The thermo-reductive RecoPhos Process

Transcription

1 The thermo-reductive RecoPhos Process From Sewage Sludge Ashes to elementary Phosphorus for industrial Applications Dr. Daniel Steppich SGL GROUP The Carbon Company RecoPhos Demonstration Event Leoben, February 24 th 2015 Contact: D Meitingen

2 RecoPhos - Project Company profile: One of the world s largest manufacturers of carbon-based products Comprehensive portfolio ranging from carbon and graphite products to carbon fibers and composites 43 production sites worldwide Sales of ~ 1.5 bn in 2013 Head office in Wiesbaden/ Germany ~ 6,300 employees worldwide Stock listed in Germany Service network covering more than 100 countries 2

3 Outline Sewage Sludge Treatment Production of elementary Phosphorus Thermal Phosphorus Market Overview 3

4 Sewage Sludge Treatment Europe Sewage sludge production (~10 Mio mt DM per year) Sewage sludge disposal routes Netherlands 4% Rest 21% Germany 19% Landfill 10% Others 14% Poland 6% Italy 10% France 11% Spain 12% United Kingdom 17% Incineration 23% Agriculture 53% Significant share of thermal treatment in Germany Mono-incineration prerequisite for P recovery Germany has the biggest market place in Europe 4 References: Brandt, Masterarbeit Nutzung von Klärschlamm als Rohstoffquelle, Universität Rostock, 2011 Eurostat, 2011

5 Sewage Sludge Treatment Germany Sewage sludge(germany): ~1.85 Mio mt DM/a 55% 29% 13% 3%: Others Thermal Treatment Direct use in agriculture Landscaping ~ 1,0 Mio mt DM/a ~ mt TM/a ~ mt TM/a 77% 23% Mono-Incineration: ~ mt DM/a* SSA: ~ mt P in SSA: ~ mt P/a Co-Incineration * Maximum mono-incineration capacity(2011): ~ mt DM/a 5 References: Krüger, Monitoring von Klärschlammmonoverbrennungsaschen hinsichtlich ihrer Zusammensetzung zur Ermittlung ihrer Rohstoffrückgewinnungspotentiale und zur Erstellung von Referenzmaterial für die Überwachungsanalytik, Texte 49/2014, Umweltforschungsplan des Bundesministeriums für Umwelt, Naturschutz, Bau und Reaktorsicherheit Statistisches Bundesamt, Pressemitteilung Nr. 421 vom :

6 Outline Sewage Sludge Treatment Production of elementary Phosphorus Thermal Phosphorus Market Overview 6

7 Production of elementary P Woehler- Process Reference: Lecture Schlammbehandlung / Prof. Thomanetz, University of Stuttgart 7 After termination of Thermphosin 2012 there is no European producer of elementary phosphorus.

8 Production of elementary P RecoPhos - Process 8

9 Production of elementary P Comparison Woehler process High CAPEX, maintenance costs -> needs high throughput to be economical RecoPhos Process Simple design, easier maintenance, smaller scale possible Pelletizing/ sintering of raw material required (including binder) No pelletizing/ sintering Woehlerprocess cannot accommodate with high content of SSA (P-loss to Fe x P) Only SSA from Al-precipitation Energy efficient heating due to furnace design (>95%) By-products: Construction material RecoPhos can run entirely on SSA; SSA from Al-precipitation possible Energy demand comparable to Woehler process; slightly higher heat losses in product gas stream RecoPhos slag to be used in cement or concrete industry 9

10 Production of elementary P Energy Consumption(calculated*) System Efficiency induction system ~ 0.9 heat demand /power input ~ 0.8 Process P recovery efficiency (60 90%) Input Materials P-content (6-13%), Additives (~12% C, slag tuner), Ferich/ Al-rich ash, 10 Energy requirement per unit P produc ced [kwh/kg P] Power input* P recovery rate Additives Scenario 1 600kW 70% 120kg/h Scenario 2 600kW 85% 120kg/h Scenario 3 600kW 85% 60kg/h * effective power + losses Scenario 4 400kW 85% 60kg/h Hot feed to InduCarb reactor Calculated for a reactor comprising a throughput of ~500kg sewage sludge ash per hour; P conc ~ 8%; Fe conc. ~11%

11 Outline Sewage Sludge Treatment Production of elementary Phosphorus Thermal Phosphorus Market Overview 11

12 Thermal Phosphorus Market Overview Value Chain Raw material End product Rock phosphate therm. (~5%) P 4 Sulfides Oxides Chlorides Therm. H 3 PO 4 True derivates Food, techn. applications wetchem. (~95%) MGA PWA Fertilizer Fertilizer, feed additives 12 MGA: Merchant Grade Phosphoric Acid PWA: Purified Wet Acid

13 Thermal Phosphorus Market Overview Value chain - RecoPhos Raw material End product Sewage sludge ash* therm. P 4 Sulfides Oxides Chlorides Therm. H 3 PO 4 True derivates Food, techn. applications From sewage sludge ash to elementary P as raw material for industrial applications! 13 * ~ t/a in Germany

14 Thermal Phosphorus Market Overview White Phosphorus Product Tree Further applications of elementary phosphorus include (but are not limited to) flame retardants, additives in chlorinating, batteries, herbicides, pesticides, catalysts, chemical synthesis, disinfection, plastic production, reduction, pyrotechnics, bleaching, lubricants, corrosion protection, water treatment, doping, matches, etc. 14 References: Gantner, Schipper, Weigald, Technological use of phosphorus: the non-fertilizer, non-feed and non-detergent domain, Appendix 8, in: Sustainable Phosphorus Management: A Global Transdisciplinary Roadmap (Scholz et. al.), 2014

15 Thermal Phosphorus Market Overview Annual production of elementary P ~ mt /a Phosphorus pentasulphide 5% Sodium Red phosphorus hypophosphite 1% 2% Phosphorus trichloride 18% Other applications 4% Thermal phosphoric acid 70% China, US, Kazakhstan and Vietnam cover most of the world production. EU market for thermal phosphorus ~ mt/a P production of a typical submerged arc furnace ~25.000mt/a 15 References:

16 Summary Germany largest producer of sewage sludge ashes in Europe Sewage sludge ash as the main input material for the thermo-reductive RecoPhos process Production of elementary phosphorus for applications outside the fertilizer industry All process by-products are economically valuable 16

17 Thanks a lot!!! Contact Dr. Daniel Steppich Meitingen, Germany Tel.: