Ocean County Utilities Authority Brick

1. INTRODUCTION

The Northern Water Pollution Control Facility (NWPCF), located in Brick Township, serves as the critical wastewater treatment hub for the rapidly growing municipalities of northern Ocean County, New Jersey. Operated by the Ocean County Utilities Authority (OCUA)—a regional leader recognized for its pioneering “OceanGro” biosolids program—this 32-MGD secondary treatment plant protects the environmentally sensitive Barnegat Bay watershed and the Atlantic coastline.

Commissioned in the mid-1970s following the Clean Water Act, the facility has evolved from a conventional activated sludge plant into a resilient infrastructure asset. Following the devastation of Superstorm Sandy in 2012, the plant has seen significant capital investment aimed at hardening electrical systems and modernizing discharge infrastructure. Today, it treats wastewater from diverse residential, commercial, and light industrial sources across seven municipalities, ensuring compliance with strict NJDEP coastal discharge standards.

2. FACILITY OVERVIEW

A. Service Area & Coverage

The NWPCF serves the “Northern Planning Area” of Ocean County. This region is unique due to its mix of dense year-round residential zones (Brick, Lakewood) and seasonal coastal communities (Point Pleasant Beach, Bay Head, Mantoloking). The collection system feeding the plant is extensive, comprising over 40 pump stations and miles of force mains and gravity interceptors that navigate complex coastal geography, including crossings under the Metedeconk River.

B. Operational Capacity

The facility is designed for an average daily flow of 32 million gallons per day (MGD). Historical data indicates an operating range between 20 and 24 MGD, providing a comfortable capacity buffer of approximately 25-30%. However, hydraulic peaking factors are significant due to the age of the collection system in older shore towns, which contributes to inflow and infiltration (I/I) during heavy precipitation events. The plant is engineered to handle peak hydraulic flows significantly higher than its average design rating to prevent bypass events.

C. Discharge & Compliance

Treated effluent is discharged into the Atlantic Ocean. Unlike inland plants that discharge into fresh waterways requiring tertiary nutrient removal, the NWPCF operates under NJDEP Coastal Discharge requirements. The outfall pipe extends approximately one mile offshore, utilizing a diffuser array to ensure rapid mixing and dispersion. The facility consistently achieves high removal rates for Total Suspended Solids (TSS) and Biochemical Oxygen Demand (BOD), maintaining compliance with the “85% removal” requirement standard for secondary treatment.

3. TREATMENT PROCESS

The Northern Water Pollution Control Facility utilizes a conventional activated sludge process train designed for robust removal of organics and solids.

A. Preliminary Treatment

Raw wastewater enters the headworks where it passes through mechanical bar screens to remove large debris, rags, and plastics. Following screening, the flow enters aerated grit chambers. These chambers reduce the velocity of the influent, allowing inorganic solids (sand, gravel, coffee grounds) to settle while keeping organic matter in suspension. The removal of grit is critical to protecting downstream pumps and preventing accumulation in the digesters and aeration tanks.

B. Primary Treatment

The screened and degritted wastewater flows into rectangular primary clarifiers. Here, the velocity is further reduced to allow settleable solids to drop to the bottom as primary sludge, while oils and grease float to the surface for skimming. The primary treatment stage typically removes 50-60% of suspended solids and 30-40% of BOD, significantly reducing the organic load on the biological stage.

C. Secondary Treatment (Activated Sludge)

The biological treatment core consists of aeration basins utilizing a conventional activated sludge process. Microorganisms (mixed liquor) consume the remaining dissolved organic matter in the presence of oxygen.

• Aeration: Air is supplied via mechanical surface aerators or diffused air systems, maintaining dissolved oxygen levels required for aerobic respiration.
• Secondary Clarification: The mixed liquor flows into secondary clarifiers where the biological floc settles out. A portion of this settled sludge is returned to the aeration tanks (Return Activated Sludge – RAS) to maintain the biological population, while the excess is removed (Waste Activated Sludge – WAS).

D. Disinfection

The clarified effluent undergoes disinfection using sodium hypochlorite (liquid chlorine). The effluent passes through chlorine contact tanks designed to provide sufficient detention time for pathogen inactivation. Prior to discharge into the Atlantic Ocean, the effluent is monitored for chlorine residual to ensure it meets permit limits, though coastal discharge limits for residual chlorine are distinct from freshwater discharge requirements.

E. Solids Handling (Regional Integration)

The NWPCF acts as a feeder facility for OCUA’s regional biosolids strategy. Primary sludge and WAS generated at the Brick facility are thickened on-site (typically using gravity belt thickeners or dissolved air flotation) to reduce volume. The thickened sludge is then pumped via force main or trucked to the Central Water Pollution Control Facility (CWPCF) in Berkeley Township.

At the Central facility, sludge from the Northern, Central, and Southern plants is combined and processed through OCUA’s fertilizer manufacturing division. The sludge is anaerobically digested and then dried using thermal drying technology to produce “OceanGro,” a Class A EQ (Exceptional Quality) granular fertilizer sold commercially. This regional approach eliminates the need for incineration or landfilling at the Brick site.

F. Process Control

The plant utilizes a SCADA (Supervisory Control and Data Acquisition) system to monitor flows, tank levels, dissolved oxygen, and equipment status. This system allows for automated control of RAS/WAS rates and chemical dosing.

4. INFRASTRUCTURE & FACILITIES

A. Physical Plant

The site spans several acres in a mixed residential/commercial zone of Brick Township. The architecture is functional and industrial, featuring enclosed headworks and solids handling buildings to contain odors and noise. The facility includes administration offices, a process control laboratory, and maintenance garages.

B. Energy Systems

Energy efficiency is a key operational metric. The plant utilizes Variable Frequency Drives (VFDs) on major pumps and blowers to match energy consumption with biological demand. Following Superstorm Sandy, the facility received major upgrades to its backup power generation capabilities, ensuring 100% operational capacity during grid failures.

C. Odor Control

Given its proximity to residential neighborhoods, odor control is a top priority. The NWPCF employs chemical scrubbers (wet scrubbers using sodium hypochlorite and caustic soda) and activated carbon adsorption systems to treat foul air extracted from the headworks, primary clarifiers, and sludge thickening areas.

5. RECENT UPGRADES & MAJOR PROJECTS

Upcoming/Planning:
OCUA continues to invest in the rehabilitation of the interceptor system feeding the Northern plant. Projects in the Capital Improvement Plan (CIP) focus on relining aging concrete gravity mains in the Lakewood and Brick areas to reduce infiltration and prevent corrosion.

6. REGULATORY COMPLIANCE & ENVIRONMENTAL PERFORMANCE

The NWPCF operates under a New Jersey Pollutant Discharge Elimination System (NJPDES) permit regulated by the NJDEP.

• Effluent Limits: The permit focuses on CBOD5 (Carbonaceous Biochemical Oxygen Demand), TSS (Total Suspended Solids), pH, and Chlorine Produced Oxidants.
• Performance: The facility consistently meets the “85% Removal” requirement for BOD and TSS, often achieving removal rates exceeding 90-95%.
• Coastal Protection: Regular monitoring is conducted for Enterococcus and Fecal Coliform to protect bathing beaches. The plant has an excellent record of preventing beach closures related to wastewater discharge.
• Industrial Pretreatment: OCUA maintains a robust Industrial Pretreatment Program (IPP) to monitor discharges from industrial users in Lakewood and Brick, preventing toxic substances from entering the treatment plant.

7. CHALLENGES & FUTURE PLANNING

A. Infrastructure Aging

Like many facilities built in the 1970s, the Northern plant faces the challenge of aging concrete and mechanical systems. OCUA utilizes an aggressive asset management program to schedule replacements of clarifier mechanisms, pumps, and valves before failure occurs.

B. Resiliency and Climate Change

Located near the coast, the facility is vulnerable to storm surge and sea-level rise. Future planning prioritizes the hardening of pump stations throughout the service area and the protection of the treatment plant perimeter. Electrical equipment elevation and flood-proofing are standard requirements for all new capital projects.

C. Population Growth

The service area, particularly Lakewood Township, is experiencing rapid population growth. While the plant currently has hydraulic capacity, the organic loading (BOD load) is carefully monitored. Future master planning may involve process intensification strategies to handle increased biological loads without expanding the physical footprint of the aeration basins.

8. TECHNICAL SPECIFICATIONS SUMMARY

9. FAQ SECTION

Q1: Does the Northern Plant produce the OceanGro fertilizer on-site?
No. The Northern facility thickens the sludge, but it is transported to the Central Water Pollution Control Facility in Berkeley Township. The Central facility houses the fertilizer manufacturing division and thermal dryers that process solids from all three OCUA plants.

Q2: Where does the treated water go?
The treated effluent is pumped through a long ocean outfall pipe that extends approximately one mile into the Atlantic Ocean, where it is dispersed via a diffuser system to ensure minimal environmental impact.

Q3: How does the plant handle power outages during storms?
Following Superstorm Sandy, OCUA invested heavily in emergency power systems. The Northern facility is equipped with large-scale diesel backup generators capable of running the entire treatment process and essential pumping operations during grid failures.

Q4: Is the plant at capacity?
No. The plant is designed for 32 MGD and currently operates around 22-24 MGD. However, rapid growth in Lakewood and surrounding areas requires constant monitoring of capacity and infrastructure needs.

Q5: Does the Northern Plant remove Nitrogen and Phosphorus?
As an ocean discharger, the plant is primarily regulated for Carbonaceous BOD and TSS removal. It does not currently require the intense tertiary nutrient removal processes (like denitrification filters) that are mandated for plants discharging into confined freshwater bodies or estuaries, though it achieves incidental nutrient reduction through solids removal.

Q6: How are odors controlled at the site?
OCUA utilizes a combination of chemical wet scrubbers and activated carbon filters. Air is captured from odor-generating sources (like the headworks and thickening buildings) and forced through these treatment units before being released to the atmosphere.