required if the maximum
phenol concentration <100 mg/L, the average concentra-
tion is >50 mg/L, the ratio of maximum to average is
>1.5, and flow equalization is included in the treat-
ment system.
x) Total dissolved solids >10,000 mg/L requires ion ex-
change .
Date: 4/1/83
IV.3.2.1-A3
-------
e) Design Factor
The user may select either of two methods for estimating the cost
of an activated sludge system. The first requires that the user
determine the required basin volume and the second utilizes only
influent wastewater flow. These two methods are addressed below:
i) Basin Volume Method
This method requires that the user calculate the basin
volume from the hydraulic detention time. Detention
time may be estimated for a particular influent BOD
concentration as follows by using combinations of MLVSS
and F/M ratios that correspond to standard operating
modes:
So
where: t
So
Xv
F/M
(Xv) x (F/M)
detention time, days
influent BOD, mg/L
MLVSS, mg/L
food to microorganism ratio
Typical ranges for the key operating parameters under
standard operating modes (conventional activated sludge,
extended aeration) are presented in Table IV.3.2.1-A1.
Note that performance is not considered. For further
information see Section A 5,a.
Basin volume is calculated as follows:
Metric
BV = FLOW x t x 86400
where: BV
FLOW
t
86400
English
basin volume, L
influent flow, L/s
detention time, days
conversion factor, sec/day
BV = FLOW x t
where: BV
FLOW
t
basin volume, million gallons
influent flow, mgd
detention time, days
Date: 4/1/83
IV.3.2.1-A4
-------
Q
U
h—
1^
i-
u
<
U.
o
CO
ce
u
u
|
^
eg
<
a.
Z
O
CO
LJ
Q
^
LJ
5£
CC
£
CO
U
o
z
<,__,
"^^
CCr-
1
O J-
Z t.-nf-
h- CO
«f «"
^. 2.
IT LJ
Ul-
O.CO
0>
CO
1
--!
H CO
.
1
r—
CM'
CO
>
LJ
_l
CO
<
1-
10
^
o
O^.
0±»<
Q*"
C7\
O\
1
O
00
VO
4)1
O
C
03
C£
£
^
LL.
•
o
1
(f\
CM
O
..
--x
_l
•V
Oi^^
E 0)
~-o
c
CO (U
CO 0£
5~
_l
•s.
^^
O
o
o
^
1
o
o
lf\
^^
O
P O)
c c —
o> ra _i
3CC-V
— O
c^Q E
r" rt
& *— ^ '^«
— 03
O
o
CM
A
eo "a
C CO
O -P
.-no
•P > C31
C — TJ
CD -P D
0)
•o
i
> 0-
C
-------
ii) Simplified Method
Flow is the principal design factor for this method.
The design equations shown above were solved for F/M
ratios of 0.1 and 0.3, appropriate MLVSS concentrations,
and various influent BOD concentrations. The user must
select either the set of curves for F/M =0.1 (typical
extended aeration) or the set of curves for F/M =0.3
(typical activated sludge) and estimate the cost from
the curve most closely corresponding to the influent
BOD concentration. Note that performance is not con-
sidered. For further information see Section A 5, a.
iii) Associated Factors
Requirements for aeration, land, nutrient addition, and
waste sludge handling for activated sludge must be
calculated separately. These are discussed in Section
A 4, Miscellaneous Costs. Clarification systems are
discussed in Section IV.3.1.18-A.
f) Subsequent Treatment
Subsequent treatment requires a solids separation process, usually
clarification.
A 2. Capital Costs
Two capital cost estimating procedures are presented in this
section for activated sludge basins without aeration. The first
involves estimation of capital cost based on the estimated basin
volume of the activated sludge system. The capital cost of the
system as a function of basin volume is presented in Figure
IV.3.2.1-A2. Capital costs for two standard types of activated
sludge systems at various influent BOD concentrations are
presented in Figures IV.3.2.1-A3 and -A4 as a function of waste-
water flow rate. The user should select the set of operating
conditions presented in the curves that most nearly match the
situation at hand.
a) Cost Data
The items included in the capital cost estimates are as follows
[4-2]:
Dual aeration basins (3.05 m (10 ft) depth assumed)
<2,080 m3 (550,000 gal) - all concrete
^2,080 m3 (550,000 gal) - earthen basins with membrane
liners and concrete abrasion
pads under aerators
Date: 4/1/83 IV.3.2.1-A6
-------
@
I
H
H
53
I
W
H
v>
z
o
o
z
o
3
_i
i
01*
H Q
51 S
U !/)
CO
•
>
H
O
M
En
JO SQNVSnOHJL '18OO
Date: 4/1/83
IV.3.2.1-A7
-------
FLOW. LITERS PER SECOND
219
438
657
876
OC
o
o
i
o
o
III
a
o
8
10 IS
FLOW, MILLION GALLONS PER DAY
20
FIGURE IV.3.2.1-A3. CAPITAL COST VS FLOW AT
VARIOUS INFLUENT BOD CONCENTRATIONS FOR
ACTIVATED SLUDGE SYSTEMS OPERATING AT
F/M = 0.3 AND MLVSS = 2500. [4-10]
Date: 4/1/83
IV.3.2.1-A8
-------
FLOW. LITERS PER SECOND
219 438 657
876
16
15
oc
-J
O
o
i
o
x
o
u
K
O
(0
o
o
FLOW. MILLION GALLONS PER DAY
FIGURE IV.3.2.1-A4. CAPITAL COST VS FLOW AT
VARIOUS INFLUENT BOD CONCENTRATIONS FOR
ACTIVATED SLUDGE SYSTEMS OPERATING AT
F/M = 0.1 AND MLVSS - 3500. [4-10]
Date: 4/1/83
IV.3.2.1-A9
-------
Splitter box with two sluice gates
Sludge recycle pumps (two to three)
Piping
Instrumentation:
Sludge wasting control
Sludge recycle control
Dissolved oxygen monitor
Temperature monitor
pH monitor and control
Defoamer storage and feed
b) Capital Cost Curves
i) Basin Volume Method
Curve - see Figure IV.3.2.1-A2.
- Cost (thousands of dollars) vs. basin
volume (million liters or million gallons)
- Curve basis, cost estimates for systems
at four flow rates: 8.76, 43.8, 219, and
876 L/s (0.2, 1.0, 5.0, and 20.0 mgd) and a
detention time of 24 hours.
ii) Simplified Method
1. F/M ratio = 0.3 (activated sludge)
Curve - see Figure IV.3.2.1-A3
Cost (hundred thousand dollars) vs. flow
(liters per second or million gallons per
day)
- Curve basis, cost estimates for systems at
three influent BOD levels: 250,500, and
1,000 mg/L, and a detention time based on the
F/M ratio.
2. F/M ratio =0.1 (extended aeration)
Curve - see Figure IV.3.2.1-A4
- Cost (hundred thousand dollars) vs. flow (liters
per second or million gallons per day)
- Curve basis, cost estimates for systems at
three influent BOD levels: 250,500, and
1,000 mg/L, and a detention time based on the
F/M ratio.
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Date: 4/1/83 IV.3.2.1-A10
-------
Variable operating costs include power and defoaming agent. In
addition, accounts of the need for nutrients, aeration require-
ments, and sludge generation should be kept for use in costing
ancillary parts of the system. Fixed operating costs include
labor, supervision, overhead, maintenance, laboratory labor,
services, insurance and taxes, and service water. All fixed and
variable operating costs should be adjusted to current levels
using an appropriate index or unit cost factor.
a) Variable Costs
i) Power Requirement (does not include aeration power)
[4-1]. These equations were developed using regression
analysis procedures.
Metric
KW = (0.127 x FLOW) + 0.843
where: KW = power requirement, kilowatts
FLOW = influent flow, L/s
English
HP = (7.46 x FLOW) +1.13
where: HP = power requirement, Hp
FLOW = influent flow, mgd
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
24 = hours/day
EC = electricity cost, $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
EC = electricity cost, $/Kw-hr
24 = hr/day
0.746 = Kw-hr/Hp-hr
iii) Defoamer Requirement, based on maintaining 0.5 mg/L in
system
Date: 4/1/83 IV.3.2.1-A11
-------
Metric
DF = (0.5 x 10'6) x FLOW x 86400
where: DF = defoamer requirement, Kg/day
0.5 x 10"6 = concentration of defoamer, Kg/L
FLOW = influent flow, L/s
86400 = seconds/day
English
DF = 0.5 x FLOW x 8.34
where: DF = defoamer requirement, Ib/day
0.5 = concentration of defoamer, 0.5 mg/L
FLOW = influent flow, mgd
8.34 = conversion factor
iv) Defoamer Cost
DC = DF x N
where: DC = defoamer cost, $/day
N = price of defoaming agent, $/Kg or $/lb
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.2.1-A2, including values for the cost basis and the
unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after design and costing for all unit
processes are completed (see Section IV.3.5). The aeration,
nutrient addition, and land requirements, as well as the expected
waste sludge generated are calculated during the activated
sludge design in order to facilitate cost estimates for sub-
sequent systems. Methods for computing these quantities are
described below [4-1].
a) Aeration Oxygen Requirements
This is determined as the oxygen transfer in Kg/hr (Ib/hr) re-
quired to maintain the level of biological activity in the system
as designed (i.e., BOD removal, basin solids). The oxygen
transfer should satisfy both the oxidation and endogenous uptake
requirements.
Date: 4/1/83 IV.3.2.1-A12
-------
TABLE IV.3.2.1-A2.
FIXED 0 & M COST BASIS AND UNIT
COST FACTORS FOR ACTIVATED SLUDGE
SYSTEMS [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.40 Weeks (9.60 hrs/day)
10% Labor (0.96 hrs/day)
75% Labor Cost
0.20 Shifts
1.03% Capital
0.40% Capital
2.50% Capital
0.08 L/s
(1.72 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 8/13/82
IV.3.2.1-A13
-------
Because performance is not addressed in the design equation
presented in Section A l,e, the user is responsible for making an
independent estimate of BOD removal based on their understanding
of the relative biodegradability of the waste. To aid the
user in making this estimate, additional information on biological
kinetics is presented in Section A 5,a. The reader is also
referenced to Volume III Section III.3.2.1 for further infor-
mation. Two methods for estimating aeration requirements are
presented below. Use of the first method requires input generated
in the basin volume capital cost estimating method while the second
method requires no such special input.
i) Basin Volume Method
Metric
where:
OR = (AP x BODR) + (BP x ENDOG)
OR = total oxygen requirement, Kg 02/hr
AP = oxygen required for BOD oxidation
= 0.7 Kg 02/Kg BOD (default value)
BODR = BOD removed, Kg/hr
= (So - Se) x FLOW x 0.0036
So = influent BOD, mg/L
Se = effluent soluble BOD, mg/L
FLOW = influent flow, L/s
0.0036 = conversion, mg/s to Kg/hr
^ BP = oxygen required for MLVSS oxidation,
Kg 02/hr/Kg MLVSS
= 0.014 -(0.004 x t), BP £0
t = detention time, days
ENDOG = active biomass under aeration, Kg
= Xv x BV x 10"6
Xv = MLVSS, mg/L
BV = basin volume, L
= FLOW x t
10~6 = mg/Kg
English
OR = (AP x BODR) + (BP x ENDOG)
where: OR = oxygen requirement, Ib 02/hr
AP = oxygen required for BOD oxidation
= 0.7 Ib 02/lb BOD (default value)
BODR = BOD removed, Ib/hr
= (So - Se) x FLOW x 8.34 * 24
So = influent BOD, mg/L
Se = effluent soluble BOD, mg/L
FLOW = design influent flow to system, mgd
8.34 = conversion factor
24 = hours/day
Date: 4/1/83
IV.3.2.1-A14
-------
BP = oxygen required for MLVSS oxidation,
Ib 02/hr/lb MLVSS,
= 0.014 - (0.004 x t), BP £ 0
t = detention time, days
ENDOG = the active biomass under aeration, Ib
= Xv x BV x 8.34
Xv = mixed liquor volatile suspended solids,
MLVSS, mg/L
BV = basin volume, million gallons
= FLOW x t
The oxygen uptake rate is checked to assure that it is
less than 100 mg/L/hr.
Metric
UT = OR x 106 T BV
where: UT = oxygen uptake rate, mg/L/hr
OR = oxygen requirement, Kg/hr
BV = basin volume, L
106 = mg/Kg
English
UT = OR * (BV x 8.34)
where: UT = oxygen uptake rate, mg/L/hr
OR = oxygen requirement, Ib/hr
BV = basin volume, million gallons
8.34 = conversion factor
If the calculated uptake rate is greater than 100
mg/L/hr, then the basin volume is increased and
another design investigated (e.g., Xv, t, or Se
varied).
ii) Simplified Method
Oxygen requirements may also be estimated by the use
of empirical oxygen requirement values from the literature,
Some typical values are presented in Table IV.3.2.1-A3.
Metric
OR = 02RATE x (So - Se) x FLOW x 0.0036
Date: 4/1/83 IV.3.2.1-A15
-------
Q
Ul
1-
^
>
1-
o
rf
Ul
o
1—
CO
Ul
0
z
CO
u.
o
CO
a:
Ul
^_
UJ
^
ec
a.
0
z
K.
a. CM
Or-
1
<*"
CO
OUI
— H
CO CO
UJ>
QIO
ZLd
OO
SQ
0-J
OCO
,
to
1
.
CM
•
CO
•
>
—
LU
_J
co
^
i—
0)
o
13
3
_»
CO
CU
4J
CO
CD
3:
•o
0)
•D >
U O
> E
O CU
E <-
0)
o
OCO
o
a .a
__
O1V. CO
X CU
"V O) O
g) *O
C7I3 1
T3 —
3CO iTl
CO A
— O
C7I
^: t-
o
L.
•o
CU O
O CU
£ i. \O
a>
S-O r-
o
DCQ 1
O
ca.a d-
Ol^x r-
^CM
CM
—
Ol
"^
Ci-
CO
co
01-1
cz:
•5-J
o a
-1 £
QO
00
CD O
CO
(S
.
3
-10 O
1 P-
^>^^ r~~ "^
03 O f IfN
•a o r-
"XI- 1 1
0 1 0
ox o--
CO CO -~-
•a r-
EQ
O
ca
&
~
c
o
.—
4-3
CO
&.
CU
^
•a
Ul 4)
CO TO
0) C
O CO CU
ED -P
> X
Q. h- 1 Ul
VO
o'
1
•tf
o
^
•
r-
I
CO
d
o ^^
r** o
VOVO
1
1
0
OC\I
ITN
r—
TO
CD
CO
._
4J
O
^
ca
c
o
— 0)
•p 01
C-D
CU 3
ceo
o
o
CO
^ •
o
o
1
1
U"^
\f\ I—
o' o'
CJX lA
, .
o »-
1 1
1^ I-
CJ i-
O •*"•
oo o~
oco j-o
d- r- co eo
r- CM
1 1
1 1
o o
or- o<-
ir\— oo~^
u*\
T3
2
CO
> C
0
JJ ._
O CO -P
< aico
CO U
0) -P —
•p a) co d-
CO d '~
CC T3 QJ l_
3 " -P
£ — Ol —
C7ICO CZ
X CO
Date: 4/1/83
IV.3.2.1-A16
-------
where: OR = total oxygen requirement, Kg/hr
02RATE = required oxygen transfer, Kg 02/Kg BOD
removed.
So = influent BOD, mg/L
Se = effluent soluble BOD, mg/L
FLOW = influent flow, L/s
0.0036 = conversion, mg/s to Kg/hr
English
OR = 02RATE x (So - Se) x FLOW x 8.34 * 24
where: OR = total oxygen requirement, Ib/hr
02RATE = required oxygen transfer, Ib 02/lb BOD
removed
So = influent BOD, mg/L
Se = effluent soluble BOD, mg/L
FLOW = influent flow, mgd
8.34 = conversion
24 = hours/day
b) Nutrients
Nutrient requirements may be estimated based on a BOD to nitrogen
to phosphorus ratio of 100:5:1. If a deficiency is found, it is
noted for subsequent use in designing the nutrient addition
system (Section IV.3.2.1-C).
i) Nitrogen Required. This is determined by first calcu-
lating the effluent ammonia concentration from the
activated sludge process.
EA = NH3 - (0.05 x BOD)
where: EA = effluent ammonia concentration, mg/L
NH3 = average influent ammonia, mg/L
BOD = average influent BOD concentration, mg/L
• If EA £ 0, then no ammonia addition is required.
• If EA < 0, then ammonia addition is required.
Metric
AR = AD x FLOW x 0.086
where: AR = ammonia required, Kg/day
AD = ammonia deficit, mg/L
= -EA
= (0.05 x BOD) - NH3
FLOW = influent flow, L/s
0.086 = conversion factor
Date: 4/1/83 IV.3.2.1-A17
-------
English
AR = AD x FLOW x 8.34
where: AR = ammonia required, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
ii) Phosphorus Required. This is determined by first cal-
culating the effluent phosphorus concentration from the
activated sludge process.
EP = P04 - (0.01 x BOD)
where: EP = effluent phosphate concentration, mg/L
P04 = average influent phosphate, mg/L
BOD = average influent BOD, mg/L
The phosphate requirement is checked at both the high
and low ends of the BOD concentration range. If EP
-------
where:
Land
BV
1.2
0.001
DEPTH
land required for activated sludge basin, m2
basin volume, liters
factor for 20% additional land
m3/L
basin depth, m
English
Land = BV x (1.2 x 106) r (7.48 x DEPTH)
where: Land
BV
1.2 x 106
7.48
DEPTH
land required for activated sludge basin, ft2
basin volume, million gallons
conversion factor including 20% allowance,
million gallon to gallons
conversion factor, gallon/ft3
basin depth, ft
d) Sludge Generation
The amount of waste sludge generated by the process may be esti-
mated either from empirical values such as those shown in Table
IV.3.2.1-A3 or from estimated'process conditions.
i) For conventional activated sludge system (detention _<24
hours), the sludge generated is calculated as follows:
WS = (So - Se) x 0.3 x 1.18
where: WS = waste activated sludge, mg/L
So = influent BOD, mg/L
Se = effluent soluble BOD, mg/L
0.3 = net sludge produced per mg/L BOD removed
1.18 = ratio of MLSS to MLVSS (~ 85% volatile)
ii) For extended aeration (detention >24 hours), a reduced
sludge generation is made.
NS = WS x (1 - RSG)
where: NS = net sludge production, mg/L
WS = waste sludge computed for conventional
activated sludge, as computed above, mg/L
RSG = reduced sludge generation factor
= (t - 1) x 24 x 0.01
t = hydraulic detenton, days
24 = hour/day
0.01 = adjustment factor representing 1% per hour
reduction for detention time >24 hr.
Date: 4/1/83
IV.3.2.1-A19
-------
iii) Sludge produced
Metric
SLUDGE = (NS or WS) x FLOW x 0.086
where: SLUDGE = waste sludge produced, Kg/day
NS or WS = as defined above, mg/L
FLOW = influent flow, L/s
0.086 = conversion factor
English
SLUDGE = (NS or WS) x 8.34 x FLOW
where: SLUDGE = waste sludge produced, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
iv) For use of the simplified design procedures, estimates
such as those in IV.3.2.1-A3 or other sources may be used
to estimate sludge production.
Metric
SLUDGE = WSR x (So - Se) x FLOW x 0.086
where: SLUDGE = waste sludge produced, Kg/day
WSR = waste sludge production rate, Kg
sludge/Kg BOD removed
SO = influent BOD, mg/L
SE = effluent soluble BOD, mg/L
English
SLUDGE = WSR x (So - Se) x FLOW x 8.34
where: SLUDGE = waste sludge produced, Ib/day
WSR = waste sludge production rate,
Ib sludge/lb BOD removed
A 5. Modifications
a) Additional Design Considerations
In developing estimates for aeration requirements, sludge
generation, and designs for subsequent treatment processes
it is necessary that some estimate of the treatment efficiency
of the activated sludge system be developed. Such an estimate
may be as simple as an educated guess or as complicated as
extensive experimentation and pilot plant operation. Many
mathematical models have also been developed to simulate the
Date: 4/1/83 IV.3.2.1-A20
-------
activated sludge process. One such model, the modified
Eckenfelder equation is briefly discussed below [4-1]:
i) Design Equation
This approach requires that the influent BOD be known,
the biological kinetics rate constant (K factor) be
known, and that a basin mixed liquor volatile solids
(MLVSS) be known or assumed. It is also required that
the conditions selected for the MLVSS be consistent with
the detention time selected (or computed) and with the
organic loading, using the food to microorganism (F/M)
ratio [F/M = So/(Xv x t)]. Another factor that is
significant in the design is the temperature of the
system. This will affect both the reaction kinetics
and the oxygen transfer requirements.
One basic form of the modified Eckenfelder equation is:
t = (So2 - So x Se) T (KT x Xv x Se)
where: t = detention time, day
So = influent BOD, mg/L
Se = effluent soluble BOD, mg/L
Xv = mixed liquor volatile suspended solids, mg/L
KT = (Eckenfelder) treatability factor, day"1 at
temperature T (Note: this is a waste
specific factor)
The waste conditions normally determine So and KT and the
values of t, Xv, and Se are varied as necessary to maintain
the system within one of the standard operational modes
(e.g., activated sludge, extended aeration). Typical con-
ditions for several of the standard operating modes are
shown in Table IV.3.2.1-A1.
ii) Temperature Correction
The reaction rate, KT, is dependent upon the biodegrad-
ability characteristics of the waste and the temperature.
The KT rate of BOD may be adjusted for the operating
temperature of the basin as follows:
KT = K20 x (1.07)(T ~ 20)
where: KT = rate at operating temperature, day"1
K20 = rate at 20°C, day -1
T = operating temperature, °C
Date: 4/1/83 IV.3.2.1-A21
-------
iii) Solids Check
When the influent TSS to the activated sludge basin is
between 50 to 150 mg/L, there may be the need to provide
pretreatment to avoid diluting the MLVSS with the in-
fluent solids. The maximum allowable influent solids is
based on the MLVSS computed for the system [4-1].
ATSS = 25 + 0.05 x Xv
where: ATSS = allowable influent TSS, mg/L
Xv = mixed liquor volatile suspended solids,
mg/L
If the influent TSS > ATSS, then pretreatment to remove
solids is recommended.
iv) Treatment Efficiency
The modified Eckenfelder equation may be rearranged in
order to show treatment efficiency in terms of soluble
BOD removal. Insoluble BOD removed is not considered
in this equation.
Efficiency = 1 - (Se * So)
= 1 - [(So - Se) T (KT x Xv x t)]
If the other design variables are fixed, and Se is allowed
to float, efficiency can be expressed as a function of
the KT rate. Since KT rates are not available for most
types of wastes and must be determined experimentally,
it is often difficult to estimate designs and treatment
efficiencies in the early stages of a project. If no KT
rate is available for the waste of interest the follow-
ing information may assist the user in understanding the
relationship between KT rates and treatment efficiency:
1) The relative biodegradability of wastes in terms of
modified Eckenfelder K rates may be broadly classified
as follows:
Highly degradable K20 = 20
Easily degradable K20 = 10
Moderately degradable K20 = 2
Slowly degradable K20 =0.5
Biostatic or toxic K20 = 0
2) Figures IV.3.2.1-A5 and A6 represent the BOD removal
efficiency of activated sludge units as a function of KT
rates for the two sets of operating conditions used in
the simplified design approach in Part Al,e,ii. Figure
IV.3.2.1-A5 represents the BOD removal efficiency vs. KT
Date: 4/1/83 IV.3.2.1-A22
-------
100
u
a
2
ik
ik
ui
o
2
Ui
<£
O
O
0
80
76-
70
6 10 16 20 £6 30
ECKENFELDER K RATE
-------
rates for an activated sludge system operating at an F/M
ratio of 0.3. Figure IV.3.2.1-A6 represents the BOD
removal efficiency vs. KT rate for an activated sludge
system operating at an F/M ratio of 0.1. These may be
useful as general indicators of the potential performance
of two common types of activated sludge systems.
Date: 4/1/83 IV.3.2.1-A24
-------
I.
a.
b.
II.
DESIGN FACTOR
Basin Volume =
FLOW =
CAPITAL COST
Cost =
ACTIVATED SLUDGE
SUMMARY WORK SHEET
REFERENCE: IV. 3. 2.1 -A
CAPITAL
million gallons
mgd
x ( r 204.7) =
Cost from curve current index
III
a.
b.
IV.
a.
b.
c.
d.
e.
f.
V,
VI.
a.
c.
e.
. VARIABLE 0 & M
Power =
HP
Defoamer =
FLOW
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service,
I&T:
Service Water:
YEARLY 0 & M
UNCOSTED ITEMS
Oxygen Transfer
Phosphorus
x x 17.9
EC, $/Kw-hr
x x 4.17
, mgd Defoamer, $/lb
x
hr/day $/hr
x
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x % r 365
capital, $ %/100 day/yr
x
thou gpd $/thou gal
365
$/day
—
.
.
.
X
day/yr sum $/day
$
0 & M
$/yr
= Ib/hr b. Ammonia = Ib/day
OR NH3
Ib/day d. Land = ft2
P04
Sludge Generated = Ib/day
SLUDGE
LAND
Date: 4/1/83
IV.3.2.1-A25
-------
ACTIVATED
SLUDGE
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Capital Cost Index =
2. EC: Electricity Cost =
3. Defoamer Cost =
4. Labor =
5. Supervision =
6. Overhead =
7. Lab Labor =
8. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
9. Service Water =
$/Kw-hr
$/lb
$/hr
$/hr
% Labor f 100 = %/100
$/hr
% Capital
% Capital
% Capital
% r 100 = %/100
$/thou gal
I. DESIGN FACTOR
a. Wastewater Characteristics
FLOW
Inf. BOD (So)
b. Basin Volume Method
1. F/M =
Xv = mg/L
2. t = T ( x
So, mg/L Xv, mg/L
3. BV = x
mgd
mg/L
) = days
F/M
million gallons
t, days FLOW, mgd
Date: 4/1/83
IV.3.2.1-A26
-------
c. Simplified Method
1. Select conditions:
Inf. BOD = mg/L
F/M = "
FLOW = mgd
II. CAPITAL COST
a. For Basin Volume Method Use Figure IV.3.2.1-A2
Cost = $
b. For Flow Method use either Figure IV.3.2.1-A3 or IV.3.2.1-A4
Cost = $
III. VARIABLE 0 & M
a. Power = ( x 7.46) + 1.13 = Hp
FLOW, mgd
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Oxygen Transfer Requirement, Basin Volume Method
1. BODR = ( - ) x ( ) x 0.348 = Ib/hr
So, mg/L Se, mg/L FLOW, mgd
2. BP = 0.014 - (0.004 x ) = Ib 02/hr/lb MLVSS, BP > 0
t, days
3. BV (Basin Volume) = x = million gallons
FLOW, mgd t, days
4. OR = [0.7 x ] + [ x ( x x 8.34)]
BODR, Ib/hr BP Xv, mg/L BV, mil gal
= Ib/hr, oxygen transfer requirement
5. Oxygen Uptake Rate Check
UT = f ( x 8.34) = mg/L/hr
OR, Ib/hr BV, mil gal
Date: 4/1/83 IV.3.2.1-A27
-------
If UT > 100 mg/L/hr, Basin volume must be increased and activated
sludge system redesigned.
b. Oxygen Transfer Requirement, Simplified Method.
OR =
(
x 0.348 =
02RATE So, mg/L Se, mg/L FLOW, mgd
c. Ammonia Required
AR = [(0.05 x ) - ] x
8.34 =
BOD, mg/L NH3 in, mg/L FLOW, mgd
d. Phosphorus Required
PR = [(0.01 x ) - ] x
x 8.34 =
BOD, mg/L P04 in, mg/L FLOW, mgd
e. Land Required
LAND =
.x 160,400 T
BV, mil gal
f. Sludge Generation
1. Activated Sludge
WS = [(
DEPTH, ft
) x 0.354] =
mg/L
So, mg/L Se, mg/L
2. Extended Aeration (WS based on above calculation)
NS =
x [1.24 - (0.24 x
)] =
WS, mg/L
3. Sludge Mass
SLUDGE =
t, day
mg/L
x 8.34 =
NS, t > 1 day FLOW, mgd
WS, t £ 1 day
Ib/day
g. Simplified Sludge Estimate
SLUDGE = x (
- ) x x 8.34 =
WSR, Ib/lb So, mg/L Se, mg/L FLOW
Ib/day
Ib/hr
Ib NH,
day
Ib PO,
day
Date: 4/1/83
IV.3.2.1-A28
-------
IV.3.2.1-B. Aeration
Introduction
Aeration is a necessary component for aerobic, biological waste-
water treatment processes. Available methods included mixing
technologies (surface or submerged mixers) and diffused air
systems (air or oxygen). The aeration technology is not specifi-
cally discussed in Volume III of the Treatability Manual, but it
is included in discussions on Activated Sludge (Section III.3.2.1),
Nitrification (Section III.3.2.3), and Digestion (Section III.3.4.2)
B 1. Basis of Design
This presentation is for design and costing of low speed, plat-
form mounted surface turbine aerators for biological wastewater
treatment systems. Factors influencing the design of an aeration
system include: basin volume, oxygen transfer requirements, and
mixing requirements. Aeration systems are designed in this
method to maintain at least 2.0 mg/L dissolved oxygen in the
basin at 30°C with a maximum transfer rate limit of 100 mg 02/L-hr.
The power required to effect the necessary oxygen transfer and
the power required to maintain mixing in the basin are calculated
and the larger of these values is selected as the basis of design.
System costs are estimated on the basis of the number of aerators
required and the cost of each aerator where cost per aerator is a
function of its power rating. An initial estimate of the number
of aerators and individual power rating of the aerators may be
made by the user. Supplemental information on considerations
such as commercially available sizes, spacing and basin surface
coverage are presented in Section B5, Modifications.
a) Source
This cost estimate method was derived from the BAT Effluent
Limitations Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries.
b) Required Input Data
Wastewater flow, L/s (mgd)
Oxygen Requirements of the unit processes, Kg 02/hr
(Ib 02/hr)
Volume of basin for which aeration system being designed,
million liters (million gallons)
c) Limitations
The following limitations on the design of aeration systems are
assumed [4-2]:
Date: 4/1/83 IV.3.2.1-B1
-------
maximum 75 KW (100 Hp)/aerator
minimum 4 KW (5 Hp)/aerator
maximum transfer ra^e, 100 mg 02/L-hr
minimum power for mixing, 20 KW/million liters
(0.1 Hp/1000 gal)
minimum dissolved oxygen in basin, 2.0 mg/L
d) Pretreatment
Not Applicable.
e) Design Equation
The principal factor used in the design and costing of aeration
systems is the power per aerator. This is a function of required
oxygen transfer, mixing, temperature, and other factors discussed
in Section B5. The power per aerator is based on the total
number of units required to provide the total power requirement.
The total power requirement is selected as the larger of the
oxygen transfer or mixing requirement.
i) Total Power Requirements
• Total Power for Oxygen Transfer (at 30°C)
Metric
TKW = OR * (1.02 x 0.476)
where: TKW
OR
1.02
0.476
total aeration power, KW
Oxygen transfer requirement for the unit
process, Kg 02/hr (from activated sludge
or nitrification designs)
standard oxygen transfer rate, Kg O2/KW-hr
conversion factor for standard to actual
oxygen transfer adjustment at 30°C
(limiting case conditions)
English
THP = OR r (3.0 x 0.476)
where: THP
OR
3.0
0.476
total aeration horsepower, Hp
Oxygen transfer requirement for the unit
process, (Ib 02/hr) (from activated sludge,
or nitrification designs)
standard oxygen transfer rate, Ib 02/Hp-hr
conversion factor for standard to actual
oxygen transfer adjustment at 30°C (limit-
ing case conditions)
Date: 4/1/83
IV.3.2.1-B2
-------
• Total Power for Mixing
Metric
TKWC = 20 x BV
where: TKWC = total power required for mixing, KW
20 = minimum mixing power, KW/million liters
BV = basin volume, million liters
English
THPC = 0.1 x BV x 1,000
where: THPC = total horsepower required for mixing, Hp
0.1 = minimum mixing power, 0.1 Hp/1000 gallons
BV = basin volume, million gallons
• Total Power = greater value TKW or TKWC, (THP or THPC)
ii) Power Per Aerator
Metric
IKW = Total Power * n
where: IKW = individual aerator size, KW
Total Power = total power requirement, KW
n = number of aerators
English
IHP = Total Horsepower * n
where: IHP = individual aerator size, horsepower
Total Horsepower = total power requirement, Hp
n = number of aerators
The number of aerators may be estimated or selected based
on total power requirements, commercially available aerator
sizes, basin geometry, and aerator spacing. This is ex-
plained in more detail in Section B 5, Modifications.
f) Subsequent Treatment
Not Applicable
B 2. Capital Costs
The power per individual aerator is the principal cost factor
necessary in estimating capital costs. The total cost is then
developed by multiplying the cost per aerator derived from the
Date: 4/1/83 IV.3.2.1-B3
-------
cost curve (Figure IV.3.2.1-B1) by the number of aerators
necessary. Costs estimated using these curves must be adjusted
to a current value using an appropriate current cost index.
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-2]:
Fixed mounted, low speed, turbine surface aerator
Platform support concrete piers, steel supports
Concrete abrasion pad
Railing and grating
Instrumentation
b) Capital Cost Curve
Curve - see Figure IV.3.2.1-B1.
- Cost (thousands of dollars) vs. Power per Aerator
(kilowatts or'horsepower)
- Curve basis, cost estimate on four standard size
aerators 0.75, 7.5, 37 and 75 Kw (1, 10, 50,
and 100 horsepower).
Scale factor
- The total cost is equal to the cost per aerator
multiplied by the number of aerators required.
Total Cost = n x Cost per Aerator
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
B 3. Operation and Maintenance Costs
Operating costs are comprised of both variable and fixed compo-
nents. Aerator power requirement is the only variable operating
cost. Fixed operating costs include labor, supervision, over-
head, laboratory labor, maintenance, services, insurance and
taxes, and service water. All fixed and variable operating costs
should be adjusted to current levels using an appropriate index
or unit cost factor.
a) Variable Cost
i) Power Requirements = Total Power Requirements (see
Section B l,e, Design Equation)
Date: 4/1/83 IV.3.2.1-B4
-------
AERXTION. KILOWATTS PER AERATOR
O
Q
U.
O
to
Q
O
X
h-
»
oc
O
oc
Ul
OC
Ul
0.
H
CO
O
U
70-
60-
7.4 16 22 30 37 45 52 60 67 74
0
10
2'o
40
30 40 50 60
AERATION. HORSEPOWER PER AERATOR
100
FIGURE IV.3.2.1-B1. CAPITAL COST ESTIMATE
FOR AERATION [4-10]
Date: 4/1/83
IV. 3.2.1-B5
-------
ii) Power Cost
Metric
PC = (TKW or TKWC) x 24 x EC
where: PC = power cost, $/day
TKW = total aerator power, KW
TKWC = total power required for mixing, KW
24 = hr/day
EC = electricity cost, $/KW-hr
English
PC = (THP or THPC) x 24 x 0.746 x EC
where: PC = power cost, $/day
THP = total aerator horsepower, Hp
THPC = total horsepower required for mixing, Hp
24 = hr/day
0.746 = KW-hr/Hp-hr
EC = electricity cost, $/Kw-hr
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.2.1-B1 [4-11].
B 4. Miscellaneous Costs
Costs for engineering, and common plant items such as piping and
buildings, are calculated after the completion of costing for
individual units (see Section IV.3.5). Aeration basins are
costed in other technology sections.
B 5. Modification
The number and arrangement of aerators may be determined by
considering the total power requirements, basin geometry, com-
mercially available sizes of aerators, spacing, and circle of
influence of the individual aerators.
a) Oxygen Transfer Performance Correction
A typical value of 1.02 Kg 02/KW-hr (3.0 Ib 02/Hp-hr) is used for
the standard oxygen transfer rate in the design equation. The
standard oxygen transfer rate is based on tap water at 20°C. The
correction factor included to convert the oxygen transfer rate to
field conditions was computed using the following equation:
T - ?n
Na = NT * [(3 x CSS - CL) * 9.17] x (1.025) x (a)
Date: 4/1/83 IV.3.2.1-B6
-------
TABLE IV.3.2.1-B1. FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR AERATION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.10 Weeks (2.40 hrs/day)
10% Labor (0.24 hrs/day)
75% Labor Cost
0.00 Shifts
5.24% Capital
0.40% Capital
2.50% Capital
0.00 Thou L
(0.00 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/Thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.2.1-B7
-------
where: Na = field condition oxygen transfer, Kg/KW-hr or
Ib/Hp-hr
NT = standard condition oxygen transfer, Kg/KW-hr or
Ib/Hp-hr
U = salinity - surface tension correction factor
CSS = oxygen saturation concentration for wastewater
at given atmospheric conditions and temperature,
mg/L
CL = operating oxygen concentration, mg/L
T = temperature, °C
a = oxygen transfer correction factor for wastewater
9.17 = saturation dissolved oxygen at 20°C, mg/L
The field oxygen transfer correction factor calculated for use in
this design method is based on a basin temperature of 30°C using
the conditions indicated below.
Na = 0.476 x NT
where: Na = field condition oxygen transfer rate Kg/KW-hr or
Ib/Hp-hr
NT = standard condition oxygen transfer rate, Kg/KW-hr
or Ib/Hp-hr
& = 0.9
CSS =7.63 mg/L at 30°C
CL = 2.0 mg/L
T = 30°C (worst case condition)
a = 0.7
The correction factor may be calculated for other operating
conditions by substituting the appropriate conditions.
b) Total Power Requirements
The power required both for oxygen transfer and for adequate
mixing is estimated. Mixing power and aeration power are com-
pared and the greater power requirement is chosen for design and
costing. The determination of total power requirements was dis-
cussed previously (Section B l,e, Design Equation).
c) Surface Area and Basin Geometry
The surface area of the aeration basin affects the number and
arrangement of individual aerators. The surface area of a basin
of given volume is determined in the following manner:
i) For basin volumes <4.16 million liters (1.1 million
gallons) the surface area is determined as follows
(assuming a square basin, with vertical walls):
Date: 4/1/83 IV.3.2.1-B8
-------
Metric
SA = BV x 106 * (1000 x D)
where: SA = surface area, m2
BV = basin volume, million liters
1000 = L/m3
D = basin depth, m
(assumed to be 3.66 m)
English
SA = BV x 10s T (7.48 x D)
where: SA = basin surface area, ft2
BV = basin volume, million gallons
7.48 = conversion factor, gallon/ft3
D = basin depth, ft
(assumed to be 12 ft)
ii) For basin volumes >4.16 million liters (1.1 million
gallons) the surface area is determined as follows
(assuming a rectangular basin with L = 2W, and 2:1 side
slopes):
SA = L x W
= L2 * 2
where: SA = basin surface area, m2 or ft2
W = basin width, m or ft
L = basin length, m or ft
Using the conditions stated above for side slopes and
assuming a 3.66 m (12 ft) depth, the relationship be-
tween flow and length is computed as follows:
Metric
L = [(2 x BV x 106) r (3660) - 53.5]0'5 -11
where: L = length of basin at the water level, m
BV = basin volume, million liters
English
L = [(2 x BV x 106) * (7.48 x 12) -576]0'5 -36
where: L = length of the basin at the water level, ft
BV = basin volume, million gallons
Date: 4/1/83 IV.3.2.1-B9
-------
d) Individual Aerator Power Selection
The number of individual aerators, required power rating of each
unit, and adjustment of the size to agree with commercially avail-
able units is determined as follows:
i) Four aerators are initially assumed and the individual
power is estimated. A minimum of 3.73 KW (5.0 Hp) per
aerator and 3 aerators per basin are required.
IP = TP * n
where: IP = individual power, IKW or IHP
TP = total power, TKW or TKP
n = number of aerators
ii) The calculated individual power ratings are converted to
the next larger commercially available size. The sizes
as used in this case are: 5, 7.5, 10, 15, 20, 30, 40,
50, 60, 75, and 100 horsepower. Metric equivalents are:
3.7, 5.6, 7.5, 11, 15, 22, 30, 37, 45, 56, and 75 KW.
If the calculated IP value is 575 KW (100 Hp), then the
number of aerators is increased by two and a new IP is
calculated until it is less than 75 KW (100 Hp).
e) Aerator Placement/Spacing
The selected number and size of the aerators is examined to
ensure that the entire basin surface can be aerated. This re-
quires that the center-to-center spacing of the aerators be
estimated and compared to the circle of influence for the se-
lected aerator size. The number of aerators then must be ad-
justed to ensure complete basin coverage.
i) The aerator spacing is determined as follows:
AERSP = (SA * n)°'5
where: AERSP = the center-to-center aerator spacing,
m or ft
SA = basin surface area, m2 or ft2
n = number of aerators
This calculation models each aerator as a square cover-
ing an area of SA/n. It assumes that a symmetrical
layout is used in a rectangular basin (i.e., an even
number of aerators).
Date: 4/1/83 IV.3.2.1-B10
-------
ii) The circles of influence of various size aerators were
related by linear regression techniques as follows:
Metric
- If IKW < 11.2 Kw
COI = (1.66 x IKW) +3.96
- If IKW 2 11.2 Kw
COI = (0.233 x IKW) + 19.2
where: COI = diameter (circle of influence), m
IKW = individual aerator power, KW
English
- If IHP < 15 Hp
COI = (4.07 x IHP) +13.0
- If IHP > 15 Hp
COI = (0.571 x IHP) + 63.0
where: COI = diameter (circle of influence), ft
IHP = individual power of aerators
iii) The aerator spacing and circle of influence are compared
for the final selection of a design condition.
- If COI _> AERSP:
leave n and IKW (IHP) as originally calculated
- If COI < AERSP:
increase n by two and recalculate IKW (IHP), AERSP
and COI
Date: 4/1/83 IV.3.2.1-B11
-------
AERATION
SUMMARY WORK SHEET
I. DESIGN FACTOR
Horsepower per Aerator = Hp; Number =
II. CAPITAL COST
Cost = x
Cost from curve number of aerators
x ( T 204.7) =
current index
III. VARIABLE 0 & M
a. Power = x x 17.9
Hp EC, $/Kw-hr
IV. FIXED 0 & M
a . Labor : x
hr/day $/hr
b. Supervision: x
hr/day $/hr
c. Overhead: x
Labor, $/day %/100
d. Lab Labor: x
hr/day $/day
e. Maint, Service, x f 365
I&T: capital, $ %/100 day/yr
f. Service Water: x
thou gpd $/thou gal
V. YEARLY 0 & M 365
day/yr
VI. UNCOSTED ITEMS
REFERENCE :
$/day
=
=
.
.
x
sum $/day
IV.3.2.1-B
CAPITAL
$
0 & M
—
$/yr
Date: 4/1/83
IV.3.2.1-B12
-------
AERATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Capital Cost Index =
2. EC = Electricity Cost =
3. Labor =
4. Supervision =
5. Overhead =
6. Lab Labor =
7. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
8. Service Water =
$/Kw-hr
$/hr
$/hr
% Labor T 100 =
$/hr
% Capital
% Capital
% Capital
f 100 =
fc/100
%/100
$/thou gal
. DESIGN FACTOR
a. Total Horsepower Required for Oxygen Transfer
THP =
T 1.43 =
oxygen transfer requirement, Ib/hr
b. Total Horsepower Required for Mixing
Hp
THPC =
x 100 =
Hp
basin volume, mil gal
c. Total Horsepower = greater of THP or THPC =
Hp
d. Initial Estimate of Individual Aerator Horsepower
IHP = T
Total Horsepower, Hp number aerators
minimum, 5 Hp per aerator and 3 aerators per basin
e. convert Aerators to next larger commercial size
IHP = 5, 7.5, 10, 15, 20, 30, 40, 50, 60, 75, 100
IHP = Hp
Hp
Date: 4/1/S3
IV.3.2.1-B13
-------
f. Basin Geometry (surface area)
1. If basin volume < 1.1 million gallons, square
SA =
x 11,100 =
ft*
BV, mil gal
2. If basin volume > 1.1 million gallons, rectangular
SA = [(
x 22,300 - 576)°'5 -36 ]2 f 2 =
BV, mil gal
g. Check Aerator Spacing
1. AERSP = (
0.5
SA, ft2 number aerators
2. If IHP < 15 Hp
COI = 4.07 x
+ 13 =
IHP, Hp
If IHP > 15 Hp
COI = 0.571 x
+ 63 =
ft
ft
IHP, Hp
3. If COI > AERSP, leave n and IHP
If COI < AERSP, increase n and go back to step d.
ft2
ft
II. CAPITAL COST
III. VARIABLE 0 & M
Power =
IHP, Hp Number aerators
HP
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83
IV.3.2.1-B14
-------
IV.3.2.1-C. Nutrient Addition
Introduction
A nutrient addition system may be required for biological unit -
processes to provide sufficient nitrogen and phosphorous in the
wastewater to ensure that neither nutrient becomes the limiting
factor in the biological growth reactions. The nutrient addition
technology is not discussed specifically in Volume III of the
Treatability Manual, but it may be required for biological treat-
ment (Section 111. 3.2).
C 1. Basis of Design
This presentation is for the addition of ammonia and phosphorus
to biological wastewater treatment systems in order to maintain
the proper nutrient balance. Systems of the type considered are
represented in Figure IV.3.2.1-C1. The principal cost and design
factor is the amount of each nutrient required per day. The
nutrient addition systems are designed to serve the needs of the
whole'plant, rather than one unit process. Therefore, the nutri-
ent requirements for all biological processes in the system
should be summed in order to arrive at the proper design sizing
for any nutrient addition system. Nutrient requirements may be
accounted for in two ways: (1) the mass requirements of each
unit process may be calculated individually and summed, or (2)
the effluent concentration deficit of each nutrient may be cal-
culated for each unit process, and the concentration of ammonia
and phosphorus needed to make up the deficit determined at the
end of the last biological process based on the sum of the deficits
from all preceding units.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
b) Required Input Data
These are two input data possibilities.
i) Sum of previously calculated ammonia and phosphorus re-
quirements for all biological processes, Kg/day (Ib/day).
ii) Wastewater flowrate L/s (mgd) and ammonia and phosphorus
deficit concentrations (mg/L).
Date: 4/1/83 IV.3.2.1-C1
-------
Z
\\
]
il
si
z
o
o
s
O
CM
H
O
H
Date: 4/1/83
IV.3.2.1-C2
-------
c) Limitations
Nutrient addition is unnecessary if sufficient amounts of re-
quired nutrients are already present in the wastewater.
d) Pretreatment
None required.
e) Design Equation
Nutrient requirements may be based on the deficit in the final
effluent. It is also possible to sum the calculated mass nutri-
ent requirements for each affected unit process. Both methods
are presented below.
i) Ammonia Requirement
• Summation method
NRQD = Z AR
where: NRQD = total required ammonia, Kg/day or Ib/day
AR = ammonia required for unit process, Kg/day
or Ib/day
(from the design of the unit processes)
• Concentration method (deficit)
Metric
NRQD = FLOW x 0.086 x NABS
where: NRQD = total required ammonia, Kg/day
FLOW = influent flow, L/s
0.086 = conversion factor
NABS = absolute value of the ammonia deficit con-
centration, mg/L
English
• NRQD = FLOW x 8.34 x NABS
where: NRQD = total required ammonia, Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
NABS = absolute value of the ammonia deficit
concentration, mg/L
Date: 4/1/83 IV.3.2.1-C3
-------
ii) Phosphorus Requirement
• Summation method
PREQD = I PR
where: PREQD = total required phosphorus (as P04),
Kg/day or Ib/day
PR = phosphorus requirement for unit process,
Kg/day or Ib/day (from the design of the
unit processes)
• Concentration method
Metric
PREQD = FLOW x 0.086 x PARS
where: PREQD = total required phosphorus
(as P04), Kg/day
FLOW = influent flow, L/s
0.086 = conversion factor
PABS = absolute value of the phosphorus deficit
concentration, mg/L
English
PREQD = FLOW x 8.34 x PABS
where: PREQD = total required phosphorus (as PO4), Ib/day
FLOW = influent flow, mgd
8.34 = conversion factor
PABS = absolute value of the phosphorus deficit
concentration, mg/L
f) Subsequent Treatment
None specified.
C 2. Capital Costs
The quantity of ammonia and phosphorus added per day is the
principal cost factor in nutrient addition. The capital cost of
ammonia and phosphorus addition systems is shown as a function of
the amount of nutrient added in Figures IV.3.2.1-C2 and
IV.3.2.1-C3 respectively. Costs estimated using these curves
must be adjusted to a current value using an appropriate current
cost index.
Date: 4/1/83 IV.3.2.1-CU
-------
a) Cost Data
Items included in capital cost curve estimates are described
below [4-2].
i) Ammoni a
Metric
Ammonia storage tank:
System Flow Storage Capacity
0 - 8.76 L/s 68 Kg cylinders
8.76 - 43.8 L/s 1030 liters
43.8 - 219 L/s 2720 liters
>219 L/s 8330 liters
Evaporator (for systems >8.76 L/s)
Metering pumps (all wetted parts glass or stainless)
Instrumentation, piping
English
Ammonia storage tank:
System Flow Storage Capacity
0-0.2 mgd 150 Ib cylinders
0.2 - 1.0 mgd 272 gallons
1.0 - 5.0 mgd 720 gallons
>5.0 mgd 2200 gallons
Evaporator (for systems >0.2 mgd)
Metering pumps (all wetted parts glass or stainless)
Instrumentation, piping
ii) Phosphorus
Phosphoric acid storage tank, 878 L or 232 gal, all
flows
Metering Pumps (all wetted parts glass or stainless)
Instrumentation, piping
b) Capital Cost Curves
i) Ammonia Curve - see Figure IV.3.2.1-C2
- Cost (thousands of dollars) vs. nutrient
(Kg/day or Ib/day of ammonia).
- Curve basis, cost estimates at four flowrates
8.76, 43.8, 219, and 876 L/s (0.2, 1.0, 5.0,
and 20 mgd).
ii) Phosphorus Curve - see Figure IV.3.2.1-C3
- Cost (thousands of dollars) vs. nutrient
(Kg/day or Ib/day phosphorus).
- Curve basis, cost estimates at four flowrates
8.76, 43.8, 219, and 876 L/s (0.2, 1.0, 5.0,
and 10 mgd).
Date: 4/1/83 IV.3.2.1-C5
-------
AMMONIA, KILOGRAMS PER DAY
0)
K
O
O
u.
O
CO
907
1134
80
0»
O
O
600
1000 1600 2000
AMMONIA. POUNDS PER DAY
2500
FIGURE IV.3.2.1-C2. CAPITAL COST (ESTIMATE FOR
NUTRIENT ADDITION (AMMONIA)
[4-10]
PHOSPHORUS, KILOGRAMS PER DAY
46.4 90.7 136
to
CC
O
Q
U.
O
00
CO
W
O
O
227
too 200 ago 400 900
PHOSPHORUS, POUNDS PER DAY
FIGURE IV.3.2.1-C3. CAPITAL COST ESTIMATE FOR NUTRIENT
ADDITION (PHOSPHORUS) [4-10]
Date: 1/4/83
IV.3.2.1-C6
-------
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
C 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Nutrient chemical usage constitutes the only significant variable
cost. The cost per Kg or Ib of phosphoric acid remains relatively
constant while the cost per Kg or Ib of ammonia can vary signif-
icantly depending on whether it is delivered in cylinders or bulk
tanks. Labor, supervision, overhead, laboratory labor, main-
tenance, services, insurance and taxes, and service water are the
fixed operating costs. All operating costs should be adjusted to
current levels using an appropriate index or unit cost factor.
a) Variable Costs
i) Power Requirements - minimal, not included in cost
estimate
ii) Chemical Requirements - see Section C l,e, Design
Equation
iii) Chemical Costs, ammonia and phosphoric acid
CC = Q x N
where: CC = Chemical cost, $/day
Q = calculated requirement for nutrient,
Kg/day or Ib/day
N = unit cost of nutrient, $/Kg or $/lb
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.2.1-C1, including values for the cost basis and unit
costs for both ammonia and phosphorus addition [4-11].
C 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as
piping and buildings, are calculated after the completion of
costing for individual units (see Section IV.3.5).
C 5. Modifications
None.
Date: 4/1/83 IV.3.2.1-C7
-------
TABLE IV.3.2.1-C1.
FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR AMMONIA AND PHOSPHORUS
ADDITION [4-11]
Ammonia Addition
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.5 Weeks (1.20 hrs/day)
10% Labor (0.12 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
0.00% Capital
0.40% Capital
2.50% Capital
0.757 L/s
(17.28 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
Phosphorus Addition
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.05 Weeks (1.20 hrs/day)
10% Labor (0.12 hrs/day)
75% Labor Cost
0.00 Shifts
3.94% Capital
0.40% Capital
2.50% Capital
0.00 L/s
(0.00 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.2.1-C8
-------
I.
II.
DESIGN FACTOR
Ammonia =
CAPITAL COST
Ammonia : $
AMMONIA ADDITION
SUMMARY WORK SHEET
REFERENCE: IV.3.2.1-C
CAPITAL
Ib/day, required for activated sludge
x ( T 204.7) =
cost from curve current index
III
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
. VARIABLE 0 &
Ammonia Cost:
AC =
M
X
Ammonia Ib/day Ammonia $/lb
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service
I&T:
Service Water.-
YEARLY 0 & M
X
hr/day $/day
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x f 365
capital, $ %/100 day/yr
X
thou gpd $/thou gal
365
$/day
X
day/yr sum $/day
$
0 & M
$/yr
UNCDSTED ITEMS
Date.- 4/1/83
IV.3.2.1-C9
-------
I.
II.
DESIGN FACTOR
P04 = I
PHOSPHORUS ADDITION
SUMMARY WORK SHEET
REFERENCE: IV.3.2.1-C
CAPITAL
+ + = Ib/day
act sldg nitri denit
CAPITAL COST
P04 = $
X ( r
204.7) =
cost from curve current index
III
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
. VARIABLE 0 &
M
Phosphorus Cost:
PC = x
P04 Ib/day P04 $/lb
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service
I&T:
Service Water:
YEARLY 0 & M
x
hr/day $/hr
X
hr/day $/hr
X %
Labor, $/day
X
hr/day $/hr
X r 365
capital, $ %/100 day/yr
X
thou gpd $/thou gal
365
$/day
x
day/yr sum $/day
$
0 & M
—
$/yr
UNCOSTED ITEMS
Date: 4/1/83
IV.3.2.1-C10
-------
IV.3.2.1-D. Heating/Cooling
D 1. Basis of Design
This presentation is for the heating or cooling of a wastewater
stream. The heating or cooling of a waste stream may be required
for the adequate performance of a wastewater treatment process or
operation or may be required for a wastewater discharge to meet
water quality criteria. A costing methodology is described in
this section for: (1) heating a wastewater stream by direct
steam injection; (2) cooling a wastewater stream by a shell-and-
tube heat exchanger; and (3) cooling a wastewater stream by a
mechanical draft cooling tower. The extent of heating or cooling
is set by the conditions required by the subsequent unit process
(e.g., activated sludge system or other biological treatment
system) or discharge conditions.
When heating is required, a direct steam injection system is
used. Since the cost of the injectors are minor with respect to
the cost of the steam generation equipment, no capital cost is
estimated. The steam cost is included in the determination of
operation costs.
When cooling is required, both a heat exchanger and a cooling
tower are examined and the type of system that is appropriate for
the required flow rate and heat exchange rate is selected. A
heat exchanger, such as that illustrated in Figure IV.3.2.1-D1,
is selected when such a unit would require less than 464 square
meters (5,000 square feet) of exchanger capacity. The cost
factor for a heat exchanger cooling system is the required
cooling surface area.
A cooling tower system, such as that illustrated in Figure
IV.3.2.1-D2, also is considered whenever cooling is required.
The cooling duty and tower requirements are calculated on the
basis of the ambient conditions (wet-bulb temperature), the waste
characteristics (flow rate and inlet temperature), and the re-
quired outlet conditions (outlet temperature).
a) Source
This cost estimate method was derived from the BAT Effluent
Limitations Guidelines engineering study for the Organic
Chemicals/ Plastics and Synthetic Fibers Industries [4-2].
b) Required Input Data
Wastewater flow L/s (gpm)
Wastewater characteristics: inlet temperature °C (°F);
target outlet temperature °C (°F)
Ambient conditions: wet bulb temperature °C (°F)
Date: 4/1/83 IV.3.2.1-D1
-------
I
-I'
GO
-tXMXJ-CXJ-
txa
S
I
-CX)—Tv^-
05
W
a
u
X
w
w
o
fc,
Q
O
en
CO
w
u
§
Q
I
H
H
Date: 4/1/83
IV.3.2.1-D2
-------
ii
If
O
-d II
ill
-CZZD!
K
I
EH
u
o
o
u
o
H
Q
CO
w
u
o
CN
Q
I
ro
H
s
D
O
H
frt
Date: 4/1/83
IV.3.2.1-D3
-------
c) Limitations
Cooling - heat exchanger only used if required cooling surface
area <464 m2 (<5000 ft2)
d) Pretreatment
None specified.
e) Design Factor
The need for heating or cooling is established by the need of
subsequent unit operations. The design factors for these options
are described.
i) Heating
There is no system design for heating. The entire cost
is assumed to be the required steam usage (see Section
D 3) .
ii) Cooling
The design of a cooling system may include either a heat
exchanger or a cooling tower. Both systems are evaluated
and the lower cost system is selected. However, the
heat exchanger system is not used if the exchanger area
exceeds 464 square meters (5000 square feet).
• Heat Exchanger Method
The heat exchanger cost factor is the surface area
required for achieving the required cooling.
Metric
where:
AREA = DUTY * [(TOUT - TCW) x 1130]
heat exchanger surface area, m2
heat transfer requirement, KJ/hr
= MFLOW x (TOUT - TIN) x 12.5
MFLOW = mass wastewater flow, Kg/hr
= FLOW x 3600
flow, L/s
mass flow rate conversion, L/s to Kg/hr
required wastewater outlet temperature,
°C
wastewater inlet temperature, °C
(10% flow variance) x (11.4 KJ/hr-m2-°C)
cooling inlet water temperature, °C
water-water transfer rate, KJ/hr-m2-°C
AREA
DUTY
FLOW
3600
TOUT
TIN
12.5
TCW
1130
Date: 4/1/83
IV.3.2.1-D4
-------
English
AREA - DUTY * [(TOUT - TCW) x 100]
where: AREA = heat exchanger surface area, ft2
DUTY = heat transfer requirement, BTU/hr
= MFLOW x (TOUT - TIN) x 1.1
MFLOW = mass wastewater flow, Ib/hr
= FLOW x 500
flow, gpm
mass flow rate conversion, gpm to
Ib/hr
TOUT = required wastewater outlet
temperature, °F
wastewater inlet temperature, °F
(10% flow variation) x (1.0 BTU/hr
ft2-°F)
cooling inlet water temperature, °F
water-water transfer rate,
BTU/hr-ft2-°F
FLOW
500
TIN
1.1
TCW
100
This design is based on cooling water provided at the
same flow rate as the wastewater flow rate. Thus the
(TOUT - TCW) term represents the log mean temperature
difference between the wastewater and cooling water.
• Cooling Tower Method
The cooling tower design factors are the number of
cooling tower units required and the wastewater flow
rate.
NCTU = FLOW x RF
where: NCTU
FLOW
RF
A,B
WBT
RANGE
TOUT
= number of cooling tower units
= wastewater flow rate, L/s or gpm
= rating factor
= A x (RANGE)6
coefficients (see Table IV.3.2.1-D1)
wet bulb temperature, °C or °F
TIN - TOUT
required wastewater outlet temperature,
°C or °F
TIN = wastewater inlet temperature, °C or °F
The necessary coefficients A and B are functions of the
ambient wet bulb temperature (WBT) and the approach
temperature (APROACH). The wet bulb temperature repre-
sents the ambient conditions selected for the location
of the treatment plant. The approach temperature repre-
sents the difference between the outlet temperature of
the wastewater (TOUT) and the atmospheric wet-bulb
Date: 4/1/83
IV.3.2.1-D5
-------
TABLE IV.3.2.1-D1. COEFFICIENTS FOR DETERMINING RATING
FACTOR FOR THE COOLING TOWER SYSTEM [4-2]
WET BULB
TEMPERATURE
°C °F
26.7 80
25.6 78
2U.lt 76
23.3 71
22.2 72
21.1 70
18.3 65
15.6 60
DESIGN
APPROACH*
°C
11.1
8.9
6.7
5.6
U.I4
11.1
8.9
6.7
5.6
(t.U
11.1
8.9
6.7
5.6
14.14
11.1
8.9
6.7
5.6
14.M
11.1
8.9
6.7
5.6
l*.U
13.3
10
7.8
5.6
I*.U
13.3
11.1
8.9
6.7
5.6
16.7
13.3
11.1
8.9
6.7
°F
20
16
12
10
6
20
16
12
10
8
20
16
12
10
8
20
16
12
10
8
20
16
12
10
8
24
18
1l»
10
8
21*
20
16
12
10
30
2U
20
16
12
RATING FACTOR
COEFFICIENTS**
A
0.102
0.112
0. 13U
0. 178
0.221
0. 105
0.11U
0.156
0. 191
0.223
0.0968
0.112
0.173
0.17U
0.213
0.107
0.125
0.160
0.189
0.209
0.106
0.1214
0.166
0.200
0.199
0.095
0.107
0.139
0.200
0.233
0.096
0.108
0.137
0.180
0.192
0.0814
0.094
0.111
0.1K7
0.176
B
0.536
0.577
0.606
0.569
0.562
0.542
0.58M
0.570
0.517
0.570
0.583
0.603
0.563
0.612
0.612
0.570
0.598
0.600
0.595
0.63U
0.588
0.612
0.609
0.603
0.672
0.57U
0.633
0.633
0.62l«
0.61*5
0.612
0.637
0.61*0
0.6149
0.691
0.591
0.661
0.670
0.659
0.703
•cooling tower outlet temperature (TOUT) minus wet bulb temperature (WBT)
••ooefficients: RF = A x (Range)(B)
Date; 4/1/83
IV.3.2.1-D6
-------
plant. The approach temperature represents the differ-
ence between the outlet temperature of the wastewater
(TOUT) and the atmospheric wet-bulb temperature. The
coefficients in the table are selected for the condi-
tions that correspond to the listed wet-bulb tempera-
ture, using the next highest wet-bulb temperature condi-
tion when the selected value is intermediate to those in
the table. The approach is then used to select the A
and B coefficients for calculating the rating factor.
When the approach lies between conditions in the table,
the rating factor is interpolated from the result of
calculating the two rating factors. An approach that is
lower than the values in the table cannot be achieved by
this method requiring that the design conditions be
adjusted (i.e., select a higher TOUT). The A and B
coefficients for the largest approach are used if the
actual approach exceeds the highest listed,
f) Subsequent Treatment
The heated/cooled wastewater will require treatment or discharge.
D 2 Capital Costs
There are no capital costs estimated for the heating option. The
capital costs for the heat exchanger cooling system are based on
the heat exchanger surface area requirements, with a maximum
system size of 464 square meters (5000 square feet) (see Figure
IV.3.2.1-D3). The capital costs for a cooling tower are based on
two factors: flow and the number of cooling tower units. The
flow is used to determine the cost of associated equipment (Figure
IV.3.2.1-D4) as well as the cost of each cooling tower unit
(Figure IV.3.2.1-D5). The number of cooling tower units, deter-
mined as described in Section Dl,e, is multiplied times the cost
per cooling tower unit to establish the tower capital cost, which
is added to the auxiliary equipment cost to get the system cost.
Cost estimated using these curves must be adjusted to a current
value using an appropriate current cost index.
a) Cost Data
i) Items included in the capital cost estimates for the
heat exchanger cooling system include:
Tube and shell heat exchanger
Pumps, piping
Instrumentation, electrical
ii) Items included in the capital cost estimates for the
cooling tower system include:
Cooling tower
Crossflow mechanical draft type
Date: 4/1/83 IV.3.2.1-D7
-------
Auxiliary equipment
Pumps, piping
Instrumentation, electrical
b) Capital Cost Curves
i) Heat exchanger system - see Figure IV.3.2.1-D3
- Cost (thousands of dollars) vs. surface area
(square meters or square feet)
- Curve basis, cost estimate on systems with surface
areas of 18.6, 46.4, 186, and 464 m2 (200, 500,
2000, and 5000 ft2)
ii) Cooling tower system -
- Cost:
COST = EQUIP + (NCTU x DCPTU)
where: COST = capital cost for cooling tower
system (in July 1977 dollars)
EQUIP = cost for auxiliary equipment - see
Figure IV.3.2.1-D4, Cost (thousands
of dollars) vs. flow (liters per
second or thousand gpm)
NCTU = number of cooling tower units re-
quired (see Section Dl,e)
DCPTU = dollar cost per cooling tower unit -
See Figure IV.3.2.1-D5, Cost per
Cooling Tower Unit (dollars) vs.
Flow (liters per second or thousand
gpm)
- Curve basis: vendor information
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index, = 204.7
D.3 Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable components will depend upon the system selected and may
include utilities (steam, cooling water) and power. Fixed oper-
ating costs include labor, supervision, overhead, laboratory
labor, maintenance, services, insurance and taxes, and service
water. All fixed and variable operating costs should be adjusted
to current levels using an appropriate index or unit cost factor.
Date: 4/1/83
IV.3.2.1-D8
-------
SURFACE AREA.8QUARE METERS
186 279 372
464
ISO!
30,
1000 2000 3000 4000
SURFACE AREA. SQUARE FEET
0000
FIGURE IV.3.2.1-D3. CAPITAL COST ESTIMATE FOR HEAT
EXCHANGER [4-10]
Date: 4/1/83
IV.3.2.1-D9
-------
FLOW, LITERS PEA SECOND
,13 .25 ,38 .50 ,63 ,78 .88 1.O
S BOO—
O
O 4OO-
O
O 300-
O «OO -
H
8IO0-
O
1
X1
^
X
x
^
1" 1
X
*'
x
x
X
<
/•
X
>
^
r
;. i
S
/
^
X
/I
f i
y
'
/
/
/
1 1
/*
/
i
^
^
^
9 I1
^
^
x
1
/
'
t T
X
^
f'
¥ T
#
FIGURE IV.3.2.1-D4.
«
ff
<
^
I
•
2
3
1C
Ul
S
O
»-
o
o
o
o
tr.
ui
0.
so
10
.13
a
FLOW. THOUSAND GALLONS PER MINUTE
CAPITAL COST ESTIMATE FOR COOLING TOWER
AUXILIARY EQUIPMENT [4-10)
FLOW. LITERS PER SECOND
.25 .38 .50 -63 .76 .88 1.0
.38
4.
i
v»
10 12 14
FLOW. THOUSAND GALLONS PER MINUTE
FIGURE IV.3.2.1-D5. CAPITAL COST ESTIMATE FOR COOLING TOWER
UNIT COST (COST PER COOLING TOWER UNIT)
[4-10]
Date: 4/1/83
IV.3.2.1-D10
-------
a) Variable Costs - Heating
i) Utilities Required - steam is required for heating
Metric
STM = MFLOW x (TOUT - TIN) x 0.043
where: STM = steam usage, Kg/hr
MFLOW = wastewater flow, Kg/hr
= FLOW x 69.6
FLOW = wastewater flow, L/s
69.6 = mass flow rate conversion, L/s to Kg/hr
TOUT = required outlet temperature, °C
TIN = inlet temperature, °C
0.043 = 1.1 x 24 x 4.17 * 2560
= (110% design factor) x (hr/day) x
(KJ/Kg-°C) * (KJ/Kg steam)
English
STM = MFLOW x (TOUT - TIN) x 0.024
where: STM = steam usage, Ib/hr
MFLOW = wastewater flow, Ib/hr
= FLOW x 500
FLOW = wastewater flow, gpm
500 = mass flow rate conversion, gpm to Ib/hr
TOUT = required outlet temperature, °F
TIN = inlet temperature, °F
0.024 = 1.1 x 24 x 1 r 1100
= (110% design factor) x (hr/day)
x (BTU/lb-°F) f (BTU/lb steam)
ii) Utilities Cost, Heating
TSC = STM x 24 x CPP
where: TSC = total steam cost, $/day
STM = steam usage, Kg/hr or Ib/hr
24 = hr/day
CPP = cost per Kg or Ib of steam, $/Kg or $/lb
b) Variable Costs - Cooling by Heat Exchanger
i) Power Requirements - total power includes pumps. The
following equation was developed using regression analysis
procedures [4-1].
Metric
TPHK = (0.039 x AREA) - 0.105
Date: 4/1/83 IV.3.2.1-D11
-------
where: TPHK = total power required for heat exchanger, Kw
AREA = heat exchanger surface area, m2
English
TPHE = (0.00488 x AREA) - 0.141
where: TPHE = total power required for heat exchanger, Hp
AREA = heat exchanger surface area, ft2
ii) Utilities Required - cooling water is required as the
heat transfer medium
CW = FLOW
where: CW = cooling water required, L/s or gpm
FLOW = wastewater flow, L/s or gpm
iii) Power Cost
Metric
PC = TPHK x 24 x EC
where: PC = total power cost, $/day
TPHK = total power for heat exchangers, Kw
24 = hr/day
EC = electricity cost, $/Kw-hr
English
PC = TPHE x 0.746 x 24 x EC
where: PC = total power cost, $/day
TPHE = total power for heat exchangers, Hp
0.746 = Kw-hr/Hp-hr
24 = hr/day
EC = electricity cost, $/Kw-hr
iv) Cooling Water Cost
Metric
WC = CW x 86400 x CPL
where: WC = water cost, $/day
CW = cooling water, L/s
86400 = seconds/day
CPL = cost per liter, $/L
Date: 4/1/83 IV.3.2.1-D12
-------
English
WC = CW x 1440 x CPG
where: WC = water cost, $/day
CW = cooling water, gpm
1440 = minute/day
CPG = cost per gallon, $/gal
c) Variable Costs - Cooling by Cooling Tower
i) Power Requirements - total power includes pumps. The
following equation was developed using regression analysis
procedures [4-1].
Metric
TPCK = (1.15 x FLOW) - 15.7
where: TPCK = total power for cooling tower, Kw
FLOW = wastewater flow rate, L/s
English
TPCT = (0.097 x FLOW) - 21.0
v/here: TPCT = total power for cooling tower, Hp
FLOW = wastewater flow rate, gpm
ii) Power Cost
Metric
PC = TPCK x 24 x EC
where: PC = power cost, $/day
TPCK = total power for cooling tower, Kw
24 = hr/day
EC = electricity cost, $/Kw-hr
English
PC = TPCT x 0.746 x 24 x EC
where: PC = power cost, $/day
TPCT = total power for cooling tower, Hp
0.746 = Kw-hr/Hp-hr
24 = hr/day
EC = electricity cost, $/Kw-hr
Date: 4/1/83 IV.3.2.1-D13
-------
d) Fixed Costs
The fixed 0 & M components for Heat Exchangers and Cooling Towers
are listed in Table IV.3.2.1-D2 including values for the cost
basis and the unit costs [4-11].
D.4 Miscellaneous Costs
Costs for engineering, and other common plant items such as land,
piping, buildings, etc., are calculated after completion of costing
for individual units (see Section IV.3.5).
A.5 Modifications
None are applicable.
Date: 4/1/83 IV.3.2.1-D14
-------
TABLE IV.3.2.1-D2.
FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR HEAT EXCHANGERS AND COOLING
TOWERS [4-11]
HEAT EXCHANGER
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
COOLING TOWER
Element
Labor (1,2)
Supervision (I)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.10 Weeks (2.40 hrs/day)
10% Labor (0.24 hrs/day)
75% Labor Cost
0.00 Shifts
4.73% Capital
0.40% Capital
2.50% Capital
0.00 L/s
(0.00 Thou gpd)
Cost Basis
(Equivalent Unit Quantity)
0.10 Weeks (2.40 hrs/day)
10% Labor (0.24 hrs/day)
75% Labor Cost
0.00 Shifts
4.00% Capital
0.40% Capital
2.50% Capital
0.00 L/s
(0.00 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.2.1-D15
-------
I.
a.
b.
c.
II.
DESIGN FACTOR
HEAT ING/ COOL ING
SUMMARY WORK SHEET
REFERENCE: IV.3.2.1-D
(Heating or Heat Exchanger or Cooling Tower)
Heating by steam injection = no capital cost
Heat Exchanger Cooling: Surface Area = ft2
Cooling Tower:
CAPITAL COST
Cost =
Flow = gpm; NCTU =
x ( f 204.7)
Cost from curve current index
III
a.
b.
c.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
. VARIABLE 0 &
Power
Cooling water
Steam
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service
I&T:
Service Water:
YEARLY 0 & M
M
= x x 17.9
HP EC, $/Kw-hr
= x x 1440
FLOW, gpm CPG,$/gal
x x 24
STM,lb/hr CPP,$/lb
x
hr/day $/hr
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x T 365
capital, $ %/100
x x 1000
thou gpd $/thou gal
365
day/yr
$/day
.
x
sum, $/day
$
=
$/yr
UNCOSTED ITEMS
Date: 4/1/83
IV.3.2.1-D16
-------
HEATING/COOLING
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS: TECHNOLOGY =
(select: a)heating; b)heat exhanger; c)cooling tower)
1. Current Index =
2. EC: Electricity Cost =
3. CPG: cooling water =
4. CPP: steam cost =
5. Labor =
6. Supervision =
7. Overhead =
8. Lab Labor =
9. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
10. Service Water =
Capital Cost Index
$/Kw-hr
$/gallon
$/lb
$/hr
$/hr
% Labor * 100 =
$/hr
%/100
% Capital
% Capital
% Capital
% r 100 =
$/thou gal
%/100
I. DESIGN FACTOR
a. Heating - no capital cost
b. Heat Exchanger
1. MFLOW =
x 500 =
Ib/hr
FLOW, gpm
2. DUTY =
(
) x 1.1 =
BTU/hr
MFLOW, Ib/hr TIN, °F TOUT, °F
3. AREA = f [( - ) x 100] =
DUTY, BTU/hr TOUT, °F TCW, °F
MFLOW = mass wastewater flow rate, Ib/hr
TOUT,TIN = required discharge temperature and wastewater inlet temperature
TCW = cooling water temperature
4. If AREA <5000 ft2, use heat exchanger for wastewater cooling
purposes.
Date: 4/1/83
IV.3.2.1-D17
-------
c. Cooling Tower
1. Rating Factor, RF
FLOW = gpm, wastewater flow rate
2. Wet bulb temperature, WBT = °F
3. Approach = ( - ) = °F
TOUT, °F WBT, °F
4. Range = - = °F
TOUT, °F TIN, °F
5. Rating Factor Coefficients A = _ B =
(from Table IV.3.2.1-D1)
RF = x (
A RANGE B
6. Number of Cooling Tower Units, NCTU
NCTU = x
FLOW, gpm RF
II. CAPITAL COST
a. Heating - none
b. Heat Exchanger - from cost curve. Figure IV.3.2.1-D3
c. Cooling Tower -
(i) Tower Cost (Basis, July 1977 Dollars)
FLOW = thousand gpm
EQUIP = (from Figure IV.3.2.1-D4)
DPCTU = (from Figure IV.3.2.1-D5')
COST = + ( x ) =
EQUIP NCTU DPCTU
(note - adjust cost to reflect current index for heat exchanger
or cooling tower as indicated on Summary Work Sheet)
Date: 4/1/83 IV.3.2.1-D18
-------
III. VARIABLE 0 & M
a. Heating
Steam Requirements
1. MFLOW, Ib/hr = x 500 =
FLOW, gpm
2. STM = x ( - ) x 0.024 = Ib/hr
MFLOW, Ib/hr TOUT, °F TIN, °F
b. Heat Exchanger
1. Power Requirements
TPHE = ( x 0.00488) - 0.141 = Hp
AREA, ft2
2. Cooling Water Required
CW = gpm
FLOW
c. Cooling Tower
(i) Power Requirements
TPCT = ( x 0.097) - 21.0 = Hp
FLOW, gpm
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83 IV.3.2.1-D19
-------
IV.3.2.3 NITRIFICATION/DENITRIFICATION
Introduction
Nitrification/denitrification represents two biological treatment
processes, with the first representing the conversion of ammonia
to nitrate (through the intermediate formation of nitrite) and
the second process representing the conversion of nitrate to the
free gas nitrogen. The processes are described in more detail in
Volume III of the Treatability Manual, Section III.3.2.3. Cost-
ing methodologies and cost data for industrial wastewater treat-
ment applications are presented below.
IV.3.2.3-A. Nitrification
A 1. Basis of Design
The cost estimate is for the biological conversion of ammonia to
nitrate (nitrification). A system of the type considered is
represented in Figure IV.3.2.3-A1. The capital cost factor is the
basin volume required for the process. The system is assumed to
convert 95 percent of influent ammonia to nitrate. The hydraulic
detention time required to achieve this removal is computed
assuming a basin mixed liquor volatile suspended solids concen-
tration of 2,000 mg/L and a temperature-dependent reaction rate.
The basin pH must be maintained between 7.0 and 9.0, with lime
added as required to replace alkalinity destroyed by the reaction
or not available in the influent. Nutrients may also be re-
quired. Aeration capital cost and operating cost are computed
as shown in IV.3.2.1-B based on the horsepower required.
a) Source
This cost estimate method was derived from the BAT Effluent
Limitations Guidelines engineering study for the Organic
Chemicals/Plastics and Synthetic Fibers Industries.
b) Required Input Data
Wastewater flow L/s (mgd)
Wastewater characteristics
treatable pollutants (mg/L) [ammonia nitrogen, organic
nitrogen, total Kjeldahl nitrogen (TKN)], alkalinity,
(mg/L as CaCO3), temperature (°C), pH, BOD5 (mg/L),
phosphate (mg/L)
c) Limitations
This process is not considered to be applicable if influent TKN
is less than 10 mg/L.
Date: 4/1/83 IV.3.2.3-A1
-------
§
H
M
£3
g
M
Q
8
W
u
§
PL.
ro
•
CM
O
Date: 4/1/83
IV.3.2.3-A2
-------
d) Pretreatment
The following conditions require pretreatment as indicated [4-1]:
i) If influent pH >9.0 or pH <7.0, then neutralization is
required upstream of nitrification.
ii) If influent temperature >38°C or <10°C, then heat trans-
fer (cooling or heating) is required upstream of
nitrification.
iii) If influent BOD >125 mg/L, then activated sludge treat-
ment is required upstream of nitrification.
iv) If influent BOD to TKN ratio >3.0, then activated
sludge treatment is required upstream of nitrification.
v) If influent TDS >10/000 mg/L, then ion exchange is re-
quired upstream of nitrification.
vi) If influent ammonia plus organic nitrogen >2/000 mg/L,
then ammonia stripping is required upstream of nitrifi-
cation.
e) Design Equation
The cost factor for the nitrification process is the required
basin volume. The basin volume may be computed as follows:
Metric
BV = FLOW x 86400 x DT
where: BV = bed volume, liters
FLOW = influent flow, L/s
86400 = s/day
DT = detention time, days
= No - Ne
Qn x Xv
No = influent ammonia plus organic nitrogen, mg/L
Ne = effluent ammonia plus organic nitrogen, mg/L
Xn = MLVSS (default value 2000 mg/L)
Qn = nitrification rate (16 to 38°C), day ~*
English
BV = FLOW x DT
where: BV = basin volume, million gallons
FLOW = influent flow, mgd
Date: 4/1/83 IV.3.2.3-A3
-------
DT = detention time, days
= No - Ne
Qn'x Xv
No = influent ammonia plus organic nitrogen, mg/L
Ne = effluent ammonia plus organic nitrogen, mg/L
Xv = MLVSS (default value 2000 mg/L)
Qn = nitrification rate (16 to 38°C), day"1
The effluent ammonia plus organic nitrogen concentration is esti-
mated based on a 95% reduction or a minimum effluent concentration
of 3 mg/L. The nitrification rate varies significantly with the
wastewater temperature. The nitrification rate may be calculated
as a percentage of the rate at 30°C as follows [4-1]:
Qn = 0.3 x (0.036 x T - 0.094)
where: 0.3 = nitrification rate at 30°C, day"1
T = wastewater temperature in the basin, °C
Requirements for aeration, nutrient addition, lime addition, and
byproducts handling must be calculated separately. These are
discussed in Sections A 2,d, Associated Cost and A 4, Miscel-
laneous Costs.
f) Subsequent Treatment
i) Clarification will be required for solids separation.
ii) Denitrification may be required for nitrate removal.
A 2. Capital Costs
The nitrification process capital cost is based on the basin
volume required to achieve the desired hydraulic detention time.
The capital cost curve for the basin is presented in Figure
IV.3.2.3-A2. Capital costs for aeration, nutrient addition, lime
addition, and sludge handling must be calculated separately.
Costs estimated using these curves must be adjusted to a current
value using an appropriate current cost index.
a) Cost Data
Items included in the capital cost estimates for the nitrifi-
cation basin are as follows [4-2]:
Splitter box
Nitrification basin, dual chamber (concrete up to 3.78
million liters (1.0 mil gal), or earthen basin with
membrane liner >3.78 mil liters (>1.0 mil gal))
Sludge recycle pumps (three)
Piping
Instrumentation
Date: 4/1/83
IV.3.2.3-A4
-------
b) Capital Cost Curves
Curve - see Figure IV.3.2.3-A2
- Cost (thousands of dollars) vs. basin volume,
(million liters or million gallons).
- Curve basis, cost estimates on five systems with
basin volumes of 0.148, 0.742, 3.72, 7.42, and
14.9 million liters (0.039, 0.196, 0.982, 1.96, and
3.93 million gallons) (basin volumes were based on
a detention time of 4.7 hours for flow rates of
8.76, 43.8, 219, 438, and 876 L/s (0.2, 1.0, 5.0,
10, and 20 mgd)).
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plarit Index = 204.7
d) Associated Costs
The capital costs in Figure IV.3.2.3-A2 include only the basin
structures and piping. The complete cost estimate for a nitri-
fication system requires that capital costs also be developed for
aeration, nutrient (phosphorus) addition, lime addition, and
byproduct treatment.
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component associated with the basin is power for pumps.
In addition, variable costs will include phosphorus for nutrient
requirements (if needed), lime for alkalinity control, aeration
horsepower, and byproduct treatment (discussed in Section A 4,
Miscellaneous Costs). Fixed operating costs include labor,
supervision, overhead, laboratory labor, maintenance, services,
insurance and taxes, and service water. All fixed and variable
operating costs should be adjusted to current levels using an
appropriate index or unit cost factor.
a) Variable Cost
i) Power Requirements - pumps; aeration equipment not
included (see Section IV.3.2.1-B, Aeration). This
equation was developed using regression analysis pro-
cedures [4-1].
Metric
KW = (9.97 x VOL) + 0.586
where: KW = power required, kilowatts
VOL = basin volume, million liters
Date: 4/1/83 IV.3.2.3-A5
-------
BASIN VOLUME, MILLION LITERS
0 3.8 7.6
1000
11
15
BASIN VOLUME, MILLION GALLONS
FIGURE IV.3.2.3-A2.
CAPITAL COST ESTIMATE FOR
NITRIFICATION [4-10J
Date: 4/1/83
IV.3.2.3-A6
-------
English
HP = 50.6 x VOL + 0.786
where: HP = power required, Hp
VOL = basin volume, million gallons
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power, KW
24 = hours/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = power, Hp
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.2.3-A1, including values for the cost basis and the
unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5). Accounts should be
kept of the quantities of miscellaneous items required for use in
subsequent costing procedures for aeration, nutrient addition,
lime addition, and byproduct (sludge) treatment.
a) Land
The amount of land required for nitrification systems is estimated
to be 120% of the surface area of the basin as follows:
Metric
LAND = VOL x 1.2 x 1000 * 3.05
Date: 4/1/83 IV.3.2.3-A7
-------
TABLE IV.3.2.3-A1. FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR NITRIFICATION [4-11]
Element
Labor (1)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.30 Weeks (7.20 hrs/day)
10% Labor (0.72 hrs/day)
75% Labor Cost
0.20 Shifts (1.14 hrs/day)
1.36% Capital
0.40% Capital
2.50% Capital
0.08 Thou L
(1.72 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$0.13/Thou L
($0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.2.3-A8
-------
where: LAND = land requirement, m2
VOL = basin volume, million liters
1000 = conversion, m3/million L
3.05 = basin depth, m
English
where:
LAND = VOL x (1.2 x 10s) * (10 x 7.48)
LAND
VOL
10
7.48
b) Aeration
land requirement, ft2
basin volume, million gallons
basin depth, ft
conversion factor, gal/ft3
The oxygen transfer required to maintain the system as designed
may be estimated as follows [4-1]. This information is then used
in the design of an appropriate aeration system (see Section
IV.3.2.1-B).
Metric
Na = [0.7 x 0.086 x FLOW x BOD x 3600]
+ [BP x 2000 x BV x 0.086]
+ [4.6 x (NH3 + ORN) x 0.086 x FLOW x 3600:
where: Na
0.7
0.086
FLOW
BOD
BP
BV
2000
4.6
NH3
ORN
3600
86400
English
Na =
required amount of oxygen transfer, Kg/hr
Kg O2/Kg BOD removed
conversion factor
influent wastewater flow, L/s
average BOD, mg/L
0.014 - [0.004 x BV * (FLOW x 86400)]
basin volume, million liters
MLVSS concentration, mg/L
Kg 02/Kg ammonia plus organic nitrogen
average influent ammonia nitrogen, mg/L
average influent organic nitrogen, mg/L
s/hr
s/day
[(0.7 x 8.34 x FLOW x BOD) * 24]
+ [BP x 2000 x BV x 8.34]
+ [4.6 x (NH3 + ORN) x 8.34 x FLOW * 24]
where:
Na
0.7
8.34
FLOW
BOD
required amount of oxygen transfer,
Ib 02/lb BOD removed
conversion factor
influent wastewater flow, mgd
average BOD, mg/L
Ib/hr
Date: 4/1/83
IV.3.2.3-A9
-------
BP = 0.014 - (0.004 x BV r FLOW)
BV = basin volume, million gallons
2000 = MLVSS concentration, mg/L
4.6 = Ib 02/lb ammonia plus organic nitrogen
NH3 = average influent ammonia nitrogen, mg/L
ORN = average influent organic nitrogen, mg/L
24 = hr/day
c) Nutrient (Phosphorus) Addition
Phosphorus addition is only required if the concentration in the
influent to nitrification is less than the required concentration
as calculated below.
P04 = 0.01 x [BOD + 0.167 x (ORN + NH3)]
where: P04
0.01
BOD
0.167
ORN
NH3
phosphate concentration required, mg/L
ratio of phosphorus to BOD
influent BOD5/ mg/L
equivalent BOD demand of the nitrogen compounds
influent organic nitrogen, mg/L
influent ammonia nitrogen, mg/L
The capital and operating cost to provide this nutrient for the
whole plant can be developed in Section IV.3.2.1-C, Nutrient
Addition.
d) Lime Addition
Lime is required to maintain alkalinity in the basin at a minimum
of 200 mg/L. The amount of lime required to provide adequate
influent alkalinity and replace that destroyed during nitrifica-
tion may be estimated as follows:
Metric
where:
LIME = 0.086 x FLOW x [0.74 x (200 - ALK) + 5.4 x
(No - Ne)]
LIME = lime addition rate, Kg/hr
FLOW = influent flow rate, L/s
0.74 = ratio of lime to CaCO3/ equivalent weights
200 = desired alkalinity level as CaC03/ mg/L
ALK = influent alkalinity as CaC03/ mg/L
5.4 = ratio of hydrated lime to nitrogen removed
No = influent ammonia plus organic nitrogen, mg/L
Ne = effluent ammonia plus organic nitrogen, mg/L
English
LIME =
8.34
Ne)]
FLOW x [0.74 x (200 - ALK) + 5.4 x (No -
Date: 4/1/83
IV.3.2.3-A10
-------
where: LIME = lime addition rate, Ib/day
FLOW = influent flow rate, mgd
0.74 = ratio of lime to CaCO3/ equivalent weights
200 = desired alkalinity level as CaC03, mg/L
ALK = influent alkalinity as CaCO3/ mg/L
5.4 = ratio of hydrated lime to nitrogen removed
No = influent ammonia plus organic nitrogen, mg/L
Ne = effluent ammonia plus organic nitrogen, mg/L
The design and cost of lime addition systems is based on the
needs of the entire plant rather than for individual unit proces-
ses. Lime costs are determined after completion of design of all
unit processes (see Lime Handling, Section IV.3.1.13-C).
e) Sludge
The quantity of waste biological solids generated by the nitrifi-
cation process are calculated for use in the subsequent design
and costing of byproduct handling facilities. The amount of
sludge generated by the nitrification process may be estimated as
follows [4-1]:
Metric
where:
SLDG = 0.086 x FLOW x [0.05 x (NH3 + ORN)
+ (0.3 x BOD)]
SLDG = waste sludge generated, Kg/day
0.086 = conversion factor
FLOW = influent flow rate, L/s
0.05 = Kg sludge generated/Kg nitrogen
NH3 = influent ammonia nitrogen, mg/L
ORN = influent organic nitrogen, mg/L
0.3 = Kg sludge generated/Kg BOD
BOD = influent BOD to nitrification unit, mg/L
English
where:
SLDG = 8.34 x FLOW x [0.05 x (NH3 + ORN) + (0.3 x BOD)]
SLDG = waste sludge generated, Ib/day
8.34 = conversion factor
FLOW = influent flow rate, mgd
0.05 = Ib sludge generated/lb nitrogen
NH3 = influent ammonia nitrogen, mg/L
ORN = influent organic nitrogen, mg/L
0.3 = Ib sludge generated/lb BOD
BOD = influent BOD to nitrification unit, mg/L
A 5. Modifications
None required.
Date: 4/1/83
IV.3.2.3-A11
-------
I.
a.
II.
Cost
III.
a.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
c.
e.
NITRIFICATION
SUMMARY WORK SHEET
REFERENCE: IV.3.2.3-A
DESIGN FACTOR CAPITAL
Basin Volume = million gallons
BV
CAPITAL COST
x ( * 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
FIXED 0 & M
Labor: x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor: x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
$/day
—
.
.
.
=
x
day/yr sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Land = ft2 b. Oxygen =
Ib/hr
LAND Na
Nutrient = Ib/day d. Lime = Ib/day
P04
Biological Sludge = Ib/day
SLDG
LIME
Date: 4/1/83
IV.3.2.3-A12
-------
NITRIFICATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. Labor =
4. Supervision =
5. Overhead =
6. Lab Labor =
7. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
8. Service Water =
Capital Cost Index
$/Kw-hr
$/hr
$/hr
% Labor r 100 =
$/hr
%/100
% Capital
% Capital
% Capital
f 100 =
%/100
$/1000 gal
I. DESIGN FACTOR
a. Wastewater Characteristics
Influent Flow =
Influent Alkalinity =
Wastewater temperature =
Influent Ammonia-Nitrogen =
Influent Organic-Nitrogen =
Influent Phosphorus =
Influent BOD5 =
b. Influent Ammonia + Organic Nitrogen
No = +
mgd (FLOW)
mg/L (ALK)
°C (T)
mg/L (NHO)
mg/L (ORN)
mg/L (P04)
mg/L (BOD)
Influent Ammonia- Influent Organic-
Nitrogen (NHO), mg/L Nitrogen (ORN), mg/L
c. Effluent Ammonia + Organic Nitrogen
Ne = 0.95 x
mg/L
No, mg/L
If Ne < 3.0 mg/L, then use Ne = 3.0 mg/L
mg/L
Date: 4/1/83
IV.3.2.3-13
-------
d. Determine nitrification rate
Qn = 0.30 x (0.036 x - 0.094) = day'1
T, °C
If T > 30°C, use Qn = 0.30 day"1
e. Hydraulic Detention Time
DT = ( - ) T ( x 2000) = days
No,mg/L Ne,mg/L Qn, day"1
f. Basin Volume
BV = x = million gallons
FLOW, mgd DT, days
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = (50.6 x ) + 0.786 = Hp
BV, million gallons
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Land Requirements
LAND = ( x 1.2 x 106) T (74.8) = ft2
BV, mil gal
b. Aeration (oxygen) Requirements
Na = {0.243 x x }
FLOW,mgd BOD,mg/L
+ {[0.014 - (0.004 x T )] x x 16700}
BV,mil gal FLOW,mgd BV,mil gal
+ {1.60 x ( + ) x } = Ib/hr
NHO, mg/L ORN, mg/L FLOW, mgd
Date: 4/1/83 IV.3.2.3-A14
-------
c. Nutrient (Phosphorus) Requirements
P04 = 0.01 x [ + 0.167 x ( + )]
BOD,mg/L ORN,mg/L NHO,mg/L
= mg/L
d. Lime Requirements
LIME = x 8.34 x [0.74 x (200 - )
FLOW,mgd ALK,mg/L
+ 5.4 x ( - )] = Ib/day
No, mg/L Ne, mg/L
e. Waste Biological Sludge Production
SLDG = x 8.34 x [0.05 x ( + ) +
FLOW, mgd NH3, mg/L ORN mg/L
(0.3 x ) = Ib/day
BOD mg/L
Date: 4/1/83 IV.3.2.3-A 15
-------
IV.3.2.3-B. Denitrification
B 1. Basis of Design
This cost estimate is for the biological conversion of nitrate to
nitrogen gas (denitrification). A system of the type considered
is represented in Figure IV.3.2.3-B1. The cost factor is the
basin volume required for the process. The system is based on a
continuous-flow stirred-tank denitrification basin with an asso-
ciated aerated stabilization basin for stripping gaseous CO2 and
N2 byproducts. It is assumed that an effluent organic plus
nitrate and nitrite nitrogen concentration of 2.0 mg/L can be
attained. The hydraulic detention time required to achieve the
assumed or target effluent concentration must be calculated.
Methanol is required as the carbon source for this process, at a
ratio of 4:1 methanol to nitrate/nitrite nitrogen.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemical/Plastics and Synthetic Fibers Industries
[4-2]. The method for developing the design factor is based
on assumptions and procedures in the Contractor Developed
Design and Cost Model [4-1].
b) Required Input Data
Wastewater flow L/s (mgd)
Wastewater characteristics
nitrate plus nitrite nitrogen (mg/L), temperature (°C),
pH, total dissolved solids (mg/L), phosphorus (mg/L)
c) Limitations
Process is not applicable if influent nitrate plus nitrite nitro-
gen is less than 2 mg/L.
d) Pretreatment
Pretreatment should be provided as indicated for the following
conditions:
i) If influent pH >8.0 or pH <6.0, then neutralization
is required upstream of denitrification.
ii) If influent temperature >38°C or <10°C,
then heat transfer (cooling or heating) is required up-
stream of denitrification.
iii) If total dissolved solids >10,000 mg/L, then ion ex-
change is required upstream of denitrification.
Date: 4/1/83 IV.3.2.3-B1
-------
O
H
E-i
<
U
H
fe
H
W
Q
O
fa
s
-------
e) Design Equation
The cost factor for the denitrification process is the required
basin volume. The basin volume is computed as follows:
Metric
VOL = FLOW x DT x 86400
where: VOL = denitrification basin volume, liters
FLOW = influent flow, L/s
DT = detention time, days
= Do-De
y x Xv
Do = influent N03-N + NO2-N, mg/L
De = effluent N03-N + N02-N, mg/L
Xv = MLVSS, mg/L
V = denitrification rate, day"1
= 0.25 x [(0.0416 x T) - 0.244], day'1
T = temperature, °C (T <30°C)
86400 = seconds per day
English
VOL = FLOW x DT
where: VOL = denitrification basin volume, million gallons
FLOW = influent flow, mgd
DT = detention time, days
= Do - De
V x Xv
Do = influent N03-N + NO2-N, mg/L
De = effluent N03-N + N02-N, mg/L
Xv = MLVSS, mg/L,
V = denitrification rate, day"1
= 0.25 x [(0.0416 x T) - 0.244], day"1
T = temperature, °C (T <30°C)
The estimated effluent quality (2 mg/L organic plus nitrate and
nitrite nitrogen) is dependent on certain assumptions regarding
temperature, pH, and operating conditions. Influent pH is
assumed to be 6.0 to 8.0 units, dissolved oxygen <0.1 mg/L, TDS
<10,000 mg/L, and methanol feed 4 Kg CH3OH/Kg N03-N + N02-N
(4 Ib CH3OH/lb N03-N + N02-N).
Requirements for land, nutrient (phosphorus) addition, and by-
products (sludge) handling must be costed separately. These
requirements are discussed in Section B 4, Miscellaneous Costs.
Date: 4/1/83 IV.3.2.3*B3
-------
f) Subsequent Treatment
i) Clarification will be required for solids separation.
ii) Byproduct treatment is required for excess biological
sludge production.
B 2. Capital Costs
The denitrification capital cost is based on the denitrification
basin volume required to achieve the desired hydraulic detention
time. The capital cost curve is presented in Figure IV.3.2.3-B2.
Costs estimated using this curve must be adjusted to a current
value using an appropriate current cost index.
a) Cost Data
The items included in the capital cost estimates include [4-2]:
Flow splitter box
Denitrification basin (concrete, except at 11.4 mill
liters (3.0 mil gal), where denitrification basin is
an earthen basin with membrane liner)
Stabilization basin (attached to denitrification basin,
sized for 0.5 hour hydraulic detention).
Mixers (six, sized for 0.013 Kw/1000 L (0.067 Hp/1000 gal))
Aerator, fixed mounted (one to six, sized for 0.02 Kw/1000 L
(0.1 Hp/1000 gal) stabilization basin volume)
Methanol storage tank (two week supply)
Methanol feed pumps (two, variable speed)
Sulfuric acid storage tank
Acid feed pumps (two)
Piping
Instrumentation
b) Capital Cost Curves
Curve - see Figure IV.3.2.3-B2
- Cost (thousands of dollars) vs. basin volume (million
liters or million gallons)
- Curve basis, cost estimates on four denitrification
systems having a denitrification basin volume of
0.114, 0.568, 2.84, and 11.4 million liters (0.03,
0.15, 0.75, and 3.0 million gallons). These
correspond to flows of 8.76, 43.8, 219, and 876 L/s
(0.2, 1.0, 5.0, and 20 mgd).
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
Date: 4/1/83 IV.3.2.3-B4
-------
BA8M VOLUME. MILLION LITERS
BASIN VOLUME. MILLION GALLONS
FIGURE IV.3.2.3-B2. CAPITAL COST ESTIMATE FOB
DENITRIFICATION [4-10]
Date: 4/1/83
IV.3.2.3-B5
-------
B 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable components include power for the mixers, aerator, and
pumps; and methanol costs. In addition, variable cost will
include phosphorus for nutrient requirements (if needed) and
byproduct treatment (discussed in B 4, Miscellaneous Costs).
Fixed operating costs include labor, supervision, overhead,
laboratory labor, maintenance, services, insurance and taxes, and
service water. All fixed and variable operating costs should be
adjusted to current levels using an appropriate index or unit
cost factor.
a) Variable Costs
i) Power Requirements - Pumps, mixers, aerators. The
following equations were developed using regression
analysis procedures [4-1].
Metric
KW = (23.4 x VOL) + 0.586
where: KW = power, kilowatts
VOL = basin volume, million liters
English
HP = (119 x VOL) + 0.786
where: HP = power, Hp
VOL = basin volume, million gallons
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost, $/KW-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
Date: 4/1/83 IV.3.2.3-B6
-------
iii) Methanol Requirements
Metric
MF = 4 x Do x 0.086 x FLOW
where: MF = methanol feed rate, Kg/day
4 = methanol to nitrogen feed ratio
Do = influent N02-N + N03-N, mg/L
0.086 = conversion factor
FLOW = influent flow, L/s
English
MF = 4 x Do x 8.34 x FLOW
where: MF = methanol feed rate, Ib/day
4 = methanol to nitrogen feed ratio
Do = influent N02-N + N03-N, mg/L
8.34 = conversion factor
FLOW = influent flow, mgd
s>
iv) Methanol Cost
MC = MF x CC
where: MC = methanol feed cost, $/day
MF = methanol feed rate, Kg/day or Ib/day
CC = methanol chemical cost, $/Kg or $/lb
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.2.3-B1, including the cost basis and unit costs [4-11].
B 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5). Accounts should be
kept of the quantities of miscellaneous items required for use
in subsequent costing procedures.
a) Land
The land requirements for the basin and associated equipment are
estimated to be 120% of the basin surface area [4-1].
Metric
LAND = VOL x (1.2 x 106) * (3.048 x 1000)
Date: 4/1/83 IV.3.2.3-B7
-------
where: LAND = land requirement, m2
VOL = volume, million liters
3.048 = basin depth, m
1000 = conversion L/m3
English
LAND = VOL x (1.2 x 106) * (10 x 7.48)
where: LAND = land requirement, ft2
VOL = basin volume, million gallons
10 = basin depth, ft
7.48 = conversion factor, gal/ft3
b) Nutrient (Phosphorus) Addition
Phosphorus addition is only required if the concentration in the
influent to denitrification is less than the required concentra-
tion.
PO4 = 0.0233 x DO
where: P04 = phosphate concentration required, mg/L
0.0233 = required ratio of phosphate to N02-N + N03-N
DO = influent N02-N + N03-N, mg/L
The capital and operating cost to provide this nutrient can be
developed in Section IV.3.2.1-C, Nutrient Addition.
c) Sludge Generation
Waste biological sludge that will require treatment and/or dis-
posal is computed for use in subsequent design and costing of
byproduct handling facilities:
Metric
SLDG = 0.7 x (Do - De) x 0.086 x FLOW
where: SLDG = waste sludge generated, Kg/day
0.7 = Kg sludge generated/Kg NO2-N + N03-N removed
Do = influent N02-N + NO3-N, mg/L
De = effluent N02-N + NO3-N, mg/L
0.086 = conversion factor
FLOW = influent flow, L/s
English
SLDG = 0.7 x (Do - De) x 8.34 x FLOW
Date: 4/1/83 IV.3.2.3-B8
-------
where: SLDG = waste sludge generated, Ib/day
0.7 = Ib sludge generated/lb N02-N + N03-N removed
Do = influent N02-N + N03-N, mg/L
De = effluent N02-N + N03-N, mg/L
8.34 = conversion factor
FLOW = influent flow, mgd
B 5. Modifications
None required.
Date: 4/1/83 IV.3.2.3-B9
-------
TABLE IV.3.2.3-B1. FIXED O & M COST BASIS AND UNIT COST
FACTORS FOR DENITRIFICATION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.30 Weeks (7.20 hr/day)
10% Labor (0.72 hr/day)
75% Labor Cost
0.20 Shifts (1.14 hr/day)
2.68% Capital
0.40% Capital
2.50% Capital
0.075 L/s
(1.72 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.2.3-B10
-------
I.
a.
II.
DESIGN FACTOR
Basin Volume =
CAPITAL COST
Cost =
DENITRIFICATION
SUMMARY WORK SHEET
REFERENCE: IV.3.2.3-B
CAPITAL
million gallons
VOL
x ( * 204.7)
Cost from curve current index
III
a.
b.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
b.
c.
. VARIABLE 0 &
Power =
Methanol =
MF,
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor :
Maint, Service,
I&T:
Service Water:
YEARLY 0 & M
UNCOSTED ITEMS
Land =
M
x x 17.9
Hp EC, $/Kw-hr
x
Ib/day CC,$/lb
x
hr/day $/hr
x
hr/day $/hr
x
Labor, $/day %/100
X
hr/day $/hr
x f 365
capital, $ %/100 day/yr
x
thou gpd $/thou gal
365
$/day
—
.
.
X
day/yr sum, $/day
$
0 & M
$/yr
ft2
Nutrient (phosphorous) = mg/L
Biological Sludge Produced = Ib/day
Date: 4/1/83
IV.3.2.3-B11
-------
DENITRIFICATION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. MC: Methanol Feed Cost = $/lb
4. Labor = $/hr
5. Supervision = $/hr
6. Overhead = % Labor r 100 = %/100
7. Lab Labor = $/hr
8. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = * 100 = %/100
9. Service Water = $/thou gal
I. DESIGN FACTOR
a. Wastewater Characteristics
Influent Flow = mgd (FLOW)
Influent pH = 6.0 < < 8.0
Design Wastewater Temperature = 10°C < < 38°C (T)
T
Influent nitrate plus nitrite cone. = mg/L (DO)
Influent total dissolved solids = mg/L (TDS)
Effluent nitrate plus nitrite cone. = mg/L (DE) (2.0 mg/L
minimum level)
*
b. Denitrification Rate
1. If T >30°C, vi = 0.25
2. If T <30°C, v = 0.25 x [(0.0416 x ) - 0.244] = day'1
T, °C
c. Hydraulic Detention Time
DT = ( - ) f ( x 2000) = days
DO,mg/L DE, mg/L y, day"1
Date: 4/1/83 IV.3.2.3-B12
-------
d. Basin Volume
VOL =
FLOW, mgd DT, days
million gallons
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = (119 x
) + 0.786 =
VOL, mil gal
b. Methanol Requirements
MF = 33.4 x >
DO, mg/L
horsepower
Ib/day
FLOW, mgd
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Land Requirements (10 foot depth)
LAND = (
x 16,000) =
ft2
VOL, mil gal
b. Nutrient (Phosphorus) Requirements
P04 = 0.0233 x
DO, mg/L
mg/L
c. Sludge Produced
SLDG = 0.7 x (
) x 8.34 x
DO, mg/L DE, mg/L
FLOW,mgd
Ib/day
Date: 4/1/83
IV.3.2.3-B13
-------
IV.3.4.1 GRAVITY THICKENING
Introduction
Thickening operations are intended to reduce the volume of sludge
to be further processed and normally constitute intermediate
steps precedina dewatering or stabilization. The most common
methods of sluage thickening are the gravity thickening and
dissolved air flotation (DAF) thickening. For further details on
thickening processes, refer to Volume III, Section III.4.1 of the
Treatability Manual. Costing methodologies and cost data for
this technology are presented below.
IV.3.4.1-A. Gravity Thickening
A 1. Basis of Design
This is a presentation of design factors and costs for gravity
thickening of wastewater sludges. Gravity thickening is basic-
ally a sedimentation process in which solids are settled to the
thickener bottom, raked to a sludge hopper, and are periodically
removed and discharged to a dewatering process. A system of the
type considered is illustrated in Figure IV.3.4.1-A1. The super-
natant or overflow, containing some solids (500 mg/L assumed) and
probably a high BOD, is returned to the plant for further treat-
ment.
Determination of the primary design factor, thickener surface
area, is based on surface solids loading in Kg/m2/day (Ib/ft2/day)
Typical solids loadings vary depending on the type of sludge
being thickened. For combinations of sludge types, a weighted
average approach is used to define the solids loading to the
thickener. Typical values for the solids loading rate, influent
solids concentration, and expected underflow solids concentration
of each sludge type are shown in Table IV.3.4.1-A1.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
b) Required Input Data
Type of sludge
Amount of each type of sludge to be thickened Kg/day (Ib/day)
Total quantity of solids to be thickened Kg/day (Ib/day)
c) Limitations
None specified.
Date: 4/1/83 IV.3.4.1-A1
-------
bJ
CO
o =>
"3
~
<=> >-
2 *>
3
3 Q
* Z
H
W
«
D
O
H
Date: 4/1/83
IV.3.4.1-A2
-------
TABLE IV.3.4.1-A1. VALUES OF SOLIDS LOADING RATE, INFLUENT SOLIDS
CONCENTRATION, AND UNDERFLOW SOLIDS CONCENTRATION
[4-1].
Expected Expected
Solids Influent Solids Underflow
Sludge Loading Rate Concentration Concentration
Number Sludge Type (Ib/ft2/day)(Kg/m2/day) (%) (%)
11 Lime Precipitate 40 195 10.0 15
12 Aluminum Precipitate 24 117 1.5 10
13 Iron Precipitate 15 73 3.0 30
14 Sulfide Precipitate 15 73 3.0 10
50 Primary Solids 20 98 3.0 9
51 Scrubber Sludge 20 98 3.0 9
*60 Waste Activated Sludge 5 24 1.0 3
65 Digested Sludge 5 24 1.5 3
80 Filter Backwash 20 98 3.0 9
(Inorganic)
*90 Filter Backwash 5 24 1.0 3
(Organic)
*If digested sludge (65) appears as an input, waste activated sludge (60)
and organic filter backwash (90) are set to zero.
Date: 4/1/83 IV.3.4.1-A3
-------
d) Pretreatment
None specified.
e) Design Equation
The total thickener surface area is calculated by summing the
individual area required for each sludge type based on the solids
loading rates from Table IV.3.4.1-A1.
Metric
AREA = E [Q(i) * LOADING (i)]
where: AREA
Q (D
LOADING (i)
total area requirement for thickener, m2
quantity of sludge type (i), Kg/day
solids loading rate for sludge type (i),
Kg/m2/day (Table IV.3.4.1-A1)
English
AREA = Z[Q(i) * LOADING(i)]
where: AREA
Q (D
LOADING (i)
total area requirement for thickening,
quantity of sludge type (i), Ibs/day
solids loading rate for sludge type (i),
Ib/ft2/day (Table IV.3.4.1-A1).
ft2
f) Subsequent Treatment
Further sludge dewatering such as vacuum or pressure filtration
generally is required prior to final diposal of sludge. Thickener
overflow also is returned to the plant for treatment.
A 2. Capital Costs
The cost factor for gravity thickening is the surface area of the
unit. This parameter is the independent variable of the capital
cost curve for this unit process (Figure IV.3.4.1-A2). Costs
estimated using this curve must be adjusted to a current value
using an appropriate cost index.
a) Cost Data
Items included in the capital cost curve estimates are as follows
[4-2]:
Thickening tank, steel
Thickener mechanism, picket type except hopper bottom for
smallest 2.13 m dia (7 ft. dia) unit
Pumps, progressive cavity (2)
Date: 4/1/83
IV.3.4.1-A4
-------
Piping
Instrumentation
b) Capital Cost Curves
Curve - Figure IV.3.4.1-A2.
- Cost (hundred thousand dollars) vs total surface area
(hundred square meters or hundred square feet).
- Curve basis, cost estimates for the gravity thick-
ening process based on total surface area of
gravity thickeners of 2.13, 3.05, 4.57, 9.14, 12.2,
and 18.3 m (7, 10, 15, 30, 40, and 60 feet) in
diameter with surface areas of 3.53, 7.34, 16.7, 66,
117, and 263 m2 (38, 79, 180, 710, 1260, and 2830
ft2) respectively.
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component includes power, while the fixed component
includes labor, supervision, overhead, laboratory labor, mainte-
nance, services, insurance and taxes, and service water. All
fixed and variable operating costs should be adjusted to current
levels using an appropriate index or unit cost factor.
a) Variable Cost
i) Power Requirements - mechanism and pump
Metric
KW = (0.02 x AREA) + 0.556
where: KW = power required, kilowatts
AREA = total required thickener surface area, m2
English
HP = (0.00248 x AREA) + 0.746
where: HP = power required, Hp
AREA = total required thickener surface area, ft2
Date: 4/1/83 IV.3.4.1-A5
-------
TOTAL SURFACE AREA. HUNDRED SQUARE METERS
46.46 92.0 130.4 1S6.S 232.2
278.7
J
— 1 A.
o 3
o
o
z
<
99
^ 4f
O
HI
OE
O
Z
3
X
•
£ i-
i
j
i
T
'
>
)
'
r1
/
r
/
•
(
•*
M
^
a
^
^
x
1
,
•1
s
4
.
S
4
1
S
A
X
M
X
)
x
k
4
r
^l
^
X
1
^
0
^
a
•*
0
ix
^
**•
X
*.
X1
^
2
x
Oi
x«
[>(
X1
J
^
x"
^
^
x-
x
2
^
'6
0<
0
^
J
^
t*
jn
•
i
n
SO
TOTAt SURFACE AREA. HUNDRED SQUARE FEET
FIGURE IV.3.4.1-A2. CAPITAL COST ESTIMATE FOR GRAVITY
THICKENING [4-10]
Date: 4/1/83
IV.3.4.1-A6
-------
ii) Power Cost
Metric
PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power required, kilowatts
24 = hr/day
EC = electricity cost, $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = power required, Hp
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
b) Fixed Costs
The fixed 0 & M components for this technology are listed in
Table IV.3.4.1-A2, including the cost basis and unit costs [4-11].
A 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as
piping and buildings, are calculated after the completion of
costing for individual units (Section IV.3.5).
A 5. Modifications
None necessary.
Date: 4/1/83 IV.3.4.1-A7
-------
TABLE IV.3.4.1-A2. FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR GRAVITY THICKENING [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.15 Weeks (3.60 hrs/day)
10% Labor (0.36 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
7.37% Capital
0.40% Capital
2.50% Capital
0.08 L/s
(1.83 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.4.1-A8
-------
I.
GRAVITY THICKENING
SUMMARY WORK SHEET
REFERENCE: IV. 3. 4.1 -A
DESIGN FACTOR CAPITAL
Total Thickener Surface Area = ft2
II.
CAPITAL COST
Cost = x ( f 204.7)
III
Cost from curve current index
. VARIABLE 0 & M
Power = x x 17.9
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
Hp EC, $/Kw-hr
FIXED 0 & M
Labor: x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor: x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
$/day
—
.
.
.
X
day/yr sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Date: 4/1/83
IV.3.4.1-A9
-------
GRAVITY THICKENING
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Labor = $/hr
4. Supervision = $/hr
5. Overhead = % Labor * %/100
6. Lab Labor = $/hr
7. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = HZZZZ * 10° = %/100
6. Service Water = $/thou gal
I. DESIGN FACTOR
a. See Work Table 1.
1. Enter quantity of each sludge type in Column A.
2. Divide quantity of each sludge (from Column A) by corresponding
solids loading rate (from Column B) and enter the results in
Column C.
3. Sum Column C to get the total thickener surface area.
AREA = ft2
Sum Column C
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = (0.00248 x ) + 0.746 = Hp
AREA, ft2
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83 IV.3.4.1-A10
-------
o
<
u
cc
o
u_
cc
CO
cc
z
u
o
X
o
o
a:
CO
CO
o
§
<
o
LJ
_J
CO
I-
ce
o
CO
\
-p
II 4-
CO U
CO (A
CO
P
co —
cc >
CO
wo
c ^.
«—» 4J
•Od-
CO
0 0
-1
(-'
0)
0
T3
3
_
V)
to «-
(710)
T3 ***
3 E
— 3
coz
0
.^
co
p
CO
p
—
a
u
CO
i-
a.
CO
E
J
—
—
^
CO
a>
4J
CO
4->
—
a
-—
u
Q)
a.
E
3
c
*—
E
3
—
^
CVJ
—
lf>
—
co
P
CO
4}
.—
a
o
a.
C
o
—
CO
—
lA
—
CO
4J
CO
4J
•—
a.
~
u
CO
a.
CO
•o
™
^_
—
3
CO
Jf
—
o
CM
(A
•a
•_
0
CO
b
co
E
(.
a.
O
O
CM
CO
Ol
T3
3
i_
CO
^2
3
L.
y
CO
^
tTl
lA
CO
(71
•a
3
_
CO
T3
CO
p
CO
>
4J
U
<
CD
4J
U)
CO
»
o
VO
*
lA
CO
CJl
T3
3
os
CO — ~
p p
CO CO
-------
IV.3.4.2 DIGESTION
Introduction
Digestion is a method of sludge stabilization that uses bacteria
to degrade organic matter. Alternatives include aerobic and
anaerobic processes. The process is described in more detail in
Volume III of the Treatability Manual, Section III.4.2. Costing
methodologies and cost data for industrial wastewater treatment
applications are presented below.
IV.3.4.2-A. Aerobic Digestion
A 1. BasJ
-------
ul
*D
O ul
r- 0
»~
2 i/>
3
O O
o •*
u.' 3
> uJ
O t~
I
|
O
M
O
H
1
g
Q
13
VJ
OT
P-i
i—I
CM
*
ro
M
8
M
Date: 4/1/83
IV.3.4.2-A2
-------
Metric
VOL = RT x LPS x 86,400
where: VOL
RT
LPS
SLDG
SC =
86,400
English
VOL = RT x GPD
digester basin volume, L
hydraulic retention time, days (15 days unless
otherwise specified)
sludge flow rate, L/s
SLDG * SC
total sludge to be digested, Kg/day (dry solids
basis; sum of activated sludge and organic
backwash solids)
influent solids concentration, % * 100
(SC = 0.01 without or SC = 0.025 with thickening)
[4-1]
sec/day
where: VOL
RT
GPD
SLDG
8.34
SC
= digester basin volume, gallon
= hydraulic retention time, days
(15 days unless otherwise specified) [4-1]
= sludge flowrate, gpd
= SLDG * (SC x 8.34)
= total sludge to be digested, Ib/day (dry solids
basis; sum of activated sludge and organic backwash
solids)
= Ib/gal
= influent solids concentration, % * 100
(SC = 0.01 without or SC = 0.025 with
thickening) [4-1]
f) Subsequent Treatment
Normally aerobic digestion is followed by solids separation and
dewatering. The supernatant or filtrate is returned to treatment
and the solids are disposed of by landfill'ing or incineration.
A 2. Capital Costs
The principal cost factor for aerobic digestion is the required
digester basin volume. The estimated capital cost for aerobic
digestion is presented in Figure IV.3.4.2-A2 as a function of
basin volume. Costs estimated using the cost curve must be
adjusted to a current value using an appropriate current cost
index.
Date: 4/1/83
IV.3.4.2-A3
-------
a) Cost Data
The items included in the capital cost estimates are [4-2]:
Digestion basin, depth 3.66 m (12 ft) plus 0.914 m (3 ft)
freeboard (Steel tank for 114,000, 397,000, and
1,140,000 liters (30,000, 105,000, and 300,000 gallon)
designs, with earthen basin and membrane liner for
3,410,000 (900,000 gallon) basin)
Pumps, variable speed progressive cavity (two)
Floating low speed aerators (two)
Piping
Instrumentation
b) Capital Cost Curves
Curve - see Figure IV.3.4.2-A2
- Cost (thousands of dollars) vs. volume
(thousands liters or thousand gallons).
- Curve basis, cost estimate for four systems with
basin volumes of 114,000, 397,000, 1,140,000, and
3,410,000 liters (30,000, 105,000, 300,000, and
900,000 gallons).
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component includes power, while the fixed component
includes labor, supervision, overhead, laboratory labor, main-
tenance, services, insurance and taxes, and service water. All
fixed and variable operating costs should be adjusted to current
levels using an appropriate index or unit cost factor.
a) Variable Cost
i) Power Requirements - aerators and pumps. The following
equation was developed using regression analysis pro-
cedures [4-1].
Metric
KW = (2.38 x 10-s x VOL) - 1.44
where: KW = power, kilowatts
VOL = digester basin volume, liter
Date: 4/1/83 IV.3.4.2-A4
-------
BASIN VOLUME. THOUSANDS OF LITERS
•
O *****
Hi
2OO—
w *UW
O
z
^
d 4 BO—
1 OO*.
H
0
o
Oft—
<
5
4
i
/
r
1
-i
-
.j
2
,
w
\
\C
f
\
/
A
2
X
j
4
x
C
"*
>
X"
*^
l<
^
>i
y
1C
^
r
X
ri
<
X
»
*
14
^
)
<^
;n
^
K
•*
X
0
)
••
*^
I
0H
'I
+
!(
*
>
>
1
I-J
•»
ic
<••
>
W
.2
VOLUME. THOUSANDS GALLONS
FIGURE IV.3.4.2-A2. CAPITAL COST ESTIMATE
FOR AEROBIC DIGESTION [4-10]
Date: 4/1/83
IV.3.4.2-A5
-------
English
HP = (1.21 x 10
"*
VOL) - 1.93
where: HP
VOL
ii) Power Cost
Metric
power, Hp
digester basin volume, gallon
PC = KW x 24 x EC
where:
PC
KW
24
EC
power cost, $/day
power, kilowatts
hr/day
electricity cost $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
24 = hr/day
0.746 = Kw-hr/Hp-hr
EC = electricity cost, $/Kw-hr
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.4.2-A1, including the cost basis and the unit costs
[4-11].
A 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV. 3. 5). The amount of sludge
remaining after digestion should be calculated for use in the
sizing and costing of subsequent sludge handling systems.
a) Remaining Sludge Quantity
The quantity of sludge remaining after aerobic digestion is
calculated based on an assumed ratio of 80% volatile to 20%
non-volatile influent solids and a reduction of 4% per day at
20°C of the volatile fraction to a maximum 70% reduction [4-1].
This rate may be adjusted for temperature as necessary.
SLGR = NVSS + [VSS x
RT
(1 - RATE) ]
Date: 4/1/83
IV.3.4.2-A6
-------
TABLE IV.3.4.2-A1. FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR AEROBIC DIGESTION [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.15 Weeks (3.60 hrs/day)
10% Labor (0.36 hrs/day)
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
2.39% Capital
0.40% Capital
2.50% Capital
0.056 L/s
(1.29 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.4.2-A7
-------
where: SLGR = quantity of sludge remaining after digestion,
Kg/day or Ib/day
NVSS = influent nonvolatile solids, Kg/day or Ib/day
= 0.2 x SLDG, [4-1]
SLDG = total influent sludge, Kg/day or Ib/day
VSS = influent volatile solids, Kg/day or Ib/day
= 0.8 x SLDG, [4-1]
RATE = reduction rate of VSS per day
T-?n
= 0.04 x (1.06)1 ^u [4-1]
0.04 = rate of reduction (4%/day) at T = 20°C [4-1]
T = reaction temperature, °C
RT = hydraulic retention time, days
= (15 days unless otherwise specified) [4-1]
A 5. Modifications
None Required.
Date: 4/1/83 IV.3.4.2-A8
-------
I.
AEROBIC DIGESTION
SUMMARY WORK SHEET
REFERENCE: IV.3.4.2-A
DESIGN FACTOR CAPITAL
Basin Volume = thousand gallons
II.
Cost
III.
CAPITAL COST
x ( f 204.7)
Cost from curve current index
VARIABLE 0 & M
Power = x x 17.9
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
Hp EC, $/Kw-hr
FIXED 0 & M
Labor : x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor-. x
hr/day $/hr
Maint, Service, x T 365
I&T: capital, $ %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
day/yr
$/day
*
X
sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Digested Biological Sludge Remaining =
Ib/day
Date: 4/1/83
IV.3.4.2-A9
-------
AEROBIC DIGESTION
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. Labor =
4. Supervision =
5. Overhead =
6. Lab Labor =
7. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor sum =
8. Service Water =
Capital Cost Index
$/Kw-hr
$/hr
$/hr
% Labor * 100 =
$/hr
%/100
% Capital
% Capital
% Capital
T 100 =
%/100
$/thou gal
I. DESIGN FACTOR
a. Quantity of waste activated sludge (WAS) =
b. Quantity of organic filter backwash (OFB) =
c. Total quantity of sludge to be digested
SLDG = ( ) + (
OFB, Ib/day
WAS, Ib/day
d. Sludge Flow Rate
1. If thickening is not provided:
Ib/day
Ib/day
Ib/day
GPD = (
0.0834 =
SLDG, Ib/day
2. If thickening is provided:
gpd,
GPD = (
0.209 =
SLDG, Ibs/day
e. Digester basin Volume
VOL = ( ) x (
GPD, gpd RT = 15, days
gpd,
gallons
II. CAPITAL COST
Date: 4/1/83
IV.3.4.2-A10
-------
III. VARIABLE 0 & M
Power Requirements
HP = (
VOL, gallons
x 1.21 x 1CT4) - 1.93 =
Hp
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Remaining Sludge Quantity
1. Rate of Reduction of VSS
Temperature, T =
RATE = 0.04 x (1.06)v
2. Influent Solids
NVSS = x 0.20 =
°C
- 20)
fraction/day
SLDG, Ib/day
VSS =
x 0.80 =
SLDG, Ib/day
3. Retention Time
Ib/day
Ib/day
RT =
days
4. Sludge Remaining
SLGR =
x (1 -
NVSS, Ib/day VSS, Ib/day
Ib/day
RATE
RT, days
Date: 4/1/83
IV.3.4.2-AU
-------
IV.3.4.3 DEWATERING
introduction
Dewatering is desirable to reduce sludge volume prior to trans-
porting and landfilling, or to prepare sludge for incineration or
composting. Some dewatering processes use natural means (e.g.,
evaporation, percolation) for moisture removal. Others use
mechanical devices (e.g., filters, centrifuges) to hasten the
dewatering process. Further details describing these dewatering
processes can be found in Volume III, Section III.4.3 of the
Treatability Manual. Costing methodologies and cost data for
industrial wastewater treatment applications are presented below.
A. Vacuum and Pressure Filtration
A 1. Basis of Design
This presentation is for vacuum filtration (rotary vacuum fil-
ters), or pressure filtration (filter press) of wastewater sludge.
Process flow diagrams for vacuum and pressure filtration are
presented in Figures IV.3.4.3-A1 and A2, respectively. Vacuum
filtration is used for most applications because of lower cost.
However, pressure filtration may be considered for use prior to
incineration of biological sludge since it produces a sludge (35
to 50% solids) which is dry enough for self-sustained combustion.
Pressure filtration may also be selected for its greater ability
to reduce sludge volume in cases where landfill area is limited.
The surface area of the operating filter is the basis for deter-
mining costs associated with a filtration sludge dewatering
system. Factors which affect filter surface area are filter
yield and operation time. Incoming sludges are characterized as
to amount (Kg/day, Ib/day) and sludge type. The amount of condi-
tioning chemicals (lime and FeCl3) and the expected filter yield
are then estimated for each sludge type from factors presented in
Table IV.3.4.3-A1 depending on whether a vacuum or pressure
filter is to be used. The total filter area is then computed
based on the amount of surface area required for each type of
sludge, the expected time of operation, and practical limitations
on the sizes of filter units commercially available. Most vacuum
filters require that the filter surface be washed after the cake
has been removed. If a pressure filter is selected, a thin layer
of diatomaceous earth also is applied on the pressure filter
medium to enhance the filter's ability to remove suspended solids.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries [4-2].
The method for developing the design factor is based on assump-
Date: 4/1/83 IV.3.4.3-A1
-------
3
O
H
H
53
D
P>
U
33
O
CM
CM
01
cn
w
o
§
a.
i
ro
ro
W
O
H
Date: 4/1/83
IV.3.4.3-A2
-------
1•
t^
$
s
H
Pn
D
W
cn
H
PS
O
t,
Q
O
CO
w
u
8
•
CM
I
on
Date: 4/1/83
IV.3.4.3-A3
-------
w
d
w p
u 5
^ t-i
S w
2 P^
o w
S3
W 2
Pn M
H
2 w
0
1—1 1 — p
1 0 7
CO fe v^
• < — i
en o .— ,
• H -i
H <
a
<*- 3
— « a
— s_ a.
•v
fli ^
W t- E
u. c
n to
E SZ l-
V Q-
(1) >
*J i- E
~ ^ -
U- 0 C
>
J"
U ri
-—
Q) *-
- 0 «
OS* 0)
£ • a.
U "D
0 i- E
*- 3 I
s. O C
£ ^>
C
0
0) *
3 t-
— O
W tf
OJ L-
u\ a:
•D ^
3 E
S§§?$!?!SMM!S£
OOOOiAiAiACMWlTVCVJ
^VO^^WMtM^^CMHN
(*!•—•- — (\JC\JC\J<— «— W«-
CO (\l CO
OO--OCOcOoO(\JC\tcDC\J
^VO-OXJWWCSJ^^Mtn
«---~~iAinooa>o
QJ fl> — .
*J £71 O
4-> — V) 3 CO
a. -^— to tu o»c
O « O ^--D Q U>
0) QJ O tO 0) 3 £(-
^. *J-- a O
flj 0) w >> 3 «.'^'—
ij.jj.- — OEtrt** »«<0
— ._ t, o — — (0 < 5 S
a.aoa)Ei-(-> • jcjc
t_ QJ &. o — S o o
oy-c*-^^"*J*J no)
0 o o u nu-oeoco
L. L. QJ u) (_ ^ d)
0. Q, 0 "O ' « OJ 4J U L.
g 3< < OO WO)
— — 0) 3 • t- C (0 — — —
•-rljpo.3-oO'-Oir\oo
«—•-'- *-C*4ifMA^O*OflOOs
TD
O
V)
W
i
f
>»
•o
c
o **-
0
3-1**
O 3 Wi
CO
U- C/}
•o
u -o O
— Q) *»
to O
•o > a
§££
0^«
(A 0)
(fl V W
(0 O
£2-0
o
(fl —
« Q E
UQU
Date; 4/1/83
IV.3.4.3-A4
-------
tions and procedures in the Contractor Developed Design and Cost
Model [4-1].
b) Required Input Data
Amount and type of each sludge to be dewatered Kg/day
(Ib/day)
Number of hours of operation per week
Desired dewatered sludge solid content (%)
Ultimate means of sludge disposal (incineration or landfill)
c) Limitations
i) Sludge dewatering is not used for combustible type
residuals (DAF float, oil, solvent extraction residues,
and steam stripping residues).
ii) Maximum size for vacuum filters is considered to be 35
m2/unit (377 ft2/unit).
iii) Maximum size for pressure filters is considered to be
465 m2/unit (5,000 ft2/unit).
d) Pretreatment
Thickening is generally used prior to dewatering but is not re-
quired in every case.
e) Design Factor
i) Vacuum Filter
The primary factor used for design of vacuum filters is
the surface area per filter. The total filter area is
the sum of the filter area required for dewatering each
sludge type. The filter area required for each sludge
type is determined by summing the amount of each type of
sludge with the amount of chemicals (lime and ferric
chloride) required for conditioning and dividing the sum
by the expected filter yield for that sludge type (Table
IV.3.4.3-A1). Surface area per filter is calculated by
taking the total filter area and adjusting for the hours
of operation and the number of filters. The maximum
area per filter is assumed to be 35 m2 (377 ft2) [4-1].
AREA = !{[Q(n) + (Q(n) x LIME(n)) + (Q(n) x FECL(n))]
* YIELD(n)} x 7 * (HR x N)
Date: 4/1/83 IV.3.4.3-A5
-------
where: Q(n)
LIME(n)
quantity of sludge of type (n), Kg/day or
Ib/day
lime loading factor for sludge type
(n), as fraction of sludge, %/100
(Table IV.3.4.3-A1)
FECL(n) = ferric chloride loading factor for
sludge type (n), as fraction of
sludge, %/100 (Table IV.3.4.3-A1)
YIELD(n) = expected yield for sludge type (n),
(Table IV.3.4.3-A1)
days/week
hours per week of operation, hr/week
number of operating filters
7
HR
N
The hours per week of operation are balanced against the
maximum practical size for an individual filter, assumed to
be 35 m2 (377 ft2). Several trial runs are made to deter-
mine the optimum number of filters and hours of operation.
It is initially assumed that the filter operates five days
per week, eight hours per day (40 hr/wk). If the filter
area required exceeds the maximum practical area (35 m2, 377
ft2), the hours of operation are increased to two shifts (80
hr) then three shifts (120 hr) up to three shifts, seven
days per week (168 hr) until the required area equals the
available area. If the required filter area cannot be met
with a three shift operation, additional filters are added
and the operation hours procedure is repeated until the
required area is met.
Once the area of a single filter is computed, it is adjusted
to one of the standard filter sizes shown in Table IV.3.4.3-A2,
In addition to operating filters, each system is assumed to
include one spare filter unit.
TABLE IV.3.4.3-A2. STANDARD VACUUM FILTER SIZES AND BASE POWER
REQUIREMENTS [4-2]
Filter Area
(m2) (ft2)
Base Power
Kilowatts Horsepower
Filter Area
,(n>2) (ft*)
Base Power
Kilowatts Horsepower
0.93
1.8
2.6
4.4
5.8
10
19
28
47
62
4
6
9
.1
.0
.7
11
13
5
8
.4
.1
13
15
18
12
19
28
6.6
9.2
& 14
& 23
& 35
71
99
132 &
207 &
302 &
151
251
377
18
24
31
46
84
24
32
42
62
112
Date: 4/1/83
IV.3.4.3-A6
-------
ii) Pressure Filter
The primary factor used for design of pressure filters is the
area per filter. First, the total filter area is determined by
summing the filter surface area required for each sludge type.
The filter surface area required for each sludge type i's calcu-
lated by summing the amount of each type of sludge with the
amount of chemicals (lime and ferric chloride) required for
conditioning and dividing the sum by the expected filter yield
for that sludge type (Table IV.3.4.3-A1). Total filter area is
then determined by summing the area requirements for all types
of sludge being dewatered. Surface area per filter is deter-
mined by adjusting the total filter area for the hours of opera-
tion and the number of filters required. The maximum practical
size for an individual filter is to be 465 m2 (5000 ft2) in this
case [4-1].
AREA = £{[Q(n) + Q(n) x LIME(n) + Q(n) x FECL(n)]
T YIELD(n)} x 7 * (CYCLES x 2.67 x N)
where: AREA = surface area per filter, m2 or ft2 (maximum = 35 m'
or 5,000 ft2)
Q(n) = quantity of sludge of type (n), Kg/day or Ib/day
LIME(n) = lime requirement for sludge of type (n),
as fraction of sludge, %/100 (Table
IV.3.4.3-A1)
FECL(n) = FeCl3 requirement for sludge of type (n),
as fraction of sludge, %/100 (Table IV.3.4.3-A1)
7 = days/week
CYCLES = number of filter operation cycles per week
2.67 = hr/cycle
N = number of filters required (initially 2)
YIELD(n) = expected filter yield for sludge of type (n),
(Table IV.3.4.3-A1), Kg/hr/m2 or lb/hr/ft2
The number and surface area of the filter units is determined by
balancing the cycles per week of operation against the maximum
practical filter size, 465 m2 (5,000 ft2). It is initially
assumed that the filter operates five days per week, three cycles
per day (15 cycles per week). If the surface area per filter
estimated using these conditions exceeds the maximum practical
size, the cycles of operation are increased to two shifts (30
cycles/week) or three shifts (45 cycles/week) on up to three
shifts, seven days per week (63 cycles/week) until the estimated
area of a single filter no longer exceeds the 465 m2 (5,000 ft2)
limit or the decision is reached to add another filter. If at
the conclusion of the surface area calculation, the number of
cycles/week exceeds 30, another operating filter is added. One
spare filter is always included in addition to the operating
units.
Date: 4/1/83 IV.3.4.3-A7
-------
f) Subsequent Treatment
Landfill or incineration.
A 2. Capital Costs
Vacuum Filtration
The cost factor for vacuum filtration is the surface area of the
operating filter drum(s). This parameter is the independent
variable of the cost curve for this unit process (Figure IV.3.4.3-A3)
Since the curve gives the cost per filter, the cost must be
multiplied by the number of filters (operating plus one spare) to
obtain capital cost. The number of filters is the scale factor
for this unit process.
Pressure Filtration
The cost factor for pressure filtration is the required surface
area of the individual filter press. This parameter is the
independent variable of the cost curve for this unit process
(Figure IV.3.4.3-A4). Since the curve gives the cost per filter,
the cost must be multiplied times the number of filters (operat-
ing plus one spare) to obtain capital cost. The number of fil-
ters is the scale factor for this unit process.
Costs estimated using these cost curves must be adjusted to cur-
rent values using an appropriate current cost index.
a) Cost Data
i) The items included in the capital cost estimates for the
vacuum filtration process are as follows [4-10]:
Package Vacuum Filter Units -
vacuum filter,
vacuum pumps,
filtrate pumps,
filtrate receivers,
vacuum pump silencers.
Belt conveyors
Tanks, vessels and drums
Miscellaneous mechanical equipment
Piping
Instrumentation
ii) The items included in the capital cost estimates for the
pressure filtration process are as follows [4-10]:
Package Pressure Filter Units -
pressure filter,
ferric chloride system,
Date: 4/1/83 IV.3..4.3-A8
-------
pre-coat system,
conveyors,
control valves and pumps.
b) Capital Cost Curves
i) Vacuum Filtration
Curve - Figure IV.3.4.3-A3.
- Cost (thousands of dollars) vs. surface area of
individual operating filter drum (square meters
or square feet)
- Curve basis, cost estimates to dewater the
sludge produced by systems at four flow rates,
8.76, 43.8, 219, and 876 L/s (0.2, 1.0, 5.0, and
20 mgd) corresponding to filter areas of 1.8,
5.3, 14, and 44 m2, (19, 57, 150, and 470 ft2)
Scale Factor - number of filters (operating plus spare)
Capital Cost = cost per filter x no. filters
ii) Pressure Filtration
Curve - Figure IV.3.4.3-A4.
- Cost (thousands of dollars) vs. surface area of
individual filter (square meters or square feet)
- Curve basis, cost estimates to dewater the
sludge produced by systems at four flow rates,
8.76, 43.8, 219, and 876 L/s (0.2, 1.0, 5.0,
and 20 mgd)
Scale Factor - number of filters (operating plus one
spare)
Capital cost = cost per filter x no. filters
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component includes power, chemicals, and wash water. The
fixed component includes labor, supervision, overhead, laboratory
labor, maintenance, services, insurance and taxes, and service
water. All fixed and variable operating costs "should be adjusted
to current levels using an appropriate index or unit cost factor.
Date: 4/1/83 IV.3.4.3-A9
-------
SURFACE AREA. SQUARE METERS
•.20
ie.e
27.9
•7.2
4«.4
400
Ik
o
I
§
o
300
200
100-
100 200 360
•URFACE AREA. SQUARE FEET
400
FIGURE IV.3.4.3-A3. CAPITAL COST ESTIMATE
FOR VACUUM FILTRATION [4-10]
Date: 4/1/83
IV.3.4.3-A10
-------
FILTER AREA. SQUARE METERS
02.0 186.8 278.7 871.6 464.6 611
16OO-
1 W|
1OOO-
m
-
-
-I
/
r
-
/
f-
f
-
t
f
f
/
/
/
/
7
-
/-
/
4
/
r
/*
/
-
/
r iot» so
FN.
*
/
'
-
7
f
^
•
L
,x
00 SO
TER AREA. SOU
^
/
-
-
_
/
--
i/
—
,«
-
-
'
^
, 4
-
-
-
s
L
-
-
00 40
ARE FEET
/
-
/
-
--
x
L-
X1
--
-
/
--
-
.,
^
DO 8d
x
-
<•
^
--
-
-
-
-
L-
-
oo ed
ioo
FIGURE IV.3.4.3-A4. CAPITAL COST ESTIMATE FOR PRESSURE
FILTRATION [4-10]
Date: 4/1/83
IV.3.4.3-A11
-------
a) Variable Cost
i) Power Requirements Vacuum Filtration - pumps, conveyors,
mixers. This equation was developed using regression
analysis procedures.
Metric
KW = [BKW + (0.0334 x AREA) + 1.89] x HR
x N * 168
where: KW = power requirement, kilowatts
BKW = base power for standard filter size
(Table IV.3.4.3-A2)
AREA = individual filter area, m2
HR = hours of operation per week, hr
N = number of filters
168 = hours per week
English
HP = [BHP + (0.00414 x AREA) + 2.53] x HR
x N * 168
where: HP = horsepower requirement, Hp
BHP = base horsepower for standard filter
sizes (Table IV.3.4.3-A2)
AREA = individual filter area, ft2
ii) Power Requirements - Pressure Filtration - pumps,
conveyors, mixers. This equation was developed using
regression analysis procedures.
Metric
KW = [(0.056 x AREA) + 26.3] x N x CYCLES
x 2.67 * 168
where: KW = power requirement, kilowatts
AREA = individual filter area, m2
N = number of filters
CYCLES = filter cycles per week
2.67 = hours per cycle
168 = hours per week
English
HP = [(0.007 x AREA) + 35.3] x N x CYCLES
x 2.67 * 168
Date: 4/1/83 IV.3.4.3-A12
-------
iii)
where: HP = horsepower requirement, HP
AREA = individual filter area, ft2
Power Cost
Metric
where:
English
PC = KW x 24 x EC
PC = power cost, $/day
KW = power requirements, kilowatts
24 = hr/day
EC = electricity cost, $/Kw-hr
PC = HP x 0.746 x 24 x EC
where: PC = power cost, $/day
HP = horsepower required, Hp
0.746 = kw-hr/Hp-hr
iv) Chemical Requirements
Ferric chloride and lime
- The amount of ferric chloride and lime required for
either vacuum or pressure filtration is determined as
follows:
Metric
LIME = Z[Q(n) x LIME(n)]
FECL = Z[Q(n) x FECL(n)]
where: LIME
FECL
total amount of lime required, Kg/day
total amount of ferric chloride
required, Kg/day
Q(n) = amount of sludge of type (n), Kg/day
FECL(n) = FeCL3 requirement for sludge of type
(n), as fraction of sludge, %/100
(see Table IV.3.4.3-A1)
LIME(n) = lime requirement for sludge of type
(n), as fraction of sludge, %/100
(see Table IV.3.4.3-A1)
English
LIME = S[Q(n) x LIME(n)]
FECL = I[Q(n) x FECL(n)]
Date: 4/1/83
IV.3.4.3-A13
-------
where: LIME = total amount of lime required, Ib/day
FECL = total amount of ferric chloride re-
quired, Ib/day
Q(n) = amount of sludge of type(n), Ib/day
Diatomaceous Earth
- The amount of diatomaceous earth required to precoat
a pressure filter is determined by:
Metric
DE = AREA x CYCLES x 0.39 x N
where: DE = quantity of diatomaceous earth, Kg/day
based on an application rate of 39 Kg
of precoat per 100 m2 of filter
AREA = individual filter area, m2
CYCLES = number of filter cycles per day
0.39 = application rate, 39 Kg/100 m2
N = number of filters
English
DE = AREA x CYCLES x 0.08 x N
where: DE = quantity of diatomaceous earth, Ib/day
based on an application rate of 8 Ibs
of precoat per 100 ft2 of filter
AREA = individual filter area, ft2
0.08 = application rate, 8 lb/100 ft2
v) Chemical Cost (except lime*)
The cost of ferric chloride and diatomaceous earth may
be determined as follows:
Ferric chloride
FC = FECL x CCF
where: FC = daily cost for ferric chloride, $/day
FECL = total amount of ferric chloride re-
quired, Kg/day or Ib/day
CCF = cost of ferric chloride, $/Kg or $/lb
Diatomaceous Earth
DEC = DE x CCD
Date: 4/1/83 IV.3.4.3-A14
-------
where: DEC = daily cost for diatomaceous earth, $/day
DE = daily quantity of diatomaceous earth,
Kg/day or Ib/day
CCD = cost of diatomaceous earth, $/Kg or $/lb
*It is assumed that lime is supplied to each unit from
a central lime handling facility. Thus, the cost of
lime for any one process depends on the total lime re-
quirements of the plant as a whole. Lime requirements
for these and other unit processes requiring lime should
be summed and the costs estimated as shown in the Lime
Handling Section (Section IV.3.1.13-C).
vi) Wash Water Requirements for Vacuum Filter
Metric
WATER = (16 x AREA x N x HR x 1440) * (168 x 1000)
where: WATER = wash water requirement, thousand
liters/day
wash rate, L/min-m2
16.3
AREA
N
HR
1440
168
surface area of each filter, m2
number of operating filters
hours of operation per week, hr
minutes/day
hours/week
English
WATER = (0.4 x AREA x N x HR x 1440) * (168 x 1000)
where: WATER = wash water requirement, thousand
gallons/day
0.4 = wash rate, gal/min-ft2
AREA = surface area of each filter, ft2
N = number of operating filters
HR = hours of operation per week, hr
1440 = minutes/day
168 = hours/week
vii) Water Cost
WC = WATER x CPT
where: WC
CPT
WATER
water cost, $/day
cost of water, $/thou liters or $/thou gal
total water required, thou liters/day or
thou gal/day
Date: 4/1/83
IV.3.4.3-A15
-------
b) Fixed Costs
The fixed 0 & M components for both vacuum and pressure filtra-
tion are listed in Table IV.3.4.3-A3 including the cost basis and
the unit costs [4-11].
A 4. Miscellaneous Costs
Cost for engineering/ and common plant items such as piping and
buildings, are calculated for the plant as a whole after comple-
tion of costing for individual units (See Section IV.3.5).
A 5. Modifications
a) Filter Cake Weight
The total filter cake weight (dry sludge plus remaining moisture)
is calculated by dividing each dry sludge weight by the fraction
of solids in the cake after filtration (See Table IV.3,4.3-Al).
WW = E[Q(n) r F(n)]
where: WW = total wet weight of filter cake, Kg/day or Ib/day
Q(n) = quantity of sludge solids of type (n), Kg/day (dry)
or Ib/day (dry)
F(n) = fraction of solids in cake after filtration for
sludge type (n), as %/100 (see Table IV.3.4.3-A1)
Date: 4/1/83 IV.3.4.3-A16
-------
TABLE IV.3.4.3-A3.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR VACUUM FILTRATION AND
PRESSURE FILTRATION [4-11]
VACUUM FILTRATION
Element
Labor (1,2,4)
Supervision (1,4)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
10% Labor
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
6.10% Capital
0.40% Capital
2.50% Capital
0.038 L/s
(0.86 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou liters
($ 0.50/thou gal)
PRESSURE FILTRATION
Element
LaDor (1,2,4)
Supervision. (1,4)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
10% .Labor
75% Labor Cost
0.10 Shifts (0.57 hrs/day)
0.50% Capital
0.40% Capital
2.50% Capital
0.79 L/s
(18.10 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou liters
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
(4) Labor and Supervision requirements are scaled to conform
with the hours of operation or cycles of operation calcu-
lated in Section A,le.
Vacuum Filtration
Labor = HR * 7
Supervision = 0.1 x Labor
Pressure Filtration
Labor = (CYCLES x 2.67) * 7
Supervision = 0.1 x Labor
Date: 4/1/83
IV.3.4.3-A17
-------
I.
a.
b.
II.
DESIGN FACTOR
Filter Area of
Scale Factor =
CAPITAL COST
Cost =
III
a.
b.
c.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
VACUUM FILTER DEWATERING
SUMMARY WORK SHEET
REFERENCE: IV.3.4.3A
CAPITAL
individual operating drum = ft2
total number of filters
x x ( T 204.7)
Cost from curve scale factor current index
. VARIABLE 0 & M
Power
Ferric Chloride
Wash water
FIXED 0 & M
Labor:
Supervision:
Overhead:
Lab Labor:
Maint, Service,
I&T:
Service Water:
YEARLY 0 & M
x x 17.9
Hp EC, $/Kw-hr
= X
Ibs/day $/lb
= X
thou gal/day $/thou gal
X
LQ, hr/day $/hr
x
SQ, hr/day $/hr
x
Labor, $/day %/100
x
hr/day $/hr
x f 365
capital, $ %/100 day/yr
X
thou gpd $/thou gal
365
day/yr
$/day
=
x
sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Lime =
Ibs/day
Date: 4/1/83
IV.3.4.3-A18
-------
VACUUM FILTER DEWATERING
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. EC: Electricity Cost =
3. Ferric Chloride =
4. Labor =
5. Supervision =
6. Overhead =
7. Lab Labor =
8. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
9. Wash water and
Service Water =
Capital Cost Index
$/Kw-hr
$/lb
$/hr
$/hr
% Labor r 100 =
's/100
$/hr
% Capital
% Capital
% Capital
%/100
$/thou gal
DESIGN FACTOR
a. To determine the total filter surface area, see Work Table 1
1. Enter dry weight (Ib/day) of each sludge type in Column A
2. Multiply quantity of each sludge type (from Column A) by factor for
ferric chloride requirement (from Column B) and enter results in
Column C
3. Multiply quantity of each sludge type (from Cc-lumn A) by factor for
lime requirement (from Column D) and enter results in Column E
4. Sum the ferric chloride requirement from Column C and lime require-
ment from Column E for each sludge type and enter results in Column F
5. Sum the sludge weight from Column A and the chemical weight from
Column F for each sludge type and enter results in Column G
6. To get the area required to filter each sludge type, divide the total
cake weight (Column G) by the filter yield (ColumnNH) for each sludge
type and enter results in Column I
7. Sum Column I to determine total area required to filter the total
quantities of all sludge and conditioning chemicals applied
Date: 4/1/83
IV.3.4.3-A19
-------
"O L. 0) -^-*J >
(C ® oj £ cr>x d- n
—1 (. — 4J — to 3 O CTX
< 3 — Ul — —•«(-
7 U. (0 £
*
, *«~
+J 0) U u. >
C71— BJ
4J<*-T3 6 + -0
C O 3
- o (- a
(0 -f TJ
-p e 3 -N
O QJ CTO JC
O CC
UJ
1 X
CC — (1
•o
§•0 *N
o-o «
01 CC?^
*- o *- a
U. £ 3
o c
— (DO)
CD) 1- I- T3 £
O t- - 0)
*J
c to i
CO X
CT O —
h-
v
0
•o.
to
o
o
0
o
o
o
o
o
o
V
me Precipita
3
^
BO
0
o
CVJ
o
o
d
0)
n
Q.
uminum Prec i
5
~
N
-
O
N
O
§
o
o
ffi
rrtc Chlorid
Precipitate
4J
O.
u
£
o.
V
•o
d-
5
^
o
CO
CO
o
d
o
o
A.F. Chemica
Float
6
o
(U
o
00
00
o
d
m
0
d
^
1
u
a.
(A
WO
(A —
0) _
0.
O
in
o
(D
CO
0
d
IT*
o
o
,.
I
3
L.
cinerator Sc
Sludge
c
\f\
o
CVJ
in
o
o
0
o
•o
ste Activate
Sludge
$
s
o
o
d
X
•D
0)
(0
0)
01
a
£
0
CO
CO
o
o
in
o
o
Iter Backwas
( Inorganic)
£
o
CO
o
CM
in
o
o
s
o
Iter Backwas
(Organic)
£
£
ii
— OB CO
x o £
III
UJtd
*!
Is-1
I"..
oo
UJ
p
Iv)
Date; 4/1/83
IV.3.4.3-A20
-------
b. To determine the design area per filter use, use Work Table 2 to test
various combinations of filter numbers and hours of operation
1. Enter the sum of Column I from Work Table 1 on the first line of
Column A of Work Table 2
2. Compute the initial operating area of an individual filter by
multiplying Column A by the factor (7 f (HR x N)) in Column D.
Enter the product in Column E and test to see if it exceeds the
maximum filter area (377 ft2). If the initial estimate of filter
area exceeds 377 ft2, increase the number of hours and number of
filters and recalculate area until the individual operating areas
(Column E) does not exceed 377 ft2
WORK TABLE 2.
CALCULATIONS TO DETERMINE ADJUSTMENT FACTORS SO AS NOT TO
EXCEED MAXIMUM FILTER AREA
Sum I
B
Number
of filters, N
Hrs of Operation
per week, HR
D
Factor
Indiv. Operating
Area A x D (not to
exceed 377 ft2)
1
1
1
1
2
2
2
2
40
80
120
168
40
80
120
168
0.175
0.088
0.058
0.042
0.088
0.044
0.029
0.021
n
168
n
3.
4.
The minimum number of working filters (N) in Work Table 2 with operating
area less than or equal to 377 ft2 is the design selected.
For the N-value selected, the minimum number of hours of operation
per week is the design mode selected.
HR =
hours/week
5. Compute the individual filter area
AREA = (
x 7) * (
ft*
6.
SUM I, ft2 hr/day
Scale Factor for cost purposes
If AREA > 10 ft2
SCALE FACTOR = Total number of filters =
HR, hrs N, filters
+ 1 =
filters
N, filters
Date: 4/1/83
IY.3.4.3-A21
-------
If AREA < 10 ft2
SCALE FACTOR = Total number
7. Using the table below, select
(FS) and the base horsepower
(AREA) estimated in step 5.
costing purposes.
Filter Size
of filters = filters
N
the appropriate standard filter size
(BHP) for the individual filter area
This is the area that should be used for
Filter Size
Computed (AREA), ft2 Standardized (FS), ft2 Base Horsepower (BHP)
AREA < 5
5 < AREA <. 20
20 < AREA * 30
30 < AREA < 47
47 < AREA * 62
62 < AREA * 71
71 < AREA S 100
100 < AREA S 132
132 < AREA S 165
165 < AREA <, 207
207 < AREA S 251
251 < AREA < 302
302 < AREA < 377
Design filter area =
10 5.4
19 8.1
28 13
47 15
62 18
71 24
99 32
132 42
151 42
207 62
251 62
302 112
377 112
ft2, Base Horsepower = Hp
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = [ + (0.00414 x
) + 2.53] x x * 168 = Hp
BHP AREA, ft2 HR, hr N
b. Ferric Chloride Requirements
FECL =
•
Ibs/day
Sum of Column C in Work Table 1
c. Wash Water Requirements
WATER = ( x
AREA, ft2 N
x x 0.00343 = thou gal
HR
Date: 4/1/83
IV.3.4.3-A22
-------
IV. FIXED 0 & M
a. Labor Quantity
LQ = * 7 = hr/day
HR, hr/week
b. Supervision Quantity
SQ = x 0.1 = hr/day
LQ, hr/day
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Lime Requirements
LIME = Ibs/day
Sum of Column E in Work Table 1
Date: 4/1/83 IV.3.4.-3-A23
-------
I.
a.
b.
II.
PRESSURE FILTER DEWATERING
SUMMARY WORK SHEET
REFERENCE: IV.3.4.3A
DESIGN FACTOR CAPITAL
Surface area of filter = ft2
Scale Factor =
total number of filters
CAPITAL COST
Cost = x x ( r 204.7)
III
a.
b.
c.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
a.
Cost from curve scale factor current index
. VARIABLE 0 & M
Power = x x 17.9
Hp EC, $/Kw-hr
Ferric Chloride = x
Ibs/day $/lb
Diatomaceous Earth = x
Ibs/day $/lb
FIXED 0 & M
Labor : x
LQ, hr/day $/hr
Supervision: x
SQ, hr/day $/hr
Overhead: x
Labor, $/day %/100
Lab Labor : x
hr/day $/hr
Maint, Service, x * 365
I&T: capital, $ %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
day/yr
$/day
x
sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Lime = Ibs/day
Date: 4/1/83
IV.3.4.3-A24
-------
PRESSURE FILTER DEWATERING
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. Ferric Chloride = $/lb
4. Diatomaceous Earth = $/lb
5. Labor = $/hr
6. Supervision = $/hr
7. Overhead = % Labor f 100 = %/100
8. Lab Labor = $/hr
9. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor Sum = r 100 = %/100
10. Service Water = $/thou gal
I. DESIGN FACTOR
a. To determine the total filter surface area, see Work Table 1
1. Enter dry weight (Ib/day) of each sludge type in Column A
2. Multiply quantity of each sludge type (from Column A) by factor
for ferric chloride requirement (from Column B) and enter results in
Column C
3. Multiply quantity of each sludge type (from Column A) by factor
for lime requirement (from Column D) and enter results in Column E
4. Sum the ferric chloride requirement from Column C and the lime
requirement from Column E for each sludge type and enter results
in Column F
5. Sum the sludge weight from Column A and the chemical weight from
Column F for each sludge type and enter results in Column G
6. To get the area required to filter each sludge type, divide the
total cake weight (Column G) by the filter yield (Column H) for each
sludge type and enter results in Column I
Date: 4/1/83 IV.3.4.3-A25
-------
7. Sum Column I to determine total area required to filter the total
quantities of sludge and conditioning chemicals applied
b. Make an initial estimate of the individual filter surface area
1. AREA = (
Sum I, ft2-hr/day
ft2
x 7) * (
CYCLES =15
N = 2
x 2.67)
2. If AREA > 5000 ft2, go to Step c
3. If AREA < 5000 ft2, the initial estimate of individual surface
area is adequate and the AREA, CYCLES, and number of filters (n)
may be used to estimate capital cost
c. To determine the design area per filter for greater than the minimum
conditions, use Work Table 2 to test various combinations of filter
numbers and cycles of operation
1. Enter the sum of Column I from Work Table 1 on the first line of
Column A of Work Table 2
2. Columns B and C show the number of cycles per week of operation
and number of filters for each trial. Multiply the total area
(SUM I) by the factor [7 * (CYCLES x N x 2.67)] in Column D and
enter the results in Column E. If the area exceeds 5000 ft2,
increase the cycles of operation and/or the number of filters
until the area in Column E no longer exceeds 5000 ft2
WORK TABLE 2. CYCLES PER WEEK AND CORRESPONDING NUMBER OF FILTERS
SUM I
B
Cycles/wk
(CYCLES)
Number of
Filters (N)
Factor
Individual Filter
Area (A x D) (not
to exceed 5000 ft2)
30
45
63
15
30
45
63
•
63
2
2
2
3
3
3
3
0.0437
0.0291
0.0208
0.0582
0.0291
0.0194
0.0139
n
Date: 4/1/83
IV.3.4.3-A26
-------
3. List the information needed for costing as determined from Work
Table 2
AREA = ft2
N = filters
CYCLES = cycles/week
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = [(0.007 x ) + 35.3] x x x 0.016 = Hp
AREA, sq ft N CYCLE
b. Ferric Chloride Requirements:
FECL =' Ib/day
Sum of Column C in Work Table 1
c. Diatomaceous Earth Requirements
DE = x x 0.08 x = Ib/day
AREA, sq ft CYCLESN
IV. FIXED 0 & M
a. Labor Quantity
LQ = x 0.381 = hr/day
CYCLE, cycles/week
b. Supervision Quantity
SQ = 0.1 x = hr/day
LQ, hr/day
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Lime Requirements
LIME = Ib/day
Sum of Column E in Work Table 1
Date: 4/1/83 IV.3.4.3-A27
-------
H
O
H
H
S
i-r
H
W
q
o
H
c/>
§
n
H
U
P^
w
W H
i-J
l-l
H^
s
^
V 4. CD *J >
(-. J) £ CT — (*. CO
to — o *» o •o z -a
—1 <1> 3 *J — (0 3 X tJX
(-a — uj — o v> <-
er ~"*
a »-
•*-> Q) "O O" *-
O *J — v) £
XI 0) — 0) XX
a - - n *j
X u. > — (*.
U
tf) — •
* — u. >
>> CO <0
4J 0) O + 13
Ol ^ <•- "D £ < £
C O 3 Q) •
3 W O
a -*
ra CD ra
U t- + -D
M « E 3 O £>
*j D a — •—
O £ Q)
UJ
i — >
ee co
UJ| -O -O
g 2J ^
-J 3
a
c
01 0)
<- E E
Q| O - 03
«J J W.
O
™ 0 C
(_ C3
cc
1 —
ce x
fl> — «
Ol o -o -a
•--•ox
t. o (--
Q)
O er
u c
«- cS 1
O i. - (
O u. O -
CO — -
O O <
<•- cc
4J C31
- -a >
*J 3 CO
c — -o
co to x
3 A
o
1
h-
1
1
(/]
01 '
•o .
3
, Hz
fO
o
0
C)
o
o
o
o
0)
*
a.
u
£
a.
i
-1
^
o
o
o
D
"!
o
0)
CO
a
u
V
L.
a.
1
c
E
3
<
C\J
O
0
d
o
o
,
o
V
•a
t- +*
o n
o a
u u
._ (J)
u u
s. a.
a
<*>
o
o
o
o
o
d
0)
n
._
a.
o
I
o
•D
^
3
«
^
CVJ
OJ
IT>
O
O
§
d
_
(Q
O
1
• n
u. o
Q
O
cj
lA
0
0
§
O
c
(0
E
t_
a.
Ui
o —
u o
oco
a.
o
LA
CM
CM
lA
O
O
§
d
t_
V
Q
3
L,
tf)
rator
ge
11
a to
c
^
in
CO
0
d
o
o
•o
V
4J
IB
o a
< en
a 3
oco
a
5
o
lA
CO
O
cj
0
o
40
,£
•o
a>
(A
0)
01
o
!A
C>J
(M
O
d
o
o
o
c
ta
So
i -
a c
S|,
s!
§
iA
CO
0
0*
s
.
o
c
Ifl
5
0 O
CO C
i- Si
a <-
— £.
§
II
^ <0
oo
u
§""
U
Date: 4/1/83
IV,3,4.3-A28
-------
IV.3.4.4 COMBUSTION
Introduction
Combustion is employed to reduce the quantity of sludges and
process residuals requiring disposal. Combustion may also be
employed to finally stabilize sludges, destroy toxics and recover
energy from waste materials. Variations of the process include
direct incineration of process waste streams prior to any kind of
waste treatment and incineration of biological sludges or liquid
waste treatment residues prior to disposal. Incineration pro-
cesses are described in more detail in Volume III, Section III.4.4
of the Treatability Manual. Costing methodologies and cost data
for industrial wastewater treatment applications are presented
below.
IV.3.4.4-A. Multiple Hearth Incineration
A 1. Basis of Design
This presentation is for determining the cost of a multiple
hearth furnace, considered applicable for the incineration of
biological sludges and mixed biological and liquid residue wastes.
A typical multiple hearth incinerator for combustion of biological
and mixed sludges is shown in Figure IV.3.4.4-A1. For liquid
residues alone, a vertical liquid waste-type incinerator is used.
Liquid residues are considered to include oil and residues from
extractional and distillation processes and contain no biological
sludges whatsoever. The various types of sludges or residues
that are considered combustible in a multiple hearth incinerator
are identified along with important physical characteristics in
Table IV.3.4.4-A1.
The principal design factor for biological sludge and mixed waste
incineration is the effective surface area of the multiple hearth
incinerator. Determination of the hearth surface area, which
dictates associated costs, is based on a surface solids loading
rate of 39 Kg wet sludge/m2/hr (8 Ib wet sludge/ft2/hr) [4-2].
The inlet temperature of biological and mixed sludges and residues
is assumed to be 15.5°C (60°F), and the incinerating temperature
is assumed to be 982°C (1800°F).
a) Source
This cost estimate method was derived from the BAT Effluent
Limitations Guidelines engineering study for the Organic Chemicals/
Plastics and Synthetic Fibers Industries [4-2].
Date: 4/1/83 IV.3.4.4-A1
-------
isinnnnn
o
EH
<
04
W
W
SC
W
1-1
OH
Pi
o
s
o
H
o
o
W
U
O
Pi
PH
w
o
M
fa
Date: 4/1/83
IV.3.4.4-A2
-------
S3
O
H
H
C3
W P3
O O
fe H
M 2
S3 S3
O H
M CJ
W H
rd
Q H
2 PH
CcJ
H 0
P4
•J
H
_J LJ
LJ3
=) U
^
LJ
H- 2
UJ<
X >
z
Ul
c
X
V
4
E
UJ LJ
- H
J* C
o:a'ZJ
LJ— O
h- 3 CO
5-L.
z
oz
z —
)_
LJ
II
2 J
H" C
LJ
S£
_) I
S*0
1
A.
tr
L
en
s
o
z
<
ac
LJ
i
a
Ul
g
0
1
- V
38
CD
^O
2*
A
a
a
—
5
-^
3£
p-o
(A V
E:
a. u.
•o
3 01
(0 —
u.
09 X
3 J
M *•
U--
O. U-
Vacuun
i 1 te red
u.
§!§§§
§0000
ooo o
CM CM CM CM CM
CM "*) CM CM CVJ
§o ooo
oooo
moooo
ON NO CO ifN CD
^-•^ <«>^«i«r
SOOOO
OOOO
(Mf-CO-00
fMNOftjfvjN
ooooo
roo MMfO
OOOOO
1 1 1 1 1
"^^MMM
o'd • « •
ooo
CM \f\ fNJ CM CM
oo • • •
000
0)
JZ
**
o
tt
u o
u. — <»>
< O C LJ
Q OH n l/t h-
K- E 3 <- — <
(O w o — O — 5
< n t- crt — O
i o d- o
Oil w « w"S- 3
— -D jj-Q (B W O
U — — re 3 > O —
O eo — > — J£ — -1
yj — O — W t> O>
yen *J no
i o-oco —
gTX 0) 0^
O (6 fl> U) OCO 0)
*j ep *J >
U. — (A Q>— "O O
CiOiOU- <« «
OOOiT\O
*
OOO
ooo
co cor-
8§§
oom
CJCO (M
000
§00
oo
\OCJ (M
MW
§§§
CM ON ON
r^r- r-
POCM CM
Soo
do'd
000
odd
odd
i i i
i i i
«
3
O*O
K —
(A
C 0)
OK
W 01
0 C
i- a
** a
u'C
4J
4J(A
C
— o
.- 0 w
o««
oo —
"*
v
tt}
(«
-
o
(0
2
^J
fa
§
C
1
i
3
-------
b) Required Input Data
Type(s) of waste to be incinerated
Amount of each type of waste to be incinerated Kg/day
(Ib/day)
c) Limitations and Default Values
The waste material must be combustible and combustion must be
complete to avoid possible production of toxic byproducts.
d) Pretreatment
Biological solids are assumed to be dewatered prior to inciner-
ation. Digestion of biological solids prior to incineration is
considered uneconomical and is not recommended [4-1].
e) Design Equation
i) Multiple Hearth Incinerator
If any type of sludge, mixture of sludges, or mixture of
sludges and liquid wastes is present, a multiple hearth
incinerator is used. For liquid residues or process
streams alone, a vertical liquid waste incinerator (not
addressed) is used. The primary factor used for design
of a multiple hearth incinerator is the required effec-
tive furnace surface area. The required hearth surface
area is calculated by dividing the wet weight of bio-
logical and mixed sludge to be incinerated by the solids
loading rate.
Metric
AREA = Q * 39
where: AREA
Q
Q(n)
SR(n)
39 =
English
required hearth surface area, m2
total weight of material passing into
the incinerator, Kg/hr
[I(Q(n) * SR(n))] * 24
dry quantity of each type of biological
sludge or mixed sludge present, Kg/day
solids ratio for each type of sludge de-
pending on the method of dewatering
(Table IV.3.4.4-A1)
assumed solids loading rate, Kg/m2/hr
[4-1]
AREA = Q * 8
Date: 4/1/83
IV.3.4.4-A4
-------
where: AREA = required hearth surface area, ft2
Q = total wet weight of material passing into
the incinerator, Ib/hr
= [Z(Q(n) * SR(n))] * 24
Q(n) = dry quantity of each type of biolog-
ical sludge or mixed sludge present,
Ib/day
SR(n) = solids ratio for each type of sludge
depending on the method of dewatering
(Table IV.3.4.4-A1)
8 = assumed solids loading rate, Ib/ft2/hr
[4-1]
f) Subsequent Treatment
Final disposal of ash is carried out by landfilling or contract
hauling.
A 2. Capital Costs
The primary factor used for determining capital cost for multiple
hearth incineration is the effective surface area of the hearth
(Figure IV.3.4.4-A2). Costs estimated using these curves must be
adjusted to a current value using an appropriate cost index.
a) Cost Data
The items included in the capital cost estimate for the multiple
hearth incinerator are as follows [4-2]:
Multiple Hearth Incinerator including:
Furnace
Gas scrubber
Exhaust packed tower
Ash handling system
Fuel oil storage tank, horizontal flat ends
Scrubber recirculation storage tank, vertical open top
Sludge feed and storage tank, 2 weeks supply, truncated cone
bottom
Caustic storage tank, insulated, covered and heated
Packed tower pumps
Fuel oil pumps, gear type (2)
Sump pumps (2)
Scrubber recirculating pumps, centrifugal (2)
Caustic feed pumps, centrifugal (2)
Air blowers
Tower agitators
Feed conveyor
Piping
Instrumentation
Date: 4/1/83 IV.3.4.4-A5
-------
b) Capital Cost Curve
i) Multiple Hearth Incinerator
Curve - Figure IV.3.4.4-A2.
- Cost (thousands of dollars) vs. surface area
(square meters or square feet).
- Curve basis, cost estimates for systems to
incinerate dewatered sludge produced by four
flow rates, 8.76, 43.8, 219, and 876 L/s (0.2,
1.0, 5.0, and 20.0 mgd).
c) Cost Index
Base Period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components.
Variable operating costs include power, water, supplemental fuel,
and steam. Fixed operating costs include labor, supervision,
overhead, laboratory labor, maintenance, services, insurance and
taxes, and service water. All fixed and variable operating costs
should be adjusted to current levels using an appropriate index
or unit cost factor.
a) Variable Costs
i) Power Requirements - for fuel oil pumps, scrubber
recirculation pumps, caustic feed pumps, sump pumps,
conveyor, bin discharger, and incinerator. The follow-
ing equation was developed using regression analysis
procedures [4-1].
Metric
KW = (1.81 x AREA) + 19.3
where: KW = power required, kilowatts
AREA = required hearth area, m2
English
HP = (0.225 x AREA) +25.9
where: HP = power required, Hp
AREA = required hearth area, ft2
Date: 4/1/83
IV.3.4.4-A6
-------
Ill
3
o
I—I
I
§
H
1
w
1
O
s
H
cn
8
3
H
H
5!
o
o-
CD
6
WVTKX1 JO SONVSnOHl '18OO
Date: 4/1/83
IV.3.4.4-A7
-------
ii)
Power Cost
Metric
. PC = KW x 24 x EC
where: PC = power cost, $/day
KW = power required, kilowatts
24 = hr/day
EC = electricity cost $/Kw-hr
English
PC = HP x 24 x 0.746 x EC
where: PC = power cost, $/day
HP = required horsepower, Hp
EC = electricity cost, $/kw-hr
24 = hr/day
0.746 = kw-hr/Hp-hr
iii) Supplemental Fuel Requirements
Supplemental fuel requirements are determined after
estimating the following: (1) the heat contribution
from incoming biological and mixed sludges and residues;
(2) the heat leaving the incinerator in the form of
combustion gases; (3) the heat needed to evaporate water
from the sludges; and (4) auxiliary heating needed to
maintain an incinerator temperature of 982°C (1800°F).
Metric
FUEL = AUXHT x 24 * (41,900 x 0.868)
where: FUEL = supplemental fuel required, L/day
AUXHT = auxiliary heat required, KJ/hr
24 = hr/day
41,900 = heating value of No. 2 fuel oil, KJ/Kg
0.868 = Kg/L of No. 2 fuel oil
English
FUEL = AUXHT x 24 * (18000 x 7.25)
where: FUEL = supplemental fuel required, gal/day
AUXHT = auxiliary heat required, Btu/hr
24 = hr/day
18000 = heating value of No. 2, fuel oil, Btu/lb
7.25 = Ib/gal of No. 2 fuel oil
Date: 4/1/83
IV.3.4.4-A8
-------
The following steps are followed to determine the aux-
iliary heating requirements (AUXHT):
• Step 1; Determine the heat value of the sludges
entering the incinerator.
Metric
HEATIN = I[Q(n) x HV(n)] * (120 * 7)
where: HEATIN = heat value of wastes entering the
multiple hearth incinerator, KJ/day
Q(n) = dry or undiluted quantity of each type
of biological sludge or liquid residue,
Kg/day
HV(n) = heating value of each sludge, KJ/Kg
120 * 7 = 120 hours/7 days of operation
English
HEATIN = Z[Q(n) x HV(n)] * (120 * 7)
where: HEATIN = heat value of wastes entering the
multiple hearth incinerator, Btu/day
Q(n) = dry or undiluted quantity of each
type of biological sludge or liquid
residue, Ib/day
HV(n) = heating value of each sludge, Btu/lb
(Table IV.3.4.4-A1)
120 f 7 = 120 hours/7 days of operation
• Step 2; Determine the quantity of water which must
be evaporated from the sludges and residues.
EVAP = WETWT - DRYWT
where: EVAP
WETWT
total water to be evaporated, Kg/day or
Ib/day
total weight of wet sludge and diluted
liquid residue, Kg/day or Ib/day
= Z[Q(n) * SR(n)]
DRYWT = total dry weight of sludge and
undiluted liquid residue, Kg/day or
Ib/day
Q(n)
SR(n)
dry weight of sludge or undiluted liquid
residue, Kg/day or Ib/day
solids fraction of sludge or non-
water fraction of liquid residue
(Table IV.3.4.4-A1)
Date: 4/1/83
IV.3.4.4-A9
-------
• Step 3; Determine the amount of heat leaving the
incinerator in the combustion gases assuming 100%
excess air.
Metric
HEATOUT = I[Q(n) * 2 x Fv(n) x 2] * (120 * 7)
where: HEATOUT = heat leaving the incinerator, KJ/hr
Q(n) = dry weight of sludge or undiluted
liquid residue, Kg/day
Fv(.n) = fuel value of sludge or liquid residue,
KJ/Kg-mole
120 * 7 = 120 hours/ 7 days of operation
English
HEATOUT = Z[Q(n) * 2 x Fv(n) x 2] * (120 * 7)
where: HEATOUT = heat leaving the incinerator,
Btu/hr
Q(n) = dry weight of sludge or undiluted
liquid residue, Ib/day
Fv(n) = fuel value of sludge or liquid
residue, Btu/lb-mole
(Table IV.3.4.4-A1)
120 * 7 = 120 hours/7 days of operation
• Step 4; Determine the additional heat required to
completely incinerate biological and mixed sludge and
residue and maintain the incinerator at 982°C
(1800°F).
COMHT = HEATOUT - HEATIN
where: COMHT = additional heat required to incin-
erate wastes, KJ/hr or Btu/hr
HEATOUT = heat leaving the incinerator, KJ/hr or
Btu/hr
HEATIN = heat value of waste entering the
incinerator, KJ/hr or Btu/hr
* Step 5: Determine the total auxiliary heating
requirement to burn wastes and evaporate water.
Metric
HTTOT = EVAP x 4654 * (120 * 7) + COMHT
Date: 4/1/83 IV.3.4.4-A10
-------
where: HTTOT = total heating required, KJ/hr
EVAP = water to be evaporated, Kg/day
4654 = heat required to evaporate water,
KJ/Kg
COMHT = additional heat required to incinerate
wastes, KJ/hr
English
HTTOT = EVAP x 2000 * (120 * 7) + COMHT
where: HTTOT = total heating required, Btu/hr
EVAP = water to be evaporated, Ib/day
2000 = heat required to evaporate water and
bring the vapor to 1800°F [4-2], Btu/lb
COMHT = additional heat required to incinerate
wastes, Btu/hr
• Step 6: The minimum auxiliary heating required to
allow for start-up and backup is estimated as 10
percent of the heat needed to evaporate sludge water.
Metric
MINHT = 0.1 x EVAP x 4654 * (120 * 7)
where: MINHT = minimum auxiliary heating required,
KJ/hr
English
MINHT = 0.1 x EVAP x 2000 * (120 * 7)
where: MINHT = minimum auxiliary heating required,
Btu/hr
• Step 7: Determine the auxiliary heating requirement
as follows:
- If HTTOT > MINHT, then AUXHT = HTTOT
- J^f MINHT > HTTOT, then AUXHT = MINHT
iv) Supplemental Fuel Cost
FC = UFC x FUEL
where: FC = supplemental fuel cost, $/day
UFC = unit cost of supplemental fuel, $/L or
$/gal
FUEL = supplemental fuel requirement, L/day or
gal/day
Date: 4/1/83 IV.3.4.4-All
-------
v) Water Requirements
The total water requirement is the summation of quench
water and scrubber water.
Metric
WATER
where: WATER
Quench Water
QW
HEAT
QW + SW
total water requirement, L/s
quantity of quench water, L/s
(HEAT r 3600) * (2398 x 1.0 x 0.5)
total amount of heat released in the
multiple hearth incinerator, KJ/hr
= (HEATIN + AUXHT)
HEATIN = heat value of wastes entering incinerator,
KJ/hr (see Section A3, a, iii)
AUXHT = auxiliary heating required, KJ/hr
3600 = seconds per hour
2398 = heat removal value for kilogram of water,
KJ/Kg
kilograms per liter
1.0 =
Scrubber Water
SW =
FAN =
WWOL =
EXSTVOL =
HEATOUT =
FV =
10.8 =
367
294
60
2.01
EVAP
18
2398
quantity of scrubber water, L/s
FAN x 2.01 t 60
size of fan required, m3/min
(WVVOL + EXSTVOL) x 10.8 x (367 * 294)
* 60
water vapor volume moved by fan,
Kg-mole/hr
[(HEAT * 2398) + EVAP] * 18
volume of combustion gases, Kg-mole/hr
HEATOUT * FV
(see Section A3, a, iii)
fuel value of exhaust gases
volume occupied by a kilogram mole of
gas at standard temperature and pressure
[4-1], m3
air temperature, "Kelvin [4-1]
fuel temperature, °Kelvin [4-1]
minute/hour
water flow rate required per m3 of air,
L/m3
total quantity of water evaporated, Kg/hr
molecular weight of water, Kg/mole
heat removed per pound of water, KJ/Kg
Date: 4/1/83
IV.3.4.4-A12
-------
English
WATER
where: WATER
Quench Water
QW
QW + SW
total water requirement, thou gal/day
quantity of quench water, thou
gal/day
= (HEAT x 106 x 24) T (1030 x 8.34 x 0.5
x 1000)
HEAT = total amount of heat released in the
multiple hearth incinerator, million
Btu/hr
= (HEATIN + AUXHT) * 106
106 = Btu/million Btu
HEATIN = heat value of wastes entering incinerator,
Btu/hr (see Section A3, a, iii)
AUXHT = auxiliary heating required, Btu/hr
(see Section A3, a, iii)
24 = hours per day
1030 = heat removal value for pound of
water, Btu/lb
8.34 = pounds per gallon
1000 = gal/thou gal
Scrubber Water
SW =
FAN =
WWOL =
EXSTVOL =
HEATOUT =
FV =
387 =
660
530
60
0.015
1440
1000
quantity of scrubber water, thou gal/day
FAN x 0.015 x 1440 * 1000
size of fan required, ft3/min
(WWOL + EXSTVOL) x 387 x (660 * 530) * 60
water vapor volume, moved by fan,
Ib-mole/hr
[(HEAT x 106 r 1030) + EVAP] * 18
volume of combustion gases, Ib-mole/hr
HEATOUT * FV
(see Section A 3, a, iii)
fuel value of exhaust gases
volume occupied by a pound mole of
gas at standard temperature and pressure
[4-1], ft3
air temperature, °Rankine [4-1]
fuel temperature, "Rankine [4-1]
minute/hr
water flow rate required per ft3 of
air, gal/ft3
minute/day
gal/thou gal
Date: 4/1/83
IV.3.4.4-A13
-------
EVAP = total quantity of water evaporated,
Ib/hr
18 = molecular weight of water, Ib/mole
1030 = heat removed per pound of water, Btu/lb
vi) Water Cost
Metric
W = WATER x WC x 86400
where: W = water cost, $/day
WATER = total water required, L/s
WC = unit cost of water, $/L
86400 = s/day
English
W = WATER x WC
where: W = water cost, $/day
WATER = total water required, thou gal/day
WC = unit cost of water, $/thou gal
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.4.4-A2 including values for the cost basis and the
unit costs [4-11].
A 4. Miscellaneous Costs
Cost for engineering, and other common plant items such as piping
and buildings, are calculated after the completion of costing for
individual units (See Section IV.3.5).
(a) Ash
The amount of ash resulting from the incineration of biological
sludge or biological sludges mixed with liquid residues is deter-
mined as follows:
ASH = 0.7 x I[Q(n) x A(n)]
where: ASH = total amount of ash, Kg/day or Ib/day
Q(n) = quantity of sludge of type n, Kg/day or Ib/day
A(n) = fraction ash content for sludge type n
(Table IV.3.4.4-A1) [4-1]
A 5. Modifications
None required.
Date: 4/1/83 IV.3.4.4^A14
-------
TABLE IV.3.4.4-A2.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR SLUDGE INCINERATION [4-11]
Element
Labor (1)
Supervision
Overhead (1)
Laboratory
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Ecjuivalent Unit Quantity)
0.71 Weeks (2) (24.0 hr/day,
5 days/week)
10% Labor (2.4 hr/day)
75% Labor Cost
0.10 Shifts (3) (0.57 hr/day)
2.01% Capital
0.40% Capital
2.50% Capital
0.038 L/s
(0.86 Thou gpd)
(July 1977)
$ 9.80
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.4.4-A15
-------
MULTIPLE HEARTH INCINERATOR
SUMMARY WORK SHEET REFERENCE:
I.
a.
II.
DESIGN FACTOR
Hearth Surface AREA =
CAPITAL COST
Cost = x (
III.
a.
b.
c.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
ASH
Cost from curve current
VARIABLE 0 & M
Power = x
Hp EC, $/Kw-hr
Supplemental Fuel =
ft*
* 204.7)
index
x 12.78
X
F, gals/day 0, $/gal
Water = x
W,thou gals/day
FIXED 0 & M
Labor :
$/day
Supervision:
Labor, $/day
Overhead:
Labor, $/day
Lab Labor:
Labor, $/day
Maint, Service,
I&T: capital, $
Service Water:
thou gpd
YEARLY 0 & M
UNCOSTED ITEMS
Ib/day
X,$/thou gal
%
x %
x %
%
X
$/thou gal
365
$/day
=
.
$/day
.
.
=
.
x
day/yr sum, $/day
IV.3.4.4-A
$
—
$/yr
Date: 4/1/83
IV.3.4.4-A16
-------
MULTIPLE HEARTH INCINERATOR
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. EC: Electricity Cost = $/Kw-hr
3. 0 = Supplemental Fuel Cost = $/gal
4. X = Water Cost = $/thou gal
5. Labor = $/day
6. Supervision = % Labor
Overhead = % Labor
Lab Labor = % Labor
Other Labor Factor = Sum Above
7. Maintenance = % Capital
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor = % * 100 = %/100
8. Service Water = $/thou gal
I. DESIGN FACTOR
a. List quantities of dry sludge and mixed liquid wastes in Column B of
Work Table 1.
b. Type of sludge dewatering device (vacuum or pressure filter) used
prior to incineration =
c. If vacuum filter utilized before incineration, divide the quantity of
dry sludge (from Column B) by the corresponding solid ratio (from
Column C) and enter the results in Column E.
d. If pressure filter utilized before incineration, divide the quantity
of dry sludge (from Column B) by the corresponding solid ratio (from
Column D) and enter the results in Column E.
e. For liquid wastes which are to be incinerated along with the sludge,
divide the quantities in Column C by the non-water fractions in
Column D and enter the resulting wet weights in Column E.
Date: 4/1/83 IV.3.4.4-A17
-------
WORK TABLE 1. CALCULATION TO
A B
Type of Sludge Quantity of Dry
Sludge, Q(n)
(Ibs/day)
DETERMINE THE AMOUNT OF WET SLUDGE
C D E
Solid Ratio Solid Ratio Quantity of
for Wet for Wet Wet Sludge,
Sludge, SR Sludge, SR Q (Ibs/day)
(Vacuum) (Pressure)
Solid
DAF Chemical Float
DAF Oil/Solids
Waste Activated Sludge
Digested Sludge
Filter Backwash
(organic)
Liquid
Oil
Solvent Extraction Residue
Stream Stripping Residue
Sum =
B, Ibs/day
f. Sum Column E to determine total
Sum E = Ib/day
g. Required Hearth Area
AREA = f
0.2 0.3
0.5 0.5
0.12 0.35
0.12 0.35
0.12 0.35
Quantity of Non-Water
Liquid Waste Fraction
Ibs/day Ibs/day
0.95
0.65
0.95
Sum =
E, Ibs/day
quantity of wet sludge
8 = ft*.
Sum Column E, Ibs/day
II. CAPITAL COST
III. VARIABLE 0 & M
a. Power Requirements
HP = (0.225 x ) + 25
.9 = Hp
AREA, ft2
b. Supplemental Fuel Requirement
1. Determine heat value of sludges entering the incinerator (See
Table IV.3.4.4-A1).
Date: 4/1/83
IV.3.4.4-A18
-------
• List the dry weights of sludges and the undiluted weights of
liquid wastes entering the incinerator in Column B of Work
Table 2.
• Multiply the dry weight of each waste in Column B by the cor-
responding heating value in Column C and enter the resulting
heat value in Column D.
• Sum Column D.
. HEATIN = x 0.058 = Btu/hr
SUM D
2. Determine the quantity of water to be evaporated from sludge and
liquid waste (see Work Table 1)
. WETWT = Ib/day
SUM COLUMN E
. DRYWT = Ib/day
SUM COLUMN B
• EVAP = - = Ib/day
WETWT, Ib/day DRYWT, Ib/day
3. Determine the amount of heat leaving the incinerator in the com-
bustion gases (see Work Table 2).
• Multiply the dry weight of wastes from Column B by the fuel
value of the wastes from Column E and enter the results in
Column F.
• Sum Column F = Btu
• HEATOUT = x 0.058 = Btu/hr
SUM F
4. Determine the additional Jieat required to completely incinerate
biological and mixed sludge and residues
COMHT = - = Btu/hr
HEATOUT HEATIN
5. Determine the total auxiliary heating requirement to burn wastes
and evaporate water.
HTTOT = x 116.667 + = Btu/hr
EVAP COMHT
Date: 4/1/83 IV.3.4.4-A19.
-------
6. Determine the minimum auxiliary backup heating requirement.
MINHT = x 11.667 = Btu/hr
EVAP
7. Determine the auxiliary heating requirement.
. If HTTOT > MINHT, AUXHT = Btu/hr
HTTOT
• If MINHT > HTTOT, AUXHT = Btu/hr
MINHT
8. Determine Supplemental Fuel Requirement
FUEL = ._ x 1.84 x 10-« = gal/day
AUXHT, BTU/hr
c. Water Requirements
The total water requirement is the summation of quench water and scrubber
water requirements
1. Determine quench water (QW) requirement.
• HEAT = ( + ) f 106 = million Btu/hr
HEATIN AUXHT
• QW = x 5.59 = thou gal/day
HEAT
2. Determine scrubber water requirement.
• Volume of water vapor in exhaust
WWOL = ( x 971) + T 18 = Ib-mole/hr
HEAT EVAP
• Volume of combustion gases
EXSTVOL = r 9700 = Ib-mole/hr
HEATOUT
• Capacity of exhaust fan
FAN = ( + ) x 8.03 = cfm
WWOL EXSTVOL
• SW = x 0.0216 = thou gal/day
FAN
Date: 4/1/83 IV.3.4.4-A20
-------
3. Total water requirement
WATER =
QW
SW
thou gal/day
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
a. Determine quantity of ash to be disposed of (see Work Table 3)
b. Enter quantity of each waste type in Column B
c. Multiply quantity of each waste type (from Column B) by the fractions in
Column C and enter results in Column D
d. Sum Column D
e. ASH = (
) x 0.7
Sum D, Ibs/day
Ibs/day
WORK TABLE 3.
Waste Type
B
Quantity of
Waste
Ibs/day
Ash
Fraction of
Waste
Ash
Ibs/day
DAF Chemical Float
0.35
Oil
0.05
Oil & Solids (from DAF)
0.05
teste Activated Sludge
0.35
Digested W.A.S.
0.35
Solvent Extraction Residue
0.05
Steam Stripping Residue
0.05
Filter Backwash (organic)
0.35
Sum =
Ibs/day
Date: 4/1/83
IV.3.4.4-A2I
-------
IV.3.4.5 LANDFILL/OUTSIDE CONTRACTOR
Introduction
Landfill disposal is the most widely used method of final solid
waste disposal. Factors considered in selecting a site for a
landfill include zoning restrictions, public acceptance, acces-
sibility, and size requirements. Because the waste operating
facility is often a considerable distance from the landfill site,
an important element of the total cost may be the transportation
system. In order to function properly, a landfill must have
proper geologic conditions and a suitable cover material. Land-
fill disposal is described in more detail in Volume III of the
Treatability Manual, Section III.4.5. Costing methodologies and
cost data for this technology are presented below.
IV.3.4.5-A. Landfill
A 1. Basis of Design
This presentation is for the disposal of wastewater sludge and
incinerator ash in landfills. A landfill of the type considered
is illustrated in Figure fV.3.4.5-A1. The principal design
factor considered is the area required for the landfill and
leachate collection and treatment facilities. The area required
is determined from the sludge loading rate. Loading rates vary
depending on the type of sludge and whether it has been dewatered
by vacuum or pressure filtration (Table IV.3.4.5-A1). It is
assumed that sludge is mixed with soil to achieve a final solids
concentration of 80% for disposal. Because sludge handling and
dewatering is uneconomical when sludge volumes are small, an
outside contractor may be used to dispose of low volumes of
sludge wastes.
The landfill is constructed as two-year capacity cells. If no
depth is specified, a default value of three meters (ten feet) is
assumed. Computed area requirements are increased by 25 percent,
prior to costing, to allow for cell construction and access re-
quirements. It is assumed that the landfill is constructed on a
suitable site on company property away from the sludge production
area and has a usable life of 20 years. The hauling distance to
the landfill is assumed to be 5 miles unless otherwise specified.
a) Source
This cost estimate method was derived from the BAT Effluent
Limitations Guidelines engineering study for the Organic Chemi-
cals/Plastics and Synthetic Fibers Industries [4-2]. The method
for developing the design factor is based on assumptions and procedures
in the Contractor Developed Design and Cost Model [4-1].
Date: 4/1/83 IV.3.4.5-A1
-------
3
H
H
Q
I
03
CO
D
O
Date: 4/1/83
IV.3.4.5-A2
-------
CO
cc
^
>
<£.
O
U.
CO
o
^-
sc.
CO
o
J
o
CO
1-
UJ
^
o
z
^
CO
UJ— •
rf 1
CCJ
o"
ZbJ
5g
o
0-1
_ico
_IU-
,— 'o
U-CO
QLJ
<; >_
_) t—
«
^
^
I
ir\
•
.»
to
«
^^
^
UJ
_J
CO
^
h-
CD
O
•o
3
co
P
CD
s
^
0
o
(0
K
(fl
•0
O
co
^*.
+d
|
CD
(.
U
«*>^^^ 4«h ««k^^ ««^
ooocoooooo o oo\ o
h-CMCM(Mr-r~r^oocM CM r-oo o
o CM oj CM o o o mm o o oo ir\
oo oo oo oo ITMT> in to to ir\ ir» IT\CM to
o oo oo oo cvi CM CM r~ r~ co to CM<- r~
I- r-t-i- CMCMr-CM
OOOOOOOlTMTlO O OO\ in
f- lfMAUM»- r- r- CM CM CM CM r^CO CM
•~~ — -^ CO
t- — J£ C CO
0) CO *» O O >
P CO C CO to JQ JC
ro P P — t- ca t. o
p ro ro CO ocoajto
CO — CO P O O) C C i- O CO
43 O. P •— ~~ CO °O CO J3 *~ J^ •-* CD
Co — co Q.U. (OCn3O)lfl (OOP- <-
POP— •OT3 — 'O to — — — UIAI. u. —
— (X — (. U O CO • C/5 O ro O P -D —
U UQ CO P P>POO >>— LL-
COECO E «-OT3«J to 3 — to —
Q. C O- T3 J3 i- J3 PCDOCDO(0(OCO —
*^ *^ U CD .0 Q) o c fl) c ^ o^ i c
OECd- E3PCO— 1 O.t-O&%(0
E30 — U.--l-(0010— O>>OS-OO)
H< — COQCXCoSo K ^O
.T-CMrod'OO'- OlTiCM lT> 0 1- O
^ p" r- T" CM m in vo vo ^ r** oo oo o\
* *
*
0
c
co
o
•o
c
(0
^^
o
VO
CO
at
•o
in
•^
q)
*>
1
4J
O
CO
0)
in
to
^
c^.
O
in
CD
4J
—
P
C •
(0 O
3 i-
CT Q)
N
CO
PO
* O
p p
c
CO-D
in co
CO E
t. 3
O.M
(0
in co
CO
^*> &_
m co
vo
Q
COO
C71—
•a
3 f
— in
in to
CD o
P CO
in a
CO
o><-
.- CD
T3 P
_
4- —
^ (^
4:
CD
4-
CO
co
CD
P
in
to
en
C
._
p
3
._
I.
p
C
O
o
CO
p
—
^
p
c
CO
in
CO
c.
a.
(0
„
CM
r-
CD
P
in
CO
^
V)
(0
O
a
(^
o
c
o
p
to
L.
0)
C
._
O'
c
•
P O
0 «-
CO CD
(- N
•~
•0 CD
n
o o
(- p
•o
C CO
co E
(0 3
CO
«- in
— co
£
*
Date: 4/1/83
IV.3.4.5-A3
-------
b) Required Input Data
Dry weight of incoming individual types of sludge solids
Kg/day (Ib/day)
Landfill haul distance (miles)
Depth of landfill meter (feet)
c) Limitations
None specified.
d) Pretreatment
Pretreatment consists of either vacuum or pressure filtration to
dewater sludges.
e) Design Equation
The landfill design is based on the area required to dispose of
sludges over a 20 year period. The required total area is com-
puted based on the amount of incoming sludge as follows:
Metric
AREA = VOL * DEPTH
where: AREA = Landfill area, hectares
VOL = total volume of all sludges,
hectare-meter
= {I [DW(i) * LR(i)]} x 365 x 20 x
1.25 * 1000
DW(i) = dry weight of incoming
sludge, Kg/day
LR(i) = loading rate of sludge(i),
Mg/hectare-meter
365 x 20 = days in design life (20 years), days
1.25 = factor adjustment to allow for area requirements
for cell construction and access
1000 = Kg/Mg
DEPTH = landfill depth, m
English ,
AREA = VOL * DEPTH
where: AREA = landfill area, acres
VOL = total volume of all sludges, acre feet
= {Z [DW(i) * LR(i)]} x 365 x 20 x 1.25 * 2000
DW(i) = dry weight of incoming sludge (i),
Ib/day
Date: 4/V83 IV.3.4.5-A4
-------
LR(i) = loading rate of sludge (i), ton/acre
foot
365 x 20 = days in design life (20 years), days
1.25 = factor adjustment to allow for area requirements
for cell construction and access
2000 = Ib/ton
DEPTH = landfill depth, feet
f) Subsequent Treatment
Landfill leachate is collected and treated prior to discharge.
A 2. Capital Costs
The landfill area is the principal cost factor used in estimating
capital cost. Costs for both single lined and double lined
landfills may be estimated separately. The double lined landfill
is included to represent the cost of disposing of sludges which
may be of concern due to'toxicity or other problems. The in-
stalled cost of a single lined landfill is represented in Figure
IV.3.4.5-A2 while the cost for a double lined landfill is
represented in Figure IV.3.4.5-A3. The capital cost estimate
includes the first two year landfill cell. The cost of con-
structing additional cells is considered a maintenance item.
Costs estimated using the cost curve must be adjusted to a
current value using an appropriate cost index.
a) Cost Data
Items included in the capital cost estimate are as follows [4-2]:
i) Lined Landfills
Rainfall runoff and leachate channeled to central
drainage basin
Package physical/chemical treatment facilities
Underdrain system
Plastic membrane liner covered with 0.61 meters
(2 feet) of sand for the first two year
landfill cell
Monitoring wells
ii) Double Lined Landfills
All equipment for single lined landfill plus
following items:
One additional sand/impermeable liner provided
One additional leachate collection system
b) Capital Cost Curve
i) Lined Landfill
Curve - see Figure IV.3.4.5-A2.
- Cost (millions of dollars) vs. area (hectares
or acres).
Date: 4/1/83 IV.3.4.5-A5
-------
- Curve basis, cost estimate for four landfills
of 1.09, 4.94, 15.7, and 52 hectares (2.7,
12.2, 38.7, and 128.6 acres).
ii) Double Lined Landfill
Curve - see Figure IV.3.4.5-A3.
- Cost (millions of dollars) vs. area (square
kilometers or acres). «
- Curve basis, cost estimate for four landfills
of 1.09, 4.94, 15.7, and 52 hectares (2.7,
12.2, 38.7, and 128.6 acres).
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
A 3. Operation and Maintenance Costs
Operating costs include fixed and variable components. The
variable component includes hauling costs. Fixed costs include
labor, supervision, overhead, laboratory labor, maintenance, ser-
vices, insurance and taxes, and service water. All fixed and
variable operating costs should be adjusted to current levels
using an appropriate index or unit cost factor.
a) Variable Costs
i) Hauling Cost
Metric
HC = HD x WW x CF
where: HC
HD
WW
DW(i)
SR(i)
CF =
hauling cost, $/day
hauling distance, kilometers
wet weight of the sludge, Kg/day
E [DW(i) f SR(i)]
quantity of sludge type i, Kg/day dry
fraction of solids in cake after filtration
for sludge type (i) (see Table IV.3.4.3-A1)
hauling cost factor, $/Kg-kilometer
English
HC = HD x WW x CF
Where: HC
HD
WW
hauling cost, $/day
hauling distance, mi
wet weight of the sludge, Ib/day
= Z[DW(i) T SR(i)]
DW(i) = quantity of sludge type i,
Ib/day (dry)
Date: 4/1/83
IV.3.4.5-A6
-------
AREA, HECTARES
<
s
J
o •-_
o *^
1^
2 2-
z z
2
.j
5 -ii_
-j
5
o
>
*
f
Ji
a
u.
3
.(
x"
1
9
0
s
1
<
6
£
r
4
2
»*
0
>
X
i
^
24
X1
6
IF
.3
s
0
IE
r
14
^
^
J
32
<
a
c
j
*•
0
fl
J
^
E
X
8
^
^
10
x1
1C
.5
ft
>
^
4
8
,
I!
6
X*
!C
1
>
d
1
5
4
J.7
0
FIGURE IV.3.4.5-A2. CAPITAL COST ESTIMATE
FOR LANDFILL (LI;1ED) [4-10]
CO
o
2
2
S
o
o ac
•_
*•-
i
-
-
-h
J
/
3
f
'
A
9 re
,
'
''
.
/
/
P
\t
REA, HECTARES
,2 24_,3 _3:
X
/
._
/
-
/
j
i/
/
r
^
'
i—
*
1.3 4
-------
SR(i) = fraction of solids in cake after filtration
for sludge type i (see Table IV.3.4.3-A1)
CF = hauling cost factor, $/lb-mile
(default value = 0.0004 $/lb-mile) [4-2]
b) Fixed Costs
The fixed O & M components for this technology are listed in
Table IV.3.4.5-A2, including the cost basis and the unit costs
[4-11].
A.4 Miscellaneous Costs
Costs for engineering, and other common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5).
A. 5 Modifications
None required.
Date: 4/1/83 IV.3.4.5-A8
-------
TABLE IV.3.4.5-A2.
FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR LANDFILL OPERATIONS
[4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory
Maintenance (4)
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.83 Weeks (20.0 hrs/day)
10% Labor (2.00 hrs/day)
75% Labor Cost
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
0.15 Shifts (3)(0.86 hrs/day) $10.70/hr
NA NA
0.40% Capital NA
2.50% Capital NA
0.128 L/s
(2.93 Thou gpd)
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
;Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section ).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
(4) Annual maintenance cost for this technology includes the
average annual cost of developing new 2-year landfill
cells. Maintenance costs are calculated as a percentage of
the capital costs. The percentage varies with the total
landfill area as follows:
Landfill Area (acres)
Area < 2.8
2.8 £ Area < 12.2
12.2 £ Area < 38.7
38.7 <, Area < 128.6
128.6 £ Area
% of Capital Cost for Maintenance
15.1
11.0 + (1.5 x Area)
27.0 + (0.25 x Area)
34.0 + (0.06 x Area)
41.4
Date: 4/1/83
IV.3.4.5-A9
-------
I.
DESIGN FACTOR
Landfill Area =
II.
Cost
CAPITAL COST
=
LANDFILL
SUMMARY WORK SHEET
REFERENCE: IV.3.4.5-A
CAPITAL
acres
x ( * 204.7)
Cost from curve current index
III.
a.
IV.
a.
b.
c.
d.
e.
f.
V.
VI.
VARIABLE 0 &
Hauling Cost =
FIXED 0 & M
Labor :
Supervision:
Overhead:
Lab Labor:
Maint, Service
I&T:
Service Water:
YEARLY 0 & M
M
X X
Distance, CF, Wet weight
Miles $/lb-mile Ib-day
X
hr/day $/hr
X
hr/day $/hr
X
Labor, $/day %/100
X
hr/day $/hr
x f 365
capital, $ %/100 day/yr
x
thou gpd $/thou gal
365
$/day
—
/
.
.
.
x
day/yr sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Date: 4/1/83
IV.3.4.5-A10
-------
LANDFILL
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index = Capital Cost Index
2. CF = Hauling Cost
Factor = $/lb-mile
3. Labor = $/hr
4. Supervision = $/hr
5. Overhead = % Labor * 100 = %/100
6. Lab Labor = $/hr
7. Maintenance = % Capital (See Section IV)
Services = % Capital
Insurance/Taxes = % Capital
Other 0 & M Factor sum = * 100 = %/100
8. Service Water = $/1000 gal
I. DESIGN FACTOR
B. For those sludges dewatered using vacuum filtration, use Work Table 1
1. Enter incoming dry sludge weights (DW) by type in column C
2. Divide dry sludge weights (DW) by loading rates (LR) from column A
and enter the results (initial landfill volume) in column D.
3. Sum column D
4. To determine landfill area (AREA) for vacuum dewatered sludge enter
the sum of column D (initial landfill volume) and the expected land-
fill depth (default value is 10 ft) in the following Equation.
AREA = x 4.56 * = acres
SUM D (VOL) DEPTH
b. For those sludges dewatered using pressure filtration, use Work Table 2.
Follow the same procedure as described for Work Table I.
AREA = x 4.56 * = acres
SUM D (VOL) DEPTH
Date: 4/1/83 IV.3.4.5-A11
-------
c. Total Basin Area =
acres
Area, acres Area, acres
Work Table I Work Table II
II. CAPITAL COST
III. VARIABLE 0 & M
a. For those sludges dewatered using vacuum filtration, use Work Table I.
1. To determine the wet weight of each sludge, divide dry weights (DW),
Column C by the solids/moisture ratio (SR) from column B and enter
the results in column E.
2. Sum column E and enter the results in the equation in Part III c below
b. For those sludges dewatered using pressure filtration, use Work Table II.
Follow the same procedure as described for Work Table I.
c. Total Weight Hauled = + =
Wet weight, Ibs/day Wet weight, Ibs/day Wet weight,
Work Table I Work Table II Ibs/day
IV. FIXED 0 & M
a. Determine maintenance cost factor (% capital) from the following table.
AREA (From Ic)
(acres)
<2.8
2.8 to 12.2
12.2 to 38.7
38.7 to 128.6
>128.6
Factor
Calculation
15.1
11.0 + 1.526 x
27.0 + 0.249 x
34.0 + 0.0578 x
41.4
Maintenance
% Capital
15.1
AREA, acres
AREA, acres
AREA, acres
41.4
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83
IV.3.4.5-A12
-------
w
I
i
— CD
.O
UJI.C II
.?UJ
I
*
_J
~"o
01 -
0 II
E
30
O
5
*» >
011:
01 o«
o
30:
*•«
jp r
mi
M *
— 0
L
AJ
0 1
Sc
"'Is
•5 c
5-
*
t
>-
O
C
•t
•o
Scrubber Slu
«
CM
0
m
CM
1
3
(0
•o
0)
Waste Active
.S
CM
O
in
CM
0
Ol
3
OT
•D
0
M
O
Ol
5
in
VO
*
S
o
o
CM
Ineration)
o
c
< 0
Incinerator
(direct wast
CM
r*
2
S
o
o
CM
ration)
£S
Incinerator
(byproduct i
m
r-
in
CM
O
g
Backwash
i.
S
Inorganic Fi
o
-------
11
E
D Q
O
g
Ol— V
0) to
£.0
o
to
L. —
3 IT
O •
«l *J
— 0
s
a:
A
*<*.
to i
CO «-
a: c
c *
•o e
I-
i-
i
i
V
u.
o
m
o
o
r-
0)
CO
a.
u
a.
i
^.
o
o
o
CJ
to
(0
a
u
0)
u
o.
1
Alum in
CM
O
O
o
CM
CO
Q.
U
I
e
0
o
o
o
CVJ
0
CO
a
0
0)
L.
CV
>
P r i ma r
o
m
o
o
r-
C7I
•o
3
in
L.
(0
Scrubb
^
m
m
o
o
o
to
•o
V)
•o
CO
"
Waste
o
A
O
O
o
IB
cn
3
•o
to
Digest
in
*
S
0
o
cy
"c"
o
to
to
c
u
c
.c —
< 0)
L M
O ca
2*
O U
c to
— L.
(V
*
*
s
o
o
CM
C
o
(0
1.
c
£. O
(A C
t- 4->
o u
*» 3
09 <-
c a
OX
in
r*
5
o
o
f-
«
to
o
m
CO
u.
u
c
Inorga
s
o
Ox
to
C
0
f
5
13
Q)
A
So
Throwa1
(60» S
F-
CO
in
o
o
o
.c
to
i
m
u
to
.u
U.
O
C
n
at
t_
0
o
It
3 «w
to
II
ll
2
o
o
— o
« o
e o
S c
S 5
a. a
^o §
4J U C
Date: 4/1/83
IV.3.4.5-A14
-------
IV.3.4.5-B. Outside Contractor
B 1. Basis of Design
This presentation is for the disposal of wastewater sludge and
incinerator ash using an outside contractor. The principal
design factor considered for this service is the volume required
to store liquid residue and sludge generated over a 30-day period.
The volume required is determined from the dry weight of incoming
sludge solids, the ratio of dry sludge weight to wet sludge
weight, and the density of the liquid sludge to be stored.
Typical values for these factors are indicated in Table IV.3.4.5-B1,
The design for the storage facility includes a concrete base, one
or more storage tanks, centrifugal pumps, pipes, valves, and
necessary instrumentation. The contractor hauling distance is
assumed to be 10 miles if no other distance is specified.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries
[4-2]. The method for developing the design factor is based
on assumptions and procedures in the Contractor Developed
Design and Cost Model [4-1].
b) Required Input Data
Dry weight of each sludge type Kg/day (Ib/day)
Total sludge weight Kg/day (Ib/day)
c) Limitations
None specified.
d) Pretreatment
None required.
e) Design Equation
The design of storage facilities required for outside contractor
hauling is based on the volume necessary to store liquid residue
and sludge generated over a 30-day period. The required volume
is computed from the amount of incoming sludge as follows:
Metric
VOL = 30 x I [DW(i) * SF(i) * SD(i)]
Date: 4/1/83 IV.3.4.5-B1
-------
TABLE IV.3.4.5-B1.
SLUDGE FRACTION AND LIQUID SLUDGE DENSITY FOR
VARIOUS TYPES OF SLUDGE [4-2].
Sludge
Number
**11
**12
**13
**14
20
*30
40
**50
**51
60
*70
*71
**72
**75
**80
**81
90
SF SD
Sludge Fraction, Liquid Sludge
Kg or Ib Dry Sludge/ Density
Sludge Type Kg or Ib Wet Sludge Ib/gal Kg/L
Lime Precipitate
Aluminum Precipitate
Iron Precipitate
Sulfide Precipitate
DAF Chemical Float
Oil
Oil plus Solids from DAF
Primary Solids
Scrubber Sludge
Waste Activated Sludge
Solvent Extraction Residue
Steam Stripping Residue
Incinerator Ash (direct
waste incineration)
Incinerator Ash (byproduct
incineration)
Inorganic Filter Backwash
Throwaway Activated Carbon
Organic Filter Backwash
0.100
0.015
0.030
0.015
0.200
0.950
0.500
0.030
0.030
0.010
0.650
0.950
0.600
0.600
0.010
0.600
0.010
8.34
8.34
8.34
8.34
8.50
8.00
8.34
8.34
8.34
8.34
8.34
8.34
8.34
8.34
8.34
8.34
8.34
1.0
1.0
1.0
1.0
1.02
0.96
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
*Liquid sludge residue
**Inorganic sludge
Date: 4/1/83
IV.3.4.5-B2
-------
where: VOL = total storage volume, L/month
30 = days/month
DW(i) = dry weight of incoming sludge(i), Kg/day
SF(i) = solids fraction of incoming sludge(i),
Kg dry sludge/Kg wet sludge
SD(i) = sludge density, Kg/L
English
VOL = 30 x I [DW(i) * SF(i) * SD(i)]
where: VOL
30
DW(i)
SF(i)
gallon/month
total storage volume,
days/month
dry weight of incoming sludge(i), Ib/day
solids fraction of incoming sludge(i),
Ib dry sludge/lb wet sludge
SD(i) = sludge density, Ib/gallon (see Table IV.3.4.5-B1)
f) Subsequent Treatment
Treatment of sludges by contract hauler prior to disposal.
B 2. Capital Costs
On-site storage volume is the principal cost factor used in esti-
mating capital cost. The cost of storage for either sludge or
liquid wastes alone or sludge and liquid wastes combined may be
estimated by this method. The cost of storing the combined
wastes is assumed to be 1.3 times the standard cost for the
combined waste. The additional cost reflects the cost of storage
tank agitators necessary to produce a relatively homogeneous
mixture. The installed cost of on-site waste storage vessels
without agitators is represented in Figure IV.3.4.5-B1. Costs
estimated using the cost curve must be adjusted to a current
value using an appropriate cost index.
a) Cost Data
Items included in the capital cost estimate are as follows [4-2]:
Concrete base
Storage tanks
Centrifugal pumps
Pipes and valves
Instrumentation
b) Capital Cost Curve
i) Curve - see Figure IV.3.4.5-B1.
- Cost (thousands of dollars) vs. storage volume
(thousand liters or thousand gallons)
Date: 4/1/83
IV.3.4.5-B3
-------
- Curve basis, cost estimate for four storage
vessel volumes 7570, 18,900, 56,800, and
98,400 liters (2,000, 5,000, 15,000, and
26,000 gallons).
ii) Scale Factor
If both liquid waste and sludge are stored together:
COST = Standard Cost from Curve x 1.3
c) Cost Index
Base period, July 1977, St. Louis
Chemical Engineering (CE) Plant Index = 204.7
B 3. Operation and Maintenance Costs
Operating costs include both fixed and variable components. The
variable component includes power, hauling, and disposal. Fixed
costs include labor, supervision, overhead, laboratory labor,
maintenance, services, insurance and taxes, and service water.
All fixed and variable operating costs should be adjusted to
current levels using an appropriate index or unit cost factor.
a) Variable Cost
i) Power Requirements [4-1]. The following equations were
developed using regression analysis procedures.
Metric
KW = (VOL x 5.48 x ID'5) + 0.356
where: KW = power, kilowatts
VOL = storage vessel volume, liter"
English
HP = (VOL x 2.78 x 10"4) + 0.474
where: HP = power, Hp
VOL = storage vessel volume, gallons
ii) Power Cost
Metric
PC = KW x 24 x EC
Date: 4/1/83 IV.3.4.5-B4
-------
STORAQC VOLUME.THOUSAND8 OF LITERS
10
so
46
•0
7ft
t1 M
W.
^
3 60-
40-
Q
z
<
§ 30-
o
p
t 20.
o
o
1O-
,
0.
<
'
9
/
>
^
r
s
f
\s
I
Jt
J
f
^
^
*
1
X
»
x
^
^
^
1
«*•
2
^
P*
K"
B.
^
1
•^
6
•*
--
,•«*
2
*
0
r
**
-•
2
r"
4
**
JL
2
6
STORAGE VOLUME. THOUSANDS'OF GALLONS
FIGURE IV.3.4.5-B1. CAPITAL COST ESTIMATE FOR OUTSIDE
CONTRACTOR [4-10]
Date: 4/1/83
IV.3.4.5-B5
-------
where: PC = power cost, $/day
KW = power, kilowatts
24 = hr/day
EC = electricity cost $/Kw-hr
English
PC = HP x EC x 24 x 0.746
where: PC = power cost, $/day
EC = electricity cost, $/Kw-hr
24 = hr/day
0.746 = Kw-hr/Hp-hr
iii) Hauling Cost
Metric
HC = HCF x WW x HD
where: HC = hauling cost, $/day
HCF = hauling cost factor, $/Kg-kilometer
(factor = 0.0005 $/Kg-kilometer unless
otherwise specified)
WW = wet weight of sludge and residue to be
hauled, Kg/day
= I[DW(i) T SF(i)]
DW(i) = dry weight of sludge and residue to be
hauled, Kg/day
SF(i) = solids fraction of the wet weight of sludge,
Kg dry solids/Kg wet solids
HD = hauling distance, kilometer
(assumed to be 16.1 kilometers)
English
HC = HCF x WW x HD
where: HC = hauling cost, $/day
HCF = hauling cost factor, $/lb-mile
(factor = 0.0004 $/lb-mile unless
otherwise specified) [4-2]
WW = wet weight of sludge and residue to be
hauled, Ib/day
= Z[DW(i) r SF(i)]
DW(i) = dry weight of sludge and residue to be
hauled, Ib/day
SF(i) = solids fraction of the wet weight of sludge,
Ibs dry solids/lbs wet sludge
HD = hauling distance, miles (assumed to be 10
miles unless otherwise specified) [4-2]
Date: 4/1/83 IV.3.4.5-B6
-------
(iv) Disposal Cost - regular wastes with no toxicity or other
problems
Metric
DC = DCF x XWW r 1000
where: DC = disposal cost, $/day
DCF = disposal cost factor, $/Mg
(factor = 39.7 $/Mg unless otherwise
specified)
WW = wet weight of sludge and residue to be
hauled, Kg/day
= I[DW(i) * SF(i)]
DW(i) = dry weight of sludge and residue to be
hauled, Kg/day
SF(i) = solids fraction of the wet weight of sludge,
Kg dry solids/Kg wet sludge
1000 = Kg/Mg
English
DC = DCF x WW T 2000
where: DC = disposal cost, $/day
DCF = disposal cost factor, $/ton
(factor = 36 $/ton unless otherwise
specified) [4-2]
WW = wet weight of sludge and residue to be
hauled, Ib/day
= E[DW(i) v .SF(i) ]
DW(i) = dry weight of sludge and residue to be
hauled, Ib/day
SF(i) = solids fraction of the wet weight of sludge,
Ibs dry solids/lbs wet sludge
2000 = Ib/ton
v) Disposal Cost - combustible and inorganic sludges with
toxicity or other problems
Metric
DC = [(DCFI x IWW) + (DCFC x CWW) ] * 1000
where: DC = disposal cost, $/day
DCFI = inorganic sludge disposal cost
factor, $/Mg (factor = 230 $/Mg
unless otherwise specified)
IWW = inorganic sludge wet weight, Kg/day
DW(j) = dry weight of inorganic sludges (j),
Kg/day
Date: 4/1/83 IV.3.4.5-B7
-------
SF(j) = solids fraction of the wet weight of
sludge, Kg dry solids/Kg wet sludge
DCFC = combustible sludge disposal cost factor,
$/Mg (factor =314 $/Mg unless other-
wise specified)
CWW = combustible sludge wet weight, Kg/day
= Z[DW(K) * SF(K)]
DW(K) = dry weight of combustible sludges (K),
Kg/day
SF(K) = solids fraction of the wet weight of
sludge, Kg dry solids/Kg wet sludge
1000 = Kg/Mg
English
DC'= [(DCFI x IWW) + (DCFC x CWW)] * 2000
where: DC
DCFI
disposal cost, $/day
inorganic sludge disposal cost factor,
$/ton (factor = 209 $/ton unless otherwise
specified) [4-2]
IWW = inorganic sludge wet weight, Ib/day
= I[DW(j) * SF(j)]
DW(j) = dry weight of inorganic sludges(j), Ib/day
SF(j) = solids fraction of the wet weight of sludge,
Ib dry solids/lb wet sludge
DCFC = combustible sludge disposal cost factor,
$/ton
(factor = 285 $/ton unless otherwise
specified) [4-2]
CWW = combustible sludge wet weight, Ib/day
= I[DW(k) * SF(k)]
DW(k) = dry weight of combustible sludges(k), Ib/day
SF(k) = solids fraction of the wet weight of sludge,
Ibs dry solids/lbs wet sludge
2000 = Ibs/ton
b) Fixed Costs
The fixed O & M components of this technology are listed in Table
IV.3.4.5-B2, including the cost basis and the unit costs [4-11].
B 4. Miscellaneous Costs
Costs for engineering, and other common plant items such as land,
piping, and buildings, are calculated after completion of costing
for individual units (see Section IV.3.5).
B 5. Modifications
None required.
Date: 4/1/83
IV.3.4.5-B8
-------
Table IV.3.4.5-B2. FIXED 0 & M COST BASIS AND UNIT COST
FACTORS FOR OUTSIDE CONTRACTOR WASTE
DISPOSAL [4-11]
Element
Labor (1,2)
Supervision (1)
Overhead (1)
Laboratory (3)
Maintenance
Services
Insurance & Taxes
Service Water
Cost Basis
(Equivalent Unit Quantity)
0.036 Weeks (0.86 hrs/day)
10% Labor (0.09 hrs/day)
75% Labor Cost
0.036 Shifts (0.21 hrs/day)
5.60% Capital
0.40% Capital
2.50% Capital
0.001 L/s
(0.02 Thou gpd)
Base Unit Cost
(July 1977)
$ 9.80/hr
$11.76/hr
NA
$10.70/hr
NA
NA
NA
$ 0.13/thou L
($ 0.50/thou gal)
NA - not applicable
(1) Labor may vary from 0.7 to 1.2 times the standard amount
indicated depending on the overall scale of the plant.
Labor, Supervision, and Overhead may be adjusted for the
scale of the plant as indicated in Miscellaneous Costs
(Section IV.3.5).
(2) One week = 7 days = 168 hours =4.2 shifts
(3) One shift = 40 hours
Date: 4/1/83
IV.3.4.5-B9
-------
I.
a.
II.
Cost
III.
a.
b.
c.
d.
IV.
a.
b.
c.
d.
e .
V.
VI.
OUTSIDE CONTRACTOR
SUMMARY WORK SHEET
REFERENCE: IV.3.4.5-B
DESIGN FACTOR CAPITAL
Storage Vessel Volume = gallons
CAPITAL COST
x ( T 204.7)
Cost from curve current index
VARIABLE 0 & M
Power - x x 17.9
Hp EC, $/Kw-hr
Hauling = x x 10
Wet Weight, HCF, $/lb-mile distanc
Ib/day miles
Disposal (sludge, no toxicity or other problems
x T 2000
Total Wet Disposal Cost Ib/ton
Weight, Ib/day Factor, DCF, $/ton
Disposal (sludge with toxicity problems)
:; [( x ) + (
DCFI , Inorganic Wet DCFC,
$/ton weight, Ib/day $/ton
x )] * 2000 =
Combustible
WW, Ib/day
FIXED 0 & M
Labor : x
hr/day $/hr
Supervision: x
hr/day $/hr
Overhead: x
Labor, $/day %/100
Maint, Service, x f 365
I&T: capital, $ %/100 day/yr
Service Water: x
thou gpd $/thou gal
YEARLY 0 & M 365
$/day
e,
)
= $
X
day/yr sum, $/day
$
0 & M
$/yr
UNCOSTED ITEMS
Date: 4/1/83
IV.3.4.5-B10
-------
OUTSIDE CONTRACTOR
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Current Index =
2. HCF = Hauling Cost Factor =
3. DCF = Disposal Cost Factor
(Non-toxics) =
4. DCFI = Inorganics Disposal Cost
Factor (Toxics) =
5. DCFC = Combustibles Disposal
Cost Factor (Toxics) =
6. Labor =
7. Supervision =
8. Overhead =
9. Laboratory Labor =
10. Maintenance =
Services =
Insurance/Taxes =
Other 0 & M Factor Sum =
11. Service Water =
Capital Cost Index
$/lb-mile
$/ton
$/ton
$/ton
$/hr
$/hr
% Labor * 100 =
$/hr
%/100
% Capital
% Capital
% Capital
T 100 =
fc/100
$/1000 gal
I. DESIGN FACTOR
a. To determine storage vessel volume use Work Table I.
1. To determine the volume of each sludge, divide dry weights (DW)
from Column A by the sludge fraction (SF) from Column B, and divide
this by liquid sludge density (SD) from Column C. Enter the result
in Column D.
2. Sum the items in Column D and enter the results in the equation
below.
3. Total storage vessel volume (VOL) = 30 x
SUM D
gallons
II. CAPITAL COST
Date: 4/1/83
IV.3.4.5-B11
-------
III. VARIABLE COST
a. Power requirements
HP = ( x 2.78 x ID'4)
Storage Vessel Volume,
+ 0.474 = Hp
b. To determine wet weight of sludge to use in calculating hauling costs
use Work Table II
1. To determine wet weight of inorganic and combustible sludges,
divide dry weights (DW) from Colume A by the sludge factor (SF)
from Column B. Enter the results in the inorganics (Column C)
or combustible sludge (Column D) as appropriate.
2. Total weight hauled = +
Inorganics Wet weight Combustible Wet weight
Work Table II Work Table II
Sum Column C Sum Column D
Wet weight
Ib/day
c. To determine disposal costs for sludges without toxicity or other
problems
Total Wet weight (From III b 4) = Ib/day
d. To determine disposal costs for sludges with toxicity or other problems
1. Inorganic sludge wet weight (Work Table II, sum of
column C) = Ib/day
2. Combustible sludge wetweight (Work Table II, sum of
column D) = Ib/day
IV. FIXED 0 & M
V. YEARLY 0 & M
VI. UNCOSTED ITEMS
Date: 4/1/83 IV.3.4.5-B12
-------
U 0)
E
\ 3 —
CD 0 CD
Q) —
< CTKO
•o o
II 3 —
a to
o
c/7
M
C
03 —
"D O
— J3
CO —
•o
CT
U.
CO
C CD
0 >
+-»J3
O —
CQU.
43
ta
4J
a
o
0
(_
a.
E
C
E
3
*
r"
CO
00
o
0
0
Jj
a
o
V
t.
0,
c
o
L-
*"
ro
CO
lA
O
O
Q>
CO
4-1
a
u
0)
a.
V
•a
E*.
3
CO
^
m
CO
o
o
CM
0
4->
CO
o
u.
CQ
o
E
V
u
O
O
e\j
O
CO
O
0
o
o
o
CO
CO
CO
O
o
lf\
o
u.
2
E
O
V)
V)
a.
o
o
-3-
CO
00
O
fO
O
O
•a
o
1
a.
O
CO
CO
o
o
o
a>
en
3
CO
L.
(U
B
D
o
lA
CO
CO
O
O
o
V
3
CO
CO
4J
CO
4J
u
2
CO
o
PO
00
o
SO
o
0
3
•o
O
CO
OO
o
O\
O
U
3
•o
(0
11)
a:
c
a
a
L.
(O
E
CO
CD
CO
^
CO
CO
0
o
VO
0
c
o
c
a>
m
CO
u
0)
•o
(O
(_
0
CO
L.
(U
c
u
c
CM
en
CO
O
O
0
c
1
^
o
3
•o
£
a.
c.
t.
o
4J
-------
O
o
01
ecw >
(0
*££
u **—
(A
a s
i
O
o
a
3
(A >
X. CD
O "O
II fl) —
O t- ""
O
c
u.
C/)
I'
o —
«•*-
L. >
CD u- fl
0
V)
!-i
x"
a
«
u
X
X
X
X
X
o
o
o
0)
L.
a.
-
X
X
X
X
X
o
o
to
m
Q.
u
£
1
A turn in
CJ
x
X
x
o
o
o
43
a
a>
u
a.
c
8
2
X
^
in
o
o
a
a
o
£
09
su i r i d
-
xxxxx
1
o
to
o
h.
to
a
'i
u
u.
8
xxxxx
o
m
Ot
o
0
o
w
X
§
o
u.
1
(A
I
(A
3
a
o
?
X
g
0
(*»
o
o
M
•o
5
1
(.
a.
o
^
X
J.
o
PO
o
o
to
vt
i.
Q)
Scrubb
in
xxxxx
o
o
o
d Sludge
I
£
4J
IA
O
«
XXXXX
S
VO
O
tion Residue
u
Extra
*>
So 1 ven
o
r-
X
2
0
g Residue
c
0.
(X
t.
w
E
(0
01
U)
p
x
X
X
8
o
c
o
-
o
M
h ( d i rect wa
CA
S
s
1 nc 1 ne
N
x
X
X
§
-------
IV.3.5 MISCELLANEOUS COSTS AND TOTAL PLANT COSTS
Introduction
There are certain costs associated with building a treatment
plant which cannot be directly attributed to any particular unit
process. Transformers, area lighting, offices, laboratories, and
other such general facilities are partly a function of the size
of the plant, and partly fixed in cost since there are certain
minimum sizes mandatory for facilities. Costing methodologies
for these common, miscellaneous facilities are presented below.
A. Miscellaneous Direct Costs and Total Plant Costs
A 1. General
This presentation is for determination of miscellaneous costs
associated with construction of industrial wastewater treatment
facilities. This method requires that adjustments be made to the
amounts of labor, supervision, overhead, laboratory labor, and
service water to account for the relative size of the plant and
associated services. The sums of the capital costs, power re-
quirements, and total number of unit processes serve as the basis
for estimating costs for yard piping, buildings, transformers,
yard lighting, motor controls, a sanitary waste pumping station,
and engineering services. Total land requirements are also
determined for all unit processes as well as ancillary facilities.
Finally, the total capital cost and total annual operation and
maintenance cost for the entire wastewater treatment facility are
calculated from the component costs.
a) Source
The unit cost information in this section was derived from the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industries
[4-2]. The method for developing the design factor is based on
assumptions and procedures in the Contractor Developed Design and
Cost Model [4-1] .
b) Reciuired Input Data
Total number of unit processes
Total adjusted capital cost of unit processes, $(current)
Total power requirements of all unit processes, Kw or Hp
Total labor requirements of all unit processes, hr/day
Total supervision requirements for all unit processes,
hr/day
Total laboratory labor requirements for all unit processes,
hr/day
Total labor, supervision, and laboratory labor requirements
for "in-plant" processes, hr/day
Date: 4/1/83 IV.3.5-A1
-------
Total number of unit processes for which land requirements
have been previously calculated
Total land requirements of unit processes for which land
requirements had been calculated, m2 or ft2
A 2. Miscellaneous Direct Costs [4-11]
There is the need to include several cost items for the entire
treatment facility that are not included in the individual unit
process cost estimates.
a) General Yard Piping
The cost of general yard piping is computed as a fraction of the
total capital cost of the unit processes to be constructed.
YP = 0.0875 x TCUP
where: YP = yard piping cost, $
TCUP = total capital cost (adjusted to current
dollars) for all unit process, $
b) Laboratory and Office Building
The cost of the necessary laboratory and office facilities are
computed on the basis of the total number of unit processes to be
constructed.
If TNUP <, 10
BLDG = $78,000
Lf TNUP > 10
BLDG = [1,200 + (100 x (TNUP - 10))] x 65
where: TNUP = total number of unit processes
BLDG = building cost, 1977 dollars
This cost must be updated to a current level using an appropriate
cost index or factor.
c) Sanitary Waste Pumping Station
A sanitary waste pumping station is generally provided for a new
plant.
PS = $5,000
This facility is estimated at a fixed cost of $5,000 in 1977
but must be adjusted to a current cost using an appropriate cost
index or factor.
Date: 4/1/83 IV.3.5-A2
-------
d) Transformer Cost
The cost of transformers for the plant is estimated on the basis
of total power demand. Total power for all unit processes is
first converted to power demand and appropriate size transformers
are matched and costed according to the following schedule:
i) Total Power Demand [4-11]
Metric
KVA = TKW x 1.16
where: KVA = total power demand, kilovoIt-ampere
TKW = total power requirements, kilowatts
English
where:
KVA = THP x 0.866
KVA = total power demand, kilovoIt-ampere
THP = total horsepower requirements, Hp
ii) Transformer Cost
KVA Range
Transformer Cost (TC)
(1977 dollars)
KVA
500
1000
1500
2000
2500
500
KVA
KVA
KVA
KVA
KVA
1000
1500
2000
2500
3000
59400
74600
74600
74600
74600
42900
59400
74600
The cost of transformers estimated using this schedule
must be updated to a current level using an appropriate
cost index or factor.
e) Motor Control Center
The cost of the motor control center for the plant is based on
the total power requirements of the individual unit processes.
Metric
where:
MOCONC = TKW x 80.4
MONCONC = cost of motor control center, 1977
TKW = total power requirements of plant,
dollars
kilowatts
Date: 4/1/83
IV.3.5-A3
-------
English
MOCONC = THP x 60
where: MOCONC = cost of motor control center, 1977 dollars
THP = total horsepower requirement of the
plant, Hp
This cost must be updated from 1977 dollars to a current level
using an appropriate cost index or factor.
f) Yard Lighting
The cost of yard lighting is computed on the basis of the number
of unit processes to be considered.
YLIGHT = (3 x TNUP + 6) x 770
where: YLIGHT = cost of yard lighting, 1977 dollars
TNUP = total number of unit processes to be
constructed
This cost must be updated to a current level using an appropriate
cost index or factor.
A 3. Engineering Services [4-11]
The cost of engineering services is based on the total capital
cost of the facilities to be constructed, adjusted to current
dollars.
ECOST = FACTOR x (TCUP + TMISC)
where: ECOST = engineering cost, $
FACTOR = fraction of total capital costs charged
for engineering
= (-7.3 x 10-9) x (TCUP + TMISC) + 0.182 or
a minimum of 0.06
TCUP = total capital cost of unit processes, $
TMISC = total capital cost of miscellaneous items, $
= YP + BLDG + PS + TC + MOCONC + YLIGHT
YP = yard piping cost, $
BLDG = building cost, $
PS = pump station, $
TC = transformer cost, $
MOCONC = cost of motor control center, $
YLIGHT = cost of yard lighting, $
The estimates for the TMISC components are developed as described
in Part A2.
Date: 4/1/83 IV.3.5-A4
-------
A 4. Labor Adjustments [4-1, 4-2]
The labor, overhead, and service water estimates presented for
the individual unit processes were based on a typical plant.
Adjustments may be made to the total labor, supervision, over-
head, laboratory labor, and service water estimates to account
for the relative scale of the facilities to be constructed. It
is assumed that if the treatment plant is small, it will probably
be operated on a part-time basis by other existing operators and
receive incremental supervision. On the other hand, if the plant
is very large, it will probably require extra environmental
attention by virtue of its potential impact on any receiving body
of water, and will be set up as a self-sufficient operation.
This would require more labor than normal. To account for rela-
tive scale labor, costs are adjusted as follows:
TABLE IV.3.5-A1. LABOR ADJUSTMENT FACTORS [4-2].
Capital Cost* Factor to Adjust
of Plant "Normal" Labor
Less than $500,000 0.7
$500,000 to $1,500,000 0.9
$1,500,000 to $20,000,000 1.0
Over $20,000,000 1.2
*A11 of these capital cost ranges are based on 1977 capital
costs (Chemical Engineering (CE) Plant Index = 204.7). They
should be adjusted to a current price index prior to use.
The plant labor adjustment is performed as follows:
The total labor requirements of the primary and end-of-pipe
unit processes are totaled and the number of people adjusted to
remove any "fractional" people. This final labor count is used
to adjust all labor accounts (labor, supervision, overhead,
laboratory labor) for pretreatment and end-of-pipe treatment pro-
cesses. Water use is also adjusted by this same factor on the
basis that clean-up, washdowns, miscellaneous services such as
shops, and other service water using activities would be modified
approximately in proportion to the labor staff.
In these labor adjustments, only primary treatment and end-of-
pipe treatment labor items are evaluated and adjusted. In-plant
unit processes such as steam stripping, solvent extraction, and
in-process incineration are not included since it is assumed that
they are attached to a product/process, and therefore need no
adjustment. (Note all terms are defined after part e, below).
Date: 4/1/83 IV.3.5-A5
-------
a) Labor
ADJLABOR = [(TOTLABOR - IPLABOR) x NFACTOR
+ IPLABOR] x LPAY
b) Supervision
ADJSUPER = 0.1 x ADJLABOR x (SPAY * LPAY)
c) Overhead
ADJOH = 0.75 x ADJLABOR
d) Laboratory Labor
ADJLAB = [(TOTLAB - IPLAB) x NFACTOR + IPLAB]
x LABPAY
e) Service Water
ADJSW = (TOTSW - IPSW) x NFACTOR + IPSW
where: ADJLABOR = total adjusted labor cost, $/day
TOTLABOR = total unadjusted labor, hr/day
IPLABOR = total labor for in-plant processes, hr/day
NFACTOR = labor adjustment factor
(see Table IV.3.5-A1)
LPAY = pay rate for labor, $/hr
ADJSUPER = total adjusted supervision cost, $/day
SPAY = pay rate for supervision, $/hr
ADJOH = total adjusted overhead, $/day
ADJLAB = total adjusted laboratory labor cost,
$/day
TOTLAB = total unadjusted laboratory labor, hr/day
IPLAB = total laboratory labor for in-plant
processes, hr/day
LABPAY = pay rate for laboratory labor, $/hr
ADJSW = total adjusted service water cost, $/day
TOTSW = total service water cost, unadjusted,
$/day
IPSW = total in-plant service water cost, $/day
A 5. Land Requirements [4-1]
The cost of land is highly variable depending on location and
other factors. Total land requirements for a plant may be esti-
mated using guidelines outlined below. Costs may be estimated
if information on local conditions can be obtained.
Date: 4/1/83 IV.3.5-A6
-------
a) Land Requirements Previously Calculated
Sum the land requirements for the unit processes (UP) for which
land requirements were calculated independently. Do not include
landfill areas.
UPLAND = m2 or ft2
sum of land for
unit processes
b) Land Requirements Not Previously Calculated
Sum the number of unit processes to be constructed for which land
requirements were not previously calculated and select an appro-
priate land allowance from the following table:
NLUP =
number of UP's with
no land estimates
Number of Unit Processes Land Allowance
Without Land Estimates per Unit Process
(NLUP) (ALLOW)
m2 ft2
Greater than 10 232 2,500
5 to 9 325 3;500
3 or 4 418 4,500
1 or 2 465 5,000
c) Total Land Requirement
Metric
LAND = [UPLAND + (NLUP x ALLOW)] * 10,000
where: LAND = total land requirement, hectares
UPLAND = total land requirement for unit, processes
(UP's) previously calculated, m2
NLUP = number of UP's without previous land require-
ments
ALLOW = land allowance per UP, m2
10,000 = m2/hectare
English
LAND = [UPLAND + (NLUP x ALLOW)] * 43560
where: LAND = total land requirements, acres
UPLAND = total land requirements for unit processes
(UP's) previously calculated, ft2
NLUP = number of UP's without previous land
requi rements
Date: 4/1/83 IV.3.5-A7
-------
ALLOW = land allowance per UP, ft2
43560 = ft2/acre
A 6. Total Capital and 0 & M Costs [4-1]
After any necessary miscellaneous costs have been calculated and
necessary adjustments have been made, the final estimates are
prepared for total capital cost and O & M.
a) Capital Costs
Total capital costs are the sum of all unit process costs, all
miscellaneous direct costs, and engineering costs. Note that
land is not included, but may be if land costs can be estimated:
CAPCOST = TCUP + TMISC + ECOST
where: CAPCOST = total adjusted capital cost for all
facilities, current $
TCUP = total adjusted capital cost for all unit
processes, current $
TMISC = total adjusted miscellaneous cost,
current $
ECOST = total engineering cost, current $
b) Operation and Maintenance Costs
Total 0 & M costs for the whole plant are the sum of all adjusted
and unadjusted variable and fixed O & M elements for the unit
processes.
i) Variable O & M
TVOM = TPC + TCC + TSC + TWC + TFC + TLHC + OCHC
+ OCDC
where: TVOM = total variable O & M cost, current $/day
TPC = total power cost, current $/day
TCC = total chemical cost, current $/day
= I cost of all chemicals used by unit
processes including lime, current $/day
TSC = total steam costs, current $/day
TWC = total process/cooling water cost, $/day
TFC = total fuel cost, current $/day
TLHC = total landfill hauling cost, current $/day
OCHC = outside contractor hauling cost, current
$/day
OCDC = outside contractor disposal cost, current
$/day
Date: 4/1/83 IV.3.5-A8
-------
ii) Fixed 0 & M
TFOM = ADJLABOR + ADJSUPER + ADJOH + ADJLAB
+ ADJSW + TIAT + TMAINT + TSER
where: TFOM = total
ADJLABOR = total
ADJSUPER = total
ADJOH = total
ADJLAB = total
$/day
ADJSW = total
TIAT = total
TMAINT = total
TSER = total
fixed 0 & M cost, current $/day
adjusted labor, current $/day
adjusted supervision, current $/day
adjusted overhead, current $/day
adjusted laboratory labor, current
adjusted service water, current $/day
insurance and taxes, current $/day
maintenance cost, current $/day
plant services, current $/day
iii) Total Annual 0 & M
TAOM = 365 x (TVOM + TFOM)
where: TAOM = total annual 0 & M, current $/yr
TVOM = total variable O & M, current $/day
TFOM = total fixed 0 & M, current $/day
365 = day/year
A 7. Modifications
All of the miscellaneous direct costs and adjustments described
in this section may not be applicable in every case, and some may
be deleted or modified at the discretion of the user. Also, the
financial, legal, and administrative costs of constructing new
wastewater treatment facilities have not been included in this
cost estimate. Although these are not considered capital cost
items in this analysis, they can have a significant effect on the
cost of the plant.
Date: 4/1/83
IV.3.5-A9
-------
MISCELLANEOUS AND TOTAL PLANT COSTS
SUMMARY WORK SHEET REFERENCE IV.3.5-A
I. UNIT PROCESS CAPITAL COST $ CAPITAL
a. Total Adjusted Capital Cost for Unit Processes
(TCUP)
II. TOTAL MISCELLANEOUS DIRECT COSTS
a. Yard Piping (YP)
b. Laboratory, Office Building (BLDG)
c. Sanitary Waste Pump Station (PS)
d. Transformer (ATC)
e. Motor Control Center (MOCONC)
f. Yard Lighting Y(LIGHT)
g. Total Miscellaneous Direct Costs
(TMISC)
III. ENGINEERING COSTS
Engineering fee (ECOST)
IV. TOTAL DIRECT CAPITAL COSTS (LESS LAND)
Total Direct Capital Cost (TCUP + TMISC + ECOST) = $
V. ADJUSTED 0 & M $/day 0 & M
a. Total Power Cost
b. Total Chemical Cost
c. Total Steam Cost
d. Process Water Cost
e. Fuel Cost
f. Total Hauling/Disposal Cost
g. Adjusted Labor Cost (ADJLABOR)
h. Adjusted Supervision Cost (ADJSUPER)
i. Adjusted Overhead Cost (ADJOH)
j. Adjusted Laboratory Labor Cost (ADJLAB)
k. Adjusted Service Water
1. Maintenance, Insurance, Taxes, and Services
m. Total 0 & M 365 x = $
SUM
VI. LAND REQUIREMENTS
LAND = acres
Date: 4/1/83 IV.3.5-A10
-------
MISCELLANEOUS AND TOTAL PLANT COSTS
WORK SHEET
REQUIRED COST FACTORS AND UNIT COSTS
1. Labor, LPAY = $/hr
2. Supervision Labor, SPAY = $/hr
3. Lab Labor, LABPAY = $/hr
I. TOTAL CAPITAL COSTS FOR UNIT PROCESSES
a. Prepare a summary of costs by unit process using Work Table 1.
1. Enter the name of the unit process and indicate by a mark
whether it is used as an in-plant or end-of-pipe treatment
technology. The in-plant distinction generally has to do
with whether the unit process is used to treat a segregated
waste stream with the object of recovering or reusing the
stream.
2. Fill in the rest of the table from the summary work sheets
which were prepared for each of the unit processes previously.
3. Sum all of the columns for all unit processes. Separately
sum the labor, supervision, overhead, laboratory labor,
and service water requirements for those unit processes
which have been designated as "in-plant" and enter the
sums in the indicated spaces.
4. From Work Table I
Total number of unit processes (B + C) =
TNUP
Total number of in-plant processes (B) =
Total number of unit processes with
land requirements =
Total capital cost for all unit = $
processes (D) TCUP
Total horsepower requirements (E) = Hp
THP
Date: 4/1/83 IV.3.5-A11
-------
II. TOTAL MISCELLANEOUS DIRECT COSTS
a. General Yard Piping
YP = 0.0875 x = $
TCUP(D)
b. Laboratory and Office Building
If TNUP (B + C) < 10
BLDG = 78000 x ( * 204.7) = $
current index
If TNUP (B + C) > 10
BLDG = [1200 + (100 x ( - 10))] x 65
TNUP
x ( i- 204.7) = $
current index
c. Sanitary Waste Pumping Station
PS = 5000 x ( r 204.7) = $
current index
d. Transformer
1. KVA = x 0.866 =
THP(E), Hp
2. Determine Transformer Cost from following table:
KVA Range Transformer Cost (TC)
(1977 dollars)
KVA < 500 0
500 < KVA < 1000 59400
1000 < KVA < 1500 74600
1500 < KVA < 2000 74600 + 42900
2000 < KVA < 2500 74600 + 59400
2500 < KVA < 3000 74600 + 74600
3. ATC = x ( f 204.7) = $
TC, $ current index
e. Motor Control Center
MOCONC = x 60 x ( T 204.7) = $
THP(E), Hp current index
Date: 4/1/83 IV.3.5-A12
-------
f. Yard Lighting
YLIGHT = [(3 x ) + 6] x 770 x ( * 204.7)
TNUP(B + C) current index
= $
g. Total Miscellaneous Direct Costs (Sum of steps a to f)
TMISC = + + + +
YP(Ia) BLDG(Ib) PS(Ic) ATC(Id) MOCONC(Ie)
+ = $
YLIGHT(If)
III. ENGINEERING COSTS
a. Determine fee basis
FACTOR = [-7.3 x 10'9 x ( + )] + 0.182
TCUP(D), $ TMISC(IIg), $
= or minimum of 0.06
b. ECOST = x ( + ) = $
FACTOR TCUP(D), $ TMISC(IIg), $
IV. TOTAL CAPITAL COSTS
SUM OF PARTS I, II, AND III
V. ADJUSTED 0 & M
a. Total Power Cost
Work Table I, sum of column F = $/day
b. Total Chemical Cost
Work Table I, sum of column G = $/day
c. Total Steam Cost
Work Table I, sum of column H = $/day
d. Process Water Cost
Work Table I, sum of column I = $/day
e. Fuel Cost
Work Table I, sum of column J = $/day
Date: 4/1/83 IV.3.5-A13
-------
f. Total Hauling/Disposal Cost
Work Table I, sum of column K =
$/day
g. Adjusted Labor Cost
1. Capital Cost of Plant Facilities (excluding land)
CAPCOST = + +
- $
TCUP(D) TMISC(IIg) ECOST(IIIb)
2. Adjust the range of labor, overhead, and service water adjustment
factors as follows:
Adjust Capital Cost Ranges
to Current Level
(1) 500,000 x (
) * 204.7 = $
Adjustment
If CAPCOST Factor
(NFACTOR)
less than (1) 0.7
index
(2) 1,500,000 x (
* 204.7 = $
index
(3) 20,000,000 x (
(1) to (2)
(2) to (3)
0.9
1.0
T 204.7 = $
index
greater than (3) 1.2
3. Adjustment Factor =
4. From Work Table 1
Total Labor Hours =
NFACTOR(Vb)
TOTLABOR(Li)
In-Plant Labor Hours =
5. Adjusted Labor
ADJLABOR = [(
hr/day
hr/day
IPLABOR(Lii)
)
TOTLABOR
], hr/day
IPLABOR NFACTOR(Vg3) IPLABOR
= $/day
LPAY, $/hr
h. Adjusted Supervision Cost
ADJSUPER = 0.1 x
ADJLABOR(VgS) SPAY,$/hr LPAY, $/hr
= $/day
Date: 4/1/83
IV.3.5-A14
-------
i. Adjusted Overhead
ADJOH = 0.75 x ^_ = $/day
ADJLABOR(VgS)
j. Adjusted Laboratory Labor Cost
1. From Work Table 1
Total Lab Labor Hours = hr/day
TOTLAB(Qi)
In-Plant Lab Labor Hours = hr/day
IPLAB(Qii)
2. Adjusted Lab Labor
ADJLAB = [( - ) x + ], hr/day
TOTLAB IPLAB NFACTOR(VgS) IPLAB
x = $/day
LABPAY, $/hr
k. Adjusted Service Water Cost
1. From Work Table 1
Total Service Water = $/day
TOTSW(Vi)
In-Plant Service Water = $/day
IPSW(Vii)
2. Adjusted Service Water
ADJSW = ( - ) x ^_ + = $/day
TOTSW IPSW NFACTOR(Vg3) IPSW
1. Maintenance, Insurance, Taxes, and Services Cost
Work Table I, sum of column S = $/day
m. Total Operation and Maintenance
sum of a to f = Total 0 & M
VI. LAND REQUIREMENTS
a. From Work Table 1
1. Sum of land for UP's with land (column V) = ft2
UPLAND
Date: 4/1/83 IV.3.5-A15
-------
2. Number of unit processes without land estimates =
NLUP
b. Land Requirements Not Previously Calculated
Number of UP's Without
Land Estimates (NLUP)
> 10
5 to 9
3 or 4
1 or 2
ALLOW =
Square Feet Allowance
per Unit Process (ALLOW)
2500
3500
4500
5000
Total Land Requirement
LAND = [ + (
UPLAND
NLUP
)] r 43,560 =
acres
ALLOW
Date: 4/1/83
IV.3.5-A16
-------
CO
w
oo
to
w
u
o
ft
P-I
PS
O
oo
H
oo
Q
O
9
H
oo
:=>
i-i
i-3 ^-*
• O h- (/) (0
O
w°
-------
CO
u
§
H
H
o
{*<
O
U
Q
W
H
C/3
gs
M MH
Fk O
U CS
fH. H
O PS
si
w
W
I
H
a
> <
UJ
13 oar
— UJ
i
OZK
Z —
Z *.
(/> UJ LJ UJ
f-OU
Z — Z
z£
oe >
ce
OK
t-O
ss
S-i
a 5
O
4
X
cc
a. uj
>
o
Z
o
0 -
v>
cc
UJ
^
V
s g
a
^
_j
a: a:
_J O O
-ooi-
x a — a: c
!!l°
c/
u
ce
< 0.
z
i
a
VI
(Q
•a
(0
CT
3 CD
o-o
4J
T
X,
«)
>
(D
>
a
x
i_
5
T?
x,
>
a
x,
>
(D
t
JT
>
a
•x
jr
>
t
— 00
"•^^
O
OK
K- *—
-
CO — 1
— a.
CL —
i •>«•
c
r
^
o
— ce
— o
^^eo
wt-
oo
K —
~K
~z
*p
oo
1- t-
— ^»
**o
C CO
O- CL
5-
—
... .— .
— oe
4^0
cm
"5
Q. a.
i —
c —
-------
IV.4 INDUSTRY COST DATA
Chapter 4 is reserved for possible future inclusion of industry
specific wastewater treatment cost data in Volume IV of the
Treatability Manual.
Date: 4/1/83 IV.4-1
-------
IV.5. COMPUTER COST MODELS
IV.5.1 GENERAL DISCUSSION
The cost estimating methods presented in Chapter 3 of this volume
are applicable for non-computer applications. The USEPA and
others have developed computerized cost estimating methods that
can be used for more complex and more comprehensive evaluations.
These vary in their application to industrial wastewater treat-
ment systems.
IV.5.2 CONTRACTOR DEVELOPED DESIGN AND COST MODEL - OVERVIEW
The Contractor Developed Design and Cost Model is a computerized
design, performance, and cost allocation model developed for the
BAT Effluent Limitations Guidelines engineering study for the
Organic Chemicals/Plastics and Synthetic Fibers Industry [4-1].
The Model is composed of a group of inter-related programs which
will design, cost, and predict performance of a wastewater treat-
ment plant (including by-product handling systems) given the
characteristics of the raw wastewater and the desired effluent
characteristics. It is driven by a group of files which include
waste stream and pollutant specific data and unit process costing
data used in the design and costing of the wastewater treatment
systems. A generalized flow diagram of the Model design process
is presented in Figure IV.5-1.
The Model can operate in two primary modes. In the Treatment
Unit Process Trail (TUPT) mode it will select the unit processes
needed to treat a user specified raw waste load, order the unit
processes in an initial sequence, and develop performance and
cost predictions on the system. The initial sequence may then be
refined and adjusted by the user as necessary and the Model will
recalculate the performance and cost predictions. The second
major operation mode is the Specified Unit Process Trail (SUPT)
in which the selection and sequence of unit processes are speci-
fied by the user and the Model performs only the performance and
cost predictions. In either mode, the user can specify certain
design parameters for the unit operations/processes (fixed design
parameters) which then will be used during treatment performance
calculations. This enables the user to incorporate existing
units into the design of the Model. The user also can specify
special requirements for the design (e.g., haul distance for land
disposal of sludge, temperature of cooling water) or for the
costing (e.g., labor rates, utility and chemical unit costs,
capital cost index). The user is required to provide waste
specific treatability parameters for the design of certain unit
processes (e.g., reaction rate coefficient for activated sludge,
adsorbability coefficient for activated carbon).
Date: 4/1/83 IV.5.1-1
-------
FIGURE IV.5-1. SIMPLIFIED LOGIC FLOW DIAGRAM OF THE
CONTRACTOR DEVELOPED DESIGN AND COST MODEL [4-2]
PLANT SELECTION
PROCESS AND
PRODUCTION
MASTER
PROCESS FILE
ALL PARAMETERS
•V PROCESS
I
EFFLUENT
TARGET
FILE
INFLUENT
LOADING TO
TREATMENT
TREATMENT
CATALOG
ALL TREATMENT
PROCESSES
DESIGN
TREATMENT
PLANTS
PARAMETER
TREATMENT
AND SELECTION
FILE
PLANT
CAPITAL
COSTS
COST CURVES
PLANT
OPERATING
COSTS
I
OPERATING
COSTS iASIS
ALLOCATE
COSTS TO
CONTRIBUTING
PRODUCT/
PROCESSES
ALLOCATION
FORMULAS
Date: 4/1/83
IV.5.1-2
-------
IV.5.2.1 Model Operating Sequence
The Model operates as a series of programs called and executed
under the control of a master program. These programs use infor-
mation in working files set up from information in the main files
or from input by the user. The master program function is to
call the various operating programs into the computer. The
operating programs access the necessary input data from the
files, operate on these data, generate required output, write the
output into appropriate working files, and then returns control
to the master program. The next appropriate operating program is
then called into the computer by the master program.
The sequence of operation for the Model generally follows the
order:
(1) Pre-Edit. Input data are verified to confirm all
required data are present and in proper order. •
(2) Edit. Input is verified to confirm that the proper
format is used for all data fields, and the data are
consistent with the run mode selected.
(3) Selected Treatment System and Data Required for Model
Run. When the Model Select option is used (TUPT), this
step involves the Model selecting and sequencing a
treatment sybtem based on the pollutant parameters in
each waste stream. When the SUPT option with a raw
waste load is specified, this operating step is re-
placed by the user supplied input. (For the Organic
Chemicals/Plastics and Synthetic Fibers Industry, there
is another option where the Model can access file data
for specific types of facilities.)
(4) Treatment System Performance Calculations. Each unit
process specified for the treatment system is called in
proper sequence and executed as a separate program.
Each unit process is represented by a program that
sizes the required equipment, calculates the effluent
from the unit process (i.e., performance of the process
in removing the wastewater pollutants), calculates
byproducts generated by the process, calculates the
basis for operating and maintenance costs (e.g., unit
quantities), and defines the basis for the capital cost
estimate (e.g., the surface area of a clarifier).
(5) Compare and Resequence Evaluation. The effluent from
each unit process is checked against the target dis-
charge level to determine if treatment is complete.
This step also will address any problems that occur
when the treatment system performance calculations are
being performed. For example, when the Model Select
Date: 4/1/83 IV.5.1-3
-------
option is used to design a treatment system, the Model
will resequence the selected order of unit processes in
this step if it is required to meet treatment objec-
tives. This may include adding or deleting unit pro-
cesses as well as reordering their occurrence in the
treatment system.
(6) Byproduct System Design and Performance. The Model
addresses byproduct treatment after all of the forward
flow treatment system calculations are completed. When
the SUPT option is being used, the byproduct system
design step will involve executing the appropriate unit
process programs in the specified sequence. When the
Model Select (TUPT) option is being used, the appro-
priate byproduct treatment system unit processes will
be selected, and the unit process programs executed in
the proper sequence. The Model has an option that will
allow input of a byproduct system and waste load di-
rectly for evaluation, which operates similar to the
SUPT option. The byproduct unit process programs
operate similar to the treatment system unit processes.
(7) Cost Calculation, Allocation, and Reporting. The final
operating step in the Model is the development of the
system cost estimate. The capital cost and operation
and maintenance costs for each unit process in the
treatment and byproduct systems are calculated using
results from the unit process programs and file data on
unit costs (these are digital cost curves for capital
costs and unit cost factors for operation and mainten-
ance costs). The cost calculation also will develop
system costs not computed in any unit process program
(e.g., lime handling system, yard piping) and will
adjust some costs according to the total size of the
system (e.g., labor, laboratory cost). The Model will
allocate costs according to the contributing source, if
this is desired (e.g., to determine treatment cost for
each input waste stream). The Model reports are gener-
ated in this step.
IV.5.2.2 Major Files
The Model is "file-driven" which means that all important data
are stored in various permanent files. For each run the master
program sets up working files by selecting applicable data from
the permanent files or using data input by the user. These
working files are then used to supply the information speci-
fically required for executing the run and to record the results.
The permanent files accessed by the model to develop the working
files include the following:
Date: 4/1/83 IV.5.1-4
-------
VOLUME IV REFERENCES
4-1. U.S. Environmental Protection Agency. Contractors engi-
neering report, analysis of organic chemicals and plastic/
synthetic fibers industries, toxic pollutants, Appendix L:
computerized wastewater treatment model-technical documen
tation. Prepared for Effluent Guidelines Division, Wash
ington, B.C.; 16 November 1981. 520 pp.
4-2. U.S. Environmental Protection Agency. Public Record In-
formation. Detailed cost documentation for the contractor
developed design and cost model. Prepared for USEPA Effluent
Guidelines Division, Washington, D.C. by Catalytic, Inc.
This reference includes the following files from the Public
Record for the Organic Chemicals/Plastic and Synthetic
Fibers Effluent Guidelines Rulemaking: Book I. Equipment
Sizing Calculations, 1978/1979. pp. 60800-609309. Book
III, Part I. Equipment Sizing/Costs. pp. 608697-609083.
Book IV, Part II. Equipment Sizing/Costs. pp. 609090-609171.
Book V, Part III. Equipment Sizing/Costs, pp. 609172-609309.
USEPA Guidelines Cost Estimates SES. pp. 616001-616467.
Backup for Unit Operations Costs, Parts I and II. pp.
616468-617183.
4-3. Uhl, Vincent W. A standard procedure for cost analysis of
pollution control operations; Volume I. User guide, Volume
II, appendices. EPA-600/8-79/018. Prepared for U.S.
Environmental Protection Agency, IERL, Research Triangle
Park, NC; 1979.
4-4. Perry, R.H., and C.H. Chilton, eds. Chemical engineers'
handbook. 5th ed. McGraw-Hill Book Company. New York,
NY; 1973.
4-5. Peters, M.S., and K.D. Timmerhaus. Plant design and eco-
nomics for chemical engineers. 2nd ed. McGraw-Hill Book
Company. New York, NY; 1968. 850 pp.
4-6. ENR index history. Engineering News-Record, 208, No. 11,
March 18, 1982. pp. 116-123.
4-7. U.S. Environmental Protection Agency. Costs of environ-
mental control technologies granular activated carbon
applications in water and wastewater treatment (draft).
Contract No. 68-03-3038. Prepared for Office of Environ-
mental Engineering Technology, Work Group on Costs of
Environmental Control Technologies, IERL, Cincinnati, OH;
1982. 260pp.
4-8. Liptak, B.C. Environmental engineer's handbook Volume I,
water pollution. Chilton. Radnor, PA; 1974
Date: 4/1/83 IV.6-1
-------
4-9. Elton, Richard L. and Davis L. Ford. Removal of oil and
grease from industrial wastewaters. Chemical engineering/
deskbook issue. Volume 84, No. 22. McGraw-Hill Book
Company. New York, NY; 1977. 212 pp.
4-10. Capital costs records file. Data generated from contractor
developed design and cost model.
4-11. Capital cost operators file. Data generated from contractor
developed design and cost mode. 1980.
4-12. Catalytic Incorporated. Treatment catalog for the Catalytic
computer model. Philadelphia, PA; 1980. Variously paginated.
Date: 4/1/83 ' IV.6-2
irU.S. GOVERNMENT PRINTING OFFICE : 1984 0 - 432-455 (Vol. 4)
------- |