ECSM 2010 Conf._Budapest

1 /ECSM 2010 – 2nd European Conference on Sludge Management

Budapest, Hungary, 9&10 September, 2010Sewage Sludge as Renewable Energy

Istvan Zsirai

ECSM 2010 – 2nd European Conference on Sludge ManagementBudapest, Hungary 9 & 10 September, 2010

SEWAGE SLUDGE AS RENEWABLE ENERGY

István ZsiraiVice President, Global Supply Chain, GE Power & Water,Water & Process Technologies, Trevose, US



Istvan Zsirai

Sewage Sludge as Renewable Energy

1. SEWAGE SLUDGE VOLUME INCREASE IN THE EU REGION2. CURRENT STRATEGIES AND APPLIED TECHNOLOGIES TO HANDLE

ORGANIC SLUDGES3. SEWAGE SLUDGE AS RENEWABLE ENERGY4. FACTORS INFLUENCING FUTURE SLUDGE HANDLING STRATEGIES5. DISCUSSION/CONCLUSIONS

SEWAGE SLUDGE VOLUME INCREASE IN THE EU REGION



Istvan Zsirai

Sewage Sludge volume increase in the EU RegionIn the Member States of EU the agriculture usage of sewage sludge reaches 42% avg. and there are more than 7 countries within the EU27 where the usage is beyond 60% in agriculture.There are also more than 7 countries with less than 3% up to zero. Sludge is applied to less than5% of agriculture land in EU and contributes <5% of the total amount of organic manure used.Many states have stopped the Sludge to Landrecycling in the last 5 years.The EU Sewage Sludge Directive was adopted more than 20 years ago with a view to encourage the application of sewage sludge in agriculture and to regulate its use as to prevent harmful effects on soil, vegetation, animals and humans .

Recycled to Land Incineration Landfill Other Recycled to Land Incineration Landfill Other 42 27 14 16 44 32 7 16

EU27 2010 distribution estimate % EU27 2020 distribution estimate %

2010 estimate 2020 estimateUSA 7.000.000 10.000.000

Austria 273.000 280.000UK 1.640.000 1.640.000

Scotland 200.000 200.000Spain 1.280.000 1.280.000

Sweden 250.000 250.000France 1.300.000 1.400.000

Germany 2.000.000 2.000.000Italy 1.500.000 1.500.000

Romania 165.000 520.000Portugal 420.000 750.000Poland 520.000 950.000Hungary 175.000 200.000

EU27 11.500.000 13.500.000

Sludge Production Volume Tds/aCountries

Global Sludge Production > 50M Tds/a



Istvan Zsirai

• The population of the EU will grow slowly, from about 499 million in 2010 to just under 514 million in 2020 (according to Eurostat projections)

• While industrial production will grow, process improvements, pollution prevention and improved on-site treatment will reduce sludge coming from industry.

• Continued increased level of sewer connection and wastewater treatment across the EU27, which means more sewage sludge being produced which will need proper sludge management.

• Increased industrial water pre-treatment and pollution prevention, reducing or eliminating discharge of toxic substances (heavy metals, chemicals) and improving sludge quality.

• General phasing out of sludge being sent to landfill due to EC restrictions.• The use of raw sludge will be no longer accepted, sludge shall be treated.• Due to global population growth ( to 8 billion/2030) the demand for clean water

will be trippled and the demand for electricity will have two folds growth.• Main alternative to „sludge to land” is likely to be incineration with energy

recovery.This will compensate landfill disposal discontinuation.• Due to Climate Change Policy and Renewable Energy Policy the sludge

management will be influenced with novel technologies like AAD, Gasification, Pyrolysis, Fuel Crops, SCWO, Incineration,Biodiesel, Bio-hydrogen,etc.

Expected Trend for the next 10-30 years



Istvan Zsirai

Global 2030 needs

2x Electricity

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

2008 2010 2015 2020 2025 2030

Emerging

Developed

Billions of kW hours

19.9

U.S.

0

5

10

15

20

Saudi Ara

biaAlgeria

Korea

France

SpainIndiaJa

panRuss

iaChina

50.2

62.2

Brazil

*at same consumption rate

3x Water(In billion cubic meters)

CURRENT STRATEGIES AND APPLIED TECHNOLOGIES TO HANDLE ORGANIC SLUDGES



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Approved method for stabilization/disinfection in sludge

Source:Ødegaard, H., Paulsrud, B., Karlsson, I. “Sludge disposal strategies and corresponding treatment technologies aimed atsustainable handling of wastewater sludge”, 2010



Istvan Zsirai

Source: Endre Juhász dr. publication, 2007.

l

Multiple-stage utilization of sewage & organic sludgeRegional/rural

transported sludge

Bioethanol, Biodiesel flora

* sludge disposal only in the year of planting

III. Pelet, briquette, compost fuel production heat + electric energy production

Composting

Other agricultural utilization built environment energy forest*

Energy Flora *

energy grass

Liquid fuel production II. Biomass heat + electric energy production

Sewage Treatment PlantWastewate treatment

Agricultural utilizationIrrigation - Sludge disposal

rape, maize, sweet sorghum, elephantgrass, sunflower,

energyhemp, chinese reed stb

Sludge handling

I. Anaerob digestion

biogas-energy production

Solardewatering

drying

Sewage Organic food waste water

Treatedw

astewater

Concentratedraw

sludgeinjection

Dig

este

dsl

udge

Dew

ater

edsl

udge

Heat energy prod.Electric energy prod.

Road transport(fecalia)

Dr. Stadler

patented process

Brown coal and/orlignit coal

l

SEWAGE SLUDGE AS RENEWABLE ENERGY



Istvan Zsirai

Renewable Energy generation from Sewage

Source: Parliamentary Office of Science and Technology, UKApril, 2007 number 282Modified by Istvan Zsirai



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Aqua Citrox® SWCO technology (Chematur Eng.AB)

Source: J. O’Regan, S. Preston, A. Dunne: Supercritical Water Oxidation of Sewage Sludge

Under normal conditions, water is seen in any of its three states: steam, liquid water, or ice. If water is heated and compressed to sufficiently high temperature and pressure, water enters a 4th stateknown as the super critical state. In the case of water this occurs above 374 °C and 221 bar

In the reactor oxygen is injected to start the oxidation reaction. The reaction is exothermic and temperatures increase as the reaction progresses. After passing through the reactor the effluent flows through the economiserwhere it heats the incoming stream. In larger plants the heat of reaction can be recovered via a steam generator for power generation. District heating is also an option depending on the plants location. Following any heat recovery the effluent is cooled to its exit temperature by a cooler prior to passing through the pressure reduction system where the pressure is lowered to <10 barg. The effluent then passes to a gas /liquid separator where the CO2, N2 and residual O2 are separated from the liquid stream. The inorganic residue is removed from the liquid stream. This stream has a COD of <5mg/ltr.



Istvan Zsirai

Sludge Gasification Process ( Primenergy LLC.)

The steps in this integrated process design are:1. High moisture content sewage sludge at 25% solids, either digested or undigested, is introduced into a thermal dryer. The

two common types of dryers are direct contact, which uses heated air as the drying medium, or indirect contact, which usessteam or heated oil as the drying medium.

2. Dried biosolids are discharged from the dryer. Moisture content is reduced to approximately 10%, creating a qualitybiosolids fuel.

3. The dried biosolids are fed into the gasification and energy conversion process. 4. The remnant ash is discharged from the gasification process. At this point over 85% of the weight of the wet sludge has

been removed. 5. The synthesis gas is oxidized in a series of stages and the released thermal energy is captured either in heated air or in the

production of steam. 6. The thermal energy is directed to the dryer, providing the energy necessary for the evaporation of the moisture contained in

the wet sludge. 7. Environmentally compliant dryer exhaust, spent productions of combustion and moisture, are vented to the atmosphere.

Source: Primenergy, A Safe Alternative



Istvan Zsirai

Source: REN21 2006 update + EER

Wind & Solar PV annual installations(GWs)

‘03‘00 ‘06

84

Wind

17

‘09

37

55

‘12

~22%

CAGR

~41%

24% CAGR

SolarPV

Focusing on electricity growth rates

Tidal<1%

Tidal<1%

Biomass19%

Biomass19%

Small hydro32%

Small hydro32%

Geothermal<1%

Geothermal<1%

ConcentratedSolar <1%

ConcentratedSolar <1%

Wind40%

Wind40%

Solar PV<1%

Solar PV<1%

Global Renewables

Sewage Sludge to Energywill grow drastically in the next20 years and get significant %on the Renewable Energy mapSludge

?%



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Sludge to Energy

Global production of Sewage Sludge exits 50M Tds/aRaw Sludge 25.5 MJ/kgds [ 100 %]Surplus active sludge 20.9 MJ/kgds [ 88 %]Digested raw sludge 11.6 MJ/kgds [ 45 %]Digested mixed sludge 13.4 MJ/kgds [ 52 %]Biobriquette, biopellet app.14.0 -18,0 MJ/kg [~ 63 %]

FACTORS INFLUENCING FUTURE SLUDGE HANDLING STRATEGIES



Istvan Zsirai

Factors Influencing Future Sludge Handling Strategies1. Legislation, Law Enforcement

• EU Urban Wastewater Treatment Directives, EU Waste Management Licensing Regulation• EU Water Framework Directives, EU Sewage Sludge Directives• EC Bathing Water Directive, EU Animal By-product Regulation• EU 20-20-20 Directives, EU ETS & CCA’s,EU Directives on Renewable Energy• Kyoto Protocol,reduction of GHG emission, Upcoming Regulation on EDC’s.

2. Economical incentives• Government fundings, special incentives for Renewable Energy investments• Water-Energy Relationship• Energy and Sewage Relationship

3. Public concerns, acceptance• Odour, dust, noise of traffic movement • Problems of potentially toxic elements (PTEs) in sewage sludge • Sewage sludge contains a number of volatile organic compounds • Environment quality goals for a poison-free environment

4. Technology development• Beside of implemented incineration and biogas generation processes there are lot of novel

technologies on market offering more benefits, better and easier sludge handling• Leading global companies are developing and implementing new sludge mgmt processes• Sewage Sludge is a new target for renewable energy generation

5. Product development• There are matured product on market enabling to turn sludge to energy in an economic way• Jenbacher generators• Anvanced Anaerob Digestion• SWCO• Etc…..



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EU 20-20-20

Reduction of GHG by 20%Increase Renewable Energy ratio by 20 %Decrease primer energy usage by 20%

1. Speed up the coal free energy implementation

Mandatory target of EU to achieve till 2020 minimum 20% Renewable Energy ratio in the total energy mix. For the Bio-Diesel ratiothere is a special target a minimum 10% , which shall be achieved..

2. Energy efficiency

As per the Commettee the primer energy usage shall be decreased by 20% till 2020.

3. GHG reduction

As per the Commettee the GHG emission shall be reduced by20% till 2020.

GE Power & Water

Update on GE’s



Istvan Zsirai

GE is a world leader in renewable energy solutions

Wind

SolarEFS

Jenbacher

$5B invested since ‘02

ecomaginationecomagination



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Jenbacher gas engines

A leading manufacturer of gas-fueled reciprocating engines for PG

• Power range from 0.25MW to 4MW, 4 platforms (Type 2, 3,4 & 6) / 11 products

• Generator sets, cogeneration systems, container solutions

• Delivered engines: about 8,500 units / ~10000 MW

• Diversified customer base: farmers, small Industries, Commercial buildings, IPPs, utilities …

• Service offerings: CSA’s,T&Ms,parts,repairs,upgrades,Remote diagnostics



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Jenbacher solutions

Landfill Gas Biogas

Coal Mine Gas Cogeneration

1MW saves 32,000 CO2

tons/y

(eq. 15,000 cars)

5,000 cowsfuel 1MW

1MW saves 32,000 CO2

tons/y

J624 (4MW) avoids 32,000 barrels of oil

Approx. 70% of JB …..

DISCUSSIONCONCLUSIONS



Istvan Zsirai

The Sewage Sludge is not waste, rather a potentialsource of energy, throught its components is such a

Raw Material, which directly or indirectly – viaappropriate changeover – able to replace or to

complement primer materials (chemical fertiliser) and/or energy (termal, electrical) !

Conclusion



Istvan Zsirai

Key Takeaways

• Focus on „Sludge to Energy”

• Energy objectives to Sewage Treatment

• Sludge is a growing part of Renewable Energy

• Sludge might effect the EU 20/20/20 results

• $30B market by 2020

Documents

ECSM 2010 Conf._Budapest