From discussion to implementation

Transcription

1 From discussion to implementation P recovery from sewage sludge/ash Dr. Christian Kabbe Isle Utilities 3rd EUROPEAN NUTRIENT ECOMONDO November 2018, Rimini, Italy

2 TOGETHER WE ARE Sewage REVOLUTIONISNG (sludge) is a THE WAY renewable EMERGING nutrient TECHNOLOGIES resource AND still SUSTAINALE waiting to SOLUTIONS be tapped to ARE it s full COMMERCIALISED potential in a sustainable way 20/11/2018 isleutilities.com

3 Intro Germany and future sewage sludge management 2017 the year of change and shortage Stricter requirements (nutrient load limitations, shorter time windows for land application, more monitoring efforts) Lack of both, land and incineration capacities Regional cost explosion for sludge disposal Collateral impacts on Germany s neighbours Utilities start reacting on future proof concepts

4 Pillars of Nutrient Recovery & Recycling in Germany Dewatered sludge / Biosolids N & P recovery from aqueous phase P recovery from solid phase / ashes ~34% ~66% food fertiliser / agriculture us sewage nutrients WWTP sewage sludge Challenge: Enabling techn. alternatives to complement /compensate traditional route!

5 Sewage Sludge - Destinations in Europe - Diversity Percentage of sludge use/disposal route 100% 90% 80% 70% 60% 50% 40% 30% Other Storage Landfill Incineration Landscaping Green Areas Forestry Agriculture 20% 10% 0% AT BE BG CH CY CZ DE DK EE ES FI FR GR HU IE IT LT LU LV MT NL NO PL PT RO SE SI SK UK European Country Sources: EurEau 2016, EUROSTAT 2016, DESTATIS 2016, BAFU 2016 Total sludge quantity covered: appr. 10 million tons of dry solids per year!

6 Germany 2017+: a template to adapt, but not just to copy as is 2017 new fertilising ordinance (DÜV) limits nutrient loads applied to land and acutely reduces sludge disposal capacities -> cost explosion! new fertiliser ordinance (DÜMV) sets stricter quality criteria (less sludge conform) monitoring cost 2017 new sewage sludge ordinance (AbfKlärV) enters into force 2023 all WWTP have to submit sludge management concepts considering P recovery 2029 P recovery oblig. for all WWTP above 100,000 p.e. (ban from land application) 2032 P recovery oblig. for all WWTP > 50,000 p.e. o Even smaller WWTP have to recover P, if no land application possible o On-site WWTP: P recovery to deplete below 20 g P/kg DM or at least by 50% o After thermal-pretreatment recoverable separate storage of ash/concentrate or recovery process with >80% recovery rate o o o o What is missing? No marketable recycling concepts included No measure to secure proper ash quality (all sludge can be inc. in mono-inc.) Reverence value for P should refer to mineral sludge phase, not to DS Who pays for what? (Inc. and recovery from ash monopoly?)

7 Sewage Sludge - Destinations in Germany 2016 and 2030 YEAR Estimated trend for future disposal routes by 2030 Other Agriculture and landscaping Co-incineratioon Mono-incineration % 10% 10% 78% % 26% 34% 38% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% SHARE OF SLUDGE DISPOSAL ROUTE Total municipal sludge quantity: 1.77 million tons of dry solids per year!

8 Hotspots for P recovery & Recycling for WWTP > p.e. grit chamber primary clarification aeration secondary clarification influent effluent 2029/32+ Land appl. prohibited Co-incineration only for sludge with < 2%P Mono-incineration allowed without restriction, but P recovery from ash afterwards required thickening waste activated sludge P re-dissolving pre-treatment agriculture 2c process water biogas dewatering 2b 1 2a 3 Priority for utilities: Long term disposal security Cost control Lowest financial risk anaerobic digestion Integrated in WWTP Site by Site incineration Downstream WWTP Clusters

9 Global implementation without law enforcement just to recover as such? More than 100 full-scale plants operational world-wide! > 80 recover (> 60 are municipal)

10 Amended from P-REX and Kraus Availability of Solutions? Yes! there are Where? Re-dissolution modules Recovery modules Integrated recovery at WWTP Without enforced re-diss. Poly-phosphate re-diss. prior digestion Thermal hydrolysis Chemical re-dissolution Wasstrip Acidogen. Lysotherm Pondus Stuttgart Multiwas + Phosforce, CalPrex TDH EXTRAPHOS Crystallizatio n in sludge matrix Crystallizatio n in sludge liquor or adsorption at CSH after dewatering AirPrex EloPhos Pearl Phosphogreen STRUVIA /DCP Rephosmaster STRUVEX Phosnix AD-HAP HAP CalPrex DCP Down-stream recovery from sewage sludge Pre-treatment Sewage sludge monoincineration Thermal alternatives Chemically Thermal P recovery & recycling Conv. Fertiliser Manufact. SSP/TSP/NP/NPK/PK Glatt SERAPLANT NPK METAWATER HAP AshDec, EuPhoRe Mineral Phosphates RecoPhos (InduCarb) P 4 EcoRin P-rich slag Ash2Phos & CleanMAP DCP, MAP, SSP, EcoPhos and TetraPhos tech. grade H 3 PO 4 Solvent Extraction tech. grade H 3 PO 4 Thermphos P 4 Mephrec P-rich slag KUBOTA P-rich slag Direct application Agriculture Landscaping Full-scale Demo/Pilot

11 Source: amended from Kraus 2016 Nutrient Recovery Cascades for P & N + Energy are state of the art! Primary Sludge Biogas to CHP Dewatered Sludge Digestion Dewatering Waste Activated Sludge Digestion Thermal hydrolysis Predewatering Drivers are: Operational needs/reduced maintenance Return Load H 2 SO 4 or HNO 3 NaOH N recovery DAS or AN MgCl 2 Crystallization Benefits like reduced sludge volume for disposal -> reduced cost Synergies with energy recovery Improved overall WWTP performance to meet stricter P consents

12 Challenges and keys to Success and Sustainability? Only technologies, yielding homogenous products or raw materials, independent from input material quality and mutually meeting both criteria, energy efficiency and resource efficiency will have a chance for wide-spread application under sustainability aspects. Keys: Heavy metal depletion (high quality products) Moderate energy (and chemicals) consumption (cost) Market for known recovered P (commercial products) (real value and price) Kabbe 2017

13 Germany substantial increase of mono-incineration Currently appr. 668 kt DS mono-incineration capacity 2017 (municipal sludge) After 2029/32 at least Mg DS capacity needed to comply with sludge reg (Ecoprog 2017) likely more Most new capacities between 2022 and 2027 (already +600 kt DS in prep. announced) -> future SSA quantity > Mg/a (> Mg P/a) Outotec

14 No Recycling without Value Chains Commodities Recovery End-of-Waste border line Recycling Other industries Household, industry WWTP Raw material Fertiliser Fertiliser Agriculture Supply Cost? Profits? Demand Waste, raw material or product? -> Question of volume, homogenity and still of origin! Sludge organic fertiliser NP fertiliser with proven good fert. eff., very interesting for organic farming DCP approved P fertiliser (component) Ash generally barely plant available, rather raw material processing needed MAP/DAP main N&P components in fertiliser production (commodities) MGP / P 4 commercial products with broad application (commodities) (Biochar) actually Pyrochar! No fertiliser!

15 TOGETHER Wisdom just WE written ARE REVOLUTIONISNG on paper will THE WAY EMERGING be dust TECHNOLOGIES one day; Only AND the wisdom SUSTAINALE applied SOLUTIONS will shape ARE COMMERCIALISED our future! 20/11/2018 isleutilities.com

16 Wrap-up & Outlook Shortage in legal sludge disposal capacities will remain until mid-to end-2020-ies Manure is key competitor for land application and farmers first choice! New German legislation fosters sludge mono-incineration and therefore drying as well -> co-incineration capacities declining as capacities for imported sludge German sludge first, imported sludge not even second! Disposal cost already did and will raise substantially! Re-normalization not before 2030 expected! Site-by-site P recovery on-site WWTP needs to be linked with operational needs and benefits and will play a limited complementary role Ash-based route will become the major route for P recovery from sewage in Germany (> Mg SSA, > Mg P) -> lowest risk for invest. and sludge disposal route Known materials easier to integrate in market! Recyclates need to fit into existing markets, not the other way around!

17 Thank you ISLE UTILITIES Germany Rudower Chaussee Berlin, Germany ISLE UTILITIES Italy Via Branze Brescia, Italy Bringing Technologies to Life