Water Industry in 2050 Water companies vision on challenges and technological needs

Transcription

1 Water Industry in 2050 Water companies vision on challenges and technological needs Sylvie Baig Marielle Coste Workshop 3 Brussels, September

2 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 2

3 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 3

4 Water cycle in industry Inlet Drinking water Ground water Surface water Storm water Desalinated sea water Urban WW Uses Cooling water Boiling water Process water Ultrapure water Recycling, Re use Outlet Urban WWTP On site WWTP (primary, secondary and tertiary treatment) 4

5 Water is of prime importance for industry Water in industry Water is used as utility in non strategic processes: cooling, steam generation, sanitation, fire network Water is essential upstream of manufacturing/extraction process: material transport and washing Water has many uses in the manufacturing/extraction process itself (solvent, raw material, equipment cleaning ). In this last application, criteria for water quality depend directly from the industrial process and are production specific. Water is a highly valuable asset Water related cost can reach up to 25% of the production cost Access to water is key element for production sustainability Sustainable development Meeting the needs of the present without compromising the ability of future generations to meet their own needs Hanover Principles Expo 2000, World Commission on Environment Industries wants Environmental Performance Industry creates more pressure on water resources from the impacts of wastewater discharges and their pollution potential than by the quantity used in production. Industries adopt environmental performance indicators setting targets on reduction of water consumption and pollution emissions due to shareholders and market pressure Rising communication standards bring environmental performance at corporate level In wide Europe (44 countries), around companies had ISO certificates in

6 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 6

7 Integrated water management Raw materials Resources Eco industrial approach Barriers and incentives Energy Water Industry plant Reduce Reuse Recycle Policies & Regulations Economics Technologies Products By products, Waste Risks Environment Human health Production 7

8 Access to Water Generic drivers Sustainability and regulatory constraints Water availability is becoming an increasing issue in many geographies Authorities tend to limit withdrawal by industrial sites, thus constraining industrial growth Over the global availability issue, needs for agriculture, industry and domestic uses will possibly compete. Upon population growth by 40 to 50 %. within the next fifty years coupled with industrialization and urbanization Regulations on effluent quality are becoming increasingly stringent Load vs concentration, water efficiency in IPPC BREFS Reduction of global pollution at source Europe no more pioneer Most industrial players are seeking a green image Polluter as public perception New non financial rating Operating costsreduction Process Industry does pay continuous efforts for cost reduction Rationalization of investments Control of operating costs Reliability of water management Water management is out of core process for process industry Water related risks are assessed on process failure issues High requirements water quality/technologies Industry generates more and more complex / steam specific wastewaters 8

9 Industry sectors Sectors with: High level of water dependance High improvement potential An improved industrial water management will lead to water saving, which has two environmental benefits i) water will be released either as natural asset or for other human activities; ii) CO 2 emissions will be reduced as a result of less energy consumption. In EU countries There is a quite high saving potential in the industrial sector, especially in the sectors of chemicals, refineries, basic metals, paper, food processing. Numerous industries have particularly high water demands: Power generation Refineries Pulp and Paper Metals and Mining Oil and gas Food and Beverage Microelectronics Chemical production Pharmaceuticals Textiles Potential water saving in Belgium, Finland, Germany, Italy, Netherlands, Portugal, Sweden are: Chemical (2 500 Mm 3 ) Steel and iron, Pulp and paper, Mining ( Mm 3 ) Food and drinks, Textiles and Oil and petrochem ( Mm 3 ) Dworak T. et al,

10 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 10

11 Technical Challenges Define and use water quality fit for use Process specifications Address the element «water in industry» as part of the total water system Cooperation with the urban and agricultural fields Ref. WSSTP SRA Close the water cycle, leading to a zero discharge system Water recycling Water reuse thus dealing with the concentration of pollutants. Develop sustainable use of resources (discharge, waste, energy) Recovery of added value products from water with selective processes Decrease of the energy consumption, energy production from wastewater Sustainable water system as part of sustainable production (factory of the future) Address protection of environment, health and safety, also including regulatory requirements and emerging concerns Final effluent of stable quality from a highly variable (in load and composition) influent 11

12 Challenges along the water cycle by 2050 From raw water intake to wastewater and sludge disposal Process water Production adaptation to salinity & organics variations in raw water Temporary units for crisis management Wastewater treatment Meet more stringent discharge limits Low costs for recycling / reuse Valorisation of metal/organic byproducts, concentrates, of WW, of waste under material / energy Reduction of sludge production Reduction of chemicals use Use only green chemicals Resource Ensure Sustainability Use Alternative water resources Utility water Recycle Use of Alternative resource / reuse Better use of waste heat Management of (eco)risks Green process 12

13 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 13

14 Market data Industry counts for $ 12 bn market for water equipment and services, $ 11 bn market for chemicals in 2009 with similar growth rate of capital expenditure (5.6%) than the total water market over Chemicals and Equipment dominate in the industrial water market. Market overview 2009 Global industrial market $23 bn Services 7.6% Chemicals 50.1% Water equipment 42.3% This market will grow faster than the global economy as a whole reflecting the impact of: Water scarcity environmental protection Urbanization Related rising in living standards. GWI,

15 Market data The Market, huge in volume with CAGR of 7.1 7,5% by , is characterized by: Shift in the type of technologies away from usual technologies Shift in the geographical focus of the market base towards Asia and Latin America. Equipment market overview Total market value 2010: $14.1bn Total market value 2016: $21.7bn Segmentation by industry sectors by decreasing market value 2016 > $2bn > $1bn < $1bn Food & beverage Oil&Gas Pharma Power Pulp & paper Chemicals Electronics Mining Refining Metals Textiles Automotive GWI, 2011 Equipment categories with highest growth rates , by increasing size of market 2016 UF/MF membranes Reverse Osmosis/NF Ion exchange/edi Disinfection/Oxidation Zero Liquid Discharge Industrial W&WWTE Market 2010 $14.97 bn CAGR Global 7.1% West Europe 3.7% East Europe 5.9% North America 2.6% Latin America 9.7% ME & Africa 8% APAC 10.6% Frost & Sullivan, 2010 GWI,

16 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 16

17 2050 Targets Water management options Development of industrial ecosystems, green design Integrated water management Application of advanced treatment technologies and combination Development of closed loop recycling and reuse Insertion of industry plant within user basin Resources Source segregation Treatment for higher quality Treatmentof stream specific effluents Recycling Reuse Extended wastewater treatment more efficient treatment technologies Wastewater Discharge In plant control Process intensification Cleaner process technologies Volume reduction Requirement of higher quality Alternative resources Desalination of sea water Extended treatment of urban wastewater Groundwater reclamation 17

18 Extended Wastewater treatment Examples BOD SS Organics, µpollutants, color Membrane foulants Ions Scaling& biofouling Microorganisms Coag/floc Filters Industrial Water Wastewater for reuse Primary treatments Biological treatment Coag/floc Filters Coag/floc Filters Coag/floc Filters Backwash Waste AOP Ads AOP Ads AOP Ads Prefiltration Decarbo Prefiltration Decarbo Prefiltration Decarbo Waste NF RO NF RO NF RO Concentrate Chemicals Softening Chemicals Softening Chemicals Softening Cl2 O3 Cl2 O3 Cooling Water Boiler Water Process Water Wastewater Wastewater AOP : Advanced OxIdation Process Ads : Adsorption 18

19 Technologies Functions involved All terms of the water balance for cost effective solutions protecting the environment and enabling sustainable use of water Flowrate Recover Suspended Solids Concentrate Separate Treat sludge Ionic load Concentrate Regenerate Precipitate Organic load Make it react Treat sludge Concentrate Treat brine 19

20 Technology needs Technology area Technology need Major driver Biological treatment Persistent organics treatment Reliable and extended treatment regarding the high variability of influents on due to load and temperature variation, complex matrix with toxic constituents (metals, organics, ) and «high salinity/conductivity» Anaerobic treatment with energy recovery Cost effective oxidative treatments with control of by products Catalytic combined processes for adsorption and/or oxidation Regulations Technology Regulations Regulations Green biocide for biofouling control Membrane Low scaling membrane treatment Cost Membranes with modified surface to limit scaling and fouling Ceramic membranes with catalytic properties Increase of membranes capacity by nanotechnologies Low energy desalination Membrane processes for high load effluent (New geometry of membranes (easy to clean) and new operating conditions) Combined membrane processes for energy savings Regulations Technology Technology Selective separation Functionalized membrane Technology Highly selective adsorbent easy to regenerate Cost Cost Cost Cost Business 20

21 Technology needs Technology area Technology need Major driver By product valorization Salt removal Selective separation of valuable inorganics (e.g. metals) Selective separation of concentrated organic compounds Salt separative treatment integrated in industrial re use strategy in order to limit corrosion and scaling Cost Cost Business Brine treatment Energy saving membrane concentrate treatment Cost Process intensification Engineered systems Tools Energy saving distillation processes Low fouling selective membrane for electrodialysis treatment Evaporation / Crystallization (precipitation or thermal) processes with by product control Improvement of kinetics, reduction of unit size Low energy gas/water/sludge handling Reliable on line sensors and bio sensors Monitoring of processes Cost Cost Cost Cost Cost Cost Innovations expected in Materials Chemicals Engineered systems Processes 21

22 Focus on brine issue Chemical industry is the main producer of Chloride through industrial brines A lot of other sources of brines (part. chlorides) Discharge by activity Industry Discharge in t /y Chemical industry Treatment of waste Steel industry Energy Oil&Gas Agro-alimentaire et Boissons Energie Sidérurgie, métallurgie, coke Bois, papier et carton Déchets et traitements Chimie et Parachimie Pétrole et Gaz Industrie du cuir, tannerie Pulp & paper Agri food Leather, tannery

23 Focus on environmental impact tools In connection with micropollutant treatment in waste waters Development of new environnemental impact indicators for : Toxicity Biotoxicity Bioindicator (Fish, watchfrog.) Development of micropollutant analysis in waste waters (endocrine disruptors, pesticides ) Example : Watchfrog, Endocrine disrupting effects evaluation tool based on transgenic fluorescent biosensors, i.e. reporter tadpoles and reporter fish fry Fluores cence analysis WATCHFROG Industrial WWTP Comparison of fluorescence levels Fluores cence analysis WATCHFROG 23

24 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 24

25 Ultrapure water for pharmaceuticals Pump Micro Filter Activated carbon Reverse Osmosis Polishing filter Break Tank Tank* Points of Use Electrolytic Ozone Generator Pumps Ultraviolet 25

26 All water treatment techniques that apply equally to the production of drinking water and sanitation. Examples of operational treatment lines Food Industry: Screening MBR for water recycling in boiler, cooling, rinsing Paper industry: Clarification Biofiltration for recycling into production Surface treatment Recycling/reuse in industry Filtration Cation exchange Anion exchange for recycling of rinse water in closed circuit. Evaporation for recycling in degreasing baths. Automotive: Clarification, UF for water recycling in paint booths Textile: Clarification RO for recycling in production, air conditioning in spinning and weaving workshops. Semiconductors: UF EDI or Ion Exchange Biofilter RO for recycling rinse water in the extra loop of ultrapure water. Food industry, textile: Clarification Activated Sludge or MBR Ozonation Biofiltration for recycling under water for washing, refrigeration, fire systems. Thermal Power plant: Biofiltration Clarification Filtration RO Ion Exchange for the reuse of wastewaters from rolling mill (downstream industry), and recycling of cooling condensates in cooling towers and boilers. 26

27 Reuse for Industry KRANJI (Singapore) VEOLIA Situation Rapid industrial, economic and social development. Sharp Industry increases in water demand. The Needs Supply high quality water REUSE for industrial. Saving drinking water. Veolia Water s solution Upgrading existing Waste Water Treatment Plant, via addition of advanced membrane filtration (MF+RO) & disinfection (UV). Production of m 3 /d REUSE water for Industry. Results Reclaimed water for: o Industrial customers. o Catchmentreservoir for IPU. Reduced need of imported/desalinated water. 27

28 Refinery and petrochemical complex in sensitive area m 3 /d of waste water. Limited water resources: 50 % of WW reuse in addition to conventional recycling loops Stringent discharge limits Reuse for Industry Petrochemical industry China Degrémont/ Ondeo Industrial Solutions discharge limits reuse limits Turbidity 3 COD(mg/L) BOD5(mg/L) 20 5 SS(mg/L) 70 Cl (mg/l) 30 TDS (mg/l) 600 Secondary clarified water Reuse Media filtration Ozone Biofiltration UF RO Ozone Biofiltration Discharge 28

29 Refinery Italy Ondeo Industrial Solutions Reuse within industry users Full reuse of refinery wastewater in power plant Upgrading of the existing biological WWTP with UF with submerged membranes Two stage RO for production of 350 m 3 /h and discharge reduction by 35 % NaClO H2SO4 FeCl3 Waste Water from Biological Treatment Storage Tanks UF Reject Thickening Sludge dewatering (Centrifuge) FeCl3 Poly Poly NaClO Citric Acid UF Membranes 500 D 64/64 RO Reject Storage Tanks UF Permeate Storage Tank GAC Filtration H2SO4 H2SO4 PT 191 NaHSO3 Biocide Reverse Osmosis First Pass Reverse Osmosis RO Reject NaOH Second Pass Discharge to Sea PC RO Wash Water Storage Tank RO Permeate Storage Tank RO permeate to demi plant 29

30 Reuse for Municipal and Industry DURBAN (South Africa) VEOLIA Situation Metropolitan population: 1 million 3 million. Water scarcity and overload long sea outfall. Needs Providing basic services to the growing population, 26% live in townships. Increasing volumes of higher quality water to industrial customers. Veolia Water s solution 20 year BOOT contract, operation May A successful trisector partnership. Leading edge technologies. Lower cost, high quality water supply to: othe Mondi Paper Mill = m3/d. osapref Refinery boiler feed = m3/d. Results Reduced water bill by 40%. Freed up potable water for people (8% demand). 30

31 Reuse/recycling in Pulp and Paper industry Paper industry has done a lot of actions to reduce its water consumption Re use and recycling of water Identification of water needs in term of quantity and quality > Water fit for use Feed back on the implementation of these solutions Water consumption minimization Identification of the potential negative consequences : Scaling, biofilm, corrosion Water consumption for production of different paper grades Printing paper Magazine Paper (LWC) Newsprint Corrugated / paperboard Tissue Accessible value* (m 3 /t) (*) 8 13 (*) (*) Those values take into account the Best Available Technologies and particularly water circuits closure. They are only achieved in the most performing mills, in Finland and Germany for paper grades, in Germany and France for Tissue. 31

32 Urban WW Reuse for Industry Pulp and paper industry Urban WW re use in Madrid UCM Reduce water consumption Find new water sources Mill effluent Reclaimed water UCM HPM: 0,9% of the total water consumption in the Madrid Community WWTP (municipal) 600 Hm 3 /y 17,3 % of the total consumption of the Madrid Industry MF/UF + OI + UV HPM consumes the same water than a city of 62,000 people Presented by UCM in I-Sup Brugges

33 Integrated water management system Refinery Mexico Degrémont Water withdrawal reduction 84% Capacity barrels per day Priority use of dam water for human consumption Full recycling of wastewater to the fire circuit and cooling towers Capacity : 360 m 3 /hr Catalytic sulphideoxydation DAF treatment Biological treatment Reuse of urban wastewater Seawater desalination 33

34 Water needs 430 m 3 /h Integrated water management system Refinery Mexico Degrémont vs 2480 m 3 /h initially Alternative resources Urban WW Seawater Industry effluents Proven technologies for reuse Cooling water Service water Effluents 34

35 Framework, Water in industry Towards Integrated water management system Technical challenges by 2050 Market data Technology needs for 2050 Current technical baseline Early achievements Conclusions Outline 35

36 Conclusions Water in industry Many uses Cost and Environmental performances Integrated water management system approach Under strong drivers: Access to water, Regulatory constraints, Cost reduction, Water management reliability Chemical industry in the Top industries concerned Technical challenges by 2050 Along the water cycle In connection with direct environment: resources, users Market data Current business baseline and forecast, technology segmentation 36

37 Conclusions Technology needs for 2050 Numerous, with regulations, business, cost as drivers Directed according to an Integrated Water Management System Advanced treatment technologies and combination Closed loop recycling and reuse Water technologies in addition to Process technologies Insertion of industry plant within user basin Large room for innovation by 2050 in numerous technology fields: chemicals, materials, processes, engineered systems Opportunities for water and process industries/r&d Current technical baseline Early achievements Recycling and reuse of water, integrated water management: a reality Proven techniques combined in more and more complex treatment lines An approach now fundamental for «the clean and sober factory of the future» Knowledge of global water needs of an industrial site Optimized management and control of these needs with in process measures Expanded scope: Degraded resources, Recycling and reuse Management on user basin basis in addition to the watershed management 37