SRF Could Help Illinois Water Reuse Project

When the Cronus fertilizer plant slated to be built near Tuscola, Illinois is fully operational, much of their water will come from the Urbana-Champaign Sanitation District (UCSD) roughly 20 miles north. UCSD has agreed to pipe over 6 million gallons of effluent to the plant everyday for industrial uses. We sat down with UCSD director Rick Manner last fall to discuss the project and what it will mean for UCSD operations. 

Tell us a little about UCSD.

We treat the sewage from the cities of Urbana and Champaign and the villages of Savoy and Bondville. About 10 percent of our customers are in the unincorporated areas around Champaign and Urbana.

In a typical day in normal weather, we discharge about 22 million gallons of sewage. About two-thirds of that comes out of our plant in northeast Urbana, which flows into the Saline Branch of the Salt Fork River and ultimately into the Vermillion and Ohio rivers. Over in southwest Champaign, about a third of our water comes out of our Southwest Plant. That goes into the Copper Slough, which flows into the Kaskaskia and then the Mississippi River.

In extreme drought conditions, we are down to a total of about 12 million gallons a day, with about three-quarters from our Northeast Plant and one quarter from our Southwest Plant.

That said, our sewers are actually going to be rearranged a little in the near future. Right now, there are a lot of tall buildings being built on campus, and those sewers that they are discharging to are getting the challenge of 20-story buildings where there was previously a mom-and-pop business or a two-story building. It’s actually producing a good deal of burden on those sewers, so we will be rearranging some of our flows within the sewers. We’ll be diverting flows from the Northeast Plant and pushing it over to our Southwest Plant. So, even in times of drought, we will be at about a 60/40 split.

We need to do this to deal with our own sewer issues. But it so happens that it helps in regards to Cronus. The Southwest Plant is closer to them, and that is where they are going to be getting their water from. So, an increase in flow at the Southwest Plant ends up coming at a fortuitous time for them because they are looking to buy some of our effluent from that Southwest Plant.

Why are they interested in buying the effluent?

Cronus Fertilizer is proposing to build just west of Tuscola. Contemporary fertilizer manufactures use natural gas as a primary ingredient, and with that natural gas, there is a lot of energy coming into the process. So, they end up evaporating a lot of water just to keep their equipment cool. If they didn’t do that, the temperature would increase too much and they wouldn’t get the results they want. Overall, they are looking at buying 6.3 million gallons a day of our treated effluent. Of that, about 80 percent will be boiled away and evaporated and the remaining 20 percent will still be discharged and have to meet discharge limits.

They could be using water from other sources, but they approached us about the idea of reusing our effluent, which is water already coming out of the Mahomet Aquifer. This way the water will get a second use—reuse, if you will—down in Tuscola. And Cronus doesn’t have to draw new water out of the aquifer. That is the advantage of reusing effluent.

How would the effluent be transported, and who is responsible for that infrastructure?

Champaign and Tuscola are 20 miles apart, but it happens that our treatment plant and their proposed fertilizer plant are literally north and south relative to each other. So, they are looking at building a 20-mile, 2 ft-diameter pipe that would connect up our treatment plant to their fertilizer plant. They would design, build, and operate that pipeline.

The reason Cronus is in this situation is somewhat interesting. They are proposing to build the fertilizer plant in Tuscola because there are two or three large natural gas pipelines that cross there. But Tuscola doesn’t have a very good water supply. They are not on top of the aquifer anymore. They get their drinking water from a pipeline from the Champaign-Urbana area—from the Bondville wells of Illinois American Water. But the drinking water pipe is not large enough to handle a 6-million-gallon-a-day increase. So, they would be looking at a new pipe either way.  

What changes will UCSD have to make at the plant to move water through the pipeline?

We will need to put in some good size pumps that could pump the water 20 miles south down to Tuscola. That’s the first big infrastructure exclusively for the benefit of Cronus. But we would get reimbursed for that. We get more than reimbursed for that. That’s one of the reasons we are interested in doing this. Not only does it help protect the aquifer, but the payments that Cronus is proposing would help our bottom line.

When we were looking into this scenario, one of the things we became acutely aware of is that there is great sensitivity to not going to zero discharge, even in times of drought. Our rate payers and our board and everybody who commented would like to see some continuing flow to the creeks. To accommodate that, we are building a storage lagoon at our Southwest Plant. The storage lagoon would fill up when there is a lot of rain and moisture in the spring and then would be there holding our final effluent in quantity in case of a drought like we had in 2012.

That lagoon would be another bit of infrastructure that USCD would look into building that would benefit Cronus. Again, though, we would be compensated for that construction project. But in the long run, that is something the sanitation district will benefit from. We know that Champaign and Savoy are growing towards the southwest, so we know the flows are going to be increasing there. When that lagoon is no longer needed to get us through a drought while still meeting Cronus’s demand, we would use it to store influent instead. The lagoon would be turned into what we call an equalization basin, which would allow us to store high volumes of flow so that we don’t have to treat it that same day. We could treat it when our flows are more reasonable. My successor, or my successor’s successor, is going to benefit from that lagoon being built. 

Check back here for part two of our interview to learn about how the State Revolving Loan Fund features in this story and how the district determined the market value of their effluent. 

Operator Math Part 3: Continuous Education

This is the third and final installment of our operator math series, and we’re closing with an eye to the future. When the exams are done and you’re thrown back into the stress of daily operations, it’s easy for math skills to get a little rusty.

Here are some great videos, blog series, and more to help you test and strengthen your knowledge of commonly—and not so commonly—used formulas and functions. And many of these resources can also double as exam prep, making them something you can turn to again and again.

Problem of the Day

Wastewater Technology Trainers gives you a keep your skills sharp and review at your own pace with their Problem of the Day blog series. Each problem is provided in the form of a downloadable document containing a page or two about working in the wastewater treatment industry followed by the sample problem. Although each of the documents appear similar at first, you’ll find the problems generally begin on the second or third page following a schedule of problems provided on earlier dates. 

Indigo Water Group Math Videos

This series of 13 videos walks through the procedures for solving common water or wastewater math problems. Viewers are able to learn how to solve problems in a step-wise process by following along with the video, which demonstrates and explains each step. The series contains three unit conversion tutorials, five geometry tutorials, three dosing tutorials, one that calculates pump run time to reduce MLSS concentration, and one that calculates VSS loading rate to an anaerobic digester.

CAwastewater.org Math Videos

These 19 HD-quality videos were created by operators for operators. They provide instruction, examples, and advice on math topics covered by the Grads 1-5 exams offered in California.

Big Books of Math Problem Generator

Also from Indigo Water Group, this tool gives you a new set of problems with every click. Each set is provided as an Excel spreadsheet, allowing you to easily work through the solutions at your own pace. Click on the “Math Problem Generator” link at the bottom of the page.

Skills Builder

This webpage allows you to test your knowledge of wastewater and laboratory topics using Skills Builder—a set of quizzes provided by WEF as a free resource for operator education. The quizzes incorporate math, safety, and a variety of other topics. Skills Builder provides feedback on your answers as well as references for follow-up study sources. Results are completely confidential and are not recorded. 

Industry groups and not-for-profits, including our partners at the Rural Community Assistance Partnership, also regularly host operator math training courses and webinars. Learn about these and other training opportunities with our Event Calendar.   

Operator Math Part 2: Online Tools and Apps

Last week, we shared a few basic tips to help you master some of the calculations used in day-to-day operations. Understanding these and other functions and formulas is an integral part of the job, but working through the problems can be intimidating. Fortunately, there is a large bank of online tools and apps geared toward water and wastewater professionals that puts solutions literally at your fingertips. 

Of course, mobile technology is fast-moving and new tools are being released almost daily. Here are just a few of the ones available at no cost right now.

Online tools

From the Pennsylvania Department of Environmental Protection:

• Temperature Conversion  
• Millions of Gallons Conversion
• Loadings Calculator
• Pounds of Chemical per Gallon
• Tank Volume Calculations
• Dry Chemical Calculation
• Removal Efficiency
• mL per Minute Conversion
• Food to Microorganism Calculator
• Metric Conversions

From the Missouri Rural Water Association:

• Circular Break Around Pipe
• Hole in Pipe
• Rectangular Break Along Pipe
• Monthly Water Loss
• Annual Water Loss Average
• Well Drawdown and Specific Capacity
• Pipe Disinfection
• Tank Disinfection
• Well Casing Disinfection
• Solution Strength Mix

Device apps

From Georg Fischer AG:

• FlowCalc – Apple

From Pipeflowcalculation.com:

• Pipe Diameter Calculator – Android

Be sure to check back here next week for the last post in our operator math series. We’ll have resources to help you keep your calculation skills sharp.

Operator Math Part 1: Practical Guidelines

Mathematical calculations can be a challenge for even for the most veteran of water and wastewater operators. The formulas for volume, chemical dosage, filtration, pipe velocity, and other daily problems vary of course, but there are a few underlying guidelines that can help you make sure your answer is correct regardless of the calculation you’re working on. 

This is the first in a three-part series dedicated to operator math. The tips below are adapted from information provided by the South Dakota Department of Environmental and Natural Resources.

1. Learn what a formula means, not just when it is used. This will help you remember when to use πR2H to calculate the volume of a cylinder instead of 2πRH—the formula for measuring the surface area of a cylinder’s sides.
2. Use unit labels throughout your calculation to help you easily see whether you need to multiply or divide.
3. Always convert percentages to decimals.
4. Convert “inches” to “feet” unless you’re trying to solve a pressure problem. Using “inches” in any other problem will almost always leave you with the wrong answer.
5. Make sure the units you end with match the problem you are trying to solve. If a volume calculation results in a “square feet” or “square yards” answer, something went wrong along the way.
6. Trust your suspicions. If the answer doesn’t seem right, check that you used the right formula and units before running the problem again.

For those looking for more detailed and specific instruction, our documents database is a great place to start. Here are some of the resources you’ll find if you search “math.”

Basic Math Handbook

This 24-page handbook is a basic math study tool. It provides formulas for basic geometry, velocity & flow rates, and pressure, force & head, and contains several typical water problems that show users how to apply the formulas in real-world scenarios. 

Formula and Conversion Sheet for Drinking Water Treatment and Distribution

This 1 page document provides conversions and formulas for water treatment & distribution operators in studying for a certification exam. 

Chlorine Contact Time Calculations

This 7-page document provides guidelines on how to solve math problems that deal with calculating chlorine contact time. It includes important equations and practice problems with solutions. 

Industrial Math Formulas

This 7-page document provides a list of valuable formulas and conversion factors important for wastewater operators. 

Intermediate Water Math

This 37-page study guide contains 82 intermediate water math questions. Solutions to the problems are provided at the end of the document. 

Advanced Wastewater Math

This 29-page study guide contains 35 advanced wastewater math questions. Solutions to the problems are provided at the end of the document.