RDP EnVessel Processing in

Cookeville, Tennessee

February 1996

Table of Contents

 

1. Introduction

1. Analyses
2. Regulatory Discussion
3. Potential Markets
4. Index of Photos
5. Project Contacts
6. Letter from Mayor
   

 

149 Yadkin Valley Road · Advance, NC 27006 · (910) 998-8184 · FAX (910) 998-2495

The City of Warren, Ohio

Biosolids Evaluation

RDP EnVessel Processing in

Cookeville, Tennessee

February 1996

Prepared by EWR, Inc.

Advance, North Carolina

i. Introduction

This report was prepared by Environmental Waste Recycling, Inc., at the request of the City of Warren, Ohio. The purpose of the report is to evaluate Warren's Biosolids after processing by an RDP unit located in Cookeville, TN. We have evaluated the product relative to beneficial use through land application concentrating in two areas:

• Federal regulatory requirements
  
• Potential markets

 

On-Site Processing

Approximately 25 wet tons of Warren's Biosolids were processed at the Cookeville, TN location on January 12, 1996. Robert Christy (RDP), David Wanucha (EWR), Tom Graham & staff (Cookeville, TN) and Larry Stadwick & Tom Angelo (Warren, OH) were all present during the processing. The processing went along without any major problems. A hopper used to transfer untreated Biosolids to a conveyor belt feeding the processing unit became inoperative during start-up. Because of this, it was then necessary to use a front-end loader and manual labor with shovels to feed untreated Biosolids onto the unit's conveyor belt. It took over 5 hours to process the entire 25 wet tons. After processing and prior to loading end dump, samples were taken for TCLP, total metals and nutrients, pH and fecal coliforms. Analyses are enclosed.

After processing, the Biosolids were transported to an EWR facility located in Advance, NC and unloaded, where the Biosolids will be used as a soil conditioner for landscaping and lawn establishment.

Summary

The Biosolids product produced by the Cookeville, TN RDP facility meets all federal regulatory requirements to be classified as an exceptional quality (EQ) product. It contains many essential crop nutrients and is suitable for many reuse options, including agricultural and artificial soils. Using current fertilizer costs, a 2.5 dry ton per acre agronomic application rate is worth over $47.00 per acre. Analyses and discussions are enclosed to support the findings. Copies of photographs taken before, during and after the processing are enclosed in the Appendix section of the report, along with contacts consulted during the preparation of this report.

 

 

 

149 Yadkin Valley Road · Advance, NC 27006 · (910) 998-8184 · FAX (910) 998-2495

1. Analyses

 

 

 

 

 

 

 

PAR Laboratories, Inc.
2217 GRAHAM PARK DRIVE
P O. BOX 411483
CHARLOTTE, NC 28241-1483
704/588-8333

 

 

 

February 12, 1996

Method 1311

Reference No: 96 359

Made For: Environmental Waste Recycling

149 Yadkin Valley Road
Advance, NC 27006

Attention: David Wanucha

Analyses of: Submitted Sample for TCLP

Marked: Warren, OH

Received On: 1/23/96

Extracted On: 1/29/96 @1700 DF

Analyses:

 

Respectfully Submitted:
PAR Laboratories, Inc.

J ohn S. Rice
Laboratory Director

 

 

 

 

 

The City of Warren, Ohio

Biosolids Evaluation

 

2. Regulatory Discussion

 

In order to beneficially recycle biosolids via land application (agricultural utilization) or to distribute and market (D/M) biosolids products, the biosolids must meet all of the applicable requirements contained in 40 CFR Part 503, Subpart B. Therefore, in evaluating biosolids management options for Warren, Ohio or for any other treatment works treating domestic sewage (TWTDS), it is most important to characterize their biosolids relative to three key regulatory parameters under 50 CFR Part 503:

 

1. Pollutant Concentrations

2. Pathogen Reduction

3. Vector Attraction Reduction (VAR)

 

40 CFR Part 503 is centered around these three primary criteria. Minimum requirements for land application are: meeting the ceiling concentration levels in Table 1 of 503.13, being Class B for pathogen reduction, and meeting one of the VAR options 1 through 10. General requirements (503.12), site restrictions (503.32(b)) and management practices (503.14) apply to biosolids unless they meet all of the following criteria:

 

• All parameters are below the ceiling and pollutant concentration levels in Tables 1 and 3 of 503.13.

• Class A pathogen reduction is achieved.

• One of the VAR options 1 through 8 is met.

 

Biosolids products meeting all of these three criteria, and thus being exempt from the general requirements, site restrictions and management practices, are commonly referred to as exceptional quality (EQ) biosolids.

 

Pollutant Concentrations

Table I at the end of this section shows a comparison of Warren's biosolids to the ceiling and pollutant concentration values found in Tables 1 and 3 of 40 CFR Part 503.13, Subpart B. respectively. Note that Warren's biosolids are below all of the ceiling and pollutant concentration values, which means that these biosolids can be land applied without having to keep track of cumulative loading rates. (See also biosolids analysis report in Analyses section of this report for comparison). Also note in Table I how Warren's biosolids compares to three commonly used commercial fertilizers relative to pollutant concentration levels.

 

Pathogen Reduction

Warren's biosolids have been subjected to treatment by the RDP process. Actual operating temperatures at the Cookeville, TN facility were maintained at 160 degrees F for 35 minutes. This treatment regime does consistently meet the requirements for Class A under 40 CFR Part 503.32(a). The RDP process has two potential ways of achieving Class A: (1) meeting the time and temperature requirements for Alternative 1 stipulated in 503.32(a)(3), or (2) being PFRP per Alternative 5 in 503(a)(7).

Located at the end of this section is a graphical representation of the requirements for Class A, Alternative 1. Note that for a time period of 35 minutes a temperature of about 68 to 69 degrees C must be maintained. To be PFRP and meet Class A, Alternative 5, the temperature of the biosolids must be maintained at 70 degrees C or higher for 30 minutes (see item 7, Appendix B to 503).

In addition to the performance-based criteria, it is also required that fecal coliform or Salmonellae be monitored (as indicator organisms) to detect regrowth, per 503.32(a)(3). Fecal coliform density must be < 1000 MPN per gram total solids. Results for the pile processed at Cookeville, TN are favorable at < 1 (please see Analyses section for fecal coliform report). Therefore, based upon the above reported data, the conclusion is that Class A is met for Warren's biosolids.

 

Vector Attraction Reduction

RDP claims to meet VAR via Option 6, whereby the pH of the biosolids must be raised to 12 or higher by alkali addition, and, without the addition of more alkali, shall remain at 12 or higher for two hours and then at 11.5 or higher for an additional 22 hours. This has been confirmed by the Cookeville, TN wastewater treatment plant lab and by PAR Laboratories in Charlotte, NC.

 

Monitoring, Reporting and Recordkeeping Requirements

One of the most important parts of any Biosolids utilization program is monitoring. Perhaps the second most important part is the paperwork. These are two aspects of a Biosolids utilization program that are often overlooked and can come back to haunt the most conscientious municipality. These requirements are outlined specifically in 503.16 for monitoring, 503.17 for recordkeeping, and 503.18 for reporting. Annual reports are due by February 19 of each year. Monitoring is based on amount of dry tons or metric tons per 365-day period that are applied to the land. If, for example, the City of Warren prepares and land applies between 1,500 to 15,000 metric tons per year, the City must monitor for pollutants, pathogens and VAR six times per year.

TABLE I

Comparison of EPA's Ceiling and Pollutant Concentrations to Warren, Ohio's Biosolids and other Commonly Used Commercial Fertilizers

PARAMETER	Ceiling Concentration mg/kg	Pollutant Concentration mg/kg	Warren, OH Biosolids mg/kg	Fertilizer (1) mg/kg	Fertilizer (2) mg/kg	Fertilizer (3) mg/kg
Arsenic	75	41	2.48	NA	NA	0.9
Cadmium	85	39	2.00	1.5	45	101
Copper	4,300	1,500	132.00	81	260	5.9
Lead	840	300	53.00	84	2,700	5.6
Mercury	57	17	0.87	NA	NA	0.1
Molybdenum	75	*	7.00	NA	NA	7.0
Nickel	420	420	46.00	21	27	303
Selenium	100	100	13.98	NA	NA	NA
Zinc	7,500	2,800	393.00	250	8,800	1,070

Note: Federal Register dated Wednesday, October 25, 1995 voided Tables 1, 2, 3, and 4 of 503.13 for Chromium and changed the Selenium value from 36 mg/kg to 100 mg/kg in Table 3 of 503.13.

* Federal Register dated Friday, February 25, 1994 voided Tables 2, 3, and 4 of 503.13.

BD = Below Detection

NA = Not Available

(1) = Chippewa Valley 1000 Natural Organic Fertilizer

(2) = Ironite Natural Fertilizer

(3) = 0rtho Superphosphate

 

The City of Warren, Ohio

Biosolids Evaluation

 

3. Potential Markets

Biosolids from Warren, OH contain many essential plant nutrients that can be used for a variety of purposes. Some of the beneficial-use markets for the material include: agricultural, horticultural, and artificial soil. One of the more common uses is as a fertilizer supplement in production agriculture. According to Mr. David James, the Trumbull County Agriculture & Horticulture Extension Agent, many farmers in the County would be willing to try the product as a nutrient supplement and lime source. Soils located in the area are naturally low in pH and fertility levels need annual replenishing due to crop uptake and removal of nutrients. This market has tremendous potential with thousands of acres of available farmland within 30 miles of the City of Warren.

 

Application Rate Evaluation for Agricultural Use

The application rate evaluation spreadsheet located at the end of this section indicates the nutrient, lime and metal loadings provided by an agronomic loading rate of approximately 2.5 dry tons per acre. Generally speaking, crop requirements for the three macronutrients (nitrogen, phosphorus, potash) are satisfied by this rate, with the exception of potash. Additional potash will be needed to supplement Warren's Biosolids. This is true for most municipal Biosolids. Other essential nutrients are supplied as well, to include: sulfur, calcium, magnesium, iron, copper and zinc.

 

The spreadsheet shows that a 2.5 dry ton per acre loading rate, using current commercial fertilizer costs, would amount to a worth of $47.29 per acre. This is a low-end figure using 1.0 ton per acre lime as the rate limiting factor. The loading rate could be doubled or even tripled if a soil test indicated the need for more than 1.0 ton per acre of lime and if crop nitrogen requirements called for higher nitrogen loadings. The value assumes all nutrients are available to the crop and includes a spreading charge. Actual application rates will vary and should be based on the desired crop yield and a recent soil test. Nutrient requirements for various crops produced in the region can be obtained from the Agriculture Extension Service. Enclosed for review are nutrient requirements for various crops.

 

Other Beneficial Uses

Besides agricultural use, another potential market for Warren's Biosolids is for use as an artificial soil. These markets include those already existing for naturally occurring soils:

• Landfill cover materials (daily, intermediate, and final);
• Land reclamation material (abandoned mines, strip mines or pits);
• Blend materials for manufactured, organic topsoils; and
• Natural soil substitutes, amendments, or conditioners.

Landfills require soil for covering trash on a daily basis and for final cover during final closeout. Warren's Biosolids may be suitable for this purpose if the end product is consistent relative to the percent solids concentration. Another benefit of using a lime-stabilized material for cover in or on a landfill is that the product will tend to increase the pH of rainwater as it percolates through the cover material. This will tend to improve leachate quality and reduce the solubilizing of metals.

Land reclamation is another promising end use. Many abandoned mine sites possess acid soils which will benefit from alkaline additions and organic material. Areas that need reclamation include: borrow pits, construction sites and abandoned strip mines.

Blending with composts and other inorganic materials will provide a product useful as a designer topsoil for golf course use, athletic fields and public parks. The highway department could use the product on median strips or other areas where landscaping is practiced for city beautification projects.

 

Limiting Factor

Since lime is used in the RDP process to generate heat and increase pH to meet regulatory requirements for vector attraction reduction and pathogen reduction, the calcium carbonate equivalency (CCE) or neutralizing power of the end product will be the limiting factor. This will depend on final use of the product but should be considered during the planning stages. For example, if final use was as a landfill cover material, maintaining a high percent solids would be limiting before the CCE. If, however, the end use was for agriculture, rates would be limited by CCE and not so much the amount of water in the material.

If the Biosolids were subject to cumulative loading rates, the most limiting metal would be molybdenum and it would take 424 years to reach the maximum allowable amount. This is a hypothetical case since metal concentrations are well below the pollutant concentration levels as outlined in 40 CFR 503 and tracking cumulative loadings is not necessary. Please see Regulatory section for more detail. Site life calculations are one tool that can be used to show how innocuous the City of Warren's Biosolids are.

Note on nitrogen: Keep in mind that, since samples were taken immediately after leaving the processing unit just prior to loading the end dump, TKN levels may be less than what is indicated by the enclosed analysis. There may be some additional nitrogen losses as chemical reactions continue to volatilize gaseous ammonia, which could result in lower TKN concentrations and therefore less available nitrogen for crop production.

Application Rate Evaluation

Example Application Rate (lbs/ac) for: Warren, OH

		7 cubic yards/ac      	OR                2.69 Dry Tons/Ac (Assume 2000 lbs/cy)

Nitrogen PAN*	51.9
Phosphorus	59.8
Potassium	8.6
Sulfur	35.6
Lime	2019.6

Calcium	1023.8
Magnesium	19.4
Iron	65.20
Manganese	11.96

 

		EPA Cumulative Limits lbs. /acre (per CFR 503)	Site Life yrs.
Copper	0.7	1339	1,882
Zinc	2.1	2500	1,181
Cadmium	0.0	34	3,155
Chromium	0.2	N/A	N/A
Nickel	0.2	375	1,513
Lead	0.3	267	935
Arsenic	0.0	36	2,694
Mercury	0.0	15	3,200
Selenium	0.1	89	1,181
Molybdenum	0.0	16	424

* Plant Available Nitrogen								* *Assume complete crop uptake

 

Biosolids Value $ $	Plant Available Nitrogen (PAN) at S. 14 per lb	$7.27
per acre	Phosphate at $. 08 per lb.	$4.. 79
	Potash at $.08 per lb.	$0.69
	Spreading Cost per ac.	$4.00
	Magnesium at.32 per lb.	$6.21
	Sulfur at .20 per lb.	$7.11
	Micromix at .36 per lb.	$0. 72
	Lime at 1 ton per ac.	$16.50
	**Total value/ac	$47.29

 

SUGGESTED AGRONOMIC APPLICATION RATES FOR:
PLANT AVAILABLE NITROGEN (PAN), PHOSPHATE (P₂O₅), AND POTASH (K₂O)

CROP	AVERAGE YIELD/AC.	PAN (lbs/ac.)	P2O5 (lbs/ac.)	K2O (lbs/ac.)
Corn Grain	100 bu	160	100	50
Corn Silage	20 tons	220	120	120
Cotton	1500 lbs.	70 - 100	40	45
Small Grains	65 bu	100	20	40
Soybeans	45 bu	150 - 200	80	40
Fescue, Timothy, Orchard-Grass Hays	4.0 tons	250	45	90
Coastal Bermuda	4.0 tons	350	40	160
Sorghum, Millet, Sudan, & Hybrids (Silage, Grain)	(23 tons) (65 bu)	180 - 220	80	80

bu = bushels			P2O5 = (P) (2.29)			K2O = (K) (1.2)

LITERATURE CITED

Suggested rates are based in part on the following references:

Crop Fertilization Based on North Carolina Soil Tests, NCDA, Agronomic Division.

1991 North Carolina Agricultural Chemicals Manual, NCSU, College of Agriculture and Life Science.

General Guidelines for Land Treatment of Sludge, WRRI, NCSU, 1983.

Agronomv Handbook, A&L Agricultural Laboratories, Richmond, VA.

Soils, 5th Edition, R.L. Donahue, R.W. Miller, J.C. Shickluna, Prentice-Hall, Inc., Englewood Cliffs, NJ, 1983.

Land Application of Wastewater Sludge, American Society of Civil Engineers, New York, NY, 1987.

 

4. Index of Photos

A. The City of Warren's biosolids arriving in Cookeville, TN for processing.

B. Unloading untreated biosolids.

C. Unloading untreated biosolids.

D. Observing unloaded biosolids.

E. Feeding conveyor with untreated biosolids.

F. Feeding conveyor with untreated biosolids.

G. Observing RDP processing.

H. Loading hopper with untreated biosolids.

I. Feeding conveyor.

J. Observing conveyor operation.

K. RDP control/monitoring panel.

L. Feeding conveyor.

M. Planning.

N. Spreader vehicle.

O. Loading spreader vehicle.

P. Loading end dump.

Q. Untreated pile.

R. Treated pile.

S. Treated pile at EWR location.

T. Final end use EWR location. Before lawn establishment.

 

5. Project Contacts

 

Mr. David James

Trumbull County Agriculture Extension Agent

216-675-2595

Fertilizer prices from:

Mike Fenton

Western Reserve Farm Cooperative

Andover, OH office

216-393-2565

City of Warren

Water Pollution Control Dept.

2323 Main Street

Warren, Ohio 44481

Thomas A. Angelo

Superintendent

Phone (330) 841-2591

Facimile (330) 841-2717

Email: tangelo@cisnet.com

 

6. Letter from Mayor

CITY OF WARREN OHIO
Henry J. Angelo, Mayor

CITY OF WARREN OHIO

BIOSOLIDS PROCESSING

JANUARY 12, 1996

We will be flying into Nashvllle on January 16 at 9:33 A M

On Wednesday January 17 American Waste Management will arrive in Cooksville with
sludge cake from the City of Warren to be processed starting at 7:00 A M.

Thursday January 18 a lab tech from EWR will pick up a sample to test and American
Waste Management will truck the remainder to EWR at an unknown time that evening.

On Friday January 19 Larry Stadwick and Tom Angelo will visit EWR to talk to Grace
and tour facility.

Friday at 2:05 will fly out of Greenshoro to return to Warren.

This Agency is en Equal Provider of Services end an Equal Opportunity Employer - C.R.A. 1964"

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