Nutrient removal upgrade of BioMAX wastewater treatment plants for BHP

EEI was engaged by Dardanup Butchering Company (DBC) to design, and commission a new wastewater treatment system for their meat processing plant in Picton, Bunbury to replace their old treatment system. Based on analysis of baseline data, EEI decided to install its proprietary EEI Hybrid Anaerobic Reactor Technology (EEI-HART) and Advanced Nitrogen Removal Using Ponds (ANRUP) system for this project. Previous computer models and laboratory scale studies in the development stages on these processes have contributed significant knowledge of operational aspects. However, there was a significant lack of data on the constructability, operational constraints in a field situation. The HART system was to treat a daily wastewater flow of up to 0.5 MLD with a BOD of 9, 000 mg/L and total nitrogen of 300 to 400 mg/L. The HART system is 4,500ML HDPE lined steel tank and has the advantages of both UASB system and counter current mixing technology for rapid carbon removal and to avoid extra alkalinity addition

The system was constructed in nearly 40% of the cost of conventional pond system, and over the last 12 months of operation shows that this system has successfully treated wastewater to achieve a reduction of 99.9% of BOD, and about 90% reduction of TN. The HART system produces biogas with about 70% CH4 content but only <5% CO2 and non-detective levels of H2S. The system produces minimal sludge and the HAR system can contain the sludge from the treatment system for over 2 years before regular desludging commences. The system operation is monitored remotely.

The United Nations agency for climate change, UNFCCC's Clean Development Mechanism (CDM) engaged Dr Raj Kurup to develop a methodological tool to determine emissions from anaerobic digestion projects. The project was commissioned in 2011 and the final product was approved the board of CDM in April 2012 as an approved methodological tool. The tool can be downloaded from the attachment.

Meat and Livestock Australia engaged EEI to author a book on Water Quality of Northern Australia and its impact on ruminant health and productivity. The project included review of water quality of groundwater resources of northern Australia, and its impact of livestock health. In collaboration with faculty from Veterinary School of Murdoch University, this project assessed the groundwater quality, mapped the groundwater quality profile and provided solutions for treatment of those parameters that exceeded the limits for livestock. Also, the project covered the on-site testing procedure for regular assessment of groundwater quality that can be carried out by producers.

BioMAX Pty Ltd has engaged EEI to upgrade its wastewater treatment plants installed at various mining sites of BHP in Newman. This project will evaluate the performance of the plants, and upgrade the systems to provide advance levels of removal of total nitrogen and total phosphorus.

EEI is providing technical and consulting services for an environmentally sustainable wastewater treatment for the proposed eco-tourism development project at Broome. At this stage, the project is in the final stages of approvals from various regulatory authorities.

Kimberly Freerange Beef Pty Ltd appointed EEI to obtain operating licence from the Department of Environment & Conservation (now Department of Environment Regulation) to reopen a previously operated abattoir in Gingin, Western Australia. Following review of the existing operating and wastewater treatment facilities, projected throughput, EEI provided independent consultant reports to DEC. Based on EEIs reports, DEC approved Kimberly Freerange Beef Pty's application to start processing operations at their newly acquired Gingin abattoir.

Environmental Engineers International was commissioned by Vernon Arms and White Lakes Brewery in Rockingham, Western Australia to develop a nutrient and irrigation management plan (NIMP) for its treated effluent disposal from its new craft brewery. EEI applied its nutrient management model, which is based on the risk approach to estimate the irrigation area required. The project was completed in mid 2016.

In 2016, Environmental Engineers International was commissioned by the Indigenous Land Corporation (ILC) of Commonwealth of Australia to develop a stormwater management plan and design an evaporation pond for the Roebuck Live Export Depot in Broome, Western Australia.

The Department of Environment and Regulation had established a moderate risk of the worksite’s current system discharging nutrient rich stormwater from cattle holdings into groundwater and nearby water bodies. In which case, this would cause severe damage to the local eco-system by damaging plant growth and increasing toxicity of local river systems. Undoubtedly, this risk will only increase with any further expansion of the worksite.

Through 1D modelling, analysis of the 10-year average reoccurrence index (ARI) and worksite soil testing EEI were able to assist in creating a design report for a sitewide stormwater management system. This enabled Roebuck Export Depot to employ an appropriate evaporation pond to manage any oncoming rainfall. Evaporation ponds are generally constructed in order to prevent contaminated water stream from a process or catchment area from mixing with the natural water system. Solar energy is utilised to slowly evaporate the stored pond water, concentrating solid contaminants and allowing for their efficient removal.

Figure 1: Soil Sample Analysis

EEI recommended Roebuck Export Depot to implement a sedimentation pond prior to the evaporation pond to cater for site specific issues such as silting. This significantly reduced the ongoing maintenance requirements and costs of the project for the client.

EEI was also able to save the client capital costs by undertaking a risk assessment of the ponds constructed as unlined posts. The site soil permeability was higher than the required amount, indicating that the ponds would usually have to be lined. However, EEI looked closely at the depth to groundwater, phosphorus retention of the soil, the pond’s ability to foster conversion of ammonium nitrogen and recommended a exemption for the client. This exemption was approved by the department of environment and regulations, which saved the client a large capital and operating costs of lining the required ponds.

Fugitive greenhouse gas emissions from wastewater treatment: Understanding emission generation processes and development of appropriate sampling methods Greenhouse gas (GHG) emissions resultant from wastewater treatment operations represent an area of great uncertainty in which the total global effects are currently unknown. This is the result of many countries having no regulatory requirements or managing protocols in place, and as such there is a general lack of credible data and understanding of fugitive emissions from various treatment processes. Methane (CH4), and Nitrous Oxide (N2O) have been identified as the most significant GHGs released from wastewater treatment plants due to their significant global warming potential. The purpose of this study is to provide a comprehensive overview of key emission generation processes and develop standardised sampling methods which can be implemented to establish comprehensive inventories of emissions and process data.This study involved a critical review of literature, field data collection and laboratory investigations. The study found that there existed a gap of available data of N2O and CH4 emissions during various unit process of wastewater treatment and approved methods used obsolete assumptions. Through the development of accurate inventories, future efforts can be expended in the development of models to validate methodologies against expected emissions.

This project was carried out in collaboration with UWA.

This is an ongoing R&D project that EEI has embarked on. The initialresearch was carried out in collaboration with Integrated Rural Technology Centre (IRTC) in Kerala India. Following the promising results of the initial research, EEI has undertaken a collaborative research with University of Western Australia (UWA), Water Corporation of WA and Department of Agriculture of WA. This research also supported two B.Eng honours projects at the School of Environmental Systems Engineering at UWA. In the first phase, the organic product was tested for sludge thickening applications. The current phase involves application of this organic product for drinking water treatment. The research results are very promising. Although it is in the early stages, there is a great potential to replace alum with this product and can provide a better environmental solution for water treatment in both urban and rural situations.

Alternative Uses, Treatment and Disposal of Wastewater from Potential Development of Western Australia's Unconventional Gas Resources.

This is a collaborative research project with University of Western Australia.

Interest in unconventional gas is experiencing rapid growth on a global scale. The emergence of such an industry in WA brings a host of new environmental and economic challenges, such as the management of industrial waste streams, specifically produced water. This study investigates the various options for alternative uses, treatment and disposal of produced waters from potential development of Western Australia's prospective unconventional gas (UCG) resources. Treatment options are analysed in consideration of produced water quality and quantity, for a range of end-use criteria, within the context of relevant regulations and guidelines. Influential factors are considered in a spatial analysis in conjunction with an extensive literature review. Existing land and water use is also considered in assessing the regional viability for alternative use, treatment and disposal options, as well as the potential for synergistic opportunities with local industries. The analysis constructs an outlook for WA and it is established that growth in WA's UCG industry is likely to reveal unique opportunities in the future.

A joint research and development project with University of Western Australia

Wastewater Treatment Plant (WWTP) plays an irreplaceable role in the overall wellbeing and development of societies. Wastewater treatment is an ongoing process that requires high-energy consumption, and this demand contributes negatively to climate change. Nonetheless, there are options available for energy production and recovery in WWTPs during its treatment process, which can also reduce the negative environmental impacts. This study aims to investigate the potential of energy production and recovery at one WWTP, and the reduction of environmental impacts achieved.

The study site is a WWTP situated at Subiaco of Western Australia, operated by Water Corporation. The research evaluated sludge samples from the Subiaco WWTP at the UWA SESE laboratory for the characteristics of the sludge. Laboratory batch scale anaerobic digestion studies were also carried out to evaluate the efficiency of the system. The results of this study were then compared with data from the neighbouring WWTPs that use anaerobic treatment for sludge stabilisation. Further analyses were carried out to determine the economical values of the generated energy potential and the reduced environmental impacts.

The experimental results showed that sludge samples from the Subiaco WWTP had a biogas production capacity of 0.015 m3/L sludge or 0.6 m3/VS, with a potential energy production of 40.4 megawatt-hour (MWh) per day. The biogas conversion to electricity used a combined heat and power (CHP) unit with an assumed efficiency factor of 70 %, and results indicated that Subiaco WWTP has the potential to recover 78 % of its overall energy consumption through anaerobic treatment, with a generated value of A$1,012,291 per year. The payback period of purchasing a CHP unit using this generated value alone in the Best Case scenario is between 2.2 to 9.6 years, and 4.2 to 12.5 years in the Worst Case scenario. The amount of avoided carbon dioxide (CO2) emission from the substitution of treatment system is 7,475 metric tons annually. This study had successfully demonstrated the sustainability and economical advantage of an anaerobic treatment process, and concluded that energy production and recovery is a feasible option for Subiaco WWTP.

Environmental Engineers International successfully completed a specialist project awarded by South32 to complete a desktop concept study on "A sustainable treatment solution for Worsley Alumina process waste stream". EEI's report has presented an innovative solution that can be implemented for the Worsley Alumina plant.

Environmental Engineers International successfully completed a specialist project awarded by South 32. EEI was required to complete a desktop study on sustainable treatment solutions for Worsley Alumina's process waste stream. EEI's report was able to present an innovative solution that can be implemented for the Worsley Alumina plant.

EEI was employed by Mount Barker Chicken Abattoir as an EPCM consultant for wastewater treatment. 

Mount Barker Chicken Abattoir commissioned EEI to provide a solution for the odour generation from the treatment plan and to improve their treated water quality.  EEI was able to implement creative solutions such as a floating straw bed for odour control and ANRUP system for nutrient removal.

These solutions EEI provided enabled continuous operation of the plant, the removal of over 95% of targeted parameters such as BOD, TN, TP, TS and no reported odour emission from the plant. EEI’s technologies provided a cost effective and efficient solution for Mount Barker Chicken to treat their wastewater.

In 2017, RMAX engaged Environmental Engineers International to carry out a risk assessment and provide disposal options for the wastewater produced by the boilers and cooling towers at their Kewdale facility.

With large scale polystyrene and polypropylene production, chemicals are often applied in excess to ensure the condition of the water to be suitable for the equipment. This practise can often result in some of the chemicals being retained in the wastewater. Considering that the RMAX facility produces 4KL of wastewater a week, a environmental assessment was necessary to determine impacts on equipment and local ecosystem. By providing a review of the wastewater quality and quantity, EEI was able to identify the current pH level, and any toxic or excess nutrients in the water system that may affect corrosion of equipment and toxicity of wastewater.

Following the analysis and testing of the water, EEI was able to construct and propose various options for disposal and treatment of the wastewater that adhere to environmental contamination standards.

EEI was employed in 2018 to assess the existing wastewater treatment facilities and produce a wastewater management plan for Pickering Brook Primary School. We identified a series of key risks with the School’s existing infrastructure for the Department.

EEI was tasked with designing a new wastewater treatment process that would allow for safe environmentally friendly on-site disposal and irrigation. Given the risks and challenges associated with School requirements, EEI recommended a specially modified below ground wastewater treatment plant. The system was specifically designed to incorporate an advanced nitrogen removal process, ensure no odour generation, and include a double barrier system (two forms of disinfection) to address the existing issues.

EEI’s technical expertise in chemical free nutrient removal and biological systems was critical in ensuring the brief was successfully completed.

Environmental Engineers International (EEI) was commissioned to conduct a geotechnical investigation of the Pickering Brook Primary School Oval and engineering design study to confirm the viability of land disposal for the School’s treated wastewater.

EEI determined the soil and groundwater profile, drainage characteristics, and other soil properties to design a suitable irrigation rate for the site. The geotechnical investigation revealed the School Oval had a consistent hard impermeable rock/clay layer that could limit subsurface disposal through infiltration. EEI conducted a vigorous assessment of the site soil and meteorological data, and considered stakeholder values in finding a solution that could be accepted by the School community.   

Through EEI’s attention to detail, a solution to this technically challenging project was delivered promptly to provide certainty for the School’s future.

In 2019, EEI was commissioned by Adaman Resources to assess the existing wastewater treatment plant for the West Australian Kirkalocka mine site and provide support in securing approvals from the Department of Water and Environmental Regulation and the Department of Health. EEI was able to investigate the current wastewater treatment system to identify potential flaws and inefficiencies in the existing process. With analysis on each inefficiency, EEI provided the service of developing multiple options to fix the relevant issues.

To prevent significant environmental damage to ground water and nearby water bodies, the plant’s wastewater required to be distributed and disposed of evenly over the environment, preventing a pooling effect of wastewater. The standard solution to this problem is an expensive subsurface leach drain system. However, EEI was able to apply fundamental engineering principles while considering the site environmental risk factors of the site to design an economical drainage channel system as opposed to a capitally intensive subsurface leach drain.

Accompanying this, EEI was able to develop a maintenance plan for the system. We determined if the wastewater treatment plant system and disposal area are maintained regularly and with an annual inspection by a certified environmental engineer, any repairs /faults fixed immediately, the system may have a service life of over 15 years.