TWE Rosemount Craig Galletly
“Vintage at the Treatment Plant” - from an Operator’s perspective
Craig Galletly (on behalf of the entire Rosemount team) WWTP Operator Rosemount Estate Winery - TWE
Contents… • Rosemount winery’s WWTP • How do we monitor the WWTP’s health? – Water quality monitoring frequency, methods and interpretation – SCADA graphs and their interpretation – Using SCADA for Process Management
• Contingencies options when all else fails. • How to reduce incoming load (Cleaner Production). – Quick wins – Success stories
• The results. • And…. a cheatsheet!
WWTP: Big Expensive Things Rosemount Wastewater Treatment Plant (WWTP) Inflow Composite Sample before entering initial 40 KL tank. Aeration Lagoon (1.6 ML)
PLC automation. Irrigation and sludge return pumps.
Decant pipe
Settling Tank. Tk 4 (Not in view) Baleen Filter (initial solids screening) & VBelt
Surge Storage (800 KL) Ute
Decant Water Sump. Irrigated or pumped to holding Dam.
Dam (30 ML)
Tank 1. Aeration, Setting, Sledge return & treated water decanted.
Sludge Tank.
Treatment Flow
Solids Removal
Rosemount Vintage WWTP Process Map Winery Inflow
Raw Water Tank
Coarse Filtration
Buffer (holding) Tanks
Aeration Lagoon
Vol: 1.6ML Vol: 30ML Power: 30kw blower Rosemount Winery WWTP Acts as Polishing Vintage: 3 x 30kwPond •Annual inflow: 22-25ML (including rainfall) surface aerators •Annual crush: 12,000-15,000 tonne •Treats ~60,000kg of COD/year
De-watering Vol: 250kL process Vol: 50kL ~150 tonnes Power: 13.5kwbiosolids blower Vol: 750kL (3Decant xfilter 250kL) Feeds Baleen removed annually Air operated line
Tank.1 (S.B.R.)
Decant Solids to to V-Belt Dam
Water Quality: Daily checks
Inflow: pH >8: Heavy cleaning in cellar pH 1800: Product spill, cleaning. EC 8.3: Unusual, check cleaning in cellar pH 1800: Treated water quality impact
Water Quality: Routine checks
Tank.1 & Lagoon: pH 800: High suspended solids, poor settling. DO2: Quality assurance check with inline meter.
Dam: DO2 8.5: Common, reduce likelihood of reuse. EC >1500: Water quality parameters.
Water Quality: Weekly checks Composite Decant: COD (filtered) >100: Untreated water to Dam. Ammonia =0: No residual ammonia. Ammonia >5: Overdosing of nutrient. Nitrate >2: Must stay low, can cause pH drop. Phosphorus >10: Cleaning, algal issues in Dam
Composite Inflow: COD (filtered) >8,500: Refers to COD load
Tank.1 & Lagoon: Suspended Solids 5000 Ammonia =0: No nutrients available for bugs. Ammonia >5: Overdosing of nutrient. Nitrate >2: Must stay low, can cause pH drop.
WWTP Monitoring Rosemount’s learning's… Measure then Manage Have an organised monitoring and analysis schedule Analysis can be costly – Reagents and labour What’s the point in measuring it if you don’t use it? Results should dictate operational requirements
Quality Assurance: How do we know the results are correct?
SCADA: Overview
SCADA: Trending
- Checked first/last thing everyday! -
Monitor pump performance Tank level sensor validation Inflow/Outflow flow rates Tank volumes Batch processing efficiency DO2 recovery
DO2 Concentration.
SCADA: Process Management Highly concentrated wastewater fed in
DO2 recovery = Organics processed DO2 consumed
And so on and so on….
Time (24 hours)
SCADA: A good day!
6 processing cycles in 24hrs 170-220kL inflow 220-250kL outflow Surge storage increasing
SCADA: A not so good day. 3 processing cycles in 24hrs 170-220kL inflow 150-170kL outflow DO2 recovery struggling Surge tank storage reducing Pull contingency trigger now?
SCADA: A bad day L 14 hours for DO2 recovery Unable to process water 170-220kL inflow 40kL outflow Surge storage all but gone Contingency!!!
Contingency options for Rosemount Surge storage?
- 3 days during peak Vintage - Not enough time!
Bypass WWTP?
- Irrigate to Woodlot? - Gives woodlot nutrient dose - Allows WWTP to recover
Better to fully treat half of your water than half treat all of it!
Contingencies: Why? Rosemount
Mclaren Flat
Increase treatment efficiency How?
Rinsewater capture!
Managing the ‘Capacity Gap’ Objective: Reduce ‘Capacity Gap’ and reduce treatment problems (hopefully!) Method: Rinsewater capture -Capture initial water rinse (~1,000L) of Cold Stability (tartrated) tanks. -Store in redundant wine tank for WWTP feed prior to Vintage -Stored for 5 months to allow heavy solids to settle out -Clear supernatant fed to WWTP in controlled amounts -High potassium lees/solids sent to TARAC for processing Benefits: -Increased WWTP treatment capacity for early Vintage organic load -Reduced Potassium levels in treated wastewater Dam -Reduced non-vintage treatment costs
Reduce Winery load (Cleaner Production)
The Rosemount Chronicles (An experiment in common sense)
Knowledge
Get it
Share it
Resource Management: Our Basic Philosophy •
Set realistic goals – Don’t kill the WWTP (Sounds stupid? This was ours)
•
Research – Understand what problematic wastewater looked like
•
Education/Awareness – Knowledge is power
•
Give people the opportunity to do the right thing
•
Be Pragmatic – What happens in the real world?
See what happens
Cleaner Production Obstacles Cost Cost Cost (You get the point) - Productivity - Labour - Equipment - Disposal
No Money? No Worries.
Identified problematic Wastewater Product Waste: Spills – High in organics and potassium. Juice, Lees and Desludge – Highest in organic load and potassium. Cleaning – Usually very high in sodium. – Principle source of Salt in finished water. This can degrade soils (illegal). Pollutants (SO2 water, Ammonia water) – Impacting plant health quickly decreases plant functionality
Cleaner Production Initiatives
Caustic re-use and capture
- 1,000L caustic solution made - Re-used until
Craig Galletly (on behalf of the entire Rosemount team) WWTP Operator Rosemount Estate Winery - TWE
Contents… • Rosemount winery’s WWTP • How do we monitor the WWTP’s health? – Water quality monitoring frequency, methods and interpretation – SCADA graphs and their interpretation – Using SCADA for Process Management
• Contingencies options when all else fails. • How to reduce incoming load (Cleaner Production). – Quick wins – Success stories
• The results. • And…. a cheatsheet!
WWTP: Big Expensive Things Rosemount Wastewater Treatment Plant (WWTP) Inflow Composite Sample before entering initial 40 KL tank. Aeration Lagoon (1.6 ML)
PLC automation. Irrigation and sludge return pumps.
Decant pipe
Settling Tank. Tk 4 (Not in view) Baleen Filter (initial solids screening) & VBelt
Surge Storage (800 KL) Ute
Decant Water Sump. Irrigated or pumped to holding Dam.
Dam (30 ML)
Tank 1. Aeration, Setting, Sledge return & treated water decanted.
Sludge Tank.
Treatment Flow
Solids Removal
Rosemount Vintage WWTP Process Map Winery Inflow
Raw Water Tank
Coarse Filtration
Buffer (holding) Tanks
Aeration Lagoon
Vol: 1.6ML Vol: 30ML Power: 30kw blower Rosemount Winery WWTP Acts as Polishing Vintage: 3 x 30kwPond •Annual inflow: 22-25ML (including rainfall) surface aerators •Annual crush: 12,000-15,000 tonne •Treats ~60,000kg of COD/year
De-watering Vol: 250kL process Vol: 50kL ~150 tonnes Power: 13.5kwbiosolids blower Vol: 750kL (3Decant xfilter 250kL) Feeds Baleen removed annually Air operated line
Tank.1 (S.B.R.)
Decant Solids to to V-Belt Dam
Water Quality: Daily checks
Inflow: pH >8: Heavy cleaning in cellar pH 1800: Product spill, cleaning. EC 8.3: Unusual, check cleaning in cellar pH 1800: Treated water quality impact
Water Quality: Routine checks
Tank.1 & Lagoon: pH 800: High suspended solids, poor settling. DO2: Quality assurance check with inline meter.
Dam: DO2 8.5: Common, reduce likelihood of reuse. EC >1500: Water quality parameters.
Water Quality: Weekly checks Composite Decant: COD (filtered) >100: Untreated water to Dam. Ammonia =0: No residual ammonia. Ammonia >5: Overdosing of nutrient. Nitrate >2: Must stay low, can cause pH drop. Phosphorus >10: Cleaning, algal issues in Dam
Composite Inflow: COD (filtered) >8,500: Refers to COD load
Tank.1 & Lagoon: Suspended Solids 5000 Ammonia =0: No nutrients available for bugs. Ammonia >5: Overdosing of nutrient. Nitrate >2: Must stay low, can cause pH drop.
WWTP Monitoring Rosemount’s learning's… Measure then Manage Have an organised monitoring and analysis schedule Analysis can be costly – Reagents and labour What’s the point in measuring it if you don’t use it? Results should dictate operational requirements
Quality Assurance: How do we know the results are correct?
SCADA: Overview
SCADA: Trending
- Checked first/last thing everyday! -
Monitor pump performance Tank level sensor validation Inflow/Outflow flow rates Tank volumes Batch processing efficiency DO2 recovery
DO2 Concentration.
SCADA: Process Management Highly concentrated wastewater fed in
DO2 recovery = Organics processed DO2 consumed
And so on and so on….
Time (24 hours)
SCADA: A good day!
6 processing cycles in 24hrs 170-220kL inflow 220-250kL outflow Surge storage increasing
SCADA: A not so good day. 3 processing cycles in 24hrs 170-220kL inflow 150-170kL outflow DO2 recovery struggling Surge tank storage reducing Pull contingency trigger now?
SCADA: A bad day L 14 hours for DO2 recovery Unable to process water 170-220kL inflow 40kL outflow Surge storage all but gone Contingency!!!
Contingency options for Rosemount Surge storage?
- 3 days during peak Vintage - Not enough time!
Bypass WWTP?
- Irrigate to Woodlot? - Gives woodlot nutrient dose - Allows WWTP to recover
Better to fully treat half of your water than half treat all of it!
Contingencies: Why? Rosemount
Mclaren Flat
Increase treatment efficiency How?
Rinsewater capture!
Managing the ‘Capacity Gap’ Objective: Reduce ‘Capacity Gap’ and reduce treatment problems (hopefully!) Method: Rinsewater capture -Capture initial water rinse (~1,000L) of Cold Stability (tartrated) tanks. -Store in redundant wine tank for WWTP feed prior to Vintage -Stored for 5 months to allow heavy solids to settle out -Clear supernatant fed to WWTP in controlled amounts -High potassium lees/solids sent to TARAC for processing Benefits: -Increased WWTP treatment capacity for early Vintage organic load -Reduced Potassium levels in treated wastewater Dam -Reduced non-vintage treatment costs
Reduce Winery load (Cleaner Production)
The Rosemount Chronicles (An experiment in common sense)
Knowledge
Get it
Share it
Resource Management: Our Basic Philosophy •
Set realistic goals – Don’t kill the WWTP (Sounds stupid? This was ours)
•
Research – Understand what problematic wastewater looked like
•
Education/Awareness – Knowledge is power
•
Give people the opportunity to do the right thing
•
Be Pragmatic – What happens in the real world?
See what happens
Cleaner Production Obstacles Cost Cost Cost (You get the point) - Productivity - Labour - Equipment - Disposal
No Money? No Worries.
Identified problematic Wastewater Product Waste: Spills – High in organics and potassium. Juice, Lees and Desludge – Highest in organic load and potassium. Cleaning – Usually very high in sodium. – Principle source of Salt in finished water. This can degrade soils (illegal). Pollutants (SO2 water, Ammonia water) – Impacting plant health quickly decreases plant functionality
Cleaner Production Initiatives
Caustic re-use and capture
- 1,000L caustic solution made - Re-used until
