Chemical Industry working for Efficiency:new approaches to improve water management

Acqueau Workshop: Industrial Waste Water Treatment

Helsinki, March 12th 2015

Antonia Morales PerezChristina Juengfer - Dechema

Presenting Cefic

Funded in 1972, Cefic is the voice of the European chemical industry.Represents 29.000 large, medium and small chemical companies, with640 members and affiliates. The network is complemented bypartnerships with other industry associations representing various sectorsin the value chain.

1.2 million direct jobs

559 billion sales in 2012,≈ 20% worldwide sales

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Chemical Industry,on the right track

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Innovation

Sustainability Resource Efficiency

SusChem ETP andthe National Technology Platforms (NTPs)

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SusChem:European Technology Platform for Sustainable Chemistry

Who we are :SusChem - the European technology and innovation platform for sustainable chemistry bringing together industry, academia and society

SusChem Mission : To initiate and inspire European chemical and biochemical innovation to respond effectively to society’s challenges

SusChem Vision :To achieve a competitive and innovative Europe where chemistry provides sustainable solutions for future generations

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E4WATER - CASE STUDY OVERVIEW

The research leading to these results has received funding

from the European Union Seventh Framework Programme

(FP7/2007-2013) under grant agreement n° 280756.

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E4WATER CASE STUDIES (CS)

CS4: Italy/ Czech Republic:

in-process water loop closure,

new technology trains

CS1: Netherlands:

Mild desalination,

alternative water

sources

CS2: Belgium:

multi-company

site, Identification

of Synergies

CS5: France: Integrated

water management at a

petrochemical site

CS3: Spain: water loop closure, ensure

process continuation

CS6: Denmark: Industrial

Symbiosis, new

technologies for an

integrated water

management systemWater use ↓

Waste water production ↓

Energy use ↓

Economical efficiency ↑

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Mild desalination of water streams for optimum reuse in

industry or agriculture at affordable costs - Lead by Dow

Terneuzen, NetherlandsSite: Dow Terneuzen, in the south

of the Netherlands, close to the

community

Production: plastics/ chemicals

Situation:

-Scarce fresh water region

-Relative diluted water streams with

different flows

Objectives/Challenges:

-use more streams in the region

(rain water, agriculture, municipal

and industrial waste water)

-find the possibility to collect and

desalinate all streams for low cost

water management.

CASE STUDY 1 - OVERVIEW

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Selected raw water streams: collected Rain /Surface Water, Treated Process Waste Water,

Blowdown from process cooling towers

demo facility:

Robust pretreatment: Coagulation/Flocculation, Ultrafiltration

mild desalination: 2 parallel trains: (1) Nanofiltration, (2) Electrodialysis Reversal

(EDR)

First results:

rain/surface water + treated ww tolerate a fairly modest pretreatment

Cooling tower blow down water apparently is more challenging, due to the nature of the

constituents present in the water

CASE STUDY 1 – FIRST RESULTS AND OUTLOOK

OUTLOOK: scale up mild

desalination units to produce

water from various sources

at affordable costs

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Production: chlorine (Cl2), sodium hydroxyde

(NaOH), Hydrogen (H2) und sodium

hypochlorite (NaOCl).

Enhance the water reuse by global management and synergy

identification on a multi-company site - Lead by SolVic, Belgium

Situation:

-Pressure on fresh water resources.

-Regulatory demands.

-Treatment of high inorganic loaded wastewater,

-Recycle for high quality use,

-Facilitate use of reclaimed water

Objectives:

-Managing the total quantity of waste water

-Upgrade low quality water ( effluents, rain- & freatic water)

streams for re-use

-industrial experimental garden: permanent modular

industrial scale demo unit for water/wastewater or effluent

re-use and for testing new technologies and new materials

Site: Solvic Lillo, Port of Antwerp – Chemical

Cluster

„Multi Company Site“

CASE STUDY 2 - OVERVIEW

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Industrial experimental garden

Different water sources on site

Stage 1 DEMO + Stage 2 DEMO: RO

based desalination installation that aims to

produce high quality process water. Served

as basis for a full scale unit

Stage 3 DEMO: external ww with high salt

concentration for the chlor-alkali process.

Pilot: “Mobile Kit” for recycling in the process

of Solvic. Can be transported and used on

other multi-company site to test the

possibility of recycling waste water in the

same process

Industrial experimental garden: will

provide a platform for demo scale testing of

technologies that allow to improve water and

salt reuse in chemical industry; incorporate

industrial symbiosis

CASE STUDY 2 – FIRST RESULTS AND OUTLOOK

Outlook: continuing with working on the

water management concept to come

close to zero salt waste and zero liquid

discharge.

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Ensure process continuation by closing the water loop and

minimizing fresh water use - Lead by SolVin, Spain

Site: North of Spain, region of Barcelona

Production: PVC, Vinyl products

Situation:

- Waste water has complex organic

load, high flow

- Fresh water limitations

- Emissions taxes

- Plant capacity increase

Objectives:

-Water-loop closure for PVC process up to

90%

-Management of the concentrates

-Pre-basic design

CASE STUDY 3 - OVERVIEW

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MBR Pilot Plantis running: a submerged hollow fibre membrane is used for the UF (good

experience in lab tests). Aim: the treated water is meant to reach the quality specifications for

recycling back to the original process after a desalination step by RO recycling back

Results:

After one month of treatment: an almost acclimatization of biosludge was achieved, with

PVA removals higher than 98%

After six months of treatment: COD and BOD removals are in the range of 80-90% and

>95%, respectively.

In parallel: lab-scale MBR. Aim: to check the replication potential of the treatment route by

testing different PVC effluents qualities applying the same commercial membrane quality.

CASE STUDY 3 – FIRST RESULTS AND OUTLOOK

Outlook:

Solvin will keep

working on its

water

management

concept on

different

production sites

throughout

Europe.

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Enhance in-process water loop closure by integrating biocidal with

wastewater treatment technologies - Lead by PGB N.V., Italy

Site: different production sites in Italy

Production: liquid consumer goods products in

Fabric Care, Home Care and Beauty Care

Situation: high concentrated wash water

generated during cleaning and sanitisation

(COD 20,00 – 50,00 mg/l)

Aim:

-Cleaning and Sanitization water from liquid consumer

goods products in Fabric Care, Home Care and Beauty

Care

-Progress beyond state of the art: combine „waste water

treatment“ technology and „pasteurization/sterilisation“

technology to recycle high concentrated wash water

generated during cleaning and sanitisation

CASE STUDY 4 - OVERVIEW

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Tests on 2 innovation pathways

1: segregation and separation technologies (e.g.

sensors, membranes, evaporators etc.)

2: use of traditional wastewater treatment

technology for this kind of water

several products were tested to see how the

technologies interact with different types of surfactants

which can be present in household chemical products :

anionic, cationic, non-ionic and amphoteric surfactants.

Based on test results: a treatment system has been

defined, combining Nano Filtration Tubular

membranes with MBR.

This treatment system will reduce the overall cost of

wash water handling and will allow treated water to be

recycled into the process as cooling tower feed water.Plan of the 6 ton/day membrane unit for the

Procter & Gamble E4Water pilot site

Outlook:

final lab testing to finalize the design criteria for the Tubular membranes

Test of treatment system (Tubular Nanofiltration + MBR) in P&G plants with different types of surfactant

containing products.

lab testing with different types of technologies on the 3th innovation pathway (use of biocidal

technologies) to define the technology to be able to reuse/recycle chemicals which are inside the wash

water.

CASE STUDY 4 – FIRST RESULTS AND OUTLOOK

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Towards integrated water management system in petrochemical site

- Lead by Total Petrochemicals, France

Site: Costal region (regulatory restrictions,

increasing salinity)

Production: base chemicals and their related

polymers – polyethylene, polypropylene and

polystyrene

Situation:

- Waste water and cooling water streams with

organic and inorganic loads and very high flows

- High consumption rate for cooling and boiler

feed

Aims:

-New water management system that integrates

three major water streams:

•Plant waste water

•Water streams in cooling circuit loop

•Water blow down for the cooling circuit

- Enhanced recycling in cooling circuit

-Reduction of water abstraction > 40 %

-Compliance with limits for wastewater discharge

-Process reliability

CASE STUDY 5 - OVERVIEW

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COOLING TOWER BLOWDOWN PLANT for water

reuse purposes.

Ultrafiltration (UF): filtration flux, filtration time,

coagulant are adapted to get the right Trans

Membrane Pressure. So far, optimized parameters

are close to a filtration flux of 65 lmh and a filtration

time of 40 minutes.

Reverse Osmosis (RO) is feeded by UF. Specific

attention is paid on the permeat quality while RO

brines will have to achieve existing emission limit

values on discharge waters. So far, a concentration

rate of 4 for inorganics has been observed between

inlet UF and outlet RO

COOLING WATER CIRCUIT TREATMENT:

sand filter: ensure a “downstream protection” of

total suspended solids of 10 mg/L

1st disinfection: UV pilot: tested UV doses showed

effect under Legionella concentrations: stabilization at

low dose and decrease at high dose.

2nd disinfection: ozonation: showed effective

controlling of microbial flora in the cooling tower pilot.

EXTENDED WASTEWATER TREATMENT PLANT:

•biofilter: showed efficiencies consistent with

expectations (85% of BOD removal, 50% of COD

removal)

•ozonation: still operated in batch sequences at

doses lower than 15 mg/L. A last O3 campaign is

foreseen after the membranes are stabilized.

•UF/ RO: as follow

CASE STUDY 5 – FIRST RESULTS AND

OUTLOOK

Results:

3 treatment lines for recycling

water

Outlook.

determine the optimal treatment pathway on a

petrochemical plant for achieving the objective at

least a 40% reuse rate

Lab works for identified complex streams

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Bioextraction technology in a symbiotic industrial wastewater

treatment concept creating added value - Lead by Cluster Biofuels

Denmark

Objectives:

deliver an industrial wastewater treatment system, based on

microalgae, where the maximum removal of nutrients equals

maximum added value:

Site: Industrial Symbiosis Kalundborg

Situation: industrial ecosystem, where the residual by-

product of one enterprise is used as a resource by another

enterprise, in a closed cycle. Local collaboration: public and

private enterprises buy and sell residual products, resulting in

mutual economic and environmental benefits.

CASE STUDY 6 - OVERVIEW

-Maximize nutrient removal from waste streams via microalgae growth

-Define the best method for separation of the resulting biomass from the purified water

-Characterize the biomass components to identify added value targets

-Evaluate extraction technologies for the different targets

-Access and evaluate the overall bio-extraction technology in an industrial symbiosis wastewater treatment concept

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ACTIVITIES

-screening of technologies for pre- and post-treatment activities.

-Selection of suitable ww for microalgae production

-Suggestion of best microalgae candidates for ww treatment based

on a high-throughput screening method in microtiterplates coupled to

a fluorescence plate reader.

-completion and official opening of the RTD microalgae facility at the

WWTP in Kalundborg (October 8th 2013)

FIRST INITIAL TESTS ON BIOMASS PRODUCTION AND

NUTRIENT REMOVAL

- on one of two screened process water stream

-in a large-scale photobioreactor (4.000 liter)

-initial tests on pre-treatment of the process water (mechanical

sterilization) and post-treatment of the generated algae biomass

(dewatering/harvesting)

-Analytical protocols established for biochemical composition of

microalgae biomass and for the microplate screening procedure

validated to mesoscale.

-Chemical analysis on the process water before and after treatment

and on the generated biomass, in order to identify the potential in

nutrient removal and biomass quality generated as a result of a low

nutrient based process water growth media, a freshwater microalgae

strain and winter process conditions (low light and temperatures).

CASE STUDY 6 – FIRST RESULTS

AND OUTLOOK

OUTLOOK:

-Large-scale trials in multiple batch

reactors and combined continuous

configuration, on pre-gasified and

mechanical sterilized high nutrient

industrial process water.

-Process optimization and

evaluation on bioextraction concept

combined with an industrial

symbiosis approach.

-Potentials from added value

evaluated with reference to

downstream processing in a

suggested biorefinery concept

-Commercialisation potentials of the

Kalundborg concept - Business

Case

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