Continuous Thermal Hydrolysisftp.weat.org/Presentations/14-Bonkoski_THP_Energy_Nuetrality.pdf · Continuous Thermal Hydrolysis . The Path to Energy Neutrality . Nick Bonkoski August

Continuous Thermal Hydrolysis

The Path to Energy Neutrality

Nick Bonkoski

August 1, 2013

Overview

Thermal Hydrolysis Basics

Batch to Continuous

Exelys Specifics

Focus on Energy Neutrality

Developing Project – Lille, FR

Conclusions

Questions

Thermal Hydrolysis

Overview

Crack long chain Molecules using temperature and pressure

Release additional energy in the sludge

300 – 350 F 130 – 160 psi

Thermal Hydrolysis Overview

Presenter

Presentation Notes

Veolia Biothelys process, looking to optimize further By the nature of batch processes, more valves, pumps, tankage

Thermal Hydrolysis Benefits

Class A End Product

BIOGAS PRODUCTION

VS REDUCTION

DIGESTER

CAPACITY and MIXING

DEWATERABILITY

VOLUME OF SLUDGE FOR

DISPOSAL

2

Presenter

Presentation Notes

Biogas production is enhanced when increasing VSR Mixing is improved with lower viscosity Solids can be fed at 10-12%DS which increases capacity and decreases potential capital investment in new digestion facilities. Should be kept to this range to prevent ammonia toxicity. Sludge can be dewatered to 30%DS in BFP’s and centrifuges

Batch to Continuous Thermal Hydrolysis

BioThelysTM – Batch Thermal Hydrolysis

Principle: operates a thermal lysis of the organic matter maintained at 165 C (329 F) during ½ hour and consequently improves the biogas production

DS 16%

DS 12%

12

Bio Thelys™ and CAMBI™ Reactor Arrangement

Critical analysis of Batch THP

Over dimensioned capital equipment:

• Feeding pumps: 3 times average flow

• Feeding circuits: 6 times average flow

• Steam injection: 6 times average flow

• Boiler: 3 times average flow

• More Valves & Instrumentation

Consequences

• High CAPEX Costs

• High OPEX and Maintenance

• Underutilization of capital equipment

EXELYSTM – Layout Comparison

EXELYSTM – Continuous Plug Flow

BioThelysTM – Batch Process

EXELYSTM – The Evolution of Thermal Hydrolysis

A continuous system

Reduces investment costs

Reduced Footprint

Simplifies operation and maintenance tasks

Higher solids composition processing capability, reducing heat requirements

Improve the energy efficiency

Same solubilization effect as batch THP

Presenter

Presentation Notes

% solids, traditionally 20-25% solids

EXELYSTM - Continuous Thermal Hydrolysis

Presenter

Presentation Notes

30 min to travel through the reactor at temp and pressure After the HX sludge is diluted before going to the digesters

EXELYSTM - Vertical Reactor Specifics

Increased Thermal Efficency

Non-Condensable Gas Collection

Compact Design

Reduced Footprint

Dewatered Sludge

Steam Injection

Hydrolyzed Sludge

EXELYS™-LD (Lysis – Digestion)

15

EXELYS™-DLD (Digestion – Lysis – Digestion) Maximum biogas production while using only waste heat

Smaller EXELYS – Waste Heat Recovered

Presenter

Presentation Notes

Use waste heat from CHP for steam Digestion before EXL provides solids, less steam required, more efficient Max energy generator

EXELYSTM – Primary Pasteurization

Reduce Exelys capital costs and energy consumption

Heat from Exelys used for pasteurization

No dilution water needed

Primary Sludge Pasteurization

Waste Activated

Sludge

EXELYSTM – Hydrolysed Sludge

Before TH

After TH

Focusing on Energy Neutrality

19

What do we see today? Waste products

Sludge = Waste

Sludge = Energy and resources

Presenter

Presentation Notes

So when you see this photo many will probably think that it is a pile of shit. But when we look we see a pile of biomass with many exercise options. We want to show you today.��First we enter the same number of steps back to see the big picture. Så når I ser dette foto vil mange nok tænke, at det er en dynge lort. Men når vi ser det ser vi en dynge biomasse med mange udnyttelsesmuligheder. Det vil vi gerne vise jer i dag. Først træder vi lige mange skridt tilbage for at kunne se det store perspektiv.

Bio-refinery

Electricity CO2 neutral

Chemicals

Reused nutrients Bio-plastic

Clean water Resources

Electricity – CO2 neutral

Heat – CO2 neutral

The Future of Waste Water Treatment

Presenter

Presentation Notes

Here is a picture of how the future wastewater treatment looks.��The pictures must show that focuses on creating valuable products out of raw material, which is wastewater.��It is today possible to utilize the sludge as an energy resources, and this has been possible for years. The figure is to illustrate that we are now focusing on creating the CO2 neutral cleaners and not only that, but also the energy-producing wastewater treatment plants.��But it is too narrow to consider only the sludge as an energy resource. The organic part of the sludge can also be used as a substitute for oil for the production of such plastics. Nutrients like phosphorus can be recycled from the sludge and used as fertilizer. These are technologies being developed and continuously improved in line with the surrounding world demands increased. Her ser i et billede på, hvordan fremtidens spildevandsbehandling ser ud. Billederne skal vise, at der fokuseres på at skabe værdifulde produkter ud af råmaterialet, der er spildevandet. Det er idag muligt at udnytte slammet som en energimæssig ressouce, og dette har været muligt i en årrække. Figuren skal illustrere, at vi nu fokuserer på at skabe det CO2 neutrale renseanlæg og ikke bare det, men også det energi-producerende renseanlæg. Men det er for snævert kun at betragte slammet som en energimæssig ressource. Den organiske del af slammet kan også udnyttes som erstatning for olie til produktion af eksempelvis plastik. Næringsstoffer som fosfor kan genanvendes fra slammet og bruges som gødning. Dette er teknologier der er under udvikling og som løbende forbedres i takt med at omverdens krav øges.

Approaching Energy Neutrality

Marquette Lez Lille, France

23

Marquette Lez Lille – Project Overview

Built in 1969 in Northern France

No longer in compliance (N & P limits)

Complete Process upgrade under construction

Plant flow 185 MGD

Collection from 85 towns servicing over 1,000,000 people

Contract Price - $230 M Veolia operating facility during construction and for 18 mo after startup.

Comissioning started early 2013

Marquette Lez Lille – Process Upgrade Specifics

Primary treatment: MultiFloTM

Storm water line: MectanTM – ActifloTM – ActydinTM

Biological treatment: HyBasTM

Tertiary treatment: HydrotechTM Discfilter

Sludge Treatment: ExelysTM – BioConTM

Air Treatment: AquilairTM – AziliarTM

Marquette Lez Lille – EXELYSTM DLD

Drivers

Power sold to the grid at $140 – 170 /MWh

Rate depends on current power / heat balance and efficiency

Electricity purchased at $0.18 kw

Sludge Disposal costs $160 – 190 / tDS around Lille

Plant currently disposes of 22,000 tDS/yr @ 25%

Compliance with Multiple European Initiatives

Biogas generation

Thermal Recovery

Solids Reduction


Two – 1.6 MG Primary digesters

Digested Primary and Hybas sludge mixed and dewatered via centrifuges

Four – DN 450 Exelys reactors (22,000 tDS/year)

One – 1.6 MG digester with combined hydrolyzed sludge

Post digestion centrifuges followed by BioCon sludge Dryer

System Design


9000 MW/yr generated and sent back to grid

2 x 620 KW - 1 x 300 KW (thermal)

Biogas / Natural gas boiler providing steam for Exelys and heat for BioCon

Biogas storage and scrubbing (activated carbon and H2O removal)

Real time biogas flow and analyzers

Heat from cogen used for 1st stage digestion and other processes

Additional heat into plant wide heat loop

Energy Generation and Heat Recovery

Marquette Lez Lille – Sludge Project Review

Plant will be fully commissioned by 2015

Some upstream processes already online

Energy Neutrality reached for entire plant by 2016

Based on Economic POV, not in terms of kWh

Maximize Green Energy Production through Exelys

9000 MW/yr @ $155 /MW = $1,400,000 /yr

Heat Recovery back to other onsite processes

Maximize Sludge Reduction Via BioCon

Initial Class A market for Sludge

Goal to utilize dried sludge as onsite fuel source

New Greenfield facility in place of existing plant

Design focuses on environmental impact to area

Small Footprint created to promote local biodiversity among plants

Buildings designed to blend into landscape

QUESTIONS

Nick Bonkoski Regional Sales Manger – BioSolids and BioEnergy

I. Kruger Inc [email protected]

(484) 459-3762 BOOTH 11

Documents

Continuous Thermal Hydrolysisftp.weat.org/Presentations/14-Bonkoski_THP_Energy_Nuetrality.pdf · Continuous Thermal Hydrolysis . The Path to Energy Neutrality . Nick Bonkoski August