dewaco – your best partner -...

DEWACO Your Best partner

DEWACO LTD

Established: 1986Head office and workshop: Laitila, FinlandOverseas sales office: Beijing, ChinaActivities: Designing, manufacturing, marketing of

sludge handling equipmentRepresentatives: Over 20 countriesInstallations: Over 80 countries

Sentica PartnersMain owner of Dewaco

Group of 14 mid- and small size high-tech companies

Total turnover 180 MEUR

Total number of personnel in Group companies over1.800

Dewaco CAVIA-technology

Product and consept comes from successful teamwork between Dewaco, Finnsonic, YIT and TechnicalResearch Centre of Finland

Ultrasound technology comes from Finnsonics30 years of experience and deep understanding ofhigh intensity ultrasound applied on liquids

Business comes from mutual ownership of Dewacoand Finnsonic enabling well coordinated andconsistent collaboration

The latest and very powerful driver to promote CAVIA-technology is the global struggle against climatechange

Aviation Automotive Machinery Electronics OEM

& Engineering

Ti Automotive

FinnSonic was founded in 1979.The first products were small ultrasonic cleaners.

Since then, FinnSonic has grown to be the biggest manufacturer of industrial cleaning machines inScandinavia.

Dewaco CAVIA-technology for our future

The main idea is in utilizing CAVIA-technology to intensifyWWTPs sludge digestion

FINANCIAL benefits for a customer: Earnings from enhanced biogas production = cost free energy Savings from diminishing residual sludge volume

ENVIRONMENTAL added value: Increased volume of biogas from the existing digester means more

cheap, green, sustainable energy Less residual sludge to be transported and treated means lower loadon environment

Dewaco CAVIA system

USE OF CAVIA SYSTEM IN DIGESTING AND WASTE WATERTREATMENT PLANTS

1. OPERATION PRINCIPLES OF DIGESTER AND WWTP PLANT- HOW THE PLANTS OPERATE AND WHAT DO THEY PRODUCE- IN ENERGY PRODUCTION THE EFFICIENCY IS IMPORTANT

2. WHERE AND HOW THE CAVIA SYSTEM CAN BE USED- CAVIA ENHANCES THE EFFICIENCY IN THE ABOVE PLANTS

3. WHY THE DIGESTER AND WWTP PLANT BENEFIT FROM THECAVIA SYSTEM AND HOW THE CAVIA ENHANCES THE EFFICIENCY OFTHE PLANTS ENERGY PRODUCTION AND REJECT QUALITY

Dewaco CAVIA system

USE OF CAVIA SYSTEM IN DIGESTING AND WWTP PLANT

Dewaco CAVIA system

USE OF CAVIA SYSTEM FOR DIGESTING

BIOGAS RAW MATERIAL BY TYPE

Municipal solid wasteMixed wasteWaste from food industryOutdated food from shopsBakery wasteWashing waters from industryWaste water treatment sludgeSeptic wasteAgricultural wastePig manure + strawOther animal manuresPrimary sludgeActive sludgeSecondary sludge

Dewaco CAVIA system

USE OF CAVIA SYSTEM FOR DIGESTING

1 m3 of methane (100%) equals 10 kWh energy content

Energy content. examples: 1 m3 of biogas with methane of60% equals of 6 kWh of total energy.

When using the biogas in- steam boiler with effiency of 80-90% you shall have realpower of 4,8-5,4 kWh-gas engine : with 35% electrical efficiency you shall have the2,1 kWh of electricity and heat maximum of 3 kWh.The heat is recovered from engine cooling and exhaust gases-micro turbine: 30% electrical power, 1,8 kWh from 1 m3 ofbiogas with 60% of methane.

-All this energy can be enhanced with the use of CAVIAsystem by 25 to 40%-In addition, the use of CAVIA system will decrease the plantcost by reducing the reject sludge amount by 15-25%


PHYSICAL BASICS OF TECHNOLOGY :

Cavitation the phenomenon

Cavitation is generated by high frequency mechanical vibration (ultrasound)

?Ultrasound = sound frequencybeyond the audible limit of humanear

InfrasoundHumanhearing Ultrasound

20 Hz 20 000 Hz


PHYSICAL BASICS OF TECHNOLOGY :

Cavitation the phenomenon

Intensive high frequency energy in liquid generates CAVITATION.

In cavitation millions of microscopic high vacuum bubbles are generated inliquid.

Bubblesize

Time

Cavitation bubbles expand, oscillate and implode

Cavitationbubble

Dewaco CAVIA technology

MECHANICAL EFFECTS OF CAVITATION AT LIQUID/SOLIDINTERFACES

1. Pressure/ heat impacts

These phenomens disintegrate flocks, cells, micro-organisms

Pressures over 1000 bar and temperatures of severalthousands of degrees have been reported

Cavitation (implosions) generates microscopic butvery strong impacts at solid surfaces

2. Microturbulences at the surfaces

The very strong over-/under pressure vibrataion generatesmicroscopic but aggressive turbulent streaming at the solidsurfaces

3. Direct effects of pressure vibrations at material surfcases

The strong under/ over pressure vibration effect solid materials alsodirect. These mechanical foreces expand and compress material onmicroscopic level resulting e.g. opening of poruses in materials etc.

Dewaco CAVIA system

POSITIVE CONSEQUENCIES:

Breaking organisms releases nutrients activating the anaerobic bacteria

Activated bacteria population generates a secondary processboosting the whole digestion process

Dewaco CAVIA system

NORMAL FERMENTATION PROCESS IN BIOGASPLANT

HYDROLYSIS FERMENTATION BACTERIAL PROCESS I BACTERIAL PR IICASETOGENIC METHANOGENICCarbon-

hydratesSugars

Organic acidsand alcohols

Fats

Proteins

Fatty acids

Amino acids

HydrogenCarbon dioxideAmmonia

HydrogenAcetic acidsCarbon dioxide

MethaneCarbon dioxide

Digestion is a complex, multistage chemical process where allmechanisms and interdependencies of various factors are notknown with all details

Dewaco CAVIA system

CAVIA ENHANCED FERMENTATION PROCESS IN BIOGASPLANT

HYDROLYSIS FERMENTATION BACTERIAL PROCESS I BACTERIAL PR IICASETOGENIC METHANOGENICCarbon-

hydratesSugars

Organic acidsand alcohols

Fats

Proteins

Fatty acids

Amino acids

HydrogenCarbon dioxideAmmonia

HydrogenAcetic acidsCarbon dioxide

MethaneCarbon dioxide

CAVIA REACTORFaster degradation of macromolecules = highway for gas production

-increased biogasproduction-higher organic reduction


The key component of CVT-technology is the CVT-reactor (=cavitation reactor)

The reactor does NOT consist of a sonotrode immersed in sludge, but a tubularvibrating reactor, through which the sludge flows

TUBULAR REACTOR

SLUDGE

The principle offers following advantages:1) Easy mounting at an existing sludge piping

2) Tubular geometry concentrates the power effectively on sludge flowing though

3) The surface transferring vibration energy into sludge is large providing large active area

and lower erosion


Symmetric cross section:No part of sludge canescape from treatment

Tubular cross section:Cavitation energy penetratesdeeper due to that fields getsummarized in centre

Tubular cross section:Cavitation energy istransferred to sludgethrough a large surface

Tubular reactor construction advantages

A lot of development effort was put on:

1. Good energy transfer fromreactor walls to sludge

2. Low cavitation erosion to reach long life time

3. Effective power penetration in highvicosous sludge

ENERGY

ENERGY


ConventionalTransducer

ImprovedTransducer

Transducerfor sludge


1. Good energy transfer from reactor walls to sludge

2. Low cavitation erosion to reach long life time

3. Effective power penetration in high viscous sludge

Important targets in development work have been:

The most modern development tools of VTT were used

All three factors much depend on vibration mode of transducer surface.This was developed and verified e.g. by using laser scanned videos.

ConventionalTransducer

ImprovedTransducer

Transducerfor sludge

Perint laatta.avi Palkki.aviV35_20kHzkaann.avi

Dewaco CAVIA system

Cavia type generator for sludgetreatment

Cavia type impedance adaptor forsludge treatment

Dewaco CAVIA remote monitoring system

GENERATOR

3 x 400 V,50/60 Hz

IMPEDANCEADAPTOR

HF

WWTP

Remote login viaInternet VPN(or GPRS)

Dewaco

Server

PLC/Dewaco

125 parameters23 settings

Modbus

RS 485

GPRS

HFCPLDIGPT-output

DSC control ofActual powerPhase angle

REACTOR

CPLD = Complex Programmable Logic Device DSC = Digital Signal Control

Dewacos delivery limit

Dewaco CAVIA remote monitoring system

Advantages of remote log in:

Regular and easy follow up by Dewaco to secureproper function

Easy readjustment of parameters by Dewaco incase circumstances change in plant

Effective consulting of WWTPs own personnel inany practical question


Generators parameter list view on computer screen for checking and setting

CAVITATION TREATMENT SYSTEM

More Biogas Less residual sludge Improved dewatering Less chemicals Less expenses

Wastewater Primarysedimentation

Aerobictreatment

Secondarysedimentation

Purified wastewater

Thickening bygravitation

CAVIA-reactors

Thickening byGravity table

Digestion

Dewatering

Sludge

Primary sludge

Return sludge


Dewaco CAVIA system- technical information


DIMENSIONING OF CAVIA-INSTALLATION:

Main principles:1)ONLY biosludge (excess sludge) is cavitation treated not primary sludge

2)ONLY abt. 30% of biosludge is treated

3)DS-VALUE of biosludge going into treatment should be abt. 4%

The must information to design/size the cavitation unit (*

How big volume is fed into digester m3/day * m3/day

What is the DS value of sludge fed in * %

What is the mixing ratio of sludge fed into digester -primary/biosludge *

% primary% bio

Does the feeding go continuously or in periods if inperiods, what kind of periods *

Dewaco CAVIA system

Advantage and Feature ofAdvantage and Feature ofDEWADEWA CavitationCavitation systemsystem

- extremely high biogas improvement, as high as 40% - extremely high sludge reduction approx. 25% - high unit capacity - whole set control system - easy to handle including set adjustment and training - to increase overall digesting capacity - to reduce further sludge handling cost - one-body flange to flange installation, easy to connect with

s existing digestion system, turn-key system. - In bigger installations these modules are multiplied to match the total volumes

Dewaco CAVIA systemDewaco CAVIA system -- Riihimki WWTPRiihimki WWTP

Example situation of operation in Riihimki WWTP:Cavia started on week 31, Cavia stopped on week 44!

020040060080010001200

2425262728293031323334353637383940414243444546Week

m3/tVS

3/t VS) app 40% ! "#$%!%

Average results received in Riihimki WWTP:

Weekly report from plant:

TESTS AND RESULTSTESTS AND RESULTS ANALYSED BY TECHNICAL RESEARCH CENTRE OF FINLAND :ANALYSED BY TECHNICAL RESEARCH CENTRE OF FINLAND :

0

5

10

15

20

25

24 29 34 39 44Week

BiogasandVS-reduction

0

20

40

60

80

100

ProportionofUS-sludge(%)

VS-reduction (%)Biogas production per feeded sludge ((m3/d)/(m3/d))Proportion of US-sludge in excess sludge (%)

2,5

3

3,5

24 29 34 39 44Week

Drysolidsofdigestedsludge(%)

US-sludge


0

200

400

600

800

1000

1200

22 27 32 37 42 47Week

Biogasproduction(m

3 /tVS)

0

20

40

60

80

100

ProportionofUS-sludge(%)

BiogasUS-sludge

Dewaco CAVIA system

SLUDGE AMOUNTS to Digester: Total Primary volume 220 m3/d @ 7%DS Total TSAS volume 2210 m3/d @ 0,7%DS

Only TSAS sludge will be treated, AND only 1/3 of total TSAS volume DS% for cavitation must be app. 3-6%DS (4%DS)

1/3 of TSAS will be thickened with Belt thickener to 4%DS! i.e. CAVIA will treat average 5,4m3/h @ 4%DS

Required amount of reactors: (1 reactor can handle max. 2 m3/hr @ 4%DS) - 3 reactors required! Customer purchased 3+1 reactors = 2 similar packages,both with 2 reactors

Treated sludge will be fed directly to digester tank together with other sludgevolumes.

Result: 20% more biogas + 15% less residual sludge

Dewaco CAVIA system

SLUDGE AMOUNTS to Digester: Total Primary volume 220 m3/d @ 7%DS = 15,4 tDS Total TSAS volume 2210 m3/d @ 0,7%DS = 15,5 tDS Result: 20% more biogas + 15% less residual sludge

BIOGAS AMOUNT Estimation without Cavia 2 500 000 m3/a (not confirmed) Addition with Cavia: 500 000 m3/a (addition 20%)

RESIDUAL SLUDGE AMOUNT - without Cavia = 30,9 tDS/d - with Cavia (estimation 15 % less residual) = 26,3 tDS/d Sludge reduction 4,6 tDS/d (15% less handling, transportation, polymercosts,space for landfilling etc.) = 1 600 tDS/a

POWER CONSUMPTION app. 70% of installed power = 15 kW/h

DIFFERENTIATING FROM COMPETITORS WITH COMPARABLE SOLUTION:

COMPETITORS DEWACOMany competitors are spin off fromuniversity background with nooverall know how of practical WWTP-technology

Dewaco is a well establishedcompany with own productdevelopment, sales channels,production and abt. 30 years ofpractical experience in sludgetechnology

Many competitors offer onlyultrasonic components and nototal solution

Dewaco offers a full conceptincluding all necessary technologywith correct dimensioning, after salesservice etc.

Many competitors buy the keycomponents from some ultrasonicmanufacturer with no deep goingcollaboration

Dewco owns the key technology andbuys it from a sister company inthe same group

Many competitors use standardsonotrodes developed for otherpurposes and only now applied tosludge treatment

Dewaco has developed a specialtubular reactor designedspecially for sludge treatment

Dewaco CAVIA system

Dewaco CAVIA system

RiihimkiRiihimki WWTP, FinlandWWTP, Finland

Customer:Municipality of Riihimki

Treated amount:Total TSAS volume 180 m3/dCAVIA use 60 m3/d

Start up made on 30.7.2007Delivery: 1 nos. of CAVIA system, with 3 reactors1 nos. of DEWA Belt Thickener BTN1020

Average results received in Riihimki WWTP:1. Increased biogas production (500 700 m3/t VS) app 40%2. Increased VS reduction (8 14 %)3. Increased TS of digested sludge (2,8 3,2 %)

Dewaco CAVIA system

New reference from PolandNew reference from Poland

Klimzowiec WWTP, in Chorzow, Poland

Customer:Cadaqua int. (Spain)

Treated amount:Total TSAS volume 2210 m3/d @ 0,7%DSCAVIA will treat 4,5-7,6 m3/h @ 4%DS, average 6m3/h

Delivery:2 nos. of CAVIA system, both with 2 reactors2 nos of Belt thickeners BTN2535 (thickening)2 nos of Belt filter presses FPD21 (after digestion)

Installation on 17.12.2010, Start up on 21.1.2011

Dewaco CAVIA system- Belt thickening (thickening sludge to digester)

Belt thickenrs are giving very reliable and high DS resultsPrice level is much lower compared with centrifugesTotal operational costs are much lower (energy,maintenance etc.)Unit capacity can be huge up to 200 m3/hr

Reference in Gryaab WWTP, GothenburgSweden-4 nos of BTN2535 units installed- Capacity each 150 m3/hr(infeed 0,1%DS, outlet 5-8%DS)

Dewaco CAVIA system

dewaco – your best partner -...

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