E4water: Water challenges for the chemical industry

Transcription

1 INDUSTRIAL USERS EXPERIENCE - AQUATECH AMSTERDAM 2015 E4water: Water challenges for the chemical industry Operational excellence in water supply & treatment November 5 th 2015 Niels Groot, Dow Benelux B.V., the Netherlands Nov 5th 2015

2 RESOURCE AVAILABILITY INDUSTRY MANAGEMENT TREATMENT SUPPLY Thanks to co-workers in The E4water consortium, especially the Case Study of Evides/Dow and Nathalie Swinnen of Inovyn

3 The Status of Water Water as a resource Water scarcity Water for the Public Water in the Industry

4 Water Scarcity

5 Water in the industry Water IN Fresh water River water Groundwater Drinking water Brackish water Sea water Recycled water Water USE Solvent Carrier media Heat exchange Water OUT Discharge to the environment Evaporation Final products Waste

6 Integrated Resource Water Management Water allocation deal with availability / demand More holistic approach is essential Cope with conflicting demands Efficient, equitable and sustainable development and management

7 The concerns of the industry Physical risk Quantity (-) : water scarcity (+) : floods Quality : salinity, pollution, Regulatory risk Constraints on water abstraction (permit) Increase of water price Reputational risk Negative image in media Securing production capacity

8 The progressive changes Water Management At production level At site level At industrial park level At water catchment basin Waste Water Treatment Discharge Permit European Directives Impact on the environment Best REFerence documents with Achievable Emission Levels

9 The Commitments of The Industry (*) We set ourselves global long-term goals for the future: by 2020, we want to reduce the use of drinking water in production processes by half compared to 2010 and establish sustainable water management at all sites in areas of water stress. (...) Globally monitor site water usage, quality and discharges; Run site-specific projects for water reuse, recycling, reduction, or wastewater treatment; regular review and assess risks and necessary investment decisions Water risk assessments began in 2012 and continued in 2013, focusing on water scarcity areas, as well as on locations with a relatively large contribution to DSM s discharge of pollutants (COD, nitrogen or phosphorus) or to water consumption. In 2013 sites were included which use large volumes of water for once-through cooling. (*) excerpts from annual reports

10 Dow 2025 Sustainability Goals By 2025, Dow will reduce its freshwater intake intensity at key water stressed sites and its waste intensity footprint by 20 percent Learn

11 The industry is also a solution provider Plastic piping to reduce leaks Innovative products Prevention of evaporation from ground Innovative applications Innovative technologies New membrane developments New cooling systems (air) Water energy nexus Service Water and wastewater conditioning Water and wastewater treatment

12 Energy & Water Solutions The Portfolio Dow Microbial Control Dow Water & Process Solutions Dow Oil, Gas & Mining Dow Alternative Energy Putting You in Control Purifying the Essentials of Life Breakthroughs for New Frontiers Reliable Renewable Performance Advanced sustainable microbial control Deep understanding of customer needs focused on optimized local solutions Growing > GDP in target global segments of energy, water, hygiene, as well as other industrial markets. Key capabilities/applications: Well souring control Industrial cooling water Fabric odor-elimination In can preservation Dry film protection Leader in providing differentiated technology and applying expertise to solve customers most pressing separation and purification problems Strong growth in target segments; industrial water, energy, power generation, pharma, food & beverage. Key capabilities/applications: Water reuse Desalination Chromatographic separation Industrial Water Power Generation With combined chemical and oil/gas expertise, help customers optimize supply, improve efficiencies and manage emissions Focus: exploration, EOR, transmission, production, refining and gas processing Key capabilities/applications: Rheology Modifiers Phase separation Flow Assurance Gas treating Subsea insulation Provides more efficient and reliable solutions for creating and conserving energy Applies award-winning innovations in materials science to improve performance in generating and harnessing electricity Key capabilities/applications: Residential roofing Commercial roofing Lithium-ion batteries 12

13 Purifying the Essentials of Life Untreated Water Ultrapure Water High-Solids Filtration Ultrafiltration Reverse Osmosis & Nanofiltration ION Exchange Resins Electrodeionization Trademark of The Dow Chemical Company ( Dow ) or an affiliated company of Dow. 13

14 Success Stories Terneuzen, The Netherlands: Retrofit of seawater feed to secondary wastewater feed saves water, energy, costs The Challenge A desalination system had been installed for industrial-grade water for a local production facility in a water-scarce area, but the customer wanted to find an alternative and more economical source for feedwater. Dow s Solution Plant re-engineered using DOW FILMTEC RO elements to convert from seawater feed to municipal wastewater feed. The Result Economical, excellent performance even with frequent and rigorous cleanings. Operating costs decreased by 50%. Additional Benefits 65 percent reduction in energy use. Improved water usage and sustainability for region. Trademark of The Dow Chemical Company ( Dow ) or an affiliated company of Dow. 14

15 Economically and Ecologically Efficient Water Management in the European Chemical Industry Vision: A new paradigm for water management in the European chemical industry 19 partners from European Chemical Industry, and affiliated partners Coordinator: DECHEMA Project costs: 19 million May April 2016 Six case studies led by chemical industry partners (

16 The E4Water Vision

17 Case study 1 - Dow, The Netherlands Mild desalination of water streams for optimum reuse in industry or agriculture at affordable costs Situation: - Brackish (< 2 g/l salt) water streams - Surface water & Industrial effluents (up to 500 m³/h) Industry site characteristics: - Facilitate use of reclaimed water in industrial water management process due to shortage of fresh water Success indicators: - Reduce fresh water dependency by > 20% - Symbiotic integration of industrial, urban and agricultural sector

18 Dow Terneuzen Quick Facts Second biggest Dow site globally 440 hectares 1,700 employees contractors 17 Plants incl. 3 Ethylene crackers 800+ different chemicals and plastics 85% of products exported Located in a Water Stressed Delta Fresh Water Annual Use is 22 Million M³ Zeeuws-Vlaanderen 1-2 Million M 3 water locally sourced Most water sourced remotely: pipeline ~120km Surface & Ground water mildly brackish

19 Dow strives to become independent of remote supply Annual fresh water demand of >20 million m³ Biesbosch Surface Water Dow wastewater Dow Terneuzen Fresh water supply 120 km Dow - Bioxplant Replace source by: process water rainwater wastewater Biesbosch water Municipal wastewater Intern reuse (condensate) Terneuzen - WWTP Regional fresh water scarcity reduce water footprint

20 Regional Robust Water system Key attributes Surplus of 100 million m³ of brackish water is discharged annually Save scarce potable water sources by regional reuse Nature, landscape and recreation will benefit. (treated) waste water, diffuse discharges, rain water Water NEXUS Treatment wetlands E4Water Influent buffer Effluent buffer Agricultural usage Mild desalination Industrial reuse

21 Desalination modules Rain / polderwater Future situation Spui kom E4-Water project on mild desalination River (brackish water) Fresh Water supply Agriculture Domestic use WWTP municipal WRWL Green Infrastructure Industry WWTP industry Biox CTBD

22 E4Water Mild Desalination Demo pilot Key characteristics: m³/day - Handle varying raw water streams - Produce water for reuse (< 1 ms/cm) - Identify robust technology - Max production costs 0.4 /m³ - Leverage to other users Treated waste water Collected rain water ELSTA Cooling tower BD Westelijke Rijkswaterleiding

23 Opening by MEP Lambert van Nistelrooij Flocculator & Lamella Separator Nanofiltration unit

24 Demo Facility Evides/Dow

25 Case study 2 - Solvic NV, Belgium Enhance the water reuse by global management and synergy identification on a multi-company site Situation: - Wastewater and cooling water streams with variable flows ( m³/h) - Inorganic loads (up to > 5 g/l salts) - Enabling synergy effects with neighborhood industries in the Port of Antwerp Chemical Cluster Industry site characteristics: - Pressure on fresh water resources - Regulatory demands Success indicators: - Reduce freshwater dependency by up to 50% - Reduce energy demand - Realize symbiotic link to neighborhood industry

26 Case Study 3 Solvin (Martorell, Spain) Water reclamation in the PVC polymerization step using MBR and subsequent RO Quality targets : PVA < 1 mg/l N-NH4 < 2 mg/l BOD 5 ~ 0 TOC < 10 mg/l Al < 0.1 mg/l Conductivity < 10 μs/cm

27 Case study 4 - Procter & Gamble (Rakona, Check Republic) Enhance in-process water loop closure by integrating biocidal with wastewater treatment technologies Situation: -Wastewater with high concentrated organic load and low flow (< 1m³/h, g/l COD) Industry site characteristics: -Treatment of complex concentrated organic water streams to avoid heat technologies and to unlock further recycling and reuse Success indicators: - Closing process loop - Replacing incineration by treatment train - Economic feasibility (baseline = incineration with 100 /t)

28 Case study 5 Total (France) Towards integrated water management system in petrochemical site Situation: -Wastewater / cooling water streams with organic and inorganic loads and high flows - High consumption rate for cooling and boiler feed Industry site characteristics: - Enhanced recycling in cooling and process circuit - wastewater reuse in cooling and operation / production processes Success indicators: - Reduce freshwater dependency by up to 30% - Reduce energy demand

29 Case study 6 Kalundborg (Denmark) Bioextraction technology in a symbiotic industrial wastewater treatment concept creating added value Industrial Symbiosis for the exploitation of residual water streams: One companies waste becomes anothers ressource Upgrading gasified industrial proceswater to plant substrate by microfiltration Remediation of proceswater by microalgae bioextraction Upcycling of nutrient and CO 2 to plant based protein, lipids, carbohydrates and bioactive components Harvesting of microalgae by microfiltration

30 Exploitation of new integrated approaches

31 Conclusion Water matters to the industry Water is a resource Targets, KPIs require efficiency Water management becomes a necessity in the industry Industry is taking the lead contributing to innovative solutions E4Water Tools help identifying hot spots Risk assesment Water is making its way in Circular Economy Industrial cases, multiple projects under way

32 Dow Benelux Terneuzen Connecting Chemistry & Water with Passion Water Each drop counts!