AWWU BiosolidsManagement
OpportunitiesAugust 2, 2016
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Overview
• Introductions• Discussions of Biosolids Issues Faced by AWWU• Biosolids Processing Options – Today and into the Future• Potential Opportunities for
– Dewatering– Drying– Pyrolysis/Gasification
• WERF Participation• Q&A
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Biosolids Issues faced by AWWU
• Open discussions
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Biosolids Processing Options – Today and into the FutureTodd Williams
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Trends in Biosolids Management
• What are the trends?– Improved quality due to regulatory and public concerns
• Class B to Class A• Research towards reduction/elimination of trace constituents
– Reaction to climate change• GHG emission reductions• Climate change adaptation
– Energy efficiency/optimization• Advanced anaerobic digestion
– Thermal hydrolysis• Co-Digestion (FOG and HSW) to generate more biogas
– Biogas for driving CHP and biogas upgrading• Whole plant optimization
– Carbon redirection• Energy Recovery from Thermal Systems
– Future Technology development• Gasification• Pyrolysis• Hydrothermal liquefaction• Supercritical water oxidation
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Trends in Biosolids Management
• What are the trends?– Improved quality due to regulatory and public concerns
• Class B to Class A• Research towards reduction/elimination of trace constituents
– Reaction to climate change• GHG emission reductions• Climate change adaptation
– Energy efficiency/optimization• Advanced anaerobic digestion
– Thermal hydrolysis• Co-Digestion (FOG and HSW) to generate more biogas
– Biogas for driving CHP and biogas upgrading• Whole plant optimization
– Carbon redirection• Energy Recovery from Thermal Systems
– Future Technology Development• Gasification• Pyrolysis• Hydrothermal liquefaction• Supercritical water oxidation
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FOG and HSW Addition to Digesters and CHP is Trending up•3 Times as many WRRF’s are without Anaerobic Digestion (AD)
as those with AD
•3 Times as many WRRF’s with AD do not generate power or drive plant equipment as those that do
•6 Times as many WRRF’s do not import FOG or high strength waste to feed digesters as those that do
• Plenty of opportunity exists for development of energy recovery at WRRF’s in the next decade. This is a big trend.
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Emerging Technologies for Biosolids Management as Defined by the USEPA
• Established – Technologies widely used (i.e. generally more than 25 facilities throughout the U.S.) are considered well established.
• Innovative – Technologies meeting one of the following qualifications: (1) have been tested at a full-scale demonstration site in this country; (2) have been available and implemented in the United States (U.S.) for less than 5 years; (3) have some degree of initial use (i.e. implemented in less than twenty-five utilities in the U.S;. and (4) are established technologies overseas with some degree of initial use in the U.S.
• Embryonic – Technologies in the development stage and/or tested at laboratory or bench scale. New technologies that have reached the demonstration stage overseas, but cannot yet be considered to be established there, are also considered to be embryonic with respect to North American applications
Note : Red lettering indicates suggested deletion to this definition by CH2M
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Biosolids Stabilization Technologies
Anaerobic Digestion
Aerobic Digestion
Conventional (Mesophilic)
Anaerobic Digestion (MAD)
Conventional Aerobic
DigestionAerobic
Thermophilic Pretreatment
(ATP)Auto-
ThermophilicAerobic
Digestion (ATAD)
Aerobic/Anoxic Digestion
Temperature Phased
Anaerobic Digestion
(TPAD)
ThermophilicAnaerobic Digestion
Pre-pasteurization
Composting Drying Chemical Stabilization
High TemperatureCombustion/
Oxidation
Windrow
Enclosed/In-vessel
Vermi-Composting
(mix with earthworms)
Aerated Static Pile
Direct Thermal Drying
(Drum, Belt)
Indirect Thermal Drying
(Paddle, Auger. Disc.)
Vertical Tray Dryers
Flash Dryer
Solar Drying (greenhouse or open air)
FluidizedBed Drying
Alkaline Stabilization
EnVesselPasteurization
(RDP)
Lystek
SchwingBioset
FluidizedBed ReactorIncinerator
Multiple Hearth
Furnace Incineration
Supercritical Water
Oxidation
Pyrolysis
GasificationMAD with Post
Aerobic Digestion
VitAg/AnuviaFertilizer
Universe of Biosolids Alternatives
Pre-Digestion Conditioning or
Hydrolysis
Thermal Hydrolysis (Steam)
Thermal Hydrolysis(No Steam)
Chemical/Thermal Hydrolysis
Biological (Acid) Hydrolysis
Intermediate Thermal
Hydrolysis
Solid Stream Thermal
Hydrolysis
Recuperative Thickening
Hydrothermal Liquefaction
Membrane Covered Pile
Pulsed Electric Hydrolysis
High Solids Digestion
Hybrid Compost Systems
NuTerra
Dryer/Furnace
Multi-Stage Digestion
Embryonic
Innovative
Established
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Phosphorus Recovery / Struvite Management
• A component of sustainable nutrient management and resource recovery
• Produces P fertilizer that has value– Worth about $40 per ton on open
market
• Minimize impact of sidestream, especially at Bio-P WWTPs
• Drastically reduces struvite issues• Control Ca and Mg in the biosolids for
best results• Good information from WERF
Studies
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PrimaryClarifier
FinalClarifier
AnaerobicDigester Dewatering
Incineration
RAS
WAS
Centrate/Filtrate
Ash
PrimarySludge
Potential Locations for Nutrient Recovery at Water Resource Recovery Facilities
N and P recovery
P recovery
N and P recovery
Bio-P Process
P recovery
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Solids Management Facility Plan at Green Bay led from incineration to digestion and incineration
• 2005 – 2008 NEW Water and CH2M developed the Solids Management Facility Plan (SMFP)
– Planning to 2035– 73 solids unit processes considered– From 52 remaining after screening, 17
process configurations (pc) developed– 6 alternatives selected and evaluated
in detail
• Capacity– 43 dtpd average– 56 dtpd max month
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Selected Solids Processing Solution
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Solids Building Overview
Nutrient Recovery
Dewatering Pre-Drying
Cake Pumping
Incineration Cogeneration
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Resource Recovery and Electrical Energy (R2E2) Project
• NEW Water is implementing the SMFP through R2E2– NEW Water expectations
• Estimated capital cost US $169 million• Construction completion 2018• R2E2 will generate 70% to 75% of GBF power and heating requirements
– Status• Construction commenced July 2015• Progress as of July 2016
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Future Technology Development Status• Embryonic Technologies
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EmbryonicGenifuel - Hydrothermal Liquefaction
and Catalytic Gasification
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Genifuel Status
• Proof of Concept Bench testing at Pacific Northwest National Laboratory
• Bench Tested Primary, Waste Activated and Digested Sludges
• Yield of 25-37% crude oil on mass basis, 39-59% on carbon basis
• High methane content (>75%) in gas• Metro Vancouver is participating• Looking for full scale demonstration
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Embryonic – Aquacritox Supercritical Water Oxidation
• Complete conversion of organics in less than a minute
• Complete conversion of N possible at higher temperatures (540°C)
• Planned pilot testing in Orange County, CA
• Water above 374°C (700°F) and 221 bar (3,000 psi), reaches supercritical state
• Eco-Innovation Initiative funded demo is being developed in Cork, Ireland
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Embryonic – KORE Encore Pyrolysis
• Ran pilot at LA San Districts for 5 years
• Full scale demonstration project is under construction, on line late 2016
• Thermo chemical pyrolysis that generates a liquid fuel.
• Biochar results• Syngas is transformed by
Fischer-Tropsch process to produce advanced biofuels such as bio-diesel
• Patented process with turnkey developers.
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Drying
Dave Parry
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The Universe of Biosolids Dryers
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Technology Features – Drum Dryers
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Technology Features – Drum Dryers
• Advantages– Product quality– High capacity/throughput– Operating experience
• Disadvantages– High cost– High safety provisions– Complexity, O&M– Not amenable to heat recovery
• Installations– Jones Island, UOSA, Changi, Louisville (DB), Corona, Bonita Springs,
Leesburg, Blue Lake (DB), Stamford, Philadelphia (DB)
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Technology Features – Belt Dryers
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Technology Features – Belt Dryers
• Advantages– Product quality (moderate)– Safety (lower temp & low dust)– Waste heat opportunities
• Disadvantages– Large footprint vs capacity– Moderate complexity, O&M
• InstallationsKarlsruhe, Germany, St. Joseph, MO, Cape Girardeau, MO, Shamokin, PA, Milton, PA, Oak Harbor, WA, Avonmouth, UK, Grudziadz, Poland, Balingen, Germany
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Technology Features – Belt Dryer Waste Heat Recovery Opportunities
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Pyrolysis/Gasification
Dave Parry
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Pyrolysis/Gasification – Thermal Conversion
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Pyrolysis, gasification and combustion in the flaming match
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Pyrolysis of Biosolids Status• Encina pilot demonstration by
Anaergia – low temperature– Containerized pyrolyzer utilizing
electric screw– Technology installed and in
operation– Processes 1,000 lb/hr of dried
biosolids pellets (50% of plant production)
– Produce biochar to commercialize recognizing higher value as a fertilizer / soil amendment
– Pyro oil and gas directed to Digester #5 for co-digestion with plant sludge. Give sludge a second chance!
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Gasification/Pyrolysis Status
• North America– Maxwest
• Sanford, FL – Downflow fixed bed, Fenton dryer• Upgraded to fluid bed, Therma-Flite dryer• Bankruptcy in 2014, sold technology to PHG
– Nexterra• Upflow gasifier, Kamloops product development centre• Active in biosolids (~2010 to ~2014)• Pilot tested MV biosolids, Stamford, CT pellets in Kamloops• Changed focus in 2014 until future
– PHG Energy• Downflow fixed bed (biosolids/woodwaste) and fluid bed• Covington, TN, developing project with Delta Diablo, CA
– Laboratory Scale Research• Marquette University• Pacific Northwest Labs
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Gasification/Pyrolysis Status
• Europe– Kopf- Syngas
• Fluid Bed, gas conditioning, syngas electricity production• Balingen
– Pilot and full-scale– Shutdown in 2014
• Mannheim– Completed in 2013– Low production
• Kopf refocused business away from gasification– Pyreg Linz-Unkel on-line in 2016 in Germany– UK
• Universities and Water Companies doing research• Early stage of development• Thames Water building a 15 dt/d pyrolysis system in London using
EPi Energy technology
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Pyreg® 3.8 dtpd facility in Linz-Unkel Germany
Open Discussion