KWRD - Phase 1B Plant Improvements
Continuing Past Trends of Improvement; Making Investments in the Future
A Brief Overview of the Kishwaukee Water Reclamation District
What and Where is the Kishwaukee Water Reclamation District?
The Kishwaukee Water Reclamation District (formerly the DeKalb Sanitary District) is a Sanitary District located in DeKalb, Illinois. Similar to a School District, Library District or Park District, a Sanitary District is an administrative and political unit of government. Sanitary Districts treat wastewater that is generated by private citizens, commercial businesses, and industrial entities. In doing so, the Kishwaukee Water Reclamation District ensures that any and all water used within our service area is treated and sanitized before reaching the Kishwaukee River.
Any water that goes down a drain within our service area enters into our collection system. This water is then conveyed through the collection system to our wastewater treatment plant and treated through a variety of processes to remove pathogens, organic compounds, solids, and other potentially hazardous materials from wastewater. The treated wastewater is then discharged into the Kishwaukee River as clean effluent.
A Unique Government Entity
The Kishwaukee Water Reclamation District is a unique government entity. The Kishwaukee Water Reclamation District is an administrative and political unit of government that, as a Sanitary District, is separate from the state, city or town within which it resides. So, the Kishwaukee Water Reclamation District is independent from the City of DeKalb government, even though the District treats sanitary waste from the City. This unique situation allows the District to expand its service area to other entities and communities near DeKalb, such as Northern Illinois University.
Furthermore, the District is now focusing on becoming a regional wastewater authority. This means that the District is expanding its collection system to encompass a wider area, thus treating the wastewater from communities that neighbor DeKalb. In doing so, this will allow a wider range of customers to be served by the District, and will also reduce the amount of superfluous, smaller satellite wastewater treatment plants in the region.
Investing in the Future - A History of Improvements to the Treatment Plant
Throughout its long history, the Kishwaukee Water Reclamation District (KWRD) has remained committed to provided safe and proper sanitary sewer service for its customers. KWRD has made many substantial improvements to the wastewater treatment plant located at 1301 Sycamore Rd. With what started as a very small operation in 1929, having just a few drying beds, KWRD has expanded to address the growing needs of DeKalb-area communities, improve standards for operations and operator workflow, and meet increasingly stringent environmental regulations.
Past Treatment Plant Improvements
While Phase 1B is the largest and most recent improvement, there have been many improvements and expansions to the treatment plant. Previous plant improvements, like Phase 1B, were intended to enhance the treatment plant's capacity for treating high volumes of wastewater, especially during storm events, and to improve the effluent that is discharged into the Kishwaukee River by recovering excess nutrients like nitrogen that can cause damage to aquatic ecosystems.
The following is a list that summarizes the major improvement projects that have been completed in the District's history:
- 1954: Upgrade to treatment plant and sewers (added new primary clarifier, new final clarifier, and anaerobic digester; remodeled trickling filters)
- 1967: Upgrade to treatment plant and sewers (added another digester, new final clarifiers and chlorine tanks, and remodeled old tanks)
- 1977: Primary and intermediate clarifiers were remodeled
- 1980: Construction of Advanced Secondary Treatment using RBC bio-discs for ammonia removal and Tertiary filtration
- 1984: Construction of excess flow treatment processes using primary settling, rapid sand filtration, and disinfection
- 1987: District takes over ownership of sanitary collection system for City of DeKalb (descried in detail below)
- 1997: Upgrade to treatment plant (added single stage activated sludge nitrification process, new headworks including screening, grit removal, flow measuring and raw sewage pumping)
- 1999: Construction of Sodium Hypochlorite disinfection facilities
Phase 1A - Biosolids Rehabilitation
Another major improvement, which took place between 2009 and 2012, was the Phase 1A Plant Improvements. This project, named Biosolids Rehabilitation, was aimed at improving the way that KWRD processes and utilizes organic waste compounds, also called biosolids or sludge. Biosolids are the solid organic materials that are settled out of the treated wastewater. These materials go through a process called anaerobic digestion, in which beneficial anaerobic bacteria convert the sludge into methane and biomass.
Phase 1A improved this biosolids treatment process in a variety of ways. The project overhauled the District's anaerobic digesters by constructing a digester operations building, which allows KWRD to better monitor the health and efficiency of the four existing digesters. The digesters were then connected to the new Sludge Handling Building, which replaced the old open-air drying beds. This sludge handling building allows KWRD to treat biosolids (sludge) in a two-fold manner, either by thickening sludge from the treatment process for it to be digested or by dewatering sludge from the sludge storage tank and turning it into usable biomass. This biomass is then dewatered, brought to our temporary storage facility, and can be used by farmers as fertilizer.
A look at the KWRD anaerobic digesters, which were renovated and improved during the Phase 1A Plant Improvements.
Phase 1B - A Basic Overview
The Necessity for Phase 1B
The Phase 1A Improvements project overhauled the District's systems for processing biosolids. However, even with this improved biosolids process, the processes and equipment that had been operating up to that point would soon be behind future environmental regulations. In 2014, District leadership identified the following goals that needed to be achieved to meet the needs of the future:
- Continuously achieve more stringent NPDES treatment limit for ammonia and new limit for phosphorus
- Improve WWTP's hydraulic characteristics by utilizing hydraulic grade to allow the treatment process to be gravity-driven
- Ensure treatment processes that maximize the District's ability to automate/centralize/simplify operations
- Reuse existing infrastructure and equipment to the extent it is practical and economical
- Site buildings/tanks to enable easy expansion for future treatment capacity needs and treatment processes as new treatment standards are promulgated
Initiating the Project
Securing Funds: Before any work on Phase 1B could commence, a variety of barriers needed to be overcome. First, with the project being a major overhaul of both the District's operations and equipment, a large amount of funds were needed to conduct the improvements. To acquire the needed funds, the District applied for a loan through the Illinois EPA Water Pollution Control Loan Program (WPCLP). This program, part of the State Revolving Funds program, provides below-market-interest loans to wastewater treatment facilities undergoing major overhauls and improvements.
The Phase 1B Improvements project was approved for the WPCLP at a loan amount of roughly $53 million to complete the project. With the loan funds procured, the District then went to bid to hire the construction contractor that would facilitate the project. The selected contractor was Williams Brother Construction Company based out of Peoria, IL.
A sign notifying the public of the Phase 1B project.
Expanding District Property: In addition to project funding, the increased land footprint needed to accommodate the project required that the District's property boundary be expanded. After review the options, the District decided that the best method of expanding the treatment plant property was to acquire the properties along Hollister Ave (a street that ended at the District's main gate). Between 20XX and 20XX, the District offered to purchase these properties from the homeowners.
By 2017, all properties along Hollister Ave had been purchased, and the District's property boundary was expanded by roughly XX acres. This property expansion allowed the District to fulfill the planned improvements and process revisions. Furthermore, by designing the expansion to locate the new Administrative building along Sycamore Rd, the project also created a safer barrier of separation between the public and the operating treatment plant.
Getting into the Details of Phase 1B
The Phase 1B Improvements project encompassed a wide array of revisions and enhancements. These changes were focused on a few major considerations involved in the overhaul of the KWRD treatment plant. Some notable considerations included improving the ability for KWRD equipment to remove permitted contaminants and remain within new IEPA limits, and allowing for easy treatment plant expansions to anticipate future growth. Also, improving energy efficiency and reducing overall energy costs were important factors that determined the types of systems and equipment that were installed as part of Phase 1B.
Improving Treatment Capabilities
Meeting Future Regulations: The equipment installed through the Phase 1B Improvements project replaced the District's aging equipment with modern and more efficient treatment equipment and processes. This new equipment is able to meet the increasing regulatory requirements for wastewater treatment as directed by the Environmental Protection Agency. This upgrade to the KWRD treatment process ensures that KWRD meets anticipated ammonia, phosphorus, nitrogen, and wet weather regulations. Phase 1B also improved the liquid treatment disinfection process by converting the existing raw sewage pumps into a new UV treatment system. By reducing the amount of regulated contaminants that are present in the effluent leaving the treatment plant, and by reducing the amount of chemicals like chlorine used to treat wastewater, KWRD will be able to better protect the health of aquatic life in the Kishwaukee River.
Increasing Flow Capacity and Hydraulics: The new treatment plant equipment was also selected and installed to increase the total flow that the KWRD wastewater treatment plant can process on any given day. Before Phase 1B, the KWRD wastewater treatment plant was rated at a permitted daily flow of 6.83 MGD (Million Gallons per Day) and a maximum flow of 18.13 MGD. With the new equipment and hydraulic systems operational, the daily maximum flow has been increased to 24 MGD and 30 MGD with the inclusion of hydraulic storage equipment (excess flow tanks). By converting the old primary clarifiers to excess flow tanks, this allows KWRD to better handle major wet weather events.
This image shows the proposed installations and improvements designed for Phase 1B.
Planning Ahead
Anticipating Future Expansions: The Phase 1B Improvements project was designed to allow easy access to equipment and simplify hydraulics. The improvements project was also designed to improve operational workflow by simplifying equipment and operations monitoring. As treatment and regulatory requirements continue to increase, KWRD will likely need to engage in further improvements projects. The property expansion and equipment installations were intended to allow KWRD to make similar improvements and changes in the future, such as increasing the permitted daily flow of KWRD wastewater treatment to at least 12 MGD. Thus, the finished treatment plant site contains open areas that will allow the addition of future equipment and treatment processes.
Improving Electrical Systems and Energy Consumption: In addition to the improved treatment processes and hydraulics, the improvements made through Phase 1B also encompass improvements to KWRD energy consumption. For instance, the following are a few examples of improved electrical/energy considerations through Phase 1B:
- New electrical building designed through Phase 1B provides a place to house electrical switchgear, automatic transfer switch, and dual fuel generators.
- New aeration tanks utilize top-down mixers that consume less electricity than the old submerged mixers.
- Occupancy/motion-based indoor lighting systems
- Reflective building roofs to improve heating/cooling energy consumption
- Installation of high-efficiency sewage pumps and motors
Being a Good Neighbor
Phase 1B provided a wide array of improvements to the KWRD wastewater treatment process and operational workflow. However, Phase 1B was also planned with the intention of improving the District's role in the community.
Engaging The Public: The Phase 1B project incorporated principles aimed at improving the ability for DeKalb residents, District customers, and members of the public to engage and interact with the District easily and safely. The new Administrative and Lab Building, which houses the District's meeting rooms and administrative personnel, was constructed outside the main treatment plant and allows access from Sycamore Road. Thus, members of the public that are interested in interacting with the District can easily do so. KWRD welcomes members of the public to come and discuss any concerns, bill payment information, or upcoming meetings and projects. Members of the public are also encouraged to be part of the conversation during the District's monthly Board meetings, which can be accessed by the public via a Zoom link in each Board Meeting Agenda (posted on the KWRD website).
Introducing New Safety Measures: Much of the design work that went into the treatment plant expansion also incorporates safety as a guiding principle. An important aspect in the location of the new Admin/Lab Building was to ensure that members of the public could interact with District administration without entering the main treatment plant facility. As the treatment plant equipment and machinery is in operation 24 hours per day, it would therefore be unsafe for members of the public to enter the main facility without KWRD personnel accompanying them. Furthermore, new fencing and automatic gates have been installed across the expanded KWRD property to ensure the highest possible degree of safety.
Technical Exhibit: View the Progress of Phase 1B Improvements Project
Looking Forward: What the Future Holds for KWRD
The Phase 1A and 1B Improvements projects have helped KWRD make massive strides towards increasing the reliability of our wastewater treatment process, our ability to anticipate future growth, and the energy efficiency of our operations. However, these projects were not simply about improving the ways that the treatment plant functions. These projects, and future planned developments, also denote a major shift in the way that KWRD aims to pursue its mission.
Pursuing Energy Neutrality
KWRD has made major improvements to the energy efficiency of the various treatment processes and equipment that make wastewater treatment possible. As mentioned in the previous sections, equipment installations such as VFD pumps, energy efficient aeration systems, and LED occupancy-based lighting systems allow KWRD to conserve electricity and money. Nonetheless, KWRD has also made it a priority to achieve net energy neutrality, meaning that KWRD will produce as much energy as it consumes, by 2025.
The Net-Zero Energy Plan: To achieve energy neutrality, KWRD has drafted the Net-Zero Energy Plan. The Plan is divided into five initiatives that encompass the implementation of renewable energy-producing systems and more sustainable operating practices. The Plan aims to reduce energy consumption wherever possible and produce energy equal to the energy load consumed by KWRD (roughly 13,050kWh per day). The Net-Zero Energy Plan is designed as follows:
- Initiative #1 - CHP Unit 1 (Completed March 2020): As part of the Phase 1B Improvements project, KWRD installed a CHP generator capable of converting biogas into usable energy.
- Initiative #2 - CHP Unit 2 (2021): KWRD is expected to bring its second CHP generator online by the end of 2021. With the amount of available biogas, these two CHP generators will generate a large portion of the District's energy load.
- Initiative #3 - Digester 1A Mixing (2021): Anaerobic Digester 1A currently utilizes an aging JetMix mixing pump and is slated to be upgraded to a top-down mixer that consumes 87.5% less energy.
- Initiative #4 - Solar Power (2022-25): Many open areas within the KWRD facility have been identified as potential sites to house solar panel arrays. Based on the space available, KWRD could generate a combined total of 3,359kWh per day.
- Initiative #5 - Hydrokinetic Power (2025): The District's effluent flow can be utilized to generate electricity by installing a micro-turbine at the point of the treatment plant outfall.
This map shows the KWRD electrical grid and meters. The Net-Zero Energy Plan would allow KWRD to produce enough energy to power all five meter areas.
Pursuing Grant Funding: KWRD has made a goal of engaging in energy efficiency programs offered by state and federal government agencies. To date, KWRD has received roughly $275,000 in grant funding to pursue various energy efficiency initiatives across the District wastewater treatment plant.
Becoming Responsible Environmental Stewards
With the property acquisition and expansions that allowed KWRD to implement the Phase 1B Improvements project, the District property now extends across 42 acres. While this property expansion was intended to provide room for the new treatment equipment and processes, much of the expanded land footprint is vacant of any actively operating equipment and/or buildings. KWRD has therefore made it a primary goal to install pollinator habitat in open areas, thereby seeding traditional turf grass only in areas where access to machinery and equipment is necessary. This builds upon the District's previous work in converting roughly 3 acres of turf grass to native habitat in 2017.
This map shows the sites installed with pollinator habitat seed mixes. The areas in red were seeded by Williams Brothers Construction Inc. as part of the Phase 1B Improvements project, while the areas in blue were seeded by the DeKalb County Soil and Water Conservation District as part of a joint project with the DeKalb Park District.
