EPA-600/2-77-216
December 1977
Environmental Protection Technology Series
TRANSPORT OF SEWAGE SLUDGE
Municipal Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
-------
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 Envirdnmental 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.
-------
EPA-600/2-77-216
December 1977
TRANSPORT OF SEWAGE SLUDGE
by
William F. Ettlich
Culp/Wesner/Culp
Clean Water Consultants
El Dorado Hills, California 95630
Contract No. 68-03-2186
Project Officer
Frank L. Evans, III
Wastewater 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
-------
DISCLAIMER
This report has been reviewed by the Municipal Environmental Research
Laboratory, U.S. Environmental Protection Agency, and approved for publica-
tion. 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.
11
-------
FOREWORD
The 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 testimony to the deterioration of our natural environment.
The complexity of that environment and the interplay between 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 for the prevention, treatment, and management
of wastewater and solid and hazardous waste pollutant discharges from municipal
and community sources, for the preservation and treatment of 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.
This report presents data from which costs may be estimated for transport
of liquid and dewatered sewage sludge and for construction costs and operating
and maintenance requirements for associated handling facilities.
Francis T. Mayo, Director
Municipal Environmental Research
Laboratory
111
-------
ABSTRACT
The overall objective of this project was to develop organized informa-
tion on the costs of various sewage sludge transport systems. The method
used to prepare the cost data is presented, and the data are organized to
facilitate manual calculation of total transport costs for a variety of
conditions. Included are transport of liquid and dewatered sludge by truck
and rail, and transport of liquid sludge by barge and pipeline.
The data include the installed cost for each system, sludge processing
requirements, fuel consumption, manpower, and other operation and mainte-
nance requirements. The construction costs and operation and maintenance
requirements for the loading, unloading, and sludge handling facilities
are tabulated separately from the requirements for direct transport so that
the data can be applied to a variety of specific applications.
Results of the study are related in tabular and graphical presentations
to appropriate parameters cubic yards for dewatered sludge and gallons
for liquid sludge.
This report was submitted in partial fulfillment of Contract 68-03-2186
by Culp/Wesner/Culp - Clean Water Consultants under the sponsorship of the
U.S. Environmental Protection Agency. The report covers the period from
June 1975 to August 1976, and work was completed as of April 1977.
IV
-------
CONTENTS
Disclaimer ............................
Foreword .............................
Abstract ............................. 1V
Figures ............................. V1
Tables .............................. ix
Abbreviations ........................... xl
Acknowledgements ......................... x11
1. Introduction ...................... -'
2. Summary of Results ................... 3
Dewatered sludge .................. 25
Liquid sludge ................... 2^
3. Methods and Assumptions ................. 27
General ...................... 27
Mode and sludge type ................ 28
Factors in calculation ............... 28
Sludge volume ................... 47
Transport distance ................. 47
Transport cycle timing ............... 47
Daily operating schedule .............. 47
Transport equipment ................ 61
Facilities ..................... 62
Capital costs ................... ^2
Operation and maintenance requirements ....... 62
Escalation .................... ^2
General assumptions ................ 66
4. Special Transport Mode Considerations .......... 67
Truck transport .................. 67
Barge transport .................. 67
Railroad transport 68
69
References ............................
74
Metric Conversions ........................
Appendices
A. Truck transport .................... 7°
79
B. Barge transport ....................
C. Railroad transport ................... 82
D. Pipeline transport ................... 85
v
MOTE: The List of Errata dre ow -Hie last
-------
FIGURES
Number Page
1 Truck transport total annual cost without
facilities, liquid sludge, 1975 4
2 Truck transport total annual cost without
facilities, liquid sludge, 1975 5
3 Truck transport total annual cost with loading
and unloading facilities, liquid sludge, 1975 6
4 Truck transport total annual cost with loading
and unloading facilities, liquid sludge, 1975 7
5 Truck transport total annual cost without
facilities, dewatered sludge, 1975 8
6 Truck transport total annual cost without
facilities, dewatered sludge, 1975 9
7 Truck transport total annual cost with loading
and unloading facilities, dewatered sludge, 1975 .... 10
8 Truck transport total annual cost with loading
and unloading facilities, dewatered sludge, 1975 .... 11
9 Barge transport total annual cost without
facilities, 4 percent liquid sludge, 1975 12
10 Barge transport total annual cost without
facilities, 4 percent liquid sludge, 1975 13
11 Barge transport total annual cost with loading
and unloading facilities, 4 percent liquid
sludge, 1975 14
12 Barge transport total annual cost with loading
and unloading facilities, 4 percent liquid
sludge, 1975 15
VI
-------
FIGURES (continued)
Number Page
13 Barge transport total annual cost without
facilities, 10 percent liquid sludge, 1975 16
14 Barge transport total annual cost without
facilities, 10 percent liquid sludge, 1975 17
15 Barge transport total annual cost with loading
and unloading facilities, 10 percent
liquid sludge, 1975 18
16 Barge transport total annual cost with loading
and unloading facilities, 10 i srcent
liquid sludge, 1975 19
17 Railroad transport total annual cost without
facilities, liquid sludge, 1975 20
18 Railroad transport total annual cost with
loading and unloading facilities,
liquid sludge, 1975 21
19 Railroad transport total annual cost without
facilities, dewatered sludge, 1975 22
20 Railroad transport total annual cost with
loading and unloading facilities,
dewatered sludge, 1975 23
21 Pipeline transport costs, liquid sludge, 1975 ...... 24
22 Truck fuel requirements, liquid sludge, 1975 29
23 Truck fuel requirements, dewatered sludge, 1975 30
24 Truck use, liquid sludge, 1975 31
25 Truck use, dewatered sludge, 1975 32
26 Truck operator, liquid sludge, 1975 , 33
27 Truck operator, dewatered sludge, 1975 34
28 Barge tug billing time, 4 percent liquid
sludge, 1975 35
VI1
-------
FIGURES (continued)
Number
Page
29 Barge tug billing time, 10 percent liquid
sludge, 1975 36
30 Barge tug operating time, 4 percent liquid
sludge, 1975 37
31 Barge tug operating time, 10 percent liquid
sludge, 1975 38
Vlll
-------
TABLES
Number Page
1 Figure Number Index for Transport Mode
Total Annual Cost 25
2 Types of Sludge Studied, by Transport Mode 28
3 Truck Data, 1975 39
4 Truck Operation Summary, Liquid Sludge, 1975 40
5 Truck Operation Summary, Dewatered Sludge, 1975 41
6 Truck Facilities Capital and Operation and
Maintenance Data, Liquid Sludge, 1975 42
7 Truck Facilities Capital and Operation and
8
9
10
11
12
13
14
15
Barge Characteristics, 1975
Barge Operation Summary, 4 Percent Liquid Sludge, 1975 . .
Barge Operation Summary, 10 Percent Liquid Sludge, 1975. .
Barge Facilities Capital and Operation and Maintenance
Data, 4 Percent Liquid Sludge, 1975
Barge Facilities Capital and Operation and Maintenance
Data, 10 Percent Liquid Sludge, 1975
Railroad Operation Summary, Liquid Sludge
Railroad Operation Summary, Dewatered Sludge
Railroad Facilities Capital and Operation and Maintenance
T /
44
45
46
48
49
50
51
Data, Liquid Sludge, 1975 52
16 Railroad Facilities Capital and Operation and Maintenance
Data, Dewatered Sludge, 1975 53
IX
-------
TABLES (continued)
Number Pa9e
17 Pipeline Pumping Station Energy 54
18 Pipeline Operating and Maintenance Labor and Supplies. . . 55
19 Pipeline Size, Sludge Flow and Sludge Volume 56
20 Pipeline Sludge Pumping Characteristics 57
21 Pipeline Cost 58
22 Pipeline Crossing Costs 58
23 Annual Sludge Volume 59
24 Transport Distance ^9
25 Transport Cycle Timing 60
26 Railroad Transit Time 60
27 Transport Facilities ^3
28 Amortization Factors 64
29 Summary of Escalation Factors 65
-------
ABBREVIATIONS
cu yd cubic yard
fps feet per second
ft feet
gal gallon
gph gallon per hour
hp horsepower
in inch
kwh kilowatt-hour
Ib pound
Ib/cu ft pound per cubic foot
mg million gallons
mgd million gallons per day
mpg miles per gallon
mph miles per hour
rpm revolutions per minute
XI
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ACKNOWLEDGMENTS
Culp/Wesner/Culp - Clean Water Consultants are grateful to the owners
and operators of municipal treatment plants, equipment manufacturers, con-
sulting engineers, and the U.S. Environmental Protection Agency for data
and information necessary for the preparation of this report.
The substantial and beneficial assistance of Robert A. Olexsey and
others within the Ultimate Disposal Section, U.S. Environmental Protection
Agency was invaluable to completion of this study.
-------
SECTION 1
INTRODUCTION
Traditionally, land disposal of municipal sewage sludge has been the
least costly method for ultimate disposal of these sludges. Unlike compet-
ing, on-site disposal alternatives such as incineration, heat treatment,
and digestion, land disposal has not been a capital intensive technique, the
major capital investment being the cost for the land itself. The greatest
costs associated with land disposal are the operational costs for applica-
tion of the waste at the disposal site, and the cost of transporting the
sludge from the collection site to the disposal site.
Urban pressures have forced authorities charged with sludge disposal to
seek disposal sites that are located great distances, often hundreds of
miles, from the large population centers that produce the sludge. The costs
of transporting the sludge to disposal sites have taken on increasing impor-
tance .
Transport to disposal sites has been accomplished by truck or rail haul
transport of liquid or dewatered sludge, and barge or pipeline transport of
liquid sludge- The cost effectiveness of each method varies with the locale,
transport distance, and volume of sludge.
Even if land disposal is not the ultimate fate of the sludge, some form
of transport may be required. For instance, sludge produced by a number of
treatment plants may be collected at a single facility for combined disposal.
In all cases, the transport mechanism chosen will be that method judged to
be the most cost effective alternative.
Among the considerations in the design of a sludge handling and disposal
system are:
1. Determining whether sludge should be transported to distant
disposal sites or disposed of at the point of production.
2. Determining the optimum moisture content of the sludge (liquid,
dewatered cake, dried) as a function of the disposal process
selected and transport distance required.
3. Selecting the transport mode: truck, rail, barge or pipeline.
This report presents estimated capital costs and operating and mainte-
nance requirements for various sludge transport modes as they apply to
-------
municipal facilities. These data are applicable to preliminary estimates for
general planning, studies of alternatives, or to long-range financial or
facilities planning. Careful review of the methodology, features, and com-
ponents included in the data is encouraged if these data are used for speci-
fic project planning purposes. Comparison of alternative schemes may be
made, however, if costs are within 15 percent, the cost difference may not
be real, and more intensive analysis may be needed to discern real differ-
ences between the alternatives under study.
Manual calculation methods are included that allow transport systems
costs to be calculated at any point in time by using current or estimated
future unit costs or cost escalation factors. Suggested, published indices
are included in this report.
-------
SECTION 2
SUMMARY OF RESULTS
The results of this study are summarized in the various figures and
tables.
The information in this report is usable in making manual calculations
of transport system costs and is intended to be developed into a computer
program to facilitate cost calculations.
Three methods of manual cost calculation are possible using the infor-
mation in this report. The first method involves calculation of each com-
ponent of cost such as fuel, electric energy, and man hours. This method
allows flexibility in making total cost determinations because current unit
costs can be used, and the impact of the various component costs can be
adjusted for particular situations. Some time is required to calculate the
cost of each alternative by this method.
As an aid in making manual calculations, outlines and example calcula-
tions are provided for each transport mode as follows:
Mode Outline
Truck Appendix A
Barge Appendix B
Railroad Appendix C
Pipeline Appendix D
The applicable figures and tables are referenced in each appendix.
When the total cost calculation is completed, it can be converted to any
desired units.
The second manual method is simplified to the point of determining the
total costs graphically without calculating each component individually.
This method is limited because unit costs cannot be escalated. With current
rates of inflation, the unit cost assumptions used in preparing graphs will
soon be out of date. For truck, barge, and railroad, the terminal facilities
and associated operation and maintenance costs are separated from the
actual point to point transport costs to make the information more useful.
The total annual costs with and without facilities are shown in Figures 1
through 21 as indexed in Table 1.
-------
100,000
10,000
1.000
10
!
S 4 5 67 89
100
ANNUAL SLUDGE VOLUME, mg
Figure 1. Truck transport total annual cost without facilities,
liquid sludge, 1975.
(*) English units are used uniformly in this report because many of the
English measures are common in the sanitary field. Conversion factors
are contained in the List of Metric Conversions.
-------
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Figure 2. Truck transport total annual cost without facilities,
liquid sludge, 1975.
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ANNUAL SLUDGE VOLUME, mg
Figure 3. Truck transport total annual cost with loading and
unloading facilities, liquid sludge, 1975.
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Figure 4. Truck transport total annual cost with loading and
unloading facilities, liquid sludge, 1975.
-------
10,001),
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ANNUAL SLUDGE VOLUME. 1000 cu yd
Figure 5. Truck transport total annual cost without facilities,
dewatered sludge, 1975.
-------
-
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ANNUAL SLUDGE VOLUME, 1000 eu yd
Figure 6. Truck transport total annual cost without facilities,
dewatered sludge, 1975.
-------
10.000
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100
10 100
ANNUAL SLUDGE VOLUME, 1000 cu yd
Figure 7. Truck transport total annual cost with loading and
unloading facilities, dewatered sludge, 1975.
10
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ONE WAY
DISTANCE,
MILES
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ANNUAL SLUDGE VOLUME, 1000 cu yd
2 3 4 56
Figure 8. Truck transport total annual cost with loading and
unloading facilities, dewatered sludge, 1975.
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Figure 9. Barge transport total annual cost without facilities,
4 percent liquid sludge, 1975.
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Figure 10. Barge transport total annual cost without facilities,
4 percent liquid sludge, 1975.
13
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ANNUAL. SLUDGE VOLUME, mg
Figure 11. Barge transport total annual cost with loading and
unloading facilities, 4 percent liquid sludge, 1975.
14
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unloading facilities, 4 percent liquid sludge, 1975,
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100.000
10,000
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10 100
ANNUAL SLUDGE VOLUME, mg
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10 percent liquid sludge, 1975.
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Figure 14. Barge transport total annual cost without facilities,
10 percent liquid sludge, 1975.
1
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ANNUAL SLUDGE VOLUME, mg
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Figure 15. Barge transport total annual cost with loading and
unloading facilities, 10 percent liquid sludge, 1975.
18
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Figure 16. Barge transport total annual cost with loading and
unloading facilities, 10 percent liquid sludge, 1975.
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ANNUAL SLUDGE VOLUME, mg
Figure 17. Railroad transport total annual cost without facil-
ities, liquid sludge, 1975.
20
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1,000
ANNUAL SLUDGE VOLUME, mg
Figure 18. Railroad transport total annual cost with loading
and unloading facilities, liquid sludge, 1975.
-------
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1,000
ANNUAL SLUDGE VOLUME, 1,000 cu yd
Figure 19. Railroad transport total annual cost without facil-
ities, dewatered sludge, 1975.
-------
g
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ANNUAL SLUDGE VOLUME, 1,000 cu yd
2 3456 789
1,000
Figure 20. Railroad transport total annual cost with loading
and unloading facilities, dewatered sludge, 1975.
2
-------
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AILY HOURS
F OPERATION
DAILY HOURS
OF OPERATION
10
PIPELINE SIZE. In
Figure 21. Pipeline transport costs, liquid sludge, 1975.
24
-------
TABLE 1. FIGURE NUMBER INDEX FOR TRANSPORT
MODE TOTAL ANNUAL COST
Liquid sludge Dewatered sludge
Mode
Truck
Barge
Railroad
Pipeline
Without
facilities
1 & 2
9-12
17
21
With
facilities
3 & 4
13 - 16
18
21
Without
facilities
5 & 6
19
With
facilities
7 & 8
20
The third method, an alternative to the second manual method, is to
develop new total cost curves periodically with updated unit cost input
using the Executive Computer Program. Periodic development of total cost
curves will greatly simplify manual determination of transport costs and
should reduce the chance of error inherent in making the manual calculations.
Use of the computer to develop updated curves will allow more points to be
calculated and plotted, thus making the curves more widely applicable.
It is beyond the scope of this work to provide a complete computer pro-
gram for calculation of transport costs; however, a program can be developed
using the information in this report.
The data contained in this report are intended primarily as an aid in
determining costs for various transport modes. Final comparisons between
alternative transport modes for a given situation should then be made after
all costs applicable to each mode are compiled. The information in this
report is not intended to give a direct comparison between modes, however,
certain generalized observations can be developed.
DEWATERED SLUDGE
1. Total annual cost for railroad is less than truck for all annual
sludge volumes and distances studied herein with and without
facilities.
2. Railroad facilities are more capital intensive than truck
facilities.
3. Transport equipment can be leased in both cases.
LIQUID SLUDGE
1. Truck is the least expensive mode for one way distances of 20 miles
or less and sludge volumes less than 10 to 15 mg per year.
2. Pipeline is the least expensive mode for all cases when the annual
sludge volume is greater than approximately 30 to 70 mg (depending
on distance).
3. Pipeline is not economically attractive for annual sludge volumes
25
-------
of 10 mg or less because of the high capital investment.
4. Pipeline is capital intensive and the terminal points are not
easily changed. Pipeline is ideal for large volumes of sludge
transported between two fixed points.
5. Rail and barge are comparable over the 7 to 700 mg volume range
for long haul distances.
6. Barge is more economical than rail for short to medium distances
for annual sludge volumes greater than 30 mg.
26
-------
SECTION 3
METHODS AND ASSUMPTIONS
GENERAL
The solids content of sludges from similar unit processes vary from
plant to plant. All parameters and costs in this study are based on the
units pertinent to the haul rather than units basic to the characteristics
of the sludge. Liquid sludge costs are based on gallons of liquid trans-
ported and dewatered on' cubic yards. The solids content of each form of
sludge can vary over a range with minor changes in the actual transport cost.
There will be essentially no change with liquid sludges in the range of 1
to 5 percent solids. In theory, there will be some change in costs with
dewatered sludges if the density varies from the assumed 55 Ib/cu ft. If
the actual density is less than that assumed, it is possible for the truck
to carry a larger volume load without exceeding legal weight limits. Con-
versely, the theoretical truck volume capacity will be less if the actual
density is higher than the assumed density. These differences should
decrease or increase the number of annual truckloads respectively and thus
change the annual costs somewhat. Normally, the trucks will have a fixed
,capacity and will be loaded conservatively based on maximum expected sludge
density and, therefore, it is unlikely that savings would be realized in
actual operations. Potential average change in costs would be plus or
minus 10 to 15 percent for variations in sludge density of plus or minus 10
Ib/cu ft above and below the assumed 55 Ib/cu ft. This estimate is based on
judgement and could vary widely from case to case.
The costs can be converted to other units, such as dollars per dry ton-
mile, after the total costs for a case have been determined.
Transport, for purposes of this study, is considered to be point to
point movement of sludge rather than movement and ultimate disposal such as
barging or pumping to sea. Costs for these forms of movement and disposal
can be determined using the method herein, but this is not a basic goal of
the study.
The methods developed and presented in this study are organized so
costs for a particular case can be determined by manual calculations or
programmed into the MEKL, Cincinnati, Executive Computer Program. Most
information is developed in basic units such as gallons of fuel or manhours
so that current costs can be applied at the time of calculation. Some items
must be presented in 1975 dollars, such as facilities costs, and a method of
escalation is suggested for each of these cases.
27
-------
MODE AND SLUDGE TYPE
The types of sludge studied and the transport modes are shown in
Table 2.
TABLE 2. TYPES OF SLUDGE STUDIED,
BY TRANSPORT MODE
Form of sludge
Liquid,
percent solids
Transport mode 4 10 Dewatered
Truck x x
Barge x x
Railroad x - x
Pipeline x - -
The 4 percent liquid is typified by an anaerobically digested sludge,
the 10 percent a settled, digested sludge (lagoon storage for example), and
the dewatered sludge is a typical vacuum filter cake. Both of the liquid
sludges can be pumped, and the dewatered sludge can be moved with belt con-
veyors.
FACTORS IN CALCULATION
The factors that must be considered in calculation of total transport
costs for each mode are listed and referenced to the applicable figure or
table. Because the facilities costs are subject to wide variation, depending
on climate, designer, and other factors, they are presented separately.
Facilities cost information from other sources can be used in making cost
determinations if desired.
1. Truck Transport
Point to Point Costs
Truck fuel - Figures 22 and 23.
Truck maintenance - Tables 3, 4, and 5 and Figures 24 and 25.
Truck operator - Figures 26 and 27.
Amortization of truck capital cost - Tables 3, 4, and 5.
Facility Costs
Amortization of facilities capital costs - Tables 6 and 7.
Facilities operation and maintenance - Tables 6 and 7.
2. Barge Transport
Point to Point Costs
Towing (tug) service - Figures 28 and 29.
Tug operating time (information only) - Figures 30 and 31.
Barge maintenance - Tables 8, 9, and 10.
Amortization of barge capital cost - Tables 8, 9, and 10.
28
-------
10,000
-
"-
1.000
100
ANNUAL SLUDGE VOLUME, mg
Figure 22. Truck fuel requirements, liquid sludge, 1975
.
-------
.
.
l.OOUg
8
-
-
-
2
100
9
6
'
4
3
2
10
9
8
7
6
S
4
!
2
1
I
7
6
5
4
3
2
0.1
1 y~
r
/
/
y,
%
\ y
jj
/
,
',
<
-'
.-
1
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/
1
fe^>
\f ₯ S s
S S ./( .x
v/>
S *y /
s/
/ /
/
/
f s
- >
/ /
/
i
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v
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/
// /
/
/
/
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JCZ
z
/
|
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-
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/ L<
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///
X^
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s f
y
s '
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/ jf
/
/
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/
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-
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/
/
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V_V^/j/
^
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7
4
Xx'>
i>^
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/
r
.
/
:
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/
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1
x
-»-
E
L. RO
* /w
+ f .
'-/,\l '
' / in
'//
' r 5
« / in
'X 5
/ f
ON
-Dl!
Ml
I
.--
- £i
A
K<
-
r
:E. -
15-CU
10-CU
Mill
ro TRUCK
YD TRUCK
YD TRUCK
1
SS7B9
10 - ' 9ioo >9i,ooo
ANNUAL SLUDGE VOLUME, 1000 cu yd
Figure 23. Truck fuel requirements, dewatered sludge, 1975.
30
-------
I
-
--
£
Z
ANNUAL SLUDGE VOLUME, mg
Figure 24. Truck use, liquid sludge, 1975.
-------
s
.
10,0009
a
D
-
_
1,000
9
'
-
100
9
-
5
t
!
2
- :
I
e
9
i
2
1
7
/;
y
pf
/
^
/
^
r
/,
'/>
//
£~ ^
/ ,
^
'/j
'
1
'
7
:
'
g
>
7
?
/
i
;
,
,
'
\
/
.'.
.-
X
,"
, '
''
r~vf
-/*
^ '
4
^
' X
/
^
7
*s
/
f
, /I
/ ./ /
& / /s
J #
v//
i /X
9i
^ X^
L /^
/
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±2j
K ^
^
/ ,
^
/^
-
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/ ^
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x
,
.
-
'
'
-
,*
jfr
T~s
//
'/
'/,
^
'
I
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' \
-
i
80
r 80
/40
/ ^
y80 '
' / on
^ in
'/ 10
' y
/ x^
^ 5-
/
~ ON
ni
Ml
E WA
>TAN(
_ES
Y
F
30-CU YD TRUCK
15-CU YD TRUCK
10-CU YD TRUCK
ill ii L__i_L_
2 S4 6789 2 3 4 56789 2 3 4 56789 Z 31 = 5 7 BS
1.0 10 100 1.000 10.00C
ANNUAL SLUDGE VOLUME. 1000 cu yd
Figure 25. Truck use, dewatered sludge, 1975.
-------
i,ooo,ooo9
4
100,000
9
;
5
4
0
e
o
2
uT
s
10,000
g
- s
2 6
s
O 4
^ 3
r>
z ,
z
<
1,000
I
-
100
-
1 :
y/^
3
X
/
'/
'
/
f
' /,
//
V
?
//
.
-
-
::
'
'
---jj
-T-&
>>/.
I
E
/
7^
--^-
y^
'/'
/ y^
' ^^ ^^
'-#-f
/ //
//
' /
A
^-/i
/j
&
P
'^L
'
7 //
^
z^^
'
%J^J
$ W
',
//
-j-j 4
/ 40
/
'/20
~C , 40
7 y?i°
1 /-^ 80
^^r^
?§^
^ /
// 5
5
Oh
Dl
Ml
r
.
-tfti
-£
t
1
1
5500-GAL TRUCK
2500-GAL TRUCK
1200-GAL TRUCK
i i i i I I 1 IJ 1 1 L_L_L
2 34S6789 2 S4
1.0 10
ANNUAL SLUDGE VOLUME, mg
Figure 26. Truck operator, liquid sludge, 1975
33
-------
100.000 9
:
-
.
-
.-
10.000
1.000
6789
10,000
ANNUAL SLUDGE VOLUME. 1000 cu yd
Figure 27. Truck operator, dewatered sludge, 1975.
34
-------
01
h
B
~
<
2
2
1,000
10,000
ANNUAL SLUDGE VOLUME, mg
Figure 28. Barge tug billing time, 4 percent liquid sludge, 1975
-------
C
i
0.1
5 6 789
10,000
ANNUAL SLUDGE VOLUME, mg
Figure 29. Barge tug billing time, 10 percent liquid sludge, 1975.
36
-------
-
II
-
-
-
-
z
<
56789
10,000
ANNUAL SLUDGE VOLUME, mg
Figure 30. Barge tug operating time, 4 percent liquid sludge, 1975.
-------
1
%
Ul
UJ
"1
o
-I
-
z
1.0
2 34 S6789
10
100
ANNUAL SLUDGE VOLUME, mg
56789
10.000
Figure 31. Barge tug operating time, 10 percent liquid sludge, 1975.
38
-------
TABLE 3. TRUCK DATA, 1975
(*)
Type
sludge
Liquid
Liquid
Liquid
Dewatered
Dewatered
Dewatered
Capacity
1200 gal
2500 gal
5500 gal
10 cu yd
15 cu yd
30 cu yd
Type of
truck
2-axle tanker
3-axle tanker
Semi, tanker
2-axle dump
3-axle dump
Semi , dump
Capital +
cost, $
25,000
42,000
55,000
25,000
42,000
50,000
Fuel use,
mpg
4.5
4.5
3.5
4.5
4.5
'3.5
Operation Cost,
$/mile
0.20
0.25
0.30
0.20
0.25
0. 30
(*) This information was developed from personal contacts with eight Sacramento area truck
and trailer dealers.
(+) Excluding operator and fuel.
(+) Based on Wholesale Price Index for Item 141102, motor trucks, of 150.2.
(/*) Based on Wholesale Price Index for Item 1412, motor vehicle parts, of 170.3.
-------
TABLE 4. TRUCK OPERATION SUMMARY, LIQUID SLUDGE, 1975
Annual
sludge
volume,
mg
1.5
5
15
50
150
One-way
distance
miles
5
10
20
40
sr
5
10
20
40
80
5
10
20
40
80
5
10
20
40
80
5
10
20
40
80
Trips per
1200
gal
1,250
1,250
1,250
1,250
1,250
4,167
4,167
4,167
4,167
4,167
12,500
12,500
12,500
12,500
12,500
41,667
41,667
41,667
41,667
41,667
125,000
125,000
125 ,000
125,000
125,000
2500
gal
600
600
600
600
600
2,000
2,000
2,000
2,000
2,000
6,000
6,000
6,000
6,000
6,000
20,000
20,000
20,000
20,000
20,000
60,000
60,000
60,000
60 , 000
60,000
year
5500
gal
273
273
273
273
273
909
909
909
909
909
2,727
2,727
2,727
2,727
2,727
9,091
9,091
9,091
9,091
9,091
27,273
27,273
27,273
27,273
27,273
(*)
Trucks needed
8 hr/day operation .... Truck use
(22 hr/day operation) 1,000 miles/year
1200 2500 5500
gal gal gal
1(1)
1(1)
2(1)
2(1)
4(2)
2(1)
3(1)
4(2)
6(3)
12(4)
5(2)
7(3)
12(4)
18(7)
35(12)
17(6)
24(9)
39(13)
58(24)
116(39)
50(18)
70(25)
116(39)
174(70)
350(116)
1(1)
1(1)
1(1)
1(1)
2(1)
1(1)
2(1)
3(1)
3(2)
6(2)
3(1)
4(2)
6(2)
9(4)
17(6)
8(3)
12(4)
19(7)
28(12)
56(19)
24(9)
34(12)
56(19)
84(34)
167(56)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
2(1)
3(1)
2(1)
2(1)
3(1)
4(2)
8(3)
4(2)
6(2)
9(3)
13(6)
26(9)
11(4)
16(6)
26(9)
38(16)
76(26)
1200
gal
13
25
50
100
200
42
83
167
333
667
125
250
500
1,000
2,000
417
833
1,667
3,333
6,667
1,250
2,500
5,000
10,000
20,000
2500
gal
6
12
24
48
96
20
40
80
160
320
60
120
240
480
960
200
400
800
1,600
3,200
600
1,200
2,400
4,800
9,600
5500
gal
3
6
11
22
44
9
18
36
73
145
27
55
109
218
436
91
182
364
727
1,455
273
546
1,091
2,182
4,364
Truck fuel
1,000 gal/year
1200
gal
2.9
5.6
11.1
22.2
44.4
9.3
18.4
37.1
74.0
148.2
27.8
55.6
111.1
222.2
444.4
92.7
185.1
370.4
740.7
1,481.6
277.8
555.6
1,111.1
2,222.2
4,444.4
2500
gal
1.3
2.7
5.3
10.7
21.3
4.4
8.9
17.8
35.6
71.1
13.3
26.7
53.3
106.7
213.3
44.4
88.9
177.8
355.6
711.1
133.3
266.7
533.3
1,066.7
2,133.3
5500
gal
0.8
1.6
3.1
6.3
12.6
2.6
5.1
10.3
20.9
41.4
7.7
15.7
31.1
62.3
124.6
26.0
52.0
104.0
207.7
415.7
78.0
156.0
311.7
623.4
1,246.9
Truck operators
1,000 man-hours/yr
1200 2500
gal gal
1.6 0.8
2.1 1.0
3.2 1.6
4.8 2.3
7.9 3.8
5.3 2.5
7.1 3.4
10.8 5.2
16.0 7.7
26.5 12.7
15.8 7.6
21.3 10.2
32.3 15.5
48.0 23.0
79.5 38.1
52.7 25.3
71.0 34.1
107.7 51.7
160.0 76.8
264.9 127.2
158.1 75.9
213.1 102.3
323.1 155.1
479.9 230.3
794.8 381.5
5500
gal
0.3
0.5
0.7
1.0
1.7
1.2
1.5
2.4
3.5
5.8
3.5
4.6
7.0
10.5
17.3
11.5
15.5
23.5
34.9
57.8
34.5
46.5
70.5
104.7
173.4
(*) 360 days per year.
(+) See Table 3.
(?) Based on truck operating hours plus 10 percent.
(#) Allows average of 2 hours per day for maintenance.
-------
TABLE 5.
TRUCK OPERATION SUMMARY,
DEWATERED SLUDGE, 1975
Annual
sludqe
volume,
1000
^ujd_
1.5
5
15
50
One way
distance ,
miles
5
10
20
40
80
5
10
20
40
BO
5
10
20
40
80
5
10
20
40
80
5
10
20
40
80
Trucks needed,
8 hours/day operation
(24 hours/day operation!
(#)
10
cu yd
150
150
150
150
150
500
500
500
500
500
1,500
1,500
1,500
1,500
1,500
5,000
5,000
5,000
5,000
5,000
15,000
15,000
15,000
15,000
15,000
15
rM] yd
100
100
100
100
100
333
333
333
333
333
1,000
1,000
1,000
1,000
1,000
3,333
3,333
3,333
3,333
3,333
10,000
10,000
10,000
10,000
10,000
30
cu yd
50
50
50
50
50
167
167
167
167
167
500
500
500
500
500
1,667
1,667
1,667
1,667
1,667
5,000
5,000
5,000
5,000
5,000
10
cu yd
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
2(1)
3(1)
5(2)
2(1)
3(1)
5(2)
7(3)
14(5)
6(3)
9(3)
14(5)
21(9)
42(14)
15
cu yd
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
2(1)
3(1)
2(1)
2(1)
4(2)
5(2)
10(4)
4(2)
6(2)
10(4)
14(6)
28(10)
30
cu yd
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
1(1)
2(1)
3(1)
5(2)
2(1)
3(1)
5(2)
7(3)
14(5)
Track use ,
1,000 miles/year
Truck fuel,
1,000 gal/year
10 15 30 10
cu yd cu yd cu yd nn yd
1.5 1 .5 .3
3 2 1 .7
6 4 2 1.3
12
24
5
10
20
40
80
15
30
60
120
240
50
100
200
400
800
150
300
600
,200
,400
8
16
3
7
13
27
53
10
20
40
80
160
33
67
133
267
533
100
200
400
BOO
1,600
4
a
2
3
7
13
27
5
10
20
40
80
17
33
67
133
267
50
100
200
400
BOO
2.
5.
1.
2.
4.
8.
17.
3.
6.
13.
26.
53.
11.
22.
44.
7
3
1
2
4
9
8
3
7
3
7
3
1
2
4
88.9
177.
33.
66.
133.
266.
533.
8
3
7
3
7
3
15 .
cu yd
.2
.4
.9
1
3
1
2
6
11
2
4
8
17
35
7
14
29
59
118
22
44
88
177
355
.8
.6
.7
.6
.9
.0
.8
.2
.4
.9
.8
.6
.3
.9
.6
.3
.4
.2
.4
.9
.8
.6
30 .
cu yd
.2
.3
.6
1
2
2
3
7
1
2
5
11
22
4
9
19
38
76
14
28
57
114
.1
.3
.6
.9
.0
.7
.7
.4
.9
.7
.4
.9
.9
.4
.1
.0
.3
.3
.6
.1
.3
228.6
Truck operators,
1,000 man-hours/yr
10
cu yd
.2
.3
.5
.7
1.2
.6
.9
1.3
1.9
3.2
1.9
2.6
3.9
5.8
9.5
6.3
8.5
12.9
19.2
31.8
19.0
25.6
38.8
57.6
95.4
15
cu yd
.1
.2
.3
1
2
1
1
2
3
6
4
5
8
12
21
12
17
25
38
6.
.4
.6
.4
.6
.9
.3
.1
.3
.7
.6
.(
.4
.2
.7
.6
.8
.2
.7
.1
.9
.4
36
30
cu yd
.1
.1
.1
.2
.3
.2
.3
.4
.6
1.1
.6
.9
1.3
1.9
3.2
2.1
2.8
4.3
6.4
10.6
5.8
8.5
12.9
19.2
31.8
360 days per year.
See Table 3.
Based on truck operating hours plus 10 percent.
Allows average of 2 hours per day for maintenance.
-------
10
TABLE 6. TRUCK FACILITIES CAPITAL AND OPERATION
AND MAINTENANCE DATA, LIQUID SLUDGE, 1975(*)
Item
(**)
Capital Cost, $ : +.
Loading pump, pipe, hose
Loading truck encl. W
Truck ramp for unloading
Unloading truck encl. and office
Total
Annual amortization
Operation and maintenance per year:
Electrical energy, kwh
(Pumping, heat, light) .
Maintenance supplies, $
Operation and maintenance
manpower, man-hours
1.5
7,500
5,000
15,000
10,000
37,500
3,218
25,000
1,500
1,000
Annual
5
7,500
7,000
15,000
10,000
29,500
3,390
35,000
2,000
1,500
sludge volume, mg
15
8,500
10,000
30,000
15,000
63,500
5,450
55,000
3,000
2,000
50
14,000
20,000
50,000
20,000
104,000
8,924
90,000
3,500
3,000
150
20,000
25,000
75,000
30,000
150,000
12,870
145,000
4,000
4,000
(*) Assumptions: Pumps and piping sized to fill truck in 20 minutes maximum; no storage at
plant, use plant sludge storage; storage at unloading site is a part of
another unit process; gravity unloading at disposal site.
(**) EPA treatment plant index = 232.5.
(+) Estimated from Black & Veatch Report and Adjusted to EPA Treatment Plant Index.
(£) Estimated from Richardson Engineering Services
(?) Based on $30/sq ft for office and $20/sq ft for truck enclosure.
-------
TABLE 7. TRUCK FACILITIES CAPITAL AND OPERATION AND
MAINTENANCE DATA, DEWATERED SLUDGE, 1975(*)
Annual sludge volume, cu yd
Item 1.5 5 15 50 150
(**)
Capital Cost^ $ :
Conveyor (* + 10,000 10,000 10,000 20,000 20,000
Loading hopper 10,000 10,000 10,000 15,000 20,000
Loading truck encl. 5,000 5,000 5,000 10,000 10,000
Truck ramp 15,000 15,000 15,000 20,000 30,000
Unloading truck encl. and office ^ 10,000 10,000 10,000 15,000 25,000
Total 50,000 50,000~ 50,000 80,000 105,000
Annual amortization ($) 4,290 4,290 4,290 6,865 9,010
Operation and maintenance per year:
Electrical energy, kwh 22,000 32,000 50,000 82,000 1.35,000
Maintenance supplies, $ 1,500 2,000 3,000 3,500 4,000
Operation and maintenance
manpower, man-hours 1,000 1,500 2,000 3,000 4,000
(*) Assumptions: Equipment sized to fill truck in 20 minutes maximum; loading hopper sized
for one trtick load and gravity discharge into truck; storage at unloading
site is a part of another unit process; gravity unloading at disposal site
(Dump or power ram for truck unloading).
(**) EPA treatment plant index = 232.5.
(+) Estimated from Black & Veatch Report
(^) Estimated from Richardson Engineering Services
(^) Based on $30/sq ft for office and $20/sq ft for truck enclosure.
-------
TABLE 8. BARGE CHARACTERISTICS, 1975
(*)
1
2
Size,
gal
300,000
500,000
850,000
,000,000
,000,000
1
1
1
1
3
Ave rage
1975
capital
cost,
$
,000,000
,250,000
,750,000
,950,000 (*)
,000,000(70
Annual
amortization,
$/year(+)
94,000
118,000
165,000
184,060
283,170
Barge
maint.
cost,
$/year
15,000
20,000
25,000
28,000
35,000
Tug
size,
total
hp
1,200
2,000
2,000
2,500
2,500
Tug
billing
rate
(total) ,
$/hour
140
150
150
160
160
Tug fuel
consumption,
gal/day
2,000
2,500
2,500
3,000
3,000
(*) These data were developed from personal communications with two barge and tug operators.
(+) Calculated at 7 percent over 20-year life.
(£) Cost obtained from Fader
-------
TABLE 9. BARGE OPERATION SUMMARY, 4 PERCENT LIQUID SLUDGE, 1975
it*
on
Tug billing time,
Annual
sludgo
vol ume ,
mg
7.5
15
75
150
750
On-? way
distance
mi les
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
300,000
qri]
1
1
1
1
1
1
1
1
1
1
1
1
2
3
5
2
2
3
6
10
-
_
_
-
-
Barges required
500,000 050,000
gal
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
2
4
6
4
6
9
16
30
gal
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
4
2
3
6
10
18
300,000
gal
25
25
25
25
25
50
50
50
50
50
250
250
250
250
250
500
500
500
500
500
2,500
2,500
2,500
2,500
2,500
Trips per
500,000
gal
15
15
15
15
15
30
30
30
30
30
150
150
150
150
150
300
300
300
300
300
1,500
1,500
1,500
1,500
1,500
year
850,000
gal
9
9
9
9
9
18
18
18
18
18
89
89
89
89
89
177
177
177
177
177
883
883
883
b83
883
300,000
73 1
431
719
1,294
2,444
4,744
863
1,438
2,588
4,888
9,488
4,313
7,188
12,938
24,438
47,438
8,630
14,380
25,880
48,880
94,880
hours per year
500,000
gal
259
431
776
1,466
2,846
518
863
1,553
2,933
5,693
2,588
4,310
7,760
14,660
28,460
5,180
8,630
15,530
29,330
56,930
25,880
43,100
77,600
146,660
284,600
850,000
gal
156
259
466
880
1,708
311
518
932
1,760
3,416
1,536
2,559
4,606
8,700
16 , 888
3,053
5,089
9,160
12,302
33,586
15,232
25,386
45,695
86,313
167,550
Tug fuel calculation
300,000
gal
12
24
48
96
192
24
48
96
192
384
120
240
480
960
1,920
240
480
960
1,920
3,840
days per year
500,000
gal
7
14
28
56
112
14
28
56
112
224
70
140
280
560
1,120
140
280
560
1,120
2,240
700
1,400
2,800
5,600
11,200
time.
850,000
gal
4
9
17
35
69
9
17
35
69
138
43
85
171
341
682
85
170
339
679
1,357
423
846
1,693
3,385
6,770
-------
TABLE 10. BARGE OPERATION SUMMARY, 10 PERCENT LIO.UID SLUDGE, 1975
Annual
sludge
volume.
ing
3
6
30
60
300
Barges required
One way
distance.
miles
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
300,000
gal
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
2
4
3
4
6
11
20
500,000
gal
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
2
2
4
7
12
850,000
qal
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
2
4
7
Trips per year
300,000
gal
10
10
10
10
10
20
20
20
20
20
100
100
100
100
100
200
200
200
200
200
1,000
1,000
1,000
1,000
1,000
500,000
gal
6
6
6
6
6
12
12
12
12
12
60
60
60
60
60
120
120
120
120
120
600
600
600
600
600
850,000
gal
4
4
4
4
4
7
1
7
7
7
35
35
35
35
35
71
71
71
71
71
353
353
353
353
353
Tug hilling time.
hours per year
300,000
gal
173
288
518
978
1,898
345
S75
1,035
1,955
3,795
1,730
2,880
5,180
9,780
18,980
3,450
5,750
10,350
19,550
37,950
17,300
28.9OO
51,800
97,800
189,800
500,000
gal
104
173
311
587
1,139
207
34S
621
1,173
2,277
1,040
1,730
3,110
5,870
11 , 390
2,070
3,450
6,210
11,730
22,770
10,400
17,300
31,100
58,700
113,900
850,000
gal
69
115
207
391
759
121
201
362
684
1,328
604
1,006
1,811
3,421
6,641
1,125
2,041
3,674
6,940
13,472
6,089
10,149
18,268
34,506
66,982
Tug fuel calculation time,
days per year
300,000
gal
5
10
19
38
77
10
19
38
77
153
50
100
190
380
770
100
190
380
770
1,530
500
1,000
1,900
3,800
7,700
500,000
gal
3
6
12
23
46
6
12
23
46
92
30
60
120
230
460
60
120
230
460
920
300
600
1,200
2,300
4,600
850,000
gal
2
4
8
16
31
4
^
14
27
54
17
34
67
134
268
34
68
136
272
544
169
338
677
1,353
2,706
-------
Facility Costs
Amortization of facilities capital cost - Tables 11 and 12.
Facilities operation and maintenance - Tables 11 and 12.
3. Railroad Transport
Point to Point Costs
Railroad tariffs - Tables 13 and 14 and report text.
Rail tank car lease (including maintenance), Liquid Sludge -
Table 13.
Facility Costs
Amortization of facilities capital cost - Tables 15 and 16.
Facilities operation and maintenance - Tables 15 and 16.
4. Pipeline Transport
Pumping and pumping station electrical energy - Table 17.
Operation and maintenance labor - Table 18.
Operation and maintenance supplies and parts - Table 18.
Amortization of pipeline and pumping station capital cost - Tables 19,
20, 21, and 22.
SLUDGE VOLUME
The range of annual sludge volume used for each transport mode is shown
in Table 23. In some cases it was not practical for a specific mode to
cover the full range because of practical limits. Each volume is roughly
related to a secondary treatment plant size.
TRANSPORT DISTANCE
The range of transport distance assumed for each mode is shown in
Table 24.
TRANSPORT CYCLE TIMING
The assumed transport speeds, loading, and unloading times are shown in
Table 25. The actual speed of rail movements is meaningless because the
transit time includes other factors such as switching, train make up, weigh-
ing, and similar delays in movement. The total point to point transit time
is more meaningful for rail movements and is a major factor in determining
the number of cars to be leased. The transit time is not important for
dewatered sludge cars if the railroad furnishes the cars. The transit time
will vary greatly from case to case and the objective when using leased
cars is to reduce the time to a minimum. Table 26 shows some typical times
and the magnitude of the problem.
DAILY OPERATING SCHEDULE
Certain limitations may be placed on daily operating schedules for
47
-------
TABLE 11. BARGE FACILITIES CAPITAL AND OPERATION AND
MAINTENANCE DATA, 4 PERCENT LIQUID SLUDGE, 1975
CD
Annual sludge volume,
Item
Capital Cost, $:
Sludge storage at
loading facility (+}
Loading and unloading
pumping (+)
Loading and unloading
piping (*)
Loading and unloading docks
and facilities (12)
Total
Annual Amortization
Operation and Maintenance Per Year:
Maintenance, man-hours (+)
Operation, man-hours/barge load
Operation and maintenance
supplies, $ (+)
Dock maintenance, $
Electrical energy, kwh
(pumping, light, heat etc.)
7.5
102,000
78,000
20,000
200,000
400,000
34,324
680
12
4,200
6,000
35,000
15
102,000
78,000
20,000
200,000
400,000
34,324
680
12
4,200
6,000
40,000
75
252,000
154,000
40,000
200,000
646,000
55,433
1,640
12
12,600
6,000
90,000
mg
150
252,000
154,000
40,000
200,000
646,000
55,433
1,640
12
12,600
6,000
140,000
750
405,000
154,000
40,000
300,000
899,000
77,143
2,400
12
20,000
10,000
480,000
(*) Assumptions: Pumps and piping sized to fill barge in 4 hours; storage at plant equal to one
days production or 2 barge loads minimum; storage at unloading area is a
part of another unit process.
( + ) Estimated from Black & Veatch Report^ and adjusted to EPA Treatment Plant Index = 232.5.
(t) Estimated from Richardson Engineering Services '^' .
-------
TABLE 12. BARGB FACILITIES CAPITAL AND OPERATION AND
MAINTENANCE DATA,10 PERCENT LIQUID SLUDGE, 1975
Annual sludge volume,
Item
Capital Cost, $ :
Sludge storage at
loading facility ( + )
Loading and unloading
pumping (+)
Loading and unloading
piping (^)
Loading and unloading docks
and facilities <12)
Total
Annual Amortization
Operation and Maintenance Per Year:
Maintenance, man-hours (+)
Operation, man-hours/barge load
Operation and maintenance
supplies, $ (+)
Dock maintenance, $
Electrical energy, kwh
(pumping, light, heat etc.)
102
78
20
200
400
34
4
6
32
3
,000
,000
,000
,000
,000
,324
680
12
,200
,000
,000
102
78
20
200
400
34
4
6
34
6
,000
,000
,000
,000
,000
,324
680
12
,200
,000
,000
30
102,
78,
20,
000
000
000
200,000
400,
34,
4,
000
324
680
12
200
6,000
50,
000
mg
60
252
154
40
200
646
55
1
12
6
82
,000
,000
,000
,000
,000
,433
,640
12
,600
,000
,000
300
252
154
40
200
646
55
1
12
6
140
,000
,000
,000
,000
,000
,433
,640
12
,600
,000
,000
(*) Assumptions: Pumps and piping sized to fill barge in 4 hours; storage at plant equal to one
days production or 2 barge loads minimum; storage at unloading area is a
part of another unit process.
(+) Estimated from Black & Veatch Report(1) and adjusted to EPA Treatment Plant Index = 232.5.
(t) Estimated from Richardson Engineering Services '2' -
-------
TABLE 13. RAILROAD OPERATION SUMMARY, LIQUID SLUDGE
Ln
o
Annual
sludge
volume ,
mg
7.5
15
75
150
750
One way
distance,
miles
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
20
40
80
160
320
Car
size,
qal<*>
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
20,000
Car
year
375
375
375
375
375
750
750
750
750
750
3,750
3,750
3,750
3,750
3,750
7,500
7,500
7,500
7,500
7,500
37,500
37,500
37,500
37,500
37,500
loads
day
I
1
1
1
1
2
2
2
2
2
10.4
10.4
10.4
10.4
10.4
21
21
21
21
21
104
104
104
104
104
Load
time(+) ,
hours
5
5
5
5
5
5.5
5.5
5.5
5.5
5.5
6
6
6
6
6
7
7
7
7
7
19
19
19
19
19
Unload
time (+),
hours
5
5
5
5
5
5.5
5.5
5.5
5.5
5.5
6
6
6
6
6
7
7
7
7
7
19
19
19
19
19
Transit
time (*)
hours
96
96
144
168
192
96
96
144
168
172
91
96
144
168
192
96
96
144
168
192
96
96
144
168
192
Round
trip
time,
hours
106
106
154
178
202
107
107
155
179
203
108
108
156
180
204
110
110
158
182
206
134
134
182
206
230
Cars
required
5
5
7
8
9
9
9
13
15
17
47
47
68
78
89
97
97
139
160
181
581 3
581 3
789 3
893 3
997 3
Annual
volume W
tons
31,238
31,238
31,238
31,238
31,238
62,475
62,475
62,475
62,475
62,475
312,375
312,375
312,375
312,375
312,375
624,750
624,750
624,750
624,750
624,750
,123,750
,123,750
,123,750
,123,750
,123,750
(*) 20,000-gal rail car full maintenance lease rate is $445/month from GATX.
(+) Times based on information provided by GATX; however their numbers have been modified to fit
the study conditions.
(*) Based on information provided by Southern Pacific Railroad, Sacramento,
(70 For billing purposes
-------
TABLE 14. RAILROAD OPERATION SUMMARY, DEWATERED SLUDGE
Annual
sludge One way
volume, distance,
1,000 cu yd miles
7.5 20
40
80
160
320
15 20
40
80
160
320
75 20
40
80
160
320
150 20
40
80
160
320
750 20
40
80
160
320
Car
(*)
size, '
cu yd
50
50
50
50
50
50
50
50
50
50
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
Car loads
year
150
150
150
150
150
300
300
300
300
300
750
750
750
750
750
1,500
1,500
1,500
1,500
1,500
7,500
7,500
7,500
7,500
7,500
day
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
2
2
2
2
2
4
4
4
4
4
21
21
21
21
21
4
4
4
4
4
8
8
8
8
8
Annual
volume/"1"'
tons
5,569
5,569
5,569
5,569
5,569
11,138
11,138
11,138
11,138
11,138
55,688
55,688
55,688
55,688
55,688
111,375
111,375
111,375
111,375
111,375
556,875
556,875
556,875
556,875
556,875
(*) Based on use of rail company cars.
(+) For billing purposes.
-------
TABLE 15. RAILROAD FACILITIES CAPITAL AND OPERATION AND
MAINTENANCE DATA, LIQUID SLUDGE,
in
NJ
Annual sludge volume,
Item
Capital cost, $:
Sludge storage at loading
facility (+)
Loading pumping^4"'
Loading piping and
appurtences (*)
Loading and unloading rail
sidings and switches '
Loading and unloading building
and site work
Total
Annual amortization
Operation and maintenance per year:
Maintenance, man-hours ^
Ope r at i on , mam- hou rs
Operation and maintenance
supplies, $ t+'
Rail maintenance, $
Electrical energy, kwh
7.5
31,000
38,000
10,000
37,000
64,000
180,000
15,446
130
475
2,000
35,000
15
45,000
38,000
12,000
43,000
64,000
202,000
17,334
260
727
3,000
40,000
75
102,000
67,000
49,000
80,000
84,000
382,000
32,780
340
9,000l7f'
2,237
4,000
90,000
mg
150
144,000
77,000
50,000
156,000
136,000
563,000
48,311
500
10,500(#)
3,635
8,000
140,000
750
405,000
81,000
50,000
372,000
248,000
1,156,000
99,196
If2°°f#)
28,500tff;
10,000
20,000
480,000
(*) Assumptions: Pumping and piping sized to fill 1, 2, 10, 20, & 100 unit car trains in 1.5,
2, 3, 15 hours respectively; storage at plant equal to one days production;
storage at unloading area is a part of another unit process; rail cars discharge
by gravity into unloading storage.
(+) Estimated from Black & Veatch Report' and adjusted to EPA Treatment Plant Index = 232.5.
(£) Estimated from Richardson Engineering Services'2^.
(T*) One man for total load and unload time.
(#) Two men for total load and unload time.
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TABLE 16. RAILROAD FACILITIES CAPITAL AND OPERATION AND
MAINTENANCE DATA, DEWATERED SLUDGE, 1975(*)
Annual sludge volume, 1000 cu yd
Item 7.5
Capital cost, $:
Loading sludge hoppers^"1"' 24,000
Loading conveyors (+> 20,000
Loading and unloading rail
sidings and switches'"1"' 37,000
Loading and unloading building
and site work 64,000
Total 145,000
Annual amortization 12,442
Operation and maintenance per year:
Maintenance, man-hours^) 130
Operation, man-hours 1,650^
Operation and maintenance
supplies, $ (JF) 475
Rail maintenance, $ 2,000
Electrical energy, kwh 92,000
(*) Assumptions: Loading storage hopper sized
from storage hopper; storage
15
24,000
20,000
37,000
64,000
145,000
12,442
260
3,300(5^
727
2,000
92,000
for one car
at unloading
75
28,000
20,000
37,000
64,000
149,000
12,786
340
2,237
2,000
92,000
150
56,000
40,000
73,000
84,000
253,000
21,710
500
4,125(7
3,635
4,000
169,000
load; gravity loading
area is
process; rail cars dump by gravity into unloading
750
112,000
80,000
258,000
160,000
610,000
52,344
1,200
-) io,ooo<#)
10,000
25,000
308,000
into car
a part of another unit
storage.
( + ) Estimated from Richardson Engineering Services '2).
(-F) Same as for liquid sludge case.
(T^) One man for total load and unload time.
(#) Two men for total load and unload time.
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TABLE 17. PIPELINE PUMPING STATION ENERGY
Pipeline Power, kw/
size
in
4
6
8
10
12
14
16
18
20
(*)
, 1000 gph -
ft head
0.0078
0.0070
0.0070
0.0055
0.0048
0.0045
0.0050
0.0046
0.0045
Motor efficiency =
Annual energy, kwh/ft head
operation shown (*)
Pumping only
4 8
81.8 163.5
343.4
613.2
766.5
924.0
1,100.6
1,752.0
2,017.1
2,358.5
(19)
90% ; pump
12
245.3
515.1
919.8
1,149.8
1,386.0
1,651.0
2,628.0
3,025.7
3,537.7
efficiency =
20
408.8
858.5
1,533.0
1,916.3
2,310.0
2,752.0
4,380.0
5,042.8
5,896.2
80%; kw/1000
for daily hours of
Total station (+)
4
90
-
-
-
-
-
-
-
-
gph- ft
8
180
378
675
843
1,016
1,211
1,927
2,219
2,594
head =
12
270
567
1,012
1,265
1,525
1,816
2,891
3,328
3,891
0.00315
20
450
944
1,686
2,108
2,541
3,027
4,818
5,547
6,486
(Pump eff) (Motor eff)
(+) Total station energy = 1.10 x pimping energy.
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TABLE 18. PIPELINE OPERATING AND MAINTENANCE LABOR AND SUPPLIES
Pipeline size, in
4
6
8
10
12
14
16
18
20
Annual operation and maintenance
labor, man-hours per pumping
station
700
720
780
820
840
870
910
940
980
Annual operation and main-
tenance parts and supplies ,
$/pumping station ^ '
640
670
750
820
890
940
1,680
1,750
1,840
(*) For short pipelines, use operation and maintenance labor and supplies cost for one
pumping station as a minimum.
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TABLE 19. PIPELINE SIZE, SLUDGE FLOW
AND SLUDGE VOLUME
Pipeline
size ,
in
Sludge flow
rate , gpm @
3 fps
velocity
Pipeline capacity at 3 fps velocity
for various daily hourly operating
periods, mgd
4 8 12 20
4 120 0.03 0.06 0.09 0.14
6 280 - 0.13 0.20 0.34
8 500 - 0.24 0.36 0.60
10 800 - 0.38 0.58 0.96
12 1,100 - 0.53 0.79 1.32
14 1,400 - 0.67 1.01 1.68
16 2,000 - 0.96 1.44 2.40
18 2,500 - 1-20 1.80 3.00
20 3,000 - 1.44 2.16 3.60
56
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TABLE 20. PIPELINE SLUDGE PUMPING CHARACTERISTICS
en
Pipeline
size, Flow,
in gpm
4
6
8
10
12
14
16
18
20
120
280
500
800
1,100
1,400
2,000
2,500
3,000
Hydraulic
loss, ft/
100 ft (C=90)
2.10
1.40
1.02
0.82
0.61
0.45
0.45
0.39
0.33
Approximate head
available each
pumping station,
ft(*)
400+
450+
260
230
230
210
210(*)
225(1=)
200 (*)
Pump Pump
efficiency, station
percent cost, $ (^)
45
50
50
64
73
78
70
76
78
47,000
57,000
71,000
88,000
108,000
123,000
154,000
185,000
216,000
Pumping station
spacing- level
terrain, ft
19,048
32,143
25,490
28,049
37,705
46,667
46,667
57,179
60,606
(*) Based on non clog, centrifugal, 1,780 rpm pumps.
(+) Pumps in series for additional head.
(%) Pumps in parallel for additional capacity.
(TO EPA Treatment Plant Index = 232.5.
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TABLE 21. PIPELINE COST
Pipeline cost, $/ft
4
6
8
10
12
14
16
18
20
30
15.25
16.25
17.75
19.25
20. 75
23.75
25.75
28.25
32.75
44.25
(*) Assumes: No rock and no major unusual problems;
one major highway crossing per mile;
one single rail crossing per 5 miles'
nominal number of driveways and minor
roads; EPA Sewer Index - 248.7
(+) Costs for installed pipelines buried 3-6 ft; for
6 - 10 ft of depth add 15 percent and for hard rock
excavation, add 70 percent to the costs.
TABLE 22. PIPELINE CROSSING COSTS
(*)
Crossing Unit cost ,
Highway, two-lane 11,000
Highway, four-lane 13,000
Highway, divided multiple-lane 22,000
Railroad crossing (per track) 8,000
Small river 50,000
Major river 200,000
(*) These costs to be added to the applicable costs
from Table 21.
58
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TABLE 23. ANNUAL SLUDGE VOLUME
Mg/year
at 4
percent
1.5
7.5
15
75
150
750
1,300
Liquid
( *)
Mode
T-R
T-B-R
T-B-R-P
T-B-R-P
T-B-R-P
B-R-P
P
Dewatered
ing/year
10 percent
3
6
30
60
300
Mode
B
B
B
B
B
B
cu yd /
year
1,500
7,500
15,000
75,000
150,000
750,000
Mode
T
T-R
T-R
T-R
T-R
R
Approximate
secondary
treatment
plant size,
mgd
1
5
10
50
100
500
(*) Mode Symbols: T = truck; B = barge; R = railroad; P = pipeline.
TABLE 24. TRANSPORT DISTANCE
One way
distance, miles
Transport mode
Pipeline
Barge
Truck
Rail
5
10
20
40
80
160
320
Any
Distance
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
59
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TABLE 25. TRANSPORT CYCLE TIMING
Mode
Average speed
mph
Load time,
minutes(hours)
Unload time
minutes(hours)
Truck
Barge
25 for first
20 miles, 35
for rest
30
300
(*) Includes 4 hours to makeup and spot cars.
15
300
*)
Railroad -
Pipeline
1 and 2 car unit
4 and 10 car unit -
20 car unit
100 car unit
-
(5.5)
[l}
-
U9)<*>
-
TABLE 26. RAILROAD TRANSIT TIME
(*)
One way
distance, miles
Round trip transit
time, days
20
40
80
160
320
4
4
6
7
8
(*) Based on information from Southern Pacific
Railroad, Sacramento.
60
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certain types of transport. This has been true for a case in Washington,
D.C. where truck operations were restricted to daylight hours. The follow-
ing assumptions have been made in this study regarding operations, however,
this will vary widely.
Truck: 8 and 22 hours per day, 360 days per year (8 hours used
for calculations).
Barge: 24 hours per day, 360 days per year as required.
Railroad: As required to load trains.
Pipeline: 8, 12, and 20 hours per day, 360 days per year.
TRANSPORT EQUIPMENT
There is a wide variety of equipment available for transporting sewage
sludge. Each type of transport equipment is normally available in a number
of configurations and sizes. For simplification, the following equipment
was used as a basis for this study. Each size was applied to its practical
limits and, in most cases, one size of equipment could not economically or
practically cover the full range of sludge volume.
1. Truck
1200-gal tank truck, gasoline
2500-gal tank truck, diesel
5500-gal semi-tank truck, diesel
10-cu yd dump truck, gasoline
15-cu yd dump truck, diesel
30-cu yd semi-dump truck, diesel
See Table 3 for truck characteristics
2. Barge
300,000-gal barge
500,000-gal barge
840,000-gal barge
See Table 8 for barge characteristics including 5,000,000 - and
2,000,000-gal sizes
3. Railroad
Single 20,000-gal tank cars
10 unit tank train (20,000-gal cars)
20 unit tank train (20,000-gal cars)
100 unit tank train (20,000-gal cars)
Tank cars must be provided by the shipper; either purchase, lease, or
contract.
61
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- 50-cu yd (35-ton) hopper or side dump car
100-cu yd (70-ton) hopper or side dump car
These cars are provided by the railroad when available. It is assumed
in this study they are available, however, in actual cases they may
have to be provided by the shipper.
4. Pipeline
See Tables 19 and 20 for the pipeline and pumping station characteris-
tics.
FACILITIES
A broad range of facilities (terminal installations) will be designed
for sludge transport systems depending on climate, type of sludge, type of
transport equipment, the design engineer, and other factors. The assumptions
made for purposes of this study are shown in Table 27, realizing that wide
deviations will be experienced in actual installations. In all cases it
was assumed that these facilities were constructed concurrently with other
plant construction work.
CAPITAL COSTS
All capital costs are amortized at 7 percent straight line over the
following equipment life. All capital equipment is assumed to have zero
residual value except trucks. Applicable amortization factors (capital
recovery) are provided in Table 28.
Trucks, 6 years, 15 percent residual value.
Truck terminal facilities, 25 years.
Barges, 20 years.
Barge terminal facilities, 25 years.
Railroad cars, leased, 12 year, typical GATX terms.
Railroad terminal facilities, 25 years.
Pumping stations, 25 years.
Pipeline, 25 years.
OPERATION AND MAINTENANCE REQUIREMENTS
Operation and maintenance costs were calculated based on actual pumping
time for energy, and on published estimating information or actual exper-
ience for other factors. Where published or actual information was not
available the requirements were estimated. Where operation and maintenance
personnel are required less than full time, it is assumed they can charge
the balance of their time to other unit processes.
ESCALATION
Escalation factors are recommended for each item which is expressed in
1975 dollars. A summary of these escalation factors is shown in Table 29.
All of these factors are readily available and continuously updated.
62
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TABLE 27. TRANSPORT FACILITIES
Transport mode
Item Truck Railroad Barge Pipeline
Liquid:
Loading storage No(+) Yes Yes
Loading equipment Yes Yes Yes
Dispatch office Yes Yes Yes
Dock and control bldg. N/A N/A Yes
Railroad siding(s) N/A Yes N/A
Unloading equipment Yes Yes Yes
Unloading storage (*) No No No
Dewatered:
Loading storage
Loading equipment
Dispatch office
Dock and control bldg.
Railroad siding(s)
Unloading equipment
Unloading storage
Yes (?0
Yes
Yes
N/A
N/A
Yes
No(*)
Yes(^)
Yes
Yes
N/A
Yes
Yes
No(*)
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(*) Storage assumed to be a part of another unit process.
(+) Storage required for one or two truckloads is small compared with
normal plant sludge storage.
(T«O Elevated storage for ease of gravity transfer to trucks and rail
cars.
(#) Pipeline facilities consist of pipeline and pumping stations.
63
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TABLE 28. AMORTIZATION FACTORS
Amortization Amortization Amortization factor
period, years rate , percent (capital recovery factor)
6 6 0.20336
7 0.20980
8 0.21632
10 0.22961
12 0.24323
20 6 0.08718
7 0.09439
8 0.10185
10 0.11746
12 0.13388
25 6 0.07823
7 0.08581
8 0.09368
10 0.11017
12 0.12750
64
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TABLE 29. SUMMARY OF ESCALATION FACTORS
Factor
Source
Base factor for this study
EPA Treatment Plant Index
EPA Sewer Index
WPI Item 1412 - Motor Vehicle
Parts
WPI Item 141102 - Motor Trucks
WPI Item 114 - General Purpose
Machinery and Equipment
WPI Item 107 - Fabricated
Structural Metal Parts
WPI Item 144 - Railroad
Equipment
WPI Item 11410207.03 -
Centrifugal Pump, 1,000
gpm, 130 ft, 1750 rpm
Railroad Rates
EPA
EPA
U.S. Dept. of Labor
U.S. Dept. of Labor
U.S. Dept. of Labor
U.S. Dept. of Labor
U.S. Dept. of Labor
U.S. Dept. of Labor
Railroad Rate Depts.
(*)
232.5 (April, 1975)
248.7 (April, 1975)
170.3
150.2
174.8
189.9
201.8
139.2
November 30, 1975
{*) U.S. Dept. of Labor Wholesale Price Indexes (WPI) are published monthly in "Wholesale
Prices and Price Indexes", Library of Congress Catalog Number L53-140.
-------
GENERAL ASSUMPTIONS
The following general assumptions and unit costs were used in this
study as applicable.
1. Truck fuel $.60 per gal.
2. Electricity $0.04 per kwh.
3. All labor at $8.00 per hour including fringes.
4. General, overhead, and administrative costs at 25 percent of total
operation and maintenance cost.
5. Level terrain for pipeline.
6. Where not needed full time, operation and maintenance personnel can
charge balance of their time to other unit processes.
66
-------
SECTION 4
SPECIAL TRANSPORT MODE CONSIDERATIONS
A number of assumptions must be made in a study of this type especially
where manual calculations are required. As mentioned before, the computer
program should be flexible enough to allow rather broad operating parameters.
Some of the special considerations for each transport mode are outlined
herein along with a discussion of some of the more influential parameters for
each mode.
TRUCK TRANSPORT
In some cases, truck operations will be limited to daylight hours or to
certain routes by local requirement. The study assumed 8 hour per day oper-
ation. The most cost effective utilization of capital equipment is contin-
uous operation, but this may not be possible in all cases. The effect of
the daily operation hours on number of trucks is shown in Tables 4 and 5.
The effect is significant. There are many different types and configurations
of trucks available, however, general purpose type trucks were selected for
this study. This selection coincides with previous work.(2°) Truck trans-
port was based on agency ownership and operation of trucks and facilities.
In many cases the trucks will be provided and operated by a contractor in
which cases profit should be included in calculations.
BARGE TRANSPORT
In general, the larger barges are much more cost effective than smaller
barges. Larger barges have deeper drafts and, therefore, may not be prac-
tical for many inland waterways. The major factor in barging is the cost
of tug (towing) services and the larger barges minimize this cost. This is
illustrated in the example in Appendix B. This study was based on barges
up to 850,000-gal size, but barge data is included for larger barges up to
2,000,000-gal size. It is easy to incorporate these larger sizes in manual
calculations as shown in Appendix B, but, practically, these larger barges
may not be applicable to many cases. Barge transit times will be variable
depending on traffic, draw bridges, locks, tides, currents, and other fac-
tors. The average speed of 4 mph used in this study is an average and
speeds in open water may exceed 7 mph. The use of self propelled barges is
practiced by New York City, but most agencies use standard barges and a
towing service. The tug is a more versatile power unit and, in general,
smaller crews can be used than with self propelled barges according to a
west coast tug operator. The barge is normally unmanned during transit
The tug crew is immaterial to this study, but may consist of 4 to 6 persons
67
-------
at an average hourly rate of $13.00 including fringes, according to west
coast operators. The tug billing time is based on round trip transit time
and unloading time plus 15 percent for miscellaneous use. The fuel calcula-
tion time is based on round trip transit time plus 15 percent.
Loading is normally accomplished by either a gravity pipeline or
pump(s) and pipeline from a storage tank. A barge is normally filled in
2 to 5 hours according to personal communications with several existing
operations.
Unloading requires a pump(s) and pipeline to a storage system . The
pump can be barge or dock mounted and can be diesel or electric.
Barge transport was based on agency ownership and operation of barges
and facilities and contract towing. In many cases, the barge operation will
be performed by a contractor and profit should be included in calculations.
RAILROAD TRANSPORT
A significant factor in rail transport relates to the cars and their
use. Railroads may provide hopper type cars for dewatered sludge if they
are available, however, the shipper will usually have to provide tank cars
according to railroad companies. Tank cars are normally leased from a manu-
facturer on a full maintenance basis. The number of tank cars required is
related to the round trip transit time and this time can be significant.
This study was based on timing experienced by Southern Pacific in California.
The times may be reduced in special cases and this will have a significant
effect on the number of rail tank cars needed and, hence, on capital or
lease costs.
Rail rates vary widely, but in general, rates in various parts of the
country vary according to the following average according to an experienced
rail traffic consultant.
Approximate Railroad
Area Rate Variation
North Central and Central Average rate as outlined herein
Northeast 25 percent higher than average
Southeast 25 percent lower than average
Southwest 10 percent lower than average
West Coast 10 percent higher than average
The rates used in this study were adjusted to the average National
level (North Central and Central). Obtaining representative typical rates
from railroad companies is very difficult, however, the following average
rates were used in this study. These rates were current on November 30,
1975 and can be adjusted by applying subsequent published rate increases.
68
-------
One way distance, Rate,
miles $/net ton
20 2.10
40 3.00
80 4.10
160 6.50
320 12.50
The railroads generally allow a rebate of $0.06 to $0.20 per mile per
car if the shipper provides the car. In this study, a rebate of $0.15 was
assumed.
Rail transport was based on agency ownership and operation of the facil-
ities, agency leasing and operation of tank cars, railroad supply of de-
watered sludge cars, and railroad movement of all cars. There are very few
past and present examples of rail transport of sewage sludge to use for
guidelines.
PIPELINE TRANSPORT
A number of assumptions were made for this study, and most are related
to past or present actual operations. The liquid sludge was assumed to be
reasonably free of grit and grease, similar to anaerobic digester effluent.
Raw sludge can also be transported by pipeline, but the grease may
require additional maintenance. The solids content does not affect the
calculations within the range of 0 to 4 percent solids. The minimum pipe-
line size considered in this study is 4 in. Although the literature
describes installations with smaller pipelines , these small pipelines
represent special design cases, and are, therefore, not covered in this
general study.
Sludge pumps are assumed to be of the dry pit, horizontal or vertical,
nonclog or slurry centrifugal type operating at 1,780 rpm. Lower speed
pumps are available and might be selected for specific projects depending on
the special conditions. These pumps are relatively inefficient at low flows,
but approach 80 percent efficiency at optimum conditions. They are widely
used for sludge pumping applications . Other types are used,
but this study did not attempt to optimize the pumping for each pipeline
size. The assumed purap characteristics are shown in Table 20 and are based
on manufacturers' published data . Because of the high friction loss
in the 4 and 6 in pipelines the corresponding pumping stations for these
lines contain more than one pump in series in order to develop higher pumping
heads and minimize the number of stations. Two pumps are operated in
parallel for the 16, 18, and 20 in pipelines because of the high flows. Each
pumping station contains facilities for pipeline cleaning, pig handling, and
macerators to assure a controlled maximum particle size in the pumped sludge.
Operating experience from existing installations indicates that special
conditioning of liquid sludge is not required prior to transport by pipeline
except for macerators which are used in some installations. Most pipelines
do have facilities for routine cleaning and plastic pigs are commonly used.
69
-------
Pig insertion and retrieval facilities are included in the pumping stations
and the operation and maintenance costs include those associated with the
use of pigs.
The pipeline is based on use of cement lined cast iron or ductile iron
which is typical for sludge pipelines. The cement lining provides long
life and a smooth interior surface. A "C" factor of 90 is used for purposes
of hydraulic calculations . Installation is assumed to be in normal
soil conditions with average shoring and water problems typical to shallow
force main installations. Installation is assumed to be above hard rock.
The pipeline installed cost in Table 21 includes on major highway crossing
per mile and one single track railroad crossing per five miles plus a number
of driveway and several minor road crossings per mile. These costs should
be typical for average installations to be expected for sludge pipelines.
The pipeline costs were developed from recent Engineering News Record bid
breakdowns and a summary prepared by a major consulting engineer
The construction cost of small pipelines has increased at a rate much
greater, than,.the construction indexes would indicate from past reported
(15F 1167 . ,, , . , , ,. , .
costs especially when considering an average number of driveway,
road, highway, and rail crossings.
The literature indicates that sludge pipeline velocity can range from
about 2.5 to 8 fps for satisfactory operation, but a velocity o:f 2.5 to 3.0
fps is used by a number of consultants in pipeline design
The pipelines in this study were designed based on an operating velocity
of 3 fps. The resulting pipeline sizing agrees within one. pipe size to that
used by Smith and developed by Linaweaver and Clark
The depth of the pipeline will not affect the capital cost within the
range of 3 to 6 ft of burial in normal soil. Most sludge pipeline installa-
tions will be within this depth range. For burial depths up to 10 ft the
pipeline unit capital cost should be increased 15 percent.
Hard rock excavation can normally be avoided in installing pressure
pipelines, but may be unavoidable in some areas. The pipeline unit capital
cost should be increased 70 percent for those lengths where hard rock exca-
vation is necessary.
The operation and maintenance costs for the pumping stations include
pipeline operation and maintenance. The operation costs for the pipeline
itself are insignificant to the other costs
Sludge puirping station costs were determined from the Black & Veatch
study for raw wastewater pumping stations, adjusted for cost escalation
using the EPA Treatment Plant Index,, and then compared to actual and pro-
posed sludge pumping stations . The estimated costs for raw waste-
water pumping stations as presented in the Black & Veatch Study were felt
to represent the closest relationship to the dilute sludge pumping stations
in this study because they included some form of pretreatment and because
special excavation costs were not included (piling, rock, and special
70
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dewatering). The costs correlated well with examples of dilute sludge
pumping stations actually bid or studied.
The operation and maintenance labor and supplies will vary to a degree
with the number of hours of operation per day, but the difference in the
total costs is insignificant so these factors were considered constant for
a given size pipeline.
Proper design of sludge pipelines should provide nearly 100 percent
availability and, therefore, auxiliary sludge storage volume is not pro-
vided in this study. Normal plant sludge storage should be adequate.
Facilities at the discharge end of the pipeline such as lagoons, de-
watering equipment, or spreading equipment are assumed to be a part of
other unit processes.
Pipeline transport was based on agency ownership and operation of all
portions of the system.
71
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REFERENCES
1. Black & Veatch Consulting Engineers. Estimating Costs and Manpower
Requirements for Conventional Wastewater Treatment Facilities. EPA
Contract 14-12-462. October, 1971.
2. Richardson Engineering Services, Inc. Process Plant Construction
Estimating Standards. 1975.
3. U.S. Department of Labor, Bureau of Labor Statistics. Wholesale
Prices and Price Indexes, March, 1975. Library of Congress Catalog
Number L53-140.
4. Metropolitan Denver Sewage Disposal District No. 1. Contract Docu-
ments for Hauling and Disposing of Sewage Sludge From the Treatment
Plant of the MDSDD #1. 1973 (covers period 1973 through 1976).
5. Fader, Samuel W. Barging Industrial Liquid Wastes to Sea. Journal
WPCF 44. (1972).
6. Cunetta and Meier. Sludge Handling at New York's Newtown Creek
Facility. Journal WPCF. 40: 643 (April, 1968).
7. Dalton and Murphy. Land Disposal IV:Reclamation and Recycle. Journal
WPCF. 45:1489 (July, 1973).
8. Raynes, Bertram C. Economic Transport of Digested Sludge Slurries.
Journal WPCF. July, 1970, 1379.
9. CH2M Hill. Metro Denver Sewage Treatment Plant Expansion. April,
1972. pp. 8-10.
10. Weller, Lloyd W. Pipeline Transport and Incineration. Water Works
and Wastes Engineering. September, 1965.
11. Spaar, Anton E. Pumping Sludge Long Distances. Journal WPCF.
August, 1971. 1702.
12. Pacific Pumping Company. Section D2, Non-clog Dry Pit Pump, Catalog.
13. McGraw-Hill. Engineering News Record. Unit Prices Sections.
April 3, 1975, page 33; April 10, 1975, page 143; May 1, 1975,
page 44; May 15, 1975, page 116; May 29, 1975, page 48; June 5,
1975, page 42; July 3, 1975, page 38; and July 17, 1975, page 61.
72
-------
14. CH2M Hill. Support data for "Wastewater Treatment Study, Montgomery
County, Maryland". November, 1972.
15. Smith, Robert and'Eilers, Richard G. Economics of Consolidating
Sewage Treatment Plants by Means of Interceptor Sewers and Force
Mains, EPA. April, 1971 and March 10, 1971.
16. Linaweaver, F.P., Jr., and Clark, C. Scott. Costs of Water Trans-
mission. Journal AWWA. 56:1549 (December, 1964).
17. Black & Veatch Consulting Engineers. Bid tabulation for Dallas
Whiterock Wastewater Treatment Plant.
18. Ingersoll-Rand Company. Cameron Hydraulic Data. 13th Edition
page 12.
19. McGraw-Hill Book Co. Marks' Standard Handbook for Mechanical
Engineers. Seventh Edition, page 15-66.
20. McMichael, Walter F. Costs of Hauling and Land Spreading Of Domestic
Sewage Treatment Plant Sludge. NERC, EPA. Program element 1BB043.
February, 1974. Distributed by NTIS.
73
-------
METRIC CONVERSIONS
English Unit
cu ft
cu ft
cu yd
ft
fps
gal
gal
gpm
hp
in
Ib
Ib/cu ft
mgd
mile
mpg
mph
sq ft
rag
ton
Multiplier
0.028
28.32
0.765
0.3048
0.3048
0.003785
3.785
0.0631
0.7457
2.54
0.454
0.016
3,785
1.61
0.425
1.6
0.0929
3,785
0.907
Metric Unit
cu m
1
cu m
m
mps
cu m
1
I/sec
kw
cm
kg
g/cu m
cu m/day
km
km/1
km/h
sq m
cu m
metric ton
74
-------
APPENDIX A. TRUCK TRANSPORT
MANUAL CALCULATION OF TRANSPORT COST USING COST COMPONENTS
Point to point haul cost, $/year
(cost, $J
(excluding driver and fuel)
Fuel
/Annual gal
I used, from
V Figure 22 or/
Truck^maintenance (
/Annual truck\ X* "N.
/ miles, from \ /Cost, $/mile A /Current WPI'
V Figures 24' / I from 1 I Item 1412
Xor 25 S V Table 3 / V 170.3
Truck driver ^ '
/Annual driver\ /Cost, $/man\
/ man-hours, N I hour with j
I from Figure j V fringes J
\26 or 27 S \ '
Total direct truck operation and maintenance
Add results of paragraphs 1, 2, and 3
Total truck operation and maintenance with overhead
and supervision
Xrotal direct ^\
/ truck operation\
I and maintenance I
\cost, $ ./
.amortization
~>» x
/Total truckX
I investment, \
I I »
\ from I
V^Table 3 >/
Bsidual^^
Value, A
Normally j
15 percent^
of new
Current WPI>
Itera 141102
\
150.2
/
/Timor tization
[factor, from
X^Table 28
'n\ L , ,
\./Residu
>m ITl
A""'
sidual\ nn
J \^
terestl
rate
)
7. Total annual point to point truck haul cost
Add results of paragraphs 5 and 6.
Facilities cost, S/year
1. Facilities amortization (assume no residual value).
Determine facilities capital cost from Table 6 or 7
or other information. Be sure to consider both
loading and unloading facilities.
/facilities^ Xcurrent
( capital J / EPA Plant
\cost, S /
Index
* v
/Amortization \
( factor, from)
V Table 28 J
^ ^
,232.5
Facilities operation and maintenance, see Table 6
a. Electrical energy
/Electrical \ [Cost,
\energy, kwh,
or 7.
/Cost,
75
-------
Operation and maintenance labor
>or, *\
i-hours )
v/^/cia L-J,\-tlI cuiu uia-i 11 k-ctit*u\,t; .L
/Labor, *\ /Cost, S/\
I man-hours) f man-hour \
\- 'I with J
\fringes ^X
Maintenance supplies
/Supplies, S\
ncp supplies
, $\ /Current WPI\
) [ Item 114 )
V 174-8 /
d. Total direct facilities operation and maintenance
Add results of Paragraphs 2a, b, and c
3. Total facilities operation and maintenance with overheads
and supervision
tal directS.
facilities \ f \
operation and I J1.25J
maintenance J
,,cost, S /
4. Facilities annual cost
Add results of Paragraphs 1 and 3
C. Total annual cost
Add results of Paragraphs A7 and B4
D. Total annual cost, S/dry ton-mile one way
1. Dewatered
Total annual cost, $
_ _
^ /il cu ft\ /55 IbN /" ton 'S /Percent solids'N /bne way haul S
, 1 I cu yd )(cu ftj \2 , 000 lb/ \^ 100 / \distance, miles/
/
2' Li
-------
5. Truck amortization
(3 year amortization, 10 percent
interest for private company)
Using formula from paragraph A. 6,
Appendix A, Cost = 53,520
6. Contractor profit
(Total cost) (0.07) - 22,820
Total Calculated point to point cost = $348,840
D. Actual costs, Metropolitan Denver Sewage
Disposal District No. 1 at minimum or
$2.30 per cu yd. » $358,800
$ 2.30/cu yd
E. The District of Columbia recently received a bid
of $3.50/wet ton (approximately $2.36 per cu yd)
for hauling dewatered digested sludge 26 miles
one way with open dump vehicles.
77
-------
APPENDIX B. BARGE TRANSPORT
MANUAL CALCULATION OF TRANSPORT COST USING COST COMPONENTS
A. Point to point haul cost, S/year
1. Barge maintenance - *. >
Xsarge "\ /Current WPI\ /Number of
/ maintenance^ ( Item 107 1 I barges from'
I cost, from ) \ 189.1 J V Table 9
\Table 8 y \^ 10
2. Towing cost
d["ug billing's * \
:ime, hours/ \ /Tug billing\
fear, from 1 ( rate, I
?igure 28 or I V S/hour ^/
>9 or Table / X
9 or 10 */
Barge amortization
/Number of"\ XBarge "\ Amortization^
/ barges \ / capital \f factor from
I required, I I cost, S, Nlable 28 ^
V from Table I \ from I = $
\9 or 10 / \Table 8/
Tug fuel (information only), gal/year
/^ug running\ /^ug fuel\
f time, days, \/ usage \
I from Table Jj gal/day, I
V 9 or 10 S \ from I
>Table 8/
Total annual point to point haul cost
Add results of paragraphs 1, 2, and
on\ /Current WPI\
m 1 I Item 107 1
J \ 189.1 /
B. Facilities cost, $/year
1. Facilities amortization
Determine facilities capital cost from Table 11
or 12 or other information. Be sure to consider
both loading and unloading facilities^, v
/FacilitiesN /Current EPAX /AmortizationN
[ capital ) ( Treatment \ ( factor, from 1
\post, S J \ Plant Index I \Table 28 /
^ ' \S. 232.5 /
2. Facilities operation and maintenance, see Tables 11 or 12.
a. Sludge holding and pumping maintenance
/Labor, \ /Cost man-hour $/\
\man-hours/ ^with fringes J
b. Sludge holding and pumping maintenance supplies
/Supplies, S ' ~
I from Table
V 14 or 15
olding and pumping main
s, $\ /Current WPI\
le 1 I Item 114 I
5 J \ 174.8 J
78
-------
Sludge holding and pumping operation
/Labor, X /Barge trips/N /Cost $/*\
I man-hours/ J I year, from 1 ( hour with 1
\^barge trip/ \Table 9 or 10/ \fringes J
Dock maintenance
/ftock \ /Current WPI\
f maintenance,) I Item 114 J
\ $ / \ 174.8 J
e. Electrical energy
/Electrical "N /Cost A
\energy, kwh/ V/kwh/ = $
f. Total direct facilities operation and maintenance
Add results of paragraphs 2a,b,c,d, & e = $
3. Total facilities operation and maintenance with overheads
and supervision
/"Total directN. / \
/ facilities \ (1-25)
I operation and J \ /
V maintenance I " '
\>cost, $ ^/
4. Facilities annual cost
Add results of paragraphs 1 and 3 = '
C. Total annual cost
Add results of paragraphs A5 and B4 " '
D. Total annual cost, $/dry ton-mile one way
Total annual cost, $
/AnnualX /B. 33 lb\ / ton \ /TPercentX /fcne way haul N
(volume,) V. gal ,/^2,000 lb/ (solids JVdistance, miles./ - i
\gal S ^ 100 /
E. Add contractor profit to any portions of work performed under
private contract (normally 7 percent)
ILLUSTRATIVE MANUAL CALCULATION
A. Example for City of Philadelphia, 1975.
B. Conditions:
1. Liquid sludge, approximately 10 percent solids
2. Contract barge operation
3. Discharge at sea
4. 150 million gal per year
5. Barge capacity approximately 2 million gal
6. One way distance 150 miles
7. Contract price $9.10/1,000 gal
8. Average 2 1/2 trips per week
9. Round trip time, 48 hours
C. Calculated cost, $/year
1. Barge maintenance
($35,000X1) " $35,000
2. Towing cost
(Round trip time) (Trips/year) (Hourly charge) (1.15)
(48) (130) (160) (1.15) " 1-148,160
3. Barge amortization
(1) ($3,000,000) (0.09439) - 283,170
4. Total annual barging cost " 1,466,JJU
5. Contractor profit
($1,466,330) (0.07) - 102,64J
Total calculated cost ' $1>5"o'2/1/000 gal
79
-------
NOTE: The study figures were not used in this calculation because the barge size
was greater than that used in the figures. The barge draft for large size
barges may be too great for many applications, therefore, smaller barges were
used in preparation of the figures in this study. This example illustrates the
ease of calculating special cases using barge data in Table 8 and the basic
formulas in Appendix B. This example also illustrates the economics of large
barges. If a 850,000-gal barge sire were used, the cost would have been
approximately $21/1,000 gal or double. The difference is the increased towing
time which is the major cost item.
80
-------
APPENDIX C. RAILROAD TRANSPORT
MANUAL CALCULATION OF TRANSPORT COST USING COST COMPONENTS
A. Point to point haul cost, dewatered sludge, $/year
/^Ann ua l^N.
I sludge \ /27 cu ft\ /55 Ib \ / ton \ /kail rate
I volume, J \^ cu yd J \ cu ft^ \2,000 Ib/ V^S/ton
\»cu y<1^^/
This is the total point to point cost
B. Point to point haul cost, liquid sludge, $/year
1. Railroad charges
/'Annual^V ,
t sludge J /8. 33 x 10 IbN / ton "\ /Rail rate N
V volume ,J \ mg J \2,OOQ Iby \. S/ton }
^» m f
mg f
(Current rail rate can be determined by escalating
the rates in the study by subsequent increases)
Railroad mileage credit (for shipper supplied cars)
/Round trip \ /"Trips\ /kailroadN.
I haul distance,] [ per V mileage I
)
,
V miles ) \year ^/j credit,
3. Rail tank car leasing (including maintenance)
/Number of\ /^Vnnual full ^
/ tank cars \ / maintenance I
I required, I V lease rate, $J
\ from Table/ ^
V 13 /
4. Total annual point to point haul cost, liquid sludge
Add results of paragraphs Bl and 3
and subtract B2
C. Facilities cost, S/year
1. Facilities amortization
Determine facilities capital cost from Table 15
or 16 or other information. Be sure to consider
both loading and unloading facilities.
C?acilities\ /Current EPAX /AmortizationX
capital J / treatment \ I factor - from 1
rost, S J \ plant index J V Table 28 J
' \^ 232.5 /
2. Facilities operation and maintenance, see Tables 15 and 16.
a. Sludge holding and pumping maintenance
/tabor, *\ /Cost, N
n-hours/ [ S/man-hour J
\}
-------
Sludge holding and pumping supplies
/'Supplies ,\ /Current WPI\
S J [ Item 114 )
174.8 X
Sludge holding and pumping operation
0
ig an
/'Labor, N /Cost, "*\
\_jnan-hours/ / $/man-hour J
\with fringes/
tnce
/Current WPJ\
( Item 144 J
\ 201.8 y
<»with fringes/
Rail maintenance
.11 N
main- \
tenance,)
.$ /
e. Electrical energy
/Electrical"N /Cost, "\
^energy, kwh/ V $Awh/ = S
f. Total direct facilities operation and maintenance
Add results of paragraphs 2a, b, c, d, and e
3. Total facilities operation and maintenance with overheads
and supervision
0^ ^
total directX
facilities \ r v
>peration and I I1'25) = ^
jaintenance / '
tost, $ S
4. Facilities annual cost
Add results of paragraphs 1 and 3 = $
D. Total annual cost
1. Dewatered sludge
Add results of paragraphs A and C4 $
2. Liquid sludge
Add results of paragraphs B4 and C4 = $
E. Total annual cost, $/dry ton-mile one way
1. Dewatered
^ Total annual cost, $
XAnnual'\/!7 cu ft\ /S5 lb\ / ton \ /Percent solids\ /One way haul \
I volume, Kcu yd } \CM ft/ V,000 lb/ \^ 100 J \distance, miles/
\cu yd^/
Liquid
Total annual cost,
QnnualX /B. 33 Il3\ S ton "\ /"Percent solids^ /bne way haul X
olume.J \gaLl J ^2,000 lb/ V^ 1°°
gal /
/ \distance, miles/
S
F. Add Contractor profit to any portions of work performed under
private contract (normally 7 percent) .
ILLUSTRATIVE MANUAL CALCULATION
A. Conditions:
1. Liquid sludge, 4 percent
2. 24 hour, 365 day operation
3. Tank cars owned by agency
4. 75 rag sludge per year
5. 160 mile one way haul
6. 20,000-gal tank cars
7. Complete operation by agency
B. Calculated cost, $/year
1. Railroad,charges
(75 x 10 ) /fe.3J\ ($6.50) - $2,030,438
V200Q/
82
-------
2. Railroad mileage credit
(320) (3,750) (30.15) = (180,000) credit
3. Rail tank car full maintenance lease
(78) ($5,640/year) = 439,920
4. Facilities amortization
(382,000) (0.08581) = 32,780
5. Facilities operation and maintenance
a. Sludge handling and pumping maintenance
(340) (8.00) = 2,720
b. Sludge holding and pumping supplies = 2,237
c. Sludge holding and pumping operation
(9,000) (8.00) = 72,000
d. Rail maintenance = 4,000
e. Electrical energy = 1,800
f. Total direct facilities
operation and maintenance = 82,757
6. Total facilities operation and maintenance
with overheads and supervision
($82,757) (1.25) = $103,446
7. Facilities annual cost - 136,226
8. Total annual cost = $2,426,584
9. Cost per dry ton - mile one way
(2,000) ($2,426,584) (100)
(75 x 10") (8.33) (4) (160) - $1.21
83
-------
APPENDIX D. PIPELINE TRANSPORT
MANUAL CALCULATION OF TRANSPORT COST USING COST COMPONENTS
A. Determine pipeline size from project information or from
sludge volume and daily hours of operation and Table 19.
Pipeline
/Pipeline\ /'Unit cost,^ /Cxi
( length, ) ( 9/ft, from J ( Pi
V ft y Viable 21 .y V
B. Pipeline capital cost, $/year
1. Pipeline
'"Current EPA
Pipeline Index
248.7
Note: Increase costs for any deep trenching or rock
excavation, see Table 21.
2. Extra railroad crossings, $
(Pipeline unit costs in Table 21 assume one crossing
per 5 miles)
/Rail \ /Unit cost, $ N /Current EPA \
^crossings/ \from Table 22/ (pipeline index)
\ 248.7 J
3. Major road crossings, $
(Pipeline unit costs in Table 21 assume one major
road crossing per mile)
/Major road\ /Unit cost, $ \ /Current EPA X
\crossings / ^from Table 2J/ [pipeline Index)
\ 248.7 /
4. Pipeline amortization ^
/Add results of \ /Amortization factorj
.
of \
1,2,3/
(paragraphs 1,2,3/ \from Table 28 J
C. Pumping station capital amortization and operation and
maintenance, $/year
1. Electrical energy
« $
/CostA
/PipelineX /Hydraulic ^\ /Pipeline \
I length, J I loss, ft/100 J + I elevation J
head, 1 \^00 ft / I ft pipeline, I V change, +y
from j X^rom Table 20/ \ ft /
t>le
Nunber of pumping stations
'Total system head, ft j
.(Pipeline loss + elevation^
rHead per pimping station, ^\ « pumping stations required
from Table 20 J
3. Operation and maintenance labor .
/Nratoer ofN /Operation andX /Cost, $/man-hour)
[ pumping 1 I maintenance, \ \with fringes
iJ \ man-hours, "
\Table 18
i and\
ce, \
;,fron I
84
-------
Operation and maintenance supplies and parts
/Number or\ /Operation and>v /tost,
/ pumping I / maintenance, \ / man-hour |
\stations J \ nan-hours, from / V with J
\Table 18 ^/ V^fringes^/
Total operation and maintenance with overhead and
supervision
/Add results of
I paragraphs 1,
N3 and 4
Pumping station amortization
/Number °f\ /Cost per\ /EPA CurrentN /AmortizationS
I pumping J (station, \ ( Plant Index J ( factor, from)
\stations / I ? from / N. 232.5 / Vjable 28 /
\Tahlf 7n J X /
V " \Tabl
D. Total annual cost
Add results of paragraphs B4 and C6 =
E. Total annual cost, S/dry ton-mile
Total annual cost, $
CinnualX/8. 33 lb\ / ton \ /Percent solidsN /"Pipeline length ,\
'Olume,) \^ gal J V.OOO lb/ I 100 J I miles )
gal /
F. Add contractor profit to any portions of work performed under
private contract (normally 7 percent).
ILLUSTRATIVE MANUAL CALCULATION
A. Conditions:
1. Liquid sludge, 4 percent, digested
2. 30 miles
3. 75 mg sludge per year
4. Complete operation by agency
5. 12 hours pumping per day
6. Current EPA Pipeline Index - 248.7
7. No special extra crossings or excavation
8. Amortization over 25 years at 7 percent
9. No elevation change in pipeline
10. Electrical energy $0.02/kwh and labor SB.OO/hour including fringes
B. Calculated cost
1. Pipeline size, from Table 19; 6 in,75 mg per year or 0.2 mgd
2. Pipeline capital cost, $, Table 21
(30) (5280)(S16.25) = $2,574,000
3. Pipeline amortization, $/year
($2,574,000) (0.08581) 220,875
4. Pumping station electrical energy, $/year. Table 17
Pumping station electrical <
($0.02) (567) P(30) (5280)"]
I 100 J
Number of pumping stations, Table 20
2218
(1.4) +0 = $25,148
450
6. Operation and maintenance labor, $/year, Table 18
(5) (720) ($8.00) = $28,000
7. Operation and maintenance supplies and parts, $/year. Table 18
(5) ($670) (1) = $3,350
8 Total operation and maintenance with overhead and supervision, $/year
($25,148 -f $28,800 + $3,350) (1.25) = $71,623
9. Pumping station amortization, $/year
(5) ($57,000) (1) (0.08581) = $24,456
10. Total annual cost, $/year
$220,875 + $24,456 + 71,623 = $316,954
85
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-77-216
3. RECIPIENT'S ACCESSION«NO.
4. TITLE AND SUBTITLE
TRANSPORT OF SEWAGE SLUDGE
5. REPORT DATE
December 1977 (Issuing Date)
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
William F. Ettlich
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Culp/Wesner/Culp
Clean Water Consultants
Box 40
El Dorado Hills, California 95630
10. PROGRAM ELEMENT NO.
1BC611
11. CONTRACT/GRANT NO.
Contract No. 68-03-2186
12. SPONSORING AGENCY NAME AND ADDRESS
Municipal Environmental Research LaboratoryCin.,OH
Office of Research & Development
U. S. Environmental Protection Agency
Cincinnati, Ohio 45268
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
EPA/600/14
15. SUPPLEMENTARY NOTE5:
Project Officer: Francis L. Evans, III Task Director: Dr. J B Farrell
EPA-MERL-WRD, Cincinnati, OH 45268
513/684-7610
EPA-MERL-WRD, Cinti., OH
is. ABSTRACT This project was initiated with the overall objective of developing organized
information pertaining to the costs of various sewage sludge transport systems.
Transport of liquid and dewatered sludge by truck and rail and liquid sludge by barge
and pipeline is included. The report contains the method used in preparing the cost
data and the data is organized to facilitate manual calculation of total transport
costs for a variety of conditions.
The data includes the installed cost for each system, sludge processing require-
ments, fuel consumption, manpower, and other operation and maintenance requirements.
Loading, unloading, and sludge handling facilities construction costs and operation
and maintenance requirements are tabulated separately from the requirements for direct
hauling so the data can be applied to a variety of specific applications.
Results of the study are related in tabular and graphical presentations to
appropriate single haul parameters; cubic yards for dewatered sludge and gallon for
liquid sludge.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Sludge, Sludge digestion, Sludge disposal,
Sludge drying, Transportation, Highway
transportation. Marine transportation,
Pipeline transportation, Rail transporta-
tion, Cost comparison, Cost analysis, Cost
estimates, Prices
b.IDENTIFIERS/OPEN ENDED TERMS
Sludge treatment, Sludge
transport (truck, rail,
barge, pipeline), Liquid
sludge disposal systems,
Dewatered sludge disposal
systems, Ocean transpor-
tation
c. COSATI Field/Group
13B
IS. DISTRIBUTION STATEMENT
Release to public
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
98
20. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Fo:rn 2220-1 (9-73)
86
z U.S KIVlRKMDtT PRINTING QfFlCt 1978 7^7-140/6651
-------
November 1978
ERRATA TO
TRANSPORT OF SEWAGE SLUDGE
(EPA-600/2-77-216, December 1977, NTIS PB278195/AS)
ERRATA CHANGES
Page 35, Figure 28 -- Change ordinate (y-axis) from ANNUAL TUG BILLING TIME,
hours to^ ANNUAL TUG BILLING TIME, 1000 hours.
Page 36, Figure 29 -- Change ordinate (y-axis) from ANNUAL TUG BILLING TIME,
hours t£ ANNUAL TUG BILLING TIME, 1000 hours.
Page 43, Table 7 -- Change Annual sludge volume, cu yd tp_ Annual sludge
volume, 1000 cu yd.
Page 53, Table 16 -- Change under 7.5 and 15 Annual sludge volume, 1000 cu yd
heading, the last line in Table item--Electrical energy,
kwh--from 92,000 to_ 40,000 under 7.5 heading and from
92,000 to^ 50,000 under 15 heading.
Page 54, Table 17 -- Change note bottom of Table shown as (*) Motor
efficiency = 90%(19); pump efficiency = 80%;
kw/1000 gph-ft head = 0.00515
(Pump eff)(Motor eff)
to
(*) Motor efficiency = 90%(19); pump efficiency as
shown in Table 20; kw/1000 gph-ft head =
0.00315
(Pump eff)(Motor eff) .
Page 59, Table 23 -- Substitute Table 23 as shown below for Table 23 in
report on Page 59.
TABLE 23. ANNUAL SLUDGE VOLUME
Mg/year
at 4
percent
1.5
7.5
15
75
150
750
1,300
(*) Mode
Liquid
ModeC*)
T-R
T-B-R
T-B-R-P
T-B-R-P
T-B-R-P
B-R-P
P
Symbols:
Dewatered
mg/year
10 percent
3
6
30
60
300
T = truck;
Mode
B
B
B
B
B
B =
cu yd/
year
1,500
7,500
15,000
75,000
150,000
750,000
barge; R =
Mode
T
T-R
T-R
T-R
T-R
R
railroad;
Approximate
secondary
treatment
plant size,
mgd
1
5
10
50
100
500
P = pipeline.
Project Officer
Frank L. Evans, III
Wastewater Research Division
Municipal Environmental Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
------- |