awwu biosolids management opportunities

AWWU BiosolidsManagement

OpportunitiesAugust 2, 2016

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Residuals Resource Recovery

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.


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


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

awwu biosolids management opportunities

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