&EPA
United States
Environmental Protection
Agency
Municipal Environmental Research
Laboratory
Cincinnati OH 45268
EPA-600/2-79-162b
August 1979
Research and Development
Estimating Water
Treatment Costs
Volume 2
Cost Curves
Applicable to
1 to 200 mgd
Treatment Plants
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2 Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the ENVIRONMENTAL PROTECTION TECH-
NOLOGY series. This series describes research performed to develop and dem-
onstrate instrumentation, equipment, and methodology to repair or prevent en-
vironmental degradation from point and non-point sources of pollution. This work
provides the new or improved technology required for the control and treatment
of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-79-162b
August 1979
ESTIMATING WATER TREATMENT COSTS
Volume 2. Cost Curves Applicable to
1 to 200 mgd Treatment Plants
by
Robert C. Gumerman
Russell L, Gulp
Sigurd P. Hansen
Culp/Wesner/Culp
Consulting Engineers
Santa Ana, California 92707
Contract No. 68-03*2516
Project Officer
Robert M. Clark
Drinking Water Research Division
Municipal Environmental Research Laboratory
Cincinnati, Ohio 45268
MUNICIPAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Municipal Environmental Research
Laboratory, U.S. Environmental Protection Agency, and approved for publication.
Approval does not signify that the contents necessarily reflect the views and
policies of the U.S. Environmental Protection Agency, nor does mention of
trade names or commercial products constitute endorsement or recommendation
for use.
ii
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FOREWORD
The U.S. Environmental Protection Agency was created because of increasing
public and government concern about the dangers of pollution to the health
and welfare of the American people. Noxious air, foul water, and spoiled land
are tragic testimonies to the deterioration of our natural environment. The
complexity of that environment and the interplay of its components require a
concentrated and integrated attack on the problem.
Research and development is that necessary first step in problem solution,
and it involves defining the problem, measuring its impact, and searching for
solutions. The Municipal Environmental Research Laboratory develops new and
improved technology and systems to prevent, treat, and manage wastewater and
solid and hazardous waste pollutant discharges from municipal and community
sources, to preserve and treat public drinking water supplies, and to minimize
the adverse economic, social, health, and aesthetic effects of pollution.
This publication is one of the products of that research - a most vital
communications link-between the researcher and the user community.
The cost of water treatment processes that may be used for the removal
of contaminants included in the National Interim Primary Drinking Water
Regulations is of interest to the U.S. Environmental Protection Agency,
State and local agencies, and consulting engineers. Volume 2 presents
construction and operation and maintenance cost curves for 72 unit processes
that are especially applicable to water supply systems with treatment
capacities between 1 and 200 mgd. These 72 processes were selected for their
ability to remove (either individually or in combination) contaminants
included in the National Interim Primary Drinking Water Regulations
Francis T. Mayo
Director
Municipal Environmental Research
Laboratory
iii
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ABSTRACT
This report is Volume 2 of a four-volume study that presents construction
and operation and maintenance cost curves for 99 unit processes that are
especially applicable (either individually or in combination) to the removal
of contaminants listed in the National Interim Primary Drinking Water Regula-
tions. This volume discusses 72 unit processes that are particularly suited
to large water supply systems with treatment capacities between 1 and 200 mgd
(3,785 and 757,000 m3/d). Information is also included on enhanced virus and
asbestos removal using modifications of standard unit processes.
Volume 1 summarizes the four volumes and discusses the cost-estimating
approaches that were used to develop the cost curves and the treatment tech-
niques applicable to contaminant removal. Volume 1 also presents a series of
examples demonstrating the use of the cost curves. Volume 3 presents cost
curves applicable to small water supply systems with capacities between 2,500
gpd and 1 mgd (9.46 and 3,785 m3/d). Volume 4 is a computer program user's
manual and contains a computer program that can be used to retrieve and update
all cost data contained in the four volumes.
Conceptual designs were formulated for each unit process and from these,
construction costs were then developed. The construction costs are presented
in tabular form in terms of eight categories: Excavation and sitework, manu-
factured equipment, concrete, steel, labor, pipe and valves, electrical and
instrumentation, and housing. The construction cost curves were checked for
accuracy by a second consulting engineering firm, Zurheide-Herrmann, Inc.,
using cost-estimating techniques similar to those used by general contractors
in preparing their bids. Construction costs are also shown plotted versus the
most appropriate design parameter for the process, such as pounds per day for
chemical feed systems and square feet of surface area for filters.
Operation and maintenance requirements were determined individually for
three categories: Energy, maintenance material, and labor. Energy require-
ments for the building and the process were determined separately.
All costs are presented in terms of October 1978 dollars, and a discussion
is included on cost updating. For construction cost, either of two methods may
be used. One is the use of indices that are specific to each of the eight cate-
gories used in the original determination of construction cost. The second
method is the use of an all—encompassing index such as the Engineering News
Record Construction Cost Index. Operation and maintenance requirements may be
readily updated or adjusted to local conditions, since labor requirements are
expressed in hours per year, electrical requirements in kilowatt hours per year,
diesel fuel in gallons per year, and natural gas in standard cubic feet per year.
This report was submitted in fulfillment of Contract No. 68—03—2516 by
Culp/Wesner/Culp under the sponsorship of the U.S. Environmental Protection
Agency. This report covers the period November 1, 1976 to January 1, 1979,
and work was completed as of July 2, 1979.
iv
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CONTENTS
Foreword iii
Abstract ....... iv
Figures viii
Tables xxii
Abbreviations and Symbols xxxi
Metric Conversions xxxii
Acknowledgements xxxiii
1. Introduction , 1
Scope 1
Background 1
Purpose and objectives . 3
2. Cost Curves 5
Construction cost curves ... 5
Operation and maintenance cost curves 7
Updating costs to time of construction 8
Firms that supplied cost and technical information .... 10
Chlorine storage and feed systems 11
Chlorine dioxide generating and feed systems ....... 13
Ozone generation systems and contact chambers 23
On-site hypochlorite generation systems ......... 29
Alum feed systems 43
Polymer feed systems 53
Lime feed systems 53
Potassium permanganate feed systems 59
Sulfuric acid feed systems ..... 67
Sodium hydroxide feed systems .... 76
Ferrous sulfate feed systems 82
Ferric sulfate feed systems 82
Ammonia feed facilities 88
Powdered activated carbon feed systems 98
Rapid mix 105
Flocculation 118
Circular clarifiers 128
Rectangular clarifiers - 128
Upflow solids contact clarifiers 136
Tube settling modules 142
Gravity filtration structures 142
Filtration media 150
Backwash pumping facilities . 156
Hydraulic surface wash systems ...... 162
Air-water backwash facilities 171
Wash water surge basins 171
Modification of rapid sand filters to high rate filters , 179
Continuous automatic backwash filters 179
v
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CONTENTS (Continued) Page
Recarbonation basins .... 182
Recarbonation - liquid C02 as C02 source 188
Recarbonation - submerged burners as C02 source 196
Recarbonation - stack gas as CC>2 source 196
Multiple hearth recalcination ..... 202
Contact basins ............. 211
Pressure diatomite filters 211
Vacuum diatomite filters 217
Pressure filtration plants 231
In-plant pumping 235
Wash water storage tanks 235
Reverse osmosis 246
Ion exchange - softening 251
Pressure ion exchange - nitrate removal 261
Activated alumina for fluoride removal 271
Gravity carbon contactors - concrete construction .... 276
Gravity carbon contactors - steel construction 282
Pressure carbon contactors 297
Conversion of sand filter to carbon contactor 304
Granular activated carbon 304
Capping sand filters with anthracite ..... 310
Off-site regional carbon regeneration - handling and
transportation 310
Multiple hearth granular carbon regeneration 314
Infrared carbon regeneration furnace 327
Granular carbon regeneration - fluid bed process 331
Powdered carbon regeneration - fluidized bed process . . . 338
Powdered carbon regeneration - atomized suspension process 345
Chemical sludge pumping - unthickened sludge ....... 351
Chemical sludge pumping - thickened sludge . . 359
Gravity sludge thickeners 359
Vacuum filters 368
Sludge dewatering lagoons 378
Filter press 385
Decenter centrifuges 396
Basket centrifuges 401
Sand drying beds 409
Belt filter press 419
Sludge disposal to sanitary sewers 419
Sludge hauling to landfill or farms 427
Raw water pumping facilities 431
Finished water pumping facilities ............ 443
Clearwell storage .... 443
Aeration 452
Administration, laboratory and maintenance building . . . 464
3. Asbestos and Virus Removal by Modification of Standard
Treatment Processes 474
Operating strategies for virus and asbestos removal . . . 474
Asbestos removal 475
vi
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CONTENTS (Continued) - Page
:•'
Virus removal . . 477
Cost estimates for unit processes to remove asbestos
and virus .............. 479
4. Facility Layouts For Typical 1, 10, and 100 mgd Plants .... 486
5. Example Calculation for a 40-mgd Conventional Treatment Plant 497
References . ....... 505
vii
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FIGURES
Number Page
1 Construction Cost for Chlorine Storage and Feed Systems .... 17
2 Operation and Maintenance Requirements for Chlorine Storage and
Feed Systems, Cylinder Storage - Building Energy, Process
Energy, and Maintenance Material ..... 18
3 Operation and Maintenance Requirements for Chlorine Storage
and Feed Systems, Cylinder Storage - Labor and Total Cost . . 19
4 Operation and Maintenance Requirements for Chlorine Storage and
Feed Systems, On-Site Storage Tank and Rail-Car Feed -
Building Energy, Process Energy, and Maintenance Material . . 20
5 Operation and Maintenance Requirements for Chlorine Storage
and Feed Systems, On-Site Storage Tank and Rail-Car Feed -
Labor and Total Cost 21
6 Construction Cost for Chlorine Dioxide Generating and
Feed Systems ...... 25
7 Operation and Maintenance Requirements for Chlorine Dioxide
Generating and Feed Systems - Building Energy, Process
Energy, and Maintenance Material 26
8 Operation and Maintenance Requirements for Chlorine Dioxide
Generating and Feed Systems - Labor and Total Cost 27
9 Construction Cost for Ozone Generation Systems 30
10 Construction Cost for Ozone Contact Chambers 32
11 Operation and Maintenance Requirements for Ozone Generation
Systems - Building Energy, Process Energy, and Maintenance
Material 34
12 Operation and Maintenance Requirements for Ozone Generation
Systems - Labor and Total Cost 35
13 Construction Cost for On-Site Hypochlorite Generation 37
viii
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Number Page
14 Operation and Maintenance Requirements for On-Site Hypochlorite
Generation Systems - Building Energy, Process Energy, and
Maintenance Material 41
15 Operation and Maintenance Requirements for On-Site Hypochlorite
Generation Systems - Labor and Total Cost 42
16 Construction Costs for Alum Feed Systems - Dry and Liquid ... 45
17 Operation and Maintenance Requirements for Liquid Alum Feed
Systems - Building Energy, Process Energy, and Maintenance
Material 48
18 Operation and Maintenance Requirements for Liquid Alum Feed
Systems - Labor and Total Cost 49
19 Operation and Maintenance Requirements for Dry Alum Feed
Systems - Building Energy, Process Energy, and Maintenance
Material . 50
20 Operation and Maintenance Requirements for Dry Alum Feed Systems
Labor and Total Cost , 51
21 Construction Cost for Polymer Feed Systems . 55
22 Operation and Maintenance RequiBements for Polymer Feed Systems -
Building Energy, Process Energy, and Maintenance Material . . 56
23 Operation and Maintenance Requirements for Polymer Feed Systems -
Labor and Total Cost 57
24 Construction Cost for Lime Feed Systems 60
25 Operation and Maintenance Requirements for Lime Feed Systems -
Building Energy, Process Energy, and Maintenance Material . . 62
26 Operation and Maintenance Requirements for Lime Feed Systems -
Labor and Total Cost 63
27 Construction Cost for Potassium Permanganate Feed Systems ... 66
28 Operation and Maintenance Requirements for Potassium Permanganate
Feed Systems - Building Energy, Process Energy, and Maintenance
Material , 68
29 Operation and Maintenance Requirements for Potassium Permanganate
Feed Systems - Labor and Total Cost 69
30 Construction Cost for Sulfuric Acid Feed Systems . . 72
ix
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Number Page
31 Operation and Maintenance Requirements for Sulfuric Acid Feed
Systems - Building Energy, Process Energy, and Maintenance
Material , 73
32 Operation and Maintenance Requirements for Sulfuric Acid Feed
Systems - Labor and Total Cost 74
33 Construction Cost for Sodium Hydroxide Feed Systems ...... 77
34 Operation and Maintenance Requirements for Sodium Hydroxide
Feed Systems - Building Energy, Process Energy and Maintenance
Material 79
35 Operation and Maintenance Requirements for Sodium Hydroxide
Feed Systems - Labor and Total Cost 80
36 Construction Cost for Ferrous Sulfate Feed Systems ....... 84
37 Operation and Maintenance Requirements for Ferrous Sulfate Feed
Systems — Building Energy, Process Energy, and Maintenance
Material 85
38 Operation and Maintenance Requirements for Ferrous Sulfate Feed
Systems - Labor and Total Cost ...... 86
39 Construction Cost for Ferric Sulfate Feed Systems 90
40 Operation and Maintenance Requirements for Ferric Sulfate Feed
Systems - Building Energy, Process Energy and Maintenance
Material . 91
41 Operation and Maintenance Requirements for Ferric Sulfate Feed
Systems - Labor and Total Cost 92
42 Construction Cost for Ammonia Feed Facilities 95
43 Operation and Maintenance Requirements for Anhydrous Feed
Facilities — Building Energy, Process Energy, and Maintenance
Material . ........ 99
44 Operation and Maintenance Requirements for Anhydrous Ammonia Feed
Facilities - Labor and Total Cost 100
45 Operation and Maintenance Requirements for Aqua Ammonia Feed
Facilities - Process Energy and Maintenance Material 102
46 Operation and Maintenance Requirements for Aqua Ammonia Feed
Facilities - Labor and Total Cost 103
47 Construction Cost for Powdered Activated Carbon Feed Systems . , 106
x
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Number Page
48 Operation and Maintenance Requirements for Powdered Activated
Carbon Feed Systems - Building Energy, Process Energy, and
Maintenance Material 109
49 Operation and Maintenance Requirements for Powdered Activated
Carbon Feed Systems - Labor and Total Cost 110
50 Construction Cost for Rapid Mix Ill
51 Operation and Maintenance Requirements for Rapid Mix - Process
Energy and Maintenance Material 115
52 Operation and Maintenance Requirements for Rapid Mix - Labor
and Total Cost . 116
53 Construction Cost for Flocculation - Horizontal Paddle Systems . 119
54 Construction Cost for Flocculation - Vertical Turbine
Flocculators 123
55 Operation and Maintenance Requirements for Flocculation, Horizontal
Paddle Systems - Process Energy and Maintenance Material . . . 125
56 Operation and Maintenance Requirements for Flocculation, Horizontal
Paddle Systems - Labor and Total Cost 126
57 Construction Cost for Circular Clarifiers 130
58 Operation and Maintenance Requirements for Circular Clarifiers -
Process Energy and Maintenance Material 132
59 Operation and Maintenance Requirements for Circular Clarifiers -
Labor and Total Cost 133
60 Construction Cost for Rectangular Clarifiers 135
61 Operation and Maintenance Requirements for Rectangular Clarifiers -
Process Energy and Maintenance Material 138
62 Operation and Maintenance Requirements for Rectangular Clarifiers -
Labor and Total Cost 139
63 Construction Cost for Upflow Solids Contact Clarifiers 141
64 Operation and Maintenance Requirements for Upflow Solids Contact
Clarifiers - Process Energy and Maintenance Material 143
65 Operation and Maintenance Requirements for Upflow Solids Contact
Clarifiers - Labor and Total Cost 144
xi
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Number Page
66 Construction Cost for Tube Settling Modules , 148
67 Construction Cost for Gravity Filtration Structures 152
68 Operation and Maintenance Requirements for Gravity Filtration
Structures - Building Energy and Maintenance Material .... 153
69 Operation and Maintenance Requirements for Gravity Filtration
Structures - Labor and Total Cost . 154
70 Construction Cost for Filtration Media 158
71 Construction Cost for Backwash Pumping Facilities . . 161
72 Operation and Maintenance Requirements for Backwash Pumping
Facilities — Process Energy and Maintenance Material .... 163
73 Operation and Maintenance Requirements for Backwash Pumping
Facilities - Labor and Total Cost 164
74 Construction Cost for Hydraulic Surface Wash Systems 167
75 Operation and Maintenance Requirements for Hydraulic Surface Wash
Systems - Process Energy and Maintenance Material 168
76 Operation and Maintenance Requirements for Hydraulic Surface
Wash Systems - Labor and Total Cost 169
77 Construction Cost for Air-Water Backwash Facilities 173
78 Operation and Maintenance Requirements for Air-Water Backwash
Facilities - Process Energy and Maintenance Material .... 174
79 Operation and Maintenance Requirements for Air-Water Backwash
Facilities - Labor and Total Cost 175
80 Construction Cost for Wash Water Surge Basins 178
81 Construction Cost for Modification of Rapid Sand Filters to
High-Rate Filters 181
82 Construction Cost for Continuous Automatic Backwash Filters . . 184
83 Operation and Maintenance Requirements for Continuous Automatic
Backwash Filters - Building Energy, Process Energy and
Maintenance Material 186
84 Operation and Maintenance Requirements for Continuous Automatic
Backwash Filters - Labor and Total Cost ..... 187
xxi
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Number Page
85 Construction Cost for Recarbonation Basins 190
86 Construction Cost for Recarbonation - Liquid CC>2 as C02 Source . 191
87 Operation and Maintenance Requirements for Recarbonation - Liquid
C02 as C02 Source - Building Energy, Process Energy and
Maintenance Material 194
88 Operation and Maintenance Requirements for Recarbonation - Liquid
C02 as C02 Source - Labor and Total Cost 195
89 Construction Cost for Recarbonation - Submerged Burners as
C02 Source 198
90 Operation and Maintenance Requirements for Recarbonation -
Submerged Burners as C02 Source - Natural Gas, Process Energy,
and Maintenance Material 199
91 Operation and Maintenance Requirements for Recarbonation -
Submerged Burners as C02 Source - Labor and Total Cost .... 200
92 Construction Cost for Recarbonation - Stack Gas as C02 Source . 204
93 Operation and Maintenance Requirements for Recarbonation - Stack
Gas as C02 Source - Process Energy and Maintenance Material . 206
94 Operation and Maintenance Requirements for Recarbonation - Stack
Gas as C02 Source - Labor and Total Cost 207
95 Construction Cost for Multiple Hearth Recalcination 210
96 Operation and Maintenance Requirements for Multiple Hearth
Recalcination - Natural Gas, Building Energy, Process Energy
and Maintenance Material 213
97 Operation and Maintenance Requirements for Multiple Hearth
Recalcination - Labor and Total Cost 214
98 Construction Cost for Contact Basins 215
99 Construction Cost for Pressure Diatomite Filters . , 220
100 Operation and Maintenance Requirements for Pressure Diatomite
Filters - Building Energy, Process Energy, and Maintenance
Material . 222
101 Operation and Maintenance Requirements for Pressure Diatomite
Filters - Labor and Total Cost 223
102 Construction Cost for Vacuum Diatomite Filters 227
xixi
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Number Page
103 Operation and Maintenance Requirements for Vacuum Diatomite
Filters — Building Energy, Process Energy, and Maintenance
Material 229
104 Operation and Maintenance Requirements for Vacuum Diatomite
Filters - Labor and Total Cost 230
105 Construction Cost for Pressure Filtration Plants 233
106 Operation and Maintenance Requirements for Pressure Filtration
Plants - Building Energy, Process Energy, and Maintenance
Material 237
107 Operation and Maintenance Requirements for Pressure Filtration
Plants - Labor and Total Cost 238
108 Construction Cost for In-Plant Pumping 239
109 Operation and Maintenance Requirements for In-Plant Pumping -
Process Energy and Maintenance Material 241
110 Operation and Maintenance Requirements for In-Plant Pumping -
Labor and Total Cost 242
111 Typical Wash Water Storage Tank 245
112 Construction Cost for Wash Water Storage Tanks 248
113 Construction Cost for Reverse Osmosis 250
114 Operation and Maintenance Requirements for Reverse Osmosis -
Building Energy, Process Energy, and Maintenance Material . . 253
115 Operation and Maintenance Requirements for Reverse Osmosis -
Labor and Total Cost 254
116 Construction Cost for Pressure and Gravity Ion Exchange
Softening 257
117 Operation and Maintenance Requirements for Pressure Ion Exchange
Softening - Building Energy, Process Energy and Maintenance
Material 262
118 Operation and Maintenance Requirements for Pressure Ion Exchange
Softening - Labor and Total Cost 263
119 Operation and Maintenance Requirements for Gravity Ion Exchange
Softening - Building Energy, Process Energy and Maintenance
Material 264
xiv
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Number • Page
120 Operation and Maintenance Requirements for Gravity Ion Exchange
Softening - Labor and Total Cost 265
121 Construction Cost for Pressure Ion Exchange Nitrate Removal . . 269
122 Operation and Maintenance Requirements for Pressure Ion Exchange
Nitrate Removal - Building Energy, Process Energy and
Maintenance Material 272
123 Operation and Maintenance Requirements for Pressure Ion Exchange
Nitrate Removal - Labor and Total Cost 273
124 Construction Cost for Activated Alumina Fluoride Removal .... 278
125 Operation and Maintenance Requirements for Activated Alumina for
Fluoride Removal - Building Energy and Maintenance Material . 279
126 Operation and Maintenance Requirements for Activated Alumina for
Fluoride Removal - Labor and Total Cost 280
127 Construction Cost for Gravity Carbon Contactors - Concrete
Construction 285
128 Operation and Maintenance Requirements for Concrete Gravity Carbon
Contactors - Building Energy, Process Energy, and Maintenance
, Material Needed for 7.5 and 12.5 min Empty Bed Contact Time . 286
129 Operation and Maintenance Requirements for Concrete Gravity Carbon
Contactors - Labor and Total Cost Needed for 7.5 and 12.5 min
Empty Bed Contact Time 287
130 Construction Cost for Steel Gravity Carbon Contactors 293
131 Operation and Maintenance Requirements for Steel Gravity Carbon
Contactors - Building Energy, Process Energy, and Maintenance
Material 294
132 Operation and Maintenance Requirements for Steel Gravity Carbon
Contactors - Labor and Total Cost 295
133 Typical Activated Carbon Column Installation .......... 299
134 Construction Cost for Pressure Carbon Contactors . . 303
135 Operation and Maintenance Requirements for Pressure Carbon
Contactors - Building Energy, Process Energy and Maintenance
Material 306
136 Operation and Maintenance Requirements for Pressure Carbon
Contactors - Labor and Total Cost 307
xv
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Number Page
137 Construction Cost for Conversion of Sand Filter to Carbon
Contactor 309
138 Material Cost for Granular Activated Carbon, Including Cost
for Purchase, Delivery, and Placement 311
139 Construction Cost for Capping Sand Filters with Anthracite . . 313
140 Construction Cost for Off-Site Regional Carbon Regeneration
Handling and Transportation ... 316
141 Operation and Maintenance Requirements for Off—Site Regional
Carbon Regeneration Handling and Transportation - Diesel Fuel
and Maintenance Material Needed for 10, 25, and 100-mile Haul
Distances 318
142 Operation and Maintenance Requirements for Off-Site Regional
Carbon Regeneration Handling and Transportation - Labor and
Total Cost for 10, 25, and 100-mile Haul Distances ..... 319
143 Construction Cost for Multiple Hearth Granular Carbon
Regeneration , 323
144 Operation and Maintenance Requirements for Multiple Hearth
Granular Carbon Regeneration — Building Energy, Process
Energy, Natural Gas, and Maintenance Material 325
145 Operation and Maintenance Requirements for Multiple Hearth
Granular Carbon Regeneration - Labor and Total Cost 326
146 Construction Cost for Infrared Carbon Regeneration Furnace . , 330
147 Operation and Maintenance Requirements for Infrared Carbon
Regeneration Furnace - Building Energy, Process Energy, and
Maintenance Material 333
148 Operation and Maintenance Requirements for Infrared Carbon
Regeneration Furnace - Labor and Total Cost 334
149 Construction Cost for Granular Carbon Regeneration - Fluid
Bed Process 337
150 Operation and Maintenance Requirements for Granular Carbon
Regeneration, Fluid Bed Process - Natural Gas, Process Energy,
and Maintenance Material 340
151 Operation and Maintenance Requirements for Granular Carbon
Regeneration, Fluid Bed Process - Labor and Total Cost . . , 341
xvi
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Number Page
152 Typical Process Diagram for Fluidized Bed Powdered Carbon
Regeneration System 342
153 Construction Cost for Powdered Carbon Regeneration - Fluidized
Bed Process 344
154 Operation and Maintenance Requirements for Powdered Carbon
Regeneration, Fluidized Bed Process - Natural Gas, Process
Energy, and Maintenance Material ...... 346
155 Operation and Maintenance Requirements for Powdered Carbon
Regeneration, Fluidized Bed Process - Labor and Total Cost . 347
156 Schematic of the Atomized Suspension, Powdered Carbon
Regeneration System 349
157 Construction Cost for Powdered Carbon Regeneration - Atomized
Suspension Process 353
158 Operation and Maintenance Requirements for Powdered Carbon
Regeneration, Atomized Suspension Process - Natural Gas,
Process Energy, and Maintenance Material 355
159 Operation and Maintenance Requirements for Powdered Carbon
Regeneration, Atomized Suspension Process - Labor and Total
Cost 356
160 Construction Cost for Chemical Sludge Pumping - Unthickened
Sludge •. 358
161 Operation and Maintenance Requirements for Chemical Sludge
Pumping - Unthickened Sludge — Building Energy, Process Energy,
and Maintenance Material 360
162 Operation and Maintenance Requirements for Chemical Sludge
Pumping - Unthickened Sludge - Labor and Total Cost 361
163 Construction Cost for Chemical Sludge Pumping - Thickened Sludge 363
164 Operation and Maintenance Requirements for Chemical Sludge
Pumping, Thickened Sludge - Building Energy, Process Energy,
and Maintenance Material s. 365
165 Operation and Maintenance Requirements for Chemical Sludge
Pumping, Thickened Sludge - Labor and Total Cost 366
166 Construction Cost for Gravity Sludge Thickeners . . : 370
167 Operation and Maintenance Requirements for Gravity Sludge
Thickeners - Process Energy and Maintenance Material .... 371
xvii
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Number Page
168 Operation and Maintenance Requirements for Gravity Sludge
Thickeners - Labor and Total Cost 372
169 Typical Vacuum Filter Installation 375
170 Construction Cost for Vacuum Filters 377
171 Operation and Maintenance Requirements for Vacuum Filters -
Building Energy, Process Energy, and Maintenance Material . . 380
172 Operation and Maintenance Requirements for Vacuum Filters -
Labor and Total Cost 381
173 Construction Cost for Sludge Dewatering Lagoons 384
174 Operation and Maintenance Requirements for Sludge Dewatering
Lagoons - Diesel Fuel and Maintenance Material 387
175 Operation and Maintenance Requirements for Sludge Dewatering
Lagoons - Labor and Total Cost 388
176 Typical Filter Press Installation 390
177 Construction Cost for Filter Press 392
178 Operation and Maintenance Requirements for Filter Press -
Building Energy, Process Energy and Maintenance Material . . 394
179 Operation and Maintenance Requirements for Filter Press -
Labor and Total Cost 395
180 Typical Decanter Centrifuge Installation 398
181 Construction Cost for Decanter Centrifuges 400
182 Operation and Maintenance Requirements for Decanter Centrifuges -
Building Energy, Process Energy, and Maintenance Material . . 403
183 Operation and Maintenance Requirements for Decanter Centrifuges -
Labor and Total Cost 404
184 Typical Basket Centrifuge Installation 406
185 Construction Cost for Basket Centrifuge 408
186 Operation and Maintenance Requirements for Basket Centrifuges -
Building Energy, Process Energy and Maintenance Material . . 411
187 Operat-ion and Maintenance Requirements for Basket Centrifuges -
Labor and Total Cost 412
xviii
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Number Page
188 Construction Cost for Sand Drying Beds 414
189 Operation and Maintenance Requirements for Sand Drying Beds -
Diesel Fuel and Maintenance Material 416
190 Operation and Maintenance Requirements for Sand Drying Beds -
Labor and Total Cost 417
191 Typical Belt Filter Press Installation . 420
192 Construction Cost for the Belt Filter Press 423
193 Operation and Maintenance Requirements for the Belt Filter Press-
Building Energy, Process Energy and Maintenance Material . . . 424
194 Operation and Maintenance Requirements for the Belt Filter Press-
Labor and Total Cost 425
195 Initial Construction Cost for Liquid Sludge Handling - 5-,
20-» and 40-mile Haul Distances . 432
196 Initial Construction Cost for Dewatered Sludge Hauling 5-, 20-,
and 40-mile Haul Distances 434
197 Operation and Maintenance Requirements for Liquid Sludge Hauling -
Diesel Fuel and Maintenance Material Needed for 5-, 20-,
and 40-mile Haul Distances 436
198 Operation and Maintenance Requirements for Liquid Sludge Hauling -
Labor and Total Cost Needed for 5-, 20-, and 40-mile Haul
Distances . 437
199 -Operation and Maintenance Requirements for Dewatered Sludge
Hauling - Fuel and Maintenance Material Needed for 5-, 20-,
and 40-mile Haul Distances 439
200 Operation and Maintenance Requirements for Dewatered Sludge
Hauling - Labor and Total Cost Needed for 5-, 20^, and
40—mile Haul Distances 440
201 Construction Cost for Raw Water Pumping Facilities 442
202 Operation and Maintenance Requirements for Raw Water Pumping
Facilities - Process Energy and Maintenance Material Needed
for 30- and 100-ft TDH 444
203 Operation and Maintenance Requirements for Raw Water Pumping
Facilities - Labor and Total Cost for 30- and 100-ft TDH . . . 445
xix
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Number ' Page
204 Construction Cost for Finished Water Pumping Facilities -
100- and 300-ft TDH 447
205 Operation and Maintenance Requirements for Finished Water Pumping
Facilities - Process Energy and Maintenance Material for 100-
and 300-ft TDH 449
206 Operation and Maintenance Requirements for Finished Water Pumping
Facilities - Labor and Total Cost for 100- and 300-ft TDH . . 450
207 Construction Cost for Below-Ground and Ground-Level Clearwell
Storage 455
208 Construction Cost for Diffused Aeration Basins 457
209 Construction Cost for Aeration Towers 460
210 Operation and Maintenance Requirements for Diffused Aeration
Basins - Maintenance Material, Building Energy, and Process
Energy 462
211 Operation and Maintenance Requirements for Diffused Aeration
Basins - Labor and Total Cost 463
212 Operation and Maintenance Requirements for Aeration Towers -
Process Energy and Maintenance Material 466
213 Operation and Maintenance Requirements for Aeration Towers -
Labor and Total Cost 467
214 Construction Cost for Administrative, Laboratory and
Maintenance Building 469
215 Operation and Maintenance Requirements for Administration,
Laboratory, and Maintenance Building - Building Energy and
Maintenance Material 472
216 Operation and Maintenance Requirements for Administration,
Laboratory, and Maintenance Building - Labor and Total Cost . 473
217 Flow Diagram for Automatic Coagulant Dosage Control 482
218 Facility Layout for 1-mgd Treatment Plant .... 487
219 Sectional Views of 1-mgd Water Treatment Plant 488
220 Facility Layout for 10-mgd Water Treatment Plant . . 489
221 Partial Plan for Sedimentation Basins for 10-mgd Water Treatment
Plant 490
xx
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Number Page
*f
222 Filter Layout for 10-mgd Water Treatment Plant 491
223 Facility Layout for 100-mgd Water Treatment Plant 492
224 Partial Plan for Filters for 100-mgd Water Treatment Plant . . . 493
225 Sectional Views of Filters for a 100-mgd Water Treatment Plant . 494
226 Partial Plan for Flash Mix and Flocculation Basins for 100-mgd
Water Treatment Plant ....... 495
227 Partial plan of Sedimentation Basin for 100-mgd Water Treatment -
Plant 496
228 General Contractor's Overhead and Fee Percentage Versus Total
Construction Cost 499
229 Legal, Fiscal and Administrative Costs for Projects Less than
$1 Million 500
230 Legal, Fiscal and Administrative Costs for Projects Greater
Than $1 Million . 501
231 Interest During Construction for Projects Less Than $200,000 . . 502
232 Interest During Construction for Projects Greater Than $200,000 503
xxi
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TABLES
Number Page
1 Construction Cost for Chlorine Storage and Feed Systems -
Cylinder Storage ..... 14
2 Construction Cost for Chlorine Storage and Feed Systems -
On-Site Storage Tank with Rail Delivery 15
3 Construction Cost for Chlorine Storage and Feed Systems -
Direct Feed from Rail Car 16
4 Operation and Maintenance Summary for Chlorine Storage and
Feed Systems 22
5 Construction Cost for Chlorine Dioxide Generating and Feed
Systems 24
6 Operation and Maintenance Summary for Chlorine Dioxide
7
8
9
10
11
12
13
14
15
16
Operation and Maintenance Summary for Ozone Generation
Systems .........
Construction Cost for On-Site Hypochlorite Generation Systems
Operation and Maintenance Summary for On-Site Hypochlorite
Operation and Maintenance Summary for Alum Feed Systems . . .
Operation and Maintenance Summary for Polymer Feed Systems . .
Construction Cost for Lime Feed Svstems
"n
39
40
44
47
52
54
58
61
xxii
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Number Page
18 Operation and Maintenance Summary for Lime Feed Systems .... 64
19 Construction Cost for Potassium Permanganate Feed Systems ... 65
20 Operation and Maintenance Summary for Potassium Permanganate
Feed Systems 70
21 Construction Cost for Sulfuric Acid Feed Systems 71
22 Operation and Maintenance" Summary for Sulfuric Acid Feed Systems 75
23 Construction Cost for Sodium Hydroxide Feed Systems ...... 78
24 Operation and Maintenance Summary for Sodium Hydroxide Feed
Systems 81
25 Construction Cost for Ferrous Sulfate Feed Systems 83
26 Operation and Maintenance Summary for Ferrous Sulfate
Feed Systems , 87
27 Construction Cost for Ferric Sulfate Feed Systems ....... 89
28 Operation and Maintenance Summary for Ferric Sulfate Feed
Systems 93
29 Construction Cost for Anhydrous Ammonia Feed Facilities .... 96
30 Construction Cost for Aqua Ammonia Feed Facilities ...... 97
31 Operation and Maintenance Summary for Anhydrous Ammonia Feed
Facilities . 101
32 Operation and Maintenance Summary for Aqua Ammonia Feed
Facilities 104
33 Construction Cost for Powdered Activated Carbon Feed Systems . 107
34 Operation and Maintenance Cost for Powdered Activated Carbon
Feed Systems 108
35 Construction Cost for Rapid Mix, G = 300 112
36 Construction Cost for Rapid Mix, G = 600 . 113
37 Construction Cost for Rapid Mix, G = 900 114
38 Operation and Maintenance Summary for Rapid Mix 117
xxiii
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Number Page
39 Construction Cost for Flocculation - Horizontal Paddle Systems,
G = 20 120
40 Construction Cost for Flocculation - Horizontal Paddle Systems,
G = 50 121
41 Construction Cost for Flocculation - Horizontal Paddle Systems,
G = 80 122
42 Construction Cost for Flocculation - Vertical Turbine
Flocculators 124
43 Operation and Maintenance Summary for Flocculation -
Horizontal Paddle Systems ..... 127
44 Construction Cost for Circular Clarifiers 129
45 Operation and Maintenance Summary for Circular Clarifiers ... 131
46 Construction Cost for Rectangular Clarifiers 134
47 Operation and Maintenance Summary for Rectangular Clarifiers . . 137
48 Construction Cost for Upflow Solids Contact Clarifiers 140
49 Operation and Maintenance Summary for Upflow Solids Contact
Clarifiers 145
50 Conceptual Design for Tube Settling Modules 146
51 Construction Cost for Tube Settling Modules ..... 147
52 Conceptual Designs for Gravity Filtration Structures
(24 to 36 inch media depth) 149
53 Construction Cost for Gravity Filtration Structures ...... 151
54 Operation and Maintenance Summary for Gravity Filtration
Structures 155
55 Filter Media and Gravel Underdrain Characteristics ....... 157
56 Construction Cost for Filtration Media 159
57 Construction Cost for Backwash Pumping Facilities 160
58 Operation and Maintenance Summary for Backwash Pumping
Facilities 165
59 Construction Cost for Hydraulic Surface Wash Systems 166
xxiv
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Number • Page
60 Operation and Maintenance Summary for Hydraulic Surface
Wash Systems 170
61 Construction Cost for Air—Water Backwash Facilities 172
62 Operation and Maintenance Summary for Air-Water Backwash
Facilities 176
63 Construction Cost for Wash Water Surge Basins 177
64 Construction Cost for Modification of Rapid Sand Filters to
High-Rate Filters 180
65 Conceptual Design for Continuous Automatic Backwash Filter . . . 182
66 Construction Cost for Continuous Automatic Backwash Filter . . . 183
67 Operation and Maintenance Summary for Continuous Automatic
Backwash Filter 185
68 Construction Cost for Recarbonation Basin 189
69 Construction Cost for Recarbonation - Liquid C0£ as C02 Source . 192
70 Operation and Maintenance Summary for Recarbonation - Liquid
C02 as C02 Source 193
71 Construction Cost for Recarbonation - Submerged Burners as
C02 Source . 197
72 Operation and Maintenance Summary for Recarbonation - Submerged
Burners as C02 Source . 201
73 Construction Cost for Recarbonation - Stack Gas as C02 Source . 203
74 Operation and Maintenance Summary for Recarbonation - Stack
Gas as C02 Source 205
75 Conceptual Design for Multiple Hearth Recalcination 208
76 Construction Cost for Multiple Hearth Recalcination 209
77 Operation and Maintenance Summary for Multiple Hearth
Recalcination 212
78 Construction Cost for Contact Basins . 216
79 Conceptual Design for Pressure Diatomite Filters 218
xxv
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Number Page
80 Construction Cost for Pressure Diatomite Filters 219
81 Operation and Maintenance Summary for Pressure Diatomite Filters 221
82 Conceptual Design for Vacuum Diatomite Filters ......... 225
83 Construction Cost for Vacuum Diatomite Filters 226
84 Operation and Maintenance Summary for Vacuum Diatomite Filters . 228
85 Conceptual Design for Pressure Filtration Plants 232
86 Construction Cost for Pressure Filtration Plants ... 234
87 Operation and Maintenance Summary for Pressure Filtration Plants 236
88 Construction Cost for In-Plant Pumping 240
89 Operation and Maintenance Summary for In-Plant Pumping 243
90 Conceptual Designs for Wash Water Storage Tanks 244
91 Construction Cost for Wash Water Storage Tanks 247
92 Construction Cost for Reverse Osmosis 249
93 Operation and Maintenance Summary for Reverse Osmosis 252
94 Conceptual Design for Pressure Ion Exchange Softening 256
95 Construction Cost for Pressure Ion Exchange Softening 258
96 Conceptual Design for Gravity Ion Exchange Softening . 259
97 Construction Cost for Gravity Ion Exchange Softening 260
98 Operation and Maintenance Summary for Pressure Ion Exchange
Softening 266
99 Operation and Maintenance Summary for Gravity Ion Exchange
Softening 267
100 Conceptual Designs for Pressure Ion Exchange Nitrate Removal . . 268
101 Construction Cost for Pressure Ion Exchange Nitrate Removal . . 270
102 Operation and Maintenance Summary for Pressure Ion Exchange
Nitrate Removal ...... 274
xxvi
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Number Page
103 Conceptual Design for Activated Alumina for Fluoride Removal . . 275
104 Construction Cost for Activated Alumina for Fluoride Removal . . 277
105 Operation and Maintenance Summary for Activated Alumina
for Fluoride Removal 281
106 Construction Cost for Concrete Gravity Carbon Contactors
7.5 min Empty Bed Contact Time and 5 ft Bed Depth 283
107 Construction Cost for Concrete Gravity Carbon Contactors
12.5 min Empty Bed Contact Time and 8.3 ft Bed Depth 284
108 Operation and Maintenance Summary for Gravity Carbon Contactors 288
109 Conceptual Design for Steel Gravity Carbon Contactors
20-ft Carbon Bed Depth ..... 289
110 Construction Cost for Steel Gravity Carbon Contactors 12-ft
Diameter Tanks 291
111 Construction Cost for Steel Gravity Carbon Contactors 30—ft
Diameter Tanks 292
112 Operation and Maintenance Summary for Steel Gravity Carbon
Contactors 296
113 Conceptual Design for Pressure Carbon Contactors 298
114 Construction Cost for Pressure Carbon Contactors - 7.5 min
Empty Bed Contact Time and 5 ft Bed Depth 300
115 Construction Cost for Pressure Carbon Contactors - 15-min
Empty Bed Contact Time and 10-ft Bed Depth .......... 301
116 Construction Cost for Pressure Carbon Contactors - 30-min
Empty Bed Contact Time and 20-ft Bed Depth 302
117 Operation and Maintenance Summary for Pressure Carbon Contactors 305
118 Construction Cost for Conversion of Sand Filter to Carbon
Contactor 308
119 Construction Cost for Capping Sand Filters with Anthracite . . . 312
120 Construction Cost for Off-Site Regional Carbon Regeneration -
Handling and Transportation 315
121 Operation and Maintenance Summary for Off-Site Regional Carbon
Regeneration Handling and Transportation 317
xxv ii
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Number Page
122 Conceptual Design for Multiple Hearth Granular Carbon
Regeneration ..... 321
123 Construction Cost for Multiple Hearth Granular Carbon
Regeneration 322
124 Operation and Maintenance Summary for Multiple Hearth Granular
Carbon Regeneration 324
125 Conceptual Design for Infrared Carbon Regeneration Furnace . . . 328
126 Construction Cost for Infrared Carbon Regeneration Furnace . . . 329
127 Operation and Maintenance Summary for Infrared Carbon
Regeneration Furnace 332
128 Conceptual Design for Granular Carbon Regeneration - Fluid
Bed Process 335
129 Construction Cost for Granular Carbon Regeneration - Fluid
Bed Process 336
130 Operation and Maintenance Summary for Granular Carbon Regeneration
Fluid Bed Process . 339
131 Construction Cost for Powdered Carbon Regeneration - Fluidized
Bed Process 343
132 Operation and Maintenance Summary for Powdered Carbon
Regeneration - Fluidized Bed Process 348
133 Conceptual Design for Powdered Carbon Regeneration — Atomized
Suspension Process ......... 350
134 Construction Cost for Powdered Carbon Regeneration - Atomized
Suspension Process 352
135 Operation and Maintenance Summary for Powdered Carbon
Regeneration - Atomized Suspension Process 354
136 Construction Cost for Chemical Sludge Pumping - Unthickened
Sludge 357
137 Operation and Maintenance Summary for Chemical Sludge Pumping -
Unthickened Sludge 362
138 Construction Cost for Chemical Sludge Pumping - Thickened Sludge 364
139 Operation"and Maintenance Summary for Chemical Sludge Pumping -
Thickened Sludge . ..... 367
xxviii
-------
Number • Page
140 Construction Cost for Gravity Sludge Thickeners . . . . . -. . . -369
141 Operation and Maintenance Summary for Gravity Sludge
Thickeners ...... '.'..-'.,'...... '373
142 Conceptual Design for Vacuum Filters ..... 374
143 Construction Cost for Vacuum Filters . . . . 376
144 Operation and Maintenance Summary for Vacuum Filters 379
145 Conceptual Design for Sludge Dewatering Lagoons ........ 382
146 Construction Cost for Sludge Dewatering Lagoons ........ 383
147 Operation and Maintenance Summary for Sludge Dewatering Lagoons 386
148 Conceptual Design for Filter Press . . - 389
149 Construction Cost for Filter Press 'v . . .... . . 391
150 Operation and Maintenance Summary for Filter Press ...... 393
151 Conceptual Design for Decanter Centrifuge .....'...... 397
152 Construction Cost for Decanter Centrifuge 399
153 Operation and Maintenance Summary for Decanter Centrifuges . . 402
154 Conceptual Design for Basket Centrifuge - .' . . 405
155 Construction Cost for Basket Centrifuge . . . . . V . 407
156 Operation and Maintenance Summary for Basket Centrifuges . . . 410
157 Conceptual Design for Sand Drying Beds . . . . . . . . .... 413
158 Construction Cost for Sand Drying Beds ............ 415
159 Operation and Maintenance Summary for Sand Drying Beds .... 418
160 Conceptual Design for the Belt Filter Press . . . 421
161 Construction Cost for the Belt Filter Press . . . . .'. .... . 422
162 Operation and Maintenance Summary for the Belt Filter Press ... 426
163 Annual Cost for Sludge Disposal to Sanitary Sewers . . . . . . 428
164 Cost-Estimating Criteria for Liquid and Dewatered Sludge Hauling 429
xxix
-------
Number Page
165 Initial Construction Cost for Liquid Sludge Hauling 430
166 Initial Capital Cost for Dewatered Sludge Hauling 433
167 Operation and Maintenance Summary for Liquid Sludge Hauling . . 435
168 Operation and Maintenance Summary for Dewatered Sludge Hauling 438
169 Construction Cost for Raw Water Pumping Facilities 441
170 Operation and Maintenance Summary for Raw Water Pumping
Facilities 446
171 Construction Cost for Finished Water Pumping Facilities .... 448
172 Operation and Maintenance Summary for Finished Water Pumping
Facilities 451
173 Conceptual Design for Clearwell Storage 452
174 Construction Cost for Below-Ground Clearwell Storage 453
175 Construction Cost for Ground-Level Clearwell Storage 454
176 Construction Cost for Diffused Aeration Basins 456
177 Construction Cost for Aeration Towers 459
178 Operation and Maintenance Summary for Diffused Aeration Basins 461
179 Operation and Maintenance Summary for Aeration Towers 465
180 Construction Cost for Administrative, Laboratory and
Maintenance Building 468
181 Operation and Maintenance Summary for Administrative, Laboratory
and Maintenance Building 471
182 Construction Cost for Total Particle Counter Systems 480
183 Construction Cost for Coagulation Control with Pilot Filters . 483
184 Construction Cost for Filter Effluent Turbidimeters 485
185 Design Criteria and Cost Calculation for a 40-mgd Conventional
Treatment Plant 498
186 Annual Cost for a 40-mgd Conventional Treatment Plant 504
xxx
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ABBREVIATIONS AND SYMBOLS
ft — foot
ft2 — square foot
ft3 — cubic feet
G — velocity gradient - feet per second per foot
gal — gallon
gpd — gallons per day
gpd/ft2 — gallons per day per square foot
gpm — " gallons per minute
hr — hours
kg — kilogram
kw-hr — kilowatt-hour
1 — liter
Ib — pound
Ipd — liters per day
lpd/m3 — liters per day per cubic meter
Ips — liters per second
m — meter
m2 — square meter
m — cubic meter
m3/d — cubic meters per day
m3/s — cubic meters per second
mg — million gallons
mg/1 — milligrams per liter
mgd — million gallons per day
min — minutes
mph — miles per hour
psi — pounds per square inch
scf — standard cubic foot
tdh — total dynamic head
tu — turbidity unit
yd3 — cubic yards
yr — year
xxxi
-------
English Unit
cu ft
cu yd
ft
gal
gal
gpd/ft2
gpm
Ib
mgd
mgd
sq ft
METRIC CONVERSIONS
Multiplier
0.028
0.75
0.3048
3.785
0.003785
0.003785
40.74
0.0631
0.454
3785
0.0438
0.0929
Metric Unit
m3
m3
m
1
m3
m3/d
lpd/m2
1/8
kg
m3/d
m3/sec
xxxii
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ACKNOWLEDGEMENTS
This report was prepared under the direction of Dr. Robert M. Clark,
EPA Municipal Environmental Research Laboratory, Office of Research and
Development. The report was prepared by Robert C. Gumerman, Russell L.
Gulp, Sigurd P. Hansen, Thomas S. Lineck, and Bruce E. Burris of Gulp/
Wesner/Culp. Ms. Karin J. Wells of Culp/Wesner/Culp was responsible for
typing of the final report.
Mr. Ronald M. Dahman of Zurheide-Herrmann, Inc., was responsible for
checking all unit costs. Dr. Isadore Nusbaum and Mr. Dean Owens were
respective sub-consultants on the reverse osmosis and ion exchange curves.
Special acknowledgement is given to Mr. Keith Carswell, Dr. Robert M.
Clark, Mr. Jack De Marco, Dr. Gary Logsdon, Dr. 0. Thomas Love, Mr. Benjamin
Lykins, Jr., Mr. Thomas J. Sorg, all of the EPA Municipal Environmental
Research Laboratory, who reviewed the Final Report.
Mrs. Anne Hamilton was the technical editor for all four volumes of
this Report.
xxxiii
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Page Intentionally Blank
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SECTION 1
INTRODUCTION
SCOPE
This report is Volume 2 of a four-volume study that presents construction
and operation and maintenance cost curves for 99 unit processes that are
especially applicable (either individually or in combination) to the removal
of contaminants listed in the National Interim Primary Drinking Water
Regulations. This volume discusses 72 unit processes that are particularly
suited to large water supply systems, 1 to 200 mgd (3,785 to 757,000 m3/d).
Information is also included on enhanced virus and'asbestos removal using
modifications of standard unit processes. The costs were developed to a
high level of accuracy initially and were then checked by a second
engineering consulting firm, Zurheide-Herrmann, Inc., using cost-estimating
techniques similar to those used by general contractors in preparing their
bids. The cost information for the 72 unit processes is presented in both
graphic and tabular form for both construction and operation and maintenance.
A description of the methodology used to derive the cost curves and to update
them is presented in Volume 1 of the report.
BACKGROUND
The Safe Drinking Water Act, Public Law 93-523,l enacted on December 16,
1974, empowered the Administrator of the U.S. Environmental Protection
Agency (EPA) to control the quality of the drinking water in public water
systems by regulation and other means. The Act specified a three-stage
mechanism for the establishment of comprehensive regulations for drinking
water quality:
1. Promulgation of National Interim Primary Drinking Water
Regulations.
2. A study to be conducted by the National Academy of Sciences (NAS)
within 2 years of enactment on the human health effects of
exposure to contaminants in drinking water.
3. Promulgation of Revised National Primary Drinking Water
Regulations based on the NAS Report.
National Interim Primary Drinking Water Regulations were promulgated on
December 24, 1975,2 and July 9, 1976, and they became effective on June 24,
1977. These Regulations-were based on the Public Health Service Drinking
Water Standards of 1962, as revised by the EPA Advisory Committee on the
Revisions and Application of the Drinking Water Standards. They are intended
to protect health to the maximum extent feasible using treatment methods that
1
-------
are generally available and take cost into consideration. The National
Interim Primary Drinking Water Regulations contain maximum contaminant levels
(MCL) and monitoring requirements for 10 inorganic chemicals, 6 organic
pesticides, 2 categories of radionuclides, coliform organisms, and turbidity.
An amendment to the National Interim Primary Drinking Water Regulations was
proposed on February 9, 1978.^ This amendment would establish regulations
for total trihalomethanes and establish treatment technique requirements for
the control of synthetic organic chemicals for community water systems
serving populations of more than 75,000. Secondary Drinking Water Regulations
were proposed by EPA on March 31, 1977.5 A list of the contaminants presently
included in the National Interim Primary Drinking Water Standards, along with
the MCL for each contaminant, is presented in Volume 1 of this report.
The Interim Regulations are devoted to contaminants affecting the health
of consumers, whereas the secondary regulations include those contaminants
that deal primarily with aesthetic qualities of drinking water. The Interim
Primary Regulations are applicable to all public water systems and are
enforceable by EPA or the States that have accepted primacy. Secondary
regulations are not Federally enforceable and are intended as guidelines
for the States.
The National Academy of Sciences (NAS) Summary Report was delivered
to Congress on May 26, 1977, and the full report, Drinking Water and Health6
was delivered on June 20, 1977. The NAS Summary Report was also published
in the Federal Register on Monday, July 11, 1977. Based on the completed
NAS report and the findings of the Administrator, EPA will publish:
1. Recommended MCL's (health goals) for substances in drinking water
that may have adverse effects on humans. These recommended levels
will be selected so that no known or anticipated adverse effects
would occur, allowing an adequate margin of safety. A list of
contaminants that may have adverse effects but that cannot be
accurately measured in water will also be published.
2. Revised National Primary Drinking Water Regulations. These will
specify MCL's or require the use of treatment techniques. MCL's
will be as close to the recommended levels for each contaminant
as feasible. Required treatment techniques for those substances
that cannot be measured will reduce their concentrations to a
level that is as close to the recommended level as feasible.
Feasibility is defined in the Act as use of the best technology,
treatment techniques, and other means that the Administrator finds
are generally available (taking costs into consideration).
On February 9, 1978, the EPA proposed to amend the National Interim
Primary Drinking Water Regulations by adding regulations for organic chemical
contaminants in drinking water. The proposed amendment1* consisted of two
parts:
1. An MCL of 0.10 mg/1 (100 parts per billion) for total trihalomethanes
(TTHM), including chloroform.
-------
2. A treatment technique requiring the use of granular activated
carbon for the control .of synthetic organic chemicals. Three
criteria that the granular activated carbon must achieve are:
(1) an effluent limitation of 0.5 yg/1 for low molecular weight
halogenated organics (excluding TTHM), (2) a limit of 0.5 mg/1
for effluent total organic carbon concentration when fresh
activated carbon is used, and (3) the removal of at least 50
percent of influent total organic carbon when fresh activated
carbon is used.
These proposed amendments are initially applicable to community water
systems serving populations of more than 75,000.
PURPOSE AND OBJECTIVES
The purpose of Volume 2 is to present the cost of treatment processes
and techniques that are applicable to the treatment of flows between 1 and
200 mgd. Construction costs were developed and are presented in terms of
eight individual components; operation and maintenance costs were developed
and are presented in terms of four components. This approach was used to
facilitate both the original cost derivation, as well as to facilitate the
updating'of costs.
The unit processes presented in this volume, listed in order of their
presentation are:
Chemical Feed Processes
Chlorine Storage and Feed Systems
Chlorine Dioxide Generating and Feed Systems
Ozone Generation Systems and Contact Chambers
On-Site Hypochlorite Generation Systems
Alum Feed Systems
Polymer Feed Systems
Lime Feed Systems
Potassium Permanganate Feed Systems
Sulfuric Acid Feed Systems
Sodium Hydroxide Feed Systems
Ferrous Sulfate Feed Systems
Ferric Sulfate Feed Systems
Ammonia Feed Facilities
Powdered Activated Carbon Feed Systems
Flocculation, Clarification, and Filtration Processes
Rapid Mix
Flocculation
Circular Clarifiers
Rectangular Clarifiers
Upflow Solids Contact Clarifiers
Tube Settling Modules
Gravity Filtration Structures
Filtration Media
Backwash Pumping Facilities
Hydraulic Surface Wash Systems
-------
Air-Water Backwash Facilities
Wash Water Surge Basins
Modification of Rapid Sand Filters to High-Rate Filters
Continuous Automatic Backwash Filters
Recarbonation Basins
Recarbonation - Liquid C0£ as C0£ Source
Recarbonation - Submerged Burners as CC>2 Source
Recarbonation - Stack Gas as C02 Source
Multiple Hearth Recalcination
Contact Basins
Pressure Diatomite Filters
Vacuum Diatomite Filters
Pressure Filtration Plants
In-Plant Pumping
Wash Water Storage Tanks
Reverse Osmosis and Ion Exchange Processes
Reverse Osmosis
Ion Exchange - Softening
Pressure Ion Exchange - Nitrate Removal
Activated Alumina for Fluoride Removal
Activated Carbon Processes
Gravity Carbon Contactors - Concrete Construction
Gravity Carbon Contactors - Steel Construction
Pressure Carbon Contactors
Conversion of Sand Filter to Carbon Contactor
Granular Activated Carbon
Capping Sand Filters with Anthracite
Off-Site Regional Carbon Regeneration - Handling and Transportation
Multiple Hearth Granular Carbon Regeneration
Infrared Carbon Regeneration Furnace
Granular Carbon Regeneration - Fluid Bed Process
Powdered Carbon Regeneration - Fluidized Bed Process
Powdered Carbon Regeneration - Atomized Suspension Process
Sludge Pumping, Dewatering, and Disposal Costs
Chemical Sludge Pumping - Unthickened Sludge
Chemical Sludge Pumping - Thickened Sludge
Gravity Sludge Thickeners
Vacuum Filters
Sludge Dewatering Lagoons
Filter Press
Decanter Centrifuges
Basket Centrifuges
Sand Drying Beds
Belt Filter Press
Sludge Disposal to Sanitary Sewers
Sludge Hauling to Landfill
Miscellaneous Processes
Raw Water Pumping Facilities
Finished Water Pumping Facilities
Clearwell Storage
Aeration
Administration, Laboratory, and Maintenance Building
-------
SECTION 2
COST CURVES
CONSTRUCTION COST CURVES
The construction cost curves were developed using equipment cost data
supplied by manufacturers, cost data from actual plant construction, unit
takeoffs from actual and conceptual designs, and published data. When unit
cost takeoffs were used to determine costs from actual and conceptual designs,
estimating techniques from Richardson Engineering Services Process Plant
Construction Estimating Standards,7 Mean's Building Construction Cost Data,
and the Dodge Guide for Estimating Public Works Construction Costs9 were
often utilized. The cost curves that were developed were then checked and
verified by a second engineering consulting firm, Zurheide-Herrmann, Inc.,
using an approach similar to that which a general contractor would utilize
in determining his construction bid. Every attempt has been made to present
the conceptual designs and assumption that were incorporated into the curves.
Adjustment of the curves may be necessary to reflect site-specific conditions,
geographic or local conditions, or the need for standby power. The curves
should be particularly useful for estimating the relative economics of
alternative treatment systems and for the preliminary evaluation of general
cost level to be expected for a proposed project. The curves contained in
this report are based on October 1978 costs.
The construction cost was developed by determining and then aggregating
the cost of eight principal components which were utilized primarily to
facilitate accurate cost updating (discussed in a subsequent section of
this chapter). The division will also be helpful where costs are being
adjusted for site-specific, geographic, and other special conditions. The
eight categories include the following general items:
Excavation and Sitework. This category includes work related only
to the applicable process and does not include any general sitework
such as sidewalks, roads, driveways, or landscaping.
Manufactured Equipment. This category includes estimated purchase
cost of pumps, drives, process equipment, specific purpose controls,
and other.items that are factory made and sold with equipment.
Concrete. This category includes the delivered cost of ready-mix
concrete and concrete-forming materials.
-------
Steel. This category includes reinforcing steel for concrete and
miscellaneous steel not included within the manufactured equipment
category,
Labor. The labor associated with installing manufactured equipment and
piping and valves, constructing concrete forms, and placing concrete
and reinforcing steel are included in this category.
Pipe and Valves. Cast iron pipe, steel pipe, valves, and fittings
have been combined into a single category. The purchase price of
pipe, valves, fittings, and associated support devices are included
in this category.
Electrical Equipment and Instrumentation. The cost of process electrical
equipment, wiring, and general instrumentation associated with the
process equipment is included in this category.
Housing. In lieu of segregating building costs into several components,
this category represents all material and labor costs associated with
the building, including heating, ventilating, air conditioning, lighting,
normal convenience outlets, and the slab and foundation.
The subtotal of the costs of these eight categories includes the cost
of material and equipment purchase and installation, and the subcontractor's
overhead and profit. To this subtotal, a 15-percent allowance has been added
to cover miscellaneous items not included in the cost takeoff, as well as
contingency items. Experience at many water treatment facilities has
indicated that this 15-percent allowance is reasonable. Although blanket
application of this 15-percent allowance may result in some minor inequities
between processes, these are generally balanced out, during the combination
of costs for individual processes into a treatment system.
The construction cost for each unit process is presented as a function
of the most applicable design parameter for the process. For example,
construction costs for gravity filters are plotted versus square feet of
filter surface area, whereas ozone generation system costs are presented
versus pounds per day of feed capacity. Use of such key design parameters
allows the curves to be utilized with greater flexibility than if cost
information were plotted versus flow.
The construction costs shown in the curves do not equal the final
capital cost for the unit process. The construction cost curves do not
include costs for special sitework, general contractor overhead and profit,
engineering, land, or legal, fiscal, and administrative and interest during
construction. These cost items are all more directly related to the total
cost of a.project than to the cost of the Individual unit processes. They
therefore are most appropriately added following summation of the cost of
the individual unit processes, if more than one unit process is required.
An example calculation for a 40-mgd conventional treatment plant is presented
in a subsequent section of this volume, and a number of other examples are
given in Volume 1 of this report. These examples illustrate the recommended
method for the addition of these costs to the construction cost.
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OPERATION AND MAINTENANCE COST CURVES
Operation and maintenance curves were developed for: (1) energy
requirements, (2) maintenance material requirements, (3) labor requirements,
and (4) total operation and maintenance cost. The energy categories included
are: process energy, building energy, diesel fuel, and natural gas. The
operation and maintenance requirements were determined from operating data
at existing plants, at least to the extent possible. Where such information
was riot available, assumptions were made based on the experience of both- the
author and the equipment manufacturer, and such assumptions are stated in
the description of the cost curve.
Electrical energy requirements were developed for both process energy
and building-related energy, and they are presented in terms of kilowatt-hours
per year. This approach was used to allow adjustment for geographical
influence on building-related energy. For example, though lighting require-
ments average about 17.5 kw-hr/ft2 per year throughout the United States,
heating, cooling, and ventilating requirements vary from a low of about
8 kw-hr/ft2 per year in Miami, Florida, to a high of about 202 kw-hr/ft2 per
year in Minneapolis, Minnesota. The building energy requirements presented
for each process are in terms of kilowatt-hours per year, and were calculated
using an average building-related demand of 102.6 kw-hr/ft2 per year. This
is an'average for the 21 cities included in the Engineering News Record
(ENR) Index. An explanation of the derivation of this figure is included
in Volume 1, Appendix B, of this report. The computer program developed as
a portion of this project will allow use of other building—related energy
demands than 102.6 kw—hr/ft2 per year. Process electrical energy is also
included in the electrical energy curve and was calculated using manufacturers
data for required components. Where required, separate energy curves for
natural gas and diesel fuel are also presented. When using the curves to
determine energy requirements, the design flow or parameter should be
utilized to determine building energy, and the operating flow or parameter
should be used to determine process energy, diesel fuel, and natural gas.
Maintenance material costs include the cost of periodic replacement of
component parts necessary to keep the process operable and functioning.
Examples of maintenance material items included are valves, motors, instru-
mentation, and other process items of similar nature. The maintenance
material requirements do not include the cost of chemicals required for
process operation. Chemical costs must be added separately, as will be
shown in the subsequent example. The operating parameter should be used
to determine maintenance material requirements.
The labor requirement curve includes both operation and maintenance
labor, and it is presented in terms of hours per year. The operating
parameter should be used to determine the labor requirement.
The total operation and maintenance cost curve is a composite of the
energy, maintenance material, and labor curves. To determine annual energy
costs, unit costs of $0.03/kw-hr of electricity, $0.0013/scf of natural gas,
and $0.45/gal of diesel fuel were utilized. The labor requirements were
converted to an annual cost using an hourly labor rate of $10.00/hr, which
-------
includes salary and fringe benefits^ The computer program that was developed
as a portion of this project and that is presented in Volume 4 of this report
will allow utilization of other unit costs for energy and labor.
UPDATING COSTS TO TIME OF CONSTRUCTION
Continued usefulness of the curves developed as a portion of this
project depends on the ability of the curves to be updated to reflect
inflationary increases in the prices of the various components. Most
engineers and planners are accustomed to updating costs using one all-
encompassing index, which is developed by tracking the cost of specific
items and then proportioning the costs according to a predetermined ratio,
The key advantage of a single index is the simplicity with which it can be
applied. Although use of a single index is an uncomplicated approach, there
is much evidence to indicate that these time-honored indices are not under-
stood by many users and/or are inadequate for application to water works ,
construction.
The most frequently utilized single indices in the construction industry
are the ENR Construction Cost Index (CCI) and Building Cost Index (BCI) .
These ENR indices were started in 1921 and were intended for general con-
struction cost monitoring. The CCI consists of 200 hr of common labor,
2,500 Ib of structural steel shapes, 1.128 tons of Portland cement, and
1,008 board feet of 2 x 4 lumber. The BCI consists of 68.38 hr of skilled
labor plus the same materials included in the CCI. The large amount of labor
included in the CCI was appropriate before World War II; however, on most
contemporary construction, the index labor component is far in excess of
actual labor used.
To update the construction cost using the CCI, which was 265.38 in
October 1978, the following formula may be utilized:
Updated Cost = Total Construction Cost from Curve ( oo —
/DJ. JO
This approach may also be utilized in the computer program that was
developed for this report.
Although key advantages of the ENR indices include their availability,
their simplicity, and their geographical specificity, many engineers and
planners believe that these indices are not applicable to water treatment
plant construction. The rationale for this belief is that the indices do
not include mechanical equipment or pipe and valves that are normally
associated with such construction, and the proportional mix of materials
and labor is not specific to water treatment plant construction.
An approach that may be utilized to overcome the shortcomings of the
ENR indices relative to water works construction is to apply specific indices
to the major cost components of the construction cost curves. This approach
allows the curve to be updated using indices specific to each category and
weighted according to the dollar significance of the category. For the eight
-------
major categories of construction cost, the following Bureau of Labor Statis-
tics (BLS)*0 and ENR indices were utilized as a basis for the cost curves
included in this report.
Cost Component
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical Equipment and
Instrumentation
Housing
ENR Wage Index (Skilled Labor)
BLS General Purpose Machinery
and Equipment - Code 114
BLS Concrete Ingredients -
Code 132
BLS Steel Mill Products -
Code 1013
ENE Wage Index (Skilled Labor)
BLS Valves and Fittings -
Code 114901
BLS Electrical Machinery and
Equipment - Code 117
ENR Building Cost Index
October 1978
Value ofIndex
247
221.3
221.1
262.1
247
236.4
167.5
254.76
The principal disadvantages of this approach are the lack of geographical
specificity of the BLS indices and the use of seven indices rather than a
single index.
To update the construction costs using the above two ENR and six BLS
indices, the construction cost from the construction cost curve must
first be broken down into the eight component categories. One acceptable
method of accomplishing this breakdown is to utilize all the detailed cost
estimates included in the construction cost table to determine the average
percent of the subtotal construction cost for each of the eight (or fewer)
construction cost components. The appropriate index for each component can
then be used to update the component cost. For example, in the construction
cost table for chlorine storage and feed systems, cylinder storage, the sum
of the manufactured equipment costs for the six designs is $327,110, and the
subtotal of construction costs for these six designs is $811,580. The ratio
of these two costs is 0.4031, meaning that on the average, manufactured
equipment is 40.31 percent of the subtotal construction cost. Therefore, if
the construction cost curve gives a construction cost of $150,000, and the
BLS General Purpose Machinery and Equipment Index is 250, the manufactured
equipment cost would be:
Manufactured Equipment Cost = 0.4031 ($150,000) (
250
221.3
•) = $68,310
-------
When this approach is used with each of the components of construction cost,
the updated sum gives the subtotal of construction cost, and the updated
total construction cost is obtained by adding 15 percent to this updated
subtotal cost. Either this approach or the previously described approach
using the CGI may be used with the computer program presented in Volume 4
of this report.
Updating of total operation and maintenance costs may be accomplished
by updating the three individual components: energy, labor, and maintenance
material. Energy and labor are updated by applying the current unit costs
to the kilowatt hour and labor requirements obtained from the energy and
labor curves. Maintenance material costs, which are presented in terms of
dollars per year, can be updated using the Producer Price Index for Finished
Goods.*^ The maintenance material costs in this report are based on an
October 1978 Producer Price Index for Finished Goods of 199.7
FIRMS THAT SUPPLIED COST AND TECHNICAL INFORMATION
During the development of both construction and operation and maintenance
cost curves, a large number of equipment manufacturers and other firms were
contacted to determine cost and technical information. The help provided by
those firms that did respond is sincerely appreciated, for the information
furnished was instrumental in assuring a high level of accuracy for the
curves. The manufacturers and other firms that provided input to this
study were:
Acrison, Inc.
Advance Chlorination Equipment
Aqua-Aerobic Systems, Inc.
Aquafine Corporation
BIF, a Division of General Signal Corporation
Bird Centrifuge
Capital Control Company ,
Ralph B. Carter Company
Chemical Separations Corporation
Chicago Bridge and Iron Company
Chicago, Rock Island and Pacific Railroad Company
Chromalloy, L.A. Water Treatment Division
Clarkson Industries, Inc., Hoffman Air & Filtration Division
Colt Industries, Inc., Fairbanks Morse Pump Division
Continental Water Conditioning'
Copeland Systems
Crane Company, Cochrane Environmental Systems
Curtiss-Wright Corporation
DeLaval Turbine, Inc.
Dorr-Oliver, Inc.
bravo Corporation
E.I. Dupont De Nemours & Company, Inc.
The Duriron Company, Inc., Filtration Systems Division
The Eimco Corporation
Electrode Corporation, A Subsidiary of Diamond Shamrock Corporation
Englehard Industries ( .
10
-------
Envirex, Inc., - A Rexnord .Company . ~ : : - - ; . • •• •
Environmental Conditioners , . • • •. .. .. •
Environmental Elements-Corp., Subsidiary of Koppers Co., Inc.
• Envirotech Corporation • - •
•Fischer and Porter Company , - • - • . - -
FMC Corporation
General Filter Company
Infilco Degremont, Inc. ' - ' - . •• •
Ionics, Inc. •
Jphns-Manville • • •
Kaiser Chemicals . . • • • .
Keystone Engineering - •.. • :•••>•• • , • .
Komline-Sanderson Engineering Corporation
Merck & Co., Inc., Calgon Company ;
Mixing Equipment Company, Inc. • • • .. . •• • .
Morton-Norwick Products, Inc., Morton Salt Company
Muscatine Sand and Gravel " .
Nash Engineering Company
Neptune Micro Floe, Inc. • •
Nichols Engineering & Research Corp., Neptune International Corp;
Northern Gravel Company
Ozarfe-Mahoning Company • .- . •
Pacific Engineering &-Production Company of Nevada ' •
PACO
R.H. Palmer Coal Company
Passavant Corporation
PCI Ozne Corp., A Subsidiary of Pollution Control Industries, Inc.
Peabody Welles, Inc. ' • -
Peerless Pump - - '•"•
Pennwalt Corporation
The Permutit Company, Inc., Division of Sybron Corporation
Reading Anthracite Company •• •
Robbins & Meyers, Inc., Moyno Pump Division .
Rohm and Haas Company, Fluid Process Chemicals Department
Shirco, Inc.
D.R. Sperry & Company •• - •'!•..
Sybron Corporation, R.B. Leopold Co. Division
TOMOC02 Equipment Company .
Union Carbide Corporation — Linde Division ;
Universal Oil Products Company, Fluid Systems Division .•• ' . -
U.S. Filter Co., Inc., Califilco Division :<•
Westvaco Corporation, Chemical Division ..'.
Western States Machine Company • • .;••-•'
Worthington Pump, Inc.
Zimpro, Inc. • - . ..
CHLORINE STORAGE AND SYSTEMS .-..-:•
Construction Cost ' ' ' -"......•
The costs for chlorine feed facilities have been based on use of '150 Ib
cylinders for feed rates up to 100 lb/day and ton cylinders for feed rates
11
-------
up to 2,000 Ib/day. For rates of 2,000 Ib/day and greater, three options
were considered: (1) ton cylinders, (2) on-site storage with bulk rail
delivery, and (3) direct feed from a rail car.
Cylinder Storage—
The maximum chlorinator capacity utilized was 8,000 Ib/day, and one
standby chlorinator was included for each installation. The costs include
cylinder scales for all installations, and evaporators are included for
delivery rates of 2,000 Ib/day and greater. Residual analyzers with flow-
proportioning controls were included for flow rates greater than 1,000 Ib/day.
Costs were also included for injector pumps capable of delivering sufficient
water at 25 psi to allow production of a 3,500-mg/l, high-strength solution.
Housing cost includes both the chlorinator room and the cylinder storage
room. All cylinders were assumed to be stored indoors, with 30 days of
storage provided. For feed rates greater than 100 Ib/day, electrically
operated, monorail trolley hoists were included.
On-Site Storage Tank with Rail Delivery—
Use of an on-site storage tank would eliminate the housing requirement
for cylinder storage, the monorail and hoist, the cylinder scale, cylinder
trunnions, and the cylinder manifold piping. However, additive costs are
incurred for the tank and its supports, a tank sun shield, load cells for
the tank, a railhead connection and associated track, unloading platform, an
air padding system, expansion tanks, and miscellaneous gauges, switches,
and piping. All considerations relating to the chlorinators, evaporators,
and other feed equipment remain the same as for the ton cylinder curve.
The amount of chlorine storage provided with the on-site tank is 30 days.
The rail siding costs include the cost of a turnout from the main
line, 500 ft of on-site track, and the unloading platform. Piping costs
would be strongly influenced by the location of the storage tank relative
to the chlorinators. Normally the storage tank is located near the plant
boundary. Valving is more complex than with ton cylinders, mainly because of
the unloading system, the use of duplicate heads for gas or liquid feed,
and the air padding system.
This curve may be adapted to bulk truck delivery by removing the cost
of the rail siding.
Direct Feed from Rail Car—
Chlorine may be fed directly from the rail car to the evaporator,
eliminating the requirement for an on-site storage tank. Ownership of the
rail car may be by the utility or the chlorine manufacturer. In the latter
case, a high cost per ton of chlorine must be paid to account for amortiza-
tion and maintenance costs of the car. Chlorinator, evaporator, and other
feed equipment costs are the same as for feed from ton cylinders. Rail
siding costs are the same as for on-site storage with rail delivery.
12
-------
Estimated construction costs are shown in Tables 1, 2, and 3 for feed
systems between 10 and 10,000 Ib/day, and the costs are shown graphically
in Figure 1. As may be seen, construction costs for cylinder storage
become greater than costs for on-site storage when the feed capacity
approaches the range of 2,000 to 4,000 Ib/day. It should also be noted that
the cost of the chlorine itself is also less when it is purchased in bulk
rather than in ton cylinders.
Operation and Maintenance Cost
Power requirements include heating, lighting, and ventilation of the
chlorination building and the cylinder storage area, the electrical hoist
when ton cylinders are used, evaporators when feed is 2,000 Ib/day or
greater, and the injector pump for the high-strength chlorine solution,
This pump was sized to deliver sufficient flow for a maximum chlorine
concentration of 3,500 mg/1 in the high-strength solution. Where on-site
storage tanks were utilized, the electrical hoist power requirements are
eliminated, and heating, ventilating, and lighting power are significantly
reduced as a result of elimination of indoor storage facilities,
Maintenance material requirements were based upon experience at operating
plants and are essentially the same for use of cylinders, on-site storage,
or rail-car storage and_^£eed. Cost of chlorine is not included in the
maintenance material estimates.
Labor requirements for cylinders were based on loading and unloading
cylinders from a delivery truck, time to connect and disconnect cylinders
from the chlorine headers, and the time for routine daily checking of the
cylinders. For on-site tank storage, labor consists of time to unload a
bulk delivery truck or rail tanker. The rail car storage concept requires
labor only to move the rail car into place and to connect and disconnect
the cars from the feed system. Common to all installations would be the time
required for daily checking and periodic maintenance of the chlorine handling
system.
Figures 2 and 3 present operation and maintenance curves for chlorine
feed systems using cylinder storage. For feed rates greater than 2,000
Ib/day and use of an on-site storage tank with rail delivery or the rail-car
storage and feed, operation and maintenance requirements are shown in
Figure 4 and 5. Table 4 presents a summary of operation and maintenance
requirements for all three storage concepts.
CHLORINE DIOXIDE GENERATING AND FEED SYSTEMS
Cons true tionCos t
Chlorine dioxide is most commonly generated by mixing a high-strength
chlorine solution with a high-strength sodium chlorite solution. Mixing
takes place in a PVC chamber filled with porcelain Raschig Rings, the chamber
referred to as the chlorine dioxide generator. Chlorine dioxide may also
be generated by acidifying solutions of sodium chlorite and sodium hypochlorite
with sulfuric acid. This method is only applicable in very small installations
with little operator time available, and it is not'included in this cost curve.
13
-------
Table 1
Construction Cost
Chlorine Storage and Feed Systems - Cylinder Storage
Chlorine Feed Capacity - Ib/day
Cost Category I0 500 1.000 2,000 5,000 10.000
Manufactured Equipment $ 6,760 $21,630 $41,630 $65,950 $76,780 $114,360
Labor 820 2,610 5,030 7,960 9,270 13,810
Pipe and Valves 540 1,710 3,300 5,230 6,080 9,060
Electrical and Instrumentation 770 2,450 4,710 7,460 8,690 12,940
Housing 2,430 18,360 27,760 46,550 100,440 186,490
SUBTOTAL 11,320 46,760 82,430 133,150 201,260 336,660
Miscellaneous and Contingency 1,700 7,010 12,360 19,970 30,190 50,500
TOTAL 13,020 53,770 94,790 153,120 231,450 387,160
-------
Table 2
Construction Cost for Chlorine Storage and Feed
Systems - On-Site Storage Tank with Rail Delivery
Chlorine Feed Capacity
(Ib/day)
Cost Category 2,000 5,000 10,000
Manufactured Equipment
Equipment $85,950 $103,780 $150,360
Rail Siding 48,410 48,410 48,410
01 Steel 2,400 3,800 6,200
Labor 11,560 15,470 23,810
Pipe and ?alves 5,230 6,080 9,060
Electrical and Instrumentation 7,460 8,690 12,940
Housing 2,770 2,770 4,050
SUBTOTAL 163,780 189,000 254,830
Miscellaneous and Contingency 24,570 28,350 38,220
TOTAL 188,350 217,350 293,050
-------
Table 3
Construction Cost for Chlorine Storage and
Feed Systems - Direct Feed from Rail Car
Chlorine Feed Capacity
Cost Category (Ib/day)
Manufactured Equipment
Equipment
Rail Siding
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
2,000
$ 65,950
48,410
7,960
5,230
7,460
2,770
137,780
20,670
158,450
5,000
$76,780
48,410
9,270
6,080
8,690
2,700
151,930
22,790
174,720
10,000
$114,360
48,410
13,810
9,060
12,940
4,050
202,630
30,390
233,020
-------
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17
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Figure 3. Operation and maintenance requirements for chlorine
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19
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process energy and maintenance material.
20
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feed systems, on-site storage tank and rail-car feed - labor and total cost.
21
-------
Table 4
Operation and Maintenance Summary for
Chlorine Storage and Feed Systems
feed Rate (Ib/day)
Cylinder Storage:
10
500
1,000
2,000
5,000
10,000
On-Site Storage, Rail Delivery:
2,000
5,000
10,000
Direct Feed from Rail Car:
2,000
5,000
10,000
Energy kw-hr/yr
Building
9,230
69,770
105,490
176,890
381,670
708,660
5,130
10,260
10,260
5,130
10,260
10,260
Process
570
1,120
2,230
6,210
15,530
30,990
1,740
4,340
8,690
1,740
4,340
8,690
Maintenance
Labor
Total Material $/yr hr/yr
9,800
70,890
107,720
183,100
397,200
739,650
6,870
14,600
18,950
6,870
14,600
18,950
1,530
3,060
3,530
4,700
5,880
8,230
4,700
5,880
8,230
4,700
5,880
8,230
437
663
1,267
2,043
3,140
5,443
926
1,100
1,144
754
790
796
Total Cost*
$/yr
6,190
11,820
19,430
30,620
49,200
84,850
14,170
17,320
20,240
12,450
14,220
16,760
Calculated using $0.03/kw-hr and $10,00/hr of labor
-------
In theory, 1.34 Ib of pure sodium chlorite and 0.5 Ib of chlorine react
to give 1 Ib of chlorine dioxide. However, since sodium chlorite is normally
purchased with a purity of 80 percent, 1.68 Ib of sodium chlorite are
required per Ib of chlorine dioxide generated. Chlorine is normally used
at a 1:1 ratio with sodium chlorite to insure completion of the reaction and
to lower the pH to 4. The cost curves have been developed using 1.68 Ib of
chlorine and 1.68 Ib of sodium chlorite per Ib of chlorine dioxide generated.
Costs have been based on the addition of costs for a sodium chlorite
mixing and metering system, plus a chlorine dioxide generator, to the
appropriate-sized chlorine feed system. The sodium chlorite system consists
of a polythelene day tank, a mixer for the day tank, and a dual head metering
pump. The chlorine dioxide generator is a PVC tube filled with porcelain
Raschig Rings or other turbulence-producing media, and it is sized for a
detention time of about 0.2 tnin.
*
Estimated construction costs are shown in Table 5 and Figure 6.
Operation and Maintenance Cost
Electrical requirements include power for the gaseous chlorination
system, the sodium chlorite mixing and metering system, and building heating,
lighting, and ventilation.
Maintenance material requirements are based on experience with gaseous
chlorine systems and liquid metering systems. Chemical costs for sodium
chlorite and chlorine are not included.
Labor requirements consist of labor for gaseous chlorination systems,
plus the labor required to mix the sodium chlorite solution, to adjust its
feed rate, and to maintain the mixing and metering equipment.
Figures 7 and 8 present operation and maintenance curves for chlorine
dioxide generation systems. A summary of operation and maintenance require-
ments is presented in Table 6.
OZONE GENERATION SYSTEMS AND CONTACT CHAMBERS
Construction Cost
Ozone may be generated on-site using either air or pure oxygen. Costs
were developed for generation rates between 10 and 3,500 Ib/day. For systems
up to 100 Ib/day, air was assumed to be the feed. At generation rates
greater than 100 Ib/day, pure oxygen generated on-site is the feed for the
ozone generator.
The manufactured equipment cost for ozone generation includes the gas
preparation equipment, oxygen generation equipment (at more than 100 Ib/day),
the ozone generator, dissolution equipment, off gas recycling equipment,
electrical and instrumentation costs, and all required safety and monitoring
equipment. All ozone-generating equipment was considered to be housed, but
23
-------
to
Table 5
Construction Cost for
Chlorine Dioxide Generating and Feed Systems
Chlorine Dioxide Feed Capacity - Clb/day)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1
$ 12,190
5,630
460
600
3,620
22,500
3,380
25,880
10
$ 13,950
8,630
940
770
4,050
28,340
4,250
32,590
100
$ 18,740
14,440
1,060
1,310
10,270
45,820
6,870
52,690
1,000
$67,110
72,710
5,300
6,560
45,940
197,620
29,640
227,260
5,000
$ 116,770
127,910
9,300
11,580
167,050
432,610
64,890
497,500
-------
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CHLORINE DIOXIDE FEED CAPACITY - kg/day
Figure 6. Construction cost for
chlorine dioxide generating and feed systems.
25
-------
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CHLORINE DIOXIDE FEED CAPACITY- Ib/Day
456 789
10,000
(_
10 100 1000
CHLORINE DIOXIDE FEED CAPACITY-kg/day
Figure 7, Operation and maintenance requirements for chlorine dioxide
generating and feed systems - building energy,
process energy, and maintenance material.
26
-------
I
7
6
5
4
100,000
10,000,
8
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CHLORINE DIOXIDE FEED CAPACITY-Ib/Day
1 1 1
10 100 1000
CHLORINE DIOXIDE FEED CAPACITY - kg/Day
2 3456 789(0,000
Figure 8. Operation and maintenance requirements for chlorine dioxide
generating and feed systems - labor and total cost.
27
-------
Table 6
Operation and Maintenance Summary for
Chlorine Dioxide Generating and Feed Systems
CO
00
Chlorine Dioxide
Feed Rate Energy (kw-hr/yr)
(Lb /day)
1
10
100
1,000
5,000
Building
12,310
12,310
26,680
58,480
136,460
Process
3,290
3,290
3,640
12,740
35,890
Total
15,600
15,600
30,320
71,220
172,350
Maintenance
Material Labor
($/yr) (hr/yr)
$1,110
1,850
2,830
5,160
8,610
481
604
873
2,342
5,632
Total Cost*
($/yr)
$6,390
8,360
12,470
30,720
70,100
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
all oxygen-generating equipment is located outside on a concrete slab.
Construction costs for ozone-generating systems are shown in Figure 9 and
Table 7.
The ozone contact chamber is a covered, reinforced concrete structure
with a depth of 18 ft, and a length-to-width ratio of approximately 2:1.
Partitions are utilized within the chamber to assure uniform flow distribution.
Ozone dissolution equipment costs are included within the ozone generation
cost curve and are not included with the ozone contact chamber. Construction
costs for contact chambers are shown in Figure 10 and Table 8.
Operation and Maintenance Cost
For ozone generation systems that produce less than 100 Ib/day, electri-
cal energy is required for the ozone generator and building heating, cooling,
and lighting requirements. Ozone generation using air feed requires 11 kw-
hr/lb of ozone generated. For larger, oxygen-fed systems, the power require-
ments are 7.5 kw-hr/lb of ozone-generated. These figures include oxygen
generation, ozone generation, and ozone dissolution.
Maintenance material requirements are for periodic equipment repair
and replacement of parts. Based on manufacturers' recommendations, an
annual maintenance material requirement of 1 percent of construction cost
was utilized.
Labor requirements are for periodic cleaning of the ozone generating
apparatus, maintenance of the oxygen generation equipment, annual maintenance
of the contact basin, and day-to-day operation of the generation equipment.
Operation and maintenance requirements are shown in Figures 11 and 12 and
are summarized in Table 9.
ON-SITE HYPOCHLORITE GENERATION SYSTEMS
Construction Cost
Sodium hypochlorite may be produced in an electrolysis cell using salt,
water, and electrical energy. There are presently available two basic types
of equipment that generate sodium hypochlorite solution. Open-cell systems
have an electrolysis cell that includes an anode and cathode, with the actual
cell arrangement varying between manufacturers. Membrane-type systems utilize
a cell that has a membrane separating the anode and cathode compartments.
A principal difference between the open-cell and membrane systems is the
final sodium hypochlorite concentration. Manufacturers report a hypochlorite
concentration of about 80,000 mg/1 for the membrane cell and only about 5,000
to 8,000 mg/1 for the other electrolysis cells. This has a pronounced effect
on the required size of the hypochlorite storage facilities and feed systems.
A construction cost curve is shown in Figure 13 for systems with
chlorine-producing capacities ranging from 10 to 10,000 Ib/day of chlorine
equivalent (Note: 1 Ib Cl2 is equivalent to 1.05 Ib sodium hypochlorite).
29
-------
i
7
6
5
4
3
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1
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0 234 56789100 234 567891000 20003 4 56789
10,000
GENERATION CAPACITY - Ib/Doy
10 100 1000
GENERATION CAPACITY - Kg/Day
Figure 9. Construction cost for ozone generation systems.
30
-------
Table 7
Construction Cost for
Ozone Generation Systems
Ozone Generation Capacity - (Ib/day)
Cost Category
Manufactured Equipment $
Concrete
Steel
Labor
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL $
10
34,210
0
0
5,090
6,430
45,730
6,860
52,590
100
$152,350
0
0
35,410
9,000
196,760
29,510
226,270
500
$543,130
1,630
1,680
120,850
13,600
680,890
102,130
783,020
1,000
$727,560
1,630
1,680
150,420
25,060
906,350
135,950
1,042,300
2,000
$1,135,720
2,380
2,440
218,100
38,230
1,396,870
209,530
1,606,400
3,500
$1,615,980
2,380
2,440
286,200
44,770
1,951,770
292,770
2,244,540
-------
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CONTACT CHAMBER VOLUME - ft3 100.00C
10 100 1000
CONTACT CHAMBER VOLUME - m3
Figure 10. Construction cost for ozone contact chambers.
32
-------
Table 8
Construction Cost for
Ozone Contact Chambers
Contact Chamber Volume (ft3)
Cost Category
Excavation and Sitework
Concrete
Steel
Labor
SUBTOTAL
Miscellaneous and Contingency
TOTAL
460
$ 490
900
1,620
2,260
5,270
790
6,060
4,600
$1,710
5,250
9,270
12,820
29,050
4,360
33,410
23,000
$2,700
8,780
14,980
20,510
46,970
7,050
54,020
46,000
$5,410
16,380
25,750
37,960
85,500
12,820
98,320
92,000
$10.820
31,600
53,580
72,870
168,870
25,330
194,200
-------
100,000
9'
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GENERATION RATE- Ib/Doy
456 789
10,000
10
100
GENERATION RATE - kg/day
-4-
1000
Figure 11. Operation and maintenance requirements for ozone generation
systems - building energy, process energy, and maintenance material.
34
-------
1,000,000
i
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100
GENERATION RATE-kg/day
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Figure 12, Operation and maintenance requirements for
ozone generation systems — labor and total cost.
35
-------
OJ
Table 9
Operation and Maintenance Summary for
Ozone Generation Systems
Ozone Generation
Rate (Ib/day)
10
100
500
1,000
2,000
3,500
Electrical
Building
5,750
9,850
16,420
30,780
71,820
123,120
Maintenance
Energy (kw-hr/yr) Material
Process
40,150
401,500
1,368,750
2,737,500
5,475,000
9,581,250
Total
45,900
411,350
1,385,170
2,768,280
5,546,820
9,704,370
($/yr)
$1,430
3,060
10,770
14,270
22,120
31,150
Labor
(hr/yr)
550
550
910
1,830
2,190
2,920
Total Cost*
($/yr)
$8,310
20,900
61,430
115,620
210,430
351,480
Calculated using $0.03/kw-hr and $10.00/hr of labor-
-------
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HYPOCHLORITE GENERATION- Ib /Day OF EQUIVALENT CHLORINE l0'00
ib 160 idoo
HYPOCHLORITE GENERATION - kg/day of EQUIVALENT CHLORINE
Figure 13. Construction cost for on-site hypochlorite generation.
37
-------
For systems with a chlorine-producing capacity of up to 2,500 Ib/day, the
equipment utilized in the cost curve was based on the open—cell systems.
For systems from 2,500 to 10,000 Ib/day of chlorine, membrane-type systems
were utilized because of their lower cost.
Components included in the construction cost estimate include the
electrolysis cells, power rectifier, salt storage tank and brine dissolver,
brine storage tank, water softener, brine transfer and metering pumps,
hypochlorite transfer and metering pumps, hypochlorite storage tank, piping
and valves, flowmeters, electrical control equipment, and housing. It was
assumed that the hypochlorite is pumped by a metering pump to a location
for in—line mixing. The salt storage tank and brine dissolver was assumed
to be located outside of the housing for systems with chlorine-producing
capacities of 500 Ib/day and greater.
A water softener is normally utilized, since cleaning requirements are
minimized when the total hardness of the water used for brine make-up is
less than 30 mg/1. Use of purified salt is essential, either purchased or
purified on-site. Small systems generally use purchased purified salt, but
for systems with a chlorine-producing capacity of greater than 2,000 Ib/day,
it becomes economical to use a brine purification system and the less
expensive rock salt. A brine purification system is included in the cost
estimate for systems larger than 2,000 Ib/day. The salt storage tank and
brine dissolver is assumed to have a storage capacity of 1 month, and the
sodium hypochlorite storage tank has a 24-hr capacity.
A relatively rapid increase in the cost of hypochlorite-generating
equipment occurs as the chlorine-producing capacity increases from about
100 to 500 Ib/day. This increase occurs because systems of 100 Ib/day and
smaller capacity are predesigned and purchased, as prefabricated units,
whereas most systems of 500 Ib/day and larger capacity are custom designed
for the particular installation.
A detailed construction cost breakdown for on-site hypochlorite genera-
tion systems is presented in Table 10.
Operation and Maintenance Cost
Operation and maintenance costs have been developed from information
provided by manufacturers of on-site hypochlorite generation systems and
also from operation and maintenance cost guarantees contained in several
competitive bids. Operation and maintenance requirements are summarized
in Table 11 and illustrated in Figures 14 and 15.
Energy requirements vary from about 2.0 to 4.7 kw-hr/lb of chlorine
equivalent, with the lowest energy consumption by the membrane-type cell.
Energy requirements were developed using an electrolysis cell and rectifier
usage of 2.5 kw-hr/lb of equivalent chlorine. Energy is also required for
the electrical control system, the brine transfer and metering pumps, and the
sodium hypochlorite transfer and metering pumps. These energy requirements
are included under process energy. Electrical energy for lighting, heating,
and ventilating is included under building energy.
38
-------
Table 10
Construction Cost for
On-Site Hypochlorite Generation Systems
Hypochlorite Generation Rate (Ib/day Equivalent Chlorine)
Cost Category
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
10
5,940
0
Q
3,150
1,050
6,650
16,790
2,520
19,310
50
$12,730
0
0
5,260
2,460
7,670
28,120
4,220
32,340
250
$68,960
0
Q
24,170
3,750
11,120
108,000
16,200
124,200
1,000
$190,960
190
260
62,010
14,660
20,650
288,730
43,310
332,040
2,500
$307,660
370
530
97,750
20,940
23,630
450,880
67,630
518,510
5,000
$424,350
370
530
126,130
34,550
32,710
618,640
92,800
711,440
10,000
$583,490
560
790
173,430
34,550
36,820
829,640
124,450
954,090
-------
Table 11
Operation and Maintenance Summary for
On-Site Hypochlorite Generation Systems
Hypochlorite Generation
Rate (Ib/day
Equivalent Chlorine
10
50
250
1,000
2,500
5,000
10,000
Energy (kw-hr/yr) Maintenance
i) Building
5,130
10,260
30,780
87,210
99,960
135,430
158,300
Process
9,120
45,600
228,000
912,000
2,280,000
4,560,000
9,120,000
Labor
Total Material ($/yr) ( hr/yr)
. 14,250
55,860
258,780
999, 2iO
2,379,960
4,695,430
9,278,300
$ 920
1,820
3,960
9,840
20,630
37,630
70,880
330
510
710
1,080
1,920
2,700
3,820
Total Cost*
( $/yr)
$4,650
8,600
18,820
50,620
111,230
205,490
387,430
^Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
10,000
10 JL
S 6 789
HYPOCHLORITE GENERATION-Ib/Doy OF EQUIVALENT CHLORINE I0>000
It
1060
HYPOCHLORITE GENERATION - kg/day OF EQUIVALENT CHLORINE
Figure 14. Operation and maintenance requirements for on-site hypochlorite
generation systems - building energy, process energy, and maintenance material.
41
-------
!,OOO,OOO
IT
100,000
10,000 10,000
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The largest maintenance material requirement is for electrode replacing
or replacement. For estimating purposes, it was assumed that the electrodes
were replated, or recoated, every 2 years. For the-electrolysis cell utilizing
a membrane, the entire electrolysis cell (including the anode, cathode,
membrane, and cell frame) was assumed to be replaced every 3 years. Other
maintenance material requirements are for cell gaskets for the membrane cell,
for other miscellaneous parts associated with the electrolysis cells, and for
materials needed for periodic repair of pumps, motors, and electrical control
equipment. Salt requirements of the different manufactured equipment vary
considerably. The reported salt requirements vary from about 2.0 to 4.5 Ib
of salt/lb chlorine equivalent, with the lowest salt consumption by the
membrane-type system. Cost of salt is not included in the cost curves.
Labor requirements are for salt delivery and handling, operation of
electrolysis cells, operation and maintenance of pumps, electrode replating
or replacing, occasional cleaning of electrolysis cells, and supplying and
mixing brine purification chemicals for the larger systems. Labor requirements
range from nearly 1 hr/day for the smallest system up to about 11 hr/day for
the 1,000 Ib/day system. The reduction in the labor requirement for the
range from 100 to 200 Ib/day of chlorine is attributable to a change in the
method of salt delivery, from a more labor intensive use of salt in bags to
bulk salt delivery by pneumatic truck. The increase in the range from 1,500
to 2,500 Ib/day is due to the added labor required for brine purification,
which is included for systems with a chlorine-producing capacity of greater
than 2,000 Ib/day.
ALUM FEED SYSTEMS
Construction Costs
Liquid Alum—
Costs estimated for liquid alum feed systems are based on use of liquid
alum, which has a weight of 10 Ib/gal and contains the equivalent of 5 Ib
of commercial dry alum per gal. Fifteen days of storage are provided, using
fiber glass reinforced polyester (FRP) tanks. The FKP tanks were assumed
to be uncovered and located indoors for smaller installations, and outdoors
for larger installations. Outdoor tanks are covered and vented, with
insulation and heating provided to prevent crystallization, which occurs at
temperatures below 30°F.
Dual-head metering pumps were used to pump liquid alum from the storage
tank and to meter the flow directly to the point of application. No
provision was made for dilution of the liquid alum before application. A
standby metering pump was included for each installation. All pipe utilized
to convey the liquid alum was 316 stainless steel, and 150 ft of pipe,
along with miscellaneous fittings and valves, was included for each
metering pump.
Construction costs for liquid alum feed are presented in Table 12 and
Figure 16,
43
-------
Table 12
Construction Costs for
Liquid Alum Feed Systems
_ Feed Capacity (Ib/hr)
Cost Category _ 5.4 ; '_'_54 ; 54CT '
_ __ .......
Manufactured Equipment $ 4,460 $5,810 $25,410 $~200,22Q
Labor ,1.000 1,230 4,440 36,340
Pipe and Valves 1,000 1,000 1,000 4,970
Electrical and Instrumentation 3,140 3,400 4,920 14,760
Housing 5,890 14,960 27,670 9,000
SUBTOTAL 15,490 26,400 63,440 265,290
Miscellaneous and Contingency 2 ,320 3,960 9,520 39 ,790
TOTAL 17,810 30,360 72,960 305,080
44
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10 100 1000
ALUM FEED CAPACITY—kg/hr
Figure 16. Construction costs for alum feed systems -
dry and liquid.
45
-------
Dry Alum—
Cost estimates for solid alum feed facilities are based on use of
commercial dry alum with a density of 60 lb/ft3. A 5-min detention period
is required in the dissolving tank, and 2 gal of water is used/lb alum.
Fifteen days of dry alum storage is included, using mild steel storage hoppers
located indoors. Conveyance of alum from bulk delivery trucks to the hoppers
done pneumatically, with the blower located on the delivery truck. The
largest hopper capacity utilized was 6,000 ft . For installations too small
for bulk delivery, bag loaders are used on the feeder. All hopper facilities
included dust collectors.
Volumetric feeders for the smaller installations and mechanical weigh
belt feeders for the large installations and their respective solution tanks
were located directly beneath the storage hoppers, eliminating the need for
bucket elevators or other conveyance devices from below-ground storage.
Such installation does, however, make the building cost somewhat greater
than other possible arrangements. Conveyance from the solution tanks to
the point of application was by dual—head diaphragm metering pumps.
Construction cost estimates for solid alum feed are presented in
Table 13 and Figure 16.
Operation and Maintenance Cost
Electrical requirements are for solution mixers, feeder operation,
building lighting, ventilation, heating, and (in the case of larger liquid
feed installations) for heating of outdoor storage tanks. The sharp
decrease in the building energy curve for high feed rates is attributable
to the use of outdoor storage tanks, as contrasted to use of indoor
storage tanks at lower flow rates. "
Maintenance material costs were estimated on the basis of 3 percent of
the manufactured equipment cost, excluding storage tank cost. Alum costs
are not included in the maintenance material costs.
Labor requirements consist of time for chemical unloading and routine
operation and maintenance of feeding equipment. Liquid alum unloading
requirements were calculated on the basis of 1.5 hr/bulk truck delivery,
and dry alum requirements on the basis of 5 hr/50,000 Ib. For dry feed
installations using alum from bags, 8 hr was used per 16,000 Ib removed and
fed to the bag loader hopper. Time for routine inspection and adjustment
of feeders is 10 min/feeder per shift for dry feed and 15 min/metering pump
per shift of liquid feed. Maintenance requirements were 8 hr/year for
liquid metering pumps and 24 hr/year for solid feeders and the solution tank.
Figures 17 to 20 present operation and maintenance costs for both liquid
and dry alum feed. A summary of operation and maintenance requirements is
presented in Table 14.
46
-------
Table 13
Construction Costs for
Dry Alum Feed Systems
Feed Capacity (Ib/Mr)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
ia
$ 7,960
440
2,130
1,160
6,430
18,120
2,720
20,840
100
$13,900
1,190
2,660
2,370
14,240
34,360
5,150
39,510
1,000
$35,600
2,550
3,190
5,190
54,910
101,440
15,220
116,660
5,000
$170,740
12,780
15,940
19,890
186,980
406,330
60,950
467,280
47
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LIQUID ALUM FEED RATE-kg/hr
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Figure 17. Operation and maintenance requirements for liquid alum
feed systems - building energy, process energy, and maintenance material,
48
-------
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LIQUID ALUM FEED RATE - kg/hr
Figure 18. Operation and maintenance requirements for liquid alum
feed systems - labor and total cost.
49
-------
3 4 5 6789IOO 234 567891000
DRY ALUM FEED RATE-lb/hr
456 789
10,000
10
1— • 1
100 1000
DRY ALUM FEED RATE — kg/br
Figure 19. Operation and maintenance requirements for dry alum feed systems
building energy, process energy, and maintenance material.
50
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DRY ALUM FEED RATE -kg/hr
Figure 20. Operation and maintenance requirements for dry alum
feed systems - labor and total cost.
51
-------
Table 14
Operation and Maintenance Summary
for Alum Feed Systems
Ui
Alum Feed
Rate (Ib/hr)
Dry Alum:
10 Ib/hr
100 Ib/hr
1,000 Ib/hr
5,000 Ib/hr
Liquid Alum:
5.4 Ib/hr
54 Ib/hr
540 Ib/hr
5,400 Ib/hr
Energy (kw-hr/yr)
Building
6,160
23,090
63,920
320,630
5,130
24,210
99,520
10,260
Process
4,900
4,900
6,530
9,800
3,270
3,270
5,430
116,340
Total
11,060
27,990
70,450
330,430
8,400
27,480
104,970
126,600
Maintenance
Material
($/yr)
$190
220
320
1,420
70
70
110
350
Labor
( hr/yr)
288
332
1,124
4,624
63
63
63
315
Total Cost*
( $/yr )
$3,400
4,380
13,670
57,570
950
1,520
3,890
7,300
^Calculated using, $0.03/kw-hr and $10.00/hr of labor.
-------
POLYMER FEED SYSTEMS
Construction Cost
Cost estimates for polymer feed systems are based on the use of dry
polymers, fed manually to a storage hopper located on the chemical feeder.
Chemical feed equipment is based on preparation of a 0.25-percent stock
solution. No provision has been made for standby or redundant equipment,
as polymer would generally be utilized only as a coagulant aid or a filter
aid, and thus an equipment breakdown could be tolerated for a short period
of time while equipment is being repaired.
Costs for polymer feed systems are presented in Table 15 and
Figure 21,
Operation and Maintenance Cost
Energy requirements for the feeder and metering pump were calculated
using motor horsepower requirements recommended by manufacturers. Building
energy requirements are based on completely housed systems.
Maintenance material costs used are 3 percent of manufactured equipment
and pipe/valve costs. These costs do not include the cost of polymer.
Labor requirements are for bag unloading (1 hr/ton of bags), the dry
chemical feeder (110 hr/year for routine operation and 24 hr/year for
maintenance), and the solution metering pump (55 hr/year for routine
operation and 8 hr/year for maintenance).
Figures 22 and 23 present the estimated operation and maintenance
requirements for feeding of a 0.25-percent polymer solution. The operation
and maintenance requirements are summarized in Table 16.
LIME FEED SYSTEMS
Construction Cost
Construction costs were developed for lime feed systems that used
hydrated lime at feed rates up to 50 Ib/hr and quicklime at higher rates.
Two curves were developed for quicklime - one that used new lime, and one
that used a combination of new and recalcined lime. The use of recalcined
lime lowers the storage requirement and therefore decreases the cost of the
lime feed facilities for a given capacity, .
Hydrated lime was assumed to be purchased in 100-lb bags and to be fed
using either a volumetric or gravimetric feeder to a dissolving tank having
a 5—min detention time. In the dissolving tank, the lime is mixed to a
6-percent slurry and fed by gravity to the point of application.
53
-------
Table 15
Construction Costs for
Polymer Feed Systems
_ Polymer Feed Capacity (Ib/day)
Cost Category 1 10 100 200
Manufactured Equipment $ 11,670 $11,670 $14,730 $18,970
Labor 700 700 700 760
Pipe and Valves 280 280 280 300
Electrical and Instrumentation 1,290 1,290 1,290 1,290
Housing 3,600 3.600 4,050 4,500
SUBTOTAL 17,540 17,540 21,050 25,820
Miscellaneous and Contingency 2,630 2,630 3,160 3,870
TOTAL 20,170 20,170 24,210 29,690
54
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POLYMER_ FEED CAPACITY-Ib/dgy
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POLYMER FEED CAPACITY-kg/day
Figure 21. Construction cost for polymer feed systems.
55
-------
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POLYMER FEED RATE -kg/day
Figure 22. Operation and maintenance requirements for polymer feed systems
building energy, process energy, and maintenance material.
56
-------
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POLYMER FEED RATE-kg/day
Figure 23. Operation and maintenance requirements for
polymer feed systems - labor and total cost.
57
-------
oo
Table 1.6
Operation and Maintenance Summary
for Polymer Feed Systems
Maintenance
Polymer Feed
Rate (Ib/day)
1
10
100
200
Energy (kw-hr/yr)
. Building
8,210
8,210
9,230
10,260
Process
17,300
17,300
17,300
17,300
Total
25,510
25,510
26,530
27,560
Material
( $/yr )
260
280
310
470
Labor
( hr/yr)
198
199
215
234
Total Cost*
( $/yr )
3,010
3,040
3,260
3,640
*Calculated using $0.03/kw-hr and $10.QO/hr of labor.
-------
Quicklime is purchased in bulk, with 90 percent purity and a density of
60 Ib/ft , and stored in elevated hoppers above the lime slakers. Lime is
conveyed pneumatically from delivery truck to the storage hopper. Hoppers
include a dust collector, bin gate, and flexible connection to the slaker.
Hoppers were sized for a 30 day storage of lime, except when recalcination
is used (then only a 3 day storage of the new lime was provided). The
slaker mixes water with lime on a 2:1 weight basis, and the lime slurry is
conveyed in an open gravity channel to the application point. Although
all applications may not be able to use gravity conveyance in a channel,
it is highly recommended from a maintenance standpoint. Standby slakers are
included for all installations using quicklime.
Estimated construction costs are presented in Figure 24 and Table 17.
Operation and Maintenance Cost
, Process energy requirements are for the feeder, slaker, and grit removal
and are based on motor sizes for the various equipment. Annual maintenance
material costs were based on 3 percent of manufactured equipment costs,
excluding the cost of the storage hopper. Lime cost is not included in the
maintenance material costs.
Labor requirements for unloading are 5 hr/50,000 Ib for bulk delivery
and 8 hr/16,000 Ib for bag delivery and feed. Operation and maintenance
time for the lime feeder, the slaker, and the associated grit removal is
3 hr/feeder per slaker per day. For smaller installations using hydrated
lime, a routine operation .time of 20 min/day was used for the solid feeder
and the solution tank.
Annual operation and maintenance requirements are presented in Figures
25 and 26. A summation of operation and maintenance requirements is
presented in Table 18.
POTASSIUM PE1MANGANATE FEED SYSTEMS •
Construction Cost
Cost estimates were developed for facilities using dry, 97 percent
pure potassium permanganate purchased in drums and mixed to solution on-
site. Solutions are mixed to 4 percent on a daily basis and fed from the
day tank using a dual-head diaphragm pump. For very low dosage rates, a
dilution to 0.4 percent is necessary to produce a large enough volume to
feed with the metering pump. Storage is provided for 15 days of dry
potassium permanganate. Standby metering pumps are included for all
installations.
Estimated construction costs are shown in Table 19 and Figure 27.
59
-------
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LIME FEED CAPACITY - Ib/hr I0,00(
fb ibo idoo
LIME FEED CAPACITY - kg/hr
Figure 24. Construction cost for lime feed systems.
60
-------
Table 17
Construction Cost for
Lime Feed Systems
Lime Feed Capacity (Ib/hr)
Without Lime Rec
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
Without
10
$ 5,400
420
2,500
1,440
9,450
19,210
2,880
22,090
Lime Recalcination
100
$44,870
1,240
2,500
6,880
9,450
64,940
9,740
75,680
1,000
$62,160
1,510
3,120
6,880
26,250
99,920
14,990
114,910
With Lime Recalcination
1,000
$48,870
1,510
3,120
6,880
9,450
69,830
10,470
80,300
10,000
$80,660
3,060
6,250
12,320
26,250
128,540
19,280
147,820
-------
10,000
cc
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LIME FEED RATE - Ib/hr
4 5 6789
10,000
100
LIME FEED RATE—kg/hr
10* 00
Figure 25. Operation and maintenance requirements for lime feed systems
building energy, process energy and maintenance material.
62
-------
3 4
56789100 2 34 56789WOO
LIME FEED RATE- !b/hr
456 789
10,000
10
100
FEED RATE
kg/hr
1000
Figure 26. Operation and maintenance requirements for
lime feed systems - labor and total cost.
63
-------
Table 18
Operation and Maintenance Summary
for Lime Feed Systems
o\
Lime -Feed
Rate (Ib/hr)
Energy (kw-hr/
Building
Process
Total
Maintenance
Material ($/yr)
Labor
(hr/yr)
Without Recalcination :
10
100
1,000
With Recalcination:
1,000
10,000
23,090
23,090
64,130
23,090
64,130
3,270
4,900
4,900
4,900
29,390
26,360
27,990
69,030
27,990
93,520
$ 160
1,240
1,360
1,360
1,910
166
1,183
1,975
1,975
6,570
Total Cost*
($/yr)
$ 2,610
13,910
23,180
21,950
70,420
^Calculated using $0.03/kw-hr and $10.00/hr of labor,
-------
Table 19
Construction Cost for
Potassium Permanganate Feed Systems
Feed Capacity (Ib/day)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
1
$2,340
480
970
3,190
1,260
8,240
1,240
9,480
10
$ 2,600
480
970
3,190
1,580
8,820
1,320 '
10,140
100
-$ 3,380
540
970
3,190
1,950
10,030
1,500
11,530
500
$ 5,220
770
970
3,190
2,940
13,090
1,960
15,050
-------
7
6
S
4
9
8
7
6
5
4
100,000
9
8
1000
345 678910
3 456 789KX)
2 3456 789
1000
POTASSIUM PERMANGANATE FEED CAPACITY - !b/day
, 1 ,
10 100
POTASSIUM PERMANGANATE FEED CAPACITY - kg/day
Figure 27. Construction cost for potassium permanganate feed systems.
66
-------
Operation and MaintenanceCost
Process energy requirements are for the solution mixers and the metering
pumps. Annual maintenance material costs were calculated at 3 percent of the
cost of manufactured equipment.
Labor requirements are for unloading drums of chemicals, preparation of
the 4 percent solution, and routine operation of the solution metering pump.
One hour per day was used to prepare the 4 percent solution (0.1 hr/day for
the 0.4 percent solution). Routine inspection and adjustment of the metering
pumps is 15 min per shift, and maintenance requirements were 8 hr/year.
Figures 28 and 29 present the operation and maintenance requirements
for potassium permanganate feed facilities, A summary of these requirements
is presented in Table 20.
SULFURIC ACID FEED SYSTEMS
Cons true t ion Cos t
Construction cost estimates were developed for sulfuric acid feed systems
capable of metering concentrated (93 percent) sulfuric acid from a storage
tank directly to the point of application. For sulfuric acid feed rates
up to 200 gpd, the concentrated acid was assumed to be delivered to the plant
site in drums, and at larger flow rates, it was assumed to be delivered in
bulk. Acid purchased in bulk was assumed to be stored outdoors in FRP tanks,
and acid purchased in drums was assumed to be stored indoors. Fifteen days
of sulfuric acid storage was provided, and a standby metering pump was
included for all installations except the smallest.
Estimated construction costs are presented in Table 21 and Figure 30.
Operation and Maintenance Cost
Process electrical energy requirements are for the metering pump. The
increase in building energy requirements at the lower feed rates is attribut-
able to the greater building area required for indoor storage of the sulfuric
acid drums.
Maintenance material requirements were estimated at 3 percent of the
equipment cost, excluding the cost of storage tanks.
Labor requirements are for chemical unloading and for the metering pumps.
Unloading times of 0.25 hr/drum of acid and 1.5 hr/bulk truck delivery were
utilized. Metering pump routine operation is 15 min/pump per day, and
maintenance requirements are 8 hr/feeder per year.
Estimated operation and maintenance requirements are presented in
Figures 31 and 32, and a summary of the requirements is presented in
Table 22.
67
-------
2 -
3 4 5678910 234 56789100 Z
POTASSIUM PERMANGANATE FEED RATE-lb/day
4 5 67i»
1000
10 100
POTASSIUM PERMANGANATE FEED RATE-kg/day
Figure 28. Operation and maintenance requirements for potassium permanganate
feed systems - building energy, process energy and maintenance material.
68
-------
POTASSIUM PERMANGANATE FEED RATE-lb/day
3 456 789
1000
-*-
-4-
10 100
POTASSIUM PERMANGANATE FEED RATE-kg/day
Figure 29. Operation and maintenance requirements for potassium
permanganate feed systems - labor and total cost.
69
-------
Table 20
Operation and Maintenance Summary for
Potassium Permanganate Feed Systems
Potassium Permanganate
Feed Rate
(Ib/day)
1
10
* 100
500
Energy (kw-hr/yr)
Building
1,390
1,730
2,770
4,850
Process
3,270
3,270
3,270
6,530
Total
4,660
5,000
6,040
11,380
Maintenance
Material ($/yr)
$ 70
80
100
160
Labor
( hr/yr )
101
436
443
504
Total Cost*
( $/yr )
$ 1,220
4,590
4,710
5,540
*Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Table 21
Construction Cost for
Sulfuric Acid Feed Systems
FeedCapacity (gpd)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
10
$1,560
640
1,090
1,670
1,520
7,480
1,120
8,600
100
$3,440
820
1,090
2,920
1,560
9,830
1,470
11,300
1,000
$12,400
2,840
2,150
2,920
1,560
21,870
3,280
25,150
5.000
$41,000
11,840
2,150
2,920
1,560
59,470
8,920
68,390
-------
100,000
9
8
6
5
en
o
10,000
i 1
g 6?
g 5
£ 4
§ 3
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1,000
10 a 3 4 56789100
FEED CAPACITY - gpd
234 567891000 2 34 56789
10,000
—«—
O.I
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FEED CAPACITY - nrVd ay
10
Figure 30. Construction cost for sulfuric acid feed systems.
72
-------
1000
-w-
<
a:
100
9
8
7
6
5
4
10
I
6
5
4
1000
MAIN
MATERIAL
ENAN
3 4 56789100 234 56789OOO
FEED RATE - gpd
3 456 789
10,000
O.I
I
FEED RATE-m3/day
10
Figure 31. Operation and maintenance requirements for sulfuric acid feed
systems - building energy, process energy and maintenance material.
73
-------
2 3 4 5 6789100 2
FEED RATE -gpd
3 4 567891000 234 5 6 7§9
10,000
0,1
.0
FEED RATE - m3/dy
Figure 32.
Operation and maintenance requirements for sulfuric
acid feed systems - labor and total cost.
74
-------
Table 22
Operation and Maintenance Summary
for Sulfuric Acid Feed Systems
Ln
Sulfuric Acid Feed Rate Energy (kw-hr/yr)
(gpd)
10
100
1,000
5,000
Building
6,160
2,050
2,050
2,050
Process
1,630
1,630
1,630
3,270
Total
7,790
3,680
3,680
5,320
Maintenance
Material ($/yr)
$ 60
100
120
130
Labor
(hr/yr)
72
154
200
613
Total Cost*
($/yr)
$ 1,010
1,750
2,230
6,420 ;
*Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
SODIUM HYDROXIDE FEED SYSTEMS
Construction Cost ;
Costs were developed for sodium hydroxide feed rates between 10 and 10,000
Ib/day. Dry sodium hydroxide was considered to be used at rates less than 200
Ib/day, with liquid sodium hydroxide used at higher feed rates.
Dry sodium hydroxide (98.9 percent pure) is delivered to the plant site
in drums and then mixed to a 10 percent solution on-site. A volumetric feeder
is utilized to feed sodium hydroxide to the mixing tank. Two day tanks are
necessary - one for mixing a 10 percent solution, and one for feeding. The
use of two tanks is necessary because of the slow rate of sodium hydroxide
addition necessary as a result of the high heat of solution. Each tank is
equipped with a mixer, and a dual-head metering pump is used to convey the
10 percent solution to the point of application.
For feed rates greater than 200 Ib/day, a 50 percent sodium hydroxide
solution is purchased premixed and delivered by bulk transport. The 50
percent solution contains 6.38 Ib of sodium hydroxide/gal. For the 50 percent
solution, 15 days of storage was provided in FRP tanks. Dual-head metering
pumps are used to convey solution to the point of application, and a standby
metering pump was provided in each case.
Pipe and valving is required for water conveyance to the dry sodium
hydroxide mixing tanks and between the metering pumps and the point of
application. The storage tanks are located indoors, since 50 percent sodium
hydroxide begins to crystallize at temperatures less than 54°F.
Estimated construction costs are shown in Figure 33 and on Table 23.
Operation and Maintenance Cost
Process energy requirements are for the volumetric feeder and mixer
(smaller installations only) and the metering pump. A maintenance material
requirement of 3 percent of equipment cost, excluding the storage tank cost,
was utilized.
Labor requirements are based on unloading time for dry sodium hydroxide
in drums, or the liquid 50 percent sodium hydroxide purchased in bulk for the
larger installations. For installations using dry sodium hydroxide, addition-
al labor is required for routine operation time for the volumetric feeder.
This time is 10 min/day per feeder. In addition, for each installation,
operation time for the dual head metering pump is 15 min/day, with an annual
maintenance time of 8 hr.
Figures 34 and 35 show the operation and maintenance requirements for
sodium hydroxide feed systems. A summary of these requirements is presented
in Table 24.
76
-------
-4-
10
S 6789100 a 3 456789(000 2 3 4 5
SODIUM HYDROXIDE FEED CAPACITY-Ib/day 10.°00
100 ~"~ innn~~~
SODIUM HYDROXIDE FEED CAPACITY - kg/day
Figure 33. Construction cost for sodium hydroxide feed systems,
77
-------
Table 23
Construction Cost for
Sodium Hydroxide Feed Systems
Feed Capacity (Ib/day)
00
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
10
$ 6,440
640
850
3,190
1,010
12,130
1,820
13,950
100
$7,010
640
850
3,190
2,100
13,790
2,070
15,860
1,000
$5,720
790
850
3,190
8,400
18,950
2,840
21,790
10,000
$19,450
4,120
850
3,460
48,380
76,260
11,440
87,700
-------
7
6
5
4
1000
•w-
I
ir
ui
100
9'
8
7
6
5
4
1000
10
3 4 56789100 234 567891000 234 56789
SODIUM HYDROXIDE FEED RATE-lb/day 10,000
100 1000
SODIUM HYDROXIDE FEED RATE-kg/day
Figure 34. Operation and maintenance requirements for sodium hydroxide
feed systems - building energy, process energy and maintenance material,
79
-------
I
7
6
5
3
2
10,000
o
o
IOOO
9t
8 -
7 -
6 -
5 **
4 -
IOOO
9
8
6
5
LABOR -
O
3
2
10
10
TOTAL
ADOIl
2 34 56789100 234 56789WOO 2 3
SODIUM HYDROXIDE FEED RATE -Ib/day
10 100 IOOO
SODIUM HYDROXIDE FEED RATE-kg/day
4 5 6789
10,000
Figure 35. Operation and maintenance requirements for sodium
hydroxide feed systems - labor and total cost.
80
-------
oo
Table 24
Operation and Maintenance Summary
for Sodium Hydroxide Feed Systems
Sodium Hydroxide
Feed Rate Energy (kw-hr/yr) Maintenance Labor Total Cost***
(Ib/day)
10*
*
100
1,000**
10,000**
Building
1,110
3,470
13,860
79,830
Process
3,270
3,270
4,900
8,160
Total
4,380
6,740
18,760
87,990
Material ($/yr)
$140
180
120
130
(hr/yr)
124
124
85
278
($/yr)
$1,510
1,620
1,530
5,550
* Purchased as solid and mixed to a 10% solution on site
** Purchased as 50% solution
*** Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
FERROUS SULFATE FEED SYSTEM
Construction Cost
Cost estimates for ferrous sulfate feed systems are based on use of
FeSOjt-7H20 with a density of 64 Ib/ft . A 5-min detention period is required
in the dissolving tank, and a 6 percent solution is fed to the point of
application. Fifteen days of ferrous sulfate storage is included, using
mild steel storage hoppers located indoors. Ferrous sulfate is conveyed
pneumatically from bulk delivery trucks to the hoppers, with the blower
located on the delivery truck. The largest hopper capacity utilized was
6,000 ft^. For installations too small for bulk delivery, bag loaders '.are
used on the feeder. All hopper facilities included dust collectors.
Volumetric feeders for the smaller installations and mechanical weigh
belt feeders for the large installation and their respective solution tanks
xrere located directly beneath the storage hoppers, eliminating the need for
bucket elevators or other conveyance devices from below-ground storage.
Such installation does, however, make the building cost somewhat greater
than other possible arrangements. Conveyance from the solution tanks to the
point of application was by dual-head diaphragm metering pumps.
Construction cost estimates for ferrous sulfate feed are presented in
Table 25 and Figure 36.
Operation and Maintenance Cost
Electrical requirements are for solution mixers, feeder operation and
building lighting, ventilation, and heating. Maintenance material costs
were estimated on the basis of 3 percent of the manufactured equipment cost,
Ferrous sulfate costs are not included in the maintenance material costs.
Labor requirements consist of chemical unloading and routine operation
and maintenance of feeding equipment. Ferrous sulfate unloading requirements
were calculated on the basis of 5 hr/50,000 Ib. For installations using
ferrous sulfate from bags, 8 hr were used/16,000 Ib fed to the bag loader
hopper. Time for routine inspection and adjustment of feeders is 10 min/
feeder per shift. Maintenance requirements were 8 hr/year for liquid
metering pumps and 24 hr/year for solid feeders and the solution tank.
Figures 37 and 38 present operation and maintenance requirements.
A summary of operation and maintenance requirements is presented in
Table 26.
FERRIC SULFATE FEED SYSTEMS
Construction Cost
Cost estimates for ferric sulfate feed facilities are based on use of
Fe2(SOif)3'3H20 with a density of 80 Ib/ft3. A 20-min detention period is
required in the dissolving tank, and a 20 to 25 percent solution is fed to
the point of application. Fifteen days of storage is included, using mild
82
-------
00
Table 25
Construction Cost for
Ferrous Sulfate Feed Systems
Feed Capacity (Ib/hr)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
10.7
$ 7,500
420
2,000
1,110
6,000
17,030
2,550
19,580
107
$13,100
1,130
2,500
2,260
13,300
32,290
4,840
37,130
1,070
$33,560
2,430
3,000
4,960
51,270
95,220
14,280
109,500
5,350
$160,940
12,160
15,000
19,000
174,590
381,690
57,250
438,940
-------
1000
10
456789100 2 3 456 789KXJO 2 3 456789
FERROUS SULFATE FEED CAPACITY-Ibs/hr I0>000
j 1 __
100 1000
FERROUS SULFATE FEED CAPACITY-kg/hr
Figure 36. Construction cost for ferrous sulfate feed systems,
84
-------
IO.OOO
2 -
3 4 56789100 234 567891000 2
FERROUS SULFATE FEED RATE - Ib/hr
4 5 67«9
10,000
10
100 1000
FERROUS SULFATE FEED RATE-kg/hr
Figure 37. Operation and maintenance requirements for ferrous sulfate
feed systems - building energy, process energy, and maintenance material.
85
-------
7
6
5
4
7
6
5
4
100,000
6
5
4
9
8
7
6
5
4
3
to
o
u
10,000 10,000
9
e
6
5
4
Z
- .- 2
1000 1000
100
10
TO
'Al.
con
3 4 56789100 234 567891000 2
FERROUS SULFATE FEED RATE-lb/hr
3 456 789
10,000
-t-
10 100 1000
FERROUS SULFATE FEED RATE-kg/hr
Figure 38. Operation and maintenance requirements for ferrous sulfate
feed systems - labor and total cost.
86
-------
00
—I
Table 26
Operation and Maintenance Summary
for Ferrous Sulfate Feed Systems
Feed Rate
(Ib/hr)
10.7 .
107
1,070
5,350
Energy (kw-hr/yr)
Building
6,160
23,090
63,920
320,630
Process
4,900
4,900
6,530
9,800
Total
11,060
27,990
70,450
330,430
Maintenance
Material ($/yr)
$ 180
210
300
1,330
Labor
(hr/yr)
288
332
1,124
4,624
Total Cost*
($/yr)
$ 3,390
4,370
13,650
57,480
^Calculated using $O.Q3/kw-hr and $10.00/hr of labor.
-------
steel storage hoppers located indoors. Ferric sulfate is conveyed pneu-
matically from bulk delivery trucks to the hoppers, with the blower located
on the delivery truck. The largest hopper capacity utilized was 6,000 ft3,
and all hopper facilities included dust collectors. For installations too
small for bulk delivery, bag loaders are used on the feeder.
Volumetric feeders were used for all installations. The solution tank
was located directly beneath the storage hoppers, thus eliminating the need
for bucket elevators or other conveyance devices from below-ground storage.
Such installation does, however, make the building cost somewhat greater
than other possible arrangements. Conveyance from the solution tanks to the
point of application was by dual-head diaphragm metering pumps.
Construction cost estimates for ferric sulfate feed are presented in
Table 27 and Figure 39.
Operation and Maintenance Cost
Electrical requirements are for solution mixers, feeder operation, and
building heating, lighting, and ventilation. Maintenance material costs
were estimated on the basis of 3 percent of the manufactured equipment cost.
Ferric sulfate costs are not included in the maintenance material costs.
Labor requirements consist of time for chemical unloading and routine
operation and maintenance of feeding equipment. Ferric sulfate unloading
requirements were calculated on the basis of 5 hr/50,000 Ib. For installa-
tions using ferric sulfate from bags, 8 hr were used/16,000 Ib fed to the bag
loader hopper. Time for routine inspection and adjustment of feeders is
10 rain/feeder per shift. Maintenance requirements were 8 hr/year for liquid
metering pumps and 24 hr/year for solid feeders and the solution tank.
Figures 40 and 41 present operation and maintenance requirements. A
summary of operation and maintenance requirements is presented in Table 28,
AMMONIA FEED FACILITIES
Construction Cost
A concept that may be used to provide disinfection without producing
TTHM is the ammonia-chlorine process. Ammonia is added to water before
chlorination, and chloramines are formed when chlorine is added. A
chlorine/ammonia ratio of 3:1 is required to produce a combined chlorine
residual that is mainly monochloramine.
Ammonia may be fed in either of two forms—anhydrous ammonia or aqua
ammonia. Anhydrous ammonia is purchased as a pressurized liquid and is fed
through evaporators and ammoniators and then as a gas to the point of
application. Aqua ammonia is a solution of ammonia and water that contains
29.4 percent ammonia. Aqua ammonia is metered as a liquid directly to the
point of application.
88
-------
Table 27
Construction Cost for
Ferric Sulfate Feed Systems
Feed Capacity (Ib/hr)
oo
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
13.3
$ 7,500
420
2,000
1,100
6,000
17,020
2,550
19,570
. 133
$ 13,100
1,130
2,500
2,260
13,300
32,290
4,840
37,130
1,330
$ 33,560
2,430
3,000
4,690
51; 270
94,950
14,240
109,190
6,600
$ 160,940
12,160
15,000
19,000
174,590
381,690
57,250
438,940
-------
I
H
tn
o
o
t-
O
ID
O
CJ
7
6
5
4
1.000.000
100.000
9
8
10,000
1000
10 2345 6789100 2 3456 7891000 2 3456 789
10,000
FERRFC SULFATE FEED CAPACITY-Ibs/hr
-f-
10 100 1000
FERRIC SU.LFATE FEED CAPACITY-kg/hr
Figure 39. Construction cost for ferric sulfate feed systems.
90
-------
10,000
MAINTENA
MATERIAL
4 56789100 234 567891000
FERRIC SULFATE FEED RATE-lbs/hr
456 789
10,000
-I 1
10 100
FERRIC SULFATE FEED RATE-kg/hr
1000
Figure 40. Operation and maintenance requirements for ferric sulfate feed
systems - building energy, process energy, and maintenance material.
91
-------
8
6
5
4
100,000
6
5
4
I
fc
o
10,000 O.OOO
1
- I
:§ 8
. 03
1000 ,,000
4 56789100 234 567891000 2
FERRIC SULFATE FEED RATE-lbs/hr
4 5 6789
10,000
10
100 1000
FERRIC SULFATE FEED RATE-kg/hr
Figure 41. Operation and maintenance requirements for ferric
sulfate feed systems - labor and total cost.
92
-------
VO
Table 28
Operation and Maintenance Summary
for Ferric Sulfate Feed Systems
Feed Rate
(Ib/hr)
13.3
133
1,330
6,660
Energy (kw-hr/yr)
Building
6,160
23,090
63,920
320,630
Process
4,900
4,900
6,530
9,800
Total
11,060
27,990
70,450
330,430
Maintenance
Material ($/yr)
$ 180
210
300
1,330
Labor
(hr/yr)
288
332
1,124
4,624
Total Cost*
($/yr)
$ 3,390
4,370
13,650
57,480
Calculated using $0.03/kw-hr and $10.0Q/hr of labor.
-------
Generally speaking, aqua ammonia is readily available near large cities,
and it is most commonly found in larger plants. A technical disadvantage of
anhydrous ammonia can result if the gas produced by the ammoniator is used
to produce a high-strength solution to be fed to the application point.
In certain cases, magnesium precipitation occurs because of pH elevation
that results from addition of the ammonia solution. In some cases, this
severely restricts effective ammoniator capacity.
Construction cost curves include only ammonia storage and feed facilities.
Separate curves are included in this report for chlorine feed systems.
Anhydrous Ammonia—
The cost curves include bulk ammonia storage for all feed rates, "with
10 days of storage provided. The storage tanks include the tank and its
supports, a scale, an air padding system, and all required gauges and
switches. The ammonia feed system consists of an evaporator for flows in
excess of 2,000 Ib/day, an ammoniator, and flow-proportioning equipment.
Dry ammonia gas was assumed to be fed directly to the point of application,
rather than metering a high-strength ammonia solution to the point of
application.
The construction cost curve for anhydrous ammonia feed facilities is
presented in Figure 42, and a detailed breakdown of construction cost is
shown in Table 29.
Aqua Ammonia—
Aqua ammonia is stored in a horizontal pressure vessel with a length/
width ratio of approximately 3:1. Only one tank was used for each installa-
tion, and the assumed usable storage capacity was 10 days. Construction
costs include the tank and its supports, required piping and valving for
filling the tank from a bulk delivery truck and for conveying from the tank
to the metering pump, and the metering pump. A housing cost is not included
because only the metering pump is housed, and it could easily be located in
a number of other housed areas.
The construction cost curve for aqua ammonia feed systems is presented
in Figure 42 and a detailed breakdown is contained in Table 30.
Operation and Maintenance Cost
Anhydrous Ammonia Feed Facilities--
Electrical energy requirements are for heating, lighting, and ventila-
ting of the ammoniator building, and operation of the evaporators. Evapo-
rators are'only included for-systems of 2,000 Ib/day or greater, and
evaporator energy requirements were calculated on the basis of 23.8 kw-hr/ton
of ammonia.
94
-------
I
7
6
5
4
3
2
f
6
5
4
3
a
1,000,000
9
8
6
5
4
T
i-
CO 9
0 '
o
0 100,000
5 1
i J
H- 6
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3
2
10,000
*f
^
***
**
0"^
**
^
**
+
+
^
<•
»
«
»
j^^1
+^
^
^
^jf
^^
4?
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X
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URDUS
AMMC
AM
NIA
WO
Ml.
\
•
100 234 567891000 234 56789KMQO 20QOO 4 56789
FEED CAPACITY-lb/day
100 FEED SSciTY- kg/day 10'°°0
Figure 42. Construction cost for ammonia feed facilities.
95
-------
vO
ON
Table 29
Construction Cost for
Anhydrous Ammonia Feed Facilities
Feed Capacity (Ib/day)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
250
$13,260
3,990
2,390
3,250
4,500
27,390
• 4,110
31,500
500
$19,520
5,680
3,520
3,770
4,500
36,990
5,550
42,540
1,000
$30,450
9,250
5,500
6,180
4,500
55,880
8,380
64,260
2,500
$38,830
10,620
7,000
8,480
4,500
69,430
10,410
79,840
5,000
$59,200
13,870
10,670
10,990
6,430
101,160
15,170
116,330
-------
Table 30
Construction Cost for
Aqua Ammonia Feed Facilities
FeedCapacity (lb/day)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
250
$ 8,090
1,010
670
1,050
10,820
1,620
12,440
500
$ 10,430
1,020
670
2,510
14,630
2,190
16,820
1,000
$13,480
1,190
910
2,930
18,510
2,780
21,290
2,500
$19,340
1,280
1,690
5,230
27,540
4,130
31,670
5,000
$28,340
1,430
1,690
7,540
39,000
5,850
44,850
-------
Maintenance material requirements were based on operating experience
at chlorination facilities of similar size. Anhydrous ammonia costs are not
included in the maintenance material costs.
Labor requirements are for transfer of the bulk anhydrous ammonia from
the delivery truck or rail car to the on-site ammonia storage tank, plus
day-to-day operation and maintenance requirements. A bulk unloading time
of 3 hr/shipment was utilized. Operation and maintenance requirements varied
from roughly 1.5 hr/day for the smaller systems to 3 hr/day for larger systems.
Figures 43 and 44 present the operation and maintenance curves, and
Table 31 presents a summary of the operation and maintenance requirements.
Aqua Ammonia Feed Facilities—
Electrical energy costs are only for operation of the metering pump.
Because of the small indoor area required for the metering pump and standby
pump, no allowance is included for building heating, lighting, and ventilation.
Transfer of aqua ammonia from the bulk truck to the storage tank was assumed
to be by a pump located on the bulk truck.
Maintenance material costs are for repair parts for the metering pump,
valve repair, and painting of the storage tank. Aqua ammonia costs are not
included in the maintenance material costs.
Labor costs include 15 min/day for operational labor, 24 hr/year for
maintenance labor, and 1 hr/unloading of the bulk delivery truck.
Operation and maintenance requirements are presented in Figures 45 and
46 and summarized in Table 32.
POWDERED ACTIVATED CARBON SYSTEMS
Construction Cost
The systems were sized for feeding of an 11-percent slurry (1 percent
carbon/gal of water). The 11-percent slurry is stored and continuously
mixed in uncovered concrete tanks, which are placed below ground level,
except for approximately the top foot. For feed capacities of less than
700 Ib/hr, 8 days of storage in two equal sized basins is included. For
greater feed rates, 2 days of storage in a single basin is included. Mixers
were sized based on a G value equal to 600. Storage/mixing basins include
equipment for powdered activated carbon feed from bags in smaller installations
and from trucks or railroad cars in larger installations.
For feed rates of less than 20 Ib carbon/hr, a diaphragm type metering
pump is used to feed directly from the mixing/storage tank to the point of
application. For rates greater than 20 Ib/hr, a positive displacement-type
pump is used to transfer slurry continuously to an overhead rotodip volu-
metric feeder that feeds directly to the point of application.
98
-------
f
6
5
4
3
2
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6
5
4
3
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iooc
MAINTENANCE MATERIAL- $/yr
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100 2 345 67891000 234 56789ffi»OOO HOpOO 4 56789
AMMONIA FEED RATE-lb/Day
100 1000 10,000
AMMONIA FEED RATE -kg/day
Figure 43. Operation and maintenance requirements for anhydrous ammonia
feed facilities - building energy, process energy, and maintenance material.
99
-------
§
7
6
5
4
100,000
£10,000
-W- 8
±1
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s3
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t- 2
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9
8
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1000
9
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-02
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-1- 100
ABCR
TOT^L COST
100 2 345 67891000 234 56789IOJOOO 20pOO * S 6789
AMMONIA FEED RATE-lb/Day
_j 1_
10 ioo
AMMONIA FEED RATE— kg /Day
10,000
Figure 44. Operation and maintenance requirements for anhydrous ammonia
feed facilities - labor and total cost.
100
-------
Ammonia
Feed Rate
(Ib/day)
250
500
1,000
2,500
5,000
Table 31
Operation and Maintenance Summary
for Anhydrous Ammonia Feed Facilities
•
Energy
(kw-hr/yr)
Building Process
10,260
10,260
10,260
10,260
15,390
—
—
8,690
21,720
43,450
Total
10,260
10,260
18,950
31,980
58,840
Maintenance
Material
($/yr)
$ 3,060
3,530
4,700
5,880
8,230
Labor
(hr/yr)
500
580
630
780
990
Total Cost*
($/yr)
$ 8,370
9,640
11,570
14,640
19,900
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
1
6
5
4
3
2
1
6
5
4
3
2
1000
MAINTENANCE MATERIAL- $/yr
m w 4» w m-^ooto,^ N « * 01 oi-^a>«
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AMMONIA FEED RATE- ib/doy
. J — — — — _.. — _ -, * _ _.- _. ..i -
100
1000 10, OOO
AMMONIA FEED RATE-kg/doy
Figure 45. Operation and maintenance requirements for aqua ammonia
feed facilities - process energy and maintenance material.
102
-------
2 -
6
5 -
4 -
3 -
2 -
10,000
9
1 5
fc 4
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9
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7
6
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7
6
5
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I
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5
4
3
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9
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6
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CM
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100 234 5 6789K300 234 56789iOpOO 234 56789
AMMONIA FEED RATE-lb/Doy
,.i i — i — —
100 1000
AMMONIA FEED RATE -kg/day
10,000
Figure 46. Operation and maintenance requirements for aqua ammonia
feed facilities - labor and total cost.
103
-------
o
-tr-
32
Operation and Maintenance Summary
for Aqua Ammonia Feed Facilities
Ammonia Feed
Rate (Ib/day)
250
500
1,000
2,500
5,000
Process Energy
(kw-hr/yr)
570
570
570
570
570
Maintenance Material
($/yr)
$ 110
160
270
430
640
Labor
(hr/yr)
152
152
152
152
152
Total Cost
$ 1,650
1,700
1,810
1,970
2,180
^Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Construction cost is shown in Figure 47 and presented in detail in
Table 33.
Operation and Maintenance Cost
Energy requirements are based on the rated horsepower of pump motors
and continuous mixing of the 11-percent carbon slurry at a G value of 600.
Maintenance material requirements consist of oil for gearbox drives
and for minor repair of pumps and motors, as well as the associated electrical
switching gear.
Labor requirements for carbon unloading were based on rates of 10 win/
50 Ib bag, 2 hr/9,000 Ib truckload, and 4 hr/27,000 Ib railroad car.
Requirements for the mixing/storage basin are 30 min/day per basin for
inspection and routine maintenance, and 16 hr/year per basin for cleaning and
gearbox oil change. Slurry pumps would require 1 manhour/day per pump.
Table 34 summarizes the operation and maintenance requirements, which
are also shown in Figures 48 and 49.
RAPID MIX
Construction Cost
Construction costs were calculated for reinforced concrete basins, with
total volumes ranging from 100 to 20,000 ft3. The largest basin capacity
utilized was 2,500 ft , and common wall construction was utilized when more
than one basin was required. Mixer costs are for vertical shaft, variable
speed turbine mixers with 304 stainless steel shafts and paddles and TEFC
motors. Construction costs for G values of 300, 600, and 900 (3, 6, and 20
foot-pounds/second per ft^, respectively) and a water temperature of 15°C are
presented in Figure 50 and in Tables 35 to 37.
Operationand Maintenance Cost
Power requirements are a function of G and water temperature. At a
water temperature of 15°C and G values of 300, 600, and 900, energy require-
ments were calculated on the basis of respective horsepower per unit volume
requirements of 3, 6, and 20 foot-pounds/second per ft3. An overall
mechanism efficiency of 70 percent was utilized.
Maintenance material costs consist of oil for the gearbox drive unit.
Labor requirements were determined using a jar testing time of 1 hr/day
for plants under 50 mgd and 2 hr/day for plants over 50 mgd, 15 min/mixer
per day for routine operation and maintenance, and 4 hr/mixer per 6 months
for oil changes. An allowance of 8 hr/basin per year was also included for'"
draining, inspection, and cleaning.
Figures 51 and 52 show operation and maintenance curves for the rapid
mix units, and a summary of these requirements is presented in Table 38.
105
-------
•w-
234 56789100 234 567891000
FEED CAPACITY- Ib/hr
20003 4 56789
10,000
10
IOO
1000
FEED CAPACITY-kg/hr
Figure 47. Construction cost for powdered activated carbon feed systems.
106
-------
Table 33
Construction Cost for
Powdered Activated Carbon Feed Systems
Feed Capacity (lb/hr)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
3.5
$ 90
8,680
290
250
590
18,240
23,540
6,430
58,110
8,720
66,830
35
$ 360
22,490
1,060
1,810
2,230
18,550
24,410
6,430
77,340
11,600
88,940
350
$ 1,480
70,450
4,140
7,430
8,960
18,910
26,100
6,430
143,900
21,580
165,480
700
$ 2,230
126,040
5,910
10,820
13,150
19,750
52,950
6,430
237,280
35,590
272,870
7,000
$ 11,140
537,490
29,560
54,060
65,740
89,660
114,930
6,430
909,010
136,350
1,045,360
-------
o
oo
Table 34
Operation and Maintenance Cost for
Powdered Activated Carbon Feed Systems
Feed Rate
(Ib/hr)
3.5
35
350
700
7,000
Energy (kw-hr/yr)
Building
10,260
10,260
10,260
10,260
10,260
Process
7,000
59,000
482,000
946,000
2,294,000
Total
17,260
69,260
492,260
956,260
2,304,260
Maintenance
Material ($/yr)
$ 2,140
4,280
8^550
14,970
66,280
Labor
( hr/yr)
85Q
1,110
1,840
2,010
11,000
Total Cost*
($/yr)
$ 11,160
17,460
41,720
63,760
245,410
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
100,000
7
6
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9
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10
IYATERI/
BUILDING
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^lEI^GY
:E:
ER<»
34 56789100
234 567891000 20003
FEED RATE-lb/hr
456 789
10,000
100
FEED CAPACITY-kg/hr
loo
Figure 48. Operation and maintenance requirements for powdered activated
carbon feed systems - building energy, process energy, and maintenance material.
109
-------
!,OOO,000
IT
100,000
to 4
S 3
10,000 10,000
- 3
a:
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9
8
7
6
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10
34 56789100 234 567891000
FEED RATE-ib/hr
LABOF
03
20003 456 789
(0,000
10
life"
idoo
FEED CAPACITY-kg/hr
Figure 49, Operation and maintenance requirements for powdered
activated carbon feed systems - labor and total cost.
110
-------
9
8
7
6
5
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3
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9
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Figure 50. Construction cost for rapid mix.
1H
-------
Table 35
Construction Cost
for Kapid Mix, G = 300
Total Basin Volume (ftj)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
100
$ 220
3,070
390
570
1,230
6,980
12,460
1,870
14,330
500
$ 380
3,680
870
' 1,350
2,300
6,980
15,560
2,330
17,890
1,000
$ 490
4,920
1,280
2,010
3,410
6,980
19,090
2,860
21,950
5,000
$ 1,360
17,380
3,610
5,600
8,500
10,760
47,210
7,080
54,290
10,000
$ 2,720
34,750
7,220
11,180
17,020
20,130
93,020
13,950
106,970
20,000
$ 5,460
69,510
14,450
22,360
34,040
37,680
183,500
27,520
211,020
-------
Table 36
Construction Coat
for Rapid Mix, G = 600
Total Basin Volume (ft3 )
u>
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
100
$ 220
3,450
390
570
1,300
6,980
12,910
1,940
14,850
500
$ 380
4,920
870
1,350
2,560
6,980
17,060
2,560
19,620
1,000
$ 490
7,380
1,280
2,010
3,870
6,980
22,010
3,300
25,310 '
5,000
$1,360
26,730
3,610
5,600
9,390
11,580
58,270
8,740
67,010
1U,000
$2,720
53,470
7,220
11,180
18,770
20,860
114,220
17,130
131,350
20,000
$5,460
106,940
14,450
22,360
37,540
39,530
226,280
33,940
260,220
-------
Table 37
Construction Cost
for Rapid Mix, G = 900
Total Basin Volume (ft3 )
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
100
$ 220
4,310
390
570
1,230
6,980
13,700
2,050
15,750
500
$ 380
9,830
870
1,350
2,300
6,980
21,710
3,260
24,970
1,000
$490
14,760
1,280
2,010
3,410
7,180
29,130
4,370
33,500
5,000
$ 1,360
66,840
3,610
5,600
13,140
7,470
98,020
14,700
112,720
JL 0,000
$ 2,720
133,670
7,220
11,180
26,280
8,760
189,830
28,470
218,300
20,000
$ 5,460
267,340
14,450
22,360
52,550
16,100
378,260
56,740
435,000
-------
10,000,000
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100 2 34 567891000 234 56789K3000 20000 4 56789
TOTAL RAPID MIX VOLUME - ff3 100,00
10 IOO IOOO
TOTAL RAPID MIX VOLUME-i
Figure 51. Operation and maintenance requirements for
rapid mix - process energy and maintenance material.
115
-------
1,000,000
.000
§ 6
o 5
J
<
10,000 10,000
100
S
6=
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COST
3 4 5 6789IOOO 234 5678910000 20000 4 56789
TOTAL RAPID MIX VOLUME-ff3 IOO.OOO
10
-J-
100
TOTAL RAPID MIX VOLUME-m3
_j_
IOOO
Figure 52. Operation and maintenance requirements for
rapid mix - labor and total cost.
116
-------
Table 38
Operation and Maintenance Summary
for Rapid Mix
Total Basin
Volume (ft3)
100
500
1,000
2,500
5,000
10,000
20,000
Process Energy- (kw-hr/yr)
G - 300
5,090
25,450
50,900
127,250
254,500
509,000
1,018,000
G = 600
10,180
50,900
101,800
254,500
509,000
1,018,000
2,036,000
G = 900
33,930
169,670
339,330
848,330
1,696,700
3,393,300
6,786,670
Maintenance
Material
($/yr)
$ 20
30.
40
60
80
160
320
Labor
(hr/yr)
470
470
470
510
580
1,160
1,590
Total Cost ($/yr)*
G = 300
$ 4,870
5,490
6,270
8,980
13,510
27,030
46,760
G = 600
$ 5,030
6,260
7,790
12,800
21,150
42,300
77,300
G = 900
$ 5,740
9,820
14,920
30,610
56,780
113,560
219,820
^Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
FLOCCULATION
Construction Cost
Estimated flocculation basin costs are for rectangular-shaped, reinfor-
ced concrete structures 12 ft deep. A length-to-width ratio of approximately
4:1 was used for basin sizing, and the maximum individual basin size utilized
was 12,500 ft3. Common wall construction was used where the total basin
volume exceeded 12,500 ft3. Structural costs for vertical turbine floccula-
tors are somewhat higher that for the horizontal paddle type because of
the required structural support above the basin. Costs were calculated
for use of horizontal paddle flocculators and total basin volume of 1,800
to 1 million ft3 (only 1,800 to 25,00 ft3 for vertical turbine type).
Horizontal paddles are less expensive for use in larger basins, and they
generally provide more satisfactory operation in the larger basins,
particularly when tapered flocculation is practiced.
G values of 20, 50, and 80 were used to calculate manufactured equipment
costs. All drive units are variable speed to allow maximum flexibility.
Although common drive for two or more parallel basins is commonly utilized,
the estimated costs were calculated using individual drive for each basin.
Estimated costs are shown in Figure 53 and Tables 39 to 41 for horizontal
paddle systems and in Figure 54 and Table 42 for vertical turbine floccula-
tors.
Operation and Maintenance Cost
Energy requirements for G values of 20, 50, and 80 were calculated on
the basis of respective horsepower per unit volume requirements of 0.01,
0.06, and 0.17 foot-pounds/second per ft3. An overall motor/mechanism
efficiency of 60 percent was utilized.
Maintenance material costs are based on 3 percent of the manufactured
equipment costs. Although equipment costs vary somewhat with the maximum
design value for G, the maintenance material costs are based on a G value
of 80.
Labor requirements are based on routine operation and maintenance of
15 min/day per basin (maximum basin volume = 12,500 ft3) and an oil change
every 6 months requiring 4 hr per change. No allowance is included for
jar test time, as this is included in the rapid mix operation and maintenance
curves.
Figures 55 and 56 present operation and maintenance requirements for
G = 20, 50, and 80 for horizontal paddle flocculation. Costs for vertical
turbine flocculators are nearly identical and are not shown separately.
However, the cost curves are applicable to vertical turbine flocculators
only up to basin volumes of 25,000 ft3. Table 43 summarizes the operation
and maintenance requirements.
118
-------
7
6
5
4
1,000,000
-m-
I
V)
o
o
o
13
cc
I-
05
z
o
o
100,000
9
8
6
5
4
10,000
9
8
7
6
5
4
1,000
1000
6 =
80
<;=
45 678910,000 2 345 6789100,000 2 345 6789
TOTAL BASIN VOLUME-ft3 1,000,000
30 1000
TOTAL BASIN VOLUME -m
1
10,000
Figure 53. Construction cost for flocculation -
horizontal paddle systems.
119
-------
Table 39
Construction Cost for Flocculation -
Horizontal Paddle Systems, G = 20
Total Basin Volume (ft3 )
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1,800
$ 470
12,140
1,400
2,360
7,080
6,980
30,430
4,560
34,990
10,000
$2,550
28,240
7,610
12,550
20,220
28,320
99,490
14,920
114,410
25,000
$4,290
31,420
12,740
20,440
28,110
28,320
125,320
18,800
144,120
100,000
$9,970
54,500
29,770
46,500
69,940
28,320
239,000
35,850
274,850
500,000
$40,080
118,350
120,280
175,290
187,360
141,610
782,970
117,450
900,420
1,000,000
$77,640
232,730
232,960
339,510
373,420
283,220
1,539,480
230,920
1,770,400
-------
Table 40
Construction Cost for Flocculation -
Horizontal Paddle Systems, G = 50
Total Basin Volume (ft3)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1,800
$ 470
12,140
1,400
2,360
7,080
6,980
30,430
4,560
34,990
10,000
$2,550
28,250
7,610
12,550
20,220
28,320
99,500
14,920
114,420
25,000
$4,290
35,410
12,740
20,440
29,420
28,320
130,620
19,590
150,210
100,000
$ 9,970
74,400
29,770
46,500
75,460
28,320
264,420
39,660
304,080
500,000
$40,080
220,800
120,280
175,290
221,200
141,610
919,260
137,890
1,057,150
1,000,000
$ 77,640
433,640
232,960
339,510
439,770
283,220
1,806,740
271,010
2.077.750
-------
Table 41
Construction Cost for Flocculation -
Horizontal Paddle Systems, G = 80
Total Basin Volume (ft3 )
fo
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1,800
$ 470
12,140
1,400
2,360
7,080
6,980
30,430
4,560
34,990
10,000
$ 2,550
34,210
7,610
12,550
22,190
28,320
107,430
16,110
123,540
25,000
$ 4,290
44,360
12,740
20,440
32,370
28,320
142,520
21,380
163,900
100,000
$ 9,970
115,770
29,770
46,500
90,170
28,320
320,500
48,070
368,570
500,000
$ 40,080
427,670
120,280
175,290
289,520
141,610
1,194,450
179,170
1,373,620
-------
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7
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5
4
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3
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CONSTRUCTION COS
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-.
000 2 345 678910,000 234 56789100,000 2- 345 6789
TOTAL BASIN VOLUME -ft 3 1,000,00
100 1000 10,000
TOTAL BASIN VOLUME-m3
Figure 54. Construction cost for flocculation -
vertical turbine flocculators.
123
-------
Table 42
Construction Cost for Flocculation -
Vertical Turbine Flocculators
Total Basin Volume (ftj)
Cost Category
^ Excavation and Sitework
S3
.*• Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
G=20
$ 630
7,300
1,930
3,170
7,240
6,980
27,250
4,090
31,340
1,800
G=50
$ 630
7,300
1,930
3,170
7,240
6,930
27,250
4,090
31,340
10,000
G=80
$630
7,300
1,930
3,170
7,240
6,980
27,250
4,090
31,340
G=20
$2,
14,
7,
12,
22,
28,
87,
13,
100,
520
640
720
470
100
320
770
170
940
G=50
$2
15
7
12
22
28
89
13
102
,520
,910
,720
,470
,470
,320
,410
,410
,820
G=80
$2,520
15,910
7,720
12,470
22,470
28,320
89,410
13,410
102,820
G=20
$3,250
29,170
12,300
19,400
37,070
28,320
129,510
19,430
148,940
25,000
G=50
$3,250
29,170
12,300
19,400
37,070
28,320
129,510
19,430
148,940
G=80
$3,250
34,480
12,300
19,400
38,380
28,320
136,130
20,420
156,550
-------
1,000,000
100,000 100,000
10,000 10,000
9"P 9
. 8
- >> 7
UJ
<
2
1000,
8
7
6
5"
4
3
100
h i 5
* A
cc
Z 2
u
1000
9
8
7
6
5
4
3
100
PROCfSS
ENER
6=20
MAINTENANC
MATIiRIAL
1000 234 5678910,000 234 56789100,0002
TOTAL BASIN VOLUME-ft3
3 456 789
1,000,000
TOTAL BASIN VOLUME — m3
10,000
Figure 55. Operation and maintenance requirements for flocculation, horizontal
paddle systems - process energy and maintenance material.
125
-------
100,
i
000
10,000
o
o
10QO 1000
9
8
7
6
5
100]
9
8
7
., 6
I
CO
10
T)
COST
L/ BOI?
G= 2
1000 234 5678910,000 234 5 6 7 89100,000 Z
TOTAL BASIN VOLUME —ft3
3 456 789
1,000,000
100 1000
TOTAL BASIN VOLUME -m3
—I
10,000
Figure 56. Operation and maintenance requirements for flocculation,
horizontal paddle systems - labor and total cost.
126
-------
N3
"•J
Table 43
Operation and Maintenance Summary
Flocculation - Horizontal Paddle Systems
Total Basin
Volume (ft3)
1,800
10,000
25,000
100,000
500,000
1,000,000
Energy (kw-hr/yr)
G = 20
330
1,960
4,900
19,600
98,020
198,230
G = 50
2,070
11,870
29,630
118,720
593,590
1,188,300
G = 80
6,100
33,660
84,080
336,550
1,682,750
—
Maintenance
Material
(S/yr)
$ 410
1,050
1,050
4,010
14,430
28,860
Labor
(hr/yr)
99
199
199
397
496
990
Total Cost ( $/yr )*
G - 20
$ 1,410
3,100
3,190
8,570
22,330
44,710
G = 50
$1,460
3,400
3,930
11,540
37,200
74,410
G = 80
$1,580
4,050
5,560
18,080
69,870
—
*Calculated using $0.03/kw-hr and $10.00/hr of labor
-------
CIRCULAR CLARIFIERS
Construction Cost
Circular clarifiers may be used for the removal of settleable solids
in water, either before treatment or following treatment by softening or
coagulation and flocculation. Cost estimates were made for center feed
circular clarifiers with a 12-ft sidewall depth, and for sludge removal
from a sump located at the circular center..
The construction cost estimates include the center feed clarifier
mechanism, weirs, baffles, troughs, and a circular reinforced concrete
structure. For clarifier diameters greater than 80 ft, an inboard steel
weir trough was also included. Piping to and from the clarifier is not
included in the cost estimates.
Table 44 presents the construction costs for circular clarifiers with
diameters between 30 and 200 ft; the costs are also shown in Figure 57.
Operation and Maintenance Cost
Process energy requirements were calculated using manufacturers'
estimates of motor size and torque requirements for alum, ferric, and lime
sludges. The heavier lime sludge calls for an approximate 50-percent increase
in power requirements.
Maintenance material costs are for parts required for periodic mainten-
ance of the drive mechanism and weirs. Labor requirements are for periodic
checking of the clarifier drive mechanism, as well as periodic maintenance
of the mechanism and weirs.
Operation and maintenance requirements are summarized in Table 45 and
are also shown in Figures 58 and 59.
RECTANGULAR CLARIFIERS
Construction Cost
Rectangular clarifiers may be used following treatment by coagulation
and flocculation or by softening. Cost estimates were made for clarifiers
that have a 12-ft sidewall depth and that use chain and flight sludge
collectors.
The construction cost includes the chain and flight collector, the
collector drive mechanism, weirs, the reinforced concrete structure complete
with inlet and outlet troughs, a sludge sump, and sludge withdrawal piping.
Costs for the structure were developed assuming multiple units with common
wall construction. Yard piping to and from the clarifier is not included
in the cost estimates.
Construction cost estimates for rectangular clarifiers are presented
in Table 46 and in Figure 60.
128
-------
Table 44
Construction Cost for
Circular Clarifiers
Surface Area (SA = ft2) and Diameter (ft)
VO
Cost Category
Excavation & Sifiework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
707 SA
30 ft
$ 1,530
28,740
4,860
14,160
10,770
8,090
5,940
74,090
11,110
85,200
1,590 SA
45 ft
$ 2,430
34,410
7,710
21,090
16,180
8,420
5,940
96,180
14,430
110,610
5,027 SA
80 ft
$ 4,900
69,580
15,480
67,240
30,960
11,540
7,560
207,260
31,090
238,350
10,387 SA
115 ft
$ 7,860
97,180
24,800
129,250
46,980
15,660
8,270
330,000
49,500
379,500
155393 SA
140 ft
$ 10,280
132,350
32,400
188,720
60,110
21,590
10,870
456,320
68,450
524,770
22,698 SA
170 ft
$ 13,520
189,060
42,560
249,570
77,640
26,590
12,370
611,310
91,700
703,010
31,416 SA
200 ft
$ 17,130
226,980
53,860
335,140
96,320
42,520
13,060
785,010
117,760
902,760
-------
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SINGLE BASIN AREA -ft* 100,001
It 1 '
10 100 1000
SINGLE BASIN AREA-m2
Figure 57. Construction cost for circular clarifiers.
130
-------
Table 45
Operation and Maintenance Summary
for Circular Clarifiers
Clarifier Size Energy (kw-hr/yr) Total Cost ($/%£_).*
Diameter
ft
30
45
80
115
140
170
200
Area
ft
707
1,590
5,027
10,387
15,394
22,698
31,416
Lime
Sludge
4,900
5,380
6,540
8,820
10,450
12,420
14,380
Ferric &
Alum Sludge
3,270
3,760
4,900
6,050
7,190
9,150
11,100
Maintenance
Material ($/yr)
$ 250
420
1,050
1,750
2,300
3,050
4,100
Labor
(hr/yr)
150
170
230
' 310
360
420
500
Lime
Sludge
$ 1,900
2,280
3,550
5,110
6,210
7,620
9,530
Ferric &
Alum Sludge
$ 1,850
2,230
3,500
5,030
6,120
7,520
9,430
^Calculated using $0.03/kw-hr and $10,QQ/hr of labor.
-------
MNTENA
MATERIAL
100
10
3 4 5 6789IOOO 234 56789K3pOO
SINGLE BASIN AREA-ff2
-f-
4 5 6T«9
IOO.OOO
1 1
100 1000
SINGLE BASIN AREA-m2
Figure 58. Operation and maintenance requirements for circular
clarifiers - process energy and maintenance material.
132
-------
100,000
IO.OOO 10,000
I
h-
OJ
o
o
1000 , 100,0
9
2 -
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SINGLE BASIN AREA-ff2
-*-
4 5 6789
100,000
100 1000
SINGLE BASIN AREA-m2
Figure 59. Operation and maintenance requirements for
circular clarifiers - labor and total cost.
133
-------
Table 46
Construction Cost for
Rectangular Clarifiers
Area (ft2) and Length x Width (ft)
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
240 ft2
30 x 8ft
$ 1,060
8,540
2,970
6,400
6,220
6,960
1,510
33,660
5,050
38,710
600 ft2
60 x 10ft
$ 2,000
12,080
5,490
13,110
11,260
7,400
1,760
53,100
7,670
61,070
1,260 ft2
90 x 14ft
$3,060
24,470
8,430
19,440
17,320
9,100
1,860
83,680
12,550
96,230
2,240ftz
140 x 16ft
$ 4,680
32,020
12,820
32,620
26,390
12,500
2.020
123,050
18,460
141,510
3,600ftz
200 x 18ft
$ 6,670
53,110
18,190
51,250
37,570
16,100
2.110
185,000
27,750
212,750
4,800ft2
240 x 20 ft
$8,090
63,440
22,070
69,680
45,300
21,450
2.400
232,430
34,860
267,290
-------
81
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SINGLE BASIN AREA-m2
Figure 60. Construction cost for rectangular clarifiers,
135
-------
Operation, and Maintenance Cost
Process energy requirements were calculated based on manufacturers'
estimates of motor size and torque requirements for alum, ferric, and lime
sludges. The heavier lime sludges call for an approximate 50-percent
increase in power requirements.
Maintenance material costs are for parts required for periodic mainten-
ance of the drive mechanism and weirs. Labor requirements are for periodic
checking of the clarifier drive mechanism, as well as periodic maintenance
of the mechanism and weirs.
Operation and maintenance requirements are summarized in Table 47 and
shown in Figures 61 and 62.
UPFLOW SOLIDS CONTACT CLA1IFIERS
Construction Cost
Upflow solids contact clarifiers combine mixing, coagulation and
flocculation, liquid—solids separation, and sludge removal into a single
basin. Generally, rapid mix and coagulation/flocculation are accomplished
in the center of the unit, with upflow clarification through a sludge blanket
in the outer portion of the basin. Upflow solids contact clarifiers are
generally selected on the bases of a lower cost and the operational
advantages of combining several processes into a single basin.
Estimated construction costs were made for circular units within a
reinforced concrete structure. The factory-manufactured reactor clarifier
unit was a center feed type and included all mixers, the center column
(when used), a sludge scraper, and a steel wall between the inner and outer
compartments. Units less than 45 ft in diameter were bridge supported,
and those greater than 45 ft in diameter were supported by the center column.
All units were assumed to have a sidewall depth of 16 ft, although greater
depths may be utilized.
Estimated construction costs are shown in Table 48 and Figure 63.
Operation and Maintenance Cost
Energy requirements for the flash mix, flocculation mixer, and mechanism
drive were calculated using manufacturers' recommended motor sizes. Flash
mix G values of 70, 110, and 150 were utilized.
Maintenance material requirements are relatively low for upflow solids
contact clarifiers and were estimated at 1.5 percent/year of the initial
clarifier mechanism cost.
Labor requirements are for operational control of the coagulant dose and
the clarifier mechanism, as well as for maintenance of the drive units and
mixers. A daily requirement of 1 hr/clarifier was used for jar testing to
determine coagulant dose. Adjustment of the labor requirement for daily jar
testing may be necessary if there is more than one clarifier.
136
-------
w
Table 47
Operation and Maintenance Summary
for Rectangular Clarifiers
Clarifier Size
Area (ft
240
600
900
1,260
1,600
2,240
2,520
3,600
4,000
4,800
:2) LxW (ft)
30 x 8
60 x 10
80 x 12
90 x 14
100 x 16
140 x 16
140 x 18
200 x 18
200 x 20
240 x 20
Process Energy (kw-hr/yr)
Lime Sludge
3,270
3,700
4,060
4,490
4,900
6,040
6,540
9,000
9,800
12,400
Alum Sludge
3,270
3,560
3,790
4,100
4,380
4,900
5,250
6,540
7,980
8,500
Maintenance
Material ($/vr)
$ 280
350
400
400
500
610
650
850
980
1,250
Labor
(hr/yr)
170
200
220
250
280
330
360
420
460
510
Total Cost* ($/yr)
Lime Sludge
$ 2,080
2,460
2,720
3,030
3,450
. 4,090
4,450
5,320
5,870
6,720
Alum Sludge
$ 2,080
2,460
2,710
3,020
3,430
4,060
4,410
5,250
5,820
6,610
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
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Figure 61. Operation and maintenance requirements for
rectangular clarifiers - process energy and maintenance material,
138
-------
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7 -
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100 1000
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Figure 62, Operation and maintenance requirements for
rectangular clarifiers - labor and total cost.
139
-------
Table 48
Construction Cost for
Upflow Solids Contact Clarifiers
Net Effective Settling Area(ft2) and Diameter (ft)
Cost Category*
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
255 ft2
20 ft
$ 1,460
41,500
3,590
5,310
15,700
2,140
69,700
10,460
80,160
643 ft2
30 ft
$ 2,380
47,000
5,570
8,160
20,700
2,140
85,950
12,890
98,840
1,457 ft?
45 ft
$ 4,000
65,000
8,780
12,650
30,380
2,140
122,950
18,440
141,390
2,544 ft2
60 ft
$ 5,920
86,000
12,270
17,430
40,950
2,140
164,710
24,710
189,420
4,455 ft?
80 ft
$ 8,920
122,500
17,370
24,240
57,200
2,140
232,370
34,860
267,230
10,370 ft2
125 ft
$ 17,570
186,250
30,700
41,360
91,980
2,210
370,070
55,510
425,580
14,544 ft2
150 ft
$ 23,510
230,000
39,200
51,970
114,100
2,210
460,990
69,150
530,140
-------
IO.OQ2
100
34 567891000 234 56789(OpOO 2
NET EFFECTIVE SETTLING AREA - ft2
3 456 789
100,000
10
100 1000
NET EFFECTIVE SETTLING AREA- m2
Figure 63. Construction cost for upfT_ow solids contact clarifiers.
141
-------
Figures 64 and 65 present the estimated operation and maintenance
requirements for upflow solids contact clarifiers, and Table 49 summarizes
these requirements.
TUBE SETTLING MODULES
Construction Cost
Tube settling modules employing principles of shallow depth sedimentation
can be incorporated in clarification basins to reduce significantly the size
and associated construction cost of new basins. The modules may also be
used to improve performance or increase capacity at existing facilities.
Tube modules may be applied successfully in circular or rectangular basins
of either the horizontal flow or upflow design.
In basins of either rectangular or circular configuration, the tube
modules that are constructed of light weight, high-strength plastic, are
simply supported by light-weight structural members. Tube modules are
available from numerous manufacturers in widths of 2.5 to 3.0 ft and in
lengths up to 12 ft.
Conceptual designs that were used in the cost estimates are presented
in Table 50. The basins were sized with rise rates through the area covered
by tube modules and over the entire basin of 2.5 gpm/ft2 amd 2 gpm/ft2,
respectively. By leaving a portion of the basin open, a zone is created
for inlet turbulence dissipation. This transition zone is separated by
a baffle extending from the bottom of the modules to 6 in. above the
operating water level. Uniform effluent collection is a requirement for
optimum utilization of tube settlers. To meet this requirement, effluent
launders are spaced at 12-ft centers in all basins. Basin configurations
and widths were selected to limit tube module support member length to a
maximum of 20 ft. Since the hydraulic and structural requirements for tube
clarification systems are unique, the costs include tube modules, tube
module supports and anchor brackets, transition baffle, effluent launders
with V-notch weir plates, and installation. These costs may be added to the
cost of conventional basin construction costs to arrive at a total facility
cost.
Construction costs are shown in Table 51 and also in Figure 66.
GRAVITY FILTRATION STRUCTURES
Construction Cost
Conventional gravity filtration structure costs are based on use of
cast-in-place' concrete with a media depth of 2 to 3 ft and a total depth of
16 ft for 'the filter box. Construction cost estimates have been based on the
conceptual designs outlined in Table 52. At flows less than 5 mgd, two
filters were used, but at 5 mgd and greater,.a minimum of four filters was
utilized. Maximum filter size was limited to 1,275 ft2, and above 700 ft2,
the filters are dual-celled to allow backwashing of each half separately.
This approach allows a significant reduction in the size of wash water and
142
-------
10,000
100
3 4
5 67891000 234 56789BpOO 2
NET EFFECTIVE SETTLING AREA-f(2
4 5 67t9
100,000
10
•4-
100 1000
NET EFFECTIVE SETTLING AREA- m2
Figure 64. Operation and maintenance requirements for upflow solids contact
clarifiers — process energy and maintenance material.
143
-------
to
o
o
I
6
5
4
3
100,000
lopoo
9T
8
7
6
5
4
1000
9
8
6
5
4
1000
9
8
7
w 6
- 5
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[T
O
CD
<
100
TC
iTAl.
= 150
COST
1
100 234 567891000 234 56789IOpOO 234 56789
NET EFFECTIVE SETTLING AREA-ft2 100,000
—1— ( 1
10 IOO 1000
NET EFFECTIVE SETTLING AREA - m2
Figure 65. Operation and maintenance requirements for upflow solids
contact clarifiers -"labor and total cost.
144
-------
Table 49
Operation and Maintenance Summary
for Upflow Solids Contact Clarifiers
Ln
Clarifier Size
Diameter
(ft)
20
30
45
60
80
125
150
Net Effective
Setting Area (ft
1,
2,
4,
10,
14,
255
643
457
544
455
370
544
Maintenance
Energy (kw-hr/yr)
2) G=70
8
11
17
26
42
84
130
,170
,440
,970
,140
,480
,950
,700
G=110
8,170
1,4,700
37,580
45,740
75,150
182,980
294,070
G=150
13,070
24,510
44,110
71,880
140,500
346,350
424,770
Material
($/yr)
$580
650
900
1,080
1,440
2,070
2,340
Labor
(hr/yr)
480
480
571
571
571
662
662
Total
G=70
$5,630
5,790
7,150
7,570
8,420
11,240
12,880
Cost* ($/yr)
G=110
$5,630
5,890
7,740
8,160
9,400
14,180
17,780
G=150
$5,770
6,190
7,930
8,950
11,370
19,080
21,700
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Table 50
Conceptual Design for
Tube Settling Modules
Plant Capacity
(mgd)
1
10
50
100
200
Tube Module
Area (ft2)
280
2,800
14,000
28,000
56,000
Sedimentation
Basin Area (ft2)
350
3,500
17,500
35,000
70,000
Number of
Sedimentation Basins
2
2
2
2
4
Basin Dimensions
Length
18
60
110
220
220
(ft)
Width
10
30
80
80
80
-------
.Table 51
Construction Cost for
Tube Settling Modules
Tube Module Area (ft2)
Cost Category
»-»
**"
"-1 Manufactured Equipment
Steel
Labor
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
280
$ 4,200
2,000
2,500
8,700
1,300
10*000
2,800
$31,000
19,500
11,200
61,700
9,260
70,960
14,000
$147,000
95,000
49,000
291,000
43,650
334,650
28,000
$282,000
155,000
95,000
532,000
79,800
611,800
56,000
$504,000
300,000
224,000
1,028,000
154,200
1,182,200
-------
T
6
5
4
1,000,000
I
w
o
o
z
pr 100,000
W
o
10,000
9 —
8 —
7 —
6 —
5 —
IOO 234 567891000 234 56789ICpQO 834 56789
TUBE MODULE AREA~ff2
10
100 1000
TUBE MODULE AREA-m2
Figure 66. Construction cost for tube settling modules.
148
-------
Table 52
Conceptual Designs for
Gravity Filtration Structures
(24 to 36 Inch Media Depth)
Total Filter Filters Housing Requirement (ft2)
Plant Flow (mgd)
1
5
10
50
100
200
Area (ft2)
140
700
1,400
7,000
14,000
28,000
Number
2
4
4
10
14
22
Area Each (ftz)
70
175
350
700*
1,000*
1,275*
Basic
150
' 420
800
2,900
4,060
6,380
Total
430
1,480
2,720
11,600
21,110
40,190
*Dual-celled filters.
-------
waste piping. On the designs up to and including 10 mgd, raw water was fed
to the filter, using a gullet between the pipe gallery and the filter structure.
Only one valve was used to admit raw water to the dual-celled filters, since
the filters operate as one until the end of the filter cycle, even though they
are backwashed separately. For designs up to and including 10 mgd, piping
was used to convey product water in the pipe gallery, but larger designs used
a covered concrete box structure in the center of the pipe gallery. Basic
housing requirements include housing only the pipe gallery, which is located
beneath the filter control area. The filter structure need not be housed
except in severe winter climates, where other precautions such as diffused air
addition near the filter periphery are not taken. The cost curves include,
however, housing of the entire filter structure.
Costs for filtration structures are presented in Table 53 and Figure 67.
These costs include the filter structure, underdrains, wash water troughs,
a pipe gallery, required piping and cylinder operated butterfly valves, filter
flow and headloss instrumentation, a filter control panel, and the total
housing requirement. The costs do not include the cost of backwash water
storage facilities, backwash pumping facilities, filtration media, or surface
wash piping and pumps. These facilities were not included, since their use
and sizing varies with each design, and they are most appropriately added
separately.
Operation and Maintenance Cost
Energy requirements are only for building heating, ventilation, and
lighting. All process energy required for filtration is included in the
backwash and surface wash curves.
Maintenance material includes the cost of general supplies, instrumenta-
tion repair, and the periodic addition of filter media. Costs are based on
costs experienced at several plants.
Labor costs include the cost of operation, as well as the cost of
instrument and equipment repairs, and supervision.
Figures 68 and 69 present the operation and maintenance requirements,
and Table 54 summarizes these requirements.
FILTRATION MEDIA
Construction Cost
Cost estimates have been prepared for three types of commonly used
filtration media: rapid sand, dual media (coal-sand), and mixed media
(coal-sand-garnet). The advantage of rapid sand medium is its low initial
cost and simplicity of placement, whereas its disadvantages are the relatively
low application rates and limited suspended solids loading. Though the more
sophisticated dual and mixed media allow higher filtration rates and suspended
solids loading than rapid sand, they are higher in initial cost and require in-
place processing. Common practice is to backwash the media during placement
and then to skim a shallow layer from the surface to remove excessive fines.
150
-------
Table 53
Construction Cost for
Gravity Filtration Structures
Total Filter Area (ft2) and Plant Flow Rate (mgd)
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
140 ft2
1 mgd
$ 1,950
26,360
13,400
11,550
40,580
20,580
13,390
17,400
145,210
21,780
166,990
700 ftx
5 mgd
$ 3,620
56,960
27,040
19,960
88,490
79,020
38,410
40,480
353,980
53,100
407,080
1,400 ft2
10 mgd
$ 5,520
78,300
41,660
30,120
150,870
127,340
38,410
70,590
542,810
81,420
624,230
7,000 ft7
50 mgd
$ 16,220
305,170
95,490
73,530
356,380
420,670
99,140
291,940
1,658,540
248,780
1,907,320
14,000 ftz
100 mgd
$ 25,590
529,360
154,790
123,160
508,980
590,150
168,840
514,330
2,615,200
392,280
3,007,480
28,000 ftz
200 mgd
$ 43,410
982,390
275,570
209,960
1,000,670
1,125,500
265,310
968,520
4,871,330
730,700
5,602,030
-------
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152
-------
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structures - building energy and maintenance material.
153
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Figure 69. Operation and maintenance requirements for gravity
filtration structures - labor and total cost.
154
-------
Table 54
.Operation and Maintenance Summary
for Gravity Filtration Structures
Total Filter
Area (ft2)
140
700
1,400
7,000
14,000
28,000
Building
Energy
(kw-hr/yr )
44,120
151,850
279,070
1,190,160
2,165,890
4,123,490
Maintenance
Material ($/yr)
$ 800 :
2,510
4,020
13,200
21,600
36,700
Labor
(hr/yr)
900
1,500
2,100
4,600
7,000
18,000
Total Cost*
( $/yr>
$ 11,120
22,070
33,390
94,900
156,580
340,400
*Calculated using $0.03/kw-hr and $10.00/hr of labor.
155
-------
Cost estimates have been made for purchase and placement of 30-in. of
media over a 12-in. gravel underdrain. These estimates are applicable to '
either gravity or pressure filters, although pressure filters are often
designed with a somewhat deeper gravel support layer. Characteristics of
all three media and the gravel underdrain are presented in Table 55. Costs
were developed as a function of filter area using a filtration rate of
2 gpm/ft2 for rapid sand, and 5 gpm/ft2 for dual media and mixed media.
For plants with total filter areas of 140 ft2 and less, materials were
considered to be truck shipped in 100 Ib bags. For total filter areas
between 140 and 2,000 ft2, rail shipment in 100 (lb bags was assumed, and
for larger filter areas, rail shipment by bulk was assumed.
The estimated costs include media cost, shipping, and installation.
The cost of a trained technician to direct placement of the mixed media is
also included. Freight cost represents a nationwide average. Estimated
filtration media costs are presented in Figure 70 and Table 56.
BACKWASH PUMPING FACILITIES
Construction Cost
The cost of the backwash pumping system must be added to the basic cost
for the filtration structure, filter media cost, surface wash, and any
required backwash water storage capacity to arrive at the filtration facility
cost. Included within the backwash pumping system cost is the cost of
required pumps and motors, including one standby unit, flow control, filter
backwash sequencing control, pump station valving, the backwash header
cost not included in the filter structure, and motor starters. Backwash
piping and valving was sized for a velocity of 7 ft/second. Housing costs
are not included. The assumed pumping head for the backwash pump was 50
ft total dynamic head (TDK) , and the maximum design rate for backwash was
18 gpm/ft2. The largest pump utilized was 7,000 gpm, and one standby pump
was included for all installations.
Construction cost estimates are shown by cost component on Table 57 and _
Figure 71. Costs are presented as a function of backwash pumping capacity, as
the rate for any given size of filter will vary with the type of media utilized,
Operation and Maintenance Cost
Operation and maintenance curves are presented on the basis of total
filter area. A backwash frequency of two per day with a 10-min duration per
wash was assumed. For dual-cell filters, a backwash is defined as a backwash
of both cells.
Energy requirements were calculated using a backwash rate of 15 gpm/ft2,
a pumping head of 50 ft TDK, and an overall motor/pump efficiency of 70
percent. Energy requirements are based on a backwash period of 10 min twice
a day.
156
-------
Table 55
Filter Media and Gravel Underdrain Characteristics
Item
Rapid Sand
Dual Media
Mixed (Tri) Media
Gravel Underdrain (common to all
media)
Characteristics
30 in. of 0.42 to 0.55 mm effective
size silica.sand, uniformity coefficient
less than 1.6
20 in. of 1.0 to 1.2 mm effective size
anthracite coal, uniformity coefficient
less than 1.7.
10 in. of 0.42 to 0.55 mm effective size
silica sand, uniformity coefficient less
than 1.6
16.5 in. of 1.0 to 1.1 mm effective size
anthracite coal, uniformity coefficient
less than 1.7
9 in. of 0.42 to 0.55 mm effective size
silica sand, uniformity coefficient less
than 1.6
4.5 in. of 0.18 to 0.28 mm effective
size garnet or ilmenite sand, uniformity
coefficient less than 1.8
3 in. of 1-1/2" x 3/4" silica gravel
3 in. of 3/4" x 3/8" silica gravel
3 in. of 3/8" x 3/16" silica gravel
3 in. of 3/16" x #10 silica gravel
157
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Figure 70. Construction cost for filtration media.
158
-------
Table 56
Construction Cost for
Filtration Media
Plant
Capacity
(mgd)
1
5
10
50
100
200
Filter Bed Area (ftz)
Rapid
Sand
350
1,750
3,500
17,500
35,000
70,000
Dual and
Mixed Media
140
700
1,400
7,000
14,000
28,000
Filter
Rapid Sand
$ 6,500
26,270
29,070
140,570
280,320
559,800
Media Costs Installed
Dual Media
$ 5,800
18,160
33,030
113,950
217,400
431,280
Mixed Media
$ 9,000
25,720
48,860
181,410
355,530
699,780
-------
Table 57
Construction Cost for
Backwash Pumping Facilities
Pumping Capacity . mgd (gpm)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1,260
(1.8)
$11,400
3,050
9,780
13,350
37,580
5,640
43,220
3,150
(4,5)
$14,600
4,410
17,690
16,040
52,740
7,910
60,650
6,300
(9.1)
$38,380
4,880
17,690
16,740
77,690
11,650
89,340
18,000
(25.9)
$76,780
9,290
33,390
28,070
147,530
22,130
169,660
22,950
(33)
$95,970
12,440
44,780
33,250
186,440
27,970
214,410
-------
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BACKWASH PUMPING CAPACITY - liters/sec
Figure 71. Construction cost for backwash pumping facilities.
161
-------
Maintenance material costs are for repair of the backwash pumps, the
motor starters, and valving. Labor requirements are for maintenance labor
only, as all operation labor is included in the filtration structure curve.
Figures 72 and 73 present the operation and maintenance requirements,
which are also summarized in Table 58. The total cost curve is based on a
10 min backwash at 15 gpm/ft2, two washes per day, and a 50 TDK. If different
conditions were utilized, the total cost should be adjusted accordingly.
HYDRAULIC SURFACE WASH SYSTEMS
Construction Cost
The cost of hydraulic surface wash systems is presented separately from
the backwash system, as some plants may not use surface wash in conjunction
with backwashing. If surface wash is utilized, the cost must be added to
the cost of the backwash system, the filter structure, the filter media, and
any required backwash storage capacity to arrive at the total cost of filtra-
tion. Cost estimates include dual pumps with one as standby, electrical
control, piping, valves, and headers within the filter pipe gallery. ' No
allowance for housing is included, as this is included in the filtration
structure cost. Surface wash pumps are sized to provide approximately 50
to 85 psi at the arms, in accordance with manufacturers* recommendations.
Costs are based on the total filter area of a plant, using the filter
conceptual designs presented in the gravity filtration structure section.
Dual-arm agitators were used with an application rate recommended by the
manufacturer. One agitator was included for filter areas up to and including
75 ft2, four agitators for the 350 to 700 ft2 filters, and six'and eight
agitators for the 1,000 and 1,275 ft2 filters, respectively. It was assumed
that the wet well for the surface wash pumps is the same as for the backwash
pumps. The construction cost estimates are shown in Table 59 and Figure 74,
Operation and Maintenance Cost
Energy requirements were calculated using two surface washes/day, a
wash time of 8 min, application rates recommended by manufacturers (which
were approximately 1.5 gpm/ft2 of filter surface for the dual-arm agitators),
a TDK of 200 ft, and an overall motor pump efficiency of 70 percent.
Maintenance material requirements are for repair of the pump(s), motor
starter, valves and .surface agitators. Two surface wash operations/day were
assumed. Labor requirements are for maintenance of equipment only and are
based on manufacturers' estimates. Operation labor is included with the
basic filter.
Figures 75 and 76 present the operation and maintenance requirements
for hydraulic surface wash systems. The total cost must be added to the costs
for filter backwashing and filter operation to arrive at the total operation
and maintenance cost for filter operation. An operation and maintenance
summary for hydraulic surface wash systems is presented in Table 60.
162
-------
10,000
i
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. MAINTENANCE MATERIAL — $ /yr
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TOTAL FILTER AREA-m2
Figure 72. Operation and maintenance requirements for backwash pumping
facilities - process energy and maintenance material.
163
-------
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Figure 73. Operation and maintenance requirements for backwash
pumping facilities - labor and total cost.
164
-------
l/i
Table 58
Operation and Maintenance Summary
for Backwash Pumping Facilities
Total Filter Area
(ft2)
140
700
1,400
7,000
14,000
28,000
Process Energy
(kw-hr/yr)
3,340
16,720
33,440
167,240
334,460
670,120
Maintenance
Material ($/yr)
$ 700
1,100
1,800
3,400
4,200
5,700
Labor
(hr/yr)
190
210
250
300
350
370
Total Cost*
($/yr)
$ 2,700
3,700
5,300
11,420
17,730
29,500
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Table 59
Construction Cost for
Hydraulic Surface Wash Systems
Total Filter Area (ft2)
Cost Category 140 700 1,400 7,000 14,000 28,000
Manufactured Equipment $ 9,170 $12,050 $35,090 $82,010 $172,440 $401,200
Labor 1,300 2,770 5,170 14,710 29,430 66,600
Pipe and Valves 2,570 5,100 7,020 13,390 32,290 59,870
Electrical and Instrumentation 12,670 17,920 20,440 37,900 61,120 92.360
SUBTOTAL 25,710 37,840 67,720 148,010 295,280 620,030
Miscellaneous and Contingency 3,860 5,680 10,160 22,200 44.290 93,000
T01^ 29,570 43,520 77,880 170,210 339,570 713,030
-------
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1 —
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TOTAL FILTER AREA-m2
100
Figure 74. Construction cost for hydraulic surface wash systems.
167
-------
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TOTAL FILTER AREA-m2
!000
Figure 75. Operation and maintenance requirements for hydraulic surface wash
systems - process energy and maintenance material.
168
-------
100
3 4 567891000 234 56789ICNOOO
TOTAL FILTER AREA-ft2
456 789
IOO.OOO
10
-t-
100 1000
TOTAL FILTER AREA-m2
Figure 76. Operation and maintenance requirements for hydraulic
surface wash systems - labor and total cost.
169
-------
Table 60
Operation and Maintenance Summary
for Hydraulic Surface Wash Systems
Total Cost*
($/yr)
o ___ . _. ._. .._ 1,720
2,980
6,210
10,550
20,640
Total Filter
Surface Area (ft2)
140
700
1,400
7,000
14,000
28,000
Process Energy.
( kw-hr/yr)
2,310
9,640
22,020
90,300
202,460
397,490
Maintenance
Material
($/yr)
$200
250
300
400
500
600
Labor
(hr/yr)
54
118
202
310
398
812
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
AIR-WATER BACKWASH FACILITIES
Construction Cost
The introduction of air into the filter underdrains before backwash is
a concept that was developed to reduce the quantity of wash water utilized.
The air is introduced first to scour material from the filter bed, and then
backwash is used to restratify the filter bed. Although a different type
of underdrain is required for air-water backwash than for conventional wash,
the costs for the two types of underdrains are comparable.
The cost estimates that were developed are for both the air supply and
water supply components of the backwash system. The air compressor and motor
drives, backwash pumps and motor drives, filter backwash sequencing control,
the air supply header and piping to the filters, the wash water piping
outside of the basic filter structure, and all required valving and electri-
cal equipment and instrumentation are included in the cost estimate. One
standby air compressor and backwash pump is included for each installation.
Facilities were sized based on air flow of 5 efm/ft2 of filter area at 8 psi
and a maximum wash rate of 18 gpm/ft2 of filter area. No allowance was
included for housing, since housing costs were included with the basic
filter structure.
The construction cost for the air-water- backwash facilities is shown
in Table 61 and Figure 77. ,
Operation and Maintenance Cost
The operation and maintenance costs are a composite of the "air system
costs and the backwash system costs. Costs were calculated based on 5 min
of air addition per backwash at a rate of 5 cfm/ft2 and a pressure of 8 psi,
followed by a backwash of 5 min at a rate of 15 gpm/ft^ Process energy
costs are based on two backwashes/day per filter.
Labor and maintenance material requirements are essentially the same as
for water backwash systems.
Figures 78 and 79 show the operation and maintenance requirements for
air-water backwash systems. A summary of these requirements is presented
in "Table 62.
WASH WATER SURGE BASINS
Construction Cost
When filter wash water is recycled through the plant, treated in a
separate plant, or discharged to a sanitary sewer, a surge basin may be used
to even out 'the flow. Construction costs were developed for covered, below-
ground, reinforced concrete basins. Level control instrumentation is included
in the cost estimates. The cost for pumping facilities to return water for
treatment or to pump it to a sewer are not included. Construction costs for
wash water surge basins are shown in Table 63 and Figure 80.
171
-------
Table 61
Construction Cost for
Air-Water Backwash Facilities
NJ
Total Filter Area (ft2)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
140
$26,520
5,350
13,910
14,250
60,030
9,000
69,030
700
$ 34,330
9,060
30,970
16,820
91,180
13,680
104,860
1,400
$ 66,100
11,620
48,780
17,490
143,990
21,600
165,590
7,000
$ 70,060
20,120
93,700
18,190
202,070
30,310
232,380
14,000
$ 121,000
32,160
162,240
29,010
344,410
51,660
396,070
28,000
$ 147,440
50,590
323,000
34,560
555,590
83,340
638,930
-------
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Figure 78. Operation and maintenance requirements for air-water
backwash facilities - process energy and maintenance material.
174
-------
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100,000
100
TOTAL FILTER AREA-
IO'OD
Figure 79. Operation and maintenance requirements for air-water
backwash facilities - labor and total cost.
175
-------
Table 62
Operation and Maintenance Summary
for Air-Water Backwash Facilities
'liter Area (ft2)
140
700
1,400
7,000
14,000
28,000
Process Energy
(kw-hr/yr)
3,390
16,920
33,890
169,440
338,950
679,160
Maintenance
Material ($/yr)
$ 700
1,100
1,800
3,400
4,200
5,700
Labor
(hr/yr)
190
210
250
300
350
370
Total Cost*
($/yr)
$ 2,700
3,710
5,320
11,480
17,870
29,770
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Table 63
Construction Cost for
Wash Water Surge Basins
Basin Capacity (gal)
Cost Category
Excavation and Sitework
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
10,000
$ 200
11,560
7,990
18,270
5,500
1,300
44,820
6,720
51,540
50,000
$ 520
39,310
25,170
58,500
7,500
1,300
132,300
19,850
152,150
100,000
$ 1,250
71,480
44,680
107,590
11,000
6,000
242,000
36,300
278,300
500,000
$ 4,400
143,680
70,770
182,150
16,000
6,000
423,000
63,450
486,450
-------
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-------
MODIFICATION OF RAPID SAND FILTERS TO HIGH-RATE FILTERS
Construction Cost
Many existing rapid sand filtration plants originally designed with a
filtration rate of 2 gpm/ft2 can be upgraded to high-rate filtration (4 to
5 gpm/ft2 filtration rates) without requiring structural modifications. The
upgrading involves removal of existing sand media and underdrain gravel,
replacement"of effluent piping and flow control devices with larger piping
and a new rate of flow controller, and installation of mixed or dual-media
materials.
Costs were developed for accomplishing these modifications for plants
with total filtration bed areas ranging from 140 to 28,000 ft2. Filter sizes
and configurations for which costs were developed are the same as those used
in the gravity filtration structure curve. Included is the cost of removing
sand and gravel, and hauling it to disposal on the plant site. It was
assumed that the existing filter bottom would be compatible with the new
filtration system and would be retained unchanged. .It is also assumed that
the existing backwash system will provide a minimum wash rate of 15 gpm/ft2.
The cost^s include new effluent piping, a new, pneumatically operated butterfly
valve, and a rate of flow controller mounted in existing filter control
consoles.
Costs for accomplishing these modifications are presented in Table 64
and Figure 81. Filtration media costs must also be added to these costs
to obtain the total cost for conversion to high-rate filtration.
CONTINUOUS AUTOMATIC BACKWASH FILTERS
Construction Cost
The continuous automatic backwash filter is an adaptation of rapid sand
filtration principles. The filter bed is contained in a shallow rectangular
concrete structure that is laterally divided into compartments. Each compart-
ment is, in effect, a single filter. Filter flow rate is based on declining
rate, as there are no rate-of-flow controllers. An attractive feature of the
filter is that operating head losses are generally less than 1 ft of water.
A motor driven carriage assembly equipped with a backwash pump and a washwater
collection pump backwashes each compartment sequentially as it traverses the
length of the filter.
Costs were developed for filter units capable of handling flows from
1 to 200 mgd at a filtration rate of 2 gpm/ft . Conceptual designs are listed
in Table 65. A filter box depth of 5 ft was used for all sizes of filters,
and each size of. plant utilizes a minimum of two filters. The filter units
are essentially self-contained and require no interconnecting piping,
Filtered water, influent, and backwash water are conducted to and from the
filter by troughs or channels integrally cast within the concrete filter
structure.
179
-------
Table 64
Construction Cost for
Modification of Rapid Sand Filters to High-Rate Filters
oo
o
Total -.Filter Area, (ft2)
Cost Category
Labor
Pipe & Valves
Electrical &
Ins tr umentat ion
SUBTOTAL
Miscellaneous &
Contingency
TOTAL COST
140
$8,600
8,940
3,900
21,440
3,220
24,660
700
$11,140
17,400
8,500
37,040
5,560
42,600
1,400
$23,900
23,000
12,200
59,100
8,870
67,970
7,000
$58,400
78,000
20,000
156,400
23,460
179,860
14,000
$91,700
143,000
28,000
262,700
39,400
302,100
28,000
$157,300
260,000
46,000
463,300
69,500
532,800
-------
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Figure 81. Construction cost for modification of
rapid sand filters to high-rate filters.
181
-------
Table 65
Conceptual Design for
Continuous Automatic Backwash Filter
Plant Flow Total Filter Filters
mgd Area (ft2) Number Area, (ft2) Housing, (ft2)
1 360 2 180 1,088
5 1,750 2 875 3,332
10 3,520 2 1,760 6,120
100 35,200 20 1,760 81,600
200 70,400 40 1S760 162,625
The nature of the equipment requires that it be housed for protection
from inclement weather and freezing temperatures. Housing costs were
developed, assuming total enclosure of the filters with minimum additional
space for access on two of the four sides for maintenance,
The costs are presented in Table 66 and Figure 82 and include the
filtration structure, internal mechanical equipment, partitions, underdrains,
rapid sand filter media (depth generally 11 in.) wash water collection trough
over-head pump carriage, electrical controls, and instrumentation.
Operation and Maintenance Cost
Energy requirements are for building heating, lighting, and ventilation
and for pumping costs related to backwashing of the automatic backwash filter.
It was assumed that the entire filter unit is housed.
Maintenance material costs include general supplies, pump maintenance
and repair parts, replacement sand, and other miscellaneous items.
Labor costs were estimated from projected maintenance time requirements
and are related to general supervision and maintenance.
Table 67 summarizes the operation and maintenance requirements, which are
illustrated in Figures 83 and 84.
RECARBONATION BASINS
Cons truetion Cos t :
Costs were developed for recarbonation basins, including the reinforced
concrete structure, complete with influent and effluent channels, foam
supression piping and sprayers, and handrails surrounding the basin. C02
gaseous or liquid C02 is utilized, as well as the concentration of COa in the
182
-------
oo
Table 66
Construction Cost for
Continuous Automatic Backwash Filter
_ Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Piping and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
$ 290
103,380
11,640
5,080
24,380
11,160
5,230
29,770
190,930
28,640
219,570
Total
1,7^0
$ 1,400
185,650
29,440
13,130
55,710
14,990
7,330
84,820
392,470
58,870
451,340
Filter Area
3,520
$ 2,630
361,760
48,980
21,690
105,110
22,320
12,560
138,800
713,850
107,080
820,930
(ft2)
35,200
$ 24,170
3,262,210
501,160
201,870
813,290
58,460
197,130
1,679,270
6,737,560
1,010,630
7,748,190
70.400
$ 47,300
6,513,820
992,490
399,680
1,522,990
116,920
388,390
3,273,930
13,255,520
1,988,330
15,243,850
-------
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Figure 82. Construction cost for continuous automatic backwash filters.
184
-------
Table 67
Operation and Maintenance Summary for
Continuous Automatic Backwash Filter
00
Ul
Plant Flow (mgcf)
1
5
10
100
200
Total Filter
Area (ft2)
360
1,750
3,520
35,200
70,400
Energy (kw-hr/yr)
Building
111,629
341,863
627,912
8,372,160
16,685,325
Process
3,854
13,624
42,890
428,900
857,800
Total
115,483
355,487
670,802
8,801,060
17,543,125
Maint enance
Material
(S/yr)
$690
1,500
2,350
20,310
37,420
Labor
(hr/yr)
728
832
1,040
10,000
18,000
Total Cost*
($/yr)
$ 11,430
20,480
, 32,870
384,340
743,710
Calculated using $0.03/kw-hr and $10.00/hr of labor-
-------
lOOJXDO
2 -
100
4 567891000 234 5678910(000
TOTAL FILTER AREA, ft2
456 789
100,000
10
100
TOTAL FILTER
AREA -m 2
1000
Figure 83. Operation and maintenance requirements for continuous automatic
backwash filters — building energy, process energy, and maintenance material.
186
-------
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Figure 84. Operation and maintenance requirements for continuous
automatic backwash filters - labor and total cost.
187
-------
gas or liquid. Costs for the CC>2 piping and diffusers are included with the
cost of C0£ feed systems. Electrical costs are also included in the costs
for C02 feed systems.
Construction costs are presented in Table 68 and are shown in Figure 85.
EECARBONATION - LIQUID C02 AS C02 SOURCE
Construction Cost
Liquid C02 is often used for recarbonation because of the flexibility of
control, the low maintenance requirement, and the high transfer efficiency.
Carbon dioxide is delivered to the plant site in bulk form, and stored in
pressure vessels. To maintain pressure in the storage tank, liquid C(>2 is
withdrawn from the tank, passed through a vaporizer, and returned as a gas
to the tank. Carbon dioxide gas is withdrawn from the tank, reduced in
pressure to prevent dry ice formation, and fed through a V-notch-type C02
feeder. Generally, a solution-type feeder is used rather than a gas feeder,
since solution feed to the recarbonation basin provides a superior method of
application.
Costs were developed for systems capable of C02 feed rates between 380
and 1,500 Ib/day. The costs include a storage tank with 10 days of storage,
a C02 vaporizer, a solution-type C02 feeder, an injector pump for the solution
water, a stainless steel main header, diffuser pipes for the recarbonation
basin, and an automatic control system using pH measurement for control to
the C02 feeder. One standby C0£ feeder and vaporizer is included for each
installation.
Housing costs are only for the C02 feed and vaporizing equipment. No
provision has been made for the enclosure of the CQ2 storage tank.
Construction costs are shown in Figure 86 and Table 69.
Operation and Maintenance Cost
Process energy requirements are principally for the injector pump and
the C02 vaporizer. Injector pump energy requirements were calculated using
a water requirement of 60 gal/lb of C02 and a total pumping head of 25 psi.
Vaporizer energy requirements were calculated using 1 kw-hr/27 Ib of C02 fed.
Maintenance material requirements were estimated on the basis of
experienced requirements at chlorine feed facilities, which utilize similar
equipment. -
Labor requirements are only for periodic checking and adjustment of the
feeder and vaporizer, since filling of the bulk C02 storage tank is performed
by the tank truck driver.
Maintenance material requirements are summarized in Table 70 and
presented in Figures 87 and 88.
188
-------
Table 68
Construction Cost for
Recarbonation Basin
oo
<£>
Single Basin Volume (ft3)
Cost Category
Excavation and Sitewdrk
Concrete
Steel
Labor
Pipe & Valves
SUBTOTAL
Miscellaneous & Contingency
TOTAL
770
$ 520
1,380
2,250
2,830
90
7,070
1,060
8,130
1,375
$ 620
1,860
3,010
3,800
130
9,420
1,410
10,830
2,750
$ 980
2,820
4,670
5,730
250
14,450
2,170
16,620
5,630
$1,390
4,050
6,560
8,090
480
20,570
3,090
23,660
8,800
$1,790
5,190
8,320
10,240
680
26,220
3,930
30,150
17,600
$3,050
8,570
13,960
16,740
1,360
43,680
6,550
50,230
35,200
$5,570
15,320
25,240
29,730
3,360
79,220
11,880
91,100
-------
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SINGLE BASIN VOLUME-ft 3
-4-
4 5 6789
100,000
(0 100
SINGLE BASIN VOLUME -
1000
Figure 85. Construction cost for recarbonatlon basins.
190
-------
8
7
6
5
4
3
2
7
6
5
4
3
2
1,000, OC
9
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Table 69
Construction Cost for
Recarbonation - Liquid CO, as C02 Source
Installed Capacity (Ib/day)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
380
$27,000
7,650
1,530
7,360
43,540
6,530
50,070
750
$31,000
8,780
2,340
7,360
49,480
7,420
56,900
1,500
$35,250
12,170
4,620
7j360
59,400
.8,910
68,310
3,750
$49,250
17,330
8,710
1,160
82,650
12,400
95,050
7,500
$73,000
28,990
16,940
8,450
127,380
19,110
146,490
15,000
$141,000
58,010
37,540
8,900
245,450
36,820
282,270
-------
\o
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Table 70
Operation and Maintenance Summary for
Recarbonation - Liquid C02 as C02 Source
ailed Capacity
(Ib CO, /day
380
750
1,500
3,750
7,500
15,000
Energy (kw-hr/yr)
Building
10,260
10,260
10,260
10,260
15,390
20,520
Process
7,070
14,020
27,970
66,080
132,220 .,
264,450
Total
17,330
24,280
38,230
76,340
147,610
284,970
Maintenance
Material ($/yr)
$ 2,860
3,300
4,400
5,500
7,700
10,000
Labor
( hr/yr)
91
91
91
182
182
273
Total Cost*
($/yr>
$ 4,290
4,940
6,460
9,610
13,950
21,280
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
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Figure 87
CO2 as
Operation and maintenance requirements for recarbonation - liquid
source - building energy, process energy, and maintenance material.
194
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Figure 88. Operation and maintenance requirements for recarbonation
liquid CC>2 as CO2 source - labor and total cost.
195
-------
RECARBONATION - SUBMERGED BURNERS AS C02 SOURCE
Construction Cost
Sulfur-free fuels such as natural gas, propane, or butane may be combined
with air and burned in a submerged unit to produce carbon dioxide. The
advantages of recarbonation using a submerged burner are the high transfer
efficiency, a high level of control, and a relatively low level of mainten-
ance. The key disadvantage of this form of recarbonation is the need for a
sulfur-free fuel.
Estimated construction costs are based on use of natural gas in submerged
burners. Manufactured equipment included in the costs consists of the stain-
less steel submerged burner assembly, a centrifugal compressor to compress
air for the submerged burner, a pump to supply impingement water to the
submerged burner, and a centralized control panel. Pipe and valving costs are
also included for conveyance of the air/natural gas mixture and the impinge-
ment water to the submerged burner assembly. Instrumentation costs are for
automatic control using an electronic pH recording and control system. For
systems using manual control, instrumentation costs should be deleted.
Generally, the largest capacity used for an individual submerged burner
assembly is 10,000 Ib/day. When greater rates are required, multiple burners
are used. Also, since the burners generally have only a 2:1 delivery range,
the requirement to vary C02 delivery over a greater range will require
multiple burners rather than a single larger burner assembly.
Construction costs are presented in Table 71 and Figure 89.
Operation and Maintenance Cost
Process electrical requirements are for the pump supplying impingement
water at 75 psig and for the air compressor delivering the air/natural gas
mixture to the submerged burner at 9 psig. Natural gas requirements were
based on manufacturers' recommendations.
Maintenance material requirements were estimated at approximately 5
percent/year of initial manufactured equipment costs.
Labor requirements are based on an oil change for the compressor every
100 hr, cleaning the air filter inlet once a month, and performing quarterly
and annual maintenance as recommended by the burner manufacturer.
Operation and maintenance requirements are presented in Figures 90 and
91 and summarized in Table 72.
RECARBONATION - STACK GAS AS C02 SOURCE
Construction Cost
Water-sealed compressors are adequately suited to the compression of
stack gases that have been passed through a wet scrubber. In sizing the
196
-------
VO
Table 71
Construction Cost for
Recarbonation - Submerged Burners as C02 Source
Installed Capacity (Ib/day)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
500
$27,800
9,890
5,000
3,950
46,840
7,000
53,640
1,000
$29,500
10,790
5,880
3,950
50,120
7,520
57,640
3,000
$35,100
12,800
10,650
4,600
63,150
9,470
72,620
5,000
$40,560
14,920
10,650
5,050
71,180
10,680
81,860
8,000
$49,660
18,260
14,400
5,050
87,370
13,110
100,480
10,000
$53,440
19,620
14,400
5,050
92,510
13,880
106,390
-------
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INSTALLED CAPACITY - Ib C02/day
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INSTALLED CAPACITY-kg C02/day
Figure 89. Construction cost for recarbonation - submerged
burners as C02 source.
198
-------
6
5
4
100,000,000
10,000,000
9P-
8
i 7
to 6
§ 5
4
1,000,000
9'
8
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3 4
567891000 234 56789IOpOO
DELIVERY RATE-lb C02/day
3 456 789
100
1000
DELIVERY RATE - kg
1
10,000
Figure 90. Operation and maintenance requirements for recarbonation -
submerged burners as C<>2 source - natural gas, process energy,
and maintenance material.
199
-------
I
6
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6
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DELIVERY RATE-lb C02/day
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34 56789
1000 10,000
DELIVERY RATE-kg C02/day
Figure 91. Operation and maintenance requirements for recarbonation
submerged burners as CC»2 source - labor and total cost.
200
-------
Table 72
Operation and Maintenance Summary for
Recarbonation - Submerged Burners as C02 Source
Installed Capacity
(Ib C0?/day)
500
1,000
2,000
3,000
5,000
8,000
10,000
Process Energy
(kw-hr/yr)
49,020
89,870
126,800
159,480
228,760
294,120
359,480
Natural Gas
(scf/yr)
1,576,800
3,153,600
6,307,200
9,460,800
15,768,000
25,228,800
31,536,000
Maintenance
Material ($/yr)
$1,540
1,760
1,980
2,140
2,310
2,420
2,640
Labor
(hr/yr)
80
80
80
80
80
80
80
• Total Cost*
($/yr)
$5,860
9,360
14,780
20,020
30,470
44,840
55,220
Calculated using $0.03/kw-hr, $0.0013/scf of natural gas, and $10.00/hr of labor.
-------
compressors, consideration should be given to multiple units to allow greater
flexibility in rate of delivery. Flexibility can also be achieved by bleeding
air into the stack gas before compression or by bleeding off a portion of
the compressed COg . Such adjustments should be linked with a pH monitor,
Construction costs were developed for C02 compression systems that
include the compressors, a compressed CC>2 supply line to the recarbonation
basin, diffuser piping in the recarbonation basin, and a pH-controlled feed
system.
Construction costs are summarized in Table 73 and presented in Figure 92.
Operation and Maintenance Cost
Process energy requirements were based on compression of the stack gas
to 8 psi. Where greater pressures are required, appropriate adjustments
should be made in the energy requirements.
Maintenance material costs are for compressor repair parts, valve
maintenance, and maintenance of the electrical components. Labor requirements
are for maintenance of the compressor and related accessories.
Operation and maintenance requirements are summarized in Table 74 and
presented in Figures 93 and 94.
MULTIPLE HEARTH RECALCINATION
Construction Cost
Dewatered lime sludge, 30 to 60 percent solids, may be recalcined in a
multiple hearth furnace. In the furnace, water and carbon dioxide are driven
off from the lime sludge, leaving calcium oxide (quicklime), which may be
slaked and reused. To avoid a buildup of inert solids in the system, it is
necessary to waste a portion of the dewatered lime sludge or the recalcined
lime.
Construction costs for lime-recalcining multiple hearth furnaces include
the basic furnace and its associated screw conveyors, combustion'air systems
and cooling air fan, a stack gas scrubber, and controls. Conceptual designs
for eight furnace configurations for which cost estimates were made are
presented in Table 75.
Construction costs are presented in Table 76 and shown graphically in
Figure 95.
Operation and Maintenance Cost
Process electrical energy costs include the center shaft drive, center
shaft cooling fan, turboblower for burners, product cooler, and an induced
draft fan. No allowance is included for carbon dioxide compressors, which
are included with the stack gas recarbonation curves. Process energy consump-
tion is not significantly affected by feed composition or moisture content.
Building energy requirements are only for lighting and ventilation.
202
-------
Table 73
Construction Cost for
Recarbonation - Stack Gas as C02 Source
Capacity - (lb/C02/day*)
to
o
UJ
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
2,500
$18,280
7,200
1,500
3,000
29,980
4.500
34,480
9,350
$ 32,200
21,170
10,400
10,500
74,270
11,140
85,410
21,700
$ 38,490
24,940
14,080
17,000
94,510
14,180
108,690
50,000
$ 77,500
39,640
21,280
20,500
158,920
23,840
182,760
*Based on a CO concentration in the stack gas of 0.0116 Ib CO /ft3.
-------
i
7
6
5
4
3
2
9
8
6
5
4
3
2
1,000,0
9
8
6
5
4
3
•vt
t *
V)
o
o
IOO.OC
o 1
CONSTRUCT
p
§ ro w * 01
-------
Table 74
Operation and Maintenance Summary for
Recarbonation - Stack Gas as CO Source
K>
O
Ui
Average Feed Rate (Ib GO^/day)
2,500
9,350
21,700
50,000
Process
Energy
(kw-hr/yr )
43,260
161,670
375,370
866,210
Maintenance
Material ($/yr)
$ 2 , 000
3,600
5,200
7,900
Labor
(hr/yr)
100
250
440
750
Total Cost*
( $/yr)
$ 4,300
10,950
20,860
41,390
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
1000
45 678910,000
4 56789100,000 2
4 56789
1000
FEED RATE-lbs C02/ddy
-4-
10,000
FEED RATE-kg C02/day
100,000
Figure 93. Operation and -maintenance requirements for recarbonation - stack
gas as CC>2 source - process energy and maintenance material.
206
-------
100,000
I
7
6
5
4
3
h.
i> 2
i
t-
(O
g IQOC
_j &
C5 "
>- 5
4
3
2
IOOO
9"
8
7
6
5
4
3
2
91
8
7
6
5
4
3
2
7
6
4
0
6
5
4
3
2
IOOO
9
8
- •_ 4
.c
O
- < 2
100
\- 9
7
6
4
V
^
_X
>
X
/
X
s
/
^
*>
r
0f
^
<•
#
/
4
/
v^
X
X
^
X
LA
>
j
X
BO
4
^
/
r
R
1
0
T
t
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T
IOOO 2 345 678910,000 234 56789100,000 2 345 6789
FEED RATE - Ibs C02/doy
io'oo 10,600 106,000
FEED RATE— kg C02/day
Figure 94. Operation and maintenance requirements for recarbonation
stack gas as C02 source - labor and total cost.
207
-------
Table 75
Conceptual Design for
Multiple Hearth Recalcination
o
oo
ffective Hearth
Area (ft2)
179
269
436
548
732
1,050
1,981
2,925
Furnace
9'
10'
12'
14'
16'
18'
22'
22'
Diameter
3"
9"
10"
3"
9"
9"
3"
3"
Number of
Hearths
6
6
6
6 .
6
6
8
12
Housing
(ft2)
400
400
700
750
925
1,050
1,525
1,525
Building
Height (ft)
35
35
35
35
40
40
50
60
-------
Table 76
Construction Cost for
Multiple Hearth Recalcination
to
o
Cost Category
Manufactured
Equipment
Labor
Pipe & Valves
Electrical &
Instrumentation
Housing
SUBTOTAL
Miscellaneous &
Contingency
TOTAL
179
269
Effective Hearth Area (ft2)
—732
436
548
1.050
1.981
2.925
$500,500 $539,000 $693,000 $847,000 $1,001,000 $1,155,000 $1,424,500 $1,694,000
214,500 231,000 297,000 363,000 429,000 495,000 610,500 726,000
9,790 9,790 9,790 9,790 17,030 17,030 17,830 32,160
6,200 6,200 7,650 7,810 9,280 9,940 15,630 16,560
68,300 68,300 98,000 103,000 132,000 146,600 205,400 216,100
799,290 854,290 1,105,440 1,330,600 1,588,310 1,823,570 2,273,860 2,684,820
119,890 128,140 165,820 199,590 238,250 273,540 341,080 402,720
919,180 982,430 1,271,260 1,530,190 1,826,560 2,097,110 2,614,940 3,087,540
-------
CONSTRUCTION COST-
. 10,000,000
10 234 56789100 234 567891000 2000 4 56789
EFFECTIVE HEARTH AREA-ff2 10,000
I 10 100
EFFECTIVE HEARTH AREA-rt»2
Figure 95. Construction cost for multiple hearth recalcination,
210
-------
Natural gas requirements were calculated from manufacturers' recommenda-
tions using a dewatered sludge with a 45—percent solids content. Natural gas
was considered to have a BTU content of 1,000/scf. When No, 2 fuel oil is
utilized rather than natural gas, the number of gallons required can be
calculated from the required BTU's of natural gas.
Maintenance material requirements are for routine repair of motor, drive
assembly, and the refractory material. Labor requirements are principally
for operation rather than maintenance and they are not significantly influenced
by the sludge moisture content.
A summary of operation and maintenance requirements is presented in
Table 77, and these requirements are also shown in Figures 96 and 97.
CONTACT BASINS
Construction Cost
A contact basin-having a detention time of 1 hr is frequently used in
direct filtration plants. The contact basin is normally located between
rapid mix and filtration, and it is intended to even out surges in raw water
turbidity and to serve as a sand trap. The contact basin allows plant
operators to .accommodate sudden turbidity variations, and it also provides
chlorine contact time before filtration. The contact basin is not intended
to remove flocculated turbidity and is not equipped with a sludge collector.
Seasonal draining is normally sufficient to remove collected material.
Costs were developed for open, reinforced concrete contact basins. The
conceptual designs for .the basins were similar to rectangular clarifiers,
with an 11-ft water depth. Costs are presented using single basin volume as
the design parameter, although common wall construction was used in estimating
costs. The construction costs are shown in Figure 98 and Table 78.
PRESSURE DIATOMITE FILTERS
Construction Cost ,
Diatomite filtration, also known as precoat or diatomaceous earth filtra-
tion, is applicable to direct treatment of surface waters or ground waters
for removal of relatively low levels of suspended solids. In a pressure
diatomite filter, the precoat material is applied to a supporting structure
or septum within a pressure vessel, through which the water is passed under
pressure for removal of suspended materials. When the pressure drop makes
it impracticable to continue filtration, the filtering material is washed
from the septum. In contrast to sand filtration, where the sand is washed
and reused, the precoat filtering material is expended to waste, and a
fresh coating is formed for each run. To prevent premature plugging of the
precoat during a filter run, diatomaceous earth is fed continuously at a
controlled rate with the water being treated.
Construction costs have been developed for a series of diatomaceous
earth filter units capable of handling flows ranging from 1 to 200 mgd.
211
-------
Table 77
Operation and Maintenance Summary
for Multiple Hearth Recalcination
Effective Hearth Electrical Energy (kw-hr/yr) Natural Gas Maintenance Labor Total Cost*
(hr/yr) ($/yr)
3,000 $82,640
4,000 100,540
5,300 133,010
6,500 163,390
7,900 196,150
10,000 274,120
15,000 460,400
20,000 736,300
Calculated on the basis of $Q.03/kw-hr, $0.0013/scf, and $10.00/hr of labor.
NJ
1 — i
N3
Area (ft2)
179
269
436
548
732
1,050
1,981
2,925
Building
7,880
7,880
13,790
14,780
18,220
20,690
30,040
30,040
Process
330,000
395,000
500,000
585,000
680,000
850,000
1,400,000
2,680,000
Total
337,880
402,880
513,790
599,780
698,220
870,690
1,430,040
2,710,040
(sc^yr x
28
31.5
42
53
64
100
185
320
W6 ) Material ($/yr)
$ 6,100
7,500
10,000
11,500
13,000
18,000
27,000
39,000
-------
7
6
5
4
3
2
1000
9
8
7
6
0 5
x 4
<: s
•*-
o
w 2
1
100
_j \ 9
< 8
CC 7
=> 6
5 5
2 4
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E
10
9
8
7
6
5
4
3
2
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ioo,c
: |
- "** 4
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< *
cc
_ lil p
H-
IO.OOC
- 9"1
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- i *
- • < 3
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IOOC
9
8
i- 7
5
4
2
10,00
F 9
7
4
3
2
00 I,OC
9
8
s
— CS 5
CE
UJ
z
LU
) IOO.C
9
8
6
4
3
2
I0,0<
f- 9
7
6
5
4
3
2
IOOO
0,000
0,000
«*
500
<
*
30
*
_^
^^
^
J^^
X1
m^^
x^
x*
^
Jt
x
x
-------
a
7
6
5
4
3
2
1,000
6
5
4
< 3
-a»-
1 2
1-
/
^
x
y
X
^
X
/
r
T
L
D'
\\
"i
3(
i
)l
{
COST
100
345 67891000 234 58789IOPOO 2
EFFECTIVE HEARTH AREA- ff2
3 456 789
10
100 1000
EFFECTIVE HEARTH AREA-m2
Figure 97. Operation and maintenance requirements for
multiple hearth recalcination - labor and total cost.
214
-------
9
8
7
6
5
4
3
2
9
B
6
5
4
3
2
1,000,
9
8
7
6
5
4
•*»•
I
1-
C/) o
0 *
O
o 100,0
i_ 9
o 8
=> 7
tc s
i 4
O
3
2
10, os;
300
so
)0
^
X
x
(*"'
^
X
«*
+
s
s
Jfr
^
f
x
^
1000
34 5678910,000 234 56789100,0002
SINGLE BASIN VOLUME- ft3
3 4 56789
1
-4-
100
I0°0
SINGLE BASIN VOLUME -
10,000
Figure 98. Construction cost for contact basins.
215
-------
Table 78
Construction Cost for Contact Basins
Basin Volume (ft3) and Eength and Width (ft)
N>
Cost Category
Excavation and Site-
work
Concrete
Steel
Labor
SUBTOTAL
Miscellaneous &
Contingency
TOTAL
2,640 ft3
30' x 8'
$ 1,250
3,490
5,900
6,960
17,600
2,640
-20,240
10,560 ftd
80' x 12'
$2,680
7,370
12,440
14,390
36,880
5,530
42,410
13,860 ft3
100' x 16'
$3,510
9,690
16,130
18,640
47,970
7,200
55,170
27,720 ftd
140' x 18'
$4,710
12,950
21,480
24,660
63,800
9,570
73,370
39,600 ft*
200' x 18'
$6,320
17,230
28,680
32,700
84,930
12,740
97,670
52,800 ft*
240' x 20'
$7,590
20,710
34,270
38,970
101,540
15,230
116,770
-------
The conceptual designs used to develop these construction costs are presented
in Table 79. A filtration rate of approximately 1.6 gal/min per ft2 of
filter area, in accordance with manufacturers' recommendations, was used to
size the filters. The cost estimates are for a complete installation,
including diatomaceous earth storage, preparation and feed facilities,
pressure filtration units, filter pumps and motors, filter valves, intercon-
necting pipe and fittings, and control panel for automatic operation. The
costs also include complete housing of the filters. Excluded are costs
associated with pretreatment, clearwell storage, and high-service pumping.
Construction costs are presented in Table 80 and also in Figure 99.
Operation and Maintenance Qost
Process energy usage is for filter pumps, backwash pumps, mixers, and
other items associated with the filter system. A cycle time of 24 hr
between backwashes was assumed in developing electrical requirements. The
energy requirements do not include energy associated with raw water or
finished water pumping.
Maintenance material requirements are related primarily to replacement.
of pump seals, application of lubricants, instruments and chemical feed pump
replacement parts, and general facility maintenance supplies. Maintenance
material cost estimates were furnished by manufacturers and are based on
years of experience. Costs for treatment chemicals, including diatomaceous
earth, are excluded. It should be noted that diatomaceous earth is a costly
chemical, and its cost must be included.
Labor requirements were developed assuming that the diatomite filter
installation operates automatically and virtually unattended. Operator
attention is only necessary for preparation of body feed and precoat and for
verification that chemical dosages are proper and that the equipment is
producing a quality filtered water. Ho allowance was included for adminis-
trative or laboratory labor,
Operation and maintenance requirements are summarized in Table 81 and
illustrated in Figures 100 and 101.
VACUUM DIATOMITE FILTERS
Construction Cost
Diatomite filtration, also known as diatomaceous earth or precoat
filtration, can fee used for removal of relatively low levels of suspended
solids from surface or ground waters. In most surface water applications,
pretreatment to remove the major amount of suspended material must be
provided to allow satisfactory and economical operation. Ground waters
containing low to moderate levels of oxidized iron and manganese can be
treated successfully with diatomite filters.
The vacuum diatomite filter is composed of a multiplicity of flat,
rectangular, filtering leaves arranged vertically at uniform spacing within
217
-------
Table 79
Conceptual Design for
Pressure Diatomite Filters
S3
1— "
oo
Plant Flow
(mgd)
1
5
10
100
200
Number of
units
. 2
3
5
18
35
Tank Diameter
(in.)
54
68
68
2-76
2-76
Filter Surface
Area (ft2)
916
3,093
5,155.
. 47,340
92,050
Housing Requirements*
(ft2)"
1,500
2,160
3,000
16,400
31,800
*Assumes that filter equipment is completely housed.
-------
Table 80
Construction Cost for
Pressure Diatomite Filters
Plant Flow (mgd)
r.nsf Cafppnry 1
Excavation & Sitework $ 500
Manufactured Equipment 155,000
Concrete 2,800
Steel 1,550
Labor 40,000
Pipe & Valve, Pumps 7,400
Electrical & Instrumentation 14,300
Housing 19,300
SUBTOTAL 240,850
Miscellaneous & Contingency 36,130
TOTAL 276,980
5
$ 700
330,000
4,000
2,200
78,000
16,800
15,600
42,000
489,300
73,400
562,700
10
$ 1,000
525,000
5,500
3,100
125,000
30,000
62,000
75,000
826.600
123,990
950,590
100
$ 5,400
4,200,000
30,300
16,900
990,000
350,000
1,100,000
362,000
7,054,600
1,058,200
8,112,800
200
,$11,000
. 8., 000, 000
60,000
32,800
1,800,000
700,000
2,200,000
690,000
13,493,800
2,024,070
15,517,870
-------
3 4 5678910 Z 3 4 56789100
PLANT CAPAC!TY-mgd
3456 789
0.1
PLANT CAPACITY-m3/sec
10
Figure 99. Construction cost for pressure diatomite filters.
220
-------
N)
Table 81
Operation and Maintenance Summary
for Pressure Diatomite Filters
Plant Flow
(mgd)
1
5
10
100
200
Energy (kw-hr/yr)
Building Process Total
159,000 125,200 284,200
222,000 626,000 848,000
308,000 1,245,000 1,553,000
1,683,000 11,242,000 12,925,000
3,263,000 23,178,000 26,441,000
Maintenance
Material ($/yr)
$ 1,500
3,000
5,000
35,000
65,000
Labor
(hr/yr)
2,920
5,840
8,760
23,500
35,040
Total Cost*
($/yr)
$ 39,230
86,840
139,190
657,750
1,208,630
Calculated using $0.03/kw-hr and $10.OO/ hr of labor.
-------
100,000
DC
UJ
10,000 10,000,000
o
z
1000
4 5678910 234 5 6 789100
PLANT FLOW RATE-mgd
3 456 789
O.I
1
1.0
PLANT FLOW RATE- m3/sec
10
Figure 100. Operation and maintenance requirements for pressure
diatomite filters - building energy, process energy, and maintenance material,
222
-------
3 4
5678910 234 56789(00
PLANT FLOW RATE-mgd
345 6789
0,1
1
I
PLANT FLOW RATE-mVsec
10
Figure 101. Operation and maintenance requirements for
pressure diatomite filters - labor and total cost.
223
-------
a shallow, open, baffled tank. Each unit is composed of a support structure,
septum, and filtrate collector connected to a submerged suction manifold.
Influent is introduced to each filter unit by gravity at a controlled rate.
A filter pump applying suction to each filter leaf removes collected water
and discharges it to storage or to distribution, depending on system design.
During a normal operating cycle, the porous filter leaves are first precoated
with a layer of diatomaceous earth. The porosity is maintained through the
cycle by continuous application of body feed at a controlled rate along with
influent. Cake discharge is accomplished by stopping flow and draining the
tank, which dislodges the cake from the septum. The dislodged cake is
carried to the plant sewer as the unit is drained.
Construction costs were for a complete installation, including diatoma-
ceous earth storage, preparation and feed facilities, vacuum filtration units,
filter pumps and motors, filter valves, interconnecting pipe and fittings,
and control panel for automatic operation. These costs also include sitework
and excavation within the immediate vicinity of the building, building pre-
treatment, clearwell storage, and high-service pumping. Conceptual designs
used in these cost estimates are shown in Table 82. A filtration rate of
approximately 1 gal/min per ft^ of filter area was used to size filters, in
accordance with manufacturers' recommendations.
Cost estimates for the vacuum diatomite filters are presented in Table
83 and Figure 102.
Operation and Maintenance Cost
Operating and maintenance requirements shown in Table 84 were developed
for the conceptual designs presented in Table 82. The information used to
develop these requirements was furnished by manufacturers and is representa-
tive of minimum operating requirements.
Process electrical energy usage is for filter pumps, backwash pumps,
mixers, and other items associated with the filter.system. A cycle time of
24 hr between backwashes was assumed in developing electrical requirements.
The process energy requirements do not include those associated with raw
water or finished water pumping.
Maintenance material requirements are related primarily to replacement
of pump seals, application of lubricants, instrument and chemical feed pump
replacement parts, and general facility maintenance supplies. Costs for
treatment chemicals, including diatomaceous earth, are excluded.
Labor requirements were developed assuming that the diatomite filter
installation operates automatically and virtually unattended. Operator
attention is only necessary for preparation of body feed and precoat, chemical
feed adjustment, and measurement of product water quality.
The operation and maintenance requirements summarized in Table 84 are
illustrated in Figures 103 and 104.
224
-------
Table 82
Conceptual Design for
Vacuum Riatomite Filters
Plant Flow Total Filter Area Housing Requirements
(mgd) (ft2)* lumber of Units (ft2)
K 1 720 1 740
5 3,060 3 3,500
10 6,120 6 5,600
100 61,200 60 54,000
200 122,400 120 108,000
*Based on a filtration rate of approximately 1 gal/m'in per ft2 of filter surface area.
-------
Table 83
Construction Cost for
Vacuum Diatomite Filters
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
Plant Flow (mgd)
1-
$480
45,000
550
540
30,000
20,500
10,800
22,200
130,070
19,510
149,580
5
$1,040
160,000
2,700
1,500
110,000
77,000
26,000
98,000
476,240
71,440
547,680
10
$3,300
320,000
4,000
3,000
200,000
200,000
46,000
151,200
927,500
139,130
1,066,625
100
$ 27,000
3,000,000
35,000
28,000
1,800,000
1,960,000
450,000
1,300,000
8,600,000
1,290,000
9,890,000
200
$43,000
6,000,000
65,000
56,000
4,000,000
3,900,000
890,000
2,500,000
17,454,000
2,618,000
20,072,000
-------
Z 34 5678910 234 56789KX)
PLANT CAPACITY—mgd
3456 789
-4-
•4-
0.1
1.0 10
PLANT CAPACITY- m3/8CC
Figure 102. Construction cost for vacuum diatomite filters.
227
-------
Table 84
Operation and Maintenance Summary
for Vacuum Diatoraite Filters
t-o
Ni
00
Plant Flow (mj
1
5
10
100
200
?d) Building
75,900
359,100
574,600
5,540,000
11,080,000
Energy (kw-h
Process
64,120
288,360
576,700
5,760,000
11,521,000
r/yr)
Total
140,020
647,460
1,151,300
11,300,000
22,601,000
Maintenance
Material ($/yr)
$ 750
2,400
5,000
40,000
70,000
Labor
(hr/yr)
2,900
5,800
8,800
24,000
35,000
Total Cost*
($/yr)
$ 33,950
79,820
127,540
619,000
1,098,030
^Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
4 5678910 234 56789100
PLANT CAPACITY-mgd
3 456 789
0.1
1
I
PLANT CAPACITY -m3/sec
10
Figure 103. Operation and maintenance requirements for vacuum
diatotnite filters - building energy, process energy, and maintenance material.
229
-------
I
7
6
5
4
1,000,000
V)
o
o
fe
iOO.TOO lOO.OOO
9
8
6
10,000 10,000
3
2
1000
LABOR
TOTAL
3T
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3 4 5678910 234 5 6 789KJO
PLANT CAPACITY-mgd
1
3 456 ?89
r
10
PLANT CAPACITY -m3/sec
Figure 104. Operation and maintenance requirements for vacuum
diatomite filters - labor and total cost.
230
-------
PRESSURE FILTRATION PLANTS
Construction Cost
Costs have been developed for pressure filtration plants that are
suitable for use with 24 to 36-in. deep filter beds consisting of rapid sand,
dual media, or mixed media. Regardless of the media used, structural and
hydraulic requirements of these media are similar. Filtration rates ranging
between 2 and 7 to 8 gpra/ft2 are possible, depending on the media utilized.
Cost estimates are based on use of either vertical or horizontal
cylindrical ASME code pressure vessels of 50 to 75 psi working pressure.
Each plant consists of a minimum of four vessels, with conceptual designs
as shown in Table 85. Filter vessels are provided with a pipe lateral under-
drain, and filter media are supported by graded gravel. This type of under-
drain is suitable for water backwash with surface wash assist. For air-water
backwashing, the pipe laterals are replaced with a nozzle underdrain.
Costs include a complete filtration plant with vessels, cylinder operated
butterfly valves, filter face piping and headers within the filter gallery,
filter flow control and measurement instrumentation, headloss instrumentation,
and a master filter control panel. The filters are designed to backwash
automatically on an input signal such as headloss, turbidity breakthrough, or
elapsed time, or by manual activation. Not included in the cost estimate
are supply piping to the filtration units from other unit processes, filter
supply pumping, backwash storage and pumping, surface wash or airwash supply
facilities, or filtration media. Housing requirements are based on the
minimum rectangular space into which the facilities will fit. The basic
housing includes covering of the pipe gallery (including a small portion of
the ends of the tanks and a minimal service area for control panel) and other
appurtenances related to the filtration structure (except for the 1 mgd plant,
which because of its design and configuration is totally housed). The total
housing requirement is for complete housing of the filters and pipe gallery,
which would only be necessary in the most severe climates.
Estimated construction costs, including only basic housing, are shown
in Figure 105 and in Table 86.
Operation and Maintenance Cost
Energy requirements were developed from the conceptual designs for
process and for heating, lighting, and ventilating the basic housing require-
ment. Process energy is for the filtration system supply pumps and backwash
pumps. Continuous 24 hr/day, 376 day/year operation with one backwash per
day of 10 min duration was assumed. It was further assumed that the surface
wash supply would be obtained from the pressurized distribution system with
suitable means for backflow prevention.
Maintenance material costs are for additional filter media, charts and
ink for recorders, and miscellaneous repair items for electrical control
equipment and valves.
231
-------
Table 85
Conceptual Design for
Pressure Filtration Plants
Filter Vessels
to
UJ
10
Plant Flow
(mgd)
1
10
50
100
200
Total Filter
Area (ft2)*
140
1,400
7,200
14,000
28,000
Number
4
4
18
35
70
Diameter and
Length (ft)
**
10 x 35
10 x 40
10 x 40
10 x 40
Area Plant Area
Each (ft2) Requirements, (ft2)
35
350
400
400
400
2,100
5,000
13,750
26,050
64,200
Housing
+ Basic
2,100
2,000
8,200
14,950
28,500
(ft2)
Total*
2,100
5,000
13,750
26,050
64,200
* Filter rate approximately 5 gpm/ft2.
** Seven foot diameter vertical pressure filters approximately 10 ft tall.
+ Rectangular space covering entire plant area.
§ Entire plant enclosed.
-------
I
7
6
5
4
3
2
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9
8
6
5
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100 234 567891000 234 56789!OpOO 234 56789
FILTER AREA-ff2 IOO.OOO
,„£ * * - -
!0 100 1000
FILTER AREA-m2
Figure 105. Construction cost for pressure filtration plants.
233
-------
Table 86
Construction Cost for
Pressure Filtration. Plants
Plant Capacity(mgd) and Filter Area (ft2)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concret e
Steel
Labor
Piping and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
-Miscellaneous and Contingency
TOTAL
1 mgd,
140 ft2
$ 980
100,670
690
290
9,620
23,630
20,080
65,970
221,930
33,290
255,220
10 mgd,
1,400 ft2
$1,730
250,630
940
500
24,510
70,900
51,720
62,870
463,800
69,570
533,370
50 mgd,
7,200 ft2
$4,050
1,181,820
4,710
2,510
184,990
635,640
298,130
211,620
2,523,470
378,520
2,901,990
100 mgd,
14,000 ft2
$ 7,990
2,485,650
9,410
5,010
369,970
1,271,290
614,310
368,200
5,131,830
769,770
5,901,600
200 mgd
28,000 ft
$ 14,500
4,705,010
17,650
10,020
739,950
2,542,580
1,188,810
686,810
9,905,330
1,485,800
11,391,130
-------
Labor requirements were based on review of records from operating plants.
Table 87 and Figures ,106 and 107 present operation and maintenance costs.
IN-PLANT PUMPING ' ,
Construction Cost •
Construction cost estimates were developed for in-plant pumping facilities
with capacities between 1 and 100 mgd. The pumps'utilized were constant speed,
vertical turbine pumps driven by drip—proof, high-thrust, vertical motors.
The pumps are capable of pumping against total dynamic heads up to about 75 ft.
A standby pump and motor was included for each installation. The estimates
include a wet well and valying and piping to connect the pumps to a common
manifold. Piping was sized for a velocity of approximately 5 ft/second.
The costs that were developed were comparable for systems capable of
pumping against total dynamic heads between 35 and 75 ft. Figure 108 and
Table 88 present the construction cost.
Operation and Maintenance Cost
Process energy requirements were calculated for 35 ft and 75 ft TDH,
using a motor efficiency of 90 percent and a pump, efficiency of 85 percent.
Maintenance material includes repair parts for pumps, motors, valves, and
electrical starters and controls.
Labor requirements are based on operation and maintenance of the pumps,
motors, and valvin'g, plus maintenance of electrical controls.
Figures 109 and 110 present operation and maintenance requirements, and
Table 89 summarizes these requirements.
WASH WATER STORAGE TANKS
Construction Cost
Where topography is favorable, elevated storage tanks may be utilized
to supply filter wash water by gravity flow. Customarily, a minimum of 15 ft
between the top of the filter wash trough and the bottom of the storage tank
is provided, although the wash system hydraulics must be considered in
selection of a minimum elevation difference.
Elevated tanks are erected in the field using factory—formed steel plates.
Costs were developed for cylindrical tanks, 35 ft in overall height and
painted both inside and out. The costs are based on the conceptual designs
presented in Table 90. Tanks are covered and are furnished with access
ladder, manholes, outlet/inlet, drain and overflow nozzles, and handrails
around hatches and on ladders. The tanks are supported on an oil-impregnated
sand cushion and by a concrete ring footing wall. A typical wash water
storage tank is shown in Figure 111. Costs do not include pumping facilities
or pipes for conveyance of water to the storage tank, or between the storage
tank and the filter gallery.
235
-------
N)
W 1
Os *•
10
50
100
200
Table 87
Operation and Maintenance Summary
for Pressure Filtration Plants
Filter
Area (ft2)
140
1,400
7,000
14,000
28,000
Maintenance
Energy (kw-hr/yr) Material
Building
215,460
205,200
841,320
1,533,870
2,924,100
Process
35,597
330,316
1,652,776
3,303,155
6,606,310
Total "
251,057
535,516
2,494,096
4,837,025
9,530,410
($/yr)
$1,280
7,800
27,800
48,110
85,520
Labor
(hr/yr)
1,460
2,920
8,760
11,680
20,440
Total Cost*
$23,410
53,070
190,220
310,020
575,830
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
100,000
I
7
6
5
4
3
2
10,0
INTENANCE MATERIALS - $/yr
n cn-goowO to CM A 01 w-KStf)
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100
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AREA-m2
1000
Figure 106. Operation and maintenance requirements for pressure filtration
plants - building energy, process energy, and maintenance material..
237
-------
§
6
5
4
1,000,000
100,000
9
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100 2345 6789JOOO 234 5678910000 2'
FILTER AREA—ft2
3 456 789
100,000
100
FILTER AREA-m2
•4-
1000
Figure 107. Operation and maintenance requirements for
pressure filtration plants - labor and total cost.
238
-------
8
7
6
5
4
3
2
9
8
6
5
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3
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2 34 5678910 234 56789100 2 34 56789
PUMPING CAPACITY -mgd
o'.i i.'o ib
PUMPING CAPACITY -nr>3 /sec
Figure 108. Construction cost for in-plant pumping.
239
-------
Table 88
Construction Cost for
In-Plant Pumping
Pump ing Cap ac i ty (mgd)
-P-
o
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
1
$ 100
6,300
970
1,610
5,570
5,090
3,170
1,500
24,310
3,650
27,960
5
$100
9,110
970
1,610
10,410
12,330
4,930
1,500
40,960
6,140
47,100
10
$130
14,780
1,510
2,450
24,070
16,300
7,390
3,000
69,630
10,440
80,070
50
$360
48,650
4,770
7,630
63,330
6.0,230
25,760
14,520
225,250
33,790
259,040
100
$ 600
83,400
8,030
12,500
129,130
114,200
47,240
28,830
423,920
63,590
487,510
200
$1,030
152,900
14,090
21,330
331,030
222,080
89,360
58,080
889,900
133,490
1,023,390
-------
3 4 5678910 334 56789100
PUMPING RATE-mgd
3 456 789
O.I
PUMPING RATE-m3/sec
10
Figure 109. Operation and maintenance requirements for in-plant
pumping - process energy and maintenance material.
241
-------
1,000,000
345 6T89IO 2 3456 789WO
PUMPING RATE-mgd
345 6789
0.1
1
i.O
PUMPING RATE-m3/sec
!0
Figure 110. Operation and maintenance requirements for
in-plant pumping - labor and total cost.
242
-------
Table 89
Operation and Maintenance Summary
for In-Plant Pumping
Process_.Energv (kw-hr/yr)
Pumping Rate (mgd)
B i
w
5
1Q
50
100
200
35' TDH
52,470
262,330
524,650
2,623,250
5,246,500
10,493,000
75' TDH
112,430
562,130
1,124,250
5,621,250
11,242,500
22,485,000
Maintenance
Material ($/yr)
$ 350
850
1,600
8,000
15,000
25,000
Labor
(hr/yr)
520
630
740
1,540
2,690
5,130
Total Cost* ($/y
35' TDH
$7,120
15,020
24,740
102,100
199,300
391,090
75' TDH
$8,920
24,010
42,730
192,040
379,180
750,850
*Calculated using $0.03/kw-hr and $10.00/h* of labor.
-------
Table 90
Conceptual Designs for
Wash Water Storage Tanks*
Storage Volume Tank Dimensions (ft)
__ (gal) Diameter"^ Height Number of Tanks
21,000 11 35 1
105,000 24 35 1
450,000 50 35 1
900,000 50 35 2
*Tanks have domed roof, roof and shell access manways, inlet/outlet, drain
overflow and vent-flanged nozzles, and caged access ladder with handrails
around roof manway.
"'Tanks less than 50 ft in diameter are fabricated of field-erected 3/16 in.
plate, 50 ft tanks are fabricated from 1/4 in. tank.
-------
Shell manhole
Shell manhole
Inlet-outlet
Access manhole
ELEVATION
Ring wall •
Slope = VSJ'IZ'-N -
-^
$'<
i -
Slope f ioor @ 1% from
sg. to shell — ^
K L,.. , "•
_, "*"
= ^
' 1
: ,.,ina
<
^
^/
CM
] .
X
'Tank bottom
Figure 111. Typical wash water storage tank.
245
-------
Construction costs are presented for wash water storage tanks in Table
91 and Figure 112.
REVERSE OSMOSIS
Construction Cost
Reverse osmosis utilizes membranes to remove a high percentage of almost
all inorganic ions, turbidity, bacteria, and viruses. Most organic matter
is also removed, with the exception of several materials, including most
halogenated and low molecular weight compounds.
Commercial units are available in sizes up to about 5,000 gpd for the
membrane elements and up to 30,000 gpd for the reverse osmosis modules
(pressure vessels). Therefore, large-scale plants would be composed of many
(small, parallel modules. Components taken into account in the construction
cost estimates include housing, structural steel and miscellaneous metalwork.
tanks, piping, valves, pumps, reverse osmosis membrane elements and pressure
vessels, flow meters, cartridge filters, acid and polyphosphate feed equipment,
and cleaning equipment. The cost curves are based on the use of either
spiral-wound or hollow fine-fiber reverse osmosis membranes.
The efficiency of the membrane elements in reverse osmosis systems may
be impaired by scaling because of slightly soluble or insoluble compounds,
or by fouling as a result of the deposition of colloidal or suspended
materials. Because of this, a very important consideration in the design of
a reverse osmosis system is the provision of adequate pretreatment to protect
the membrane from excessive scaling and fouling and to avoid frequent cleaning
requirements. In the development of the cost curves, adequate pretreatment
was assumed to precede the reverse osmosis process, and costs for pretreatment
are not included in the estimates.
The construction cost curve applies to waters with a total dissolved
solids (TDS) concentration ranging up to about 10,000 mg/1. Other considera-
tions, such as calcium sulfate and silica concentrations and also the desired
water recovery, affect costs more than the influent TDS concentration.
The temperature of the feedwater is assumed to be between 65° and 95°F, and
the pH of the feedwater is adjusted to about 5.5 to 6.0 before the reverse
osmosis process. A single-pass treatment system (only one pass through the
membrane) is assumed, with an operating pressure of 400 to 450 psi. The
assumed water recoveries for different flow ranges are as follows:
Flow Range (mgd); Water Recovery (%)
1 - 10 80
10 - 200 85
Brine disposal costs are not included in the estimates.
Construction costs are presented in Table 92 and also in Figure 113.
246
-------
Table 91
Construction Cost for
Wash Water Storage Tanks
Storage Volume (gal)
to
Cost Category
Excavation & Site Work
Concrete
Steel
Labor
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
21,000
$ 260
130
3,810
4,530
8,730
1,310
10,040
105,000
$ 730
280
15,750
19,760
36,520
5,480
42,000
450,000
$ 1,780
560
49,940
60,440
112,720
16,910
129,630
900,000
$ 3,180
1,120
100,070
116,300
220,670
33,100
253,770
-------
•*}•
10,000
3 4 56789100,0002 3 4 567891^0,0002
STORAGE VOLUME -gallons
4 5 6789
-f-
100,000
1,000,000
STORAGE VOLUME -Lilers
10,000,000
Figure 112. Construction cost for wash water storage tanks.
248
-------
Table 92
Construction Cost for
Reverse Osmosis
Plant Capacity (mgd)
Cost Category 1.0 10 100 200
Manufactured Equipment $474,210 $ 3,458,480 $29,174,260 $56,438,930
Labor 70,420 346,850 2,312,340 2,837,870
Electrical and Instrumentation 65,740 486,270 3,635,690 6,947,480
Housing 64.260 462.650 2.409,660 4.176,740
SUBTOTAL 674,630 4,754,250 37,531,950 70,401,020
Miscellaneous and Contingency 101,190 713.140 5.629.790 10.560.150
TOTAL 775,820 5,467,390 43,161,740 80,961,170
-------
i
6
5
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2 34 5678910 234 56789100
PLANT CAPACITY-mgd
-4-
200 3 456789
10,000
100,000 1,000,000
PLANT CAPACITY - m3/doy
Figure 113. Construction cost for reverse osmosis.
250
-------
Operation andMaintenance Cost
Electrical energy usage is included for the high-pressure feedwater
pumps, based on an operating pressure of 450 psi and on the water recoveries
listed in the construction cost write-up. For other pumps and chemical feed
equipment, an energy usage of 10 percent of the usage for the high-pressure
pumps was assumed. Electrical energy for lighting, heating, and ventilating
was calculated based on an estimated floor area required for complete housing
of the reverse osmosis equipment.
The largest maintenance material requirement is for membrane replacement;
a membrane life of 3 years was used in the cos-t estimates. Other maintenance
material requirements are for replacement of cartridge filters, for membrane
cleaning chemicals, and for materials needed for periodic repair of pumps,
motors, and electrical control equipment. The maintenance material costs
vary from 17.5 c/1,000 gal for plants-above 10 mgd to 25 0/1,000 gal for plants
below 1 mgd. Costs for pretreatment chemicals such as acid and polyphosphate
are not included in the estimates. The chemicals utilized and the dosages
required will show great variability between different water supplies and
should be determined from pilot plant testing.
Labor requirements are for cleaning and replacing membranes, replacing
cartridge filters, maintaining the high pressure and other pumps, preparing
treatment chemicals and determining proper dosages, maintaining chemical feed
equipment, and monitoring performance of the reverse osmosis membranes.
Membrane cleaning was assumed to occur monthly. In estimating labor require-
ments, a minimum of about 1.5 hr/day of labor was assumed for the smallest
plant.
Operation and maintenance requirements are summarized in Table 93 and
illustrated in Figures 114 and 115.
ION EXCHANGE - SOFTENING
Cons truction Cost
Cation exchange resins can be utilized for the removal of not only
hardness, but also other constituents such as barium, trivalent chromium,
lead, manganese, mercury, and radium. Pressure units are generally competi-
tive with gravity units at low capacities, but gravity units are more economi-
cal at higher flows. An advantage of pressurized exchange units is the
capability of pumping through the softener and directly to the clearwell, or
other point, possibly eliminating the need for double pumping.
Facilities were sized on an exchange capacity of 20 kilograins/ft^ and
a hardness reduction of 300 mg/1. Regeneration facilities were sized on the
basis of 150 bed volumes treated before regeneration and a regenerant require-
ment of 0.275 Ib of sodium chloride/kilograin of exchange capacity. The
total regeneration time required in 50 min. Of this time, 10 min is for
backwash, 20 min is for regeneration brine contact time (brining and dis-
placement rinse), and 20 min is a fast rinse at 1.5 gpm/ft3. Feedwater was
251
-------
Ln
Table 93
Operation and Maintenance Summary
for Reverse Osmosis
Plant Capacity Energy (kw-hr/yr)
(mgd )
1.0
10
100
200
Building
105,400
840,000
7,560,000
15,120,000
Process
2,409,000
22,082,500
220,825,000
441,650,000
Total
2,514,400
22,922,500
228,385,000
456,770,000
Maintenance
Material ($/yr)
$ 97,280
748,340
6,831,280
13,683,940
Labor
(hr/yr)
1,840
2,840
6,670
11,550
Total Cost*
($/yr)
$ 191,100
1,464,420
13,749,530
27,502,540
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
1,000,000,000
1
6
5
4
3
2
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MAINTENANCE MATERIAL- $/yr
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Figure 114. Operation and maintenance requirements for
reverse osmosis - building energy, process energy, and maintenance material.
253
-------
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Figure 115. Operation and maintenance requirements for
reverse osmosis - labor and total cost.
254
-------
assumed to be of sufficient clarity to require backwashing only for res,in
reclassification. Backwash pumping facilities and media installation are
included in the construction cost. In-plaee resin costs of $45.00/ft
were utilized.
No facilities are included in the construction cost for spent brine
disposal.
Pressure Ion Exchange Softening—
Construction costs were developed for pressure ion exchange using the
conceptual information presented in Table 94. The contact vessels are
fabricated steel with a baked phenolic lining added after fabrication, and
constructed for 100 psi working pressure. The depth of resin was 8 ft, and
the contact vessel was designed to allow for as much as 80 percent media
expansion during backwash. A gravel layer between underdrains and media
was not included.
Regeneration facilities include two salt storage/brining basins, which
are open, reinforced concrete structures, constructed with the top foot
above ground level. Saturated brine withdrawal from the salt storage/
brining basins is 26 percent by weight. A saturated brine storage of 2.5
days of normal use was provided in the storage/brining basins. Punjping
facilities were included to pump from the brining tanks to the contact
vessels. An eductor is utilized to add sufficient water to dilute the brine
to a 10-percent concentration as it is being transferred from the salt
storage/brining tank to the contact vessel.
Construction costs for pressure ion exchange softening are presented
in Figure 116 and summarized in Table 95.
Gravity Ion Exchange Softening—
Construction costs were developed for gravity ion exchange using the
conceptual designs presented in Table 96. The structures are similar to those
used for gravity filtration, but they have larger influent channels to allow
a higher loading per square foot of surface area and they use an 18-ft wall
depth to allow a loading of 8 gpm/ft2. An 8-ft resin depth was utilized,
and underdrains not requiring an overlying gravel layer were utilized.
Piping was modified from gravity filtration by the addition of a regenerant
line. Facilities included for regenerant storage and dilution to 10 percent
were similar to those described for pressure ion exchange.
Construction costs for gravity ion exchange softening are presented in
Figures 116 and in Table 97.
Operation and Maintenance Cost
Electrical requirements are for regenerant pumping, rinse pumping, backwash
pumping, and building heating, lighting, and ventilation. Backwash pumping
was based on a 10-min wash period at 8 gpm/ft2. Regenerant pumping was based
on a regeneration rate of 7 gal/min per ft3 of resin and a regeneration time of
20 min rinse at a rate of 30 gal/ft3 of media. All pumping was assumed to be
255
-------
Table 94
Conceptual Design for
Pressure Ion Exchange Softening
Total Salt
K> Plant Number of Diameter of Housins St<
Ln
Plant
Capacity (mgd)
1.1
3.7
6.1
12.3
49
122.6
Number of
Contactors
2
3
5
10
40
100
Diameter of
Contactors (ft)
8
12
12
12
12
12
Housing
(ft2)
558
1,232
1,980
3,960
15,840
31,680
Storage - Brining
Capacity (ft3)
918
3,146
5,244
10,488
41,954
104,890
-------
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CAPACITY— m3/day
1,000,000
Figure 116. Construction cost for pressure and
gravity ion exchange softening.
257
-------
03
Table 95
Construction Cost for
Pressure Ion Exchange Softening
Plant Capacity(mgd)
Cost Category
Excavation and Sitework
Manufactured Equipment
Equipment
Resin
Concrete
Steel
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1.1
$ 410
24,830
28,790
1,340
2,130
14,050
15,140
33,190
19,280
139,160
20,870
$160,030.
3.7
$ 820
65,200
97,190
2,640
4,180
32,000
43,210
48,680
35,070
328,990
49,350
378,340
6.1
$ 1,090
110,430
161,980
3,510
5,530
54,450
82,880
81,550
62,220
563,640
84,550
648,190
12.3
$ 2,190
220,160
323,970
7,020
11,060
108,830
165,760
192,210
113,250
1,144,450
171,670
1,316,120
49.0
$ 4,490
880,760
1,295,850
13,860
21,700
407,910
663,030
716,590
390,200
4,394,390
659,160
5,053,550
122.6
$ 9,220
2,203,390
3,238,400
27,850
43,600
1,019,880
1,417,630
1,819,780
763,590
10,543,340
1,581,500
12,124,840
-------
Table 96
Conceptual Design for
Gravity Ion Exchange Softening
Total Salt
Storage and
Plant
Capacity (mgd)
1.5
7.5
15
75
150
Number
of Beds
2
4
4
10
14
. ft2 /Bed
70
175
350
700
1,000
Housing
(ft2)
150
420
800
2,900
4,060
Brining Capacity
(ft 3)
1,300
6,490
12,990
64,930
129,850
-------
Table 97
Construction Cost for
Gravity Ion Exchange Softening
Cost Category
Excavation and Sitework
Manufactured Equipment
Equipment
Resin
Concrete
Steel
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
Plant Flow Rate (mgd)
1.5
$3,670
43,560
40,000
9,270
9,340
22,390
23,140
20,090
17,400
188,860
28,330
217,190
7.5
$6,500
93,880
200,720
21,320
18,120
58,080
64,890
57,620
40,480
561,610
84,240
645,850
15 '
$9,720
146,160
401,010
32,400
25,720
81,250
89,350
57,620
70,590
913,820
137,070
1,050,890
75
$ 33,250
559,210
2,005,070
104,220
92,290
299,240
262,240
148,710
291,940
3,796,170
569,430
4,365,600
150
$ 57,920
1,018,490
4,010,130
139,280
160,410
511,350
393,490
253,260
514,330
7,058,660
1,058,800
8,117,460
-------
against a 25-ft TDK. Feed water pumping costs are not included.
Maintenance material costs for periodic repair and replacement of
components were estimated based on 1 percent of the construction cost. Resin
replacement costs are for resin lost annually by physical" attrition as well
as loss of capacity because of chemical fouling. A 3-percent annual loss of
resin capacity because of physical and chemical causes is typical for cation
resins. In addition, the resin must be completely replaced every 8 to 10
years. To account for this loss of resin and the required replacement, an
annual cost equivalent to 13 percent of the resin cost is also included in
the maintenance material. No costs are included for regenerant.
Labor requirements are for operation and maintenance of the ion exchange
vessels and the pumping facilities. Hours were estimated based on filtration
plants and filter pumping facilities of comparable size. Labor requirements
are also included for periodic media addition and replacement of the media
every 8 to 10 years.
No costs are included for spent brine disposal. Operation and maintenance
requirements are presented in Figures 117 to 120 and are, summarized in Tables
98 and 99 for pressure and gravity ion exchange softening.
PRESSURE ION EXCHANGE - NITRATE REMOVAL
Construction Cost
Strongly basic anion exchange resins may be used for the removal of
nitrates, and also sulfates, fluorides, and some forms of organic and
inorganic mercury. When a strongly basic anion exchanger is operated on the
chloride form, the sulfate is selectively removed over nitrate, and the
nitrate is selectively removed over fluoride. Therefore, the larger the
nitrate-to-sulfate raio, the greater is the nitrate removal capacity of the
resin. Generally, fluoride removal by anion exchange resins is not
considered practical because of the low capacity.
Costs were developed for treatment of a water supply with the following
anion content: nitrate = 100 mg/1; sulfate = 80 mg/1; other anions = 120
mg/1. The assumed nitrate capacity for the strongly basic anion exchange
resin operated on the chloride form was 7 kilograins of nitrate/ft , when
operated to nitrate breakthrough. It must be noted that other quality water
supplies may result in significantly different exchange capacities, and
pilot-scale studies are recommended before design. A sodium chloride
regenerant was utilized, with a regenerant requirement of 15 lb/ft3 resin.
A total regeneration time of 54 min was utilized. Backwash required
10 min, the brine contact and displacement rinse, 24 min, and the fast rinse,
an additional 20 min.
Construction costs were developed for pressure anion exchange, using
fabricated steel contact vessels with a 100-psi working pressure and a baked
phenolic lining. A 6-ft bed depth was utilized, although tanks were sized
for up to 80 percent resin expansion during backwash. A gravel layer between
261
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Flgure 117. Operation and maintenance requirements for pressure ion exchange
softening - building energy, process energy and maintenance material.
262
-------
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PLANT FLOW RATE - m3/day
Figure 118. Operation and maintenance requirements for pressure
ion exchange softening - labor and total cost.
263
-------
g 100,000 1,000,000
Z
3 4 5678910 234 56789100
PLANT FLOW RATE - mgd
200 3456 789
10,000
100,000 1,000,000
PLANT FLOW RATE-m3/day
Figure 119. Operation and maintenance requirements for gravity ion exchange
softening - building energy, process energy, and maintenance material.
264
-------
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7
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So"
100,000
PLANT FLOW RATE-mVday
1,000,000
Figure 120. Operation and maintenance requirements for gravity
ion exchange softening - labor and total cost.
265
-------
ho
Table 98
Operation and Maintenance Summary
for Pressure Ion Exchange Softening
Plant Flow
Rate (ragd)
1.1
3.7
6.1
12.3
49
122.6
Energy (kw-hr/yr)
Building
57,250
126,400
203,150
406,300
1,625,180
3,250,370
Process
2,270
7,620
12,570
25,350
100,970
252,630
Total
59,520
134,020
215,720
431,850
1,726,150
3,503,000
Maintenance
Material
(S/yr)
$ 5,010
16,190
- 26,770
53,260
211,560
523,070
Labor
(hr/yr)
2,160
2, 700
3,000
3,400
6,900
13,600
Total Cost*
($/yr)
$28,400
47,210
63,240
100,210
332,340
764,160
*Calculated using $0,03/kw-hr and $10.00/hr of labor-
-------
OH
Table 99
Operation and Maintenance Summary
for Gravity Ion Exchange Softening
Plant Flow
Rate (mgd)
1.5
7.5
15
75
150
Energy (kw-hr/yr)
Building Process
44,120 1,470
151,850 7,370
279,070 14,730
1,190,160 73,700 1
2,165,890 147,310 2
Total
45,590
159,220
293,800
,263,860
,313,200
Maintenance
Material
( $/yr )
$ 7,440
' 32,810
63,120
306,640
607,100
Labor
(hr /yr )
2,230
3,090
3,570
9,600
17,460
Total Cost*
($/yr)
$ 31,110
68,490
107,630
440,560
851,100
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
the resin and the underdrains was not utilized. Resin placement and backwash
pumping costs are included in the construction cost.
Regeneration facilities include two salt storage/brining basins, which
are open, reinforced concrete structures constructed with the top foot above
ground level. Saturated brine withdrawn from the salt storage/brining basins
is 26 percent by weight. A saturated brine storage of 2.5 days normal use
was provided in the storage brining/basins. Pumping facilities were included
to pump from the brining tanks to the contact vessels. An eductor is
utilized to add sufficient water to dilute the brine to a 10 percent concen-
tration as it is being transferred from the salt storage/brining tank to the
contact vessel.
Conceptual designs that were used to estimate costs are presented in
Table 100.
Table 100
Conceptual Designs for
Pressure Ion Exchange Nitrate Removal
Plant Capacity Diameter of
(mgd) Number of Contactors Contactors (ft) Housing (ft2)
1.2 2 8 930
3.9 3 12 2,375
6.5 5 12 3,910
13 10 12 6,920
No facilities are included in the construction cost for disposal of
spent regenerant. Construction costs for pressure ion exchange nitrate
removal are presented in Figures 121 and summarized in Table 101.
Operation and Maintenance Cost
Electrical energy costs are for backwash pumping, rinse pumping, regen-
erant pumping, and building heating, lighting, and ventilation. Backwash
pumping was based on a 10-min wash at 3 gpm/ft2. Regenerant pumping was
based on a rate of 1 gal/min per ft3 of resin for 24 min, and fast rinse
pumping was based on a rate of 8 gal/min per ft2 for 20 min. All pumping
was assumed to be against a 25 ft TDH.
Maintenance material costs for periodic repair and replacement of
components were estimated based on 1 percent of the construction cost. Resin
replacement costs are for resin lost annually by physical attrition as well
as loss of capacity as a result of chemical fouling. As anion resin is
typically replaced every 3 to 5 years, a 25 percent annual resin replacement
was included to account for resin fouling and resin loss. Regenerant costs
are not included in the maintenance material cost.
Labor requirements are for operation and maintenance of ion exchange
vessels and the pumping facilities. Hours were estimated based on filtration
268
-------
9
8
7
6
5
10,000,000
v>
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-t-
4 5678910 234 56789100
CAPACITY- mgd
-4-
200 3 456789
1
10,000
100,000
CAPACITY-m3/day
Figure 121. Construction cost for pressure ion exchange
nitrate removal.
269
-------
Table 101
Construction Cost for
Pressure Ion Exchange Nitrate Removal
_Cost Category
Excavation and Sitework
Manufactured Equipment
Equipment
Media
Concrete
Steel
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
Plant Capacity (mgd)
1.1
$ 740
39,960
92,790
2,410
3,830
17,420
14,040
27,700
21,920
220,810
33,120
253,930
3.7
$ 1,140
89,580
313,160
3,580
5,680
33,510
38,780
38,510
35,660
559,600
83,940
643,540
6.1
$ 1,470
137,770
521,940
4,750
- 7,530
61,460
69,740
60,820
57,440
922,920
138,440
1,061,360
12.3
$ 1,970
258,230
1,043,880
6,320
9,950
125,080
139,480
120,210
79,820
1,784,940
267,740
2,052,680
-------
plants and filter pumping facilities of comparable size. Labor requirements
are also included for periodic media addition and replacement of the media
every 4 years.
No costs are included for spent brine disposal. Operation and maintenance
curves are presented in Figures 122 and 123 and are summarized in Table 102.
ACTIVATED ALUMINA FOR FLUORIDE REMOVAL
Construction Cost
Water supplies with fluoride concentrations of 10 mg/1 or greater can
be effectively treated by contact with activated alumina. Fluoride reductions
to less than 0.5 mg/1 are generally achieved by activated alumina contact,
with blending being utilized to meet desired fluoride concentrations. Treat-
ment is generally selective for fluoride and arsenic, although small amounts
of other anions often are removed. Regeneration of the activated alumina
with caustic removes both exchanged fluoride and arsenic.
Facilities were sized based on a fluoride exchange capacity of 0.6
percent by weight, or 0.25 Ib of fluoride/ft3 of activated alumina, and a
fluoride reduction from 3 to 0.5 mg/1. Operation was assumed to be at pH 5.5,
although higher pH values may be used with a resulting lower exchange capacity.
The cost of pH adjustment, if required, is not included and must be added
separately. Regeneration facilities were sized on the basis of batch rather
than continuous regeneration, because of the significant savings in regenera-
tion chemical cost when batch regeneration is utilized. However, a reduced
capacity of the facilities results from the increased regeneration time.
Two 1-hr contacts with 0.1 N sodium hydroxide were included for fluoride
removal from the alumina, followed by a 1/2-hr contact with 0.05 N sulfuric
acid for neutralization of remaining caustic. An activated alumina void
volume of 2.28 gal/ft3 and in-place resin costs of $13.86/ft3 were utilized.
Feed water was assumed to be sufficiently low in suspended solids so that
backwashing was only occasionally necessary, although backwashing facilities
are included in the construction cost.
Construction costs were developed for activated alumina ion exchange
using the conceptual information presented in Table 103. The contact vessels
are fabricated steel with a baked phenolic lining; they are constructed for
100 psi working pressure. The depth of resin was 10 ft, and the contact
vessel was designed for 80 percent media expansion during backwash. A gravel
layer between underdrains and media was not included.
Regeneration storage facilities were sized for a 30—day requirement.
Sodium hydroxide required for regeneration was assumed to be purchased in a
solid form for capacities less than 10 mgd, and as a 50 percent solution for
larger plants. A caustic dilution tank was included when the 50-percent
solution was used. Because of the small requirement for sulfuric acid, a
concentrated sulfuric acid storage tank was only included for 70 mgd and
larger plants, although a sulfuric acid dilution tank was included in each
case. Metering pumps were included for transfer of concentrated caustic
and sulfuric acid to the dilution tanks, and pumping facilities were included
to pump from the dilution tanks to the exhausted contactor.
271
-------
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4 5678910 234 56789100
PLANT FLOW RATE - mgd
200 3 456 789
10,000
100,000
PLANT FLOW RATE-m3/day
Figure 122. Operation and maintenance requirements for pressure ion exchange
nitrate removal - building energy, process energy, and maintenance material.
272
-------
$
7
6
5
4
3
2
1,00
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100
9
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8 3
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6
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9
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9
8
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IR
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r
10,000
3 4 5678910 234 56789100
PLANT FLOW RATE-mgd
-4-
200 3 456 789
100,000
PLANT FLOW RATE - tn3/day
Figure 123. Operation and maintenance requirements for pressure
ion exchange nitrate removal - labor and total cost.
273
-------
Table 102
Operation and Maintenance Summary for
Pressure Ion Exchange Nitrate Removal
Maintenance
Plant Enerev fkw-hr/vr")
NJ
Plant
Capacity (mgd)
1.1
3.7
6.1
12.3
Energy (kw-hr/yr)
jBuilding
56,090
126,400
203,150
313,960
Process
1,900
6,380
10,510
21,200
Total
57,990
132,780
213,660
335,160
Material
($/yr)
/$ 25,770
85,240
141,830
283,000
Labor
(hr/yr)
2,200
2,500
3,000
3,300
Total Cost*
$49,510
114,220
178,240
326,050
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Table 103
Conceptual Design for
Activated Alumina for Fluoride Removal
Diameter of
Plant Capacity (mgd) Number of Contactors Contactors (ft) Housing (ft2)
0.7 2 6 252
2.0 2 10 700
6.8 5 12 1,980
27 20 12 7,920
54 40 12 15,840
135 100 12 31,680
275
-------
All facilities were assumed to be located indoors. Construction costs
are presented in Table 104 and in Figure 124.
Operation and MaintenanceCost
Electrical energy costs' are for regenerant pumping, occasional backwash
pumping, and building heating, ventilation, and lighting. The latter require-
ments constitute the majority of the energy requirements. Use of an outdoor
installation would have a very significant impact on energy requirements.
Process energy is extremely small, as it is used only for regenerant pumping.
If backwash were required, process energy requirements would increase
significantly.
Maintenance material costs are for periodic repair and replacement of
components, and they were estimated on the basis of 1 percent of the construc-
tion cost. An activated alumina replacement cost was also included in
maintenance material, at an annual rate of 10 percent. Regenerant costs are
not included in the maintenance material costs.
Labor requirements are principally for regenerant preparation and
regeneration of the activated alumina. Labor requirements also include
periodic media addition to make up losses and occasional replacement.
Operation and maintenance curves are presented in Figures 125 and 126
and summarized in Table 105.
GRAVITY CARBON CONTACTORS - CONCRETE CONSTRUCTION
Construction Cost
Concrete gravity carbon contactors are essentially identical to gravity
filtration structures, and the same conceptual layout was used for both.
Costs were developed for carbon bed depths of 5 ft and 8.3 ft, which provide
empty bed contact times of 7.5 and 12.5 min, respectively, at an application
rate of 5 gpm/ft2.
Carbon removal from the contactor is accomplished using a series of
troughs located at the carbon/support gravel interface. The carbon slurry
is then pumped to dewatering and regeneration facilities. Carbon removal
troughs and piping were sized to maintain a velocity of 3 ft/second with
a carbon slurry of 3 Ib carbon/gal. The troughs, each of which have plug
style valves, are manifolded into a spent carbon transfer system.
Regenerated carbon is transported through a similar piping system.
The costs presented are for a complete carbon contacting facility,
including the contactor structure, cylinder-operated butterfly valves,
liquid and carbon handling piping with headers in a pipe gallery, flow
measurement and other instrumentation, master operations eontrol panel and
building. Housing requirements were developed assuming that the entire
carbon contactor structure is enclosed.
276
-------
-•J
•"•4
Table 104
Construction Cost for
Activated Alumina for Fluoride Removal
Plant Capacity (mgd)
Cost Category
Manufactured Equipment
Equipment
Activated Alumina
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
0.7
$26,760
8,300
10,280
16,260
10,050
6,960
78,610
11,790
90,400
2.Q
$ 44,580
14,770
13,490
19,320
11,360
27,630
131,150
19,670
150,820
6,8
$ 138,330
83,080
48,010
69,030
22,300
62,120
422,870
63,430
486,300
27
$ 522,210
332,310
192,020
273,210
60,300
210,980
1,591,030
238,650
1,829,680
54
$ 1,031,270
664,610
384,060
542,650
119,030
374,840
3,116,460
467,470
3,583,930
135
$2,564,560
1,661,530
1,282,370
1,368,060
284,750
744,320
7,905,590
T, 185, 840
9,091,430
-------
g
7
6
5
4
3
2
I0,00(
1
6
5
4
3
2
1,000
9
S
6
5
4
3
2
I00,(
9
8
7
6
5
4
3
2
10,0
*
3,000
,000
iogs
-------
1,000,000
§
7
6
5
4
3
2
100,0
NTENANCE MATERIAL - $/yr
O
"o
o
u -t> ui o>-goou> o ro cu * en o>-w«>
< *
2
2
1000
7
6
5
4
3
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7
6
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3
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r Hi
6
4
3
1,000
9
8
:
-------
I
6
5
4
1,000,000
100,000
9
8
I
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5
en
O
o
I
100.000
9
8
6
5
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10,000 10,000
-*
8
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TOTAL
L/SBOFI
C05iT
1 2345 678910 2 3456 789100 200 3 456 789
PLANT FLOW RATE - mgd
10,000
100,000 1,000,000
PLANT FLOW RATE-m3/day
Figure 126. Operation and maintenance requirements for activated
alumina for fluoride removal - labor and total cost.
280
-------
Table 105
Operation and Maintenance Summary for
Activated Alumina for Fluoride Removal
to
00
Plant Capacity Energy (kw-hr/yr)
(mgd)
0.7
2.0
6.8
27
54
135
Building
17,640
49,000
138,600
554,400
1,108,800
2,217,600
Process
40
100
350
1,410
2,820
7,050
Total
17,680
49,100
138,950
555,810
1,111,620
2,224,650
Maintenance
Material
($/yr)
$ 1,900
3,250
15,000
59,500
118,800
297,930
Labor
(hr/yr)
2,400
2,580
2,940
4,490
7,560
17,580
Total Cost*
($/yr)
$26,430
30,520
48,570
121,070
227,750
540,470
Calculated using $O.Q3/kw-hr and $10.00/hr of labor.
-------
Not included in the cost estimate for the carbon contactor are backwash
pumping, the initial activated carbon charge, spent or regenerated .activated
carbon handling outside of the contactor pipe gallery, and carbon regeneration
and preparation facilities. Separate curves are presented for these costs.
In developing construction costs, it was assumed that all carbon in a
contactor would be removed and replaced with regenerated carbon in a single
operation. This handling method requires that regeneration facilities be
designed to store both spent and regenerated carbon in quantities equal
to the amount in one contactor.
Estimated construction costs are presented in Tables 106 and 107 and in
Figure 127.
Operation and Maintenance Cost
Building energy requirements are for building heating, ventilation, and
lighting. Process energy is required for backwash pumping and carbon slurry
pumping during carbon removal and replacement. The backwash frequency was
assumed to be once/day for 10 min at 12 gpm/ft2. For carbon removal, a
regeneration frequency of every 2 months and a slurry concentration of 3 Ib
of carbon/gal of watdr were utilized. Process energy requirements are
virtually identical for the two different carbon bed depths.
Maintenance material costs include the cost of general supplies, backwash
and carbon transport pump maintenance, instrumentation repair, and other
miscellaneous items. The cost for replacement of carbon lost during contactor
operation and carbon regeneration is not included in the maintenance material
costs.
Labor costs include the cost of operating the contactors, the backwash
pumps, and the carbon slurry pumps, as well as the cost of instrument and
equipment repairs and supervision.
Figures 128 and 129 present the operation and maintenance requirements,
and Table 108 summarizes these requirements.
GRAVITY CARBON CONTACTORS - STEEL CONSTRUCTION
Construction Cost
i
For carbon treatment facilities requiring in excess of about 30,000
of carbon contact volume, the use of large-diameter, field-erected, steel
gravity contactors may offer an economic advantage over smaller diameter,
factory-built, pressure carbon columns. Costs were developed for 20 ft and
30 ft-diameter steel, gravity contactors, using the conceptual design
information in Table 109. A carbon bed depth of 20 ft, with an overall
vessel height of 35 ft, was used in the cost analysis. The units are
designed for down—flow operation, and the system hydraulics were sized
using an application rate of 5 gpm/ft2, which provides a 30 min empty bed
contact time.
282
-------
Table 106
Construction Cost for Concrete Gravity Carbon Contactors
7.5 min Empty Bed Contact Time and 5 ft Bed Depth
Total Contactor Volume (ft3) and Area (ft2)
KJ
O3
w
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
Volume/Single
Contactor
COST/SINGLE
Contactor
700 ft*
140 ft2
$ 1,660
29,000
12,330
10,630
37,330
33,570
. 14,730
17,400
156,650
23,500
180,150
350 ft?
$90,070
3,500 ft*
700 ft2
$ 3,050
62,660
24,880
18,360
81,410
108,700
42,250
40,480
381,790
57,270
439,060
875 ft3
$109,770
7,000 ft*
1,400 ft2
$ 4,660
. 86,130
38,330
27,710
138,800
206,130
42,250
70,590
614,600
92,190
706,790
1,750 ft3
$176,700
35,000 ftd
7,000 ft2
$ 13,670
335,690
87,850
67,650
327,870
597,380
109,050
291,940
1,831,100
274,670
2,105,770
3,500 ft3
$210,580
70,000 ft3
14,000 ft2
$ 21,600
582,300
142,410
113,300
468,260
863,970
185,720
514,330
2,891,890
433,780
3,325,670
5,000 ft3
$237,550
140,000 ftd
28,000 ft2
$ 36,630
1,080,360
253,520
193,160:
920,890
1,463,150
291,840
968,520
5,208,070
781,210
5,989,280
6,360 ft3
$290,460
-------
to
oo
Table 107
Construction Cost for Concrete Gravity Carbon Contactors
12.5 Empty Bed Contact Time and 8.3 ft Bed Depth
Total Contactor Volume (ft3) and Area (ft2!
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
Volume/Single
Contactor
COST/SINGLE
Contactor
1,160 ftd
140 ft2
$ 2,220
29,000
15,010
12,940
45,450
33,570
14,730
17,400
170,320
25,550
195,870
580 ft3
5,810 ftd
700 ft2
$ 4,080
62,660
30,300
20,690
99,170
108,700
42,250
40,480
408,330
61,250
469,580
1,450 ft3
11,620 ft*
1,400 ft2
$ 6,210
86,130
51,180
38,800
168,990
206,130
42,250
70,590
670,280
100,540
770,820
2,905 ft3
58,100 ftd
7,000 ft2
$ 18,240
335,690
111,090
82,360
399,150
597,380
109,050
291,940
1,944,900
291,740
2,236,640
5,810 ft3
116,200 ftd
14,000 ft2
$ 28,800
582,300
180,500
137,940
570,050
863,970
185,720
514,330
3,063,610
459,540
3,523,150
8,300 ft3
232,400 ft*
28,000 ft2
$ 48,770
1,080,630
308,640
235,150
1,159,990
•1,463,150
291,840
968,520
5,556,690
833,500
6,390,190
10,560 ft3
$97,940
$117,400
$192,710 $223,660
$251,650
$290,460
-------
1,000,000
-w-
I
h-
co
o
o
o
Z>
a:
t/5
z
o
o
100
4 567891000 234 56789IOpOO 2 3
INDIVIDUAL CONTACTOR VOLUME-ft3
456 789
100,000
10
100 1000
INDIVIDUAL CONTACTOR VOLUME-m3
Figure 127. Construction cost for gravity carbon contactors
concrete construction.
285
-------
100,000
7
6
5
ec
UJ
£ 10,000 1,000,000
Ul
tJ
<
z
LU
1,000
9"
8
7
6
5
_ i
100000
Jtt
t 3
o
S 2
z
u
10,000
9
1000
1000
234 5678910,000 234 56789100,000 234 56789
TOTAL CONTACTOR VOLUME -FT3 Ip
-4-
•^-
100 1000
TOTAL CONTACTOR VOLUME - m3
-f-
10,000
Figure 128. Operation and maintenance requirements for
concrete gravity carbon contactors - building energy, process energy,
and maintenance material needed for 7.5 and 12.5 min empty bed contact times.
286
-------
1000
3 4 5 6789IOPOO 234 56789100,0002
TOTAL CONTACTOR VOLUME -ff3
456 789
1,000,000
100 1000
TOTAL CONTACTOR VOLUME -m3
10,000
Figure 129. Operation and maintenance requirements for concrete gravity
carbon contactors - labor and total cost needed for
7.5 and 12,5 min empty bed contact time.
287
-------
Table 108
Operation and Maintenance Summary for
Gravity Carbon Contactors
oo
Maintenance
Total
Contactor
Volume (ft3)
700
3,500
7,000
35,000
70,000
140,000
1,160
5,810
11,620
58,200
116,200
232,400
Electrical
Building
7.5 min
44,120
151,850
279,070
1,190,160
2,165,890
4,123,490
12.5 min
44,120
151,850
279,070
1,190,160
2,165,890
4,123,490
Energy (kw-hr/yr)
Process
empty bed
690
3,410
6,820
34,080 1
68,150 2
136,540 4
empty bed
690
3,410
6,820
34,080 1
68,150 2
136,540 4
Total
contact time,
44,810
155,260
285,890
,224,240
,234,040
,260,030
contact time,
44,810
155,260
285,890
,224,240
,234,040
,260,030
Material
($/yr)
5 ft bed
800
2,510
4,020
13,200
21,600
36,700
Labor
(hr/yr)
depth
900
1,500
2,100
4,600
9,000
18,000
Total Cost*
($/yr)
11,140
22,170
33,600
95,930
178,620
344,500
8.3 ft bed depth
800
2,510
4,020
13,200
21,600
36,700
900
1,500
2,100
4,600
9,000
18,000
11,140
22,170
33,600
95,930
178,620
344,500
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
Table 109
Conceptual Design for Steel Gravity Carbon Contactors
20-ft Gar'bon Bed Depth
Plant
Flow
(mgd)
10
50
100
200
Total Contactor
Bed Area ( ft2)
20' diam.
1,570
7,850
15,700
31,400
30' diam.
—
7,065
14,130
28,260
Number of
Contactors
20' diam.
5
25
50
100
30' diam.
—
10
20
40
Total Carbon
Volume (ft3)
20' diam.
31,400
157,000
314,000
628,000
30' diam.
—
141,300
282,600
565,200
Plant Area
Requirements (ft2)
20' diam. 30' diam.
6,500
33,000
66,000
126,000
—
26,000
50,000
95,000
-------
The vessels are constructed of factory—formed steel plates erected at
the jobsite. Units are provided with a nozzle-style underdrain, eliminating
the need for a supporting gravel layer. Carbon is removed from each contactor
as required for regeneration through multiple carbon drawoff pipes in the
underdrain support plate. Regenerated carbon is returned through a piping
system to the top of each contactor.
The costs presented are for a complete carbon contacting facility,
including vessels, face and interconnecting piping, access walkways, cylinder-
operated butterfly valves on all hydraulic piping and manually operated
ball or knife-type valves on carbon handling system, flow control and other
instrumentation, master operations control panel, and a building to house the
contactors completely.
Not included in the construction costs are carbon contactor supply
pumping, surface wash and backwash pumping, the initial activated carbon
charge, spent or regenerated carbon handling facilities (exclusive of piping
within the contactor building), or carbon regeneration or preparation
facilities. Curves for estimating the costs for these facilities are
presented separately.
Estimated construction costs for gravity carbon contactors are presented
in Tables 110 and 111 for 20 ft and 30 ft diameter units, respectively.
Figures 130 shows the construction cost curve for gravity carbon contactors.
Operation and Maintenance Cost
Building energy requirements are for building heating, ventilation,
and lighting. Process energy is required for the backwash pumping and carbon
slurry pumping during carbon removal and replacement. The backwash frequency
was assumed to be once/day for 10 min at 12 gpm/ft2. For carbon removal, a
regeneration frequency of every 2 months and a slurry concentration of 3 Ib
of carbon/gal of water were utilized.
Maintenance material costs include the cost of general supplies, backwash
and carbon transport pump maintenance, instrumentation repair, and other
miscellaneous items. The cost for replacement of carbon lost during contactor
operation and carbon regeneration is not included in the maintenance material
costs. A separate curve is provided for makeup carbon, and this cost must be
added separately.
Labor costs include the cost of operating the contactors, the backwash
pumps, and the carbon slurry pumps, as well as the cost of instrument and
equipment repairs and supervision.
Figures 131 and 132 present the operation and maintenance requirements,
and Table 112 summarizes these requirements.
290
-------
Table 110
Construction Cost for Steel Gravity Carbon Contactors
20-ft Diameter Tanks
Total Contactor Volume
Cost Category
Excavation and Sitework-
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
•Miscellaneous and Contingency
TOTAL
VOLUME/SINGLE
CONTACTOR
COST/SINGLE
CONTACTOR
31,400 ft3
$ 2,050
340,970
7,650
3,810
66,220
140,730
n 50,460
169,000
780,890
117,130
898,020
6,280 ft3
157,000 ftd
$ 6,560
1,619,750
27,470
14,040
314,270
675,500
207,800
792,000
3,657,390
548,610
4,206,000
6,280 ft3
314,000 ftd
$11,600
3,170,980
47,290
24,370
584,390
1,437,110
406,820
1,584,000
7,266,560
1,089,980
8,356,540
6,280 ft3
628,000 ft3
$21,760
6,137,800
91,580
45,690
1,075,550
2,644,620
787,250
3,024,000
13,828,250
2,074,240
15-902,490
6,280 ft3
$179,600
$168,240 $167,130 $159,020
-------
NJ
Table 111
Construction Cost for Steel Gravity Carbon Contactors
30-ft Diameter Tanks
Total Contactor Volume
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
VOLUME/SINGLE
CONTACTOR
.— "
141,300 ft*
$ 7,150
1,327,160
29,680
15,230
263,820
565,490
170,640
624,000
3,003,170
450,480
3,453,650
14,140 ft3
282,600 ft*
$ 13,140
2,595,980
56,180
28,690
488,740
1,092,710
332,910
1,200,000
5,808,350
871,250
6,679,600
14,140 ft3
565,200 ftd
$ 25,020
5,139,970
111,290
55,180
942,800
2,111,020
659,530
2,280,000
11,324,810
1,698,720
13,023,530
14,140 ft3
COST/SINGLE
CONTACTOR $ 345,370 $ 333,980 $ 325,590
-------
I
7
e
5
4
3
2
9
8
6
5
4
3
a
1,000,00
-m- 9
7
6
O K
0 5
4
z
2 3
fe
i ~ 2
OT
Z
8 100,0
9
8
7
6
5
4
3
2
0
00
x
/
/
/
J
*
t
S
/
S
x
r
1000 2 345 678910,000 234 56789100,000 2 3 4 5 6789
INDIVIDUAL CONTACTOR VOLUME -ft 3
100
1000 10,000
INDIVIDUAL CONTACTOR VOLUME- n»3
Figure 130. Construction cost for steel gravity carbon contactors.
293
-------
100,000
•«*
I
u
10,000
u
u
1,000,000
Ul"
10,000
45 6789100,0002 3 4 5 6 ?89IpOO,000
TOTAL CONTACTOR VOLUME - ff3
345 6789
1000 10,000
TOTAL CONTACTOR VOLUME -
100,000
Figure 131. Operation and maintenance requirements for steel gravity carbon
contactors - building energy, process energy, and maintenance material.
294
-------
-w-
I
H
V)
o
o
8
6
5
4
3
2
,000.
f
6
5
4
3
2
IOO.C
9'
8
7
6
5
4
3
2
IO.OC
7
6
5
4
3
2
- £
7
6
5
4
3
2
000
: *
6
5
3
)00 IOC
p 9
8
6
5
4
3
2
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9
8
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x^
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r
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/
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y
r
/
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TOTAL
LABOF
C
l
OS
T
10,000 2 34 56789100,0002 3 4 567891,000,0002
TOTAL CONTACTOR VOLUME -ff3
3 4 56789
1000
TOTAL
10,000 100,000
CONTACTOR VOLUME -m3
Figure 132. Operation and maintenance requirements for steel
gravity carbon contactors - labor and total cost.
295
-------
to
VO
Table 112
Operation and Maintenance Summary
for Steel Gravity Carbon Contactors
Contactor
Diameter (ft)
20
20
20
20
30
30
30
Carbon
Volume (ft3)
31,400
157,100
314,000
628,000
141,300
282,600
565,200
Electrical
Building
666,900
3,385,800
6,771,600
12,927,600
2,668,000
5,130,000
9,750,000
Energy
Process
12,030
60,170
120,340
240,680
54,150
108,300
216,600
( kw-hr/yr)
Total
678,930
3,445,970
6,891,940
13,168,280
2,722,150
5,238,300
9,966,600
Maintenance
Material
($/yr)
5,350
21,380
37,420
69,490
16,040
26,730
42,760
Labor
(hr/yr)
3,000
7,000
14,000
27,000
6,800
13,500
26,000
Total Cost*
($/yr)
55,720
194,760
384,180
734,540
165,700
318,880
601,760
*Galculated using $O.Q3/kw-hr and $10.00Ar of labor.
-------
PRESSURE CARBON CONTACTORS
Construction Cost
Construction costs were developed for pressure granular activated
carbon contactors constructed of shop-fabricated steel tankage. Bed depths
of 5, 10, and 20 ft were used, which provide empty bed contact times of
7.5, 15, and 30 min at a hydraulic loading rate of 5 gpm/ft2. Conceptual
design information is shown in Table 113, and a typical layout for pressure
carbon contactors is shown in Figure 133. The practical upper limit for
pressure carbon contactors is generally in the range of 20 to 25 mgd.
The cost for the steel contactors was based on pressurized downflow
operation using cylindrical ASM! code pressure vessels with a design working
pressure of 50 psi. Vessels used were either 10 ft or 12 ft in diameter by
14, 23, and 33 ft in overall height. Carbon contactors are furnished with
a nozzle-style underdrain and are designed for rapid removal of spent carbon
and recharge of virgin carbon.
The costs presented are for a complete carbon contacting facility,
including vessels, cylinder-operated butterfly valves, liquid and carbon
handling face piping with headers within the carbon contactor building,
flow measurement and other instrumentation, master operations control panel,
and building. Not included in the cost estimate are carbon contactor supply
and backwash pumping, initial activated carbon charge, spent or regenerated
activated carbon handling, and carbon regeneration and preparation facilities.
Separate curves are provided for these facilities.
Housing requirements were developed assuming that the carbon columns are
totally enclosed. Additional space for pipe galleries and operating and
maintenance service areas are also included in the area requirements.
Estimated construction costs are presented in Tables 114, 115, 116, and
in Figures 134.
Operation and Maintenance Cost
Electrical energy requirements were computed assuming that the carbon
contactors serve as both filters and carbon contactors; thus periodic
backwashing is required. Backwash pumping requirements are based on one
backwash/day for 10 min duration at a rate of 12 gpm/ft2. Energy requirements
are for backwash pumping, for pumping of spent carbon to regeneration
facilities, and for return of regenerated carbon. Carbon was assumed to be
removed and replaced every 2 months. Energy for supply pumping to contactors
is not included. Building energy requirements are for heating, lighting,
ventilating, instrumentation, and other general building purposes. It was
assumed that the contactors were completely housed.
Maintenance material costs reflect estimated annual requirements for
general supplies, pumps, instrumentation repair, valve replacement
or repair, and other miscellaneous work items. Costs for replacement of
carbon lost during contactor operation and carbon regeneration are not
297
-------
Table 113
Conceptual Design for
Pressure Carbon Contactors
Plant Flow Number of
Diameter of
Total Carbon Volume4"
Total Contactor* (ft3 @ detention times)
Plant Area3
S3
VO
(X
(mgd)
1
10
50
Contactors
2
12
60
Contactors (ft)
10
12
12
Area (ft2)
157
13,57
6,786
7.5
6
33
min
780
,790
,930
15
1
13
67
min
,570
,570
,860
30
3
27
135
min
,140
,140
,720
Requirements
1,750
4,800
21,000
*Carbon contactors sized for 5 gpm/ft2 application rate.
"h/olumes determined at bed depth of 5, 10, and 20 ft.
Assumes that carbon contactors are totally enclosed.
-------
-CARBON COLUMN
PLAN VIEW
CARBON RETURN LINE-)
69
j
T
1
1 (
I fj—
INFLUENT
HEADER
BACKWASH
INLET
HEADER
12 ft dla.
PRESSURE
VESSEL
BACKWASH
WASTE HEADER
E EFFLUENT
HEADER
SPENT CARBON
TRANSFER LINE
ELEVATION VIEW
Figure 133. Typical activated carbon column installation.
299
-------
Table 114
Construction Cost for Pressure Carbon Contactors -
7.5 min Empty Bed Contact Time and 5 ft Bed Depth
OJ
o
o
Total Contactor Volume (ft3) and Area (ft2)
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
VOLUME/SINGLE
CONTACTOR
780 ftj,
157 ft2
$ 530
49,010
2,190
1,130
8,500
15,250
15,630
32,550
124,790
18,720
143,510
390 ft3
6,790 ftd,
1,357 ft2
$ 1,440
409,290
5,650
2,830
55,200
135,310
82,910
125,160
817,790
122,670
940,460
565 ft3
33,930 ftd,
6,786 ft2
$ 6,180
1,944,170
24,730
12,360
262,400
679,880
"429,660
512,400
3,871,780
580,770
4,452,550
565 ft3
COST/SINGLE
CONTACTOR
$71,760
$78,370
$74,210
-------
Table 115
Construction Cost for Pressure Carbon Contactors -
15-min Empty Bed Contact Time and 10-ft Bed Depth
Total Contactor Volume (ft3) and Area (ft2)
Cost Category
Excavation & Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe & Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
1,570 ft3,
157 ft2
$ 530
55,460
2,190
1,130
8,990
16,780
15,680
41,850
142,610
21,390
164,000
13,570 ftd ,
1,357 ft2
$ 1,490
452,720
5,650
2,830
58,570
147,490
82,910
163,000
914,660
137,200
1,051,860
67,860 fta ,
6,786 ft2
$ 6,180
2,161,360
24,730
12,360
280,050
728,540
429,660
700,290
4,343,170
651,480
4,994,650
C°CONTACTOR $82,000 $87,660 $83,240
-------
Table 116
Construction Cost for Pressure Carbon Contactors -
30-rain Empty Bed Contact Time and 20-ft Bed Depth
Total Contactor Volume (ft3) and Area (ft2)
Co
o
NJ
Cost Category
Excavation '& Sltework
Manufactured Equipment
Concrete
Steel
Labor
Pipe & Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
VOLUME/ SINGLE
CONTACTOR
3,140 ft3,
157 ft2
$ 530
77,300
2,630
1,240
10,340
18,500
16,420
79,050
206,010
30,900
236,910
1,570 ft2
27,140 ft3,
1,357 ft2
$ 1,400
749,560
6,780
3,110
67,370
221,730
87,100
303,420
1,440,460
216,070
1,656,530
2,250 ft2
135,720 ft3,
6,786 ft2
$ 6,180
3,560,370
29,680
13,600
322,060
1,120,350
451,200
1,332,250
6,835,690
1,025,350
7,861,040
2,250 ft2
COST/SINGLE
CONTACTOR
$ 171,520
$ 154,140
$ 143,960
-------
3 4 567891000 234 56789IOpOO 2 34 56789
INDIVIDUAL CONTACTOR VOLUME- ff3
-t-
-f-
10 100 1000
INDIVIDUAL CONTACTOR VOLUME - m3
Figure. 134. Construction cost for pressure carbon contactors.
303
-------
included. A separate curve is provided for makeup carbon, and this cost
must be added separately.
Labor costs are related to operation of the facility and include those
required to maintain equipment and supervise operation.
Operation and maintenance requirements for pressure carbon contactors
are summarized in Table 117 and Figures 135 and 136.
CONVERSION OF SAND FILTER TO CARBON CONTACTOR
Construction Cost
Existing rapid sand or dual-media filters can be converted to carbon
contactors by removing filter media and replacing it with granular activated
carbon. Filter box dimensions will generally permit installation of a 30'to
36 in. deep carbon bed that will provide 9 to 11 min of empty bed contact
time at 2 gpm/ft2. The existing underdrain and support gravel design can be
retained unmodified. The only required modifications are installation of a
spent carbon collector and transport system and a similar system for return
of reactivated carbon to the contactors. Continued operation at the original
design filtration rate of 2 gpm/ft2 will require no modification of existing
filter rate controls or instrumentation. The backwash rate will be reduced
from 15 gpm/ft2 to 10 gpm/ft2 for activated carbon.
Cost curves were developed for modifying existing filters with total bed
areas ranging from 350 to 70,000 ft2. The costs include those related to
removing and disposing of existing sand (or coal-sand) and gravel, installing
carbon collection troughs and related piping and valving outside of filter,
installing slurry pumps and related controls for transport of spent carbon to
dewatering and regenerating facilities, reactivated carbon storage tank,
reactivated carbon return eductors, and distribution piping systems to
contactors. Carbon transport piping was sized on the basis of 3 Ib of carbon/
gal of water.
The costs for accomplishing these modifications are presented in Table
118 and in Figure 137.
Operation and Maintenance Cost
Operation and maintenance costs should be virtually the same as after
conversion as before, and thus preconversion experience at the existing plant
is the best guide to operation and maintenance costs.
GRANULAR ACTIVATED CARBON
Material Cost
Virgin carbon is generally purchased in 2-ft3 bags for quantities of
40,000 Ib and less, with larger quantities generally transported in bulk by
rail. Costs were developed for purchase and placement of virgin carbon in
a contactor. These costs may be used for either pressure or gravity carbon
304
-------
Table 117
Operation and Maintenance Summary
for Pressure Carbon Contactors
Total Maintenance
Surface
urea (ft2 )
157
1,357
6,786
Energy (kw-hr/yr)
Process
916
7,967
39,746
Building
179,550
492,480
2,154,600
Total
180,470
500,450
2,194,350
Material
($/yr)
1,600
8,020
37,420
Labor
(hr/yr)
2,000
3,500
7,500
Total Cost*
($/yr)
27,010
58,030
178,250
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
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Figure 136. Operation and maintenance requirements for
pressure carbon contactors - labor and total cost.
307
-------
Table 118
Construction Cost for
Conversion of Sand Filter to Carbon Contactor
Contactor Area (ft2)* and Volume (ft3)*
u>
o
00
Cost Category
Manufactured Equipment
Labor
Piping & Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
350 ftz,
875 ft3
$ 11,670
8,620
10,470
1,730
32,490
4,870
37,360
1,750
4,375
$ 22
28
52
3
106
15
122
ft^,
ft3
,280
,270
,240
,300
,090
,910
,000
3,500
8,750
$ 23
48
84
3
160
24
184
ft*
ft3
,870
,030
,770
,540
,210
,030
,240
17,500 ftz,
43,750 ft3
$ 85,400
174,900
443,780
12,560
716,640
107,500
824,140
35
87
$
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,500
150
338
893
22
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210
,616
ft^,
ft3
,650
,970
,410
,300
,330
,800
,130
70,000 ft^
175,000 ft3
$ 294,930
646,400
1,644,380
43,970
2,629,680
394,450
3,024,130
*Area of existing filters.
~*"Assumes carbon bed dpeth of 30 in.
-------
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Figure 137. Construction cost i?or conversion of
sand filter to carbon contactor.
309
-------
contactors to obtain the complete cost of the carbon contactor. The curve
may also be used to determine the cost of makeup carbon to replace carbon
lost during contactor operation and carbon regeneration. The cost curve is
presented in terms of pounds of carbon, and a density of 26 lb/ft3 may be
used to convert between volume and weight. Figure 138 presents a cost curve
for purchase, delivery, and placement of virgin carbon.
CAPPING SAND FILTERS WITH ANTHRACITE
Construction Cost
A popular technique for increasing the capacity of existing rapid sand
filter installations involves removing the top 6 to 12 in: of sand and
replacing it with anthracite coal. The coarser coal permits suspended solids
penetration into the filter bed, allowing operation of the filter beds at
higher flow rates and for longer periods between backwash. In many situations,
this modification can effect a 30 to 50 percent increase in capacity and a
reduction in wash water usage.
Cost curves were developed assuming the removal of 12 in. of sand and
replacement with 12 in. of anthracite coal for total filter bed areas ranging
from 350 to 70,000 ft2. The costs include labor for removing the sand from
the filter and disposing of it on-site, material and freight costs for
anthracite coal, and installation .ibor. The labor costs were developed
assuming that sand removal from filters smaller than 3,500 ft2 would be
accomplished by manual labor. For larger filters, manual labor was supple-
mented with mechanical equipment.
Construction costs are summarized in Table 119 and illustrated in
Figure 139.
OFF-SITE REGIONAL CARBON REGENERATION - HANDLING AND TRANSPORTATION
Construction Cost
Construction costs were developed for combination granular activated
carbon dewatering/storage bins. These facilities would be required for
storage and dewatering of carbon removed from pressure or gravity contactors
before transport to off-site regeneration facilities. Such storage is
generally provided where spent carbon must be accumulated before it can
be economically handled, transported, and regenerated at a regional facility.
Two different design configurations were used to develop the cost
curves. Storage bins of 2,000 ft3 and less are elevated, 12 ft diameter,
cylindrical tanks with conical bottoms. The 5,000 ft3 bin is an elevated,
three-hopper, rectangular tank. For larger storage requirements, multiple
units would 'be used.
Tanks are elevated for gravity loading to dump trucks. The overall
height of the storage bins was limited to 30 ft. All designs include stain-
less steel dewatering screens and associated piping and valving to conduct
water to waste drains. Tanks are field fabricated of braced, 1/4 in.,
shop-formed steel plate protected by a suitable coating system. The tanks
310
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CARBON QUANTITY— Ib
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100,000
CARBON QUANTITY-kg
,
1,000,000
Figure 138. Material cost for granular activated
carbon, including cost for purchase, delivery, and placement.
311
-------
Table 119
Construction Cost for
Capping Sand Filters with Anthracite
OJ
Cost Category
Material
Labor
SUBTOTAL
Miscellaneous and
Contingency
TOTAL COST
Filter Area (ft2)
350
$1,390
660
2,050
310
2,360
1,750
$6,940
2,140
9,080
1,360
10,440
3,500
$11,600
5,600
17,200
2,580
19,780
17,500
$58,000
27,100
85,100
12,770
97,880
35,000
$116,000
50,800
166,800
25,020
191,820
70,000
$232,000
102,000
334,000
50,100
385,100
-------
100
10
345 67891000 a 3 4 5 6789K>pOO 2
TOTAL FILTER AREA~ff2
4 5 6789
100,000
TOTAL FILTER AREA-m2
1000
Figure 139. Construction cost for capping sand filters with anthracite.
313
-------
are located outside and are supported on pier footings. No paving for the
access area is included. No costs are included for trucks necessary to haul
dewatered carbon to the regional regeneration facility. These costs must be
added separately.
Construction costs are summarized in Table 120 and illustrated in Figure
140.
Operation and Maintenance Cost
Granular activated carbon may be removed from the contactor, dewatered,
and hauled to a regionally located regeneration facility serving a number of
treatment plants within a distance of up to 100 miles. Included in the costs
are the fuel, labor, and maintenance requirements to load spent carbon from
dewatered carbon storage tanks to 30 yd^, semi-dump trailers, haul to the
regeneration facility, unload, reload reactivated carbon from bulk storage,
return to the treatment plant, and discharge either to on-site storage tanks
or directly to the carbon contactors. For all travel distances it was assumed
that the entire operation would be accomplished in an 8-hr day.
The annual fuel requirements are based on a diesel fuel consumption of
3.5 miles/gal.
Maintenance materials are only for the trucks and were computed assuming
a unit cost of $0.30/mile.
A summary of the operation and maintenance requirements is presented
in Table 121 and Figures 141 and 142. The total costs represent the labor,
energy, and maintenance requirements related only to the handling and trans-
portation of activated carbon. The costs do not include the cost of regenera-
tion at the regional regeneration facility.
MULTIPLE HEARTH GRANULAR CARBON REGENERATION
Construction Cost
Granular activated carbon is effectively regenerated in multiple hearth
furnaces by exposure to properly and closely controlled conditions of tempera-
ture, oxygen, and moisture content of the atmosphere within the furnace.
During the process, adsorbed organics are oxidized and driven off, restoring
the adsorptive properties of the activated carbon. The multiple hearth
furnace is a cylindrical, refractory-lined shell carrying a series of fired
refractory hearths located one above the other. A revolving insulated
central shaft and attached radial rabble arms move the material across
the hearth, directing material alternately outward or inward as material
drops from one level to the next.
The required size of a multiple hearth furnace is a function of the
required frequency of regeneration, the carb.on dosage used (.which is a
function of the nature of the organics adsorbed), the allowable hearth
loading of the furnace, and anticipated downtime. These factors must be
considered in selecting the required furnace size.
314
-------
Ul
Table 120
Construction Cost for
Off-Site Regional Carbon Regeneration - Handling and Transportation
On-Site Storage Capacity (ft3)
Cost Category.
Excavation and Sitework
Manufactured Equipment
Concrete.
Steel .
Labor
Pipe and Valves
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1,000
$ 210
3,240
1,170
5,630
12,090
1,380
23,720
3,560
27,280
5,000
$ 370
13,050
f 1,750
30,900
29,430
3,830
79,330
11,900
91,230
20,000
$ 1,470
50,600
6,360
122,500
123,640
14,990
319,560
47,950'
367,490
-------
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1000 234 5678910,000 234 56789100,0002 3 4 56789
ON-SITE CARBON STORAGE CAPACITY -ff3
•4-
100 1000 10,000
ON-SITE CARBON STORAGE CAPACITY-m3
Figure 140. Construction cost for off-site regional carbon
regeneration handling and transportation.
316
-------
Table 121
Operation and Maintenance Summary for Off-Site Regional
Carbon Regeneration Handling and Transportation
Maintenance
UJ
1— >
-4
Carbon
Regenerated
(Ibs/yr)
30,000
150,000
500,000
1,000,000
3,000,000
Diesel
haul
5.7
28.6
97
194
582
Fuel* (gal/yr)
25~mi
haul
14.3
71.4
243
486
1,430
100-mi
haul
57
286
971
1,943
5,829
Material ($/yr)
10-mi
haul
6
30
110
210
650
25-mi
haul
20
90
280
550
1,640
100-mi
haul
60
320
1,090
2,180
6,540
Labor* (hr/yr)
10-mi
haul
6.8
34
116
232
780
25-mi
haul
11
55
187
374
1,200
100-mi
haul
14
70
238
476
1,428
Total Cost5
10-mi
haul
80
380
1,310
2,620
8,710
25-mi
haul
140
670
2,260
4,510
14,280
($/yr)
100-mi
haul
230
1,150
3,910
7,810
23,440
*Based on 3.5 miles/gal for 30-yd3 semi-dump truck.
"*"A11 distances are one-way.
*Labor for loading and unloading carbon and for hauling.
Calculated using diesel fuel at $0.45/gal and labor at $10.00/hr
-------
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ioo
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1 ;
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4
10
9
8
7
6
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345 6789 2 3 456789
10,000 100,000 !,OOO,OOO
CARBON REGENERATED - Ib/yr
456 789
10,000,000
10,000
- 1
100,000
CARBON REGENERATED- kg /yr
1,000,000
Figure 141. Operation and maintenance requirements for off-site regional
carbon regeneration handling and transportation - diesel fuel and
maintenance material needed for 10, 25, and 100-mile haul distances.
318
-------
100,000
345 6789 2 3 4 5 6 789
10,000 100,000 1,000,000
CARBON REGENERATED - !b/yr
3 456 789
10,000,000
10,000
100,000 1,000,000
CARBON REGENERATED-kg/yr
Figure 142. Operation and maintenance requirements for off-site regional
carbon regeneration handling and transportation - labor and total cost
for 10, 25, and 100-mile haul distances.
319
-------
Construction costs were developed for a series, of single furnaces with
various hearth areas. Conceptual designs for multiple hearth furnaces
used in the cost estimates are shown in Table 122. The costs include the
basic furnace, center shaft drive, furnace and cooling fans-, spent carbon
storage and dewatering equipment, auxiliary fuel system, exhaust scrubbing
system, regenerated carbon handling system, quench tank, steam boiler,
control panel, and instrumentation. The equipment costs that are on a
furnished and installed basis were obtained from equipment manufacturers.
Housing requirements were developed from manufacturers* recommendations.
Construction costs for a complete carbon regeneration furnare
and supporting equipment are presented in Table 123 and illustrated in
Figure 143.
Operation and Maintenance Cost
Operation and maintenance costs were developed for single-furnace
multiple hearth carbon regeneration systems, with effective hearth areas
between 27 and 1,509 ft2. The costs presented are for operation 100percent
of the time, and correction must be made once the actual percentage of time
in operation has been determined. Process electrical energy and natrual gas
requirements were determined using a hearth carbon loading of 40 to 50 Ib/ft2
per day.
Process electrical energy requirements were developed from manufacturers'
information listing connected and operating horsepower requirements for
furnaces of various sizes, and assuming that the furnace operates 100 percent
of the time. Appropriate correction must be made for the actual percentage
of the time that the furnace is operated. Building energy requirements are
only for lighting and ventilation.
Natural gas requirements were calculated from manufacturers' recommenda-
tions assuming that the feed activated carbon has a moisture content of 50
percent and that the furnace operates continuously. The natural gas require-
ment must be adjusted to account for the percentage of downtime. A heat
value of 1,000 BTU/scf of natural gas was assumed in determining energy
requirements. Where an alternate fuel such as No. 2 Fuel Oil is utilized in
place of natural gas, the appropriate number of gallons required can be
calculated using an overall fuel BTU value equal to that of natural gas.
Maintenance material costs were developed from information furnished by
equipment suppliers. They are related to maintenance and repair of electrical
drive machinery, replacement of rabble arms, and damaged refractory materials.
Operating labor is related principally to operation of the equipment.
Estimates were developed from information furnished by equipment suppliers
and operating installations.
Table 124 presents the operation and maintenance requirements, which
are also shown in Figures 144 and 145.
320
-------
Table 122
Conceptual Design for
Multiple Hearth Granular Carbon Regeneration
Furnace Configuration
Building Area
Requirements (ft2)
750
750
900
1,200
1,800
2,400
Effective Hearth
Area (ft2)
27
37
147
359
732
1,509
I.D.
30"
30"
39"
10'-6"
14'-6"
20'-0"
Number of
Hearths
6
6
6
5
6
6
-------
Table 123
Construction Cost for
Multiple Hearth Granular Carbon Regeneration
Furnace HearthArea (ft2)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and
Contingency
TOTAL
27
$220,660
117,720
8,330
8,290
109,670
464,670
69,700
534,370
37
$ 275,830
147,150
8,330
8,340
109,670
549,320
82,400
631,720
47
$ 519,830
273,280
8,330
8,340
124,230
934,010
140,100
1,074,110
359
$ 647,140
346,850
14,480
9,190
175,100
1,192,760
178,910
1,371,670
732
$1,039,660
557,060
23,450
14,930
245,790
1,880,890
282,130
2,163,020
1,509
$ 1,304,880
704,210
48,800
26,980
334,460
2,419,330
362,900
2,782,230
-------
I
7
6
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8
7
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§ 1
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100,000
9
8
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0 2 3456 78 9 100 2 3456 7891000 2 3 456789
SINGLE FURNACE HEARTH ARE A -ft2 IO.OOO
.. 1 1. — — iin.i — !_..__ _-_
SINGLE
10 100
FURNACE HEARTH AREA -m2
Figure 143. Construction cost for multiple
hearth granular carbon regeneration.
323
-------
Table 124
Operation and Maintenance Summary for
Multiple Hearth Granular Carbon Regeneration
U)
KJ
Effective
Hearth Area
(ft2)
27
37
147
359*
732
1,509
Regenerated
Carbon
(Ib/day)
1,224
1,670
6,624
13,680
32,400
66,960
Electrical Energy
(kw-hr/yr)
Building
14,630
14,630
17,550
23,400
35,100
46,800
Process
261,400
326,750
424,770
588,150
849,550
1,307,000
Total (
276,030
341,380
442,320
611,550
884,650
1,353,800
Natural Gas
scf/yr x 10s)
5.80
7.72
26.2
48.26
108.40
207.75
Maintenance
Material Labor
($/yr)* (hr/yr)
$ 2,990
3,740
6,410
8,550
11,760
16,040
900
950
3,400
6,200
10,500
17,000
Total
Cost*
($/yr)
$ 27,810
33,520
87,740
151,630
284,220
496,730
*Makeup carbon costs are not included.
+Calculated using $0.03/kw-hr, $0.0013/scf and $10.00/hr of labor.
-------
3 4 56789100 E 3 4 567891000 2
SINGLE FURNACE HEARTH AREA -ft 2
456 789
10,000
10
SINGLE FURNACE HEARTH AREA-m'
-4—
100
Figure 144. Operation and maintenance requirements for multiple hearth
granular carbon regeneration - building energy,
process energy, natural gas, and maintenance material.
325
-------
1
6
5
4
i ,000,000
100,000
9'
w 8
•? 7
«£. 6
I 5
c/> ^
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O
10,000
9
8
7
6
5
4
3
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9 —
1000
9
8
- w 7
4
- § 3
m
100
10
LABOF
TO
%L
CC'SI
4 56789100
SINGLE FURNACE
234 567891000
HEARTH AREA-ff2
5 6789
10,000
SINGLE
10
FURNACE
HEARTH AREA - m2
100
Figure 145. Operation and maintenance requirements for multiple hearth
granular carbon regeneration - labor and total cost.
326
-------
INFRARED CARBON REGENERATION FURNACE
Cons true t ion Cos t
Granular activated carbon can be regenerated in furnaces using infrared
energy as the heat source. Only electrical power is required to operate the
furnace. In an infrared furnace, the carbon is moved through the furnace on
a conveying belt that passes the carbon beneath infrared heating elements in
a controlled atmosphere. Reactivation time can be varied by controlling
conveyor speed and/or varying the depth of carbon on the belt. The furnaces
are factory constructed in modules of various widths, which allows assemblage
of furnaces with, a wide range of regeneration capacities. The smallest
furnace will economically process carbon quantities of as low as 100 Ib/hr,
which makes this process attractive for small installations. The largest unit
will process approximately 60,000 Ib/day. Another advantage of infrared
furnaces is that the furnace design permits start-stop operation without
furnace damage or excessive operating cost.
Conceptual designs were developed using information provided by the
equipment manufacturer (Table 125) . Construction costs were developed as
a function of pounds per day of regeneration capacity, and are based on
manufacturers* design and loading parameters. The costs include the premanu-
factured furnace modules (drying, pyrolysis, and activation), spent carbon
holding tank, dewatering feed screw, quench tank, after burner, wet scrubber,
exhaust gas blower, all duct work, scrubber water piping and valving within
process limits, and process electrical equipment and controls.
The equipment is entirely housed in a prefabricated metal building
erected on a slab foundation. Open sidewall construction was assumed for
the furnace area to facilitate heat removal.
Construction costs are presented in Table 126 and are illustrated in
Figure 146.
Operation and Maintenance Cost
Operation and maintenance requirements and associated costs were
developed with the aid of information furnished by the manufacturer. Although
the process is relatively new and operational experience is somewhat limited,
operational data from the few full-scale installations that are in service
was found to agree with that reported in manufacturers' technical bulletins.
It is especially important to note that the yearly operational requirements
presented assume 24-hr/day operation, 7 days/week, and 365 days/year.
Process energy requirements are related to operation of the infrared
heating units, cooling and exhaust blowers, and the scrubbing water system.
Building energy is for lighting and ventilation only.
Maintenance material includes the replacement cost of tungsten filament
quartz heating units that have a life expectancy of about 5,000 hr, replace-
ment of small moving parts associated with dewatered carbon hauling and the
scrubbing system, and general equipment maintenance.
327
-------
Table 125
Conceptual Design for
Infrared Carbon Regeneration Furnace
oo
Furnace Size
oo
Unit Capacity (ibs/day) Width by Length (ft) Building Area Requirements (ft2)
2,400 4 x 20 480
16,800 7 x 48 2,500
38,400 8.5 x 72 3,900
60,000 9.5 x 100 6,000
-------
Table 126
Construction Cost for
Infrared Carbon Regeneration Furnace
Furnace Capacity (Ib/day)
UJ
ho
<£>
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
2,400
$160,000
48,000
3,500
21,000
21,000
253,500
38,030
291,530
16,800
$ 360,000
100,000
5,500
53,000
60,000
578,500
86,780
665,280
38,400
$ 620,000
174,000
7,500
81,000
82,000
964,500
144,680,
1,109,180
60,000
$ 940,000
235,000
10,000
113,000
149,000
1,447,000
217,050
1,664,050
-------
7
6
5
4
6
5
4
3
2
1,000,000
9
OT
o
o
Z
O
8 100,000
1000 2 345 678910,000 234 56789100,000 2 345 6789
FURNACE CAPACITY - Ibs/day
1000
10,000 100,000
FURNACE CAPACITY-kg/day
Fip.ure 146. Construction cost for infrared carbon
regeneration furnace.
330
-------
Labor requirements are for operation and maintenance of the equipment.
Operating attention is required only to oversee performance of the equipment
and make occasional process adjustments. Maintenance attention is required
on an infrequent basis, principally to service moving parts.
Operation and maintenance requirements are summarized in Table 127 and
are also presented in Figures 147 and 148.
GRANULAR CARBON REGENERATION - FLUID BED PROCESS
Construct ion Cost
Recently an improved fluid bed furnace (FBF) has been developed for
regeneration of granular activated carbon and is performing successfully at
several installations. Unlike other FBF, this furnace does not utilize an
inert heat source medium such as sand. The' granular carbon is maintained in a
fluidized condition by hot gases and is regenerated in the process. Regenera-
tion of granular carbon has been accomplished at capacities approaching 70
Ib/hr per ft2 of reactor bed area. The process'promises to have widespread
application for regeneration of granular carbon.
Construction costs were developed for a complete FBF system, which •
includes spent and regenerated carbon storage, carbon dewatering system, the
fluid bed reactor, fluidizing air blower, quench tank," particulate scrubber,
interconnecting piping" and electrical equipment within process area limits,
and controls and instrumentation. Costs were supplied by the manufacturer on
a furnished and installed basis for furnace capacities ranging from 6,000 to
24,000 Ib/day. The furnaces were sized by the manufacturer using a loading
rate of 70 to 73 Ib/hr per ft2 of reactor bed area. Furnaces are housed in
a steel building 35 ft in overall height for protection from adverse weather,
Table 128 presents the conceptual design utilized in the cost estimates.
The construction costs are presented in Table 129 and Figure 149.
Operation and Maintenance Cost
Process electrical requirements were provided by the manufacturer and
represent average operating conditions. Continuous 24-hr/day, 365-day/year
operation was assumed in calculating energy and other operation and mainten-
ance requirements. The major electrical requirement is for the fluidizing
air blower.
Natural gas requirements were computed from manufacturers' reported
regeneration heat requirements of 2,000 BTU/lb of carbon. In addition, it
was assumed that natural gas was used to provide regenerating steam at 0.75
Ib/lb of carbon regenerated, A natural gas heating value of 1,000 BTU/scf
was used to determine fuel requirements. Where an alternate fuel such as
No. 2 fuel oil is utilized in place of natural gas, the appropriate number
of gallons required can be determined using a total fuel BTU value equal to
that of natural gas.
331
-------
w
U)
Table 127
Operation and Maintenance Summary for
Infrared Carbon Regeneration Furnace
Carbon Regeneration Energy (KW hr/yr)
Rate (Ibs/day )
2,400
16,800
38,400
60,000
Building
7,540
39,300
61,300
94,300
Process
701,680
4,522,000
10,206,000
15,820,000
Total 1
709,220
4,561,300
10,267,300
15,914,300
Maintenance
Material ($/yr)
8,900
21,000
28,000
33,600
Labor
(hr/yr)
2,380
4,900
9,380
13,300
Total Cost*
(S/yr)
53,980
206,840
429,820
644,030
^Calculated using $0.03/kw-hr and $10.0Q/hr of labor.
-------
1000,. 10,00.0
1000 2 345 678910,000 234 56789100,000 2 345 6789
CARBON REGENERATION RATE - Ib./doy
1000
1 1
10,000 100,000
CARBON REGENERATION RATE-kg/day
Figure 147, Operation and maintenance requirements for infrared carbon
regeneration furnace - building energy, process energy, and maintenance material.
333
-------
1
6
5
4
3
2
I.OOO.C
6
5
4
4* 3
-w-
1 2
1-
o
° 100,0
rj 9
i ?
H 6
5
4
3
2
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9
B
7
6
5
4
3
2
7
6
5
4
3
2
100
9
8
6
5
4
3
2
00
9
8
6
5
4
3
2
.0 10,00
9
8
:
y
/
i
/
f
0
T
L
tv
/
1
i
. COS
BOR
r
000 2 345 678910,000 234 56789100,000 2 345 6789
CARBON REGENERATION RATE-lbs/day
1000 10,600 100,000
CARBON REGENERATION RATE-kg/day
Figure 148. Operation and maintenance requirements for infrared carbon
regeneration furnace - labor and total cost.
334
-------
Table 128
Conceptual Design for
Granular Carbon Regeneration - Fluid Bed Process
Carbon Regeneration Reactor Housing
Capacity (ibs/day) Bed Area (ft ) Requirements (ft, )
6,000 4 1,400
12,000 8 1,800
18,000 12 2,200
24,000 16 2,600
335
-------
Table 129
Construction Cost for
Granular Carbon Regeneration - Fluid Bed Process
Carbon Regeneration Capacity (Ib/day)
Cost Category
Manufactured Equipment
Labor
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL COST
6,000
£ 570,000
180,000
10,000
60,000
820,000
123,000
943,000
12,000
$ 650,000
205,000
11,000
75,000
941,000
141,150
1,082,150
18,000
$ 710,000
225,000
11,000
90,000
1,036,000
155,400
1,191,400
24,000
$ 755,000
240,000
12,000
106,000
1,113,000
166,950
1,279,950
-------
I
7
6
5
4
3
2
10,000,
1
6
5
4
"** 3
l
co 2
O
0
§ 1,000
CONSTRUCTI
5
.P ro en * 01 cn^jooto
a
8
7
6
5
4
3
2
000
000
300
-•
a
v
0
•
'
***«
1000 2 345 678910,000 234 5678900,000 2 345 6789
REGENERATION CAPACITY - Ibs/day
1000
10,000 100,000
REGENERATION CAPACITY - kg/day
Figure 149. Construction cost for granular carbon
regeneration - fluid bed process.
337
-------
Maintenance material costs were estimated by the manufacturer at 2
percent of equipment capital costs. The maintenance material includes replace-
ment parts for electrical drive machinery, damaged refractory materials, and
other general maintenance items.
Labor requirements were related directly to operation and maintenance of
the equipment and were furnished by the equipment manufacturer.
Operation and maintenance requirements are listed in Table 130 and
illustrated by curves in Figures 150 and 151.
It should be noted that these requirements are for 24-hr/day operation.
To estimate the requirements for less than 24-hr/day operation, it is recom-
mended that the value for the operation and maintenance component be multiplied
by the ratio of hours per day of operation divided by 24.
POWDERED CARBON REGENERATION - FLUIDIZED BED PROCESS
Construction Cost
Powdered activated carbon has been successfully regenerated on a pilot '
scale using a fluidized bed furnace (FBF). However, the lack of full-scale
experience contributes a degree of uncertainty to the validity of the design
criteria and resulting cost estimates. In spite of the lack of full-scale
operating information, the cost estimate is adequately supported by the
similarity of design criteria, capital and operating cost information, and
operating power requirements that were obtained from several manufacturers.
The FBF system consists of a vertical, refractory-lined steel cylinder
with an orificed grid in the lower section to support a bed of graded silica
sand. Air at about 7 psig is introduced into the windbox beneath the orificed
grid in sufficient quantity to fluidize the sand bed. A fuel source is
added along with the fluidizing air to maintain a temperature of 1,300°F
within the glowing mass of sand. The large reservoir of uniformly heated
sand stabilizes the regeneration of the powdered carbon. Wet, spent carbon
is added above the sand layer, and regenerated carbon is separated from the
fluidizing sand and withdrawn at the base of the unit. A small amount of
carbon along with ash is swept out with exhaust gases, where it is captured
by a cyclone separator and a venturi scrubber. A schematic flow diagram
for the regeneration system is shown in Figure 152.
Construction costs were developed for complete FBF systems, which
included the fluidized bed reactor, cyclone and venturi separators, heat
exchangers, fluidizing air blower, carbon feed and removal equipment, process
pumps and piping, and controls and instrumentation. The furnaces were sized
using a loading of 3 Ib of carbon/ft2 per hr, a loading rate that has been
used successfully in pilot tests. Furnaces were assumed to be located out
of doors, and no housing costs are included.
The construction costs are presented in Table 131 and also in Figure 153.
338
-------
UJ
VO
Table 130
Operation and Maintenance Summary for
Granular Carbon Regeneration - Fluid Bed Process
Carbon Regeneration
Rate (Lb/day )
6,000
12,000
18,000
24,000
Process Energy
(kw-hr/yr)
131,400
262,800
394,200
525,600
Natural Gas
(scf/yr)
6,830,700
13,660,000
20,440,000
27,322,860
Maintenance
Material ($/yr)
$ 15,540
17,940
19,400
20,860
Labor
(hr/yr)
2,400
2,650
3,050
3,330
Total Cost*
($/yr)
$' 52,360
70,080
88,300 ,
105,450
Calculated using $0.03/kw-hr, $0.0013/scf for natural gas, and $10.00/hr of labor.
-------
100
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1000
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4 5678910,000 234 86789100,0002
CARBON REGENERATION RATE - Ibs/day
•4-
3 456 799
10
,000
CARBON REGENERATION RATE-
100,000
kg/day
Figure 151. Operation and maintenance requirements for granular carbon
regeneration, fluid bed process - labor and total cost.
341
-------
AFTER BURNER
1300* F
WET
CARBON
REGENERATED
CARBON
T
AIR
^
/
-FLUIDI2
BED REX>
1300* F
ED
CTOR
I
FLUIDIZED AIR
BLOWER
VENTURI
EXHAUST GAS
180" F
SCRUBBER
MAKEUP
WATER
Figure 152. Typical process diagram for fluidized bed
powdered carbon regeneration system.
342
-------
Table 131
Construction Cost for
Powdered Carbon Regeneration - Fluidized Bed Process
Regeneration Capacity (Ib/day)
Cost Category
j£ Manufactured Equipment
U>
Labor
Electrical
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
209
$250,000
188,000
80,000
20,000
538,000
80,700
618,700
" 834
$ 370,000
267,500
112,500
24,000
774,000
116,100
890,100
8,340
$ 1,000,000
700,000
300,000
30,000
2,030,000
304,500
2,334,500
16,680
$ 1,350,000
: 945,000
405,000
36,000
2,736,000
410,400
3,146,400
33,360
$2,400,000
1,600,000
600,000
45,000
4,645,000
696,750
5,341,750
-------
100.000
100
3 4 567891000 234 5 6 7 89K3pOO 2
REGENERATION CAPACITY-Ibs/day
3 456 789
100,000
100
-*-
1
1000 10,000
REGENERATION CAPACITY - kg/day
Figure 153. Construction cost for powdered carbon
regeneration - fluidized bed process.
344
-------
Operation and Maintenance Cost
Process electrical energy requirements were developed from manufacturers'
listing of connected and operating horsepower for furnaces of various sizes.
Continuous 24-hr/day, 365-day/year furnace operation was assumed in calculating
energy and other operation and maintenance requirements.
Natural gas requirements were calculated from manufacturers' recommenda-
tions, assuming that the feed-carbon had a moisture content of 73 to 78
percent. A natural gas heating value of 1,000 BTU/scf was used to determine
energy requirements. Where an alternate fuel such as No. 2 fuel oil is
utilized in place of natural gas, the appropriate number of gallons required
can be calculated using a total fuel BTU value equal to that of natural gas.
Maintenance material costs were estimated from information furnished by
equipment manufacturers. They are related to maintenance and repair of
electrical drive and control machinery, replacement of FBF refractory materials.
replacement of silica sand, and other general equipment maintenance items.
Labor requirements are related directly to operation of the equipment.
Equipment manufacturers furnished information from which labor requirements
were estimated.
Figures 154 and 155 present the operation and maintenance requirements,
which are summarized in Table 132.
POWDERED CARBON REGENERATION - ATOMIZED SUSPENSION PROCESS
Construction Cost
One possible technique for reactivation of spent powdered activated
carbon is the atomized suspension technique process, known as the AST process.
To date only one installation is in service, a fact that contributes some
uncertainty in the design criteria and construction cost estimates.
In the AST process, filter press dewatered, spent powdered carbon is
mixed with water to- form a slurry, then pumped through a spray nozzle where
it is atomized with steam into the top zone of a three-zone AST reactor
chamber. The reactor is normally 1 to 3 ft in diameter by 10 to 50 ft tall,
depending on regeneration capacity. In the top zone the carbon is heated to
about 1,200°F, evaporating the water and drying the carbon particles. In
the middle zone, the adsorbate or contaminants on the powdered carbon are
pyrolyzed, leaving a small residual char deposit in the original powdered
carbon. This char is removed in the third zone, completing the reactivation.
A flow schematic of the AST process is illustrated in Figure 156. Table 133
lists design criteria that were used to develop the cost estimate.
A cost curve was developed with data furnished by the manufacturer for
units of 1,000 and 10,000 Ib/day regeneration capacity. These represent the
smallest and largest units economically feasible. The manufactured equipment
cost includes the basic reactor, spent carbon slurry storage tank, furnace
feed pump, regenerated carbon recovery equipment, and exhaust scrubbing
345
-------
CO
<
o
too
7
6
5
3
2
10
I
7
6
5
4
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1
9
8
7
6
5
9
8
7
6
5
2 -
roog, 10,000
100
4 567891000 234 56789K)pOO
CARBON REGENERATION RATE - Ibs/day
456 7S9
100,000
100 1000 10,000
CARBON REGENERATION RATE-kg/day
Figure 154. Operation and maintenance requirements for powdered
carbon regeneration, fluidized bed process -
natural gas, process energy, and maintenance material.
346
-------
7
6
5
4
1,000,000
I?
•to-
I
J-
in
o
o
7
6
5
4
3-
a
<
.o
100,000
9 "
e
7
6
5
4
3 -
9
8
7
6
5
9
8
7
6
5
9
8
6
5
4
10,000 10,000
at
e
7
6 -
5 -
4
3 -
a -
i
tr
o
m
1000'
TOTAL
HOST
100 234 567891000 234 §6789BpOO 234 56789
CARBON REGENERATION RATE-!b /day 100,000
100
1000 10,000
CARBON REGENERATION RATE-kg/day
Figure 155. Operation and maintenance requirements for powdered carbon
regeneration, fluidized bed process - labor and total cost.
347
-------
Table 132
Operation and Maintenance Summary for
Powdered Carbon Regeneration - Pluidized Bed Process
to
*»
oo
Carbon Regeneration
Rate (Ib/day)
220
910
8,160
18,320
32,570
Process Energy
(kw-hr/yr)
90,000
400,000
2,400,000
4,300,000
8,000,000
Natural Gas
(scf/yr)
900,000
3,300,000
24,000,000
53,000,000
95,000,000
Maintenance
Material ($/yr)
$ 2,500
3,000
4,000
5,000
6,900
Labor
(hr/yr)
1,150
1,300
1,700
2,600
3,700
Total Cost*
($/yr)
$ 21,740
32,290
124,200
228,900
407,400
^Calculated using $0,03/kw-hr, $0.0013/scf, and $10.00/hr of labor.
-------
STEAM
SPENT POWDERED
ACTIVATED CARBON
SLURRY SUPPLY
SURGE
TANK
SLURRY FEED PUMP
DISENGAGEMENT
CHAMBER
SCRUBBER
RECYCLE
PUMP
REACTIVATED
CARBON
SLURRY
Figure 156. Schematic of the atomized suspension,
powdered carbon regeneration system.
349
-------
Ui
o
Regeneration Capacity
(lb/day
1,000
10,000
Table 133
Conceptual Design for
Powdered Carbon Regeneration -
Atomized Suspension Process
Number of
Reactors
1
1
Reactor Dimensions (ft)
Diameter
1
3
Height
20
40
Process Area Requirement
(ft2)
1,200
1,600
-------
facilities - all furnished and installed. Installation labor is estimated
to be 25 to 30 percent of the total installed price. Housing is not included
since the process could easily be located out-of-doors.
Table 134 and Figures 157 present estimated construction costs.
Operation and Maintenance Cost
Operation and maintenance costs were developed for AST process carbon
regeneration facilities with capacities of 1,000 and 10,000 Ib/day. These
operating costs are from the manufacturers' estimate, using information
obtained from a prototype production unit and from a single full-scale unit
currently in service.
Process energy requirements are for process pumping and reactor air
supply. Continuous 24-hr/day operation was assumed for 340 days/year,
according to the manufacturer's recommendation, allowing 25 days of downtime
for maintenance.
Natural gas requirements were calculated from the manufacturer's informa-
tion; they assume that dewatered carbon is made up into a 30-percent dry solids
slurry for injection into the reactor. A heating value of 1,000 BTU/scf was
used to compute natural gas requirements. If an alternate fuel such as.No. 2
fuel oil is to be utilized, the appropriate number of gallons required can be
calculated using a total fuel BTU value'equal to that of natural gas.
Maintenance material costs were estimated by the equipment manufacturer
and relate to repair of electrically driven machinery, heating units, and
controls and routine maintenance of the system. Labor requirements relate
directly to operation of the equipment. No maintenance labor is included.
Operation and maintenance requirements are summarized in Table 135 and
shown in Figures 158 and 159.
CHEMICAL SLUDGE PUMPING - UNTHICKENED SLUDGE
Construction Cost
Chemical sludge originating in clarifiers or recarbonation basins is
relatively dilute and can be conveyed by gravity to the sludge pumping station
wet well. Costs were developed for chemical sludge pumping stations having
separate wet and dry wells. Variable speed, horizontal, centrifugal pumps were
used for pumping of the dilute sludge, and one standby pump was included for
each pumping station. Pipe and valves were sized for velocities of approxi-
mately 5 ft/second. Pumping station costs were estimated on the basis of a
12 ft depth and stairway access for stations with capacities greater than
100 gpm. Housing for electrical equipment and access to the dry well is
located above the dry well, but the housing does not cover the entire dry well.
Construction costs are summarized in Table 136 and illustrated in
Figure 160.
351
-------
Table 134
Construction Cost for
Powdered Carbon Regeneration
Atomized Suspension Process
Regeneration Capacity (Ib/day)
to
U!
Cost Category
Manufactured Equipment*
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
1,000
$200,000
30,000
54,000
284,000
42,600
326,600
10,000
$ 1,500,000
225,000
104.000
1,829,000
274.350
2,103,350
* Includes installation labor-
-------
9
8
7
6
5
4
3
2
IO.OOC
9
8
6
5
4
3
2
1,000,0
' 1
« I
o 6
O 5
Z 4
0
CONSTRUCT
0
O
b ro <•
M
8
7
6
5
4
3
2
),000
>00
oo
s
/
x^
>
/
(^
J*
^
/
/
/
^
/
t I
100 2345 67891000 2 3456 78910000 2 345 6789
REGENERATION CAPACITY- Ibs/day
—I
100
1000 10,000
REGENERATION CAPACITY - kg/day
Figure 157. Construction cost for powdered carbon
regeneration - atomized suspension process.
353
-------
Table 135
Operation and Maintenance Summary
for Powdered Carbon Regeneration -
Atomized Suspension Process
Process Energy
(kw-hr/yr )
46,670
445,000
Natural Gas
(scf/yr)
6,000,000
55,000,000
Maintenance
Material ($/yr)
2,000
3,000
Labor
(hr/yr)
1,020
1,520
Total Cost*
($/yr)
21,400
103,050
Carbon Regenerated
(lbs/day)+
1,000
10,000
+340 days/year operation @ 3 shifts per day.
^Calculated using $0.03/kw-hr, $0.0013/scf and $10.00/hr of labor.
-------
!00_
S
o
-------
8*
7
6
5
4
3
2
100,0
1
6
5
4
< 3
•«•
' 2
«
O
O
10,00
rf 9'
** n
H |
0 7
I- 6
5
4
3
2
IOOC
9
8
T
6
5
4
3
2
6
5
4
3
2
00
6
5
4
3
2
0 I0,0(
9
8
6
w
J2
CC
O
- 03 2
) IOOC
9
8
7
6
5
4
3
2
30
3
«
*
jl
//
***— "
-•
JA
X
--*1
iX
•—
i^
r
••
^
m
^^
••
f
• '
V
, TOTAl
1 LABO
. C
?
3S
T
*
100 2 34 5 6789IOOO 234 56789K>pOO 234 56789
CARBON REGENERATION RATE-ibs/doy
100
1 1
' 1000 10,000
CARBON REGENERATION RATE-kg/day
Figure 159. Operation and maintenance requirements for powdered carbon
regeneration, atomized suspension process - labor and total cost.
356
-------
Ui
Table 136
Construction Cost for
Chemical Sludge Pumping - Unthickened Sludge
Pumping Capacity (gpm)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Pipe & Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
20
$ 470
4,370
1,500
1,510
5,280
2,560
6,290
5,880
27,860
4,180
32,040
100
$ 600
6,230
2,210
2,130
8,060
4,570
7,390
5 ',880
37,070
5,560
42,630
500
$ 810
8,210
3,220
3,120
12,880
10,870
7,880
5,880
52,870
7,930
60,800
1,000
$ 970
10,390
4,100
3,940
17,400
18,190
9,380
8,100
72,470
10,870
83,340
5,000,
$1,840
23,320
9,270
8,640
47,850
42,810
10,380
8,100
152,210
22,830
175,040
10,000
$ 2,220
38,440
12,310
11,070
64,720
79,060
12,510
11,700
232,030
34,810
266,840
-------
•w-
3 4 56789100 234 567891000
PUMPING CAPACITY - gpm
-t-
456 789
10,000
10 100
PUMPING CAPACITY-iJters/see
Figure 160. Construction cost for chemical sludge pumping -
unthickened sludge.
358
-------
Operation and Maintenance Cost
Process electrical energy costs are based on pumping a lime sludge
against a total dynamic head of 30 ft. An overall motor-pump efficiency
of 65 percent was utilized.
Maintenance material requirements are for periodic repair of the pumps,
motors, and electrical control units-. Labor requirements are for periodic
checking of pumps and motors, and for periodic maintenance.
Figures 161 and 162 present operation and maintenance curves, and a
summary of these requirements is presented in Table 137.
CHEMICAL SLUDGE PUMPING - THICKENED SLUDGE
Construction Cost
Thickened sludge from gravity sludge thickeners can be pumped using
progressive cavity pumps. Costs were developed for such pumping stations,
with the pumps drawing thickened sludge directly from the gravity thickener.
The pumps were assumed to be located in a building used for other purposes,
such as sludge dewatering or lime recalcination. The estimated costs include
the pump and .motors, required pipe and valving within the building, electrical
equipment and instrumentation, and housing.
Construction costs are shown in Figures 163 and Table 138.
Operation and Maintenance Cost
Process electrical energy costs are based on pumping a thickened lime
mud against a total dynamic head of 50 ft and manufacturers' estimates of
connected horsepower.
Maintenance material requirements are for periodic repair of the pumps,
motors, and electrical control units. Labor requirements are for periodic
checking of the pumping equipment, and for periodic maintenance.
Figures 164 and 165 present operation and maintenance curves, and a
summary of the operation and maintenance requirements is presented in
Table 139.
GRAVITY SLUDGE THICKENERS
Construction Cost
Gravity sludge thickeners are often used before dewatering by centrifuge
vacuum filter, filter press, or other methods. Gravity thickeners are similar
to circular clarifiers, although the thickener mechanism is somewhat different.
Construction costs consist of the cost of the thickener mechanism and
its installation, and the cost of a reinforced concrete structure. The cost
of the reinforced concrete structure was calculated using a 12—ft side wall
359
-------
100,000
3 4 56789100 Z 3 4 56789000
PUMPING RATE -gpm
-*-
456 789
10,000
10 100
PUMPING RATE -liters/sec
Figure 161. Operation and maintenance requirements for chemical sludge
pumping - unthickened sludge - building energy, process energy,
and maintenance material.
360
-------
100,000
2 3 4 5 678S100 2 34 56789WOO 234 567*9
PUMPING RATE-gpm 10,000
To iSo
PUMPING RATE-liters/sec
Figure 162. Operation and maintenance requirements for chemical sludge
sludge pumping - unthickened sludge - labor and total cost.
361
-------
Table 137
Operation and Maintenance Summary for
Chemical Sludge Pumping - Unthickened Sludge
Pumping Rate (gpm)
20
CO
5 100
500
1,000
5,000
10,000
Electrical
Building
10,260
10,260
10,260
15,390
15,390
20,520
Energy (kw-hr/yr)
Process Total
1,280 11,540
6,400 16,660
31,940 42,200
63,970 79,360
319,860 335,250
639,710 660,230
Maintenance
Material (;$/yr)
$ 2,260
3,430
5,580
8,670
22,740
39,740
Labor
(hr/yr)
75
140
280
380
710
940
Total Cost *
($/yr)
$ 3,360
5,330
9,650
14,850
39,900
68,950
*Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
100,000
w
o
o
z
(T
OT
o •
o
4 5 6789100 234 567891000
PUMPING CAPACITY-gpm
•4-
5 6789
10,000
10 100
PUMPING CAPACITY-liters/sec
Figure 163. Construction cost for chemical sludge pumping
thickened sludge.
363
-------
Table 138
Construction Cost for
Chemical Sludge Pumping - Thickened Sludge
Pumping Capacity (gpm)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL
5
$4,130
810
390
940
JUZOO
7,970
1,200
9,170
25
$7,330
1,280
470
1,020
JUZpo
11,800
1,770
13,570
50
$8,130
1,550
630
1,180
JUZOO
13,190
1,980
15,170
200
$20,080
3,850
920
1,770
1,400
30,020
4,500
34,520
500
$28,050
5,750
1,320
2,100
iiMO
40,620
6,090
46,710
1,250
$44,630
8,970
1,520
2,370
1,400
60,890
9,130
70,020
-------
10,000 1,000,000
r
<
a:
< 1000 100,000
2 -
3 4 5678910 234 56789100
PUMPING RATE - gpm
3 456 789
1000
-f.
10 100
PUMPING RATE-liters/sec
Figure 164. Operation and maintenance requirements for chemical
sludge pumping, thickened sludge - building energy, process energy,
and maintenance material.
365
-------
CO
o
o
§
7
6
5
4.
3
2
IOO.C
6
5
4
2
10,00
9
8
7
4
3
2
IOOC
9"
8
7
6
5
4
3
2
7
6
5
4
3
2
too
t 89
6
5
4
3
2
0 100
9
8
7
6
5
4
3
100
i I i i i i i i i
LABOR -
ro OJ -f» Ul <7)-^C9<£
3
X
^
^
*•
^
^
^
^
*
•<
^
_rf*
j-X^
'^
x
—^^
^p
x*
*~
X
^»
^
««
^
•*
^
^
«<
TOTAI
COST
_^r
ir
^
-------
Table 139
Operation and Maintenance Summary for
Chemical Sludge Pumping - Thickened Sludge
U2
Energy
ig Rate (gpm)
5
25
50
200
500
1,250
Building
5,130
5
5
10
10
10
,130
,130
,260
,260
,260
(kw-hr/yr)
Process
4
19
32
65
261
424
,900
,600
,660
,320
,300
,610
Total
10,
24,
37,
75,
271,
434,
030
730
790
580
560
870
Maintenance
Material ($/yr)
- $1,
1,
1,
4,
6,
9,
090
760
990
550
290
700
Labor
(hr/yr)
50
75
105
190
280
400
Total Cost*
($/yr)
$1
3
4
8
17
26
,890
,250
,170
,720
,240
,750
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
depth. Concrete effluent troughs were utilized for all sizes, with the weir
baffle located on the inboard side of the concrete trough. All mechanisms
were assumed to be supported by the center column and include a steel bridge
from the edge of the thickener to the center column.
Construction costs are presented in Table 140 and Figure 166.
Operation and Maintenance Cost
Process energy requirements were calculated for lime, alum, and ferric
sludges| they are only for driving the thickener mechanism. Energy require-
ments for sludge pumping are not included, as a separate curve is provided
for thickened sludge pumping.
Maintenance material costs and labor requirements are for repair and
normal maintenance of the thickener drive mechanism and the weirs.
Figures 167 and 168 present curves for operation and maintenance
requirements, and Table 141 summarizes these requirements.
VACUUM FILTERS
Construction Cost
Vacuum filters have had extensive application to dewaterlng of wastewater
treatment sludges, but they have only recently been applied to the dewatering
of1 water plant sludges. With proper sludge conditioning, even difficult to*
dewater sludges such as alum sludge can be successfully processed with
vacuum filters.
Construction costs were developed for single and multiple installations
capable of handling sludge volumes ranging from 3,600 to 720,000 gpd.
Conceptual design information for these installations is shown in Table 142.
Equipment was selected assuming a feed sludge concentration of 1 percent
solids, a minimum sludge cake solids concentration of 20 percent, and
continuous 24-hr/day operation. The costs include the vacuum drum filter,
vacuum and filtrate pump assemblies, precast pump and storage tanks, belt
conveyor, interconnecting piping, electrical controls and housing. Figure
169 illustrates a typical installation.
Table 143 presents construction costs for vacuum filter installations
with filter areas ranging from 9.4 to 1,320 ft2. Figure 170 illustrates the
construction costs for vacuum filters presented as a function of filter
surface area.
Operationand Maintenance Cost
Electrical energy requirements are for both building and process energy.
Process energy requirements were based on manufacturers* design values of
total connected horsepower for the drum drive, discharge roller, vacuum
and filtrate pumps, precoat pump, tank agitators, and belt conveyor. A
filter loading of approximately 1.7 Ib of dry solids/hr per ft2 with a
368
-------
Table 140
Construction Cost for
Gravity Sludge Thickeners
Surface Area (ft ) and Diameter (ft)
Cost Category
Excavation & Sitework
ON Manufactured Equipment
Concrete
Steel
Labor
Electrical &
Instrumentation
SUBTOTAL
Miscellaneous &
Contingency
TOTAL
314 ft2,
20 ft
$980
26,250
3,110
4,460
10,080
1,420
46,300
6,950
53,250
1,256 ft2,
40 ft
$2,120
40,000
6,730
9,430
18,790
1,420
78,490
11,770
90,260
2,827 ft2,
60 ft
$3,430
52,500
10,850
14,880
27,840
1,460
110,960
16,640
127,600
5,026 ft2,
80 ft
$4,900
61,250
15,480
20,840
36,840
1,460
140,770
21,120
161,890
7,854 ft2,
100 ft
$6,530
63,750
20,610
27,290
45,420
1,510
165,110
24,770
189,880
12,271 ft2,
125 ft
$8,800
73,000
27,740
36,060
57,780
1,550
204,930
30 , 740
235,670
17,671 ft2,
150 ft
$11,320
101,000
35,600
45,600
73,770
1,730
269,020
40 , 350
309,370
-------
100
3 4 567891000 234 56?89K!pOO 200,0004 56789
SURFACE AREA- ff2
10
-t-
100 1000
SURFACE AREA-m2
Figure 166. Construction Cost for gravity sludge thickeners.
370
-------
i
7
6
5
4
10,000
I-
6
5
£ 4
r 3-
2. 2
a:
UJ
1000
9
8
7
6
5
4
100
7
6
5
4
3
2
1000
100 234 567891000 234 56789»pOO 20pOO 4 56789
SURFACE AREA-ft2
-I 1 1
10 100 1000
SURFACE AREA-m^
Figure 167. Operation and maintenance requirements for gravity
sludge thickeners - process energy and maintenance material.
371
-------
I
6
5
4
3
100,000
CO
O
u
10,000
iooq
9"
8
6
5
4
3
10,000
9
8
loog
9
8
I 4
EC
O 3
DO
J. !00t
10
TOT4
LAB(!R
COST
100 234 5 6?B9!pOO 2jQOO 4 56?89K5pOO
SURFACE AREA-ft 2
20,000 4 5 6?«9
H 1—
100 1000
SURFACE AREA-mz
Figure 168. Operation and maintenance requirements for gravity
sludge thickeners - labor and total cost.
372
-------
Table 141
Operation and Maintenance Summary for
Gravity Sludge Thickeners
CO
Surface
Area
(ft2)
314
1,256
2,827
5,026
7,854
12,271
17,671
Diameter
(ft)
20
40
60
80
100
125
150
Energy (kw-h
Alum & Ferric
Sludge
3,270
4,900
6,540
10,460
12,420
18,300
28,750
ir/yr)
Lime
Sludge
3,270
4,900
7,520
12,420
18,950
29,080
39,210
Maintenance
Material ($/yr)
$140
350
470
1,000
1,400
1,850
2,400
Labor
(hr/yr)
125
160
200
230
280
310
390
Total Cost*
Alum & Ferric
Sludge
$1,490
2,100
2,670
3,610
4,570
5,500
7,160
($/yr)
Lime
Sludge
$1,490
2,100
2,700
3,670
4,770
5,820
7,480
^Calculated using $Q.Q3/kw-hr and $10.00/hr .of labor..
-------
Table 142
Conceptual Design for
Vacuum Filters
Total Installed
Machine Capacity (gpd)*
3,600
18,000
36,000
360,000
720,000
Total Filter „
Surface Area (ft )
9.4
38
71
628
1,320
Number of
Machines
1
1
1
2
3
Housing
Requirements
1,280
1,350
1,480
2,150
3,625
(ft2)
2
*Based on average loading of 1.7 lb of dry _solids/hr per ft and a feed sludge flow of .1 percent
solids concentration.
-------
1
j
1
1
1
1
1
1
1
1
1
1
1
1
Vacuum 1
Filter j
1
1 i i
MO
-
II 1 C
i
I
Vacuum |
Filter |
1
1
U@
j
J
D
Control
panel Vacuum &
filtrate assembly
D
r
rSludge
conveyor
_l
Precoat
assembly
PLAN VIEW
Vacuum &
Vacuum filtrate assembly
filter
Sludge pumps
& mechanical
equipment
ELEVATION VIEW
Figure 169. Typical vacuum filter installation.
375
-------
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
Table 143
Construction Cost for
Vacuum Filters
2
Total Filter Area (ft )
9.4
$ 65,600
22,500
3,500
2,500
52,800
146,900
22,040
168,940
38
$73,500
26,000
3,500
2,500
59,400
164,900
24,740
189,640
71
$85,700
29,500
3,800
2,800
63,600
185,400
27,800
213,200
628
$262,000
118,000
5,300
7,500
81,700
474,500
71,180
545,680
1,320
$445,000
198,000
8^500
23,200
127,000
801,700
120,260
921,960
-------
10
3 4 5 6789100 2
TOTAL FILTER
3456 7891000
AREA - ff2
3 456 789
1.0
!0
TOTAL FILTER AREA-m;
100
Figure 170, Construction cost for vacuum filters,
377
-------
minimum cake solids concentration of 20 percent was used in computing energy
requirements. These conditions are characteristic of alum sludge dewatering.
Sludge dewatering characteristics will affect filter loading rates, which in
turn will have an impact on energy usage. Appropriate correction must be
made for a lower loading rate than 1.7 Ib of dry solids/hr per ft2.
Labor and maintenance material costs were also obtained from equipment
suppliers; they represent estimated annual requirements for filter operation
and maintenance, and for replacement parts.
Operation and maintenance requirements are summarized in Table 144 and
illustrated in Figures 171 and 172. Operation and maintenance requirements
vary widely depending on hours/day of operation, feed sludge concentration,
and filter loading. Appropriate corrections should be made when conditions
vary significantly from those that were used to derive the operation and
maintenance requirements.
SLUDGE DEWATERING LAGOONS
Construction Cost
Sludge dewatering or storage lagoons are used at many plants to receive,
store, and partially dewater waste sludge before further treatment or ultimate
disposal. In some plants, filter backwash water is also discharged to a
lagoon for clarification and storage. Generally, when sufficient land area is
available, lagooning represents the lowest cost system for sludge dewatering.
Construction costs were estimated for unlined lagoons with a 10—ft water
depth and a 2—ft freeboard depth. Dikes were assumed to have a 10—ft crest
width and 3:1 side slopes. It was assumed that the excavation volume is
equal to the dike fill volume. Lagoons were designed with an inlet structure
that would prevent disturbance of settling material, and an outlet structure
to skim clarified water. Conceptual designs used to estimate costs are
presented in Table 145.
Construction costs are presented in Table 146 and Figure 173. The costs
are shown as a function of effective volume, which is the volume of the lagoon
minus freeboard volume. The costs do not include land cost.
Operation and Maintenance Cost
Operation and maintenance requirements are primarily associated with
sludge removal from the lagoons. Depending on the climate and the ability of
water to percolate from the lagoon, sludge can thicken to a solids content of
15 to 40 percent (17 to 20 percent average) during 6 months of storage.
Removal is generally done with a front-end loader or with dragline dredging.
Dredging is used to allow further dewatering by air drying on the lagoon
periphery. After air drying, the concentrated sludge is removed by a front-
end loader. The costs and requirements presented are for a combination of
these approaches. Sludge was assumed to be removed from a lagoon, on the
average of once every 2 years, and hauled in dump trucks to within 1 mile
of the lagoons. If a further haul distance is required, curves provided
elsewhere in this report for sludge hauling should be utilized.
378
-------
Table 144
Operation and Maintenance Summary for
Vacuum Filters
W
•vl
VO
Total Filter
Area (ft2)
9.4
38
71
628
1,320
Sludge Flow
Rate (gpd)*
3,600
18,000
36,000
360,000
720,000
Energy (kw-hr/yr)
Building
131,330
138,500
151,850
220,600
372,000
Process
94,600
126,140
197,100
1,088,000
2,365,000
Total
225,930
264,640
348,950
1,308,600
2,737,000
Maintenance Labor
Material ($/yr) (hr/yr)
$3,000
7,800
11,000
50,000
82,000
800
1,050
1,900
6,500
11,000
Total Cost*
($/yr)
$17,780
26,240
40,470
154,260
274,110
2
*Based on average loading at 1.7 Ib/day per ft of dry solids and a feed sludge flow at 1 percent
solids concentration. .
^Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
100,000
DC
u
10,000 1.000,000
w
u
2
<
UJ
I-
z
1000 100,000
9'
I 8
2 -
3 4
456 789
10,000
56789100 234 567891000
TOTAL FILTER AREA- ft 2
1 : ' 1—
10 100
TOTAL FILTER AREA-m2
Figure 171. Operation and maintenance requirements for vacuum
filters - building energy, process energy, and maintenance material.
380
-------
1,000,000
I
6
5
4
3
•*»- 2
1
H
w
o IOO.C
t f
H b
O 5
4
3
2
IO.OC
9"
8
7
6
5
4
3
2
9"
8
7
6
5
4
3
2
9
8
7
6
5
4
2
)00
9
8
6
4
3
)0 10.0C
9
8
4
w
-C
1
IOOC
- K 9
- ° I
" < I
- _l 6
4
O
100
30
5
f— —
X-*
i^
x-
X
J
X
X
X
X
K*
/
J
^
I*
«•
^
^
jj
^0*
^r
.
/
^x
x^
X
X
,X
X
x
x
^
x
j
/
/
*
^
^
X
TOTA
X L*
L <
BO!
:OS
\
T
,
10 234 56789100 234 56789WOO 234 56789
TOTAL FILTER AREA ~f»2 10,000
— I 1 i „, „. .,, .,
1.0 10 100
TOTAL FILTER AREA-n»2
Figure 172. Operation and maintenance requirements for vacuum
filters - labor and total cost.
381
-------
Table 145
Conceptual Design for
Sludge Dewatering Lagoons
oo
Effective Storage
Volume (ft3)
40,000
400,000
4,000,000
8,000,000
LagoonDimensions (ft)
Length . Width
100
330
440
440
20
60
80
80
Number of Lagoons
2
2
10
20
-------
Table 146
Construction Cost for
Sludge Dewatering Lagoons
Effective Storage Volume (ft )
Co
03
Cost Category
Excavation & Sitework
Concrete
Steel
Labor
Pipe & Valves
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
40,000
$2,500
700
100
2,800
2,400
8,500
1,280
9,780
400,000
$21,000
800
110
20,000
6,000
47,910
7,190
55,100
4,000,000
$125,000
10,000
1,200
69,000
40,000
245,200
36,780
281,980
8,000,000
$260,000
19,000
2,300
110,000
75,000
466,300
69,950
536,250
-------
7
6
5
4
1,000,000
w
o
o
O
O
cc
w
z
o
o
100,000
9
8
6
5
4
10,000
9
8
7
6
5
4
10,000 234 56789100,0002 3 4 567891000,000 3 4 56789
EFFECTIVE STORAGE VOLUME - ff3 10,000,000
1 1 1
1000 10,000 100,000
EFFECTIVE STORAGE VOLUME-n)3
Figure 173. Construction cost for sludge dewatering lagoons.
384
-------
Energy requirements are for diesel fuel used in the removal and transport
of sludge. Maintenance material is for periodic lagoon grading and restora-
tion of dikes and roadway maintenance. Labor requirements are for sludge
removal and transport, and for lagoon maintenance.
Operation and maintenance requirements are summarized in Table 147
and illustrated in Figures 174 and 175.
FILTER PRESS
Construction Cost
The filter press has gained popularity for dewatering water treatment
plant sludges because it can produce a high solids content cake suitable for
direct disposal by landfill. The introduction of semi-automatic presses
along with other labor and maintenance saving improvements has further
stimulated interest in filter presses for water treatment plant sludge
dewatering.
Construction costs were developed for a series of single and multiple
filter press systems ranging in size from 4.3 to 896 ft . The largest single
press utilized in the cost estimates had a capacity of 224 ft3. Conceptual
designs providing press sizing information are shown in Table 148. A
typical arrangement for a filter press installation is shown in Figure 176.
The construction costs include the filter press, feed pumps (including one
standby), a lime storage bin and feeders, a sludge conditioning and mixing
tank, an acid wash system, and housing.
Construction costs are summarized in Table 149 and are illustrated
in Figure 177.
j
Operation and Maintenance Cost
Operation and maintenance costs were developed for a 4 percent feed
sludge concentration, a filter loading of 5 to 5.6 Ib of dry solids/ft3 per
hour, a dry solids density of 75 lb/ft3, and 19 hr of operation/day. The
remaining 5 hr/day are devoted to press preparation, sludge removal, cleanup,
and maintenance.
Most of the process energy consumed by the filter press is related to
operation of the feed pump. Energy is also consumed by the open—close
mechanism and the tray mover. Pumping power requirements were calculated
fbr a solids loading of 4 percent at a cycle time of 2.25 hr, with a 0.33—hr
turnaround time between cycles. Power required for chemical preparation,
mixing, and feeding is also included in process energy. Energy requirements
related to building heating, lighting, and ventilation were also developed
using the housing area requirements presented in Table 148.
Maintenance material costs and labor requirements were estimated based
on manufacturers' experience and data from several operating installations.
Operation and maintenance costs are summarized in Table 150 and
illustrated in Figures 178 and 179.
385
-------
Table 147
Operation and Maintenance Summary for
Sludge Dewatering Lagoons
OJ
00
CJ>
Volume of Sludge Removed
(ft3)*
10,000
100,000
500,000
1,000,000
5,000,000
Diesel Fuel
(gal/yr)+
100
950
4,650
8,850
42,450
Maintenance
Material ($/yr)i
$50
220
600
900
2,000
Labor
(hr/yr)
94
900
3,600
7,000
30,000
Total Cost!
($/yr)
$1,040
9,650
38,690
74,880
321,110
3
*Assuraes sludge density of 70 Ib/ft with 17 to 20 percent solids concentration.
+No. 2 diesel fuel used for loader and dump truck.
iExclusive of removal equipment maintenance.
Calculated using diesel fuel at $0.45/gal" and labor at $10.00/hr.
-------
10,000
I
7
6
5
4
3
2
100
MAINTENANCE MATERIAL- $/yr
O "» w * 01 w-^oowo M CM 4» "> si-!*®
9
8
7
6
5
4
3
2
9
8
7
6
5
4
3
2
0 IOO.C
- 9
6
4
3
2
10,00
9
" t. 8
- "x 7
- o 6
U °" «s
I 3
- d 4
- "- 3
_j
UJ
LU
Q
100
_ 0
8
7
4
2
100
00
0
_j*
_^r
-------
1,000,000
100,000
o
o
O
10,000 10,000
10,000 234 56789100,0002 3 4 5 6 7 8 9|pOO,000
VOLUME OF SLUDGE REMOVED - ft3/yr
345 6789
10,000,000
1000 IO.OOO 100,000
VOLUME OF SLUDGE REMOVED ~ffl3/yr
Figure 175. Operation and Maintenance requirements for sludge
dewatering lagoons - labor and total cost.
388
-------
Table 148
Conceptual Design for
Filter Press
Total
Filter Press
Volume (ft3)
4.3
24
50
224
448
896
Number of
Filter Presses
1
1
1
1
2
4
Housing
Requirements
(ft2)
1,200
2,200
2,400
3,300
4,550
7,000
389
-------
Sludge to fitter presses
Filter
press
Platform
•Sludge supply
line
Sludge trans-
fer pumps
Lime supply
line
PLAN VIEW
ELEVATION VIEW
Figure 176. Typical filter press installation.
390
-------
Cost Category
w
vo Manufactured Equipment
Labor
Pipe & Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
Table 149
Construction Cost for
Filter Press
3
Total Filter Press Volume (ft )
4.3
$92,000
27,600
3,000
2,700
54,000
179,300
26,900
206,200
24
$168,000
50,400
3,200
2,800
90,200
314,600
47,200
361,800
50
$245,000
75,000
4,000
3,000
97,200
424,200
63,630
487,830
224
$425,000
127,000
5,000
3,500
129,000
689,500
103,430
792,930
448
$680,000
190,000
6,600
6,400
160,000
1,043,000
156,450
1,199,450
896
$1,245,000
350,000
10,000
11,000
224,000
1,840,000
276,000
2,116,000
-------
7
6
5
4
10,000,000
o
o
o 1,000,000
O
13
ce
-------
Table 150
Operation and Maintenance Summary for
Filter Press*
Filter Press Energy (kw-hr/yr) Maintenance Labor Total Cost+
Volume (ft3) Building Process Total Material ($/yr) (hr/yr) ($/yr)
/ 4.3 123,100 24,400 147,500 $1,000 6,935 $74,780
w 24 225,700 64,000 289,700 1,800 6,935 79,840
VO
w 50 246,200 112,000 358,200 2,600 8,400 97,350
224 338,600 320,000 658,600 4,600 10,400 128,360
448 466,800 624,000 1,090,800 7,900 18,700 227,620
896 718,200 1,240,000 1,958,200 13,000 34,000 411,750
*Process energy, maintenance material, and labor requirements are typical for a 4 percent feed
sludge concentration, a filter loading of 5-5.6 Ib dry solids/ft^ per hr, a dry solids density
of 75 Ib/ft3, and 19 hr of operation/day.
j
+Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
7
6
5
4
1,000,000
100,000 100,000
•*»•
I
UJ
S
£
O
UJ
_ t
>-
_ (E
10,000 IO.OOO
1000
M
AIN
ATE RIAL
FEU AN
4 5678910 234 56789100 Z
TOTAL FILTER PRESS VOLUME - ft3
456 789
1000
— 1
O.I
TOTAL
FILTER
-1
1
PRESS
VOLUME
10
-m3
Figure 178. Operation and maintenance requirements for filter press
building energy, process energy and maintenance material.
394
-------
7
6
5
4
1,000,000
CO
O
o
100,000 100,000
9
8
7
6
5
4
3
10,000
7
6
5
4
1000
4 5678910 234 56789100
TOTAL FILTER PRESS VOLUME—
5 6 789
1000
1
O.I
TOTAL
FILTER
1
1
PRESS
VOLUME
-n>3
1
10
Figure 179. Operation and maintenance requirements for filter press
labor and total cost.
395
-------
DECANTER CENTRIFUGES
Construction Cost
Decanter or solid bowl centrifuges have had widespread application in
the dewatering of water treatment plant sludges, with the bulk of the
applications being for lime softening sludges. Recent improvements in
machine design, however, coupled with the use of polymer as a sludge
conditioner, have expanded the application to alum sludges with reported
good success. Generally, a sludge cake with 20 percent solids can be
produced from a 1-percent solids feed.
Costs of decanter-style centrifuges and related appurtenances have been
developed for a full-scale range of single units with capacities ranging
from 10 to 500 gpm. Table 151 presents conceptual design information for
machines in this capacity range. The costs developed include those for the
decanter centrifuge and provisions for preparation, storage, and application
of polymers. The costs do not include sludge or centrate pumping or dewatered
sludge conveyance. It was assumed that centrifuges would be located for
bottom discharge to trucks or storage bins.
Housing requirements were developed from equipment manufactuers' layout
drawings. Building costs were estimated using the building arrangement
shown in Figure 180, they assume a two-story building of concrete block
construction.
Estimated construction costs are shown in Table 152 and also in
Figure 181.
Operation and Maintenance Cost
Process energy usage was computed from manufacturers' information on
connected and operating horsepower for main drive and back drive units and
for polymer preparation and feed equipment. The power requirements reported
are for the relatively new, low-speed machines. The process energy does
not include energy related to feed sludge pumping and handling of dewatered
sludge.
Maintenance material costs were furnished by equipment suppliers and
represent an industry-wide average for annual expenditures for replacement
parts and miscellaneous components, and for general machine maintenance.
Conveyor replacement or resurfacing of conveyor flights is a major mainten-
ance task associated with decanter centrifuges and may be required as
frequently as once every 8,000 hr, or as infrequently as once every 30,000
hr of operation, depending on the material of construction, service
conditions, and other factors.
Labor requirements for operation and maintenance were computed based
on 24 hr of continuous operation. The major portion of the operating labor
is devoted to machine start-up and adjustment, polymer preparation, and
occasional maintenance involving machine and motor lubrication.
396
-------
Table 151
Conceptual Design for
Decanter Centrifuges
Machine Capacity 2
gpm gpd Number of Machines Housing area (ft )
10 14,400 1 1,000
25 36,000 1 1,200
38 54,720 1 1,200
250 360,000 1 2,100
500 720,000 1 2,300
-------
PLAN VIEW
•U
-'
•fll
1
k
^
./•roiymer reea line
j
JT^I
O
I 1
Oi
Sludge
pump
Centra te
utnp-
Centra te
return
Sludge
SECTION VIEW
Figure 180. Typical decanter centrifuge installation.
398
-------
Table 152
Construction Cost for
Decanter Centrifuges
Machine Capacity (gpm)
Cost Category
Jg Manufactured Equipment
VO
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
10
$ 65,500
23,000
7,000
4,500
44,000
144,000
21,600
165,600
25
$75,000
26,400
7,500
4,500
53,000
166,400
24,960
191,360
38
$90,000
31,000
8,300
5,000
53,000
187,300
28,100
215,400
250
$205,000
53,000
24,000
10,800
88,000
380,800
57,120
437,920
500
$295,000
88,000
38,000
10,800
94,000
525,800
78,870
604,670
-------
I
6
5
4
3
2
1
6
5
4
•M- 3
1
1- ,
W 2
O
O
z l,000,(
0 9
^ §
o 7
1 ?
- 4
8 3
2
IOO.C
9
8
7
6
5
4
3
2
DOO
)00
— *•*
«**•
ip"
**
^
^
•»
«•
^x^*
1 "^
X
x
^
rf'
^
2 345 678910 2 3456 789100 2 345 6789
MACHINE CAPACITY -gpm I0°°
O.I 1.0 10
MACHINE CAPACITY- liters/sec.
Figure 181. Construction cost for decanter centrifuges.
400
-------
A summary of operation and maintenance requirements is presented in
Table 153 and illustrated in Figures 182 and 183. It should be noted that
total operation and maintenance costs will vary considerably, depending on
hours per day of operation. If operation is less than 24 hr/day, appropriate
corrections should be made in operation and maintenance requirements.
BASKET CENTRIFUGES
Construction Cost
Basket style centrifuges, because of design and operating features, are
ideally suited to dewatering of light, delicate, hard-to-handle sludge
encountered in water treatment. With the introduction of automatic machines
that operate on a preprogrammed cycle with minimal operator attention, the
application nf basket centrifuges has greatly expanded for water treatment
plant sludge dewatering.
Construction costs were developed for single and multiple units capable
of handling alum sludge. For equipment selection purposes, it was assumed
that the' settled sludge is concentrated to a 1-percent solids sludge stream
before centrifugation. Centrifuges were selected to produce a sludge cake
with a minimum solids content of 20 percent. Conceptual designs used in the
cost estimates are presented in Table 154.
In addition to the basic machines, the costs include equipment for
polymer preparation, storage, and application. The costs do not include
those for sludge and centrate pumping, sludge conveying, and sludge storage.
It was assumed that centrifuges are located for bottom discharge to trucks
or storage bins.
I
Housing requirements were developed from equipment manufacturers'
recommended layouts. Building costs were estimated for a two-story structure
of concrete and concrete block construction of a general arrangement, as
shown in; Figure 184.
i
Table 155 and Figure 185 present construction costs of basket centrifuge
installations as a function of total installed machine capacity.
i
Operation and Maintenance Cost
Electrical energy requirements were computed from connected and operating
horsepower information provided by equipment manufacturers. Basket centrifuge
operating horsepower, computed on the basis of a complete cycle involving
machine acceleration, sludge feeding, skimming, decelerating, and sludge
plowing,1 averages 40 to 60 percent of the connected horsepower. Electrical
power for polymer preparation and feeding is included, but energy for sludge
pumps and sludge conveying equipment is not included.
i
Maintenance material costs were furnished by equipment manufacturers
and represent an industrywide average of annual expenditures for maintenance,
replacement parts, lubrication, and other consumable items associated with
basket centrifuge operation.
!
' 401
-------
o
to
Table 153
Operation and Maintenance Summary for
Decanter Centrifuges
Feed Sludge Flow
gpm
10
25
38
250
500
gpd
14,400
36,000
54,720
360,000
720,000
Energy (kw-hr/yr)
Building
102,600
123,120
123,120
215,460
235,980
Process
11,980
32,680
42,820
326,750
653,500
Total
114,580
155,800
165,940.
542,210
889,480
Maintenance
Material ($/yr)
$1,500
3,000
3,500
10,000
15,000
Labor
(hr/yr)
730
1,095
1,825
2,190
3,285
Total Cost*
($/yr)
$12,240
18,620
26,730
48,170
74,530
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
1000
100,000 100,000
cc
Ld
< 10,000 10,000
Ld
o
z
<
z
Ld
2 -
4 5678910 234 56789OO 2
FEED SLUDGE FLOW RATE-gpm
3 456 789
O.I
H—
1.0
—I-
10
FEED SLUDGE FLOW RATE - liters/sec
Figure 182. Operation and maintenance requirements for decanter
centrifuges - building energy, process energy and maintenance
material.
403
-------
100,000
o
o
<
O
10,000 IO.OOO
9T 9
7
2 -
3 4 5678910 234 56789KX) 2
FEED SLUDGE FLOW RATE - gpm
3 456 789
O.I
1.0 IO
FEED SLUDGE FLOW RATE - liters/sec.
Figure 183. Operation and maintenance requirements for decanter
centrifuges - labor and total cost.
404
-------
Table 154
Conceptual Design for
Basket Centrifuges
r\
o Total Machine Capacity (gpd) Machine Size (in.) Number of Machines Housing Requirements (ft )
Ui
3,600 30 x 18 1 1,600
36,000 40 x 24 1 1,600
180,000 48 x 30 3 2,400
360,000 48 x 30 6 4,800
720,000 48 x 30 12 9,600
-------
Polymer feeding assembly
'Polymer assembly
D
Basket
Centrifuge
rSludge pump
Ceritrate
pump
$3
Sludge discharge chute
0 I 0
SECTION VIEW
Figure 184. Typical basket centrifuge installation.
406
-------
Table 155
Construction Cost for
Basket Centrifuges
Total Machine Capacity (gpd)
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
3,600
$55,000
18,000
7,200
2,500
78,000
160,700
24,100
184,800
36,000
$65,000
20,000
7,200
2,500
78,000
172,700
25,900
198,600
180,000
$236,000
75,000
20,800
5,300
104,000
441,100
66,170
507,270
360,000
$440,000
140,000
39,700
9,500
175,000
804,200
120,630
924,830
720,000
$878,000
270,000
50,000
16,000
284,000
1,498,000
224,700
1,722,700
-------
7
6
5
4
10,000,000
W
O
O
1,000,000
9
o
r>
cc
o
o
100,000
9
8
7
6
5
4
1000 2 345 678910,000 234 56789100,000 2
TOTAL MACHINE CAPACITY - gpd
3 456 789
1,000,000
10,000 100,000 1,000,000
TOTAL MACHINE CAPACITY-liters/day
Figure 185. Construction cost for basket centrifuges,
408
-------
Labor requirements for operation and maintenance assume 24 hr of continu-
ous operation. The major portion of the operating labor is devoted to
machine start-up and adjustment, polymer preparation, and required
maintenance.
Operation and maintenance requirements are presented in Table 156 and
Figures 186 and 187. Operation and maintenance costs will vary widely
depending on sludge dewatering characteristics and specific operating
conditions related to the installation; appropriate adjustment should be
made if conditions vary significantly from those stated above.
SAND DRYING BEDS
Construction Cost
Sand drying beds are an economical method of producing a dry sludge cake
with little or no pretreatment required, although polymer addition may be
used. Dewatering is by a combination of draining and air drying, and beds
perform best when both of these processes are optimized. Removal of dried
sludge is normally accomplished by front-end loader. Although sand drying
beds offer a low-cost approach to sludge drying, this advantage may be offset
by the land area required and poor performance during cold or wet periods.
Cost estimates were made for uncovered and unlined sand drying beds.
The estimates include the sludge distribution piping, 9 in. of sand media
overlying 9 in. of gravel media, 2-ft-high concrete dividers between beds,
and an underdrain system to remove percolating water. Land costs were not
included in the cost estimates. Conceptual designs that were used in
estimating costs are shown in Table 157.
Presented in Figure 188 are the estimated construction costs, which are
also shown in Table 158.
Operation and Maintenance Cost
Energy requirements are for a front-end loader to remove dried sludge
from the beds and to prepare the bed for the next sludge application. A
cleaning and preparation time of 3 hr for a 4,000 ft2 bed, a diesel fuel
consumption of 4 gal/hr, and 20 cleanings/bed per year were used to calculate
fuel requirements.
Maintenance material requirements are for replacement of sand lost
during bed cleaning. One-quarter inch of sand loss per cleaning was used to
calculate maintenance material costs.
Labor costs are for sludge removal and bed preparation, and they are
based on experience at operating installations. '
Figures 189 and 190 present the operation and maintenance requirements
and Table 159 summarizes these requirements.
409
-------
Table 156
Operation and Maintenance Summary for
Basket Centrifuges
Sludge Flow
Rate (gpd)
3,600
36,000
180,000
360,000
720,000
Energy
Building
82,850
115,520
630,150
1,260,290 1,
2,457,590 2,
(kw-hr/yr)
Process
65,350
98,020
588,150
176,290
352,590
Total
148,200
213,540
1,218,300
2,436,580
4,810,180
Maintenance
Material ($/yr)
$1,800
2,200
6,600
13,200
26,400
Labor
(hr/yr)
510
610
1,700
3,000
5,500
Total Cost*
($/yr)
$11,350
14,710
60,150
116,300
225,700
Calculated using $Q.03/kw-hr and $10,00/hr of labor.
-------
100,000
< 2
K
s 10,000 10,090,000
«u I
CJ* f
2
UJ
1000 1,000,000
1000 2 345 678910,000 234 56789100,0002
FEED SLUDGE FLOW RATE-gpd
345 6789
1,000,000
10,000
100,000 1,000,000
FEED SLUDGE FLOW RATE - liters /day
Figure 186. Operation and maintenance requirements for basket
centrifuges - building energy, process energy and maintenance
material.
411
-------
1,000,000
i
7
6
5
w 4
\ 3
I 2
O
o
100,0
-J 9'
I !
5
4
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8
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7
6
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1000 2 345 678910,000 234 56789100,000 2 345 6789
FEED SLUDGE FLOW RATE - gpd ,000,000
10,000 100,000 1,000,000
FEED SLUDGE FLOW RATE-liters/day
Figure 187. Operation and maintenance requirements for basket
centrifuges - labor and total cost.
412
-------
5,000
10,000
50,000
100,000
400,000
Table 157
Conceptual Design for
Sand Drying Beds
2
Total Bed Area (ft ) Number of Cells Dimensions of Cell (ft)
2
4
10
10
20
Length
100
100
100
200
200
Width
25
25
50
50
100
-------
7
6
5
4
3
2
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6
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8
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6
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000 2 34 5678910,000 234 56789100,0002 3 4 56789
TOTAL BED AREA -ft 2 1,000,000
i i — ~i_.-.. _.,...__
100
1000 10,000
TOTAL BED AREA -n«2
Figure 188. Construction cost for sand drying beds.
414
-------
Table 158
Construction Cost for
Sand Drying Beds
Total Bed Area (ft )
Ln
Cost Category
Excavation & Sitework
Concrete & Media
Steel
Labor
Pipe and Valves
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
5,000
$ 1,000
1,800
450
12,000
4,200
19,450
2,920
22,370
10,000
$1,600
2,400
700
21,000
6,000
31,700
4,760
36,460
50,000
$7,500
11,400
3,000
88,000
28,000
137,900
20,680
158,580
100,000
$15,000
20,800
6,000
168,000
54,000
263,800
39,570
303,370
400,000
$30,000
80,000
23,000
384,000
210,000
727,000
109,050
836,050
-------
100,000 100,000
r
10
1000
3 4 5678910,000 234 56789100,0002
TOTAL BED AREA-ft*
456 789
1,000,000
100
—I . 1—
1000 10,000
TOTAL BED AREA-m2
Figure 189. Operation and maintenance requirements for sand drying
beds - diesel fuel and maintenance material.
416
-------
1,000,000
100,000 IOO.OOJ)
f
I
h-
W
o
o
10,000 10,000
- _
8 - 8
? - 7
6 - 6
5- ,_ 5
i
(T
O
m
IOOQ' 1000
100
1000 2 34 5678910,000 234 56789100,0002 3 4 56789
TOTAL BED AREA-ft* I.OOO.OOO
100
1000 10,000
TOTAL BED AREA-m2
Figure 190. Operation and maintenance requirements for sand drying
beds - labor and total cost.
417
-------
Table 159
Operation and Maintenance Summary for
Sand Drying Beds
03
Total Sand Drying
Bed Area (ft2)
5,000
10,000
50,000
100,000
400,000
Diesel Fuel
(gal/yr)
300
600
3,000
6,000
24,000
Maintenance
Material ($/yr)
$150
310
1,540
3,090
12,340
Labor
(hr/yr)
700
900
2,100
4,000
16,000
Total Cost*
($/yr)
$7,290
9,580
23,890
45,790
183,140
*Calculated using $0.45/gallon for diesel fuel and $10.00/hr for labor.
-------
BELT FILTER PRESS
Construction Cost
The belt filter press is applicable for dewatering sludge from water
treatment plants and it can produce a sludge with a consistency suitable for
land disposal. The belt filter press combines features of both the vacuum
filter and the pressure filter, and under certain conditions it offers
advantages over either of these two methods of sludge dewatering.
Construction costs were developed for belt filter press dewatering
systems that included the belt press unit,"wash pump, conditioning tank, feed
pump, polymer storage tank and pump, belt conveyor, and electrical control
panel. A typical installation is illustrated in Figure 191. Machines are
generally sized using metric dimensions and are rated on the basis of sludge
flow in gpm/m of belt width. For water treatment sludges, a value of 15
gpm/m of belt width is the manufacturers' loading recommendation. Table 160
provides conceptual design information and assumptions utilized for belt
filter press systems with sludge handling capacities between 15 and 450 gpm.
Estimated construction costs are presented in Table 161 and shown
graphically as a function of total installed machine capacity in Figure 192.
Operation and Maintenance Cost
Process energy requirements were developed from the total connected
horsepower for the belt drive unit, belt wash pump, conditioning tank, feed
pump, polymer pump and tanks, belt conveyor, and electrical control panel.
A feed concentration of 1 percent alum sludge and a belt filter loading of
15 gpm/m of machine width was used in selecting unit sizes and determining
power requirements. Twenty-two hours of continuous operation with 2 hr of
downtime for routine maintenance was assumed in calculating process energy
requirements,
Labor and maintenance material requirements were estimated from
information provided by equipment manufacturers.
Figures 193 and 194 and Table 162 present operation and maintenance
requirements for the belt filter press. The assumptions used in developing
these costs should be noted, as operation and maintenance costs vary widely
depending on the nature and solids concentration of the sludge being
processed, and adjustments may have to be made on a case—by-ease basis.
SLUDGE DISPOSAL TO SANITARY SEWERS
Annual Cost
Disposal of sludge to sanitary sewers is usually beneficial to the
wastewater treatment facility, as it normally enhances sedimentation in the
primary clarifiers. At the same time, however, the volume of sludge at the
wastewater treatment facility increases, placing an additional load on the
sludge treatment and disposal facilities.
419
-------
ELEVATION
Figure 191. Typical belt filter press installation.
420
-------
to
Table 160
Conceptual Design for the
Belt Filter Press
Total Installed Machine
Capacity* (gpm)
15
30
225
450
Belt Width
(m)
1
2
3
3
Number
Of Units
1
1
6
12
Housing
Requirements
1,100
1,400
2,800
5,400
(ft2
*Total installed machine capacity is based on manufacturers' recommended loading of 15 gpm/m
of belt width.
-------
Table 161
Construction Cost for the
Belt Filter Press
Total Installed Machine Capacity (gpm)
to
Cost Category
Manufactured Equipment
Labor
Pipe and Valves
Electrical & Instrumentation
Housing
SUBTOTAL
Miscellaneous & Contingency
TOTAL COST
15
$ 95,000
28,500
8,000
2,500
48,400
182,400
27 , 360
209,760
30
$140,000
42,000
8,200
2,500
58,800
251,500
37,730
289,230
225
$1,040,000
310,000
33,000
6,500
112,000
1,501,500
225,230
1,726,730
450
$2,000,000
600,000
55,000
12,000
194,000
2,861,000
429,150
3,290,150
-------
9
8
7
6
5
4
3
2
10,000,0
9
8
7
6
5
4
T *
i-
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o
o 1,000,0
H 9
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to 5
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9
8
7
6
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r
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0,1
4 5678910 234 56789K50 234 56789
TOTAL INSTALLED MACHINE CAPACITY-gpm
1 , ,
1.0 10
TOTAL INSTALLED MACHINE CAPACITY-liters/sec.
Figure 192. Construction cost for the belt filter press.
423
-------
4 5 6789IO 234 56789100
FEED SLUDGE FLOW RATE-gpm
3 4 5 6789
-t-
1.0 10.0
FEED SLUDGE FLOW RATE-liters/sec.
Figure 193. Operation and maintenance requirements for the belt
filter press - building energy, process energy and maintenance
material.
424
-------
I
6
5
4
3
2
I,000,OC
6
5
4
3
><
T 2
en
8 I00,0(
f ?
° I
4
3
2
10,00!
9
8
7
6
5
4
3
2
8
7
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5
4
3
2
0
9
c 8
6
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— 4.
- • 3
30 IOO,C
9
8
7
4
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OR
234 5678910 234 SSTiSKX) 234 §6789
FEED SLUDGE FLOW RATE-gpm
4 . 1 - . , , i _
0,1
FEED SLUDGE FLOW RATE-liters/see
Figure 194. Operation ancj maintenance requirements for the belt
filter press - labor and total cost.
425
-------
Table 162
Operation and Maintenance Summary for the
Beit Filter Press
to
Feed Sludge
Flow Rate
(gpm)
15
30
225
450
Belt
Width (m)
1
2
3
3
Number of
Machines
1
1
6
12
Energy (kw-hr/yr)
Building
112,900
143,600
287,300
554,000
Process
102,000
149,800
1,078,000
2,157,000
Total t
214,900
293,400
1,365,300
2,711,000
Maintenance
laterial ($/yr)
$1,400
2,200
16,000
30,000
Total
Labor Cost*
(hr/yr) ($/yr)
1,100 $18,850
1,300 24,000
5,800 114,960
12,000 231,330
*Calculated using $0.03/kw-hr and $10.00/hr labor.
-------
The cost for sludge treatment,-and disposal at the wastewater facility
varies widely from location to location, depending on the concentration of
the water treatment plant sludge, the wastewater quality, and the degree,.of
treatment provided.
In accordance with PL 92-500, the Federal Water Pollution Control Act •
Amendments of 1972, most wastewater treatment agencies are implementing or
have implemented revenue programs that allocate the true cost of treatment,
to various categories of discharge. To estimate the cost of treating sludge
from a water treatment plant, a charge of $250/million gal of wastewater was
used. The wastewater was assumed to have a BOD of 225 mg/1 and TSS of 275
mg/1. The $250 charge was allocated - 34 percent to flow, 33 percent to BOD,
and 33 percent to suspended solids, which is equivalent to $85/million gal
of flow, $0.44/lb BOD, and $0.36/lb of suspended solids. Table 163 presents
the annual cost of discharging water treatment sludges with BOD values of
50 mg/1 at various flow rates and suspended solids concentrations to this
wastewater system. Costs are not altered significantly by sludge BOD values
up to 150 mg/1. Other factors that should be considered in determining the
feasibility and cost of sewer discharge are the availability of trunk sewer
capacity and the cost of using this capacity.
SLUDGE HAULING TO LANDFILL OR FARMS
Construction Cost
Sludge may be conveyed to landfill or farms in a liquid form using tank
trucks or in a dewatered form using dump trucks. Normally, hauling of liquid
sludge would only be economical for smaller plants, whereas hauling of
dewatered sludge is usually only economical for larger installations.-
Separate cost estimates have been made for each form of sludge hauling.
Cost estimates are based on agency ownership of the trucks and a truck
usage of 8 hr/day. When other than daylight operation is possible and/or
local requirements on route utilization allow operation over a 24-hr day,
a substantial savings in capital expenditure will occur. Serious considera-
tion should be given to operation over time periods greater than 8 hr/day.
If such operation is possible, the costs persented must be adjusted to reflect
the higher daily usage rate.
The criteria utilized to develop costs for liquid and dewatered sludge
hauling are presented in Table 164.
Liquid Sludge—
Costs were developed for hauling liquid sludge with volumes ranging
between 1.25 and 100 million gal/year, for one-way distances between 5 and
40 miles. All estimates were for the use of a 5,500-gal tanker truck, which
is more cost effective than smaller-sized tankers. The number of trucks
required and the initial capital cost for liquid sludge loading facilities are
shown in Table 165. Loading facilities include a truck-loading enclosure and
appropriate piping and valving to allow loading in a maximum time of 20 min.
Pumping facilities are not included in these costs, as separate curves are
427
-------
to
oo
Table 163
Annual Cost for
Sludge Disposal to Sanitary Sewers*
Sludge Volume Suspended Solids Concentration (mg/1)
gpm
20
100
500
1,000
5,000
10,000
mgd
0.0288
0.144
0.72
1.44
7.20
14.40
1,000
$4,240
21,200
106,000
212,000
1,060,000
2,120,000
5,000
$16,850
84,270
421,250
842,500
4,212,500
8,425,000
10,000
$32,600
163,110
815,500
1,631,000
8,155,000
—
50,000
$158,760
793,800
3,969,000
7,938,000
—
—
1100,000
$316,440
1,582,200
7,911,000
—
—
—
*Costs are based on a wastewater charge of $250/million gal for wastewater with a BOD of 225 mg/1
and a suspended solids concentration of 275 mg/1. The $250/million gal charge was assumed to be
allocated as follows: 34 percent to volume, 33 percent to BOD, and 33 percent to suspended solids.
-------
VO
Table 164
Cost-Estimating Criteria for Liquid and Dewatered Sludge Hauling*
Sludge
Type
Liquid
Dewatered
Truck
Capacity
5,500/gal
10/yd3
30/yd3
Fuel
Diesel
Gas
Diesel
Capital Cost
$63,240
28,750
57,490
Mileage
(mpg)
3.5
4.5
3.5
Fuel Cost
($/gal)
$0.45
0.55
0.45
Operator
Cost ( $/gal)
$15.00
15.00
15.00
Operation
Cost ($/mil6
$ 0.328
0.219
0.328
"^Operation cost excludes operator and fuel cost.
*Note: The following transport cycling criteria were also utilized :
Loading time - 20 rain/truck
Unloading time - 15 min/truck
Speed - 25 mph for 1st 20 miles of one-way distance
35 mph for more than 20 miles of one-way distance
-------
Table 165
Initial Construction Cost for
Liquid Sludge Hauling
Annual Volume One Way
of Sludge Haul Distance
(million gal/yr) miles
1.25 5
20
40
5.0 5
20
40
20 5
20
40
50 5
20
40
100 5
20
40
Number of
Trucks
Required
1
1
1
1
1
2
2
4
6
4
9
13
8
17
26
Initial
Cost of
Trucks
$ 63,240
63,240
63,240
63,240
63,240
126,480
126,480
252,960
379,440
252,960
569,160
822,120
505,920
1,075,080
1,644,240
Construction Cost
of Loading
Facilities
$ 15,500
15,500
15,500
15,500
15,500
15,500
15,500
15,500
- 15,500
31,000
31,000
31,000
46,500
46,500
62,000
Total
Initial
Cost
$ 78,740
78,740
78,740
78,740
78,740
141,980
141,980
268,460
394,940
283,960
600,160
853,120
552,420
1,121,580
1,706,240
-------
provided for chemical sludge pumping. The initial capital costs are
illustrated in Figure 195.
Dewatered Sludge—
Costs were also developed for hauling dewatered sludge with volumes of
1,000 to 300,000 yd3/year over one-way distances between 5 and 40 miles.
Loading facilities include a sludge conveyor, a hopper capable of holding
1.5 truckloads of sludge, and an enclosure for the sludge hopper. When more
than one hopper was required, multiple conveyors and enclosures were utilized.
The initial capital cost for loading facilities and trucks is shown in
Table 166 and Figure 196.
Operation and Maintenance Cost
Energy requirements for sludge hauling are for diesel fuel. The mileage
estimates utilized for various truck configurations used in the cost estimates
are shown in Table 164. Process energy for sludge pumping at the treatment
facility is not included; the cost curves for chemical sludge pumping should
be utilized if pumping is required.
Maintenance costs for the trucks were calculated on a $/mile—traveled
basis, using the per-mile costs included in Table 164. The maintenance costs
do not include fuel.
Labor requirements are for the truck operators. A loading time of 20
min and an unloading time of 15 min were utilized, and it was assumed that
the truck operator would be responsible for each.
Operation and maintenance costs for liquid sludge hauling are presented
in Table 167 and in Figures 197 and 198. Dewatered sludge hauling operation
and maintenance costs are presented in Table 168 and in Figures 199 and 200.
RAW WATER PUMPING FACILITIES
Construction Cost
Costs were developed for raw water pumping facilities, but the costs
exclude a wet well and housing, since these requirements will be extremely
variable from location to location. The costs include pumps, valves and
manifold piping, and electrical equipment and instrumentation. Pumps were
constant speed vertical turbine type, driven by drip-proof, high-thrust
vertical motors. A standby pump equal in capacity to the largest pump was
also included. Manifold piping was sized for a velocity of 5 ft/second.
Estimated construction costs are shown in Table 169 for pumping against
TDK of 30 and 100 ft. The costs are also presented in Figure 201.
Operation and Maintenance Cost
Process energy requirements were calculated for 30 and 100-ft TDK,
using a motor efficiency of 90 percent and a pump efficiency of 85 percent.
431
-------
7
6
5
4
3
2
10,000,0
1
6
5
4
3
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1 6
1- 5
to
0 4
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100,0
9
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7
6
5
4
3
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0
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40 M
20 Ml
5 MIL
LE5
.ES
ES
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E
-
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234 5678910 234 56789100 234 56789
ANNUAL VOLUME OF SLUDGE HAULED -m.g./yr
10,000 100,000 1,000,000
ANNUAL VOLUME OF SLUDGE HAULED -m3/yr
Figure 195. Initial construction cost for liquid sludge handling
5-, 20-, and 40-mile haul distances.
432
-------
Annual Volume
of Sludge
(yd3/yr)
1,000
10,000
50,000
150,000
300,000
Table 166
Initial Capital Cost for
Dewatered Sludge Hauling
One -Way
Haul Distances
(miles)
5
20
40
5
20
40
5
20
40
5
20
40
5
20
40
Size of
Trucks
(yd3)
10
10
10
30
30
30
30
30
30
30
30
30
30
30
30
Initial Cost
of Trucks
$ 28,750
28,750
28,750
57,490
57,490
57,490
57,490
114,980
172,470
114,980
287,450
402,430
229,960
574,900
804,860
Construction
Cost of
Loading
Facilities
$ 15,900
15,900
15,900
32,800
32,800
32,800
32,800
32,800
48,700
32,800
48,700
65,600
65,600
81,500
114,300
Total
Initial
Cost
$44,650
44,650
44,650
90,290
90,290
90,290
90,290
147,780
221,170
147,780
336,150
468,030
295,560
656,400
919,160
-------
10,000
1000 2 345 678910,000 2 3 4 5678900,000 2 345 6789
ANNUAL VOLUME OF SLUDGE HAULED -yd^/yr '.000,000
—) 1 1
1000 10,000 100,000
ANNUAL VOLUME OF SLUDGE HAULED-m3/yr
Figure 196. Initial construction cost for dewatered sludge hauling-
5-, 20-, and 40-mile haul distances.
434
-------
Table 167
Operation and Maintenance Summary
for Liquid Sludge Hauling
*•
w
Ui
Annual Volume
of Sludge
(million gal/yr)
1.25
5
20
50
100
One-Way
Haul Distances
(miles)
5
20
40
5
20
40
5
20
40
5
20
40
5
20
40
Diesel
Fuel
(gal/yr)
700
2,600
5,200
2,600
10,400
20,800
10,400
41,600
83,100
26,000
104,000
208,000
51,900
207,600
415,200
Maintenance
($/yr)
$ 750
2,980
5,980
2,980
11,940
23,850
11,940
47,560
95,420
29,820
119,260
238,520
59,630
238,520
477,040
Labor
(hr/yr)
260
540
790
1,045
2,140
3,160
4,180
8,540
12,650
10,455
21,360
31,640
20,910
42,730
63,270
Total Cost*
($/yr)
$ 4,970
12,250
20,170
19,830
48,720
80,610
79,320
194,380
322,570
198,350
486,460
806,720
396,640
972,890
1,612,930
^Calculated using $0.45/gal of diesel fuel and $15/hr of labor.
-------
1,000,000
I
3 4 5678910 234 56789100 234 56789
ANNUAL VOLUME OF SLUDGE HAULED -m.g./yr
-*-
10,000 100,000 1,000,000
ANNUAL VOLUME OF SLUDGE HAULED - m3/yr
Figure 197. Operation and maintenance requirements for liquid sludge
hauling - diesel fuel and maintenance material needed for
5-, 20-, and 40-mile haul distances.
436
-------
1,000,000
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ANNUAL VOLUME OF SLUDGE HAULED -m.g./yr
10,000 100,000 ,000,000
ANNUAL VOLUME OF SLUDGE HAULED - m3/yr
Figure 198. Operation and maintenance requirements for liquid sludge
hauling - labor and total cost needed for
5_5 20-, and 40-mile haul distances.
437
-------
Table 168
Operation and Maintenance Summary
for Dewatered Sludge Hauling
OJ
CXI
Annual Volume
of Sludge
(yd3/yr)
1,000
10,000
50,000
150,000
300,000
One-Way
Haul Distance
(miles)
5
20
40
5
20
40
5
20
40
5
20
40
5
20
40
Diesel
Fuel
(gal/yr)
220
890
1,700
1,000
3,800
7,600
4,900
19,100
38,000
14,300
57,100
114,300
28,600
114,300
228,600
Maintenance
($/yr)
$ 220
880
1,750
1,090
4,370
8,740
5,470
21,870
43,740
16,400
65,600
131,200
32,800
131,200
262,400
Labor
(hr/yr)
120
240
350
380
780
1,200
1,900
3,900
5,800
5,900
11,800
17,400
11,500
23,500
34,800
Total Cost*
($/yr)
$ 2,120
4,880
7,770
7,240
17,780
30,160
36,180
88,970
147,840
111,340
268,300
443,640
218,170
535,140
887,270
^Calculated using '$0.45/gal of diesel fuel and $15/hr of labor.
-------
1000
4 5678910,000 234 56789100,0002 3
ANNUAL VOLUME OF SLUDGE HAULED-yd3/yr
4 5 6?»9
1,000,000
1000
10,000 100,000
ANNUAL VOLUME OF SLUDGE HAULED -m3/yr
Figure 199. Operation and maintenance requirements for dewatered
sludge hauling - fuel and maintenance material needed
for 5-» 20-, and 40-mile haul distances.
439
-------
1,000,000
1000
1000
345 678910,000 234 56789100,000 2 3
ANNUAL VOLUME OF SLUDGE HAULED-yd^/yr
-4-
4 5 6789
1,000,000
1
10,000 100,000
ANNUAL VOLUME OF SLUDGE HAULED-
Figure 200. Operation and maintenance requirements for dewatered sludge
hauling - labor and total cost needed for 5-, 20-, and 40-mile haul distances,
440
-------
Table 169
Construction Cost for
Raw Water Pumping Facilities
Plant Capacity
1mgd 10
30-ft100-ft 30-fl
Cost Category
1 mad
30-ffc 100-ft
TDK TDH
10 mgd
30-ft 100-ft
TDH TDH
100 mgd
30-ft 100-ft
TDH TDH
200 mgd
30-ft 100-ft
TDH TDH
Manufactured Equipment $ 7,890 $8,680 $17,880 $30,150 $127,600 $192,270 $243,600 $367,060
Labor 3,510 3,650 8,200 8,770 50,060 53,030 96,460 102,130
Pipe and Valves 5,090 5,090 16,300 16,300 97,550 97,550 186,770 186,770
Electrical & Instrumentation 3,060 3,860 4,620 8,470 26,160 93,240 52,770 192,270
SUBTOTAL 19,550 21,280 47,000 63,690 301,370 436,090 580,600 848,230
Miscellaneous & Contingency 2,930 3,190 7,050 9,550 45,210 65,410 87,090 127,230
TOTAL 22,480 24,470 54,050 73,240 346,580 501,500 667,690 975,460
-------
7
6
5
4
9
a
7
6
5
1.000.000
9
8
6
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10,000
I
100
0
Oil
DH
345 S789IO 2
PUMPING
3 456 789100
CAPACITY -mgd
345 5789
10,000
100,000 1,000,000
PUMPING CAPACITY - m3 /day
Figure 201. Construction cost for raw water pumping facilities.
442
-------
Maintenance material includes repair parts for pumps and motors, valves, and
electrical starters and controls. • • -
Labor'requirements are based on operation and maintenance of the pumps,
motors, and valving, plus maintenance of electrical controls.
Figures 202 and 203 present operation and maintenance requirements, and
Table 170 summarizes these requirements.
FINISHED WATER'PUMPING FACILITIES
Construction Cost
Depending on distribution system layout and storage, finished water
pumping requirements may be greater than the average daily plant flow. To
account for such variations in capacity of the finished water pumping
facilities, costs were developed for facilities with a capacity range between
1.5 and 300 mgd. Pumps utilized were the vertical turbine type driven by
1,800 rpm, constant speed, drip proof, high thrust, vertical motors. One
standby pump with capacity equal to the largest pump was also provided.
The costs include all electrical equipment and instrumentation as well
as valving and manifolding within the pumping station. Manifold piping was
sized for a velocity of 5 ft/second. No costs are included for housing or
a wetwell, as it was assumed that the clearwell would serve as the wetwell.
Separate cost curves are provided for clearwell storage.
Figure 204 and Table 171 present the construction costs for finished
water pumping facilities.
Operation and MaintenanceCost
Process energy requirements were calculated for 100 and 300-ft TDK
using a motor efficiency of 90 percent and a pump efficiency of 85 percent.
Maintenance material includes repair parts for pumps, motors, valves, and
electrical starters and controls.
Labor requirements are based on operation and maintenance of the pumps,
motors, and valving, plus maintenance of electrical controls.
Figures 205 and 206 present operation and maintenance requirements, and
Table 172 summarizes these requirements.
CLEARWELL STORAGE
Construction Cost
Product water is commonly stored at the plant site before high-service
pumping, as a supplement to distribution system storage. In many cases,
filter or granular activated carbon wash water pumps also draw from the
clearwell, eliminating the need for a separate sump. Clearwell storage may
be either below ground in reinforced concrete structures, or above ground
443
-------
IOO.OOO
345 678910 2 3456 789100
AVERAGE PUMPING RATE-mgd
4-
3 456 789
10,000 100,000 1,000,000
AVERAGE PUMPING RATE - m^/day
Figure 202. Operation and maintenance requirements for raw water
pumping facilities - process energy and maintenance material
needed for 30- and 100-ft TDH,
444
-------
§
7 -
6
•5
4
3 -
1,000,000
•vt-
1
en
O
100,000 10,000
- I
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O 6
10,000 1000
"~
._ 100
4 5678910 234 56789100
AVERAGE PUMPING RATE— mgd
345 6789
10,000
100,000 1,000,000
AVERAGE PUMPING RATE - m3/day
Figure 203. Operation and maintenance requirements for raw water
pumping facilities - labor and total cost for 30- and 100-ft TDK.
445
-------
Table 170
Operation and Maintenance Summary
for Raw Water Pumping Facilities
Capacity /Pumping Head
1 mgd :
30 ft
100 ft
£ 10 mgd:
OS
30- ft
100 ft
100 mgd:
30 ft
100 ft
200 mgd:
30 ft
100 ft
Process
Energy
( kw-hr/yr )
44,940
74,930
449,420
749,260
4,494,240
7,492,580
8,988,490
14,985,170
Maintenance
Material ($/yr)
$ 350
350
1,600
1,600
15,000
15,000
25,000
25,000
Labor
(hr/yr)
520
520
740
740
2,690
2,690
5,130
5,130
Total Cost*
($/yr)
$6,900
7,800
22,480
31,490
176,800
266,680
345,950
525,860
*Calculated using $0.03/kw-hr and $10,00/hr of labor,
-------
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2 34 5678910 234 56789100 2 34 56789
INSTALLED PUMPING CAPACITY-mgd
10,000
1,000,000
INSTALLED PUMPING CAPACITY- m^/day
Figure 204, Construction cost for finished water
pumping facilities - 100- and 300-ft TDK.
447
-------
Table 171
Construction Cost for
Finished Water Pumping Facilities
Plant Capacity
1.5 mgd I5mgd 150 mgd 3 UP mgd
30-ft 100-ft 30-ft 100-ft 30-ft 100-ft 30-ft 100-ft
^ Cost Category TDH TDH TDH TDH TDH TDH TDH TDH
*•
°° Manufactured Equipment $ 9,260 $15,410 $35,630 $89,700 $259,000 $567,600 $501,810 $1,142,350
Labor 3,310 3,880 9,180 11,580 66,950 80,400 104,360 158,840
Pipe and Valves 5,200 5,200 16,570 16,570 139,200 139,200 270,100 270,100
Electrical & Instrumentation 3,340 7,180 14,120 38,450 164,640 210,490 290,320 400,230
SUBTOTAL 21,110 31,670 75,500 156,300 629,790 997,690 1,166,590 1,971,520
Miscellaneous & Contingency 3,170 4,750 11.330 23.450 94.470 149.650 174.990 295.730
TOTAL 24,280 36,420 86,830 179,750 724,260 .1,147,340, 1,341,580 2,267,250
-------
100,000,000
100
,3 4 5678910 234 56789100 2
AVERAGE PUMPING RATE-mgd
4 S 6789
10,000
-i-
100,000 1,000,000
AVERAGE PUMPING RATE - mVdoy
Figure 205. Operation and maintenance requirements for finished water
pumping facilities - process energy and maintenance material
for 100- and 300-ft TDK.
449
-------
!0,000£00
I
7
6
5
4
1,000,000
v>
o
u
I
10,000
9
8
7
6
5
4
3
2
1000
raopoo 10,000
9
f
6
5
4
3 4
10,000
5678910 234 56789KX)
AVERAGE PUMPING RATE-mgd
-J-
3 456 789
-*-
100,000 1,000,000
AVERAGE PUMPING RATE -m3/day
Figure 206. Operation and maintenance requirements for finished water
pumping facilities - labor and total cost for 100- and 300-ft TDK-
450
-------
Ln
Table 172
Operation and•Maintenance Summary for
Finished Water Pumping Facilities
;ity/Pt
1.5
15
150
300
.imping Head
mgd :
100 ft
300ft
mgd :
100ft
300ft
mgd :
100ft
300ft
ragd :
100ft
300ft
Energy
(kw-hr/yr)_
' 74,930
224,790
749,260
2,247,780
7,492,580
22,477,740
14,985,170
44,955,510
Maintenance
Material ($/yr)
$ 410
410
2,380
2,380
20,000
20,000
37,500
37,500
Labor
(hr/yr)
534
534
843
843
3,910
3,910
7,690
7,690
Total Cost*
($/yr)
$ 8,000
13,090
33,290
78,240
283,880
733,430
563,960
1,463,070
^Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
in steel tanks. Instrumentation and control of the clearwell water level
is very important in terms of pacing the plant output. In addition,
instrumentation for turbidity and chlorine measurement, as well as other
quality control operations, is normally provided with the clearwell.
Conceptual designs for below and above-ground-level clearwells are shown
in Table 173.
Table 173
Conceptual Designs for Clearwell Storage
Below-Ground Clearwells
Size (ft)
Ground-Level Clearwells
Size (ft)
Capacity (gal) Length Width
Capacity (gal) Diameter
10,000
50,000
100,000
500,000
1,000,000
7,500,000
11
18
26
58
82
224
11
18
26
58
82
224
12
20
20
20
20
20
8,500
37,600
88,100
475,900
846,000
4,606,200
9,400,400
12
20
25
45
60
140
200
10
16
24
40
40
40
40
Construction costs are shown in Table 174 for below-ground clearwells and
in Table 175 for ground-level clearwells. Figure 207 presents the costs for
both types of clearwells.
AERATION
Construction Cost
Aeration is a useful technique for the removal of TTHM and other volatile
organic compounds from water, as well as for the oxidation of iron and
manganese compounds. Two techniques are available - diffused aeration basins
and/or aeration towers. These techniques are discussed individually in the
following sections.
Diffused Aeration Basins—
Costs were developed for open, reinforced concrete basins with a depth of
12 ft. The basins were rectangular in shape, with common wall construction
and a length-to-width ratio of 4:1. The maximum individual basin size
utilized was 3,800 ft3 with multiple basins utilized when the total basin
volume exceeded 3,800 ft3. Direct drive centrifugal compressors were used
for the air supply, and porous diffusers placed at close intervals over the
entire basin bottom were used for air introduction. The air supply system
was sized for 5 scfm/ft2 of basin floor area. Although removals are a
function of air-to-water ratio, contact time, and water temperature, an
air-to-water ratio of 10 ft3 of air to 1 ft3 of water should be sufficient
for the removal of TTHM. Construction costs are shown in Table 176 and
Figure 208.
452
-------
Table 174
Construction Cost for
Bel'ow-Ground .Clearwell Storage
Ul
W
Clearwell Capacity (gal)
Cost
Excavation &
Concrete
Steel
Labor
Electrical &
SUBTOTAL
Miscellaneous
TOTAL
Category
Sitework
Instrumentation
& Contingency
10
$
8
5
13
1
28
4
32
,000
140
,250
,700
,050
,270
,410
,260
,670
50,000
$ 190
14,430
9,240
21,480
1,270
46,610
6,990
53,600
100,
$
23,
14,
35,
6,
79,
11,
91,
000
410
280
550
040
010
290
890
180
500
$ 2
66
32
84
6
191
28
219
,000
,030
,330
,670
,090
,010
,130
,670
,800
1,000,
$19,
105,
113,
109,
9^
357,
53,
410,
000
440
520
050
290
800
100
570
670
7,500,000
$ 30,020
622,500
350,700
394,160
9,800
1,407,180
211,080
1,618,260
-------
Table 175
Construction Cost for
Ground-Level Clearwell Storage
Clearwell Capacity (gal)
Ul
Cost Category
Manufactured Equipment
Concrete
Steel
Labor
Pipe and Valves
Electrical & Instrumentation
SUBTOTAL
Miscellaneous & Contingency
TOTAL
8,500
$ 6,710
5,420
4,030
810
3,350
1,270
21,590
3,240
24,830
37,600
$ 15,580
5,580
4,310
850
4,950
1,270
32,540
4,880
37,420
88 , 100
$ 29,520
5,890
4,580
850
7,390
6,010
54,240
8,140
62,380
475,900
$.78,520
8,530
6,620
1,230
9,900
6,010
110,810
16,620
127,430
846,000
$ 128,920
11,130
8,610
1,590
13,820
6,010
170,080
25,510
195,590
4,606,200
$ 459,080
43,870
33,950
6,290
22,280
6,010
581,480
87,220
668,700
9,400,400
$ 797,040
84,850
65,640
12,150
36,360
6,010
1,002,050
150,310
1,152,360
-------
10,000
4 56789100,0002 3 4 5 6 7 8 9IpOO.OOO2
STORAGE VOLUME -gallons
456 789
10,000,000
-t-
100
1000
STORAGE VOLUME-m3
10,000
Figure 207. Construction cost for below-ground and
ground-level clearwell storage.
455
-------
Ul
Table 176
Construction Cost for
Diffused Aeration Basin
Aeration Basin Volume ( ft3)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical and Instrumentation
Housing
SUBTOTAL
Miscellaneous and Contingency
TOTAL
1,900
$ 450
48,000
1,380
2,100
15,500
14,400
14,000
95,830
14,370
110,200
19,000
$ 4,700
310,000
9,000
13,700
94,000
87,000
19,200
537,600
80,640
618,240
94,000
$ 9,300
1,050,000
29,000
44,100
295,000
284,000
40 ,000
1,751,400
262,710
2,014,110
190,000
$ 19,000
1,900,000
57,000
87,000
495,000
475,000
48,000
3,081,000
462,150
3,543,150
380,000
$ 29,000
3,700,000
110,000
167,000
965,000
903,000
96,000
5,970,000
895,500
6,865,500
-------
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000 2 34 5678910,000 234 56789100,0002 3 4 56789
AERATION BASIN VOLUME -ft3 1,000,000
100 IOOO !0(000
AERATION BASIN VOLUME-m3
Figure 208. Construction cost for diffused aeration basins.
457
-------
Aeration Towers—
Stripping of volatile organics from water supplies can be accomplished
in aeration towers similar to those used for oxidation of iron and manganese.
The degree of removal of a specific organic compound by this technique depends
on volatility of the compound, air-to-water ratio and contact time in the
tower, water temperature, and many other factors. Limited experience with
the process indicates that loading intensities matching those used for iron
and manganese oxidation in towers with media depths of 15 to 25 ft will
provide between 40 and 90 percent removal of volatile organic compounds.
Estimated cons'truction costs are for rectangular aeration towers with
16—ft of PVG media and an overall tower height of 22—ft. For towers of less
than 6,400 ft^, units are shipped assembled and have reinforced fiberglass
skin supported by a galvanized metal framework. Towers of greater volume
are field erected from factory-formed components- and are similar in design
and construction to industrial cooling towers. The exterior skin of
corrugated asbestos cement panels is attached to a structural steel framework.
Towers are supported by a reinforced concrete basin. The basin collects
tower underflow and serves as a pump sump. The cost estimate does not
include tower supply pumps or tower underflow pumps. All aeration towers
have electrically driven, induced-draft fans with fan stacks and drift
eliminators.
Construction costs for aeration towers are shown in Table 177 and
Figure 209.
Operation and Maintenance Cost
Diffused Aeration Basins—
Process energy requirements are for operation of the direct drive
centrifugal air compressors. Continuous, 24-hr/day, 365-day/year operation
was assumed.
Maintenance materials include lubricants, replacement components for
air compressors, and air diffusion equipment. Estimates were developed
from review of costs associated with activated sludge aeration facilities.
Labor requirements include maintenance of air compressors, air piping,
valving, and diffusers and for general maintenance of aeration basins.
Estimated operation and maintenance requirements are presented in
Table 178 and Figures 210 and 211.
Aeration Towers—
Process electrical energy requirements are for operation of the induced
draft fan. A 24-hr/day, 365-day/year operation was assumed. In some
instances, pumping energy may also be required, but it is not included
because the requirement for it and the rate and head of pumping will vary
from application to application. Units are not housed, eliminating the
need for building-related energy.
458
-------
Ul
Table 177
Construction Cost
for Aeration Towers
Aeration Tower Volume (ft3)
Cost Category
Excavation and Sitework
Manufactured Equipment
Concrete
Steel
Labor
Electrical & Instrumentation
SUBTOTAL
Miscellaneous and Contingency
TOTAL
680
$ 100
16,000
1,600
2,400
3,100
800
24,000
3,600
27,600
6,400
$ 220
110,000
10,000
14,000
18,000
3,000
155,220
23,280
178,500
32,000
$ 900
192,000
18,000
26,000
42,000
13,000
291,900
43,790
335,690
64,000
$1,500
352,000
30,000
43,000
74,000
20,000
520,500
78,080
598,580
128,000
$ 3,000
640,000
57,000
85,000
147,000
30,000
/ 962,000
144,300
1,106,300
256,000
$ 6,000
1,025,000
110,000
160,000
289,000
48,000
1,638,000
245,700
1,883,700
-------
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6
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345 678910,000 2 3456 789100,000 2 3
AERATION TOWER VOLUME-ft3
456 789
1,000,000
-f-
-4-
100 1000 10,000
AERATION TOWER VOLUME —m3
Figure 209. Construction cost for aeration towers.
460
-------
Table 178
Operation and Maintenance Summary
for Diffused Aeration Basins
Aeration Basin Volume *
1,900
19,000
94,000
190,000
380,000
(ft d) Building
16,000
24,000
50,000
60,000
120,000
Energy (kw-hr/yr)
Process
281,400
2,810,000
14,285,000
28,570,000
57,140,000
Maintenance
Labor
Total Material ($/yr) (hr/yr)
297,400
2,834,000
14,335,000
28,630,000
57,260,000
$ 3,000
9,000
14,000
18,000
30,000
1,500
4,000
10,000
20,000
40,000
Total*
Cost($/yr)
$ 26,920
134,020
544,050
1,076,900
2,147,800
Calculated using $0.03/kw-hr and $10.00/hr for labor.
-------
100,000,000
1000 234 5678910,000 334 56789100,0002 3 4 56789
•a 1,000,000
AERATION BASIN VOLUME- ft3 ' '
100 1000
AERATION BASIN VOLUME-m3
10,000
Figure 210. Operation and maintenance requirements for diffused aeration
basins - maintenance material, building energy, and process energy.
462
-------
10,000
I"
7
6
5
4
,000
,000,000
to
o
o
i-
o
100,000 100000
ft 9
8 - 8
7 - 7
6 - 6
10,000 10,000
1000
1000 2 34 5678910,000 234 5678900,0002
AERATION BASIN VOLUME -ft3
TJ
CO
LABC
456 789
1,000,000
100 1000
AERATION BASIN VOLUME —
10,000
Figure 211. Operation and maintenance requirements for diffused
aeration basins - labor and total cost.
463
-------
Maintenance materials include replacement packing media, lubricants for
fans and motors, and other miscellaneous items. Labor requirements include
fan and motor maintenance, weekly hosing of distributing nozzles and media
to remove slime growths, and occasional repair or replacement of damaged
packing media.
Estimated operation and maintenance requirements are presented in
Table 179 and Figures 212 and 213.
ADMINISTRATION, LABORATORY AND MAINTENANCE BUILDING
Construction Cost
Most water treatment plants include building area for administrative
offices, laboratory, maintenance or shop area, and general storage. The
amount of area set aside for these functions varies widely from one plant to
another. Factors such as plant capacity, extent of administrative functions
conducted at the treatment facility (whether solely for the plant or for other
functions also), funding availability, and designer preference will have a
significant effect on the amount of building area designated for these
functions.
The construction cost curve was developed using building areas obtained
from a review of over a dozen water treatment facilities, with capacities
ranging between 1 and 100 mgd. It should be noted that these area require-
ments exclude the area required for chemical storage, which is included in
the cost curves for the individual chemical feed systems. In developing the
construction cost curve, it was recognized that building costs are variable,
depending on the function and design of the facility. Costs can range from
as little as $20 to $25/ft2 for storage areas to $75 to $80/ft2 for
laboratories. A weighted composite cost of $45/ft2 was selected to develop
a cost curve. The cost curve does not include laboratory analytical equip-
ment or supplies, maintenance equipment, or vehicles.
The estimated construction costs are shown as a function of plant
capacity in Table 180 and also in Figure 214.
Operation and Maintenance Cost
Operation and maintenance requirements related to administrative,
laboratory, and maintenance functions were developed for treatment plant
capacities between 1 and 200 mgd. Information on staffing requirements
and maintenance material costs was obtained from various water treatment
facilities and supported by extrapolation from published information for
wastewater treatment plants.
Building energy requirements were developed from the building area
requirements shown in Table 180. Maintenance material costs are related
to operation and maintenance of administrative facilities that are not
directly assignable to specific plant components. Such expenses include
office supplies, communications, dues, subscriptions, office equipment
repairs, travel expenses, training course expense, and custodial supplies.
464
-------
Table 179
Operation and Maintenance Summary
for Aeration Towers
Aeration Tower
Volume (ft3)
680
$ 6,400
01 32,000
64,000
128,000
256,000
Process Energy
(kw-hr/yr)
3,270
65,440
327,200
654,400
1,309,000
2,618,000
Maintenance
Material ($/yr)
$ 600
1 ,000
3,000
6,000
12,000
25,000
Labor
(hr/yr)
50
160
300
500
900
1,700
Total Cost'
$ 1,200
4,560
15,820
30,630
60,270
120,540
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
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AERATION TOWER VOLUME - ff 3 ,000,000
• , i
100 1000 10,000
AERATION TOWER VOLUME-m3
Figure 212. Operation and maintenance requirements for aeration towers
process energy and maintenance material.
466
-------
1,000,000
-tfl-
tn
o
o
o
100,000 10,000
f
1000
345 678910,000 234 56789100,000 2
AERATION TOWER VOLUME - ft 3
•4-
3 456 789
1,000,000
100
1000
AERATION TOWER VOLUME
10,000
Figure 213. Operation and maintenance requirements for aeration
towers - labor and total cost.
467
-------
Table 180
Construction Cost.for
Administrative, Laboratory and Maintenance Building
Building Area Construction
Plant Capacity.(mgd) Requirements (ft2) Cost* ($)
1 550 $ 24,750
10 2,000 90,000
50 6,000 225,000
100 7,200 324,000
200 10,000 450,000
*Based on a weighted composite cost of $45/ft2.
468
-------
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o
o
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cr
O
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1,000,
9
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7
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100,000
234 5678910 234 56789KX)
PLANT CAPACITY-mgd
3 456 789
10,000
100,000 1,000,000
PLANT CAPACITY-m3/day
Figure 214. Construction cost for administrative,
laboratory, and maintenance building.
i
469
-------
Labor requirements are limited to those whose time and effort are
related only to administration and management of the plant, such as superin-
tendent, assistant superintendent, plant chemist, bacteriologist, clerk, and
maintenance supervisor. Note that operation and maintenance labor, which is
included under each specific unit process, is excluded from these curves.
Operation and maintenance requirements are summarized in Table 181 and
illustrated in Figures 215 and 216.
470
-------
Table 181
Operation and Maintenance Summary for
Administrative, Laboratory and Maintenance Building
Plant Capacity (mgd)
1
10
50
100
200
Building Energy
(kw-hr/yr)
56,400
205,000
513,000
739,000
1,030,000
Maintenance
Material
($/yr)
$ 2,000
4,500
10,000
15,000
20,000
Labor
(hr/yr)
1,460
6,200
10,400
12,500
16,000
Total Cost*
($/yr)
$ 18,290
72,650
129,390
162,170
210,900
Calculated using $0.03/kw-hr and $10.00/hr of labor.
-------
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7
6
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3 4 5678910 234 56789100
PLANT CAPACITY-mgd
3 456 789
10,000
100,000 1,000,000
PLANT CAPACITY-m3/day
Figure 216. Operation and maintenance requirements for administration,
laboratory, and maintenance building - labor and total cost.
473
-------
SECTION 3
ASBESTOS AND VIRUS REMOVAL BY MODIFICATION OF STANDARD TREATMENT PROCESSES
OPERATING STRATEGIES FOR VIRUS AND ASBESTOS REMOVAL
The conventional water treatment processes of coagulation, filtration,
and disinfection provide good removal of both asbestos and virus. When
desired or necessary, asbestos and virus removals can be increased by
modifying or adding to standard processes and by exercising more extensive
and rigid control of treatment plant operations. In general, removals of
both constituents can be correlated with filtered water turbidities.
Filtered water with a turbidity of less than 0.1 turbidity units (TU)
ordinarily would be substantially free of asbestifortn fibers of the amphibole
group. In addition, Hudson11 demonstrated a relationship between filtered
water turbidities and residual virus particles that suggests that low
turbidity is consistent with maximum virus removal. On the other hand,
complete virus removal must ultimately be considered to be dependent on the
process of disinfection. Coagulation and filtration can provide substantial"
virus removal, but complete removal can be assured only by proper disinfection.
To insure that filtered water has the lowest possible turbidity, all
suspended material must be properly coagulated before filtration. Coagula-
tion and filtration are extremely interdependent processes. In fact, they
are so closely related that they can best be visualized and considered as
parts of a single coagulation-filtration process. One technique designed
to establish the adequacy of coagulation utilizes a pilot filter to filter
a sample of coagulated water immediately after application of chemical
coagulants. Several manufacturers have developed equipment designed for
this purpose. Continuous monitoring of the pilot filter effluent turbidity
with a recording turbidimeter establishes whether an adequate coagulant
dosage has been applied to the incoming raw water. With this equipment, the
operator can preselect the maximum allowable filtered water turbidity, which
if exceeded, initiates an alarm signifying an inadequate coagulant dosage.
The high turbidity condition is then corrected by increasing the coagulant
dosage. By using the pilot filter technique for coagulation monitoring,
there is minimal danger that an improperly coagulated water will reach the
plant filters and lead to production of an unsatisfactory filtered water
turbidity. -Pilot filters enhance filter performance and increase
assurances that filtered water will be substantially free of asbestos and
virus particles. Perhaps of equal importance is the installation and
operation of continuous turbidity monitoring equipment on each plant filter
effluent line.
474
-------
ASBESTOS REMOVAL
Considered that the need for asbestos removal has only recently been
recognized (about 1973), it is significant that the best methods for treat-
ment are now rather well established. Generally, filter plants should be
designed and operated to produce finished water turbidities of 0.1 to 0.2 TU
to accomplish virtually complete removal of asbestos—like fibers.
The operating strategy for coagulation, filtration, and disinfection
system to remove asbestos involves several factors. Good coagulation is
absolutely essential. In this regard, two or three stages of rapid mixing
may be required, with several points for application of coagulant chemicals
and coagulant aids. Good control of the coagulation process is necessary.
This may be accomplished by use of a pilot filter, coagulant control center,
or other means. Provision should be made for the introduction of polymer
to the flash mixers, the flocculation chambers, the filter beds, or any
combination of the three locations. In some cases, the use of two different
polymers may be helpful. Amphibole fiber removal accomplished by tri-media
filters exceeds that accomplished by the dual-medial filters. Therefore, -
a positive-head, tri-media filter designed to operate at a rate of 290
m /nr* per day (5 gpm/ft2) at design flow is recommended. Although sedimenta-
tion is not required for fiber removal, presedimentation could be used to
reduce the solids loading to the filters and to extend filter run lengths.
In some instances, direct filtration may be practical. Quality control of
filter operations should be based on maintaining a finished water having a
turbidity of not greater than 0.1 TU.
In-line turbidimeters should be used for continuous monitoring of the
raw and finished water turbidity, as well as that of the effluent from the
pilot filter and each individual plant filter unit. Analyses for asbestiform
fiber counts should be performed regularly on raw and finished water samples
to check on the efficiency of fiber removal. Provisions must be made to
insure that asbestos fibers in settling basin sludge and settled filter
backwash water do not reach the original water sources. A wash water
recovery system is advisable. Sludges may go to a lagoon or sanitary landfill.
The potential modifications required at most existing filter plants
to enhance asbestos removal include:
1. Addition of one or two stages of rapid mixing;
2, Provision for feeding polymers or other coagulants or coagulant
aids not used in normal treatment;
3. Addition of a pilot filter, a coagulant control center, and
automated sampling devices;
4. Provision for mixed-media filters rather than dual or single-media
filters;
475
-------
5. Installation of turbidity monitoring equipment on each filter
effluent line and on the clearwell or combined finished water
discharge line;
6. Provision for higher-than—normal filter backwash rates;
7. Addition of a wash water recovery system.
8. Provision for safe (usually lagoon or landfill) disposal of
settling basin and backwash sludge containing asbestos; and
9. Acquisition of laboratory equipment to measure asbestos fiber
removal.
Experts in water treatment will recognize that many, if not all, of
these features have been incorporated into many new water purification
plants built since about 1960. Also, many older plants have recently added
these features to improve finished water quality, control of plant operations,
and the reliability of treatment processes.
Added Costs For Asbestos Removal In New Plants.
If the best in coagulation, filtration, and disinfection are needed in
a new plant for purposes other than asbestos removal, then the only additional
construction costs to be allocated totally to asbestos removal would be for
the above items 1, 2, 6, 8, and 9. The cost of items 3, 4, 5, and 7 could
be prorated between asbestos removal and the other purposes served by these
features. The total construction cost attributable to asbestos removal could
then be estimated by use of the cost curves contained in this report for;
1. Rapid mix
2. Polymer feed systems
3. Alum feed systems
4. Backwash pumping facilities
5. Sludge dewatering lagoons
6. Total microscopic particle counter
The the total construction cost of the appropriate items from the above
list must be added to the costs for the contractor's overhead and profit,
land, interest during construction, engineering, and legal, fiscal, and
administrative services. Costs for operation and maintenance of the above
items can be estimated from the operation and maintenance cost curves
included in this report. Examples are contained in Volume 1 to show the
method of determining capital cost, operation and maintenance cost, and
total cost.
Added Costs For Asbestos Removal In Existing Plants
If an existing plant is to be modified for the purpose of removing
asbestos, then the total cost of all new facilities would be allocated to
asbestos removal. In addition to the items shown on the above list, other
modifications or additions that may be required are:
476
-------
1. Modification of rapid sand filters to high-rate filters
2. Wash water surge basin
3. Coagulation control with pilot filters
4. Automatic chemical dosage control with pilot filters
5. Addition of in-line turbidimeter
Construction and operation and maintenance curves for these facilities
or modifications are included within this report. Items 1 and 2 are included
with the cost curves for 1 to 200-mgd treatment facilities, and items 3, 4,
and 5 are included within this section.
One additional possibility is that a need may arise for more highly
skilled operators. Such an additional cost would also have to be charged
to asbestos removal.
VIRUS REMOVAL
As mentioned previously, complete virus removal can be obtained only
by adequate disinfection. Suitable drinking water disinfectants for use in
virus inactivation include free chlorine, ozone, and chlorine dioxide. In
cases where trihalomethane production is a problem, chlorine-ammonia may
also be considered if properly used.
Excess turbidity can encapsulate virus and prevent contact with the
disinfectant applied to the water. Organic matter, iron, manganese, color
bodies, and other substances can react with some disinfectants and reduce
the total amount of the disinfectant remaining to inactivate the virus.
Removal of turbidity and other foreign substances by coagulation, settling,
and filtration thus greatly facilitates proper disinfection by optimizing
conditions under which disinfection takes place. It is generally agreed
that turbidities should be reduced to less than 1.0 TU before final disin-
fection. There is some support for the idea that further reduction of
turbidity to the 0.1 to 0.2 TU range provides even better conditions for
disinfection, but this view is not universal.
One operating strategy for virus Inactivation is as follows:
1. The turbidity of the water should be < 1.0 TU, and preferably
<0.1 TU.
2. The pH of the water should be close to 7.5 for waters containing
ammonia, or <7.0 for ammonia-free waters.
3. Rapid, uniform mixing of water and chlorine must be provided.
4. A concentration of 0.5 to 1.0 mg/1 of undissociated hypochlorous
acid (HOC1) must be maintained in the water being treated for a
contact period of 30 min.
477
-------
Ozone has a greater germieidal effectiveness against virus than does
chlorine, and its potency is not affected by pH or ammonia content. With
proper mixing and the recommended dosage of not <1 mg/1 ozone, a contact
time of 5 min is adequate in clear water (<1 TU).
In many older, existing filter plants there are several potential
changes that could be made to improve virus removal, including:
1. Provision for feeding polymers not used in normal treatment to
rapid mix or flocculation basins and to filter beds.
2. Provision for mixed-media or dual-media rather than single-media
filters.
3. Installation of turbidity monitoring equipment immediately ahead
of the point of chlorine addition as well as on each filter effluent.
4. Addition of pilot filter, coagulant control center, and automated
sampling devices.
B. Disinfection (with chlorine)
5. Improved mixing at point of chlorine addition.
6. Installation of continuous-recording chlorine residual analyzer.
In most new plants, most of all of these items would be provided, and
the costs to be allocated to virus removal could be prorated based on all
benefits realized from installation and use of such facilities.
In existing plants, if the sole or main purpose of the improvements
is to increase viral inactivation, then the total cost of improvements
should be charged to virus removal.
The cost estimates in this report that can be used to determine the
construction and operation and maintenance costs for virus removal are:
1. Breakpoint Chlorination - Chlorine storage and feed systems
2. Ozone generation systems and contact chambers.
3, Chlorine dioxide generating and feed systems.
4. Polymer feed systems.
5. Coagulation control with pilot filters.
6. Modification of rapid sand filters to high-rate filters.
7. Automatic chemical dosage control with pilot filters.
478
-------
Cost curves for items 1, 2, 3, 4 and 6 are included with the cost curves
for 1 to 200-mgd treatment facilities, and items 5 and 7 are included in
this section. After the necessary individual 'construction cost items are
selected for a project and totaled, applicable allowances must be added for
contractor's overhead and profit, engineering, interest during construction,
and legal, fiscal, and administrative costs. Costs for operation and
maintenance can be estimated from the cost curves for the same items plus
the costs for chemicals. Examples are provided in Volume 1 of this report
to illustrate the method for adding these costs to obtain the total cost of
treatment.
COST ESTIMATES FOR UNIT PROCESSES TO REMOVE ASBESTOS AND VIRUS
Filtered Water Quality Monitoring With Total Particle Counters
Continuous filter effluent quality monitoring is a prerequisite to
achieving maximum assurance of removal of asbestiform particles and virus.
Turbidity measurement, which is a widely used technique, provides an indirect
indication of the effectiveness of the filtration process in removing these
contaminants. A total particle counter, however, provides a direct measure-
ment of the particulate material present in water and is not influenced by
particle size, shape, refractive index, and other parameters as are turbidity
measurements. For these reasons, the total particle counter offers promise
of being a very useful and sensitive process control tool in water treatment
practice, and especially where there is proven presence of asbestiform
fibers in drinking water supplies.
Although there are several techniques for measuring and counting
particles in water, the only instrument currently available that lends itself
to continuous monitoring and flexible operation (batch or continuous sampling)
is the HIAC Particle Size Analyzer. This instrument operates on the principal
of light blockage, in which particles passing by a window or accurately
established area are measured and counted individually according to their
maximum projected area or equivalent spherical diameter. Particles ranging
in size from 1 to 9,000 urn can be measured; however, the most common size
range for use in water treatment is 2.5 to 150 urn.
The total particle counter can be used either as a laboratory unit or
installed on filter effluent piping to provide continuous monitoring of
filtered water quality. The number of units employed in a treatment
facility could vary, depending on numerous factors. «
A single unit would suffice as a laboratory tool to analyze filtered
effluent samples periodically for correlation to turbidity results and for
general monitoring at other process points. A more elaborate installation
would involve placement of particle counter sensors at each filter effluent,
much as is currently done with turbidimeters.
Construction costs for total particle counting systems are presented in
Table 182. Costs are presented for a laboratory unit with 12 particle-size-
range sensors useful as a research tool and for a continuous filter effluent
479
-------
Table 182
Construction Cost for Total Particle Counter Systems
Equipment Description
Filter Effluent
Cost Category Laboratory Unit Monitor (per filter)
Equipment $ 15,000 $ 6,000
Pipe and Valves — 350
Installation Labor — 250
Electrical Equipment — 200
TOTAL COST $ 15,000 $ 6,800
480
-------
monitoring system that includes a unit with only three sensors covering the
size range typical of particles in filtered waters. The latter system
includes sample pumps and electrical interconnection between sensor and
readout device.
Coagulation Control with Pilot Filters
To insure that filtered water has the lowest possible turbidity, all
suspended material must be properly coagulated before filtration. One
technique designed to establish the adequacy of coagulation utilizes a pilot
filter to filter a sample of coagulated water immediately .after application
of chemical coagulants. Several manufacturers have developed equipment
designed for this purpose. Continuous monitoring of the pilot filter effluent
turbidity with a recording turbidimeter establishes whether an adequate
coagulant dosage has been applied to the incoming raw water. With this
equipment, the operator can preselect the maximum allowable filtered water
turbidity, which, if exceeded, initiates an alarm signifying an inadequate
coagulant dosage. The high turbidity is then corrected by increasing the
coagulant dosage. With the pilot filter technique for coagulation
monitoring, there is minimal danger that an improperly coagulated water will
reach the plant filters and lead to production of an unsatisfactory filtered-
water turbidity. Pilot filters enhance filter performance and increase
assurances that filtered water will be substantially free of asbestos and
virus particles. Figure 217 is a schematic flow diagram showing the
location of a pilot filter used to monitor coagulation.
Two models are available from suppliers. One model contains a single
pilot filter in which the sample flow to the turbidimeter is interrupted
each time the pilot filter is backwashed. A second model utilizes two pilot
filters, allowing continuous monitoring, even with one filter being back-
washed. The single filter unit is generally reserved for small plants
(less than 5 mgd).
Construction costs for coagulation control provisions are presented in
Table 183. As can be seen, the cost of this equipment is not related to
treatment plant capacity. Costs include the pilot filter module, rapid mix
sample pump, and chemical feed package.
Automatic Chemical Dosage Control WithPilot Filters
At least one manufacturer offers a pilot filter accessory that auto-
matically adjusts coagulant dosage to match raw water coagulant demands.
This automatic dosage control makes possible continuous feeding of coagulant
at the precise dosage necessary to maintain a preset filtered water clarity.
Turbidity readings from the pilot filter turbidimeters are fed into a black
box, which in turn controls the output of chemical feed pumps. The operator
establishes this clarity by either increasing or decreasing the chemical
dosage, depending on whether the pilot filter turbidity is below or above
the set point value. Changes in plant flow rate are also compensated for
in the controller.
481
-------
I—
I ALUM ,
FEED !
PUMFjl
\
AUTOMATIC
CONTROLLER-'
^ALKALINITY
FEED PUMP
SAMPLE
COAGULANT CONTROL
•_—— — —1 CENTER —s
CONTROL FILTERS-, I ~
| TURBIDI-
METER-
M» ^—FLOW CONTROL
M=LOW MEASUREMENT
TREATMENT PLANT
FLASH MIX BASIN
Figure 217. Flow diagram for automatic coagulant
dosage control.
482
-------
00
Co
Table 183
Construction Cost for Coagulation Control with Pilot Filters
Equipment Description
Cost Category
Manufactured Equipment
Pumps, Piping & Valves
Installation Labor
SUBTOTAL
Electrical Equipment
TOTAL COST
Single-
Pilot Filter
$24,000
350
1,000
25,350
3,800
2.9,150.
Automatic Chemical Dosage
Dual- Control Accessory and
Pilot Filter Dual- Pilot Filter
$32,900
400
1,500
34,800
5,220
40,020
$38,400
400
1,500
40,300
6,050
46,350
-------
This type of control device eliminates possible over or under feed of
coagulant, which can lead to high filtered-water turbidities. With this
equipment, there is increased assurance that the plant filters will continu-
ally produce a high clarity (turbidity <0.1 TO), filtered water supply
containing the lowest possible level of asbestos or virus particles.
A schematic flow diagram that shows the location of the automatic
chemical dosage control is shown in Figure 217, Costs for this accessory
are presented in Table 183. Note that the control device needs a continuous
turbidity input signal so it can only be used with a dual pilot filter.
The unit is mounted in the coagulation control center cabinetry and output
signals are extended to plant chemical feed pumps.
Filter Effluent Turbidimeters
Continuous monitoring of filtered water turbidity with accurate, low-
cost turbidimeters is an indirect but applicable method of determining the
effectivenss of asbestiform fiber and virus removal by the filtration process,
Generally speaking, the measurement of turbidity may be used to indicate the
probable escape of virus or asbestiform particles into the drinking water
supply.
For the measurement of extremely small amounts of turbidity, the
principle of light scattering (nephelometry) is used. In the turbidimeter,
an intense light is reflected at right angles to the light beam by
particles in the water. The amount of reflected light is directly dependent
on the concentration of particles in the water. The reflected light is
sensed by a photocell, which transmits a signal proportional to the amount
of turbidity to a meter calibrated in turbidity units.
Construction costs were developed for a turbidimeter assembly suitable
for continuous monitoring of turbidity from individual filters, a well
supply, water distribution system, or from other sources. Included is a
nephelometry-style turbidimeter with mounting panel, air removal tube,
locally mounted master indicator, and power supply. For remote readout,
an indicator, shielded cable, and an output signal transmitter are necessary
and are included in the cost estimates. In gravity filtration plants, the
sensing unit and power supply are generally mounted in the filter gallery.
A sample pump is generally necessary to provide a uniform flow of water to
turbidimeters located in the gravity filter pipe gallery, and it is included
in the costs. The costs also include sample piping and valving between the
turbidimeter and the plant filter, and electrical interconnection between the
turbidimeter and remove readout instrumentation. The construction cost
estimate is shown in Table 184.
484
-------
Table 184
Construction Cost for Filter Effluent Turbidimeters
Cost Category Cost
Manufactured Equipment $ 1,300
Labor 200
Pumps, Pipe and Valves 350
Electrical & Instrumentation 200
SUBTOTAL 2,050
Miscellaneous & Contingency 210
TOTAL 2,260
485
-------
SECTION 4
FACILITY LAYOUTS FOI TYPICAL 1, 10, AND 100 MGD PLANTS
Figures 218 through 227 contain facility layouts and cross-sections for
typical 1, 10, and 100-mgd water treatment plants. These layouts are
included to illustrate typical layouts and space requirements for treatment
plants. The drawings are not intended to be utilized for detailed design
purposes, but rather to acquaint those unfamiliar with water treatment
plants with the basic plant configurations.
486
-------
03
DESIGN CRITERIA
PiaNTFLOW:
FLASH MIX BASINS:
NunWt
Dttnlin
Vobsi*
Ml»r:
H,
Velocity jndirat
FLOCCULATION BASINS:
OBlenlioo
Volme
Flo emulators:
Number
TvDe
HP
V»locity graditnl
SEDIMENTATIOH BASINS;
Number
0«rflo« rat.
VehHM
W!f)
gal well
32 ft/latin
Chain & High
2
RopW «md
2 gpm/ftZ
Figure 218. Facility layout for 1-mgd treatment plant.
-------
3ECTIOKJ I
SECTION £
Figure 219. Sectional views of 1-mgd water treatment plant.
488
-------
00
Figure 220. Facility layout for 10-mgd water treatment plant.
-------
VO
o
Figure 221. Partial plan for sedimentation basin for 10-mgd water treatment plant.
-------
vO.
Figure 222. Filter layout for 10-mgd water treatment plant.
-------
DDDDO
3UXXU COUfCTD*
10
COUK7I&J UHMCftt
IfuwjAr 1
1 •*" 1
_H
DESICH OHTER1A
FLAHT FIW:
FLASH MIX BASINS:
Nwker
D«ttnl!«n
V*|MM
Wiita;
NwnWt
HP
Vilocll/ graAMI
FLOCCUUTIOK BASINS:
Nwilxr
Dihrrllon
Volume
1st s
Kwibtf
Typ«
HP
raillnrt
2nd stags:
Nunlxr
Type
HP
V«!ocilf trnJitnl
SEDIMENTATION BASINS;
Nnlar
O.trflowrou
Vo ln>
W«ir hoglh
Weir * v.rllow ran
Typ e stodge co Hector
FILTERS:
NumUr
Tjrpt
Fihwnt*
Bacicwash rale
NomiMil
Moximgm
1W
2
1 •»!«
35.CXXJ ^.1
50
TOO itc-'
Mmlfl
525,000 gal «cfi
3/fa»ln
Vtrflccl lurbini
5
75 «e-' muCnrioblt}
8/bojin
Vertical lurbiiw
'» ,
25 sec-' mixtnrioblt)
4.37 mil ggl »ch
1.000 (l/b.,in
2J4MO g p J/f i2
TfQyellin^ bridge
14
RGB id sand
18 jpm/fl2
SEDMSUTATIOU SWIU PLAU
Figure 223. Facility layout for 100-mgd water treatment plant.
-------
VO
PARTIAL PUU - FILTERS
Figure 224. Partial plan for filters for 100-mgd water treatment plant,
-------
6ECTKXJ A
• ftifl OPIPAIQH
Figure 225. Sectional views of filters for a 100-mgd water treatment plant.
-------
ui
~*t&Xauw*
tunv&sr
>- y
hfl
i j i as ;.
RWTIAL FLAU-FLA6H MIX - R.OCCULCTOU B4SIMS
i / i
ii
!/ '
-7s*£ *£Oi£
' cat(*r?w
Figure 226. Partial plan for flash miK and flocculation basins for 100-mgd water treatment plant,
-------
vo
H-AU OF SEOMEIJTATlOU BiiSlU
Figure 227. Partial plan of sedimentation basin for 100-mgd water treatment plant.
-------
SECTION 5
EXAMPLE CALCULATION FOR A 40-MGD CONVENTIONAL TREATMENT PLANT
This example demonstrates the use of the curves included in Volume 2 to
develop the cost of a 40-mgd conventional treatment plant, including sludge
handling facilities. In this example, the plant design capacity is 40 mgd,
but the facility is only operating at 70 percent of capacity, or 28 mgd.
The design criteria and operating conditions for the complete facility
are shown in Table 185. As shown, the complete facility consists of all
unit processes necessary for a complete and operating plant. The unit
processes are design criteria, which are presented in Table 185, represent
a hypothetical situation and should not be considered to be applicable to
all treatment plants of this general capacity.
The total of the construction costs for the individual unit processes
shown in Table 185 yield a subtotal cost that is the basis for a number of
special costs more appropriately related to the subtotal of construction
cost than to the construction cost of each individual unit process. These
special costs include: (1) special sitework, landscaping, roads, and inter-
face piping between processes, (2) special subsurface consideration, arid
(3) standby power. The special costs will vary widely, depending on the
site, the design engineer's preference, and regulatory agency requirements.
Addition of these special costs to the aggregate cost of the unit processes
gives the total construction cost.
To arrive at the total capital cost, the following costs must be added
to the total construction cost: (1) general contractor's overhead and profit,
(2) engineering, (3) land, (4) legal, fiscal and administrative, and
(5) interest during construction. Curves for these costs (except for
engineering and land) are presented in Figures 228 to 232. A curve for
engineering cost is not included, as the cost varies widely, depending on
the need for preliminary studies, time delays, size and complexity of the
project, and any construction-related inspection and engineering design
activities.
Table 186 presents a calculation of total annual cost and cost per
1,000 gal treated. This calculation involves a number of variables such as
amortization rate and period, labor rate (including fringes and benefits),
electrical rates, and natural gas rates. The variables used in Table 186
are representative of U.S. averages, but they may vary significantly among
geographical areas.
497
-------
T«M« I«S
Design Criteria ind Co»c Calculation tat a
40 mgi Conventional Tre«t»*«t Mant
*»
VD
00
Syitea and Design Criteria
Aiwa Feed Syitea - 40 mg/1
Sodium Hydroxide Feed Syttea -
. 15 ag/l
Polymer Feed System - 0.2 mg/l
Rapid Hlx - 45 see,, C-600
Floeculation - 35 »in.', G»50
Rectangular Clarif iers -
1,000 gp-d/ft2
Gravity Filtration - 5 gpn/ft2
Filter Media - Hixed Media
Surface Wash
Backwash Pumping - 18 gpm/ft2
Wa*h Hater Surge Basin
Chlorine Feed System - 2 «g/l
Clearwetl Storage - Below Ground
Finished Water Pumping
Gravity Thickener
Basket Centrifuge
Dewatered Sludge Hauling - 20 miles
Administrative, Laboratory &
Maintenance Building
Subtotal
Sitewark, Interface Piping, Roads,
8 5*
Subsurface Considerations
Standby Power
Total Construction Cost
General Contractor's Overhead and
Profit
Subtotal
Engineering ? 10Z
Subtotal
Land, 13 acres 9 $26,000/acre
Legulj Fiscal, and Administrative
Interest during Construction - 7Z
Figure
Number**
16,
33,
21,
50,
53,
"60j
67,
70
7.4,
71,
80
1, 2
207
204,
166,
185,
196,
214,
19, 20
34, 35
22, 23
51, 52
55 , 56
61, 62
68, 69
75, 76
72, 73
, 3
205, 206
167, 168
186, 187
199, 200
215, 216
—
—
—
—
—
—
—
— .
—
_
—
—
Design
Parameter
556 Ib/hr :
5000 Ib/day
67 Ib/day
2785 ft3
130,000 ft3
40,000 ft3
5560 ft2
5560 ft2
5560 ft2
10,010 gptn
200,000 gal
670 Ib/day
2,500,000 gal
55 mgd
850 ft2
115,000 gprf
20,000 yd3/yr
40 stgd
—
-_
—
—
--
—
—
-_
— •
—
—
Construction
Cost
J 71,440
47,300
22,400
44,210
447,070
2,247<330
1,747,730
148,200
160,850
122,530
357,600
68,980
912,030
415,030
73,520
334,810
81,510
216,200
7,518,740
375,940
0
0
7,894,680
789,470
8,684,150
868,420
9,552,570
26,000
67,030
688,790
Operating Energy Diesel Fuel
Parameter (ku-hr/yr) (*«l/yl
350 Ib/hr
3300 Ib/day
45 Ib/day
2785 ft3'
130,000 ft3
40,000 ft3
5560 ft2
-
5560 ft2
5560 ft2
-
450 Ib/day
-
28 mgd
850 ft2
70,000 gpd
12,000 yd3/yr
40 mgd
—
•~
—
—
—
—
„„
—
—
—
46,260
46(860
26,280
284,180
154,370
70,560
978,200
0
76,960
132,840
0
79,800
0
4,689,640
4,140
476,760
0
493,660
7, 560*510
—
—
—
-_
—
0
0
0
0
0
0
c
0
0
0
0
0
0
0
0
0
4,820
0
4,820
—
—
^_
--
„
.
__
;
Maintenance Labor
Material- ($/yr) (hr/»r)
100
250
300
60
4,770
10,050
12, 170
0
400
3,170
0
2,520
0
4,200
230
3,000
5 , 250
9,430
55,900
—
i_
__
„
__
—
_ _
„
*,-.
— -,
65
150
207
499
394
4,344
4,4 64
0
310
294
0
747
0
1(107
145
8,300
914
8.596
30,534
i._
—
__
_
^_
__
_.
_.
„„
-..
Total Capital Cost
*Hs«* * ttgur* malura refer to Voltaic 2 of thli *«port.
510,334,390
-------
12
to
U. z
gi
11
HI
o
DC -I
oo
OU-
I- O
10
o
o
if)
2.5 5 10 25 50
TOTAL CONSTRUCTION COSTS, million dollars
100
Figure 228. General contractor's overhead and fee
percentage versus total construction cost.
499
-------
7
6
5
4
3
2
100,0
il
6
5
4
-3
-ov
I
« z
tn
O
o
I0,0(
> 9
1 *
S *
fe 5
z 4
I 3
<
0 2
Z
<
_J
o IOO°
tn 9
EL B
a !
UJ
_« 4
3
2
100
00
DO
.X
/
f
/
/
<>
X
/
,
X
x
X
X
^X"
^
"?r
X
X
^
2 34 56789 234 56789 2
IO.OOO IOO.OOO I.OOO.OOO
SUM OF CONSTRUCTION, ENGINEERING AND LAND COSTS-$
3 456 789
Figure 229. Legal, fiscal and administrative costs for
projects less than $1 million.
500
-------
I
7
6
5
4
3
2
7
6
5
4
3
2
IOO.C
f»- Q
1 8
t- 7
o !
0 5
4
Ul
> ,
LEGAL, FISCAL AND ADMINISTRATI
5 P
§ N w * oi tn^ioxo § r» c
)00
0
2 3 45678!
00,000 ,ooc
SUM OF CONSTR
^
X
X
^
S
^
x"
) 2 345678
),OOO IO.OO
UCTION, ENGINEERING AN
^x*
^x""1^
J ^"^
,*'
"
•
X
*
9 2 345678
0,000 100,000.0
D LAND COSTS- 4
9
00
Figure 230. Legal, fiscal and administrative costs
for projects greater than $1 million.
501
-------
10,000
I
6
•**• 5
i «
o
i
8
o
o
1000
S
8
6
5
4
JL
CO
UJ
IT
UJ
IOO
9
8
7
6
5
4
3
2
10
10,000 234 56789100,0002 3 4 56789 2'.
SUBTOTAL OF ALL OTHER COSTS- $ 1i°OQ,000
3 4 5 6789
Figure 231. Interest during construction for
projects less than $200,000.
502
-------
io.ooo.poo
I.OOO.OOO
-«v
I
z
100,000
0
Z
o:
C/J
UJ
10,000
9F—-
8 —
7 —
1000
qpqr
/-t
10%
IOO.OOO
34 56789 2
1,000,000
34 56789 2
IO,OOO,OOO
34 56789
100,000,000
SUBTOTAL OF ALL OTHER COSTS -
Figure 232. Interest during construction for
projects greater than $200,000.
503
-------
Table 186
Annual Cost for a 40 mgd
Conventional Treatment Plant
Item; • Total Costs/year
Amortized Capital §7%, 20 years ...... . . $ 975,460
Labor, 30,534 hr @ $10/hr, (Total labor
Costs Including Fringes & Benefits) ..... 305,340
Electricity, 7,560,510 kw-hr @ $0.03 ...... 226,820
Fuel, 4,820 gal 8 $0.65/gal ....... '. . . . 3,130
Maintenance Material .............. 55,900
Chemical, Alum, 1,533 tons/yr @ $70/ton;
Polymer, 16,425 Ib/yr @ $2/lb
Sodium Hydroxide, 602 tons/yr @ $200/ton;
Chlorine, 82 tons/yr @ $300/ton . ...... 285,250
Total Annual Cost .......... $1,851,900
'Cents par 1,000 8,1 treated - "
= 18. 12«:/ 1,000 gal treated
504
-------
REFERENCES
1. Public Law 93-523, Safe Drinking Water Act, 93rd Congress. S. 433,
December 16, 1974.
2. National Interim Primary Drinking Water Regulations, U.S. Environmental
Protection Agency, Water Programs, Federal Register, 40:248:59566,
December 24, 1975.
3. Drinking Water Regulations, Radionucleides, U.S. Environmental
Protection Agency, Federal Register, 41:133:28402, June 9, 1975.
4. Control of Organic Chemical Contaminants in Drinking Water, U.S.
Environmental Protection Agency, Interim Primary Drinking Water
Regulations, Federal Register, 43:28:5756, February 9, 1978.
5. National Secondary Drinking Water Regulations; Proposed Regulations,
U.S. Environmental Protection Agency, Federal Register, 42:132:35764,
July 11, 1977.
6. Drinking Water and Health; Recommendations of the National Academy
of Science. Federal Register, 42:132:35764, July 11, 1977.
7. Process Plant Construction Estimating Standards, Volumes 1, 2, 3, & 4,
Richardsons Engineering Services, Inc., Solana Beach, California.
8. Building Construction Cost Data, Robert Snow Means Company, Inc.,
Dexbury, Mass.
9. Bodge Guide to Public Works and Heavy Construction Costs, Dodge
Building Cost Services, McGraw-Hill, 1221 Avenue of the Americas,
New York, New York.
10. Producer Prices and Price Indexes, Data for October, 1978. Bureau of
Labor Statistics, U.S. Department of Labor.
11. Hudson, H.E., High Quality Water Production and Viral Disease.
Waterworks Assoc., October 1962, p. 1265
505
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-79-162b
3. RECIPIENT'S ACCESSION NO,
4. TITLE AND SUBTITLE
ESTIMATING WATER TREATMENT COSTS
Volume 2, Cost Curves Applicable to 1 to 200 mgd
Treatment Plants
5, REPORT DATE
August 1979 (Issuing Date)
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
Robert C. Gumerman, Russell "L. Gulp, and
Sigurd P. Hansen
8, PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Culp/Wesner/Culp
Consulting Engineers
2232 S.E. Bristol, Suite 210
Santa Ana, California 92707
10, PROGRAM ELEMENT NO.
1CC614, SOS 1, Task 38
11. CONTRACT/GRANT NO.
68-03-2516
12. SPONSORING AGENCY NAME AND ADDRESS
Municipal Environmental Research Laboratory—Gin.,OH
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
EPA/600/14
IB. SUPPLEMENTARY NOTES Project Officer: Robert M. Clark (513) 684-7488,
See also EPA-600/2-78-182 (NTIS PB284274/AS); Volume 1, EPA-600/2-79-162a; Volume 3,
EPA-600/2-79-162c; and Volume 4, EPA-600/2-79-162d.
15. ABSTRACT
This report discusses unit processes and combinations of unit processes that are
capable of removing contaminants included in the National Interim Primary Drinking
Water Regulations. Construction and operation and maintenance cost curves are
presented for 99 unit processes that are considered to be especially applicable to
contaminant removal. The report is divided into four volumes. Volume 1 is a summary
volume. Volume 2 presents cost curves applicable to large water supply systems with
treatment capacities between 1 and 200 mgd, as well as information on virus and
asbestos removal. Volume 3 includes cost curves applicable to flows of 2,500 gpd to
1 mgd. And Volume 4 is a computer program user's manual for the curves included in
the report. For each unit process included in this report, conceptual designs were
formulated, and construction costs were then developed using the conceptual designs.
The construction cost curves were checked for accuracy by a second consulting engi-
neering firm, Zurheide—Herrmann, Inc., using cost—estimating techniques similar to
those used by general contractors in preparing their bids. Operation and maintenance
requirements were determined individually for three categories: Energy, maintenance
material, and labor. Energy requirements for the building and the process are
presented separately. Costs are in October 1978 dollars.
17.
KEY WOFiDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COS AT I Field/Group
Economic analysis, Environmental
engineering, Operating costs, Computer
programming, Water treatment, Cost indexes,
Water supply, Cost estimates, Cost analysis
Energy cost's, Cost curves,
Safe Drinking Water Act,
Interim primary standards,
Unit processes, Treatment
efficiency
13B
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
540
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 {Rev. 4-77)
506
» U.S. BOvsmMIS! rawlmoOfflCt: I9JO-657-146/5615
------- |