Henrico County Water Reclamation Facility Richmond

FACILITY BASIC INFORMATION

Plant Name: Henrico County Water Reclamation Facility (WRF)

Location: 9101 WRF Road, Henrico, VA 23231

Operating Authority: Henrico County Department of Public Utilities (DPU)

Design Capacity: 75 MGD (Million Gallons per Day)

Current Average Flow: ~45-50 MGD

Population Served: ~340,000 residents

Service Area: Henrico County, portions of Goochland County, Hanover County, and the City of Richmond

Receiving Water Body: James River (Chesapeake Bay Watershed)

NPDES Permit Number: VA0063690

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Year Commissioned: 1989

TARGET AUDIENCE

• Municipal consulting engineers evaluating BNR (Biological Nutrient Removal) optimization.
• Wastewater treatment plant operators and DPU managers.
• Environmental regulators focusing on Chesapeake Bay TMDL compliance.
• Engineering firms pursuing regional infrastructure upgrades.
• University researchers in environmental engineering.

1. INTRODUCTION

The Henrico County Water Reclamation Facility (WRF) serves as the cornerstone of wastewater infrastructure for the greater Richmond metropolitan area’s northern and eastern suburbs. Commissioned in 1989 and operated by the Henrico County Department of Public Utilities, this advanced treatment facility is permitted for a design flow of 75 MGD, making it one of the largest and most technically sophisticated plants in the Commonwealth of Virginia.

Located roughly 10 miles southeast of downtown Richmond along the James River, the facility plays a pivotal role in the protection of the Chesapeake Bay watershed. Through a series of strategic capital improvements totaling over $150 million in the last two decades, the plant has evolved from a conventional secondary treatment plant into a high-performance nutrient removal facility. It consistently meets stringent Total Nitrogen (TN) and Total Phosphorus (TP) limits, exemplifying the successful application of Biological Nutrient Removal (BNR) and tertiary filtration technologies at scale.

2. FACILITY OVERVIEW

A. Service Area & Coverage

The Henrico WRF serves a rapidly growing suburban and semi-urban service area covering approximately 245 square miles. While the primary jurisdiction is Henrico County, inter-jurisdictional agreements allow the facility to accept flow from neighboring Goochland County, Hanover County, and specific sectors of the City of Richmond. The collection system feeding the WRF is extensive, comprising over 1,500 miles of sanitary sewer lines and more than 60 sewage pumping stations. The customer base is a mix of dense residential zones, commercial retail centers (Short Pump area), and light industrial facilities.

B. Operational Capacity

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The facility currently operates with a design hydraulic capacity of 75 MGD. Historical data indicates an average daily flow (ADF) ranging between 45 and 50 MGD, resulting in a capacity utilization of approximately 60-65%. This reserve capacity positions Henrico County favorably for projected regional growth over the next 10-15 years. The plant is designed to handle significant peak wet weather flows, utilizing equalization basins to manage hydraulic surges and prevent bypass events.

C. Discharge & Compliance

Treated effluent is discharged via a submerged multi-port diffuser into the James River, a major tributary of the Chesapeake Bay. Adherence to the Virginia Pollutant Discharge Elimination System (VPDES) permit (VA0063690) is strictly monitored. As a significant discharger within the Chesapeake Bay watershed, the facility operates under the General Virginia Pollutant Discharge Elimination System Watershed Permit Regulation for Total Nitrogen and Total Phosphorus Discharges and Nutrient Trading, requiring rigorous nutrient reduction strategies.

3. TREATMENT PROCESS

The Henrico WRF utilizes an advanced multi-stage treatment train designed specifically to maximize nutrient removal efficiency. The process flow moves from preliminary screening through advanced biological treatment and tertiary filtration.

A. PRELIMINARY TREATMENT

Raw influent enters the headworks where it passes through coarse and fine mechanical bar screens to remove large debris, rags, and plastics. Following screening, the flow enters vortex grit removal chambers. These systems utilize centrifugal force to separate heavy inorganic solids (sand, gravel, coffee grounds) from the organic liquid stream. This stage is critical for protecting downstream pumps and preventing volume loss in the digesters. The headworks is enclosed and ventilated through chemical scrubbers for odor control.

B. PRIMARY TREATMENT

Wastewater flows into large circular primary clarifiers. Here, the velocity of the water is reduced, allowing settleable organic solids to drop to the bottom as primary sludge, while grease and oils float to the surface for skimming. The primary treatment stage typically removes 30-40% of the Biochemical Oxygen Demand (BOD) and 50-60% of Total Suspended Solids (TSS), significantly reducing the organic load on the secondary biological stage.

C. SECONDARY TREATMENT (Biological Nutrient Removal)

The heart of the Henrico WRF is its Biological Nutrient Removal (BNR) system. The facility utilizes an activated sludge process configured for nitrogen and phosphorus removal (likely a variation of the VIP or MLE process).

• Anaerobic Zones: Promote the growth of Phosphorus Accumulating Organisms (PAOs) for biological phosphorus removal.
• Anoxic Zones: facilitate denitrification, where nitrate is converted to nitrogen gas.
• Aerobic Zones: Provided with oxygen via fine-bubble diffusion, enabling nitrification (ammonia conversion to nitrate) and BOD oxidation.

Following aeration, the mixed liquor flows to secondary clarifiers where the biological biomass separates from the treated water. A portion of the biomass is returned to the head of the aeration basins (RAS), while excess biomass is wasted (WAS) to solids handling.

D. TERTIARY TREATMENT

To meet the ultra-low nutrient limits required for the Chesapeake Bay, the facility employs deep bed gravity filters (sand/anthracite media). These filters polish the secondary effluent, removing remaining suspended solids and particulate phosphorus. The filters also serve as a denitrification site if an external carbon source (like methanol) is added, further reducing Total Nitrogen levels.

E. DISINFECTION

Historically a chlorination facility, the WRF was upgraded to Ultraviolet (UV) disinfection. The UV system inactivates pathogens by disrupting their DNA without introducing chemical byproducts into the James River. This transition eliminated the need for dechlorination chemicals (sulfur dioxide) and improved the safety profile of the site by removing bulk hazardous gas storage.

F. SOLIDS HANDLING

Solids processing is a major operational component:

• Thickening: Primary sludge is thickened via gravity, while waste activated sludge (WAS) is thickened using Dissolved Air Flotation (DAF) or rotary drum thickeners.
• Digestion: Thickened sludge undergoes anaerobic digestion. This process stabilizes the solids, reduces pathogen content, and generates biogas (methane).
• Dewatering: Digested biosolids are dewatered using high-speed centrifuges to produce a “cake” material.
• Disposal: The resulting Class B biosolids are typically hauled off-site for beneficial reuse via land application on permitted agricultural fields, recycling nutrients back into the soil.

G. PROCESS CONTROL

The entire facility is monitored via a centralized SCADA (Supervisory Control and Data Acquisition) system. Operators monitor dissolved oxygen levels, oxidation-reduction potential (ORP), and return rates in real-time to optimize the BNR process.

4. INFRASTRUCTURE & FACILITIES

A. Physical Plant

The WRF occupies a sprawling site off Kingsland Road. The campus includes the main operations center, a fully accredited environmental laboratory, maintenance shops, and the massive concrete tankage required for 75 MGD of treatment. The layout is designed with redundancy, allowing individual treatment trains to be taken offline for maintenance without compromising permit compliance.

B. Energy Systems & Cogeneration

The Henrico WRF is a leader in energy recovery. The facility utilizes a Cogeneration (Combined Heat and Power – CHP) system. Biogas produced in the anaerobic digesters is captured, scrubbed, and used to fuel internal combustion engines. These engines generate electricity to power plant equipment and produce heat, which is captured to maintain the temperature of the digesters. This circular energy loop significantly reduces the facility’s reliance on the electrical grid and lowers operational carbon footprints.

C. Odor Control

Given the proximity to developing residential areas, odor control is a priority. The facility utilizes multi-stage chemical scrubbers (wet scrubbers) and activated carbon filters at high-generation points, including the headworks, primary clarifiers, and sludge processing buildings.

5. RECENT UPGRADES & MAJOR PROJECTS

Henrico County maintains an aggressive Capital Improvement Program (CIP) to ensure asset reliability and regulatory compliance.

Nutrient Reduction Upgrades (Chesapeake Bay Program)

• Scope: Implementation of advanced BNR zones and tertiary filtration improvements.
• Driver: Compliance with the Chesapeake Bay TMDL requirements for Nitrogen and Phosphorus load reductions.
• Outcome: The facility successfully meets “State of the Art” nutrient limits, significantly reducing the algae-blooming nutrient load entering the James River.

UV Disinfection Conversion (2010s)

• Scope: Replacement of chlorine gas and sulfur dioxide systems with large-scale UV reactor banks.
• Investment: Multi-million dollar capital project.
• Benefit: Enhanced safety for operators and the surrounding community; elimination of chlorine residuals in the effluent.

Cobbs Creek Reservoir Infrastructure (Ongoing/Recent)

• Context: While primarily a water supply project, the Cobbs Creek Reservoir project involves significant pipeline and pumping infrastructure that integrates with the county’s overall water resource management strategy, ensuring long-term flow management stability.

Current/Upcoming Projects (2024-2027)

According to recent CIP documents, upcoming investments focus on:

• Solids Handling Rehabilitation: Upgrades to centrifuges and digester cleaning/rehabilitation.
• Aging Infrastructure Renewal: Replacement of electrical switchgear and aging mechanical pumps at the main lift station.
• SCADA Modernization: Implementation of AI-driven process control logic for energy optimization in aeration basins.

6. REGULATORY COMPLIANCE & ENVIRONMENTAL PERFORMANCE

A. Permit Requirements

The facility operates under VPDES Permit VA0063690. Key effluent parameters include:

• Total Nitrogen (TN): Annual average load limits (highly restrictive).
• Total Phosphorus (TP): Typically < 0.3 mg/L (monthly average).
• BOD5 & TSS: < 10 mg/L (monthly average) typical for this class of facility.
• E. coli: Strictly monitored for recreational water safety.

B. Compliance History

The Henrico WRF maintains an exemplary compliance record. It is a frequent recipient of the NACWA (National Association of Clean Water Agencies) Peak Performance Award, often achieving Gold or Platinum status, which signifies years of perfect compliance with NPDES permit limits. The facility has successfully avoided significant consent decrees through proactive planning and investment.

7. OPERATIONAL EXCELLENCE

Staffing: The facility is staffed 24/7/365. It employs a team of licensed wastewater operators (Class I through IV), industrial mechanics, instrumentation technicians, and laboratory analysts. The on-site laboratory is VELAP (Virginia Environmental Laboratory Accreditation Program) certified.

Technology: The DPU utilizes a sophisticated Asset Management Program to predict equipment failure and schedule preventative maintenance, transitioning from a reactive to a proactive maintenance culture.

8. CHALLENGES & FUTURE PLANNING

A. Current Challenges

• PFAS (Per- and Polyfluoroalkyl Substances): Like all US utilities, Henrico is preparing for upcoming EPA regulations regarding “forever chemicals” in both effluent and biosolids.
• Workforce Development: Addressing the “Silver Tsunami” of retiring senior operators and recruiting new technical talent.
• Wet Weather Flows: Managing Inflow and Infiltration (I&I) in the older parts of the collection system during extreme storm events.

B. Future Planning

The DPU’s master planning accounts for continued population growth in the Short Pump and eastern Henrico corridors. Future expansions may not necessarily increase hydraulic capacity (MGD) but will likely intensify treatment capability per gallon to meet future, stricter limits on emerging contaminants.

9. COMMUNITY & REGIONAL IMPACT

The Henrico WRF is an economic engine for the region. By providing reliable, high-capacity wastewater treatment, it enables commercial and industrial development. Furthermore, the facility’s commitment to the James River contributes to the regional tourism economy, supporting fishing, boating, and riverside recreation. The DPU actively engages with the community through educational outreach and transparency in water quality reporting.

10. TECHNICAL SPECIFICATIONS SUMMARY

11. RELATED FACILITIES

The WRF relies on a network of over 60 sewage pumping stations dispersed throughout the county. Major remote stations, such as the Strawberry Hill Pumping Station, are critical for conveying flow from the western, hillier terrain of the county to the treatment plant in the east. The facility operates independently of the City of Richmond’s WWTP, though the two systems are interconnected hydraulically in specific border zones to optimize regional flow management.

12. FAQ SECTION

Technical/Professional Questions

1. What is the design capacity of the Henrico WRF?
The facility has a permitted design capacity of 75 Million Gallons per Day (MGD).

2. Does the facility utilize chemical addition for phosphorus removal?
While the plant utilizes Biological Nutrient Removal (Bio-P), it maintains the capability for chemical polishing (typically using alum or ferric salts) to ensure compliance with extremely low Chesapeake Bay phosphorus limits.

3. How are biosolids managed at the facility?
Solids are anaerobically digested and dewatered via centrifuges. The resulting Class B biosolids are beneficially reused through land application on agricultural sites.

4. Is the facility equipped for energy recovery?
Yes, the facility employs a Cogeneration system that captures methane from the anaerobic digesters to generate electricity and heat for plant operations.

Public Interest Questions

5. Does the plant smell?
The facility employs advanced odor control technologies, including chemical scrubbers and carbon filters, to treat air from the headworks and solids handling areas, minimizing impact on neighbors.

6. Is the water released into the James River clean?
Yes. The effluent is treated to near-drinking water standards regarding clarity and pathogen reduction. It meets strict environmental standards designed to protect aquatic life in the James River.

7. How many people are served by this facility?
The facility serves a population of approximately 340,000 residents across Henrico County and surrounding jurisdictions.

Disclaimer: This article is for informational purposes for engineering and industry professionals. Specific operational data may vary based on daily conditions and recent facility modifications. For official regulatory data, please consult the Virginia Department of Environmental Quality (DEQ) or Henrico County DPU.