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13-2-2013
Anaerobic effluent treatment in the pulp and paper industry
www.paques.nl
2
Who is Paques?
Family owned business
Founded in 1960
Number of employees : ~400
Operations in The Netherlands, China, Brazil, and sales office in Canada
Worldwide presence through network of partners, partnering strategy
Innovative biological applications for wastewater and gas
2011: SKion GmbH, the investment firm of German entrepreneur Susanne Klatten (BMW, ALTANA, SGL) purchases 20% shares
2011: JV with Shell for biological gas desulphurization
3
4
Paques has around 1500 references worldwide
Mainly anaerobic water treatment (energy from wastewater) and biogas desulphurization
Market leader in pulp & paper, beer & beverage and food sector
Strong portfolio in sulphur based biotechnology
Growing and developing in:
Metal and Mining
Oil and Gas through Paqell
Petrochemical
Algeae
Biobased chemicals
Who is Paques?
5
Meet safe water discharge requirements
Reduce water consumption (water footprint)
Produce green gas (carbon footprint)
Upgrade biogas
Resource recovery from used water
By offering:
Biological processes and engineering packages
Integrated solutions Reliable
High uptime
Energy efficient
Best performance with attractive economics
Paques helps companies to:
6
Process design
Basic and detailed engineering
Manufacturing
Contracting
Construction
Research & Development
Laboratory services
Pilot testing
Consultancy and services
Paques services
7
More than 1,500 reference plants in more
than 60 countries in the following industries:
Pulp and Paper
Beer and Beverages
Food
Distilleries
Chemical industry
Metal and Mining
Oil and Gas
Municipalities
8
Anaerobic Waste Water Treatment
Pulp & Paper
9
Purpose
Removal of organic contaminants
Biogas production
Paques
The word leader in anaerobic treatment
More than 875 references in more than 60 countries
Anaerobic COD removal
10
Smurfit Kappa Roermond Papier 1983
11
100st IC reactor in P&P
started up in 2008
DS Smith France
12
Sludge granulation is the most popular anaerobic technology to treat pulp & paper effluent
UASB/IC
75%
AF
2%CSTR
7%
FB
2%
EGSB
14%
13
No.1 in anaerobic treatment of wastewater for pulp & paper industry
PAQUES
59%
A
17%
B
8%
C
6%
D
6%E
4%
14
Traditional aerobic process
BOD + O2 H2O + CO2 + BIOMASS
CO2 + H20
45
45
10 100
Aerobic sludge
Effluent
Aerobic biomass (~4 g/l MLSS)
Aerobic sludge
High growth rate
High energy requirement
High sludge production
Flocculant sludge
15
Concerns of Aerobic Treatment
- Important Space needed - Energy Requirement for Aeration - Important Sludge Production - Sensitive to Loading Variation - Problems of Sludge Separation
16
Anaerobic process
COD CH4 + CO2 + BIOMASS
Anaerobic methanogenic biomass
Low growth rate
Production of reusable methane (green energy)
Low sludge production (& biomass is asset rather than waste)
Granular biomass
Anaerobic biomass
CO2 + H20
45
45
10
Effluent 100
Aerobic sludge
CH4 + CO2
75
20
100
5
Effluent
Anaerobic sludge
17
Why anaerobic pre-treatment ?
- reduced energy consumption
- reduced sludge production
- more stable operation
- energy production
- reduced green house effect
In aerobic
plant
Revenue
18
Secondary Clarifier before anaerobic system installed
19
Secondary Clarifier after anaerobic system installed
20
Improvement of aerobic sludge
Before anaerobic
system installed
After anaerobic
system installed
21
Lab testing: Oxitop
22
Pilot testing
23
24
High rate (20-30 kg COD/m3/d)
Small footprint
Low hydraulic retention time
Self regulating system
Intensely mixed biomass at bottom reactor
Optimal sludge retention at top reactor
BIOPAQIC reactor
25
26
Advantages BIOPAQ IC reactor
Proven technology, > 875 BIOPAQ references
Closed system, corrosion free materials
Minimal foot-print (space saving and odor emission
surface limited)
Completely mixed reactor compartment due to Internal
Circulation principle
Optimal sludge retention due to two-staged separation
Maximal recovery of biological alkalinity, reduced
chemical costs
Robust & more stable due to
- two-staged concept
- automatic internal dilution (IC)
27
Feasibility of anaerobic effluent treatment MILL PROCESS FEASIBILITY OF ANAEROBIC
TREATMENT
Mechanical Pulping
Debarking
RMP, Ground wood
TMP, BTMP (Peroxide)
CTMP, BCTMP (Peroxide)
APMP (Peroxide)
-
+
++
+/++
++
Semi Chemical Pulping
NSSC
Soda pulping
+
+
Chemical Pulping
Sulfite pulp condensate
Sulfite bleaching: E,O,P
Sulfite bleaching: C,H,D
++
+
-
Kraft pulp condensate
Kraft bleaching: E,O,P
Kraft bleaching: C,H,D
++
+
-
Dissolving pulp condensate
Bleaching: E,O,P
Bleaching: C,H,D
+
+
-
Secondary Fibres
Wastepaper, DIP ++
Non-wood (soda) Pulping
Straw, Bagasse, Cotton Linters
+
28
Raw material and COD removal
Raw material COD efficiency %
OCC 75 85
MWP 65 - 75
MOW 60 - 70
ONP 50 - 55
Mech. pulp / spruce 50 - 55
Mech. pulp / aspen 65 - 75
Condensates 75 - 95
29
General flow diagram
Sludge
dewatering
N,P
Effluent
Primary clarifier Aeration tanks
Sec. clarifier
sieve
Influent
Return sludge
Biogas
Gasholder Flare
IC reactor Conditioning
tank
30
Zero discharge concept at paper mill
Conditioning tank IC Reactor
Aereation
Water storage tank
Secondary clarifier
Aereation basins
31
SCA Newhythe - UK
IC diameter 9.5 m
Height 20 m
Volume 1,400 m3
Flow 6,000 m3/d
COD 5,000 mg/l
COD 30 tpd
32
COD-load (kg/d)
IC Reactor COD load
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
1-1
-2004
15-1
-2004
29-1
-2004
12-2
-2004
26-2
-2004
11-3
-2004
25-3
-2004
8-4
-2004
22-4
-2004
6-5
-2004
20-5
-2004
3-6
-2004
17-6
-2004
1-7
-2004
15-7
-2004
29-7
-2004
12-8
-2004
26-8
-2004
9-9
-2004
23-9
-2004
7-1
0-2
004
21-1
0-2
004
4-1
1-2
004
18-1
1-2
004
2-1
2-2
004
16-1
2-2
004
30-1
2-2
004
kg
CO
D/d
33
Final effluent COD (mg/l)
Final Effluent COD
0
20
40
60
80
100
120
140
160
180
200
1-1
-2004
15-1
-2004
29-1
-2004
12-2
-2004
26-2
-2004
11-3
-2004
25-3
-2004
8-4
-2004
22-4
-2004
6-5
-2004
20-5
-2004
3-6
-2004
17-6
-2004
1-7
-2004
15-7
-2004
29-7
-2004
12-8
-2004
26-8
-2004
9-9
-2004
23-9
-2004
7-1
0-2
004
21-1
0-2
004
4-1
1-2
004
18-1
1-2
004
2-1
2-2
004
16-1
2-2
004
30-1
2-2
004
CO
D (
mg
/l)
34
COD removal (%)
IC Reactor COD removal efficiency (%)
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
1-1
-2004
15-1
-2004
29-1
-2004
12-2
-2004
26-2
-2004
11-3
-2004
25-3
-2004
8-4
-2004
22-4
-2004
6-5
-2004
20-5
-2004
3-6
-2004
17-6
-2004
1-7
-2004
15-7
-2004
29-7
-2004
12-8
-2004
26-8
-2004
9-9
-2004
23-9
-2004
7-1
0-2
004
21-1
0-2
004
4-1
1-2
004
18-1
1-2
004
2-1
2-2
004
16-1
2-2
004
30-1
2-2
004
Eff
icie
ncy (
%)
35
SAICA 3, Spain
Diameter 9.5 m Height 24 m Volume 1,680 m3
Flow 8,000 m3/d COD 5,800 mg/l COD 47 tpd
36
SAICA 3: Biogas production and VLR
15.000
15.500
16.000
16.500
17.000
17.500
18.000
18.500
JAN FEB MAR APR MAY JUN JUL AUG
Bio
gas p
rod
ucti
on
in
m3/h
22
23
24
25
26
27
28
29
30
VL
R i
n k
g C
OD
/ m
3.d
Biogas production Nm3/h VLR in kg COD / m3.d
Loading rate and biogas
37
VLR vs COD Efficiency
0
10
20
30
40
50
60
70
80
90
100
0,0 5,0 10,0 15,0 20,0 25,0 30,0 35,0 40,0 45,0
VLR kg/m3/d
CO
D e
ffic
ien
cy
Performance at high loading
Volumetric Loading Rate (VLR) in kg COD/m3.d Loading rate versus biogas
38
Palm Wrth, Germany
Diameter 9.5 m Height 24 m Volume 2 x 1,680 m3
Flow 9,000 m3/d COD 5,500 mg/l COD 50 tpd
39
Papierfabrik Palm, Germany TL, CM
BIOPAQIC
2 x 1680 m, Gasbuffer 500 m, Gasflare 1200 m/h
THIOPAQ60/1.2
40
Ruhrverband, Germany Tissue
BIOPAQIC
2 x 195 m
THIOPAQECO
2004
41
Emin-Leydier, France Diameter 9.5 m Height 24 m Volume 1,680 m3
Flow 6,500 m3/d COD 5,500 mg/l COD 36 tpd
42
Cartonneries de Gondardennes France TL, CM
Turn-key wwtp
Anaerbic + aerobic
BIOPAQIC 1190 m
Gasbuffer 30 m
Gasflare 900 m/h
2006
43
Rock-Tenn Solvay Paperboard, USA
44
Smurfit Kappa, UK
IC 6 x 24 m Flow 3000 m3/d COD 6000 mg/l
45
Stora Enso, Germany
Hagen Kabel (LWC from spruce)
Diameter 2 x 8 m Flow 24,000 m3/d
Height 20 m COD 1,200 mg/l
Volume 2 x 1,000 m3 COD 30 ton/d
Eilenburg (DIP, Newsprint)
Diameter 4 x 5 m Flow 15,000 m3/d
Height 16 m COD 1,500 mg/l
Volume 4 x 310 m3 COD 22 ton/d
46
Mechanical Pulping Process: TMP by Sound Raw materials: Masson Pine Production: 200tpd WWTP biological start up in 2001
Nanping Paper, China
47
Mechanical Pulping Process: PRC-APMP by Andritz Raw materials: Aspen Production: 500tpd WWTP biological start up in 2002
Yueyang Paper, China
48
UPM Kymmene, Germany SC/LWC
49
Fujian Nanping Paper, China TMP/DIP
50
YueYang Paper, China
Mechanical Pulping: Aspen/Eucalyptus
51
Chen Loong, China
52
M-Real, Austria Sulphite Condensate