Jones & Henry has provided engineering solutions at the City of Kalamazoo Water Reclamation Plant since its inception in 1947.
The City of Kalamazoo Water Reclamation Plant’s antiquated, failing belt presses and transport conveyors required significant maintenance attention. The conveyor system required belt vulcanization only available from a single craftsman remaining in West Michigan. As component after component failed and replacement parts and support became harder to locate, the City began to ponder the opportunity for a new process for producing high solids content sludge cake. As they have done since 1954, the City requested Jones & Henry deliver the best engineering solution for the water reclamation plant project.
In 2015, Jones & Henry worked with the City to pilot study solids handling equipment. The pilot included multiple technologies including centrifuges, belt filter presses, rotary presses, screw presses, and volute presses. Our team evaluated the capital and annual operating costs, concluding centrifuges were the best option from a cost standpoint. Centrifuges were also considered better for odor control and would use less process water. Pilot tests for centrifuges indicated that if the total solids content of sludge cake could be increased to 25%, there is a potential to save more than $600,000 in annual operating costs due to the reduced weight of cake sent to landfill.
The primary project objective was to deliver the best possible system improvements to deliver the highest solids content sludge possible and the lower landfill fees that would accompany it.
Jones & Henry began to work on designing the new system to fit the existing belt filter press building while keeping the belt presses operational throughout. The design included positive displacement cake pumps to convey the sludge cake.
The staging of the project and the sequence of construction were elements that received significant attention from our engineering staff. The project would only be successful if the existing systems could be relied upon throughout construction. Our team worked with City maintenance staff to include modifications to the existing equipment, to allow it to be relocated throughout construction as new areas for improvements work were needed. Valving and control improvements ensure operational reliability and flexibility.
Jones & Henry has also provided construction administration and engineering. Unforeseen site conditions have required significant revisions to account for failing infrastructure and unsuitable soils beneath existing buildings. The onsite resident project representative (RPR) was key to evaluating the site and providing design options that could be completed in a timely fashion so as not to disrupt the Contractor’s critical path. This project is nearing final completion and current change orders account for less than 3% of the original bid. During the current supply chain conditions and with all the unforeseen conditions, cost control of this project has been incredible.
