1. The document discusses smart solutions for advanced sewage sludge treatment using the Ostara Process to recover phosphorus and nitrogen from sewage sludge.
2. The Ostara Process involves installing a Pearl reactor to precipitate struvite from the wastewater treatment process, recovering up to 85% of phosphorus and 25% of nitrogen.
3. Recovering nutrients in this way produces a valuable fertilizer called Crystal Green while reducing operational challenges at the wastewater treatment plant.
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More Related Content
Ostara
1. Smart solutions at advanced sewage sludge treatment
plant.
Lviv, 07.10.2016 Aleksander Suszyński, PhD Eng.
4. Phosphourous recovery (up to 90 %)
and Nitrogen (up to 25 %) from
recirculated load of nutrients
Example:
WWTP capacity of 60 000 – 90 000 m3
/d
Production of fertilizer 250 – 450 t/year
Savings in range of 550 000 – 850 000 €/year*
*Polish conditions.
Digestion chamber
OSTARA Process - Pearl
8. Ostara’s Growing Installation Base
2005 Year Ostara was founded
40
Number of employees
including: Research,
Operations, Fertilizer Sales
14
Number of commercial
installations worldwide
5 Number of countries with
deployed Ostara solutions
Technology recently implemented in Madrid by Veolia
In Poland there have been conducted already pilot tests in Warsaw, Poznań, Gdynia,
Jarocin, at the moment pilot tests are conducted in Rzeszow
13. Costly Chemical P Removal
Increases Sludge Volumes
SLUDGE
ANAEROBIC
DIGESTION
CENTRATE
THICKENING
PRIMARY ACTIVATED SLUDGE SECONDARY CLARIFICATION
WAS
DEWATERING
F
e
Increases chemical costs
Generates inert sludge
Consumes alkalinity
14. Pearl®
+ WASSTRIP®
Solve Operational Challenges while Maximizing P Available for Recovery
WASSTRIP®
Alleviates struvite
in digester
PEARL®
Recovers high
value fertilizer
ANAEROBIC
DIGESTION
BIOSOLIDS
THICKENING
PRIMARY ACTIVATED SLUDGE SECONDARY CLARIFICATION
DEWATERING
16. Flow sheet – OSTARA Process
MAGNESIUM ADDITION
PEARL
DEWATERING
CLASSIFYING
FEED
DRYING
BAGGING
Product is dried and
bagged on site, ready for
market
24. Main advantages of OSTARA Process implementation:
1.Reduction of secondary load of nutrients at WWTP –
up to 90 % of P and 25 % N.
2.Limitation of struvite generation in digestion
chambers and other equipment.
3.Decraese of sewage sludge being generated up to 25
%.
4.Better dewatering performacne up to 4 % DS. more
5.Minimalisation or lack of dosing chemicals for
Phosphourous precipitation reason.
6.Production of valuable fertilizer.
26. 26
Sludge Drying
Dewatered Sludge Dried Granules
• 18 - 35% DS
• Sticky
• Caloric heating value
< 1 MJ/kg
• biologically active
( digestion processes )
• > 90% DS
• free flowing
• Caloric heating value
- 8 - 11 MJ/kg (digested)
- > 12 MJ/kg ( non-
digested )
• pathogen free
• biologically stable
by
from Waste to Product
Transfer of the dewatered sludge
Why Drying??
27. environmental solutions
Dewatered sludge
20-30% DS
Dried sludge
90%DS
How attractive is dried sludge as a potential
alternative fuel
If we dry up to 90 % DS. sludge with 65 % organic LCV > 13 MJ/kg of granulate
28. environmental solutions
Thermal sewage sludge dryers in PolandThermal sewage sludge dryers in Poland
28
Siedlce
Płock
Płońsk
Ozimek
Końskie
Wieruszów
Chełm
Olkusz
Siedlce
Płock
Ciechanów
Szczecin („Zdroje”)
Poznań
Włocławek
Grudziądz
Białystok
Warszawa
(„Południe”)Grodzisk
Mazowiecki
Piaseczno
Lublin
Radom
Częstochowa
Ruda Śląska Rzeszów
Świdnica
Thermal dryers
Tarnów
Opole
Kędzierzyn-Koźle
Wrocław
Thermal dryers in perspective
Toruń
Koszalin Suwałki
Żywiec
Stalowa Wola
Ciechanów
Tomaszów Mazowiecki
Puławy
Płock
SiedlcePruszków
Żyrardów
Kozienice
Myszków
Skarżysko-Kamienna
Bełchatów
Płońsk
Wieruszów
Bytom
At the moment in PolandAt the moment in Poland
there are 33 thermal sewagethere are 33 thermal sewage
sludge municipal dryers, nextsludge municipal dryers, next
30 are in perspective…30 are in perspective…
Legnica
Kraśnik
Łowicz
Lubartów
Białobrzegi
4 of them are using heat4 of them are using heat
generated in sewage sludgegenerated in sewage sludge
mono incineration plantsmono incineration plants
All other uses in practice onlyAll other uses in practice only
natural gasnatural gas
At majority of drying plantsAt majority of drying plants
big technical problemsbig technical problems
occured that some of foreignoccured that some of foreign
manufaturers had to resignmanufaturers had to resign
from presence at polishfrom presence at polish
marketmarket
29. environmental solutions
Diagram of complex managaement of sewage sludge using waste heat
Power plant
Waste heat
Thermal drying
Valuable alternative fuel –
Dried sludge> 90 % s.m.
LCV a. 12 – 14 MJ/kg
Mechanically dewatered sludge
LCV a. 2 MJ/kg
Steam/flue gases/thermal oil
Solution in 100 % waste free from WWTP
Point of view
Dried sludge is seen as CO2 neutral fuel
Possibility of acquiring sludge from different
plants
Optimal solution for WWTP located nearby
Power Palnts
Operation costs are reduced by 50 – 70 % in
comparison to standard solution
30. environmental solutions
RADOM
3150 kg H2O/h
KOSZALIN
1300 kg H2O/h
SUWAŁKI
1404 kg H2O/h
TORUŃ
2600 kg H2O/h
REALIZED
THERMAL
DRYERS IN
POLAND BY
KREVOX
ŻYRARDÓW
750 kg H2O/h
31. environmental solutions
Investor: Municipal Waterworks in Radom Sp. z o.o.
Start of the realization: 04.2007
Basic technical data:
•1 proces line of the belt drying system
–direct drying,
–Dual burner (natural gas, oil),
–capacity: 3150 kg H2O/h,
–Guaranteed specific thermal energy consumption
0,9 kWh/ kg H2O.
Investment in Radom
32. environmental solutions
Investment in Torun
Basic technical data:
–Triple burner (natural gas, biogas, oil),
–capacity: 2600 kg H2O/h,
–guaranteed specific thermal
energy consumption
0,85 kWh/ kg H2O.
33. environmental solutions
Investment in Koszalin
Investor: Municipal Waterworks in Koszalin Sp. z o.o.
Signing of the agreement: 19.09.2011
Realization time: 15 months
Basic technical data:
– Natural gas burner
– Capacity:
1300 kg H2O/h
– guaranteed specific thermal
energy consumption:
< 0,85 kWh/ kg H2O
34. environmental solutions
Investment in Suwałki
Investor: Municipal Waterworks in Suwałki Sp.z o.o.
Signing of the agreement: 25.07.2011
Basic technical data:
– Dual burner (biogas, LPG)
– Capacity: 1404 kg H2O/h
– Guaranteed specific thermal energy consumption
0,85 kWh/ kg H2O
35. environmental solutions
Investment in Żyrardów
Investor: Municipal Waterworks in Żyrardów Sp. z o.o.
– Dual burner (biogas, natural gas)
– Capacity: 742 kg H2O/h
– Amount of mechanically dewatered sludge: 948 kg/h for 20 % DS
– Guaranteed specific thermal energy consumption: 0,85 kWh/kg H2O
– Guaranteed specific electrical energy consumption: 0,1 kWh/kg H2O
36. environmental solutions
Phosphourous recovery (up to
85 %) and Nitrogen (up to 25
%) from recirculated load of
nutrients
Example:
WWTP capacity of 60 000 – 90 000 m3
/d
Production of fertilizer 250 – 450 t/year
Savings in range of 550 000 – 850 000 €/year*
*Polish conditions.
Digestion chamber
OSTARA Process - Pearl
38. environmental solutions
THANK YOU for Your attention
Lviv, 07.10.2016 Aleksander Suszyński, PhD Eng.
aleksander.suszynski@krevox.com
39. Sewage sludge as a source of energy
and precious minerals
Nutrient Recovery
Phosphorus (85%)
Nitrogen (25%)
Digestion tank
Thermal hydrolysis
Editor's Notes
The phosphorus cycle today is unsustainable.
Phosphate rock is mined from stores in select places of our globe.
Phosphorus fertilizer refining creates phosphate hazardous waste.
Fertilizer is used to feed crops and livestock, runoff, leaching.
Without phosphorus treatment, treatment plants discharge P to the surface waters.
All this phosphorus in our surface water has resulted in environmental impacts such as dead zones and eutrophication of our waterways. The EPA estimates that more than 15,000 bodies of water have nutrient impairments including highly used recreational areas such as the Chesapeake Bay, Lake Erie, and (insert local place) right in your backyard.
And why do we do what we do?
The phosphorus cycle today is broken, in every sense
Globally we are facing a nutrient crisis
With deadzones the size of the state of Georgia (95,000 miles) due to nutrient pollution from both point and non-point sources and unsustainable supply and demand of this very valuable nutrient
And this is how Ostara solves this problem.
MAP SOURCE: http://anz.ipni.net/article/ANZ-3186, Source, USGS Mineral Commodity Summaries, http://minerals.usgs.gov/minerals/pubs/commodity/phosphate_rock/index.html#mcs)
Although the stocks of rock phosphate, the main source of mineral P fertilizers, are difficult to assess, there is a growing concern that mines might be depleted within a century
Morocco listed as 50000 BMT (billion metric tonnes), source: http://pdf.usaid.gov/pdf_docs/Pnadw835.PDF
Ostara recovers P from nutrient rich waters allowing discharge criteria to be met while producing a high value fertilizer
We help treatment plants meet their discharge limits by recovering P.
Our fertilizer production process is significantly more sustainable than that used for traditional P fertilizers.
And Crystal Green, our fertilizer product, is the most sustainable P fertilizer available because it is only available to plants when they need phosphorus.
It is nice to talk about what we do, but it is nice to talk about where we have done it.
Pima County – 33-calowa rura zwęziła się do 1-cala w ciągu 2 tygodni.
HRSD – rura zwęziła się od 8-cali do 1-cala w ciągu 6 tygodni.
Problem jest zazwyczaj rozwiązywany przez dodanie chlorku żelaza (co uniemożliwia biologiczne wykorzystanie P)
Wytrącanie struwitu w komorach fermentacyjnych
Nuisance struvite is a challenge for treatment plants. It can form in digesters where the presence of ammonia from the digestion process combined with dissolved ortho-p and magnesium forms struvite. We also see this accidental struvite forming in centrate lines and as part of added biosolids volume.
Treatment plants could choose to use chemicals to remove phosphorus.
Here you see a treatment plant schematic showing a conventional treatment process including primary treatment, activated sludge, and secondary clarification where chemicals are being used for phosphorus removal.
Using metal salts like alum and ferric chloride is expensive and creates large amounts of biosolids.
There is a better way to remove phosphorus.
WASSTRIP and Pearl work together as part of the treatment plant process to recover phosphorus as a high-value fertilizer.
WASSTRIP intercepts the WAS upstream of thickening. After thickening the filtrate is sent to Pearl. This filtrate is high in dissolved P and magnesium, but low in ammonia.
The Thickened sludge goes to digestion where methanogens break down the carbon and create ammonia and methane gas in the process.
After dewatering, centrate or other dewatering liquor that is high in ammonia is also routed to Pearl.
These two influent streams combine to create the perfect environment for the formation of prills.
There are numerous benefits to using this process. Let’s walk through them now.
We have talked about Ostara’s recovery solution which is a combination of Pearl and Wasstrip.
This picture shows a schematic of what is happening in the pearl reactor. You have nutrient rich influent and wasstrip feed that comes into the bottom of the fluidized bed upflow reactor.
Chemicals are added to create ideal reaction conditions with supersaturated magnesium at the proper pH.
Reactor contents are recycled and treated effluent flows from the top of the reactor.
Periodically an operator will start a harvest cycle to harvest Crystal Green.
We then heat treat, dry, classify and bag the market ready product in a fully-automated system.
Our process not only creates a highly clean and pure end product; it creates a product that is ready for sale.
Load: 65 kgs
Production: 500 tonnes
Metric sizes underneath
Load: 1260 kgs
Production: 10000 tonnes
Horticulture picture
This data comes from dissolution studies conducted in June 2012
With MAP, the P releases faster than plants can take it up. P is lost to soil and water environment and not available to the plant later in the season.
As you can see, the Crystal Green releases more slowly than MAP, providing continuous feeding of P throughout the growing season and reducing the potential for P to enter the water environment.
Source: Applied Chemical Technologies dissolution study conducted June 2012
This curve shows that under these conditions, CG releases nutrients more slowly than MAP (monoammonium phosphate). It also shows that the particle size of Crystal Green influences its release pattern, with smaller granule sizes releasing slightly faster and having a shorter longevity.
The X-axis scale is generically labeled “time” because although these data experiment is measured in hours, the release of Crystal Green in normal field conditions is on a scale of months.
Principle: A representative unground sample is exposed to a series of solvent extractions. Each extract is analyzed for the nutrient(s) of interest. Conditions are used to accelerate the release of nutrients compared to normal soil conditions.
5 grams of product is added to each column. Each extraction uses 475 mL of extraction solution (0.2% citric acid), which was circulated through the column at 50 deg C for 2-8 hours.
9 extractions total were done, but only 7 are shown on this graph because all product was released after 7 extractions.