Environmental Assessment of an Innovative Plant for the Wastewater Purification in the Beverage Industry

Transcription

1 Environmental Assessment of an Innovative Plant for the Wastewater Purification in the Beverage Industry Marco Bortolini, Lucia Botti, Mauro Gamberi, Riccardo Manzini, Cristina Mora, Alberto Regattieri Alma Mater Studiorum Bologna University Department of Industrial Engineering Poznan, Poland, August 2 nd 2017

2 Aim & Research Direction Focus To reduce the water intensity in the FOOD & BEVERAGE INDUSTRY (F&B) proposing a technology integrated to a ready-to-use plant to locally recover and reuse the process wastewater (up to 25,000 recovered litres/hour); To evaluate the environmental impact of the plant manufacturing and assembly phases from a Design for Environment perspective. Final mission To outline the components, materials and processes having critic environmental impact to adopt, in the future, alternative technologies and materials.

3 Presentation Agenda 1. Background and overview on European and Italian regulations of water use within F&B; 2. Functional description of the plant; 3. Review of Life Cycle Assessment (LCA) methodology and assessment methods; 4. Environmental assessment of the plant manufacturing and assembly: Life Cycle Inventory (LCI), Assessment (LCA) and interpretation keys; 5. Conclusions and future developments.

4 Background Water is known as the blue gold, the key of life, and its availability is crucial for the equal growth of communities (UN Millennium Development Goal Report, 2011). Focusing on the European Union (EU) area, the highest amount of water consumption is from industry. Furthermore, among all industrial activities, Food & Beverage industry is known as a very water intensive sector (~ liters/hour of raw water generating thousands of litres of wastewater per day). Wastewater recovery is a MUST at the EU level: To save the environment water footprint of processes; To comply with the EU regulations; To match high technical/economic target in product/market. Global investments in wastewater treatments: $150 billion/year; $12 billion/year for equipment; Trend until 2020: +6%.

5 Reference regulation framework EU LEVEL Ec No. 178/2002, Council Directive 98/83/EC 1. Increase efficiency standards for water using products, +16% by 2030; 2. European Food Safety Authority to promote, apply and control the procedures in matters of food safety; 3. Obligation of protecting human health from the adverse effects of any contamination of water intended for human consumption; 4. Sets quality standards to achieve and forces the member states to follow the principles of planning, regulating, monitoring, informing and reporting toward the F&B stakeholders about the quality level of water. ITALY National regulations 1. Legge 36/94 setting the concepts of water saving, recovery and reuse; 2. D.Lgs. 152/99 (Testo unico sulle acque) transfering to regions the responsibility of setting rules for water saving, control and reuse; 3. GAB/DEC/93/06 prohibiting the use of recovered and purified wastewater within F&B and pharmaceutical industries except in the case of a local recover; 4. D.Lgs. 31/2001 actuating the EU Council Directive 98/83/EC and regulating the water quality control and responsibilities of industry and the control Authority.

6 Research Context: The Less Water Bev.Tech. EU Project Headquarter in Fornovo di Taro, Parma, Italy; Active in the F&B process business since 1967; 57 employees (23 in R&D) ~20M /y turnover; Businesses in EU, Africa, Mid/South America, Middle East; High customization solutions. Official Project Web-Site for detailed info & docs: Industrial Mechanical Plant Engineering group & lab; Design, field-test and support in industrial process & advanced manufacturing technologies; Strong connection with industry to «transfer techs.». Design of project/machinery software solutions and commissioning, training to the final user; Fully conversant in manufacturing automation platforms including Siemens, Allen Bradley and Omron, alongside the SCADA/HMI solutions.

7 Local Water Recovery Plant (1) Target: mid-size F&B Italian company producing soft drinks, non-carbonated beverages, juices and vegetable sauces. Annual water intensity: 2.4 billion liters/year actually supplied from five wells and managed in open-loop. Water streams: Fillers: 3 lines, l/h, continuous; Osmosis retentate: l/h, continuous; CIP: 4000 l/h, discontinuous & highly polluted; Cooling towers: 2,000 l/h, continuous; Syrup room: 1000 l/h discontinuous. Focus l/h (plant capacity)

8 Local Water Recovery Plant (2) Acid neutralization (e.g. PPA) Ultrafiltration membranes (suspended solids) Reverse Osmosis membranes (dissolved solids) UV (microbiological charge)

9 LCA Methodology (1) LCA is an useful standard technique to evaluate the environmental impacts of a product throughout its whole life (from a cradle to grave/cradle perspective) LCA spreads around the world since the development of standards by ISO (International Standards Organization) in Environmental Product Declaration Re-design of product and services The LCA framework includes four steps (ISO 14040:2006): 1. Goal and scope definition 2. Inventory Analysis (LCI) 3. Impact assessment (LCIA) 4. Interpretation

10 LCA Methodology (2) Life cycle impact assessment (LCIA) is carried out using SimaPro Consultants with the use of three methods: 1. Eco-indicator 99 Hierarchical version (EI99H) 2. ReCiPe H/A 3. IPCC 2007 Global Warming Potential (GWP) by Pré ECO-INDICATOR 99 Focuses on the evaluation of midpoint indices: damage on human health, measured in DALY (Disability Adjusted Life Years); ecosystem quality, quantified in PAF m2 year (Potentially Affected Fraction); resource preservation, evaluated in MJ surplus RECIPE H/A Focuses on the evaluation of three endpoint categories: damage to human health (HH), measured in DALY ; damage to ecosystem diversity (ED), measured in Ecosystem species*yr; damage to resource availability (RA), measured in Resources Surplus Cost. GLOBAL WARMING POTENTIAL is defined as the climatic warming potential of a greenhouse gas relative to that of carbon dioxide. The GWP of a gas is measured in mass of equivalent carbon dioxide CO 2eq.

11 Plant LCA (1) GOAL AND SCOPE DEFINITION INVENTORY The boundaries of the system are from the cradle to the gate of the industry, considering: raw material extraction processes; manufacturing and assembly of components; transports; energy. The environmental impact evaluation of the manufacturing and assembly phases of the industrial system; Functional Unit: the construction of an innovative plant for water treatment and wastewater recovery and purification in the F&B industry. INPUTS PROCESSES OUTPUTS Raw material Energy Transportation System boundary Raw material Acquisition Manufacturing Assembly ATMOSFERIC EMISSIONS WATERBORNE WASTE SOLID WASTE The USE of the plant and its DISPOSAL are not considering in this study

12 Plant LCA (2) INVENTORY: The plant is subdivided in the following functional parts: Cleaning In Place (CIP) Carbon Filter Pump for water recovery Reverse Osmosis Tank 8000 l Tank 3000 l Ultrafiltration Ultra Violet Treatment (UV) Electrical system The ELETRICAL SYSTEM is not considering in this study For the key functional parts, all the constitutive components and materials are considered within the analysis. Energy: Medium voltage Italian electricity with importation. Transportation: is considered for all the components and materials. The vehicles considered for the transportations are lorry >16t, fleet average and lorry t, EURO4. Database: data bank of SimaPro 7.3.3; data collected from direct observation, literature and other data banks; simplifying hypotheses concerning material or processes.

13 Plant LCA (3) IMPACT ASSESSMENT EcoIndicator 99 Reverse Osmosis, Ultrafiltration and Carbon Filter are the units with the highest environmental burden Pt Reverse Osmosis has the major impact in Resp. Inorganics, Carcinogens and Fossil Fuels. Carbon Filter introduces significant damages in Resp. Inorganics and in Land Use. Ultrafiltration generates significant damage in Fossil Fuels and in Resp. Inorganics.

14 Plant LCA (4) IMPACT ASSESSMENT ReCiPe Pt Reverse Osmosis, Ultrafiltration and Carbon Filter are the components with the highest environmental burden. Reverse Osmosis have the major impact in Climate Change and Fossil Depletion. Ultrafiltration generates significant damage in Fossil Depletion and in Climate Change. Carbon Filter introduces significant damages in Agricultural land occupation and in Particulate matter formation.

15 Plant LCA (5) GWP 100a Impact Category Unit Total IPCC GWP 100a Carbon Filter N.4 Pump for Water Recovery Reverse Osmosis Tank 30k Tank 8k Ultrafiltration UV CIP kg CO2 eq 60872,6 3696,9 2165,9 1430, ,5 525, , ,78 158,78 Reverse Osmosis is the group with the major impact. The manufacturing of this component produces 32,400 kg CO 2eq that represent the 53.2% of the total kg CO 2eq. The ultrafiltration group is the second in term of GWP emissions.

16 Plant LCA (6) Since Reverse Osmosis, Ultrafiltration and Carbon Filter are the parts with the greatest impact, the manufacturing and assembly phases of these components are considered in order to find the processes or the sub-components generating the majority of the damage. REVERSE OSMOSIS The major damaging contribution is due to the pressure vessel and pump components. Future change in manufacturing of this component is desirable for a more sustainable design.

17 Conclusions The three methods considered lead to common results: In manufacturing and assembly phase of the water recovery plant Reverse Osmosis, Ultrafiltration and Carbon Filter are the components with the highest environmental burden; The major damaging contribution is due to the pressure vessel and pump components; Reverse Osmosis is responsible of the 53.2% of the total kg CO2 eq. emitted, of the 44.85% of damage Pt in Ecoindicator99 and of 45.78% of damage Pt in ReCiPe H/A; The impact categories of Eco-indicator 99 method, characterised by major damage, are Resp.Inorganics (38.69%), Carcinogens (26.35%) and Fossil Fuels (14.95%). As regards ReCiPe H/A the impact categories mainly interested are Fossil Deplation (25.65%), Climate Change Human Health (24.14%) and Climate change Ecosystem (15.79%).

18 Future Developments Analysis of the whole life cycle of the plant with particular attention to the use phase, in which the water recovery could have a positive effect on the environmental impact for the ground water s consumption avoided; Comparison between a traditional system without water recovery and the system with the prototype object of this study is desirable; Changes to the prototype design, toward an eco-design perspective, with equal performance; Sensitive analysis, with the aim of defining the better configuration in an environmental point of view.

19 Eng. Marco Bortolini, Ph.D. Department of Industrial Engineering (DIN) Alma Mater Studiorum Bologna University Thank You