WASTE/WATER TREATMENT FOR INDUSTRIES. Energy Technology Environmental Technology Manufacturing

Transcription

1 WASTE/WATER TREATMENT FOR INDUSTRIES Energy Technology Environmental Technology Manufacturing

2 OVERVIEW Company Introduction Industrial vs. Municipal Wastewater Treatment Industrial Effluent Treatment by WEHRLE Additional Benefits Summary Waste/Water Treatment for Industries 2

3 OVERVIEW Company Introduction Industrial vs. Municipal Wastewater Treatment Industrial Effluent Treatment by WEHRLE Additional Benefits Summary Waste/Water Treatment for Industries 3

4 COMPANY INTRODUCTION WEHRLE & Treatment of Industrial Effluents 1 st plant built in 1990 & still in operation! 32% 300+ reference installations in >30 countries 68% Plant design, building, operation, optimisation Waste derived effluent Industrial effluent Market leader in landfill leachate treatment = "Premier League" of wastewater treatment (vs. conventional wastewater treatment) Waste/Water Treatment for Industries 4

5 COMPANY INTRODUCTION Company Video Link to company video: Waste/Water Treatment for Industries 5

6 OVERVIEW Company Introduction Industrial vs. Municipal Wastewater Treatment Industrial Effluent Treatment by WEHRLE Additional Benefits Summary Waste/Water Treatment for Industries 6

7 COD/BOD/etc. concentration INDUSTRIAL VS. MUNICIPAL WASTEWATER TREATMENT Industrial Effluent Treatment: Two Philosophies WEHRLE Typical Applications Leachate Treatment Characteristics Compact & highly efficient reactors Industrial Effluent Treatment Suppliers for municipal WWTP Quantity of Water Municipal Waste Waters Large size concrete plants Waste/Water Treatment for Industries 7

8 INDUSTRIAL VS. MUNICIPAL WASTEWATER TREATMENT Municipal Wastewater Treatment Large flow rate / low pollution No significant differences between plants No significant changes over seasons Focus: treat wastewater Costs: public Comfortable size operation team Plant design typ. 2½ times average need Location: outside city Industrial Effluent Treatment Small flow rate / medium to high pollution Every plant is different Changes with every production shift Focus: produce / be profitable Costs: client Small team, outsourcing possible Compact plant, flexible operation Neighbourhood friendly, no odours This is not the business of WEHRLE This is the business of WEHRLE Waste/Water Treatment for Industries 8

9 INDUSTRIAL VS. MUNICIPAL WASTEWATER TREATMENT Municipal Wastewater Treatment Small plant (approx. 7,800 m³/d): Industrial Effluent Treatment Large plant (3,100 m³/d) Waste/Water Treatment for Industries 9

10 LOAD of INFLUENT INDUSTRIAL VS. MUNICIPAL WASTEWATER TREATMENT Technology Portfolio for Wastewater Treatment Anaerobic Bioreactors Aerobic Jet Zone Bioreactors Aerobic Membrane Bioreactors Typically used for municipal wastewater treatment Chemical / Physical CAS SBR subm. MBR EFFLUENT QUALITY Waste/Water Treatment for Industries 10

11 INDUSTRIAL VS. MUNICIPAL WASTEWATER TREATMENT Impressions Waste/Water Treatment for Industries 11

12 OVERVIEW Company Introduction Industrial vs. Municipal Wastewater Treatment Industrial Effluent Treatment by WEHRLE Additional Benefits Summary Waste/Water Treatment for Industries 12

13 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE Main Customer Benefits from WEHRLE Technology 1 Most compact biological treatment plants in the world 2 Highest process flexibility to cope with production changes 3 Designed for low operation costs (OPEX) / Cost of Ownership Waste/Water Treatment for Industries 13

14 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 1 Example: MBR Raw Effluent Feed Bioreactor / Aeration Tank Aeration Biomass Separation Clean Effluent Discharge Clean Effluent Tank Wash Tank Ultrafiltration Waste/Water Treatment for Industries 14

15 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 1 Compactness through Efficient Jet Aeration Solid state no maintenance No precipitation, no clogging Allows high tanks, therefore: longer oxygen contact time lesser air volume needed (less foaming) lesser energy Air dispersion optimised O 2 transfer Waste/Water Treatment for Industries 15

16 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 1 In comparison: Plate Membrane Aerators Precipitation, membranes can tear Maintenance inside tank needed or lifting equipment for aerator assembly Limitation of tank height, therefore: larger tank is needed larger blower is needed Waste/Water Treatment for Industries 16

17 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 1 Aeration efficiency depending on biology tank height Typical range for WEHRLE / ejector principle Waste/Water Treatment for Industries 17

18 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 1 Compactness through Efficient Biomass Separation M e m b r a n e B i o r e a c t o r Biological Treatment Ultrafiltration Wastewater Discharge COD degradation Biomass separation Waste/Water Treatment for Industries 18

19 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 1 Compactness through Efficient Biomass Separation Maintains a high concentration of microorganisms in the bioreactor High sludge age: specialised micro-organisms for difficult tasks Complete and save biomass retention: easy to upgrade with post treatment - if required Modular design: simple and low-cost upgrades to extent capacity Containerised solutions possible simple and quick on-site installation Waste/Water Treatment for Industries 19

20 CASE STUDY Application Effluent Type Flow Rate Food & Beverage S.C. Cadbury Romania S. A. Sweets and chocolate production Bucharest / Romania 50 m³/d Process/System BIOMEMBRAT Membrane Bioreactor Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2009 Component Inlet Outlet Performance Comment QR 2x2 COD 5,000 mg/l < 125 mg/l > 97 % Most compact, space saving concept for urban district with environmentally aware and demanding neighbourhood.

21 CASE STUDY Application Effluent Type Flow Rate Household & Personal Care (HPC) HPC production m³/d Unilever Rus St. Petersburg / Russia Process/System Equalisation BIOMEMBRAT Membrane Bioreactor Design Construction Operation Commissioning WEHRLE Umwelt Client Client 2013 Component Inlet Outlet Performance Comment QR 2x2 COD 18,600 mg/l < 1,400 mg/l > 92 % Super-compact indoor plant that reliably treats Detergents 6,500 mg/l 140 mg/l > 97 % effluent with a high foaming tendency.

22 CASE STUDY Application Effluent Type Flow Rate Food & Beverage Potato crisps and snack production 2,000 m³/d KP Foods UK Billingham / Great Britain Process/System Dissolved Air Flotation BIOMEMBRAT Membrane Bioreactor Water disinfection, booster station Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2009 Component Inlet Outlet Performance Comment QR 2x2 COD 750 mg/l < 50 mg/l > 90 % Biggest UF plant ever built inside a container: 2 loops, each equipped with 8 x 10 UF modules. The treated water is being recycled for internal use.

23 CASE STUDY Application Effluent Type Flow Rate Pulp & Paper Effluent from paper manufacturing 4,100 m³/d A-Jin Paper & Packaging Co. Ltd. Daegu / South Korea Process/System BIOSTREAM Jet Reactor (CJR) Design Construction Operation Commissioning TECHNOCON* TECHNOCON* Client 2004 Component Inlet Outlet Performance Comment BOD 1,500 mg/l 225 mg/l 85 % *WEHRLE Umwelt technology partner Volumetric loading rate: 10 kg BOD 5 /m³ d Reactor volumes: 2 x 320 m³ for 4,100 m³/d and 5,200 kg/d BOD eliminated!

24 COD concentration, mg/l COD elimination, % INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 2 Highest Process Flexibility: COD concentration inlet/outlet MBR, removal efficiency Reliable, trouble-free operation even during and in the aftermaths of production stand-stills (early January 2015 for several days) and peak inlet COD periods No limitation of the production by the ETP! COD concentration permeate MBR outlet COD buffer concentration tank MBR inlet Removal efficiency Waste/Water Treatment for Industries 24

25 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 2 Exemplary ETP design Pre-Treatment Main Treatment Post Treatment Waste/Water Treatment for Industries 26

26 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 2 Exemplary ETP design Pre-Treatment Main Treatment Post Treatment Waste/Water Treatment for Industries 27

27 CASE STUDY Application Effluent Type Flow Rate Chemical Road tanker rinse water 100 m³/d Bertschi AG Birrfelden / Switzerland Process/System BIOMEMBRAT Membrane Bioreactor 2014: heat exchanger for heat recovery Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2007 Component Inlet Outlet Performance Comment QR 2x2 COD 10,000 mg/l < 1,000 mg/l > 90 % High and extremely variable contamination levels in the effluent treated by a pressurised membrane bioreactor.

28 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 3 Designed for low OPEX: Electricity costs in relation to COD load MBR plants with low COD load (~ ,500 mg/l ) 22% MBR plants with high COD load (~ 5, ,000 mg/l ) 23% Note: Aeration cost with WEHRLE jet airation aerators are typically 64% 14% various UF 19% 58% 40 60% lower compared to plate membrane aerators. To t a l e n e r g y c o n s u m p t i o n d o m i n a t e d by: hydraulic flow COD/BOD load Waste/Water Treatment for Industries 29

29 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 3 Designed for low OPEX, example for MBR = Low demand on chemicals (i.e. less chemical cost + ordering + storage + labour) e.g. for CIP cleaning: typical every 6 12 weeks with 10 l / loop, standard chemicals = Low demand on manpower (high degree of automation, optional remote access) typical: 1 1½ persons, single shift cost-effective outsourcing of plant operation = Long membrane module lifetime Self-cleaning effect on external side-stream membranes reduce fouling = Simple and cheap upgrade for water re-use or capacity increase modular design, directly connectable to post-treatment (no suspended solids in effluent) Waste/Water Treatment for Industries 30

30 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 3 Anaerobic Processes Aerobic degradation CO 2 ~50% Effective reduction of COD load (80 95%) No aeration required 100% carbon effluent ~1% surplus sludge 45 50% Very little surplus sludge reduction Generation of biogas Anaerobic degradation biogas 75 85% Positive energy yield from biogas 100% carbon effluent 5 20% surplus sludge 1 5% Waste/Water Treatment for Industries 31

31 CASE STUDY Application Effluent Type Flow Rate Food & Beverage Animal food & rendering plants 466 m³/d SONAC / SNP Lingen / Germany Process/System BIODIGAT -SB (high-rate EGSB) Biogas treatment Combined Heat & Power Plant Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2009 Component Inlet Outlet Performance Comment QR 2x2 COD 13,500 mg/l 2,700 mg/l 80 % The anaerobic treatment results in a significant COD 4,665 kg/d COD load reduction and allows the increase of production capacity with existing aerobic wwtp. 2,000 m³/d of biogas are being generated and converted into electricity and heat by the CHP.

32 INDUSTRIAL EFFLUENT TREATMENT BY WEHRLE 3 Optional remote control: off-site access for operator and for WEHRLE to support operator in case of faults / efficiency optimisation / training System Alarm via SMS Different access levels possible, e.g. visualisation only Communication devices: PC/Laptop, tablet, smart-phone Waste/Water Treatment for Industries 33

33 OVERVIEW Company Introduction Industrial vs. Municipal Wastewater Treatment Industrial Effluent Treatment by WEHRLE Additional Benefits Summary Waste/Water Treatment for Industries 35

34 ADDITIONAL BENEFITS WEHRLE Process Technologies Anaerobic Jet Loop (BIOSTREAM) Cross Flow Low-Energy AirLift Biogas generation & surplus sludge reduction Ultra compact, special purpose jet loop reactor (also available as MBR) High flux with low membrane area Low Energy MBR with intermittend cross-flow cleaning Low Energy MBR with air support Waste/Water Treatment for Industries 37

35 COD concentrations [mg/l] ADDITIONAL BENEFITS Application of different Treatment Systems I n d u s t r i a l e f f l u e n t s M u n i c i p a l w a s t e w a t e r Anaerobic Jet Loop M B R / e x t e r n a l m e m b r a n e s Cross Flow LE Cross Flow Airlift MBR Submerged Hydraulic rates [m³/d] Invest dominated by: Other parts of the treatment plant Membrane Surface Waste/Water Treatment for Industries 38

36 ADDITIONAL BENEFITS Water re-use with post treatment (NF/RO) after Cross-Flow MBRs Characteristics of MBRs removal of all biodegradable substances no suspended solids in the effluent Effects for NF/RO post treatment Less fouling: reduction of cleaning cycles extension of membrane life time use of cheaper spiral modules homogenization of substances in the effluent good and steady filtration little ph-adjustment required MBR outlet = inlet NF/RO NF/RO outlet Waste/Water Treatment for Industries 39

37 CASE STUDY SUBSTANCE RECOVERY Application Effluent Type Flow Rate Food & Beverage ProMinent Fluid Controls, S. A. Brine from the sugar production Mauritius m³/d Process/System Nanofiltration Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2010 Component Inlet Outlet Performance Comment QR 2x2 COD 18,000 mg/l 4,000 mg/l 80 % Recovery of brine solution and reduction of sugar colourants, in the sugar cane industry, reducing the order amounts for NaCl by over 70%

38 CASE STUDY HEAT RECOVERY, CHEMICALS SAVING Application Effluent Type Flow Rate Laundry Work wear washing water 30 m³/d ALSCO Berufsbekleidungs-Service GmbH Frankfurt / Germany Process/System BIOMEMBRAT -LE (Low-Energy MBR) Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2011 Component Inlet Outlet Performance Comment COD 4,000 mg/l < 400 mg/l > 90 % The compact design and highly efficient oxygen transfer of the WEHRLE MBR avoids foaming of the effluent without the need of anti-foaming agents.

39 CASE STUDY WATER SUPPLY Application Effluent Type Water Supply / Boiler Feed Water Well Water Tamoil Collobey, Switzerland Logo Flow Rate 768 m³/d (Permeate) Process/System Pre-Treatment, incl. UF Reverse Osmosis Design Construction Operation Client Commissioning 2003 Component Inlet Outlet Performance Comment Recovery rate 43 m³/h 32 m³/h 75 % Pre-treatment with automated backwash filter Conductivity 1,100 µs < 0.2 µs > 99.9 % 40 Container plant for UF & RO

40 CASE STUDY PLANT UPGRADES Application Effluent Type Flow Rate Petrochemical Oil refinery 5,640 m³/d IRPC Public Company Limited Rayong / Thailand Process/System BIOMEMBRAT Membrane Bioreactor Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2013 Component Inlet Outlet Performance Comment QR 2x2 COD 700 mg/l < 120 mg/l > 83 % Upgrade of the capacity of the existing conventional biological treatment plant to a load of 3,948 kg/d COD with 7 membrane loops. Biggest MBR in South-East Asia!

41 ADDITIONAL BENEFITS Anaerobic Digestion of Solid (Organic) Waste Wet digestion process Efficient pre-treatment and impurities removal Pasteurization of substrates possible Ideal for food waste, kitchen waste, pharmaceutical waste as well as liquid waste Highly automated process, low manpower Conversion/reduction rate of org. DS 70 95% Gas yield up to 600 m³/t DS Sustainable solution combined waste to energy and fertilizer recovery process Waste/Water Treatment for Industries 44

42 CASE STUDY Application Effluent Type Flow Rate Pharmaceutical Pharmaceuticals production 4,700 m³/d UK Pharma company (name undisclosed) Irvine / Great Britain Process/System Anaerobic Solid Digestion Design Construction Operation Commissioning WEHRLE Umwelt WEHRLE Umwelt Client 2014 Component Inlet Outlet Performance Comment TSS 18,800 kg/d < 2,000 kg/d > 90 % For the existing wastewater treatment plant: energy consumption reduced by 8,500 kwh/d chemicals demand reduced by % final effluent quality considerably improved Biogas gain Electricity gain Heat gain 8,600 15,000 16,000 m³/d kwh/d kwh/d

43 OVERVIEW Company Introduction Industrial vs. Municipal Wastewater Treatment Industrial Effluent Treatment by WEHRLE Additional Benefits Summary Waste/Water Treatment for Industries 46

44 SUMMARY TECHNOLOGY deriving from landfill leachate treatment, one of the harshest wwtp applications focused on highest performance & efficiency, therefore low Cost of Ownership industrial water supply / industrial wastewater treatment / organic waste treatment EXPERIENCE reference projects in several industrial applications with different types of effluent familiar with industrial requirements & expectations references in over 30 countries in the world delivering solutions beyond conventional technologies SERVICES more than just a plant-builder: we help finding the optimum plant parameters for efficient operation plant operation, efficiency analysis & optimization, upgrades Online-Shop for easy and fast ordering of spare parts Waste/Water Treatment for Industries 47

45 WEHRLE Umwelt GmbH Bismarckstr Emmendingen Deutschland Energy Technology Environmental Technology Manufacturing