ApplyPONDUSThermochemicalHydrolysis(TCHP)forImprovingBiogasProduction,DigestedSludgeDewaterabilityandEnergyBalanceofSolidsHandlingProcesses
NEWEA2018ANNUALCONFERENCESession241/24/2018
GerhardForstner
Agenda
PONDUS®Technology
Installations
Summary
PONDUS® InstallationsinKenoshaWWTP
Installation Viscosityreduction
Biogasproduction
Digestedsludge
dewaterability
Benefits
PONDUSThermochemicalHydrolysisProcess
Reducesludgeviscosity(- 80%)
Improvebiogasproduction(+20%– 30%)
Increasedigestercapacity Improvesludgedewaterability(CakeTS>3%points)
Benefits
PONDUSThermochemicalHydrolysisProcess
PONDUS Thermo-Chemical HydrolysisClass B Option
PrimarySludge
WasteActivatedSludge
Heatexchanger
BlendSludge
NaOHdosing
PONDUSThermochemicalHydrolysisProcess
PONDUSThermochemicalHydrolysisProcessPONDUS Thermo-Chemical Hydrolysis
Class B Option
Gifhorn,Germany (2005) Uelzen,Germany (2014) Kenosha,US (2015)
PONDUSThermochemicalHydrolysisProcess
PONDUS Thermo-Chemical HydrolysisClass A Option
Heatexchanger
Re-coolingexchanger
FeedSludge
HydrolyzedSludge
NaOHdosing
PONDUSThermochemicalHydrolysisProcessPONDUS
Thermochemical HydrolysisClass A Option
Retention time is guaranteed by bath operation.
Nordhorn,German(2014)
PONDUSThermochemicalHydrolysisProcess
WasteWaterTreatmentPlant CapacityWWTP CapacityWAS YearBuilt Notes
Location PeopleEquivalent gpm m³/d
Gifhorn,German 95,000 9.7 50 2005 24hoperation
Ratekau,German 50,000 11 26 2007 12h operation,nghtstandbyoperation
Uelzen,German 110,000 11.9 65 2014 24hoperation
Nordhorn,German 200,000 7.9 25 2014 24hoperation,sometimesaspasteurizationinbatch
Kenosha,USA 100,000 23 125 2016 24hoperation
Wolfsburg,German 185,000 26 139 2016 24hoperation
Agenda
PONDUS®Technology
Installations
Summary
PONDUS® InstallationsinKenoshaWWTP
Installation Viscosityreduction
Biogasproduction
Digestedsludge
dewaterability
Benefits
KenoshaEnergyOptimizedResourceRecoveryProject
Improveefficiencyofanaerobicdigestion
ImproveenergyefficiencyfortheWRRF
ProduceClassAbiosolids
- Thickeningcentrifuges (THKSeries)-PONDUSthermochemicalhydrolysis
- Mesophilicanaerobicdigesterwithupgradedhydraulicmixingsystem- Combinedheatandpower
-KleinBeltDryer
Objectives Processes
KenoshaWWTP
PumpStation
GritChamber
PrimaryClarifier
BiologicalTreatment
SecondaryClarifier Disinfection
RawWW
LakeDischarge
PrimarySludge
WasteActivatedSludge
AnaerobicDigestion
Cake
WastewaterTreatment
SludgeTreatment
Dewatering
KleinDryer ClassABiosolids
PONDUSTCHP
BiogasUtilization
BiogasCleaning
CombinedHeat&Power
Landfill
PONDUSThermo-ChemicalHydrolysisProcessatKenoshaWWTP
RetentionTime:2– 2.5hours,temperature:150F(designed)NaOH dosingrate:0.2%ofTWASflowwithtotalsolidsof6%
ThickeningandDewateringCentrifugesPrimarySludgeThickening
CentrifugeWASThickening
CentrifugeDigestedSludgeDewatering
Centrifuge
AnaerobicDigestion
NewlyinstalledmixingPump
CleanedandCompressedDigesterGasDelivery
GasCompression,MoistureandSiloxaneRemovals
CombinedHeatandPower
KRAFTPowerGasEngine KRAFTPowerElectricGenerator
HeatSupplyfromCogenCoolingEquipment
PONDUSPerformance
••Reducesludgeviscosity
••Enhancebiogasproductionandenergyproduction
••Improvedigestedsludgedewaterability
ReduceTWASViscosityTWAS
HydrolyzedTWAS(LTWAS)
0
10,000
20,000
30,000
40,000
50,000
0 10 20 30 40 50 60
App
aren
t Vis
cosi
ty (m
Pa.s
)
Stir RPM
TWAS
NaOH dosing alone
PONDUS TCHP Treatment
• HydrolyzingeffectonTWASverifiedbymicroscopicpictures
• IndividualeffectofNaOHandheating
• EnhancedanaerobicdigesterbypumpingandmixingthickersludgetoAD
• WASTHKcakepumpv.s.PONDUSdischargepump
ReducedTWASViscosity
ImproveBiogasProduction
100,000
120,000
140,000
160,000
180,000
200,000
220,000
240,000
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
BiogasProdu
ctionofPrim
aryAD
s(cfd)
201720162012
VolatileSolidsReduction
201260%
• Sixoperatinganaerobicdigesterswerereducedtothree
• VSRwasmaintainedabove63%exceptoccasionstheplantreceivedaluminumsludgefromadrinkingwatertreatmentplant
0
10
20
30
40
50
60
70
80
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
VolatileSolid
sRed
uctio
n(%
)
2016
2017
CakeSolidsofDewateredSludge• Cakesolidsofupto31%TS
wasachievable• Cakesolidswasmaintained
around27%- 28%duringAug2016– Feb2017foreasypipingtoabeltdryerfollowedbydewateringcentrifuge.
• Lubricationsystemwasinstalledonsludgepipebetweendewateringcentrifugeanddryer
• Cakesolidswasmaintainedbetween28%- 29%duringMar– Aug2017.20
21
22
23
24
25
26
27
28
29
30
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Tota
l Sol
ids
(%)
2016 Cake Solids %
2017 Cake Solids %
PolymerCurveofDewateringCentrifuge
22%
23%
24%
25%
26%
27%
28%
29%
30%
20 25 30 35 40 45
Cak
e So
lids
(% T
S)
Polymer Dosage (lb/dry ton)
PONDUS TreatmentPrior PONDUS Treatment
Polymerreduction
Cake DrynessImprovement
SolidsRecoveryofDewateringCentrifuge
97.0%
97.5%
98.0%
98.5%
99.0%
99.5%
100.0%
28.5%
29.0%
29.5%
30.0%
30.5%
31.0%
31.5%
32.0%
32.5%
33.0%
40 50 60 70 80
Rec
over
y
Tota
l Sol
ids
Sludge Flow Rate (gpm)
RecoveryCake
Polymer: K275FLXActive Dosing: ~33 lb/dt
Summary
• Implementationofthermochemicalhydrolysisimprovedthedewaterabilityby>2.5%pointswithmaximumcakedrynessof31%.
• ThethermalhydrolysisreactoreffectivelyhydrolyzedTWASwithpresenttotalsolidsof6-7%.Atleast5-foldreductionofdynamicviscosityofTWASbythermochemicalhydrolysis.
• Monthlyaveragebiogasproductionwasincreasedby20%- 27%in1.5yearsofprojectimplementation.
Thankyou!
Gerhard ForstnerE-mail: [email protected] a division of Centrisys CorporationPhone: +1 (262) 705-9973
Melissa Arnot, P.E.E-mail: [email protected] Water UtilityDirector of Operations262.653.4339 phone
