DEMINERALIZED WATER LOOP CLOSURE IN PVC PROCESS TOWARDS WASTE WATER RECYCLING FOR POLYMERIZATION PURPOSES

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1 DEMINERALIZED WATER LOOP CLOSURE IN PVC PROCESS TOWARDS WASTE WATER RECYCLING FOR POLYMERIZATION PURPOSES 1 This project has received funding from the European Union s Seventh Programme for research, technological development and demonstration under grant agreement No

2 UNSUSTAINABLE WORLD TODAY S ECONOMICAL GROWTH MEANS ENERGY IRRATIONAL CONSUMPTION UNCONTROLLED WASTE GENERATION ABUSIVE WATER USE 2

3 LOCATION OF INOVYN ESPAÑA 3 Martorell, Barcelona Production of PVC since 1972 (former SOLVIN)

4 WATER AS RAW MATERIAL ETHYLENE VINYL CHLORIDE THERMIC ENERGY PVC WATER Na(OH) SODIUM HYPOCHLORITE SALT RECOVERED FROM SURIA HYDROCHLORIC ACID 4 ELECTRIC POWER HYDROGEN

5 GOAL AT INOVYN ESPAÑA SIGNIFICANT WATER USE REDUCTION 75m 3 /h GROUND INTAKE CURRENT WATER INTAKE 230m 3 /h E4Water: 25m 3 /h CURRENT PVC PROCESS 100m 3 /h OTHER SITE PROCESSES 130m 3 /h SEA DISCHARGE 5 UP TO 657,000m 3 /y OF WATER INTAKE REDUCTION

6 CURRENT LAYOUT & FUTURE E4Water Monomer Additives Demin. water Recycled water Dryer PVC resins Autoclave Stripping Centrifuge PCT MBR+RO Reclaimed water to process Wastewater (RO) 6 Waste biosludge (MBR)

7 7 RECYCLED WATER REQUIREMENTS RECYCLED WATER MUST ACHIEVE DEMINERALIZED GRADE Poly-vinyl alcohol < 1 mgl -1 N-NH 4 + < 2 mgl -1 BOD 5 ~0 Conductivity < 10 μscm -1 Al < 0.1 mgl -1 TOC < 10 mgl -1

8 CHALLENGES AND INNOVATION BIOLOGICAL DEGRADATION IN MBR OF POLY-VINYL ALCOHOL NEVER TESTED WITH PVC WASTE WATER WASTE WATER NEVER USED BEFORE TO PRODUCE DEMINERALIZED WATER IN PVC INDSUTRY UNCERTAINTY USING THIS DEMINERALIZED WATER AT POLYMERIZATION STAGE 8

9 OBJECTIVES 1 Demonstrate water close-up technical feasibility 2 Water must be used in PVC polymerization 3 Economical feasibility study. Drivers for implementation 4 Modelling for optimization & LCA-LCC studies 9

10 LAB TEST TO SELECT PILOT TECHNOLOGY CHOSEN PILOTING TECHNOLOGIES MBR JUSTIFICATION SHOWN OPTIMAL BIOLOGICAL DEGRADATION REDUCED SPACE & MODULAR COST EFFECTIVE RO RO LESS ELECTRICITY CONSUMPTION (1 st UNSUSTAINABILITY) WIDE WORKING RANGE 10

11 PILOT TEST 1m 3 /h OF WATER TREATMENT 1year PILOTING TESTED AEROBIC/ANOXIC CONDITIONS TESTED DIFFERENT R.O. YIELDS 11 SUCCESSFULLY ACHIEVED WATER QUALITY GOALS

12 PILOT TEST 100 GRAPHICAL RESULTS 180 removal, % %COD removal % PVA removal % BOD removal PVA in feed PVA, mgl time, days 12

13 ARRANGEMENT FOR FULL SCALE-UP MBR Sludge adaptation period 2 to 4 weeks Phosphorus must be added HRT 6h MLSS range 8-10g/l Flux range LMH R=6 RO Two pass Two stages per pass Antiscalant dosage Biofouling control by biocide Working TºC < 30ºC Recovery range 60-75% 13

14 POLYMERIZATION TRIALS PVC SHOWN NO DIFFERENCE BETWEEN USING FRESH OR RECYCLED DEMINERALIZED WATER FRESH RECYCLED 14 14

15 POLYMERIZATION TRIALS K-58 PVC GRADE Demin water #1 Demin water #2 MBR RO water #1 K value 58,4 58,3 57,9 58,4 Bulk density g/ml 0,527 0,535 0,531 0,534 D50 µm Span 0,74 0,66 0,72 0,73 WI 70,2 71,5 71,7 70,9 b* 4,34 4,30 3,93 4,34 CAP 15min % 87,9 91,0 88,1 93,1 Porosity % 20,6 20,1 20,5 20,2 MBR RO water #2 15

16 PRE-BASIC DESIGN 16

17 BUDGET ESTIMATE IF 1.9M FOR 50m 3 /h TREATMENT 2.5M FOR 100m 3 /h TREATMENT Treated flowrate above 50m 3 /h Fresh demin. water above 1,25 /m 3 15 years depreciation FEASIBLE OR Drought forces above 3% PVC production reduction 17 Return < 1 year INOVYN FEASIBLE

18 STRATEGY 18 STRONGER POSITION FACING DROUGHTS AS PRODUCTION LOSS IS AVOIDED Production restriction without E4Water (%) Investment recovery with E4Water (months)

19 SITE MODELING AND LCA FULLY FUNCTIONAL MODEL DONE (TUB) & LCA (IVL) 19

20 PROJECT REPLICATION The MBR lab scale confirms the results obtained by the previous test performed by VITO (flat sheet IPC) and UCM with the Zeeweed membrane, and demonstrates the feasibility of the application of this technology to the range of PVC-S wastewaters at Solvay. 20

21 PROJECT REPLICATION PVC effluent family S-PVC (INOVYN) S-PVC + fillers S-PVC +fillers +copo PVC plants all European Solvay/inovyn plants PVC effluent one wastewater treatment route 21

22 QUESTIONS Water is the driving force of all nature. Leonardo da Vinci 22