Hampton Roads Sanitation District Boat Harbor Treatment Plant Newport News

FACILITY BASIC INFORMATION

1. INTRODUCTION

The Boat Harbor Treatment Plant (BHTP) serves as a critical node in the Hampton Roads Sanitation District’s (HRSD) regional interceptor system. Located in the industrial heart of Newport News, Virginia, adjacent to the expanding coal terminals, this 25-MGD facility provides essential wastewater treatment for the heavily populated Peninsula region. Originally commissioned in 1948 as a primary treatment facility, BHTP has undergone significant evolution to meet the stringent nutrient reduction goals of the Chesapeake Bay Preservation Act.

Operated by HRSD, a political subdivision of the Commonwealth of Virginia, the plant utilizes the proprietary Virginia Initiative Plant (VIP) process—a biological nutrient removal technology developed in-house by HRSD engineers that has since been adopted globally. As the utility moves toward the implementation of the Sustainable Water Initiative for Tomorrow (SWIFT), the Boat Harbor facility stands as a testament to the district’s balance of robust legacy infrastructure with cutting-edge environmental stewardship.

2. FACILITY OVERVIEW

A. Service Area & Coverage

The Boat Harbor Treatment Plant services a highly urbanized and industrial catchment area encompassing significant portions of the City of Newport News and the City of Hampton. The collection system feeding BHTP is unique; HRSD operates as a wholesale utility, accepting flow from municipal collection systems into its large-diameter regional interceptors. The service area is characterized by a mix of residential zones, commercial corridors, and heavy industrial facilities, including shipyards and port infrastructure.

B. Operational Capacity

The facility is rated for a hydraulic design capacity of 25.0 million gallons per day (MGD) with a peak hydraulic capacity reaching approximately 50 MGD to handle wet weather events. Currently, the plant processes an average daily flow of approximately 16 MGD, providing sufficient buffer capacity for regional growth. The plant is designed to handle significant diurnal variations typical of urban service areas.

C. Discharge & Compliance

Treated effluent is discharged into the Lower James River via a submerged outfall. Because the James River is a tributary to the Chesapeake Bay, the facility operates under strict National Pollutant Discharge Elimination System (NPDES) limits regarding Total Nitrogen (TN) and Total Phosphorus (TP). The plant consistently achieves high compliance rates, operating well within the limits established by the Virginia Department of Environmental Quality (DEQ) to combat eutrophication in the estuary.

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3. TREATMENT PROCESS

The Boat Harbor Treatment Plant employs a sophisticated treatment train designed to maximize biological nutrient removal (BNR) within a compact physical footprint.

A. Preliminary Treatment

Raw wastewater enters the headworks where it undergoes aggressive physical separation.

• Screening: Mechanical bar screens remove rags, plastics, and large debris to protect downstream pumps.
• Grit Removal: Vortex grit chambers utilize centrifugal force to separate inorganic solids (sand, gravel, coffee grounds) from the organic waste stream.
• Odor Control: Given the plant’s proximity to commercial zones, the headworks is enclosed and ventilated through chemical scrubbers (typically wet scrubbers utilizing caustic and hypochlorite) to mitigate hydrogen sulfide (H₂S) emissions.

B. Primary Treatment

Flow proceeds to primary clarifiers where gravity sedimentation removes approximately 60% of Total Suspended Solids (TSS) and 30-40% of Biochemical Oxygen Demand (BOD). Primary sludge is collected via bottom scrapers and pumped to the solids handling complex. The primary effluent flows to the biological reactors, carrying soluble BOD necessary for the downstream biological processes.

C. Secondary Treatment (The VIP Process)

The core of the BHTP is the high-rate activated sludge system utilizing the Virginia Initiative Plant (VIP) process. Developed by HRSD, this process is specifically configured for high-efficiency Biological Nutrient Removal (BNR).

• Anaerobic Zone: Promotes the growth of Phosphorus Accumulating Organisms (PAOs) to facilitate biological phosphorus removal.
• Anoxic Zone: Facilitates denitrification, where nitrates recycled from the aerobic zone are converted into nitrogen gas.
• Aerobic Zone: Provides dissolved oxygen for nitrification (ammonia to nitrate conversion) and BOD oxidation.

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• Clarification: The mixed liquor enters secondary clarifiers where biological floc settles out. A portion is returned as Return Activated Sludge (RAS) to the anaerobic zone, while the excess biomass is removed as Waste Activated Sludge (WAS).

D. Disinfection

Following secondary clarification, the effluent requires disinfection to neutralize pathogens. BHTP historically utilizes chlorination (using sodium hypochlorite) in contact tanks to achieve necessary kill rates for fecal coliform and E. coli. Prior to discharge, the water undergoes dechlorination (typically using sodium bisulfite) to remove residual chlorine, preventing toxicity to aquatic life in the James River.

E. Solids Handling

HRSD operates a regionalized solids handling approach. At Boat Harbor:

• Thickening: Primary sludge and WAS are thickened, often using Gravity Belt Thickeners (GBT) or centrifuges to reduce water volume.
• Regional Processing: Thickened sludge is typically pumped via force mains to HRSD’s larger solids processing hubs (such as the Atlantic Treatment Plant in Virginia Beach) where it undergoes high-temperature incineration or processing into Class A “Nutri-Green” biosolids fertilizer. This regional integration reduces the need for digesters and dewatering equipment at every individual site.

F. Process Control

The facility is managed via a comprehensive SCADA (Supervisory Control and Data Acquisition) system. This allows operators to monitor dissolved oxygen levels, oxidation-reduction potential (ORP), and pump statuses in real-time. Automated samplers provide composite samples for on-site and regional laboratory analysis.

4. INFRASTRUCTURE & FACILITIES

A. Physical Plant

The Boat Harbor site is compact, constrained by the James River and adjacent industrial properties. The architecture is utilitarian, designed to withstand the corrosive coastal environment. The site includes the main process buildings, a dedicated administration building, maintenance workshops, and chemical storage facilities.

B. Energy Systems

Wastewater treatment is energy-intensive. BHTP relies on grid power but employs Variable Frequency Drives (VFDs) on major pumps and aeration blowers to optimize energy consumption. By matching motor speed to actual process demand, the facility significantly reduces kilowatt-hour consumption compared to constant-speed systems.

C. Odor Control Infrastructure

Odor control is a paramount operational priority. The plant utilizes dual-stage chemical scrubbers and/or biological scrubbers to treat foul air extracted from the headworks and primary treatment areas. This infrastructure is critical for maintaining good relations with the neighboring business districts and residential communities in Newport News.

5. RECENT UPGRADES & MAJOR PROJECTS

HRSD maintains an aggressive Capital Improvement Plan (CIP) to ensure asset reliability and regulatory compliance.

Boat Harbor Primary Clarifier & Grit Removal Improvements (2018-2021)

• Scope: Rehabilitation of primary clarifiers and replacement of aging grit removal mechanisms. The project included concrete repair, coating systems, and the installation of modern, more efficient drive mechanisms.
• Budget: Approx. $15 Million
• Drivers: Aging infrastructure (asset management) and process efficiency.
• Outcome: Extended service life of critical primary treatment assets and improved TSS capture upstream of the biological reactors.

Nutrient Reduction Improvements (Ongoing)

• Scope: Optimization of the VIP process controls and aeration systems to meet tightening Total Nitrogen and Phosphorus limits under the Chesapeake Bay TMDL.
• Technical Highlights: Implementation of advanced aeration control strategies to minimize energy use while maximizing nitrification/denitrification performance.

Future: SWIFT Integration

While the initial SWIFT (Sustainable Water Initiative for Tomorrow) Research Center was built at the Nansemond Treatment Plant, HRSD’s long-term vision includes expanding SWIFT capabilities across the region. Boat Harbor is strategically located for potential future integration into the water reuse network, which would involve adding advanced treatment steps (Ozone, GAC) to treat effluent to drinking water standards for aquifer recharge.

6. REGULATORY COMPLIANCE

A. Permit Requirements

Operating under NPDES Permit VA0081256, the facility adheres to strict effluent limits. Key parameters include:

• CBOD5: Monthly average limits typically ≤ 20 mg/L.
• TSS: Monthly average limits typically ≤ 20 mg/L.
• Nutrients: Annual waste load allocations for Total Nitrogen and Total Phosphorus in accordance with the Virginia Watershed General Permit.
• Bacteria: Enterococci limits to ensure swimmable waters in the receiving body.

B. Compliance History

HRSD is widely recognized for operational excellence. The Boat Harbor Treatment Plant consistently receives Peak Performance Awards from the National Association of Clean Water Agencies (NACWA), often achieving Gold or Platinum status for consecutive years of 100% permit compliance.

7. OPERATIONAL EXCELLENCE

Staffing: The facility is staffed by Virginia licensed wastewater operators (Class I through IV). HRSD invests heavily in an apprenticeship program, ensuring a continuous pipeline of skilled technical talent.

Technology: The plant utilizes online instrumentation for continuous monitoring of nutrients (ammonia and nitrate analyzers) within the basins. This data feeds into the SCADA system, allowing for automated adjustment of internal recycle rates and aeration intensity, a hallmark of modern BNR operation.

8. CHALLENGES & FUTURE PLANNING

A. Climate Resilience

Located on the waterfront in Hampton Roads, BHTP is vulnerable to sea-level rise and storm surge. Future planning focuses heavily on hardening infrastructure, elevating critical electrical switchgear, and ensuring pump stations can operate during extreme weather events.

B. Infrastructure Aging

With original components dating back to the late 1940s, the battle against corrosion and structural fatigue is constant. HRSD’s asset management program prioritizes the rehabilitation of concrete structures and the replacement of sub-surface piping.

C. Emerging Contaminants

As with all modern wastewater facilities, BHTP is monitoring regulatory discussions regarding PFAS (Per- and polyfluoroalkyl substances). While current regulations focus on monitoring, future capital projects may require technologies capable of sequestering these “forever chemicals.”

9. TECHNICAL SPECIFICATIONS SUMMARY

10. RELATED FACILITIES

The Boat Harbor plant does not operate in isolation. It is part of the integrated HRSD network:

• Nansemond Treatment Plant: Located across the harbor, home to the SWIFT Research Center.
• Atlantic Treatment Plant: The regional hub for solids processing and incineration.
• Interceptor System: A vast network of pump stations and force mains that allows HRSD to divert flow between plants during maintenance or emergencies.

11. FAQ

Technical/Professional Questions

Q: What is the specific BNR configuration used at Boat Harbor?
A: Boat Harbor utilizes the Virginia Initiative Plant (VIP) process, a high-rate activated sludge configuration designed to optimize biological phosphorus removal and denitrification.

Q: Does the plant have on-site solids incineration?
A: No. Boat Harbor typically thickens solids on-site and transports them via the interceptor system to HRSD’s regional processing facilities (like the Atlantic Treatment Plant) for incineration or pellet production.

Q: Is the plant equipped for SWIFT (Advanced Water Treatment)?
A: Currently, Boat Harbor is a conventional advanced secondary plant. However, HRSD’s long-term plan includes the eventual implementation of SWIFT technology at multiple facilities to recharge the Potomac Aquifer.

Public Interest Questions

Q: How does the plant control odors?
A: The plant uses enclosed headworks and chemical/biological scrubbers to treat foul air before it is released, minimizing impact on the surrounding Newport News community.

Q: Can the public tour the facility?
A: HRSD offers tours for educational groups and the public, though they must be scheduled in advance. Interested parties should contact HRSD’s communications department.

Q: Where does the water go after treatment?
A: The treated, clean effluent is discharged via a submerged outfall into the James River, where it rejoins the water cycle.