Quantity, Quality and Market aspects of potential P recycling routes in Europe
Christian Kabbe
Berlin Centre of Competence for Water
Wageningen, 6th February 2013
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www.p-rex.eu
Phosphorus – bottleneck of life
www.p-rex.eu
Limited availability Strategic resource
„We may be able to substitute nuclear power for coal, and plastics for wood,
and yeast for meat, and friendliness for isolation
– but for phosphorus there is neither substitute nor replacement“.
- Isaac Asimov (1920 bis 1992) – First published 1959 (Life‘s bottleneck)
- Wastewater/sewage sludge - Biowaste - Manure - Meat and bone meal
The traditional, closed anthropogenic P cycle
www.p-rex.eu
Once upon a time, there was an unbroken circle …
http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm
Soil <-> life balance …
The modern anthropogenic P „cycle“
www.p-rex.eu
Disruption of P cycle: Urbanization Industrialisation Globalisation
Problems: - Discoupling of food production and consumption - Pollutants/contamination - Inefficient use
Challenges for the future: - Increasing P demand - Decreasing quality of fossil P rock - Limited availability - Separation of nutrients from pollutants for recycling
Need of mineral fertilizer to compensate losses!
EU needs to import 975,000 t of mineral P!!!
http://www.nhm.ac.uk/research- curation/research/projects/ phosphate-recovery/ceep11.htm
Building Bridges!
EU FP7 Project
Sustainable sewage sludge management fostering phosphorus recovery and energy
efficiency
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www.p-rex.eu
Closing the loop, but where and how?
www.p-rex.eu
amended from: http://www.nhm.ac.uk/research-curation/research/projects/phosphate-recovery/ceep11.htm
210 Mt P rock (global mining 2012, USGS 2013)
90%
10%
Germany‘s National P Reserves
www.p-rex.eu
Waste stream Quantity of waste
stream
P-Reserve
(theoretical)
Compared to
Pmineral imported
~ 120.000 t/a
wastewater
(municipal) ~ 9,4 billion m³/a ~ 75.000 t P/a ~ 63 %
sewage sludge
(dry matter) ~ 2 million t/a ~ 67.500 t P/a ~ 57 %
meat & bone meal ~ 180.000 t/a ~ 10.800 t P/a ~ 9 %
animal excreta
manure: ~ 190 Mio m3/a
~ 240.000 t P/a Completely but not
efficiently used! solids: ?
6% of German cropland (12 million acres) short of P, whereas NS and NRW have surplus sufficient for 1 million acres from manure (Römer et. al. 2013)
(Different sources DESTATIS)
,0
200000,0
400000,0
600000,0
800000,0
1000000,0
1200000,0
1400000,0
1600000,0
1800000,0
2000000,0
2200000,0
1998 2001 2004 2007 2008 2009 2010 2011
se
wa
ge s
lud
ge
in
me
tric
to
ns d
ry m
att
er
thermal agriculture landscaping landfill other interim storage
Sewage sludge routes in Germany
www.p-rex.eu
(DESTATIS 2012)
55%
3%
13%
29%
Obviously: insufficient reuse of P
Sewage sludge routes in Europe 2010
www.p-rex.eu
(DESTATIS 2012)
Obviously: insufficient reuse of P
0
250000
500000
750000
1000000
1250000
1500000
1750000
2000000
AT BE BG CY CZ DE DK EE ES FI FR GR HU IE IT LT LU LV MT NL PL PT RO SE SI SK UK CH
other
landfill
application to land
incineration
Dry
ma
tte
r in
me
tric
to
ns
European total quantity: ~ 11 million tons sludge (dry matter)
WATERLOOP – Trinity of P Recycling
www.p-rex.eu
Food
Humans
Wastewater
WWTP
Agriculture
Sewage sludge D
ire
ct a
pp
licat
ion
o
n a
rab
le la
nd
P r
eco
very
fro
m
aqu
eo
us
ph
ase
(M
AP
)
P r
eco
very
fro
m
inci
ne
rati
on
ash
EU: 11 million tons of sludge dry matter/a ~ 350,000 t P/a
P
Global P recycling from wastewater: End of 20th century only 30%! (Liu et al. 2008)
Hot spots for P recovery in WWTP
www.p-rex.eu
(amended from Montag 2010)
Some P recovery processes in Europe
www.p-rex.eu
PEARL MAP FULL
Ash
Sludge
Sludge Liquor
LEACHPHOS P-mineral DEMO
Thermal
Leaching
P-bac (INOCRE) MAP
PHOSTRIP MAP, CaP DEMO
P-RoC CaP/CSH DEMO
PASCH CaP
MEPHREC P-slag DEMO
SEPHOS AlP
LYSOGEST MAP Full
Electrochemical MAP, CaP
PRISA MAP
Gifhorn MAP, CaP DEMO
AirPrex MAP FULL
NuReSys MAP FULL
Stuttgart MAP DEMO
THERMPHOS P4 FULL
AshDec (SUSAN) P-mineral DEMO
RECOPHOS D P-mineral DEMO
SESAL-PHOS CaP
KREPRO FeP FULL
Budenheim CaP DEMO
RECOPHOS AT H3PO4 DEMO
Crystalactor MAP, CaP FULL
Aqua Reci H3PO4
?
FIX-PHOS CaP/CSH DEMO
PHOXNAN H3PO4
REPHOS MAP Full
Wet Oxidation
With Leaching
Low Chemicals Demand
P recovery units - sludge
www.p-rex.eu
Process Operator/location Scale Output Contact
P recovery from sludge
AirPrex Waßmannsdorf (DE)
BWB full MAP
Berliner Pflanze
BWB
Dr. B. Heinzmann
AirPrex MG-Neuwerk (DE)
Niersverband full MAP
P.C.S.
W. Ewert
AirPrex BS-Steinhof (DE)
SE|BS / AVB full
MAP/
Sludge
P.C.S.
W. Ewert
AirPrex Wieden-Echten (NL) full MAP P.C.S.
W. Ewert
AirPrex Amsterdam (NL)
planned full MAP
P.C.S.
W. Ewert
CRYSTALACTOR Geestmerambacht (NL) full Ca-P DHV
A. Giesen
Gifhorn process Gifhorn (DE)
ASG full MAP
PFI
Prof. J. Müller-
Schaper
Fix-Phos Hildesheim (DE)
SEHi full
Ca-P/
Sludge
TU DA
Dr. C. Schaum
Stuttgart process Offenburg (DE) pilot MAP IAT
Mr. Meier
Budenheim process Mainz (DE)
planned pilot Ca-P
Budenheim
Dr. R. Schnee
P recovery units – process water
www.p-rex.eu
Process Operator/location Scale Output Contact
P recovery from sludge liquor / process water
REPHOS Altentreptow (DE)
Remondis Aqua full MAP
Remondis Dr. M.
Lebek
LYSOGEST Lingen (DE)
SE Lingen full MAP
P.C.S.
W. Ewert
PEARL
(PEARL 500)
Slough (UK)
Thames Water full
MAP
Crystal Green™
OSTARA
Jim Hotchkies
NuReSys
(prototype) Dairy processing (BE) full
MAP BIOSTRU
NuReSys
Dr. Wim Noerman
NuReSys Potato processing (BE) full MAP
BIOSTRU
NuReSys
Dr. Wim Noerman
P-RoC Neuburg (DE) pilot Ca-P at CSH KIT CMM
Dr. R. Schuhmann
PHOSTRIP Brussels-North (BE)
Aquiris (Veolia Eau) pilot MAP or Ca-P Veolia Eau
Process Operator/location Scale Output Contact
P recovery during or after incineration
MEPHREC Nürnberg (DE)
SUN full P-fertilizer
Ingitec
J. Mallon
SUSAN
Koenigs Wusterhausen
(DE)
RETERRA
full P fertilizer Outotec
L. Hermann
Thermphos Vlissingen (NL) full White P4 Thermphos
Willem Schipper
LeachPhos MSWI plant of Bern
(CH) pilot
MAP or
CaP
BSH
S. Schlumberger
RECOPHOS ?(DE) full P fertilizer RecoPhos
Mr. Bohndick
? Tangermünde (DE) full P fertilizer Loser Chemie
Mr. Loser
P recovery units – during or after incineration
www.p-rex.eu
Undiluted incineration -> ash
Highest recovery potential (> 90% P compared to influent)
Wh
at a
bo
ut
Aq
uaf
in a
nd
Eco
Ph
os?
P recovery - feasibility
www.p-rex.eu
dry matter
content after
deatering
cost Fe-saltdisposal cost
sludge
opex Air-
PrexRockAway total cost
TR (%) €/a €/a €/a €/a €/a
Fe-salt 20 g/m³
Influent ß= 1,329 503.953 2.585.480 0 0 3.089.433
Bio-P with
RockAway20 0 3.176.366 0 150.000 3.326.366
Bio-P with
AirPrex25 0 2.537.942 314.153 0 2.852.095
Benefits due to AirPrex unit: - Reduced maintenance (no more clogged pipes), centrifuges run smoother - Improved dewaterability of sludge (+ ~5% dry matter ) -> reduction of disposal costs - Reduced chemicals consumption - Annual cost reduction: 474,000 €
The practical example of WWTP Neuwerk (Niersverband):
(Niersverband, Bäckler 2012)
P recovery – next generation
www.p-rex.eu
WAS
Thickening 6-7% DS
Thermal Hydrolysis
Lysotherm®
(150°C, 30 Min.)
Struvit pecipitation and recycling
LysoPhos©- Process
+ Mg(OH)2 + NH4
Sludge dewatering
Sludge water to
bio- treatment
(P- reduced) Struvit washer
prim. sludge
digestion
WAS digestion
Primary sludge only
Lysotherm® - LysoPhos® = LysoGest® optimized energy and phosphate process by separate sludge treatment
How to increase P-recovery rate from wastewater?
www.p-rex.eu
Demonstration and systematic validation of technical processes at full-scale facilities
Systematic assessment and validation of the quality of obtained recycling products with regards to plant availability of phosphorus
Analysis of market barriers and market potential for novel recycling
technology and recycling products Development of strategies and recommendations for efficient and
wide-spread phosphorus recovery and market penetration from the wastewater stream with regards to specific regional conditions -> policy brief, guidance document
Project Goals
EU-wide implementation of P recovery/recycling from wastewater stream with respect to regional conditions and demands
Key deliverables
www.p-rex.eu
Integral guidance document and policy brief
Technical comparison of promising, available P-recovery/recycling technologies based on real life data (including detailed factsheets for every process, BAT)
Environmental impact and costs of compared technologies in relation to traditional valorization of sewage sludge and mineral fertilizers based on fossil P rock
Agreed methodologies for LCA and LCC to be used for other projects/assessment studies
Stakeholder workshops (market survey and regional conditions) -> broad base input
Educative film and summer school
Project website and e-market for P-recycling products
(BWB) (BWB)
P recovered P recovered
Feasibility of joint application wastewater / manure? Infratructure?
What are the real market requirements besides the legal requirements (base line)?
Market issues and synergies
www.p-rex.eu
P recovered
LEGAL framework Nutrient concentration Pollutants Plant availability Eco-toxicity Hygiene
Market framework Price Purity (MAP?) Quantity Shape Handling Operational benefits? Consumer concerns?
Example: AirPrex® Berlin-Wassmannsdorf
www.p-rex.eu
MAP ~ 60-70%
Moisture: 10%
Sand and organic matter: 10%
Approved fertilizer “Berliner Pflanze”
Sales price depends on package size:
The smaller the higher … (2.50€/kg)
Challenge and potential: improvement of yield and quality
Raw product composition
Outlook
www.p-rex.eu
Struvite recovery is state of the art for P recovery/recycling (limited to Bio-P plants and recovery max 50%)
-> already a growing market in terms of process technology, esp. when additinal benefits for operator -> still need to develop market for products (MAP, HAP etc.) several thousand tons per year within the next 2 years -> REACH!!! -> whereas legal requirements are quite clear, the real end user needs are still hidden
If recovery >80% -> mono-incineration incl. ash treatment to obtain marketable and
useful products
Infrastructure or technology applicable for manure? -> what‘s better: separation and concentration of nutrients in solid phase and then treatment of aqueous phase (or irrigation?) -> or treatment of the manure in WWTP?
The Metropolitan Case Study
www.p-rex.eu
WASTE/
WASTEWATER
P-RECYCLING
PRODUCT
AGRICULTURE
FOOD
Outlook
www.p-rex.eu
Still need to involve all stakeholders on equal eye level -> more efficient collaboration, more impact -> that‘s ressource efficiency by means!
Science Policy Industry
Policy
Science
Science
Industry
Industry
Policy
YES, TOGETHER WE CAN !!!
I f w e w a n t t o ! ! !
P Platform
Thank you for your kind attention!
www.kompetenz-wasser.de
See you there:
EU Sustainable P Conference
in Brussels 6-7th March 2013
Global TraPs World Conference
in Beijing 18-21th June 2013
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