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6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Conversion of sewage sludge into solid fuel project in the City of Osaka
– For creation of a recycling-oriented society and prevention of global warming –
Tsuyoshi Sanjo
Osaka, JAPAN
17 May 2018
1
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
• Background
• Three Key Points
• Overview
• Benefits
• The future plan for further utilization of
biomass energy
• Conclusions
Contents
2
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Osaka pref.
City area : 222 km2
Resident population: 2.66 million JAPAN
Profile of Osaka City
Osaka Castle
Dotonbori River
Universal studios
Japan
3
Tokyo
Kyoto Sewage Treatment Plants (STPs) : 12 (●)
Hirano STP
Maishima sludge treatment plant
G20 summit Osaka 2019
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Influx Reaction tank Primary
settling tank Effluent
Primary sludge
Wastewater Treatment
4
Final settling tank
Excess sludge
Gravity thickener
Thickening Dewatering
Digested sludge
(from other STPs)
Dehydrator Dewatered
sludge
Slag
Recycling (Construction
materials)
Melting furnace (2000- )
City gas
Melting
Sludge Treatment
Incineration
Ash Landfill
disposal
(waste) Kerosene
Incinerator (1982- )
New sludge-recycling facility
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
waste
End products
Ash Landfill disposal
New approach for sludge recycling
Treatment method
5
Incineration (800ºC)
End use
Incinerator
Construction work Melting (1200ºC) Slag Slag
Sewer pipe
Material
use
(Backfilling sand additive)
GL Melting
furnace
Dewatered
sludge
Energy
use Combustion with coal
Coal-fired
power plant
Solid fuel
Carbonizing facility
Conversion of sewage sludge into solid fuel project
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
6
1 Treatment method : Low-temperature Carbonization
・Creation of solid fuel (carbon neutral energy source)
2 End users : Coal-fired power plants
・Reduction of coal consumption ・Stable use of solid fuel (full recycling of sewage sludge) 3 Implementation scheme : PFI
・Utilization of a private sector’s strength ・Outsourcing of the project implementation to a private company
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Hirano STP
Project Overview
PFI
7
Dehydrator
D & B Inc.
Outsourcing Osaka
City
Carbonizing Facility
2011 2014 3 years
Design & Build
PFI Contractor
O & M Inc. Purchase & Selling Solid Fuel Inc.
Full recycle of carbonized fuel
Operation & maintenance
Coal-fired Power Plants
20 years 2034
Full recycle of carbonized fuel
Dewatered sludge (49,500 t/year)
Carbonized fuel (8,558 t/year)
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Drying (700ºC)
Coal-fired
Power Plants
Carbonization furnace
Sludge dryer
Granulator Hopper
Dewatered sludge
8
Granulating
Carbonized
fuel
Low temperature
carbonization
(250-350ºC)
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Granulated dried sludge
Flue gas
250-350ºC
Carbonization furnace ・Rotary kiln
・150t (33t-DS)/day
Carbonized fuel 13.0 MJ/kg (half of coal)
Φ 5-10 X 15 mm 9
Re-combustion furnace
850ºC
Suppression of
N2O generation
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
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Amount (t/year)
41,875
49,500 46,004
5,500 8,558 7,935
0
10,000
20,000
30,000
40,000
50,000
60,000
Generated ash
Produced
Carbonized fuel
Dewatered sludge
Planned value 3 year-average
(2011-2013)
2 year-average
(2015-2016)
Incinerator Carbonizing facility
12,000 MWh / year
(3,800 households)
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
50 400 200 1,400 2,200 2,700
7,000 7,600 4,300
11,000 500 500
-15,000
-10,000
-5,000
0
5,000
10,000
15,000
20,000
Incinerator
Sources of GHG
Chemicals
Electricity
Auxiliary fuel (city gas)
Auxiliary fuel (kerosene)
Use as coal alternative
3 year-average (2011-2013)
11
+16,750
GHG emission (t-CO2 / year)
N2O Reduction ①
Planned value 2 year-average
(2015-2016)
Carbonizing facility
+10,100 +11,000
Reduction②
-10,000 -9,000
+16,750 +100 +2,000
- 14,750 (t-CO2 / year)
(emissions from 3,090 cars
circling the globe(40,000km)
Net emission (t-CO2 / year)
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
PSC PFI
(発注前)
PFI
(契約後)
Blanket
order
order
Operation & Maintenance: 3 years
Design & Construction: 20 years
Traditional scheme (Separate order)
PFI
0
10
20 billion yen (\)
12
Project benefit 3: Life cycle cost reduction under PFI
- \1.52 billion
(- €11.6 million)
1 € = \ 131 (March 2018)
Planned amount
order
Total project cost
Project period (23 years)
Contract amount
\17.7 billion (€135 million)
- \1.89 billion
(- €14.4 million)
PFI
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Primary sludge
13
Excess sludge
Sludge Treatment
Gravity thickener
Thickening Dewatering
Dehydrator
Carbonizing
Solid
fuel Recycling
(Coal
alternative)
Melting
slag
Recycling
(Construction
materials)
Carbonizing facility (2014- )
Melting furnace (2000- )
Digested sludge
(from other STPs)
City gas
City gas
Digestion
Digestion tank
② High temperature digestion (53ºC )
Digestion gas
Mechanical
thickener
① Separate and two-stage
thickening for excess sludge
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
14
・Low-temperature carbonization technique converts
sewage sludge into solid fuel as energy source.
・Utilizing carbon-neutral carbonized fuel leads to
GHG reduction.
・By using PFI, the 23-year project implementation
including full recycling of solid fuel becomes more
efficient, economical, and stable.
Conclusions
6th EWA / JSWA / WEF Joint Conference
„The Resilience of the Water Sector“
15-18 May 2018, Munich, Germany
Coal-fired
power plants Community
Carbonizing facility
Recycle
oriented
society
Sewage sludge
Power
Promotion to use biomass fuel
Reduction of GHG emissions
15
Building a Recycle oriented society and Preventing global warming
Carbonized
fuel