energy optimization trends in biosolids management...• case studies • whole plant optimization...
TRANSCRIPT
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www.jacobs.com | worldwide
Energy Optimization Trends in Biosolids Management
By Duyen Tran, ENV SP and Todd O. Williams, P.E., BCEEJune 6, 2018
DOE Webinar – Biosolids Energy Recovery
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Residuals Resource Recovery
Energy Optimization Trends in Biosolids Management
• Fayetteville, Arkansas Case Study• What are the industry trends?
– Improved quality due to regulatory and public concerns– Nutrient recovery– Energy efficiency/optimization– Interest in non-land-based alternatives and future
technology development
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Residuals Resource Recovery
Case Study - Fayetteville, AR Biosolids Operations
• 2 WWRFs, total design 22.6 MGD• 670 acres biosolids management site
– Fertilizer production/sale– Irrigation and nutrient uptake, hay
harvesting/marketing– Application of water treatment
residuals
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Residuals Resource Recovery
History of Fayetteville Biosolids Management
1988 to 2003 – land application2003 to 2011 – landfill2012 to current – class A biosolids
– Process ~ 21,000 wet tons of sludge/yr
– Produce ~3,000 dry tons of fertilizer
– Generate ~ $60K in fertilizer sales/year
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Residuals Resource Recovery
Specific Options Comparison
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Residuals Resource Recovery
Solar House Drying Cycle
1. De-watered biosolids are trucked to the site & emptied into the “Unload Basin”
3. Solids are then spread as evenly as possible inside the houses
4. Then the ‘moles’ are turned loose to do their thing!
2. Solids are then loaded into the spreader or hauled directly into the houses with the skid-steer loader
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Residuals Resource Recovery
Thermal Drying to Class A Biosolids
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Residuals Resource Recovery
Costs
• Total capital cost is $8M– $6M for solar dryers– $2M for thermal dryer
• Actual savings is ~$500,000 in 2017 compared to landfilling
• Produces beneficial reuse products
• Solar drying reduces overall drying energy cost by ~50%
• Reduces carbon footprint
Benefits
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Residuals Resource Recovery Lessons Learned
•Sludge Composition is critical•Odor Issue•Dust Issue•Preventive Maintenance
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Residuals Resource Recovery
Looking for The Next Big Thing –Energy Reduction Alternatives
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Residuals Resource Recovery
Energy Optimization Trends in Biosolids Management
• What are the trends?– Improved quality due to regulatory and public concerns
• Class B to Class A– Nutrient Recovery– Energy efficiency/optimization
• Advanced anaerobic digestion– Thermal hydrolysis
• Co-Digestion (FOG and HSW) to generate more biogas– Biogas for driving CHP and biogas upgrading
• Case Studies• Whole plant optimization
– Carbon redirection– Interest in non-land-based alternatives and future technology development
• Gasification• Pyrolysis• Hydrothermal liquefaction• Supercritical water oxidation
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Residuals Resource Recovery
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• Several vendor systems available
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Residuals Resource Recovery
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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Residuals Resource Recovery
Pre-Digestion Mechanistic Principles for Reducing Solids Generation Evaluated in 2010 WERF Study • Biological Combination Process
– Cannibal• Physical Process
– Thermal Hydrolysis (Cambi)– Pressure Release (Crown)– Shearing (ABS Kady)
• Physical/Chemical Process– Microsludge
• Pulsed Electric Process– OpenCel
Lots of Conclusions but….only Thermal Hydrolysis installations are growing
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Residuals Resource Recovery
Thermal hydrolysis
Hygienization (Class A Biosolids)...No FC Regrowth and Low Odour
Dewaterability ...dryer cake and less solids = big volume reduction
Improvement of sludge
biodegradability...sludge reduction & biogas production
Viscosity ...easier to pump and can load digester at higher %TS
Benefits of Thermal Hydrolysis
Reduction in Anaerobic
Digestion Reactor Volume
Much higher VSLR (4-6 kg/m3/day) and reaction kinetics
Increase in biogas yield and methane
content... More energy production
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Residuals Resource Recovery
Thermal Hydrolysis is a Proven Technology Worldwide THP Systems Jan 1, 2016, Compliments of Cambii
* = operating; **operating & expanded, (*) closed down (pilot/decommissioned), *? Uncertain operating status. All other under design/construction
Over 70 Operating THPPlants Worldwide
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Residuals Resource Recovery
Thermal Hydrolysis Vendor SystemsVendor Full-Scale
FacilitiesBuilt (const.)
Capacities of Installed Base
DT/day
Since
Cambi - THP 53 (+4) 6 to 360 1995
Veolia - BioTHELYS 6 (+2) 3 to 100 2004
Veolia - Exelys 1 (+3) 10 to 66 2014
Sustec - TurboTec 2 (+0) 20 to 35 2012
Haarslev 2 (+1) 20 to 25 2014
CNP - Pondus 8 (+0) 5 to 20 2005
Lysotherm 2 (+0) 3 to 33 2016
TOTAL 2017 74 (+10) 3 to 360 1995
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Residuals Resource Recovery
WEF/NBP Study Released in July 2013
• About half of all wastewater is processed using anaerobic digestion
• 5127 Water Resource Recovery Facilities (WRRF) were surveyed, majority above 1 MGD (about 1/3 of all)
• Plenty of opportunity exists for development of energy recovery at WRRF’s in the next decade.
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Residuals Resource Recovery
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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Residuals Resource Recovery Biogas with Addition of Fats, Oil & Grease (FOG)
50 dry tons/day solids > 600,000 ft3/day of biogas $4,800/day energy value
55,000 gal/day FOG @ 5% solids + 50 dry tons/day solids > 952,000 ft3/day of
biogas $7,600/day energy value
+ $1,022,000/yr energy value with FOGF. Wayne Hill WRC, Gwinnett County, Georgia
Douglas L. Smith Middle Basin FacilityJohnson County, Kansas
50% of Plant Power Needs Met
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Residuals Resource Recovery
The Resource Recovery Model
Biosolids Fertilizer
Biodiesel
Renewable Electricity
Recycled WaterWastewater
Organic Wastes
Food Waste
Fats, Oils, and Grease
Wastewater Treatment
Plant
Nutrient Harvesting
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Residuals Resource Recovery
Renewable Energy Expansion
• Installed in 1985• Met 40-50% of demand
(2-2.5 MW net gen)• Frequent flaring of excess
biogas
Expansion (+1 turbine)
• Meets 100-200% of demand (5-10 MW net gen)
• Sell excess green energy
• Reduces air and GHG emissions
• Increases operational reliability
Original Facility (3 engines)
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Residuals Resource Recovery
First WWTP in U.S. to Become a Net Electricity Provider
2013
Generation: 6MW
Demand: 5MW
Net Sales = 1MW
Electrical Grid
Wastewater Treatment Plant
Net Electricity Provider
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Residuals Resource Recovery
Process Schematic of DC Water’s New Biosolids Program with TH and CHP
Dewatering
Lime
Store &Loadout
Class B
DAFTs
Mix
R
R
Screening and Pre-Dewatering
FinalDewatering
RecycleProcessing
R
LoadoutCambi™ THP
Steam Biogas
Biogas Treatment and CHP
Emissions
MesophilicAnaerobicDigestion
Class A
Power
R
R
GravityThickeners
Blend Tank
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Residuals Resource Recovery
Program Benefits
Reduce biosolids quantities by more than 50%
Improve product quality (Class A)
Generate 13 MW (net 10 MW, or ~40% of total grid draw) of clean, renewable power
Cut GHG emissions by a third
Saving millions of dollars annually since the facility began operating in early 2015
Reinventing Biosolids
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Residuals Resource Recovery
Green Bay Resource Recovery and Electrical Energy (R2E2) Project
R2E2 will generate 70% to 75% of overall facility power and heating requirements when it is fully operational in 2018
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Residuals Resource Recovery
VandCenter Syd (VCS), Denmark
• 3rd largest water and wastewater company in Denmark. Headquartered in Odense.
• Operates 7 WTPs and 8 WWTPs with 2,125 miles (3,400 km) of conveyance
• Ejby Mølle WWTP:
– 385,000 PE BNR facility
– 76 percent energy self-sufficient in 2011
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Residuals Resource Recovery
Ejby Mølle WWTP Energy Optimization Project Objectives
• Contribute towards achieving VCS’s corporate goal of energy self-sufficiency and carbon neutrality by 2014
• Identify energy optimization opportunities (EOOs):
– Short-term, readily implementable scenarios to reduce energy consumption and/or increase energy generation, and decrease greenhouse gas emissions
• Identify and document all options, including longer term opportunities for future consideration
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Residuals Resource Recovery
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Residuals Resource Recovery
Availability of detailed historic energy consumption and generation data was key in the evaluation of optimization opportunities
Screen, Grit, and Grease3.88% Primary Treatment
3.09%Pumping to
Trickling Filters2.15%
Pumping to Activated Sludge5.80%
Trickling Filters -Stage 2 pumping
7.30% Trickling Filters -Recirculation pumping
4.73%Trickling Filters -
WAS/Humus Pumping0.01%
Trickling Filters - Return Pumping to Act Sludge
0.64%
Activated Sludge -Anaerobic Zone Mixers
1.78%Activated Sludge -
Oxidation Ditch Aeration39.35%
Activated Sludge -Oxidation Ditch Mixing
2.09%
Activated Sludge -RAS Pumping
0.86%
Activated Sludge -WAS Pumping
0.22%
Activated Sludge - Other0.24%
Effluent Filters10.43%
Sludge Storage1.56%
Anaerobic Digestion3.83%
Thickening/Dewatering Centrifuges
6.44% Other5.59%
Ejby Mølle WWTP 2011 Annual Average Electricity Consumption
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Residuals Resource Recovery
A whole plant mass/energy model and screening criteria led to an EOO short-list
• Adopted screening criteria – Readily implementable; Primarily
process modifications– Significant impact on energy profile;
Proven elsewhere• Short-listed EOOs
– Implement chemical enhanced primary treatment (CEPT)
– Operate at shorter BNR system solids retention time (SRT)
– Decommission TFs and convert TF clarifiers to CEPT for wet weather treatment
– Reduce effluent filtration operation to 12 hours per day
• Longer term Improvements for positive net energy status
– Co-digestion of high strength waste in 2014
– Implemented deammonification for N removal in sidestreams in 2014; mainstream in 2015
– Replaced oxidation ditch mechanical aerators with fine bubble diffused aeration
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Residuals Resource Recovery
Implementation of several EOOs achieved energy self- sufficiency in 2014
Electrical Energy
Electrical + Heat Energy
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Residuals Resource Recovery
What is Carbon Redirection and why would a utility be Interested in applying it?• The diversion of biodegradable material away from the influent to a secondary treatment system
• The Good:– Lower energy usage– More biogas for beneficial use– Less biosolids production– Smaller bioreactors/more bioreactor capacity– Sets plant up for future technologies like mainstream Anammox
• The Bad:– Makes conventional nitrogen removal in secondary treatment more difficult because less carbon is
available for denitrification
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Residuals Resource Recovery
Examples of Carbon Redirection
• The diversion of biodegradable material away from the influent to a secondary treatment system
BOD5Raw
Sewage
Oxygen/Air$$$
BOD5Raw
Sewage
Oxygen/Air
$
BOD
5
BOD5
Primary Treatment
Carbon Redirection
Conventional
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Residuals Resource Recovery
Examples of Carbon Redirection
• Realizing energy savings requires anaerobic digestion, or no digestion– Aerobic digestion would just move power from the liquids to the solids train
BOD5Raw
Sewage
Oxygen/Air
$
BOD
5
BOD5
Primary Treatment
Anaerobic Digestion
Digester Gas
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Residuals Resource Recovery
Impact of Primary Clarification (1 MGD Facility)
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Residuals Resource Recovery
Growing interest in non-land application based alternatives and future technology development
Emerging technologies for biosolids management as defined by the US EPA
with suggested updates by Jacobs
• Established – Technologies widely used (i.e. generally more than 25 facilities in operation) are considered well established.
• Innovative – Technologies meeting one of the following qualifications: (1) have been tested at a full-scale demonstration site; (2) have been available and implemented for less than 5 years; (3) have some degree of initial use (i.e. implemented in less than twenty-five utilities)
• Embryonic – Technologies in the development stage and/or tested at laboratory or bench scale. New technologies that have reached the demonstration stage, but cannot yet be considered to be established
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Residuals Resource Recovery
EmbryonicGenifuel - Hydrothermal Liquefaction
and Catalytic Gasification
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Residuals Resource Recovery
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 (it was
your sludge that was tested!)• Looking for full scale demonstration
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Residuals Resource Recovery
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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Residuals Resource Recovery
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• Syngas is transformed by
Fischer-Tropsch process to produce advanced biofuels such as bio-diesel
• Patented process with turnkey developers.
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Residuals Resource Recovery
Summary
• What are the trends?– Improved quality due to regulatory and public concerns
• Class B to Class A– Nutrient Recovery– 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
– Interest in non-land-based alternatives and future technology development• Gasification• Pyrolysis• Hydrothermal liquefaction• Supercritical water oxidation
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www.jacobs.com | worldwideJune 4, 2018
© Copyright Jacobs
Thank You
Todd Williams, [email protected] Tran, [email protected]