Peter Balslev, SUEZ Environment - PhosphoGreen – experiences and success story
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Ravinteet kiertoon – vesistöt kuntoon | Kiertotalouden kärkihankkeen lähtölaukaus | Recycle nutrients for clear waters | Forum for Action 19.– 20.4.2016
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Peter Balslev, SUEZ Environment - PhosphoGreen – experiences and success story
- 2. Agenda • PhosphoGreen™ – Presentation – Background for problems & solution – Background of concept (partnership) – Technology Concept & pictures – Cases from Aarhus and Herning – Circular economy
- 3. Presentation • Peter Balslev, wastewater specialist – Aarhus Vand A/S – Suez Water A/S Suez Water A/S Aarhus Vand A/S Rugaardsvej 5, 8680 Ry, Denmark Bautavej 1, 8210 Aarhus V, Denmark Tel: +4569156600 Mobile/Direct: +45 40577390 mail; peb@aarhusvand.dk mail; peb@aarhusvand.dk
- 4. Problems Piping 4 Digester wall 50 m3 "sand" in digester
- 5. Problems (continued) 5 Scaling in old pumps
- 6. Mass balance, 0% recovery - “before situation" 66 Digester R/A Final dewat. inlet 100 141 outlet 4 rejekt 36 132 Sludge 96 Pre-dewater Pct. of inlet total-P 96% Return sludge 5 137 4% Iron chloride 41
- 7. Solution 3 steps upscaling Pilot testing Lab testing Full scale testing
- 8. Mass balance, 30% recovery - “after situation" 88 Digester R/A Final dewater inlet 100 110 outlet 4 reject 36 101 Sludge 66 Pre-dewater Pct. of inlet total-P 66% Return sludge 5 106 4% Iron chloride PhosphoGreen™ 5 36%
- 9. Analysis, dewatered sludge 9 0.00% 1.00% 2.00% 3.00% 4.00% 5.00% 6.00% sep-13 dec-13 jan-14 total-N Total-P Less phosphorus in sludge
- 10. Danish P recovery technology Partnership and development in Denmark 2012-2015 Objective • Providing a full value-chain for P recovery solution Challenge • In 2010 Aarhus Water (Denmark) experienced problems with heavy struvite formations in digester, pipes etc. • A partnership was formed to solve the problem Process, design, technology Water utilities companies facing a challenge Agricultural Knowledge Centre approval of P product as fertilizer
- 11. PhosphoGreen™ Functionality Process control • Magnesium chloride is dosed flow proportional into the reactor inlet together with inlet reject water , dosing is regulated by lab samples of PO4 weekly, or by online PO4 sensor • NaOH is dosed into the reactor controlled by pH measurement – to keep pH value around 7.5, controlled by pH meter • Air lift pump secures internal recirculation as well as CO2 stripping (pH control) • Internal recirculation pump secures up flow velocity (flow measurements and VLT on pumps)
- 12. Financial Sustainability of P recovery Value creation (Herning example) Financial balance at 45 % P recovery (in €/y) • Operational costs are approx.: 75 600 • Savings are calculated/estimated to: 101 500 • Income from sales of struvite is: 49 100 • The resulting net income is 75 000 Return of investment? • The investment cost (as sales price) for the P recovery plant was €465 000 • ROI of approx. 6.2 years when operating on both sources of reject waters, and reaching 45 % total P recovery • With ROI approx. 7 years P recovery is a sustainable investment for many water utilities • Decision is taken to commercialize the concept! Cost Unit Value Electricity Euro/year 6 100 MgCl2 ” 50 700 NaOH ” 6 700 O&M ” 12 100 Total costs to operate ” 75 600 Savings Ferric chloride (P removal) ” 53 300 Polymer(sludge dewatering) ” 2 000 Electricity (less nitrification) ” 3 900 Sludge disposal (less volume) ” 16 000 Biogas (more production) ” 5 600 Less struvit fighting (O&M costs) ” 20 700 Total Saving for WWTP ” 101 500 Income Sales of struvit/ MAP (350€/t) ” 49 100
- 13. PhosphoGreen™ PhosphorCare™ Concept commercialization • First the concept was validated for technical stability and positive business case. • “Water Contractor companies” were selected to sell the solutions in Denmark and abroad: – Stjernholm generally in Denmark (under name Phos4Cone™) in cooperation with SUEZ Water on larger projects – SUEZ generally abroad (PhosphoGreen™)
- 14. Value making of PhosphorCare™ fertilizer PhosphorCare™ Agricultural tests 2014-15 • Corn and Rye growth tests • Classification of PhosphorCare™ as fertilizer. • “Farm-tests” for handling and use. • Target: to form a consolidated method of how and where to use PhosphorCare™ PhosphorCare™ Approval 2014 • Application for approval issued Q1 2014 • Approval from Danish national EPA and Ministry of agriculture and food obtained Q3 2014 • REACH registration Q4 2014 Sales channel • Kongerslev Kalk has signed a 2 year agreement with Aarhus Vand and Herning Vand for the distribution and sales of PhosphorCare • Aarhus Vand and Herning Vand is open for new water companies to join their sales group • SUEZ Water is working on a road map to establish struvite import from France to Denmark / Kongerslev Photo: Kongerslev Kalk’s bag proposition
- 15. Quality of struvite, Aarhus plant no heavy metals! Sludge Struvite 3 samples Land application in DK. DM % 23,7 N % of DM 5,4 P % of DM 3,22 N % of sample 5,8 P % of sample 12,3 Mg % of sample 10,3 Cd mg/kg 0,9 <0,02 0.8 Hg mg/kg 0,5 <0,1 0.8 Pb mg/kg 23 <0,2 120 Ni mg/kg 24,4 0,3 30 Cr mg/kg 17,1 <0,1 100 Zn mg/kg 580 2,7 4000 Cu mg/kg 230 0,7 1000 Cd mg/kgP 28 <0,16 100 Hg mg/kgP 16 <0,8 200 Pb mg/kgP 714 <1,67 10000 Ni mg/kgP 758 2,7 2500
- 16. Application of PhosphoGreenTM in the process line application field • WWTP capacity > 40,000 PE • biological phosphorus removal • anaerobic digestion • phosphorus conc. in digested sludge centrates ≥ 70 mg/L anaerobic digestion PhosphoGreenTM dewatering primary and/or secondary sludge sludge cake for disposal water back to the headworks struvite
- 17. Front view of reactors and plant
- 18. Bottom part of the reactor and recycle pump Recycle pump
- 19. Drying of struvite product Screening of struvite product
- 20. Silo and bagging of final product
- 21. PhosphoGreen™ Summary Advantages of investment • Innovative & effective reject water treatment solution • Combines well with Anammox treatment • Overall OPEX Cost advantage • “Green Image” phosphorus recovery and reuse • ROI can be around 7 years depending on plant Value creation • No or very reduced clogging problems • Reduced chemical use for chemical P removal • Reduced costs for sludge dewatering(polymer) • Reduced energy uptake for nitrification • Less sludge produced • A fertilizer with high value: Struvite • Residual sludge with better N:P balance The product is approx. 2 mm pellets ready for use as fertilizer P=12,5% N=5,5% Mg= 10% Photo Reactors
- 23. Aarhus, Denmark, 2013 70,000 PE Our references: Herning, Denmark, 2015 150,000 PE